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Ham TS

The document outlines the technical specifications for various major electrical equipment, including distribution transformers, conductors, cables, insulators, and related accessories. It details the scope, applicable standards, service conditions, and testing requirements for the equipment, ensuring compliance with Indian and international standards. The specifications emphasize the need for high-quality materials and robust design to ensure reliable operation in diverse environmental conditions.

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0% found this document useful (0 votes)

55 views623 pages

Ham TS

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JAIPUR VIDHYUT VITRAN NIGAM

TECHNICAL SPECIFICATIONS OF VARIOUS MAJOR EQUIPMENTS

PART 2-SECTION-VI

TABLE OF CONTENTS…

S.No. Item Name Page No.

1 25 KVA, 11/0.433 KV, ALUMINIUM WOUND 3- Phase 1 - 39

LEVEL-2 (STAR-1) DISTRIBUTION
TRANSFORMERS
2 63 KVA 11/0.433 KV, ALUMINIUM WOUND 3-Phase 40 -75
LEVEL-2 (STAR-1) DISTRIBUTION
TRANSFORMERS
3 ACSR RABBIT CONDUCTOR 76 - 88
4 ACSR DOG CONDUCTOR 89 - 102
5 9 M. LONG PCC POLES OF 400 KG 103 - 113
6 9 M. LONG PCC POLES OF 200 KG 114 - 124
7 11 KV CT-PT SETS OF RATIO 200/5 Amp, 100/5 125 - 150
Amp., 50/5 Amp and 15/5 Amp.
8 FOUR CORE LT XLPE INSULATED AND PVC 151 - 169
SHEATHED ARMOURED CABLES. (4CX120 Sq.mm)
9 FOUR CORE LT XLPE INSULATED AND PVC 151 - 169
SHEATHED ARMOURED CABLES. (4Cx70 Sq.mm)
10 LT XLPE INSULATED AERIAL BUNCHED CABLES 170 - 188
WITH BARE MESSENGER WIRE WITH ALUMINIUM
CONDUCTOR FOR LT OVER HEADLINES. (1CX25+25
Sq.mm)
11 LT XLPE INSULATED AERIAL BUNCHED CABLES 189 - 207
WITH BARE MESSENGER WIRE WITH ALUMINIUM
CONDUCTOR FOR LT OVER HEADLINES. (3CX25+25
Sq.mm)
12 LT XLPE INSULATED AERIAL BUNCHED CA- 189 - 207
BLES WITH BARE MESSENGER WIRE WITH ALU-
MINIUM CONDUCTOR FOR LT OVER HEAD LINES.(
3CX50+35 Sq.mm)
13 PVC INSULATED MULTI-CORE UN-ARMOURED 208 - 229
NON-FRLS CONTROL CABLES(12CX2.5 Sq.mm)
14 PVC INSULATED MULTI-CORE UN-ARMOURED 208 - 229
NON-FRLS CONTROL CABLES(4CX4 Sq.mm)
15 11 KV CROSS-LINKED POLYETHYLENE (XLPE) IN- 230 - 252
SULATED POWER CABLES (11 KV, 3CX185 Sq.mm, HT
Power Cable)
16 200 AMP LT DISTRIBUTION KIOSK 253 - 270
17 100 Amp. DISTRIBUTION KIOSK SUITABLE 271 - 276
FORUnderground CABLE
18 11KV 45 KN PIN (COMPOSITE POLYMER INSULA- 277 - 296
TOR)
19 11KV 45 KN T&C TYPE (COMPOSITE POLY- 297 - 307
MER INSULATOR)
20 11 KV 45 KN DISC INSULATORS “B&S” TYPE 307 - 316
(PORCELAIN)
21 11 KV 45 KN DISC INSULATORS “T&C” TYPE 307 - 316
(PORCELAIN)
22 L.T. PIN INSULATORS 307 - 316
23 L.T. SHACKLE INSULATORS 317 – 329
24 11 KV GUY (STAY) INSULATORS 317 – 329
25 GALVANISED M.S FORGED PINS FOR 11 KV 329 - 338
PININSULATORS
26 GALVANISED M.S FORGED L.T. PINS 329 - 338

27 H/W FITTING FOR L.T. SHACKLE 339 - 348

28 45KN, B&S TYPE H/W FOR DISC INSULATOR 349 - 357

29 45KN, T&C TYPE H/W FOR DISC INSULATOR 349 - 357

30 SUSPENSION CLAMP & EYE HOOK WITH PCC POLE 358 - 377
CLAMP (NFC)
31 DEAD END (ANCHOR) CLAMP & EYE HOOK WITH 358 - 377
PCCPOLE CLAMP (NFC)
32 L.T. INSULATION PIERCING CONNECTORS 378 - 393
(NFC)TYPE-A
33 L.T. INSULATION PIERCING CONNECTORS 378 - 393
(NFC)TYPE-B
34 GALVANISED STEEL STAY SETS OF 394 - 405
SIZE16X1800MM
35 11 KV HORN GAP FUSE SETS WITH 1X24 KV 406 - 426
POSTINSULATORS
36 M.S.ROD TYPE EARTHING SET WITH CLAMPS AND 427 - 433
G.I.WIRE
37 HOT DIP GALVANISED STEEL STAY WIRE dia 434 - 441
7/3.15mm (7/10 SWG)
38 G.S. EARTH WIRE 8 SWG 442 – 448
39 11KV, 400 AMP. ISOLATORS WITH POST INSULA- 449 – 477
TORSWITHOUT EARTH BLADE
40 MIP METER BOX 478 – 493
41 P.G CLAMP FOR DOG 494 – 501
42 P.G CLAMP FOR RABBIT 494 – 501
43 HEAT SHRINKABLE TYPE CABLE JOINTING AND 502 - 529
TERMINATION KITS FOR 11 KV XLPE CABLES
44 DANGER LABEL/ PLATES 530 - 535
45 ALUMINUM LUGS 536 - 538
46 12 KV O/D VCB KIOSKS 539- 579
47 MS FLAT OF SIZE 50X6MM 580 - 584
48 M.S.BOLTS & NUTS OF ASSORTED SIZE 585-594
49 SUB-STATION STRUCTURE FOR MOUNTING OF 595-600
11/0.4KV TRANSFORMERS ON DOUBLE POLE
50 11 KV LINE DP 595-600
51 1.8 METRE LONG MS CHANNEL BRACKET WITH 595-600
CLAMP
52 1.4 METRE LONG MS CHANNEL BRACKET WITH 595-600
CLAMP
53 33 KV SINGLE CIRCUIT UN-GALVANISED STEEL 601- 608
LAT TICE STRUCTURES 36’ LONG ALO NG WITH
ONE 33 KVCROSS ARMS (CHANNEL) ONE TOP HAM-
PER & 48 NOS.MS BOLTS WITH NUTS
54 11 KV CROSS ARM (ANGLE) WITH CLAMP AND 608 - 615
TOP HAMPER
55 L.T. CROSS ARM (600 MM) WITH CLAMP 608-615
56 MATERIAL SPECIFICATIONS FOR SPV 616-624
*Note
 Packing material of all the equipment’s shall be retained by the Contractor.
 Marking of respective item shall be declared at the time of GTP approval.
 Type Test shall be valid as per CEA guidelines. In following equipment’s, the valid type test
period shall be as below, For other equipment not covered in below table validity period will
be 5 Years

Name of Equipment Periodicity as specified in

Guidelines issued by CEA(in
Years)
Circuit Breaker 10
Isolator 10
Light Arrestor 10
Instrument Transformer 7
Cables 10
Associates Joints of cable 10
Capacitors 10
Conductors & Earth wire 10
Insulators (Porcelain/Glass) 10
Transmission line insulator
hardware fittings and accessories 7
for conductor and ground wire
TECHNICAL SPECIFICATION FOR SUPPLY OF 25 KVA 11/0.433 KV THREE PHASE
ALUMINIUM WOUND ENERGY EFFICIENT LEVEL-2 (STAR-1) COMPLETELY SELF
PROTECTED (CSP) DISTRIBUTION TRANSFORMERS WITH PROVISION OF LT
BUSHING BOX

1. SCOPE:

This specification covers the design, engineering, manufacture, assembly, inspection and
testing at manufacturer’s works before supply and delivery at site of Oil immersed, Oil Natural Air
Natural (ONAN) outdoor type 11KV/433 V, three phase, 50 Hz, outdoor Type, Aluminum Wound
Energy Efficient Level-2 (Star-1) CSP Distribution Transformers of 25 KVA ratings, complete with
fittings and accessories with provision of LT Bushing Box for use in Distribution System.

1.1 The Equipment Offered shall be complete with all parts necessary for their effective and trou-
ble-free operation. Such parts will be deemed to be within the scope of the supply irrespective of
whether they are specifically indicated in the commercial order or not.

1.1.1 It is not the intent to specify herein complete details of design and construction. The equip-
ment offered shall conform to the relevant standards and be of high quality, sturdy, robust andof
good design and workmanship complete in all respects and capable to perform continuous and sat-
isfactory operations in the actual service conditions at site and shall have sufficiently long life in
service as per statutory requirements. In actual practice, notwithstanding any anomalies, discrepan-
cies, omissions, incompleteness, etc. in these specifications and attached drawings, the design and
constructional aspects, including materials and dimensions, will be subject to good engineering
practice in conformity with the required quality of the product, and to such tolerances, allowances
and requirements for clearances etc. as are necessary by virtue of various stipulation in that respect
in the relevant Indian Standards, IEC standards, I.E. Rules, I.E Act and other statutory provisions.

1.2 The Manufacturer/supplier shall bind himself to abide by these considerations to the entire
satisfaction of the Purchaser and will be required to adjust such details at no extra cost to the purchaser
over and above the tendered rates and prices.

1.3 Tolerances on all the dimensions shall be in accordance with provisions made in the relevant
Indian/IEC standards and in these specifications. Otherwise the same will be governed by good engi-
neering practice in conformity with required quality of the product.

2. APPLICABLE STANDARDS:

Unless otherwise modified in the specifications, the Distribution Transformers, including

various accessories, shall generally comply with the following Indian Standards/REC Specifica-
tions. The standard(s) shall be with latest amendment, if any, from time to time.
Note: Wherever ISS are mentioned, equivalent or better International standards are also acceptable:

Page 1 of 623
Sr. International &
No Specification Details about internationally
. recognized standards.
IS: 1180 (PART- Specifications for outdoor type oil im- IS: 1180
1 I)/2014 mersed distribution transformers upto (PART-I)/2014
and including 2500 KVA, 33 KV Class.
Guide for loading of oil immersed
2 IS:6600/1978 IEC 76
Transformers
BS 148, D-1473, D-
3 IS:335/2018 New insulation oils for Transformers 1533 – 1934, IEC PUB
296
Dimension of Porcelain parts & Metal parts
IS:3347 (Part-I/
4 for Transformer DIN 42531 to 33
Sec. 1 & 2)
bushing (1.1 KV).
Dimensions of Porcelain (parts & Metal
IS:3347 (PART-III / parts) for Transformer bushing for use in
5 Sec-1 & 2) & heavily polluted atmosphere 12/17.5
IS:8603:2008 KV,24 KV and 36KV (amalgamating 8603
(Part1, 2 & 3):1977)
Porcelain Transformer Bushings for low
6 IS:7421
voltage – upto 1 KV.
IS:2099/1986 Porcelain Transformer bushing for AC
7
volts above 1000 volts.
IS:3639/1966
8 Fittings & accessories for Transformers
Code of practice for maintenance &
9 IS:1866/1978
supervision of insulating oil in service.
10 IS:5484 Specifications for Aluminium wire rods. ASTM B – 233
11 IS:9335 Specifications for insulating kraft paper. IEC 554
IS:1576 Specifications for solid insulating press
12 IEC 641
Boards for electrical purposes.
IS:616 (Part I) Specification for paper covered Aluminium
13
round conductors
IS:6162(Part II) Specification for paper covered Aluminium
14
rectangular conductors
IS:104 Ready mixed paint, brushing zinc
15
chromate, painting
IS:649 Testing of steel sheets and strips for
16
magnetic circuits.
IS:2362 Determination of water content in oil for
17
porcelain bushing transformers.
Dimensions for clamping arrangements for
18 IS: 4257
bushings.
Rectangular conductor for electrical
19 IS 6160
machines.

Page 2 of 623
IS:10028 Selection, Installation and maintenance of
20
transformers
21 IS: 3401 Silica gel
- REC Specification
No. 2
- REC Specification
22
No. 39/1993
- CEA Specification
Chapter 4
Testing of specific resistance of electrical
23 IS 6103
insulating liquids
Method of test for power factor and
24 IS 6262 dielectric constant of electrical insulating
liquids
Determination of electrical strength of
25 IS 6792
insulating oil
26 IS -2026 Specification for Power Transformers
Low Voltage Switchgear and Control Gear
27 IS/IEC 60947-2:2003
– Part 2: Circuit Breaker
High Voltage Fuses : Part 2: Expulsion
28 IS:9385 Part-II:1980
and similar fuses
29 IS:1554-1988 PVC insulated (heavy duty) electric cables
Specification for Conductors for Insulated
30 IS:8130-1984
Electric Cables and Flexible Cords

Note:- Besides above changes, the technical parameters of the specifications wherever are deviating
from the IS:1180 (Part-I/2014), the same shall be in accordance with IS:1180 (Part-I/2014) and its
latest amendments, if any and the changes where the IS:1180 (Part-I/2014) is silent for technical pa-
rameters, same shall be applicable as per Discom specification

Material conforming to other internationally accepted standards, which ensure equal or higher
quality than the standards mentioned above would also be acceptable. In case the Manufacturers who
wish to offer material conforming to the other standards, salient points of difference between the stand-
ards adopted and the specific standards shall be clearly brought out in relevant schedule. Four copies
of such standards with authentic English Translations shall be furnished along with the offer.

3. SERVICE CONDITIONS:

i) Peak ambient temperature : 50°C

ii) Minimum Ambient Temperature in shade : -5°C
iii) Maximum average ambient temp. in a 24 hours period in shade : 45°C

Page 3 of 623
iv) Maximum yearly weighted average ambient temperature : 35°C
v) Maximum temperature attainable by an object exposed to sun : 60°C
vi) Maximum relative humidity : 100 %
vii) Average number of thunder storm days per annum : 40
viii) Average number of rainy days per annum : 120
ix) Average annual rainfall : 15-100 cm
x) Number of months of tropical monsoon conditions : 4 Months
xi) Maximum wind pressure : 195 Kg/mt²
xii) Altitudes : Not exceeding
: 1000 mtrs.
The equipment shall be for use in moderately hot and humid tropical climate, conducive to
rust and fungus growth.

4. PRINCIPAL PARAMETERS:

The Transformers shall be suitable for outdoor installation with three phase 50 Hz 11 KV
system in which the neutral is effectively earthed and should be suitable for outdoor service as step
down transformers under fluctuations in supply voltage upto plus 10% to minus (-) 15 % permissi-
ble under Indian Electricity Act and rules there under.

The transformer shall confirm to the following specific parameters:

i) Continuous rated capacity : 25 KVA
ii) System Voltage (Max.) : 12 KV
iii) Rated HT voltage : 11 KV
iv) Rated LT voltage : 433 V (P-P) / 250 V (P-N)
(v) Line current HV : 1.31 A
(Vi) Line current LV : 33.33 A
vii) Frequency : 50 Hz
viii) No. pf phases : THREE
ix) Primary connection (HT) : DELTA
x) Secondary connection (LT) : STAR
xi) Vector Group : Dyn-11
xii) Percentage impedance at 75°C : 4.5 %
xiii) Taps (off circuits) : TAPS ARE NOT REQUIRED.
xiv) Type of cooling : ON AN
xv) Fault level of the system : 750 MVA

Primary winding shall be DELTA connected and the secondary winding shall be STAR
connected (vector symbol Dyn-11), so as to produce a positive displacement of 30° from the primary

Page 4 of 623
to the secondary vectors of the same phase. The neutral of the secondary winding shall be brought out
to a separate insulated terminal. The transformers shall be Aluminium Wound.

The transformers shall be designed and constructed to withstand without damage the thermal
and dynamic stresses of an external short circuit. The manufacturer/supplier shall furnish all relevant
design data and calculations in support of having fulfilled this requirement as stipulated in IS:2026
(Part-I)

5. NO LOAD VOLATGE RATIO:

The No load voltage ratio(s) shall be 11000/ 433 Volts.

6. THE LOSSES:

The max. allowable losses at rated voltage and frequency and at 75 Deg. C. shall be as under:

Total losses (watts) at 75 Deg. Total losses (watts) at 75 Deg.

Rating (KVA)
C at 50% loading (Max.) C at 100% loading (Max.)
25 190 635

The above specified loss values are maximum guaranteed, as per Energy Efficient level-2,
without any positive tolerance. In case the actual loss values exceed the above guaranteed values, the
transformers shall be rejected at the risk, cost and responsibility of the supplier.

7. TEMPERATURE RISE:

The temperature rises over ambient shall not exceed the limits given below:

i) Top oil temperature rise measured by thermometer 35 Deg. C.

ii) Winding temperature rise measured by resistance method 40 Deg. C.

Temperature rise test shall be conducted on Maximum measured total losses (No load at rated exci-
tation + Load loss at max. current tap at 75 oC) at 100% loading shall be supplied during temperature
rise test.

Page 5 of 623
The transformer shall be capable of giving continuous rated output without exceeding the specified
temperature rise. Bids not meeting the above limits of temperature rise will be treated as non respon-
sive.

The Hot spot temperature at annual weighted average ambient temperature of 35 o C shall not
exceed 98o C, when calculated as per IS: 2026 (Part-II).

However, the transformer shall be designed for class ‘A’ insulation.

8. UNBALANCE CURRENT:

The maximum value of unbalance current in transformers shall not exceed 2% of full load
current.

9. IMPEDANCE:

The percentage impedance at rated current and at 75°C shall be 4.5 % with (+/-) 10 % toler-
ance.

10. TAPPINGS: NO TAPS ARE TO BE PROVIDED IN THESE TRANSFORMERS.

11. FREQUENCY:

Transformers shall be designed for normal frequency of 50 Hz, but shall be capable of giving
the rated output with the variation of (+/-) 3 % from the rated frequency.

12. ELECTRICAL CLEARANCES:

(A) EXTERNAL (IN AIR)

Minimum external electrical clearances after mounting the bimetallic terminal connectors in
position shall be maintained, as under, however positive tolerance shall be acceptable without any
ceiling.

Voltage Medium Clearance

Page 6 of 623
Phase to phase Phase to earth
11000 Volt AIR 255 mm 140 mm
433 Volt AIR 75 mm 40 mm

B) INTERNAL (IN OIL):

The following minimum internal clearances shall be maintained as per details givenhere-
under:

PARTICULARS 25 KVA
a) Between HT outside surface & tank inside (non bushing side) 25 mm
b) Between HT outside surface & tank inside (HV bushing side) 40 mm
c) Between HT outside surface & tank inside (LV bushing side) 40 mm
d) Between HV windings & yokes (end insulation) 20 mm
e) Between LV windings to core (Bare conductor) 3.5 mm
f) From top of yoke to inside of top cover of tank (with gasket) 200 mm
g) Between LT/HT winding (Radial bare conductor Clearance) 11 mm
h) Phase to Phase Clearance between HV limbs 10 mm

The aforesaid external and internal clearances are minimum clearances and no negative
tolerance on these clearances shall be allowed.

13. TEST VOLTAGE:

Transformers shall be capable of withstanding the power frequency and impulse test voltage
prescribed below:

Nominal system Highest system Impulse withstand Power frequency test

Voltage (RMS) voltage (RMS) voltage voltage in (RMS)
11 KV 12 KV 75 KVp minimum 28 KV
0.433 KV ---- ---- 3 KV

Page 7 of 623
The Transformer shall have fully insulated windings designed for the above impulse level

14. HEAT DISSIPATION (COOLING) / RADIATOR CALCULATIONS & E T R / PSR

(ELLIPTICAL TUBE RADIATORS/ PRESS STEEL RADIATOR) PLACEMENT:

The transformers shall be capable of giving a continuous output without exceeding the speci-
fied temperature rise. Radiator shall preferably be provided on non LV-bushing side of the transform-
ers tank. Both fin type (PSR) and elliptical tube radiators are accepted. It should be fixed atright angle
to the side and not diagonally. The radiator fins should be made of 1.25mm thick M.S. sheet. The
header pipe connecting radiator bank to the tank shall be rectangular in shape with approximate size
of 100x20 mm. alternatively round pipe of dia 32 mm can also be used ` for
connecting the radiator bank to the tank. The placement of top header pipe to the tank body shall be
above the top of yoke, to facilitate cooling for hot oil sump over top yoke.

Cooling area of the tank/radiators should be sufficient to dissipate the guaranteed losses sat-
isfactorily. Necessary calculations in this regard shall be furnished by the Manufacturer with their
tender. For the purpose of heat dissipation calculations, the following criteria shall be adopted:

Plain surface of tank – 500 W / m2

(Note: The area of top/bottom tank surface, headers, HV/LV bushing pocket and conservator
shall not be considered for purpose of above calculations).

15. WINDING AND INSULATION:

i) MATERIALS:

Super Enamelled/Double paper covered aluminium conductors shall be used for 11 KV class
transformers of 25 KVA rating. The covering shall conform to IS:6162 (part I & II).

ii) CONSTRUCTION:

The High-tension windings shall be concentric with the Low-tension windings. The Arrange-
ment of the windings shall be robust in electrical and mechanical construction and shall permit free
circulation of oil and avoid hot spots. The LT conductor shall be rectangular in shape. Two layer of
electrical grade insulation Epoxy Dotted craft paper of 2 mil thickness or one layer of min. 4 mil
thickness shall be used for interlayer insulation both for HV and LV Coils. Insulation

Page 8 of 623
cylinder made from electric grade pre-compressed board(s) having minimum total thickness of 1.5
mm shall be used between HV and LV windings. Alternatively 20 mil pressphan paper making thick-
ness of the cylinder 1.5 mm having similar electrical properties may also be used.

FOR PHASE BARRIER, 2 NOS. OF 1 MM THICK PRESS BOARD SHALL BE USED FOR COVERING THE
TIE RODS. BESIDES, TIE RODS SHALL BE COVERED BY SRBP TUBES OF SUITABLE SIZE.

2mm press board shall be used for base support insulation and core clamping channel insula-
tion. For bottom and top yoke insulation, only PC Board of min. 2 mm thickness will be used. Also,
vertical spacers between HV and LV coils and radial spacers (tickleys)/blocks etc. shall be of PC
Board only.

A tolerance of upto plus minus 1% shall be permissible on ID and OD and axial length of HV
and LV coils. However, the above tolerances are subject to maintaining the min. required clearances.
The material and thickness of various insulation provided for phase barrier, foot plate insulation, yoke
insulation and core clamp insulation shall be clearly indicated in the drawing and in any case shall
not be inferior to those used in type tested transformers.

Minimum Nos. of coils on HV side shall be 2 (Two) per phase for 25 KVA rating transformers.
Dovetailed shaped radial spacers shall be placed between HV coil sections, suitably – locked with
vertical spacers around the circumference of the coils. The number of such spacers shall be 2 (Two).

In case of wound core one HV coil is accepted.

Current Density
The current density for HV and LV conductor shall not exceed the value given hereunder:

Rating Current density in Amp./Sq.2

HV winding LV winding
25 KVA
1.35 1.60

iii) INSULATION MATERIAL:

Electrical grade insulating Kraft paper of only Triveni / Ballarpur / Padamjee shall be used.
Press Board used shall be of senapathy whitely / Raman make. Perma wood or haldu wood blocks
shall be used for Top and Bottom yoke insulation.

Page 9 of 623
iv) CONNECTIONS AND TERMINATIONS:

A) HV Winding: The following method shall be adopted for taking out HV connections-

a) The coil series connections shall be made by soldering / brazing only, after completely removing
the insulation from the ends.

B) STARTING AND FINISHING LEADS OF HT COILS SHALL BE COVERED WITH EMPIRE SLEEVE(S) OF
PROPER SIZE. THESE LEADS SHOULD BE CLAMPED WITH THE BODY OF THE WINDING WITH THE
HELP OF COTTON TWINE DURING MANUFACTURE OF THE COILS .

c) All delta leads from the HT coils as well as HT line leads shall be taken out through multiple
paper covered (MPC) copper wires of sufficient cross section area to impart the desired me-
chanical strength. The current density in HV lead wire shall not exceed 0.8 A/mm². These
lead wires shall be provided with multi layer paper insulation of minimum 1.0 mm thickness
i.e. minimum increase in diameter due to paper insulation shall not be less than 2 mm. The
layer of glass sleeves/ glass tape shall also be provided on the delta MPC wire and it should
be further covered with minimum 12 mm dia SRBP tube. The SRBP tube shall be extended
in such a way that it is entered upto 50% of bushing height.

d) All the above leads shall then be clamped tightly with cotton twine directly on to the special
frame/bracket making “Pie” shape connection. This structure could be made up of Bakelite/
Permalli wood/laminated PC board flats, having minimum size of 25x4.5 mm for 25 KVA
Transformers. Line leads leading to the HV bushing terminals shall be directly clamped to the
horizontal support bar of the “Pie” structure so that any tension which may develop in the HT
leads due to jerks or at the time of making the connection, is not passed to the HT coils.

e) Delta joint shall be made by brazing only. One end of HT Fuse is to be connected to Delta
joint by brazing only and the other end of HT Fuse is to be connected to Bushing Rod through
Nut-Bolt method/brazing.

B) LV Winding:

A) THE LV CONNECTION SHALL BE TAKEN OUT BY CUT ON THE TOP YOKE CHANNEL DULYREIN -
FORCED TO COMPENSATE FOR THE MECHANICAL STRENGTH.

b) THE LAYERS IN LT COIL MAY BE EITHER EVEN OR ODD IN NUMBERS BUT MINIMUM LAYERS
SHALL BE TWO.
c) LV star point shall be formed of aluminium flat of sufficient strength. Leads
from winding shall be connected to the flat by brazing.

Page 10 of 623
D) FIRM CONNECTION OF LT WINDING TO BUSHING SHALL BE MADE OF ADEQUATE SIZE OF “L
SHAPE FLAT”. CONNECTION OF LT COILS TO L SHAPE FLAT SHALL BE BY BRAZING ONLY.

E) “L” SHAPE FLAT SHALL BE CLAMPED TO LV BUSHING METAL PART(S) BY USING NUT, LOCK NUT
AND WASHER.

f) Neutral of the Secondary winding (LV) shall be brought out to a separate insulated bushing.

G) FOR ALUMINIUM WINDINGS, L&T, ALKAPEE ALUMINIUM BRAZING RODS WITH SUITABLE

FLUX WILL BE USED.

16. CORE CONSTRUCTION & CORE COIL ASSEMBLY DETAILS:

A. CRGO CORE:

(i) The core shall be stack/wound type of generally high grade cold rolled grain oriented annealed
steel laminations, having low loss and good grain properties, coated with hot oil proof insulation,
bolted together to the frames firmly to prevent vibration or noise. All core clamping bolts shall be
effectively insulated. The complete design of core must ensure the permanency of the core losses with
continuous working of the transformers. The value of the flux density allowed in the designs and
grade of laminations used shall be clearly stated in the offer, along with the curves. The transformer
core shall be constructed out of the prime class of materials. CRGO/ amorphous Lamination used
shall be of prime grade and not second grade steel laminations.

(ii) It will be mandatory for all the transformer manufacturers to use only PRIME grade CRGO
Laminations with specific loss of 0.89 watt per kg. at 1.5 Tesla or any other combination of better
grades with any thickness subject to maximum specific loss of 0.89 watt per kg. at 1.5 Tesla will
also be acceptable. The manufacturer shall furnish the core loss (watt/Kg.) and power (VA/Kg)
curves of the laminations used. The core shall be properly stress relieved by annealing in inert
atmosphere. The transformer shall be suitable for over fluxing (due to combined effect of voltage
and frequency) upto 12.5% without injurious heating. The operating flux density shall be such that
there is a clear safe margin over the fluxing limit of 12.5%.

(iii) Full mitred core construction technique for stack core shall be adopted. Top yoke & bottom
yoke pieces shall all be in one single piece and no cut pieces shall be acceptable. The cross sectional
area of yoke & limb shall be approximately same.

(iv) The transformer core shall not get saturated for any value of V/f ratio to the extent of 115 %
of the rated value of V/f ratio (i.e. 11000/50) due to combined effect of voltage and frequency
without injurious heating at full load conditions. The manufacturer shall furnish necessary design
data in support of this situation.

(v) The flux density at rated voltage and frequency of core and yoke shall not be more than 1.55
Tesla. The Over fluxing shall be limited to 12.5% of rated value and flux density at 112.5% of rated
voltage does not exceeds by 1.9 Tesla. (as per amended IS:1180 (Part-I/2014) Actual core design

Page 11 of 623
along with calculations in support of it should be enclosed with the offer.

The No Load Current (magnetising current) at rated voltage and at 112.5% of rated voltage
shall not exceed the values given below:

Maximum permissible magnetising current in percentage of rated full load current

Rating At 100% rated voltage At 112.5% rated voltage
25 KVA 3.0 6.0

The tolerance on magnetizing current shall be +30% on declared value of magnetizing current as per
IS: 2026.

vi) Core clamping:

i. MS Channel of 75 x 40 x 6 mm min. size shall be used on top and bottom (for stacked core
transformers). Rolling tolerance will be as per IS:1852-1985 with latest amendment.
ii. 2 x 12 mm high tensile bolts to be used in parallel at each end.
iii. Channel on LV side to be reinforced at equidistance, if holes/cutting is done for LT lead
in order to avoid bending of channel.
iv. MS channel shall be painted with varnish or oil-resistant paint.
v. Tie-rods: 4 Nos. of M12 M.S steel rods shall be effectively insulated.
vi. All top and bottom yoke nuts & bolts and tie rods shall be painted with oil and corrosion-
resistant paint and phosphate coated paint for tie rods before use.
vii. Only prime quality CRGO sheets should be used in the transformers and noSecond/Defec-
tive/Scrap CRGO finds way into transformers.

B. AMORPHOUS METAL:

a) The core shall be high quality amorphous ribbons having very low loss formed into wound cores
of rectangular shape, bolted together to the frames firmly to prevent vibration or noise. The complete
design of core must ensure permanency of the core loss with continuous working of the transformers.
The value of the flux density allowed in the design shall be clearly stated in the offer. Curve
showing the properties of the metal shall be attached with the offer.

b) Core Clamping – Amorphous Metal and CRGO wound core Transformers

Page 12 of 623
3. Suitable provision shall be made in the bottom core clamp/bottom plate of the transformer to Arrest
movement of the active part.

c) The transformer core shall be suitable for over fluxing due to combined effect of voltage and fre-
quency upto 12.5% without injurious heating at full load conditions and shall not get saturated. The
Manufacturer shall furnish necessary design data in support of this situation.

d) Flux density should not be more than 1.38 Tesla for Amorphous core. No load current shall not
exceed 3% of full load current and will be measured by energizing the transformer at 433 volts
50 c/s on the secondary. Increase of voltage of 433 volts by 12.5% shall not increase the no load
current disproportionately high and shall not exceed i.e., 6%. Test for magnetic balance by connecting
the LV phase by phase to rated phase voltage and measurement of an, bn, cn voltage will be carried
out.

NOTE: Equal Weightage shall be given to the transformers with Amorphous metal core and
CRGO.

(C) CORE-COIL ASSEMBLY:

The core joints shall be interleaved and with full mitre design, as mentioned above. Ample
provision for free circulation of oil in the radial gap between the core & LV coils shall be made. Eyes
or lugs of sufficient size shall be provided for lifting core and winding assembly out of the tank. The
core shall be effectively earthed through copper earthing Foil of 25 mm width & 1 mm thickness
bolted on core frame channels after removing the channel paint.

For top yoke channels, if cut or holes are made for taking LV connections, suitable reinforce-
ment to channels shall be made by providing adequate size of MS Flat of the thickness not less than
6 mm.

On the core-coil assembly, core clamping channels, tie rods, core studs, spacers, assembly
base supports, etc. shall be provided as per details given hereunder:

Sr. Item Particulars

No.
a) Tie rods Minimum 4 Nos. of 12 mm each properly insulated and covered with SRBP
tubes. Tie rods shall also be provided with lock nuts.
b) Core studs Minimum 4 Nos. of 12 mm each properly insulated and covered with SRBP
tubes. The core studs shall also be provided with lock nuts.

Page 13 of 623
c) Spacers Minimum 4 Nos. dovetail type with min. peripheral coverage of 30%.

d) Support of core 2 Nos. MS channels OF 75x40 mm.

assembly base
e) Channels for 4 MS Channels of 75 x 40 mm size (applicable for CRGO transformers)
clamping core
coil assembly

Guides on all the four sides shall be provided to prevent shifting of the active parts and thereby
accidental touching the tank. Alternatively boss nut arrangement at the top of core coil assembly to
lock the same with the transformer tank be provided.
The assembly fixing boss nut(s) are to be welded, 20-30 mm off the centre line (and diago-
nally) of the tanks, so that assembly shifting during transport etc. is prevented. M S Channel, tie Rods
etc should be painted with hot oil and corrosion resistant paint after phospating.

All core-coil assembly shall be punched on core channel / a identity plate welded on core
channel with following details:

1. Name of Supplier:
2. Order / TN No:
3. Rating:

In case if above marking is not found on the core assembly of physically opened transformer
selected for physical verification during final inspection then no further inspection shall be carried
out and re-inspection charges shall be payable by the supplier.

Note: 1. If the core is rusted or holes are found during testing at CTL, then the lot may be rejected.
2. If the same observation is repeated, then apart from rejecting the lot, firm’s balance order
would be cancelled and such firms shall not be awarded any order for one year or in next
tender of tendered rating to be opened/finalized whichever is later.

17. TRANSFORMER TANK:

Transformer tank shall be rectangular in shape, robust in construction and with adequate
strength to withstand the pressures developed at the time of severe fault conditions. The tank body
shall be suitably stiffened with two stiffeners of size 50x50x6 mm angle. The edge of the angle shall
be continuously welded full length with the tank cover body as per drawing enclosed at Annexure-A.
The tank sheet shall be electrically continuous welded both from inside and outside to impart proper
mechanical strength and to plug leakage of oil. All joints of tank and fittings shall be oil tight and no

Page 14 of 623
bulging shall occur during service. The tank design shall be such that the core and windings can be
lifted freely. The tank plates shall be of such strength that the complete transformer when filled with
oil may be lifted bodily by means of lifting lugs provided. All the welding shall be continuous. The
top cover plate shall be sloping down by more than 10 mm, opposite LV bushings side. The top cover
edge should be extended by Min. 30 mm in such a manner to cover gasket each side and it should be
bent at Min. 15° angle. Accordingly length of the lifting hooks shall be extended. The top cover shall
have no cut at point of lifting lug. No negative tolerance in the tank dimensions is acceptable in actual
supply. There should be no welding on corners (two ‘C’ shape sections be welded in such a way that
the joint of the cover should be at the centre of the tank on non-bushing side). The bottom plate shall
be extended at least by 5 mm outside on all sides to facilitate proper welding with the vertical tank
walls as per drawing enclosed at Annexure-A. No grinding at welding portion is permissible. No joints
in its bottom and top cover will be allowed. LV Bushing pocket shall be continuously welded on all
side from both inside and outside on the tank wall.

B.(i) Minimum size of MS Sections to be used in construction of transformer tanks shall be as

under:

Sr. No. ITEMS 25 KVA

1 Tank Cover plate thickness (mm) 5.0
2 Tank Sides wall thickness (mm) 3.15
3 Tank bottom plate thickness (mm) 5.0
4 Conservator body (mm) 2.0
5 Detachable Conservator side Cover N.A.
6 No. of stiffeners (To be welded on four side of the tank in the 2
angle forms inverted “L”)
7 Size of M. S. stiffener (mm) 50x50x6 angle
8 Tank Top flange size (mm) 50 x 6 Flat

9 Cover Bolt Size ( Stainless Steel only) M10/ 3/8 x 1.5”

(Fixed Size)
10 Cover Bolt spacings (Maximum) 75 mm
11 Lifting lugs 2 Nos.
8t mm flat
12 Tank Base Channel of size 75x40 mm (weight = 7.14
2 (75 x 40 x 6 mm)
Kg./mtr.) ISMC Type

NOTE:

Page 15 of 623
a) Each cover bolt shall be complete with two flat washers, one nut and one spring
washer.
b) Tank base channel shall be continuous welded with tank.

The 12 Nos. nuts & bolts (4 Nos. each on length sides and 2 Nos. each on width sides of tank
body) to be tag welded on top cover/tank body of transformer.

The 04 Nos. Anti Theft Fasteners shall be provided - one each on all four sides in centre of
body of transformer.

TWO HOLES SHALL BE PROVIDED – ONE ON TOP COVER AND OTHER ON COLLAR OF TRANSFORMER
TO FACILITATE PROVIDING OF 2 NOS. POLY-CARBONATE SEALS ON LONGITUDINAL SIDE.

The above mentioned M S sections shall be subject to tolerance as per ISS.

B.(ii) MEASUREMENT OF SHEET THICKNESS OF TRANSFORMER TANK:

The following measurements shall be carried out at Central Testing Lab (CTL), JVVNL,
Jaipur on the supplies of distribution transformers:

Measurement of Transformer Tank Thickness shall be done as follows:-

1. Top Cover At 2 places to be measured & average is to be taken.

2. Bottom Cover -do-
3. Side Wall(s) On all four sides (average is to be taken)

 The nominal value of sheet thickness will be considered as mentioned in the Specification.
 Rolling tolerance will be as per ISS:1852-1985 with latest amendment and no penalty will be
charged on such measured thickness till tolerance limit of ISS.

 Sheet thickness of transformer tank for Distribution Transformers as per relevant tender
specification is as under for ready reference:

Sr. Rating Top Cover Bottom Side of Tank

No. (mm) Cover (mm) (mm)

Page 16 of 623
1 25 KVA Three Phase 5.0 5.0 3.15

The sheet thickness measurements will be carried out on all those sample transformers which
are tested in CTL and test results will be applicable to the respective sub-lot or part thereof from which
the sample is drawn.

(c) Lifting Lugs: Two Nos. welded heavy duty lifting lugs of MS plate of 8 mm thickness, suitably
reinforced by extended vertical supporting edge of same thickness in one piece having size 125 mm
width and 125 mm length, these shall be so extended that cutting of bent plate is not required.

(d) Top cover gasket Nut & Bolt:

i) The gasket of provided in between top cover plate and tank shall be of min. 6 mm thick
neoprene rubberized oil resistant cork sheets conforming to type B or C as per IS 4253
part II.
ii) Stainless Steel Nut bolts (as per IS:1180 (Part-1/2014)) shall be of size M 10 x 40 mm /
3/8x1.5” long with two flat washers, suitably spaced (as specified) to press the cover.
iii) Height of the tank shall be such that minimum clear height of 125 mm for 25 KVA rating
is achieved between top of yoke and under side of the tank cover (with gasket in place).
iv) All screws, nuts, bolts and fasteners used in transformers should be of stainless steel.
v) All sealing washers / gaskets shall be made of oil and heat resistant neoprene or
nitrile rubber. Gaskets made of natural rubber sheet are not permissible. The
minimum thickness of gaskets shall not be less than 6 mm for tank cover and 4 mm for
HT/LT gasket washers.
vi) New cork/ Talbros make neoprene/nitrile based rubberized cork sheet – grade RC-70-C
shall only be used as gasket material.
vii) The 12 Nos. nuts & bolts (4 Nos each on length sides & 2 nos each on widths sides of tank
body) to be tag welded on top cover / tank body of the transformer.
viii) The 04 Nos. Anti Theft Fasteners shall be provided - one each on all four sides in centre
of body of transformer. Two holes shall be provided – one on top cover and other on col-
lar of transformer to facilitate providing of 2 Nos. poly-carbonate seals on longitudinal
side.

e) Tank shall be reinforced by continuously welded angle on all the four sides of the walls, on the
edge of tank, as specified above. The permanent deflection shall not be more than 5 mm upto 750 mm
length and 6.5 mm upto 1250 mm length when transformer tank without oil is subjected to the vacuum
of 250 mm of Mercury.

f). PAINTING & FINISHING:

Page 17 of 623
Steel surface shall be prepared by sand/shot blast or chemical cleaning including phosphating,
as per IS:3618. Inside of tank shall be painted with varnish or oil resistance paint. For external surface,
one coat of thermo-setting powder paint or one coat of epoxy primer followed by 2 coat of polyure-
thane base paint of olive green colour confirming to Shade No. 220 of IS:5-1961 to be appliedin order
to distinguish of star label transformer. The paint thickness for normal to medium corrosive atmos-
phere is as per IS:1180 (Part-1/2014).

The requirement for the dry type film thickness (DFT) of paint and the materials to
be used shall be as given below.
Sl. Paint Type Area to be No. of Total Dry film
No. Painted coats thickness (min.)

1. Thermosetting Paint Inside 01 30 microns

Outside 01 60 microns
2. Liquid Paint
a) Epoxy( Primer) Outside 01 30 microns

b) Polyurethene base (Finish

Outside 02 25 microns each
coat)

c) Heat resistance paint (Hot oil

proof Paint) Inside 01 35/10 microns

18. FITTINGS & ACCESSORIES:

The following standard fittings shall be provided on each transformer:

a) Earthing terminals of M10x40mm/3/8x1.5” with tinned lugs and symbol – (2 Nos.)

b) Lifting lugs – (2 Nos. for main tank).
c) Rating and terminal marking plate shall be non-detachable and affixed with Min. 10 rivets (One
in centre of top and bottom and 4 Nos. each on both vertical sides at equal distance), details to
be included in one plate only. The plate shall be of stainless steel/Aluminium only, with details
clearly marked. The base plate of the Rating and terminal marking plate shall be continuously
welded with the tank. Any one corner of the Rating and terminal marking plate is to be sealed
by the inspecting officer. - (1 No.)
d) Bi-metallic terminal connectors on HT bushings and it may be ensured that connectors shall be
fitted before dispatch.
e) Oil level gauge of minimum 150 mm length of prismatic glass, indicating three positions of oil,
marked as follows, shall be provided at centre of the conservator tank:

Page 18 of 623
1) -5 °C - Min.
2) 30 °C - Nor.
3) 90 °C – Max.

f) Free Air Type Breather – (1 No.)

g) Thermometer pocket, 12.5 mm dia with cap shall be provided –– (1 No.)
h) HV BUSHING: These shall be of 17.5 KV/ 250 Amp. Class porcelain/ polycrate with non-
adjustable, single gap type arcing horns – (3 Nos.).
i) LV BUSHING: 1.1 KV/ 250 Amp. Class porcelain/ polycrate (M12 stem) – 4 Nos.
j) Under carriage: For transformers of 25 KVA rating shall conform to REC specifications.
k) Brass rod 12 mm diameter for HT – (3 Nos.)
l) Brass rod 12 mm diameter for LT – (4 Nos.)
m) Pressure Relief Valve of Aluminium body with 1” BSP Thread capable to operate at a pressure
more than 0.4 Kg/cm2 (40 KPa) positive or negative and close at 30 KPa on the top cover of the
transformer tank with Anti-Theft Clamp be welded to safeguard the valve. There shall be mini-
mum gap of 10 mm between PRV Top Surface and Anti-Theft Clamp.
n) Explosion vent: Explosion Vent shall be opening towards ground from LV bushing side with
M. S. mesh having Pipe Diameter of minimum 50 mm with 0.025mm copper shim sheet/ Bake-
lite thick sheet of 0.4mm thick as diaphragm shall be provided on the top of the cover of the
tank such that the pressure released should be directed to the ground & it should be insertedin
the top cover of tank, welded outside & inside of top cover and its pipe shall be connected with
the conservator. Length of the explosion vent should be minimum 700 mm. Nut bolts of flange
of Explosion vent should be tag welded. The vent shall be provided on opposite side of the
circuit breaker operating rod. The other end of the vent pipe shall be guarded with wire meshfor
preventing the entry of worms and nesting. The diaphragm shall burst at a pressure of 0.76 to
0.95 kg/ sq.cm. There shall be minimum 140 mm clearance between live part of HV bushingto
Explosion vent.

o) QR code laminated P touch labels shall be fixed on transformer tank body below the name plate
and on the core coil assembly (on core channel) depicting various technical details such as Name
of manufacturer, rating, Serial no, TN No. etc. QR Code with desired information to be printed
on non-tearable matt finish label and to be covered with transparent label to retain label life for
minimum 20 years. Provision of Sr. No. on QR Code to be affixed on Core Coil Assembly (on
core channel) is optional.

Note: LV/ HV Connectors shall not be the integral part of the bushing stems.

19. CONSERVATOR:

Page 19 of 623
The total inner volume of conservator shall be minimum 10 ltr. for 25KVA transformer. The inside
diameter of the pipe connecting the conservator to a main tank shall be min. of 30 mm and it should be projected
into conservator in such a way that its end is approximately 25 mm above the bottom of conservator so as to
create a sump for collection of impurities. The min. oil level (corresponding to – 5 deg. C.) should be above
the sump level. The connecting pipe from conservator tank to main tank shall have a sloping flap so that oil
falling from pipe shall not fall directly on the active job.

The oil filling hole cap of conservator should be welded with tank body with the help of suitable
inverted ‘U’ shape clamp.

20. FREE AIR TYPE BREATHER:

The breather shall be only from reputed and approved manufacturer and as per the approved
drawing. Inverted ‘U’ shape pipe shall be used for breather. Mounting arrangement of the breather
shall be flanged/threaded type as per details given in the illustrative drawing attached.

21. HV BUSHING TERMINAL DETAILS :

3 Nos. 17.5 KV / 250 A class bushings, conforming to IS:3347 & IS:2099, shall be fitted ona
pocket made on top cover. These pockets shall be such that the HV bushing is tilted more towards the
HV side. The bushing of R & B phases may also be tilted sidewise to maintain the required electrical
clearances.

The clamping ring of HV bushing shall be of galvanised MS Sheet having minimum thickness
of 1.6 mm. The total weight of all the 12 aluminium caste member of HV bushing shall not be less
than 210 grams.

The inner porcelain portion of bushings shall be projecting approx. 50% of the length inside
the conical pocket. HT bushing (s) mounting bolts should be tag welded.

The arcing horn(s) shall be single gap and fixed type. HV bushings shall be of reputed make
such as BEPCO, JAYSHREE, WSI, SESHASAYEE, JAIPUR GLASS, BPPL Bikaner, Agarwal salt
Co. Bikaner, Bais Sanitary Works, Bikaner, Krishna Ceramics, Nasirabad, ADPRO, SHINE or any
other make - approved by the purchaser. The HV bushings shall generally conform to IS: 3347 and
IS: 2099. Embossing showing the manufacturer’s name and month & year of manufacture shall be
clearly visible on HV bushings, even after fixing on transformer(s).

As mentioned earlier, suitable bi-metallic connectors shall be provided in lieu of ‘Note’ at

page 14; Cl.18 (i), having capacity of about 1.5 times the rated current of the transformer.

22. LV BUSHING TERMINAL DETAILS:

Page 20 of 623
LV Bushing side shall be opposite to the HV Bushing side. 4 Nos. LV Bushings (1.1 KV/ 250
A) shall be mounted on a special pocket on the tank wall. Projection of the LV pocket shall be such
that inner portion of the LV stem shall not project more than 20 mm inside the tank, to facilitate
unhindered lifting of the core coil assembly. Bushing stem of M12 size shall be of brass. Rest of the
components shall conform to the requirement of IS:3347 (Part I/section 2). The LV bushings shall be
of reputed make such as JSI, JAIPUR GLASS, BPPL Bikaner, Baid Sanitary Works, Bikaner,
Agarwal salt Co. Bikaner, CJI, Genesis, ADPRO or any other make approved by the purchaser. The
LV bushings shall generally conform to IS: 3347 and IS: 7421.

Provision of LV bushing with tamper proof LT bushing Protection Box:-

(i) The LV bushings are provided on sheet metal pocket on the side wall of the tank with
tamper proof LT bushing protection box as detailed below:-

(ii) The outdoor type L.T. Bushings Protection Box to be provided along with one L.T. Porce-
lain Bushing with metal part for separate ground earthing connection. The box is to be
provided to cover the L.T. bushings as shown in the drawing attached with the TS.

The Enclosure shall be fabricated by using CRCA (Cold Rolled Close Annealed) Sheet of
thickness not less than 2mm.

4 number Heavy Duty Copper Lugs suitable for 16 Sq.mm Aluminium Cable should be pro-
vided in place of L.T. bimetallic connectors as shown in the drawing enclosed with theTS.

The Heavy Duty Copper Lugs must be of standard make i.e. Jainson, Dowell‘s etc.
conforming to the relevant IS & as per drawing enclosed.

The cover box must have some slope towards outside to drain out the rainy water.

The cover box must be painted with olive green colour confirming to Shade No. 220 of IS:5-
1961 as per the procedure for painting of main tank of the DTRs.

Other descriptions of the box are as follows: -

Page 21 of 623
(A) Back Plate of the cover box:-
Size – (500 x 250 x 2mm thick M.S. Sheet)
Back cover plate should be properly welded with L.T. bushing pocket of the transformer
with the help of angle of the 25x25mm size. There should be a rectangular cut to accom-
modate the L.T. bushings pocket.

(B) LT bushing cover box:-

(i) Internal size of Box:- L = 500 mm, W = 250 mm, H = 200 mm.

(ii) Back side of the Box:- Back side of the box should be properly bolted with the welded
back plate (A) to the transformer tank by providing 25x5mm thick gasket of Neoprene
Rubberizes Cork sheet.

(iii) Front side of the box:- Front side of the box should be suitable to accommodate the slid-
ing type front cover plate (C) with provision of 3 nos. nuts & bolts of 8mm Diameteron
bottom side to tighten the cover plate.
(iv) One Hole to be provided at bottom with double compressed cable gland suitable for 10
mm2, 4 cores Aluminium armoured cable.

(v) Provision of bushing for ground earth:- On top of the cover one LT bushing with brass
metal part towards Neutral bushing side of the DTR, should be provided with earth
sticker or colour embossing with earth symbol. This bushing should be internally con-
nected in proper way with the neutral bushing of the DTR. This bushing will be usedto
connect the 2 nos. direct earth wire from the earth pit without touching the body of the
DTRs.

(C) Sliding front cover plate:-Size 500 mm x 275 mm x 2mm thick MS Sheet. The front cover
must be of single sliding door type and with the min. 15 mm wide, collar plate. The bottom
of the door must have 3 nos. holes to match the hole of bottom collar plate of the box.

The LT Bushing Box be provided as per Annexure-A. A 4m 4 Core Armoured PVC

Cable confirming to IS:1554-1988 and amendments thereof of 10 sq.mm. be provided for con-
nections of LT terminal using lugs and coming out of the LT Box through hole provided at bot-
tom.

23. TRANSFORMER OIL:

THE TRANSFORMER SHALL BE SUPPLIED COMPLETE WITH FIRST FILLING OF EHV GRADE TRANS-
FORMER OIL, UP TO THE NORMAL OIL LEVEL. THE OIL SHALL CONFORM TO IS: 335-2018 (LATEST
AMENDED) AND SHOULD BE ISI MARKED AND HAVING THE SPECIFIED AGING CHARACTERISTICS . THE
BREAK DOWN VOLTAGE VALUE OF THE FRESH OIL AFTER FILTRATION AND BEFORE FILLING IN THE

Page 22 of 623
TRANSFORMER SHOULD BE ABOVE 70 KV AND AFTER FILLING IN THE TRANSFORMER IT SHOULD BE
ABOVE 40 KV.

THE MAKE OF TRANSFORMER OIL SHALL BE EITHER APAR/SAVITA/ RAJ LUBRICANTS/

ANAMIKA/SHARAVATI/ MADRAS PETRO/ RAJ PETROL/ LUBRICHEM, MUMBAI/ OPAN-
AMA PETROCHEM, ANKELSHWAR/ TASHKENT OIL, VADODARA/ COLUMBIA. T HE
TRANSFORMER OIL SAMPLE TAKEN FROM THE TRANSFORMER SHALL BE SUBJECT TO TESTING AS PER
PROVISIONS OFIS:1866.

THE OIL MANUFACTURER’S TEST CERTIFICATE SHALL BE MADE AVAILABLE AT THE TIME OF IN-
SPECTION TO THE INSPECTING OFFICER.

24. IDENTIFICATION DETAILS:

A. RATING & TERMINAL MARKING PLATE: EACH TRANSFORMER SHALL BE PROVIDED WITH NON
DETACHABLE NAME, RATING AND TERMINAL MARKING PLATE FITTED IN A VISIBLE POSITION.
ALL DETAILS SHALL BE GIVEN ON ONE PLATE. MATERIAL OF THE PLATE SHALL BE STAINLESS
STEEL/ALUMINIUM ONLY. THICKNESS SHALL BE 0.9 MM (WITH A TOLERANCE OF ±0.1 MM). THE
PLATE SHALL BE MADE ABSOLUTELY UNDETECTABLE EITHER THROUGH WELDING OR RIVETING
OR THROUGH ANY OTHER APPROVED METHOD.

Each HV & LV terminal shall be duly indelibly marked with its terminal numbers. (e.g. HV
terminal with capital letter 1U, 1V, 1W and LV terminal by corresponding small letters 2u, 2v, 2w
and the neutral terminal by 2n) by stamping with Min. letter size of 40x40 mm. In the diagram to be
given on the name plate, the relative position of various terminals- when viewed from top – shall be
clearly shown. Inspection shall not be undertaken unless all these details are verified by the Inspecting
Officer.

Besides other particulars, following details shall also be given on the name plate:

i) P.O. No. - Month& year.

ii) Sr. No. of transformer.
iii) Date of despatch - month & year
iii) Date of expiry of guarantee period – month & year
iv) Maximum Guaranteed Losses at 50% loading & at 100% loading.
v) Name & Full address of the manufacturer.
vi) Capacity of the transformer.
vii) Rating of the transformer.
viii) Type – Oil filled naturally cooled.
ix) IS 1180 part-1/2014.
x) BIS Level-2 with BIS Licence No.
xi) TN No. / JVVNL / RDSS

ALL DETAILS ON THE NAME RATING AND DIAGRAM PLATE SHALL BE INDELI-
BLY MARKED i.e. BY ENGRAVING, STAMPING or PUNCHING.

Page 23 of 623
B. TECHNICAL CUM IDENTIFICATION PLATE - M.S. PLATE OF SIZE 125 X 75 X 2.5 MM HAVING FOL-
LOWING DETAILS PUNCHED WITH LETTERS OF SIZE 8MM X 6MM SHALL BE CONTINUOUSLY
WELDED TO THE MAIN TANK BODY BELOW THE MIDDLE HV BUSHING IN CLEARLY VISIBLE POSI-
TION:-

A) Name of the Firm

B) TN No.
C) Make
D) Sr.NO.
E) JAIPUR DISCOM / RDSS
F) Rating
G) Date of Dispatch
H) Date of Expiry of G. P.
I) Core :-
1. Core Dia
2. Core Area
J) LV Coil :-
1. ID/OD Dimensions
2. Conductor Size
K) HV Coil :-
1. ID/OD Dimensions
2. Conductor Size
L) Limb Centre
M) Window Height

Further following details is to be embossed on the width side of the tank preferably in centre
opposite to Name & Rating Plate. The dimensions of letters should be 10x10x1 mm. The punching
shall be distinct and visible.

MAKE
S. No.
TN

The details of Make, TN No. & Sr. No. of transformer shall also be punched on the top cover.
The punching shall be distinct and visible with letter size 10x10x1 mm.

25. GUARANTEED AND OTHER TECHNICAL PARTICULARS FOR

TRANSFORMERS:

Page 24 of 623
Guaranteed Technical particulars of the transformers offered shall be furnished in A-4 size
paper by the Manufacturer in the proforma appended herewith at Annexure-A (Schedule-V-A). Com-
plete details shall be furnished. Tolerances on weight quantity and dimension figures shall be ± 5%
(except for internal configuration) at the tender stage, subject to maintaining the minimum electrical
clearances as per the specification. However, no negative tolerance shall be allowed on theshort circuit
type tested design. Electrical performance data shall be subject to tolerances as per ISS,unless other-
wise specified in this specification. However, the Total losses (at 50% and 100% Loading)shall be max-
imum guaranteed without any positive tolerance.

26. TYPE TEST CERTIFICATES:

The manufacturer shall furnish type test certificates of offered design / similar design, wher-
ever available, with the bid not older than five years.

27. DRAWINGS AND OTHER DOCUMENTS:

The tenders shall be accompanied with the following drawings/Calculation sheets, as per the
offered designs. The drawings shall be only on A-3 (420 x 297 mm) size paper and calculation sheet
shall be on A-4 size paper only.
a) Name rating / diagram plate drawing.
b) Outline and general arrangement drawing.
c) Core-coil assembly drawing.
d) Core section (for limb and yoke) along with flux density calculation sheet / drawing.
e) Cooling area calculation sheet.
f) Thermal Ability short circuit calculation sheet.
g) Core loss and magnetization curves of the laminations.
h) Heat dissipation calculations (heat dissipation by tank walls excluding top and bottom
should be 500 W/m2.

28. QUALITY ASSURANCE PLAN:

THE PURCHASER INTENDS TO PURCHASE TRANSFORMERS ONLY FROM QUALITY CONSCIOUS MAN-
UFACTURERS.

THE MANUFACTURER SHALL FURNISH THE DETAILS IN RESPECT OF FOLLOWING, IN THE SCHED-
ULES PRESCRIBED HEREIN THIS SPECIFICATION, FAILING WHICH THE OFFER IS LIABLE FOR REJECTION.

a) LIST OF TESTING EQUIPMENT AND INSTRUMENTS (WITH CLASS OF ACCURACY) AVAILABLE

WITH MANUFACTURER FOR INSPECTION, TESTING AND CHECKING THE TRANSFORMERS OF-
FERED, AS PER TENDER SPECIFICATION IN THE SCHEDULE OF TESTING FACILITIES . THE CALI-
BRATION DETAILS SHOULD ALSO BE INCLUDED.
b) LIST OF MACHINES/EQUIPMENT/T&P AVAILABLE WITH THE MANUFACTURER FOR MANU-
FACTURING THE TRANSFORMERS, IN THE SCHEDULE OF PLANT AND MACHINERY.

Page 25 of 623
c) DETAILS OF TYPE TESTS CONDUCTED ON THE TRANSFORMERS OFFERED TO SUPPLY IN THE
SCHEDULE OF TYPE TEST.
d) LIST OF RAW MATERIAL COMPONENTS AND SUB-ASSEMBLY TO BE USED FOR MANUFACTUR-
ING THE EQUIPMENT OFFERED, IN THE SCHEDULE OF RAW MATERIALS AND COMPONENTS.
e) STATEMENT GIVING LIST OF IMPORTANT RAW MATERIALS, NAMES OF SUB-SUPPLIERS FOR
THE RAW MATERIALS, LIST OF STANDARDS ACCORDING TO WHICH THE RAW MATERIAL ARE
TESTED. LIST OF TESTS NORMALLY CARRIED OUT ON RAW MATERIALS IN THE PRESENCE OF
MANUFACTURER’S REPRESENTATIVE, COPIES OF TEST CERTIFICATES.
f) INFORMATION AND COPIES OF TEST CERTIFICATES IN RESPECT OF BOUGHT OUT ACCESSO-
RIES.
g) LEVEL OF AUTOMATION ACHIEVED AND LIST OF AREAS WHERE MANUAL PROCESSING EX-
ISTS.

THE MANUFACTURER SHOULD POSSESS ADEQUATE FACILITIES FOR INSPECTION AND TESTING OF
THE TRANSFORMERS, AS PER REQUIREMENT OF THE RELEVANT ISS AND THIS SPECIFICATION. IN CASE
ANY SUPPLIER IS FOUND NOT HAVING ALL THE INSTRUMENTS /EQUIPMENT REQUIRED FOR TESTING, THE
OFFER SHALL BE IGNORED. NO BORROWING OF INSTRUMENTS / EQUIPMENT SHALL BE ALLOWED. TEST-
ING OF THE TRANSFORMERS SHALL ALSO NOT BE ALLOWED AT THE WORKS OF ANY OTHER MANUFAC -
TURER. HOWEVER, TESTING MAY BE ALLOWED AT ANY GOVERNMENT TESTING LABORATORY.

29. INSPECTION AND TESTING:

(i) The inspection and testing shall be conducted as per relevant clause of the General
Conditions of Contract at the place of manufacture. The transformers shall be completely assembled
and tested at the factory. The inspection may be carried out by the purchaser at any stage of manufac-
turing. The supplier shall grant free access to the purchaser’s representative at all reasonabletimes
when the manufacturing work is in progress. Inspection and testing of any material under this speci-
fication by the purchaser shall not relieve the supplier of his obligation of supplying the materialin
accordance with the specification and shall not prevent subsequent rejection if the material is foundto
be defective.

(ii) The supplier shall afford the inspector representing the purchaser all reasonable facil-
ities, without charge, to satisfy him that the material is being manufactured in accordance with the
specification. The manufacturers must have adequate set of instruments for conducting testing asper
ISS/ Specification. The instruments for measurement of losses shall be of accuracy class of 0.5 orbet-
ter. The instruments shall be duly calibrated and Calibration Certificate should not be older than one
year on the date of presentation to the Inspecting Officer. The calibration shall be arranged from
NABL accredited testing house. A comprehensive list of testing equipment/ instruments indicating
make, Sr. No., type, class of accuracy, calibrating agency, calibration date etc. should be furnished
alongwith the bid. The calibrated instruments shall be duly sealed by calibrating agency to avoid any
tampering with calibration and the details thereof shall be clearly mentioned in the Calibration Cer-
tificate(s).

Page 26 of 623
(iii) The supplier shall keep the purchaser informed in advance, about the manufacturing
programme so that arrangements can be made for inspection. The supplier shall give minimum fifteen
days advance intimation to enable the purchaser to depute his authorised representative for in-
spection/ witnessing of various tests on the equipment/ material as detailed below:

NOTE:- Penal provision shall be made for any short technical parameters found / noticed in thetransform-
ers at any time even beyond guarantee period.

30. ROUTINE/ACCEPTANCE TESTS:

A) 100% TESTING OF THE DISTRIBUTION TRANSFORMERS SHALL BE CARRIED OUT AT FIRM’S WORKS
FOR MEASUREMENT OF TOTAL LOAD LOSSES AT 50% & 100 % LOADING. REMAINING TESTING SHALL
ALSO CONTINUE TO BE CARRIED OUT AS PER PRACTICE.

B) All the assembled/finished transformers prior to despatch shall be subjected to routine tests as
per IS:2026. Minimum 25% of the offered lot size samples subject to minimum 5 Nos will be
taken for routine and acceptance tests. The supplier shall invariably furnish manufacturer’s
routine test certificate along with inspection call of the offered transformers for pre-despatch
inspection. The inspection offers without furnishing of routine test certificates as per ISS of
all the transformers offered for final inspection shall not be entertained, and any delay on this
account shall be to firm’s account.

The selected samples shall be subjected to the following routine/acceptance tests at themanufac-
turer’s works in accordance with the relevant ISS:

Page 27 of 623
12. Physical verification of core – coil dimension, internal clearances, provisions of required oil
ducts in the HV and LV winding, conductor sizes, individual weights of HV and LV winding
core laminations etc., with reference to contract drawings and type test report(s) by disman-
tling selected unit(s). The physical verification shall be conducted on units equivalentto one
unit per 50 Nos or part thereof of offered quantity randomly selected from the offered lot. The
dismantled unit(s) after re-assembly shall be accepted by the purchaser after routine testing in
presence of his representative.
13. Oil dielectric strength (break down voltage) test shall be carried out on the transformers
opened for physical verification and average value shall be calculated.
14. Checking of manufacturer’s test certificates and invoices for major raw materials
shall be done and copies thereof duly signed by firm’s representatives and in-
specting officers shall be enclosed with the inspection report.

Invoices of CRGO/ AMORPHOUS material shall be provided by the supplier to the inspecting
officer at the time of inspection and same shall be verified by the inspecting officer.

Following tests shall also be carried out at manufacturer’s works on one complete unit of 25
KVA Transformers unit:

i) Over Flux Density Test (in the first lot and may be repeated in subsequent lots if
desired by purchaser).
ii) Measurement of unbalance current.
iii) Magnetic Balance Test (See note below)
iv) Oil Leakage Test (See note below)

Note: It will be mandatory for the manufacturer firms to maintain record of BDV value of the trans-
former oil and shall furnish to the inspecting officer who in turn shall furnish the sameto the
Nigam’s CTL for verification purpose. The Inspecting Officer during inspection shallverify
record of Meggar value of the offered DT’s and furnish the same with inspection reportto the
Nigam’s CTL. Simultaneously, record of Air Pressure Test shall also be checked by the in-
specting officer and same be furnished with report to the CTL. CTL will conduct testingof DT’s
only after receipt of record of BDV value, Meggar value and air pressure test results.

Fifteen days clear notice shall be arranged for pre-despatch inspection by purchaser’s repre-
sentative as per General Conditions of Contract.

After successful inspection, the inspecting officer shall seal each and every transformer by
sealing the transformer with 2 Nos. poly-carbonate seals on longitudinal side. Before sealing, the
inspecting officer will ensure that all the offered transformers are completed and duly fitted with
name, rating and diagram plate, identification plate (on tank body & Top cover) as specified in this
specification.

Page 28 of 623
i) INSULATION RESISTANCE MEASUREMENT:

Insulation resistance of selected samples shall be measured with a 2500 V Megger, of standard
make such as M/s AVO, M/s Sakova, M/s Wako, M/s Evershed, Vignole or Metrawatt. The minimum
insulation resistance, in Mega Ohms, shall be as indicated in the table below:

200 C 300 C 400 C 500 C 600 C

11000 Volts
800 400 200 100 50
(HV)
433 Volts 25
400 200 100 50
(LV)

PRESSURE TEST: (As per IS: 1180 (Part 1):2014) -This test shall be conducted as type test at a
Govt. approved/ a Govt. recognized/ NABL accredited laboratory. The pressure gauge and vacuum
gauge shall be duly calibrated and sealed by an independent recognized test lab(s).

The test procedure shall be as detailed below:

The tank subjected to pressure of 80 KPa for 30 minutes and vacuum of 250 mm of mercury
for 30 minutes. There should be no air leakage at any point. The Permanent deflection of flat plate,
after pressure has been released, shall not exceed the values given below:

Length of plate up to Deflection

750 mm 5.0 mm
751 to 1250 mm 6.5 mm
1251 to 1750 mm 8.0 mm

ii) MAGNETIC BALANCE TEST:

This test shall be conducted as an additional test on one sample transformer from each lot
offered for inspection.

Page 29 of 623
The application of low voltage to the middle limb will induce approximately equal voltages on
the two end limbs. The application of voltage to the end limbs will induce greater voltage in the middle
limb and less voltage in the other end limb. Uniformity of induced voltages shall confirm the health-
iness of the transformer windings.

The procedure for the test shall be as under:

a) Apply 250 Volts between LV terminals-2u-2n and measure voltages between 2v-2n & 2w –2n.
b) Apply 250 Volts between 2v-2n and measure voltages between 2u-2n & 2w-2n.
c) Apply 250 Volts between 2w-2n and measure voltages between 2u-2n & 2v-2n.

The measured voltages shall satisfy the conditions detailed as above.

iii) OIL LEAKAGE TEST (As per IS 1180 Part-1/2014):

The oil leakage test shall be conducted on one unit selected from the offered lot. The assembled
transformer for non-sealed and sealed Type with all fittings including bushing in position shall be
tested at a pressure equivalent to twice the normal head measured at the base of tank for 8 hrs. There
should be no leakage at any point.

Note: ISI marking and overall diameter of the cable used in the transformer are also to be
checked during inspection at firm’s works.

31. TYPE TESTS:

The firm shall furnish complete type test reports as per IS:1180 Part-I 2014 of this rating
transformer (submitted for BEE labeling) for verification and checking along with drawings to be got
approved later on.

TYPE TESTS REQUIRED – THE FOLLOWING TESTS SHALL BE CONDUCTED ON ONE UNIT AS PER IS:1180
PART-I 2014 AT NABL/GOVT. APPROVED LAB AS UNDER:-

i) Short circuit test for dynamic and thermal ability: The short circuit test for dynamic and thermal
ability shall be arranged at a Govt. approved/ a Govt. recognized/ NABL accredited labora-
tory/ILAC i.e. International Laboratory Accredited Laboratory/ ILAC i.e. International Labora-
tory Accreditation Cooperation (in case of foreign laboratory) on one unit.

Page 30 of 623
ii) Impulse voltage withstand test: The impulse voltage withstand test shall be arranged at any test-
ing house accredited to NABL or a Govt. approved/ a Govt. recognized/ NABL accredited labor-
atory/ILAC i.e. International Laboratory Accredited Laboratory/ ILAC i.e. International Labor-
atory Accreditation Cooperation (in case of foreign laboratory) for purpose of impulse test.The
test procedure shall conform to the requirement of Clause 13 of IS: 2026 (Part-III). Impulsevolt-
age withstand test shall be minimum 75 KVp.

iii) TEMPERATURE RISE TEST : [ AS PER IS 2026 (PART 2) ]

Temperature rise test shall be conducted on Maximum measured total loss (No load at rated ex-
citation+Load loss at max. current tap at 75 oC) at 100% loading shall be supplied during temperature
rise test at a Govt. approved/ a Govt. recognized/ NABL accredited laboratory/ILAC i.e.International
Laboratory Accredited Laboratory/ ILAC i.e. International Laboratory Accreditation Cooperation (in
case of foreign laboratory).

The transformer shall be capable of giving continuous rated output without exceeding the
specified temperature rise. Bids not meeting the above limits of temperature rise will be treated as
non responsive.

(iv) AIR PRESSURE TEST: (As per IS 1180 (Part 1):2014)

The test procedure shall be as detailed below:

The transformer tank shall be subjected to air pressure of 80 KPa for 30 minutes and vacuum
of 250 mm of mercury for 30 minutes. There should be no air leakage at any point. The Permanent
deflection of flat plate, after pressure has been released, shall not exceed the values given below:

Length of plate up to Deflection

750 mm 5.0 mm
751 to 1250 mm 6.5 mm
1251 to 1750 mm 8.0 mm

Page 31 of 623
No extra time shall be allowed for arranging these type tests. The cost of above Type Tests
shall be borne by the supplier.

The programmed indicating date and place of type test(s), be intimated enabling purchaser to
depute his representative to witness the test if desired. The testing house shall be advised to arrange
type test result directly along with drawings duly attested by the testing authority for our scrutiny and
approval. The type-tested transformer(s) shall also be accepted as the part of the supplies.

The requirement of arranging above type tests shall however not to be insisted on the suppliers
who have arranged the above type tests within last 5 years from the date of opening of this tender on
similar design. Minor changes in the present specification will not necessitate repetition of type test(s),
if design of core-coil assembly is similar in essential details.

32. RANDOM SELECTION AND TESTING (RST):

32.1 The purchaser may select transformer(s) from the supplied lot(s) at random from the stores for con-
ducting the following type tests, at any test house(s) as mentioned above. The supplier shall arrange
these tests including loading, unloading and to & fro transportation from our stores to the testhouse(s).
The charges for such tests shall be reimbursable to the supplier on actual basis on productionof docu-
mentary evidence in case the selected sample successfully withstands type test(s). In case of other-
wise, no charges will be reimbursed.

Purchaser reserves the right to carry out any site tests he may decide upon at his own expenses.
In case equipment/ material are not found as per P.O., all expenses incurred during the
testing will be to supplier’s account and material shall be replaced by the supplier at
site free of cost.
FAILURE IN TYPE TEST (S):
In the event of failure/unsatisfactory results of the transformer(s) in Dynamic & Thermal Abil-
ity to withstand Short Circuit Test/impulse type tests /Temperature rise Test/Air Pressure Test, the
supplier shall have to replace the supplies already made and no further transformers shall be accepted.
The purchaser however, at his option, may accept the transformers already supplied with the following
conditions:
i) Guarantee period of the supplied transformers issued to the field shall be increased by
double the normal Guarantee period.
ii) Bank Guarantee shall be extended to cover the additional Guarantee period.

Page 32 of 623
iii) For failure in any of the type tests listed under RST i.e., short circuit test & Impulse with-
stand test, Temperature rise test & Air Pressure Test, no further supplies shall be accepted.
The type test charges shall also not be reimbursable in this case and shall be borne by the
supplier.
iv) The transformers lying in the store(s) shall be replaced as per sub para (v) below.
v) The manufacturer shall, however, be allowed to check the reasons of failure and if need
be, to improve/modify the design. Further supplies, including replacements against sup-
plies already made, shall be accepted only after successful type test(s) are arranged onfresh
transformer(s) selected by the authorized representative of the purchaser. All the typetests
shall be arranged in case there is change in the design, otherwise, type test shall be repeated
only for the test in which failure has occurred. Charges for such test(s) shall be borne by
the supplier. However, in the event of failure of transformer in the repeat type test, the
purchaser may take following actions:
a) Cancel pending orders of the rating in which failure(s) has occurred
b) Not place any order of Distribution Transformers on the firm for one/two year(s).

32.2 Measurement of Total Losses (at 50% and 100% Loading)

i. After pre-dispatch inspection of material at firm’s works, the dispatch instructions will be
issued for the respective store(s) as per requirement of Nigam. Sample(s) will be drawn from
the lot(s) received in store(s) and will be subjected to the following test(s):

b) One transformer will be selected out of every lot of 10 Nos. or part thereof for meas-
urement of Total Losses of transformer at 50% & 100% loading at rated voltage;No
Load current (at 100% and 112.5% of rated voltage); Impedance voltage. The testing
shall be arranged either at purchaser’s own testing lab and / or at independent test lab.
The testing charges for such tests shall be borne by the purchaser. The test results will
be applicable to the respective lot of 10 Nos. from which sample was drawn. The tol-
erance in losses on account of 4m 16 sq. mm PVC Armoured Cable confirming to
IS:1554-1988, lugs and working tolerance towards crimping,connections, etc. shall be
10.0 watt at 50% loading and 39.0 Watt at 100% loading at 750C.

Note: 1. During Physical verification, one transformer will be tested on LT Bushing

(after removing cable) to ascertain the losses as per technical specification.
2. ISI marking and overall diameter of the cable are to be checked during inspection at
firm’s works as well as in CTL.

c) If dispatch instructions are less than 10 Nos. than one sample shall be selected from
each store(s) and the test results so obtained shall be for the quantity consigned/ re-
ceived by store(s).

The above information shall be mentioned in the CTL Report.

Page 33 of 623
The percentage impedance voltage at rated current shall not exceed the permissible limit of 4.5%
with plus minus 10% tolerance failing which the sub lot of transformers represented by the sample shall
be rejected.

The I.R. values of the sample(s) shall be measured at CTL, Jaipur and it must be more than
50 MEGA-OHM.

One sample (randomly selected by CTL) out of 100 Nos. transformers or part thereof shall be
selected for physical verification/ checking of window height & limb centre (with tolerance of +2
mm) and checking of insulation of HV and LV windings at CTL.

Metal Parts of Bushing assembly shall be checked in CTL as per specification/IS on the trans-
former which is physically opened in CTL (from the lot of 100 Nos. or part thereof). The tolerance
may be allowed in accordance with coarse class of IS 2102-1969. If sample does not confirmthe require-
ment of specification/IS, then lot of 100 nos. or part thereof shall be rejected.

The No Load Voltage Ratio (Transformer Turn Ratio) shall be checked in CTL with the tol-
erance as per specification/ IS 2026 on the transformer from the lot of 10 Nos. or part thereof andthe
concerned sub lot shall be rejected if not meet out the requirement of IS.

Further, Internal clearances shall be checked without opening of core coil assembly in each of
the transformers which have been selected for physical verification at CTL (i.e. one sample from a
lot of 100 nos. or part thereof) in presence of firm’s representative. No negative tolerance shall be
admissible. If clearances are not found as per specification, then the lot of 100 Nos. or part thereof
shall be rejected.

The sample of Oil be taken at CTL from the Transformer opened for physical verification in
presence of firm’s representative and same shall be tested at Nigam’s CTL/NABL accredited Lab. If
sample does not confirm the requirement of specification/IS, then lot of 100 nos. or part thereof shall
be rejected.

Besides above points following shall also be checked in CTL on the transformer opened for
physical verification and if the sample(s) does not meet the above requirements then the entire lot
shall be rejected:

1. Marking on HV terminals on transformer tank by stamping (i.e. 1u, 1v, 1w).

2. Marking on LV terminals on transformer tank by stamping (i.e. 2u, 2v, 2w & 2n).

Page 34 of 623
3. The earthing of the core through tinned copper earthing Foil of 25 mm width & 1 mm thickness
bolted on core frame channels, after removing the channel paint.

NOTE:
If the total losses are found more than 10% of specified losses at 100% loading, then apart from
rejecting the lot, firm’s balance order would be cancelled and such firms shall not be awarded any order
for one year or in next tender of tendered rating to be opened/finalized whichever is later.

If the window height and limb centre are found more than 7.5 mm, then apart from rejecting the
lot, firm’s balance order would be cancelled and such firms shall not be awarded any order for one year
or in next tender of tendered rating to be opened/finalized whichever is later. However, a tolerance of
± 2mm shall be allowed in window height.

33. GUARANTEE PERIOD:

I. Performance guarantee of the transformer(s) with LT protection unit shall be for the period of
36 (Thirty Six) months from from the date of handing over after successful installation and
commissioning.

i) THE FIRM WILL REPLACE ALL TYPE OF GP FAILED DISTRIBUTION TRANSFORMERS WITHOUT ASK-
ING ANY SEGREGATION ON ACCOUNT OF MANUFACTURING DEFECT. HOWEVER, THE DISCOMWILL
COMPENSATE THE COST OF MISSING PARTS AS PER PRACTICE IN VOGUE.

ii) THE GUARANTEE PERIOD FAILED TRANSFORMERS WILL DIRECTLY BE LIFTED BY THE SUPPLIERS
FROM THE RESPECTIVE CIRCLE STORE WITHIN A PERIOD OF 60 DAYS FROM THE DATE OF INTIMA-
TION BY THE RESPECTIVE CONSIGNEE AND WILL REPLACE DISTRIBUTION TRANSFORMERS
AGAINST G.P. FAILED WITHIN 30 DAYS FROM THE DATE OF LIFTING ALONG WITH THE JOINT IN-
SPECTION SHEET OF MISSING PARTS ISSUED BY THE RESPECTIVE CONSIGNEE . AFTER RECEIVING
THE MATERIAL AT STORE, THE SAME SHALL BE TESTED AT CTL AS PER PROVISIONS OF THE
RELEVANT CONTRACTS AND WILL BE ISSUED TO THE CIRCLE STORE AS PER REQUIREMENT ON
NIGAM’S ACCOUNT. THE INVOICES OF MISSING PARTS SHALL BE VERIFIED BY THE ACOS STORE
AS PER THE JOINT INSPECTION SHEET ISSUED BY THE CIRCLE STORE AS PER PRACTICE IN VOGUE
AND ACCORDINGLY, THE SR. A.O. (CPC) WILL MAKE THE PAYMENT OF MISSING PARTS, IF ANY.

iii) THE LOADING OF G.P. FAILED DISTRIBUTION TRANSFORMERS AT CIRCLE STORE AND UN- LOAD-
ING OF REPLACED TRANSFORMER WILL BE ON SUPPLIERS’ ACCOUNT.

iv) THE FIRM WILL REPLACE G.P. FAILED TRANSFORMERS IRRESPECTIVE OF BREAKAGE OF BODY
SEALS AS WELL AS PHYSICAL DAMAGE OF TRANSFORMER TANK BODY DUE TO BURSTING . THE
PERIOD DURING WHICH TRANSFORMER REMAINED DEFECTIVE/FAILED WILL NOT BE ACCOUNTED
IN THE PERFORMANCE GUARANTEE PERIOD. THE PERIOD OF DEFECTIVE WILL BE RECKONED
FROM THE DATE OF FIRST INTIMATION (I.E. FIELD OFFICER/CONSIGNEE WHICHEVER IS EARLIER)
TO DATE OF DELIVERY REPLACED TRANSFORMER.

Page 35 of 623
FIRMS SHALL LIFT THE G.P. FAILED TRANSFORMER(S) WITHIN A PERIOD OF 60 DAYS FROM THE
DATE OF INTIMATION BY THE RESPECTIVE CONSIGNEE AND WILL REPLACE DISTRIBUTION TRANSFORM-
ERS AGAINST G.P. FAILED WITHIN 30 DAYS FROM THE DATE OF LIFTING POSITIVELY. IN CASE FIRM FAILS
TO DELIVER REPLACED TRANSFORMER(S) WITHIN 90 DAYS FROM DATE OF INTIMATION,THE COST OF THE
TRANSFORMER(S) SHALL BE WITHHELD FROM FIRM ’S FINANCIAL HOLD AND IN CASE FIRM FAILS TO DE -
LIVER REPLACED TRANSFORMER WITHIN 90 DAYS FROM DATE OF INTIMATION, A PENALTY AT THE RATE
OF ½% PER WEEK SUBJECT TO MAXIMUM 10%, SHALL BE LEVIED FOR THE LATEDELIVERY OF REPLACED
TRANSFORMER(S).

II. IN ORDER TO ASCERTAIN THAT TRANSFORMERS HAVE SUCCESSFULLY COMPLETED GUARANTEE

PERIOD THE FOLLOWING DETAILS SHALL BE PROVIDED ON THE TRANSFORMER BODY :

A. A REPLACEMENT IDENTIFICATION STEEL PLATE ON REPLACED TRANSFORMER AGAINST G.P. FAILED

TRANSFORMER OF SIZE 75 X 75 X 2.5 MM DULY ENGRAVED WITH FOLLOWING DETAILS SHALL BE
WELDED ON THE TRANSFORMER BODY.

3ND
PARTICULARS ORIGINAL SUPPLY 1ST 2ND
REPLACEMENT REPLACEMENT REPLACEMENT
FIRM’S
NAME/LOGO
TN
RATING (KVA)
SR. NO.
DATE OF
DISPATCH
DATE OF FAILURE
GUARANTEE
PERIOD UPTO
B. SUCH METALLIC PLATE FIXED ON FIRST REPLACEMENT SHOULD NOT BE REMOVED AT THE TIME OF
SECOND REPLACEMENT OR ANY SUBSEQUENT REPLACEMENT . HOWEVER, NECESSARY DETAILS OF
FAILURE AND REPLACEMENT SHALL BE GRAVED ON THE IDENTIFICATION PLATE , EACH TIME IT IS
REPLACED IN GUARANTEE.

NOTE:- ALL OTHER PLATES SUCH AS RATING AND TERMINAL MARKING PLATE AND TECHNICAL CUM
IDENTIFICATION PLATE HAVE TO BE AFFIXED ON THE REPLACED TRANSFORMERS. IN CASE IT IS FELT
THAT THESE ARE LOOSE, THEN IT SHOULD BE REPAIRED SUITABLY BY WELDING OR RIVETING.

Page 36 of 623
III. Test checking of G.P. failed transformers will be allowed to the supplier at Nigam’s store
before lifting of G.P. failed distribution transformers to repair at supplier’s works so that minor
mistakes be rectified at Nigam’s stores. The Consignee will accordingly intimate to the Sup-
plier to lift the GP failed Distribution Transformer.The Testing Procedure of such replacedDis-
tribution Transformer including Physical Verification shall be same as per Testing of NewDis-
tribution Transformer at Firm’s Works as well as at CTL without any tolerance in the losses
at 50% and 100% loading.

NOTE:- Firm shall keep the records for at least 8 years of transformers supplied by them.

34. CSP Features:

The transformers shall have the following CSP features.

a) INRERNAL HV FUSES ON THE HT SIDE OF TRANSFORMER as per IS9385 Part-

II:1980

Specification for the H.T FUSES: Expulsion/any other suitable fuse placed in series with
primary winding. This fuse is mounted normally inside of the primary bushing and is con-
nected to the high voltage winding through a terminal block. This has to protect that part
of the electrical distribution system which is ahead of the Distribution transformers from
faults which occur inside the Distribution transformers i.e., either the windings or some
other part of the transformer.
It shall be ensured that this fuse does not blow for faults on the secondary side (LT side) of the
transformer i.e., the blowing characteristic of the fuse and LT breaker shall be so coordinated that the
fuse shall not blow for any faults on the secondary side of the transformer beyond LT breaker and
these faults shall be cleared by the LT breaker only. The fuse shall be make of
ABB/ERMCO/Global/samrakshna/Transguard or any other duly type tested make approved by
JVVNL.

ii) INTERNALLY MOUNTED OIL IMMERSED LT BREAKER ON THE LV SIDE OF THE

TRANSFORMER as per IS/IEC 60947-2:2003:
LT Circuit Breaker:All LT faults after the breaker shall be cleared by this breaker. As such, it shall
be designed for the perfect coordination with the HT fuse link. The supplier shall furnish the time/cur-
rent characteristics of LT circuit breaker and 11 kV fuses for various current multiples. The two char-
acteristics shall be drawn on the same sheet to indicate coordination between the circuit breaker
and fuse. This shall be based on the type test carried out on one of the transformers. In addition,
the supplier shall carry out coordination test as indicated above, and this forms one of the tests for
acceptance.

The breaker is to be mounted on the secondary side of the transformer under oil to minimize prem-
ature operations from primary surges as would be with undersized line fuses. Three single pole

Page 37 of 623
elements are preferred. THE BREAKER SHALL BE COORDINATED THERMALLY WITH THE
TRANSFORMER RATING TO FOLLOW CLOSELY THE VARIATIONS OF COIL TEMPERA-
TURE DUE TO FLUCTUATIONS IN LOADS AND AMBIENT TEMPERATURES.

This is to be accomplished by connecting the breaker in series between the secondary winding and
the load current. The breaker shall be located in the same oil as the core and coil assembly so that the
bimetal are sensitive to the temperature of oil as well as the load current.

(c)The circuit breaker may be an electromechanical device with three main elements viz..

(i) Temperature sensing (ii) latching and tripping and (iii) current interrupting. The temperature sens-
ing function might be accomplished through the use of bimetallic strips, which would be built into
the breaker, such that load current of the transformer flows through them. In addition to this, a
magnetic tripping device is to be provided for increasing the opening speed of the breaker under high
fault conditions. The circuit breaker shall be mounted inside of the transformer so that these bimetallic
strips are within the top oil layer of the transformer. The latching and tripping functions of the circuit
breaker may be carried out within assembly similar to those used in industrial
type air circuit breaker. The circuit breaker shall also be closed and opened manually standing on
ground and with a magnetic trip device also. The current interruption element shall consist of copper
current carrying parts plus a set of copper tungsten current interrupting contacts. The cross section
of the current carrying parts of the breaker shall withstand the full load current at a current density
not more than2.0 A/Sq.mm (for additional mechanical strength the area should be more). The mag-
netic element shall increase the opening speed of the circuit breaker under high faultcurrent condi-
tions. The response of circuit breaker to the activity shall remain unchanged by the addition of the
magnetic trip element. The specification to which the breakers conform shall be indicated. The LT
circuit breaker shall be make of samrakshna/Transguard/ Vijai Mercantile/ Global/ P&A/
ARDRY/ERMCO or any other duly type tested make approved by JVVNL.

iii) LOAD MANAGEMENT SIGNAL LIGHT:A signal light, controlled by a bimetal in the
breaker shall switch on when the transformer load reaches a predetermined level indicating that the
transformer has been overloaded. The load management signal light shall perform two functions. It
shall show visually when the particular
Transformer has been operating in an overload condition and shall provide knowledge for good sys-
tem management, the economic change out point for the transformer is fast approaching. The signal
light need not indicate temporary overloads and shall turn on only when the overload conditionhas
existed at a given level for a certain length of time.

The LT circuit breaker shall have a set of auxiliary contacts built-in for signal light operation.
These, normally open contact, shall form part of the signal light circuit. The signal light circuit shall
consist of an auxiliary transformer winding (one or two turns) which generates about 4V, for the
signal light contact set within the circuit breaker, and the signal light is to be mounted on the
transformer tank. The signal light contact set is mechanically connected to the main circuit breaker
latching and bimetal system. The signal light mechanism is adjusted so that the signal light contacts
will close at a preset thermal condition which occurs before the main latching system opens

Page 38 of 623
the main contact. The net result is a visual external indication that a preset load condition has reached
by the transformer. The signal light mechanism does not reset itself when the load drops off, the signal
light remains lighted once the signal light contacts closes and can only be turned off by manually
operating the external circuit breaker handle.

The breaker should withstand dielectric test of 11kv and the same shall be verified during
acceptance test.

The type tests shall be carried out on Circuit Breaker of rated current or higher current rating
as per IS/IEC 60947 for Sequence-I, II, and III amended unto date from any independent laboratory
recognized by NABL.

Note:- Mechanical operation test on LV circuit breaker shall be carried out in oil medium as per IS
13947.

Additional Routine and Acceptance Tests

Demonstration of Trip and Reset operation by applying atleast 500% of the rated current.

35. MAKE OF BROUGHT OUT ITEMS:

The Make of brought out items like Bushings, Transformer Oil, etc. other than Make specified in the
specification/work order may be accepted if confirms to relevant IS with due approval of JVVNL.

Page 39 of 623
TECHNICAL SPECIFICATION FOR SUPPLY OF 11/0.433KV, 63 KVA OUTDOOR THREE
PHASE ALUMINIUM WOUND ENERGY EFFICIENT LEVEL-2 (STAR-1) RATING DIS-
TRIBUTION TRANSFORMERS

1. SCOPE:

This specification covers the design, engineering, manufacture, assembly, inspection and
testing at manufacturer’s works before supply and delivery at site of Oil immersed, Oil Natural Air
Natural (ONAN) outdoor type BIS Level-2 (STAR-1) Rating, 11KV/433 V, three phase, 50 Hz,
double wound core type, outdoor Type, Aluminium Wound Distribution Transformers of 63 KVA
ratings, complete with fittings and accessories for use in Distribution System.

1.1 The Equipment Offered shall be complete with all parts necessary for their effective and trou-
ble free operation. Such parts will be deemed to be within the scope of the supply irrespective of
whether they are specifically indicated in the commercial order or not.

1.1.1 It is not the intent to specify herein complete details of design and construction. The equip-
ment offered shall conform to the relevant standards and be of high quality, sturdy, robust andof
good design and workmanship complete in all respects and capable to perform continuous and sat-
isfactory operations in the actual service conditions at site and shall have sufficiently long life in
service as per statutory requirements. In actual practice, not withstanding any anomalies, discrep-
ancies, omissions, incompleteness, etc. in these specifications and attached drawings, the design
and constructional aspects, including materials and dimensions, will be subject to good engineering
practice in conformity with the required quality of the product, and to such tolerances, allowances
and requirements for clearances etc. as are necessary by virtue of various stipulation in that respect
in the relevant Indian Standards, IEC standards, I.E. Rules, I.E Act and other statutory provisions.

1.3 Tolerances on all the dimensions shall be in accordance with provisions made in the relevant
Indian/ IEC standards and in these specifications. Otherwise the same will be governed by good en-
gineering practice in conformity with required quality of the product.

2. APPLICABLE STANDARDS:

Unless otherwise modified in the specifications, the Distribution Transformers, including

various accessories, shall generally comply with the following Indian Standards / REC Specifica-
tions. The standard(s) shall be with latest amendment, if any, from time to time.

Note: Wherever ISS are mentioned, equivalent or better International standards are also acceptable.

Page 40 of 623
Sr. Specification Details about International &
No internationally
. recognized
standards.
1 IS: 1180 (PART- Specifications for outdoor type oil immersed IS: 1180
I)/2014 distribution transformers upto and including 2500 (PART-I)/2014
KVA, 33 KV Class.
2 IS:6600/1978 Guide for loading of oil immersed Transformers IEC 76

3 IS:335/1983 New insulation oils for Transformers BS 148, D-1473,

D-1533 – 1934,
IEC PUB 296
4 IS:3347 (Part-I/ Dimension of Porcelain parts & Metal parts for DIN 42531 to 33
Sec. 1 & 2) Transformer bushing (1.1 KV).

5 IS:3347 (PART-III Dimensions of Porcelain( parts & Metal

/ Sec-1 & 2) & parts) for Transformer bushing for use in heavily
IS:8603:2008 polluted atmosphere 12/17.5 KV, 24 KV and 36KV
(amalgamating IS 8603 (Part1,2 & 3):1977
6 IS:7421 Porcelain Transformer Bushings for low voltage –
upto 1 KV.
7 IS:2099/1986 Porcelain Transformer bushing for AC volts above
1000 volts.
8 IS:3639/1966 Fittings & accessories for Transformers

9 IS:1866/1978 Code of practice for maintenance & supervision of

insulating oil in service.
10 IS:5484 Specifications for Aluminium wire rods. ASTM B – 233
11 IS:9335 Specifications for insulating Kraft Paper. IEC 554
12 IS:1576 Specifications for solid insulating press Boards for IEC 641
electrical purposes.
13 IS:616 (Part I) Specification for paper covered Aluminium round
conductors
14 IS:6162(Part II) Specification for paper covered Aluminium
rectangular conductors
15 IS:104 Ready mixed paint, brushing zinc chromate,
painting
16 IS:649 Testing of steel sheets and strips for magnetic
circuits.

Page 41 of 623
17 IS:2362 Determination of water content in oil for porcelain
bushing transformers.
18 IS: 4257 Dimensions for clamping arrangements for
bushings.
19 IS 6160 Rectangular conductor for electrical machines.
20 IS:10028 Selection, Installation and maintenance of
transformers
21 IS: 3401 Silica Gel
22 - REC
Specification No. 2
- REC
Specification No.
39/1993
- CEA
Specification
Chapter 4
23 IS:2026 (Part Power Transformers
I,II,III,IV &
V)/1981
24 IS:5/1961: Colour for ready mixed paints

Note: - Besides above changes, the technical parameters of the specifications wherever are deviating
from the IS:1180 (Part-I/2014) , the same shall be in accordance with IS:1180 (Part-I/2014) and its
latest amendments, if any and the changes where the IS:1180 (Part-I/2014) is silent for technical pa-
rameters, same shall be applicable as per Discom specification

Material conforming to other internationally accepted standards, which ensure equal or better
quality than the standards mentioned above would also be acceptable. In case the Manufacturers who
wish to offer material conforming to the other standards, salient points of difference between the stand-
ards adopted and the specific standards shall be clearly brought out in relevant schedule. Four copies
of such standards with authentic English Translations shall be furnished along with the offer.

3. SERVICE CONDITIONS:

The distribution transformers to be supplied against this specification shall be suitable for
satisfactory continuous operation under the following climatic conditions as per IS 2026 (Part- I) latest
revision.
i) Peak ambient temperature : 50°C
ii) Minimum Ambient Temperature in shade : -5°C
iii) Maximum average ambient temp. in a 24 hours period in shade : 45°C
iv) Maximum yearly weighted average ambient temperature : 35°C
v) Maximum temperature attainable by an object exposed to sun : 60°C
vi) Maximum relative humidity : 100 %

Page 42 of 623
vii) Average number of thunder storm days per annum : 40
viii) Average number of rainy days per annum : 120
ix) Average annual rainfall : 15-100 cm
x) Number of months of tropical monsoon conditions : 4 Months
xi) Maximum wind pressure : 195 Kg/mt²
xii) Altitudes : Not exceeding 1000
mtrs.
The equipment shall be for use in moderately hot and humid tropical climate, conducive to
rust and fungus growth.

4. PRINCIPAL PARAMETERS:

The Transformers shall be suitable for outdoor installation with three phase 50 Hz 11 KV
system in which the neutral is effectively earthed and should be suitable for outdoor service as step
down transformers under fluctuations in supply voltage upto plus 12.5% to minus (-) 12.5% permis-
sible under Indian Electricity Act and rules there under.

The transformer shall confirm to the following specific parameters:

i) Continuous rated capacity : 63 KVA & 100 KVA
ii) System Voltage ( Max.) : 12 KV
iii) Rated HT voltage : 11 KV
iv) Rated LT voltage : 433 V (P-P) / 250 V (P-N)
v) Frequency : 50 Hz ± 5%
vi) No. pf phases : THREE
vii) Primary connection (HT) : DELTA
viii) Secondary connection (LT) : STAR
ix) Vector Group : Dyn-11
x) Percentage impedance at 75°C : 4.5 %
xi) Taps (off circuits) : TAPS ARE NOT REQUIRED.
xii) Type of cooling : ON AN
xiii) Fault level of the system : 750 MVA
Primary winding shall be DELTA connected and the secondary winding shall be STAR con-
nected (vector symbol Dyn-11), so as to produce a positive displacement of 30° from the primary to
the secondary vectors of the same phase. The neutral of the secondary winding shall be brought outto
a separate insulated terminal. The transformers shall be Aluminium Wound.

The transformers shall be designed and constructed to withstand without damage the thermal
and dynamic stresses of an external short circuit. The manufacturer / supplier shall furnish all relevant
design data and calculations in support of having fulfilled this requirement as stipulated in IS:2026
(Part-I)

Page 43 of 623
5. NO LOAD VOLATGE RATIO:

The No load voltage ratio(s) shall be 11000/ 433 Volts.

6. THE LOSSES:

The max. allowable losses at rated voltage and frequency and at 75 Deg. C. shall be as under:

RATING (KVA) Total losses (watts) at 75 Deg. C Total losses (watts) at 75 Deg. C
at 50% loading (Max.) at 100% loading (Max.)
63 340 1140

The above specified loss values are maximum guaranteed, without any positive tolerance. In
case the actual loss values exceed the above guaranteed values, the transformers shall be rejected at
the risk, cost and responsibility of the supplier.

7. TEMPERATURE RISE:

EACH TRANSFORMER SHALL BE CAPABLE OF OPERATING CONTINUOUSLY AT ITS NORMAL RAT -

ING WITHOUT EXCEEDING FOLLOWING TEMPERATURE RISE WITH THE ABOVE SERVICE CONDITIONS
GIVEN IN CLAUSE-3.

i) 35 DEG. C IN OIL BY THERMOMETER.

ii) 40 DEG. C IN WINDING BY RESISTANCE

The Hot spot temperature at annual weighted average ambient temperature of 35 o C shall not
exceed 98o C, when calculated as per IS: 2026 (Part-II).

Page 44 of 623
HOWEVER, THE TRANSFORMER SHALL BE DESIGNED FOR CLASS ‘A’ INSULATION

8. UNBALANCE CURRENT:

The maximum value of unbalance current in transformers shall not exceed 2% of full load
current.

9. IMPEDANCE:

The percentage impedance at rated current and at 75°C shall be 4.5% with plus/minus (+/-)
10% tolerance.

10. TAPPINGS:

No taps are to be provided in these transformers.

11. FREQUENCY:

Transformers shall be designed for normal frequency of 50 Hz, but shall be capable of giving
the rated output with the variation of plus/minus (+/-) 5% from the rated frequency.

12. ELECTRICAL CLEARANCES:

(A) EXTERNAL (IN AIR)

Minimum external electrical clearances after mounting the bimetallic terminal connectors in
position shall be maintained, as under, however positive tolerance shall be acceptable without any
ceiling.

Voltage Medium Clearance

Phase to phase Phase to earth

11000 Volt AIR 255 mm 140 mm
433 Volt AIR 75 mm 40 mm

Page 45 of 623
B) INTERNAL (IN OIL):

The following minimum internal clearances shall be maintained as per details givenhere-
under:

PARTICULARS 63 KVA
a) On width side (non bushing side) 25 mm
b) On length side (bushing side HV & LV both) 40 mm
c) Between HV windings & yokes (end insulation) 20 mm
d) Between LV windings to core (Bare conductor) 3.5 mm
e) From top of yoke to inside of top cover of tank (with gasket) 75 mm
f) Between LT/HT winding (Radial bare conductor Clearance) 11 mm
g) Phase to Phase Clearance between HV limbs 10 mm

The aforesaid external and internal clearances are minimum clearances and no negative tolerance on
these clearances shall be allowed.

13. TEST VOLTAGE:

Transformers shall be capable of withstanding the power frequency and impulse test voltage
prescribed below:

Nominal system Highest system Impulse withstand Power frequency test

Voltage (RMS) voltage (RMS) voltage voltage in (RMS)
11 KV 12 KV 75 KVp (Minimum) 28 KV
0.433 KV ---- ---- 3 KV

The Transformer shall have fully insulated windings designed for the above impulse level.

Page 46 of 623
14. HEAT DISSIPATION (COOLING) / RADIATOR CALCULATIONS & E T R / PSR
(ELLIPTICAL TUBE RADIATORS/ PRESS STEEL RADIATOR) PLACEMENT:

The transformers shall be capable of giving a continuous output without exceeding the speci-
fied temperature rise. Elliptical tube radiators/Press steel radiator of section 57 of gauge 18 (withtoler-
ance as per relevant ISS) shall be acceptable on the transformers.

The radiator tubes shall be arranged in two equal banks fixed at two opposite non bushing
sides. The header pipe connecting radiator bank to the tank shall be rectangular in shape with approx-
imate size of 100x20 mm. alternatively round pipe of dia 32 mm can also be used for connecting the
radiator bank to the tank. The placement of top header pipe to the tank body shall be above the top of
yoke, to facilitate cooling for hot oil sump over top yoke.
Cooling area of the tank/radiators should be sufficient to dissipate the guaranteed losses satis-
factorily. Necessary calculations in this regard shall be furnished by the Manufacturer with theirten-
der. For the purpose of heat dissipation calculations, the following criteria shall be adopted:

i) Plain surface of tank – 500 W/m2

(Note: The area of top/bottom tank surface, headers, HV/LV bushing pocket and
conservator shall not be considered for purpose of above calculations).
ii) Elliptical tube of section 57 / Press steel radiator -- 55 watts/meter length.

Note- The provision of radiator is essential in distribution transformers to be supplied against this
tender.

15. WINDING AND INSULATION:

i) MATERIALS:

Super Enamelled /Double paper covered conductors shall be used for 11 KV class transform-
ers of 63 KVA & 100 KVA rating. The covering shall conform to IS:6162 (part I & I
ii) CONSTRUCTION:

Page 47 of 623
mm shall be used between HV and LV windings. Alternatively 20 mil pressphan paper making
thickness of the cylinder 1.5 mm having similar electrical properties may also be used.

For phase barrier, 2 Nos. of 1 mm thick press board shall be used for covering the tie rods.
Besides, tie rods shall be covered by SRBP tubes of suitable size.

2 mm press board shall be used for base support insulation and core clamping channel insula-
tion.

For bottom and top yoke insulation, only PC Board of min. 2 mm thickness will be used.
Also, vertical spacers between HV and LV coils and radial spacers (tickleys)/ blocks etc. shall
be of PC Board only.

A tolerance of upto plus minus 1% shall be permissible on ID and OD and axial length of HV
and LV coils. However, the above tolerances are subject to maintaining the min. required clearances.
The material and thickness of various insulation provided for phase barrier, foot plate insulation, yoke
insulation and core clamp insulation shall be clearly indicated in the drawing and in any case shall not
be inferior to those used in type tested transformers.

Min. number of coils on HV side shall be 4 (four) per phase for 63 KVA & 100 KVA rating
transformers. Dovetailed shaped radial spacers shall be placed between HV coil sections, suitably –
locked with vertical spacers around the circumference of the coils. The number of such spacers shall
be minimum 4(four).
In case of wound core one HV coil is accepted.

Current Density

The current density for HV and LV conductor shall not exceed the value given hereunder:

Rating Current density in Amp/mm .sq.

HV winding LV winding
63 KVA 1.6 1.6
100 KVA 1.6 1.6

iii) INSULATION MATERIAL: Electrical grade insulating Kraft paper of only Triveni / Ballarpur /
Padamjee shall be used. Press Board used shall be of senapathy whitely / Raman make. Perma wood
or haldu wood blocks shall be used for Top and Bottom yoke insulation.

Page 48 of 623
iv) CONNECTIONS AND TERMINATIONS:

A) HV Winding: The following method shall be adopted for taking out HV connections-
a. The coil series connections shall be made by soldering / brazing only, after completely
removing the insulation from the ends.
b. STARTING AND FINISHING LEADS OF HT COILS SHALL BE COVERED WITH EMPIRE
SLEEVE(S) OF PROPER SIZE. THESE LEADS SHOULD BE CLAMPED WITH THE BODY OF THE
WINDING WITH THE HELP OF COTTON TWINE DURING MANUFACTURE OF THE COILS .
c. All delta leads from the HT coils as well as HT line leads shall be taken out through
multiple paper covered (MPC) copper wires of sufficient cross section area to impart
the desired mechanical strength. The current density in HV lead wire shall not exceed
0.8 A/mm². These lead wires shall be provided with multi layer paper insulation of
minimum 1.0 mm thickness i.e. minimum increase in diameter due to paper insulation
shall not be less than 2 mm. The layer of glass sleeves/ glass tape shallalso be provided
on the delta MPC wire and it should be further covered with minimum12 mm dia SRBP
tube. The MPC should also be varnish dipped. The SRBP tube shallbe extended in such
a way that it is entered upto 50% of bushing height.
d. All the above leads shall then be clamped tightly with cotton twine directly on to the
special frame/bracket making “Pie” shape connection. This structure could be made
up of Bakelite/ Permalli wood/ laminated PC board flats, having minimum thickness
of 6 mm. Line leads leading to the HV bushing terminals shall be directly clamped to
the horizontal support bar of the “Pie” structure so that any tension which may develop
in the HT leads due to jerks or at the time of making the connection, is not passed to
the HT coils.
e. Delta joint and lead from delta joint to bushing rod shall be made by brazing only.

B) LV Winding:

A) The LV connection shall be taken out by cut on the top yoke channel duly reinforced to
compensate for the mechanical strength.

B) The layers in LT Coil may be either even or odd in numbers but minimum layers shall be two.

C) LV star point shall be formed of aluminium flat of sufficient strength. Leads from
winding shall be connected to the flat by brazing.

D) Firm connection of LT winding to bushing shall be made of adequate size of “L shape flat”.
Connection of LT coils to L shape flat shall be by brazing only.

e) “L” shape Flat shall be clamped to LV Bushing metal part(s) by using nut, lock nut and washer.

F) Neutral of the Secondary winding (LV) shall be brought out to a separate insulated bushing.

Page 49 of 623
G) For Aluminium windings, L&T, ALKAPEE Aluminium brazing rods with suitable flux will be
used.

16. CORE CONSTRUCTION & CORE COIL ASSEMBLY DETAILS:

A. CRGO CORE
(i) The core shall be stack/wound type of high grade cold rolled grain oriented annealed steel
laminations, having low loss and good grain properties, coated with hot oil proof insulation, bolted
together to the frames firmly to prevent vibration or noise. All core clamping bolts shall be effectively
insulated. The complete design of core must ensure the permanency of the core losses with continuous
working of the transformers. The value of the flux density allowed in the designs and grade of lami-
nations used shall be clearly stated in the offer, along with the curves. The transformer core shallbe
constructed out of the prime class of materials. CRGO Lamination used shall be of prime grade and
not second grade steel laminations.

(iii) Full mitred core construction technique shall be adopted. Top yoke & bottom yoke pieces
shall all be in one single piece and no cut pieces shall be acceptable. The cross sectional area of yoke
& limb shall be approximately same.

(iv) The transformer core shall not get saturated for any value of V/f ratio to the extent of 115% of
the rated value of V/f ratio (i.e. 11000/ 50) due to combined effect of voltage and frequency without
injurious heating at full load conditions. The manufacturer shall furnish necessary design data in
support of this situation.

(v) Flux density at rated voltage and frequency of core and yoke shall not be more than 1.60
Tesla. The Over fluxing shall be limited to 12.5% of rated value and flux density at 112.5% of rated
voltage does not exceed by 1.9 Tesla.

The No Load Current (magnetising current) at rated voltage and at 112.5% of rated voltage
shall not exceed the values given below:

Maximum permissible magnetising current in percentage of rated full load current

Rating At 100% rated voltage At 112.5% rated voltage
63 KVA 3% 6%

Page 50 of 623
100 KVA 3% 6%

The tolerance on magnetizing current shall be +30% on declared value of magnetizing current as per
IS: 2026.

vi) Core Clamping:

i) MS Channel of 100 X 50 x 6 mm min. size shall be used on top and bottom (for stacked
core transformers). Rolling tolerance will be as per IS:1852-1985 with latest amendment.
ii) 2 x 12 mm high tensile bolts to be used in parallel at each end.
iii) Channel on LV side to be reinforced at equidistance, if holes/cutting is done for LT
lead in order to avoid bending of channel.
iv) MS channel shall be painted with varnish or oil-resistant paint.
v) Tie-rods: 4 Nos. of M12 M.S steel rods shall be effectively insulated.
vi) All top and bottom yoke nuts & bolts and tie rods shall be painted with oil and
corrosion-resistant paint and phosphate coated paint for tie rods before use.
vii) Only prime quality CRGO sheets should be used in the transformers and no
Second/Defective/Scrap CRGO finds way into transformers.

B. AMORPHOUS METAL:

b) Core Clamping – Amorphous Metal and CRGO wound core Transformers

1. Core clamping shall be with top and bottom U-shaped core clamps made of sheet steel clamped
with MS tie rods for efficient clamping.
2. MS core clamps shall be painted with varnish or hot oil resistant paint
3. Suitable provision shall be made in the bottom core clamp/bottom plate of the transformer to
Arrest movement of the active part.

Page 51 of 623
d) Flux density should not be more than 1.6 Tesla for Amorphous core. No load current shall not
exceed 3% of full load current and will be measured by energizing the transformer at 433 volts
50 c/s on the secondary. Increase of voltage of 433 volts by 12.5% shall not increase the no load
current disproportionately high and shall not exceed i.e., 6%. Test for magnetic balance by connecting
the LV phase by phase to rated phase voltage and measurement of an, bn, cn voltage will be carried
out.

NOTE: Equal Weightage shall be given to the transformers with Amorphous metal core and CRGO.

C. CORE-COIL ASSEMBLY:

The core joints shall be interleaved and with full mitre design, as mentioned above. Ample provision
for free circulation of oil in the radial gap between the core & LV coils shall be made. Eyes or lugs
of sufficient size shall be provided for lifting core and winding assembly out of the tank. The core
shall be effectively earthed through copper earthing Foil of 25 mm width & 1 mm thickness bolted
on core frame channels after removing the channel paint.

On the core-coil assembly, core clamping channels, tie rods, core studs, spacers, assembly
base supports, etc. shall be provided as per details given hereunder:

Sr. Item Particulars

No.
a) Tie rods Minimum 4 Nos. of 12 mm each properly insulated and covered with SRBP
tubes. Tie rods shall also be provided with lock nuts.
b) Core studs Minimum 4 Nos. of 2X12 mm each properly insulated and covered with SRBP
tubes. The core studs shall also be provided with lock nuts.
c) Spacers Minimum 4 Nos. dovetail type with min. peripheral coverage of 30%.

d) Support of core 2 Nos. MS channels OF 100X50x6 mm, with minimum peripheral coverage
assembly base of 40%.
e) Channels for 4 MS Channels of 100X50x6 mm size (applicable for CRGO transformers)
clamping core
coil assembly

Page 52 of 623
Guides on all the four sides shall be provided to prevent shifting of the active parts and thereby
accidental touching the tank. Alternatively boss nut arrangement at the top of core coil assembly to
lock the same with the transformer tank be provided.

The assembly fixing boss nut(s) are to be welded, 20-30 mm off the centre line (and diago-
nally) of the tanks, so that assembly shifting during transport etc. is prevented. M S Channel, Tie Rods
etc should be painted with hot oil and corrosion resistant paint before use.
All core-coil assembly shall be punched on core channel / an identity plate welded on core
channel with following details:

1. Name of Supplier:
2. Order/TN No:
3. Rating:

17. TRANSFORMER TANK:

(a) Transformer tank shall be rectangular in shape, robust in construction and with adequate
strength to withstand the pressures developed at the time of severe fault conditions. The tank
body shall be suitably stiffened with stiffener of size 50x50x6 mm angle. The edge of the
angle shall be continuously welded full length with the tank cover body as per drawing en-
closed at Annexure-A. The tank sheet shall be electrically continuous welded both from inside
and outside to impart proper mechanical strength and to plug leakage of oil. All jointsof tank
and fittings shall be oil tight and no bulging shall occur during service. The tank designshall be
such that the core and windings can be lifted freely. The tank plates shall be of such strength
that the complete transformer when filled with oil may be lifted bodily by means of lifting
lugs provided. All the welding shall be continuous. The top cover plate shall be slopingdown
by more than 15 mm, opposite LV bushings side. The top cover edge should be extendedby Min.
30 mm in such a manner to cover gasket each side and it should be bent at Min. 15° angle.
Accordingly length of the lifting hooks shall be extended. The top cover shall have nocut at
point of lifting lug. No negative tolerance in the tank dimensions is acceptable in actualsupply.
There should be no welding on corners (two ‘C’ shape sections be welded in such a

Page 53 of 623
way that the joint of the cover should be at the centre of the tank on non-bushing side). The
bottom plate shall be extended at least by 5 mm outside on all sides to facilitate proper welding
with the vertical tank walls as per drawing enclosed at Annexure-A. No grinding at welding
portion is permissible. No joints in its bottom and top cover will be allowed. LV Bushing
pocket shall be continuously welded on all side from both inside and outside on the tank wall.

Note: In addition to two 'C' shape sections welding, the following type may also be accepted:
i) One 'L' and two 'I' shape sections
ii) One 'U' and one 'I' shape sections

(b) (i) Minimum size of MS Sections to be used in construction of transformer tanks shall be as
under:
(c)
Sr.No. ITEMS 63/100 KVA
1 Tank Cover plate thickness (mm) 5.0
2 Tank Sides wall thickness (mm) 3.15
3 Tank bottom plate thickness (mm) 5.0
4 Conservator body (mm) 2.0
5 Detachable Conservator side Cover N.A.
6 No. of stiffeners (To be welded on four
side of the tank in the angle forms inverted 1
“L”)
7 Size of M. S. stiffener (mm) 50x50x6 Angle
8 Tank Top flange size (mm) 50 x 6 Flat
9 Cover Bolt Size As per IS 1180:Part-1
(2014)**
10 Cover Bolt spacings (Maximum) 75 mm
11 Lifting lugs 2 Nos.
8 mm Flat
12 Tank Base Channel (ISMC Type) 2 (100 x 50 x 6 mm)

**All nuts , bolts/washers/Fastener used in transformers of stainless steel upto 12mm and above
12mm-steel with suitable finish like electro-galvanized with passivation or hot dip galvanized as
IS:1180Part 1/2014

NOTE:

Page 54 of 623
a) Each cover bolt shall be complete with two flat washers, one nut and one spring
washer.
b) Tank base channel shall be continuous welded with tank.

The 12 Nos. Nut Bolts (4 Nos. each on length side and 2 Nos. each on width sides of the tank
body) to be tag welded on the top cover/tank body of the transformer.

The 04 Nos. Anti Theft Fasteners shall be provided - one each on all four sides in centre of
body of transformer.

TWO HOLES SHALL BE PROVIDED – ONE ON TOP COVER AND OTHER ON COLLAR OF TRANSFORMER
TO FACILITATE PROVIDING OF 2 NOS. POLY-CARBONATE SEALS ON LONGITUDINAL SIDE.

The above mentioned MS sections shall be subject to tolerance as per ISS.

(b) MEASUREMENT OF SHEET THICKNESS OF TRANSFORMER TANK

The following measurements shall be carried out at respective Central Testing Lab (CTL) of
the Discom(s) on the supplies of distribution transformers:

Measurement of Transformer Tank Thickness shall be done as follows:-

1. Top Cover At 2 places to be measured &av-

erage is to be taken.
2. Bottom Cover -do-
3. Side Wall(s) On all four sides
(average is to be taken)
·

The nominal value of sheet thickness will be considered as mentioned in the Specification.
·· Rolling tolerance will be as per ISS:1852-1985 with latest amendment and no penalty will be
charged on such measured thickness till tolerance limit of ISS.
··· Sheet thickness of transformer tank as per relevant tender specification is as under for ready
reference:

Page 55 of 623
Sr. Rating Top Cover (mm) Bottom Cover Side of Tank
No. (mm) (mm)
1 63 KVA Three Phase 5.0 5.0 3.15

(c) Lifting Lugs: Two Nos. welded heavy duty lifting lugs of MS plate of 8 mm thickness, suitably
reinforced by extended vertical supporting edge of same thickness in one piece having size 125
mm width and 125 mm length, these shall be so extended that cutting of bent plate is not re-
quired.

(d) Top cover gasket Nut & Bolt:

i) The gasket provided in between top cover plate and tank shall be of min. 6 mm thick neo-
prene rubberized oil resistant cork sheets conforming to type B or C as per IS 4253 partII
ii) Stainless Steel Nut bolts (as per IS:1180 (Part-1/2014)) shall be of size M 10 x 40 mm /
3/8x1.5” long with two flat washers, suitably spaced (as specified) to press the cover.
iii) Height of the tank shall be such that minimum clear height of 75 mm is achieved between
top of yoke and under side of the tank cover (with gasket in place).
iv) All nuts , bolts/washers/Fastener used in transformers of stainless steel upto 12mm and
above 12mm-steel with suitable finish like electro-galvanized with passivation or hot dip
galvanized as IS:1180Part 1/2014.
v) All sealing washers / gaskets shall be made of oil and heat resistant neoprene or
nitrile rubber. Gaskets made of natural rubber sheet are not permissible. The
minimum thickness of gaskets shall not be less than 6 mm for tank cover and 4mmfor
HT/LT gasket washers.
vi) New cork/ Talbros make neoprene/nitrile based rubberized cork sheet – grade RC-70-C
shall only be used as gasket material. Alternatively, other makes of gaskets having type
designations as under can also be used, if ‘Talbros’ make gasket is not available:

S. No. Name of the firm Commercial name of gasket manufactured by the

firm.
M/s. Nu-Cork Products P. Ltd.
1. Nu-Cork (Neoprene) Nu-Cork 999 RC-70-C
Gurgaon
2. M/s. Bharat Corrub Ind.
Vadodara Chetak (Neoprene) RC-70-C

Page 56 of 623
3. M/s. Grindbeck. Gujarat
Zebra (Neoprene) RC-70-C

M/s Goodwill Rubber Ind. (P)

4. Mayur (Neoprene) RC-70C
Ltd., Calcutta.

(e) Tank shall be reinforced by continuously y welded angle on all the four sides of the walls, on the
edge of tank, as specified above. The permanent deflection shall not be more than 5 mm upto750
mm length and 6.5 mm upto 1250 mm length when transformer tank without oil is subjectedto the
vacuum of 250 mm of Mercury.

f). PAINTING & FINISHING:

Steel surface shall be prepared by sand/shot blast or chemical cleaning including phosphating,
as per IS:3618. Inside of tank shall be painted with varnish or oil resistance paint. For external surface,
one coat of thermo-setting powder paint or one coat of epoxy primer followed by 2 coat of polyure-
thane base paint of olive green colour confirming to Shade No. 220 of IS:5-1961 to be appliedin order
to distinguish of star label transformer. The paint thickness for normal to medium corrosive atmos-
phere is as per IS:1180 (Part-1/2014).
The requirement for the dry type film thickness (DFT) of paint and the materials to
be used shall be as given below.

Sl. Paint Type Area to be No. of Total Dry film

No. Painted coats thickness (min.)

1. Thermosetting Paint Inside 01 30 microns

Outside 01 60 microns
2. Liquid Paint
d) Epoxy( Primer) Outside 01 30 microns

e) Polyurethene base (Finish

coat) Outside 02 25 microns each
f) Heat resistance paint (Hot oil
proof Paint)

Inside 01 35/10 microns

Page 57 of 623
18. FITTINGS & ACCESSORIES:

The following standard fittings shall be provided on each transformer:

a) Earthing terminals of M10/ 3/8x1.5” with tinned lugs and symbol – (2 Nos.)\
b) Lifting lugs – (2 Nos. for main tank).
c) Rating and terminal marking plate shall be non-detachable and affixed with Min. 10 rivets (One
in centre of top and bottom and 4 Nos. each on both vertical sides at equal distance), details to
be included in one plate only. The plate shall be of stainless steel/Aluminium only, with details
clearly marked. The base plate of the Rating and terminal marking plate shall be continuously
welded with the tank. - (1 No.)
d) Bi-metallic terminal connectors on HV bushings and it may be ensured that connectors shall be
fitted before dispatch.
e) Oil level gauge of minimum 150 mm length of prismatic glass, indicating three positions of oil,
marked as follows, shall be provided at centre of the conservator tank:

1) -5°C - Min.
2) 30°C - Nor.
3) 98°C – Max.

f) Free Air Type Breather – (1 No.)

g) Thermometer pocket, 12.5 mm dia with cap. shall be provided –– (1 No.)

h) HV Bushings. These shall be of 17.5 KV/250 A class, with non adjustable, single gap type
arcing horns – (3 Nos.)

i) LV Bushings. 1.1 KV class, 250A (M12 stem) – (4 Nos.)

j) Under carriage: For transformers of 63 KVA & 100 KVA rating shall conform to REC specifi-
cations.
k) Brass rod 12 mm diameter for HT – (3 Nos.)

l) Brass rod 12 mm diameter for LT – (4 Nos.)

m) Pressure Relief Valve of Aluminium body with 1” BSP Thread capable to operate at a pressure
more than 0.4 Kg/cm2 (40 KPa) positive or negative and close at 30 KPa on the top cover of the
transformer tank with Anti-Theft Clamp be welded to safeguard the valve. There shall be mini-
mum gap of 10 mm between PRV Top Surface and Anti-Theft Clamp.

n) Explosion vent: Explosion Vent shall be opening towards ground from LV bushing side with
M. S. mesh having Pipe Diameter of minimum 50 mm with 0.025mm copper shim sheet/

Page 58 of 623
Bakelite thick sheet of 0.4mm thick as diaphragm shall be provided on the top of the cover of
the tank such that the pressure released should be directed to the ground & it should be inserted
in the top cover of tank, welded outside & inside of top cover. Length of the explosion vent
should be minimum 700 mm. Nut bolts of flange of Explosion vent should be tag welded. The
other end of the vent pipe shall be guarded with wire mesh for preventing the entry of worms
and nesting. The diaphragm shall burst at a pressure of 0.76 to 0.95 kg/ sq.cm. There shall be
minimum 140 mm clearance between live part of HV bushing to Explosion vent.
o) QR code laminated P touch labels shall be fixed on transformer tank body below the name plate
and on the core coil assembly (on core channel) depicting various technical details such as Name
of manufacturer, rating, Serial no, TN No. etc. QR Code with desired information to be printed
on non-tearable matt finish label and to be covered with transparent label to retain label life for
minimum 20 years. Provision of Sr. No. on QR Code to be affixed on Core Coil Assembly (on
core channel) is optional.

Note: LV/ HV Connector shall not be the integral part of the bushing stems.

19. CONSERVATOR:

When a conservator is fitted, the oil gauge and the breathing device shall be fixed to the conservator.
The conservator shall be of cylindrical shape and it should be provided above the HV bushing with a minimum
clearance of 50 mm and suitably inclined to maintain the clearance.
The conservator tank should be connected with transformer tank with the help of two hollow connect-
ing pipes and should be located at the centre of tank cover. The Flat shall not be acceptable.
The total inner volume of conservator shall be minimum 15 Liter for 63 KVA transformer. The inside
diameter of the pipe connecting the conservator to a main tank shall be min. of 30 mm and it should be projected
into conservator in such a way that its end is approximately 25 mm above the bottom of conservator so as to
create a sump for collection of impurities. The min. oil level (corresponding to – 5 deg. C.) should be above
the sump level. The connecting pipe from conservator tank to main tank shall have a sloping flap so that oil
falling from pipe shall not fall directly on the active job.

Apart from the features specified in this clause for conservator tank, the oil filling hole cap of
conservator shall be welded with tank body with the help of suitable inverted ‘U’ shape clamp.

20. FREE AIR TYPE BREATHER:

21. HV BUSHING TERMINAL DETAILS:

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The transformer shall be provided with outdoor type 3 Nos. 17.5 KV /250 A class porcelain
bushings, conforming to IS:3347/1972 & IS:2099/1973 from the manufacturer of repute. The LV/ HV
bushings shall be on the opposite side of the tank. The bushing on the top cover of the transformershall
not be acceptable. The bushings rods and nuts shall be made of brass. The HV bushing shall befitted
on a conical pocket (full length tank) on the tank body and not directly on the pipe/ flange. However,
small pieces of pipe may be mounted on conical pocket for maintaining electrical clearanceif required.
The inner porcelain portion of the bushing shall be projected about 50% of the length inside the con-
ical pocket. HT bushing(s) mounting bolts should be tag welded.
The clamping ring of HV bushing shall be of galvanised MS Sheet having minimum thickness
of 1.6 mm. The total weight of all the 12 aluminium caste member of HV bushing shall not be less
than 210 grams.

The arcing horn(s) shall be single gap and fixed type. HV bushings shall be of reputed make
such as BEPCO, JAYSHREE, WSI, SESHASAYEE, JAIPUR GLASS, BPPL Bikaner, Agarwal salt
Co. Bikaner, Bais Sanitary Works, Bikaner/KRISHNA CERAMICS, NASIRABAD, ADPRO,
SHINE or any other make - approved by the purchaser. The HV bushings shall generally conform to
IS: 3347 and IS: 2099. Embossing showing the manufacturer’s name and month & year of manufac-
ture shall be clearly visible on HV bushings, even after fixing on transformer(s).

As mentioned earlier, suitable bi-metallic connectors shall be provided, forming an integral

part of the bushing stem, having capacity of about 1.5 times the rated current of the transformer.

22. LV BUSHING TERMINAL DETAILS:

LV Bushing side shall be opposite to the HV Bushing side. 4 Nos. LV Bushings (1.1 KV/ 250
A) shall be mounted on a special pocket on the tank wall. Projection of the LV pocket shall be such
that inner portion of the LV stem shall not project more than 20 mm inside the tank, to facilitate
unhindered lifting of the core coil assembly. Bushing stem of M12 size shall be of brass. Rest of the
components shall conform to the requirement of IS:3347 (Part I/section 2). The LV bushings shall
be of reputed make such as JSI, JAIPUR GLASS, BPPL Bikaner, Baid Sanitary Works, Bikaner,
Agarwal salt Co. Bikaner, ADPRO, SHINE or any other make approved by the purchaser. The LV
bushings shall generally conform to IS: 3347 and IS: 7421.

23. TRANSFORMER OIL:

The transformer shall be supplied complete with first filling of EHV Grade transformer oil,
up to the normal oil level. The oil shall conform to IS: 335-1993 (latest amended) and should be ISI
Marked and having the specified aging characteristics. The Break Down Voltage Value of the fresh
oil after filtration and before filling in the transformer should be above 60 KV and after filling in the
transformer it should be above 40 KV.

The make of Transformer Oil shall be either APAR/SAVITA/ RAJ LUBRICANTS/ ANA-
MIKA/SHARAVATI/ MADRAS PETRO/ RAJ PETROL/ LUBRICHEM, MUMBAI/

Page 60 of 623
OPANAMA PETROCHEM, ANKELSHWAR/ TASHKENT OIL, VADODARA/COLUMBIA. The
transformer oil sample taken from the transformer shall be subject to testing as per provisions
ofIS:1866.

The oil manufacturer’s test certificate shall be made available at the time of inspection to the
inspecting officer.

24. IDENTIFICATION DETAILS:

A. RATING & TERMINAL MARKING PLATE: EACH TRANSFORMER SHALL BE PROVIDED WITH NON-
DETACHABLE NAME, RATING AND TERMINAL MARKING PLATE FITTED IN A VISIBLE POSITION.
ALL DETAILS SHALL BE GIVEN ON ONE PLATE. MATERIAL OF THE PLATE SHALL BE STAINLESS
STEEL/ALUMINIUM ONLY. THICKNESS SHALL BE 0.9 MM (WITH A TOLERANCE OF ±0.1 MM). THE
PLATE SHALL BE MADE ABSOLUTELY UNDETECTABLE EITHER THROUGH WELDING OR RIVETING
OR THROUGH ANY OTHER APPROVED METHOD.
Each HV & LV terminal shall be duly indelibly marked with its terminal numbers. (e.g. HV
terminal with capital letter 1U, 1V, 1W and LV terminal by corresponding small letters 2u, 2v, 2w
and the neutral terminal by 2n) by stamping with Min. letter size of 40x40 mm. In the diagram to be
given on the name plate, the relative position of various terminals- when viewed from top – shall be
clearly shown. Inspection shall not be undertaken unless all these details are verified by the Inspecting
Officer.

Besides other particulars, following details shall also be given on the name plate:

i) P.O. No. - month & year.

ii) Sr. No. of transformer.
iii) Date of despatch - month & year
iii) Date of expiry of guarantee period – month & year
iv) Maximum Guaranteed Losses at 50% loading & at 100% loading.
v) Name & Full address of the manufacturer.
vi) Capacity of the transformer.
vii) Rating of the transformer.
viii) Type – Oil filled naturally cooled.
ix) IS:1180( Part-1/2014)
x) BIS Level-2 with BIS Licence No.

ALL DETAILS ON THE NAME RATING AND DIAGRAM PLATE SHALL BE INDELIBLY
MARKED i.e. BY ENGRAVING, STAMPING or PUNCHING.

B. TECHNICAL CUM IDENTIFICATION PLATE - M.S. PLATE OF SIZE 125 X 75 X 2.5 MM HAVING FOL-
LOWING DETAILS PUNCHED WITH LETTERS OF SIZE 8MM X 6MM SHALL BE CONTINUOUSLY
WELDED TO THE MAIN TANK BODY BELOW THE MIDDLE HV BUSHING IN CLEARLY VISIBLE POSI-
TION:-

Page 61 of 623
I. Name of the Firm
II. TN No.
III. Make
IV. Sr.NO.
V. JAIPUR DISCOM
VI. Rating
VII. Date of Dispatch
VIII. Date of Expiry of G. P.
IX. Core :-
3. Core Dia
4. Core Area
X. LV Coil :-
1. ID/OD Dimensions
2. Conductor Size
XI. HV Coil :-
1. ID/OD Dimensions
2. Conductor Size
XII. Limb Centre
XIII. Window Height

MAKE
S. No.
TN

The details of Make, TN No. & Sr. No. of transformer shall also be punched on the top cover.
The punching shall be distinct and visible with letter size 10x10x1 mm.

25. GUARANTEED AND OTHER TECHNICAL PARTICULARS FOR TRANSFORMERS:

Guaranteed Technical particulars of the transformers offered shall be furnished in A-4 size
paper by the Manufacturer in the pro-forma appended herewith at Annexure-A. Complete details shall
be furnished. Tolerances on weight quantity and dimension figures shall be ± 5% (except for internal
configuration) at the tender stage, subject to maintaining the minimum electrical clearances as per the
specification. However, no negative tolerance shall be allowed on the short circuit type tested design.
Electrical performance data shall be subject to tolerances as per ISS, unless otherwise specified in this
specification. However, the No Load loss and Load loss figures shall be maximum guaranteed without
any positive tolerance.

Page 62 of 623
26. TYPE TEST CERTIFICATES:

The manufacturer shall furnish type test certificates of offered design / similar design, wher-
ever available, with the bid not older than five years from the date of opening of technical bid.

27. DRAWINGS AND OTHER DOCUMENTS:

a) Name rating/diagram plate drawing.

b) Outline and general arrangement drawing.
c) Core-coil assembly drawing.
d) Core section (for limb and yoke) along with flux density calculation sheet/ drawing.
e) Cooling area calculation sheet.
f) Thermal Ability short circuit calculation sheet.
g) Core loss and magnetization curves of the laminations.
h) Heat dissipation calculations (heat dissipation by tank walls excluding top and bottom
should be 500 W/m2.

28. QUALITY ASSURANCE PLAN:

The purchaser intends to purchase Transformers only from quality conscious manufacturers.

The manufacturer shall furnish the details in respect of following, in the schedules prescribed
herein this specification, failing which the offer is liable for rejection.

a) List of testing equipment and instruments (with class of accuracy) available with manu-
facturer for inspection, testing and checking the Transformers offered, as per tenderspeci-
fication in the schedule of testing facilities (Schedule-VIII). The calibration details should
also be included.
b) List of machines/equipment/T&P available with the manufacturer for manufacturing the
Transformers, in the schedule of plant and machinery (Schedule-IX).
c) Details of type tests conducted on the Transformers offered to supply in the schedule of
type test (Schedule-X).
d) List of raw material components and sub-assembly to be used for manufacturing the
equipment offered, in the schedule of raw materials and components.
e) Statement giving list of important raw materials, names of sub-suppliers for the raw ma-
terials, list of standards according to which the raw material are tested. List of tests nor-
mally carried out on raw materials in the presence of Manufacturer’s representative, cop-
ies of test certificates.
f) Information and copies of test certificates in respect of bought out accessories.
g) Level of automation achieved and list of areas where manual processing exists.

Page 63 of 623
The manufacturer should possess adequate facilities for inspection and testing of the Trans-
formers, as per requirement of the relevant ISS and this specification. In case any supplier is found
not having all the instruments/equipment required for testing, the offer shall be ignored. No borrowing
of instruments / equipment shall be allowed. Testing of the Transformers shall also not beallowed at
the works of any other manufacturer. However, testing may be allowed at any GovernmentTesting La-
boratory.

29. INSPECTION AND TESTING:

(i) The inspection and testing shall be conducted as per relevant clause of the General
Conditions of Contract (Section-II) at the place of manufacture. The transformers shall be completely
assembled and tested at the factory. The inspection may be carried out by the purchaser at any stage
of manufacturing. The supplier shall grant free access to the purchaser’s representative at all reason-
able times when the manufacturing work is in progress. Inspection and testing of any materialunder
this specification by the purchaser shall not relieve the supplier of his obligation of supplying the
material in accordance with the specification and shall not prevent subsequent rejection if the material
is found to be defective.

(iii) The supplier shall keep the purchaser informed in advance, about the manufacturing
programme so that arrangements can be made for inspection. The supplier shall give minimum fifteen
days advance intimation to enable the purchaser to depute his authorised representative for in-
spection/ witnessing of various tests on the equipment/ material as detailed below:

NOTE:- Penal provision shall be made for any short technical parameters found / noticed in thetransform-
ers at any time even beyond guarantee period.

30. ROUTINE/ACCEPTANCE TESTS:

A) 100% testing of the Distribution Transformers shall be carried out at firm’s works for meas-
urement of total load losses at 50% & 100% loading. Remaining testing shall also continue to
be carried out as per practice.

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B) All the assembled/ finished transformers prior to despatch shall be subjected to routine tests as
per IS:2026. Minimum 25% of the offered lot size samples subject to minimum 5 Nos will be taken
for routine and acceptance tests. The supplier shall invariably furnish manufacturer’s routine test cer-
tificate along with inspection call of the offered transformers for pre-despatch inspection. The inspec-
tion offers without furnishing of routine test certificates as per ISS of all the transformers offered for
final inspection shall not be entertained, and any delay on this account shall be to firm’s account.

The selected samples shall be subjected to the following routine/acceptance tests at themanufac-
turer’s works in accordance with the relevant ISS:

1. Insulation resistance
2. Separate source voltage withstand test
3. Induced over voltage withstand test
4. Measurement of windings resistance cold (at or near the test bed temperature)
5. Measurement of Voltage ratio and check of voltage vector relationship
6. Measurement of Impedance voltage and load losses at rated current and normal frequency.
7. Measurement of total losses at rated voltage and normal frequency (at 50% & 100% loading).
8. Measurement of No load current at 100 % and 112.5% of rated voltage and normal frequency.
9. Checking of rating and terminal marking plate.
10. Pressure test & oil leakage test as per IS:1180 part-1 /2014
11. Checking of weights, dimensions, fittings and accessories, tank sheet thickness, oil quantity,
material, finish, paint thickness and workmanship as per purchase order and contract draw-
ings.
12. Physical verification of core – coil dimension, internal clearances, provisions of required oil
ducts in the HV and LV winding, conductor sizes, individual weights of HV and LV winding
core laminations etc., with reference to contract drawings and type test report(s) by disman-
tling selected unit(s). The physical verification shall be conducted on units equivalentto one
unit per 50 Nos or part thereof of offered quantity randomly selected from the offered lot. The
dismantled unit(s) after re-assembly shall be accepted by the purchaser after routine testing in
presence of his representative.
During final inspection, sheet thickness shall also be measured of the transformer opened for
physical verification. The instrument for measurement of sheet thickness will be provided by
the supplier.
13. Oil dielectric strength (break down voltage) test shall be carried out on the transformers
opened for physical verification and average value shall be calculated.
14. Checking of manufacturer’s test certificates and invoices for major raw materials shall be done
and copies thereof duly signed by firm’s representatives and inspecting officers shall be en-
closed with the inspection report.

Page 65 of 623
Invoices of CRGO/AMORPHOUS material shall be provided by the supplier to the inspecting
officer at the time of inspection and same shall be verified by the inspecting officer.

Following tests shall also be carried out at manufacturer’s works on one complete unit of 63
KVA Transformers unit:

Fifteen days clear notice shall be arranged for pre-despatch inspection by purchaser’s repre-
sentative as per General Conditions of Contract.

After successful inspection, the inspecting officer shall seal each and every transformer by
sealing the transformer with 2 Nos. poly-carbonate seals on longitudinal side as per the manner men-
tioned in Clause No. 17 above. Before sealing, the inspecting officer will ensure that all the offered
transformers are complete and duly fitted with name, rating and diagram plate, identificationplate (on
tank body & Top cover) as specified in this specification.

i) INSULATION RESISTANCE MEASUREMENT:

Insulation resistance of selected samples shall be measured with a 2500 V Megger, of

standard make such as M/s AVO, M/s Sakova, M/s Wako, M/s Evershed, Vignole or Metrawatt. The
minimum insulation resistance, in Mega Ohms, shall be as indicated in the table below:

20oC 30oC 40oC 50oC 60oC

11000 Volts (HV) 800 400 200 100 50
433 Volts (LV) 400 200 100 50 25

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iii) PRESSURE TEST: (As per IS: 1180 (Part 1):2014) -This test shall be conducted as type test at a
Govt. approved/ a Govt. recognized/ NABL accredited laboratory. The pressure gauge and vacuum
gauge shall be duly calibrated and sealed by an independent recognized test lab(s).

The test procedure shall be as detailed below:

The tank subjected to pressure of 80 KPa for 30 minutes and vacuum of 250 mm of mercury
for 30 minutes. There should be no air leakage at any pont. The Permanent deflection of flat plate,
after pressure has been released, shall not exceed the values given below:
Length of plate up to Deflection

750 mm 5.0 mm
751 to 1250 mm 6.5 mm
1251 to 1750 mm 8.0 mm

iv) MAGNETIC BALANCE TEST:

This test shall be conducted as an additional test on one sample transformer from each lot
offered for inspection.

The application of low voltage to the middle limb will induce approximately equal voltages
on the two end limbs. The application of voltage to the end limbs will induce greater voltage in the
middle limb and less voltage in the other end limb. Uniformity of induced voltages shall confirm the
healthiness of the transformer windings.

The procedure for the test shall be as under:

a) Apply 250 Volts between LV terminals-2u-2n and measure voltages between 2v-2n &
2w –2n.
b) Apply 250 Volts between 2v-2n and measure voltages between 2u-2n & 2w-2n.

c) Apply 250 Volts between 2w-2n and measure voltages between 2u-2n & 2v-2n.

The measured voltages shall satisfy the conditions detailed as above.

v) OIL LEAKAGE TEST (As per IS:1180 Part-1/2014):

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The oil leakage test shall be conducted on one unit selected from the offered lot. The assembled
transformer for non-sealed and sealed Type with all fittings including bushing in position shall be
tested at a pressure equivalent to twice the normal head measured at the base of tank for 8 hrs. There
should be no leakage at any point.

31. TYPE TESTS:

Manufacturers have to furnish valid type test report of offered item not older than five years.
following Type Tests shall be conducted on one unit as per IS:1180 (Part-I)/2014 in accordance with
IS:2026 (Part-I to III) at NABL/Govt. approved Lab as under:

i) Short circuit test for dynamic and thermal ability: The short circuit test for dynamic and thermal
ability shall be arranged at CPRI, Bangalore/ Bhopal or ERDA, Vadodara on one unit of each
rating.

ii) Impulse voltage withstand test: The impulse voltage withstand test shall be arranged at any testing
house accredited to NABL for purpose of impulse test Impulse voltage withstand test shall be for
75 kvp minimum.

iii) TEMPERATURE RISE TEST : [ AS PER IS 2026 (PART 2) ]

Temperature rise test shall be conducted on Maximum measured total loss (No load at rated exci-
tation+Load loss at max. current tap at 75 oC) at 100% loading shall be supplied during tempera-
ture rise test at a Govt. approved/ a Govt. recognized/ NABL accredited laboratory/ILAC
i.e. International Laboratory Accredited Laboratory/ ILAC i.e. International Laboratory Accredi-
tation Cooperation (in case of foreign laboratory).

The transformer shall be capable of giving continuous rated output without exceeding the specified
temperature rise

(iv) AIR PRESSURE TEST: (As per IS 1180 (Part 1):2014)

This test shall be conducted as type test at a Govt. approved/ a Govt. recognized/ NABL accredited
laboratory. The pressure gauge and vacuum gauge shall be duly calibrated and sealed by an inde-
pendent recognised test lab(s).

The test procedure shall be as detailed below :

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The tank subjected to pressure of 80 KPa for 30 minutes and vacuum of 250 mm of mercury
for 30 minutes. There should be no air leakage at any pont. The Permanent deflection of flat plate,
after pressure has been released, shall not exceed the values given below:
Length of plate up to Deflection

750 mm 5.0 mm
751 to 1250 mm 6.5 mm
1251 to 1750 mm 8.0 mm

No extra time shall be allowed for arranging these type tests & BIS Certification etc. The cost of
above Type Tests shall be borne by the supplier.

The programme indicating date and place of type test(s), be intimated enabling purchaser to
depute his representative to witness the test if desired. The testing house shall be advised to arrange
type test result directly alongwith drawings duly attested by the testing authority for our scrutiny and
approval. The type-tested transformer(s) shall also be accepted as the part of the supplies.

The requirement of arranging above type tests shall however, not to be insisted on the suppliers
who have arranged above type tests within last 5 years from the date of opening of this tender on
similar design. Minor changes in the present specification will not necessitate repetition of type test(s),
if design of core-coil assembly is similar in essential details.

32. RANDOM SELECTION AND TESTING (RST):

32.1 The purchaser may select transformer(s) from the supplied lot(s) at random from the stores for con-
ducting the following type tests, at any test house(s) as mentioned above. The supplier shall arrange
these tests including loading, unloading and to & fro transportation from our stores to the testhouse(s).
The charges for such tests shall be reimbursable to the supplier on actual basis on productionof docu-
mentary evidence in case the selected sample successfully withstand type test(s). In case of otherwise,
no charges will be reimbursed.

i) Short circuit withstand test for Dynamic & Thermal ability. Measurement of total
Losses at 50% and 100% loading shall form part of tests conducted before and the after
the short circuit test and recorded in the report.
ii) Impulse test as per Clause No.13 of IS:2026 (Part-III). Impulse voltage shall be 75
KVp minimum
iii) Temperature Rise Test.
iv) Air Pressure Test at 80 KPa for 30 minutes and vacuum of 250 mm of mercury for 30
minutes for transformer upto 200 KVA rating and 80 KPa for 30 minutes and vacuum
of 500 mm of mercury for 30 minutes for transformer above 200 KVA rating and upto
including 2500 KVA rating as per IS:1180 Part-I:2014.
v) Purchaser reserves the right to carry out any site tests he may decide upon at his own
expenses. In case equipment/ material are not found as per P.O., all expenses incurred
during the testing will be to supplier’s account and material shall be replaced by the
supplier at site free of cost.

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FAILURE IN TYPE TEST(S):

In the event of failure/unsatisfactory results of the transformer(s) in Dynamic & Thermal Abil-
ity to withstand Short Circuit Test/impulse type tests, the supplier shall have to replace the supplies
already made and no further transformers shall be accepted. The purchaser however, at his option,
may accept the transformers already supplied with the following conditions:

i) Guarantee period of the supplied transformers issued to the field shall be increased by
double the normal Guarantee period.
ii) Bank Guarantee shall be extended to cover the additional Guarantee period.
iii) For failure in any of the type tests listed under RST i.e., short circuit test & Impulse with-
stand test, Temprature rise test and Air pressure test no further supplies shall be accepted.
The type test charges shall also not be reimbursable in this case and shall be borne by the
supplier.
iv) The transformers lying in the store(s) shall be replaced as per sub para (v) below.
v) The manufacturer shall, however, be allowed to check the reasons of failure and if need
be, to improve/modify the design. Further supplies, including replacements against sup-
plies already made, shall be accepted only after successful type test(s) are arranged onfresh
transformer(s) selected by the authorized representative of the purchaser. All the typetests
shall be arranged in case there is change in the design, otherwise, type test shall be repeated
only for the test in which failure has occurred. Charges for such test(s) shall be borne by
the supplier. However, in the event of failure of transformer in the repeat type test, the
purchaser may take following actions:
a) Cancel pending orders of the rating in which failure(s) has occurred, &
b) Not place any order of Distribution Transformers on the firm for one/ two year(s)

32.2 Measurement of total losses (at 50% & 100% loading):

(i) After pre-dispatch inspection of material at firm’s works, the dispatch instructions will
be issued for the respective store(s) as per requirement of Nigam. Sample(s) will be drawn from the
lot(s) received in store(s) and will be subjected to the following test(s):

a) One transformer will be selected out of every lot of 20 Nos. or part thereof for meas-
urement of total Losses at 50% & 100% loading at rated voltage; No Load current(at
100% and 112.5% of rated voltage); Impedance voltage. The testing shall be arranged
either at purchaser’s own testing lab and / or at independent test lab. The testing
charges for such tests shall be borne by the purchaser. The test results will be applica-
ble to the respective lot of 20 Nos. from which sample was drawn.
b) If dispatch instructions are less than 20 Nos. than one sample shall be selected from
each store(s) and the test results so obtained shall be for the quantity consigned/ re-
ceived by store(s).

Page 70 of 623
The percentage impedance voltage at rated current shall not exceed the permissible limit of 4.5%
with plus minus 10% tolerance failing which the sub lot of transformers represented by the sample shall
be rejected.

The I.R. values of the sample(s) shall be measured at CTL, Jaipur and it must be more than 50
MEGA-OHM.

The No Load Voltage Ratio (Transformer Turn Ratio) shall be checked in CTL with the tol-
erance as per specification/ IS 2026 on the transformer from the lot of 20 Nos. or part thereof and the
concerned sub lot shall be rejected if not meet out the requirement of IS.

Further, Internal clearances shall be checked without opening of core coil assembly in each of
the transformers which have been selected for physical verification at CTL (i.e. one sample from a lot
of 100 nos. or part thereof) in presence of firm’s representative. No negative tolerance shall be ad-
missible. If clearances are not found as per specification then the lot of 100 Nos. or part thereof shall
be rejected.

1. Marking on HV terminals on transformer tank by stamping (i.e. 1u, 1v, 1w).

2. Marking on LV terminals on transformer tank by stamping (i.e. 2u, 2v, 2w & 2n).
3. The earthing of the core through tinned copper earthing Foil of 25 mm width & 1 mm
thickness bolted on core frame channels, after removing the channel paint.

NOTE:

Page 71 of 623
If the total losses are found more than 10% of specified losses at 100% loading then apart from
rejecting the lot, firm’s balance order would be cancelled and such firms shall not be awarded any order
for one year or in next tender of tendered rating to be opened/finalized whichever is later.

33. GUARANTEE PERIOD:

I. Performance guarantee of the transformer(s) with LT protection unit shall be for the period
of 36 (Thirty Six) months from from the date of handing over after successful installation and
commissioning .

A) The firm will replace all type of GP failed Distribution Transformers without asking any seg-
regation on account of manufacturing defect. However, the Discom will compensate the cost
of missing parts as per practice in vogue.

B) The guarantee period failed transformers will directly be lifted by the suppliers from the re-
spective circle store within a period of 60 days from the date of intimation by the respective
consignee and will replace Distribution Transformers against G.P. failed within 30 days from
the date of lifting in the store/central store along with the joint inspection sheet of missing
parts issued by the respective consignee. After receiving the material at store, the same shall
be tested at CTL as per provisions of the relevant contracts and will be issued to the circle
store as per requirement on Nigam’s account. The invoices of missing parts shall be verified
by the ACOS store as per the joint inspection sheet issued by the circle store as per practice in
vogue and accordingly, the Sr. A.O. (CPC) will make the payment of missing parts, if any.

C) The loading of G.P. failed Distribution Transformers at circle store and un-loading of replaced
Transformer at store will be on suppliers’ account.

D) The firm will replace G.P. failed transformers irrespective of breakage of body seals as well
as physical damage of transformer tank body due to bursting. The period during which trans-
former remained defective/failed will not be accounted in the performance Guarantee period.
The period of defective will be reckoned from the date of first intimation (i.e. field officer/con-
signee whichever is earlier) to date of delivery replaced transformer.

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E) Firms shall lift the G.P. failed Transformer(s) within a period of 60 days from the date of issue
of notice/email by the concerned circle ACOS from where the supplier has been authorized to
lift the transformer.

F) However, the period during which Transformer remained defective/ failed will not be ac-
counted in the Performance Guarantee Period. The period of defective/ failed will be reckoned
from the date of first intimation (i.e. field officer/ consignee, whichever is earlier) to the date
of delivery after successful replaced transformer. The record of Performance Guarantee Period
of Distribution Transformer will be worked out in the above manner and record of the same
shall be maintained by the SE(I&S)/ concerned ACOS at their level to ensure that Distribution
Transformer shall work for the complete Guarantee Period.

G) The supplier will deliver back after successful replacement of G.P. failed Distribution Trans-
formers within 90 days from the date of issue of Notice/ email as mentioned above positively
as mentioned at point No. (a).

H) In case firm fails to deliver replaced Transformer(s) within 90 days from date as mentioned at
point No.(a)above, the cost of under Guarantee Period failed transformer(s) not repaired by
the firm shall be worked out on the basis of ordered price of latest TN and the same shall be
withhold tentatively from the firm’s financial hold and a penalty at the rate similar to that of
delay in delivery (as for new supplies) subject to maximum 5%, shall be levied for the late
delivery of replaced Transformer(s). The delay in delivery of G.P. replaced Distribution Trans-
former shall be worked out from the date of issue of notice/email by the concerned circleACOS
from where the supplier has been authorized to lift the transformer.

I) In case firm fails to lift the G.P. failed Distribution Transformer(s) beyond 3 months (90 days
period) as mentioned in point no. (a), Ground rent shall be recovered @1% per month or part
thereof (for actual delay in lifting the material beyond 3 months (90 days) from the date as
mentioned above, subject to a maximum of 5%. This amount of 5% will be in addition to
recovery mentioned in point no. (d). After this clause following clause will also come into
effect.

J) In case firm fails to lift the G.P. failed Transformer(s) within 6 months from date mentioned
in point no. (a), then Nigam may proceed for auction of these GP failed Distribution Trans-
former at the risk and cost of the supplier after giving 30 days final notice to the firm. The
amount recovered through auction may be adjusted in any type of recoveries (if any). There-
coveries of this point will be in addition to recoveries mentioned in point no. (d) and (e).

II. ALL THE REPLACED TRANSFORMERS BY THE MANUFACTURER UNDER GUARANTEE CLAUSE
SHALL CARRY A FURTHER GUARANTEE OF 12 MONTHS AFTER REPLACEMENT OR UNEXPIRED
GUARANTEE OF 36 MONTHS FROM THE DATE OF SUPPLY, WHICHEVER IS LATER, AFTER REPLACE-
MENT. THE BANK GUARANTEE EQUIVALENT TO COST OF REPLACED TRANSFORMERS
SHALL BE FURNISHED AFTER EXPIRY OF PERFORMANCE GUARANTEE PERIOD TO COVER SUCH
GUARANTEE. THE PURCHASER ALSO RESERVES THE RIGHT TO WITHHOLD THE PAYMENT OF SUP -
PLIER FIRM, UNDER ANY OTHER CONTRACT, IF THE PERFORMANCE OF THE SUPPLIER IN REPLACED
TRANSFORMERS IS NOT SATISFACTORY. EACH SUPPLIER SHALL INVARIABLY FURNISH

Page 73 of 623
THE DETAILED INFORMATION ABOUT THE TOTAL NUMBER OF TRANSFORMERS FAILED AND
REPLACED BY THEM, EVERY MONTH AFTER COMMENCEMENT OF SUPPLIES.

III. IN ORDER TO ASCERTAIN THAT TRANSFORMERS HAVE SUCCESSFULLY COMPLETED GUARANTEE

PERIOD THE FOLLOWING DETAILS SHALL BE PROVIDED ON THE TRANSFORMER BODY :

A. A REPLACEMENT IDENTIFICATION STEEL PLATE ON REPLACED TRANSFORMER AGAINST G.P. FAILED

TRANSFORMER OF SIZE 75 X 75 X 2.5 MM DULY ENGRAVED WITH FOLLOWING DETAILS SHALL BE
WELDED ON THE TRANSFORMER BODY.
3ND
PARTICULARS ORIGINAL 1ST 2ND
SUPPLY REPLACEMENT REPLACEMENT REPLACEMENT
FIRM’S
NAME/LOGO
TN
RATING (KVA)
SR. NO.
DATE OF DISPATCH
DATE OF FAILURE
GUARANTEE
PERIOD

UPTO

B. SUCH METALLIC PLATE FIXED ON FIRST REPLACEMENT SHOULD NOT BE REMOVED AT THE TIME OF
SECOND REPLACEMENT OR ANY SUBSEQUENT REPLACEMENT . HOWEVER, NECESSARY DETAILS OF
FAILURE AND REPLACEMENT SHALL BE GRAVED ON THE IDENTIFICATION PLATE , EACH TIME IT IS
REPLACED IN GUARANTEE.

C. THE REPLACED TRANSFORMER SHALL BE PROVIDED WITH 40 MM WIDE RED COLOR BAND ALL
AROUND TRANSFORMERS INCLUDING RADIATOR EACH TIME IT IS REPLACED IN G.P. THUS IF A
TRANSFORMER IS REPLACED THREE TIME IN G.P. THEN THERE SHOULD BE THREE COLORED BANDS
EACH OF SIZE 40 MM.
IV. TEST CHECKING OF G.P. FAILED TRANSFORMERS WILL BE ALLOWED TO THE SUPPLIER AT NI-
GAM’S STORE BEFORE LIFTING OF G.P. FAILED DISTRIBUTION TRANSFORMERS TO REPAIR AT SUP -
PLIER’S WORKS SO THAT MINOR MISTAKES LIKE LOOSING OF CONNECTIONS/REPLACEMENT

Page 74 of 623
OF FUSE WIRE/REPLACEMENT OF MCCB BE CARRIED OUT AT NIGAM’S STORES. THE DEFECTS OF
M&P BOX MAY BE REMOVED IN NIGAM’S STORE BY THE SUPPLIER, IF THE DISTRIBUTION
TRANSFORMER IS NOT FAILED. THE CONSIGNEE WILL ACCORDINGLY INTIMATE TO THE SUPPLIER
TO LIFT THE GP FAILED DISTRIBUTION TRANSFORMER. DAMAGE OF ONLY M&P BOX SHALL
NOT BE CONSIDERED AS TRANSFORMER FAILURE.

V. THE TESTING PROCEDURE OF SUCH REPLACED DISTRIBUTION TRANSFORMER INCLUDING PHYS-

ICAL VERIFICATION SHALL BE SAME AS PER TESTING OF NEW DISTRIBUTION TRANSFORMER AT
FIRM’S WORKS AS WELL AS AT CTL WITHOUT ANY TOLERANCE IN THE LOSSES AT 50% AND
100% LOADING.

NOTE:- FIRM SHALL KEEP THE RECORDS FOR AT LEAST 8 YEARS OF TRANSFORMERS SUPPLIED BY THEM.

34. TRANSFORMER LIFE:-

Transformer shall be designed/ manufactured with expected service life of 10 years, because as per
Distribution code of JVVNL, the Distribution transformers should be dismantled and sent to testing
and repair shop for overall inspection of the transformers with frequency of overhauls as 10 yearly.

35. Make of Brought Out Items:

The Make of brought out items like Bushings, Transformer Oil, MCCB etc. other than Make
specified in the specification/work order may be accepted if confirms to relevant IS with due approval
of JVVNL.

Page 75 of 623
TECHNICAL SPECIFICATION FOR ACSR RABBIT CONDUCTOR

1. SCOPE

1.1 This section provides for manufacture, testing before dispatch, supply and delivery F.O.R
Destination of Aluminium Conductor, Galvanized Steel reinforced (ACSR) Conductor for satisfac-
tory operation in various lines and sub-stations. The conductor should conform to latest IS. The re-
quirement of various type of Conductor shall be as per Schedule of Requirement Annexed withthis
Section at Schedule-I. It may be noted that the requirement indicated in the Schedule is tentativeand
may vary at the time of placement of order.

1.2 Aluminium Conductor with galvanized Steel re-enforcement shall be conforming to IS:
398(Pt.2)/1996 with latest amendments
The manufacturers should be a manufacturer of offered Conductor. The Offers from sole
selling agents / authorized dealer shall not be entertained. The firms (manufacturers) must posses
valid ISI License for the offered Conductor. The technical bid of the manufacturers shall be con-
sidered for opening in absence of non-furnishing of above required ISI License alongwith thebid.
However, price bid of the responsive manufacturers shall only be opened if manufacturer fur-
nishes above required ISI License upto the official working hours of one working day prior tothe
scheduled / notified date of opening of price bid, failing which price bid of the manufacturer shall
not be opened. The bids from trading firms shall not be considered.

2. CLIMATIC CONDITIONS:

i) Peak ambient temperature 50 deg.C

in shade.

ii) Maximum average ambient 40 deg.C

temperature in a 24 hours period
in shade.

iii) Min. ambient air temperature in shade (-) 5 deg.C

iv) Maximum temperature attainable 60 deg.C

by an object exposed to sun.

Page 76 of 623
v) Maximum relative humidity. 100%

vi) Average number of thunder 40

storm days per annum.
vii) Average number of rainy days 100
per annum.
viii) Average annual rainfall 10 to 100 cm

ix) Number of months of tropical 4 months

Monsoon conditions.

x) Maximum wind pressure. 100 kg/ Sq. Mtr.

xi) Altitude not exceeding 1000 M

3. GENERAL TECHNICAL REQUIREMENT OF ACSR CONDUCTORS:

The technical particulars shall be furnished strictly in the Performa attached at Schedule-V-A
of this specification. The specific values must be indicated against each column and no 'dash'. 'dot',
'blank' or as per IS word should be indicated in this schedule. The technical suitability shall be ad-
judged from the values furnished in the clause 3.2 “PRINCIPAL PARAMETERS”.

The ACSR conductor shall comply in all respect with IS: 398(Part.2)/1996 with latest amend-
ment, if any from the date of its applicability. Any departure from the standard be indicated in Sched-
ule-III

3.1 MATERIAL

The material offered shall be of the best quality and workmanship. The conductor shall be con-
structed from hard drawn aluminum and galvanized steel wires which have the mechanical and elec-
trical properties specified in Tables 1 & 2 of IS:398(Part.2)/1996 with latest amendment, if any, The
Zinc coating on the galvanized steel wires may be applied in accordance with IS:4826/1979 with latest
amendment if any. The EC Grade Aluminium rods for use in the manufacture of Aluminium Wires
shall conform to IS:5484/1978 amended up to date. The zinc used for galvanizingshall be Electro type
High Grade Zinc not less than 99.95 percent purity. It shall conform to and satisfy all the requirements
of IS:209/1992 amended up to date. Galvanized Steel Wire should comply mechanical properties as
per Table 2 of IS:398 (Part.2)/1996 amended upto date. The chemical composition is as per Annexure-
C of IS:398 (Part.2)/1996 amended upto date.

Page 77 of 623
3.2 PRINCIPAL PARAMETERS:

The details of ACSR Rabbit Conductor are tabulated below:-

PARTICULAR ACSR RABBIT

a) Stranding and 6/3.35 Al.
wire diameter (mm) 1/3.35 St.
b) Number of strands
Central Steel wire 1
Aluminium 6
c) Sectional area of aluminium(Sq. mm) 52.88
d) Total Sectional area (Sq. mm) 61.70
e) Overall diameter (mm) (Approx.) 10.05
f) Weight (Kg/Km) (Approx.) 214.00
g) Calculated max. DC resistance at 20 Deg. C (Ohm./ Km.) 0.5524

h) Approx. calculated breaking load (KN) 18.25

i) Modulus of elasticity (GN/Sq. meter) 79
j) Coefficient of liner Expansion per deg C. 19.1x10-6

3.3 The details of aluminium strands are as follows:

PARTICULAR ACSR Rabbit

a) Min. Breaking load of strand before stranding (KN) 1.43

b) Min. Breaking load of strand after stranding (KN) 1.36

c) Max. D.C. Resistance of strand at 20 Deg. C (ohm/Km.) 3.265

d) Diameter mm
Nominal 3.35
Minimum 3.32
Maximum 3.38

Page 78 of 623
e) Mass (Kg/Km.) 23.82

3.4 The details of steel strands are as follows:

PARATICULAR ACSR Rabbit

i) Min. Breaking load of strand before stranding (KN) 11.58

ii) Min. Breaking load of strand after stranding (KN) 11.00

iii) Diameter mm
a) Nominal 3.35
b) Max./Min 3.42/3.28

iv) Zinc coating testing 3 dips of 1 min. each

v) Min. weight of zinc coating GM/ Sq. Mtr. 237.5

vi) Mass of strand at normal diameter of strand(Kg./Km.) 68.75

3.5 Tolerance on normal sizes:

The tolerance in diameter of aluminium wires and steel wire used in the manufacture of ACSR
shall be allowed as per IS: 398/ (Part-2) /1996 amended upto date.

3.6 Stranding :

3.6.1 The wires used in the construction of a galvanized steel reinforced aluminium conductor shall
before stranding, satisfy all the relevant requirements of this specification and relevant IS.

3.2.6 The lay ratio of the different layers shall be within the limits given:
S. Particulars ACSR RABBIT
No.
1 Number of wires :
a) Aluminium 6
b) Steel 1

Page 79 of 623
2 Ratio of aluminium Wire dia-meter to Steel wire dia-
meter 1
3 Lay ratio for aluminium Wires (Outer most layer):
a) Minimum
b) Maximum

10
14
4. Lay ratio for steel core (6 wire layer)
a)Minimum
a) Maximum
--
--

NOTE: For the purpose of calculation, the mean lay ratio shall be taken as the arithmetic mean of
the relevant minimum and maximum value given in this table.

4. TESTS:
TESTS BEFORE DESPATCH: The ACSR Conductor shall be subjected at manufacturer’s
works before dispatch, to the tests mentioned here-under as per IS: 398 (Part-2)/1996 with
latest amended.

4.1 ROUTINE TESTS:

The following tests shall be conducted before and after stranding on each drum of the conduc-
tor by the manufacturer at his works as per relevant standard IS: 398 (Part-2)/ 1996 (latest amended)

a) Visual & dimensional check on drum as per specification.

b) Visual check for joints, scratches etc. and length of conductor by re-winding of conductor
on empty drum as per Specification/ IS.

c) Measurement of dia-meter of individual

Page 80 of 623
Aluminium and steel wires. (Clause-13.2)

d) Measurement of Lay Ratio. (Clause-13.8)

e) Breaking load of individual wires (Clause-13.3.1)

f) Ductility Test (Clause-13.4)

g) Wrapping Test (Clause-13.5)

h) Resistance Test (Clause-13.6)

i) Galvanizing Test (Clause-13.7)

j) Any other test as per relevant IS

4.2 ACCEPTANCE TESTS:-

The following tests shall be conducted on samples taken at random from a lot as per relevant
standard IS: 398 (Part-2)/1996 (Latest amended) in presence of purchaser’s representative:-

a) Visual & dimensional check on drum as per specification.

b) Visual check for joints, scratches etc. and length of conductor by re-winding of conductor
on empty drum as per Specification / IS.

c) Measurement of dia-meter of individual

Aluminium and steel wires. (Clause-13.2)

d) Measurement of Lay Ratio. (Clause-13.8)

e) Breaking load of individual wires (Clause-13.3.1)

f) Ductility Test (Clause-13.4)

Page 81 of 623
g) Wrapping Test (Clause-13.5)

h) Resistance Test (Clause-13.6)

i) Galvanizing Test (Clause-13.7)

5.0 TYPE TESTS:-

The type test in respect of ACSR Rabbit Conductor is already covered under Acceptance
Tests, thus requirement of furnishing type test for ACSR Rabbit Conductor is not essential along with
Bid.

6.0 SAMPLING PLAN:

6.1. Samples for Acceptance Tests: Samples shall be taken as per relevant IS i.e. IS-398 (Part-
2)/1996 with latest version.

6.2 Apart from the sample selected for carrying out Acceptance Tests at the works of the
firm during inspection, one more sample from each length be also selected out of one drum under re-
winding for carrying out various Acceptance Tests as per relevant IS. If any of the sample so selected
from each length failed in any acceptance test the entire lot under inspection is not acceptable.

6.3 TOLERANCE ON TEST RESULTS:

Tolerance on test results shall be allowed as per relevant IS/Spec. whichever is more stringent.

7.0 INSPECTION

7.1 (a) The conductor shall be manufactured in accordance with latest edition of IS:
398(Part.2)/1996 with all subsequent amendments issued from time to time for ACSR Conductor. All
the tests as laid down in the above mentioned specification on individual aluminium wire and steel
wire shall be carried out. The testing shall also include the tests on manufactured finished conductor.
Moreover the supplier shall also furnish test certificate(s) of raw materials to the inspecting officer at
the time of inspection. The inspection & testing shall be governed by Clause No.1.27 of Section-II
(General Condition of Contract).

(b) The supplier / manufacturer must offer conductor for inspection through a letter of offer
mentioning size and quantity of the conductor along with Packing List duly signed indicating drum

Page 82 of 623
Serial No. individual lengths total length, net weight & gross weight in DUPLICATE. This letter of
offer shall be addressed to this office. The packing list shall also be furnished to the Inspecting Officer
prior to carrying out the inspection at the works.

(c) The Manufacturer shall provide all adequate facilities at his works for inspection of
at least one number conductor drum or 5% conductor drums offered for inspection whichever is higher
selected at random by the authorized representative of the purchaser for checking / verification of
conductor length/ manufacturing defects by transferring the conductor from one drumto the another
empty drum and at the same time measuring the length and lay ratio of each conductorlength so trans-
ferred by means of the standard calibrated and sealed meter.

(d) If the firm is not having the necessary facilities for carrying out the required tests as per
relevant IS / Purchase Order, the supplier will arrange such testing facilities in some other Govern-
ment laboratory and shall bear the cost so incurred. But in such cases firm shall inform to the
purchaser in advance before commencement of supplies.

(e) The supplier shall provide adequate facilities for weighment of all the drums offered for
inspection.

7.2 In case of testing after re-offering as per Clause No.15 of IS:398 (Part.2)/1996, the lot under
reference will be subject to 100% checking, if required by the purchaser.

7.3 The supplier shall present the latest Calibration Certificate(s) of testing instruments / equip-
ments to be used for the testing of the material covered in the Purchase Order to the authorizedin-
specting officer / inspecting agency of the purchaser. The testing instruments / meters/ apparatus etc.
should be got calibrated by the supplier from time to time from Govt. Lab or Independent test labor-
atory / house having valid accredition from National Accredition Board for Testing and Calibrating
Laboratories for the testing equipments or original manufacturer having traceability to NABL / NPL
or equivalent accredited lab.

The calibration certificate(s) should not in any case be older than one year at the time of present-
ing the same to the inspecting officer / inspecting agency of the purchaser. The testing instruments /
equipments should be duly sealed by the Calibrating Agency and mention thereof shallbe indicated
in the calibration certificate(s).

7.4 The manufacturer will provide certificates as per the Clause No.7 of IS: 398((Part.2)/1996
“Freedom from defects" and clause No.9 “Joint in Wires" of IS:398 (Part 2) /1996for ACSR Conduc-
tor.

8.0 STANDARD LENGTH & VARIATION IN LENGTHS:

Page 83 of 623
8.1 The ACSR Rabbit Conductor shall be supplied in the standard length. The standard length
of ACSR Rabbit Conductor shall not less than the value specified below with a tolerance of (-) 5%.
More than the standard length shall be acceptable.

a) ACSR Rabbit - 1500 Mtrs.

8.2 Short length(s), if any shall not measure less than 80% of standard length as specified
above in any case. The total quantity of such short length(s) shall not exceed 5% of the quantity of
the lot offered for inspection.

8.3 The maximum permissible length per drum shall be as under subject to condition that the
manufacturer while packing the conductor in drum shall ensure that after winding complete quantity
of conductor in drum a uniform space of not less than 100 mm. remains between outer layer of con-
ductor and inner surface of the external protective lagging of the drum. This is essential to ensurethat
the conductor does not get closer to the lagging and to avoid damaged during transportation/ reeling
/ unreeling or rolling on the undulated ground / fields:

a) ACSR RABBIT - 4.4 Kms.

9.0 PACKING FORWARDING AND MARKING:

9.1 The packing shall have to be done as per standard practice worthy of road transport. The con-
ductor shall be wound in strong wooden drums so as to withstand all stresses due to transportation,han-
dling and stringing operation so that there is no damage caused to the conductor during the process
of these operations. The wooden drums shall be non-returnable and shall generally conform
IS:1778/1981 with latest amendments, however, the main parameters of the drum shall be as under:-
S.NO. PARTICULARS DIMENSION FOR ACSR RABBIT CONDUCTOR
1. Flange Dia 1250 mm (+/- 5%)
2. Flange Thickness 2x25 mm (+/- 5%)
3. Barrel Dia 500 mm (+/- 10 mm)
4. Traverse 510 mm (+/- 10 mm)
5. Number of Bolts 4 Nos.
6. Dia of Bolts
12 mm
7. Bore Dia 80 mm

Page 84 of 623
However, use of seasoned wood shall not be insisted, provided wood used should be of good
quality to withstand transportation hazards. The drums shall be having inside flanges painted with
Aluminium Paint and with Ordinary White Enamel paint from outside. The conductor on each drum
shall be securely fastened at each end. The outer end of the conductor shall be fastened inside the
drum against one of the sides of the flanges while it is under tension and shall be such that no looseness
is transmitted to the internal layers. The conductor shall be snugly, tightly and uniformly spooled on
the drums. The wrapping of conductor on the drums shall be laid snugly against side of the preceding
wrap and the first and last wrap in each layer shall fit snugly against the sides of the flanges. Drums
shall be lagged with sufficient strong wooden laggings to support the full drum without crushing. The
wooden drums after providing lagging shall be fastened by two steel wires ofmin. 3 mm. Dia over the
lagging on the two sides of adequate size to keep the lagging intact and to prevent the drum from
crushing/ damage.

Although the various dimension of the drums such as flanges, stretches, traverse and barrel di-
ameter shall depend on the quantity of conductor as offered and agreed upon, on one drum. The man-
ufacturer while packing the conductor in drum shall ensure that after winding complete quantityof
conductor in drum a uniform space of not less than 100 mm. remains between outer layer of conductor
and inner surface of the external protective legging of the drum. This is essential to ensurethat the
conductor does not get closer to the legging and to avoid damaged during transportation/ reeling /
unreeling or rolling on the undulated ground / fields.

9.2 Water proof material shall be wrapped round the barrel and inner surface of flange before wind-
ing the conductor and also wrapped round over the conductor completely wounded and under the
laggings.

9.3 The drums shall be marked clearly in block letters with water proof mark having the marking
attached to them so that there is no possibility of goods being lost or wrongly dispatched due to faulty
marking. The marking shall constitute the following:-
a) Name & full address of the consignee.
b) Destination station.
c) Serial number of drum.
d) Size of Conductor with its code name.
e) Total length of Conductor in drum, with individual length (s).
f) Number of length(s) in each drum.
g) Gross mass of drum including the tare mass of drum.
h) Tare mass of the empty drum with lagging.
i) Net mass of conductor.
j) BIS standard mark.
k) Name of the supplier.
l) Purchase order reference/TN number/RDSS.

Page 85 of 623
m) Date of expiry of warranty / guarantee period.

Besides above, an arrow shall be put on the drum so as to indicate the direction in which the
drum can be unwound. The manufacturer shall also provide his own lead seal with distinguishing
mark at the outer end of the conductor on each drum before dispatch of the material.

10. TEST CHECKING OF MATERIAL AT STORES:

a) Sample drums from the material received at stores shall be selected for testing at CTL as per
sampling plan given hereunder in presence of firm’s representative.

b) The selected sample drum for CTL testing shall be identified by the seals provided by Inspect-
ing Officer / Inspecting Agency during pre-dispatch inspection at firm’s works and these seal-
ing details shall be invariably mentioned in the selection Memo by the nominated officers of
Nigam.

c) The tests in the Nigam Testing laboratory (CTL) shall be conducted in the presence of
representative of supplier for which a 3 days notice shall be issued through Fax / Speed Post
stating Date & Time to the firm, so that supplier can depute their representative to witness
the test . In case the supplier or his representative does not turn up the testing shall be process
& completed. The payment shall be released only after receipt of successful CTL test reports
for the samples selected at purchaser’s stores for mandatory test checking the samples to be
selected from material received at Nigam’s stores by officers to be nominated by Circle SE’s
/ SE (I&S) for testing at CTL.

11. SAMPLING

Selection of samples from the material received at stores shall be done as soon as material
received in stores in the presence of representative of supplier.

One number Drum out of each lot / sub-lot of 20 Nos. Drums or part thereof for the material
received in Stores of Nigam. The selected sample drum / drums shall be transported to CTL by con-
cerned ACOS / SS.

In case of selection of sample for type test the length of the sample shall be of 20 Mtrs. The
selected and sealed sample for type test shall be identified by providing polycarbonate seals on both
ends of conductor and after forming the coil of conductor two stickers seals provided around the coil.

11.1 TESTS
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11.1.1. The following tests shall be carried out as per relevant Clause of latest IS-398
(Part2)/1996 on each selected drum by drawing sample of 5 Mtrs. at CTL from random
distance from any length of the selected drum of ACSR Rabbit Conductor during re-
winding:

a) Rewinding test (Measurement of Length and weight) & Checking

of Manufacturing defects.
b) Measurement of lay ratio during rewinding of Conductor Drum.
c) Dia. of Aluminium Strands and Steel Wires.
d) Breaking load test.
e) Resistance Test.
f) Galvanization of steel wire (Uniformity) and Mass of Zinc
Coating.
g) Verification of Water Proof marking on Drum as per
Specification.

NOTE:

(a) In addition to above tests remaining acceptance tests as per relevant IS shall also be
conducted at CTL provided the testing facility is available at CTL for these tests time
to time. Only those tests shall be conducted for which testing facilities are available
in NIGAM’s Lab.

(b) The Officer Incharge of central Testing Lab (CTL) of Nigam shall send copies of test
reports to the Purchasing Officer / Sr. AO (CPC), consignee and the supplier.

c) The payment of every lot shall be released after receipt of successful test report from Ni-
gam’s Lab (CTL) on the samples selected from the material received in Nigam stores.

11.1.2 CRITERIA FOR ACCEPTANCE:

(a) Rewinding Test (Measurement of Length and weight):

The results of measurement of length test shall be made applicable to all drums contained in
each lot/sub-lot by making deduction of less length of conductor in a sample drum. In case short

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length is observed more than one percent of the length contained in lot / sub-lot , then the lot / sub-
lot shall liable to be rejected.

The net calculated weight of ACSR Rabbit conductor corresponding to minimum prescribed
diameter in IS of Aluminium Strand & Steel Strand shall be as under:

ACSR RABBIT 208.52 Kg./Km.

If weight of conductor corresponding to minimum prescribed diameter as per IS found less up

to 2% in respect to measured length the lot shall be acceptable otherwise the entire lot for which
sample drum represents shall be rejected and to be replaced by the supplier.

(b) If the sample(s) fail in any test other than length measurement, the entire material in the
Lot shall be rejected and shall have to be replaced by the supplier.

c) If the contractor / supplier fails to lift the material declared rejected or any part thereof from
the consignee within a period of 15 days from the date of dispatch instruction from the purchaser, the
purchaser shall be entitled to effect recovery along with other actions

12.0 TEST CHARGES:

All test charges incurred towards test checking of the material received in our stores shall be
borne by the NIGAM.

Page 88 of 623
TECHNICAL SPECIFICATION FOR ACSR DOG CONDUCTOR

1. SCOPE

1.1 This section provides for manufacture, testing before dispatch, supply and delivery anywhere
in the stores of JVVNL F.O.R Destination of Aluminium Conductor, Galvanized Steel reinforced
(ACSR) for satisfactory operation in various lines and sub-stations. The conductor should conform to
latest IS. The requirement of various type of Conductor shall be as per Schedule of Requirement
Annexed with this Section at Schedule-I. It may be noted that the requirement indicatedin the Schedule
is tentative and may vary at the time of placement of order.

1.2 Aluminium Conductor with galvanized Steel re-enforcement shall be conforming to IS:
398(Pt.2)/1996 with latest amendments.

The manufacturers should be a manufacturer of offered Conductor. The Offers from sole selling
agents / authorized dealer shall not be entertained. The firms (manufacturers) must posses valid ISI
License for the offered Conductor. The technical bid of the manufacturers shall be considered for
opening in absence of non-furnishing of above required ISI License along with the bid. However,
price bid of the responsive manufacturers shall only be opened if manufacturer furnishes above re-
quired ISI License up to the official working hours of one working day prior to the scheduled / notified
date of opening of price bid, failing which price bid of the manufacturer shall not be opened.The bids
from trading firms shall not be considered.

2. CLIMATIC CONDITIONS:

i) Peak ambient temperature 50 deg.C

in shade.

ii) Maximum average ambient 40 deg.C

temperature in a 24 hours period
in shade.

iii) Min. ambient air temperature in shade (-) 5 deg.C

iv) Maximum temperature attainable 60 deg.C

by an object exposed to sun.

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v) Maximum relative humidity. 100%

vi) Average number of thunder 40

storm days per annum.

vii) Average number of rainy days 100

per annum.

viii) Average annual rainfall 10 to 100 cm

ix) Number of months of tropical 4 months

Monsoon conditions.

x) Maximum wind pressure. 100 kg/ sq. mm.

xi) Altitude not exceeding 1000 M

3. GENERAL TECHNICAL REQUIREMENT OF ACSR DOG CONDUCTOR:

The ACSR conductor shall comply in all respect with IS: 398(Part.2)/1996 with latest amend-
ment, if any from the date of its applicability. Any departure from the strandard be indicated in Sched-
ule-III

3.1 MATERIAL

The material offered shall be of the best quality and workmanship. The conductor shall be con-
structed from hard drawn aluminium and galvanized steel wires which have the mechanical and elec-
trical properties specified in Tables 1 & 2 of IS:398(Part.2)/1996 with latest amendment, if any, The
Zinc coating on the galvanized steel wires may be applied in accordance with IS:4826/1979 with
latest amendment if any. The EC Grade Aluminium rods for use in the manufacture of Aluminium
Wires shall conform to IS:5484/1978 amended up to date. The zinc used for galvanizing

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shall be Electro type High Grade Zinc not less than 99.95 percent purity. It shall conform to and
satisfy all the requirements of IS:209/1992 amended up to date. Galvanized Steel Wire should comply
mechanical properties as per Table 2 of IS:398 (Part.2)/1996 amended up to date. The chemical com-
position is as per Annexure-C of IS:398 (Part.2)/1996 amended up to date.

3.2 PRINCIPAL PARAMETERS:

The details of ACSR Dog conductor are tabulated below:-

PARTICULAR ACSR DOG

a) Stranding and 6/4.72 Al.
wire diameter (mm) 7/1.57 St.
b) Number of strands
Central Steel wire 7
Aluminum 6
c) Sectional area of Aluminum (Sq. mm) 105
d) Total Sectional area (Sq. mm) 118.5
e) Overall diameter (mm) (Approx.) 14.15
f) Weight (Kg/Km) (Approx.) 394.00
g) Calculated max. DC resistance at 20 Deg. C (Ohm./ Km.) 0.2792

h) Approx. calculated breaking load (KN) 32.41

i) Modulus of elasticity (GN/Sq. meter) 75
j) Coefficient of liner Expansion per deg C. 19.8x10-6

PARTICULAR ACSR Dog

a) Min. Breaking load of strand before stranding (KN) 2.78

b) Min. Breaking load of strand after stranding (KN) 2.64

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c) Max. D.C. Resistance of strand at 20 Deg. C (ohm/Km.) 1.650

d) Diameter mm
Nominal 4.72
Minimum 4.67
Maximum 4.77
e) Mass (Kg/Km.) 47.30

3.3 The details of aluminium strands are as follows:

3.4 The details of steel strands are as follows:

PARATICULAR ACSR Dog

i) Min. Breaking load of strand before stranding (KN) 2.70

ii) Min. Breaking load of strand after stranding (KN) 2.57

iii) Diameter mm
b) Nominal 1.57
b) Max./Min 1.60/1.54

iv) Zinc coating testing 2 dips of 1 min. each

v) Min. weight of zinc coating GM/ Sq. Mtr. 180.50

vi) Mass of strand at normal diameter of strand(Kg./Km.) 15.10

3.5 Tolerance on normal sizes:

The tolerance in diameter of aluminium wires and steel wire used in the manufacture of ACSR
shall be allowed as per IS: 398/ (Part-2) /1996 amended up to date.

Page 92 of 623
3.6 Stranding :

3.6.1 The wires used in the construction of a galvanized steel reinforced aluminium conductor shall
before stranding, satisfy all the relevant requirements of this specification and relevant IS.
3.6.2 The lay ratio of the different layers shall be within the limits given:

S. No. Particulars ACSR DOG

1 Number of wires :
a) Aluminum 6
b) Steel 7
2 Ratio of aluminum Wire dia-meter to Steel
wire dia-meter 3
3 Lay ratio for aluminum Wires (Outer most
layer):
a) Minimum
10
b) Maximum
14
4. Lay ratio for steel core (6 wire layer)
a)Minimum 13
b) Maximum 28

NOTE: For the purpose of calculation, the mean lay ratio shall be taken as the arithmetic mean of the
relevant minimum and maximum value given in this table.

4. TESTS (FOR ACSR DOG CONDUCTOR):

TESTS BEFORE DESPATCH: The ACSR Dog Conductor shall be subjected at manufac-
turer’s works before dispatch, to the tests mentioned here-under as per IS: 398 (Part-2)/1996
with latest amended.

4.1 ROUTINE TESTS:

The following tests shall be conducted before and after stranding on each drum of the conduc-
tor by the manufacturer at his works as per relevant standard IS: 398 (Part-2)/ 1996 (latest amended)

Page 93 of 623
a) Visual & dimensional check on drum as per specification.

b) Visual check for joints, scratches etc. and length of conductor by re-winding of conductor
on empty drum as per Specification/ IS.

c) Measurement of dia-meter of individual

Aluminium and steel wires. (Clause-13.2)

d) Measurement of Lay Ratio. (Clause-13.8)

e) Breaking load of individual wires (Clause-13.3.1)

f) Ductility Test (Clause-13.4)

g) Wrapping Test (Clause-13.5)

h) Resistance Test (Clause-13.6)

i) Galvanizing Test (Clause-13.7)

j) Any other test as per relevant IS

4.2 ACCEPTANCE TESTS:-

The following tests shall be conducted on samples taken at random from a lot as per relevant
standard IS: 398 (Part-2)/1996 (Latest amended) in presence of purchaser’s representative:-

a) Visual & dimensional check on drum as per specification.

b) Visual check for joints, scratches etc. and length of conductor by re-winding of conductor
on empty drum as per Specification / IS.

c) Measurement of dia-meter of individual

Page 94 of 623
Aluminium and steel wires. (Clause-13.2)

d) Measurement of Lay Ratio. (Clause-13.8)

e) Breaking load of individual wires (Clause-13.3.1)

f) Ductility Test (Clause-13.4)

g) Wrapping Test (Clause-13.5)

h) Resistance Test (Clause-13.6)

i) Galvanizing Test (Clause-13.7)

5.0 TYPE TESTS :-

For ACSR Dog Conductor, the manufacturers shall furnish the type test report as per relevant
IS:398 Pt.2)/1996 with latest amendment

The following shall constitutes type test which are to be conducted on the samples taken from
Three Drums of the conductor as per relevant IS:398 (Pt.2)/1996 with latest amendment:

a) Stress – Strain Test (Clause No.13.11 of ISS).

b) Surface Condition Test (clause No.13.9 of ISS).
c) Ultimate Breaking Load Test (Clause No.13.10 of ISS).

6.0 SAMPLING PLAN:

6.1. Samples for Acceptance Tests: Samples shall be taken as per relevant IS i.e. IS-398 (Part-
2)/1996 with latest version as the case may be.

Page 95 of 623
6.3 TOLERANCE ON TEST RESULTS:

Tolerance on test results shall be allowed as per relevant IS/Spec. whichever is more stringent.

7.0 INSPECTION

7.1 (a) The conductor shall be manufactured in accordance with latest edition of IS:
398(Part.2)/1996 with all subsequent amendments issued from time to time for ACSR Dog Conduc-
tor. All the tests as laid down in the above mentioned specification on individual aluminum wire and
steel wire shall be carried out. The testing shall also include the tests on manufactured finished con-
ductor. Moreover the supplier shall also furnish test certificate(s) of raw materials to theinspecting
officer at the time of inspection. The inspection & testing shall be governed by Clause No.1.27 of
Section-II (General Condition of Contract).

(b) The supplier / manufacturer must offer conductor for inspection through a letter of offer
mentioning size and quantity of the conductor along with Packing List duly signed indicating drum
Serial No. individual lengths total length, net weight & gross weight in DUPLICATE. This letter of
offer shall be addressed to this office. The packing list shall also be furnished to the Inspecting Officer
prior to carrying out the inspection at the works.

(e) The supplier shall provide adequate facilities for weighment of all the drums offered for
inspection.

7.2 In case of testing after re-offering as per Clause No.15 of IS:398 (Part.2)/1996 the lot under
reference will be subject to 100% checking, if required by the purchaser.

7.3 The supplier shall present the latest Calibration Certificate(s) of testing instruments / equip-
ments to be used for the testing of the material covered in the Purchase Order to the authorized

Page 96 of 623
inspecting officer / inspecting agency of the purchaser. The testing instruments / meters/ apparatus
etc. should be got calibrated by the supplier from time to time from Govt. Lab or Independent test
laboratory / house having valid accreditation from National Accreditation Board for Testing and Cal-
ibrating Laboratories for the testing equipments or original manufacturer having traceability to NABL
/ NPL or equivalent accredited lab.

The calibration certificate(s) should not in any case be older than one year at the time of pre-
senting the same to the inspecting officer / inspecting agency of the purchaser. The testing instruments
/ equipments should be duly sealed by the Calibrating Agency and mention thereof shallbe indicated
in the calibration certificate(s).

8.0 STANDARD LENGTH & VARIATION IN LENGTHS:

8.1 The ACSR Dog Conductor shall be supplied in the standard length. The standard length
of ACSR Dog Conductor shall not less than the value specified below with a tolerance of (-) 5%.
More than the standard length shall be acceptable.
-
a) ACSR DOG - 1000 Mtrs.
-
8.2 Short length(s), if any shall not measure less than 80% of standard length as specified
above in any case. The total quantity of such short length(s) shall not exceed 5% of the quantity of
the lot offered for inspection.

8.3 The maximum permissible length per drum shall be as under subject to condition that
the manufacturer while packing the conductor in drum shall ensure that after winding complete quan-
tity of conductor in drum a uniform space of not less than 100 mm. remains between outer layerof
conductor and inner surface of the external protective lagging of the drum. This is essential to ensure
that the conductor does not get closer to the lagging and to avoid damaged during transportation/
reeling / unreeling or rolling on the undulated ground / fields:
a) ACSR DOG --- 2.4 Kms.

9.0 PACKING FORWARDING AND MARKING:

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operations. The wooden drums shall be non-returnable and shall generally conform IS:1778/1981
with latest amendments, however, the main parameters of the drum shall be as under:

S.NO. PARTICULARS DIMENSION FOR ACSR DOG CONDUCTOR

1. Flange Dia 1250 mm (+/- 5%)
2. Flange Thickness 2x25 mm (+/- 5%)
3. Barrel Dia 500 mm (+/- 10 mm)
4. Traverse 510 mm (+/- 10 mm)
5. Number of Bolts 4 Nos.
6. Dia of Bolts 12 mm
7. Bore Dia 80 mm

However, use of seasoned wood shall not be insisted, provided wood used should be of good
quality to withstand transportation hazards. The drums shall be having inside flanges painted with
Aluminium Paint and with Ordinary White Enamel paint from outside. The conductor on each drum
shall be securely fastened at each end. The outer end of the conductor shall be fastened inside the
drum against one of the sides of the flanges while it is under tension and shall be such that no looseness
is transmitted to the internal layers. The conductor shall be snugly, tightly and uniformly spooled on
the drums. The wrapping of conductor on the drums shall be laid snugly against side of the preceding
wrap and the first and last wrap in each layer shall fit snugly against the sides of the flanges. Drums
shall be lagged with sufficient strong wooden laggings to support the full drum without crushing. The
wooden drums after providing lagging shall be fastened by two steel wires ofmin. 3 mm. Dia over the
lagging on the two sides of adequate size to keep the lagging intact and to prevent the drum from
crushing/ damage.

Although the various dimension of the drums such as flanges, stretches, traverse and barrel
diameter shall depend on the quantity of conductor as offered and agreed upon, on one drum. The
manufacturer while packing the conductor in drum shall ensure that after winding complete quantity
of conductor in drum a uniform space of not less than 100 mm. remains between outer layer of con-
ductor and inner surface of the external protective legging of the drum. This is essential to ensurethat
the conductor does not get closer to the legging and to avoid damaged during transportation/ reeling
/ unreeling or rolling on the undulated ground / fields.

9.2 Water proof material shall be wrapped round the barrel and inner surface of flange before
winding the conductor and also wrapped round over the conductor completely wounded and under
the laggings.

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9.3 The drums shall be marked clearly in block letters with water proof mark having the marking
attached to them so that there is no possibility of goods being lost or wrongly dispatched due to faulty
marking. The marking shall constitute the following:-

a) Name & full address of the consignee.

b) Destination station.
c) Serial number of drum.
d) Size of Conductor with its code name.
e) Total length of Conductor in drum, with individual length (s).
f) Number of length(s) in each drum.
g) Gross mass of drum including the tare mass of drum.
h) Tare mass of the empty drum with lagging.
i) Net mass of conductor.
j) BIS standard mark.
k) Name of the supplier.
l) Purchase order reference/TN number/RDSS.
m) Date of expiry of warranty / guarantee period.

10. TEST CHECKING OF MATERIAL AT STORES:

i) Sample drums from the material received at stores shall be selected for testing at CTL as per
sampling plan given hereunder in presence of firm’s representative.
ii) The selected sample drum for CTL testing shall be identified by the seals provided by Inspecting
Officer / Inspecting Agency during pre-dispatch inspection at firm’s works and these sealing
details shall be invariably mentioned in the selection Memo by the nominated officers of Nigam.

iii) The tests in the Nigam Testing laboratory (CTL) shall be conducted in the presence of repre-
sentative of supplier for which a 3 days notice shall be issued through Fax / Speed Post statingDate
& Time to the firm, so that supplier can depute their representative to witness the test . In casethe
supplier or his representative does not turn up the testing shall be proceeded & completed. The pay-
ment shall be released only after receipt of successful CTL test reports for the samples selected at
purchaser’s stores for mandatory test checking the samples to be selected from material received at
Nigam’s stores by officers to be nominated by Circle SE’s / SE (I&S) for testing at CTL.

Page 99 of 623
11.1 SAMPLING

Selection of samples from the material received at stores shall be done as soon as material
received in stores in the presence of representative of supplier.

In case of selection of sample for type test the length of the sample shall be of 15 Mtrs. The
selected and sealed sample for type test shall be identified by providing polycarbonate seals on both
ends of conductor and after forming the coil of conductor two stickers seals provided around the coil.

11.2 TESTS

11.2.1. The following tests shall be carried out as per relevant Clause of latest IS-398
(Part2)/1996 on each selected drum by drawing sample of 5 Mtrs. at CTL from random
distance from any length of the selected drum of ACSR Conductor during rewinding:-

a) Rewinding test (Measurement of Length and weight) & Checking

of Manufacturing defects.
b) Measurement of lay ratio during rewinding of Conductor Drum.
c) Dia. of Aluminium Strands and Steel Wires.
d) Breaking load test.
e) Resistance Test.
f) Galvanization of steel wire (Uniformity) and Mass of Zinc
Coating.
h) Verification of Water Proof marking on Drum as per
Specification.

11.2.2 The following tests shall be carried out as per relevant Clause of latest IS / Specifica-
tion on each selected drum by drawing sample of 5 Mtrs. at CTL from random distance
from any length of the selected drum of Conductor during rewinding:

i) Rewinding test (Measurement of Length and weight) & Checking

of Manufacturing defects.
ii) Measurement of lay ratio during rewinding of Conductor Drum

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iii) Breaking Load test
iv) Elongation Test
v) Resistance test
vi) Measurement of dia-meter of individual Aluminium.
vii) Verification of Water Proof marking on Drum as per
Specification.

NOTE: (a) In addition to above tests remaining acceptance tests as per relevant IS shall also be con-
ducted at CTL provided the testing facility is available at CTL for these tests time to time. Only those
tests shall be conducted for which testing facilities are available in NIGAM’s Lab.

(a) The Officer In charge of central Testing Lab (CTL) of Nigam shall send copies
of test reports to the Purchasing Officer / Sr. AO (CPC), consignee and the
supplier.
(b) The payment of every lot shall be released after receipt of successful test report
from Nigam’s Lab (CTL) on the samples selected from the material received
in Nigam stores.

11.3 CRITERIA FOR ACCEPTANCE:

(a) Rewinding Test (Measurement of Length and weight):

The results of measurement of length test shall be made applicable to all drums contained in
each lot/sub-lot by making deduction of less length of conductor in a sample drum. In case short
length is observed more than one percent of the length contained in lot / sub-lot , then the lot / sub-
lot shall liable to be rejected

The net calculated weight of conductor corresponding to minimum prescribed diameter in IS

of Aluminium Strand & Steel Strands shall be as under:

a) ACSR DOG 384.33 Kg./Km.

If weight of conductor corresponding to minimum prescribed diameter as per IS found less up

to 2% in respect to measured length the lot shall be acceptable otherwise the entire lot for which
sample drum represents shall be rejected and to be replaced by the supplier.

(b) If the sample(s) fail in any test other than length measurement, the entire material in the
Lot shall be rejected and shall have to be replaced by the supplier.

Page 101 of 623

c.) If the contractor / supplier fails to lift the material declared rejected or any part thereof
from the consignee within a period of 15 days from the date of dispatch instruction from
the purchaser, the purchaser shall be entitled to effect recovery along with other actions as
per Clause No. 1.62 of Section-II (General Condition of Contract).

12.0 TEST CHARGES:

All test charges incurred towards test checking of the material received in our stores shall be
borne by the NIGAM.

Page 102 of 623

TECHNICAL SPECIFICATION FOR SUPPLY OF 9 M. LONG PCC POLES OF 400 KGWORK-
ING LOAD WITH FACTOR OF SAFTY 2.0

1. SCOPE :

This specification covers the design, manufacture, inspection, testing and delivery of finished 9 metre
long- 400 Kg. rectangular shaped, solid prestressed cement Concrete poles, witnessing of tests before
despatch and its transportation from the firm’s works to consignee’s head quarters. These poles are
to be used for erection of 33 KV /11 KV over head lines and installation of transformers.

2. CLIMATIC CONDITIONS

I. Peak ambient temperature 50 Degree C

II. Maximum average ambient temperature 40 Degree C
III. Maximum temperature attainable 60 Degree C
IV. Maximum relative humidity 100 %
V. Minimum relative humidity 50 %
VI. Average number of thunder storm days per annum 40
VII. Average number of rainy days per annum 100
VIII. Average annual rainfall 10-100 cm
IX. Maximum wind pressure 100 Kg/sq.m
X. Altitudes not exceeding 1000 mtrs.

3. REQUIREMENT
These poles are required for 33/11 KV lines and installation of transformers.

The quantity indicated above is tentative and purchaser reserves right to increase/ decrease the same
at the time of finalization of tender.

4. DETAILS OF APPLICABLE STANDARDS/SPECIFICATION/MANUALS :

The pole shall comply with the relevant provisions made in the following Indian Standards Specifi-
cation (now BIS) with latest amendments / REC specifications.

1 REC manual No.13/1977 Manual on manufacturing of solid poles part-I

design aspects.

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(part-I)
2 REC manual No.13/1977 (Part.II) Manual on manufacturing of solid PCC poles
part.II manufacturing aspects.
3 REC specification No.15/1979 Prestressed cement concrete poles (FOS/2.5) for
(amended upto 1983 & thereafter 11 KV and LT lines.
4 IS:1678/1978 (Latest amended) Specification for PCC poles for overhead power
traction & telecommunication lines.
5 IS:2905/1989 (Latest amended) Method of test for PCC poles for overhead power
and telecommunication lines.
6 IS:7321/1974 (Latest amended) Code of practice for selection handling and erec-
tion of concrete poles for overhead power andtele-
communication lines.
7 IS:1343/1980(Latest amended) Code of practice for prestressed concrete
8 IS: 456/1978 (Latest amended) Code of practice for plain and reinforced concrete
9 IS: 1785(Latest amended) For HT steel wires for prestressed concrete

5. MATERIAL

The following quality of material should be used for manufacturing of PCC poles.

(i) CEMENT : The cement used in manufacture of prestressed concrete poles shall be ordinary or
rapid hardening portland cement conforming to IS:269/1976 (specification for ordinary and low heat
portland cement) or IS:8041-E-1978 (specification for rapid hardening portland cement) or portland
cement conforming to IS:8112/1976.

(ii) AGGREGATES : Aggregates used for the manufacture of prestressed concrete poles
shall conform to IS:383/1970 (specification for coarse and fine aggregates from natural sources for
concrete). The nominal maximum size of fine aggregates shall not exceed 10 mm.

(iii) WATER :Water should be free from chlorides, sulphates other salts and organic matter. Potable
water is generally suitable.

(iv) ADMIXTURES :These admixtures should not contain calcium chloride or other chlorides and
salts which are likely to promote corrosion of pre-stressing steel.

Page 104 of 623

(v) PRE-STRESSING STEEL : The prestressing steel wires including those used as untentioned
wires should conform to IS:1785 –1966 Part.I (Specification for plain hard drawn steel wire)
or IS:"6003/1970 (Specification for indented wire for prestressed concrete). The type design for plain
wires of 4 mm diameter are with a guaranteed ultimate strength of 175 Kg./sq.mm.

(vi) CONCRETE MIX :The concrete mix. shall be designed to the requirements laid down for con-
trolled concrete (also called design requirement laid down/mix. concrete) in IS:1343/1980 (Code of
practice for prestressed concrete) and IS:456/1978 (code of practice for plain and reinforced concrete)
subject to the following special conditions :

a) Min. working cube strength at 28th day should be at least 420 Kg. / cm.2
b) The mix. should contain at least 380 Kg. cement per cubic metre of concrete.
c) The concrete strength at transfer should be at least 210 Kg. / cm.2
d) The mix. should contain as low water content as is consistent with adequate workability. If it
becomes necessary to add water to increase the workability the cement content should also be raised
in such a way that the original value of water cement ratio is maintained.

(vii) REINFORCEMENT :The reinforcing bars and wires used for manufacturing of prestressed ce-
ment concrete poles shall conform to the following Indian standards.

i) Mild steel bars conforming to IS:432/1966.

ii) High tensile steel wires conforming to IS:1785/1966.

(viii) WELDING AND LAPPING OF STEEL: The high tensile steel wire shall be continuous over
the entire length of the tendon. Welding shall not be allowed in any case. However, jointing or cou-
pling be permitted provided the strength of the joint or coupling is not less than the strength of each
individual wire.

6. DESIGN REQUIREMENT :

The poles shall be designed to meet the following requirements.

a) The poles shall be planted directly in the ground with a planting depth of 1.5metres.
b) The working load on the poles shall be 400 Kg. applied at 0.6 Mtr. from top.
c) The factor of safety shall not be less than 2.0.
d) The average permanent load should be 40% of the working load.

Page 105 of 623

e) The Factor of safety against first crack load shall be 1.0
f) The ultimate moment capacity in the longitudinal direction should be atleast one fourth
of that in the transverse direction.
g) The max. compressive stress in concrete at the time of transfer of presetress should not
exceed 0.8 times the cube strength.
h) The concrete strength at transfer shall not be less than half of the 28 th day strength ensured in
the design i.e. : 420x0.5 = 210 KG./SQ.MM.
i) The cover concrete measured from outside of prestressing tendon shall be normally 20 mm.
j) At the design value of first crack load the modules of rupture shall not exceed 55.2 Kg./cm for M-
42 concrete.

7. OPTIMUM DESIGN DIMENSIONS :

Bottom depth. : 395 mm

Top depth. : 225 mm
Breadth. : 100 mm
No. of tensioned wire : 20 Nos. wires of 4 mm dia.
Configuration type. : JVVNL specification TN-

8. OTHER TECHNICAL REQUIREMENT :

A) EARTHING : Earthing shall be provided, by having continuous length of 4 mm dia G.I.wire

embeded in concrete during manufacture and the ends of G.I. wire left projected from the transverse
face of the poles to a length of 100 mm at 250 mm from top and 150 mm below groundlevel (Planting
depth to be 1.5 M) The tolerance of 25 mm shall be allowed in position of earthwire. The earth wire
shall not be allowed to entangle with prestressing wires.

B) EYE HOOKS : The eye hooks shall be provided on the middle of transverse face of the pole
as per IS: 7321/1974 at a distance of about 2.25metre from top and about 1.8metre from the bottom,
to facilitate the handling. The eye hooks shall be of 12 mm dia MS round and shall have an internal
dia of 40 mm. The tolerance of minus 5 mm and plus 20mm in internal dia of eye hooks shall be
allowed. the eye hooks in question shall be securely embeded in the pole to ensure safe handling.

Page 106 of 623

C) REINFORCEMENT :The poles offered should have 8 Nos. rings of 4 mm dia HT wires rings
on top side of the pole and 8 Nos. rings of 4 mm dia HT wire rings on the bottom side of the pole thus
total HT wire rings should be 16 in all or 4 Nos. of 6 mm dia MS round rings on top side and 4Nos.
of 6 mm dia MS round rings on bottom side are to be provided. The minimum inter spacingof 20
mm in case of 4 mm dia HT wire rings and 30 mm in case of 6 mm dia MS round rings is to be
maintained. These rings should be complete and rectangular in shape with minimum over lappingof
20 mm. No rings are to be bunched together.

D) HOLES : The poles offered should have two holes of 18 mm dia on longitudinal face of pole
(broad face) to fix top hamper. The top hole shall be at the distance of 60 mm from top of pole and
second hole will be at 160 mm from top of pole.

9. WORKMANSHIP :

(i) All materials used in the finished PCC poles and workmanship shall be of required quality. No
deviation with technical particulars required as per this tender specification shall be allowed.

(ii) Apart from the requirements regarding the design, material, process of manufacture, dimensions
shape, workmanship finishing etc., acceptability of PCC poles shall be determined by the results of
various tests to evaluate their properties as stipulated in the relevant IS/specification.

10. DRAWINGS :

Approved copy of drawing is enclosed herewith the Technical Specification and manufacturer shall
manufacture / supply the material in accordance of approved drawing of JVVNL.

11. MARKING :

(A) The poles shall be clearly & indelibly marked with the following particulars by engraving
properly at a height of 3 metres from the bottom end so as to be easily readable after erection.
Marking should not be painted.

1. S.No. of pole.
2. Date, month and year of manufacture.
3. Name/mark of manufacturer.
It should be distinct and should not resemble with mark of other manufacturers and if
it resembles with marking of other manufacturers then you should change your marking.
4. JVVNL - TN- / RDSS
5. Length and working load 9 M/400 Kg.

Page 107 of 623

(B) RED STRIP PAINTING: A strip of 30-40 mm shall be painted on one side (transverse
face) of the pole at a planting depth (1.5Metre from bottom) with oil paint of red color in such a
manner that the red strip shall be visible above the ground. Poles without marking of red strip will not
be accepted and considered as rejected.

12. INSPECTION, TESTING &CHECKING :

The inspection and testing shall be carried out at supplier’s works as per relevant ISS: GTP before
dispatch

The supplier shall incorporate the following certificate in his offer letter which should indicate Sr.
No. & total No. of poles casted on different dates, as offered for the present inspection :

a) That all the PCC poles included in the lot under the present inspection conform to the design,
strength and workmanship required as per the purchase order, GTP of the specification and contract
drawing under the TN-.

b) That none of the PCC poles offered for the present inspection was previously rejected / not con-
sidered for inspection or tested for transverse load strength by any other inspecting officer.

The supplier shall furnish the following certificates / tests results to our Inspecting Officer at the time
of inspection, if desired.

a) The supplier shall furnish test results from the manufacturer to substantiate that HT steel wire
of required quality was used in the manufacture of PCC poles under the present inspection.

b) The supplier shall certify that cement, prestressed steel wires, M.S. Bars, aggregates and other
material had been used as per the required specifications, to manufacture the PCC Poles under the
present inspection.

The supplier shall arrange the required number of PCC Poles out of the offered lots as per the sampling
plan under this specification for witnessing the various tests by Inspecting Officer. The poles so
tested in presence of the Inspecting Officer shall be preserved for atleast 30 days from the date of
inspection for subsequent checking by any other representative for the purchaser if needed.The supplier
shall intimate in writing name and address of purchaser of tested poles otherwise the PBG will not be
released.

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The supplier shall provide the following documents to Inspecting Officer, to facilitate and authenticate
the process of inspection, checking and testing.

a) One set of copies of P.O., relevant IS and specification of TN (with the latest amendment, if any)

b) Copy of approved Drawing.

c) Details of all meters/ instruments /equipments to be used in the process of checking and testing
of the material alongwith the details for their last calibration (original) certificates of calibration in-
dicating that calibration had been done to full range on all the scales to verify that the last calibration
and sealing was got done from the manufacturer or an independent test house approved by Govern-
ment within one year prior to the date of inspection.

Inspection shall not be carried out further, if the above requirements are not fulfilled satisfactorily.

A. SAMPLING:

a) Randomness is the pre requisite for sample checking and testing. Starting from any random
serial number or PCC poles in the offered lot (arranged serial number wise and sub-divided sub-lots
each not exceeding 500 Nos. of poles) every pole shall be included in the sample "r" being the next
higher integral part of N/n where N is the size of the lot or sub-lot and “n" is the sample size as per
the table below:-

Sample size and criterion for conformity :

Size of lot or sub-lot in Dimensional requirement No.of poles for

numbers transverse strength
sample size (n) Permissible No. of
(N) test (n)
defective samples
1 2 3 4
Upto 100 10 1 1
101 to 200 15 1 3
201 to 300 20 2 4
301 to 500 30 3 5

The minimum size of lot which can be offered for inspection is 100 Nos. of pole except in case
of last lot which may be for left out balance quantity. Further lot size once offered for inspection

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can’t be reduced subsequently under the re-inspection unless re-inspection charges for each sub-lot
out of the original lot is deposited.

b) Deviation in selection of samples may be effected by the Inspecting Officer only if he thinks
that the purpose of checking/testing will be better served by such deviation.

c) The number of poles, in every lot/sub lot, which does not satisfy, the requirement of overall
length, cross section and uprightness shall not exceed the corresponding number given in Col.3 of the
above Table. If the number of such poles exceeds the corresponding number, supplier shall segregate
the pole not confirming the requirement of specification and shall submit the remaining poles for
checking. Fresh poles as per sample size indicating in Col.2 will be drawn from the remaining poles
of the offered lot or sub lot and subject to similar checking. If the number of effective poles inthe
second sample of poles also exceeds the permissible number indicated in Col.3 the then the subjectlot
or sub lot under inspection will be rejected without further checking. Result of all such checking shall
be recorded.

In case of one or more poles fail during transverse load test, then twice the number of poles fromthe
sub-lots representative poles from which failed will be taken for transverse load test. If these poles
withstand the transverse load test the entire lot will be deemed to have passed the tests and will be
cleared, but if one or more pole fails during double sampling, then leaving aside the sub- lots for
which double sampling was done and where samples could not withstand transverse load test, the
remaining sub-lots representing poles from which have withstood transverse load test will be accepted
provided they satisfy clause No. 9.3.2 of IS:1678/1978. However, the destruction test from the sub-
lots will be done by the inspecting officer on the poles on which transverse load was performed and
the acceptance of these sub-lots will be on the basis of the test results observed by the inspecting
officer during destruction test on the respective representative poles.

e) All the poles subject to transverse load strength test shall be reserved for atleast 30 days from the
date of inspection for any subsequent checking by any other representative of the purchaser, if
required. These poles shall not be dispatched /supplied to the purchaser.

f) One pole from the poles subject to transverse load strength test, from every lot/sub lot, shall be
destructed for following measurement/checking.

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i) To measure clear thickness of concrete cover at three points one within 1.8 metre from the bottom
end of the pole, the second within 0.6 metre from the top end of the pole and the third at an inter-
mediate point. The mean value shall be compared with the specified value.

ii) To check Nos., size & configuration of steel reinforcement and GI earth wire.

The destructed poles shall also be preserved for at least thirty days from the date of inspection for
subsequent checking by any other representative of the purchaser if required.

B) INSPECTION :--

Inspection shall comprise of :

a) Verification of offered quantity as per packing list

b) Visual inspection for shape, workmanship and finishing of the PCC poles.
c) Checking of dimensions/quantity as per the GTP/specification
d) Verification of marking and red / black strip as per GTP

C) WITNESS OF TESTS :-

i) On PCC poles for its transverse load strength test .

ii) On one PCC pole from every lot/sub lot by destruction to ascertain the No., size and
configuration of steel reinforcement and GI earth wire etc.

The supplier should have transverse load testing arrangements of its own. Testing arrangement shall
be preferably as specified in the relevant specification i.e. IS:1678/1978 & IS:2905/1989 (both latest
amended). As per provision of Clause No.6.2.3 of IS:2905/1989 the load shall be applied at a point
stipulated in the relevant IS by means of a suitable device such as a wire rope and winch placed in
a direction normal to the direction of the length of the pole so that the minimum length of the straight
rope under pull is not less than the length of the pole.

As per provision of Clause No.6.2.5 "load measurement" of IS:2905/1989. The dynamometer or any
other satisfactory method of load measurement shall be calibrated at regular intervals (not more than
one year) and capable of measuring load to the accuracy of 50 N may be adopted.

The transverse strength test on poles shall be conducted in accordance with IS:2905. A prestressed
concrete pole shall be deemed not to have passed the test if cracks wider than 0.1 mm appear at a

Page 111 of 623

stage prior to the application of the designed transverse load at first crack and the observed ultimate
transverse load is less than the designed ultimate transverse load.

The following facilities are to be provided by the supplier at his own cost to the inspecting officerof
JVVNL.

(a) Suitable accommodation.

(b) Local conveyance between arrival point, place of stay, works and departure point.

13. TEST AT SITE :

The purchaser reserves the right to get the material tested after receipt of inspected poles at sites/
stores and claiming any compensation or rejecting the poles if not found according to specification.
All charges consequent to rejection, rectification and replacement shall be borne by the supplier.

14. TOLERANCE :

The following tolerances shall be allowed :

i) Over all length of PCC poles .................................................. ±15 mm

ii) Top and bottom dimension.
(Breadth and depth of PCC poles) ....................................... ± 3 mm
iii) Clear concrete cover over HT steel wires
(Average of measurements at three sections) ............... …. - 2 mm
iv) Uprightness of the PCC poles ................................................. 0.5 %
v) Internal dia of eye hook…......................................................... + 20 mm and – 5 mm
vi) Dia of holes ................................................................................ ± 1 mm
vii) Diameter of HT wires as per IS: 6003:2010 …………………..± 0.05 mm
viii) Diameter of GI wire as per IS:280/1979… ............................... ± 2.5%
ix) Diameter of MS rod for eye hook as per 1786/1966… ............± 4%

Higher dimensions of poles shall attract no penalty / deduction as it will not be considered as devia-
tion.

15. GUARANTEED TECHNICAL PARTICULARS :

Page 112 of 623

The manufacturer shall furnish the guaranteed technical particulars of the PCC poles as required in
the schedule-V by mentioning specific figures therein. Any item of the GTP left unfilled or simply
written as per ISS etc. shall be considered as incomplete GTP and such tender is liable to be rejected.

16. TRANPORTATION ARRANGEMENTS :

The manufacturer must furnish the location of the factory and road distances from their factory site
to various destinations (sub-divisional headquarters of JVVNL) through shortest route.

The manufacturers should also furnish the particulars of transportation vehicles owned by them. The
manufacturers who also undertake the guarantee for transportation of minimum poles daily uptocon-
signee’s headquarters within stipulated delivery period shall be preferred in deciding the quantitiesto be
ordered.

17. CRITERIA FOR ACCEPTANCE:

The inspected PCC poles should be strictly in accordance to the GTP of the specification otherwise
the material shall be treated as rejected and shall not be accepted. However, the poles with some minor
deviations may be accepted with deductions as per rates prescribed and in force
Higher dimensions of poles shall not attract any penalty / deduction, as it will not be considered as
deviation.

Page 113 of 623

TECHNICAL SPECIFICATION FOR SUPPLY OF 9 M. LONG PCC POLES OF 200 KGWORK-
ING LOAD WITH FACTOR OF SAFTY 2.5

1. SCOPE :

This specification covers the design, manufacture, inspection, testing and delivery of finished 9 metre
long- 200 Kg. rectangular shaped, solid prestressed cement Concrete poles, witnessing of tests before
dispatch and its transportation from the firm’s works to consignee’s head quarters. These poles are
to be used for erection of 11 KV & LT over head lines and installation of 11/.4 KV distribution
transformers.

2. CLIMATIC CONDITIONS

I. Peak ambient temperature 50 Degree C

3. DETAILS OF APPLICABLE STANDARDS/SPECIFICATION/MANUALS :

The pole shall comply with the relevant provisions made in the following Indian StandardsSpecifi-
cation (now BIS) with latest amendments / REC specifications.

1 REC manual No.13/1977 (part-I) Manual on manufacturing of solid poles part-I

design aspects.
2 REC manual No.13/1977 (Part.II) Manual on manufacturing of solid PCC poles
part.II manufacturing aspects.
3 REC specification No.15/1979 Prestressed cement concrete poles (FOS/2.5) for
(amended upto 1983 & thereafter 11 KV and LT lines.
4 IS:1678/1978 (Latest amended) Specification for PCC poles for overhead power
traction & telecommunication lines.

Page 114 of 623

5 IS:2905/1989 (Latest amended) Method of test for PCC poles for overhead power
and telecommunication lines.
6 IS:7321/1974 (Latest amended) Code of practice for selection handling and erec-
tion of concrete poles for overhead power andtele-
communication lines.
7 IS:1343/1980(Latest amended) Code of practice for prestressed concrete
8 IS: 456/1978 (Latest amended) Code of practice for plain and reinforced concrete
9 IS: 1785(Latest amended) For HT steel wires for prestressed concrete

4. MATERIAL

The following quality of material should be used for manufacturing of PCC poles.

(iii) WATER :Water should be free from chlorides, sulphates other salts and organic matter. Potable
water is generally suitable.

(iv) ADMIXTURES :These admixtures should not contain calcium chloride or other chlorides and
salts which are likely to promote corrosion of pre-stressing steel.

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a) Min. working cube strength at 28th day should be at least 450 Kg. / cm.2
b) The mix. should contain at least 380 Kg. cement per cubic metre of concrete.
c) The concrete strength at transfer should be at least 225Kg. / cm.2
d) The mix. should contain as low water content as is consistent with adequate workability. If it
becomes necessary to add water to increase the workability the cement content should also be raised
in such a way that the original value of water cement ratio is maintained.

(vii) REINFORCEMENT :The reinforcing bars and wires used for manufacturing of prestressed ce-
ment concrete poles shall conform to the following Indian standards.

i) Mild steel bars conforming to IS:432/1966.

ii) High tensile steel wires conforming to IS:1785/1966.

5. DESIGN REQUIREMENT :

The poles shall be designed to meet the following requirements.

a) The poles shall be planted directly in the ground with a planting depth of 1.5metres.
b) The working load on the poles shall be 200 Kg. applied at 0.6 Mtr. from top.
c) The factor of safety shall not be less than 2.5.
d) The average permanent load should be 40% of the working load.
e) The Factor of safety against first crack load shall be 1.0
f) The ultimate moment capacity in the longitudinal direction should be atleast one fourth
of that in the transverse direction.
g) The max. compressive stress in concrete at the time of transfer of presetress should not
exceed 0.8 times the cube strength.
h) The concrete strength at transfer shall not be less than half of the 28 thday strength ensured in
the design i.e. : 450x0.5 = 225 KG./SQ.MM.
i) The concrete cover measured from outside of prestressing tendon shall be 30 mm.
j) At the design value the first crack load the modules of rupture shall not exceed 55.2 Kg. / cm
for M-45 concrete

Page 116 of 623

6. OPTIMUM DESIGN DIMENSIONS :

Bottom depth 300 mm

Top depth 145 mm
Breadth. 114 mm
No. of tensioned wire 16Nos. wires of 4 mm dia
Configuration type JVVNL specification TN-

7. OTHER TECHNICAL REQUIREMENT :

A) EARTHING : Earthing shall be provided, by having continuous length of 4 mm diaG.I.wire

embeded in concrete during manufacture and the ends of G.I. wire left projected from the transverse
face of the poles to a length of 100 mm at 250 mm from top and 150 mm below ground level (Planting
depth to be 1.5 M) The tolerance of 25 mm shall be allowed in position of earthwire. The earth wire
shall not be allowed to entangle with prestressing wires.

B) EYE HOOKS : The eye hooks shall be provided on the middle of transverse face of the pole
as per IS: 7321/1974 at a distance of about 2.25 metre from top and about 1.8metre from the bottom,
to facilitate the handling. The eye hooks shall be of 12 mm dia MS round and shall have an internal
dia of 40 mm. The tolerance of minus 5 mm and plus 20mm in internal dia of eye hooks shall be
allowed. the eye hooks in question shall be securely embeded in the pole to ensure safe handling.

C) REINFORCEMENT :The poles offered should have 8 Nos. rings of 4 mm dia HT wires rings on
top side of the pole and 8 Nos. rings of 4 mm dia HT wire rings on the bottom side of the pole thus
total HT wire rings should be 16 in all or 4 Nos. of 6 mm dia MS round rings on top side and 4 Nos.
of 6 mm dia MS round rings on bottom side are to be provided. The minimum inter spacing of 20mm
in case of 4 mm dia HT wire rings and 30 mm in case of 6 mm dia MS round rings is to be maintained.
These rings should be complete and rectangular in shape with minimum over lapping of20 mm. No
rings are to be bunched together.

8. WORKMANSHIP :

Page 117 of 623

(i) All materials used in the finished PCC poles and workmanship shall be of required quality. No
deviation with technical particulars required as per this tender specification shall be allowed.

9. DRAWINGS :
Approved copy of drawing is enclosed herewith the Technical Specification and manufacturer shall
manufacture / supply the material in accordance of approved drawing of JVVNL.

10. MARKING :

1. S.No. of pole.
2. Date, month and year of manufacturing
3. Name/mark of manufacturer.
It should be distinct and should not resemble with mark of other manufacturers and if
it resembles with marking of other manufacturers then you should change your marking.
4. Length and working load 9 M/200 Kg.
5. JVVNL-TN- / RDSS

The above details should be engraved at suitable position & clearly written in visible letters having
equal & readable size otherwise the material may not be accepted.

(B) BLACK STRIP PAINTING: A strip of 30-40 mm shall be painted on one side (transverse
face) of the pole at a planting depth (1.5Metre from bottom) with oil paint of black colour in such a
manner that the black strip shall be visible above the ground. Poles without marking of blackstrip will
not be accepted and considered as rejected.

11. INSPECTION, TESTING &CHECKING :

The inspection and testing shall be carried out at supplier’s works as per relevant ISS: GTP before
dispatch in accordance with the clause No.1.27 of GCC

Page 118 of 623

The supplier shall incorporate the following certificate in his offer letter which should indicate Sr.
No. & total No. of poles casted on different dates, as offered for the present inspection

b) That none of the PCC poles offered for the present inspection was previously rejected / not con-
sidered for inspection or tested for transverse load strength by any other inspecting officer.

The supplier shall furnish the following certificates / tests results to our Inspecting Officer at the time
of inspection, if desired.

a) The supplier shall furnish test results from the manufacturer to substantiate that HT steel wire
of required quality was used in the manufacture of PCC poles under the present inspection.

The supplier shall provide the following documents to Inspecting Officer, to facilitate and authenticate
the process of inspection, checking and testing.

a) One set of copies of P.O., relevant IS and specification of TN (with the latest amendment, if any)

b) Copy of approved Drawing.

Page 119 of 623

calibration and sealing was got done from the manufacturer or an independent test house approved
by Government within one year prior to the date of inspection.

Inspection shall not be carried out further, if the above requirements are not fulfilled satisfactorily.

A. SAMPLING:

a) In a consignment, 500 poles or a part thereof of the same overall length, same dimensions and
belonging to the same batch of manufacturer shall be grouped together to constitute a lot.

For ascertaining the conformity of the materials in the lot to the requirements of the specification,
samples shall be tested from each lot separately.

The number of poles to be selected from the lot shall depend on the size of the lot and shall be
according to table as under:-

Sample size and criterion for conformity :

Size of lot or sub-lot in Dimensional requirement No.of poles for

numbers transverse strength
sample size (n) Permissible No. of
(N) test (n)
defective samples
1 2 3 4
Upto 100 10 1 1
101 to 200 15 1 3
201 to 300 20 2 4
301 to 500 30 3 5

The minimum size of lot which can be offered for inspection is 200 Nos. of pole except in case
of last lot which may be for left out balance quantity. Lot size once offered for inspection cannot be
reduced subsequently under the re-inspection, unless re-inspection charges for each lot / sub-lot out
of the original lot is deposited.

b) Deviation in selection of samples may be effected by the Inspecting Officer only if he thinks
that the purpose of checking/testing will be better served by such deviation.

Page 120 of 623

d) PCC poles, in every lot/sub lot sampled for transverse load strength test shall satisfy the re-
quirement of the test. Initially selection of sample and inspection and testing of poles will be under-
taken as usual as is being done according to IS:1678/1998 and IS:2905/1989 with latest amendments.
In case the samples selected satisfied the dimensional requirements and also withstandtransverse load
test, the lot stands cleared.
In case of one or more poles fail during transverse load test, then twice the number of originally tested
shall be selected from those already selected and subjected to the tests. If these poles withstandthe
transverse load test the entire lot will be deemed to have passed the tests and will be cleared,but
if one or more pole fails during double sampling, then leaving aside the sub-lots for which double
sampling was done and where samples could not withstand transverse load test, the remaining sub-
lots representing poles from which have withstood transverse load test will be accepted provided they
satisfy clause No. 9.3.2 of IS:1678/1978. However, the destruction test fromthe sub-lots will be done
by the inspecting officer on the poles on which transverse load was performed and the acceptance of
these sub-lots will be on the basis of the test results observed by the inspecting officer during de-
struction test on the respective representative poles.

e) All the poles subject to transverse load strength test shall be reserved for atleast 30 days from
the date of inspection for any subsequent checking by any other representative of the purchaser, if
required. These poles shall not be dispatched /supplied to the purchaser.

f) One pole from the poles subject to transverse load strength test, from every lot/sub lot, shall
be destructed for following measurement/checking.

ii) To check Nos., size & configuration of steel reinforcement and GI earth wire.

The destructed poles shall also be preserved for atleast thirty days from the date of inspection for
subsequent checking by any other representative of the purchaser if required.

Page 121 of 623

B) INSPECTION :

Inspection shall comprise of :

a) Verification of offered quantity as per packing list
b) Visual inspection for shape, workmanship and finishing of the PCC poles.
c) Checking of dimensions as per the GTP/specification

C) WITNESS OF TESTS :

i) On PCC poles selected for transverse load strength test as per sampling plan.
ii) On one PCC pole from every lot/sub lot be destructed to ascertain the No., size and
configuration of steel reinforcement and GI earth wire etc.

The supplier should have transverse load testing arrangements of its own.Testing arrangement shall
be preferably as specified in the relevant specification i.e. IS:1678/1978 & IS:2905/1989 (both latest
amended). As per provision of Clause No.6.2.3 of IS:2905/1989 the load shall be applied at a point
stipulated in the relevant IS by means of a suitable device such as a wire rope and winch placed in
a direction normal to the direction of the length of the pole so that the minimum length of the straight
rope under pull is not less than the length of the pole.

As per provision of Clause No.6.2.5 "load measurement" of IS: 2905/1989. The dynamometer or any
other satisfactory method of load measurement shall be calibrated at regular intervals and capable of
measuring load to the accuracy of 50 N may be adopted.

The transverse strength test on poles shall be conducted in accordance with IS 2905. A prestressed
concrete pole shall be deemed not to have passed the test if cracks wider than 0.1 mm appear at a
stage prior to the application of the designed transverse load at first crack and the observed ultimate
transverse load is less than the designedultimate transverse load.

12. TEST AT SITE :

The purchaser reserves the right to get the material tested after receipt of inspected poles at sites/stores
and claiming any compensation or rejecting the poles if not found according to specification. All
charges consequent to rejection, rectification and replacement shall be borne by the supplier.

13. TOLERANCE :

The following tolerances shall be allowed :

Page 122 of 623

i. Over all length of PCC poles ±15 mm
ii. Top and bottom dimension. (Breadth and depth of PCC ± 3 mm
poles)
iii. Clear concrete cover over HT steel wires (Average ofmeas- - 2 mm
urements at three sections).
iv. Uprightness or straightness of the PCC poles 0.5 %
v. Internal dia of eye hook + 20 mm and – 5 mm
vi. Dia of holes ± 1 mm
vii. Diameter of HT wires as per IS: 6003:2010 ± 0.05 mm
viii. Diameter of GI wire as per IS:280/1979 ± 2.5%
ix. Diameter of MS rod for eye hook as per 1786/1966 ± 4%

Higher dimensions of poles shall attract no penalty / deduction as it will not be considered as devia-
tion.

14. GUARANTEED TECHNICAL PARTICULARS :

The manufacturer shall furnish the guaranteed technical particulars of the PCC poles as requiredin
the schedule-V by mentioning specific figures therein. Any item of the GTP left unfilled or simply
written as per ISS etc. shall be considered as incomplete GTP and such tender is liable to be rejected.

15. TRANPORTATION ARRANGEMENTS :

The manufacturer must furnish the location of the factory and road distances from their factory site
to various destinations through shortest route.

The manufacturers should also furnish the particulars of transportation vehicles owned by them. The
manufacturers who also undertake the guarantee for transportation of minimum poles daily uptocon-
signee's headquarters within stipulated delivery period shall be preferred in deciding the quantitiesto be
ordered.

16. CRITERIA FOR ACCEPTANCE:

Page 123 of 623

Higher dimensions of poles shall not attract any penalty / deduction, as it will not be considered as
deviation.

Page 124 of 623

TECHNICAL SPECIFICATION OF 11 KV CT-PT SETS OF RATIO 200/5 Amp

3.01 SCOPE:

This specification covers the design, manufacture, assembly, testing and delivery of three
phase four wire 11 KV/ 110V oil cooled outdoor type combined CTPT units for feeder metering &
Indoor type combined CT-PT unit for consumer metering purpose having 1 No. Three phase poten-
tial transformer and 3 Nos. single phase paper impregnated oil emersed current transformers for
different phases in common tank equipped with weather proof bushing for outdoor use as per tech-
nical data incorporated in this specification.

3.02 APPLICABLE STANDARDS:

Unless otherwise modified in this specification, 11 KV CTPT SETS OF RATIO 200/5 Amp
shall comply with the following Indian Standard Specification (latest version):

IS:2705-1992 Specification for current transformers.

IS:3156-1992 Specification for voltage transformers.
IS:5621-1980 Specification for Insulators/Bushing
IS:2099-1986 Specification for insulators/ bushing
IS:3347-1986 Specification for Insulators/bushing
IS:335-1983 Specification for new insulating oil
IS : 5561 Specification for terminal connectors.

Equipments conforming to any other international standard(s) which ensure(s) equal or better
quality than the standard(s) mentioned above will also be acceptable and in such case(s) the copy of
standards (English version) adopted should be provided.

3.03 CLIMATIC CONDITIONS:

The equipment shall be suitable for operation under climatic conditions as mentioned in
standard IS.

3.04 11 KV CTPT SETS OF RATIO 200/5 Amp.

Page 125 of 623

A) 11 KV Single Phase Current Transformer (3 Nos. for R Y & B phases).

The 11 KV current Transformer shall be paper impregnate oil immersed type, single phase
50 HZ confirming to IS:2705/1992 with latest amendment in all respect except where ever modified
in this specification.

The 11 KV current Transformer shall have the following technical characteristics/ parame-
ters.
Sr. Particulars Parameters
No.
i) Normal system voltage (KV rms) 11
ii) Highest system voltage (KV rms) 12
iii) Frequency 50 Hz
iv) Impulse withstand voltage 95 KV (Peak)
v) i) One minute power frequency dry
withstand voltage (on assembled CT-
PT set)
a) primary (KV r.m.s.) 28
b) secondary (KV r.m.s.) 3
ii) One minute frequency wet Root 2x28 Rms
withstand voltage (KV Peak)
(On assembled CT-PT )

vi) Transformation ratio (CT Ratio)

a) For Consumer Metering 100/5 Amp, 50/5 Amp and
15/5 Amp

b) For Feeder Metering 200/5 Amp

vii) Rated output (VA burden) 10 VA

viii) Class of accuracy 0.5S
ix) Rated continuous thermal current 1.2 times of rated primary
current

Page 126 of 623

x) Short time thermal current rating 18 KA for 3 seconds for CT
ratio 200/5 A
18 KA for 1 seconds for CT
ratio 50/5 A & 100/5 A
6.4 KA for 1 seconds for CT
ratio 15/5 A
xi) Rated dynamic current 2.5 times of short time thermal
current rating.

xii) Number of cores One

xii) Instrument security factor Not exceeding 5
xiii) Max. ratio error As per IS:2705/1992
xiv) Max. phase angle error As per IS:2705/1992
xv) Max. temp. rise over max. ambient As per IS:2705/1992
temp. of 50 deg. C at rated continuous
thermal current at rated frequency and
with rated burden.
B) 11 KV Voltage Transformer:

11 KV voltage Transformer will be used along with CTs of description stated above. This
shall be paper impregnate oil immersed type conforming in all respect to the Indian Standards spec-
ification IS: 3156/1992 with latest amendment except where modified in this specification.

The 11 KV voltage transformer shall have the following ratings/ technical parameters:

Sr. Particulars Parameters

No.
i) Nominal system voltage (KV rms) 11
Ii) Highest system voltage (KV rms) 12
Iii) Nos. of phases Three

Page 127 of 623

iv) Impulse withstand voltage (KVP) 95
(on assembled CTPT set)
v) a) One minute power frequency
dry withstand voltage (on
assembled CT-PT set)
i) primary (KV r.m.s.) 28
ii) secondary (KV r.m.s.) 3

b) One minute frequency wet Root 2x28

withstand voltage (KV Peak) rms
(On assembled CT-PT set)
vi) Frequency 50 Hz
vii) Transformation ratio 11 KV/ 110V
(PT Ratio)
viii) Rated output (VA burden) 30 VA per phase
ix) Class of accuracy 0.5 (As per IS:3156/1992)
x) Winding connection Star/Star with HT neutral earthed.
xi) Rated voltage factor and time 1.2 continuous and 1.9 for 30
seconds.

xii) Temp. rise over max. ambient Within limits of IS:3156/1992

temp.

xiii) Max. Phase angle error Within limits of IS:3156/1992

xiv) Ratio error (Max.) Within limits of IS:3156/1992

3.05 GENERAL TECHNICAL DESCRIPTION OF 11 KV CT-PT METERING SETS:

i. The CT PT Metering set shall comply to the latest standards mentioned in thespecifi-
cation and guaranteed technical particulars.

Page 128 of 623

ii. High voltage winding of 11 KV instrument transformers shall have paper insulation im-
pregnated with oil under vacuum. The paper used for insulation shall be of high insula-
tion grade. The process of impregnation shall be detailed out in the tender.

iii. The core material of CT-PT sets shall be of high grade, non-ageing, electrical silicon
steel having low hysteresis loss and high permeability to ensure accuracy at both normal
and over current/ voltage.

iv. The instrument transformers shall be contained in a fully weather proof, outdoor type,
platform mounting and also suitable for pole mounting type tank with 6 Nos. of 12 KV
class weather proof bushing for incoming and outgoing connections.

v. The thickness of MS sheet used for fabrication of tank shall be minimum 3.15 MM for
sides and bottom and 5 MM for top cover .

vi. The 11 KV CT-PT set should have compact construction and the general arrangement
Dimensional drawing, mounting arrangement shall be got approved before commence-
ment of supplies.

vii. The external surfaces of tanks of CT-PT sets shall be painted with one coat of primer
and two coats of synthetic enamel paint of shade No. 631 of IS:5. The internal surfaces
of the tank shall be painted with two coats of a suitable heat resistant oil insoluble paint.

viii. The metering sets shall be supplied with first filling of insulating oil conforming to
IS:335 (with latest amendment).

ix. The bushings used in the CT-PT sets shall confirm to IS:2099, IS:5621 and IS:3347
(latest amendments). These shall be suitable for operation in heavily polluted atmos-
phere with creepage distance of 25 MM/KV.
x) The minimum clearance between phases and phase to earth as specified in the relevant
ISS should be maintained.

xi) The paper impregnated oil immersed type instrument transformers shall be complete
with all fittings and accessories mentioned at Clause No. 3.06 of this specification.

xii) The 11 KV CT-PT sets shall be hermetically sealed type (should not communicate with
atmospheric air) in construction without any oil conservator. The quality and work-man-
ship shall be of high standard.

xiii) For load shedding single phasing is adopted in the 11 KV system. The offered 11 KV
CT-PT set shall be suitable for working under such abnormal operation condition.

Page 129 of 623

xiv) CT-PT sets shall be used for 3 phase 4 wire KWH metering. As such 11 KV CT PT sets
shall have 3 Nos. CTs.

xv) The 11 KV CT PT sets shall have one No. of Three Phase Potential Transformer. The
primary winding of single phase PT shall be connected in star formation in the tank with
common external neutral.

xvi) The neutral of primary PT winding shall be floating. The neutral of PT Secondary wind-
ing shall be earthed.

xvii) The secondary winding neutral of PT and secondary terminals of CTs and PTs shall be
brought out in one single secondary terminal box through 3 KV bushings. The terminals
shall be marked as per ISS and supporting marking plate with earth terminal shall be
provided. The secondary terminal box compartment shall be divided in two portions -
One portion containing secondary of all CTs and the other portion shall contain all sec-
ondary PT connections with neutral and one body earthed. The whole compartment shall
be covered by one bolted cover with sealing arrangement. At least two bolts at diagonally
opposite corners of secondary terminal box shall be suitable for sealing arrangement. All
other bolted covers and inspection windows covers, where provided shall also have seal-
ing bolts for sealing purpose. Suitably shorting links shall be providedfor individual CT
shorting and PT secondary neutral.

xviii) The secondary terminal box shall have cable gland/ flange suitable to receive two Nos.
control cable of size 6 core X 4 sq.mm. and 4 core x 2.5 sq. mm at the bottom of the
secondary box for metering connections to secondary winding of 11 KV CT-PT circuits
respectively.

xix) The 11 KV CT PT Set shall have 3 Nos. incoming and 3 Nos. outgoing outdoor type
bushing. The 11 KV CT-PT Sets shall have 6 Nos. bimetallic terminal connectors
suitable for Dog Conductor for ratio 200/5 Amp. These should be type tested from
CPRI/ NABL accredited Labs. These test reports should not be older than 7 years for
Short Circuit Test. The dimension & drawing shall be furnished along with tender
duly signed and sealed by testing authority. Inspecting officer shall verify the original
type test reports at the time of inspection for terminal connectors & bushings.

xx) No oil drain plug at the bottom of the CT-PT Sets be provided.

xxi) Embossing/ punching with minimum height of 10mm of Sr. No., ratio & TN No. be
done on the tank of the CT-PT Sets.

xxii) Manufacturer’s name in short should be embossed/ punched.

xxiii) CT Ratio should be painted on tank body so that it should be visible clearly.

xxiv) The under base of CT-PT Sets of 11 KV shall be provided with 2 Nos. 75x40x6mm
Page 138 of 623
channels as shown in the figures detailed in Annexure–I to make them suitable for
fixing to a plate form or plinth. These channels shall be provided through continuous
welding with tank of the CT-PT Sets.

xxv) For feeder metering CT-PT sets i.e. rating of 200/5 A Amp. HV Metal parts (Primary
terminal) shall be of 20 mm dia and made of copper. The primary terminal shall be
along the entire length of bushing.

xxvi) The equipment shall be suitable to withstand for loading conditions when supply for
one phase is disconnected from primary side.

xxvii) Bushing rod of 20 mm dia made of copper shall be used for 11KV CT-PT Sets for
feeder metering.

xxviii) 2 Nos., 5/8” dia, 3” length earthing bolts with 2 nuts, 2 flat & 2 Nos. Spring washers
shall be provided with each CT-PT Set.

xxix) Spring loaded pressure release device shall be provided on each 11 KV CT-PT Set
for releasing of accumulated gases.

xxx) The CT-PT Set (for outdoor installation) top shall be taper / slanting with minimum
slant of 10 mm.

xxxi) The following sealing arrangement for providing seals on each 11 KV CT-PT set
shall be made by the manufacturer.

i) 4 Nos. holes of 2.5 mm dia on each bushing clamp bolts of 6 nos. HT bushings
for providing two polycarbonate seals at diagonally opposite bolts of each bush-
ing clamp in M&P lab after successful testing as required.

ii) 4 Nos. holes of 2.5 mm dia on the bolts provided at four corners of top cover for
providing two polycarbonate seals at diagonally opposite corner of CT-PT set by
the inspecting officer after successful testing and providing polycarbonate seals
in M&P lab after successful testing as required.

iii) 4 nos. sealing holes on the name plate (R&D plate so that our inspecting officer
may provide numbered seal on one side of the plate covering top & bottom holes
whereas on the remaining two holes of other side, the one numbered seal will be
provided by MT Lab after successful testing.

3.06 FITTING AND ACCESSORIES:

The outdoor platform/ pole mounting type metering equipments shall be complete with

Page 139 of 623

tank, fittings and accessories as detailed below:

1 No. Electrically welded sheet steel tank/ enclosure for accommodating above instrument
transformers with suitable bolted cover.

6 Nos. Outdoor single terminal porcelain/ Cycloaliphatic bushing of reputed make without

arcing horns. 3 Nos. for incoming and 3 Nos. for outgoing.

1 No. Secondary terminal box. The terminal box opening door/cover shall have suitable sealing
arrangement. The necessary gland/ socket shall be in the scope of supply.

1 No. Oil filling hole with cap/plug.

1 No. Toughened prismatic oil level indicator with min. oil level marking.

2 No. Lifting lugs for lifting the complete CT-PT unit.

2 Nos. Earthing terminals.

1 Set Under base channels with suitable fixing holes for mounting on plat-form/poles.

1 Set Detachable coller assembly.

1 No. Rating and diagram plate.

6 Nos. Bimetallic Terminal Connectors. [For each 11 KV CT-PT Set of ratio 200/5 Amp.]

3.07 BUSHING:

The bushing shall confirm to IS:5621-1980 and IS:2099-1986 and its subsequent amend-
ment, if any, the bushing shall be of standard make. The make and catalogue No. of bushing
shall be clearly stated in the guaranteed technical particulars. The type tests certificatesof bush-
ings not older than seven years shall also be furnished along with tenders. The bushing rods and
nuts shall be made of material as per cl.3.05 (xxv).The dimensions of 12 KV class bushings and
their related parts shall conform to the relevant Indian Standards as detailed below:

Page 140 of 623

Voltage class
Indian Standard
12 KV For porcelain parts IS:3347 For metal parts
bushing (Part-III) Sec.I-1972 or the IS:3347 (Part-III)
latest version thereof Sec.II-1967).

The minimum electrical clearance of 255 mm between phases shall be obtained with the
bushings mounted and phase to earth clearance should be maintained as specified in relevant IS/
Indian Electricity rules.

On the bushings clamp bolt of CT-PT Sets two holes on two bolts of size 2.5mm
(total 12 holes on 12 bolts) at diagonally opposite sides be provided to enable metering wing to
seal these bolts after successful testing in Meter Labs.

3.08 GUARANTEED TECHNICAL PARTICULARS, DRAWINGS AND QUALITY

ASSURANCE PLAN:

Guaranteed Technical Particulars in the proforma enclosed with this specification shall
be furnished along with the detailed general arrangement dimensional drawings mounting ar-
rangements, connection diagrams and quality assurance plan etc. with the tender. Particulars
which are subject to guarantee shall be clearly marked in GTP appended at Schedule-V.

3.09 INSTRUCTION MANUALS:

The successful tenders shall have to supply required number of operation and mainte-
nance instruction manuals along with the requisite sets of approved drawings of the equipments
covered under this specification. One set of above manuals and drawings shall alsobe sent along
with the delivery of 11 KV CT PT unit to the consignee.

3.10 STAGE INSPECTION:

Each equipment shall comply with and shall be subjected to all routine tests prescribed in
the relevant Indian Standard Specification besides routine tests, stage inspection at firm’s works
during manufacture shall also be carried out if desired by purchaser with out any extra charges.
Production schedule in advance by 15 days shall have to be given to arrange stage inspection.

3.11 INSPECTION, TESTING AND CHECKING:

3.11.1 In the event of order, the supplier shall have to get type tests conducted as per requirement
Page 141 of 623
of relevant standards/ specification conducted in the last 7 years for similar CT-PT sets
having similar specification
3.11.2 Routine tests as per relevant standard along with accuracy test of CT as per IS:2705 (Pt-
II)-1992 and that of PT IS:3156 (Pt.II)-1992 shall be carried out on each equipment
covered by this specification in the presence of purchaser’s representative. All test re-
ports shall be submitted and got approved from the purchaser before despatch of the
equipment.

3.11.3 The supplier shall simulate single phase condition in their laboratory for testing one 11
KV CT-PT set of any ratio from each lot offered for inspection under such condition for
24 hours. The errors of PT shall be measured before and after application of single phas-
ing condition for at least 24 hours and results shall be within permissible limits of speci-
fied accuracy class. This test shall be done as acceptance test.

3.11.4 One CT-PT set of each ratio in each offered lot should be subjected to temperature rise
test .The test shall be carried out simultaneously application of rated current (1.2 lb) and
rated voltage (12 KV) and also ISF test, at firm’s works free of cost.

3.11.5 During routine/ acceptance test, errors for CTs shall be conducted at 1 %, 5%,

20%, 100% and 120% of rated current and in case of PT at 80%, 100% and
120% of rated voltage.

3.11.6 Algebraic summation of errors of standard CTs/PTs to the errors observed on CTs/PTs
under test should be made to get final errors on specified percentage current/ voltage/
burden. If class of accuracy of standard CT-PT is less than 10 times of the accuracy of
CT-PT set under test.

3.11.7 Leak test :- One CT-PT set of each rating in each offered lot should be subjected to ‘Leak
Test’ through Nitrogen gas for a pressure of 10 PSI (Pound sq. inch) for half an hour and
pressure shall not drop more than 2 PSI. There should be no leakage observed at any part
of CT-PT set.

3.11.8 One CT-PT set of each rating in each offered lot shall be opened for verifying the diameter
and cross sectional area of primary coil conductors including verification of GTP.

The verification of diameter & cross sectional area of primary coil conductor of the CT-
PT Set shall be verified for any ratio at stores also. If CT-PT set fails in above verification
at stores, entire lot shall be rejected and the supplier shall lift the rejected lot. In case it
founds within specific limits, the supplier at his own cost shall reassemble/replace the
physically opened CT-PT set at works/stores.

Page 142 of 623

3.11.9 One sample of oil shall be selected for each ratio and shall be tested for a) Break down
voltage b) Tan delta at 90 Deg.C.

The oil supplied with CT PT set shall be of EHV grade Transformer oil suitable for
insulation and coding of the electric transformers of extra high voltage and shall conform
to IS 335 (with latest amendments)

If CT-PT set fails in any of the above tests/verification at works, entire lot shall be re-
jected.

3.11.10 during the inspection at firm’s works, inspecting officer / agency shall provide
polycarbonate seals on each CT-PT set as under -

i) One polycarbonate seal on one side of the plate covering top & bottom holes.
ii) Two polycarbonate seal at diagonally opposite corner of top cover of CT-PT set.

3.12 TYPE TEST:

3.12.1 Certified copies of all type tests as per IS-2705-1992, IS:3156-1992 with latest amend-
ments listed below obtained from any accredited CPRI/NABL accredited test laboratory
on similar equipments of lowest offered ratio or better (lower ratio) includedin this spec-
ification shall be furnished alongwith tenders-

i) Short Time Current Test.

ii) Lightening Impulse voltage withstand Test.

iii) Temperature Rise Test.

iv) Wet Power Frequency Voltage Withstand Test.
v) Determination of Errors according to the requirement of the appropriate Accuracy
Class.
vi) Instrument Security Factor Test.

3.12.2 The manufacturer shall submit all Type Test reports for lowest ratio of offered CTPT sets
along with tender. The type test reports shall not be older than seven years from the date
of opening of tender.

3.12.3 Manufacturer shall furnish the calculations of short time thermal current of all ratios of
offered CT PT sets, on the basis of cross-sectional area of primary conductor of Type
Page 143 of 623
tested CT PT set.

3.12.4 The purchaser shall have right to get conducted type test during currency of the contract
on the sets received in the Stores at purchaser’s cost. In case of failure in type tests,
following provisions shall be applicable: -

3.13 Failure in type tests

In the event of failure/ unsatisfactory results of the CT-PT Set(s) in Impulse/Short Circuit
test, the supplier shall have to replace the supplies already made and no further CT-PT
Sets shall be accepted. The purchaser, however, at his option, may accept the CT-PT Sets
already supplied with the following conditions:-

i) Guarantee Period of the supplied CT-PT Sets issued to the failed shall be increased
by double the normal guarantee period.
ii) Bank Guarantee shall be extended to cover the additional guarantee period.
iii) For failure in any of the type tests, i.e. Impulse Withstand test and Short Circuit
Test, no further supplies shall be accepted. The type test charges in this case shall
be borne by the supplier.
iv) The CT-PT Sets lying in the stores shall be replaced as per Sub-para (v) below.
v) The manufacturer shall, however, be allowed to check the reasons of failure and if
need be, to improve/ modify the design. Further supplies, including replacement
against supplies already made, shall be accepted only after successful type test(s)
are arranged on the fresh CT-PT set selected by the purchaser. All the type tests
shall be arranged in case there is change in design, otherwise, type test shall be
repeated only for the tests in which failure has occurred. Charges for such test(s)
shall be borne by the supplier. However, in the event of failure of CT-PT Sets, in
the repeat type test, the Company (JVVNL) may take following actions:-

a) Cancel pending orders of the rating in which failure(s) has occurred, and
b) Not place any order of CT-PT Sets on the firm for one year.

Further, it shall be ensured that all meters and instruments used during inspection/ testing
are calibrated from NABL approved test house and date of calibration should not be older
than one year at the date of presenting the same to the inspecting officer.

3.14 COMPLETENESS OF EQUIPMENT:

Any fittings, accessories or apparatus which may not have been specifically mentioned
in the specification for 11 KV CT-PT metering sets covered under the scope of this en-
quiry-, but which are usual or necessary in the equipment of similar type shall be deemed
to be included in the contract and shall be supplied by the contractor without extra
Page 144 of 623
charges. All plants and equipment shall be complete in all respect whether such details
are mentioned in the specification or not.

3.15 NAME PLATE AND MARKING:

a) The equipment shall have a non detachable type name plate which should be clearly vis-
ible and effectively secured against removal having markings as per requirement of IS.
In addition, Sr. No., Ratio and date of despatch shall have to be engraved on bushingside
of tank with letters of suitable depth & 25 mm height filled with red colour.
b) The- main and load are to be stencilled on top cover on main and load side re-
spectively.
3.16 MAINTENANCE AND GUARANTEE:

Performance guarantee of the equipment shall be for the period of 36 months from the
date of handing over after successful installation and commissioning. The month & year of ex-
piry of guarantee period shall be marked on the name plate. Equipment failed within such guar-
antee period shall have lifted from the respective circle stores and after replacement/ repairment
to be deposited at the stores free of cost within 90 days of intimation. Manufacturer shall furnish
successful routine test reports of the equipment. If purchaser desires inspection prior to despatch
an inspecting officer shall be nominated for verification for the test reports. Failed equipment (s)
shall only be lifted after receipt of replacement for the same. Transportationfor lifting of defective
material & delivery of replaced material shall be borne by the supplier.

If defective CT -PT is not replaced within the specified period as above, the following clause
shall be applicable-:

i. Firms shall lift the G.P. failed Instrument Transformer(s) within a period of 60 days
from the date of intimation by the respective consignee and will replace Instrument
Transformers against G.P. failed within 30 days from the date of lifting positively. In
case firm fails to deliver replaced Instrument Transformer(s) within 90 days fromdate
of intimation, the cost of the Instrument transformer(s) shall be withheld from firm’s
financial hold and in case firm fails to deliver replaced Instrument transformerwithin
90 days from date of intimation, a penalty at the rate of ½% per week subjectto max-
imum 10%, shall be levied for the late delivery of replaced Instrument Trans-
former(s).

ii. In case firm fails to lift the G.P. failed Instrument Transformer(s) beyond 3 months
(90 days period as mentioned in point no. (i)) from date of intimation by the con-
signee, ground rent shall be recovered @ 1% per week or part thereof (for actualdelay
in lifting the material beyond 3 months (90 days) from the date of intimation from
the consignee, subject to a maximum of 15%. This amount of 15% will be in addition
to

Page 145 of 623

(i). After this clause following clause will also come into effect.

iii. In case firm fails to lift the G.P. failed Instrument Transformer(s) within 6 months
from date of first intimation from consignee, then Nigam may proceed for auction of
these GP failed Instrument Transformer at the risk and cost of the supplier after giv-
ing 30 days final notice to the firm. The amount recovered through auction may be
adjusted in any type of recoveries (if any). The recoveries of this point will be in
addition to recoveries mentioned in point no. (i) and (ii).

iv.If such material / equipments and any part thereof is disposed off through sales, 5%
of the sale value liable to be deducted on account of cost incurred in sales proceedings
and after deduction, the balance value shall be “Net realized sale value”.
ANNEXURE-‘A’

GUARANTEED AND OTHER TECHNICAL PARTICULARS FOR 11KV CT-PT SETS (TN-
)

(I) FOR 11 KV SINGLE PHASE CURRENT

TRANSFORMERS PARTICULARS

NAME & ADDRESS OF MANUFACTURER.

MANUFACTURER'S TYPE & DESIGNATION.

NOMINAL SYSTEM VOLTAGE (KV rms)

HIGHEST SYSTEM VOLTAGE (KV rms)

INSULATION LEVEL :

a) IMPULSE WITHSTAND VOLTAGE(KV PEAK)

b) ONE MINUITE POWER

FREQUENCY DRY WITHSTAND
VOLTAGE (KV r.m.s)

(i) PRIMARY(KV rms)

(ii) SECONDARY (KV rms)

Page 146 of 623
c) ONE MINUITE POWER
FREQUENCY WET WITHSTAND
VOLTAGE (KV Peak)

RATED FREQUENCY (Hz)

TRANSFORMATION RATIO.

RATED OUTPUT (VA BUDEN)

CLASS OF ACCURACY.

SHORT TIME THERMAL CURRENT FOR

THREE SECOND.(KA rms)

RATED DYNAMIC CURRENT (KA PEAK)

RATED CONT. THERMAL CURRENT (KA rms)

MAX. INSTRUMENT SECURITY FACTOR.

Page 147 of 623

DETAIL OF WINDINGS.

Cross sectional Total weight

PARTICULARS CT RATIO No. of Turns Area of each Turn of winding in
in Sq.mm (Aprox.) Kg. per Unit

200/5 A
100/5 A
i) PRIMARY
50/5 A
15/5 A

200/5 A
100/5 A
ii) SECONDARY
50/5 A
15/5 A
GURANTEED RATIO ERROR (MAX.)

GURANTEED PHASE ANGLE ERROR

(MAX.)

MAX. TEMP. RISE OF THE WINDING

OVER
AN AMBIENT TEMP. OF 50 DEG. C AT
RATED
CONTINOUS THERMAL CURRENT,AT
RATED
FREQUENCY & WITH RATED BURDEN.

i) INSULATION CLASS

Page 148 of 623

ii) INSULATION MATERIAL USED.

CORE DETAILS:

i) MATERIAL

ii) WEIGHT OF
CORE

TYPE OF INSULTING OIL WHETHER AS

PER
IS-335 AND LATEST AMENDMENT.

WHETHER SHORT CIRCULATING

ARRANGMENT FOR CTs.

BUSHING DETAIL

a) MAKE

b) CATALOGUE
NO.

c) TOTAL CREEPAGE DISTANCE (mm)

d) IS TO WHICH BUSHING CONFORMS.

e) ARCING DISTANCE (mm)

f) MAX. CREEPAGE FACTOR.

Page 149 of 623

g) Type : Porcelain /
Cycloaliphatic

WHETHER CURRENT TRANSFORMER

USED
ARE OF RESIN CAST OIL IMMERSED
TYPE
OR OTHERWISE.
IS TO WHICH CT CONFORMS.

MAKE OF TERMINAL CONNECTOR

(II) FOR SINGLE PHASE POTENTIAL TRANSFORMERS

NAME & ADDRESS OF

MANUFACTURER.

MANUFACTURER'S TYPE &

DESIGNATION.

NOMINAL SYSTEM VOLTAGE (KV rms)

HIGHEST SYSTEM VOLTAGE (KV rms)

INSULATION LEVEL :

a) IMPULSE WITHSTAND VOLTAGE(KV

PEAK)
b) ONE MINUITE POWER FREQUENCY
WITHSTAND VOLTAGE (KV PEAK)

RATED FREQUENCY (Hz)

RATED TRANSFORMATION RATIO.

Page 150 of 623

RATED OUTPUT (VA BUDEN PER PHASE)

CLASS OF ACCURACY.

RATED VOLTAGE FACTOR AND TIME.

WINDING CONNECTIONS

a) PRIMARY

b) SECONDARY

DETAIL OF WINDINGS.

PARTICULARS NO.OF CROSS SECTIONAL TOTAL

AREA OF EACH
PT RATIO TURNS TURN WEIGHT
(approx.) IN SQ.MM. OF WDG.
In Kg.

i) PRIMARY WINDING (COPPER) 11 KV

ii) SECONDARY WINDING (COPPER) 110

GURANTEED RATIO ERROR (MAX.)

GURANTEED PHASE ANGLE ERROR

(MAX.)

GURANTEED MAX. TEMP. RISE OF THE

Page 151 of 623

WINDING OVER AN AMBIENT TEMP. OF 50
DEG. C AT RATED CONTINOUS THERMAL
CURRENT,AT RATED FREQUENCY & WITH
RATED BURDEN.

BUSHING DETAIL

a) MAKE

b) CATALOGUE NO.

c) TOTAL CREEPAGE DISTANCE (mm)

d) IS TO WHICH BUSHING CONFORMS.

e) ARCING DISTANCE (mm)

f) MAX. CREEPAGE FACTOR.

g) Type : Porcelain / Cycloaliphatic

i) INSULATION CLASS
ii) INSULATION MATERIAL
USED. CORE DETAILS:
i) MATERIAL
ii) WEIGHT OF CORE

WHETHER ANY FUSE HAVE BEEN PROVIDED

IN SECONDARY SIDE OF PT ?

WHETHER NEUTRAL OF PT FOR HT SIDE IS

ISOLATED/FLOATED ?

III OTHER PARTICULARS FOR 11 KV COMPLETELY ASSEMBLED CT-PT SETS.

PARTICULARS

OVERALL DIMENSIONS OF CT-PT SET.

MOUNTING DETAILS.

i) TOTAL MASS OF COMPLETELY

ASSEMBLED CT-PT SET WITH OIL.

ii) MASS OF IST FILLING INSULATION OIL.

iii) VOLUME OF OIL (LITRES)

i) MATERIAL OF TANK/ENCLUSURE SHEET.

ii) THICKNESS OF THE TANK
SHEET.(mm) a) BOTTOM.
b) TOP COVER

c) SIDES

MAKE/MANUFACTURER'S NAME FOR INSU-

LATING OIL TO BE USED IN CT-PT SETS.

WHETHER ALL THE FITTINGS AND

ACCESSORIES AS PER CLAUSE 3.06 OF

SPECIFICATION PROVIDED ?

WHETHER CT-PT SETS ARE SUITABLE FOR

SATISFACTORY OPERATION OUNDER AB-

NORMAL SYSTEM CONDITION VIZ., SIN-
GLE PHASING SUPPLY ARRANGEMENTBY
LOOPING SUPPLY PHASE WITH OTHER

LINE PHASE ?

MIN. ELECTRICAL CLEARANCE BETWEEN

PHASES. WITH BUSHINGS MOUNTED (MM)

MIN. ELECTRICAL CLEARANCE BETWEEN

PHASES. TO EARTH WITH BUSHING
MOUNTED (MM) ?

WHETHER OIL CONSERVATOR PROVIDED

ON CT-PT SET ?

ARRANGEMENT PROVIDED TO TAKE CARE

OF EXPANSION AND CONTRACTION IN OIL.

WHETHER PRESSURE RELIEF DEVICE

PROVIDED ?

TEST RESULTS OF OIL AS PER IS : 335

BREAK DOWN VOLTAGE

TAN DELTA AT 90 DEG. C

COLOUR OF OIL (SHALL BE COLOURLESS)

664
TECHNICAL SPECIFICATION AND SCHEDULE OF REQUIREMENT FOR SUPPLY OF ISI
MARKED VARIOUS SIZES OF FOUR CORE LT XLPE INSULATED AND PVC SHEATHED
ARMOURED CABLES.(4CX120 Sq.mm, 4Cx70 Sq.mm)

1. SCOPE:

1.1 This section provides for manufacture, testing before dispatch, supply and delivery
F.O.R. destination of ISI Marked various sizes of Four Core LT XLPE Insulated and PVC
Sheathed Armoured Circular Cables with Aluminium Conductor suitable for working voltage up
to & including 1100 Volts & Conforming to IS:7098(Pt.-I)/1988 with latest amendments. The
requirement of various sizes of Four Core LT XLPE Insulated Armoured Cables shall be as per
schedule of requirement annexed with this section at Schedule-I. It may be noted that the require-
ment indicated in the schedule is tentative and may vary at the time of placement of order. The
cables shall be ISI marked.

2. STANDARDS:

Unless otherwise stipulated in this specification the following standards with latest
amendments shall be applicable. Any departure from the Standards be indicated in Schedule-III.

i) IS:7098(Pt-.I)/1988 : XLPE Insulated cables for

working voltages up to and
including 1100 Volts.

ii) IS:8130 : Conductors for insulated

cables.

iii) IS:5831 : PVC insulation and sheath of

electric cables.

iv) IS:10810 : Methods of test for cables.

v) IS:3975/1979 : Galvanized Steel Wire/Strips.

vi) IS:10418 : Drums for electric cables.

Page 151 of 614
3. CLIMATIC CONDITIONS:

i) Peak ambient temperature in shade 50 deg.C

ii) Maximum average ambient 40 deg.C

temperature in a 24 hours period
in shade.
iii) Min. ambient air temperature in shade (-)5 deg.C

iv) Maximum temperature attainable 60 deg.C

by an object exposed to sun.

v) Maximum relative humidity. 100%

vi) Average number of thunder 40

storm days per annum.

vii) Average number of rainy days 100

per annum.

viii) Average annual rainfall 10 to 100 cm

ix) Number of months of tropical 4 months

monsoon conditions.

x) Maximum wind pressure. 100kg/sq.mm.

xi) Altitude not exceeding 1000 M

4. GENERAL REQUIREMENT:

4.1 The LT XLPE Insulated Armoured cables shall conform to IS:7098 (Pt.-
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 requirements of IS:7098(Pt-.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 associatedwith transportation, erection,
reeling and unreeling operations without getting deformed.
Page 152 of 623
4.2 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 90 degree C under
normal operation and 250 degree C under short circuit condition.
4.3 The LT XLPE Insulated Armoured Cable shall be ISI marked. The manufacturer
should be a manufacturer of tendered item. The offers from Sole Selling Agents / Authorised
Dealers shall not be entertained. The bids from the trading firms shall not be considered.

The technical bid of the manufacturer shall be considered for opening in the absence of
non-furnishing of above required ISI License along with the bid. However, Price bid of the re-
sponsive manufacturer shall only be opened if manufacturer furnishes above valid BIS Licenseup
to the official working hours of one working day prior to the schedule / notified date of openingof
price bid” along with undertaking that BIS License so furnished is valid till date and same hasnot
been withdrawn/cancelled by Bureau of Indian Standard. Similar undertaking of validity of BIS l
License be also furnished by the manufacturer who furnishes BIS License along with Technical
Bid. The firms having ISO: 9001 will be preferred.

5. 0 MATERIAL:

5.1 CONDUCTOR:
The conductor shall be composed of plain aluminium wires complying with
IS:8130/1984 with latest amendments.

The manufacturer must guaranteed the minimum weight of Aluminium in Kg/Km corre-
sponding to nominal cross sectional area of conductor as mentioned in the G.T.P.

5.2 INSULATION:

Insulation shall be Cross-Linked Polyethylene (XLPE) conforming to the

requirements given in Table-I of IS: 7098(Pt.-I)/1988 with latest amendments.

5.3 FILLERS:

5.3.1. The filler shall be of vulcanized rubber, un-vulcanized rubber, Thermoplastic ma-
terial or textile material and shall be provided to fill the gaps between cores.

5.3.2. The filler materials 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 notbe
harder than XLPE and PVC used for insulation and outer sheath respectively.

5.3.3 The Central hole/void, if any, of the cable shall be invariably filled with suitable filler
Page 153 of 623
material so that there is no gap in the center.

5.4 ARMOURING :

Armouring shall be galvanized round steel Strip.

5.5 OUTER SHEATH:

The outer sheath shall consist of type ST-2 PVC Compound conforming to the re-
quirements of IS:5831/1984.

6. CONSTRUCTION:

6.1 CONDUCTOR:

The construction of the conductor shall be as per Clause No.8.1 of IS:7098 (Pt-.I)
/1988 & relevant clause of IS:8130/1984 for all sizes of cable.

A protective barrier may be applied between the conductor and insulation. Such bar-
riers when used, shall be compatible with insulating material and suitable for the operating tem-
perature of the cable.

6.2 INSULATION:
The conductor (with protective barrier, wherever applied) shall be provided with Cross-Linked
Polyethylene (XLPE) 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.9.2of
IS:7098(Pt-.I)/1988.

6.3 CORE IDENTIFICATION:

The core shall be identified by different colouring of XLPE insulation as per Clause No.10.1 of
IS:7098(Pt.-I)/ 1988.

6.4 LAYING UP OF CORES:

The cores shall be laid up together with the suitable right hand lay. The interstices shall be filled
with non-hygroscopic material.

6.5 INNER SHEATH (COMMON COVERING):

Page 154 of 623

6.5.1 The laid up cores shall be provided with an inner sheath applied either by extrusion or by
wrapping. However, application of inner sheath by EXTRUSION shall be preferred. It shall be
ensured that it is as circular as possible. The thickness of inner sheath shall be as given in Table-
5 of IS:7098(Pt.-I)/1988.

6.5.2 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.

6.6. ARMOURING :

6.6.1 Application:- Armouring shall be applied over the inner sheath. The armour Strip shall be
applied as closely as possible with a coverage of not less than 90%.

6.6.2 The direction of lay of armour shall be left hand. A Binder Tape may be provided on the
armour.

6.6.3 Type of Armour & Dimension :- The armour shall consist of galvanized steel strips for
all sizes with the dimensions as specified in Table-6 of IS:7098(Pt-.I)/1988.

6.6.4 Joints:- The joints in the armour Strips shall be made by brazing or welding and the surface
irregularities shall be removed. A joint in any strips shall be at least 300 mm. from the nearest
joint in any other armour strip in the completed cable.

6.7 OUTER SHEATH:

6.7.1 The outer sheath shall be applied by extrusion over armouring.

6.7.2 The colour of the outer sheath shall be black.

6.7.3 The minimum thickness of PVC outer sheath shall not fall below the nominal
thickness ( ts ) specified in Table-8 of IS:7098(pt.I/1988.

7. TESTS AND TEST CERTIFICATES:

7.1 The cables should meet the requirement of all tests including optional tests as specified at
Clause No.15.4 of IS:7098(Pt.1)/1988.

The following shall constitute Routine Test:

Page 155 of 623
C o nductor resistance test.
i) High Voltage test.

The following shall constitute Acceptance Tests:

i) Tensile test (for Aluminium).

ii) Wrapping test (for Aluminium).
iii) Conductor resistance test.
iv) Test for thickness of Insulation & Sheath.
v) Hot Set Test for Insulation.
vi) Tensile strength & elongation at break of
insulation & sheath.
vii) Insulation resistance (Volume Resistivity)test.
viii) High Voltage test.
ix) Test for Armour:
a) Verification of Dimension of Wire / Strip.
b) Tensile Strength & elongation at break.
c) Uniformity of Zinc Coating.
d) Weight of Zinc Coating.
e) Winding Test on Armour.
f) Resistivity Test on Armour.

The following shall constitute Optional Tests:

i) Cold Bend Test for outer sheath.

ii) Cold Impact Test for outer sheath.

The following shall constitute Type Tests:

a) Tests of Conductor:

i) Tensile test (for aluminium)

ii) Wrapping test (for aluminium)
iii) Conductor resistance test.

b) Test for Armouring Wire / Strip.

Page 156 of 623

c) Tests for thickness of insulation and sheath.

d) Physical tests for insulation:

i) Tensile strength and elongation at break.

ii) Ageing in air oven.
iii) Hot Set test.
iv) Shrinkage Test
v) Water Absorption (Gravimetric).

e) Physical tests for Outer Sheath:

i) Tensile strength and elongation at break.

ii) Ageing in air oven.
iii) Loss of mass in air oven.
iv) Shrinkage Test.
v) Hot Deformation Test.
vi) Heat Shock Test.
vii) Thermal Stability.

f) Insulation resistance (Volume Resistivity test)

g) High voltage test.

h) Flammability test.

i) Any other test as per relevant ISS.

7.2 TYPE TESTS :

a) The material offered, shall be fully type tested as per relevant standard of specification of
IS:7098 (Part.1/1988) amended up to date.

Page 157 of 623

b) The manufacturer must also clearly indicate various testing facilities available at their works
for testing the material as per relevant standards. In case of otherwise particulars
of the place where such testing in proposed to be conducted during the course of inspec-
tion shall be indicated with the offer.

c) However, the purchaser reserves the right to demand repetition of same or all the type tests
in presence of purchaser’s representative.

d) The bidding firms (manufacturers) must have valid ISI license for the offered cable. The
manufacturer shall furnish the details of ISI License granted to them.

8. INSPECTION (TEST BEFORE DISPATCH):

8.1 The inspection may be carried out by the purchaser at any stage of manufacturer. The
Inspection & Testing shall be governed by relevant Clause No. 1.27 of Section-II (General
Conditions Of Contract). Acceptance of any equipment / material under this specification by
the purchaser shall not relieve the supplier of his obligation of furnishing equipment in accordance
with the specification and shall not prevent subsequent rejection if the equipment/material is found
to be defective.

8.2 The supplier shall keep the purchaser informed in advance about the manufactur-
ing program so that arrangement can be made for inspection.

8.3 The acceptance tests as per IS:7098(Pt.I)/1988 shall also be conducted by the man-
ufacturer before dispatch in the presence of our Representative/Inspecting Officer as per Clause
No.1.27 `Inspection & Testing' of "General Conditions of Contract" Section-II along with
verification of lengths & weight and checking the manufacturing defects, if any of samples
coils. The mass of Aluminium, 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 andshall
be conducted on first lot and any from other lot of the offered cables of each size as per Clause
No.15.4 of IS:7098(Pt-.I)/1988.

8.4 The purchaser reserves the right to insist or witnessing the acceptance/routine tests of
the bought out items.

8.5 The manufacturer shall furnish Packing list mentioning serial Nos. of Drums, length in
each drum, gross weight of drum without lagging along with inspection offer duly signed by the
authorized representative of the firm. The purchaser reserves the rights to insist for witnessing the
acceptance / routine tests of the bought out items.
Page 158 of 623
8.6 At least 5% of total numbers of drums subject to minimum of 2 in any lot put up for
inspection shall be selected at random to ascertain the length/ workmanship of cable by the fol-
lowing method :
“At the works of the manufacturer, the cable shall be transferred from one drum
to another for checking any manufacturing defects in the cable drums 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 declaredlength
by the supplier in the packing list shall be applied to all the drums if the cable is found short
during checking the sample lot(s)”.

8.7 The supplier 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/ meters/ apparatus etc. should be got calibrated by the supplier
from time to time from Govt. Laboratory or any independent test laboratory/house having valid
accreditation from National Accreditation Board for Testing and Calibrating Laboratories for the
testing equipments / original manufacturer having trace ability to NABL/NPL or equivalent.
The calibration certificate(s) should not in any case be older than one year at the timeof
presenting the same to the inspecting officer/ inspecting agency of the purchaser. The testing
instruments/ equipments should be duly sealed by the Calibrating Agency and mention thereof
shall be indicated in the calibration certificate(s).

9. TEST CHECKING OF MATERIAL AT STORES

i) Sample drums from the material received at stores shall be selected for testing at CTL as per
sampling plan given hereunder in presence of firm’s representative. The selected sample drum /
drums shall be transported to CTL by concern S.S / ACOS of Nigam.

ii) The selected sample drum for CTL testing shall be identified by the seals provided by Inspecting
Officer / Inspecting Agency during pre-dispatch inspection at firms works and these sealing details
shall be invariably mentioned in the selection Memo by the nominated officers of Nigam.

iii) The tests in the Nigam Testing laboratory (CTL) shall be conducted in the presence of repre-
sentative of supplier for which a 7 days notice shall be issued through Fax / Speed Post statingDate
& Time to the firm, so that supplier can depute their representative to witness the test . In case the
supplier or his representative does not turn up the testing shall be proceeded & completed.The pay-
ment shall be released only after receipt of successful test reports for the samples selectedat pur-
chaser’s stores for mandatory test checking on the samples to be selected from material received
at Nigam’s stores by random sample selection by the authorized committee as per CE(MM) order
No.180 dt.11.4.
i) SAMPLING:

Page 161 of 623

One number Drum out of each lot / sub-lot of 25 Nos. Drums or part thereof for the material
received in Stores of Nigam.

ii) TESTS: The following tests shall be carried out as per relevant clause of latest IS on each
selected drum by drawing sample of 10 Mtr. at CTL from random distance during re-winding:

a) Rewinding test (Measurement of Length) & Checking of Manufacturing defects.

b) Measurement of Resistance of conductor.
c) Tensile strength & Elongation at Break Test for Insulation & Sheath
d) Test for Thickness of Insulation & Sheath
e) Hot Set Test
f) Test for Armour:
i) Verification of Dimension of Wire / Strip.
ii) Tensile Strength & elongation at break.
iii) Uniformity of Zinc Coating.
iv) Weight of Zinc Coating.
v) Winding Test on Armour.
vi) Resistivity Test on Armour.
vii) Verification of armouring coverage i.e.not less than 90%
g) Verification of Marking

In addition to above tests remaining acceptance tests as per relevant IS shall also be con-
ducted at CTL provided the testing facility is available at CTL for these tests time to time. Only
those tests shall be conducted for which testing facilities are available in NIGAM’s Lab.

iii) CRITERIA FOR ACCEPTANCE:

a) 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 have be re-
placed by the supplier.

b) 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.

c) 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 supplier.

Page 162 of 623

d) If the contractor / supplier fails to lift the material declared rejected or any part
thereof from the consignee within a period of 15 days from the date of dispatch of information
from the purchaser, the purchaser shall be entitled to effect recovery along with other actions as
per Clause No. 1.62 of Section-II (General Condition of Contract).

e) The results of measurement of length test shall be made applicable to all drums
contained in each lot / sub lot by making deduction of less length of cable in a Sample Drum.

10. TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores
shall be borne by the NIGAM.

11. IDENTIFICATION:

11.1 The manufacturer shall be identified through-out the length of cable as per Clause
No.17.1 of IS:7098(Pt-I)/ 1988.

11.2 In order to distinguish these electric cables from telephone cables the word
`ELECTRIC' shall be indicated, printed or embossed throughout the length of the cable on
outer sheath.

11.3 The cable code shall be used as per Clause No.17.3 of IS:7098(Pt-.I)/1988.

11.4 The cable shall also be required to be embossed with the word ` Name of Manu-
facturer or trade name, Cable code, Voltage Grade, NAME OF DISCOM / TN,
size of cable & year of manufacture' at every meter length for which no extra charges shall be
paid. The cable should be ISI marked & same should be embossed on the outer sheath of every
meter of length of cable.

12. MARKING:

The progressive length of cable shall be marked on the outer sheath of every meter
length of cable.

13 PACKING AND MARKING:

13.1 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
Page 163 of 623
non-hygroscopic sealing material. Only one cable length shall be supplied on a drum. The shaft
diameter of Drum shall be as per relevant ISS but not less than 50 mm. The cable can also be
supplied on M-Steel Drums as per relevant ISS as applicable.

13.2 The cable shall carry the following information stenciled / painted on the drum :

i) Manufactuer's name, Brand name or trade mark.

ii) Type of cable and voltage grade.
iii) Number of Cores.
iv) Nominal Cross-sectional area of the conductor.
v) Cable Code.
vi) Length of cable on the drum.
vii) Approximate gross weight.
viii) Year of manufacture.
ix) BIS Certification mark.
x) Name of the Consignee and full destination.
xi) TN No. / JVVNL/ RDSS
xii) The word SUITABLE FOR OUTDOOR USE & LOW TEMPERATURE
CONDITIONS.

14 STANDARD LENGTH:
14.1 The cables shall be supplied in the standard length of 250 Meters for size 4CX185
Sqmm and 500 Meters for 4Cx120 Sq. mm & 4Cx70 Sq.mm.

14.2 A tolerance (+/-) 5% shall be allowed in standard length.

14.3 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.

15 GUARANTEED TECHNICAL PARTICULARS:

The manufacturer shall furnish guaranteed technical particulars

16 DRAWINGS & DOCUMENTATIONS:

The manufacturer is required to furnish the detailed constructional drawings of

cable clearly showing shape of Core, Type, Size of Fillers / Interstices along with Center Filler

Page 164 of 623

etc. The calculations of weight of different components of the cable shall also be furnished. In
absence of this, the bids are likely to be ignored. The drawings of drums shall also be furnished
as per relevant applicable ISS.

SCHEDULE-A

GUARANTEED TECHNICAL AND OTHER PARTICULARS FOR THE SUPPLY OF 4 CORE LT XLPEAR-
MOURED CABLES

S. PARTICULARS UNIT 4 CORE XLPE ARMO RED CABLES IN SQ.MM

NO.
4CX185 4CX120 4CX70
1 Manufacturer's name and works
Address

2 Standard specification to which IS:7098(Part-I):1988 with latest amendment

the material shall conform.

3 VOLTAGE GRADE 1100V

4 NO. OF CORES (4C) (4C (4C)

5 CONDUCTOR DETAILS :

a) Nominal cross section area of

:
I ) Phase Conductor(sq.mm) 185 120 70
ii) Neutral Conductor
(Sq.mm.) 185 120 70
b) No.and size of strands(in
mm) of :
As per IS-8130/1984 with latest
I) Phase Conductor(sq.mm) amendments
ii) Neutral Conductor As per IS-8130/1984 with latest
(Sq.mm.) amendments
c) SHAPE OF CONDUCTOR To be furnished by the manufacturer
d) Whether compacted or non
compacted To be furnished by the manufacturer

Page 165 of 623

e) Resistance
I) Phase Conductor(sq.mm) 0.164 0.253 0.443
ii) Neutral Conductor
(Sq.mm.) 0.164 0.253 0.443

6 INSULATION
I) Type XLPE As per IS:7098(Part-I):1988 with latest amendment
ii) Colour R,Y,B & neutral Black
iii) Thickness
A) Phase Conductor(sq.mm) As per Table - 3 of IS-7098 (Part-I):1988 with latest amendments
a) Nominal (mm)
b) Minimum (mm)
B) Neutral Conductor
(Sq.mm.) As per Table - 3 of IS-7098 (Part-I):1988 with latest amendments
a) Nominal (mm)
b) Minimum (mm)

7 Inner Sheath:

a) Material & Colour To be furnished by manufacturer

b) Process of Application To be furnished by manufacturer
c) Minimum thickness of inner
As per Table - 5 of IS-7098 (Part-I):1988 with latest amendments
sheath
8 Whether Binder Tape provided As per IS:7098(Part-I):1988 with latest amendment

9 Armouring As per IS:7098(Part-I):1988 with latest amendment

I) Material
ii) Nominal Dimension of
Armour
iii)Whether galvanised or not
iv) Total number of Armour
strips

10 Outer Sheath
I) Material Extruded PVC ST-2 type as IS 5831:1984 with latest amendment
ii) Thickness As per Table - 8 of IS-7098 (Part-I):1988 with latest amendments
a) Nominal (mm)

Page 166 of 623

b) Minimum (mm)
iii) Standrad to which it
conform As per IS:7098(Part-I):1988 with latest amendment
11 a) Type and size of filler used As per IS:7098(Part-I):1988 with latest amendment
b) MIN. WT.OF FILLER IN
To be furnished by manufacturer
KG./KM.
MAX.OVERALL DIAMETER
To be furnished by manufacturer
12 OF THE CABLE IN MM.
13 Nature of Packing Wooden drum

14 TARE WEIGHT OF DRUM To be furnished by manufacturer

a) Minimum weight of Alumin-

ium in Kg./Km. corresponding
15 2000 1297 757
to nominal cross sectional area
of conductor.(guaranteed)
b) Total weight armouring Kg/
To be furnished by manufacturer
Km.
c) Total weight of PVC contents
To be furnished by manufacturer
Kg/ Km.
(Inner / Outer Sheath /
Filler)
d) Total weight of XLPE in
To be furnished by manufacturer
Kg./Km.(Min.)
e) Total weight of finishedca-
To be furnished by manufacturer
ble Kg/Km.

250m 500m
16 i)Standard length of cable Metre 500m
ii)Tolerance. On Standard
length (+/-)5%

Whether material bears BIScer- YES , ISI MARKING embossed on outer sheath
17 tification mark
18 BIS licence no. & validity To be furnished by manufacturer
19 Embossing As per specification of TN:
20 Any other particulars

Page 167 of 623

NOTE : SPECIFIC VALUES MAY BE INDICATED IN ABOVE SCHEDULE. USE OF `DO
OR AS PER "IS" IS TO BE AVOIDED.

SCHEDULE-B

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF DRUM FOR SUPPLY OF

FOUR CORE LT XLPE INSULATED ARMOURED CABLES

S.
PARTICULARS
No. 4 CORE XLPE ARMOURED CABLES IN SQ.MM
4CX185 4CX120 4CX70
A Drum Size
B Flange Diameter(d1) (mm)
C Barrel Diameter(d2) (mm) AS PER IS:10418/1982 WITH LATEST AMENDMENTS
D Centre hole Diameter(d3) (mm)
E Overall width (L1) (mm)
F Traverse (L2) (mm)
G Thickness of Flange

H Barrel End (supporting disc

or core segment)
a) Diameter (mm)
b) Thickness (mm)

I Stretchers( Core Carrier Planks)

a) Number (Min)
b) Thickness x width (mm)

J Barrel Battens thickness

(Core Filler Planks)

K Barrel Middle Supports

(Middle Core discs)

Page 168 of 623

Thickness of External
L Laggings.(mm)

DETAILS OF METAL
COMPONENTS:
Clamping Studs with Hexagonal
M Nuts

a) Numbers
b) Diameter (mm)

N Square or Round Washers

a) Numbers
b) Diameter (mm)

O M.S. Bushes
a) Numbers
b) Thickness of Sleeve (mm)
c) Dimension of Sleeve (mm)
d) Number of Bolts
e) Diameter of Bolts

P M.S./ C.I. Centre Plate

a) Numbers
b) Dimensions of Square/
Triangular equal sides (mm)
c) Centre Plate Bolts.
Q Numbers
i) Diameter of bolts (mm)
ii) Centre Hole Diameter (mm)

NOTE : SPECIFIC VALUES MAY BE INDICATED IN ABOVE SCHEDULE. USE OF `DO

OR AS PER "IS" IS TO BE AVOIDED.

Page 169 of 614

TECHNICAL SPECIFICATION FOR SUPPLY OF LT XLPE INSULATED AERIAL
BUNCHED CABLES WITH BARE MESSENGER WIRE WITH ALUMINIUM CON-
DUCTOR FOR LT OVER HEAD LINES SUITABLE FOR WORKING VOLTAGE UPTO
& INCLUDING 1100V.( 1CX25+25 Sq. mm)

1. SCOPE:

1.1 This specification covers manufacture, testing before dispatch, supply and delivery in
the stores of JVVNL of LT XLPE Insulated Aerial Bunched Cables twisted over a central high
strength Bare Aluminium alloy messenger for use on LT overhead lines conforming to the re-
quirement of IS:14255/1995 with latest amendments. However, the insulation (XLPE) shall be
U.V. Resistant which shall be ensured by adding 2.5 +/- 0.5% Carbon Black in XLPE in well
dispersed manner.

The manufacturers should be a manufacturer of offered Aerial Bunched Cable. The man-
ufacturer must possess valid ISI License in case of Single Phase and Three Phase Aerial Bunched
Cable.The technical bid of the manufacturer shall be considered for opening in the absence of non-
furnishing of above required ISI License along with the bid. However, price bid of the responsive
manufacturer shall only be opened if manufacturer furnishes above required ISILicense upto offi-
cial working hours of one working day prior to the scheduled / notified date of opening of price
bids, failing which price bid of the manufacturer shall not be opened. The tendersfrom trading firms
shall not be considered. The firms having ISO: 9001 will be preferred

2. STANDARDS:

Unless otherwise stipulated in this specification the following standards with latest
amendments shall be applicable. Any departure from the Standards be indicated in Schedule-III.
i) IS: 14255/1995 : Aerial bunched cables for LT lines.
ii) IS:10810/1984 : Methods of test for cables. (Series)
iii) IS:8130/1984 : Conductors for insulated cables.
iv) IS:10418/1982 : Drums for Electric Cables
v) IS:398(PT-IV) /1994 : Aluminum alloy conductors.
vi) CENELAC HD 626 : Over head distribution cables of rated voltage
S1 A1/A2 2002 Uo/U(Um):0.6/1(1.2) KV.

NOTE: The specification has mostly considered references from Indian

Standard. However, reference have also been derived from the above re-
ferred International Standard in meeting the onerous site requirement
of Jaipur Discom.

Page 170 of 623

3. CLIMATIC CONDITIONS:

i) Peak ambient temperature 50 deg.C

in shade.

ii) Maximum average ambient 40 deg.C

temperature in a 24 hours
period in shade.

iii) Minm. ambient air temperature in shade (-)5 deg.C

iv) Maximum temperature attainable 60 deg.C

by an object exposed to sun.

v) Maximum relative humidity. 100%

vi) Average number of thunder 40

storm days per annum.

vii) Average number of rainy days 100

per annum.

viii) Average annual rainfall 10 to 100 cm

ix) Number of months of tropical 4 months

monsoon conditions.

x) Maximum wind pressure. 100kg/sq.mm.

xi) Altitude not exceeding 1000 M

4. PRINCIPAL PARAMETER:

Page 171 of 623

The Aerial Bunched Cables shall consist of Single Phase / Three Phase XLPE Insu-
lated Aluminium Conductors twisted over a central high strength bare aluminium alloy messenger
wire for use on LT over-head lines. The principal parameters of Aerial Bunched Cables shall be
in accordance to IS:14255/1995 (latest amendments, if any) and as enumerated in subsequent
clauses.

5. GENERAL TECHNICAL REQUIREMENTS:

5.1 The XLPE Insulated Phase Conductors shall be twisted over a central Bare Alumin-
ium Alloy Messenger Wire, which shall carry the main weight and take all the mechanicalstress.
The messenger wire shall also serve as the earth-cum- neutral wire.

The cable shall be suitable for use where the combination of ambient temperature and
temperature rise due to load, including temperature on exposure to direct sunlight results in con-
ductor temperature not exceeding the following:

Type of Insulation Normal Continuous Short Circuit

Operation Operation
Cross Linked Polyethylene (XLPE) 90 DEG.C 250 DEG.C.

6. 0 MATERIAL:

6.1 CONDUCTORS:

6.1.1 PHASE CONDUCTOR:

The conductor shall be of H2 or H4 grade Aluminium complying with the requirement

of IS: 8130/1984 or latest amendment, if any.

6.1.2 MESSENGER (NEUTRAL CONDUCTOR OR OTHERWISE):

The conductor shall be of heat treated aluminium-magnesium-silicon alloy wires

containing approximate 0.5 percent magnesium and approximately 0.5 percent silicon conforming
to IS: 398(Part-4): 1979 or latest amendment, if any.

The Messenger (Neutral conductor) or otherwise shall be either stranded circular or

compacted circular type and shall have minimum 7 strands. The surface of the conductor shall be
Page 172 of 623
smooth.

The size of messenger conductor and its breaking load shall be as given below:

S.No. Nominal Cross Sectional Area of Messenger Conductor

Phase Conductor (Sq.mm)
Nominal Cross Maximum D.C. Minimum
Section Area Resistance at 20 Breaking
(Sq.mm.) Dec.C. Load
(Ohm/Km.) (KN)
1 2 3 4 5
1 25 25 1.38 7.0

There shall be no joints in any wire of the messenger conductor except those made in the
base rod or wires before final drawing. The direction of outer layer of wires in messenger conduc-
tor shall be right hand.

6.1.3 A protective barrier may be applied between the conductor and insulation, if re-
quired. Such barrier when used shall be compatible with insulating material and suitable for the
operating temperature of the cable.

6.2 INSULATION:

The insulation shall be of CROSS LINKED POLYETHYLENE COMPOUND

(XLPE) conforming to the requirements given in Table-1 of IS:14255/1995 with latest amend-
ment, if any.

The conductor (with protective barrier, wherever applied) shall be provided with
cross-linked polyethylene insulation applied by extrusion.

The average thickness of insulation shall be not less than the nominal value (t) speci-
fied as below:

Sl. No Nominal Area of Conductor Sq.mm Nominal Thickness (t) mm.

1 25 1.2

The smallest of measured values of thickness of insulation shall not fall below the
Page 173 of 623
nominal value (t) specified in above table by more than 0.1mm + 0.1 (t).

The insulation shall be so applied that it fits closely on the conductor (or barrier, if
any) and it shall be possible to remove it without damaging the conductor.

The colour of INSULATION (XLPE) shall be Black & Messenger Wire shall be bare.

The Black Carbon Contents 2.5+/-0.5% in well dispersed manner shall be added in XLPE
for making the Insulation UV Resistant.
6.3 CORE IDENTIFICATION:

The phase conductors shall be provided with `ridge' as shown in Fig.1 of IS: 14255/
1995 for quick identification. The messenger conductor shall not have any identification mark.
The Approx. dimension of Ridges are as under:-

a) Width :- 1.00 mm
b) Height :- 0.5 mm
c) Distance Between :- 2.7 mm
Consecutive Ridges

6.4 ASSEMBLY (LAYING UP):

Insulated phase conductor shall be twisted around the bare messenger conductor without fillers
with a lay not exceeding 35 times the diameter of the insulated phase conductor.
The direction of lay shall be right hand.

6.5 COMPOSITIONS AND DESIGNATION OF FINISHED CABLES:

The composition and designation of finished cables are given in the following table:

S.No. Designation of finished cable

1 1CX25+25 Sq.mm

Note: The first part of the designation refers to the number and size of the phase conduc-
tor and the last to the size of messenger wire. The sizes shown are the nominal cross- sectional
area of the conductors.

7. TESTS:
Page 174 of 623
7.1 The material offered, shall be fully type tested as per relevant standard of specification
of IS:14255/1995 amended up to date. The manufacturer must furnish type test reports of similar
rating & design of tendered material along with bid as detailed at Schedule-IIIA “Pre-Qualification
Requirement”.
7.2 However, the purchaser reserves the right to demand repetition of some or all the type
tests in presence of purchaser's representative.
7.3 TESTS BEFORE DESPATCH:

The aerial bunched cables shall be subjected at manufacturer’s works before dis-
patch, to the following tests as per ISS/relevant standards.

7.3.1 ACCEPTANCE AND OPTIONAL TESTS:

The Aerial Bunched Cables shall be subjected at manufacturer’s works before dis-
patch to the following acceptance /optional tests as per relevant ISS in presence of the purchasers'
representative.

The following shall constitute acceptance tests and shall be conducted as per IS:
14255/1995 & IS: 5831 / 1984 and other relevant ISS with latest amendments, if any:

a) Tensile test (for phase conductor),(N.A on shaped conductor)

b) Wrapping test(for phase conductor),(N.A on shaped conductor)

c) Breaking load test for messenger conductor.

d) Elongation test for messenger conductor.

e) Conductor resistance test.

f) Test for thickness of insulation.

g) Tensile strength and elongation at break test of Insulation.

h) Hot set test for XLPE insulation.

i) Insulation resistance test and

Page 175 of 623

j) High voltage test is to be conducted on all drums of offered lot.

k) Carbon Black:
i) Contents:- 2.5+/-0.5%
ii) Disperssion :- In well dispersed manner

l) Any other test as per latest ISS.

The following shall constitute optional test:-

Bending test on complete Cable.

7.3.2 TYPE TESTS:

(i) For cable order quantity upto 20 Kms.

The first lot offered for Inspection shall not be less than 10% of ordered quantity of each size of
LT XLPE Insulated Aerial Bunched Cable with Bare messenger Wire or minimum 50% of order
quantity whichever is more.

Note :- The supplier supply cable more than deliver Schedule but quantity as per above condition
, positive PV benefit will be given as per beneficial to Nigam.

(ii) For cable order quantity more than 20 Kms.

The first lot offered for Inspection shall not be less than 10% of ordered quantity of each size of
LT XLPE Insulated Aerial Bunched Cable with Bare messenger Wire or minimum quantity of 20
Km whichever is more.

Note :-The supplier supply cable more than deliver Schedule but quantity as per above condition
, positive PV benefit will be given as per beneficial to Nigam.

“At the option of purchaser, the material received in the stores may be utilized in the field after
receipt of successful test report from CTL, for the mandatory test checking on the samples selected
from the material received at stores against first lot and subsequent lot(s) in anticipation of suc-
cessful type test report(s).”

The following tests shall be conducted as per requirements of Clause No.10.1 of IS:
14255/1995 & IS:5831 /1984 (latest amendment):

Page 176 of 623

(a) Tests on phase conductor:

i) Tensile test.(N.A. on shaped conductors)

ii) Wrapping test.(N.A. on shaped conductors)
iii) Resistance test.

(b) Tests on messenger conductor:

i) Breaking load.
ii) Elongation test.
iii) Resistance test.

(c) Physical test for XLPE Insulation:

i) Tensile strength and elongation at break.

ii) Ageing in air oven.
iii) Hot set test.
iv) Shrinkage test.
v) Water absorption (Gravimetric).

vi) Carbon black:

1. Content :- 2.5+/-0.5%
2. Dispersion:- In well dispersed manner.

(a) Test for thickness of insulation.

(b) Insulation resistance (Volume resistivity) test.
(c) High voltage test.
(d) High Voltage Test of Core in water (duration of immersion > 1 Hour) and apply Test voltage 3.5
KV AC for five minutes.( Testing Method as per CENELAC HD 626 S1 A1/A2 2002)
(e) Any other test as per ISS.

7.3.3 ROUTINE TESTS:

The following shall constitute routine tests on Aerial Bunched Cables and shall be
conducted in accordance to IS: 14255/1995 along with other relevant ISS with latest version
thereof:

Page 177 of 623

a) Conductor resistance test, and
b) High Voltage test.

7.4 SAMPLING:

The number of samples to be selected shall depend on the number of drums in the lot.
Sampling for conducting acceptance tests shall be in accordance to Clause No.10.2.1 of IS:
14255/1995, which is briefed as under:

SCALE OF SAMPLING:

Samples shall be taken and tested from each lot for ascertaining the conformity of the
lot to the requirements of the specification.

The number of drums (n) to be selected from the lot of drums (N) of consignment of
cables shall be in accordance with column 2 and 1 of the following Table respectively. The sam-
ples shall be taken at random.
In order to ensure the randomness of selection, random number tables shall be used.
Number of Drums to be selected for Sampling and Permissible Number of Defectives.
Number of Drums in the Lot Number of Drums to be Permissible Number of
taken as Sample Defectives
(1) (2) (3)
N n a
Up to 50 2 0
51 to 100 5 0
101 to 300 13 0
301 to 500 20 1
501 to above 32 2

7.5 At the works of the manufacturer, the cable shall be transferred from one drum to an-
other for checking any manufacturing defects in the cable drums selected for conducting ac-
ceptance 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
supplier in the packing list shall be applied to all the drums if the cable is found short during
checking the sample lot(s).

7.6 TOLERANCE ON TEST RESULTS:

178
The tolerance on the test results will be permissible as mentioned in the Indian
Standard.

7.7 TEST AT SITE:

The purchaser reserves the right to conduct all tests on Aerial Bunched Cables after
arrival at site and the contractor shall guarantee test certificate figures under actual service condi-
tions.

8. INSPECTION:

8.2 The Inspection may be carried out by the purchaser at any stage of manufacture /
before dispatch as per relevant standard.

8.3 The Manufacturer shall keep the purchaser informed in advance, about man-
ufacturing programme so that arrangements can be made for inspection.

8.4 The manufacturer shall furnish Packing list mentioning serial Nos. of Drums, length
in each drum, gross weight of drum without lagging alongwith inspection offer duly signed by the
authorized representative of the firm.

8.5 The supplier shall present the latest Calibration Certificate(s) of testing instru-
ments / 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/
meters/ apparatus etc. should be got calibrated by the supplier from time to time from Govt. La-
boratory or any independent test laboratory/house having valid accreditation from National Ac-
creditation Board for Testing and Calibrating Laboratories for the testing equipments / original
manufacturer having trace ability to NABL/NPL or equivalent.
8.6 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/ equipments should be duly sealed by the Calibrating Agency and mention thereof
shall be indicated in the calibration certificate(s).

179
8.7 TEST CHECKING OF MATERIAL AT STORES:

i) Sample drums from the material received at stores shall be selected for testing at CTL as per
sampling plan given hereunder in presence of firm’s representative. The selected sample drum
/ drums shall be transported to CTL by concern S.S / ACOS of Nigam.

ii) The selected sample drum for CTL testing shall be identified by the seals provided by In-
specting Officer / Inspecting Agency during pre-dispatch inspection at firms works and these
sealing details shall be invariably mentioned in the selection Memo by the nominated officers
of Nigam.

iii) The tests in the Nigam Testing laboratory (CTL) shall be conducted in the presence of rep-
resentative of supplier for which a 3 days’ notice shall be issued through Fax / Speed Post
stating Date & Time to the firm, so that supplier can depute their representative to witness the
test . In case the supplier or his representative does not turn up the testing shall be proceeded
& completed. The payment shall be released only after receipt of successful test reports for
the samples selected at purchaser’s stores for mandatory test checking on the samples to be
selected from material received at Nigam’s stores by random sample selection by the author-
ized committee as per CE(MM) order No.180 dt.11.4.2014.

i) SAMPLING:
One number Drum out of each lot / sub-lot of 25 Nos. Drums or part thereof for the
material received in Stores of Nigam.

ii) TESTS:
The following tests shall be carried out as per relevant clause of latest IS on each selected
drum by drawing sample of 10 Mtr. at CTL from random distance during re-winding:

i) Rewinding test (Measurement of Length) & Checking of Manufacturing defects.

ii) Measurement of Resistance of conductor.
iii) Tensile test for insulation.
iv) Elongation test for insulation
v) Test for thickness of insulation
vi) Hot Set Test
vii) Breaking load test on messenger wire.
viii) Verification of Marking

180
In addition to above tests remaining acceptance tests as per relevant IS shall also be con-
ducted at CTL provided the testing facility is available at CTL for these tests time to time.Onlythose
tests shall be conducted for which testing facilities are available in NIGAM’s Lab.

viii) CRITERIA FOR ACCEPTANCE:

a) If the measured of 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 have be
replaced by the supplier.

b) 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 contained in the lot / sub-lot to which the sample belongs shall be accepted with a
deduction @ 1.5% of the cost of cable for increase in resistance for every 1% or part thereof.

c) If the samples fail in any other test, the material shall be rejected and shall have to be
replaced by the supplier.

e) The results of measurement of length test shall be made applicable to all drums con-
tained in each lot / sub lot by making deduction of less length of cable in a Sample Drum.

8.8 TEST CHARGES: All test charges incurred towards test checking of the material
received in our stores shall be borne by the NIGAM.

10. (i) IDENTIFICATION:

The manufacturer shall be identified throughout the length of cable by providing legible
Embossing as under:

(ii) EMBOSSING:
The cable shall also be required to be embossed on outer sheath with the word Manu-
facturer’s Name or Trade Mark, Electric, XLPE90, Voltage Grade, NAME OF DISCOM , TN-,
RDSS, size of cable & year of manufacture’ at every meter length for which no extra chargesshall
be paid.

11 PACKING AND MARKING:

181
11.1 The cable shall be supplied on non-returnable wooden drum as per ISS
(10418/1982) of suitable size and packed (seasonal wood not be insisted). The ends of cables shall
be sealed by means of non-hygroscopic sealing material. Only one cable length shall be supplied
on a drum. The shaft diameter of drum should be as per relevant ISS but not less than 50 mm.
The cable can also be supplied on M-Steel Drums as per relevant ISS as applicable.
11.2 The cable shall carry the following information stenciled / painted on the drum:
i) Manufacturer's name, Brand name or trade mark.
ii) Type of cable and voltage grade.
iii) Number of Cores.
iv) Nominal Cross-sectional area of phase conductor.
v) Cable Code.
vi) Length of cable on the drum.
vii) Approximate gross weight.
viii) Year of manufacture.
ix) Name of the Consignee and full destination.
x) Tender number/RDSS
xi) Direction of rotation of drum by means of an arrow.
xii) IS:14255/1995

12. STANDARD LENGTH:

12.1 The cable shall be supplied in the standard length of 1000 meter for sizes 1CX25+25
Sq.mm Sq.mm.

12.2 A tolerance (+/-) 5% shall be allowed in standard length.

12.3 Non-Standard length measuring not less than 50% of standard length to complete
the ordered quantity shall be accepted up to 2% of the total ordered quantity.

13. DRAWING & DOCUMENTATION:

The manufacturer is required to furnish the detailed constructional drawing of the cable
clearly showing the various components The calculation of weights of different components of
the cable shall also be furnished in absence of this, the tenders are likely to be ignored.

14. GUARANTEED TECHNICAL PARTICULARS:

182
The manufacturer shall furnish guaranteed technical particulars in the relevant
Schedule A & VB. Any departure from the G.T.P be indicated in Schedule-A & B.

SCHEDULE- A

GUARANTEED TECHNICAL PARTICULARS OF LT XLPE INSULATED

AERIAL BUNCHED CABLE WITH BARE MESSENGER WIRE

- -
Sl. : Particulars : AERIAL BUNCHED CABLE
No. : : 1CX25+25

: : -
1 : Manufacturer's name and address :
: :
2 : Rated Voltage. : 1100 V
3 : Phase Conductor Details: :
: i) No. of Phase Conductors : 1
: ii) Nominal Sectional Area of each 25
: conductor in Sq.mm. :
: iii) No. & Size of Strands(mm) :
: iv) Min. Tensile strength of each :
: strand in N/ Sq.mm. :
v) Diameter of compacted
: conductor :
: with tolerance (in mm) :
: vi) Approx.Min. Weight of Phase : 65
: Conductor (Kg./Km.) :
vii) Max. DC resistance at 20
: Deg.C. :
: (Ohm/Km.) :
: viii) Insulation thickness (mm) :
: Nominal :
: Minimum :
IS:8130/1984 & IS:14255/1995 with latest
: ix) Standard specification to which amendments.

183
: this material shall comform. :

4 : Messenger (Neutral Conductor) :

: Details: :
: i) Nominal Sectional Area of each : 25
: conductor in Sq.mm. :
: ii) No. & Size of Strands(mm) :
iii) Diameter of compacted
: conductor :
: with tolerance (in mm) :
vi) Approx.Min. Weight of
: Messenger : 65
: Conductor (Kg./Km.) :
: v) Min. Tensile strength in KN. :
: vi) Max. DC resistance at 20 Deg.C. :
: (Ohm/Km.) :
:As per IS:398(Pt.IV)/1984 and IS:14255/1995
: vii) Standard specification to which with latest amendments.
: this material shall comform. :

5 : Insulation of Phase Conductor : :

: Black XLPE Compound (with U.V.
: i) Material resistance)
: ii) Standard specification to which :As per IS:14255/1995 with latest amendments.
: this material shall comform. :
iii) Approx. Min. Weight of XLPE (Kg/Km)
: iii) Deviation in properties.if any :

6 : Finished Cable (Complete Bunched :

: Cable): :
: i) Overall Dia (Approx.) in mm. :
: ii) Total Mass (Approx.) in Kg/Km. :
: iii) Lay pitch (mm) :
: iv) Direction of Lay :

7 : Standard length of each cable & its :

: tolerance in Mtr. :
: i) Total length of cable in a drum : 1000
184
: & its tolerance in Mtr. : +/- 5%

8 : Mass of finished cable in a :

: drum & its tolerance in Kg/Km. :

9 : Whether material bears ISI : Yes

: Certification Mark :
: :
10 : S.No. of ISI Licence and its :
: validity :
: :
11 : Max.continuous current carrying :
: capacity (Amp.).Please mention :
: Clauses/Table No. &Standrard :
: Specification, If any. :

Max.continuous conductor temp.

12 : due :
: to load :

13 : Embossing : As per Specification of TN-

: :
14 : Any other particulars :
NOTE : SPECIFIC VALUES MAY BE INDICATED IN ABOVE SCHEDULE. USE OF `DO
OR AS PER "IS" IS TO BE AVOIDED.

185
FILE : GTP-DRUM-AB Schedule-V(B)

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF DRUM FOR SUPPLY OF

LT XLPE INSULATED AERIAL BUNCHED CABLE WITH BARE MESSENGER WIRE

S. AERIAL BUNCHED CABLE

PARTICULARS
No. 1CX25+25
Drum:
i) Tare weight of drum
ii) Whether drum is wheel
mounted
iii) Standard specification to
which
drums shall comform.
iv) Drum Detail & Dimension
v) Whether 2-fully ply flange
construction or 2-fully ply plus

-----------AS PER IS: 10418 /1982 WITH LATEST AMENDMENTS--------------

1
segmental layer flange
construction.

A Drum Size (in mm)

B Flange Diameter(d1) (mm)
C Barrel Diameter(d2) (mm)
D Centre hole Diameter(d3) (mm)
E Overall width (L1) (mm)
F Traverse (L2) (mm)
G Thickness of Flange

H Barrel End (supporting disc

or core segment)
a) Diameter (mm)
b) Thickness (mm)

I Stretchers( Core Carrier Planks)

a) Number (Min)

186
b) Thickness x width (mm)

J Barrel Battens thickness

(Core Filler Planks)

K Barrel Middle Supports

(Middle Core discs)

Thickness of External
L Laggings.(mm)

DETAILS OF METAL
COMPONENTS:
Clamping Studs with
M Hexagonal Nuts
a) Numbers
b) Diameter (mm)

N Square or Round Washers

a) Numbers
b) Diameter (mm)

O M.S. Bushes
a) Numbers
b) Thickness of Sleeve (mm)
c) Dimension of Sleeve (mm)
d) Number of Bolts
e) Diameter of Bolts

P M.S./ C.I. Centre Plate

a) Numbers
b) Dimensions of Square/
Triangular equal sides (mm)
c) Centre Plate Bolts.

187
Q Numbers
i) Diameter of bolts (mm)
ii) Centre Hole Diameter (mm)
NOTE : SPECIFIC VALUES MAY BE INDICATED IN ABOVE SCHEDULE. USE OF `DO
OR AS PER "IS" IS TO BE AVOIDED.

188
TECHNICAL SPECIFICATION FOR SUPPLY OF LT XLPE INSULATED AERIAL
BUNCHED CABLES WITH BARE MESSENGER WIRE WITH ALUMINIUM CON-
DUCTOR FOR LT OVER HEAD LINES SUITABLE FOR WORKING VOLTAGE UPTO
& INCLUDING 1100V.( 3CX25+25 Sq. mm, 3CX50+35 Sq. mm)

1. SCOPE:

Mandatory Tools as specified in this specification are also covered in the scope of this
specification. The requirement of Aerial Bunched cable shall be as per schedule of requirement
annexed with this section at Schedule-I. It may be noted that the requirement indicated in the
schedule is tentative and may vary at the time of placement of order.

2. STANDARDS:

Unless otherwise stipulated in this specification the following standards with latest
amendments shall be applicable.
i) IS: 14255/1995 : Aerial bunched cables for LT lines.
ii) IS:10810/1984 : Methods of test for cables. (Series)
iii) IS:8130/1984 : Conductors for insulated cables.
iv) IS:10418/1982 : Drums for Electric Cables
v) IS:398(PT-IV) /1994 : Aluminum alloy conductors.
vi) CENELAC HD 626 : Over head distribution cables of rated voltage
S1 A1/A2 2002 Uo/U(Um):0.6/1(1.2) KV.

189
NOTE: The specification has mostly considered references from Indian
Standard. However, reference have also been derived from the above re-
ferred International Standard in meeting the onerous site requirement
of Jaipur Discom.

3. CLIMATIC CONDITIONS:

i) Peak ambient temperature 50 deg.C

in shade.

ii) Maximum average ambient 40 deg.C

temperature in a 24 hours
period in shade.

iii) Minm. ambient air temperature in shade (-)5 deg.C

iv) Maximum temperature attainable 60 deg.C

by an object exposed to sun.

v) Maximum relative humidity. 100%

vi) Average number of thunder 40

storm days per annum.

vii) Average number of rainy days 100

per annum.

viii) Average annual rainfall 10 to 100 cm

ix) Number of months of tropical 4 months

monsoon conditions.

x) Maximum wind pressure. 100kg/sq.mm.

190
xi) Altitude not exceeding 1000 M

4. PRINCIPAL PARAMETER:

5. GENERAL TECHNICAL REQUIREMENTS:

Type of Insulation Normal Continuous Short Circuit

Operation Operation
Cross Linked Polyethylene (XLPE) 90 DEG.C 250 DEG.C.

6. 0 MATERIAL:

6.1 CONDUCTORS:

6.1.1 PHASE CONDUCTOR:

The conductor shall be of H2 or H4 grade Aluminium complying with the

requirement of IS: 8130/1984 or latest amendment, if any.

6.1.2 MESSENGER (NEUTRAL CONDUCTOR OR OTHERWISE):

191
The conductor shall be of heat treated aluminium-magnesium-silicon alloy wires
containing approximate 0.5 percent magnesium and approximately 0.5 percent silicon conforming
to IS: 398(Part-4): 1979 or latest amendment, if any.

The Messenger (Neutral conductor) or otherwise shall be either stranded circular or

compacted circular type and shall have minimum 7 strands. The surface of the conductor shall be
smooth.

The size of messenger conductor and its breaking load shall be as given below:

S.No. Nominal Cross Sectional Area of Messenger Conductor

Phase Conductor (Sq.mm)
Nominal Cross Maximum D.C. Minimum
Section Area Resistance at 20 Breaking
(Sq.mm.) Dec.C. Load
(Ohm/Km.) (KN)
1 2 3 4 5
1 25 25 1.38 7.0
2 50 35 0.986 9.8

6.2 INSULATION:
The insulation shall be of CROSS LINKED POLYETHYLENE COMPOUND
(XLPE) conforming to the requirements given in Table-1 of IS:14255/1995 with latest amend-
ment, if any.
The conductor (with protective barrier, wherever applied) shall be provided with
cross-linked polyethylene insulation applied by extrusion.
The average thickness of insulation shall be not less than the nominal value (t) speci-
fied as below:

Sl. No Nominal Area of Conductor Sq.mm Nominal Thickness (t) mm.

192
1 25 1.2
2 50 1.5

The smallest of measured values of thickness of insulation shall not fall below the
nominal value (t) specified in above table by more than 0.1mm + 0.1 (t).

The insulation shall be so applied that it fits closely on the conductor (or barrier, if
any) and it shall be possible to remove it without damaging the conductor.

The colour of INSULATION (XLPE) shall be Black & Messenger Wire shall be bare.

The Black Carbon Contents 2.5+/-0.5% in well dispersed manner shall be added in XLPE
for making the Insulation UV Resistant.

6.3 CORE IDENTIFICATION:

d) Width :- 1.00 mm
e) Height :- 0.5 mm
f) Distance Between :- 2.7 mm
Consecutive Ridges

6.4 ASSEMBLY (LAYING UP):

6.5 COMPOSITIONS AND DESIGNATION OF FINISHED CABLES:

The composition and designation of finished cables are given in the following table:

S.No. Designation of finished cable

1 3CX25+25 Sq.mm

193
2 3CX50+35 Sq.mm

7. TESTS:

7.1 The material offered, shall be fully type tested as per relevant standard of specification
of IS:14255/1995 amended up to date.
7.2 However, the purchaser reserves the right to demand repetition of some or all the type
tests in presence of purchaser's representative.
7.3 TESTS BEFORE DESPATCH:

The aerial bunched cables shall be subjected at manufacturer’s works before dis-
patch, to the following tests as per ISS/relevant standards.

7.3.1 ACCEPTANCE AND OPTIONAL TESTS:

The Aerial Bunched Cables shall be subjected at manufacturer’s works before dis-
patch to the following acceptance /optional tests as per relevant ISS in presence of the purchasers'
representative.

The following shall constitute acceptance tests and shall be conducted as per IS:
14255/1995 & IS: 5831 / 1984 and other relevant ISS with latest amendments, if any:

a) Tensile test (for phase conductor),(N.A on shaped conductor)

b) Wrapping test(for phase conductor),(N.A on shaped conductor)

c) Breaking load test for messenger conductor.

d) Elongation test for messenger conductor.

e) Conductor resistance test.

f) Test for thickness of insulation.

194
g) Tensile strength and elongation at break test of Insulation.

h) Hot set test for XLPE insulation.

i) Insulation resistance test and

j) High voltage test is to be conducted on all drums of offered lot.

l) Carbon Black:
j) Contents:- 2.5+/-0.5%
ii) Disperssion :- In well dispersed manner

l) Any other test as per latest ISS.

The following shall constitute optional test:-

Bending test on complete Cable.

7.3.2 TYPE TESTS:

(i) For cable order quantity upto 20 Kms.

Note :- The supplier supply cable more than deliver Schedule but quantity as per above condition
, positive PV benefit will be given as per beneficial to Nigam.

(ii) For cable order quantity more than 20 Kms.

Note :-The supplier supply cable more than deliver Schedule but quantity as per above condition
, positive PV benefit will be given as per beneficial to Nigam.

195
“At the option of purchaser, the material received in the stores may be utilized in the field after
receipt of successful test report from CTL, for the mandatory test checking on the samples selected
from the material received at stores against first lot and subsequent lot(s) in anticipation of suc-
cessful type test report(s).”

.
The following tests shall be conducted as per requirements of Clause No.10.1 of IS:
14255/1995 & IS:5831 /1984 (latest amendment):

(a) Tests on phase conductor:

i) Tensile test.(N.A. on shaped conductors)

ii) Wrapping test.(N.A. on shaped conductors)
iii) Resistance test.

(b) Tests on messenger conductor:

i) Breaking load.
ii) Elongation test.
iii) Resistance test.

(c) Physical test for XLPE Insulation:

i) Tensile strength and elongation at break.

ii) Ageing in air oven.
iii) Hot set test.
iv) Shrinkage test.
v) Water absorption (Gravimetric).

vi) Carbon black:

1. Content :- 2.5+/-0.5%
2. Dispersion:- In well dispersed manner.

(d) Test for thickness of insulation. (e)Insu-

lation resistance (Volume resistivity) test.
196
(f) High voltage test.
(g) High Voltage Test of Core in water (duration of immersion > 1 Hour) and apply Test voltage 3.5
KV AC for five minutes.( Testing Method as per CENELAC HD 626 S1 A1/A2 2002)
(h) Any other test as per ISS.

7.3.3 ROUTINE TESTS:

The following shall constitute routine tests on Aerial Bunched Cables and shall be
conducted in accordance to IS: 14255/1995 along with other relevant ISS with latest version
thereof:

a) Conductor resistance test, and

b) High Voltage test.

7.4 SAMPLING:

SCALE OF SAMPLING:

Samples shall be taken and tested from each lot for ascertaining the conformity of the
lot to the requirements of the specification.

The number of drums (n) to be selected from the lot of drums (N) of consignment of
cables shall be in accordance with column 2 and 1 of the following Table respectively. The sam-
ples shall be taken at random.
In order to ensure the randomness of selection, random number tables shall be used.
Number of Drums to be selected for Sampling and Permissible Number of Defectives.
Number of Drums in the Lot Number of Drums to be taken Permissible Number of
as Sample Defectives
(1) (2) (3)
N n a
Up to 50 2 0
51 to 100 5 0
101 to 300 13 0
301 to 500 20 1

197
501 to above 32 2

7.6 TOLERANCE ON TEST RESULTS:

The tolerance on the test results will be permissible as mentioned in the Indian
Standard.

7.7 TEST AT SITE:

The purchaser reserves the right to conduct all tests on Aerial Bunched Cables after
arrival at site and the contractor shall guarantee test certificate figures under actual service condi-
tions.

8. INSPECTION:

8.2 The Inspection may be carried out by the purchaser at any stage of manufacture /
before dispatch as per relevant standard.

8.3 The Manufacturer shall keep the purchaser informed in advance, about man-
ufacturing programme so that arrangements can be made for inspection.

198
8.5 The supplier shall present the latest Calibration Certificate(s) of testing instru-
ments / 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/ meters/
apparatus etc. should be got calibrated by the supplier from time to time from Govt. Laboratory
or any independent test laboratory/house having valid accreditation from National Accreditation
Board for Testing and Calibrating Laboratories for the testing equipments / original manufacturer
having trace ability to NABL/NPL or equivalent.
8.6 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/ equipments should be duly sealed by the Calibrating Agency and mention thereof
shall be indicated in the calibration certificate(s).

8.7 TEST CHECKING OF MATERIAL AT STORES:

i) Sample drums from the material received at stores shall be selected for testing at CTL as
per sampling plan given hereunder in presence of firm’s representative. The selected sample
drum / drums shall be transported to CTL by concern S.S / ACOS of Nigam.

iii) The tests in the Nigam Testing laboratory (CTL) shall be conducted in the presence of
representative of supplier for which a 3 days’ notice shall be issued through Fax / Speed Post
stating Date & Time to the firm, so that supplier can depute their representative to witness the
test . In case the supplier or his representative does not turn up the testing shall be proceeded
& completed. The payment shall be released only after receipt of successful test reports for
the samples selected at purchaser’s stores for mandatory test checking on the samples to be
selected from material received at Nigam’s stores by random sample selection by the author-
ized committee as per CE(MM) order No.180 dt.11.4.2014.

iv) SAMPLING:

One number Drum out of each lot / sub-lot of 25 Nos. Drums or part thereof for the
material received in Stores of Nigam.

v) TESTS:
The following tests shall be carried out as per relevant clause of latest IS on each selected
drum by drawing sample of 10 Mtr. at CTL from random distance during re-winding:

199
i) Rewinding test (Measurement of Length) & Checking of Manufacturing defects.
ii) Measurement of Resistance of conductor.
iii) Tensile test for insulation.
iv) Elongation test for insulation
v) Test for thickness of insulation
vi) Hot Set Test
vii) Breaking load test on messenger wire.
viii) Verification of Marking

In addition to above tests remaining acceptance tests as per relevant IS shall also be con-
ducted at CTL provided the testing facility is available at CTL for these tests time to time.Onlythose
tests shall be conducted for which testing facilities are available in NIGAM’s Lab.

vi) CRITERIA FOR ACCEPTANCE:

a) If the measured of 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 have be
replaced by the supplier.

b) 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 contained in the lot / sub-lot to which the sample belongs shall be accepted with a
deduction @ 1.5% of the cost of cable for increase in resistance for every 1% or part thereof.

c) If the samples fail in any other test, the material shall be rejected and shall have to be
replaced by the supplier.

e) The results of measurement of length test shall be made applicable to all drums con-
tained in each lot / sub lot by making deduction of less length of cable in a Sample Drum.

8.8 TEST CHARGES: All test charges incurred towards test checking of the material
received in our stores shall be borne by the NIGAM.

200
9. CHALLENGE TESTING CLAUSE:

The other manufacturer can also request challenge testing for any test based on spec-
ification. The challenger would request for testing with testing fee. The challenge test fee are
proposed at least three time cost of testing. This is likely to deter un-necessary challenges. The
challenger would have the opportunity to select the sample from the store and any such challenge
should be made within the guarantee period. The party challenged, the challenger & the utility
could witness the challenge testing. The challenged testing would cover all the type tests as per
relevant IS.

The challenge test could be conducted at NABL Accredited Laboratory like ERDA,
CPRI, Bangalore / Muradnagar / Bhopal. If the values are within limit the products gets confirmed
else not confirmed. If the product is not confirmed the manufacturer would pay the challenge fee
and challenger would get the fee refunded. However, as a redressal system the challenger would
be asked for fresh selection of two more samples from the stores and the samebe tested in a NABL
Laboratory (which shall be other than previously selected NABL AccreditedLab) at the cost of
supplier in presence of party challenged, challenger and the utility. If any one or both samples
does not confirmed the tests then the product is said to have failed the tests. In such cases, the
manufacturer will be declared as unsuccessful manufacturer for the said productand balance supply
shall not be availed and the order shall be cancelled with levy of maximum penalty.

10. (i) IDENTIFICATION:

The manufacturer shall be identified throughout the length of cable by providing legible
Embossing as under:

(ii) EMBOSSING:

The cable shall also be required to be embossed on outer sheath with the word Manu-
facturer’s Name or Trade Mark, Electric, XLPE90, Voltage Grade, NAME OF DISCOM , TN-,
size of cable & year of manufacture’ at every meter length for which no extra charges shallbe paid.

11 PACKING AND MARKING:

11.1 The cable shall be supplied on non-returnable wooden drum as per ISS
(10418/1982) of suitable size and packed (seasonal wood not be insisted). The ends of cables shall
be sealed by means of non-hygroscopic sealing material. Only one cable length shall be supplied
on a drum. The shaft diameter of drum should be as per relevant ISS but not less than 50 mm.
The cable can also be supplied on M-Steel Drums as per relevant ISS as applicable.

11.2 The cable shall carry the following information stenciled / painted on the drum:

201
i) Manufacturer's name, Brand name or trade mark.
ii) Type of cable and voltage grade.
iii) Number of Cores.
iv) Nominal Cross-sectional area of phase conductor.
v) Cable Code.
vi) Length of cable on the drum.
vii) Approximate gross weight.
viii) Year of manufacture.
ix) Name of the Consignee and full destination.
x) Tender number/RDSS
xi) Direction of rotation of drum by means of an arrow.
xii) IS:14255/1995

12. STANDARD LENGTH:

12.1 The cable shall be supplied in the standard length of 1000 meter for both the sizes
3CX25+25 Sq.mm & 3CX50+35 Sq.mm.

12.2 A tolerance (+/-) 5% shall be allowed in standard length.

12.3 Non-Standard length measuring not less than 50% of standard length to complete
the ordered quantity shall be accepted up to 2% of the total ordered quantity.

13. DRAWING & DOCUMENTATION:

The manufacturer is required to furnish the detailed constructional drawing of the cable
clearly showing the various components the calculation of weights of different components of the
cable shall also be furnished in absence of this; the tenders are likely to be ignored.

14. GUARANTEED TECHNICAL PARTICULARS:

The manufacturer shall furnish guaranteed technical particulars in the relevant

Schedule VA & VB. Any departure from the G.T.P be indicated in Schedule-V.

15. MANDATORY TOOLS:

202
The successful manufacturers are required to supply essentially the following mandatory tools
free of cost, the quantity of which is indicated against each:

Pulley for A.B.C. : One Set per 25 Km. of each size of A.B. Cable

The Pulley is used to receive low voltage Aerial Bunched Cables. It should suit the
sizes of Aerial Bunched Cable as mentioned at Clause-6.5 of this specification. Fixing on poles
is ensured by a 1.20 Mtrs. strap in order not to stress the Pulley during cable unwind.

SCHEDULE-A

GUARANTEED TECHNICAL PARTICULARS OF LT XLPE INSULATED

AERIAL BUNCHED CABLE WITH BARE MESSENGER WIRE
- -
Sl. : Particulars : AERIAL BUNCHED CABLE
No. : : 3CX25+25 Sq.mm 3CX50+35
: :
1 : Manufacturer's name and address :
: :
2 : Rated Voltage. : 1100 V
3 : Phase Conductor Details: :
: i) No. of Phase Conductors : 3 3
: ii) Nominal Sectional Area of each 25 50
: conductor in Sq.mm. :
: iii) No. & Size of Strands(mm) :
: iv) Min. Tensile strength of each :
: strand in N/ Sq.mm. :
: v) Diameter of compacted :
: with tolerance (in mm) :
: vi) Approx.Min. Weight of Phase : 65 127
: Conductor (Kg./Km.) :
: vii) Max. DC resistance at 20 :
: (Ohm/Km.) :
: viii) Insulation thickness (mm) :
: Nominal :
: Minimum :
: ix) Standard specification to which IS:8130/1984 & IS:14255/1995 with latest

203
: this material shall comform. :

4 : Messenger (Neutral Conductor) :

: Details: :
: i) Nominal Sectional Area of each : 25 35
: conductor in Sq.mm. :
: ii) No. & Size of Strands(mm) :
: iii) Diameter of compacted :
: with tolerance (in mm) :
: vi) Approx.Min. Weight of : 65 95
: Conductor (Kg./Km.) :
: v) Min. Tensile strength in KN. :
: vi) Max. DC resistance at 20 Deg.C. :
: (Ohm/Km.) :
: vii) Standard specification to which :As per IS:398(Pt.IV)/1984 and IS:14255/1995
: this material shall comform. with latest amendments.

5 : Insulation of Phase Conductor : :

: i) Material : Black XLPE Compound (with U.V.
: ii) Standard specification to which : As per IS:14255/1995 with latest
: this material shall comform. :
iii) Approx. Min. Weight of XLPE (Kg/Km)
: iii) Deviation in properties.if any :

6 : Finished Cable (Complete Bunched :

: Cable): :
: i) Overall Dia (Approx.) in mm. :
: ii) Total Mass (Approx.) in Kg/Km. :
: iii) Lay pitch (mm) :
: iv) Direction of Lay :

7 : Standard length of each cable & its :

: tolerance in Mtr. :
: i) Total length of cable in a drum : 1000 1000
: & its tolerance in Mtr. : +/- 5% +/- 5%

8 : Mass of finished cable in a :

: drum & its tolerance in Kg/Km. :

9 : Whether material bears ISI : Yes Yes

: Certification Mark :
204
10 : S.No. of ISI Licence and its :
: validity :
11 : Max.continuous current carrying :
: capacity (Amp.).Please mention :
: Clauses/Table No. &Standrard :
: Specification, If any. :
12 : Max.continuous conductor temp. :
: to load :
13 : Embossing : As per Specification of TN-
14 : Any other particulars :
NOTE : SPECIFIC VALUES MAY BE INDICATED IN ABOVE SCHEDULE. USE OF `DO
OR AS PER "IS" IS TO BE AVOIDED.

205
FILE : GTP-DRUM-AB Schedule-V

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF DRUM FOR SUPPLY OF

LT XLPE INSULATED AERIAL BUNCHED CABLE WITH BARE MESSENGER WIRE TN-
S. AERIAL BUNCHED CABLE
PARTI CULARS
No. 3CX25+25 3CX50+35
Drum:
i) Tare weight of drum
ii) Whether drum is wheel
mounted
iii) Standard specification to
which
drums shall comform.
iv) Drum Detail & Dimension
v) Whether 2-fully ply flange
construction or 2-fully ply plus
1

-----------AS PER IS: 10418 /1982 WITH LATEST AMENDMENTS--------------

segmental layer flange
construction.
A Drum Size (in mm)
B Flange Diameter(d1) (mm)
C Barrel Diameter(d2) (mm)
D Centre hole Diameter(d3) (mm)
E Overall width (L1) (mm)
F Traverse (L2) (mm)
G Thickness of Flange
H Barrel End (supporting disc
or core segment)
a) Diameter (mm)
b) Thickness (mm)
I Stretchers( Core Carrier Planks)
a) Number (Min)
b) Thickness x width (mm)
J Barrel Battens thickness
(Core Filler Planks)

206
K Barrel Middle Supports
(Middle Core discs)
Thickness of External
L Laggings.(mm)
DETAILS OF METAL
COMPONENTS:
Clamping Studs with
M Hexagonal Nuts
a) Numbers
b) Diameter (mm)
N Square or Round Washers
a) Numbers
b) Diameter (mm)
O M.S. Bushes
a) Numbers
b) Thickness of Sleeve (mm)
c) Dimension of Sleeve (mm)
d) Number of Bolts
e) Diameter of Bolts
P M.S./ C.I. Centre Plate
a) Numbers
b) Dimensions of Square/
Triangular equal sides (mm)
c) Centre Plate Bolts.
Q Numbers
i) Diameter of bolts (mm)
ii) Centre Hole Diameter (mm)
NOTE : SPECIFIC VALUES MAY BE INDICATED IN ABOVE SCHEDULE. USE OF `DO
OR AS PER "IS" IS TO BE AVOIDED.

207
TECHNICAL SPECIFICATION FOR SUPPLY OF ISI MARKED PVC INSULATED
MULTI-CORE UN-ARMOURED NON-FRLS CONTROL CABLES (12CX2.5 Sq.mm,
4CX4 Sq.mm)

1.0 SCOPE:

The specification covers design, manufacturing, testing at the manufacturer’s works, inspection,
packing and delivery to the site of 1100V grade multi core, each core containing appropriate numbers of
strands of annealed bare Copper conductor, PVC (Type-A) insulated and PVC sheathed (Type-ST-1), Un-
Armoured NON-FRLS Control cables as per sizes given in the schedule of requirement attached with this
specification as per Schedule-I. It may be noted that the requirement indicated in the schedule are tentative
and may vary at the time of placement of order.

1.1 PVC INSULATED UN-ARMOUREDNON-FRLS CONTROL CABLES:

The cables are required at various 33 KV Grid Sub-Stations for the control and supervision of
outdoor / indoor switchgears and power transformers including instrumentation metering, indication and
alarm on the control panels and electrical inter-locking between high voltage equipments. With a view to
achieve these multifarious requirements, the cables will be laid between individual outdoor equipments
and from there to control relay and other allied panels located indoor. The reliability and long life of the
control cables is of paramount importance. All the control cables offered against the specification should
be suitable for climatic conditions prevailing at site, as indicated in Clause-3.

2.0 STANDARDS FOR UN-ARMOUREDNON-FRLS CONTROL CABLES:

1100V Grade multi core, each core containing seven strands of annealed bare Copper con-
ductor, PVC (Type-A) insulated and PVC sheathed (Type-ST-1), Un-Armoured NON-FRLS Con-
trol cables, shall conform in all respects to the following relevant ISS with latest editions and
amendments.

Sr. No. Standard Ref. No. Title

1. IS-1554/(Pt.-I)/1988 with latest PVC insulated (Heavy duty) Electric Cables
amendment up to date. for working voltage up to and including
1100 Volts.
2. IS-8130/1984 with latest Conductors for insulated Electric Cables
amendment up to date. and flexible cords.
3. IS-5831/1984 with latest PVC Insulation and sheath of ElectricCa-
amendment up to date. bles.
4. IS-3961/(Pt.-II)/1967 with latest Current ratings for cables:
amendment up to date PVC insulated & PVC Sheathed heavy-duty
cables.
5. IS-10418with latest amendment up Drums for Electric Cables.
to date.
208
6. IS-10810 with latest amendment up Methods of tests for cables.
to date.
3.0 CLIMATIC CONDITIONS:
The control cables shall be suitable for continuous satisfactory operation under climatic conditions
listed below:

1) Maximum ambient air 50 DEG.C.

Temperature in shade (deg. C)

2) Minimum ambient air temperature (-) 5 DEG.C.

3) Maximum relative humidity 95%

4) Minimum relative humidity 10%

5) Average No. of thunder storm 40 days

Days/annum

6) Average annual rainfall 10 TO 100 cm.

7) Average No. of months of 4 (June to Sept.)

Tropical monsoon condition.

8) Altitude above MSL Up to 1000 Mt.

9) Dust storms are liable to March to July

occur in the period

4.0 GENERAL DESIGN CRITERIA:

The Cables shall normally be laid in masonry / RCC trenches whether inside or outside the control
room building in groups in tier formation or otherwise, but at some places the cables may be laid direct in
ground or in air. The cable may even be laid in vertical formation and in steep gradients at some locations.
The cables shall be physically strong to withstand rough installation hazards and thermal / electrical / phys-
ical stresses during operation under specified climatic conditions as stated under Clause-3.

5.0 CONSTRUCTIONAL FEATURES:

209
1100 Volts grade, multi-core, Un-Armoured NON-FRLS, PVC Type-A insulated suitable
for maximum rated conductor temp. of 70° Celsius , seven strands Annealed bare copper conduc-
tor, PVC sheathed (Type-ST-1), control cables shall conform to the requirements imposedin IS:
1554 (Part- I)/1988 and its latest amendments up to date. The cable shall be suitable for usewhere
combination of ambient temperature and temperature rise due to load results in conductor temper-
ature not exceeding 70°Celsius under normal operation and 160°Celsius under short circuitcondi-
tions.

All the control cables shall bear ISI certification marks as per IS: 1554 (Part-I)/1988 with
latest amendment up to date. The cables shall have PVC fillers to provide circular cross-section
before the inner sheath is applied. The fillers should be suitable for operating temperature of the
cable compatible with the insulating material.

5.1 CONDUCTOR:

The conductor shall be stranded (7 wires per core) annealed, non-compacted, un-
tinned high conductivity electrolytic copper conforming to class-II of IS: 8130 /1964 & IS: 613
/1964 with latest amendment up to date.

5.2 INSULATION:

The insulation shall be Polyvinyl Chloride compound (PVC) conforming to re-

quirement of Type-A compound of IS: 5831/1984with latest amendment up to date. The insula-
tion shall be applied by pressure extrusion method. The insulation shall be applied in suchway
that it fits closely on conductor and it shall be possible to remove it without damage to the con-
ductor. The thickness and tolerance on thickness of insulation shall be as per clause 9.2 & 9.3of
IS: 1554 (Part-I)/1988with latest amendment up to date.

5.3 INNER SHEATH:

The inner sheath shall be of non-Hygroscopic, Polyvinyl Chloride compound

(PVC) conforming to requirements of IS: 5831/1984 with latest amendment up to date for type
ST-1.The inner sheath shall be softer than the insulation. The inner sheath shall be applied by
extrusion method& it shall be so applied that it fits closely on laid up cores and it shall be possible
to remove it without damage to the insulation. The thickness and tolerance on thickness of inner
sheath shall be as per clause 12.3 of IS: 1554 (Part-I)/1988 with latest amendment up to date. The
inner sheath shall be of colour of black.

5.4 FILLERS:

The fillers shall be of non-Hygroscopic, Polyvinyl Chloride compound (PVC) con-

forming to requirements of IS: 5831/1984 with latest amendment up to date. The material of fillers
shall be softer than the insulation. It shall be ensured that the shape is as circular as possible.The
fillers should be suitable for operating temperature of the cable compatible with the insulatingma-
terial.

210
5.5 OUTER SHEATH:

The outer sheath shall be of Polyvinyl Chloride compound (PVC) conforming to

requirements of IS: 5831/1984 with latest amendment up to date for type ST-1.The outer sheath
shall be applied by extrusion method. The thickness and tolerance on thickness of outer sheath
shall be as per clause 14.4of IS: 1554 (Part-I)/1988with latest amendment up to date. The outer
sheath shall be embossed at the interval of one meter length as per clause no. 9.0 of this specifica-
tion.

6.0 COLOUR SCHEME FOR INDENTIFICATION OF CORES:

The Colour of core insulation upto 5 Cores shall be as per clause 10.1 of IS-1554 (Part-I)
1988 and for 6Cores& above, cores shall be identified by the Colour as per clause 10.1(f) of IS-
1554 ( Part-I) 1988 & its latest amendment up to date with Grey Colour base and also individual
cores of cable containing two or more cores shall be identified by different colouring of PVC
insulation in accordance with clause 10.0 of IS: 1554 (Part- I)/1988 with latest amendment up to
date. However, the PVC sheath may be black or grey. The colour coatings employed in the for-
mation of the cables for individual cores and sheath shall be indicated in the tender.

7.0 LAYING UP OF CORES:

The cores shall be laid up together with the suitable right hand lay. The interstices shall be filled
with non-hygroscopic, PVC material.

8.0 STANDARD LENGTH:

The control cables shall be supplied in standard length of 1000 meters ± 5% for cables
sizes 4CX2.5 Sq. mm. & 2CX2.5 Sq. mm. and shall be supplied in standard length of 500 meters
± 5% for cables sizes 12CX2.5 Sq. mm and 4CX4 Sq.mm. The quantities of the non-standard
drum length to be supplied shall not exceed 5% of the ordered qty. but none of which shall be less
than 250 meters. The ordered quantity to be supplied shall be subjected to tolerance of ± 2% in
each size.

9.0 EMBOSSING:

To enable identification of control cable the word JVVNL, manufacturer’s name or mark, TN No.
& Year of manufacture, Type-PVC, Electric voltage grade and cable size shall be embossed on
the outer sheath of cable at the interval of one meter length for which no extra charges shall be
paid. The cable should be ISI marked & same should be embossed on the outer sheath of every
meter of length of cable.

10.0 MARKING:

10.1 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
211
non-hygroscopic sealing material. Only one cable length shall be supplied on a drum. The shaft
diameter of Drum shall be as per relevant ISS but not less than 50 mm. The cable can also be
supplied on M-Steel Drums as per relevant ISS as applicable.

10.2 The cable shall carry the following information stenciled / painted on the drum :

i) Reference to this Indian Standard, for example, Ref IS:1554 (Part-1)

ii) Manufactuer's name, Brand name or trade mark.
iii) Type of cable and voltage grade.
iv) Number of Cores.
v) Nominal Cross-sectional area of the conductor.
vi) Cable Code.
vii) Length of cable on the drum.
viii) Approximate gross weight.
ix) Year of manufacture.
x) BIS Certification mark.
xi) Name of the Consignee and full destination.
xii) TN number/RDSS
xiii) The word suitable for outdoor use & low temperature Conditions.

11. CURRENT RATINGS:

The current ratings of the control cables shall correspond to the values recommended as
per IS: 3961 (Part- II)/1967 and its latest amendments up to date.

12. LATENT DEFECTS ERRORS & OMISSIONS:

12.1 Any cable or part thereof that may develop defects during performance guarantee
period shall be promptly replaced by the supplier free of charge.

12.2 IF THE OPERATION OF THE CABLE AFTER INSTALLATION DURING GUARANTEE PERIOD
PROVES TO BE UNSATISFACTORY, THE PURCHASER SHALL HAVE THE RIGHT TO OPER -
ATE THE BANK GUARANTEE(S) UNTIL DEFECTIVE ARTICLES ARE TAKEN OUT OFSER-
VICE, WITHOUT LOSS OF INJURY TO THE PURCHASER & CORRECTION OF LATENT DE-
FECTS, ERRORS & OMISSIONS.

13. TESTS & INSPECTION:

212
13.1 TYPE TEST:

i) The material offered, shall be fully type tested as per relevant standard of spec-
ification of IS:1554 (Part.1/1988) amended up to date.
ii) The manufacturer must also clearly indicate various testing facilities available at their
works for testing the material as per relevant standards. In case of otherwise particulars of
the place where such testing in proposed to be conducted during the course of inspection shall
be indicated with the offer.

iii) However, the purchaser reserves the right to demand repetition of same or all the type
tests in presence of purchaser’s representative.

iv) The bidding firms (manufacturers) must have valid BIS license for the offered cable.
The manufacturer shall furnish the details of BIS License granted to them.
The details of type test are as under:

a) Test on Conductor
1. Annealing test (if applicable)
2. Conductor resistance test.

b) Tests for thickness of insulation and sheath.

c) Physical tests for insulation and outer sheath.

1. Tensile strength and elongation at break.
2. Aging in air oven.
3. Shrinkage test.
4. Hot deformation.
5. Loss of mass in air oven.
6. Heat shock test.
7. Thermal stability.

d) Insulation resistance test.

e) High voltage test (Water immersion test).
f) High voltage test at room temperature.
g) Flammability tests:

The purchaser reserves the right to get the material tested in any recognized test house and reject
the material if not found as per specification.

Note: Type test carried out by manufacturer in his own R&D unit even if recognized by
213
Govt. shall not be accepted except in case of Govt. undertaking.

13.2 ROUTINE TESTS:

All routine tests as stipulated in the relevant IS-1554 (Part-I)/1988 with its latest
amendments shall be carried out by the supplier on each lot offered for inspection.

13.3 ACCEPTANCE TESTS:

All the acceptance tests as mentioned in relevant IS-1554 (Part-I)/1988 & its latest
amendments up to date shall be carried out on samples from a lot for the purpose of acceptance
test in presence of purchaser’s representative.

13.4 INSPECTION:

i) The inspection may be carried out by the purchaser at any stage of manufacturer. The
Inspection & Testing shall be governed by Clause No. 1.27 of Section-II (General Condi-
tions of Contract). Acceptance of any equipment / material under this specificationby the
purchaser shall not relieve the supplier of his obligation of furnishing equipment in
accordance with the specification and shall not prevent subsequent rejection if the equip-
ment/material is found to be defective.

ii) The supplier shall keep the purchaser informed in advance about the manufacturing pro-
gram so that arrangement can be made for inspection.

iii) The acceptance tests as per IS-1554 (Part-I)/1988 shall also be conducted by the manufac-
turer before dispatch in the presence of our Representative /Inspecting Officer along with
verification of lengths & weight and checking the manufacturing defects, if any of samples
coils. The mass of Copper, PVC & Filler in sample coils shall also be verified by the In-
specting Officer(s).

Cold bend/ cold impact test (IS:5831/1984) shall constitute the optional tests and shall be
conducted on first lot and any from other lot of the offered cables of each size as perClause
No.15.4 of IS-1554 (Part-I)/1988.

iv) The purchaser reserves the right to insist or witnessing the acceptance / routine tests of the
bought out items.

v) The manufacturer shall furnish Packing list mentioning serial Nos. of Drums, length in
each drum, gross weight of drum without lagging alongwith inspection offer duly signed
by the authorized representative of the firm. The purchaser reserves the rights to insist for
witnessing the acceptance / routine tests of the bought out items.

214
vi) At least 5% of total numbers of drums subject to minimum of 2 in any lot put up for in-
spection shall be selected at random to ascertain the length/ workmanship of cable by the
following method :

“At the works of the manufacturer, the cable shall be transferred from one drum to another
for checking any manufacturing defects in the cable drums 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 supplier in the packing list shall be applied to all the drums
if the cable is found short during checking the sample lot(s)”.

vii) The supplier 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 tothe
authorized inspecting officer / inspecting agency of the purchaser. The testing instruments
/ meters / apparatus etc. should be got calibrated by the supplier from time totime from
Govt. Laboratory or any independent test laboratory / house having valid accreditation
from National Accreditation Board for Testing and Calibrating Laboratoriesfor the testing
equipments / original manufacturer having trace ability to NABL / NPL orequivalent.

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 / equipments should be duly sealed by the Calibrating Agency and
mention thereof shall be indicated in the calibration certificate(s).

13.5 VERIFICATION OF LENGTH:

The supplier / manufacturer shall provide all adequate facilities at his works for inspection
of at least two numbers of cable drums or five percent of the cable drums offered for inspection,
whichever is higher, selected at random by the authorized representative of the purchaser for
checking / verification of cable length / manufacturing defects by transferring the cable from one
drum to the another empty drum and at the same time measuring the length of the cable so trans-
ferred by means of a meter. The difference in the average length thus obtained from the declared
length by the supplier in the packing list shall be applied to all the drums if the cable is found short
during checking the sample lot(s).

13.6 CALIBRATION CERTIFICATE:

The successful manufacturer shall have to furnish the latest calibration certificates of the
testing instruments / equipments used for the testing of material / equipment offered to inspecting
officer(s) at the time of inspection of material / equipment. The testing instrument/equipment shall
be got calibrated by the manufacturer of testing instrument / equipment or from any Govt. / Govt.
recognized / NABL accredited testing laboratory. The calibration certificate should not be older
than one year at the time of presenting the same to the Inspecting Officer.

13.7 GENERAL:

215
All aforesaid tests shall be made prior to dispatch in the presence of representative of the
purchaser. In case of inspection waiver, test results must be sent in quadruplicate for approval. No
material shall be dispatched without prior inspection or approval of test certificate unless other-
wise agreed to in writing by the purchaser.

“At the option of purchaser, the material received in the stores may be utilized in the field
after receipt of successful test report from CTL, Jaipur for the mandatory test checking on the
samples selected from the material received at stores against first lot and subsequent lot(s) in an-
ticipation of successful type test report(s).”

13.9 TEST CHECKING OF MATERIAL AT STORES:

i) Sample drums from the material received at stores shall be selected for testing at
CTL as per sampling plan given hereunder in presence of firm’s representative. The selected sam-
ple drum / drums shall be transported to CTL by concern S.S / ACOS of Nigam.

ii) The selected sample drum for CTL testing shall be identified by the seals provided
by Inspecting Officer / Inspecting Agency during pre-dispatch inspection at firms works and these
sealing details shall be invariably mentioned in the selection Memo by the nominated officers of
Nigam.

iii) The tests in the Nigam Testing laboratory (CTL) shall be conducted in the presence
of representative of supplier for which a 7 days notice shall be issued through Fax / Speed Post
stating Date & Time to the firm, so that supplier can depute their representative to witness the
test . In case the supplier or his representative does not turn up the testing shall be proceeded &
completed. The payment shall be released only after receipt of successful test reports for the
samples selected at purchaser’s stores for mandatory test checking on the samples to be selected
from material received at Nigam’s stores by random sample selection by the authorized commit-
tee as per CE(MM) order No.180 dt.11.4.

iv) SAMPLING:

One number Drum out of each lot / sub-lot of 25 Nos. Drums or part thereof for the material
received in Stores of Nigam.

v) TESTS: The following tests shall be carried out as per relevant clause of latest IS on each
selected drum by drawing sample of 10 Mtr. at CTL from random distance during re-winding:

a) Rewinding test (Measurement of Length) & Checking of manufacturing defects.

216
b) Measurement of Resistance of conductor.
c) Tensile strength & Elongation at Break Test for Insulation & Sheath
d) Test for Thickness of Insulation & Sheath
e) Verification of Marking

vi) CRITERIA FOR ACCEPTANCE:

c) 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 supplier.

e) The results of measurement of length test shall be made applicable to all drums
contained in each lot / sub lot by making deduction of less length of cable in a Sample Drum.

14.0 GUARANTEED & OTHER TECHNICAL PARTICULARS:

14.1 Guaranteed and other technical particulars as called for in Schedule- A) &
Schedule-B) attached to this specification shall be furnished with the tender. Any additional information
considered necessary by the manufacturer with a view of high light the various technical aspects of his
offer may also be supplied on a separate sheet. Technical particulars which are subject to guarantee shall
be clearly marked.

Schedule – (A)

217
GUARANTEED TECHNICAL PARTICULARS FOR UN-ARMOURED NON-FRLS
P.V.C. INSULATED COPPER CONTROL CABLE

Sr. PARTICULARS CABLE SIZE in Sq. mm.

No.
12CX2.5 4CX4
1. Name & Address of manufacturer and trade name,
if any.
2. Nos. and cross section of cores.
3. No. of strands and diameter of each strand per core.
4. Shape and material of conductor.
5. Continuous current carrying capacity under site
conditions indicating the max. allowable conductor
temperature.
6. Thickness and material of core insulation. (in mm)
Nominal
Min.
7. Thickness and material of inner sheath (mm)
8. Diameter over inner sheath (mm)
9. Thickness and Material of outer sheath (mm)
Nominal
Min.
10. Dia. over outer sheath i.e. overall dia. (mm)
11. Min. volume resistivity of PVC Insulation at
27deg.C/70 deg. C.
12. Max. Resistance of conductor per Km of length at
20deg.C.(Ohm/Km)
13. Colour coding of cores.
14. Colour of inner and outer sheaths
15. Test voltages between Conductors and free core(s)
bunched together and earthed.
a) A.C.
b) D.C.
16. Standard length of cable per drum.
17. Min. weight (Kg/Km)
(I) Copper
(II) PVC

218
(III) Finished Cable
18. Net weight per drum length(approx.)
19. Gross weight per drum (approx.)
20. Current rating factors based on Variation in
a) Ambient air temperature.
b) Groups laid in air (Side by side).
c) Groups laid in ducts (Side by side).
21. Standards applicable.
22. Whether cable bears carry ISI Certification
Mark or not.
23. BIS license No. & its validity
24. Embossing on cable on every one meter spacing
(Yes/No):
a) JVVNL
b) Manufacturer’s name or Trade mark.
c) ISI certification mark.
d) Year of manufacture/TN-
e) Type and voltage grade
f) Cable size.
25. Marking Particulars On Drum.
26. a) Name of manufacturer/trade mark.
27. b) Cable size
28. c) Drum No.
29. d) Gross weight of drum
30. e) Tare weight
31. f) Length of cable
32. g) Direction of rotation
33. h) ISI certification
34. i) Year of manufacturing

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF DRUM FOR SUPPLY OF

UN-ARMOURED NON-FRLS P.V.C. INSULATED COPPER CONTROL CABLE

S.
PARTICULARS
No.
CABLE SIZE in Sq. mm.

219
12CX2.5 4CX2.5 4CX4 4CX2.5
A Drum Size
B Flange Diameter(d1) (mm)
C Barrel Diameter(d2) (mm) AS PER IS:10418/1982 WITH LATEST AMENDMENTS
D Centre hole Diameter(d3) (mm)
E Overall width (L1) (mm)
F Traverse (L2) (mm)
G Thickness of Flange

H Barrel End (supporting disc

or core segment)
a) Diameter (mm)
b) Thickness (mm)

I Stretchers( Core Carrier Planks)

a) Number (Min)
b) Thickness x width (mm)

J Barrel Battens thickness

(Core Filler Planks)

K Barrel Middle Supports

(Middle Core discs)

Thickness of External
L Laggings.(mm)

DETAILS OF METAL
COMPONENTS:
Clamping Studs with Hexagonal
M Nuts

a) Numbers
b) Diameter (mm)

220
N Square or Round Washers
a) Numbers
b) Diameter (mm)

O M.S. Bushes
a) Numbers
b) Thickness of Sleeve (mm)
c) Dimension of Sleeve (mm)
d) Number of Bolts
e) Diameter of Bolts

P M.S./ C.I. Centre Plate

a) Numbers
b) Dimensions of Square/
Triangular equal sides (mm)
c) Centre Plate Bolts.
Q Numbers
i) Diameter of bolts (mm)
ii) Centre Hole Diameter (mm)

221
Schedule –(A)
GUARANTEED TECHNICAL PARTICULARS FOR UN-ARMOURED NON-FRLS
P.V.C. INSULATED COPPER CONTROL CABLE

Sr. PARTICULARS CABLE SIZE in Sq. mm.

No.
12CX2.5 4CX4
35. Name & Address of manufacturer and trade name,
if any.
36. Nos. and cross section of cores.
37. No. of strands and diameter of each strand per core.
38. Shape and material of conductor.
39. Continuous current carrying capacity under site
conditions indicating the max. allowable conductor
temperature.
40. Thickness and material of core insulation. (in mm)
Nominal
Min.
41. Thickness and material of inner sheath (mm)
42. Diameter over inner sheath (mm)
43. Thickness and Material of outer sheath (mm)
Nominal
Min.
44. Dia. over outer sheath i.e. overall dia. (mm)
45. Min. volume resistivity of PVC Insulation at
27deg.C/70 deg. C.
46. Max. Resistance of conductor per Km of length at
20deg.C.(Ohm/Km)
47. Colour coding of cores.
48. Colour of inner and outer sheaths
49. Test voltages between Conductors and free core(s)
bunched together and earthed.
a) A.C.
b) D.C.
50. Standard length of cable per drum.
51. Min. weight (Kg/Km)
(I) Copper
222
(II) PVC
(III) Finished Cable
52. Net weight per drum length(approx.)
53. Gross weight per drum (approx.)
54. Current rating factors based on Variation in
a) Ambient air temperature.
b) Groups laid in air (Side by side).
c) Groups laid in ducts (Side by side).
55. Standards applicable.
56. Whether cable bears carry ISI Certification
Mark or not.
57. BIS license No. & its validity
58. Embossing on cable on every one meter spacing
(Yes/No):
a) JVVNL
b) Manufacturer’s name or Trade mark.
c) ISI certification mark.
d) Year of manufacture/TN-
e) Type and voltage grade
f) Cable size.
59. Marking Particulars On Drum.
60. a) Name of manufacturer/trade mark.
61. b) Cable size
62. c) Drum No.
63. d) Gross weight of drum
64. e) Tare weight
65. f) Length of cable
66. g) Direction of rotation
67. h) ISI certification
68. i) Year of manufacturing

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF DRUM FOR SUPPLY OF

UN-ARMOURED NON-FRLS P.V.C. INSULATED COPPER CONTROL CABLE

PARTICULARS CABLE SIZE in Sq. mm.

223
S.
No.
12CX2.5 4CX4
A Drum Size
B Flange Diameter(d1) (mm)
C Barrel Diameter(d2) (mm) AS PER IS:10418/1982 WITH LATEST AMENDMENTS
D Centre hole Diameter(d3) (mm)
E Overall width (L1) (mm)
F Traverse (L2) (mm)
G Thickness of Flange

H Barrel End (supporting disc

or core segment)
a) Diameter (mm)
b) Thickness (mm)

I Stretchers( Core Carrier Planks)

a) Number (Min)
b) Thickness x width (mm)

J Barrel Battens thickness

(Core Filler Planks)

K Barrel Middle Supports

(Middle Core discs)

Thickness of External
L Laggings.(mm)

DETAILS OF METAL
COMPONENTS:
Clamping Studs with Hexagonal
M Nuts

a) Numbers

224
b) Diameter (mm)

N Square or Round Washers

a) Numbers
b) Diameter (mm)

O M.S. Bushes
a) Numbers
b) Thickness of Sleeve (mm)
c) Dimension of Sleeve (mm)
d) Number of Bolts
e) Diameter of Bolts

P M.S./ C.I. Centre Plate

a) Numbers
b) Dimensions of Square/
Triangular equal sides (mm)
c) Centre Plate Bolts.
Q Numbers

i) Diameter of bolts (mm)

ii) Centre Hole Diameter (mm)

225
Schedule –(A)
GUARANTEED TECHNICAL PARTICULARS FOR UN-ARMOURED NON-FRLS
P.V.C. INSULATED COPPER CONTROL CABLE

Sr. PARTICULARS CABLE SIZE in Sq. mm.

No.
12CX2.5 4CX4
69. Name & Address of manufacturer and trade name,
if any.
70. Nos. and cross section of cores.
71. No. of strands and diameter of each strand per core.
72. Shape and material of conductor.
73. Continuous current carrying capacity under site
conditions indicating the max. allowable conductor
temperature.
74. Thickness and material of core insulation. (in mm)
Nominal
Min.
75. Thickness and material of inner sheath (mm)
76. Diameter over inner sheath (mm)
77. Thickness and Material of outer sheath (mm)
Nominal
Min.
78. Dia. over outer sheath i.e. overall dia. (mm)
79. Min. volume resistivity of PVC Insulation at
27deg.C/70 deg. C.
80. Max. Resistance of conductor per Km of length at
20deg.C.(Ohm/Km)
81. Colour coding of cores.
82. Colour of inner and outer sheaths
83. Test voltages between Conductors and free core(s)
bunched together and earthed.
a) A.C.
b) D.C.
84. Standard length of cable per drum.
85. Min. weight (Kg/Km)
(I) Copper

226
(II) PVC
(III) Finished Cable
86. Net weight per drum length(approx.)
87. Gross weight per drum (approx.)
88. Current rating factors based on Variation in
a) Ambient air temperature.
b) Groups laid in air (Side by side).
c) Groups laid in ducts (Side by side).
89. Standards applicable.
90. Whether cable bears carry ISI Certification
Mark or not.
91. BIS license No. & its validity
92. Embossing on cable on every one meter spacing
(Yes/No):
a) JVVNL
b) Manufacturer’s name or Trade mark.
c) ISI certification mark.
d) Year of manufacture/TN-
e) Type and voltage grade
f) Cable size.
93. Marking Particulars On Drum.
94. a) Name of manufacturer/trade mark.
95. b) Cable size
96. c) Drum No.
97. d) Gross weight of drum
98. e) Tare weight
99. f) Length of cable
100. g) Direction of rotation
101. h) ISI certification
102. i) Year of manufacturing

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF DRUM FOR SUPPLY OF

UN-ARMOURED NON-FRLS P.V.C. INSULATED COPPER CONTROL CABLE

PARTICULARS CABLE SIZE in Sq. mm.

227
S.
No.
12CX2.5 4CX4
A Drum Size
B Flange Diameter(d1) (mm)
C Barrel Diameter(d2) (mm) AS PER IS:10418/1982 WITH LATEST AMENDMENTS
D Centre hole Diameter(d3) (mm)
E Overall width (L1) (mm)
F Traverse (L2) (mm)
G Thickness of Flange

H Barrel End (supporting disc

or core segment)
a) Diameter (mm)
b) Thickness (mm)

I Stretchers( Core Carrier Planks)

a) Number (Min)
b) Thickness x width (mm)

J Barrel Battens thickness

(Core Filler Planks)

K Barrel Middle Supports

(Middle Core discs)

Thickness of External
L Laggings.(mm)

DETAILS OF METAL
COMPONENTS:
Clamping Studs with Hexagonal
M Nuts

a) Numbers
b) Diameter (mm)

228
N Square or Round Washers
a) Numbers
b) Diameter (mm)

O M.S. Bushes
a) Numbers
b) Thickness of Sleeve (mm)
c) Dimension of Sleeve (mm)
d) Number of Bolts
e) Diameter of Bolts

P M.S./ C.I. Centre Plate

a) Numbers
b) Dimensions of Square/
Triangular equal sides (mm)
c) Centre Plate Bolts.
Q Numbers
i) Diameter of bolts (mm)
ii) Centre Hole Diameter (mm)

229
TECHNICAL SPECIFICATION AND SCHEDULE OF REQUIREMENT FOR SUPPLY
OF 11 KV CROSS-LINKED POLYETHYLENE (XLPE) INSULATED POWER CABLES
(11 KV, 3CX185 Sq.mm, HT Power Cable)

1. SCOPE:

1.1 This section provides for manufacture, testing before dispatch, supply and delivery
F.O.R. destination of ISI Marked 11 KV Aluminium conductor Screened, Cross linked Polyeth-
ylene (XLPE) Insulated Armoured Shielded PVC Sheathed cable of rated voltage 11 KV (earthed
system) conforming to IS:7098 (Part-II/1985) with latest amendment. The requirement of 11 KV
Power XLPE Cables shall be as per schedule of requirement Annexed with this section at Sched-
ule-I. It may be noted that the requirement indicated in the scheduleis tentative & may vary at the
time of placement of order.

The 11 KV Aluminium Conductor, Screened CROSS-LINKED POLYETHEYLENE

(XLPE) INSULATED Armoured Shielded PVC Sheathed Power cable shall be ISI marked. The
manufacturer should be a manufacturer of tendered item. The offers from Sole Selling Agents /
Authorized Dealers shall not be entertained.

a) The Manufacture shall manufacture the 33 KV Power cable with CCV Line Process
only and offer from other type of manufacturing process (Syoplas) shall not be consid-
ered.

b) The 11 KV Power cable may be manufactures either CCV Line or Syoplas Process

The manufacturer must possess valid ISI License for the bid item. The technical bid of the
manufacturer shall be considered for opening in the absence of non-furnishing of above required
ISI License along with the bid. However, Price bid of the responsive manufacturer shall only be
opened if manufacturer furnishes above valid BIS Liscence up to the official working hours of
one working day prior to the schedule / notified date of opening of price bid” along with under-
taking that BIS License so furnished is valid till date and same has not been withdrawn/cancelled
by Bureau of Indian Standard. Similar undertaking of validity of BIS l License be also furnished
by the manufacturer who furnishes BIS License along with Technical Bid. The firm must possess
ISO-9001 or above certification.

2. STANDARDS:
Unless otherwise stipulated in this specification the following standards with latest
amendments shall be applicable. Any departure from the Standards be indicated in Schedule-III.
i) IS:7098(Part-II) : Cross linked Polyethylene
Insulated PVC sheathed cable
for voltage from 3.3 KV upto &
Including 33 KV.
ii) IS:8130 : Conductors for insulated Cables.
230
iii) IS:5831 : PVC insulation and sheath of
Electric cables.

iv) IS:3975 : Mild steel wires, strips and

tapes for armouring cables.
v) IS:10810 : Methods of test for cables.

iv) IS:10418 : Drums for Electric Cables

3. CLIMATIC CONDITIONS:

i) Peak ambient temperature 50 deg.C

in shade.

ii) Maximum average ambient 40 deg.C

temperature in a 24 hours period
in shade.

iii) Min. ambient air temperature in shade (-) 5 deg.C

iv) Maximum temperature attainable 60 deg.C

by an object exposed to sun.

v) Maximum relative humidity. 100%

vi) Average number of thunder 40

storm days per annum.

vii) Average number of rainy days 100

per annum.

viii) Average annual rainfall 10 to 100 cm

ix) Number of months of tropical 4 months

231
Monsoon conditions.

x) Maximum wind pressure. 100 kg/ sq. mm.

xi) Altitude not exceeding 1000 M

4. GENERAL REQUIREMENT:

4.1 The 11 KV power cable shall be ISI Marked Aluminium conductor screened cross
linked polyethylene insulated armoured shielded and over all PVC sheathed. The 11 KV XLPE
Cable shall conform to IS: 7098 (Part-II)/1985 with latest amendments shall bear ISI Certification
mark. The cable shall be capable of withstanding the normal stresses associated withtransportation,
erection, reeling and unreeling operations without getting deformed.

4.2 The 11 KV XLPE Cable shall be suitable for the following conditions of laying:

i) Laid directly in ground.

ii) Installed outdoor in free air in vertical position.
iii) Drawn into underground ducts.

4.3 The 11 KV XLPE Power Cable shall be suitable for use where combination of ambi-
ent temperature and temperature rise due to load results in conductor temperature not
exceeding 90 degree C. under normal operation and 250 degree C under short circuit conditions.

4.4 The cable shall be used on 11 KV earthed system. The cables shall be suitable for
continuous operation at a power frequency voltage 10% higher than rated voltage.

5.0 MATERIAL:

5.1 CONDUCTOR: The conductor shall be composed of aluminium wires complying

with the requirement of Class-2 of IS: 8130/1984 with latest amendments .

The manufacturer must guaranteed the minimum weight of Aluminium in Kg/Km

corresponding to nominal cross sectional area of conductor as mentioned in the G.T.P.

5.2 INSULATION:

232
The insulation shall be cross linked polyethylene conforming to the requirement
given in Table-1 of IS:7098(Part-II)/1985 with latest amendments .

5.3 SCREENING:

The screening shall consist of one or more of the following:

i) Non-Metallic semi conducting tape.

ii) Non-Metallic semi conducting compound and
iii) Non-Magnetic Metallic tape wire, strip or sheath.

5.4 FILLERS AND INNER SHEATH:

5.4.1 The filler and inner sheath shall be of the following:

a) Vulcanized or Un-vulcanized rubber or

b) Thermoplastic material.

5.4.2 Vulcanized or Un vulcanized rubber or Thermoplastic material used for inner

sheath shall not be harder than XLPE and PVC used for insulation and outer sheath respectively.
The filler and inner sheath material shall be chosen to be compatible with the temperature rating
of the cable and shall have no deleterious effect on any other components of the cable.

5.4.3 The Central hole / void, if any, of the cable shall be invariably filled with suitable
filler material so that there is no gap in the center.

5.5 ARMOURING:

5.5.1 The Armouring shall be of Galvanized Steel Strip.

5.5.2. Galvanized steel strips shall comply with the requirements of IS:3975/1979 with
latest amendments.

5.6 OUTER SHEATH:

233
5.6.1 The outer sheath shall be of Poly Vinyl Chloride (PVC) compound conforming to the
requirement of type ST-2 of IS:5831/1984 with latest amendments .

6. CONSTRUCTION:

6.1 CONDUCTOR:

The Conductor shall be of stranded construction complying with Class-2 of

IS:8130/1984 with latest amendments.The aluminium shall be reasonably uniform in size and
shape and its surface be free from any sharp edges.

6.2 CONDUCTOR SCREENING:

The conductor screening shall be provided over the conductor by applying non- me-
tallic semi conducing tape or by extrusion of semi conducting compound or a combination of the
two.

6.3 INSULATION:

The Conductor (with screen) shall be provided with cross linked polyethylene (XLPE)
insulation applied by extrusion. The insulation shall be so applied that it fits closely on the con-
ductor (or conductor screening) and it shall be possible to remove it without damaging the con-
ductor. The thickness of insulation and tolerance of thickness of insulation shall be as per Clause
No.11 of IS:7098 (Part-II)/1985 with latest amendments .

6.4 INSULATION SCREENING:

6.4.1 The insulation screening shall consist of two parts namely metallic and non-metallic.

6.4.2 Non-metallic part shall be applied directly over the insulation of each core and shall
consist of either a semi conducting tape or extruded semi conducting or a combination of
the two or either material with a semi conducting coating.

6.4.3 Metallic part shall consist of either tape or braid or concentric serving of wires or a
sheath should be non-magnetic and shall be applied over the non metallic part.

6.5 CORE IDENTIFICATION:

234
The core identification shall be done as per Clause-13 of IS:7098 (Part-II)/ 1985 with
latest amendments .

6.6 LAYING UP OF CORES:

The Cores (with screening) shall be laid together with a suitable right hand lay.
Wherever, necessary the interstices shall be filled with non-hygroscopic material.

6.7 INNER SHEATH (COMMON COVERING):

The laid up core shall be provided with inner sheath applied either by extrusion or by
wrapping. However, application of inner sheath by EXTRUSION shall be preferred. It shall be
ensured that the shape is as circular as possible. 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.
The thickness of inner sheath shall be as per Clause No.15.3 of IS: 7098 (Part-II)/ 1985(with latest
amendments)

6.8 ARMOURING:

The armouring shall be applied over the inner sheath. The Galvanized SteelArmoured
strips shall be applied as closely as possible with a coverage of not less than 90%.

. The direction of lay of the Armour shall be left hand. A binder tape may be applied on the ar-
mouring. The dimensions of the galvanized steel strips shall be as specified in Table-4 of IS:7098
(Part-II)/1985 with latest amendments . The joints in Armour strips if any shall be made by
brazing or welding and the surface irregularities shall be removed. A joint in any strip shall be
at least 300 mm. from the nearest joint in any other armour strips in the completed cable.

6.9 OUTER SHEATH:

6.9.1 The outer sheath shall be applied by extrusion over the armouring. The colour of
outer sheath shall be black.

6.9.2 The thickness of the outer sheath shall be as per Clause No.17.3 of IS: 7098 (Part-
II)/1985 with latest amendments.

7. TYPE TESTS:

235
7.1 The material offered, shall be fully type tested as per relevant standard of specifi-
cation of IS:7098 (Part-II/1985) amended up to date. The following shall constitute type tests:

a) Tests of Conductor:

i) Annealing test (for copper)

ii) Tensile test (for aluminium)
iii)Wrapping test (for aluminium)
iv)Conductor Resistance test

b) Tests for armouring wires/strips.

c) Tests for thickness of insulation and sheath.
d) Physical tests for insulation:
i) Tensile strength and elongation at break.
ii) Ageing in air oven.
iii) Hot test.
iv) Shrinkage test.
v) Water absorption (gravimetric).

e) Physical test for outer sheath:

i) Tensile strength and elongation at break.
ii) Ageing in air oven.
iii) Shrinkage test.
iv) Hot deformation,

f) Partial discharge test.

g) Bending test.

h) Dielectric power factor test:

i) As a function of voltage.
ii) As a function of temperature.

i) Insulation resistance (volume resistivity test).

236
j) Heating cycle test.

k) Impulse withstand test.

l) High voltage test.

m) Flammability test.

7.2 However, the purchaser reserves the right to demand repetition of same or
all the type tests in presence of purchaser’s representative.

7.3 The manufacturer must also clearly indicate various testing facilities available at
their works for testing the material as per relevant standards. In case of otherwise particulars
of the place where such testing is proposed to be conducted during the course of inspection shall
be indicated with the offer.

8. INSPECTION (TEST BEFORE DISPATCH):

8.1 The inspection may be carried out by the purchaser at any stage of manufacturer. The
Inspection & Testing shall be governed by Clause No. 1.27 of Section-II (General Conditions Of
Contract). Acceptance of any equipment / material under this specification by the purchaser
shall not relieve the supplier of his obligation of furnishing equipment in accordance with the
specification and shall not prevent subsequent rejection if the equipment/material is found to be
defective. The following Acceptance tests as per Clause No.18.2 of IS:7098(Part-II)/1985 with
latest amendments shall be conducted in presence of the purchaser's authorized representative
/ agency on each lot of offered cables:

i) Tensile Test.
ii) Wrapping Test.
iii) Conductor Resistance Test.
iv) Test for thickness of insulation & sheath.
v) Hot Set Test for insulation.
vi) Tensile strength & elongation at break test for insulation and sheath.
vii) Partial Discharge Test (for screened cables only).
viii) High voltage test and
x) Insulation resistance (Volume resistivity) Test.
xi) Test for Armour:
a) Verification of Dimension of Strip.
b) Tensile Strength & elongation at break.

237
c) Uniformity of Zinc Coating.
d) Weight of Zinc Coating.
e) Winding Test on Armour.
f)Resistivity Test on Armour.

Cold impact test for outer sheath (IS:5831/1984) with latest amendments shall con-
stitute the optional test and shall be conducted on first lot of the offered cables of each sizeas per
Clause No.18.4 of IS:7098(Part-II)/1985 with latest amendments .

8.2 ROUTINE TEST:-

The following shall constitute routine tests:

a)Conductor resistance test
b) Partial discharge test
c) High voltage test.

8.3 The manufacturer shall furnish Packing list mentioning serial Nos. of Drums, length
in each drum, gross weight of drum without lagging alongwith inspection offer duly signed by the
authorized representative of the firm. The purchaser reserves the rights to insist for witnessing the
acceptance / routine tests of the bought out items.

8.4 At least 5% of total numbers of drums subject to minimum of two (2) in the lot put
up for inspection shall be selected at random to ascertain the length of cable by the following
method.

“At the works of manufacturer of the cable shall be transferred from one drum to another
for checking any manufacturing defects in the cable, at the same time measuring its length with
the help of the graduated pulley and cyclometer. The difference in average
length thus obtained from the declared length by the supplier in the packing list shall be applied
to all the drums if the cable is found short during checking the sample lot (s).”

8.5 The supplier 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/
meters/ apparatus etc. should be got calibrated by the supplier from time to time from Govt. La-
boratory or any independent test laboratory/house having valid accreditation from National Ac-
creditation Board for Testing and Calibrating Laboratories for the testing equipments / original
manufacturer having trace ability to NABL/NPL or equivalent.

8.6 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
238
instruments/ equipments should be duly sealed by the Calibrating Agency and mention thereof
shall be indicated in the calibration certificate(s).
“ At the option of purchaser, the material received in the stores may be utilized in the field after
receipt of successful test report from CTL, Jaipur for the mandatory test checking on the samples
selected from the material received at stores against first lot and subsequent lot(s) in anticipation
of successful type test report(s).”

8.8 TEST CHECKING OF MATERIAL AT STORES:

i) Sample drums from the material received at stores shall be selected for testing at CTL as
per sampling plan given hereunder in presence of firm’s representative. The selected sample
drum / drums shall be transported to CTL by concern S.S / ACOS of Nigam.

a) The tests in the Nigam Testing laboratory (CTL) shall be conducted in the presence of rep-
resentative of supplier for which a 3 days notice shall be issued through Fax / Speed Post
stating Date & Time to the firm, so that supplier can depute their representative to witness the
test . In case the supplier or his representative does not turn up the testing shall be proceeded
& completed. The payment shall be released only after receipt of successful test reports for
the samples selected at purchaser’s stores for mandatory test checking on the samples to be
selected from material received at Nigam’s stores by random sample selection by the author-
ized committee as per CE(MM) order No.180 dt.11.4.14

b) SAMPLING:

One number Drum out of each lot / sub-lot of 25 Nos. Drums or part thereof for the material
received in Stores of Nigam.

c) TESTS: The following tests shall be carried out as per relevant clause of latest IS on each
selected drum by drawing sample of 10 Mtr. at CTL from random distance during re-winding:
a) Rewinding test (Measurement of Length) & Checking of Manufacturing defects.
b)Measurement of Resistance of conductor.
c) Tensile strength & Elongation at Break Test for Insulation & Sheath
d) Test for Thickness of Insulation & Sheath
e) Hot Set Test.

f) Test for Armour:

i) Verification of Dimension of Wire / Strip.
239
ii) Tensile Strength & elongation at break.
iii)Uniformity of Zinc Coating.
iv) Weight of Zinc Coating.
v) Winding Test on Armour.
vi)Resistivity Test on Armour.
vii) Verification of Marking

viii) CRITERIA FOR ACCEPTANCE:

a) If the measured of 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 have to be
replaced by the supplier.
b) 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 contained in the lot / sub-lot to which the sample belongs shall be
accepted with a deduction @ 1.5% of the cost of cable for increase in resistance for every 1% or
part thereof.
a) If the sample(s) fails in any other test, the material shall be rejected and shall have
to be replaced by the supplier.
b) If the contractor / supplier fails to lift the material declared rejected or any part
thereof from the consignee within a period of 15 days from the date of dispatch of information
from the purchaser, the purchaser shall be entitled to effect recovery along with other actions as
per Clause No. 1.62 of Section-II (General Condition of Contract).
c) The results of measurement of length test shall be made applicable to all drums
contained in each lot / sub lot by making deduction of less length of cable in a Sample Drum.

8.9 TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores
shall be borne by the NIGAM.

9. IDENTIFICATION:

9.1 The manufacturer shall be identified throughout the length of cable as per Clause
No.20.1 of IS:7098(Part-II)/ 1985 with latest amendments .

240
9.2 The cable code employed shall be as per Clause No.20.3 of IS:7098 (Part-II) /1985
with latest amendments .

9.3 EMBOSSING:

The cable shall also be required to be embossed with the word `Name of manufacturer or
Trade name, ELECTRIC/ Voltage Grade/ NAME OF DISCOM/ TN- cable code, size of cable &
year of manufacture at every meter length for which no extra charges shall be paid. The cable
should be ISI marked & same should be embossed on the outer sheet of every meter length of HT
Cable.

10. MARKING:
The progressive length of cable in meter shall be marked on the outer sheath of every
meter length of HT Cable.

11. PACKING AND MARKING:

11.1 The cable shall be wound on a wooden drum conforming to IS: 10418/1982 of suit-
able size. The ends of cables shall be sealed by means of non-hygroscopic material. Only
one cable length shall be supplied on a drum. The cable can also be supplied on M-Steel
Drums as per relevant ISS as applicable.

11.2 The cable drums shall carry the following information either stenciled or painted.
i) Manufacturer's name, Brand or trade mark.
ii) Type of cable and voltage grade.
iii) Number of cores.
iv) Nominal cross-sectional area of the Conductor.
v) Cable Code.
vi) Length of cable on the drum.
vii) Direction of rotation of drum (by means of an arrow).
viii) Gross mass.
ix) Year of manufacture.
x) ISI Certification mark.
xi) TN No. / JVVNL / RDSS
xii) Name of Consignee.

241
12. STANDARD LENGTH: The cable shall be supplied in standard length of 250 Mtrs with
wooden drum/steel drum in one Drum for size 11 KV, 3CX185 Sq.mm , and 500 Mtrs
with steel drum in one Drum for 3Cx120 Sq.mm .

12.1 A tolerance of (+/-) 5% shall be allowed on standard length.

13. GUARANTEED TECHNICAL PARTICULARS :

The manufacturer shall furnish guaranteed technical particulars.

GTP-11KV.XLS SCHEDUL-A

GUARANTEED TECHNICAL AND OTHER PARTICULARS FOR THE SUPPLY OF THREE CORE
11 KV XLPE CABLES.

S.No. PARTICULARS UNIT 11 KV

3CX185
1 Manufacturer's name and works address -

2 Manufacturing process ( Please specify any

one of following):
a) CCV Line Process ( Dry Curing)
b) Syoplas Process

3 Standard specification to which the material

shall conform. - ----IS:7098(part-2)/1985-----

4 Type of cable and voltage grade. - ---------Type - A2XFY------

6.35/11 KV
5 Power frequency withstand voltage KVrms. To be furnished by the manufacturer.

Permissible voltage & frequency variation

6 for To be furnished by the manufacturer.
satisfactory operation.

242
i) Voltage %
ii) Frequency %
iii) Combind voltage & frequency %

7 Conductor details :
a) Aluminium grade. - H2/H4 grade, Class-2 conforming to
IS:8130/1984 or latest version thereof.
b) Nominal cross sectional area
(guaranteed). Sq.mm 185 120
c) Shape of the stranded conductor. - -----------Compact Stranded-------------
30 15

d)Number of strands in each conductor(Min) Nos.

Sr.
No. PARTICULARS UNITS 3Cx185 3Cx120
e) Nominal diameter of each inlet wirebe-
fore stranding mm To be furnished by the manufacturer.
f) Maximum permissible resistance of Ohms/
Conductor at 20 Deg. C. Km. 0.164 0.253

8 Diameter over laid-up cores mm To be furnished by the manufacturer.

9 Conductor screening : To be furnished by the manufacturer.
a) Type and material. -
b) Continous working temp. Deg.C
c) Max. allowable temp. at termination of
Short Circuit Deg.C

10 Insulation :
-
a) Material Cross-Linked Polyethylene
conforming to IS:7098(Pt.2) latest
version.
b) Nominal thickness of insulation mm 3.6 3.6
c)Minimum thickness of insulation. mm 3.14 3.14

243
d) Approx. diameter of core over insulation. mm To be furnished by the manufacturer.

11 Insulation screening : To be furnished by the manufacturer.

a) Material. -
b) i) Approx. thickness of semi-conducting
part. mm
ii) Thickness of metallic part. mm
c) Approx. diameter of cable over screening. mm
12 Wheteher Binder Tape provided To be furnished by the manufacturer.

13 Inner sheath :
a) Material - ----IS:7098(part-2)/1985-----.
b) Process of application - To be furnished by the manufacturer
As per Table 3 of IS - 7098 Part-2/
c) Min. thickness of inner sheath.
Mm 1985 with latest amendment
d) Diameter of cable over inner sheath
mm To be furnished by the manufacturer

Sr.
No. PARTICULARS UNITS 3Cx185
14 Type of filler used To be furnished by the manufacturer
a) Material
b) Shape and size mm
c) Central filler (shape & size) mm

15 Armouring :
a) Material and type of armouring - Galvanized Steel Strip
b) Nominal dimensions of Armour mm 4.0 X0.8 mm
c) Whether galvanised. - Galvanized

244
d) Lay Ratio of Armouring
i) Minimum
ii) Maximum
e) Total Number of Armour Strips Nos. To be furnished by the manufacturer.
f) %age Covering with Armour Strip
g) Diameter of cable over armouring mm To be furnished by the manufacturer.
16 Outer sheath :

PVC Type ST-2 conforming to IS:58

a) Material - latest version
As per Table-5 of IS:7098(Pt.2)/1985 wi
b) Nominal thickness of outer sheath. mm latest amendments
c) Colour of sheath. ------------------Black-----------------
17 Approx. over all diameter of cable. mm To be furnished by the manufacturer.
18 a) Minimum weight of Aluminium in
Kg./Km. corresponding Kg/Km 1500 973
to nominal cross sectional area of
conductor.(guaran-
teed)
b) Total weight armouring Kg/ Km. Kg/Km To be furnished by the manufacturer

Kg/Km
c) Total weight of PVC contents Kg/ Km.
(Inner / Outer Sheath / Filler)
Kg/Km To be furnished by the manufacturer.
d) Total weight of XLPE including weight of
Conductor Screening and Insulation Screen-
ing

Sr.
No. PARTICULARS UNITS 3Cx185
e) Total weight of insulation screening
Kg./Km. (Mettalic) sTo be furnished by the manufacturer.
f) Total weight of finished cable Kg/Km. Kg/Km To be furnished by the manufacturer.
19 i) Standard length of cable. Mtrs 250 500
ii) Tolerance on standard length. -------------(+/-) 5% ------------------

245
20 No. of length(s) of cable on each drum. Mtrs ------------------One-------------------

Approx. gross mass of each drum including

21 cable. Kg To be furnished by the manufacturer.
22 i) Drum Size(as per IS:10418/1982) To be furnished by the manufacturer.
To be furnished in the enclosed Schedul
ii)Details of Drums V(B)
iii)Approx. net weight of each empty drum. Kg To be furnished by the manufacturer.
Max. continous AC current carrying
23 capacity : To be furnished by the manufacturer.
a) When laid directly in ground. Amps
b) When laid in covered trenches. Amps
c) When laid vertically in air. Amps
24 Recommended length of laying. cm To be furnished by the manufacturer.

Short circuit current carrying capacity and

25 duration of short circuit. KA-Sec To be furnished by the manufacturer.

26
Allowable/attainable max. conductor temp.
when carrying continous rated current. Deg.C ------------------90--------------------

Allowable/attainable max. conductor temp.

27 at the termination of short circuit current
Deg.C 250
28 Voltage drop per 1000 meters length of cable
at rated current :

a) When laid directly in ground To be furnished by the manufacturer.

Sr.
No. PARTICULARS UNITS 3Cx185
b) When laid in covered trenches. Volts
c) When laid vertically in air. Volts
29 Max. conductor temp.

246
a) When laid directly in ground. Deg.C
90

247
b) When laid in covered trenches. Deg.C ------------------90--------------------
c) When laid vertically in air. Deg.C ------------------90--------------------

As per IS - 7098 Part-2 / 1985 with lates

30 Impulse strength KV amendment

31 a) DC resistance of each conductor at 20 Ohms/K As per IS - 7098 Part-2 / 1985 with lates
Deg.C (Max.) M amendment
b) AC resistance of each conductor at 90 Ohms/K
Deg.C. (Max.) M To be furnished by the manufacturer.
Ohms/K
c) Approx. reactance of each conductor M To be furnished by the manufacturer.
Micro-F
d) Approx. capacitance of each conductor KM To be furnished by the manufacturer.
e) Insulation resistance (Min.) To be furnished by the manufacturer.
Ohm-
i) At 27 deg.cent. Cm
ii) At 90 deg.cent.
f) Loss tangent To be furnished by the manufacturer.
i) As a function of voltage
ii) As a function of temperature.

g)Dielectric constant.
- To be furnished by the manufacturer.

Charging current at normal operating Amps/K

32 voltage. M To be furnished by the manufacturer.
33 Derating factors: To be furnished by the manufacturer.
Furnish charts showing derating factors for:
i) Variation in ambient temp. from 30
DEG.C. upto 70 DEG.C. in steps of 5
DEG.C.

ii) Variation in ground temp. from 25

DEG.C. upto 60 DEG.C. in steps of 5 DEG.C

248
Sr.
No. PARTICULARS UNITS 3Cx185
iii) Different specing of cables in horizontal
single row formation for 3 Core Cables under
the following conductions of laying:
a) Cables laid on cable trays in concreteca-
ble trenches with removable covers
b) Cables laid on cable trays in air.
c) Cables laid in ground.
d) Cables laid in pipes or ducts.
e) Variation in depth of laying for cables laid
direct in ground
f) Variation in Thermal resistivity of soil for
cables laid in ground
34 Quantity Tolerance -----------------(+/-) 2%----------------

35 Recommended min. bending radius. To be furnished by the manufacturer.

36 Embossing As per specification TN-

37 BIS licence no. & validity To be furnished by the manufacturer.

38 ISO:9001 certification

39 Any other particulars To be furnished by the manufacturer.

NOTE : SPECIFIC VALUES MAY BE INDICATED IN ABOVE SCHEDULE. USE OF `DO OR AS PER
"IS" IS TO BE AVOIDED.

SCHEDULE-B

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF DRUM FOR SUPPLY OF

249
THREE CORE HT XLPE INSULATED PVC SHEATHED ARMOURED POWER CABLES

S. 3 CORE 185, sq.mm HT XLPE INSULATED PVC

PARTICULARS
No. SHEATHED ARMOURED POWER CABLES
3CX185
A Drum Size
B Flange Diameter(d1) (mm)
C Barrel Diameter(d2) (mm)
D Centre hole Diameter(d3) (mm)
E Overall width (L1) (mm)
F Traverse (L2) (mm)
G Thickness of Flange
H Barrel End (supporting disc
or core segment)
a) Diameter (mm)
b) Thickness (mm)
I Stretchers( Core Carrier Planks)
a) Number (Min)
AS PER IS:10418/1982 WITH LATEST
AMENDMENTS
b) Thickness x width (mm)

J Barrel Battens thickness

(Core Filler Planks)
K Barrel Middle Supports

(Middle Core discs)

L Thickness of External Laggings.(mm)

DETAILS OF METAL COMPONENTS:

M Clamping Studs with Hexagonal Nuts
a) Numbers
b) Diameter (mm)
N Square or Round Washers

250
a) Numbers

251
b) Diameter (mm)
O M.S. Bushes
a) Numbers
b) Thickness of Sleeve (mm)
c) Dimension of Sleeve (mm)
d) Number of Bolts
e) Diameter of Bolts

P M.S./ C.I. Centre Plate

a) Numbers
b) Dimensions of Square/
Triangular equal sides (mm)
c) Centre Plate Bolts.
Q Numbers
i) Diameter of bolts (mm)
ii) Centre Hole Diameter (mm)

252
TECHNICAL SPECIFICATION FOR SUPPLY OF SHEET METAL TYPE 200 AMP. LT
DISTRIBUTION KIOSK SUITABLE FOR 63/100 KVA DISTRIBUTION TRANSFORM-
ERS RESPECTIVELY

1. INTRODUCTION: This section describes the objective and scope of work for design,
manufactured, testing and supply of LT Distribution kiosk with all accessories.

2. OBJECTIVE: The objective is to develop an efficient and accidental free distribution

system in the jurisdiction area of Jaipur Vidyut Vitran Nigam Ltd.

3. APPLICABLE STANDARDS:

a. IS :13947/1993 (Part 3)/IEC:60947 (Pt.3) for Isolator (Switch Disconnector)

b. IS: 13947/1993 (Part2)/ IEC:60947 (Pt.2) (amended upto date) for L.T. MCCBs.
c. IS: 8623/1993 (amended upto date) for enclosure Box & for degree of protection
provided by enclosures of electrical equipments.
d. IS:4237/1982, IS:8623/1993 (amended upto date) – for general requirement of L.T.
Switchgear

4. MANUFACTURE/CONSTRUCTION OF LT DISTRIBUTION KIOSK:-

L.T. Distribution kiosk will have Isolator/Switch Disconnector as incomer and single
phase MCCBs & Link Disconnector on outgoing side with necessary interconnecting Bus
Bars/Links.

Standard General Arrangement of Isolator/Switch Disconnector, MCCBs & Link discon-

nector, Neutral Link Bus Bars, connecting links, Cable termination arrangement etcinside
the LT DISTRIBUTION KIOSK is shown in the enclosed drawing for LT Distribution
kiosk suitable for 250/315 KVA & 63/100 KVA Distribution Transformers.
5. INCOMER CIRCUIT

ISOLATOR (SWITCH DISCONNECTOR)

The Isolator shall be of heavy duty, quick make and quick break type with Arc Chute
feature. The Isolator for 400 Amp. & 200 Amp. L.T. Distribution Kiosk should have Short
Circuit rating of at least 20 kA for one second & 4 kA for two second respectively to
withstand the short circuit fault level in our distribution system.

Each LT DISTRIBUTION KIOSK shall have following rating of triple pole isolator de-
pending upon the capacity of Transformer for which it is to be used. :-

253
Sr. Rating of Rating of triple pole No. of triple pole
Transformer isolator isolator
No.
1 63 / 100 KVA 200 Amp. 1 No.
2 250 / 315 KVA 630 Amp. 1 No.

The manufacturer have to indicate makes and types of isolator and submit the complete
type test report of the isolator as per specification, along with the offer and the isolator to
be provided in the LT distribution KIOSK shall be conforming to our specification.

Isolator should be front operated triple pole type. No separate enclosure is required if the
casing of non tracking heat resistant insulating material is provided. The isolator shall be
of rebutting construction for operation. The handle of the isolator should be detachable
easily for security purpose while working on L.T. lines. The characteristics of Isolator shall
be as follows:-

Sr. Characteristic 200 Amp. L.T. Distribution

No. Kiosk
1 Rated Operational current 200 Amp
2 Mechanism Manual quick make quick
break
3 Standard applicable IS:13947/1993/ IEC 60947 Pt.3
amended up-to-date
4 Utilization category AC-23A
5 Mechanical Endurance As per IS
6 Electrical Endurance As per IS
7 Rate duty Uninterrupted
8 Making/Breaking capacity Not less than the requirement of
AC-23A category.
9 Rated Short Time withstand 4 kA for two second
current

The terminal connector strips of the isolator shall be projecting out of isolator for minimum
length of 80 mm, on cable connection side and 60 mm, on bus bar side as shown in the
drawing. The cross section of the strips shall be 30x5 Sq.mm for 63/100 KVA & 50x6 sq.
mm for rest on outside of the isolator and length & cross section inside the isolator shall
be provided as per design. The material shall be EC grade tinned copper.

All nut bolts used for assembly and connections shall be of nonmagnetic stainless steel
only.
254
6. OUT GOING CIRCUITS:

6.1(a) MCCBs

Any make of MCCB offered by the firm will be acceptable subject to having successful
type test reports.

TIME CURRENT CHARACTERISTICS:-

The L.T. MCCBs shall have the following time current characteristics:

MULTIPLE OF NORMAL TRIPPING TIME

CURRENT SETTING

1.05 More than 2.5 hrs.

1.2 More than 10 minutes and less than 2 hrs.
1.3 Less than 30 minutes
1.4 Less than 10 minutes
2.5 Less than 1 minute
4.0 Not less than 2 seconds
5.0 Less than 5 seconds
12.0 Instantaneous (less than 40 milli seconds)

For above time/current characteristics reference calibration temperature of the breaker

shall be 50 degree C. Deration, if any upto 60 degree C ambient temperature shall not
exceed 10 % of the current setting indicated above.

Each LT DISTRIBUTION KIOSK shall have 3 Nos. of single pole MCCBs per circuit to control
and protect outgoing circuits. MCCB shall be conforming to our specification and
relevant ISS.

The manufacturer have to indicate makes & type of MCCB and submit the complete type
test reports of the MCCB as per IS:13947/1993 for test sequence I, II & III complete with
certified diagram/ Oscillograms and approved drawing from NABL approved Laboratory
along with offer. The successful manufacturer shall furnish detailed type test reports of
MCCBs to be used by them, for our approval. The colour of MCCB casing for 63/100
KVA L.T. Distribution Kiosks shall be brown and for 250/315 KVA LT DISTRIBUTION

255
KIOSK shall be Gray colour. Offers without complete type test reports of MCCB as above,
may be rejected.

The MCCBs shall be manually operated type and shall have quick make quick break
mechanism. The detailed specification for MCCBs shall be as under:-

1. KVA rating 63/100

2. Rated current 200 A
3. No. of Circuits 2 Nos.
4. Fixed overload release setting (Amp.) 60 A/ 90 A
5. No. of poles 1 Ph
6. Rated service short circuit breaking capac- 13947 Pt.III (1993) 18
KA or more
ity(KA) which is equal to ultimate breaking

capacity as per IS (Ics = Icu= 18 (KA) or

more).

(The sequence of operation for this test

shall be O-t-CO-t-CO, and t=3 min.) The
test shall be done at 240V at 0.4 PF. Volt-
age rating phase to phase 415V and phase
to earth 240V.
7. Power factor for short circuit(Max.) 0.4 (lag) 0.4 (lag)
8. Utilization category A A

The Terminal Connector strips of the MCCB shall be projecting out of the MCCB for
minimum length of 40 mm on Link Disconnector side and 60 mm on busbar side as shown
in the drawings. The cross section of the strips shall be 30x3 sq. mm on outside of the
MCCB and the length and cross section inside the MCCB shall be provided as per design.
The material shall be EC grade tinned copper.

All nut bolts used for assembly and connections shall be of non-magnetic stainless steel
only.

The rated service short circuit breaking capacity as specified in at Sr.No.6 above, shall be
based on the rated service short circuit test carried out at specified power factors. For the
purpose of this test, the following operation sequence shall be followed.

Break-3 minutes interval-make-3 minutes interval make break.

256
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 break-
ers under test. MCCBs should have locking facility in ‘off’ position.

The MCCB shall directly be purchased from the manufacturer or the authorized dealer or
stockiest. The routine & acceptance test on MCCB
shall be carried out at the works of original manufac-
turer. However, in every case of purchase ofMCCB
the delivery shall be from the manufacturer’sgodown
for which a copy of bill shall be given to inspecting
officer at the time of inspection.

Single pole MCCB is to be provided with over load trip release with inverse time current
characteristics for overload protection and magnetic trip release for instantaneous tripping
in the wake of Short-Circuits.

These MCCB’s shall be confirming to IS 13947/1993 or any other relevant ISS/IEC as

amended upto date. The rated un-interrupted current of MCCB shall be 200 Amp. with the
overload release set at 160 Amp for 250/315 KVA Distribution Transformers and rated
un-interrupted current of MCCB shall be 200 Amp. with the overload release set at 60 A/
90 A for 63/100 KVA Distribution Transformers.

The MCCB’s shall be marked with ‘Brand Name’ of manufacture and Ics in KA by em-
bossing only whereas other particulars may be marked as per the manufacturers standard
practice.

The contacts of MCCB should be self-wiping type so as to keep the contacts clean and
milli-volt drop low.

6.2 LINK DISCONNECTOR: Link Disconnector of suitable capacity shall be provided between
outgoing terminal of MCCB & cable connection as shown in the drawing to facilitate me-
chanical breaking of the circuit.

Each LT DISTRIBUTION KIOSK shall have 3 Nos. of Link Disconnectors in each out-
going circuits.

The manufacturer has to indicate the Makes and Types of Link Disconnector offered.

The base of the Link Disconnector shall be of non tracking, heat resistant insulating mate-
rial of superior electrical and mechanical properties equivalent to Dough-Moulding Com-
pound (DMC) etc. up to 500 Volt for 400 Amp. The Link Disconnector shall be sturdyin
construction and easy in operation. The link of Link Disconnector shall be of tinned
257
plated E.C. grade copper. The construction of the Link Disconnector shall be such that it
shall be hinged type on cable connection end and dis-connectable at the MCCB end. The
disconnection will be with the help of special handle/puller. One handle/puller shall be
supplied along with each LT DISTRIBUTION KIOSK. The terminal connector strips of
the Link Disconnector shall be projecting out of Link Disconnector for minimum length
of 80 mm on cable connection side and 40 mm on MCCB outgoing side as shown in the
drawings. The cross section of the strips shall be 30x3 sq. mm and Cross section of knife
edge link shall be 20x4 sq. mm. The material for both the strips and links shall be tinned
E.C. grade copper.

These base of Link Disconnector shall be rated for 150 Amp. current for 63/100 KVA and
200 Amp. current for 250 /315 KVA.

All nut & Bolts used for assembly and connections shall be of non magnetic stainless steel
only.

7. BUSBARS AND CONNECTIONS: Bus Bars & inter connecting links shall be of ano-
dized Electrolytic grade aluminum as per IS 5082. All bus bars & links should be properly
drilled, de-burred and should be provided with durable PVC insulating sleeves, standard
Colour code shall be used for different phases. Minimum clearance wherever shown shall
be as per General Arrangement drawing attached. Other clearance shall be asper require-
ment of IS: 4237 amended upto date. The size of Main Bus bars and neutral busbar for dif-
ferent rating of LT Distribution Kiosk shall be as below :-

Sr. Rating of LT Distribution Size (cross-section) of main Bus- Size (cross-section) of

No. KIOSK suitable for Trans- Bar / dropper links neutral Bus-Bar
formers of
1 63 / 100 KVA 40 X 6 mm/ 25 x 4 mm 60 X 3 mm

7.1 All busbars and links should be properly drilled, de-burred and preferably brazed to mini-
mize tearing of joints. Minimum joints preferred.

7.2 Busbars shall be provided with durable PVC insulating sleeves. Standards colour code
shall be used for different phases.

7.3 Shroud Bakelite (2 mm thick) shall be provided to cover bus bar arrangement for human
safety. Shroud Bakelite sheet is to be provided on the front side for 200 AMP LT Distri-
bution Kiosk & on the front side as well as back side for 400 AMP LT Distribution Kiosk.

7.4 Two no. bus bar stiffeners shall be provided/duly supported on DMC insulator such that bus
bar should not stress of force on the MCCBs.
8. ENCLOSURES:

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8.1 The circuit breakers, Link Disconnector and Isolator shall be housed in a sheet steel enclo-
sure with the door closed. The enclosure shall comply with the requirement of IP-43type
as per relevant IS / IEC or the latest version thereof. Access to the circuit breakers includ-
ing operating handle shall be available only after the enclosure door is opened.

8.2 Four sets of louvers shall be provided to ensure that the temperature inside the enclosure
is not substantially different from that of the atmosphere. The louvers shall be provided
with perforated M.S. sheet of 1.25 mm welded from inside the LT DISTRIBUTION KI-
OSK.

8.3 Fixing of circuit breaker inside the enclosure shall be such as to allow free circulation of
air at its back and sides.

8.4 The centrally closed doors with “Godrej” type triple position locking arrangement shall be
provided. In addition to this, an arrangement for locking the doors by Sturdy rod type door
latch shall be provided on outside. Both illustrations are shown in the drawing.

8.5 The enclosure shall be made of sheet steel of not less than 2 mm thickness for 63/100
KVA.

8.6 The enclosure shall be painted with suitable weather proof & corrosion resistant enamel
paint after 7 Tank cleaning process both inside & outside. The colour of the inside paint
shall be white, while that of the outer paint shall be brown for 63/100 KVA L.T. Distribu-
tion Kiosks and gray for 250/315 KVA LT DISTRIBUTION KIOSK. Powder coating fol-
lowed with 7 tank hot phosphate cleaning process is equally acceptable. In caseof Powder
coating the colour of inside & outside surfaces shall be same i.e. brown for 63/100 KVA
rating

8.7 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 only for 63 & 100 KVA
L.T. Distribution Kiosks.

8.8 Necessary fixing arrangement shall be provided at the top of the Canopy as shown in the
drawing to ensure proper fixing on double Pole structure. In addition to this two Nos. M.S.
channel of size 75x40x40 shall be provided at the bottom of the enclosure as shown in the
drawing for fixing the enclosure on Plinth.

8.9 For all rating of LT Distribution Kiosks i.e. 63/100 KVA the top of the Distribution Kiosks
shall be provided with a sloping Canopy such that the rain water is not accumulated on the
top. The Canopy shall be of one piece construction. The side members shall be welded at
both sides. The Canopy shall project over the sides & doors. The sides section shall be

259
folded to a “U” form to make a water drawing channel. Only front opening is required for
63/100 KVA L.T. Distribution Kiosks

8.10 A suitable bimetallic cable termination arrangement with support insulators shall be pro-
vided by extending the EC gr. Tinned copper terminals of the incoming Isolator & out-
going Link Disconnector. It shall be such that after fixing relevant cable lugs, clearances
and creepages are maintained.

8.11 The 3.15 mm bottom plate shall be, detachable to facilitate easy crimping of lugs to the
cable ends and for convenience in making connections. The plate shall be provided with
holes suitable for cable sizes indicated. The bottom plate shall be provided with two air
vents with perforated M.S. sheet of 1.25 mm thick welded from inside.

8.12 The flats provided for clamping (at top & bottom) shall have horizontal slots for adjust-
ment & shall be of welded construction and the welding should be on all sides.

8.13 Required no. of knock out holes should be provided on the bottom plate. Suitable size of
PVC cable glands should be provided for these holes.

8.14 Instruction leaflet in HINDI should be provided as sticker in the LT DISTRIBUTION KI-
OSK door from inside as per Nigam’s specification.

8.15 All the knock out holes shall be of size suitable to enter single core cables having sizes as
mentioned in Clause 10.

8.16 The Danger marking with fluorescent paint shall be provided on one door and a danger
plate shall be riveted on another door, on front side.

8.17 The bimetallic lugs of adequate size required for termination of cables on Isolator and Link
disconnector at the incoming and outgoing terminals and neutral link shall be provided.
The bimetallic lugs shall be as per relevant IS and the Make shall be approved by the
Nigam.

8.18 Minimum 3 Nos. Hinges per door made of heavy duty MS Sheet of minimum length of 75
mm shall be provided from inside, duly continuous welded.

8.19 All joints for current carrying parts shall be made using non-magnetic stainless steel bolts,
2 nuts & spring washers. The nuts and bolts should be of hexagonal type with groove for
bolt.

8.20 All drawings should be in three dimensions.

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9. CABLE TERMINATION:

Suitable lugs for Incoming and outgoing feeders for different rating of LT Distribution
KIOSK as below:-

Sr. Rating of LT Distribution Incoming Outgoing cable size

No kiosk suitable for Trans- cable size
. formers of
1 63 / 100 KVA 4.0 X 120 / Single core 4 nos.
150 sq. mm 50/ 70 sq. mm

10. FINISH OF LT DISTRIBUTION KIOSKS:

10.1 All sheet metal works shall undergo the 7 tank chemical and mechanical cleaning process
before final paint. Two coats of red oxide and two coats of final paints shall be applied.
Colour of outside/inside surface shall be mentioned in this specification.

10.2 Electrostatic painting with oven drying will also be acceptable.

10.3 All other metal parts used in the LT DISTRIBUTION KIOSK’s shall be treated as under.

M.S. parts such as Bolts& Nuts, washers etc. : Electro galvanizing of Zinc except for bus
bar & links.

11. SAFETY ARRANGEMENTS: Two earthing studs of galvanized M.S. 50x12 mm shall be
provided for external earth and internal neutral connections. These should be complete
with plain washer, spring washer, nuts etc. Earthing studs must be welded to prevent re-
moval of the same from the LT DISTRIBUTION KIOSK.

11. TESTS & TEST CERTIFICATES: The routine and acceptance tests of MCCB as per relevant
IS and this specification shall be carried out at the original manufacturer’s works. In case of
brought out items, such as Isolator, Link Disconnector etc., the test certificates oforiginal
manufacturer shall be produced to the inspecting officer and shall be enclosed withthe in-
spection report.

12.1 Routine Test: (carried out on LT DISTRIBUTION KIOSK’s)

a) Overall dimensions checking

b) High voltage test as per relevant IS.

261
c) Operation test on MCCB/ Isolator /Link Disconnector.

12.2 Acceptance Tests (on complete LT DISTRIBUTION KIOSK):

Following tests shall be carried out as acceptance tests in addition to routine tests as per
sampling plan i.e. 1 no out of every lot of 50 or part thereof.

i) Insulation Resistance tests

The IR value shall be measured with meager of 1000 Volt DC voltage between terminals
as mention in the high voltage test. The IR value shall not be less than 50 Meg. Ohm.

ii) Temperature rise test on one sample of each rating : Temperature rise test will be carried
out on complete LT Distribution KIOSK with all equipments & accessories mounted in-
side as per provision of IS : 8623 , part – I -1977.

This test shall be carried out on LT DISTRIBUTION KIOSK as well as MCCB & link
Disconnector Separately.

iii) Time-Current Characteristics: With the stabilized temperature rise as per (ii) above the
MCCB should be tested for time current characteristics at 1.05 & 1.3 times of overload
release setting current and should pass the requirement given in this specification.
iv) All routine test:.

a) Visual Examination:
The LT Dist. Kiosk will be inspected visually externally and internally, fittings of all the
components in accordance with Nigam specification, drawings and relevant IS/IEC.
b) Verification of dimensions:
Verification of dimensions, external/internal clearances, will be carried out as per technical
specifications and approved drawings.
c) Verification of fittings:
Components like Isolators, MCCBs, Link Disconnectors and other fittings will be verified
as per technical specifications and approved drawings.
d) High Voltage Withstand Test at 2.5 KV:
The voltage of A.C. 2.5 KV rms, 50Hz shall be applied for one minute as per relevant IS.

e) Operation test on MCCB/Isolator/Link Disconnector.

12.3 Routine & Acceptance Test on MCCB at original manufacturer’s works.

262
To ensure the quality of MCCB, routine & acceptance tests on MCCBs may be carried out at
the works of original manufacturers. Before offering the complete box, the manufacturer
should offer the MCCBs for inspection at the works of original manufacturer. The following
tests shall be conducted only on samples MCCBs as routine/ acceptance for acceptance of the
lot of MCCBs at the works of manufacturer during inspection.

1. Visual examination and overall dimensional checking.

2. High Voltage test at 2.5 KV for one second between:

a)-Main circuit & earth.

b)-Control circuit and earth.
c)-Shorted top and bottom terminals with MCCB in open conditions.

3. Insulation resistance test (IS: 8623) with 1000 V MEGGER between above points of S.N.2.
4. Milli-volt drop (IS:5147)
5. Temperature rise test (conducted one sample of each rating out of 1000 Nos. or part thereof)
in which contact resistance (mili volt) shall also be indicated.
6. Verification of time current characteristics (conducted one sample of each rating out of 1000
Nos. or part thereof).

The criteria for selection of No. of samples and for acceptance of lot shall be on 1% quantity
or 10 Nos. samples whichever is more. Before dispatch, the MCCBs shall be inspected and
tested by the authorized inspecting officer/Agency of the Nigam at the works of the manu-
facturer.

The successful testing of all samples in respect of tests mentioned above shall be the accept-
ability criteria of the lot/sub-lot.

Balance Type test of rating offered relating to all equipments/material as per Specification
shall be arranged from first lot (without asking for any delivery extension) from CPRI/ inde-
pendent NABL accredited Lab.

12.4 TYPE TESTS:

I) ON COMPLETE LT DISTRIBUTION KIOSK

a) Temperature rise test: The temperature rise test should be carried out as per IS: 8623-1993.

Each feeder shall be loaded to its full capacity along with Incomer Isolator as below:

263
Capacity of LT DISTRIBUTION KIOSK MCCB(SP) Isolator (SP)
Suitable for transformer having rating
63 / 100 KVA 60 / 90 Amp 200 Amp, 1 No.

b) High voltage test as per IS:8623 amended upto date.

c) Short Time Withstand Current Test on distribution LT DISTRIBUTION KIOSK:-The LT
DISTRIBUTION KIOSK should be subjected to Short Time Withstand Current Test for
value of 4 KA for two second for 63/100 KVA rating all circuit independently. The test
should be carried out after by-passing MCCBs.
d) Degree of protection for IP-43 on complete unit.
e) Time/current characteristic test as per clause 13.2 (iii) of this specification as stated above.

II) ON ISOLATOR:

All type test on incoming Isolator as per IS-13947/ 1993 (Part-III)/ IEC 60947 amended
up to date. Only test report shall be submitted.

III) ON MCCB

All type test on MCCB as per IS-13947 amended upto date. Only test reports shall be
submitted.

12.5 TEST CERTIFICATES :The LT DISTRIBUTION KIOSK, Isolator and MCCB offered
shall be fully type tested as per relevant IS and this specification .

The manufacturer must furnish type test reports along with bid as per the qualification requirement
of the Tender Specification.

The detailed type Test Reports shall be furnished with relevant oscillogram drawings and
certified Drawing of the equipment tested. The purchaser reserves the right to demand
repetition of some or all type tests in presence of purchaser’s representative at purchaser’s
cost. For this purpose, the manufacturer shall quote unit rates for carrying out each Type
Test.

13. TESTING & MANUFACTURING FACILITIES: The manufacturer 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 and type tests. These facilities may be
verified by JVVNL Engineers or other testing agency , if deputed to carry out or witness
the tests in the manufacturer’s works. The manufacturer must have all the in-house testing
facilities to carry out the acceptance tests on the LT DISTRIBUTION KIOSK.

264
The manufacturer should have following minimum manufacturing facilities in house to
prove his reliability as a manufacturer of LT DISTRIBUTION KIOSKs.

Power operated shearing machine

ii) Power operated press brake.
iii) Power operated power presses
iv) Welding machines,
v) Assembling tools

The manufacturer shall furnish detailed process of painting. In case painting is to be carried
out from outside agencies, the manufacturer shall furnish the facilities available with the
sub-contractor.

14. TENDER SAMPLE:

All the testing expenditures of sample testing, Acceptance tests for routine inspection of
lots will be borne by the firm only. After successful passing of the sample unit in all the
tests at CTL or elsewhere and after obtaining the written approval from the competent
authority of Nigam, can qualify for commercial bids.

(A). Quantity ordered for a successful manufacturer on whom order is placed and this
sample will be allowed to be dispatched with the last lot of supply. Any modification,
rectification of defects etc. will also have to be carried out along with necessary testing on
this sample box/kiosk for all acceptance tests.
. However, only after successful CTL or elsewhere testing in presence of manufacturer’s /
manufacturer’s representative and after acceptable of sample material / equipment by the
purchaser, offer of the firm will be considered for opening of the financial bid. The tender
sample will be returned back on whom order is not placed. It will be responsibility of
manufacturer to collect the tender sample within 10 days on receipt of letter from Pur-
chaser. The purchaser is not responsible for any damage or loss of parts etc. if found short
during collection of tender sample. If manufacturer is not lifting the tender sample on re-
ceipt of letter from purchaser, then Nigam will not be responsible for its safe custody.The
tender sample will be considered as a part for the successful manufacturer and after suc-
cessful passing in tests at CTL or elsewhere, it will be allowed for dispatch at the destina-
tion, allotted by the purchaser along with the last lot. Supplier has to carry-out all modifi-
cations/rectification at his cost suggested by the purchaser on this sample box. Thesamples
are to be submitted to Testing office (i.e. CTL or elsewhere) under guidance of purchaser.

15. INSPECTION: All tests and inspection shall be made at the place of manufacturer.
The manufacturer shall afford the Inspector (representing the purchaser), all reasonable
facilities, without charge to satisfy him that the material is being supplied in accordance

265
with this specification. All the equipments used in testing shall be calibrated from NABL
accredited test lab & shall not be more than one year old.

16. TEST CHECKING OF MATERIAL AT STORE:

The material received in the stores of the Nigam shall be subject to the test checking at
stores as well as successful testing in CTL or elsewhere before final acceptance of the
material, the procedure for the same shall be as under: -

17.1 SAMPLING: - One sample out of each sub-lot / lot of 200 nos. for either rating LT
Distribution Kiosks or part thereof from each inspected lot received in stores shall be se-
lected from each store for test checking of material and shall be got tested. The selectionof
sample from the material received at stores shall be done as soon as material is receivedin
stores without the presence of the representative of the supplier. However, testing of sam-
ple(s) at CTL or elsewhere as arranged by Nigam shall be carried out in the presence of
firm’s/supplier’s representative after identification / confirmation by him that sample so
selected belongs to them.

17.2 TESTS: - The following tests will be conducted on the following material(s) at CTL
or elsewhere:

A). Either rating LT Distribution Kiosk: - The testing on selected complete LT Distribution
Kiosks shall be as per technical specification.

B). To ensure the quality of MCCB, routine & acceptance tests on MCCBs shall be carried
out at the works of original manufacturer and also dimensional checking on One No.
MCCB of either rating from each lot at works of original manufacturers will be carried out
by breaking the MCCB and matching the same with the internal drawing of type tested
MCCB. Besides this, dimensional checking on One No. MCCB of either rating from each
lot of material received in Nigam’s store(s) at CTL or elsewhere shall be carried out by
breaking the MCCB and matching the same with the internal drawing of type tested
MCCB. Moreover rated current capacity and over load release setting will also be tested
in CTL or elsewhere as per relevant Standarts/IS/IEC.

C). To ensure the quality of Isolator, routine & acceptance tests on Isolators shall be carried
out at the works of original manufacturer and also dimensional checking on One No. Iso-
lator of either rating from each lot at works of original manufacturers will be carried out
by breaking the Isolator and matching the same with the internal drawing of type tested
MCCB. Besides this, dimensional checking on One No. Isolator of either rating from each
lot of material received in Nigam’s store(s) at CTL or elsewhere shall be carried out by
breaking the Isolator and matching the same with the internal drawing of type tested Iso-
lator.

266
D). Any other tests for which testing facility is available in CTL or elsewhere, may also
be carried out.
E). The successful testing of all samples in respect of tests mentioned at point (A) to (D)
above shall be the acceptability criteria of the LOT/SUB-LOT.

17. QUALITY ASSURANCE PLAN :

i) Statement giving list of important raw materials, names of sub-suppliers for the raw
materials, list of standards according to which the raw material are tested, list of
tests normally carried out on raw material in the presence of Supplier's representative,
copies of test certificates.

ii) Information and copies of test certificates as in (i) above in respect of bought out items.

iii) List of manufacturing facilities available.

iv) Level of automation achieved and list of areas where manual processing exists.
v) List of areas in manufacturing process, where stage inspections are normally carried out
for quality control and details of such tests and inspections.
vi) Special features provided in the equipment to make it maintenance free.
vii) The manufacturer should have adequate facilities to carryout accurately all required tests
during manufacturing and routine/acceptance tests as per relevant ISS/IEC standards at the
final end routine/acceptance. The supplier will ensure that all testing/measuring instru-
ments/apparatus are calibrated at regular periodicity from reputed test house as per relevant
standards and a certificate of testing authority is made available to purchaser's inspector at
the time of inspection. Such calibration certificates, in any case shall not be older than one
year on the date of such tests".

viii) List of testing instruments and apparatus along with their last date of calibration, available
with the Manufacturer for testing of equipment specified and test plant limitation, if any,
vis-a-vis the type, special, acceptance and routine tests testing during manufacture speci-
fied in the relevant standards. These limitations shall be very clearly brought out in "Sched-
ule of Deviations".

2) The Supplier shall also submit the following information to the Purchaser, along with
drawings/GTPs/BOM of ordered material, within 15 days of placement of order for pur-
chaser’s approval:-

267
i) Name of the raw material as well as bought out accessories and the names of sub-suppliers
selected from those furnished along with the offer.
ii) Type test certificates of the raw material and bought out accessories.
iii) Quality Assurance Plan (QAP) with hold points for Purchaser's inspection. The QAP and
Purchaser's hold points shall be discussed between the Purchaser and the Supplier before
the QAP is finalized.

3) The Supplier shall submit the routine test certificates of bought out items and raw material
at the time of routine/acceptance testing of the fully assembled equipment.

18. GUARANTEE :
The manufacturer quoting other brand / make of Isolator, MCCBs, Link Disconnectors etc.
or any part provided in the L.T.Dist. Kiosk and Complete LTDK / equipment supplied
shall be guaranteed for a period of 24 months from the date of last dispatch.

The Stores / material as above found defective or not meeting requirement of specifications
within above guarantee period shall be replaced / repaired duly tested by the supplier free
of cost within one month of receipt of intimation by the Nigam Engineers.

19.0 Purchasing on the Risk & cost of supplier, in case of non-execution of order/ delay in
delivery.

If at any time during the currency of the contract, the performance in whole or in part be
prevented or delayed, the purchaser reserves the right to procure the material/equipment
on order or part thereof from any other source at the risk and cost of the contractor/ sup-
plier.

BILL OF MATERIAL FOR L.T. DISTRIBUTION KIOSK FOR

63/100 KVA TRANSFORMER (JVVNL)

SIZE
S.NO. ITEM
63/100 KVA
1 M.S. SHEET 2 MM THICK
2 SWITCH DISCONNECTOR (T.P.) 200A - 1 NO.
200Amp with overload release set
3 M.C.C.B. (S.P.) at 60/90 A
-6 NOS.

268
4 LINK DISCONNECTOR 150 A-6 NOS.
5 ALU. BUSBAR 40 * 6 MM
6 ALU. DROPPERS 25 * 4 MM
7 ALU. NEUTRAL BUSBAR 60 * 3 MM
COLOUR INSIDE / OUTSIDE
WHITE / BROWN
IN CASE OF ENAMEL PAINT
8
COLOUR INSIDE / OUTSIDE
BROWN
IN CASE OF POWDER COATED
9 DANGER PLATE AS / DRG. 1 NO.
10 NAME PLATE AS / DRG. 1 NO.
11 FUSE PULLAR 1 NO.
12 P.V.C. GLANDS 2"- 1 NO.
13 P.V.C. GLANDS 1 1/2" -2 NOS.
14 BUSBAR STIFFNER 2 NOS.

LEGENDS:-
1. M.S. SHEET FOR ENCLOSURE 2MM & BOTTOM PLATE 3.15MM THICK.
2. DANGER PLATE AS/SP.- 1 No.
3. NAME PLATE AS/ SP. – 1 No.
4.MCCB (S.P.) 200 A – 12 Nos.(250/315 KVA) & – 6 Nos.(63/100 KVA)
5.ISOLATOR 630 A (T.P.) – 1 No. (250/315 KVA) & 200 A – 1 No. (63/100 KVA).
6.LINK DISCONNECTOR 200 A – 12 NOS.(250/315 KVA) & 150 A – 6 Nos.(63/100
KVA)
7. Alu. BUSBAR 2x(40x8mm).(250/315 KVA) , 40x6mm.(63/100 KVA) WITH HEAT
SHRINKABLE SLEEVES.
8. Alu. DROPPERS 30x8mm.(250/315 KVA) , (25mm X 4mm) X 2 Set.(63/100 KVA)
WITH HEAT SHRINKABLE SLEEVES.
9. Alu NEUTRAL BUS BAR 60x 8.5 mm.(250/315 KVA) ,60x3mm.(63/100 KVA) OR
EQUIVALENT CROSS SECTION
10. EARTHING BOLTS WITH NUT & PLAIN, SPRING WASHER (GALVANIZED)
M12x50 MM – 2 Nos.
11. COLOUR –FOR 250/315 KVA - INSIDE WHITE & OUTSIDE DARK GREY IN CASE
OF ENAMEL PAINT.
DARK GREY INSIDE & OUTSIDE IF POWDER COATED. FOR 63/100 KVA - INSIDE
WHITE & OUTSIDE BROWN IN CASE OF ENAMEL PAINT. BROWN INSIDE & OUTSIDE
IF POWDER COATED.
Min. Clearance

a. 200 mm
b. 75,,

269
c. 60mm
d. 95mm
1. All dimensions are in mm.
Sheet-2/2
JAIPUR VIDYUT VITRAN NIGAM LIMITED
TITLE L.T. DISTRIBUTION KIOSK FOR 63/100 KVA TRANSFORMERS.

270
TECHNICAL SPECIFICATION FOR SUPPLY OF 100 AMP. LT DISTRIBUTIONKI-
OSK SUITABLE FOR UNDERGROUND CABLING

1.0 SCOPE:-

1.1 This specification provides for the design, manufacture, inspection and testing before sup-
ply for satisfactory operation. The LT Distribution Box suitable for outdoor use with floor
mounting as per requirement indicated in the drawing.

1.2 It is not the intent to specify completely herein all the details of the design and construction
of the equipment. However, the equipment shall conform in all respects to high standards
of engineering, design and workmanship and shall be capable of performing in continuous
commercial operation up to the manufacturer’s guarantee period, in a manner acceptable to
the purchaser, who will interpret the meaning of drawing and specification and shall have
the power to reject any work or material which in his judgment is not in accordance there-
with. The offered equipment shall be complete with all components necessary for theireffec-
tive and trouble free operation. Such components shall be deemed to be within the scope of
manufacturer’s supply irrespective of whether those are specifically brought out in this
specification and/or the commercial order or not.

2.0 APPLICABLE STANDARDS:-

The LT Distribution Box shall conform to the following Indian Standards which shall
mean latest revisions, amendments/ charges adopted and published, unless otherwise /
specified hereinafter. International and Internationally recognized standards to which these
standards generally correspond are also listed below:

1 IS 13947/1993 (Part 2) For LT M.C.C.B.

2. IS 1852-1985 Specification for rolling & cutting tolerances. For

hot rolled steel products.
3. IS 8623/1993 For enclosure box & for degree of protection for
cubicles control gear.
4. IS:4237/1982,IS:8623/1993 for general requirement of L.T. Switchgear
(amended upto date)
5. IS 6005 Latest code of practice for phosphate treatment of
Iron & Steel.

3.0 GERERAL TECHNICAL REQUIREMENTS:-

(a) STANDARD:

271
The kiosk type weather proof outdoor type LT Distribution Box with hinged doors, on front
& rear shall be fabricated out of 2.5mm M.S. CRCA sheet of fine quality with four legs
made out of 50X50X6mm M.S. angles. Each door shall have concealed type two Nos. leaf
hinges made of 2 mm MS sheet and 75 mm length. The box should have sloping canopy
roof as shown in the drawing. Both front and rear doors should have heavy duty M.S. hinges
and locking arrangements. 2.5mm thick bottom gland plate of M.S. with suitable individual
opening of incoming outgoing cables (3.5 X 185 Sq.mm) and services cables of sizes
(4Cx6/10/16/25 Sq.mm) as per requirement.

All the sheet steel work shall be phosphated in accordance with IS-6005 code for practice
for phosphate iron and steel and capable of withstanding the mechanical, electrical, and
thermal stresses as well as the same time ensuring the desired degree of safety. The same
shall comply in all respect with the requirements as per relevant IS. In case of any discrep-
ancy between write-up and drawing attached, the details given in drawings will prevail.
The bill of material as indicated in the drawing shall be covered in the scope of supply.

(b) GENERAL TECHNICAL REQUIREMENT

Detailed as per drawing.

The box shall be kiosk type whether proof made out of 2.50mm thick MS sheet front and
back both openable duly hinged doors with locking arrangement and all required hardware.
The box should be dust and vermin proof followed by two coats of gray paints (IP 631) /
powder coating. The box should be mounted on a separate stand of angle iron of angle size
50X50X6mm with a height of 1000 mm for grouted up to 500 mm below and above from
the ground level.

(c) EARTHING TERMINALS

Two separate earthing terminal as shown in the drawing shall be provided.

(d) DANGER PLATE

Aluminum sheet 440V danger plate of size 120X150X1mm on front door should bepro-
vided.

(e) NAME PLATE

272
Manufacturer’s name plate of aluminum sheet of size 100X100X1mm quoting the purchase
order No & Date is to be provided on the back door.

(f) SWITCH GEARS & WIRING

240 Volts, 160 Amp. at 0.4 pf Single pole MCCB 3 Nos. of Ics=18 KA with extended
incoming and outgoing terminals of any makes having fixed type thermo-magnetic trip re-
lease category P2. The overload release setting shall be 90 Amps. The name of manufac-
turer & Ics rating shall be embossed on MCCB. A Three Pole 200 Amp TPN MCCB of
Ics=18 KA with extended incoming and outgoing terminals of any make be provided at
back side of the box for protection of outgoing circuit. Complete wiring with 25 Sq.mm
single core copper PVC (85 degree C grade) insulated cable duly crimped with oxygen free
heavy duty copper terminals to connect each MCCB with EC grade aluminimum bus bars
and bus bar to MCB’s. 240V, 10 kA breaking capacity AC MCB ofrating 40 AMP SP 6
No’s. on each phase of make MDS load-contact legrand / SCHNEIDER ELECTIC MER-
LIN GERIN. / PROTEC / HAVELS/ L& T/ C&S / ABB/
HAGER / GERARD/ Indoasian/GUTS/MONTEL/HPL. Any other repute make of MCB
having successful type tests reports shall also be accepted subject to prior approval of CE
(MM),Jaipur Discom. All the 6 MCBs of one phase shall be shorted at the supply end using
copper / brass finger type shorting link. The MCB,MCCB & TPN should be fully type
tested. The successful manufacturer shall furnish detailed type test report of MCCB, MCB
& TPN for approval.

Single compression copper/ brass cable gland for cable size 3.5 core 185 Sq.mm-3 Nos. &
4 core 10 Sq.mm-16 Nos.

(g) WORKMANSHIP

The fabrication of material shall be in such a way that it is a good finish of fabricated ma-
terial. The welding wherever done should be smooth and uniform and shall be in accord-
ance with the relevant standards. The material shall be fabricated accurately as per dimen-
sions as indicated in drawings. All the steel section before any work is done on them,should
be carefully leveled and straightened. No rough edges shall be permitted anywherethrough
out the work. Holes must be perfectly circular and dimensional tolerance as givenbelow
shall be permissible. All turns, sharp edges and rough surfaces left by drill or punchor any
other process should be removed perfectly. The box should be such fabricated/welded that
the rainwater does not enter into it.

(h) TOLERANCE

The sheet metal boxes shall be subjected to a maximum of ± 2% tolerance on the overall
dimensions and rolling tolerance for sheet Distribution Box shall be as per relevant IS.

4.0 TEST
273
4.1 TESTING FACILITIES:-

The manufacturer must indicate clearly about the various testing facilities for routine / ac-
ceptance tests as per relevant ISS in respect of distribution box as are available at the
works/particulars of the place where such testing is proposed to be conducted during the
course of inspection must be indicated.

4.2 ACCEPTANCE TESTS:

a) Routine & Acceptance Test on complete box

The various tests (Acceptance/Routine) on the equipment/material shall be carried out

as per provision of Section-III (technical specification). Out of offered lot, one sample for
a lot of 50 or part thereof will be selected for carrying out following AcceptanceTests:-

1. Physical verification.
2. Dimensional checking.
3. Provision for earthing.
4. High voltage test.

The tests shall be conducted in presence of Nigam's representative.

b) Routine & Acceptance Test on MCCB at original manufacturer’s works.

To ensure the quality of MCCB, routine & acceptance tests on MCCBs may be carried out at
the works of original manufacturers. Before offering the complete box, the manufacturer
should offer the MCCBs for inspection at the works of original manufacturer. The following
tests shall be conducted only on samples MCCBs as routine/ acceptance for acceptance of the
lot of MCCBs at the works of manufacturer during inspection.

1. Visual examination and overall dimensional checking.

2. High Voltage test at 2.5 KV for one second between:

a)-Main circuit & earth.

b)-Control circuit and earth.
c)-Shorted top and bottom terminals with MCCB in open conditions.

274
5. Insulation resistance test (IS: 8623) with 1000 V MEGGER between above points of S.N.2.
6. Milli-volt drop (IS:5147)
6. Temperature rise test (conducted one sample of each rating out of 1000 Nos. or part thereof)
in which contact resistance (mili volt) shall also be indicated.
7. Verification of time current characteristics (conducted one sample of each rating out of 1000
Nos. or part thereof).

The criteria for selection of No. of samples and for acceptance of lot shall be on 1% quan-
tity or 10 Nos. samples whichever is more. Before dispatch, the MCCBs shall be inspected
and tested by the authorized inspecting officer/Agency of the Nigam at the works of the man-
ufacturer.

The successful testing of all samples in respect of tests mentioned above shall be the
acceptability criteria of the lot/sub-lot.

(c) Balance Type test of rating offered relating to all equipments/material as per Specification
shall be arranged from first lot (without asking for any delivery extension) from CPRI/
independent NABL accredited Lab.

4.3 ROUTINE TESTS:

The test specified at Clause No.4.2 shall constitute these tests and Shall be conducted on
each piece and certificate for the same shall be submitted during bulk inspection in addition
to acceptance test certificate mentioned above. Further, firm shall submit to the Inspecting
Authority the copies of the test certificate of insulator / MCCB / MCB etc.

4.4 TYPE TESTS:

Manufacturer shall submit type test certificate for the following as per relevant IS/IEC only
from NABL accredited laboratory / Govt. lab. Along with the offer and offer received with-
out these Certificates may be rejected without any further clarification/ confirmation.

1. MCCB/MCB/TPN : Type test certificates of manufacturers.

2. Complete Box : IP-33.

4.5 CTL TESTING:

The dimensional checking on One No. MCCB from each lot at Central Testing Lab of
Nigam shall be carried out by braking the MCCB and matching the same with the internal
drawing of type tested MCCB.

275
6.0 GUARANTEED TECHNICAL AND OTHER PARTICULARS: The guarantee
technical and other particulars shall be given in the proforma as per schedule. Any devia-
tion from the specifications referred to above shall be supported by adequate justifications.

GUARANTEED TECHNICAL PARTICULARS OF 100 AMP LT DISTRIBUTION BOX

FOR DISTRIBUTION BOX

(TO BE FURNISHED ALONG WITH TENDER)

Sr. Description Guaranteed value As offered

No.
1. Name and address of
manufacture/firm.
2. Dimensions of box in 500X550X700mm
MM.
3. Thickness of MS 2.5mm
sheet.
4. Bus bar material & EC grade 99.9 % pure Aluminimum (annealed)
size Size 40 x 8 mm (for all phases and neutral).
The bus bar should not crack at the bends )

5. Length of bus 505 mm for phases (as per drawing) with 3

Nos. holes for holding lugs of 185 Sq. mm ca-
ble & 3 Nos hole of size 8 mm dia per phaseand
300 mm for neutral.
6. Conical bus bar DMC 40 x 40 mm with threaded brass inserts
support of 2.5 mm min. thickness at the thread.
7. Hardware Nickel plated
8. MCCB 3 Nos. single pole 160 Amps., Min. ICS=18
KA with over load release set 90 Amp.
9. TPN 1 No. three pole 200 Amps., TPN MCCB Min.
ICS=18 KA.
10 MCB 18 Nos. Single pole 40 Amp., Min. 10 KA with
“C” curve.
11. Earthing strip on DB Hot dip galvanized 25 x 3 mm as per drawing.

276
12 Dimensions of door
locking / earthing
bolt.
6 mm
(a) Door
Locking bolts.
(b) Earthi M10 2 Nos. with two nut & two washer.
ng bolts.
13 Pad Lock On both side doors, MCB and MCCB box.
14. The complete box IP-33
shall conform to
15. Approximate weight
of complete box in
KG’s.
16. Dimensions for 500mm
grouting.

Name of Firm
Signature of Manufacturer
Designation & Seal
Date

277
TECHNICAL SPECIFICATION FOR 11KV POLYMER COMPOSITE PIN INSULATORS

3.1 SCOPE :

This specification covers design, manufacture, testing and supply of Composite Polymer Pin
Insulators for use in the 11 KV overhead transmission lines.

The Composite Pin Insulators shall be of the following type : -

Long rod type Pin Insulators intended to be mounted rigidly on a supporting structure to support
following size of conductor: -

(a) For 11 KV AAAC Rabbit

3.2 APPLICABLE STANDARDS:

3.2.1 Following Indian/ International Standards, which shall mean latest revision, with
amendments/changes adopted and published, unless specifically stated otherwise in the Specifi-
cation, shall be referred while accessing conformity of insulators with these specifications.
3.2.2 In the event of supply of insulators conforming to standards other than specified, the
Manufacturer shall confirm in his bid that these standards are equivalent or better to those spec-
ified. In case of award, salient features of comparison between the standards proposed by theMan-
ufacturer and those specified in this document will be provided by the Supplier to establishequiv-
alence.

SI. No. Indian Standard International

Title
Standard Standard

IEC: 61109 :
2008
- Definition, test methods and acceptance
1
criteria for composite insulators for a.c.
overhead lines above 1000 V
IS: 731 Porcelain insulators for overhead power lines IEC: 60383
2
with a nominal voltage greater than 1000V.

278
3 IS: 2071 Methods of High Voltage Testing EC: 60060-1

4 IS: 2486 Specification for Insulator fittings for EC: 60120

Overhead Power Lines with a nominal voltage
EC: 60372
greater than 1000V General Requirements
and Tests Dimensional Requirements Lock-
ing Devices

5 - Thermal Mechanical Performance test and

I EC: 60575
mechanical performance test on string
insulator units

6 IS: 13134 Guide for the selection of insulators in IEC: 60815

respect of polluted conditions
7 - Characteristics of string insulator units of the IEC: 60433
long rod type

SI. No. Indian Standard International

Title
Standard Standard

8 - Hydrophobicity Classification Guide STRI

guide1.92/1

9 - Radio interference characteristics of CISPR:18.2

overhead power lines and high-voltage equip- Part 2
ment

10 IS: 8263 Methods of RI Test of HV insulators IEC: 60437

11 - Standard for Insulators— Composite- ANSI

279
Distribution Dead-end Type C29.13-2000

12 IS. 4759 Hot dip zinc coatings on structural steel & ISO: 1459
other allied products ISO: 1461

13 IS: 2629 Recommended Practice for Hot, Dip ISO-1461 (E)

Galvanization for iron and steel

14 IS: 6745 Determination of Weight of Zinc Coating on ISO: 1460

Zinc coated iron and steel articles

15 IS: 3203 Methods of testing of local thickness of ISO: 2178

electroplated coatings

16 IS: 2633 Testing of Uniformity of Coating of zinc

coated articles

17 - Standard specification for glass . ASTM D

fiber strands 578-05

18 - Standard test method for compositional ASTM E

analysis by Thermo gravimetry 1131-03

19 IS: 4699 Specification for refined secondary Zinc

3.3 TECHNICAL DESCRIPTION OF COMPOSITE INSULATORS

3.3.1 Service condition

Maximum ambient temperature 50 °C

Minimum ambient temperature - 5 °C

Relative humidity 0 to 100%

Isoceraunic level 25

280
Number of rainy days per year 70 days
Annual rain fall 10 to 100 cm
Wind pressure 195 Kg/sq cm
Altitude 200 M to 1000 M

3.3.2 General Requirement

(i) The composite insulators shall generally confirm to latest Standards as listed in 3.2
(ii) Composite Insulators long rod pin type to support conductor on 11 KV Overhead Power Lines : -
(iii) The insulators shall be suitable for 3 , 50 Hz, effectively earthed 11KV overhead distribution systemin
a heavily polluted atmosphere. The conductor will be ACSR / AAA Weasel / Rabbit Conductor. The
insulator should withstand the conductor tension, the reversible wind load as well as the high fre-
quency vibrations due to wind.
(iv) Manufacturer must be an indigenous manufacturer and supplier of composite insulators of rating 11
KV or above or must have developed proven in house technology and manufacturing process for
composite insulators of above rating or possess technical collaboration/association with a manufac-
turer of composite insulators of rating 11 KV or above.The Manufacturer shall furnish necessary evi-
dence in support of the above along with the bid, which can be in the form of certificationfrom the util-
ities concerned, or any other documents to the satisfaction of the purchaser.
(v) Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing, projec-
tion etc. and selection in respect of polluted conditions shall be generally in accordance with the
recommendation of IEC-60815/IS:13134.
(vi) The material of housing / Weather sheds shall have minimum 30% Silicon content by weight.
(vii) All parts made of Forged steel or Malleable cast iron /SGI (Spheroidal graphite iron) shall be protected
by hot dip galvanizing, confirming to latest edition of IS:4759. All castings shall be free from blow
holes and other casting defects such as cracks etc.
(viii) All fittings shall be designed so that the harmful bimetallic corrosion is avoided and effects of vibra-
tion 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 in-
gress; effectiveness 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 uni-
formly.
(ix) The insulators shall have satisfactory electrical characteristics in outdoor use, and to be free from
degradation and cracking of the housing.
(ix) The insulators shall be free from the penetration of the moisture into the interfaces of the end fitting
during long term outdoor use and shall possess long term tensile withstand load characteristics.
(x) The insulators shall be free from voids and other defects in the core material and be non-igniting and
non-flammable when exposed to flame for short periods.
(xi) The manufacturer shall furnish evidence in the form of certification from the power utilities that the
281
similar type of product supplied to them had been performing satisfactorily.
(xii) The design of the insulators shall be such that stresses due to expansion and contraction in any part
of the insulator not lead to deterioration.
(xiii) The core (FRP rod) shall be sound and free of crack and voids that may adversely affect the insulators.
(xiv) Weather sheds shall be uniform in quality they shall be clean, sound, smooth and free from defects
and excessive flashing at parting lines.
(xv) 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.
(xvi) The size of composite insulator , minimum creepage distance and mechanical strength along with
hardware fittings shall be as follows:

Type of Nominal Highest Visible Wet Power Impulse Minimum Min. Min.
Composite system system discharge Frequency Withstand creepage failing Diameter
load of FRP
Insulator voltage Voltage Test withstand voltage distance
(KN) Rod
KV (rms) KV(rms) Voltage voltage KV (rms) (mm)
(mm)
KV (rms) KV (rms) [ Heavily
polluted 25
mm/KV)]
11KV Pin 11 12 9 35 75 320 5 24
Insulator

(xvii) The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed as
follows in line with-IEC 61109:

± (0.04d+1.5) mm when d ≤ 300 mm.

± (0.025d+6) mm when d > 300 mm with a maximum tolerance of ±50mm

Where d being the dimensions in mm for diameter, length or creepage distance as the
case may be.

However, no negative tolerance shall be applicable to creepage distance.

3. 3.3 Interchangeability

The composite insulators including the end fitting connection shall be of standard design suitable for use
3.3.4 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.

3.3.5 Maintenance

The composite insulators offered shall be suitable for use of hot line maintenance technique so that usual
hot line operation can be carried out with ease, speed and safety.

3.4.0 TECHNICAL DESCRIPTION OF COMPOSITE INSULATORS

3.4.1 Design and construction:

The composite Pin insulators shall be designed to meet the high quality, safety and reliability and are
capable of withstanding a wide range of environmental conditions. Composite insulators shall consists of
three parts, at least two of which are insulating parts:

(a) Core – The internal insulating part.

(b) Housing – The external insulating part.

(c) Metal and fittings – For attaching to hardware to support conductor.

3.4.1.1 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.

3.4.1.2 Housing (Sheath)

The FRP rod shall be covered by a seamless sheath of a silicone elastometric compound or silicon alloy
compound of a thickness of 3 mm minimum. It shall be one piece housing using injection Moulding
Principle to cover the core. The elastomer housing shall be designed to provide the necessary creepage
distance and protection against environmental influences, external pollution and humidity. Housing shall
confirm to the requirement of IEC 61109/2008 with latest amendments.

283
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.

3.4.1.3 Weather sheds

The composite polymer weather sheds made of silicone elastometic 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 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.

3.4.1.4 End Fittings

End fittings transmit the mechanical load to the core. They shall be made of spheroidal graphite cast iron,
malleable cast iron or forged steel or aluminum alloy and only Forged MS Steel for Lower Fitting. Hard-
ware of respective specified mechanical load and shall be hot dipped galvanised in Zinc coated withmini-
mum 99.95% purity of electrolythic high grade Zinc in accordance with IS 2629. The material usedin
fittings shall be corrosion resistant.
Metal end fittings shall be uniform and without sharp edges or corners and shall be free of cracks,
flakes, silvers, slag, blow-holes shrinkages defects and localized porosity.

They shall be connected to the rod by means of a controlled compression technique. The material used in
fittings shall be corrosion resistant. As the main duty of the end fittings is the transfer of mechanical load
to the core 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 11KV Pin Insulator shall be provided with GI Pin duly permanent fitted with the 11 KV Pin
Insulator. The GI Pin should be confirming to IS:2486-Part-II/1989.
Normal dimensions of the pin insulator shall be accordance with the Specific Techniccal Particulas. No
joints in pin will be allowed. Outer portion of pin should be Zinc coated with minimum 99.95% purity of
electrolythic high grade zinc.

The finished surface shall be smooth and shall have a good performance. The surface shall not crack or
get chipped due to ageing effect under normal and abnormal service conditions or while handling during
transit or erection.

The design of the fittings and the insulators shall be such that there is no local corona formation or dis-
charges likely to cause the interference to either should or vision transmission.

Bottom end metal fitting (Shank) of Pin insulator should be as per IS: 2486. Two number nuts as per IS
284
1363 (P-III) and 4 mm thick Spring Washer shall be as per IS 3063 with latest amendments if any, Nuts
and spring washer shall be hot dip galvanized.

The details of end fittings for fixing the same with V -Cross Arms and top clamps are given below:

Sr. Item Min. threaded Dia. Of bottom Length of

No. portion of end end fitting Pin end fitting to
Fittings be fixed

1 11 KV 150 mm 20 mm 150

Upper end fittings shall be suitable to hold AAAC/ACSR Weasel / Rabbit for 11 KV. The size of the
fittings shall be in such a way that conductor could be bound firmly so that it may not slip from the groove
while in service even under adverse conditions.

3.5. Workmanship

3.5.1 All the materials shall be of latest design and conform to the best engineering practices adopted
in the high voltage field. Manufacturers shall offer only such insulators as are guaranteed by them to be
satisfactory and suitable for continued good service in power transmission lines.
3.5.2 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.
3.5.3 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.
3.5.4 The core shall be sound and free of cracks and voids that may adversely affect the insulators.
3.5.5 Weather sheds shall be uniform in quality. They shall be clean, sound, smooth and shall be free
from defects and excessive flashing at parting lines.
3.5.6 End fittings shall be free from cracks, 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.

3.5.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent
to 610 gm/sq.m. or 87µm thickness and shall be in accordance with the requirement of IS: 4759. The zinc

used for galvanizing shall be of purity 99.5% as per IS: 4699. The zinc coating shall be uniform, adherent,
285
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 precede test. The galvanizing
shall be carried out only after any machining.

3.6.0 Equipment Marking

3.6.1 Each insulator unit shall be legibly and indelibly marked with the following details as per IEC —
61109:2008
x. Month &Year of manufacture
xi. Min. failing load/ guaranteed mechanical strength in Kilo Newton followed by the word 'KN' to
facilitate easy identification.

xii. Manufacturer's name/Trade mark

xiii. Voltage and Type

xiv. ‘NAME OF DISCOM’ / TN No. ’

iv) Bid Drawings

iv) The Manufacturer shall furnish full description and illustration of the material offered.

v) The Manufacturer shall furnish along with the bid the outline drawing (3 copies) 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 :

v. Long rod diameter with manufacturing tolerances

vi. Minimum Creepage distance with positive tolerance

vii. Eccentricity of the long rod unit

i) Axial run out

i Radial run out

iii) Unit mechanical and electrical characteristics

iv) Size and weight of 11 KV GI Pin.

v) Weight of composite long rod units

vi) Materials

vii) Identification mark

viii) Manufacturer's catalogue number

286
3.6.2 After placement of award, the Supplier shall submit full dimensioned manufacturing insulator
drawings containing all the details in four (4) copies to purchaser for approval. After getting approval
from Purchaser and successful completion of all the type tests, the Supplier shall submit 10 more
copies of the drawing to the Purchaser for further distribution and field use.

3.6.3 After placement of award the Supplier shall also submit fully dimensioned insulator crate drawing
for different type of insulators for approval of the purchaser.

3.7 Tests and Standards

Insulators offered shall be manufactured with the same configuration & raw materials as used in the
insulators for which design & type test reports are submitted. The manufacturer shall submit a certificate
for the same. The design & type test reports submitted shall not be more than 05 years old.

3.7.1 Design tests

Manufacturer should submit test reports for Design Tests as per Clause No. 10 of IEC – 61109 : 2008
along with the bid from Govt. approved/ a Govt. recognized/ NABL accredited laboratory/ ILAC i.e.
International Laboratory Accredited laboratory / ILAC i.e International Laboratory Accreditation Corpo-
ration ( In case of foreign laboratory). The design tests are intended to verify the suitability of the design,
materials and method of manufacture (technology). When a composite insulator is subjected to the design
tests, the result shall be considered valid for the whole class of insulators, which are representedby the one
tested and having the following characteristics:

• Same materials for the core, and sheds and same manufacturing method;
• Same material of the fittings, the same design, the same method of attachment;
• Same or greater layer thickness of the shed material over the core (including a sheath where used);
• Same or smaller ratio of the highest system voltage to insulation length;
• Same or smaller ratio of all mechanical loads to the smallest core diameter between fittings
• Same or greater diameter of the core.

The tested composite insulators shall be identified by a drawing giving all the dimensions with the man-
ufacturing tolerances.

Manufacturer should submit following test reports for Design Tests as per IEC-61109 (clause- 10) along
with the bid.

Additionally following tests shall be carried out or reports for the tests shall be submitted after award of
contract:

UV test : the test shall be carried out in line with clause 7.2 of ANSI C 29.13.
Design test as per IEC: 61109 (Clause-10) (Report to be submitted by the manufacturer along with offer):
-
Sr. No. Particular of Design Test Required
A Test on shed and housing material
1. Hardness test
2 Accelerated weathering test
3 Tracking and erosion test
4 Flammability test
B Test on core material
1. Dye penetration test
2. Water diffusuion test

Note: If the manufacturer only has facilities to produce insulators shorter than prescribed length of spec-
imen as mentioned in IEC 61109/62217 ,the design test may be performed on insulators of those lengths
available to him ,but the results are only valid for up to the length tested.
Additionally following tests shall be carried out and reports for the tests shall be submitted:

(i) RIV Test (Dry) :

(ii) Brittle Fracture Resistance Test
(iii) Recovery of Hydrophobicity & Corona Test
(iv) Chemical Composition test for Silicon content

Manufacturer should submit test reports for design tests as per IEC – 61109 a/w the bid

3.7.2 DESIGN TESTS REPORTS :

a) The manufacturer should furnish valid design test certificates from Govt. approved/ a Govt. rec-
ognized/ NABL accredited laboratory/ ILAC i.e. International Laboratory Accredited laboratory / ILAC
i.e International Laboratory Accreditation Corporation (In case of foreign laboratory) on similar rating
and design of tendered material/equipment . Tests carried out by manufacturer in his own R&D units even
if recognized by Govt. shall not be accepted except in case of Govt. undertakings.

b) Such design test certificates should not be older than five years as on the date of bid opening.
c) In case the manufacturer is not in a position to furnish test certificate of same rating of offered
item and furnish test certificate of higher rating from Govt. approved/ a Govt. recognized/ NABL accred-
ited laboratory/ ILAC i.e. International Laboratory Accredited laboratory / ILAC i.e InternationalLabor-
atory Accreditation Corporation ( In case of foreign laboratory) at the time of submission of bid, the bid
of the manufacturers may be considered as responsive if manufacturer gives an undertaking alongwith
BG/DD/Pay Order that test of rating offered shall be arranged from first lot (without asking for anydeliv-
ery extension) from Govt. approved/ a Govt. recognized/ NABL accredited laboratory/ ILAC i.e. Inter-
national Laboratory Accredited laboratory / ILAC i.e International Laboratory Accreditation Corporation
( In case of foreign laboratory)
3.7.3 Type Tests: -

288
The manufacturer shall furnish detailed type test reports of the offered composite Insulators as per
clause of the Technical Specifications at Govt. approved/ a Govt. recognized/ NABL accredited labora-
tory/ ILAC i.e. International Laboratory Accredited laboratory / ILAC i.e International LaboratoryAccred-
itation Corporation ( In case of foreign laboratory) to prove that the composite Insulators offeredmeet 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. The following type tests shall be conducted on a suitablenumber of
individual insulator units, components & materials and the test report should invariably be submitted with
the bid: -

3.7.3.1 The manufacturer shall submit type test reports, from any Govt. approved/ a Govt. recognized/
NABL accredited laboratory/ ILAC i.e. International Laboratory Accredited laboratory / ILAC i.e Inter-
national Laboratory Accreditation Corporation ( In case of foreign laboratory), as per IEC 61109:2008
along with the bid. Additional type tests as required above shall be carried out by the manufacturer, after
award of Contract for which no additional charges shall be payable . In case the testshave already been
carried out, the manufacturer shall submit reports for the same.
Additional type tests as required above shall be carried out by the manufacturer, after award of Con-
tract for which no additional charges shall be payable. In case the tests have already been carried out,the
manufacturer shall submit reports for the same.

SN Description of type test Procedure / Standard

1. Dry lightning impulse withstand voltage Test As per IEC 61109 : 2008
2. Wet power frequency voltage test (Clause 11.1)
As per IEC 61109 : 2008 (Clause
3. Mechanical failing load time test(routine test)
10.4.2)
4 Radio interference test As per IEC 60437
Annexure-A Or any other test methodac-
5.
Chemical composition test for silicon content ceptable to the owner
Recovery of Hydrophobicity test Annexure-A (As per STRI guide) This
6.
test may be repealed every 3 yrs

3.7.3.2 All the type test given in Clause No. 3.8.3 in addition to routine & acceptance test shall be carried
out on insulator along with hardware fittings wherever required.
3.8.3 Routine Tests

SI.No Description Standard

1 Mechanical routine test As per IEC: 61109:2008 /IS:731
2 Visual Inspection As per IEC: 61109:2008 Clause 8.2
3 Identification of marking As per IEC: 61109:2008 Clause 8.1

3.8.4 Acceptance (Sample) Tests

289
3.8.4.1 The test samples after having withstood routine lists shall be subject to the
following acceptance / sampling tests in order indicated below:

a. Verification of dimensions Clause 7.2 IEC: 61109 : 2008

b. Verification of the locking system (if applicable) Clause 7.3 IEC: 61109 : 2008
Verification of tightness of the interface between endfit-
c. tings & Insulator housing Clause 7.4 IEC: 61109 : 2008
d. Verification of the specified mechanical load Clause 7.4 IEC: 61109 : 2008
e. Galvanizing test IS:2633/IS:6745

Note : SAMPLING & TESTING : Sample procedure for testing of insulators shall be IEC 61109:2008 forAc-
ceptance and Routine tests.

3.8.5 Tests During Manufacture

Following tests shall also be carried out on all components as applicable :

A) Chemical analysis of zinc used for galvanizing

B) Chemical analysis, mechanical, metallographic test and magnetic particle inspection
for malleable castings.
C) Chemical analysis, hardness tests and magnetic particle inspection for forgings.

3.8.6 Additional Tests

3.8.6.1 The Purchaser reserves the right at his own expenses, for carrying out 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 material comply with the Spec-
ifications.

3.8.6.2 The Purchaser 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 center.
In case of evidence of noncompliance, it shall be binding on the part of the Supplier to prove the
compliance of the items to the technical specifications by repeat tests or correction of deficiencies or
replacement of defective items, all without any extra cost to the Purchaser.

3.8.7 Quality assurance plan

1. The successful manufacturer shall submit following information to the purchaser :

2. Test certificates of the raw materials and bought out accessories.

3. Statement giving list of important raw materials, their grades along with names of sub- sup-
pliers for raw materials, list of standards according to which the raw materials are tested. List
of tests normally carried out on raw materials in presence of manufacturer's representative.
4. List of manufacturing facilities available.
5. Level of automation achieved and lists of areas where manual processing
exists.

6. List of areas in manufacturing process, where stage inspections are normally carried out for
quality control and details of such tests and inspections.
7. List of testing equipment’s available with the manufacturer for final testing of equipment
along with valid calibration reports

8. The manufacturer shall submit Manufacturing Quality Plan (MQP) for approval & the same
shall be followed during manufacture and testing.
9. The successful manufacturer shall submit the routine test certificates of bought out raw
materials/accessories and central excise passes for raw material at the time of inspection.

3.9 TYPE TESTS REPORTS :

a) The manufacturer should furnish valid type test certificates from Govt. approved/ a Govt.
recognized/ NABL accredited laboratory/ ILAC i.e. International Laboratory Accredited labor-
atory / ILAC i.e International Laboratory Accreditation Corporation ( In case of foreign labor-
atory) on similar rating and design of tendered material/equipment . Tests carried out by manu-
facturer in his own R&D units even if recognized by Govt. shall not be accepted except incase
of Govt. undertakings.
b) Such type test certificates should not be older than five years as on the date of bid opening.
The various type tests as per relevant standards shall be conducted on each type of insulator.

3.10 PACKING :

3.10.1 All insulators shall be packed in suitable PVC/ plastic tubes/any other suitable packing along
with temporary wrap-on shield/shrouds for each insulator unit. The packing shall provide protection
against rodent. Further shields/shrouds shall be made of opaque, weather proof material of adequate
strength. The Supplier shall furnish detailed design of the packing. For marine transportation, crates
shall be pelleted.

3.10.2 The packing shall be of sufficient strength to withstand rough handling during transit, stor-
age at site and subsequent handling in the field.

3.10.3 Suitable cushioning, protective padding, or Dunn age or spacers shall be provided to pre-
vent damage or deformation during transit and handling.

291
3.10.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their
destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty
packing and faulty or illegible markings. Each case/crate shall have all the markings stencilled on it
in

3.10.5 The Supplier shall guarantee the adequacy of the packing and shall be responsible for any
loss or damage during transportation, handling, storage and installation due to improper packing in-
delible ink.

3.10.6 The manufacturer shall provide instructions regarding handling and storage precautions to be
taken at site.

3.11 GUARANTEE:

The supplier of insulators shall guarantee overall satisfactory performance of the insulators for the
period of 36 months from the date of handing over after successful installation and commissioning.

3.12 GUARANTEED TECHANICAL PARTICULARS:

Full guaranteed particulars should be given in the tender as called for in Schedule-V(a) for 11 KV
Polymer Composite Pin Insulators. Tenders not accompanied by Schedule-V(a), duly filled in are
likely to be ignored.

3.13 TEST CHECKING OF MATERIAL AT STORES

The material received in the stores of the NIGAM shall be subjected to the test checking at stores
before final acceptance of the material, the procedure for the same shall be as under :

2. SAMPLING
One sample out of each sub-lot / lot consisting of following quantities or part thereof each inspected
lot received in stores shall be selected from each store for test checking of material and shall be got
tested.

11 KV Polymer Composite Pin Insulator – 3000 Nos.

The sample selection shall be done as soon as the material is received in stores, without calling the
representative of supplier. However, testing at CTL or else where as arranged by NIGAM shall be
done in the presence of representative of supplier after identification/ confirmation by the supplier’s
representative that sample(s) so selected belong to them.
i) TESTING
The following tests shall be carried out on the above items :

a. Verification of dimensions
b. Verification of the locking system (if applicable)
c. Verification of tightness of the interface between
end fittings & Insulator housing
d. Verification of the specified mechanical load
e. Galvanizing test

However, only those tests shall be conducted at CTL for which facility with CTL is available.

In case if the facility for conducting any of the above test(s) is not available at the NIGAM’s CTL,
the purchaser reserve the right to get such test (s) conducted at any independent NABL Test House.

For witnessing of the testing, clear 3 days’ notice shall be given to the supplier stating date, time &
place where the test is to be conducted. The testing shall be started after identification / confirmation
of sample by the representative of the supplier that sample selected for testing pertain from the lot
supplied by them. In case the supplier does not attend for witnessing the testing ,the test shall be
proceeded and completed and action be taken as per contract. The CTL shall send two copies to the
purchaser ,consignee and the supplier.

iii) CRITERIA FOR ACCEPTANCE:- In case of failure of any of sample(s) in any of the above tests
material contained in the lot / sub-lot received in store to which the samples belong, shall be rejected.
The rejected material shall have to be replaced by the supplier free of cost.

iv) TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores shall be borne by
the NIGAM.

a) PLANT, MACHINERY & TESTING EQUIPMENTS;

ii) The manufacturer should have required plant, machinery and testing equipment formanufactur-
ing & testing of 11KV Polymer Composite Pin Insulator.
iii) The manufacturers should furnish details of plant, machinery and testing equipment with the bids
failing which bids may be ignored.
3.14. CHALLENGE TESTING :

293
The other manufacturer can also request challenge testing for any test based on specification. The chal-
lenger would request for testing with testing fee. The challenge test fees are proposed at least threetimes
the cost of testing. This is likely to deter unnecessary challenges. The challenger would have the oppor-
tunity to select the sample from the store of Nigam and any such challenge should be made withinthe
guarantee period. The party challenged, challenger and the utility could witness the challenged testing.
The challenged testing would cover all the type tests as per relevant IS.

The challenge test could be conducted at NABL accredited laboratory, like ERDA/ CPRI . If the values
are within limit, the product gets confirmed, else not confirmed. If the product is not confirmed, the
manufacturer would pay the challenge fee and challenger would get the fee refunded. However, as a
redressal system the challenger would be allowed to ask for fresh selection of two more samples from
the store of Nigam and same be tested in a NABL laboratory ( which shall be other than previously
selected NABL accredited lab) at the cost of supplier, in presence of party challenged, challenger and
the utility. If any one or both sample does not confirm the tests, then the product is said to have failed
the tests. In such cases the manufacturer will be declared as unsuccessful manufacturer for the said prod-
uct and balance supply shall not be availed and the order shall be cancelled with levy of maximum
penalty.

294
MANDATORY PARTICULARS FOR 11KV PIN INSULATOR

Type of Insulator Polymeric composite Pin Insulator

Reference Standard IEC 61109
Material of FRP Rod Borron Free ECR
Material of Sheds Silicon Rubber
Material of Top End Fittings SGCI/ MCI/ FORGED/ STELL
Material of Bottom End Fittings FORGED STEEL
Material of sealing compound RTV Silicon
Color of Sheds Grey
Rated Voltage 11 KV
Highest Voltage 12 KV
Dry Power Frequency Withstand voltage 60 KV
Wet Power Frequency Withstand voltage 35 KV
Dry Power Frequency Flashover Voltage 75 KV
Wet Power Frequency Flashover Voltage 45 KV
Dry Lightening Impulse Withstand Voltage Positive: 75 KV
Negative: 80 KV
Dry Lightening Impulse Flashover Voltage Positive: 95 KV
Negative: 100 KV
RIV at 1 MHz when energised at 10 KV / 30 < 50 microvolt
KV (rms) under dry condition
Creepage Distance (min) 320 mm
Min Failing Load 5 KN
Dia of FRP Rod 24 mm
Length of FRP Rod (min) 165 mm
Min Dia of weather sheds >90 mm
Thickness of housing 3 mm
Dry arc Distance 150 mm
Method of fixing sheds to housing Injection moulding
Visible Discharge Voltage (PF) 9 KV
No of weather sheds (min) Three
Type of Sheds Aerodynamic
Dia of bottom and fitting 20 mm
Thread length of bottom end fitting 150 mm (Min)

295
Type of Packing As per spec requirement
No of insulator in each pack Thirty
TECHNICAL SPECIFICATION FOR (1) 11 KV 45 KN DISC INSULATORS T & C TYPE
(2) 11 KV 45 KN DISC INSULATORS B & S TYPE

3.01 SCOPE :

3.01.1 This section covers for the design, manufacture, testing at manufacturer's works before
despatch, supply and delivery of Disc Insulators Tongue & Clevis type and Ball & Sockettype for
various overhead 33 KV an 11 KV Power Lines and overhead 132/33 KV Power Lines.The de-
scription of insulators & string arrangements have been given in Appendix- I, Appendix-IIand Ap-
pendix-III

3.01.2 The technical specifications, contained herein ,are for the guidance of the manufacturers.
Any deviation from the Purchaser's specification will be considered on their relative merits
in respect of performance, efficiency, durability and overall economy consistent with the re-
quirements stipulated herein after. Such deviations shall be clearly entered by the manufacturer in
the form as per schedule-VI (A&B) of the specification.

3.02 STANDARDS :

The Disc Insulator shall comply in all respects with the Indian Standard Specifications
IS:731-1971 (Second Revision), IS:3188-1980, IS:2486 (Part-I)-1993 (Second
Revision),IS:2486 (Part-II) 1989 (Second Revision) and IS:2486 (Part-III)1974,
IS:2486(Part.IV)1981 with latest amendments. The galvanisation of metallic parts shall conform
to IS:2633/1972(Latest amendments). The Insulator String shall consist of discs (B&S Type) of
dimensions specified in Appendix-I, for use on 3 phase, 50 cycle power system . All applicable
standards shall be clearly mentioned in schedule-III

3.03 MATERIALS, DESIGN & TYPE :

3.03.1 All the materials used in the manufacture of the insulators shall be of the first class quality.
The porcelain shall be sound, free from defects thoroughly vitrified and smoothly glazed.

3.03.2 The glaze shall be brown in colour . The glaze shall cover all the porcelain parts of the
insulators except those areas which serve as supports during firing or are left unglazed for the
purpose of assembly . The glaze shall be uniform, smooth, hard, dense, continuous and brilliant.

3.03.3 The design of the insulator shall be such that stresses due to expansion and contraction
in any part of the insulator shall not lead to deterioration. The porcelain shall not engage directly
with hard metal.
3.03.4 Cement used in the construction of the insulator shall not cause fracture by expansion
or loosening by contraction and proper care shall be taken to locate the individual parts, correctly
during cementing . The cement shall not give rise to chemical reaction with metal fittings and its
thickness shall be as uniform as possible.

3.03.5 All parts of different fittings which provide for interconnection shall be made such that
sufficient clearance is provided at the connection point to ensure free movement and suspension
of the insulator string assembly.

3.03.6 All hardware fittings (except those specified otherwise) shall be made of drop forged steel
or heat treated malleable cast iron, and shall be hot dip galvanized after all machining and fittings
have been completed. The material used in fittings shall be corrosion resistant.

3.03.7 The locking devices shall be resilient, corrosion resistant and of suitable mechanical
strength. The hardness and temper of the material are important for their satisfactory operation.

The locking devices shall retain their locking ability after being operated from the locking
to the coupling position at least twenty times , at normal temperature. They should be effective at
the lowest temperature likely to be encountered in service.

3.03.8 For Ball & Socket type disc insulators the cap and the pin shall be heavily galvanised and
mechanically strong. The ball shall move freely in the cap sockets, but shall be so designed that
they do not give way while in service. The dimensions of the pin ball & socket shall be conforming
to ISS 2486/part -II. The cap shall be made of malleable cast iron confirming to IS:2108-1977.
These shall be free from cracks, shrinks, air holes, burs and rough edges. The caps shall be circular,
with inner and outer surfaces concentric and of such design that they will not yield ordistort under
the stress to the porcelain shells. The pin shall be single piece made of drop forged steel and shall
be free from laps, field's burs and rough edges. All bearing surfaces shall be smooth and uniform
so as to distribute the loading stresses uniformly. The pins shall be of sucha design that they will
not yield or distort under loaded condition. They shall not be made by joining, welding, shrink
fitting or any other process from more then one piece of material. Thelocking devices `W/R' type
for Ball & Socket lockers shall be either of Phosphor bronze confirming to IS:7814-1975 or stain-
less steel confirming to IS:6603-1972 with minimumhardness of 160 HV. The dimensions shall
confirm to IS:2486(Part-3)-1974.

3.03.9 The dimension of the clevis and tongue connection shall be as shown in fig.25 and the
dimension of cross arm strap shall be as shown in fig.26 of IS:2486/Pt.II/1989 ( latest amend-
ments)

The tongue and clevis type porcelain insulators shall be as per fig.2 and its dimension shall
conform to table-2 of IS:3188/1980 (latest amendments)

The dimensions of pin ball socket shall be according to fig.8 and 9 respectively of IS:2486
(Part.II/1989) IInd revision.
298
3.04 CLASSIFICATION SIZE & NO. OF DISCS :

3.04.1 The insulators shall be of type B as specified under clause 5 "Classification" of IS:731-
1971(second revision).

3.04.2 The long rod Insulator falling under type A shall confirm to IEC:433-1980(with latest
amendments )& IEC-575/1977.

3.05 ATMOSPHORIC CONDITIONS :

3.05.1 Climatic condition : All parts and fittings shall be suitable for atmospheric condition
and shall be inherently resistant to atmospheric corrosion or be suitably protected against corro-
sion both storage & in service :

1. Min. temperature (-) 2.5 deg.C

2. Max. temperature of air in shade 50.0 deg.c.
3. Average everday temperature 32.2 deg.c.
4. Max. temperature of conductor
carrying current and exposed to sun 67 .0 deg.c.
5. Max relative humidity 90 %
6. Min relative humidity 10 %
7. Isoceraunic level 25
8. Number of rainy days per year 70
9. Annual rain fall 10 to 100 cm
10. Wind pressure(acting on full 195 kg/sq.cm
projected area
11. Altitude 200M to 1000M

3.05.2 Reference atmospheric conditions at which insulator characteristics shall be expressed

for the purpose of comparison shall be as given below :

Ambient Temperature : 20 degree C

Barometric pressure. : 1013 millibars.
Absolute humidity. : 11 g water per cubic metre
corresponding to 63 percent
relative humidity at 20 deg.C.

299
3.05.3 Tests for the purpose of this specification may be carried out under conditions naturally
obtaining at the time of test. The barometric pressure, air temperature and humidity shall be rec-
orded for the purpose of corrections. Corrections of test voltages for atmospheric conditions shall
be taken as per Appendix. "A" of IS:731/1971 (second revision) "Correction Of Test Voltages For
Atmospheric Conditions".

3.06 TESTING :

3.06.1 Sampling inspection, testing and acceptance of insulators shall be in accordance with the
latest revision of IS:731/1971 while that of hardware associated with these discs shall be as per
IS:2486(Pt.I)/1993 (second revision) IS:2486(Pt. II)/1989 (second revision) and
IS:2486(Pt.III)/1974 & IS:3188-1980 with latest amendments. Sampling inspection, testing and
acceptance of long rod insulators shall be in accordance with the latest edition of IEC :433/1980
& IEC:575/1977.

3.06.2 TEST VOLTAGE : The test voltage of the insulators shall be as given in Appendix.
II (values given are without applying correction factors).

3.07 MECHANICAL LOADS :

The insulator strings shall be suitable for the minimum failing loads specified in Table-2,
clause 7 of IS:731/1971 (IInd Revision). The load shall be supplied axially to the insulator strings.

3.08 MARKINGS :

Each insulator shall be legibly and indelibly marked to show the following :

a) Name or trade mark of the manufacturer.

b) Month and year of manufacture.
c) Minimum failing load in KNewton.
d) TN No. / JVVNL / RDSS

Marking on porcelain shall be originated and shall be applied before firing.

3.09 CREEPAGE DISTANCE :

300
The manufacturer shall specify in his tender the creepage distances of the insulator. These
values should not be less than those specified in IS:731-1971 & IS:3188-1980 (Latest amend-
ment).

3.10. TYPE TEST ON SAMPLES SELECTED

3.10.1 If the manufacturer has already got conducted the requisite type test from the first lot of
material received in Nigam’s store against any previous / earlier tender of JVVNL and such Type
Test reports are valid i.e not older than 3 years on the date of opening of Techno-Commercial
Bids, then the requirement of conducting Mandatory Type Test on the sample selected from 1 st
Lot of supply received in Nigam’s store is RELAXED. For this purpose date of conducting type
test will be considered.

3.11 TYPE TEST :

a) The following tests shall constitute the type tests and shall be carried as per the relevant clauses
of IS:731/1971 (second revision). The clause references have been given in brackets against each
test.

a) Visible discharge test (10.2).

b) Impulse voltage withstand test (10.3).
c) Wet power frequency voltage withstand test(10.4).
d) Temperature cycle test (10.6).
e) Electro mechanical failing load test 10.7)
f) Twenty four hours mechanical strength test (10.9).
g) Puncture test (10.10).
h) Porosity test (10.11).
i) Galvanizing test (10.12).

b) In addition to above, the following type tests shall be got conducted at CPRI , Banglore / any
other NABL accredited Government lab / Govt. approved Lab where facility for the same is avail-
able as per the relevant clauses of IEC standard.

a) Residual Strength Test as per IEC :60797

b) Steep Wave Front test as per IEC: 61211/2004

In case , if it is not possible to conduct the aforesaid additional type test in above manner then
the said additional type test may be allowed to arrange by the supplier at their own works or any
other manufacturers works where the requisite testing facilities for conducting the above test are
available.

3.12 ACCEPTANCE TESTS :

3.12.1 These tests shall be for the purpose of acceptance of the lot. For carrying out acceptance
test sampling procedure given in Appendix "C" of IS:731/1971 (second revision) shall be fol-
lowed.

3.12.2 The insulators selected in accordance with clause 3.11.1 above shall be divided approxi-
mately into three parts and subjected to the tests in the order as specified in clause No.
10.1.2.2 of IS:731/1971.

3.12.3 The insulators after having withstood the routine tests shall be subjected to the
acceptance tests.

3.12.4 Additional acceptance test- Insulation resistance test In addition to acceptance test as per
clause no.3.11.2, insulation resistance test shall also be conducted on the samples as per clause
No.3.11.1. The procedure for carrying out this test shall be as under:

(a) Clean insulator & dry properly, then meggar the insulator with 2.5 KV/ 5 KV meggar
(b) IR value so measured should not be less than 1000 ( one thousand) mega ohms

The testing and criteria for conformity shall be as applicable to galvanizing and puncture
test.

3.13. CRITERION OF CONFORMITY :

3.13.1 The criterion of conformity to the requirements of the tests given in 3.11.2 shall be as per
clause No.C-2, of Appendix 'C' of IS:731/1971 (second revision).

3.13.2 No part of the lot withdrawn as described in 3.12.1 above shall constitute part of any
other test submitted for the first time.

3.14 ROUTINE TESTS :

3.14.1 Routine tests shall be carried out on each insulator & to check requirements which are
likely to vary during production as per relevant IS:731/1971 (with latest amendments).

302
3.15 PACKING :

3.15.1 All insulators shall be packed in suitable crates or boxes with suitable steel bands so
as to withstand rough handling and storage at destination.The gross weight of packing shall
not exceed 50 Kgs.

3.16 DRAWINGS :

3.16.1 The manufacturer shall submit detailed drawings showing design and dimensions of insu-
lator , ball pin, socket cap & security pin . The type of the material used for various parts shall be
clearly specified on the drawing.

3.17 GUARANTEED TECHANICAL PARTICULARS :

Full guaranteed particulars including dry and wet flashovers, puncture and impulse voltages,
corona formation voltages, creepage distances, etc. should be given for in Schedule-V(A) for 11
KV 45 KN T&C Disc Insulators , Schedule-V(B) for 11 KV 45 KN B&S Disc Insulators

3.18 TEST CHECKING OF MATERIAL AT STORES

The material received in the stores of the NIGAM shall be subjected to the test checking at
stores before final acceptance of the material, the procedure for the same shall be as under :

i) SAMPLING

One sample out of each sub-lot / lot consisting of following quantities or part thereof in case
of each type of insulators from each inspected lot received in stores shall be selected from each
store for test checking of material and shall be got tested.

11 KV 45 KN Disc insulator “T&C” Type – 1000 Nos.

11 KV 45 KN Disc insulator “B&S” Type – 1000 Nos

The sample selection shall be done as soon as the material is received in stores, without
calling the representative of supplier. However, testing at CTL or else where as arranged by NI-
GAM shall be done in the presence of representative of supplier after identification/ confirmation
by the supplier’s representative that sample(s) so selected belong to them.

ii) TESTS
303
The following tests shall be carried out on the above items :

a) Visual examination, verification of dimensions, creepage distance etc.

b) Mechanical failing Load Test
c) Porosity test
d) Puncture Test

However, only those tests shall be conducted at CTL for which facility with CTL is available.

In case if the facility for conducting any of the above test(s) is not available at the NIGAM’s
CTL, the purchaser reserve the right to get such test (s) conducted at any independent NABL Test
House.

1. For witnessing of the testing, clear 7 days notice shall be given to the supplier stating date,
time & place where the test is to be conducted. The testing shall be started after identification
/ confirmation of sample by the representative of the supplier that sample selected for testing per-
tain from the lot supplied by them. In case the supplier does not attend for witnessing the testing,
the testing shall be proceeded and completed and action be taken as per the contract.

2. The CTL shall send copies of test reports to the purchaser, consignees and the supplier.
iii) CRITERIA FOR ACCEPTANCE

In case of failure of any of sample (s) in any of the tests at CTL, the material contained
in the lot / sub-lot received in store to which the samples belong, shall be rejected. The rejected
material shall have to be replaced by the supplier free of cost.

The material duly inspected/ cleared for dispatch received in stores against replacement of
rejected material shall be tested in CTL of NIGAM.

In case material received against replacement fails in CTL testing, then the following ac-
tion shall be taken :

i) Material contained in the lot / sub-lot received in stores to which the sample belong shallbe
rejected and shall be lifted by the supplier from Stores and order equal to the quantity of lot/ sub-
lot shall stand cancelled with a recovery of 5% of value of the lot / sub-lot considering it as non-
supply of material. Apart from this any lot tested for 2 nd time in CTL will attract a recovery of
Rs.5000/- at each occasion.

304
(ii) If there is more than 50% failure of samples tested in CTL, then the firm shall be debarred
from participating in future tenders for two years.

iv) TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores shall
be borne by the NIGAM.

3.19. PLANT, MACHINERY & TESTING EQUIPMENTS;

3.19.1 The manufacturer should have required plant, machinery and testing equipment for
manufacturing & testing of disc insulators.

3.19.2 The manufacturers should furnish details of plant, machinery and testing equipment
with the bids failing which bids may be ignored.

The manufacturer should have conveyor belt system at their works for conducting continuous and
hundred percent routine test on Disc Insulators The bids of manufacturer not having such arrange-
ment (infrastructure) may be ignored.

APPENDIX-I

TECHNICAL PARTICULARS

S. PARTICULARS 45 KN DISC 45 KN DISC

NO INSULATO INSULATOR
R T&C B&S TYPE
TYPE
1 INSULATORS
a) Diameter 225 mm 255 mm
b) Height 145 mm 145 mm
c) Spacing ---- 145 mm
d) Colour Brown Brown
e) Surface Glazed Glazed
f) Creepage Distance 280 mm 280 mm
g) Ball Dia 16 mm 16 mm
As per As per relevant
h) Tolerance relevant ISS ISS
2 STRING ARRANGEMENT
a) Single Tension String for
normal tension location
i) No of E&M 3 3
ii) Disc srength 45 45
b) Double Tension String for
normal tension location
i) No of E&M 3x2 3x2
ii) Disc srength 3x45 KN 3x45 KN
c) Minimum Failing Load As per relevant ISS
All Electrical & Mechnical values Conforming to Highest system voltage 36 KV / 132
KV in table -1A of string of IS:731/1971
3 Power System 33KV 3 132 KV 3 Phase 50 Cycle effectively
Phase 50 earthed
Cycle effec-
tively Non
earthed
4 36 KV(RMS) 36 KV(RMS)
Hiehest System Vol. Vol.
5 Visible Discharge 27 KV (RMS) 27 KV (RMS)
6 75 KV (RMS)
230 KV (RMS)
Wet Power Frequency withstand test
7 170 KV
(Peak)
Impulse Voltage 170 KV (Peak)
8 Power Frequency 1.3 Times the actual dry Flash over voltage of the unit

9 Minimum creepage distance 580 MM 580 MM

of the insulator string for
moderately polluted
admoshere
10 Weasel & Racoon & Dog
Conductor Rabbit
11 Stranding and wire diameter Al.30/3.0 + ST 7/3 mm

12 Approx.overall diameter 21 mm 21 mm

306
S. PARTICULARS 45 KN DISC 45 KN DISC
NO INSULATO INSULATOR
R T&C B&S TYPE
TYPE
13 Appox. Calculated breaking 9143.47 Kg 9143.47 Kg
load
14 Normal Aluminium area 207 sq mm 207 sq mm
15 Max. temperature of conduc- 67 Deg. C 67 Deg. C
tor carrying current and ex-
posed to sun

TECHNICAL SPECIFICATION FOR 11 KV 45 KN DISC INSULATORS “T&C” TYPE.

3.01 SCOPE :

3.01.1 This section covers for the design, manufacture, testing at manufacturer's works before
dispatch, supply and delivery of Disc Insulators Tongue & Clevis type and Ball & Sockettype for
various overhead 33 KV an 11 KV Power Lines and overhead 132/33 KV Power Lines.The de-
scription of insulators & string arrangements has been given in Appendix-II.

3.01.2 The technical specifications, contained herein, are for the guidance of the manufacturers.
Any deviation from the Purchaser's specification will be considered on their relative merits
in respect of performance, efficiency, durability and overall economy consistent with the re-
quirements stipulated herein after. Such deviations shall be clearly entered by the manufacturer in
the form as per schedule-VI (A&B) of the specification.

3.02 STANDARDS :

The Disc Insulator shall comply in all respects with the Indian Standard Specifications IS:731-
1971 (Second Revision), IS:3188-1980, IS:2486 (Part-I)-1993 (Second
Revision),IS:2486 (Part-II) 1989 (Second Revision) and IS:2486 (Part-III)1974,
IS:2486(Part.IV)1981 with latest amendments. The galvanization of metallic parts shall conform
to IS:2633/1972(Latest amendments). The Insulator String shall consist of discs (B&S Type) of
dimensions specified in Appendix-I, for use on 3 phase, 50 cycle power system . All applicable
standards shall be clearly mentioned in schedule-III

3.03 MATERIALS, DESIGN & TYPE :

307
3.03.1 All the materials used in the manufacture of the insulators shall be of the first class quality.
The porcelain shall be sound, free from defects thoroughly vitrified and smoothly glazed.

3.03.4 Cement used in the construction of the insulator shall not cause fracture by expansion
or loosening by contraction and proper care shall be taken to locate the individual parts, correctly
during cementing . The cement shall not give rise to chemical reaction with metal fittings and its
thickness shall be as uniform as possible.

3.03.7 The locking devices shall be resilient, corrosion resistant and of suitable mechanical
strength. The hardness and temper of the material are important for their satisfactory operation.

The locking devices shall retain their locking ability after being operated from the locking to the
coupling position at least twenty times , at normal temperature. They should be effective at the
lowest temperature likely to be encountered in service.

308
locking devices `W/R' type for Ball & Socket lockers shall be either of Phosphor bronze confirm-
ing to IS:7814-1975 or stainless steel confirming to IS:6603-1972 with minimumhardness of 160
HV. The dimensions shall confirm to IS:2486(Part-3)-1974.

3.03.9 The dimension of the clevis and tongue connection shall be as shown infig.25 and the
dimension of cross arm strap shall be as shown in fig.26 of IS:2486/Pt.II/1989 ( latest amend-
ments)

The tongue and clevis type porcelain insulators shall be as per fig.2 and its dimension shall con-
form to table-2 of IS:3188/1980 (latest amendments)

The dimensions of pin ball socket shall be according to fig.8 and 9 respectively of IS:2486
(Part.II/1989) IInd revision.

3.04 CLASSIFICATION SIZE & NO. OF DISCS :

3.04.1 The insulators shall be of type B as specified under clause 5 "Classification" of IS:731-
1971(second revision).

3.04.2 The long rod Insulator falling under type A shall confirm to IEC:433-1980(with latest
amendments )& IEC-575/1977.

3.05 ATMOSPHORIC CONDITIONS :

1. Min. temperature (-) 2.5 deg.C

2. Max. temperature of air in shade 50.0 deg.c.
3. Average everyday temperature 32.2 deg.c.
4. Max. temperature of conductor
carrying current and exposed to sun 67 .0 deg.c.
5. Max relative humidity 90 %
6. Min relative humidity 10 %
7. Isoceraunic level 25
8. Number of rainy days per year 70
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9. Annual rain fall 10 to 100 cm
10. Wind pressure(acting on full195 kg/sq.cm
projected area
11. Altitude 200M to 1000M

3.05.2 Reference atmospheric conditions at which insulator characteristics shall be expressed

for the purpose of comparison shall be as given below :

Ambient Temperature : 20 degree C

Barometric pressure. : 1013 milli bars.
Absolute humidity. : 11 g water per cubic metre
corresponding to 63 percent rela-
tive humidity at 20 deg.C.

3.05.3 Tests for the purpose of this specification may be carried out under conditions naturally
obtaining at the time of test. The barometric pressure, air temperature and humidity shall be rec-
orded for the purpose of corrections. Corrections of test voltages for atmospheric conditions shall
be taken as per Appendix. "A" of IS:731/1971 (second revision) "Correction Of Test Voltages For
Atmospheric Conditions".

3.06 TESTING :

3.06.2 TEST VOLTAGE : The test voltage of the insulators shall be as given in Appendix.II
(values given are without applying correction factors).

3.07 MECHANICAL LOADS :

The insulator strings shall be suitable for the minimum failing loads specified in Table-2, clause
7 of IS:731/1971 (IInd Revision). The load shall be supplied axially to the insulator strings.
3.08 MARKINGS :

Each insulator shall be legibly and indelibly marked to show the following :

310
a) Name or trade mark of the manufacturer.
b) Month and year of manufacture.
c) Minimum failing load in KNewton.
d) ISI certification mark if any.
e) TN No. and Name of Purchaser

Marking on porcelain shall be originated and shall be applied before firing.

3.09 CREEPAGE DISTANCE :

The manufacturer shall specify in his tender the creepage distances of the insulator. These
values should not be less than those specified in IS:731-1971 & IS:3188-1980 (Latest amend-
ment).

3.10. TYPE TEST

c) Further supplies shall not be accepted and order shall stand cancelled .
3.11 TYPE TEST :

a) Visible discharge test (10.2).

b) Impulse voltage withstand test (10.3).
c) Wet power frequency voltage withstand test(10.4).
d) Temperature cycle test (10.6).
e) Electro mechanical failing load test 10.7).
f) Twenty four hours mechanical strength test (10.9).
g) Puncture test (10.10).
h) Porosity test (10.11).

311
i) Galvanizing test (10.12).

b) In addition to above, the following type tests shall be got conducted at CPRI , Banglore /any
other NABL accredited Government lab / Govt. approved Lab where facility for the same is avail-
able as per the relevant clauses of IEC standard.

a) Residual Strength Test as per IEC :60797

b) Steep Wave Front test as per IEC: 61211/2004

3.12 ACCEPTANCE TESTS :

3.12.1 These tests shall be for the purpose of acceptance of the lot. For carrying out acceptance
test sampling procedure given in Appendix "C" of IS:731/1971 (second revision) shall be fol-
lowed.

3.12.3 The insulators after having withstood the routine tests shall be subjected to the ac-
ceptance tests.

(a) Clean insulator & dry properly, then meggar the insulator with 2.5 KV/ 5 KV meggar
(b) IR value so measured should not be less than 1000 ( one thousand) mega ohms

The testing and criteria for conformity shall be as applicable to galvanizing and puncture test.

3.13. CRITERION OF CONFORMITY :

312
3.13.1 The criterion of conformity to the requirements of the tests given in 3.11.2 shall be as per
clause No.C-2, of Appendix 'C' of IS:731/1971 (second revision).

3.13.2 No part of the lot withdrawn as described in 3.12.1 above shall constitute part of any
other test submitted for the first time.

3.14 ROUTINE TESTS :

3.14.1 Routine tests shall be carried out on each insulator & to check requirements which are
likely to vary during production as per relevant IS:731/1971 (with latest amendments).

3.15 PACKING :

3.15.1 All insulators shall be packed in suitable crates or boxes with suitable steel bands so
as to withstand rough handling and storage at destination. The gross weight of packing shall
not exceed 50 Kgs.

3.16 DRAWINGS :

3.17 GUARANTEED TECHANICAL PARTICULARS :

Full guaranteed particulars including dry and wet flashovers, puncture and impulse voltages,
corona formation voltages, creepage distances, etc. should be given in the tender as called for in
Schedule-V(A) for 11 KV 45 KN T&C Disc Insulators. Tenders not accompanied by Schedule-
V(A) duly filled in are likely to be ignored.

3.18 TEST CHECKING OF MATERIAL AT STORES

The material received in the stores of the NIGAM shall be subjected to the test checking at
stores before final acceptance of the material, the procedure for the same shall be as under :

i) SAMPLING
One sample out of each sub-lot / lot consisting of following quantities or part thereof in case of
each type of insulators from each inspected lot received in stores shall be selected from each store
for test checking of material and shall be got tested.

11 KV 45 KN Disc insulator “T&C” Type – 1000 Nos.

The sample selection shall be done as soon as the material is received in stores, without calling
the representative of supplier. However, testing at CTL or elsewhere as arranged by NIGAM shall
be done in the presence of representative of supplier after identification/ confirmation by the sup-
plier’s representative that sample(s) so selected belong to them.

ii) TESTS

The following tests shall be carried out on the above items :

a) Visual examination, verification of dimensions, creepage distance etc.

b) Mechanical failing Load Test
c) Porosity test
d) Puncture Test

However, only those tests shall be conducted at CTL for which facility with CTL is available.

In case if the facility for conducting any of the above test(s) is not available at the NIGAM’s
CTL, the purchaser reserve the right to get such test (s) conducted at any independent NABL Test
House.

1. For witnessing of the testing, clear 3 days notice shall be given to the supplier stating date,
time & place where the test is to be conducted. The testing shall be started after identification
/ confirmation of sample by the representative of the supplier that sample selected for testing per-
tain from the lot supplied by them. In case the supplier does not attend for witnessing the testing,
the testing shall be proceeded and completed and action be taken as per the contract.

2. The CTL shall send copies of test reports to the purchaser, consignees and the supplier.

iii) CRITERIA FOR ACCEPTANCE

In case of failure of any of sample (s) in any of the above tests, the material contained in the
lot / sub-lot received in store to which the samples belong, shall be rejected. The rejected material
shall have to be replaced by the supplier free of cost.
iv) TEST CHARGES :
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All test charges incurred towards test checking of the material received in our stores shall
be borne by the NIGAM.

3.19 PLANT, MACHINERY & TESTING EQUIPMENTS;

3.19.1 The manufacturer should have required plant,machinery and testing equipment for
manufacturing & testing of disc insulators.

3.19.2 The manufacturers should furnish details of plant, machinery and testing equipment with
the bids failing which bids may be ignored.

APPENDIX-II

S. PARTICULARS 45 KN DISC 45 KN DISC

NO INSULATOR T&C TYPE INSULATOR B&S
TYPE
1 INSULATORS
a) Diameter 225 mm 255 mm
b) Height 145 mm 145 mm
c) Spacing ---- 145 mm
d) Colour Brown Brown
e) Surface Glazed Glazed
f) Creepage Distance 280 mm 280 mm
g) Ball Dia 16 mm 16 mm
h) Tolerance As per relevant ISS As per relevant ISS
2 STRING ARRANGEMENT
a) Single Tension String fornor-
mal tension location
i) No of E&M 3 3
ii) Disc strength 45 45
b) Double Tension String for
normal tension location
i) No of E&M 3x2 3x2
ii) Disc strength 3x45 KN 3x45 KN
c) Minimum Failing Load As per relevant ISS As per relevant ISS
All Electrical & Mechanical values Conforming to Highest system voltage 36 KV / 132
KV in table -1A of string of IS:731/1971
3 Power System 33KV 3 Phase 50 Cycleef- 132 KV 3 Phase 50
fectively Non earthed Cycle effectively
earthed
4 Highest System 36 KV(RMS) Vol. 36 KV(RMS) Vol.
5 Visible Discharge 27 KV (RMS) 27 KV (RMS)
6 75 KV (RMS) withstand
230 KV (RMS)
Wet Power Frequency test
7 Impulse Voltage 170 KV (Peak) 170 KV (Peak)
8 Power Frequency 1.3 Times the actual dry Flash over voltage of the unit
9 Minimum creepage distance of 580 MM 580 MM
the insulator string for
moderately polluted atmosphere
10 Conductor Weasel& Rabbit Racoon & Dog
11 Stranding and wire diameter Al.30/3.0 + ST 7/3 mm

12 Approx. overall diameter 21 mm 21 mm

13 Appox. Calculated breaking load 9143.47 Kg 9143.47 Kg
14 Normal Aluminium area 207 sq mm 207 sq mm
15 Max. temperature of conductor 67 Deg. C 67 Deg. C
carrying current and exposed to
sun
TECHNICAL SPECIFICATION OF 11 KV GUY (STAY) INSULATORS, AND L.T.
SHACKLE INSULATORSFOR 11 KV TRANSMISSION AND L.T. DISTRIBUION
OVERHEAD POWER LINES

1.0 SCOPE :

1.1 This section provides for design, manufacture, inspection & testing before dispatch, sup-
ply and delivery of Porcelain 11 KVGuy (Stay) insulators, 33 KV Guy (Stay) insulators,L.T. Pin
Insulators and L.T. Shackle Insulatorsspecified herein for their satisfactory use and operationon
various 11 KV sub-transmission & L.T. distribution overhead power lines of the state.

1.2 It is not the intent to specify completely herein all the details of the design and construction
of equipment. However, the equipment shall conform in all respect to high standards of engineer-
ing, design and workmanship and shall be capable of performing in continuous commercial oper-
ation up to the manufacturer's guarantee, in a manner acceptable to the purchaser, who will inter-
pret the meanings of drawings and specification and shall have the power to reject any work or
material which in his judgment is not in accordance therewith. The offered equipment shall be
complete with all components necessary for their effective and trouble free operation. Such com-
ponents shall be deemed to be within the scope of manufacturer's supply irrespective of whether
those are specifically brought out in this specification and / or the commercial order or not.\

2.0 CLIMATIC CONDITIONS :

The insulators shall be suitable for being installed directly in air with stay wire of 11 KV and
LT overhead power lines. These shall be therefore suitable for satisfactory operation under the
tropical climatic conditions listed below :

i) Location In the state of Rajasthan

ii) Maximum ambient air 50

Temperature (deg.C)

iii) Maximum Temperature attainable 60

to an object exposed to sun (deg.C)

iv) Minimum Ambient air (-) 5.0

Temperature (deg.C)

v) Average daily ambient 40.0

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air Temperature (deg.C)

vi) Maximum relative humidity (%) 100

vii) Average rainfall per annum (mm) 100-1000

viii) Average Number of rainy 70

days per Annum
ix) Maximum altitude above mean1000
sea level (meters)

x) Isoceraunic level (Days/Annum) 40

xi) Maximum wind pressure (Kg/sq.m.) 195

xii) Seismic level 0.33 g

3.0 PRINCIPAL PARAMETERS :

3.1 The material shall conform to the following specific parameters :

S.N. Item Specification

1. Type of Installation Outdoor

2. System Voltage 415 Volt (+10%, -15%)
3. System frequency 50 Hz, + 5%
4. Number of phases Three
5. System of earthing Solidly grounded.

3.2 Details of insulators :

3.2.1 The all type of Insulators shall be suitable for use on various 11 KV/33 KV and L.T.
distribution Power lines in a moderately polluted atmosphere.

3.2.2 The 11 KV Guy (Stay ) insulators shall of size110x75x22mm having dimensions as per
fig 2 of IS:5300/1969 (latest amended).

318
3.2.3 The 11 KV Guy (Stay ) insulators shall be brown glazed and conforming to IS:5300/1969
(Latest amended) in all respects.

3.2.3 The L.T.Shackle Insulators shall of size 90x75mm having dimensions as shown in fig.3,
type-1 of IS:1445/1977 (Latest amended).

3.2.3 The L.T.Shackle Insulators shall be brown glazed and conforming to IS:1445 / 1977 (Latest
amended) in all respects.

4.0 GENERAL TECHNICAL REQUIREMENTS :

4.1 The porcelain of Insulators shall be sound, free from defects, thoroughly vitrified and
smoothly glazed.

4.2 The glaze of the insulators shall be brown in colour. The glaze shall coverthe entire porce-
lain surface parts except those areas that serve as supports during firing or are otherwise required
to be left unglazed.

4.3 The design of the insulator shall be such that the stresses due to expansion & contraction
in any part of the insulator shall not lead to its deterioration.
4.4 The dimensions of guy strain insulators essential from the point of view of inter- change-
ability shall be in accordance with IS:5300/1969(latest amended).

4.5 The insulator shall be in one piece.

4.6 The Pin Insulators shall have a top groove and both type of insulators shall
have dimensions as specified above.

4.7. The Pin Insulators shall be threaded to take mild steel pins having profile as shown in fig.5
of IS:1445/1977 (Latest amended). The Shackle Insulators shall have a `U' strap or a pair of straps
and a cotter pin or two bolts and nuts having threads in accordance with IS:4218 (Pt.VI)/1967
(latest amended). The thickness of hexagon nuts shall be in accordance with IS:1363(Part-3/1984)
(Latest amended).

5.0 INSULATOR CHARACTERISTICS :

A. The 11 KV & 33KVGuy (Stay ) insulators shall have the electrical &
Mechanical characteristics as given below:

319
11 KV&33KV

1. Designation of insulator B C
2. Length (mm) 110 140
3. Diameter (mm) 75 85
4. Cable hole dia (mm) 22 25
5. Minimum failing load KN 53 88
6. Creepage distance 48 57
7. Dry one minute power 22 27
frequency withstand voltage
KV (rms)
8. Wet one minute power 9 13
frequency withstand
voltage KV (rms)

B. The L.T. Pin Insulators & L.T. Shackle Insulators shall have the electrical &
Mechanical characteristics as given below:

1. Type of Insulator Pin Insulator Shackle Insulator

2. Size of Insulators (mm) 100x70 90x75

3. Dry power frequency 23 23
withstand Voltage KV (rms)
4. Wet power frequency 10 10
withstand Voltage KV (rms)
5. Power frequency puncture 1.3 x the actual
withstand voltage KV (rms) dry flashover voltage.
6. Min. failing load(KN) 3.5 11.5

-
6.0 IDENTIFICATION & MARKING :

6.1 Each insulator shall be legibly and indelibly marked to show the following:

i) Name or trade mark of the manufacturer.

ii) Month &Year of manufacture.
320
iii) Minimum failing load in KN
iv) ISI certification mark if any.
v) Purchaser’s Name i.e. JPD
vi) TN No. / JVVNL / RDSS

6.2 Marking on porcelain shall be printed & shall be applied before firing.

6.3 Offer not complying the condition of marking shall be treated as non-responsive.

6.4 The insulators marked with ISI Certification Mark will be given preference

7.0 DRAWINGS &DOCUMENTATION :

7.1 The manufacturer shall furnish full description and illustrated catalogues of insulators of-
fered alongwith the bid.

7.2 The manufacturer shall also furnish alongwith the bid the outline drawing of each insulator
unit comply with relevant standard with latest amendment including cross- sectional view of the
shell. The drawing shall include the following information :

i) Shell diameter and unit spacing with manufacturing tolerance.

ii) Weight of unit insulator.
iii) Identification mark.
iv) Manufacturer's catalogue number.
v) Brief installation instructions.

8.0 TESTS :

8.1 TESTS BEFORE DESPATCH :

The insulators shall be subjected at contractor's works before dispatch, to the routine
& acceptance tests given here under as per relevant IS with latest amendment.

8.2 ROUTINE TESTS :

These tests are to carried out to check various requirements of insulators which are
likely to vary during production. The following tests shall be conducted / carried out on each
insulator by the manufacturer at his works as per relevant IS with Latest amendment and he should
furnish certificate / record thereof during pre-dispatch inspection:-

i) Visual Examination

8.3 ACCEPTANCE TESTS :

These tests shall be carried out on the samplestaken from the lot for the purpose of the
acceptance of that lot and shall be carried out by the manufacturer in the presence of the

purchaser's representative(s). The following tests should be conducted in the order given below as
per relevant IS with latest amendment:

i) Verification of dimensions ii) Temperature Cycle test

iii) Mechanical strength test iv) Porosity Test

8.4 TYPE TESTS :

8.4.1 The type tests to be conducted on atleast two units 11 KV Guy Insulatorsas per relevant
IS:5300/1969 (latest amended). The following tests shall constitute the type tests and shall be
conducted in the order given below :

(i) Visual examination (clause 7.8)

(ii) Verification of dimensions (clause 7.5)
(iii) Dry one minute power frequency withstand test(clause 7.2)
(iv) Wet one minute power frequency withstand test (clause 7.3)
(v) Temperature cycle test (clause 7.6)
(vi) Mechanical strength test (clause 7.4)
(vii) Porosity test (clause 7.7)

8.4.2 The type tests to be conducted on atleast two units of LT Shackle insulator as per relevant
IS:1445/1977 (latest amended). The following tests shall constitute the type tests:

(i) Visual examination (clause 8.4)

(ii) Verification of dimensions (clause 8.5)

322
(iii) Dry power frequency voltage withstand test(clause 8.6)
(iv) Wet power frequency voltage withstandtest (clause 8.7)
(v) Temperature cycle test (clause 8.8)
(vi) Mechanical failing load test (clause 8.9)
(vii) Power frequency puncture withstand test (clause 8.10)
(viii) Porosity test (clause 8.11)

However, the purchaser reserves the right to demand repetition of some or all the type tests in
presence of purchaser's representative. For this purpose , the manufacturer should indicate unit
rate for carrying out such type tests. These test charges shall not be taken into consideration
for bid evaluation.

9.0 SAMPLING :

The sampling procedure as laid down in IS:731/1971 with latest amended ( For Guy Insu-
lators ) and IS 1445/1977 with latest amendment ( For and LT Shackle Insulators) shall be fol-
lowed for carrying out specified acceptance tests.
10.0 Type test on samples selected from material received instores from 1st offered lot :

10.1 The first lot offered shall not be less than 10 % of the ordered qty or 5000 Nos. of each type
of Insulators whichever is less.

10.2 If the manufacturer has already got conducted the requisite type test from the first lot of
material received in Nigam ’s store against any previous / earlier tender of JVVNL and such Type
Test reports are valid i.e not older than 5 years

11.0 TOLERANCE ON DIMENSIONS / TEST RESULTS :

As per IS:5300/1969 with latest amendments ( For 11 KV Guy Insulators).As per IS:1445/1977
with latest amendments ( For LT Shackle Insulators).

12.0 TESTS AT SITE :

The purchaser reserves the right to conduct all tests on each type of insulator after arrival
at site and manufacturer shall guarantee test certificates figures under actual service conditions.

13.0 TESTING FACILITIES :

The manufacturer must indicate clearly about the various testing facilities for conducting
various acceptance tests as well as routine tests as per relevant ISS as available at his works. In
case no testing facilities are available at the manufacturer's works, particulars of the place where
such testing is proposed to be conducted during course of inspection must be indicated.

14.0 INSPECTION :

14.1 All the tests as mentioned at Clause 8.2&8.3 above for pre-despatch inspection shall be
conducted at the place of manufacturer unless otherwise especially agreed upon by the manufac-
turer and purchaser at the time of purchase. The manufacturer shall afford the inspection officer(s)
representing the purchaser all reasonable facilities without charges,to satisfy him that the material
is being furnished in accordance with this specification. The purchaser has the right to have
the tests carried out at his own cost by an independent agency whenever there is a dispute regard-
ing the quality of supply.

14.2 The inspection may also be carried out by the purchaser at any stage of manufacture
/ before despatch as per relevant standard.

14.3 Inspection and acceptance of any material under the specification by the purchaser, shall not
relieve the manufacturer of his obligation of furnishing material in accordance with the specifica-
tion and shall not prevent subsequent rejection if the material is found to be defective. The manu-
facturer shall keep the purchaser informed in advance, about manufacturing programme so that
arrangements can be made for inspection.

14.4 The purchaser reserves the right to insist for witnessing the acceptance / routine testings
of the bought out items.

14.5 The manufacturer shall give 15 days advance intimation to enable the purchaser to depute
his representative for witnessing the acceptance and routine tests. The inspection charges would
be to the purchaser's account.

15.0 PACKING & FORWARDING :

15.1 Each type of Insulators shall be packed in grass & then bunch of 50Kg shall be packedin
double gunny bags or single HDP bag but suitable for rough handling & transportation. The
gross weight of each bag normally should not exceed 50 Kg.

15.2 The packing shall bear the appropriate marking of :

324
i) Particulars of material
ii) Quantity
iii) Manufacturer's identification mark
iv) Complete dispatch details such as name of consignee, destination etc.

16 TEST CHECKING OF MATERIAL AT STORES

The material received in the stores of the NIGAM shall be subjected to the test checking at
stores before final acceptance of the material, the procedure for the same shall be as under :

16.1 SAMPLING

One sample out of each sub-lot / lot of 3000 Nos. or part thereof from each inspected lot of each
type of insulators received in stores shall be selected for test checking of material and shall be got
tested. The sample selection shall be done in the presence of supplier or his authorized representa-
tive for which 7 days notice shall be given to the supplier.

16.2 TESTS

The following tests shall be carried out on the above items :

a) Visual Examination, verification of dimensions, Creepage Distance &marking.

b) Mechanical strength test.
c) Porosity test.

i) For witnessing of the testing, clear 7 days notice shall be given to the supplier stating date,
time & place where the test is to be conducted. The testing shall be started after identification /
confirmation of sample by the representative of the supplier that sample selected for testing pertain
from the lot supplied by them. In case the supplier does not attend for witnessing the testing, the
testing shall be proceeded and completed and action be taken as per the contract.

325
ii) The CTL shall send copies of test reports to the purchaser, consignees and the supplier
and Sr. Accounts Officer (CPC).

iii) Only those tests shall be conducted at CTL for which facility with CTL is available.

16.3 CRITERIA FOR ACCEPTANCE

16.4 TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores shall
be borne by the NIGAM.

17 .0 PLANT, MACHINERY & TESTING EQUIPMENTS;

17.1 The manufacturer should have required plant, machinery and testing equipment for
manufacturing & testing of each type of insulators.

17.2 The manufacturers should furnish details of plant, machinery and testing equipment with the
bids failing which bids may be ignored.

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF 11 KV GUY

(STAY)INSULATOR

1. Manufacturer's Name &

Address
i) Office :
ii) Works :

2. Standard Specification : IS : 5300/1969 Latest

to which the insulators amended.

326
shall conform

3. Size of Insulators : 110mmx75mmx22mm

(Brown glazed)
4. Tolerance on various : As per IS:5300/1969
dimensions. (Latest amended)

5. Minimum failing load(KN) : 53

6. Dry one minute power : 22

frequency withstand
voltage,KV (rms)

7. Wet one minute power : 9

frequency withstand voltage
KV (rms)

8. Weight per piece (Kg) :

(approximate)

9. Details of packing : In double gunny / single

HDP (As per cl. 15.0)
10. Creepage Distance :

11. Marking (Trade Mark) :

12. Any other particulars :

which the manufacturer may
like to give.

Signature of manufacturer with seal

327
SCHEDULE-D

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF L.T.SHACKLE

INSULATOR

1. Manufacturer's Name &Address

i) Office :
ii) Works :

2. Standard Specification : IS:1445/1977 With latest

to which the insulators amendment.
shall conform

3. Size of Insulators : 90mm x 75 mmbrown glazed.

4. Tolerance on various : + (0.04d+1.5)mm

dimensions.

5. Minimum failing load(KN) : 11.5 KN

6. Dry power frequency : 23 KV rms

withstand voltage,KV (rms)

7. Wet power frequency : 10 KV rms

withstand voltage,KV (rms)

8. Power frequency puncture : 1.3 x the actual dry flash

withstandvoltage,KV (rms) over voltage.

9. Weight per piece (Kg) :

(approximate)

10. Details of packing : In double gunny/single HDP bags and each

Insulatorwrapped in grass.Each bag
328
weighing upto50 Kg only.

11. Creepage Distance :

12. Marking : Trade mark/year of manufacture /country /

Purchaser’s Name i.e. JPD.

13. Any other particulars

which the manufacturer may
like to give.

Signature of manufacturer with seal

TECHNICAL SPECIFICATION AND OTHER REQUIREMENTS FOR GALVANISED

M.S FORGED PINS FOR 11 KV PIN INSULATORS (11 KV PINS)

1.0 SCOPE :

1.1 This specification covers the design, manufacture, inspection and testing before despatch,
supply and delivery of Galvanised M.S.Forged Pins specified herein for their satisfactory opera-
tion in 11 KV Sub-Transmission lines in Rajasthan.

1.2 The technical specifications, contained herein ,are for the guidance of the manufacturers.
Any deviation from the Purchaser's specification will be considered on their relative merits
in respect of performance, efficiency, durability and overall economy consistent with the re-
quirements stipulated herein after. Such deviations shall be clearly entered by the manufacturers
in the form as per schedule-VI of the specification.

2.0 CLIMATIC CONDITIONS:

2.1 The pins shall be suitable for being installed directly in air with power conductors of 11
KV Double Circuit and Single Circuit Sub-transmission lines. They shall be therefore suitable
for satisfactory operation under the tropical climatic conditions listed below :
i) Location in the state

ii) Maximum ambient Air Temperature (deg.C) 50

329
iii) Minimum Ambient Air Temperature (deg.C) (-) 2.5
Temperature (deg.C)

iv) Average daily Ambient Air Temperature (deg.C) 32.2

v) Maximum relative humidity (%) 100

vi) Minimum relative humidity (%) 50

vii) Average rainfall per annum (mm) 150-1000

viii) Number of rainy days per Annum 70

ix) Altitude above mean sea level (meters) 100-1000

x) Isoceraunic level (Days/Annum) 25(thunder strom)

xi) Maximum wind pressure (Kg/sq.m.) 195

xii) Seismic level (Horizontal Acceleration) 0.08 g

3.0 PRINCIPAL PARAMETERS :

The 11 KV galvanized M.S. Forged Pins suitable for use with 11 KV Pin Insulators(Confirm-
ing to ISS:731:1971 with latest amendments if any) shall comply in all respects with the ISS:2486
(Part-I):1993 & ISS:2486(Part-2/1989) (with latest amendments if any).

3.1 DETAILS OF GALVANISED M.S.FORGED PINS :

The 11 KV Galvanised M.S. forged pins should be suitable to be used with 11 KV Pin Insulator
respectively for a three phase, 11 KV Sub-transmission lines in a moderately polluted atmos-
phere.

3.2 DRAWINGS :

330
Detailed drawings must be furnished along with bid. The drawing shall comply with IS
2486(Part-I)/1993 & IS:2486 (Part-II)/1989 with latest amendment if any. The 11 KV Galvanised
M.S.Forged Pins shall be suitable for use with 11 KV Pin Insulator (confirming to IS731/1971
with latest amendment, if any) respectively.

4.0 GENERAL TECHNICAL REQUIREMENTS :

4.1 HEADS :

The head shall be of steel and shall be in accordance with Fig.1 of IS:2486 (Part-2) / 1989 with
latest amendments, if any. They shall screw into a thimble fixed in the pin hole of the insulators.
The dimensions of the gauges for these heads are given in fig. 2 to 4 of aforesaid IS.

4.2 PINS :

The 11 KV Galvanized M.S. Forged Pins suitable for use with 11 KV Pin Insulators (Con-
forming to IS:731/1971 with latest amendments if any) shall comply in all respects with the
IS: 2486 (Part-1)/1993 & IS:2486 (Part-2)/1989 with latest amendments if any. The dimensions
of the line pins shall be as given in fig. 5 of the above mentioned ISS.

4.3 STALKS :

The stalk length of line pins shall be measured above the seating face of the collor conform-
ing to IS:2486 (Part-2)/1989.

4.4 SHANKS :

The shank length of the line pins shall be measured below the seating face of the Collor &
conforming to IS:2486 (Part-2)/1989.

4.5 GALVANISED M.S.FORGED PINS :

i) GALVANISATION :

All ferrous pins and nuts shall be hot dipped galvanised. The galvanisation shall conform
to IS: 2633/1986 with latest amendments and satisfy the requirements given in IS:4759/1984. The
threads on the nuts & tapped holes shall be cutout after galvanising & shall be well oiled or
greased. Spring washers shall be electro galvanised conforming to service grade No.4 of
IS:1573/1986(latest amended).

ii) FAILING LOAD : The 11 KV Pins shall be offered for minimum failing load of 5 KN.

331
iii) DIMENSIONS : The 11 KV Pins for supply under this specification shall be of small
steel head as per figure No. 5 of IS:2486 (Part-2)/ 1989 and shall have the following dimensions.

a) Stalk length. : 165 mm

b) Shank length. : 150 mm
c) Hexagon nut : M20 as per IS:1363(Part-3) /1992
d) Spring washer : Nominal size 20 as per IS:3063/1972.

4.6. THREADS :

Threads shall be as specified in IS:4218 (Part-2) /1976 and matching with 11 KV Pin
Insulators conforming to IS:731/1971 (with latest amendments if any)

4.7 HEXAGON NUTS : - Hexagon Nuts of M-20 size shall conform to IS:1363(Part-
3):1992 (latest amended).

4.8 SPRING WASHERS : - Spring washers shall conform to IS:3063:1972 (Latest amended).

4.09 MATERIAL DESIGN AND WORKMANSHIP :

4.09.1 GENERAL :

i) All raw materials to be used in the manufacture of these pins shall be subjectto
strict raw material quality control and to stage testing/quality control during
manufacturing stage to ensure the quality of the final end product. Manufacturing shall conform
to the best engineering practices adopted in the field of high voltage transmission. Manu-
facturers shall therefore offer pins
as are guaranteed by them for satisfactory performance on 11 kV Sub-
transmission Lines.

ii) The design, manufacturing, process and material control at various stages be
such as to give maximum working load, highest mobility, best resistance to corrosion,
good finish, elimination of sharp edges and corners.

4.10 TESTS

4.10.1 TEST BEFORE DESPATCH: The 11 KV Galvanised M.S.Forged pins and accessories
shall be subjected at maker's works before despatch, to the tests mentioned hereunder as per IS:
2486(Part.1)/1993 (with latest amendments).
4.10.2 ROUTINE TESTS :

The following tests shall be conducted on each unit by the manufacturer at his works
as per relevant standard - IS:2486 (Part-1)/1993 (latest amended) :

a) Visual Examination ( Clause-8 )

4.10.3 ACCEPTANCE TESTS :

The following tests shall be conducted on samples taken at random from a lot as per rele-
vant standard, IS:2486 (Part-1)/1993 (latest amended) in presence of purchaser's representative :

a) Verification of dimensions (Clause 8 & 9.2.2 )

b) Galvanizing Test (Clause 9.4)
c) Mechanical Tests (Clause 9.5)

5.0 TYPE TESTS

5.01 The manufacturer shall furnish valid and authenticated type test certificates from a
Govt. approved / Govt. recognized / NABL Accredited laboratory / ILAC i.e. Inter-
national Laboratory Accredited Laboratory (in case of foreign laboratory) of similar
rating and design of tendered material/ equipment. Such type test certificatesshould
not be older than 5 years as on the date of bid opening. For this purpose dateof con-
ducting type test will be considered.

The type test certificate by in house laboratory of tendering firm even if it is a Govt.
approved / Govt. recognized / NABL accredited / ILAC accredited, shall not be ac-
cepted, in case of their own tender. This will not apply if tendering firm is Govt.
company / public Sector undertaking.

5.02 The manufacturer should furnish documentary evidence in support of the laboratory
whose type test have been furnished, that the said laboratory is a Govt. / a Govt.
approved / a Govt. recognized / NABL accredited laboratory / ILAC accredited (in
case of foreign laboratory).

5.03 The type test certificates shall be furnished either in original or copy duly attested by
notary.
5.04 SAMPLING : As per IS:2486 (Part-1)/1993 (latest amended)

5.05 TOLERANCE ON TEST RESULTS : As per IS:2486(Part-1)/1993 & IS:2486

(Part-2)/1989(latest amended).

6.0 TESTING FACILITIES :

The manufacturer must indicate clearly about the various testing facilities for type test as
well as for routine/sample tests as per relevant ISS is respect of M.S.Forged Pins as are available
at their works. In case no testing facilities are available at the manufacturer's works particulars
of the place where such testing is proposed to be conducted during the course of inspection must
be indicated.

7.0 INSPECTION

All the tests (as mentioned at Clause 6.1.2) and Inspection shall be made at the place
of manufacturer unless otherwise especially agreed upon by the manufacturer and purchaser at
the time of purchase. The manufacturer shall afford the inspection officer(s) representing the
purchaser all reasonable facilities without charges, to satisfy him that the material is being fur-
nished in accordance with this specification. The purchaser has the right to have the tests carried
out at his own cost by an independent agency whenever there is a dispute regarding thequality
of supply.

The Inspection may be carried out by the purchaser at any stage of manufacture/ before despatch
as per relevant standard.

Inspection and acceptance of any material under the specification by the purchaser, shall not
relieve the manufacturer of his obligation of furnishing material in accordance with the specifi-
cation and shall not prevent subsequent rejection if the material is found to be defective. The
Manufacturer shall keep the purchaser informed in advance, about manufacturing program so
that arrangements can be made for inspection.

The purchaser reserves the right to insist for witnessing the acceptance/ routine testing of the
bought out items.

The Manufacturer shall give 15 days( for local supplies) / 30 days ( in case of foreign manufac-
turer) advance intimation to enable the purchaser to depute his representative for witnessing the
acceptance and routine tests. The inspection charges would be to the purchaser'saccount.

334
8.0 PACKING & FORWARDING :

i) All 11 KV Galvanised M. S. Forged pins shall be packed in double bags, one HDP bag
(inner) and one gunny bag (outer) or in double gunny bag. The gross weight of each packing
shall not normally exceed 50 Kg.

ii) The packing shall be of sufficient strength to withstand rough handling during transit,
storage at site and subsequent handling in the field.

:
9.0 TEST CHECKING OF MATERIAL AT STORES

9.1 The material received in the stores of the NIGAM shall be subjected to the test checking
at stores before final acceptance of the material, the procedure for the same shall be as under
:

9.2 SAMPLING
One sample out of each sub-lot / lot of 3000 Nos. or part thereof from each inspected lot
received in stores shall be selected for test checking of material and shall be got tested.The
selection of sample from the material received at stores shall be done as soon as material is
received in stores without the presence of the representative of the supplier. However, testing
of sample(s) at CTL shall be carried out in the presence of representative of the supplier after
identification / confirmation by him that sample so selected belongs to them. In case the supplier
disputes that the selected samples does not pertain to them, then fresh sample shall be selected
in the presence of the representative of the supplier and test(s) be carried out.

9.3 TESTS

The following tests shall be carried out on the above items :

a) Visual Examination, Verification of Dimension, weight and marking
b) Mechanical Test.
c) Galvanisation (Uniformity) Test.

9.4 Test of the material shall be got done at the test laboratory of the respective Discom in the
presence of representative of supplier. For witnessing of the testing, clear 3 (three) days notice
shall be given to the supplier by fax/ speed post stating date, time & place where the test is
to be conducted. In case the supplier do not attend for witnessing the testing, the testing shall be
proceeded and completed and action be taken as per the contract.
9.5 The witnessing officers of the respective Discom or as designated by the purchaser shall
send copies of test reports to the purchaser, consignees and the supplier and AO (CPC) of re-
spective Discom.
9.6 Only those tests shall be conducted at CTL for which facility with CTL is available.

10.0 CRITERIA FOR ACCEPTANCE

10.1 Visual Examination, Verification of Dimension, weight and marking

. As per specification/ ISS

10.2 Mechanical test.

In case of failure of sample in Mechanical Test, the material contained in the lot
/ sub-lot to which the sample belongs, shall be rejected. The rejected material shall have
to be replaced by the supplier free of cost.

10.3 Galvanisation (Uniformity) Test.

10.3.1 The sample(s) shall be first tested for (n-2) number of dips where (n) is specified
number of dips in the contract. If the sample(s) does not pass the uniformity of Galvanisation
Test for (n-2) dips, the material shall be rejected and the material relating to relevant lot /
sub-lot to which sample(s) pertains shall have to be replaced by the supplier free of cost.

10.3.2 If the sample has passed the uniformity of Galvanisation Test for (n-2) dips, then
it shall be tested for (n-1) dips. If the sample has not passed the uniformity of Galvanisation
Test with (n-1) dips, then material pertaining to relevant lot / sub-lot shall beaccepted with a
deduction @ 10% of cost of material.

10.3.3 If the sample has passed the uniformity of Galvanisation Test with (n-1) dips,
then sample shall be tested for last one dip of one minute to complete the test for
`n' dips. If the sample does not pass the uniformity of Galvanisation Test with `n' dips, then
the material pertaining to relevant lot/ sub-lot shall be accepted with a deduction @ 5% of
cost of material.

10.3.4 If the sample(s) have passed the Test with number of dips as specified in the contract
(n), then material pertaining to relevant lot / sub-lot shall be accepted.

11.0 TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores
shall be borne by the NIGAM.

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12.0 IDENTIFICATION & MARKING :

Each 11 KV Pin shall be marked with the manufacturer's name or trade mark.

GUARANTEED TECHNICAL & OTHER PARTICULARS OF

11 KV GALVANISED M.S.FORGED PINS.
(To be filled in by the bider and sent along with bid)

S.N. Description 11 KV PINS

1. a) Manufacturer's Name & address. To be filled by manufacturer
b) Work’s address To be filled by manufacturer
2. Minimum failing load (KN) 5 KN
3. Standard specification to which the material IS: 2486 (Part-1)/1993 & IS:
shall conform. 2486 (Part-2)/1989 with latest
amendments if any.
4. Dimensions ( mm ):-
a) Total length. 315 mm
b) Shank length. 150 mm
c) Stalk length. 165 mm
5. Type of threads. As per IS 4218 (Part-2)/1976
6. Threads per inches. IS 4206
7) a Type of Galvanisation. Hot dip
b) Galvanisation shall conform to. As per IS: 2633/1986 with latest
amendments if any.
8. Hexagon nut shall conform to M-20 IS: 1363(Part-3)/1992
9. Spring washer shall conform to Size 20 IS: 3063/1974
10. Electro-galvanisation of spring washer shall As per IS: 1573/1986
conform to.
11. Packing details :-
a) Type of packing double bags, one HDP bag (in-
ner) and one gunny bag(outer)
or in double gunny bag
b) Weight of each pin (approx.) 925 gms.± 2%
c) No. of Pins in each packing. 50 Nos.
d) Weight of each package (kg) Less than 50 Kg.

337
12. Tolerance in dimensions,if any. As per IS: 2486 (Part-1)/1993
& IS: 2486 (Part-2)/1989 with
latest amendments if any
13. Tolerance in Weight ± 2% of 925 gms
14. ISI certification license number, if any.
15. Any other relevant information the bider
would like to indicate.
16. Manufacturer's trade mark to be embossed on To be filled by manufacturer
the pins.
17. Other details/informations.

Signature
Name & Designation with seal of the firm

338
TECHNICAL SPECIFICATION FOR HARDWARE FITTINGS FOR L. T. SHACKLE
INSULATORS FOR USE ON L. T. DISTRIBUTION OVERHEAD POWER LINES

1.0 SCOPE :

1.1 This specification provides for the design, manufacture, inspection and testing before dis-
patch, supply and delivery of Hardware fittings for L. T. Shackle Insulators specified herein
for their satisfactory use & operation on various distribution overhead power lines of theState.

2.0 CLIMATIC CONDITIONS :

The Hardware fittings shall be suitable for being installed directly in air with power conductors
L.T. single circuit/double circuit overhead distribution lines. These items, therefore, shall be suit-
able for satisfactory operation under the tropical climatic conditions listed below :
1. Location In the state of Rajasthan
i) Maximum ambient air Temperature 50
(deg.C)
ii) Maximum Temperature attainable to an 60
object exposed to sun (deg.C)
iii) Minimum Ambient air Temperature (-) 5.0
(deg.C)
iv) Average daily ambient air Temperature 40.0
(deg.C)
v) Maximum relative humidity (%) 100
vi) Average rainfall per annum (mm) 100-1000

339
vii) Average Number of rainy days perAn- 70
num
viii) Maximum altitude above mean sea level 1000
(meters)
ix) Isoceraunic level (Days/Annum) 40
x) Maximum wind pressure (Kg/sq.m.) 195
xii) Seismic level 0.33 g

3.0 PRINCIPAL PARAMETERS:

The material shall conform to the following specific parameters :

S.No. Item Specification

1. Type of Installation Outdoor
2. System Voltage 415 Volt(+10%, -15%)
3. System frequency 50 Hz, + 5%
4. Number of phases Three
5. System of earthing Solidly grounded.

4.0 DETAILS OF ITEMS :

The shackle insulator hardware fittings shall be suitable for use on single phase/three phase,
230/440 Volts overhead distribution lines in a moderately polluted atmosphere.

5.0 GENERAL TECHNICAL REQUIREMENTS:

5.1 GALVANISED HARDWARE FITTINGS FOR L.T. SHACKLE INSULATORS:

5.1.1 The hardware fittings for L.T. Shackle Insulators shall comply in all respects, herein oth-
erwise stated, with fig.3, type-1 of IS:7935/1975 (latest amended). The hardware fittings assembly
shall comprise the following:

i) A pair of mild steel straps,

ii) Two numbers of mild steel bolts with
hexagonal head,
iii) Two numbers of mild steel nuts of hexagonal
head to suit bolts under item (ii) above &
340
iv) Two numbers suitable washers.

5.1.2 DIMENSIONS: The dimensions of hardware fittings for L.T. shackle insulators for supply
under this specification shall conform to figure 3, type 1 of IS:7935/1975 (latest amended) and
shall have the following dimensions:

S.No. Item Dimensions

i) Length of straps 185 mm
ii) Width of straps 30 mm
iii) Thickness of straps 3 mm
iv) Diameter of holes at the end of straps 14 mm
v) Dia. of bolts 12 mm
vi) Length of bolts 115 mm
vii) Dia.of bolt head 17 mm
viii) Thickness of bolt head.(M-12)
a Nominal 7.5 mm
b Maximum 7.95 mm
c Minimum 7.05 mm

ix Thickness of nuts
a Maximum 12.2 mm
b Minimum 10.4 mm
x Shape of bolt head& nuts Hexagonal

xi Length of threaded portion of bolts. 65 mm

xii Thickness of galvanized spring washer (M- 3 mm + 0.15 MM
12)

xiii Weight of complete hardware fitting 0.475 Kgs.± 2% Tolerence

set.(approx.)

5.1.3 HEXAGONAL NUTS : Hexagonal Nuts of M-12 size shall be used & shall conform
to IS:1363(Part-3):1992 (latest amended). The nuts shall be made of material conforming toclass
4.8 of IS:1367 (Latest amended) with regard to its mechanical properties. The thickness of the hex-
agon nuts shall be in accordance with IS:1363 (Pt-3)/1984 (Latest amended). The screw threads on
the shank and the nut shall be as prescribed in IS:4218 (Pt-6)/1978 (Latest amended).

5.1.4 SPRING WASHERS : Spring washers of 3.0 mm thickness of M-12 size shall be used which
should conform to IS:3063:1994 (Latest amended).
341
5.1.5 Galvanisation: The Hardware fittings shall be hot dip galvanised. The galvanisation of
Hardware fittings shall conform to IS:2633/1972 (latest amended). The threads of nuts and tapped
holes shall be cut after galvanisation and shall be well oiled or greased. Small parts like nuts
and spring washers etc. may be electro-galvanised in accordance with IS:1573/1970 (latest
amended)

5.2 IDENTIFICATION & MARKING :

5.2.1 The hardware fittings for shackle insulators shall be marked with the manufacturer's name
or trade mark.

5.2.2 The package containing the insulator fittings may also be marked with the ISI certification
mark if available.

6.0 TESTS :

6.1 TEST BEFORE DESPATCH: The Hardare fittings for L.T.shackle insulators shall be sub-
jected at manufacturer’s works before despatch, to the tests mentioned here-under as per IS:
7935/1975 (latest amended).

6.1.1 ROUTINE TESTS :

The following tests shall be conducted on each unit by the manufacturer at his works as per
relevant standard - IS:7935/1975 (latest amended) :

a) Visual Examination ( Clause-4.4)

6.1.2 ACCEPTANCE TESTS :

The following tests shall be conducted on samples taken at random from a lot as perrele-
vant standard, IS:7935/1975 (latest amended) in presence of purchaser's representative :

a) Checking of threads on heads (Clause 4.6 )

b) Galvanizing / Electroplating test (Clause 4.7)
c) Verification of dimensions (Clause 4.5)
d) Mechanical Strength Test (Clause 4.8)

6.2 TYPE TESTS

a) The manufacturer shall furnish valid and authenticated type test certificate from a Govt. approved/
a Govt. recognized/ NABL accredited laboratory/ ILAC i.e. International Laboratory Accredited
laboratory / ILAC i.e International Laboratory Accrediation Cooperation ( In case of foreign labor-
atory) . Such type test certificates should not be older than five years as on the date of bid opening.
For this purpose date of conduction Type Test(s) will be considered.

b) The type test certificates by in house laboratory of biding firm even if it is a Govt approved/ Govt
recognized/ NABL accredited/ ILAC accredited,shall not be accepted, in case of their own bid. This
will not apply if biding firm is Govt. Company/ Public Sector Undertaking.

c) The manufacturer should furnish documentary evidence in support of the laboratory whose type
test have been furnished, that the said laboratory is a Govt/ a Govt. approved/ a Govt. recognized/
NABL accredited laboratory/ ILAC accredited ( in case of foreign laboratory)

d) The type test certificates shall be furnished either in original or duly attested by notary.

e) The bids of only those manufacturers shall be considered to be meeting the type test criteria who
furnishes complete type test certificates with the bid as per above provision.

6.2.1 The following shall constitute the type tests which are to be conducted on at least three units
of each rating as per standard IS:7935/1975 (Latest amended) and other relevant standards :-

a) Visual examination test (Clause 4.4).

b) Verification of dimensions (Clause 4.5)
c) Checking of threads on heads ( clause 4.6)
d) Galvanising/electroplating test (Clause 4.7)
e) Mechanical strength tests (Clause 4.8) (for pins only)

6.2.2 However, the purchaser reserves the right to demand repetition of some or all the type tests
in presence of purchaser's representative. For this purpose, the manufacturer should indicate unit
rates for carrying out such type tests. These test charges shall not be taken into consideration for
bid evaluation.

6.3 SAMPLING : As per IS:7935/1975 (latest amended)

6.4 TOLERANCE ON TEST RESULTS: The tolerance for dimensions when not indicated in the
drawing i.e. fig. 2 & 3 of IS:7935/1975 (Latest amended) for L.T.Pins & Hardware Fittings for
L.T.Shackle Insulators, shall be ± 5% except on collar thickness of L.T.pins for which tolerance is
allowed upto 2 mm on plus side and 0.5 mm on minus side.
6.5 TEST AT SITE:

The purchaser reserves the right to conduct all tests on Hardware fittings after arrival at site
/ store and the contractor shall guarantee test certificate figures under actual service conditions.

6.6 TESTING FACILITIES:

The manufacturer must indicate clearly about the various testing facilities for the acceptance
tests as well as routine tests as per relevant ISS as are available at their works. In case no testing
facilities are available at the manufacturer's works, particulars of the place where such testing
is proposed to be conducted during the course of inspection must be indicated.

7.0 INSPECTION

7.1 All the tests as mentioned at Clause 6.1.1 & 6.1.2 for pre-despatch inspection shall be made
at the place of manufacturer unless otherwise especially agreed upon by the manufacturer and pur-
chaser at the time of purchase. The manufacturer shall afford the inspection officer(s) repre-
senting the purchaser all reasonable facilities without charges, to satisfy him that the material is
being furnished in accordance with this specification. The purchaser has the right to have the
tests carried out at his own cost by an independent agency whenever there is a dispute regarding
the quality of supply.

7.2 The Inspection may also be carried out by the purchaser at any stage of manufacture/ before
despatch as per relevant standard.

7.3 Inspection and acceptance of any material under the specification by the purchaser, shall not
relieve the manufacturer 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.
The Manufacturer shall keep the purchaser informed in advance, about manufacturing program so
that arrangements can be made for inspection.

7.4 The purchaser reserves the right to insist for witnessing the acceptance/ routine testings of
the bought out items.

7.5 The Manufacturer shall give 15 days advance intimation to enable the purchaser to depute his
representative for witnessing the acceptance and routine tests. The inspection charges would
be to the purchaser's account.

8.0 DOCUMENTATION :
8.1 The Manufacturer shall furnish full description and illustrated catalogues of material offered
alongwith the bid.

8.2 The Manufacturer shall also furnish alongwith the bid the outline drawing of L.T. Pins & hard-
ware fittings as per reference fig. of relevant ISS.

8.3 TEST REPORTS :

8.3.1 Two sets of type test reports duly approved by the purchaser shall be submitted by the sup-
plier for distribution before commencement of supply. Adequate copies of acceptance & routine
test certificate, duly approved by the purchaser shall accompany the despatchedconsignment.

8.3.2 All records of routine test reports shall be maintained by the Supplier at his worksfor
periodic inspection by the Purchaser.

8.3.3 All test reports of tests conducted during manufacture shall be maintained by the Supplier.
These shall be produced for verification as and when requested for by the Purchaser.

9.0 PACKING & FORWARDING :

9.1 All insulator fittings shall be packed in double bags, one HDP bag (inner) and one gunny
bag (outer) or in double gunny bag. The gross mass of the each packing shall not normally exceed
50 Kg.

9.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage
at site and subsequent handling in the field.

10.0 TEST CHECKING OF MATERIAL AT STORES

The material received in the stores of the NIGAM shall be subjected to the test checking at
stores before final acceptance of the material, the procedure for the same shall be as under :

10.1 SAMPLING

One sample out of each sub-lot / lot of 3000 Nos. or part thereof from each inspected
lot received in stores shall be selected for test checking of material and shall be got tested.

345
The selection of sample from the material received at stores shall be done as soon as material
is received in stores without the presence of the representative of the supplier. However,
testing of sample(s) at CTL shall be carried out in the presence of representative of the sup-
plier after identification / confirmation by him that sample so selected belongs to them. In
case the supplier disputes that the selected samples does not pertain to them, then fresh sam-
ple shall be selected in the presence of the representative of the supplier and test(s) be carried
out.

10.2 TESTS
10.2.1 The following tests shall be carried out on the above items :
a) Visual Examination, Verification of Dimension, weight and marking.
b) Mechanical Strength Test ( for LT Pins only).
c) Galvanisation (Uniformity) Test.
Only those test shall be conducted at CTL for which facility with CTL is available.

10.2.2 Test of the material shall be got done at the test laboratory of the NIGAM or any other
test laboratory designated by the Chief Engineer (MM). For witnessing of the testing, 3(three) days
notice shall be given to the supplier stating date, time & place where the test is to be conducted.
In case the supplier do not attend for witnessing the testing, the testing shall be proceeded and
completed and action taken as per the contract.

10.2.3 The witnessing officers of the NIGAM or as designated by the purchaser shall send copies
of test reports to the purchaser, consignees and the supplier.

11. CRITERIA FOR ACCEPTANCE

12. Visual Examination, Verification of Dimension, weight and marking .

As per specification/ ISS

12.1 Mechanical Strength Test (for LT Pins only)

In case of failure of sample in Mechanical Strength Test, the material contained in the lot /
sub-lot to which the sample belongs, shall be rejected. The rejected material shall have to
be replaced by the supplier free of cost.

12.2 Galvanisation (Uniformity) Test.

12.2.1. The sample(s) shall be first tested for (n-2) number of dips where (n) is specified number
of dips in the contract. If the sample(s) does not pass the uniformity of Galvanisation Test for
(n-2) dips, the material shall be rejected and the material relating to relevant lot / sub-lot to
which sample(s) pertains shall have to be replaced by the supplier free of cost.

346
12.2.2 If the sample has passed the uniformity of Galvanisation Test for (n-2) dips, then it shall
be tested for (n-1) dips. If the sample has not passed the uniformity of Galvanisation Test with (n-
1) dips, then material pertaining to relevant lot / sub-lot shall be accepted with a deduction @ 10%
of cost of material.
12.2.3 If the sample has passed the uniformity of Galvanisation Test with (n-1) dips, then sam-
ple shall be tested for last one dip of one minute to complete the test for `n' dips. If the sample
does not pass the uniformity of Galvanisation Test with `n' dips, then the material pertaining to
relevant lot/ sub-lot shall be accepted with a deduction @ 5% of cost of material.

12.2.4 If the sample(s) have passed the Test with number of dips as specified in the contract (n),
then material pertaining to relevant lot / sub-lot shall be accepted.

13.0 TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores shall be borne
by the NIGAM.

GUARANTEED TECHNICAL & OTHER PARTICULARS OF L.T.SHACKLE HARDWARE

FITTINGS
S. Description Particulars
1. MANUFACTURER'S NAME & ADDRESS :
i) OFFICE
ii) WORKS
2. STANDARD SPECIFICATION TO WHICH THE IS:7935/1975 (FIG.3) LATEST &
H/W FITTINGS SHALL CONFORM OTHER RELEVANT ISS
3. DIMESIONS OF H/W FOR L.T SHACKLE
INSULATOR:

A) LENGTH OF STRAPS 185 MM

B) WIDTH OF STRAPS 30 MM
C) THICKNESS OF STRAPS 3 MM
D) DIAMETER OF HOLES AT THE END OF STRAPS. 14 MM
E) LENGTH OF BOLTS 115 MM
F) DIAMETER OF BOLTS 12 MM
G) DIAMETER OF BOLT HEAD 17 MM
H) THICKNESS OF BOLT HEAD 8 MM
I) THICKNESS OF NUTS
i) MAXIMUM 12.2 MM (M12)
ii) MINIMUM 10.4 MM

347
J) SHAPE OF BOLT HEAD & NUT HEXAGONAL
K) LENGTH OF THREAD PORTION OF BOLT. 65 MM
L) GALVANISED SPRING WASHER 2.5 MM + 0.15 MM
THICKNESS.(M12 SIZE)
4. TOLERANCE ON VARIOUS DIMENSIONS ± 5%
5 WEIGHT OF COMPLETE H/W SET 0.475 KG (APPROX.) ± 2%
Tolerence
6 TYPE OF GALVANISATION
i) STRAPS HOT DIP GALVANISED
ii) BOLTS HOT DIP GALVANISED
iii) NUTS & SPRING WASHERS HOT DIP/ELECTRO-
GALVANISED.THE MIN.
LOCAL THICKNESS OF ELEC-
TROPLATED ZINC COAT-
ING SHALL BE 25 MICRON AS
PER SERVICE GRADE NO.4 OF
IS:1573/1986.
7. MARKING
8. DETAILS OF PACKING double bags, one HDP bag (inner)
and one gunny bag (outer) or in
double gunny bag
9. ANY OTHER PARTICULARS WHICH THE
MANUFACTURER MAY LIKE TO GIVE.

SIGNATURE OF MANUFACTURER WITH SEAL

348
TECHNICAL SPECIFICATION AND OTHER REQUIREMENTS FOR HARDWARE
FITTINGS FOR 11 KV,45 KN DISC INSULATORS TONGUE & CLEVIS TYPE &
HARDWARE FITTINGS 11 KV,45 KN DISC INSULATORS BALL & SOCKET TYPE

3.01 SCOPE :

3.01.1 This specification covers the design, manufacture, testing supply and deliv-
ery of hardware fittings suitable for 11 KV disc insulators tongue & clevis type & Ball &
Socket Type for use on various 11 KV /33KV sub transmission lines . These fittings are to
be designed as per drawing attached at Appendix-I (A) & I(C) { for T&C type } and I (B)
& I(C) {For B&S type}

3.01.2 The technical specifications, contained herein, are for the guidance of the man-
ufacturers. Any deviation from the Purchaser's specification will be considered on
their relative merits in respect of performance, efficiency, durability and overall economy
consistent with the requirements stipulated herein after. Such deviations shall be clearly
entered by the manufacturer in the form as per schedule-VI of the specification.

3.02 STANDARD :

Hardware fittings for 11 KV disc insulators T&C & B&S type should conform to
ISS:2486 (Part.I/1993), 2486 (Part.II) 1989, ISS:2486 Part.III / 1974 and ISS:2486(Part.
IV), 1981.

3.03 GENERAL REQUIREMENT :

i) All forgings and castings shall be of good finish and free from flaws and other
defects. The edges on the outside of fittings, such as at the eye clevis and holes, shall be
rounded.

ii) All parts of different fittings which provide for inter connection shall be made
such that sufficient clearance is provided at connection point to ensure free movement. All
eye and clevis connections shall be free in this manner but care shall be taken that tomuch
clearance between eye and tongues of the clevis is avoided.

iii) All ferrous fittings and the parts other than those of stainless steel, shall be hot
dipped galvanised. Small fittings like spring washers, nuts etc. may be electrico plated
with zinc conforming to IS:1573:1970 Grade-4.

(iv) MATERIAL : The material of the fittings shall be so selected that yield strength
of the material shall not be less than maximum working load.

349
All fittings except strain clamp shall be made of drop forged or upset forged steel
(IS-2004/1978) and shall be hot dipped galvanised.

The strain clamp for aluminium AAC and ACSR Conductor shall be high strength
Aluminium alloy (IS 6051/1970). The composition of the alloy shall be declared by
the manufacturer giving reference to the relevant Indian Standard.

The cotter pins shall be provided with mild steel flat washers in addition to split
pins. The split pin to be used on the cotter pin shall be of phosphors-bronze conforming
to IS-7814/1975, stainless steel conforming to IS-5522/1992, or brass conforming to IS-
410/1977 with a minimum hardness of 160 HV.

MATERIAL FOR :

S. No. Description Particulars

a) Dead end straps. Galvanised M.S.Twisted
b) Strain bolts & nuts with spring washer Galvanised M.S.
c) Cotter pin. Phospherbronze/Brass/
stainless steel.
d) Special envelope for bolted type clamp Al.Alloy.
e) Socket eye Forged steel
f) Ball eye Forged Steel.
g) Clevis ended strain clamp. Aluminium alloy

(v) Weight of T&C & B&S type hardware fittings set shall be indicated in
GTP as per details below :-

S. No. Description “T&C” “B&S”

i) Net weight per set in kg 1.250 3.350
ii) Net weight of steel parts in 1.050 2.675
Kg.
iii) Net weight of Aluminium 0.200 0.675
part per set in Kg.

3.04 TOUNGE AND CLEVIS TYPE HARDWARE:

350
Each T&C type hardware fitting set shall be complete in every respect and shall
comprise of the following :

S. No. Description Particulars

i) Dead end straps.(As per drawing attached) One set.
ii) Strain bolt with hexgonal nuts. One No.
iii) Spring washer One No
iv) Flat washter One No.
v) Cotter pin. One No.
vi) Split pin One No
vii) Clevis ended aluminium alloy clamps One No.
suitable for ACSR conductor 7/2.11 MM,
7/2.59 MM and 7/3.35 MM. The ultimate
strength of clamps shall not be less than
3000 Kgs (As per drawing attached)

The T&C type fittings shall conform in all respect to drawing attached with the
specification.(Appendix-I A&C)

3.05 CLEVIS AND TONGUE CONNECTION :

The dimension of the tongue and clevis type connection shall conform to Fig 25 of
ISS 2486 (Part-2)/1989.

3.06 BALL AND SOCKET TYPE HARDWARES :

Each B&S type hardware fitting set shall be complete in every respect and shall
comprise of the following :

S. No. Description Particulars

i) Dead end straps.(As per drawing attached) One set.
ii) Strain bolt with hexgonal nuts. One set.
iii) Spring washer One set.
iv) Ball eye. One set.
v) Socket eye One set.
vi) Split pin One set.
vii) Flat washer One set.
viii) Cotter pin One set.
ix) Strain clamp of special envelops type One set.
made of aluminium alloy (Bolted type).
x) Security clips (W.type) Split pin shall not One set.
be accepted.

The dead end straps or cross arms straps shall comprise of a pair of twisted straps,
one strain bolt with one spring washer and hexagonal nut and split pin. The strap shall
conformed to drawing attached.(Appendix-1C)

The material for the hardware fittings shall be such that it gives the required mechanical
strength with specified dimensions. The aluminium alloy of the clamp shall conform to A-
6 of IS:617 and shall be gravity die cast.

All nuts shall be made of material conforming to properly class 5 of IS:1367:1967 with
regard to its mechanical properties. Cotter pins shall be made of forged steel conforming
to clause No. 2 of ISS:2004:1962,IS- 2004:1978.

For galvanising, zinc conforming to grade Zn-98 of IS:209/1966,IS 209/1979 shall be

used.

The B&S type fittings shall conform in all respect to drawing attached with the
specification.(Appendix-I B&1C)

3.07 GALVANISING :

The uniforminty of zinc coating of hot dipped galvanised parts shall conform
to IS:2633:1972 with latest amendments thereof, if any.

3.08 MARKING :

The clamps (aluminum portion) of each H/W fittings shall be provided with the
following marking:

a) Name of manufacturer or trade mark.

b) Year of manufacture.

352
The packages containing fittings may also be marked with the standard mark, if
available.

3.09 PACKING :

For packing double bags, one HDP bag (inner) and one gunny bag (outer) or double
gunny bag shall be employed. The packing shall be fit to withstand rough handling during
transit and storage at destination. The heads and threaded portions of the fittings shall be
properly protected against damage. The gross weight of the packing shall
not normally exceed 50 Kg. Different fittings shall be packed in different bags and shall
be completed with their minor accessories fitted in place. All nuts shall be hand tightened
over the bolts and screwed upto the farthest point.

3.10 DRAWINGS :

The Hardware fitting shall conform in all respects to drawing at Appendix-I A & IC
for T&C type and Appendix IB & IC for B&S type Disc Insulators.

The manufacturer shall submit detailed drawing showing design and dimensions.
The type of material used for various parts shall be clearly specified on the drawing.

3.11 TYPE TESTS :

3.11.01 The manufacturer shall furnish valid and authenticated type test certificates from a
Govt. approved / Govt. recognized / NABL Accredited laboratory / ILAC i.e. International
Laboratory Accredited Laboratory (in case of foreign laboratory) of similar rating and de-
sign of tendered material/ equipment. Such type test certificates should not be older than 3
years as on the date of bid opening. For this purpose date of conducting type test will be
considered.

The type test certificate by in house laboratory of tendering firm even if it is a Govt. ap-
proved / Govt. recognized / NABL accredited / ILAC accredited, shall not be accepted,in
case of their own tender. This will not apply if tendering firm is Govt. company / public
Sector undertaking.

3.11.02 The manufacturer should furnish documentary evidence in support of the labora-
tory whose type test have been furnished, that the said laboratory is a Govt. / a Govt.ap-
proved / a Govt. recognized / NABL accredited laboratory / ILAC accredited (in case of
foreign laboratory).

3.11.03 The type test certificates shall be furnished either in original or copy duly attested
by notary.
3.11.04 The bids of only those manufacturers shall be considered to be meeting the type
test criteria who furnishes complete type test certificate with the bid as per above provision.

3.12 ROUTINE AND ACCEPTANCE TESTS :

The material shall be subjected to all routine and acceptance tests specified in the
latest edition of relevant IS, before despatch. Such tests shall be withnessed by the inspect-
ing officer from the purchaser's side.

3.13 INSPECTION & TESTING :

The inspection & testing shall be governed by relevant clause of General

Conditions of Contract (Schedule-II).

3.14 TESTING FACILITIES :

The manufacturer must indicate clearly about the various testing facilities for type
tests as well as routine/sample tests as per relevant ISS in respect of hardwares are
available at the manufacturers works. In case no testing facilities are available at the man-
ufacturers works, particulars of the place where such testing is proposed to be conducted
during the course of inspection must be indicated.

3.15 DEVIATION FROM SPECIFICATION :

The technical specification contained in this section are for the guidance for the
manufacturer. Any deviation from the purchaser's specification will be consideredon
their relative merits in respect of performance efficiency durability and overall economy
consistent of the purchaser's requirements here in after stipulated. Such deviations shall be
clearly entered by the manufacturer in the form as per Schedule-VI
–A & B of the specification.

3.16 VERIFICATION OF DIMENSIONS :

The following tolerances are allowed on all dimensions to which special tolerances
do not apply :

Dimensions Tolerance
Upto and including 35 mm (+/-) 0.7 mm

354
Over 35 mm (+/-) 2%

3.17 QUANTITY :

The quantities indicated above are provisional and the purchaser, reserves the right
to increase/decrease the same at the time of placing the order.

3.18 TEST CHECKING OF MATERIAL AT STORES

3.18.1 The material received in the stores of the NIGAM shall be subjected to the test
checking at stores before final acceptance of the material, the procedure for the same shall
be as under :

3.18.2 SAMPLING

One sample out of each sub-lot / lot consisting of following quantities or part there of of
hardware fittings for disc insulators from each inspected lot received in stores shall be
selected for test checking of material and shall be got tested.

H/W fittings for 11 KV 45 KN Disc Insulator B&S type- 1000 Sets

H/W fittings for 11 KV 45 KN Disc Insulator T&C type- 3000 Sets

The selection of sample from the material received at stores shall be done as soon as ma-
terial is received in stores without the presence of the representative of the supplier. How-
ever, testing of sample(s) at CTL shall be carried out in the presence of representativeof the
supplier after identification / confirmation by him that sample so selected belongs to them.
In case the supplier disputes that the selected samples does not pertain to them,then fresh
sample shall be selected in the presence of the representative of the supplier andtest(s) be
carried out.

3.18.3 TESTS

The following tests shall be carried out on the above items :

a) Visual Examination, Verification of Dimension, weight and marking Test

b) Slip Strength Test.
c) Ultimate Strength Test.
d) Galvanisation (Uniformity) Test.

355
3.18.4 Testing of the material shall be got done at the test laboratory of the NIGAM
i.e. at CTL in the presence of the representative of the supplier. For witnessing of testing,
clear 7 days notice shall be given to the supplier by fax / speed post stating date, time &
place where the test is to be conducted. In case the supplier do not attend for witnessing
the testing, the testing shall be proceeded and completed and action be taken as per the
contract.

3.18.5 The witnessing officers of the NIGAM or as designated by the purchaser shall
send copies of test reports to the purchaser, consignees and the supplier.
3.18.6 Only those tests shall be conducted at CTL for which facility with CTL is avail-
able.

3.19. CRITERIA FOR ACCEPTANCE

3.19.1 Visual Examination, Verification of Dimension, weight and marking Test

As per specification/ ISS

3.19.2 Slip Strength test & Ultimate Strength Test :

In case of failure of sample in Slip Strength test or Ultimate Strength Test, the ma-
terial contained in the lot / sub-lot to which the sample belongs, shall be rejected. The
rejected material shall have to be replaced by the supplier free of cost.

3.19.3 Galvanisation (Uniformity) Test.

i) The sample(s) shall be first tested for (n-2) number of dips where (n) is specified
number of dips in the contract. If the sample(s) does not pass the uniformity of Galva-
nisation Test for (n-2) dips, the material shall be rejected and the material relating to rele-
vant lot / sub- lot to which sample(s) pertains shall have to be replaced by the supplier free
of cost.

ii) If the sample has passed the uniformity of Galvanisation Test for (n-
2) dips, then it shall be tested for (n-1) dips. If the sample has not passed the uniformity
of Galvanisation Test with (n-1) dips, then material pertaining to relevant lot / sub-
lot shall be accepted with a deduction @ 10% of cost of material.

iii) If the sample has passed the uniformity of Galvanisation Test with (n-1) dips,
then sample shall be tested for last one dip of one minute to complete the test for `n'
dips. If the sample does not pass the uniformity of Galvanisation Test
with `n' dips, then the material pertaining to relevant lot/ sub-lot shall be accepted witha
deduction @ 5% of cost of material.

356
iv) If the sample(s) have passed the Test with number of dips as specified in the
contract (n), then material pertaining to relevant lot / sub-lot shall be accepted.

3.20 TEST CHARGES :

All test charges incurred towards test checking of the material received in our
stores shall be borne by the NIGAM.

357
TECHNICAL SPECIFICATION FOR NFC TYPE ANCHOR (DEAD END) & SUSPEN-
SION ASSEMBLIES FOR LT AERIAL BUNCHED XLPE INSULATED ALUMINIUM
CONDUCTOR CABLES WITH BARE MESSENGER WIRE AS WELL ASINSULATED
MESSENGER WIRE FOR OVER HEAD LINES SUITABLE FOR WORKING VOLT-
AGE UPTO AND INCLUDING 1100 VOLTS

1.0 SCOPE

1.1 This specification covers manufacture, testing before dispatch, supply and delivery
F.O.R. Destination of anchor (dead end) & suspension assemblies suitable for LT Aerial
Bunched XLPE Insulated Aluminum Conductor Cables with bare messenger as well as
Insulated Messenger Wire for LT Overhead lines suitable for working voltage up to &
including 1100 Volts.

2.0 REFERENCE STANDARDS:

The design, performance and test requirements shall conform to this specification and the
following standards. However in case of any conflict, the requirements of this specification
shall prevail.

I) NFC 33-040 Suspension Equipments

II) NFC 33-041 Anchoring Devices
III) NFC 33-003 Corrosion resistance
IV) NFC 20-540 Climatic Ageing
V) IS 14255 LV Aerial Bunched Cables
VI) REC specification 32/1984 for Aerial Bunched Cables for LT lines
VII) IS 8130: Conductors for Insulated cables
VIII) IS 7098 Part 1: XLPE Insulated Cables for working voltages upto 3.3 KV
IX) IS 398 Part IV: aluminum alloy conductors
X) IS 2486 Part 1: Metal Fittings of Insulators …. Upto 1100 volts
XI) REC construction standards E-34 and E-35.
XII) IS:2629 Recommended practice for Hot Dip Galvanizing of Iron & Steel
XIII) IS:2633(IInd Revision) Methods of testing uniformity of coating of Zinc coated
articles.

The Devices shall also be compatible with the cables of sizes & dimensions as defined in
the Cable Specifications for the cables with which they are intended to be used, and this
specification.

358
3.0 CLIMATIC CONDITIONS:

i) Peak ambient temperature 50 deg.C

in shade.

ii) Maximum average ambiant 50 deg.C

temperature in a 24 hours period
in shade.

iii) Min. ambient air temperature in shade (-) 5 deg.

iv) Maximum temperature attainable 60 deg.C

By an object exposed to sun.

v) Maximum relative humidity. 90%

vi) Average number of thunder storm 40

days per annum.

vii) Average number of rainy days 100

per annum.

viii) Average annual rain fall 10 to 100 cm

ix) Number of months of tropical 4 months

monsoon conditions.

x) Maximum wind pressure. 100kg/mtr sq

xi) Altitude not exceeding 1000 m

4.0 CABLE DATA

The standard sizes and characteristics of the phase and street lighting conductors, messenger
wires shall be as specified in REC specification 32/1984 or IS: 14255-1995. The
strength of the messenger shall be not less than the Value shown in Table 1.
359
Conductor Size (Sq mm.) Messenger Rating (IS 14255)
25 7 KN
35 9.8 KN
50 14.0 KN

5.0 THE ABC ACCESSORIES

The Accessories of LT XLPE Insulated Aerial Bunched Cables (ABC) are specified below:

a) Their design should incorporate specific features to prevent damage to theinsu-

lation while meeting the required electrical, mechanical & thermal requirements.

b) The accessories should provide “Double Insulation” so that a single point failure of
insulation will not result in the system tripping.

The ABC Accessories shall consist of the following:

Description Application

Anchoring Assembly (AA) and Eye For fitting onto a pole for anchoring the
a) Hook with PCC Pole Clamps along end of a length of ABC, or for a major
with Nuts, bolts & Washers. change in direction.
Suspension Assembly (SA) and Eye For supporting a length of ABC at an in-
b) Hook with PCC Pole Clamps along termediate pole in a length, with small an-
with Nuts, bolts & Washers. gle of deviation.

6.0 Anchoring Clamp for Neutral Messenger:

Anchoring assemblies are used to firmly attach the messenger of ABC to a concrete or steel
pole and transmit the mechanical tension.

 at the end of a run

 at a major change in direction of over 30 degrees.

The clamp should consists of an Aluminium alloy corrosion resistant casted body or climat-
ically resistant polymer material, flexible rope sling (“bail”) of stainless steel and selfadjust-
ing plastic wedges which shall anchor/hold the neutral messenger without damaging the in-
sulation, if any.

360
 There shall be no loosable part in the process of clamping arrangement
 Slip strength should be not less than 90% of the strength of the messenger.
 Mechanical strength should be not less than slip strength & no permanent deformation
more than 10 mm should occur during slip test.

6.1 Anchoring Assembly

Each Anchoring assembly shall include :-

 One Eye Hook with PCC Pole Clamps along with Nuts, bolts & Washers.
 One number wedge type tension clamp as described above

The anchoring assembly shall be provided with suitable Eye Hook and pole clamp ( as per
drawing Enclosed at annexure I-A, I-B & II) to erect them on 8M & 9M PCC pole having
top and bottom dimensions as under:

TYPE OF POLE TOP DIMENSIONS BOTTOM DIMENSIONS

8 Mtr.(200 Kgs) 145 mm x 90 mm 290 mm x 90 mm

9 Mtr. (200 Kgs) 145 mm x 114 mm 300 mm x 114 mm

The Eye Hooks shall be made of forged steel (IS: 2004) or mild steel (IS:1570).

6.2 All ferrous fittings, Eye hooks, bolts, nuts and washers shall be hot dip galvanized
with Zinc Conforming to grade Zn 98 of IS:209/1966. The spring washers and nuts etc. may
be electro galvanized. Nuts shall be made of material conforming to property class 4.8 of
IS:1367/1967 for its mechanical strength.

 The Dead End clamp & hardware shall have good finish and shall be free from all flaws,
sharp radii of curvature and the edges shall be suitably rounded off.

 The above hardware/ accessories shall be suitable for use with LT Aerial Bunched XLPE
Insulated cable conforming to IS: 14255/1995.

Anchoring assemblies shall be supplied in sets to ensure compatibility of the materials

against corrosion or wear of moving parts.

6.3 Flexible Rope( Bail ) of Anchor Assembly

361
a) The Anchoring assembly shall be supplied with a stainless steel flexible Rope to
connect the Tension Clamp to the Eye Hook and pole clamp.

b) The flexible Rope forming part of clamp should be of length to maintain at least
150 mm distance between Eye Hook and body of clamp and shall have sufficient mechanical
strength to withstand the mechanical test for the complete assembly tests in this specification,
as specified in Table-I above (90% of respective messenger minimum rated breaking load).

c) The rope should have sufficient flexibility to ease the torsional movement of the
ABC System.

d) The Rope should be pre-fitted with compression type end fittings which needs to
be removable and re-fittable at one side of the clamp and locked at the other end of the
anchoring clamp.

e) A wear resistant moveable saddle should be un-loosably fitted on the Rope to pre-
vent abrasion at the point of fitting into the tension bracket. Saddle to be made of plasticfor
insulation.

f) Rope should have sufficient mechanical strength to with stand the mechan-
ical test for the complete assembly tests in this specification.

6.4 Wedge Type Tension Clamp of Anchoring Assembly

a) Wedge type clamps shall be used for clamping the messenger without damaging
the insulation if any.

b) The clamp shall be capable of clamping an uncut messenger so that it can continue
without break to the connecting point or next span.

c) The clamp shall be of aluminum or polymeric body with fully insulating type of
mechanical and weather resisting thermoplastic wedges for both bare & insulated messenger.
The insulating properties should meet the requirements of voltage tests as per clause 7.7

d) No bolts or loose parts are allowed as part of the Clamping system.

e) No tools shall be needed for fitting the messenger into the clamp.

362
f) The clamp shall be self tightening and capable of holding without slippage 90% of
the load specified in the Table-1 (90% of respective messenger minimum rated breaking
load).

7.0 Testing requirement of Anchoring Assembly

The following tests are intended to establish design characteristics

Sr Test Type Acceptance Routine

Test Test Test
a Visual √ √
b Dimensional √ √
c Mechanical & Slip strength √ √
d Voltage √ √
e Corrosion √
f Climatic √
g Galvanization Test on Eye Hook & Pole Clamp √ √ √
h Mech. strength of Eye Hook & Pole Clamp √ √ √

7.1 Visual

Design aspects of the anchoring assembly needs to be visually verified as per the descriptions
of this specification and criteria defined by the manufacturer in the quality plan and as ac-
cepted by customer. Following Mandatory marking should be available.

7.2 Marking
Anchoring, clamp, Eye Hook & Pole Clamps should bear-

- Manufacturers trade mark and logo

- Product code of Reference
- Traceability Code/ batch number

7.3 Dimensional

Overall dimensional to be verified against the GA Drawings. All dimensional re-

quirement mentioned in this specification should be verified. The manufacturer may havehis
own design, provided the design is conforming to the technical requirements of this specifi-
cation with minimum dimensions as shown in the specifications.
7.4 Mechanical & Slip Strength Test:

The Anchoring assembly should be fitted at both side of a cable one meter from the
end, in the proposed manner as shown in figure-1 below, on a suitable support using the Eye
Hook & Pole clamps.

After fitting the messenger in the clamp, load should be increased to 90% of breaking load
of Messenger held for 1 minute.

7.5 Eye Hook and Pole Clamp for Anchoring assembly should be tested for the loads
not less than slip strength of clamp with the load applied at an angle of 45º from the normal
to the surface of mounting of eye hook and pole clamp.

7.6 Requirements

There shall be no breakdown of any part of clamp assembly or slippage not greater
than 5 mm of of messenger in relation to the clamp.

.
Figure- 1

364
7.7 Voltage Test

 Voltage test is carried out on anchor clamps to ensure no damage is caused to the
insulated messenger and no separate earthing of pole is required in case of bare messenger.

 A conductive rod of dia. corresponding to the average dia. that can be accommo-
dated in the clamp is fitted into the clamp, protruding by approx. 50mm at each end of the
tightening piece as shown in Figure-2

 The rod and clamp is subjected to tensile load as stated in Table 2 below when fixed
to a support in its normal manner.

 A power frequency voltage of 6 kV is applied for 1 minute between the rod and
conductive part of the clamp or fixation point in absence of conductive part.

7.8 Requirements

No breakdown or flashover shall occur. There shall be no tripping due to leakage with a
setting of 10 ± 0.5 mA.

Figure-2

365
Item
1. Conductive Part 4. Added insulation
2. clamp body 5. Test voltage
3. Bare metallic rod

Table – 2

Conductor Size Load Applied

Sq mm Dia (mm) (N)
25-35 8-11 2000
50-70 12-14 4000

7.9 Corrosion test

This test is carried out on the anchoring assembly which is subjected to corrosion test as per
NFC 33003 or equivalent IS Standard.

7.10 Requirements

After exposure to corrosion cycle as per the above standard mechanical test as defined in
clause 7.4 of this specification to be conducted and required strength of subjected clamps
should be 75% of the minimum rated strength of respective messenger as defined in table 1
of this specification.

7.11 Climatic Ageing test

This test is carried out anchoring assembly which is subjected to corrosion test as per NFC
20540.

7.12 Requirements

After exposure to Climatic cycle as per the above standard, mechanical test as defined in
clause 7.4 of this specification to be conducted and required strength of subjected clamps
should be 75% of the minimum rated strength of respective messenger as defined in table 1
of this specification.

8.0 SUSPENSION CLAMP FOR NEUTRAL MESSENGER:

366
Suspension Assembly is used for supporting an ABC by installation on the messenger at an
intermediate point of support such as a pole. It can accommodate small angles of deviation
upto 30 deg.

The clamp should be designed to hang L T AB cable with bare or insulated neutral messen-
gers. The neutral messengers should be fixed by an adjustable grip device. A movablelink
should allow longitudinal and transversal movement of the clamp body.

 There should be no loosable part in the process of clamping arrangement.

 The clamp and the link should be made of Polymer to provide an additional Insulation
between the cable and the pole to eliminate need for earthing.
 The clamps and movable links should be made of weather and UV resistant polymer.

 Clamps should be fixed to the pole by Eye Hook & Pole Clamp. Eye Hook & Pole Clamp
should be made of corrosion resistant ( Galvanised) ferrous metal alloy.

 Ultimate tensile strength of the clamp should not be less than 90% of messenger strength
(see table 1) in direction perpendicular to the direction of the messenger.

Each Suspension Assembly shall consist of:

 One Eye Hook with PCC Pole Clamps along with Nuts, bolts & Washers.
 One number moveable (articulated) connecting link.
 One number Suspension Clamp.

The suspension assembly shall be provided with suitable Eye Hook and pole clamp ( as per
drawing Enclosed ) to erect them on 8M & 9M PCC pole having top and bottom dimensions
as under:

TYPE OF POLE TOP DIMENSIONS BOTTOM DIMENSIONS

8 Mtr.(200 Kgs) 145 mm x 90 mm 290 mm x 90 mm

9 Mtr. (200 Kgs) 145 mm x 114 mm 300 mm x 114 mm

The Eye Hooks shall be made of forged steel (IS: 2004) or mild steel (IS:1570).

 All ferrous fittings, Eye hooks, bolts, nuts and washers shall be hot dip galvanized
with Zinc Conforming to grade Zn 98 of IS:209/1966. The spring washers and nuts etc. may
be electro galvanized. Nuts shall be made of material conforming to property class 4.8 of
IS:1367/1967 for its mechanical strength.
 The suspension clamp & hardware shall have good finish and shall be free from all
flaws, sharp radil of curvature and the edges shall be suitably rounded off.

 The above hardware/ accessories shall be suitable for use with LT Aerial Bunched
XLPE Insulated cable conforming to IS: 14255/1995.

Suspension Assemblies shall be supplied in sets to ensure compatibility of the materials

against corrosion or wear of rotating/moving parts.

8.1 Suspension Clamp of Suspension assembly:

 Suspension Clamps are used for locking the messenger of the ABC Bundle without
damaging the insulation if any or allowing the messenger to become dismounted from the
fitting.

 The suspension clamp shall be made fully of insulating type of mechanically strong and
weather resistant plastic.

 The suspension clamp shall be suitable for messenger wire sizes from 25 to 50 sq mm.

 Suspension Clamps for bare messengers shall be different from and easily distinguishable
from those for insulated messengers

 Bolts and hand tools shall not be required for fixing and locking the messenger in the
clamp.

 There should be no loosable parts in the Suspension clamp.

 The suspension clamp shall be unloosably fitted to the suspension assembly.

8.2 Movable (articulated) link of Suspension assembly.

Movable links are used between the suspension Eye Hook & Pole clamp and the suspension
clamp to allow a degree of movement and flexibility between the two.

 Movable links should be made fully of insulating type of mechanically strong and
weather resistant plastic.

 The movable link shall be unloosably fitted to the suspension assembly.

9.0 TESTING REQUIREMENTS OF SUSPENSION ASSEMBLY

Following tests are intended to establish design characteristics.

Sr Test Type Acceptance Routine

Test Test Test
a Visual √ √
b Dimensional √ √
c Mechanical &Slip strength √ √
d Voltage √ √
e Corrosion √
f Climatic √
g Galvanization Test on Eye Hook & Pole Clamp √ √ √
h Mech strength of Eye Hook & Pole Clamp √ √ √

9.1 Visual

Design aspects of the suspension assembly needs to be visually verified as per the descrip-
tions of this specification and criteria defined by the manufacturer in the quality planand as
accepted by customer. Following Mandatory marking should be available.

9.2 Marking

Suspension, clamp, Eye Hook & Pole Clamps should bear-

- Manufacturers trade mark and logo

- Product code of Reference
- Traceability Code/ batch number

9.3 Dimensional

Overall dimensional to be verified against the GA Drawings. All dimensional requirement

mentioned in this specification should be verified. The manufacturer may have his own de-
sign, provided the design is conforming to the technical requirements of this specification
with minimum dimensions as shown in the specifications.

369
9.4 MECHANICAL TEST

Mechanical test of suspension assembly to be carried out separately for suspension subas-
sembly including movable link and Eye Hook & Pole Clamp.

9.5 Mechanical Test of suspension Sub Assembly

The sub assembly should be fitted in the proposed manner on a suitable support using the
Eye Hook & Pole Clamp.

The Sub Assembly of moveable link and suspension body shall be subjected to a vertically
downward load of 90% of the value shown in Table 1, applied as shown in figure 3 below.

9.6 Requirement

There shall be no breakdown of suspension assembly or slippage of messenger in relation to

the clamp.

Figure-3

Item
1. Movable Link 3. Neutral Messenger
2. Suspension Clamp 4. Rigid Fixture

9.7 Slip Strength Test :

A sample messenger shall be fitted into a fixed suspension clamp and subjected to a gradually
applied longitudinal load of 300 N. There shall be no permanent slippage. Test setup will be
similar to as shown in figure 4 below.

9.8 Requirements:

Clamp should hold a minimum of 300N without any slippage which is greater than 5 mm

Figure-4

Item
1. Clamp to be tested 3. Fixed Point
2. Marking on the cable

9.9 Eye Hook and Pole Clamp for Suspension assembly should with stand a minimum
load of 90% of the value shown in table -1 with the load applied at an angle of 33º from the
normal to the surface of mounting of eye hook and pole clamp.

9.10 Voltage Test

A copper foil is wrapped at the clamping point around the maximum size of Messenger
allowed in that clamp. An ac voltage of 6 KV is applied between the copper foil and nearest
conductive point of the clamp or, in its absence, to the point of fixation. Generalized test
setup is shown in the figure 5 as below.

9.11 Requirements:

The voltage should be withstood for 1 minute without breakdown or flashover.

371
Figure- 5

Item
1. Eye Hook 3. Neutral Sheath
2. Suspension clamp 4. Copper foil

9.12 Corrosion Test

This test is carried out on the suspension assembly which is subjected to corrosion test as per
NFC 33003 or equivalent IS Standard.

9.13 Requirements

After exposure to corrosion cycle as per the above standard mechanical test as defined in
clause 9.4-9.9 of this specification to be conducted and required strength of subjected clamps
should be 75% of the minimum rated strength of respective messenger as defined in table 1
of this specification.

9.14 Climatic Ageing test

This test is carried out suspension assembly which is subjected to corrosion test as per NFC
20540.

9.15 Requirements

After exposure to Climatic cycle as per the above standard, mechanical test as defined in
clause 9.4-9.9 of this specification to be conducted and required strength of subjected clamps
should be 75% of the minimum rated strength of respective messenger as defined in table 1
of this specification.

372
10.0 DRAWINGS:

10.1 The successful manufacturer shall, within two weeks of placement of order, submit three
sets of final versions of all the drawings for purchaser's approval. The drawings of Hard-
wares/Accessories shall be generally in conformity to the drawings enclosed at Annexure-I-
A, I-B, II, III, & IV. The purchaser shall communicate his comments/approvalon the draw-
ing(s) to the suppliers within two weeks. The supplier shall, if necessary, modify the draw-
ings and resubmit three copies of the modified drawings within two weeks for purchaser's
approval. The delay in submission of the modified drawings (if called for) complete in
all respect and in acceptable form beyond two weeks time (as stated above) shall be to
supplier's account and/or attract the provisions of GCC. After receipt of purchaser's ap-
proval, the supplier shall within two weeks, submit 1 print and two good quality reproducible
of the approved drawings for purchaser's use.

11. TESTS AND TEST CERTIFICATES:

The Hardwares /Accessories should meet the requirement of all tests as specified in respec-
tive NFC standards alongwith other relevant standards and their latest amendments.

The manufacturer shall furnish valid and authenticated type test certificates from CPRI,
Banglore / ERDA, Vadodara / ILAC i.e. International Laboratory Accredited Cooperation
(in case of foreign laboratory) only. Such type test certificates should not be older than 5
years as on the date of bid opening. For this purpose date of conducting type test will be
considered.

The type test certificate by in house laboratory of tendering firm even if it is a ILAC accred-
ited, shall not be accepted, in case of their own tender.

The manufacturer should furnish documentary evidence in support of the laboratory whose
type test have been furnished, that the said laboratory is a ILAC accredited (in case of foreign
laboratory).

The type test certificates shall be furnished either in original or copy duly attested by notary.

The bids of only those manufacturers shall be considered to be meeting the type test criteria
who furnishes complete type test certificate with the bid as per above provision.

Only those bids which accompanied with requisite type test(s) certificate(s) not older than
five years as on the date of bid opening, shall be treated as responsive.

373
12. INSPECTION:

The inspection may be carried out by the purchaser at any stage of manufacture. The suc-
cessful manufacturer shall grant free access to the purchasers representatives at areasonable
time when the work is in progress. Inspection and acceptance of any equipment/material
under this specification by the purchaser shall not relieve the supplier of his obligation of
furnishing equipment in accordance with the specification and shall not prevent subsequent
rejection if the equipment/material is found to be defective.

The Acceptance Tests shall also be conducted on each offered lot by the manufacturer before
dispatch in the presence of purchaser's authorized representative / Inspecting Officer/Agency
as per Clause No.1.27 "Inspection & Testing" of "General Conditions of Contract" Section-
II.

13. TEST CHECKING OF MATERIAL AT STORES:

The material received in the stores of the NIGAM shall be subjected to the test checking at
stores before final acceptance of the material, the procedure for the same shall be as under
:

13.1 SAMPLING

One sample out of each sub lot/ lot of 1000 sets or part thereof from each inspected lot of
each type, received in stores shall be selected for test checking of material and shall be got
tested. The selection of sample from the material received at stores shall be done as soonas
material is received in stores without the presence of the representative of the supplier. How-
ever, testing of sample(s) at CTL shall be carried out in the presence of representative of the
supplier after identification / confirmation by him that sample so selected belongs to them.
In case the supplier disputes that the selected samples does not pertain to them, thenfresh
sample shall be selected in the presence of the representative of the supplier and test(s)be
carried out.

13.2 TESTS

The following tests shall be carried out on the above items :

a) Visual examination, verification of dimensions, weight & marking.

b) All galvanized parts. - Uniformity of galvanization test.

374
The other test as per NFC/IS/REC/ Specification may also be carried out on Suspension &
Dead End Clamp subject to availability of testing facility for the same at CTL , Jaipur.

Test of the material shall be got done at the test laboratory of the NIGAM i.e CTL, Jaipur
in the presence of representative of supplier. For witnessing of the testing, clear 7 (seven)
days notice shall be given to the supplier by fax/ speed post stating date, time & place
where the test is to be conducted. In case the supplier do not attend for witnessing the
testing, the testing shall be proceeded and completed and action be taken as per the contract.

The Officer Incharge of Central Testing Lab (CTL) Jaipur shall send copies of test reports
to the purchaser, consignees and the supplier.

13.3 CRITERIA FOR ACCEPTANCE

a) Visual examination , verification of dimensions, weight and marking.

As per Specification/ GTP/ Approved drawing.

b) All galvanized parts. - Uniformity of galvanization test.

As per following criteria:-

i) The sample(s) shall be first tested for (n-2) number of dips where n is specified
No. of dips in the contract. If the sample does not pass the uniformity of galvanization test
for (n-2) dips, the material shall be rejected and the material relating to relevant sub-lot/ lot
to which the sample(s) pertains shall have to be replaced by the supplier free of cost.

ii) If the sample has passed the uniformity of galvanization test for (n-2) dips,
then it shall be tested for (n-1) dips. If the sample has not passed the uniformity of galvani-
zation test with (n-1) dips, the material pertaining to relevant lot/sub-lot shall be accepted
with a deduction @ 10% of cost of galvanized material parts.

iii) If the sample passed the uniformity of galvanization test with (n-1) dips, then
sample shall be tested for last one dip of one minute to complete the test for `n' dips. If
the sample does not pass the uniformity of galvanization test with `n' dips, then the material
pertaining to relevant lot/sub-lot shall be accepted with a deduction @ 5% of cost of
galvanized material parts.

iv) If the sample(s) have passed the test with number of dips as specified in the contract
(n), then material pertaining to relevant lot/sub-lot shall be accepted.
13.4 TEST CHARGES :

14. PACKING, MARKING AND FORWARDING:

14.1 All hardware fittings shall be packed in suitably sized strong and weather resistant
wooden cases/crates. The gross weight of the packing shall not normally exceed 50 Kg.to
avoid handling problems.

14.2 Suitable cushioning, protective padding, or spacer shall be provided to prevent damage
to or deformation of the hardwares during transit and handling.

14.3 All identical items shall be dispatched to destination duly assembled and packed.
Bolts, nuts, washers, etc. shall be packed duly installed and assembled withthe respective
parts and suitable measures shall be taken to prevent their transit loss.

14.4 All packing cases shall be marked legibly and correctly so as to ensure their safe
arrival at their destination and to avoid the possibility of goods being lost or wrongly
dispatched on account of faulty or illegible markings. Each wooden case/crate shall have all
the markings stenciled on it in indelible ink.

15. PAST SUPPLIES:

The details of past orders executed by the tendering firm may be indicated in the relevant
schedule.

16. GUARANTEED TECHNICAL PARTICULARS:

The manufacturer shall furnish guaranteed technical particulars in the relevant schedule
.

17. DEMONSTRATION & INSTRUCTION MANUAL:

376
The successful manufacturer shall submit the Instruction Manual for erection of Aerial
Bunched Cable and Hardware to the sub-division at the time of demonstration of erection of
LT Aerial Bunched Cable with Hardware.

The successful manufacturer shall give free of cost demonstration for erection of Aerial
Bunched Cable with Suspension/Dead End Clamp, If asked by Circle Superintending Engi-
neer, in any Sub Division of their Circle, during course of supply. The required Suspen-
sion/Dead End Clamp and LT AB Cable for demonstration shall be provided by Nigam.

377
TECHNICAL SPECIFICATION AND REQUIREMENT OF L.T. INSULATION PIERC-
ING CONNECTORS SUITABLE FOR LT XLPE INSULATED AERIAL BUNCHED CA-
BLES WITH BARE MESSENGER WIRE FOR LT OVER HEAD LINESSUITABLE FOR
WORKING VOLTAGE UPTO & INCLUDING 1100 VOLTS

1. SCOPE :

1.1 This specification covers manufacture, testing before dispatch, supply and delivery
F.O.R. Destination of L T Insulation Piercing connector suitable for LT XLPE Insulated Aerial
Bunched Cables with bare Messenger Wire for LT Overhead lines suitable for working voltageup
to & including 1100 Volts as per relevant NFC Standard.

The Insulation Piercing Connectors shall be supplied along with Nuts, Bolts, Washers. The re-
quirement of L T Insulation Piercing connector shall be as per schedule of requirement annexed
with this section at Annexure-I. It may be noted that the quantity in the schedule is tentative and
may vary at the time of placement of order.

2. APPLICABLE STANDARDS:

Unless otherwise stipulated in this specification the following standards with latest
amendments shall be applicable :

i) NFC - 33-020 : Insulation Piercing Connectors

ii) NFC - 33-209 : LV Aerial Bunched Cable
iii) NFC - 33-004 : Electrical Ageing Test.
iv) NFC - 20-540 : Environment Testing for outdoor.
v) IS 14255 : LV Aerial Bunched Cable.

3. CLIMATIC CONDITIONS:

i) Peak ambient temperature 50 deg.C

in shade.

ii) Maximum average ambiant 50 deg.C

temperature in a 24 hours period
in shade.

iii) Min. ambient air temperature in shade (-) 5 deg. C

378
iv) Maximum temperature attainable 60 deg.C
by an object exposed to sun.

v) Maximum relative humidity. 90%

vi) Average number of thunder storm 40

days per annum.

vii) Average number of rainy days 100

per annum.

viii) Average annual rain fall 10 to 100 cm

ix) Number of months of tropical 4 months

monsoon conditions.

x) Maximum wind pressure. 100kg/mtr sq

xi) Altitude not exceeding 1000 m

4. GENERAL REQUIREMENTS:

The L.T. Insulating Piercing Connectors are used for making Tee or Tap off connections to LT
XLPE Insulated Aerial Bunched Cables suitable up to 1.1 KV, service voltage 0.6 KV. The
L.T. Insulation Piercing Connectors are designed to make a connection between the uncut main
conductor & a branch cable conductor without removing the insulation and with single tightening.
The IPC will first pierce the insulation, then make good electrical contact between the main &
the branch conductor while simultaneously insulating & sealing the connection. The teeth of
IPC shall be compatible with aluminum phase conductor or aluminum alloy messenger. Exposed
metallic parts to be potential free during & after connector mounting.

The performance/ test requirements of insulation piercing connectors shall be as per NFC Stand-
ards 33-020.
The Insulation Piercing Connectors must be equipped with shear heads with minimum & maxi-
mum shearing torque as indicated by the manufacturer and within the range specifiedin NFC
33-020.

The L.T. Insulation Piercing Connectors shall be suitable for LT XLPE Insulated aerial bunched
cable of following type & Size:

Type Main Cable Tap Off Cable End Cap suitable

for Sealing Branch

A 16-50 Sq.mm. 2.5-10 Sq.mm. 2.5-10 Sq.mm.

B 16-50 Sq.mm. 16-50 Sq.mm. 16-50 Sq.mm.

The Insulation Piercing Connectors must be suitable for application by one worker working alone
with a 17mm/ 13mm wrench. Suitable wrenches for installing the connectors shall be included in
the scope of supply at the rate of 1 Set for each 1000 Pieces of Connectors ordered (Fraction of
1000 Pieces to be rounded down) The Insulation Piercing Connectors shall be water proof & the
water tightness and shall be ensured by appropriate elastomer material & not by grease, gel or
paste alone. The Connector shall be provided with removable end cap for sealing cut end of the
branch cable enabling tapping on both sides of the connector being in its vertical position with
bolt head upward. The end cap shall be rigid of slide type enabling easy positioning and un-loos-
able
after the tap cable is positioned. The end cap shall be equipped with a water tightness seal. Rubber
seal around piercing teeth shall be compatible with grease used. Rubber seal shall be designedin
a manner to provide proper sealing around the piercing & to avoid the damage to conductor insu-
lation beyond piercing point. Rubber parts shall comprised of material that exhibit resistance to
aging caused by heating or other weather conditions.

All the insulating material used shall be UV resistant. Metallic parts shall be hot dip galvanized or
of Stainless steel.

The Insulation Piercing Connectors shall have good finish and shall be free from all flaws, sharp
edge and suitably rounded off.

The Insulation Piercing Connectors and its components shall meet the following tests in accord-
ance with the requirements & test methods of NFC 33 – 020:

Mechanical Tests
Voltage & water tightness test
380
Electrical Ageing Test
Corrosion Resistance Test
Climatic Ageing Test
The above hardware/ accessories shall be suitable for use with LT XLPE Insulated PVC sheathed Aerial
Bunched Cable conforming to IS:14255/1995 of following sizes:

S.No. Designation of finished cable

i) 1CX25+25 mm².
ii) 3CX16+25 mm².
iii) 3CX25+25 mm².
iv) 3CX50+35 mm².
v) 3CX35+25 mm²

Note:- The first part of the designation refers to the number and size of the phase conductor and
the last to the size of messenger wire. The sizes shown are the nominal cross sectional area of
the conductors.

5.0 DRAWINGS:

The successful manufacturer shall within two weeks of placement of order furnish three sets
of final versions of all drawings of hardware/ accessories for purchaser's approval.

6.0 TYPE TESTS & TESTS CERTIFICATES:

The manufacturer shall furnish valid and authenticated type test certificates from CPRI, Banglore
/ ERDA, Vadodara / ILAC i.e. International Laboratory Accredited Cooperation (in case of foreign
laboratory) only. Such type test certificates should not be older than 5 years as on the date of bid
opening. For this purpose date of conducting type test will be considered.

The type test certificate by in house laboratory of tendering firm even if it is a ILAC accredited,
shall not be accepted, in case of their own tender.

The manufacturer should furnish documentary evidence in support of the laboratory whose type
test have been furnished, that the said laboratory is a ILAC accredited (in case of foreign labora-
tory).

381
The type test certificates shall be furnished either in original or copy duly attested by notary. The
bids of only those manufacturers shall be considered to be meeting the type test criteria who fur-
nishes complete type test certificate with the bid as per above provision.

Only those bids which accompanied with requisite type test(s) certificate(s) not older than five
years as on the date of bid opening, shall be treated as responsive.

The Insulation Piercing Connectors should meet the requirement of all tests as specified in respec-
tive NFC standard NFC-33-020 along with other relevant standards and their latest amendments.
For ready reference, the applicable tests are reproduced below :

Type Tests:

Insulation Piercing Connectors

S. No. Clause No. of NFC Description of Test

1 2.3.1 Electrical continuity
2 2.3.1 Shearhead
3 2.3.1 Mechanical Behavior
4 2.3.2 Mechanical strength of main
core
5 2.3.2 Mechanical strength of Tap core
6 2.4 Voltage and water tightness
8 2.6 Climatic Ageing
9 2.7 Corrosion Test
10 2.8 Electrical Ageing

The manufacturer must also clearly indicate various testing facilities available at their works for
testing the material as per relevant standard. In case of otherwise particulars of the place where
such testing is proposed to be conducted during the course of inspection shall be indicated.

7.0 INSPECTION:

The inspection may be carried out by the purchaser at any stage of manufacture. The successful
manufacturer shall grant free access to the purchasers representative at reasonable time when the
work is in progress. Inspection and acceptance of any equipment / material under this specifi-
cation by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in
accordance with the specification and shall not prevent subsequent rejection if the equipment /
material is found to be defective.

382
The acceptance tests shall also be conducted on each offered lot by the manufacturer before dis-
patch in the presence of purchaser's authorized representative / inspecting officer/ agency as
per Clause No.1.27 " Inspection and testing" of "General Condition of Contract" Section-
II. The acceptance tests shall be carried out as per relevant NFC standards and GTP furnished by
the manufacturer, whichever is more stringent..

8.0 Acceptance Tests :

The Acceptance Tests for Insulation Piercing Connectors shall consist of the following:

For Insulation piercing Connectors. (NFC 33-020)

S. No. Clause No. of NFC Description of Test

1 3 Marking as per clause 3
2 2.3.1 Electrical continuity
3 2.3.1 Shearhead
4 2.3.1 Mechanical strength
5 2.4 Voltage and water tightness

The supplier shall present the latest calibration certificates of testing instruments / equipments
to be used for the testing of the material covered in the purchaser order to the authorized inspection
officer/inspecting agency of the purchaser. The testing instruments/meters/ apparatus etc. should
be got calibrated by the supplier from time to time fromNABL accredited laboratory or NPL for
Indian Manufacturers or Nationally accredited test laboratory for foreign manufacturers. The cal-
ibration certificate should not be in any case be older than 1 year at the time of presenting the same
to the inspecting officer/ inspecting agency of the purchaser. The testing instruments / equipments
should be duly sealed by the calibrating agency and mention their of shall be indicated in the
calibration certificates.

9. TEST CHECKING OF MATERIAL AT STORES

The material received in the stores of the NIGAM shall be subjected to the test checking at
stores before final acceptance of the material, the procedure for the same shall be as under :

9.1. SAMPLING

One sample out of each sub-lot / lot of 5000 Nos. or part thereof for Type-A connectors and one
sample out of each sub-lot / lot of 1000 Nos. or part thereof for Type-B connectors from each
inspected lot received in stores shall be selected for test checking of material and shall be
got tested. The selection of sample from the material received at stores shall be done as soon as
material is received in stores without the presence of the representative of the supplier. However,
testing of sample(s) at CTL shall be carried out in the presence of representative of the supplier
after identification / confirmation by him that sample so selected belongs to them. In case the
supplier disputes that the selected samples does not pertain to them, then fresh sample shall be
selected in the presence of the representative of the supplier and test(s) be carried out.

9.2 TESTS

The following tests shall be carried out on the above items :

i) Visual Examination, verification of dimensions, marking.

ii) The other acceptance tests as per NFC Standard / specification may also be carried out
subject to availability of testing facility for the same at CTL, Jaipur.

9.2.1 Test of the material shall be got done at the test laboratory of the NIGAM i.e CTL, Jaipur
in the presence of representative of supplier. For witnessing of the testing, clear 7 (seven) days
notice shall be given to the supplier by fax/ speed post stating date, time & place where the
test is to be conducted. In case the supplier do not attend for witnessing the testing,the testing
shall be proceeded and completed and action be taken as per the contract.

9.2.2 The witnessing officers of the NIGAM or as designated by the purchaser shall send copies
of test reports to the purchaser, consignees and the supplier.

10. CRITERIA FOR ACCEPTANCE

i) Visual Examination, verification of dimensions, marking.

ii) The other acceptance tests as per NFC Standard / specification mayalso be carried out
subject to availability of testing facility for the same at CTL, Jaipur.

As per NFC-33-020/1998 for the above test (with latest amendment) /Specification.

11. TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores shall
be borne by the NIGAM.

384
12. EMBOSSING & IDENTIFICATION:

It should be provided in each piece as per Clause No.3 of the relevant NFC standards.

13. PACKING, MARKING & FORWARDING:

All Insulation Piercing connectors shall be packed in Cardboard Cartons. The gross weight of the
packing shall not normally exceed 50 Kgs. to avoid handling problems.

Suitable cushioning, protective padding or spacer shall be provided to prevent damage toor
deformation of the hardware during transit and handling.

All identical items shall be dispatched to destination duly assembled and packed. Bolts,
Nuts, Washers etc. shall be packed duly installed and assembled
with the respective parts and suitable measures shall be taken to prevent their transit loss.

All packing cases shall be marked legibly and correctly so as to ensure their safe arrival at their
destination and to avoid the possibility of goods being lost or wrongly dispatched on account of
faulty or illegible marking. Each case / crate shall have all the markings stenciled on it in
indelible ink.

14. PAST SUPPLIES:

The details of past orders executed by the manufacturer must be indicated in the relevant schedule.
The manufacturer must furnish the documentary proof for the orders executed in past, along with
self certified purchase specifications and drawings of the products supplied.

15. GUARANTEED TECHNICAL PARTICULARS:

The manufacturer shall furnish guaranteed technical particulars in the relevant schedule to enable
technical evaluation of the bid.

16. DEMONSTRATION & INSTRUCTION MANUAL:

The successful manufacturer shall submit the Instruction Manual for erection of Aerial Bunched
Cable and Hardware to the sub-division at the time of demonstration of erection of LT Aerial
Bunched Cable with Hardware.

385
The successful manufacturers shall give free of cost demonstration for erection of Aerial
Bunched Cable with Insulation Piercing Connector, if asked by Circle Superintending Engineer,
in any Sub Division of their Circle, during course of supply. The required I.P. Connector and LT
AB Cable for demonstration shall be provided by Nigam.

GUARANTEED TECHNICAL AND OTHER PARTICULARS

A. Suspension and Dead End Clamp Assembly:

S. No. Particulars
1.a Name of manufacturer
1.b Name & Address of Manufacturer of ABC Accessories
1.c Works address
1.d a) Is Manufacturer of Accessories an ISO 9001-2000
Company
b) Copy of ISO Certificate enclosed
2. Are GA drawings enclosed for
c) Anchor Clamps
d) Suspension Clamps
3 Are experience certificate enclosed for
e) Anchor Clamps
f) Suspension Clamps
4. Anchor Assembly
4.1.1 Material of Anchor Eye Hook & Pole Clamp
4.2.1 Is connecting device between clamp and Eye Hook &
Pole Clamp flexible.
4.2.2 Material of connecting device
4.3.1 Material of clamp
4.3.2 Any metal parts in Clamp
4.3.3 Can it accommodate uncut messenger
4.3.4 Are bolts required for tightening of messenger
4.4.1 Maximum load holding capacity (Kg.)
4.4.2 Whether the following type test report as per relevant
NFC standard furnished
a) Voltage with stand test report as per NFC.
b) Corrosion Resistance Report as per NFC.

386
S. No. Particulars
c) Climatic Ageing repot as per NFC.
d) Mechanical Test
5.0 Suspension Assembly
5.1.1 Material of Suspension Clamp with Eye Hook & Pole
Clamp
5.1.2 Max. load for deformation<10m or breakdown (kg.)
5.2.1 Is moveable link provided
5.2.2 Metarial of moveable link
5.3.1 Metarial of Suspension Clamp
5.3.2 Range of conductor size (mm. Sq.) which suspension
clamp can accommodate (mm. Sq.)
5.3.3 Are bolts required for fixing messenger.
5.4.1 Max. vertical load sustained by clamp (kg.)
5.4.2 Max. longitudinal load sustained by clamp
5.4.3 Whether the following type test report as per relevant
NFC standard furnished
a) Voltage with stand test report as per NFC.
b) Corrosion Resistance Report as per NFC.
c) Climatic Ageing repot as per NFC.
d) Mechanical Test

B. Insulation Piercing Connectors Type-A and Type-B:

Sl. No. Particulars Type-A Type-B

1. Name of Manufaturer & Address
2. Works’s Address
3. Is Manufacturer of Accessories an ISO 9001
– 2000 Company.
Copy of Certificate enclosed
Are GA drawings enclosed?
Are experience certificates enclosed?
4.0 Insulation Piercing Connectors (provide info separately for each size offered)
Type Number & Size Range
4.1 Is any metallic part carrying potential inop-
eration exposed during installation ?
Metal used for teeth.
4.2 Are end caps for branch cable ?
Slide on Type
Rigid
4.3 Are torque limiting shear heads provided on
tightening bolts?
4.4 Range of sizes accommodated for Branch &
Main (fill 4.5.1 to 4.7.5 for each size of con-
nector)
4.5.1 Rated tightening torque (Nm)
4.5.2 Min Shear head breaking torque (Nm)
Max Shear head breaking torque (Nm)
4.6.2 Max. Tensile load for no breakdown of main
conductor (for each cross-section). Kg.
4.6.3 Max. tensile on Branch conductor for noslip-
page / break Kg.
4.7 Voltage withstand under water immersion
4.8 Marking on IPC As per Clause no.3 of NFC

Signature of Manufacturer

388
390
392
393
TECHNICAL SPECIFICATION FOR GALVANISED STEEL STAY SETS OF SIZE16X1800MM

1.0 SCOPE

This specification covers the design, manufacture, inspection, testing before dispatch, sup-
ply and delivery F.O.R. destination anywhere in Jaipur Discom of hot dip galvanized steel stay
sets of size 16x1800 mm and 20X2400( oiled threads) with G.S. Anchor plates, as per pattern-1
of BS:16/1974.

1.1 Size 16X1800 mm

Hot dip galvanized steel stay sets of dia 16mm, 1800 mm long (oiled threads complete with
ratchet nut, GS anchor plates size 300x300x4 mm ( having square hole size as 18 x 18 mm in
centre) & fitted with cast iron cross head and steel bow dia 12 mm conforming to pattern-1 of
BS:16/1974

2.0 CLIMATIC CONDITIONS :

i) Maximum ambient Air Temperature (deg.C) 50

ii) Minimum ambient Air Temperature (deg.C) (-) 2.5
iii) Average daily Ambient Air Temperature (deg.C) 32.2
iv) Maximum relative humidity (%) 100
v) Minimum relative humidity (%) 50
vi) Average rainfall per annum (mm) 150-1000
vii) Number of rainy days per Annum 70
viii) Altitude above mean sea level (meters) 100-1000
ix) Isoceraunic level (Days/Annum) 25(thunder Storm)
x) Maximum wind pressure (Kg/sq.m.) 195
xi) Seismic level (Horizontal Acceleration) 0.08 g

3.0 PRINCIPAL PARAMETERS :

The hot-dip galvanized steel stay sets and anchor plates shall strictly conform to BS:16/1974
with latest amendments thereof as per pattern-1 in all respect, except herein otherwise stated. The
ratchet nut and the cross head bow shall be having three (3) cuts in place of six(6) . The dimen-
sions of the cross head portion of the bow of each type of stay set shall be

394
as per the drawing enclosed at Appendix-A (i) & (ii). Tolerances in dimensions shall be
governed by the values appearing at Schedule of GTP.

The stay sets shall have galvanizing as per BS:729/1961 part-I with latest amendments
thereof and shall be galvanized by hot dip galvanization process.

4.0 GENERAL TECHNICAL REQUIREMENTS :

i) The rod and bow shall be free from flaws and other defects, shall be of good finish and
the cross head shall not fail, draw and deformed when the assembly is tested to fracture as
their full section by tensile strength. The ratchet nuts and ratchet face of each cross head shall
be well formed, so that any nut and any cross head of the appropriate size shall provide good
ratchet action. The treads of stay sets shall be cut after galvanising and shall be lubricated with
good quality of mobile oil to prevent rusting.

(ii) The rods and bow shall be of steel suitable to give strength as per table of tensile
strength as at 5.2(a) below:

(iii) The cross head may be made of forged mild steel/ hot rolled steel. The ratchet nuts
shall be of steel or malleable cast iron.

(iv) The side of each bow shall be well riveted into the cross head ( sound / strong iron
casting) & shall not draw when the complete assembly is tested to fracture by tensile stress.

(v) In case of galvanized steel stay sets & anchor plates, all the ferrous metal parts shall
be smoothly & continuously hot dip galvanised with zinc, the nuts shall have neat fit so that they
can be turned easily through out the length of the threads on the bolts & nuts shall be capable of
developing the full strength of the bolts. The galvanising shall satisfactorily withstand the test
specified BSS:729/1961 Part.I with latest amendments.

(vi) The parts of stay sets of the same type shall be strictly interchangeable.

(vii) The steel anchor plates shall be clearly cut off and punched and shall be free from
cracks after punching.

(viii) The rods,bows and plates shall strictly conform to table 3 and 6 of BS:16/1974 ( stay
rods No.13 M & 15 M & anchor plates No.23 M1 & 45 M1) in respect of dimensions etc. and
figure 4& 5 (Pattern-I) in respect of shape etc. The dimensions of the cross head portion of the
bow shall be as per the drawing enclosed at Appendix-A of this section.

5.0 TEST :
395
5.1 TEST BEFORE DESPATCH :

The G.S.Stay Sets and accessories shall be subjected at manufacturer's works before
dispatch to the following test(s) as per BS/IS.

A) ROUTINE TEST ON EACH UNIT AS PER RELEVANT STANDARD :

The dimension of the stay rods, bows and plates shall strictly conform to table 3 and
6 of BS-16/1974 (Stay rods No.13 M & 15 M and anchor plates No.23 M-1 & 45 M-1) in respect
of dimensions etc., and fg. No.4 & 5 (Pattern-1) in respect of shape etc. the dimensionsof cross
head portion of the bow shall be as per drawing enclosed with specification .

5.2 ROUTINE / ACCEPTANCE TEST :

The following tests shall be got conducted in presence of Purchaser's representative.

a) TENSILE TEST :

The finished stay sets when subject to tensile test shall comply with the requirement
of the tensile strength as per the table given below:

S.No. Diameter of rods Breaking load

1. 20 mm 96 KN
2. 16 mm 62 KN
( 1 KN = 101.972 Kgf)

b) HOT DIP GALVANISED TEST :

The finished stay sets when subject to dip test in standard copper sulphate solution for
the testing of galvanization quality should be able to witnessed four dips of one minute each as
per BS:729/1961 Pt.I with out any copper deposits on the surface.

The weight of zinc coating should not be less than 610 grams per sq.m for rods and 460
grams per sq.m for plates as per BS:729/1961 Pt.I.

5.3 SAMPLING PLAN FOR INSPECTION:

396
Since the sampling procedure/ plan has not been mentioned in the BS:16/1974, the fol-
lowing sampling plan shall be applicable for inspection testing/ checking of the stay sets.

(i) FOR TENSILE STRENGTH TEST : 1 out of 1000 Nos.

CRITERIA FOR CONFORMITY :

If one or more sample(s) fail, twice the number of samples originally tested shallbe
selected and shall be subjected to the test. If there is no failure among these samples, thelot or
the sub lot shall be considered to have satisfied the requirement of this test. If one more sample(s)
of the second sample fails, the lot or sub lot represented by the corresponding samples shall be
considered not to have passed the test.

(ii) FOR PHYSICAL DIMENSIONAL CHECKING AND GALVANISATION TEST:

The sampling plan will be as under :

The lot offered for inspection, be divided in sub lot not exceeding 5000 Nos. sets for
each sub lot. Acceptance or otherwise of sub lot shall be determined on the basis of performance
of the samples selected from it as per details mentioned as under :

Size of sub-lot Sample Sample size Permissible Failure

size for re-
From Ist sample From total samples
inspection
size including re-
inspection
n1 n2 c1 c2
Upto 1000 2 4 0 1
1000 to 2000 4 8 0 1
2001 to 3000 6 12 1 2
3001 to 5000 10 20 1 3

5.4 CRITERIA FOR CONFORMITY

Sub lot shall be considered as conforming to the requirement of the acceptance test
if the Nos. of failure found in first samples selected as per Col. No.2 of above table, are upto
the No. mentioned in Col.4 If the No of failure is more than or equal to the sample mentioned in
Col.5 lot shall be considered as not conforming to the requirement of acceptance and shall be
rejected. If the No. of failure is between c1 and c2, a second sample of

397
stay sets shall be selected and subjected to acceptance test. If the number of failure in the two
samples sizes (n1+n2) combined is less than c2, the lot shall be considered as conforming to the
requirement of acceptance tests otherwise it shall be considered to have failed.

5.5 TOLERANCE ON TEST RESULTS :

As per BS:16/1974 and GTP of specification .

5.5.1 The purchaser reserve the right to conduct all test(s) on stay sets after arrival at site and the
contractor shall guarantee tests certificate under actual service condition(s).

6.0 INSPECTION

6.1 All the tests (as mentioned at Clause 5.1 and 5.2) and Inspection shall be made at the place
of manufacturer unless otherwise especially agreed upon by the manufacturer and purchaserat the
time of purchase. The manufacturer shall afford the inspection officer(s) representing the pur-
chaser all reasonable facilities without charges, to satisfy him that the material is being
furnished in accordance with this specification. The purchaser has the right to have the tests carried
out at his own cost by an independent agency whenever there is a dispute regarding the quality of
supply.

6.2 The Inspection may be carried out by the purchaser at any stage of manufacture/ before des-
patch as per relevant standard.

6.3 Inspection and acceptance of any material under the specification by the purchaser, shall
not relieve the manufacturer 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.
The Manufacturer shall keep the purchaser informed in advance, about manufacturing program so
that arrangements can be made for inspection.

6.4 The purchaser reserves the right to insist for witnessing the acceptance/ routine testings
of the bought out items.

6.5 The Manufacturer shall give 15 days advance intimation to enable the purchaser to depute
his representative for witnessing the acceptance and routine tests. The inspection charges would
be to the purchaser's account.

7.0 DOCUMENTATION :

398
7.1 All drawing(s) shall conform to International Standard Organization (ISO) `A' series of
drawing sheet / Indian Standards Specification IS:656. All drawing(s) shall be in ink and suitable
for microfilming. All dimension(s) shall be in SI Units.

7.2 List of drawing(s) and documents :

The manufacturer shall submit four sets of drawings, complete with fully dimensioned
elevation, cross sectional and longitudinal section drawings of each type of material and its as-
semblies. All drawings shall be to scale with full details.

All important dimensions being given therein and the material of which each part is made
of shall be clearly indicated. The drawing of cross head portion and bow and tolerance in the
dimensions as per this specification shall be forming a part of contract.

7.3 The manufacturing of the equipment shall strictly be in accordance with the approved draw-
ings and no deviation shall be permitted without the written approval of the purchaser. All manu-
facturing and fabrication work in connection with the equipment prior to the approval of the
drawing shall be at the supplier's risk.

7.4 The equipment shall conform to high standard of engineering, design workmanship andlatest
revisions of relevant standards at the time of ordering and purchaser shall have the power to reject
any work or materials which in his judgment, is not in full accordance herewith.

8.00 MARKING, PACKING & FORWARDING :

8.1 MARKING:

Each bow of stay sets shall be provided with the following marking :

a) Name of Manufacturer or Trade Mark.

b) Month & year of manufacturing.

The marking on bow should be embossed during the course of casting.

8.2 PACKING & FORWARDING :

399
8.2.1 The stay sets shall be supplied in bundles securely tied and compactly fastened. The bun-
dles of rods shall be tied by wire. The anchor plates shall be tied by wire or bolts and plates &
bow shall be supplied in gunny bags.

8.2.2 Each consignment shall be accompanied by a detailed packing list containing the follow-
ing information:

a) Name of the consignee

b) Details of consignment
c) Destination
d) Total weight of the consignment
e) Handling and unpacking instructions
f) Bill of material indicating contents of each package.

8.2.3 The offers, from manufacturers of G.S. Stay sets shall be preferred . The manufacturers
must, therefore, supply the information along with the bid regarding date of starting the manufac-
turing of the material under reference, manufacturing capacity, details of machinery installed etc.
in the schedule -IX appended with the specification.

9.0 TEST CHECKING OF MATERIAL AT STORES

The material received in the stores of the NIGAM shall be subjected to the test checking
at stores before final acceptance of the material, the procedure for the same shall be as under :

10.1 SAMPLING

One sample out of each sub-lot / lot consisting of following quantities or part thereof in case of
each type of G.S. Stay Set from each inspected lot received in stores shall be selected for test
checking of material and shall be got tested.

I. G.S Stay Set of size 16X1800 mm– 1000 sets.

The selection of sample from the material received at stores shall be done as soon as material is
received in stores without the presence of the representative of the supplier. However, testing of
sample(s) at CTL shall be carried out in the presence of representative of the supplier after

400
identification / confirmation by him that sample so selected belongs to them. In case the supplier
disputes that the selected samples does not pertain to them, then fresh sample shall be selected in
the presence of the representative of the supplier and test(s) be carried out.

10.2 TESTS

The following tests shall be carried out on the above items :

a) Visual Examination, Verification of Dimension(s), weight and marking Test

b) Tensile strength test.
c) Galvanisation (Uniformity) Test.

10.2.1 Only those tests shall be conducted at CTL for which facility with CTL is available.

10.2.2 Test of the material shall be got done at the test laboratory of the NIGAM i.e CTL, Jaipur
in the presence of representative of supplier. For witnessing of the testing, clear 3 (Three) days
notice shall be given to the supplier by fax/ speed post stating date, time & place where the
test is to be conducted. In case the supplier do not attend for witnessing the testing, the testing
shall be proceeded and completed and action be taken as per the contract.

10.2.3 The witnessing officers of the NIGAM or as designated by the purchaser shall send
copies of test reports to the purchaser, consignees and the supplier.

10.3 CRITERIA FOR ACCEPTANCE

a) Visual Examination, Verification of Dimension(s), weight and marking .

As per specification/ ISS/ BIS

b) Tensile strength test.

In case of failure of sample in tensile strength test the material contained in the lot / sub-
lot to which the sample belongs, shall be rejected. The rejected material shall have to be
replaced by the supplier free of cost.

b) Galvanisation (Uniformity) Test.

401
i) The sample(s) shall be first tested for (n-2) number of dips where (n) is specified number of
dips in the contract. If the sample(s) does not pass the uniformity of Galvanisation Test for (n-
2) dips, the material shall be rejected and the material relating to relevant lot / sub-lot to
which
sample(s) pertains shall have to be replaced by the supplier free of cost.

ii) If the sample has passed the uniformity of Galvanisation Test for (n-2) dips, then it shall
be tested for (n-1) dips. If the sample has not passed the uniformity of Galvanisation Test with
(n-1) dips, then material pertaining to relevant lot / sub-lot shall be accepted with a deduction @
10%
of cost of material.

iii) If the sample has passed the uniformity of Galvanisation Test with (n-1) dips, then sample
shall be tested for last one dip of one minute to complete the test for `n' dips. If the sample does
not pass the uniformity of Galvanisation Test with `n' dips, then the material pertaining to relevant
lot/ sub-lot shall be accepted with a deduction @ 5% of cost of material.

iv) If the sample(s) have passed the Test with number of dips as specified in the contract (n),
then material pertaining to relevant lot / sub-lot shall be accepted.

10.4. TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores
shall be borne by the NIGAM.

11.0. TYPE TEST REPORTS :

11.01 The manufacturer shall furnish valid and authenticated type test certificates from a
Govt. approved / Govt. recognized / NABL Accredited laboratory / ILAC i.e. Inter-
national Laboratory Accredited Laboratory (in case of foreign laboratory) of similar
rating and design of tendered material/ equipment. Such type test certificatesshould
not be older than 05 years as on the date of bid opening. For this purpose dateof con-
ducting type test will be considered. The date of conducting type test shall bebefore
the date of opening of Technical Bid.

402
11.02 The manufacturer should furnish documentary evidence in support of the laboratory
whose type test have been furnished, that the said laboratory is a Govt. / a Govt.
approved / a Govt. recognized / NABL accredited laboratory / ILAC accredited (in
case of foreign laboratory).

11.03 The type test certificates shall be furnished either in original or copy duly attested by
notary.

GUARANTEED TECHNICAL AND OTHER PARTICULARS OF HOT DIP GALVANISED

STEEL STAY SETS OF SIZE 16 X 1800 MM WITH ANCHOR PLATES

S. Description. Hot dip galvanized steel stay sets with anchor plates(
No. in mm)
16x1800mm
1. Maker's name and address.
2. Place where the material shall
be offered for inspection
(work’s address)
3. Standard specification to which BSS:16/1974, BSS:729/1961(Pt.I) with latest
the material confirms amendments
4. i) Diameter of stay rods 16 mm
ii) Permissible tolerance on (+/-) 0.5 mm
diameter
5. Length of stay rod. 1800 mm (With
permissible tolerance of
(+/-) 0.5%).
6. Length of threaded portion of 300 mm (With
stay rods. permissible tolerance of
(+/-) 2.5%).
7. i) Diameter of bow. 12 mm
ii) Permissible tolerance on (+/-) 0.5 mm
diameter of bow.
iii) Height of bow 400 mm
iv) Permissible tolerance on height (+/-)2.5%
of bow.
8. Size of Anchor plates. (Length 300x300x4 mm
x Breadth x Thickness)
S. Description. Hot dip galvanized steel stay sets with anchor plates(
No. in mm)
16x1800mm
Tolerance :
i) Length & width. (+/-) 5 mm
ii) Thickness. + 12.5 %, - 5 %
iii) Hole of Anchor plate. (+/-) 0.5 mm
9. Uniformity of zinc coatings
Nos. of dips withstands in
standard copper sulphate solu-
tion.
i) Stay rods. 4 dips of one minute each. As per BSS:729/1961
Pt.I.
ii) Cylindrical portion of bow
iii) Cross head.
iv) Ratchet nut.
v) Plate.
10. Weight of zinc coatings. 610 gm/sq.m for rods460 gm/sq.m for plates As per
BSS:729/1961 Pt.I.
11. Breaking load in KN for 62 KN
complete set subjected to
tensile test.
12. Packing details. As per packing and marking clause no.8.00 of
specification.
13. Stay set embossing mark As per clause no.8.1 of specification (TO BE
FILLED IN BY MANUFACTURER)
14. Tolerance on cast iron cross (+/-) 2.5%
head.
15. Tolerance on ratchet nut As per BS:16/74 Table-3 but with3 cuts for ratchet.
16. Tolerance on all forging (+/-) 2.5%
portions of stay sets.
17. Grade of oil to be applied on Any good quality of mobile oil to prevent rusting on
threaded portion. threaded portion.
18. i) Weight of complete stay set 7.5 Kg
ii) Tolerance in weight +12.5% -2%

404
Signature of Manufacturer

405
TECHNICAL SPECIFICATION FOR SUPPLY OF & 11 KV HORN GAP FUSE SETS
WITH 1X24 KV POST INSULATORS (UN-ASSEMBLED)

1.0 SCOPE :

This specification covers the design, manufacture, testing before dispatch, packing & forwarding
and delivery of 11 kV Horn Gap Fuses (including hardwares and post insulators). The Horn Gap
Fuses shall be required for protection of lines and distribution Transformers at various sites of
Jaipur Discom, the details of principal parameters/various parts of horn gap fuses are indicated in
subsequent clauses hereunder.

1.1 It is not the intent to specify completely herein all details of the design and construction
of equipments. However, the equipment shall conform in all respects to high standards of engi-
neering, design and workmanship and shall be capable of performing in continuous commercial
operation upto the Manufacturer's guarantee in a manner acceptable to the Purchaser, who
will interpret the meanings of drawings and specifications and shall have the power to reject
any work or material which in his judgment is not in accordance therewith. The offered
equipment shall be complete with all components necessary for its effective and trouble free
operation along with associated equipments, interlocks
, protection schemes etc. Such components shall be deemed to be within the scope of supply,
irrespective of whether those are specially brought out in this specification and/or the
commercial order or not.

2.0 SERVICE CONDITIONS :

Equipment to be supplied against this specification shall be suitable for satisfactory continuous
operation under the following tropical conditions :

i) Location In the state of Rajasthan

ii) Max. ambient air temp. in shade (Deg.C) 50

iii) Min. ambient air temp. (Deg.C) (-) 5

iv) Average daily ambient air temperature(Deg.C.) 45

v) Max. yearly weighted ambient temp.(Deg.C.) 35

vi) Relative humidity (%) 100

406
vii) Average annual rainfall (mm) 100 to 1000mm (de-
pending upon area)

viii) No. of rainy days P.A. 70

ix) Max. wind pressure (Kg/sq m) 195

x) Max. altitude above mean sea level (mtrs) 1000

xi) Isoceraunic level (month/year) 4 months ( June to Sept)

xii) Seismic level (horizontal acceleration) 0.08g

Note : Moderately hot and humid tropical climate conducive to rust and fungus growth. The cli-
matic conditions are also prone to wide variations in ambient conditions. Smoke is also
present in the atmosphere. Heavy lightning also occurs during June to October.

3.0 PRINCIPAL PARAMETERS :

3.1 The equipment i.e. horn gap fuse unit covered in this specification shall be a complete unit
with 2 x 24 KV Post Insulator type E-32 for use on 33 kV system and 1X24 KV Post Insulator type
E-32 for use on 11 kV system The ratings of 33 kV & 11 KV Horn Gap Fuses with post insulators
shall be as under :

PARTICULARS/ RATINGS Specified

values
HG FUSES
(11 KV H.G.)
a) Nominal system voltage kV (rms) 11
b) Rated voltage kV(rms) 12
c) Rated frequency(Hz) 50
d) One minute power frequency withstand voltage 55
kV(rms) (To earth & between poles).
e) Impulse withstand voltage kV peak).(To earth & 125
between poles).
f) Permissible temperature rise above ambient 40 deg.
temp. ( 50 deg cent.) Cent.
g) Rated Current (Amp) 100

407
3.2 The minimum mechanical & electrical values/ characteristics of 24kV Post Insulators
shall be as follows :

S. No. Particulars Specified values

1. Torsional Strength 680mm

2. Cantilever Strength 9000 N
3. Tensile Strength 30000 N
4. Compression Strength 40000 N
5 Highest system voltage (kV rms) 24
6. Dry & wet power frequency withstand test 55
voltage for one minute(kV rms)
7. Impulse withstand test 125 (KV Peak)
8. Visible discharge test 18 (KV rms)
9. Power frequency puncture withstand test voltage 1.3 times the actual dry
(kV rms) flash-over voltage of
the unit.

3.3 DIMENSIONAL CHARACTERISTICS OF POST INSULATORS :

S.No. Particulars. 1X24 KV

(11KV HG Fuse )

1. Nominal system voltage. 11 KV

2. No. of units One

3. Total height of
i) unit 254mm
ii) Stack

4. Diameter of Insula- 210mm

ting part (max.)
5. Minimum total creepage
distance of each unit 430mm
6. Top fitting pitch 76mm

408
circle diameter
7. Bottom fitting 76mm
pitch circle
diameter

3.4 One set of Horn Gap Fuse Shall consist of three single phase units of Horn Gap Fuses.

4.0 GENERAL TECHNICAL REQUIREMENTS :

HORN GAP FUSES :

4.1 The hardwares of horn gap fuses shall be designed and manufactured as per IS. The horn
gap fuse sets are to be used for protection of lines and distribution transformers. The billof
material to complete one set (i.e. for Three phases) shall be as per requirement.

4.2 The hardwares of Horn Gap Fuses shall be constructed out of the best quality of material
suitable for weather conditions prevailing in Rajasthan. The workmanship shall be in accordance
with the modern engineering practice. All ferrous parts shall be given an anticorrosive finish. The
other parts shall be substantially non corrosive. The details of various specific parts for manufac-
ture are as under :

(1) BASE CHANNEL :

The base channel shall be of size 75X40x542 mm Long ( for 11 KV HG Fuse sets) of Hot Dip
Galvanized mild . The base channel should have holes for mounting post insulators.

(2) HORN STOOL :

Two numbers of Horn Stools of Hot Dip Galvanized MS flat of size 50 x 6 mm will be used. The
Horn Stool shall be fixed on the top of the post insulators with the help of electro galvanized bolts
and spring washers. The Horn Stool must be rigid and strong enough for fixing the horn over the
top of horn stool. Over the top of the horn stool, the horn will be fixed.

(3) ARCING HORN :

Two numbers arcing horns of 12 mm dia of Hot Dip Galvanized M.S. round rod will be used. It
will be aluminum painted. The base of arching horns should be projecting to 25 mm. It shall be
409
fitted on horn stool with the help of horn clamps, nuts, bolts and spring washers. The length ofthe
horn/height should be maintained. The horn should have a hole & fixing brass thumb screw
with fly nut and flat washer to tie and tighten with the fuse wire.

(4) BRASS THUMB SCREW :

There shall be one tapped hole on each arcing horn. The brass thumb screw will be fixed in the
tapped hole provided in each arcing horn. The fuse wire is to be tied with brass thumb screw and
tightened with help of fly nut (Brass) and flat washer (Brass). The length of brass thumb screwwill
be fully threaded and screwed up to the whole depth of the horn. The design must be such that the
changing of fuse wire is convenient. There is no loose connection/contact and there shouldnot be
any possibility of thumb/jamming on account of arcing when fuse is blown off.

(5) HORN CLAMPING ARRANGEMENT :

There shall be two M.S. Horn clamp of size 50x105x6 mm fixed on horn stool with the help of
bolts and nuts, spring washers for fixing the arcing horns and clamping the conductor. The lower
part of the clamping for holding the required conductor shall be of size 50x50x6 mm. This shall
be made from M.S. sheet.

(6) EARTHING TERMINAL :

One number earthing terminal shall be provided on the flange portion of base channel. The
M.S bolt of 12 mm dia and 25 mm long shall be used with flat washer for this purpose.

(7) BOLTS, NUTS AND WASHERS :

All the bolts, nuts and washers shall be electro-galvanized. However the thumb screw and its
connecting fly nut and flat washer, to be used to fix fuse wire, will be of brass only. The size of
various bolts, nuts and washers which are in the scope of supply are as below :

S.NO. SIZE OF BOLTS, NUTS TO BE UTILISED FOR qty. for

AND WASHERS. 1 unit
of 11 KV

1. Bolt size 12mm dia, Earthing terminal 4 Nos

25mm long with flat
washer & nut.

410
2. Bolt size 12mm dia, For fixing post 8 Nos
38mm long with nuts insulators on base.
& spring washer.

3. Bolt size 12 mm dia, For fixing horn stool 4 Nos

25mm long with nuts above the post insulators. .
spring washers.

4. Bolt size 5/6 dia For fixing arcing horn on 16 Nos

1.25” long with nuts horn stool and clamping
and spring washers.

5. Brass thumb screw For fixing fuse wire 2 Nos.

(6mm dia. 30mm long) on the arcing horn.
with Brass fly nut
(30mm wing dia) flat
washer (1mm thick,
20mm outer dia and
internal dia. such as
to accommodate the 6mm
dia brass screw).

5.0 POST INSULATORS :

5.1 The 24 kV post insulators units shall be pedestal post type (conforming to IS-5350 Part-
III and IS-2544). The insulators shall be constructed out of the best quality of material suitable for
weather conditions prevailing in Rajasthan. The workmanship shall be of the highest grade and
the entire manufacture shall be in accordance with the modern Engineering practices.

5.2 Where Porcelain Insulators are offered, the insulator shall be made of homogeneous and
vitreous porcelain of high mechanical and die-electric strength. It shall have sufficient mechanical
strength to sustain electrical and mechanical loading on account of wind load, short circuit
forces etc. Glazing of the porcelain shall be of uniform brown or dark brown colour with a
smooth surface arranged to shed away rain water. The porcelain shall be free from
laminations and other flaws or imperfections that might affect the mechanical or dielectric
quality. It shall be thoroughly vitrified, tough and impervious to moisture. The porcelain and metal
parts shall be assembled in such a manner and with such material that

411
any thermal differential expansion between the metal and porcelain parts throughout the range
of temperature specified in this specification shall not loosen the parts or create undue internal
stresses which may affect the mechanical or electrical strength or rigidity of the unit as a
whole or stack of two units. The assembly shall not have excessive concentration of electrical
stresses in any section or across leakage surfaces. Cement used in the construction of post
insulators shall not cause fracture by expansion or loosening by construction and proper care
shall be taken to locate correctly the individual parts during cementing. The cement
used shall not give rise to chemical reaction with
metal fittings and its thickness shall be uniform. The insulator shall be suitable for water washing
by rain or artificial means in service condition. Profile of the insulator shall also conform
to the relevant IS.

5.3 Cap to be provided on top of the insulator shall be of malleable steel casting or of
aluminum alloy . It shall be machine finished and hot dip galvanized in case of malleable steel
casting. The cap of 24 kV Post Insulators shall have four numbers of tapped holes spaced on a
pitch circle diameter of 76mm. The threads of the tapped holes in the post insulator metal fittings
shall be cut after giving anti corrosion protection and shall be protected against rust by
greasing or other similar means, all other threads shall be cut before giving anticorrosion pro-
tection and shall conform to IS:4218 or latest version thereof. The tapped holes shall be suitable
for bolts with threads having anticorrosive protection. The effective depth of threads shall not
be less than the nominal diameter of the bolt. The cap shall beso designed that it shall be
free from visible corona.

5.4 The casting shall be free from blow holes, cracks and such other defects.

5.5 All the ferrous metal parts shall be given an anticorrosive finish and shall be hot
dip galvanized smoothly as per IS:3638 (as amended upto date), IS:2633 or any other equivalent
authoritative standard. The other parts shall be substantially non corrosive. The material shall be
galvanized only after shop operations upon it have been completed. Themetal parts before
galvanizing should be thoroughly cleaned of any paint, grease, rust, scales or alkali or any
foreign deposit which are likely to come in the way of galvanizing process. The coating on the
metal parts shall withstand minimum four one minute dips in copper sulphate solution as
per the relevant IEC/IS.

5.6 The insulator unit shall be assembled in a suitable jig to ensure correct positioning of
the top and bottom metal fittings relative to one another. The faces of the metal fittings shall
be parallel and at right angles to the axis of the insulator and the corresponding holes in the
top and the bottom metal fittings shall be in a vertical plane containing the axis of the insulator.

5.7 It shall be the sole responsibility of the Supplier to carry out thorough inspection and qual-
ity checks on the insulators at the insulator supplier's works, before offering the insulators for
Purchaser's inspection.
5.8 Two Nos. of 1 x 24 kV Post Insulator shall be provided on each pole of 11 kV Horn Gap
Fuse set. (Total six Nos. of 1 x 24 kV Post Insulator for three phases (Poles) of one set of H.G.)

5.9 The porcelain and hardware surface coming in contact with cement shall be coated with
bituminous paint for cushioning to relieve mechanical stress caused by temperature variationand
cement expansion.

5.10 The post insulators shall conform to IS:5350. The total creepage distance of 24 kV post
insulator as individual unit shall be minimum 430 mm.

5.11 Following makes of the Post Insulators shall be acceptable for the supply of Horn gap Fuse
Set

i) M/s.Jaipur Glass & Potteries, Jaipur.

ii) M/s.India Potteries, Kolkata.
iii) M/s.Bikaner Ceramices, Bikaner.
iv) M/s.CJI Porcelain, Khurja.
v) M/s.Vishal Melleable, Ankeleshwar.
vi) M/s.Allied Ceramices Pvt. Ltd., Kolkata.
vii) M/s.WSI, Chennai.
viii) M/s.IEC, Bhopal.
ix) M/s.MIL, Allahabad.
x) M/s.Jay Shree Insulators, Vadodara.
xi) M/s.Birla NGK Insulators Pvt. Ltd., Halol.
xii) M/s.MIL, Abu Road.
xiii) M/s.Sarvana Insulators Ltd., Kurinji Padi, Dist Cuddalore,
(Tamilnadu).
xiv) M/s B.H.E.L.

5.12 Besides above, the Post Insulators manufactured by the vendors approved by the Power Grid
Corporation of India Ltd (PGCIL) and National Thermal Power Corporation (NTPC) shall also
be acceptable.

6.0 TESTS :

6.1 TEST BEFORE DESPATCH :

413
The parts of H.G. Fuses i.e. Hardwares and post insulators shall be subject to under mentioned
tests separately at respective manufacturer’s works before dispatch as per relevant standards.

INSULATORS :

A) Routine test

i) Visual examination
ii) Routine electrical test
iii) Routine mechanical test

B) TYPE TESTS

i) Visual examination
ii) Verification of dimensions
iii) Visible discharge test
iv) Impulse voltage withstand test.
v) Dry power-frequency voltage withstand test.
vi) Wet power frequency voltage withstand test.
vii) Temperature cycle test.
viii) Mechanical strength :
a) Bending Test
b) Torsion Test.
c) Tensile or compressive test.
ix) Puncture test.
x) Porosity test.
xi) Galvanizing test.

C) Acceptance Tests :

i) Verification of dimensions
ii)Temperature cycle test
iii)Mechanical strength test
iv)Puncture test
v)Porosity test
vi)Galvanizing test

414
TEST ON HORN GAP FUSE UNIT COMPLETE WITH INSULATORS AND HARDWARES

A TYPE TEST (S) :

i) Visual examination
ii) Dimensional checkup
iii) Temperature rise test
iv) Power frequency H.V.Test, with inter phase distance as 1000 mm.( for 33
KV HG fuse set) and with inter phase distance as 600 mm.( for 11 KV HG
fuse set)
v) Impulse test. with inter phase distance as 600 mm.( for 11 KV HG fuse set)

B ACCEPTANCE TESTS :

i) Visual examination
ii) Dimensional checkup
iii) Temperature Rise Test
On one sample per lot

6.2 TEST ON BOUGHT OUT ITEMS :

Tests are not required to be performed on small bought out parts like Nuts, Bolts & Washers etc.
at the works of manufacturer. Furnishing of test certificates from original manufacturer(s)
shall be deemed to be satisfactory evidence. Inspection of the tests at sub contractor's works will
be arranged by the supplier when ever required.

6.3 ACCEPTANCE & ROUTINE TESTS :

6.3.1 All acceptance & routine tests as stipulated at clause No.6.1 shall be carried out in presence
of purchaser's representative at manufacturer's works of Insulators and Hardwares separately be-
fore dispatch.

6.3.2 Immediately after finalization of the programme of type/acceptance, routine testing, the
supplier shall give sufficient advance intimation to the purchaser to enable him to depute his
representative for witnessing the tests.

The test samples after having withstood the routine tests shall be subjected to the following
Acceptance tests in the order indicated below :

On Insulators

415
i) Verification of dimensions as per approved drawing / ISS.
ii) Temperature cycle test.
iii) Mechanical strength test.
iv) Puncture test.
v) Porosity test
vi) Galvanizing test

On Hardwares of Horn Gap Fuse sets

i) Visual examination
ii) Dimensional checkup
iii) Temperature Rise Test (only on one unit per lot)

Fitment of Horn gap Fuse hardwares with Insulator test

One percent of insulators inspected shall be brought at the contractor works for checking
of fitment with hardware.

6.3.3 For conducting acceptance tests on post insulators the number of post insulators or post
insulators unit shall be selected as under:-

Lot size number of post insulators unit to be selected

Upto 800 6

801 to 1300 8

1301 to 3200 10

3201 to 8000 14

8001 and above 20

6.3.4 10% samples will be selected from offered lot of complete Horn Gap Fuse sets Hardwares
for conducting acceptance tests on the same except fitment test which shall be carried out on one
percent of offered lot.

416
7.00 TYPE TEST CERTIFICATE:

a) The manufacturer shall furnish valid and authenticated type test certificate from a Govt.
approved/ a Govt. recognized/ NABL accredited laboratory/ ILAC i.e. International Labora-
tory Accredited laboratory / ILAC i.e International Laboratory Accrediation Cooperation ( In
case of foreign laboratory) of similar rating and design. Such type test certificates should not
be older than five years as on the date of bid opening. For this purposedate of conducting type
tests will be considered.

b) The type test certificates by inhouse laboratory of tendering firm even if it is a Govt ap-
proved/ Govt recognized/ NABL accredited/ ILAC accredited, shall not be accepted, in caseof
their own tender. This will not apply if tendering firm is Govt. Company/ Public Sector Un-
dertaking.

c) The manufacturer should furnish documentary evidence in support of the laboratory whose
type test have been furnished, that the said laboratory is a Govt/ a Govt. approved/ a Govt.
recognized/ NABL accredited laboratory/ ILAC accredited ( in case of foreign laboratory)

d) The type test certificates shall be furnished either in original or duly attested by notary.

e) The bids of only those manufacturers shall be considered to be meeting the type test criteria
who furnishes complete type test certificates with the bid as per above provision.

8.0 INSPECTION :

All the tests (as mentioned at Clause 6.4) and Inspection shall be made at the place of manufacturer
unless otherwise especially agreed upon by the manufacturer and purchaser at the time of pur-
chase. The manufacturer shall afford the inspection officer(s) representing the purchaser all rea-
sonable facilities without charges, to satisfy him that the material is being supplied in accordance
with this specification. The purchaser has the right to have the tests carried out at his own cost by
an independent agency whenever there is a dispute regarding the quality of supply.

The Inspection may be carried out by the purchaser at any stage of manufacture/ before dispatch
as per relevant standard.
Inspection and acceptance of any material under the specification by the purchaser, shall not re-
lieve the manufacturer of his obligation of supplying material in accordance with the specification
and shall not prevent subsequent rejection if the material is found to be defective. The Manu-
facturer shall keep the purchaser informed in advance, about manufacturing programme so that
arrangements can be made for inspection.
The purchaser reserves the right to insist for witnessing the acceptance/ routine testing of the
bought out items.

The Manufacturer shall give 15 days advance intimation to enable the purchaser to depute his
representative for witnessing the acceptance and routine tests.

The inspection charges (Inspectors traveling , boarding & lodging) would be to the
purchaser's account.

Calibration Certificates:

The supplier shall present the latest calibration certificate(s) of testing instruments / equipments
to be used for the testing of the materials covered in the purchase order to the authorized inspecting
officer/ inspecting agency of the purchaser. The testing instruments / meters/ apparatus etc. should
be got calibrated by the supplier from time to time from independent laboratory accredited from
NABL or the manufacturer of the testing instruments having traceability to NPL or NABL accred-
ited laboratory. The calibration certificates should not in any case be older than one year atthe time
of presenting the same to the inspecting officer/ inspecting agency of the purchaser. Thetesting
instruments / equipments should be duly sealed by the calibrating agency and mention thereof
shall be indicated in the calibration certificates(s).

9.0 QUALITY ASSURANCE PLAN :

9.1 The Manufacturer shall invariably furnish following information along with his offer,
failing which his offer shall be liable for rejection. Information shall be separately givenfor Horn
Gap fuses hardware unit and post insulators.

i) Statement giving list of important raw materials.

ii) Names of sub suppliers for the raw materials, list of standards according to which the raw
materials are tested, list of tests normally carried out on raw materials in presence of
Supplier's representative, and copies of test certificates.

iii) Information and copies of test certificates as in (i) and (ii) above in respect of bought out
accessories.

iv) List of manufacturing facilities available.

v) Level of automation achieved and list of areas where manual processing still exists.

418
vi) List of areas in manufacturing process, where stage inspections are normally carried out
for quality control and details of such tests and inspections.

vii) List of testing equipments available with Manufacturer for final testing of equipment and
test plant limitation if any, vis-a-vis the type, special, acceptance and routine tests specified in
the relevant standards. These limitations shall be very clearly brought outin the specified
test requirements.

9.2 The Supplier shall, within 30 days of placement of order shall submit following
information to the Purchaser.

i) List of raw materials as well as bought out accessories and the names of sub- suppliers
selected from the lists furnished along with offer.

ii) Type test certificates of the raw materials and bought out accessories.

iii) Quality Assurance Plan (QAP) with hold points for Purchaser's inspection. The quality assur-
ance plan and hold points shall be discussed between the Purchaser and Supplier
before the QAP is finalized.

9.3 The supplier shall submit the routine test certificates of bought out accessories and
central excise passes for raw materials at the time of routine testing.

10.0 DRAWING :

10.1 The one set of following drawings/documents of the equipment covered by this
specification shall be furnished by the Manufacturer along with their offer:-

i) Outline dimensional drawings of Horn Gap Fuse Set with insulator and list mentioning bill of
material with complete details regarding metal hardware fittings.

ii) Assembly drawings showing complete details of all parts and separating mechanism and
mass of main component part.

iii) Drawings showing dimension of upper and lower metal parts along with PCD of post insu-
lator.

iv) Descriptive literature and manufacturing data on insulator shall be furnished.

419
v) Type test reports ( as per Clause 6.2 of Section-VII).

vi) Test reports, literature, pamphlets of the bought out items and raw materials.

vii) Detailed views of the insulator stacks & metallic and hardware unit.

10.2 The Supplier shall within 2 weeks of placement of order shall submit 3 sets of
final versions of all the above said drawings along with bill of material, as per bidding documents
, for purchaser’s approval. The purchaser shall communicate his comments / approvalon the draw-
ing(s) to the supplier within two weeks. The supplier shall, if necessary, modify the drawings and
resubmit 3 copies of the modified drawings within two weeks for purchaser’s approval. The delay
in submission of the modified drawings (if called for ) complete in all respectand in acceptable
form beyond two weeks time (as stated above), shall be on supplier’s account.

10.3 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 Purchaser.
All manufacturing and fabrication work in connection with the equipment prior to the
approval of the drawing shall be at the Supplier's risk.

10.4 Approval of drawings/work by Purchaser shall not relieve the Supplier of his responsibility
and liability for ensuring correctness and correct interpretation of the latest revision of applicable
standards, rules and codes of practices.

11.0 PACKING AND FORWARDING :

11.1 Each Horn Gap Fuse Set Hardwares shall be legibly and indelibly marked to show the
following :

a) Name or trade mark of manufacturer.

The Post Insulators shall be legibly and indelibly marked to show the following :

b) Name or trade mark of manufacturer.

c) Month and year of manufacture.

Such marking on porcelain shall be printed, not embossed and shall be applied before firing.

420
11.2 The Horn Gap Fuse sets (hardwares) shall be suitability packed in double gunny bags wor-
thy of rail/ road transport . The supplies shall have to insert in each case / bag packing list giving
item wise details of articles in the packing as mentioned in the list. The post insulators shall be
packed in crates suitable for vertical/ horizontal transport as the case may be and suitable to
withstand handling during transport and outdoor storage during transit. The Supplier shall be
responsible for any damage to the equipment during transit due to improper andinadequate pack-
ing. The easily damageable material shall be carefully packed and markedwith the appropriate
caution symbols.

Wherever necessary, proper arrangement for lifting, such as lifting hooks etc., shall be provided.
Any material found short inside the packing cases shall be supplied by Supplier without
any extra cost.

The inspected lot of Post Insulators should be directly delivered / dispatched from their ( manu-
facturer’s) works to consignee’s stores.

11.3 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) Handling and unpacking instructions.
f) Bill of material indicating contents of each package.

12.0 TEST CHECKING OF MATERIAL AT STORES:

The material received in the stores of the NIGAM shall be subjected to the test checking at stores
before final acceptance of the material, the procedure for the same shall be as under :
12.1 SAMPLING

One sample out of each sub lot/ lot of 100 sets for 11 KV Horn Gap fuse sets or part thereof from
each inspected lot received in stores shall be selected from each store for test checking of material
and shall be got tested. The selection of sample from the material received at stores shall be done
as soon as material is received in stores without the presence of the representative of the supplier.
However, testing of sample(s) at CTL or elsewhere as arranged by JVVNL shallbe carried out in
the presence of representative of the supplier after identification / confirmation by him that sample
so selected belongs to them.

421
(a) one extra sample of 24 KV post insulator for conducting Puncture test.

12.2 TESTS

The following tests shall be carried out on the above items :

a) Visual examination , verification of dimensions, weight and marking as per PO/

GTP / approved drawing.

b) Post Insulators : - i) Mechanical strength test.

ii) Porosity Test
iii) Puncture Test

c) All galvanized parts. - Uniformity of galvanization test.

Testing of the material shall shall be got done at the test laboratory of he Nigam i.e. at CTL in the
presence of the representative of the supplier. Only those test shall be conducted at CTL for which
facility with CTL is available.

ii) The CTL shall send copies of test reports to the purchaser, consignees and the supplier.

12.3 CRITERIA FOR ACCEPTANCE

12.3 TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores shall be
borne by the NIGAM except that of personal expenses of the representative of the supplier
for witnessing the tests.
13.0 The manufacturers are required to provide one extra 24 KV Post Insulator with per set
as spare.

SCHEDULE- A

GUARANTEED TECHNICAL PARTICULARS FOR11 KV HORN GAP FUSES WITH

POST INSULATORS(TO BE FILLED IN BY MANUFACTURERS SEPARATELY FOR
HARDWARE PART AND INSULATOR PART OF HORN GAP FUSES)
A. SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS FOR HARDWARE
PART OF HORN GAP FUSES :
S.No Particulars 11 KV Horn
Gap Fuse
1 Name of Manufacturer
2 Weight of one complete Horn Gap Fuse
(Hardwares only) single phase.

3 a) Size of brass thumb screw with fly nut.

b) Size and Nos. of brass washers with each unit
4 Nos. and size of various electro plated nuts,bolts
and spring washers

5 Whether holes of base of horn stool and channel

& relevant bolts shall match with the holes of post
Insulator unit designation No. E-32 (as detailed at
Table No. 1 of IS:5360 (Part-III)/1971.
6 Tolerances (As per IS):
a) Dimensions.
b) Metal parts.

7 Standard to which galvanisation conforms

8 a) Arcing Horn size

b) Material
9 Whether suitable to withstand temperature rise of
40 deg. Cent at 50 deg cent ambient.

B) FOR INSULATOR PART (24 kV POST INSULATORS) OF HORN GAP FUSES SETS
1 Manufacturer's Name and Country of
Manufacture

423
2 Standard(s) according to which the Post
Insulators are manufactured.

3 a) Manufacturer's type/ designation of post

insulators.
b) Make
c) Drawing No
d) Catalogue No.
4 Glaze
5 Mass of insulator unit in Kg
6 No. of insulators per stack
7 Total height of post insulator Unit (mm).
8 Height of
a) Upper metal fitting.(mm)
b) Bottom metal fitting.(mm)
9 Diameter of Insulating part in mm.
10 Minimum creepage distance in mm.:
S.No Particulars 11 KV Horn
Gap Fuse
i) Total
ii) Protected
11 Dry arcing distance (mm)
12 Diameter of base plate(mm)
13 Details of holes in bottom and Upper metal fitting
for assembly with metal hardware and middle
metal fittings
i) Nos. and dia of holes with PCD in upper metal
fitting.
ii) Nos. and dia of holes with PCD in bottom
metal fitting.

14 Material used for :

i) Cap
ii) Cement
iii)Sanding
iv) Cushion
v) Porcelain Shell
vi) Paint

424
vii)Pedestal

Mechanical Values

15 Ultimate bending strength _ upright

16 Ultimate bending strength _ inverted
17 Ultimate torsional strength
18 Ultimate tensile strength
19 Ultimate compression strength

ELECTRICAL VALUES

20 Rated voltage (kV)

21 Rated frequency (Hz.)
22 Dry one minute power frequency withstandvolt-
age (kV rms)
23 Wet one minute power frequency withstand
voltage (kV rms)

24 Dry power frequency flashover voltage (kV rms)

25 Wet power frequency flashover voltage (kV rms)

26 Dry impulse withstand voltage of 1.2/50 micro

sec. positive wave(kVP)

27 Dry impulse withstand voltage of 1.2/50 micro

sec. negative wave(kVP)

28 Dry impulse flashover voltage of 1.2/50 micro

sec. Positive wave(kVP)

S.No Particulars 11 KV Horn

Gap Fuse
29 Dry impulse flashover voltage of 1.2/50 micro
sec. negative wave(kVP)

30 Power frequency puncture withstand voltage of

unit in kV (rms).

31 Visible discharge voltage KV(rms)

32 Does the post insulator unit conform to the latest
version of IS:2544 (Yes/No)

33 Whether post insulator marked with ISI

certification mark (YES/NO)

33 Statement of type test reports furnished

Name of test lab
Dt. of test
Dt of report
Rating of Equipment Tested
34 Marking

Signature of firm with stamp

Dated.

426
TECHNICAL SPECIFICATION FOR SUPPLY OF GALVANISED M.S.ROD
TYPE EARTHING SET WITH CLAMPS AND G.I. WIRE

1. SCOPE

This specification covers design, manufacture, inspection and testing before dispatch,
supply and delivery at consignees headquarter of Galvanised M.S.Rod type earthing
sets with clamps and G.I. wire. The earthing sets shall be used to protect the 33 KV, 11
KV & LT lines and sub-stations from faulty currents.

2. CLIMATIC CONDITIONS

I. Peak ambient temperature 50 Degree C

3. REQUIREMENT

The quantities mentioned in the schedule-I of requirement are provisional. However,

the type of structures and the net quantity shall be determined later-on at the time of
finalization of this tender. The purchaser also reserves the right to increase or de-
crease the tendered quantity/ weight of structure. The purchaser also reserves the rightto
split the quantity and to entrust the order for the supply on one or more suppliers. The
manufacturer shall agree to supply part quantity ordered on him at the rates/ prices men-
tioned in the tender or accepted by the purchaser.

4. ST ANDARDS

The relevant ISS: to which this material shall conform is indicated as below:-

For fabricated material

427
(i) Raw material test (Manufac turer’s Raw material test certificate as per ISS: 2062-
Grade ‘A’)
(i) Galvanisation test as per relevant IS:2633.
(ii) Checking/verification of Dimension etc. as per approved drawing.
(iv) Sampling for workmanship and dimension checking 3% of each lot and as per
ISS- 4711-1976.
For Bolt & Nuts:
(i) Sampling as per IS:2614 (1969)
(ii) Dimensions as per IS:6639(1972)/12427 (1988) for bolts and IS:1363 Part-III
(1984) for nuts.
(iii) Galvanisation (sampling) as per IS:1367 part-12 1983, mechanical properties and
chemical composition (as per IS:1367 part-III-1991/ IS:12427 (1988) for bolts and
IS:1367 Part-IV 1980/IS12427-1988 for nuts.
For Spring washers:
(i) Sampling as per IS:6821 (1973)
(ii) Dimension and testing IS:3063 (1972) and permanent set test – DIN-257 part
264.2.2 and 4.2.3
(iii) Electroplating IS:1573 (1986)
(iv) Chemical composition IS:4072 (1975)

For Galvanised steel wire:

(i) As per IS: 280(latest addition)
(ii) Testing as per IS:7887 Grade- II

5. FINANCIAL RESOURC ES AND EXPERIENCE

The manufacturer shall submit along with the tender, the details regarding his previous
experience in performing similar comparable work, the technical strength and manu-
facturing facilities available and also financial capability. The manufacturer is further
requested to furnish the information, particularly on the following points :-

(i) Standing of the firm as manufacturer or authorized dealer/sole selling agent/

sole distributor
(i) Approximate tonnage, fabricated so far at his works on monthly basis.
(ii) Testing facilities available at their works.

6. WORKMANSHIP:

The galvanized M.S. Rod shall be made to the dimension specified. The Rod shall be
solid and free from all defects and shall be uniformly galvanized. The requirement for
chemical composition of the rod, clamp, Nut-Bolts etc. shall conform to relevant ISS as
mentioned against each item of earthing sets.

7. QUALITY ASSURANCE PLAN

The supplier shall invariably furnish the following information alongwith his offer, failing

428
which his offer shall be liable for rejection.
(i) Names of sub-suppliers for the raw materials, list of standards according to which
the raw materials are tested, list of tests normally carried out on raw materialsin the
presence of supplier’s representative and copies of test certificate.
(i) Information and copies of test certificates as in (i) above in respect of bought out
material.
( i) List of manufacturing facilities available.
(iv) Level of automation achieved and lis t of areas where manual processing exists.
(v) List of areas in manufacturing process, where stage inspections are normally carried
out for quality control and details of such test and inspection.
(vi) List of testing equipments available with the supplier for final testing of Galvanised
M.S.Rod type earthing sets and test plant limitation if any vis-à-vis thetype, special
acceptance and routine tests specified in the relevant standards. These limitations
shall be very clearly brought out in schedule of deviation from specified test require-
ments.

8. INSPECTION, TESTING & CHECKING :

All the tests and inspection shall be made at the works of manufacturer unless other-
wise especially agreed upon by the manufacturer and purchaser at the time of purchase.
The manufacturer shall afford the inspecting officer(s) representing the purchaser all rea-
sonable facilities without charges, to satisfy him that the material is being furnished in
accordance with this specification. The purchaser has the right to havethe tests carried
out at his own cost by an independent agency whenever there is a disputeregarding the
quality of supply.

The inspection may be carried out by the purchaser at any stage of manufacture/
before dispatch as per relevant standard.

Inspection and acceptance of any material by the purchaser, shall not relieve the manufac-
turer 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. Themanufac-
turer shall keep the purchaser informed in advance, about manufacturing programme so that
arrangements can be made for inspection.

The manufacturer shall give 15 days advance intimation to enable the purchaser to depute
his representative for witnessing the acceptance and routine tests. The inspectioncharges
would be to the purchaser’s account.

TEST BEFORE DESPATCH:- The Galvanised M.S. Rod type earthing sets shall be sub-
ject to the following tests as per ISS at manufacturer’s works before dispatch.

ROUTINE/ACCEPTANCE TEST AS PER RELEVANT STANDARD:

For fabricated material

I) Raw material test (Manufacturer Raw material certificate as per ISS: 2062 Grade

429
A).
II) Galvanization test as per relevant IS:1367(Pt. 13th )1983.
III) Checking of Dimensions etc. as per approved drawing.
IV) Sampling of workmanship and dimension checking 3% of each lot and as per ISS:
4711-1976.
For Bolt & Nuts
i) Sampling as per IS:2614 (1969)
ii) Dimensions
i) Galvanization

For spring washers:

I) Sampling
II) Dimensions
III) Galvanization
IV) Chemical composition

Galvanised steel wire as per IS:12776/1989 latest addition.

In case manufacturer use the steel sections manufactured by prime producers then the
inspecting officer shall verify and record in the inspection report regarding stamping
and mark of prime producers.

The purchaser reserves the right to conduct all tests on M.S. Rod type earthing sets.
(Name of the equipment/material) after arrival at site and the contractor shall guarantee
test certificate figures under actual service conditions.

9. MARKING

The following marking shall be stamped / punched / emboss with a metal dye on the
both clamps and shall be legible.
i. The name of manufacturers in suitable code
ii. The word “JVVNL” & “TN No” & “RDSS”
i. Year of manufacture

If the above marking is not found on the material received in the stores, the receipted
challan shall not be given by the concerned stores. The challan shall only be issued
after verification of material by the Store officer.

Each bundle of earthing sets shall be legibly marked with the phys ical condition,
weight, date of manufacture, trade mark or the name of manufacturer. The material
which is inspected and cleared for dispatch shall be sealed with the JVVNL seal.

10. PACKING AND FORWARDING

The Galvanised M.S.Rod type earthing sets shall be supplied in bundles (containing all
items) and shall be suitably bound and fastened compactly and shall have a maximum
weight of 400 Kgs. The bundles will be suitably protected by wrapping round by hes-
sion cloth/polythene cover to avoid damage in transit and corrosion

11. TEST CHECKING OF MAT ERIAL AT STORES.

The material received in stores shall be subject to test checking in the test laboratory of
Nigam (CTL) before final acceptance of material. The procedure for the same shall be
as under:-
(i) One sample out of each sub-lot/lot of 2000 sets or part thereof from each inspected lot
received in stores shall be selected for test checking of material and shall be got tested. The
sample selection shall be done as soon as material is received in stores without the presence
of representative of supplier. However testing of sample(s) at CTL shall be carried outin
presence of representative of supplier after identification of sample by supplier’srepresenta-
tive.

(ii) Tests
(A) The following tests shall be carried out on the selected samples of completeearth-
ing set except G.S. wire at CTL.
(i) Visual examination
(ii) Verification of dimension as per specification/ GTP/approved drawings.
(iii) Galvanization uniformity test
(iv) Weighment of selected sample

(B) The following tests shall be carried out on the selected samples of G.S. wire as per
relevant standards at CTL.

(i) Galvanization uniformity test

(ii) Dimensional Check
(iii) Tensile load test

Test of the material shall be got done at the test laboratory of the Nigam i.e. CTL. For
witnessing of the testing clear 7 days notice shall be given to the supplier stating date,
time and place where the test is to be conducted. In case the suppliers do not attend
for witnessing the test, the testing shall be proceeded / completed and action shall be taken
as per the contract.

The Executive Engineer (CTL) shall send copies of test reports to the purchaser,
consignees, supplier and Sr. A.O.(CPC).

12. CRITERIA FOR ACCEPTANCE

(A) Verification of dimension.
The sample(s) shall be subjected to verification of dimension check up as per specifica-
tion/GTP/approved drawings and will be accepted as per tolerances specified
431
in specification/ relevant IS: The material will be accepted to any extent if tolerances
are in positive side. If tolerances are in negative side then the material shall be ac-
cepted to the extent as specified in IS, without any deduction. If the dimensions arein
negative side beyond the specified tolerances in IS then it will be accepted to the extent
double the negative side tolerance as specified in IS but with following deductions:-

(a) for M.S.Rod:- 2% of the cost of material

(b) Other parts :- 1% of the cost of material
If the dimensions are beyond double the permissible negative tolerance then material shall
be rejected and the supplier shall replace at his own cost.

(B) Galvanization (Uniformity) test

(i) The sample shall be first tested for (n-2) number of dips where (n) is specified number
of dips in the contract. If the sample(s) does not pass the uniformity of galvanization test
for (n-2) dips, the material shall be rejected and the material relating to relevant lot/sub- lot
to which sample(s) pertains shall have to be replaced by the supplier free of cost.

(ii) If the sample(s) has passed the uniformity of galvaniz ation test for (n-2) dips, then it
shall be tested for (n-1) dips. If the sample has not passed the uniformity of Galvanization
Test with (n-1), then material pertaining to relevant lot/sub-lot shall be accepted with a de-
duction @ 10% of cost of material.

(iii) If the sample(s) has passed the uniformity of Galvanization Test with (n-1) dips, then
sample shall be tested for last one dip of one minute to complete the test for ‘n’ dips. If the
sample does not pass the uniformity test with specified number of dips i.e. ‘n’ dips, then
material pertaining to relevant lot/sub-lot shall be accepted with a deduction @ 5% of cost
of material.

The payment shall be released only after receipt of successful test report of the sample(s)
selected at purchaser’s store for mandatory test chec king to be carried out at CTL. How-
ever, the due date for paym ent shall be considered from the date of submission of bills
along with receipted challans to A.O.(CPC), JVVNL, Jaipur

13. DEPARTURE FROM SPECIFICATION

Technical deviation including GTP and commercial deviation including delivery if any
shall be mentioned in schedule-VI-A & Schedule-VI-B “departure from specification”
attached with this specification. Mentioning of such deviations elsewhere in the offer
will not be considered as deviation. The printed terms and conditions of sales and other
if any attached with the offer will not be considered.

GUARANTEED & OTHER TECHNICAL PART ICULARS FOR GALVANISED M.S.

ROD TYPE EARTHING SET

S.NO. PARTICULARS Description

432
1 Name and address of Manufacturer :

2 Manufacturer’s works address :

3 Standard specification to which the : IS: 2062 and otherrelevant standards.

material shall conform.
4 Dimension shall confirm : For earthingsets as per approved
drawing andfor bolts, nuts&S.washer as
per relevant standard.
5 Sampling for workmanship and : 3% of offered lot
dimension
6 Galv. Shall confirm to : As per IS: 2633/1986 & relevant ISS.
No. of dips employed for 3 dips of 1 minute
galvanization 1 dip of halfminute
7 Electroplating test : As per IS:1573 (1986) andrelevant
ISS
8 Chemical composition : As per relevant ISS.
9 Tolerance :
(i) Mfg. Tolerance ± 0.5 mm (As per ISS 1852/1985)
(ii) Tolerance in length ± 0.5%
10 Packing : As per clause No.11 of specification.
11 Weight(in Kg.) of earthing set : 8.400 Kg. ± 3%
excluding G.I.Wire Bolts and Nuts
12. The suitable code of manufacturer’s :
name as per clause no.10(Marking) of
specification
13 The length of bottom conical portion : 100 mm ± 5 mm tolerance.
of MS Rod
BILL OF MATERIALS

S.No. Particulars Unit Quantity

1 Galvanised M.S. Rod 20 mm dia electrodes No. 1
having 3 Meter length
2 Earthing clamp of M.S.Flat of size 50x6 mm 220 Set (Two 1 welded
mm length welded with earth electrode Pieces) 1 bolted
3 Bolts, Nuts and Spring washers. No. 2
4 G.I.Wire Size 8 SWG having length 15 Meter No. 1

Signature of Manufacturer

Name
Designatio_
Common authorized Sealof
Manufacturer

433
TECHNICAL SPECIFICATION FOR SUPPLY OF HOT DIP GALVANISED STEEL
STAY WIRE

1. SCOPE

This specification covers, manufacture, design, inspection ,testing before dispatch & delivery at
consignees head quarter of following sizes of hot dip heavily galvanized stranded steel stay wire,
complete in all respect as per GTP/ISS

i) Hot dip galvanized steel stay wire of 550-900 N/mm Quality confirming to IS-2141/2000 in
all respect Including chemical composition (Heavily coated Hard quality) of dia 7/3.15
mm(7/10 SWG)

ii) Hot dip galvanized steel stay wire of 550-900 N/mm Quality confirming to IS-2141/2000 in
all respect Including chemical composition (Heavily coated Hard quality) of dia 7/4 mm(7/8
SWG)

2. CLIMATIC CONDITIONS

XI. Peak ambient temperature 50 Degree C

XII. Maximum average ambient temperature 40 Degree C

XIII. Maximum temperature attainable 60 Degree C

XIV. Maximum relative humidity 100 %

XV. Minimum relative humidity 50 %

XVI. Average number of thunder storm days per annum 40

XVII. Average number of rainy days per annum 100

XVIII. Average annual rainfall 10-100 cm

XIX. Maximum wind pressure 100 Kg/sq.m

XX. Altitudes not exceeding 1000 mtrs

3. REQUIREMENT

434
The tendered quantity is provisional. However, net quantity shall be determined later-on at the
time of finalization of this tender. The purchaser also reserves the right to increase or decrease the
tendered quantity. The purchaser also reserves the right to split the quantity and to entrust the
order for the supply on one or more suppliers. The manufacturer shall agree to supply part quantity
ordered on him at the rates/ prices mentioned in the tender or accepted by the purchaser.

4. STANDARDS

The finished material shall comply in all respect with the requirement of the latest edition of the
relevant ISS as mentioned below:-

(i) The hot dip galvanized stranded steel stay wire (heavily coated) shall comply with the
ISS:2141/2000, 4826/1979 and 6594/1977 with latest amendments thereof, if any in all re-
spects, except herein otherwise stated, corresponding to grade-4 550-900 N/mm sq. minimum
tensile strength quality. The galvanization coating of galvanized steel wire and technical sup-
ply conditions shall conform to IS:4826/1979 and IS:6594/1977 or latest amendment thereof
if any.

(ii) Goods meeting other authoritative standards which ensure an equal or higher quality than the
standards mentioned above will also be accepted.

(iii) The galvanized stranded steel stay wire shall be capable of withstanding the normal handling
necessary for transportation and erection.

. 5. FINANCIAL RESOURCES AND EXPERIENCE

The manufacturer shall furnish the details regarding his previous experience in performing similar
comparable work, the technical strength and manufacturing facilities available and also financial
capability along with the tender. The manufacturer is also required to furnish the following infor-
mation.
a. Standing of the firm as manufacturer/supplier
b. Approx. qty., manufacture/supplied so far at his works on monthly basis.
c. Testing facilities available at his works.

6. WORKMANSHIP:

The wire shall be manufactured from steel made by any suitable process(es) as mentioned in
IS:2141/2000 & 7887/1975 and shall not contain sulphur and phosphorus exceeding 0.060 percent
each. Each coil shall be warranted to contain the joints only as permitted under relevant
IS:2141/2000.
The galvanized stranded steel stay wire shall be well and clearly drawn to the dimension specified.
The wire shall be free from scale, irregularities, imperfections, flaws splits and other defects and
shall be uniformly galvanized having smooth and even zinc coating. The requirement for chemical
composition of the wires shall conform to the value as specified in IS:7887/1975 and IS:280/1978.

7. ISI CERTIFICATION

The manufacturer should furnish the copy of valid BIS License along with BIS License No.
with the technical bid. However in the absence of non-furnishing of above BIS license, the
technical bid of manufacturer shall be considered for opening if manufacturer furnishes a copy
of BIS License up to the official working hours of one working day prior to the schedule /
notified date of opening of price bid and it should be valid as on date of opening of technical
bid.

8. QUALITY ASSURANCE PLAN

The supplier shall invariably furnish the following information along with his offer, failing which
his offer shall be liable for rejection.

a) Statement giving list of important raw materials, names of sub-suppliers for the raw materials,
list of standards according to which the raw materials are tested, list of tests normally carried
out on raw materials in the presence of supplier’s representative and copies of test certificate.
b) Information and copies of test certificates as in (i) above in respect of bought out material.
c) List of manufacturing facilities available.
d) Level of automation achieved and list of areas where manual processing exists.
e) List of areas in manufacturing process, where stage inspections are normally carried out for
quality control and details of such test and inspection.
f) List of testing equipments available with the supplier for final testing of G.S. stay wire and
test plant limitation if any vis-à-vis the type, special acceptance and routine tests specified in
the relevant standards. These limitations shall be very clearly brought out in schedule of de-
viation from specified test requirements.

9. INSPECTION, TESTING & CHECKING BEFORE DISPATCH:

All the tests and inspection shall be carried out at the works of manufacturer unless otherwise
specifically agreed upon by the manufacturer and purchaser at the time of purchase. The manu-
facturer shall provide all reasonable facilities to the inspecting officer(s) without charges.

The inspection may be carried out by the purchaser at any stage of manufacture/before dispatch
as per relevant standard. The purchaser has the right to have the tests carried out at his own cost
by an independent agency whenever there is a dispute regarding the quality of supply.

Inspection and acceptance of any material under the specification by the purchaser, shall not
relieve the manufacturer from his obligation of furnishing material in accordance with the
436
specification and shall not prevent subsequent rejection if the material is found to be defective.
The manufacturer shall keep the purchaser informed in advance, about manufacturing program so
that arrangements can be made for inspection.

The manufacturer shall give at least 15 days advance intimation to enable the purchaser to depute
his representative for witnessing the acceptance and routine tests.

(A) TEST BEFORE DESPATCH: The stay wire shall be subject to the following tests as per ISS
at manufacturer’s works before dispatch,.

ROUTINE/ACCEPTANCE TEST:- The following tests on selected samples as per relevant

standard shall be got conducted in presence of purchaser’s representative.
i) Tensile and Elongation test
ii) Adhesion and wrap test
iii) Zinc uniformity and coating test
iv) Chemical analysis test
v) Dimension and weighment checkup of sample coils.
vi) Lay ratio

(B) SAMPLING PLAN:

As per the provisions of IS:2141/2000.

(C) TOLERANCE ON TEST RESULTS

i) Weight of the coil – 40-60 Kg per coil.

ii) Dia of wire ±2.5% of wire dia with a minimum of 0.025 mm
iii) Lay length -12 to 18 times strand dia
iv) Tensile and elongation test –As prescribed in IS:2141/2000.
v) Zinc uniformity and coating test – As per IS:4826
vi) Chemical composition test IS:7887

10. MARKING

Each coil of wire shall be legibly marked with the physical condition, size of wire, weight, date
of manufacture trade mark or the name of manufacturer. The material which is inspected and
cleared for dispatch shall be sealed with the Nigam’s seal.

11. PACKING AND FORWARDING:

437
The galvanized steel stay wire shall be supplied in coils. Each coil of GSS wire shall have single
continuous length and shall be suitably bound and fastened compactly and shall weigh 40 kgs to
60 kgs. The coils will be suitably protected by wrapping round by hession cloth/polythene cover
to avoid damage in transit and corrosion. Each coil shall be marked as mentioned above.

12. TYPE TEST / CHECKING OF MATERIAL AT STORES

The material received in the stores shall be subject to test checking at CTL of Nigam before final
acceptance of the material. The procedure for the CTL test shall be as under :

SAMPLING

One sample out of each lot/sub-lot of 400 Nos coils or part thereof from each inspected lot received
in stores shall be selected subject to maximum 7 samples for test checking of material and shall
be got tested at the CTL of JVVNL. The sample selection shall be done in the presence of supplier
or his authorized representative for which advance notice shall be given to the supplier.

TESTS AT CTL

The following tests shall be carried out on the selected samples of G.S. Stay wire as per relevant
standards:-

(a) Uniformity of galvanization test

(b) Tensile test
(c) Dimensional check

For witness the test, advance notice to the supplier shall be given by CTL, stating date, time. In
case the supplier do not attend for witnessing the testing, the testing shall be proceeded and com-
pleted and action shall be taken as per the contract.

The test reports shall be furnished to the purchaser, consignee and supplier.

TYPE TEST

The following tests shall constitute the type test;

(a) Chemical composition test as per ISS:7887/1992, 2141/2000

(b) Mechanical properties test as per ISS:2141/2000 Gr.IV
(c) Galvanisation test as per ISS:4826/1979

438
such type test reports are valid that i.e not older than 5 Years on the date of opening of Techno-Commercial
Bid,

“At the option of the purchaser, the material received in the stores may be utilized in the field after receipt
of successful test reports from CTL for the mandatory test checking on the sample(s) selected from the
material received at stores against first lot and subsequent lot(s) in anticipation of successful type test re-
port(s).”

13. CRITERIA FOR ACCEPTANCE OF ABOVE TEST

The inspected material should be strictly in accordance to the relevant ISS / GTP of the specification,
however, the material shall be accepted on the basis of test results found/observed during test at
CTL as mentioned below.

(a) For uniformity of galvanization test.

(i) The sample shall be first tested for (n-1) number of dips where n is specified No. of dips of one
minute in the contract. If the sample does not pass the uniformity of galvanization test for (n-1)
dips, the material shall be rejected and the relevant lot/sub-lot to which the sample pertains shall
have to be replaced by the supplier free of cost.
(ii) If the material has passed the uniformity of galvanization test for (n-1) dips then it shall be
tested for last one dip of one minutes to complete the test for ‘n’ dips. If the sample does not pass
the uniformity of Galvanisation Test with ‘n’ then material pertaining to relevant lot/sub-lot shall
be accepted with a deduction @ 5% of cost of material

(iii) If the sample(s) have passed the Test with number of dips as specified in the contract (n) ,
then material pertaining to relevant lot/sub-lot shall be accepted.

b) Tensile test:-

If the material fails in tensile test the same shall stands rejected.

c) Dimensional check
If the material fails in dimensional check the same shall stands rejected.

14. DEPARTURE FROM SPECIFICATION

Technical deviation including GTP and commercial deviation including delivery if any shall be
mentioned in schedule-VI-A & Schedule-VI-B “departure from specification” attached with this
439
specification. Mentioning of such deviations elsewhere in the offer will not be considered as de-
viation. The printed terms and conditions of sales and other if any attached with the offer will not
be considered.

GUARANTEED & OTHER TECHNICAL PARTICULARS OF GALVANISED STEEL STRANDED

STAY WIRE OF SIZE 7/3.15 MM AND 7/4.00 MM TO BE SUPPLIED

S.No. Description Galvanised steel stranded stay wire

Size 7/3.15 mm Size 7/4 mm
1. Firm’s Address

2. Work’s Address

3. Standard specification to which the material Indian standard specification 2141/2000

shall conform (Grade-4) 4826/1979 & 6594/1977 with
latest amendments thereof.
4. Size of wire (mm) 7/3.15 7/4 mm
5. Ultimate tensile strength of stranded wire in 700 700
N/mm sq.
6. Number of dips employed for galvanizing 2-1 minute 2-1 minutes
(after stranding)
1-1/2 minute 1-1/2 minutes
7. Weight of zinc coating in gms/M Sq. 228 247
8. Permissible tolerance on diameter of the (+/-) 2.5% (+/-) 2.5%
wire.
9. Breaking load of single wire before stranding 5.45 8.79
in KN.
10. Overall diameter of stranded wire in mm 9.45 12.0
11. Minimum percentage elongation 6.0 6.0
12. Packing details indicating bare coil weight 40-60 Kg approx.
13. Normal length without joint or weld As per IS:2141/2000
14. Breaking load of stranded wire (KN) 34. 0 54.9
15. Whether material offered shall bear ISIcer- Yes/No Yes/No
tification mark (if yes give details).
16. Any other particulars -

Signature of Manufacturer

440
Name

Designation
Seal of Manufacturer

441
TECHNICAL SPECIFICATION FOR SUPPLY OF G.S. EARTH WIRE 8 SWG (SIZE
5 MM)

1. SCOPE

This specification covers design, manufacture, inspection ,testing before dispatch & delivery at
consignees headquarter of following sizes of hot dip heavily galvanized steel wire, complete in all
respect as per GTP/ISS

i) Hot dip galvanized steel wire of 550-900 N/mm Quality confirming to IS-280/1978(latest
amended) in all respect including chemical composition (Heavily coated Hard quality) of
dia 5 mm

2. CLIMATIC CONDITIONS

I. Peak ambient temperature 50 Degree C

II. Maximum average ambient temperature 40 Degree C

III. Maximum temperature attainable 60 Degree C

IV. Maximum relative humidity 100 %

V. Minimum relative humidity 50 %

VI. Average number of thunder storm days per annum 40

VII. Average number of rainy days per annum 100

VIII. Average annual rainfall 10-100 cm

IX. Maximum wind pressure 100 Kg/sq.m

X. Altitudes not exceeding 1000 mtrs

3. REQUIREMENT

442
The tendered quantity is provisional. However, net quantity shall be determined later-on at
the time of finalization of this tender. The purchaser also reserves the right to increase or decrease
the tendered quantity. The purchaser also reserves the right to split the quantity and to entrust the
order for the supply on one or more suppliers. The manufacturer shall agree to supply part quantity
ordered on him at the rates/ prices mentioned in the tender or accepted by the purchaser.

4. STANDARDS

i) The hot dip galvanized steel wire (heavily coated) shall comply with the ISS:280/1978, with latest
amendments thereof, if any, corresponding to grade-4, 550-900 N/mm sq. minimum tensile
strength quality in all respects, except herein otherwise stated.

ii) The galvanization coating of galvanized steel wire and technical supply conditions shall conform
to IS: 4826/1979 and IS:6594/1977 or latest amendment thereof if any.

iii) Goods meeting other authoritative standards which ensure an equal or higher quality than the
standards mentioned above will also be accepted.

iv) The galvanized stranded steel wire shall be capable of withstanding the normal handling necessary
for transportation and erection.

5. FINANCIAL RESOURC ES AND EXPERIENCE

The manufacturer shall furnish the details regarding his previous experience in performing similar com-
parable work, the technical strength and manufacturing facilities available and also financial capability
along with the tender. The manufacturer is also required to furnish the following information.
a. Standing of the firm as manufacturer/supplier
b. Approx. qty., manufacture/supplied so far at his works on monthly basis.
c. Testing facilities available at his works.

6. WORKMANSHIP

The galvanized stranded steel wire shall be well and clearly drawn to the dimension specified. The wire
shall be free from scale, irregularities, imperfections, flaws splits and other defects and shall be uniformly
galvanized having smooth and even zinc coating. The requirement for chemical composition of the wires
shall conform to those given in IS/7887/1975 as mentioned in the IS:280/1978 or latest amended.

7. ISI CERTIFICATION AND TYPE TEST CERTIFICATE

The supplier must hold the licence of ISI mark. If supplier do not have ISI mark licence at the time of
submission of tender documents, the same must be submitted before commencement of supplies, other-
wise supplies shall not be accepted. Consequences on this account shall be to the suppliers account.
.

8. QUALITY ASSURANCE PLAN

The supplier shall invariably furnish the following information alongwith his offer, failing which his offer
shall be liable to be ignored.

(i) Statement giving list of important raw materials, names of sub-suppliers for the raw materials, list
of standards according to which the raw materials are tested, list of tests normally carried out on
raw materials in presence of supplier’s representative and copies of test certificate.
(ii) Information and copies of test certificates as in (i) above in respect of bought out material.
(iii) List of manufacturing facilities available.
(iv) Level of automation achieved and list of areas where manual processing exists.
(v) List of areas in manufacturing process, where stage inspections are normally carried out for quality
control and details of such test and inspection.
(vi) List of testing equipments available with the supplier for final testing of G.S. wire and test plant
limitation if any vis-à-vis the type, special acceptance and routine tests specified in the relevant
standards. These limitations shall be very clearly brought out in schedule of deviation from spec-
ified test requirements.

9. INSPECTION, TESTING & CHECKING :

All the tests and inspection shall be carried out at the works of manufacturer unless otherwise specifically
agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall provide
all reasonable facilities to the inspecting officer(s) without charges.

The inspection may be carried out by the purchaser at any stage of manufacture/before dispatch as per
relevant standard. The purchaser has the right to have the tests carried out at his own cost by an independ-
ent agency whenever there is a dispute regarding the quality of supply.

Inspection and acceptance of any material under the specification by the purchaser, shall not relieve the
manufacturer from his obligation of furnishing material in accordance with the specification and shall not
prevent subsequent rejection if the material is found to be defective. The manufacturer shall keep the
444
purchaser informed in advance, about manufacturing programme so that arrangements can be made for
inspection.

The manufacturer shall give atleast 15 days advance intimation to enable the purchaser to depute his
representative for witnessing the acceptance and routine tests.

(A) TEST BEFORE DESPATCH: The G.S wire shall be subject to the following tests as per ISS at
manufacturer’s works before dispatch,.

ROUTINE TEST/ACCEPTANCE:- The following tests as per relevant standard shall be got conducted
in presence of purchaser’s representative.
i) Tensile and Elongation test
ii) Adhesion and wrap test
iii) Zinc uniformity and coating test
iv) Chemical analysis test
v) Dimension and weighment checkup of sample coils.
vi) Lay ratio

(B) SAMPLING PLAN: As per the provisions of IS:280/1978.

(C) TOLERANCE ON TEST RESULTS as per IS:280/1978

i) Weight of the coil – 40-60 Kg per coil.

ii) Dia of wire
iii) Lay length, wrap test
iv) Tensile and elongation test
v) Zinc uniformity and coating test
vi) Chemical composition test

10. MARKING

Each coil of wire shall be legibly marked with the physical condition, size of wire, weight, date of manu-
facture trade mark or the name of manufacturer. The material which is inspected and cleared for dispatch
shall be sealed with the Nigam’s seal.

11. PACKING AND FORWARDING:

The galvanized steel wire shall be supplied in coils. Each coil of GS wire shall have single continuous
length and shall be suitably bound and fastened compactly and shall weigh 40 kgs to 60 kgs. The coils
will be suitably protected by wrapping round by hession cloth/polythene cover to avoid damage in transit
and corrosion. Each coil shall be marked as mentioned above.

445
12. TYPE TEST / CHECKING OF MATERIAL AT STORES

The material received in the stores shall be subject to test checking at CTL of Nigam before final ac-
ceptance of the material. The procedure for the CTL test shall be as under :

SAMPLING

One sample out of each lot/sub-lot of 400 Nos coils or part thereof from each inspected lot received in
stores shall be selected subject to maximum 7 samples for test checking of material and shall be got tested
at the CTL of JVVNL. The sample selection shall be done in the presence of supplier or his authorized
representative for which advance notice shall be given to the supplier.

TESTS AT CTL

The following tests shall be carried out on the selected samples of G.S. wire as per relevant standards:-

(d) Uniformity of galvanization test

(e) Tensile test
(f) Dimensional check

For witness the test, advance notice to the supplier shall be given by CTL, stating date, time. In case the
supplier do not attend for witnessing the testing, the testing shall be proceeded and completed and action
shall be taken as per the contract.

The test reports shall be furnished to the purchaser, consignee and supplier.

TYPE TEST
The following tests shall constitute the type test;

(d) Chemical composition test as per ISS:7887/1992, 2141/2000

(e) Mechanical properties test as per ISS:2141/2000 Gr.IV
(f) Galvanisation test as per ISS:4826/1979

“At the option of the purchaser, the material received in the stores may be utilized in the field after receipt of
successful test reports from CTL for the mandatory test checking on the sample(s) selected from the material re-
ceived at stores against first lot and subsequent lot(s) in anticipation of successful type test report(s).”

13. CRITERIA FOR ACCEPTANCE OF ABOVE TEST

446
The inspected material should be strictly in accordance to the relevant ISS / GTP of the specification, however,
the material shall be accepted on the basis of test results found/observed during test at CTL as mentioned
below.

(a) For uniformity of galvanization test.

(i) The sample shall be first tested for (n-1) number of dips where n is specified No. of dips of one minute
in the contract. If the sample does not pass the uniformity of galvanization test for (n-1) dips, the material
shall be rejected and the relevant lot/sub-lot to which the sample pertains shall have to be replaced by the
supplier free of cost.
(ii) If the material has passed the uniformity of galvanization test for (n-1) dips then it shall be tested for
last one dip of one minutes to complete the test for ‘n’ dips. If the sample does not pass the uniformity of
Galvanisation Test with ‘n’ then material pertaining to relevant lot/sub-lot shall be accepted with a deduc-
tion @ 5% of cost of material
(iii) If the sample(s) have passed the Test with number of dips as specified in the contract (n) , then
material pertaining to relevant lot/sub-lot shall be accepted.

b) Tensile test:-

If the material fails in tensile test the same shall stands rejected.

c) Dimensional check

If the material fails in dimensional check the same shall stands rejected.

15. DEPARTURE FROM SPECIFICATION

Technical deviation including GTP and commercial deviation including delivery if any shall be mentioned
.Mentioning of such deviations elsewhere in the offer will not be considered as deviation. The printed
terms and conditions of sales and other if any attached with the offer will not be considered.

GUARANTEED & OTHER TECHNICAL PARTICULARS OF GALVANISED STEEL WIRE OF

SIZE 5 MM TO BE SUPPLIED

S.No. Description Galvanised steel wire

5 mm dia
1 Manufacturer’s name and Address

2 Place of manufacture (works address)

3 Standard specification to which the material
conform
a. For Steel
IS : 280/1978 (with latest IS :
b. For Galvanisation
4826/1979 (amendment)
4 Size of wire (mm) 4 mm dia. 5 mm dia
5 Ultimate tensile strength of G.S. wire in 550-900 in N/mm Sq.
N/mm sq.
6 Number of dips employed for galvanizing 3 dips of 1 minute
(hot dip galvanised)
1 Dip half minute

7 Weight of zinc coating in gms/M Sq. 260 275

8 Permissible tolerance on diameter of the Plus minus 2.5 %
wire.
9 Breaking load of wire in KGF. 704.60 1100.96(min.)
10 Packing details indicating bare coil weight 40-60 Kg approx.
11 Whether material offered shall bear ISIcer- Yes
tification mark (if yes give details).
12 Any other particulars

Note: - Except particulars for S.No. 1,2, & 12 which are to be filled in by manufacturer as per his
information/status, the technical particulars given against S.No. 3 to 11 are to be confirmed by the
manufacturer. In case he wants to deviate from these, then he should specifically mention those in
schedule VI(A&B) i.e. technical deviation from the specification.
Signature of Manufacturer

Name
Designation
Common authorized Seal of Manufacturer

448
TECHNICAL SPECIFICATION AND OTHER REQUIREMENT FOR 11KV , 400 AMP.
ISOLATORS WITH POST INSULATORS WITHOPUT EARTH BLADE ASSEMBLED

1.0 SCOPE:

This specification covers design, manufacture, assembly testing at manufacturer's works, packing and &
delivery with accessories and auxiliary equipments at site(s), store(s) of 11 KV, 400 AMP. Isolators
without Earth Switch with Post Insulators required for installation at various 33/11KV Sub Stations and
11KV lines in Jaipur Discom. The manufacturer shall also provide design, drawing and billof material for
supporting structures for installation of their Isolators without earth switch.

It is not the intent to specify completely herein all details of the design and construction of equip-
ments. However, the equipment shall conform in all respects to high standards of engineering, design and
workmanship and shall be capable of performing in continuous operation upto the supplier's guarantee
acceptable to the Purchaser, who will interpret in a manner the meaning of drawings and specifications
and shall have the power to reject any work or material which in his judgment is not in accordance here-
with. The equipment offered shall be complete with all components necessary for its effective and trouble
free operation along with associated equipments, interlocks, protection schemesetc. Such components
shall be

deemed to be within the scope of supply, irrespective of whether those are specifically brought out in
this specification and/or the commercial order or not. All similar parts particularly movable ones shall
be interchangeable.

2.0 STANDARDS :

Unless otherwise specified elsewhere in this specification, the rating as well as performance and testing
of the isolators shall conform to the latest revisions and amendments of the following standards avail-
able at the time of placement of order.

Sl. Standard Title

No. No.

1. IS:9921 Alternating current isolators (disconnectors) and

Earthing switches.
2. IEC:60129 -do-
3. IS:2544/1973 Insulators.
4. IS:5350 Outdoor cylinderical post (Pt.III/1971) insulators.
5. IS:2629/1985 Recommended practice for hot dip galvanising of
iron and steel.

449
6. IS:4759/1996 Hot dip galvanisation coating on structural steel.
7. IS:2633/1986 Method of testing uniformity of coating on Zinc
coated articles.
8. IS:1573/1986 Electroplated coatings of zinc on iron and steel.

9. IS:6735/994 Spring washers.

10. IS:2016/1967 Plain washers.
11. IS:5561/1970 Electrical power connectors. (Terminal connectors)
12. Indian Electricity Rules.
13. IS:9530/1980 Recommonded practice for silver plating.
14. BS:2816/1964 Testing of silver plating thickness
15. IS:5925/1970 Recommended practice for silver plating for general
engineering purposes.

3.0 CLIMATIC CONDITIONS :

Equipment to be supplied against this specification shall be suitable for satisfactory

continuous operation under the following tropical conditions :

i) Location Anywhere in Rajasthan

ii) Max. ambient air 50
temp. in shade (deg.C)

iii) Min. ambient air temp. (-)5

(deg.C)

iv) Average daily ambient 45

air temperature(Deg.C.)

v) Max. yearly weighted 35

ambient temp.(Deg.C.)

vi) Max. Relative humidity (%) 95

vii) Average annual rainfall 100 to 1000mm

450
(mm) (depending upon area)

viii) No. of rainy days P.A. 70

ix) Max. wind pressure (Kg/sq.m.) 195

x) Max. altitude above mean 815

sea level (metres)

xi) Isoceraunic level 4 months

(days/year). (June to Sept.)

xii) Seismic level (horizontal 0.08g

acceleration).

Note : Moderately hot and humid tropical climate conductive to rust and fungus growth. The climatic
conditions are also prone to wide variations in ambient conditions. Smoke is also present inthe
atmosphere. Heavy/lightning also occurs during June to October.

4.0 PRINCIPAL PARAMETERS :

4.1 The equipment covered in this specification shall meet the technical requirements listed below
:

S.NO. Particulars 11KV Isolator

A) PARTICULARS OF SYSTEM:

i) Nominal system voltage :KV(rms) 11

ii) Highest system voltage :KV(rms) 12
iii) Rated Frequency. :Hz. 50
iv) Number of phases. 3
v) System Neutral Earthing Effectively earthed
B) Service conditions As per clause No.4.0
C)Characteristics of a disconnector
or earthing switch:
The values of the Parameters/Particulars mentioned below shall not be less than the specified against each.

S.NO. Particulars 11KV Isolator

1. Number of poles. 3

2. Class - Indoor or Outdoor Out door

3. Rated voltage :KV(rms) 11

4. Operating mechanism Manual

5. Type of disconnector.(AB) Triple pole, gang operated double break,

central post rotating.

6. Rated insulation level:

a) 1.2/50 Micro Sec. lightning

impulse withstand voltage.

i) To earth & between poles: 75

KV (Peak)
ii) Across the isolating 95
distance.KV(Peak)

b) One minute P.F. withstand 28

voltage.

452
i) To earth & between poles: 28
KV (rms)

ii) Across the isolating 32

distance.KV(r.m.s.)

7. Rated normal current-A (rms) 400

8) i) Rated short time withstand current for 16

three second. KA (rms)

ii) Rated peak withstand current: 40

KA(Peak)

4.2 SPECIFIC TECHNICAL REQUIREMENTS :

1. Phase to Phase separation(min.) 760mm

(Centre to Centre)

2. Minimum centre to centre 300mm

distance between two
poles of same phase.

3. Size of base channel on which 100x50mm

insulators are to be mounted.

4. Size of vertical operating pipe(Down pipe)

i) Length 6 m for equipment

without earth blade

ii) Nominal bore. 25mm

453
5. Minimum length of operating 500mm
handle.
6. Nominal bore of phase 20mm
coupling pipe.
7. Minimum cross-sectional 50X50X4.5mm
area of terminal pad .

8.(a)Minimum cross-sectional 220sq.mm(Min.)

area of fixed contacts. ( 55sq.mmX4 Nos.)
(b)Minimum cross-sectional 55 sq.mm
area of one finger

9. Minimum nos. of fingers 2 pairs

in a fixed contact. (4 fingers)

10. Diameter of Arcing Horn (Rod). 8 mm

11. Size of flexible earthing connnector :

i) Minimum cross-sectional ---------160 sq.mm -------------

area.
ii) Length. ----------150 mm ---------------
iii) For operating handle 50 Sq.mm.x 150 mm length

12. Name of conductor for RACCOON/ DOG

which Electric power connector (As per purchaser's choice)
shall be suitable.

13. Min. size of stainless steel

spring to be provided with
fixed contact.
i) Gauge 16SWG

ii) Outer diameter 15mm

454
iii) Minimum nos of turns per 6 nos.
coil.
iv) Min. total length. 28 mm

14. Minimum number of guides 3/2 nos.

to be provided for down pipe.

15. Minimum size of bimetallic 50X50X1 mm

strip to be provided between
Aluminium terminal connector
and copper terminal pad.

16. Top & bottom pitch circle 76 mm

diameter of post insulator
( to be procured seperately)
for which isolator hardware
shall be suitable.

17. Numbers of minimum size of 4X1/4” dia

bolts to be provided for
fixing terminal connector
with terminal pad.

18. Max. tempreture rise allowed -------25 degree cen.--------

above ambient tempreture of
50 degree centigrade

5.0 GENERAL TECHNICAL REQUIREMENTS :

5.1 The Isolators shall be constructed out of best quality of material suitable for whether conditions
prevailing in Rajasthan. The workmanship shall be of the highest grade and the entire manufacture shall
be in accordance with the modern Engineering practices. All ferrous parts shall be given an anticorro-
sive finish and shall be hot dip galvanised. The other parts shall be substantially non corrosive. The
bearings in the current path shall be shunted by flexible copper connectors of adequate cross section and
the bearing housings shall be completely weather proof with arrangement to facilitate the lubrication
of the bearings.
5.2 The Isolators shall be of tripple pole, gang operated, double break, three posts with central post
rotating, banging type suitable for outdoor horizontal mounting The operating handle shall have arrange-
ment for locking Isolators/earth switch in `ON' and `OFF' positions.

5.3 For reasons of safety, the switch isolator should be so designed that no dangerous leakage current
can pass from the terminals of one side to any terminals of the other side of the switch Isolator.

5.4 The frame of each Isolator and earthing switch shall be provided with reliable earthing terminal for
each phase for connection to an earthing conductor having a clamping bolt/screw of not less than 12mm
diameter. The terminal shall be marked with `Earth' symbol.

5.5 The isolators shall be provided with arcing horns of fixed type with make before and break after
actual making and breaking of isolator main contacts. The arcing horn shall be made of G.I. Rod and their
position shall remain unchanged after mechanical endurance test (slight welding is permitted for this fab-
rication purpose).

5.6 All similar materials and removable parts of similar equipment shall be interchangeable with each
other.

5.7 The vertical operating pipe and phase coupling pipe shall be of galvanised mild steel tube(medium
class) as per IS-1161.

5.8 Suitable arrangement shall be provided to padlock the operating handle of isolating switches and
earth switch in `ON' & `OFF' positions.

5.9 All ferrous parts shall be hot dip galvanised and uniformity of zinc coating shall satisfy require-
ment of IS-2633. The pipes /tubes shall be galvanised in accordance with IS-4736.

5.10 All contact surfaces shall be silver /nickel plated as per IEC:60129 and their temperature rise shall
be maximum 25 degree centigrade. The current density shall be less than 2.5 Amps.per Sq.mm. in
copper, or minimum cross sectional area shall be as specified.

5.11 The height of 2 x 24 KV pedestal post type(E-32) insulator (conforming to IS:5350 Part.III &
IS:2544) stack to be used with 33 KV isolator hardware shall be 508 mm.

5.12 The height of 1 x 24 KV pedestal post type(E-32) insulator (conforming to IS:5350 Part.III &
IS:2544) stack to be used with 11 KV isolator hardware shall be 254 mm and Mechanical strength (Failing
Load) shall be 9KN
456
5.12 BASE CHANNELS :

The channels shall be of sizes mentioned in clause No.4.0 "Principal parameters" of this specification
and shall conform to IS- 808.

5.13 BEARINGS :

5.13.1 The bearing assembly for each rotating central post shall have one number taper thrust roller
bearing at top & one number ball bearing at the bottom/other end of bearing housing. The
entire mechanical load shall be suspended on thrust bearings. Cross sectional drawings of the bearings
shall be furnished with the tender.

5.13.2 The vertical operating shaft shall be supported with taper thrust roller bearing on the top
and atleast two guides in between at uniform interval alongwith its length in order to
ensure smooth and easy operation.

5.13.3 A galvanised MS Angle/channel of suitable length shall be provided for fixing of fourth bear-
ing assembly. The holes provided shall be of movable type at equal distance to that of base channel
holes.

5.14 OPERATING MECHANISM :

5.14.1 The operating mechanism shall be suitable for normal operations by one man without undue
efforts. The mechanism shall be so designed that all the three blades are in positive continuous control
throughout the entire cycle of operation. It shall not be possible after final adjustment have been made
for any part of the mechanism to be displaced at any point in the travel so as to allow improper
functioning of switch, whether the switch is in opened or in closed condition.

5.14.2 All G.I. Pipes used in operating mechanism of isolators and earth switches shall be of medium
class as per IS-1161.

5.14.3 The Isolators with or without earthing switches complete with the operating mechanismshould
not come out of its own in open or closed position due to the effect of gravity, wind pressure, vibrations,
reasonable shocks or accidental touching of operating rods. The arrangement made and stoppers provided
to prevent over travel shall be clearly shown in the tender drawings.
5.14.4 The Isolators should also be capable of resisting in closed position, the dynamic and thermic
effects of the maximum possible short circuit current at the installation point. Their construction should
be such that it should not open under the influence of short circuit current.

5.14.5 The earthing of operating handle shall be made through flexible copper strip of size as per
IS:9921(Pt.III)-1982, connected to the supporting metallic structure.

5.15 CONTACTS :

5.15.1 The fixed contacts shall be of spring loaded reverse loop type as detailed in Clause No.4.2
(8&9) . The minimum length of each finger should be 105 mm or equal to type tested isolator whichever
is higher for 33KV 800 Amp. isolator.

The moving contacts shall be of solid hard drawn electrolytic copper of tubular sections.

5.15.2 The contacts and switches blades shall be of liberal cross section to withstand the rated con-
tinuous current. The copper contacts shall be silver/ nickel plated as per IEC:60129 and female contacts
fingers shall be provided with spring of Phospher Bronze or stainless steel. The spring shall be fixed
in the finger contacts through taflon/nylon insert at both ends so that no transfer of current is possible
through spring and direct electric heating of springs is avoided.

5.15.3 The contacts must be made of liberally rated electrolytic hard drawn copper suitably plated
to withstand damage on account of weather conditions prevailing at site and accidental arcing.
High pressure contact switch shall be designed with a contact pressure 1/2 (Half)Lb per Amp. of
capacity. The manufacturer shall specifically confirm that the material components and cross sectional
areas of all current carrying parts shall be either exactly sameor superior to that of isolator got
type tested for short circuit test, temperature rise test and Mili volt drop test as per relevant standards.

5.15.4 Full details of the contacts and switch blades shall be given with cross sectional drawings to
dimension. The temperature rise of the contacts shall not exceed 25 degree centigrade at an ambient
temperature 50 Degree C.

5.15.5 The current density in current carrying parts shall not exceed 2.5A per sq.mm for copper and
1.0A per sq.mm for Aluminium considering with & without holes for overlapping for which supporting
calculations must be submitted with offer.

5.16 TERMINAL PAD :

The terminal pad shall be made of electrolytic copper flat and should be liberally sized, so as
to receive terminal connectors through minimum 4 Nos. of nuts and bolts of suitable size.

458
5.17 ELECTRIC POWER CONNECTORS (TERMINAL CONNECTORS) :

5.17.1 The isolators shall be provided with 6 Nos of bimetallic rigid type universal terminal connectors
of aluminium alloy suitable for conductors as per clause No.5.0. The size of terminal connector should
match with terminal pad size. The terminal connector shall also be suitable for horizontal and vertical take
off arrangement.

5.17.2 Thickness of bimetallic strip between terminal pad and aluminium terminal connector shall be
atleast 1 mm. The current density in terminal connectors shall be less than 1.0 Amps. per Sq.mm. The
connectors shall conform to all the test requirement of IS-5561 with latest amendments.

5.18 BOLTS, NUTS & WASHERS :

5.18.1 All bolts, nuts & washers required for assembling the equipment and for fixing them on to
the structure shall be galvanized and shall be supplied with the equipment at no extra cost.

5.18.2 Bolts & nuts shall also be provided with lock washers and lock nuts required for fixing post
insulators/post insulator stacks on base plate/base channel.

5.19 ACCESSORIES AND FITTINGS :

The following accessories and fittings shall be provided with the isolators.

i) Handle suitable for pad locking in `ON' & `OFF' position.

ii) Three earthing terminals having clamping bolts of atleast 12mm diameter.

iii) Name Plate shall be provided on the equipment as per IS/9921.

iv) Galvanised arcing horns of liberally rated renewable rod type with make before
and break after arrangement.

v) Mechanical interlock for earthing swithes.

vi) Base Channels.

459
vii) Electric power connectors (Terminal connectors)

5.20 CLEARANCES :

The isolators shall have clearances conforming to relevant IS and should meet the requirements of
the impulse voltage tests as specified therein.

5.20.1 The equipment covered by this specification shall be used outdoor and maximum temperature
attained by any part of the equipment in service at site conditions and full load current shall not exceed
the permissible limits mentioned in IS:9921 at an ambient temperature of 50 Degree C. Manufacturers
are required to mention specific degree of maximum temp. rise in GTPs.

5.20.2 The temperature rise test after fitting terminal connectors shall also be carried out as routine
test on one switch isolator out of each lot offered for inspection. The limit shall not exceed those specified
under this specification.

5.20.3 Where Porcelain Insulators are offered they shall be made of homogeneous and vitreous porce-
lain of high mechanical and die-electric strength. It shall have sufficient mechanical strengthto sustain
electrical and mechanical loading on account of wind load, short circuit forces etc., Glazing of the
porcelain shall be of uniform brown or dark brown colour with a smooth surface arranged to
shed away rain water. The porcelain shall be free from laminations and other flaws or imperfections
that might affect the mechanical or dielectric quality. It shall be thoroughly vitrified, tough and impervi-
ous to moisture. The porcelain and metal parts shall be assembled in such a manner and with such
material that any thermal differential expansion between the metal and porcelain parts throughout the
range of temperature specified in this specification shall not loose the parts or create undue internal
stresses which may affect the mechanical or electrical strength or rigidity of the unit as a whole or
stack of two units. The assembly shall not have excessive concentration of electrical stresses in any
section or across leakage surfaces. Cement used inthe construction of post insulators shall not
cause fracture by expansion or loosening by construction and proper care shall be taken to locate cor-
rectly the individual parts during cementing. The cement used shall not give rise to chemical
reaction with metal fittings and its thickness shall be uniform. The insulator shall be suitable for water
washing by rain or artificial means in service condition. Profile of the insulator shall also conform to the
relevant IS.

5.20.4 Cap to be provided on top of the insulator shall be of high grade cast iron or malleable steel
casting. It shall be machine faced and hot dip galvanised. The cap of 24KV Post Insulators shall have
four numbers of tapped holes spaced on a pitch circle diameter of 76mm . The threads of the tappedholes
in the post insulator metal fittings shall be cut after giving anti corrosion protection and shallbe
protected against rust by greasing or other similar means, all other threads shall be cut before giving
anticorrosion protection and shall conform to IS: 4218 with latest version thereof The tapped holes
shall be suitable for bolts with threads having anticorrosive protection.

The effective depth of threads shall not be less than the nominal diameter of the bolt. The cap shall
be so designed that it shall be free from visible corona.
460
5.20.5 The casting shall be free from blow holes, cracks and such other defects.

5.20.6 All the ferrous metal parts shall be given an anticorrossive finish and shall be hot dip galvanised
smoothly as per IS:3638 (as amended upto date), IS:2633 or any other equivalent authoritative standard.
The other parts shall be substantially non corrosive. The material shall be galvanised only after shop
operations upon it have been completed. The metal parts before galvanising should be thoroughly
cleaned of any paint, grease, rust, scales or alkali or any foreign deposit which are likely to come
in the way of galvanising process. The coating on the metalparts shall withstand minimum four one mi-
nute dips in copper sulphate solution as per the relevantIS.

5.20.7 The insulator unit shall be assembled in a suitable jig to ensure correct positioning of the top and
bottom metal fittings relative to one another. The faces of the metal fittings shall be parallel and at
right angles to the axis of the insulator and the corresponding holes in the top and the bottom metal fittings
shall be in a vertical plane containing the axis of the insulator.

5.20.8 It shall be the sole responsibility of the Supplier to carry out thorough inspection and quality
checks on the insulators at the insulator supplier's works, before offering the isolators for Purchaser's
inspection.

5.20.9 The porcelain and hardware surface coming in contact with cement shall be coated with bitumi-
nous paint for cushioning to relieve mechanical stress caused by temperature variation and cement expan-
sion.

5.20.10 The post insulators shall conform to IS:5350. The total creepage distance of 24KV post insu-
lator as individual unit shall be minimum 430mm .

5.20.11 Following makes of the Post Insulators shall be acceptable for the supply of 33 KV &11 KV
Isolators

i) M/s.Jaipur Glass & Potteries, Jaipur.

461
x) M/s.Jay Shree Insulators, Vadodara.
xi) M/s.Birla NGK Insulators Pvt. Ltd., Halol.
xii) M/s.MIL, Abu Road.
xiii) M/s.Sarvana Insulators Ltd., Kurinji Padi, Dist Cuddalore,(Tamilnadu).
xiv) M/s BHEL
xv) M/s Topline Ceramics P. Ltd., Bikaner

Apart from above, any other firm having valid Type test reports shall also be considered.

5.20.12 Besides above, the Post Insulators manufactured by the vendors approved by the Power Grid
Corporation of India Ltd (PGCIL) and National Thermal Power Corporation (NTPC) shall also be ac-
ceptable.

6.0 TESTS :

6.1 TYPE TEST The following type tests is to be conducted on the dis-connector along with
insulators and terminal connectors.

1. Short time withstand current test -

The test is to be carried out as per provisions of IS:9921 (Part.IV). As per clause No. 3.0.2 of
(Part.IV). The test carried out on one type of disconnector will be applicable for different current and
voltage ratings but with similar components i.e. reverse loop type fixed contacts, tubular
moving contact, double break mechanism with similar post insulator. However as per clause No. 3.3.1.1
of IS:9921 (Part.IV) the isolator subjected to type tests shall be atleast favorable conditions of electro
magnetic forces than offered isolator for which necessary calculations may be submitted along with
offer.

2. High Voltage test –

The type tested isolator shall have lower or equal clearances than offered isolator i.e. for
phase to phase clearance, phase to earth clearance and clearance for isolating distance.

a) Lightening impulse voltage test.

b) Power frequency voltage withstand test.

3. Temperature rise test.

462
4. D.C. voltage drop test or measurement of resistance of main circuit.

5. Short time withstand current test on terminal connectors either as per provisions of IS:5561 or
tested along with isolator.

6. Mechanical endurance test.

7. Short time withstand current test on earth switch or the offered design should have same crosssec-
tion area of contacts to main contacts.

TYPE TEST FOR POST INSULATORS :-

1. Visible discharge test.

2. Impulse voltage withstand test on post insulators.
3. Dry and wet power frequency voltage withstand test on post insulators.
4. Temperature cycle test.
5. Test for mechanical strength.
6. Puncture test
7. Porosity test.
8. Galvanizing test.

However, the purchaser reserves the right to demand repetition of some or all the type tests in pres-
ence of purchaser's representative. For this purpose, the manufacturer should indicate unit rate for car-
rying out such type tests. These test charges shall not be taken into consideration for bid evaluation.

During type tests the disconnector shall be mounted on its own support structure or equivalent
support structure and installed with its own operating mechanism to make the type tests representative.

6.2 The manufacturer is required to conduct following routine tests as per relevant IS on the Isolators
complete with required Post Insulators at manufacturer's works .

ROUTINE TEST :

1. Routine mechanical test on post insulators.

2. Routine electrical tests on post insulators.
3. Tests as per IS:2633.

463
6.3(a) ACCEPTANCE TESTS :

The following tests shall be got conducted in presence of purchaser's representative as per relevant
standards at the place of manufacturer before despatch without any extra charges. The testsat Sr. No.1
to 6 are to be carried out on completely assembled isolator as per IS:9921(Pt.IV). The sampling for the
inspection of completely assembled isolators, offered for final inspection shall be on 10% of offered
quantity(unless otherwise specified). The tests at Sr. No.7 to 12 are to be carried out on Post insulators
as per IS:2544 and sampling will also be as per same IS, at original manufacturer’s works.

1. Measurement of resistance of main circuit of Isolator as per IS:9921 (Part.IV).

2. Mechanical operating test on atleast one sample selected at random from each
type & rating.
3. Mechanical endurance test shall be done as acceptance test on one Isolator
of each type & rating from every lot. Mechanical endurance test shall be con-
ducted on the main switch as well as earth switch of one dissconnectorof
each type & rating. Bare contacts shall not be acceptable in any case.
4. Verifications of dimensions as per approved drawing on one Isolator set of
each type & rating.
5. Temperature rise test on one set of Isolator of each rating from the offered lot.
6. Preece Test on one Isolator of each type and voltage rating as per relevant IS.
7 Verification of dimensions of post insulators.
8. Temperature Cycle Test on post insulators.
9. Mechanical strength Test on post insulators.
10. Puncture Test on post insulators.
11. Porosity Test on post insulators.
12. Galvanizing Test on post insulators.

6.3(b) TEST ON BOUGHT OUT ITEMS

Tests are not required to be performed on bought out equipments like terminal connectors etc. at the works
of manufacturer except operational tests. Furnishing Test Certificate of Isolators and Post
Insulators from the original equipment manufacturers shall be deemed to be satisfactory evidence. Inspec-
tion of the tests at Sub-contractors works will be arranged by the supplier whenever required.

6.4 TYPE TEST

464
6.4.2 One sample of each rating of Isolators type tested at any Govt. approved/ Govt. recognized/ NABL
accredited laboratory/ ILAC i.e. International Laboratory Accredited laboratory / ILAC i.e International
Laboratory Accrediation Cooperation (In case of foreign laboratory).

6.4.3 At the option of the purchaser, the material received in the stores may be utilized in the field
after receipt of successful test reports from CTL, Jaipur for the mandatory test checking on the samples
selected from the material received at stores against first lot and subsequent lot(s) in anticipation of
successful type test report(s).

The various type tests as per relevant standards shall be conducted on each type of Isolator.

6.5 TOLERANCE :

Tolerance shall be allowed as per respective /relevant Indian Standards unless otherwise specified. How-

ever, no negative tolerance shall be allowed on current carrying parts.

Tolerance of ± 5% in dimensions as well as in weight also be allowed except current carrying parts.

7.0 INSPECTION

All the tests (as mentioned at Clause No.7.3) and Inspection shall be made at the place of manufacturer
unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The
manufacturer shall offer required numbers of post insulators for Purchaser’s inspection and after clearance
of insulator, he will offer assembled Isolators for purchaser’s inspection. The manufacturer shall afford
the

inspection officer(s) representing the purchaser all reasonable facilities without charges, to satisfy him
that the material is being furnished in accordance with this specification. The purchaser has the
right to have the tests carried out at his own cost by an independent agency whenever there is a dispute
regarding the quality of supply.

The Inspection may be carried out by the purchaser at any stage of manufacture/ before despatch as
per relevant standard.

Inspection and acceptance of any material under the specification by the purchaser, shall not relieve
the manufacturer of his obligation of furnishing material in accordance with the specificationand shall
not prevent subsequent rejection if the material is found to be sub-standard. The
manufacturer shall keep the purchaser informed in advance, about manufacturing programme so that ar-
rangements can be made for inspection.

The purchaser reserves the right to insist for witnessing the acceptance/ routine testing of the bought
out items.

8.0 TEST CHECKING OF MATERIAL AT STORES

The material received in the stores of the NIGAM shall be subjected to the test checking at stores before
final acceptance of the material, the procedure for the same shall be as under :

8.1 SAMPLING

One sample out of each sub-lot / lot consisting of following quantities or part thereof from each inspected
lot received in stores shall be selected for test checking of material and shall be got tested. The selection
of sample from the material received at stores shall be done as soon as material is received in stores
without the presence of the representative of the supplier. However, testing of sample(s) at CTL shall be
carried out in the presence of representative of the supplier after identification / confirmation byhim that
sample so selected belongs to them.

11 KV 400 Amp. Isolator with out E.B. with Post Insulator – 100 sets

8.1(a) one extra sample of 24 KV post insulator for conducting Puncture test.

8.2 TESTS

The following tests shall be carried out on the above items :

a) Visual examination , verification of dimensions, weight and marking as per PO/

GTP/ Approved drawing.

b) Checking of current carrying parts as per approved drawings.

c) Post Insulators : - i) Mechanical strength test.

ii) Porosity test
iii) Puncture Test

466
d) All galvanized parts. - Uniformity of galvanization test.
e) Measurement of resistance of contacts ( IS :9921, Part-II)

Only those test(s) shall be conducted for which facility is available at CTL.

For witnessing of the testing, clear 3 (three) days notice shall be given to the supplier by fax/ speed
post stating date, time & place where the test is to be conducted. In case the supplier do not attend for
witnessing the testing, the testing shall be proceeded and completed and action be taken as per the con-
tract.

The Officer Incharge of Central Testing Lab (CTL) Jaipur shall send copies of test reports to the pur-
chaser, consignees and the supplier.

8.3 CRITERIA FOR ACCEPTANCE

a) Visual examination, verification of dimensions, weight and marking. As per Specifica-

tion/GTP/Approved drawing.

b) Checking of current carrying parts as per approved drawings.

If the dimensions of the current carrying metal part are in conformity with approved drawings, the
material shall be accepted. When the dimensions of above parts are less then those minimum specified in
the approved drawings but upto a limit of 5%, the material contained in the Lot ./ Sub-lot to which the
sample belong shall be accepted subject to the conditions that the current density in above part is incon-
formity with contract and deductions at the rate of 2% cost of above parts for every 1% or part thereof
reduction in weight due to less dimensions. The deduction shall be made for weight of above parts calcu-
lated on the basis of dimensions observed and found less. The weight shall be compared withone calcu-
lated on the basis of the minimum dimensions for the parts approved in the drawings. The ratesfor reduc-
tion shall be taken from the relevant IEEMA circular applicable on the date two month prior to the date
of supply. When the dimensions are less than more than 5% as compared to the dimensions as per ap-
proved drawings, the material contain in the lot/ sub-lot to which the sample belongs shall be rejected and
shall have to be replaced by the supplier.

c) Post Insulators : i) Mechanical strength test. ii) Porosity test

iii) Puncture test.

In case of failure of any of samples in any of the above test , the material contained in the lot / sub lot
received in the stores to which the sample(s) belong shall be rejected. The rejected material shall have to
be replaced by the supplier free of cost.

d) All galvanized parts. - Uniformity of galvanization test.

467
i) The sample(s) shall be first tested for (n-2) number of dips where n is specified No. of dips in the
contract. If the sample does not pass the uniformity of galvanization test for (n-2) dips, the materialshall
be rejected and the material relating to relevant sub-lot/ lot to which the sample(s) pertains shall have to
be replaced by the supplier free of cost.

ii) If the sample has passed the uniformity of galvanization test for (n-2) dips, then it shall be tested
for (n-1) dips. If the sample has not passed the uniformity of

galvanization test with (n-1) dips, the material pertaining to relevant lot/sub-lot shall be accepted with
a deduction @ 4% of cost of galvanized material parts.

iii) If the sample passed the uniformity of galvanization test with (n-1) dips, then sample shall be
tested for last one dip of one minute to complete the test for `n' dips. If the sample does not pass the
uniformity of galvanization test with `n' dips, then the material pertaining to relevant lot/sub- lot shall
be accepted with a deduction @ 2% of cost of galvanized material parts.

iv) If the sample(s) have passed the test with number of dips as specified in the contract (n), then ma-
terial pertaining to relevant lot/sub-lot shall be accepted.

8.4 TEST CHARGES :

9.0 DRAWINGS:

9.1 The tenders shall submit with his tender the bill of material and fully dimensional drawing of the
offered isolators clearly showing the full details of material components and cross section
of moving blade, male and female contacts, details of terminal arrangement, terminal pad, terminal
connectors, operating mechanism showing the number and type of bearings, nominal diameter and
thickness of various G.I. pipes, earth connectors etc. to be supplied by them to enable the purchaser to
examine the offer.

The manufacturer shall also furnish drawings and bill of material for supporting structures required for
Isolators, although supporting structures are not in the scope of supply.

9.2 The successful manufacturer will submit the full dimensional on A-3 size paper in triplicate for
our approval before commencement of supply. If the successful manufacturer manufacture the equipment
without obtaining approval of drawing, the purchaser will not be responsible if any part is not as per
required dimensions. Approval of drawings/work by Purchaser shall not relieve

468
the Supplier of his responsibility and liability for ensuring correctness and correct interpretation of
the latest revision of applicable standards, rules and codes of practices.

10.0 OPERATIONS AND MAINTENANCE INSTRUCTION MANUALS:

The successful manufacturers shall have to supply three sets of operations and maintenance instruction
manuals per set of isolator along with the erection manual and requisite detailed
drawings of the equipments covered by this specification.

11.0 NAME AND RATING PLATE :

All items of the equipments included in this specifications shall be provided with a weather and
corrosion proof plate of Name of Purchaser, name/trade mark of manufacturer, rating and TN in according
with the provision of the IS:9921. The name & rating plate should be riveted on base channel.Further
there should be proper marking on the base channel for identifying RYB phase.

12.0 PACKING AND MARKING:

12.1 The equipment shall be packed in crates suitable for vertical/horizontal transport, as the case
may be and suitable to withstand handling during transport and outdoor storage during transit. The
Supplier 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 sym-
bols. Wherever necessary, proper arrangement or lifting, such as lifting hooks etc., shall be provided.Any
material found short inside the packing cases shall be supplied by Supplier without any extra cost.

12.2 Each consignment shall be accompanied by a detailed packing list containing the following infor-
mation:

a) Name of the consignee.

b) Details of consignment.
c) Destination.
d) Total weight of consignment.
e) Handling and unpacking instructions.
f) Bill of material indicating contents of each package.

13.0 GUARANTEED TECHNICAL PARTICULARS:

469
Guaranteed technical particulars in Schedule-V shall be furnished along with the tender. Tenders not ac-
companied with Guaranteed technical particulars, type tests reports, detailed drawings and bill of material
etc. are liable to the rejected.

14.0 COMPLETENESS OF EQUIPMENT:

All fittings, accessories or material which may have not been specifically mentioned in this specification,
but which are usual or necessary for the equipment shall be deemed to have been included in this specifi-
cation. All equipments shall be complete in all respect.

15.0 LATENT DEFECTS, ERRORS & OMMISSIONS:

Any material/ equipments or part thereof that develops defects, errors or omissions in the apparatus, not
disclosed prior to the final acceptance by the purchaser, but occur or are disclosed during the
guarantee period, shall be corrected promptly. The equipment or part thereof shall be replaced by the
supplier free of charges and all expenses for the transportation, handling, installation of such replacement
or any other incidental charges shall be born by the supplier.

16. The manufacturers are required to provide one extra 24 KV Post Insulator with per set.

GUARANTEED TECHNICAL PARTICULARS FOR 11KV ,400 AMP. ISOLATORS . WITH POST
INSUALTORS WITHOUT E.B
(Strike out which is not applicable)

S.No. Particulars 11KV ISO-

LATORS
1 Manufacturer's Type/Designa-
tion/Installation
2 Manufacturer's Name and Country
of Manufacture
3 Standard(s) according to which the
isolators are manufactured
4 Maximum design voltage at which
the isolator can operate (kV)

5 Rated Requency (Hz)

6 Rated Voltage (KV)

7 Max. current that can be safely

interrupted by the isolator
i) Inductive (A & % PF)

ii) Capacitive (A & % PF)

8 Continuous current rating
i) Nominal (Amps)
ii) Under site conditions (Amps)
9 Rated short time withstand current
i) For 3 seconds (KA rms)
ii) For 1 second (KA rms)
iii) Rated peak withstand current
(kAp)
10 Mile Volt drop test voltage
between :
i) Contacts
ii) Terminals of each phase
11 Current density at the minimum
cross-section of:

a) Moving blade (Amps/Sq.mm.)

b) Terminal pad ( Amps/sq.mm.)

c) Male Contacts (Amps/sq.mm.)

d) Female Contacts
(Amps/sq.mm.)

e) Terminal Connector
(Amp/sq.mm)
S.No. Particulars 11KV ISO-
LATORS

471
12 Max. temp. rise of following current
carrying parts when carrying rated
current continuously (deg.C) over
an ambient of 50 deg.C instead of 40
deg.C mentioned in relevant IS.
i) Moving blades
ii) Contacts with silver plating
iii) Terminal pad.
iv) Bi-metallic terminal connector
v) Springs
13 Class (outdoor or indoor)
14 Derating factor for specified site
conditions
15 15) Insulation levels
i) Lightning Impulse withstand
voltage (kV peak)
a) Phases to Earth
b) Isolating Distance
ii) Power frequency withstand
voltage (kVrms)
a) Phases to Earth
b) Isolating Distance
16 Minimum clearance in air (mm):
i) When switch is closed:
a) Between adjacent poles of
different phases
(centre to centre)
b) Between live parts and earth
ii) When switch is open:
a) Between poles of same phase
(centre to centre)
b) Between adjacent poles of
different phases (centre to centre)
17 Design and Construction
i) No. of insulators per pole
ii) No. of breaks per pole

472
iii) Type of closing/opening mecha-
nism (Horizontal/Vertical break
straight etc.)
iv) Contacts (Male):
a) Material and grade
b) Dimensions & Cross-sectional
area in sq.mm.
v) Contacts(Female):
a) Material and grade
b) Dimensions & Cross-sectional
area in sq.mm.
vi) Moving Blades:
a) Material and grade
b) Dimensions & Cross-sectional
area in sq.mm.
S.No. Particulars 11KV ISO-
LATORS
vii) Terminal pad:

a) Material and grade

b) Dimensions & Cross-sectional

area in sq.mm.

viii) Arching horns :

a) Material and grade

b) Dimensions & Cross-sectional
area in sq.mm.
ix Springs

a) Material and grade

b) Dimensions & Cross-sectional
area in sq.mm.
x) Contact Support:
a) Material, size and length of
plate

b) Material and size of plate

xi) Rain hood - Material grade and
size

xii) Nuts and Bolts

a) Size, material and grade in live

parts
b) Size, material and grade in
other parts
xiii) Insulator base plate

Material and size & min. thickness

of plate below insulators.

xiv) Bearings:

a) Make, Type and No. of bearings

for:
i) Rotating insulator base assembly

ii) Operating mechanism

iii) Whether lubricating nipple is

provided
b) Make, and size of bearing
housing
xv) Size of GI pipes ( medium
class) used for :

S.No. Particulars 11KV ISO-

LATORS

a) Down operating pipe (mm)

474
b) Connecting pipe for same
phase (mm)
c) Connecting Pipe for adjacent
poles(mm)
xvii) Tandem pipe
a) Size class and No. of pipes
b) Size of shackle, screw
c) No. of bearings/bush and its
material and size.

xvii) Type of interlock

xviii) Type of universal/swived
joint
a) Between bearing and down pipe
b) Between down pipe and
operating mechanism
xix) Insulators
a) Type.
b) No. of units per insulator
c) Rating of insulators(KV)
d) Height of each insulator stack
(mm)
e) Bolt circle diameter(mm)
f) Tensile strength (kg).
g) Compressive strength(Kg.)
h) Torsional strength (kg.m.)
i) Cantilever strength upright
j) Power frequency dry flashover
voltage (KV) rms.
k) Power frequency wet flash-over
voltage(KV) rms.
l) Impulse flash-over
voltage(positive wave) (KV) peak.
m) Impulse withstand voltage (kv)
peak
n) Power frequency puncture
voltage (KV) rms.

475
o) Visual discharge voltage level
(KV) rms.
p) Creepage distance : Total(mm)
q) Dry arcing distance (mm)
xx) Base:
a) Size ,Nos. & length of steel
sections used
b) Overall size(mm)
c) Total weight (Kgs)
xxi) Terminal Connectors:
a) Clamp Body:
i) Alloy Composition

S.No. Particulars 11KV ISO-

LATORS
ii) Plating if any
iii) Dimension

b) Bolts and nuts size

i) Alloy composition

ii) Tensile strength

c) Type of washers used

d) Materials of braids

e) Temperature rise when carrying

rated current at 50 deg.C ambient
(deg.C)
f) Weight of each type of clamp
(Kg.)
18 Mass of isolator hardware in Kg.

A) Without earth blade

19 Type of contacts
20 Nuts & Bolts
a) Size, material & grade in live
parts
b) Terminal connectors.
c) Other parts.
21 Locking arrangement of Isolators
and earth switch operating
mechanism
22 Whether isolator hardware is
complete with all
accessories
23 Details of type test reports
furnished:
item IS:Type test Testing
Report No. authority & date
i) Isolator
ii) Terminal connector
iii) Degree of protection
24 List of brought out items
25. List of drawing furnished
26. Marking

Name of manufacturer :-
Signature & seal of manufacturer with designation

477
TECHNICAL SPECIFICATION FOR HT & MIP SHEET METAL METER BOXES

1.0 SCOPE :

This specification provides for the design, manufacture, stage inspection and testing before dis-
patch, supply and delivery of sheet metal meter boxes specified herein for their satisfactory oper-
ation. The HT meter box shall be suitable for floor mounting and MIP meter box for wallmounting
as per requirement indicated in the drawings. The wall mounting of MIP meter boxes shall be
achieved by providing four (4) grouted studs on the walls, two of them will be inside themeter
box and two will be outside the meter box as shown in the attached general arrangement drawing.
The mounting holes of the boxes must be accessible without removing any non-metallicsheet.

1.1 It is not the intent to specify completely herein all the details of the design and construction of
equipment. However, the equipment shall conform in all respects to high standards of engineering,
design and workmanship and shall be capable of performing in continuous commercial operation
up to the manufacturer's guarantee, in a manner acceptable to the purchaser, who will interpret the
meanings of drawings and specification and shall have the power to reject any work or material
which in his judgment is not in accordance therewith. The offered equipment shall be complete
with all components necessary for their effective and troublefree operation. Such components shall
be deemed to be within the scope of manufacturer's supply irrespective of whether those are spe-
cifically brought out in this specification and/ or the commercial order or not.

2.0 STANDARDS :

2.1 The meter boxes shall conform to the following Indian Standards which shall mean latest revi-
sions, amendments/changes adopted and published, unless otherwise specified hereinafter.

S.No. Indian Standard Title

1. IS:14772- 2000 General requirement for enclosure for

accessories for household and similar
fixed electrical installations.
2. IS:1852 - 1985 Specification for rolling & cutting

tolerances for hot rolled steel products

3. IS:2036 - 1974 Specification for Phenolic laminated
sheets (superseding IS:2038-1962).
4. IS:4820 - 1968 Specification for Thin vulcanized fibre

478
sheets for electrical purposes.
5. IS:808-1989 Specification for MS Channel (ISMB)

3.0 GENERAL TECHNICAL REQUIREMENTS: REQUIRE-

MENT FOR SHEET METAL METER BOXES:

a) STANDARD:

The meter boxes along with the doors shall be fabricated out of MS sheet of fine quality and
thickness as per relevant drawings attached and capable of withstanding the mechanical, Electrical
and Thermal stresses as well as the effects of humidity which are likely to be encountered in the
services and at the same time ensuring the desired degree of safety. The same shall comply in
all respect with the requirement of latest IS:14772(2000) for "Boxes for enclosure of electrical
accessories". In case of any discrepancy between write-up and drawings attached, the details given
in drawings will prevail. The bill of material as indicated in the drawings shall be covered in the
scope of supply.

All sides of the box will be fabricated out of M.S. sheet of fine quality. The two sides and rear
one will be fabricated out of one single sheet. Top and bottom will be in one piece each from one
M.S. sheet, which will be continuously welded from inside to form a complete box. The door will
be in two parts for HT meter box and in one part for MIP meter box which shall be fabricated out
of M.S. sheet(s). Each door will be fixed with the box with inside hinges in such a way that
door hinges can not be removed from out side. The doors shall be provided with handle. The
door shall be provided with a lining of minimum 5mm thick felt in order to make it dust proof.

The door shall ensure reasonable safety against the spread of fire. They should not be ignitedby
thermic over-load of live parts housed by the box.

b) SEALING ARRANGEMENT :

The doors shall also be provided with sealing arrangement from out side by fixing 30x9 mm long
, bolts at the top and bottom and the Hexagonal nuts as per arrangement shown in the enclosed
drawings. These bolts shall be welded on the collars in such a manner that the fly nuts can be
tightened from outside. These bolts should possess hole of 2 mm as in the center of the head from
where the sealing wire shall pass and the meter boxes can be sealed properly. The doors will
further be provided with a felt lining of 5 mm in order to make it dust proof.

c) EARTHING OF METER BOX :

479
The earthing bolts of size 35x9 mm made of hot dipped G.I. with four plain 1.2 mm thick G I
washers, one G I spring washer and two G I nuts on either side of the box shall be provided as
shown in the drawing for earthing of meter box. The earthing bolts provided in the meter box on
both sides should have arrangement that the bolts cannot be loosened and removed from out side.
The bolt should have the cottar pin arrangement.

d) INCOMING AND OUTGOING CABLE ARRANGEMENT :

Two holes at the bottom just below the cable fixing bracket shall be provided for entry & exitof
cable . Holes of 50mm dia shall be provided for fixing cable as shown in the drawing.

e) WINDOW GLASS

One unbreakable transparent sheet of toughened/triplex glass of thickness 6 mm for window

of required size will be provided on the upper door as per arrangement indicated in the
drawing so that the meter inside the box can be read easily. The glass sides shall be lined up with
V-shaped rubber gasket of 1mm thickness. This glass shall be fixed inside the box in a projected
groove. The glass assembly shall be secured with a zinc passivized rectangular MS frame screwed
at four corners.

f) WORKMANSHIP

The fabrication of material shall be done in such a way that there is a good finish of fabricated
material. The material shall be fabricated accurately to adhere to dimensions as per attached draw-
ings. Holes must be perfectly circular and dimensional tolerance as given below shall be permis-
sible. The box should be fabricated/welded such that the rain water does not enter into it.

g) TOLERANCE :

The sheet metal boxes shall be subjected to a maximum of plus-minus one percent(+/-1%) toler-
ance on the overall dimensions and –ive rolling tolerance for sheet metal boxes shall be as per
IS:1852/1985 & IS 513-1994 with latest amendment(s).However there shall be no limit for
+ive tolerance in thickness. The rolling tolerance for nonmetallic bakelite base sheet shall be as
per IS:2036/1995 with latest amendments. The tolerance in weight of meter box shall not be more
than plus three percent and minus zero percent(+ 3% & - 0%).

h) Painting/Protection against corrosion :

The box(es) shall be adequately protected against rust, dust and corrosion both from inside and
outside.

480
All sheet steel work shall be phosphated in accordance with IS:6005 code of practice for phos-
phating iron and steel.

Oil, grease, dirt and swarm shall be thoroughly removed by emulsion cleaning .

Rust and scale shall be removed by pickling with dilute acid followed by washing with running
water rinsing with slightly alkaline hot water and drying. After phosphating thorough rinsing shall
be carried out with clean water followed by final rinsing with dilute dichromate solution and oven
drying.

After phosphating the cabinet must be painted by electrostatic method only (powder coating) and
the minimum coating should be 50 microns. The colour shade shall be 631 of IS - 5.

i) GUARANTEED TECHNICAL PARTICULARS :

The manufacturer shall furnish all the necessary information as desired in the schedule of GTPsat
Annexure-(A & B) of this specification. If the manufacturer desires to furnish any
other information in addition to the details as asked for, the same may be furnished against the last
item for each type of box of this schedule.

j) PROTO TYPE SAMPLE :

The successful manufacturer will offer for inspection a proto type sample of HT and/ or MIP meter
boxes before commencement of supplies as per enclosed drawing.

The prototype sample is required to be offered for inspection prepared ,cut & made to size except
welding. The prototype sample shall be verified by the inspecting officer of the Nigam as per
following guidelines:-

Thickness of walls of MS sheet without paint & weld be verified. Thereafter getting the box
welded , the weight of the box be taken and recorded. Weight of proto type sample after approval
of design shall be taken with paint/Powder Coating and same shall be verified during inspection.
Four sticker seals & two polycarbonate seals be provided on proto-type meter box keeping the
door in open condition.

The inspecting officer will inspect accordingly and if any suggestion or modification are required
same will be reviewed and a final revised drawing will be furnished by the manufacturer for ap-
proval of the purchaser before taking up mass production.

481
Firms who have already supplied HT & MIP Meter Box under previous two TNs of any of
three Discoms may be exempted from approval of Proto-Type Samples, in case order is placed
upon them.

k) EMBOSSING:

The following information shall be clearly/ indelibly embossed on the meter boxes made of MS
sheet.

i) J.V.V.N.L (on the top of the door.)

ii) Manufacturer's trade name
iii) TN-. (at the bottom of the door.)
iv) Sign of Danger (in upper side of front door)
v) H.T./M.I.P. Meter box
vi) RDSS

4.0 PRINCIPAL PARAMETERS:

4.1 HT METER BOXES :

a) GENERAL TECHNICAL REQUIREMENT:

The HT metering cubicle dimensions shall be 1500 mm height x1350 mm width as viewedfrom
front side and 1250mm depth as viewed from lower side and 300 mm depth as viewed from upper
side. The box shall be suitable for housing following items :

i) 11 KV CT/PT Unit.
ii) Electronic/Static Trivector meter :
iii) Testing Terminal block

The cubicle shall be fabricated out of MS sheet of fine quality having thickness 1.6mm. The thick-
ness of the Sheet for cubicle door shall also be 1.6 mm. The cubicle shall be fabricated out of
or not more than five pieces of the M.S. Sheet(s).

i) Bottom 1250mm x 1350mm x 3 mm - 1 No.

ii) Rear 1000mm x 1350mm - 1 No.
iii) Top 1750mm x 1350mm - 1 No.
(without any joint)

482
iv) Side members 1250 width - 2 Nos.
x1000mm height upto
950 mm width and for
next 300 mm width height
is 1500mm i.e.(1250
x 1000 + 450 x 500 in all)

All above pieces should be minimum 1.6mm thick except bottom which is 3mm thick.

There should be no joint in the above pieces. All the members shall be welded with continuous
welding from inside to form a complete cubicle, since the thickness of sheet is 1.6mm.Looking to
the weight of HT meter box which is about 210 kg. or as per approved prototype sample’s
weight.MS plate of 5 mm thick with a hole of 50 mm dia shall be at both sides of the HT meter
box. The top cover sheet shall be slopping by 10 to 25 mm towards backside of the box. 2 nos.M.S
channels of size 75x40 mm with length of 1100 mm (front to rear) shall be provided at the bottom
of the box to avoid direct contact of the box with floor which will also provide ease in handling
and during fixing on the plinth.

b) DOOR:

The door shall be in two parts fabricated out of 1.6 mm thick MS Sheet. Each door shall be fixed
with the box with three inside hinges. The left hand side door shall be provided with handleand the
right hand side door shall be provided with built-in system of one handle to open and closethe doors
and to engage vertical M.S. Rods for keeping the doors in close position but without lock and key
facility. A window as per size indicated in drawing shall be provided on right hand side door of
the box .

c) SEALING ARRANGEMENT :

One `L' shape 25 mm MS strip of thickness 3 mm on both doors as shown in the drawing shall be
welded from inside for sealing purpose.

The door shall also be provided with sealing arrangements from its outside by fixing studs as per
drawing at the top & bottom with Hexagonal nuts to tighten & to keep the doors in closed position.
The size of the cut outs for the windows shall be as shown in drawing.

d) ADDITIONAL DOOR WINDOW :

i) One additional door with window as per separate drawing shall be required to be provided with
the box such that

a) meter will not be accessible physically without opening the door of the box.
b) it will not allow any external object to enter into the box.
c) it will have separate sealing arrangement as per drawing.
d) the meter shall be readable from outside through a unbreakable transparent sheet of tough-
ened/ triplex glass of thickness 6 mm for window of required size will be provided on the
upper door as per arrangement indicated in the drawing so that the meter inside the box can
be read easily.
e) Opening for push button mode display (as per drawing)

The window of this additional door shall be provided with toughened / triplex glass by securing
the same with the help of a rectangular M.S. frame which can be tightened through 4 Nos. nutbolts
of appropriate size. The 4 bolts shall be welded inside the door from its head such that the nuts can
be tightened to secure the rectangular frame. The glass sides shall be fixed inside the box in a
projected groove. This additional door shall also be required to be provided with sealing bolts
with holes and hexagonal nuts as shown in drawing

This door shall be provided with 2 nos. suitable size hinges from inside such that the hinges are
not visible from outside. This door shall be provided with U-shaped rubber gasket along the edges
of the door.

e) EARTHING OF BOX :

The earthing bolt on each side of the cubicle shall be provided as shown in the drawing. The
earthing bolts provided in the meter box on both side should have arrangement such that the bolts
can not be loosened and removed from outside. The bolts should have the cottar pin arrangement.

f) CABLE ENTRY/EXIT :

Two holes at the bottom just below the HT cable fixing bracket shall be provided for entry and
exit of 11 KV cable.The size of the hole shall be 80mm for HT cable for 25A to 200A rating. The
cable entry and exit holes should be fitted with metallic glands for proper closing and sealing after
installation of the cable.
Hole of 60 mm dia on 1350 x 100 mm sheet near the bakelite sheet for fixing TTB for 4 sq mm
cable (3nos) from CTPT secondary box.to TTB.

g) TEST TERMINAL BLOCK :

484
The HT metering box shall be provided with three phase four wire Link type meter test
terminal block (TTB) of VEECO/CAPITAL make.

NON - METALIC BAKELLITE BASE SHEET :

One non-metallic Bakelite sheet having size 400x400x4.5mm shall be provided for mountingme-
ter. Another nonmetallic bakelite sheet of size 300mx400mm shall be provided for fixing TTB.
The supply shall include such sheets as per relevant ISS. The sliding arrangement of bakelitefor
fixing meter shall be continuous key type of size 25x25x3mm.

5.1 MIP METER BOXES :

TECHNICAL REQUIREMENT

a) GENERAL :

The MIP metering cabinet dimensions shall be 1100x625x375mm as per enclosed drawing
and shall be suitable to house the 3 phase static meter in the upper compartment and current
transformers ( Resin Cast Bar Type) in the lower compartment. Both the compartments will be
separated by a portion of 1.6 mm thick MS Sheet. The cabinet shall be suitable for wall mounting.

The box shall be fabricated out of 1.6mm thick MS sheet of fine quality. The two sides and rear
one will be fabricated out of one single sheet of minimum 1.6 mm thick. Top & bottom will be in
one piece each from 1.6 mm MS sheet which will be welded from inside to form a complete box.
The top cover sheet shall be slopping by 15mm to 20 mm towards back side of the box. The
approximate weight of the meter box will be more than 46 kgs. or as per approved prototypesam-
ple’s weight.

b) DOOR

The door will be fabricated in one piece out of 1.6 mm sheet. M S angle of size of 25x25x3mm
should be welded on the back of the door at ABCDE as per drawing enclosed at a distanceof
20mm from rubber lining. The door shall be fixed with the box with two inside hinges. The door
shall be provided with handle. The door shall also be provided with sealing arrangement from
outside by fixing stud at the top middle & bottom and hexagonal nuts . These studs should possess
hole of 2mm as in center of the head from where the sealing wire shall pass & meter boxcan be
sealed properly. The door will further be provided with a lining of 5mm thick felts in order to
make it dust proof. The door shall be provided with window with additional door having size as
per relevant drawing will be provided on the door so that the meter inside the boxshall be read
easily. Four fixing clamps, two at top side and two at bottom of the meter box for fixing the
box on wall.

485
c) CABLE ENTRY/ EXIT

Two holes of 50mm dia shall be provided for fixing cable as per drawing. The cable entry and exit
holes should be fitted with metallic glands for proper closing and sealing after installation ofthe
cable.

d) ADDITIONAL DOOR WINDOW :

i) One additional door with window as per separate drawing shall be required to be provided with
the box such that

a) Meter will not be accessible physically without opening the door of the box.

b) It will not allow any external thing to enter into the box.

c) It will have separate sealing arrangement as per drawing.

d) The meter shall be readable from outside through a unbreakable transparent sheet of tough-
ened/ triplex glass of thickness 6 mm for window of required size provided on the upper door as
per arrangement indicated in the drawing so that the meter inside the box can be read easily.

e) Opening for push button mode (as per drawing)-

The window of this additional door shall be provided with toughened/ triplex glass by securing
the same with the help of a rectangular frame which can be tightened through 4 nos. nut boltsof
appropriate size. The 4 bolts shall be welded inside the door from its head such that the nuts can
be tightened to secure the rectangular frame. This glass shall be fixed inside the box in a projected
groove. This additional door shall also be required to be provided with sealing bolts with holes
and hexagonal nuts as shown in the drawing. This door shall be provided with 2 nos. suitable size
hinges from inside such that the hinges are not visible from outside. This door shall be provided
with u-shaped rubber gasket along the edges of the door.

e) MOUNTING OF NONMETALLIC BASE SHEET :

The box shall be provided with 4 rectangular brackets of size mentioned in the drawing so as to
fix bakelite sheet to mount the meter on it at a distance of about 50mm from the rear wall on which
the meter & CTs will be fixed. The supply shall include bakelite sheet as per ISS.

486
f) ARRANGEMENT OF CT MOUNTING :

The primary terminal P1 of CTs shall be mounted on porcelain supports bolted on three Nos. The
other side of CT (P2) shall also be mounted on another three Nos. porcelain supports/clits. The
position should be adjusted by sliding clits to & fro horizontally as per the requirement of primary
terminals of CTs.

g) PARTITION PLATE

There shall be one partition plate at the height of 700mm from the bottom of the box to facilitate
4 Nos. CTs

6.0 TESTS :

6.1 TESTING FACILITIES :

The manufacturer must indicate clearly about the various testing facilities for routine/acceptance
tests as per relevant ISS is respect of Meter Box as are available at their works.In case no testing
facilities are available at the manufacturer's works particulars of the place where such testing is
proposed to be conducted during the course of inspection must be indicated.

6.2 TEST VALUES :

For all acceptance tests, the acceptance values shall be the values guaranteed by the manufacturer
in the guaranteed technical particulars or the acceptance value specified in this specification
or the relevant standard whichever is more stringent.

6.3 ADDITIONAL TESTS :

The purchaser reserves the right for carrying out any other tests of a reasonable nature at the works
of the supplier/laboratory or at any other recognized laboratory/ research institute in addition to
the above mentioned acceptance and routine tests at the cost of the purchaser to satisfy that the
material complies with the intent of this specification.

6.4.1 TYPE TESTS :

Tests carried out to prove conformity with the requirement of the standard. These are intended to
prove the general qualities & design of a given type of product. Before commencement of tests,
the sample shall be visually examined & inspected for obvious visual defects in respect of com-
ponent, part and their assembly, construction, marking, mechanical hazards, earthing etc. The
external surface finish shall be even and free from finishing defects.

The following tests as per IS: 14772/2000 shall constitute the type test:

S.No. Tests

1. Marking
2. Dimensions
3 . Protection against electric shock
4. Provision For earthing
5. Construction
6. Resisting to aging, to humid condition, ingress of material.
7. Mechanical Strength
8. Resistance to heat
9. Resistance to rusting.

Criteria of acceptance: Both samples shall successfully pass all type tests for providing conformity
with the requirements of the standard. If any of the sample fails in any of the type tests, the testing
authority, at its discretion, may call for fresh sample not exceeding twice the original number and
subject to all tests or to the test(s) in which failure(s) occurred.

6.4.2 ACCEPTANCE TESTS :

The following tests shall constitute the acceptance tests :-

Tests

1. Marking
2. Dimensions
3. Protection against electric shock
4. Provision for earthing
5. . Construction

The verification of above tests shall be arranged by the supplier in the presence of purchaser’s
inspecting officer at the time of inspection.
6.4.3 ROUTINE TESTS:

The tests at s.no.(3) and (4) in the Cl.6.4.2 shall constitute this test as per IS:14772/2000.

7.0 INSPECTION & TESTING :

The inspection and testing shall be carried out by the purchaser's representative as per provisions
of relevant ISS, specification & GTP and shall be governed by clause No.1.27 entitled “inspection
and Testing" of Schedule-2" General conditions of Contract" except mentioned hereunder.

a) The supplier shall arrange fifteen days advance notice to enable the purchaser to depute the
inspecting officer for conducting necessary testing at supplier's works. Any delay beyond fifteen
days in arranging the inspection shall be to the purchaser's account.

b) In case the manufacturer does not have adequate facilities for getting all the required tests con-
ducted in his laboratory, the purchaser at his option may get these tests conducted in any reputed
testing laboratory. All the expenses for such tests to be conducted outside shall be borneby the
supplier.

c) In case material/equipment is not found ready by the representative of the purchaser deputed for
inspection to the extent of the quantity indicated in the inspection call with tolerance of (-) 10% or
if the inspection is not got carried out by any reasons on account of the supplier the re-inspection
charges shall be ` 7,500.00 for the supplier works located in Rajasthan and ` 15,000.00 for the
supplier works located outside Rajasthan will become payable by the supplier on this account to
the Accounts Officer (MM) JVVNL, Jaipur.

c) The Acceptance tests shall be carried out as per relevant ISS Latest Amended) , P.O. , GTP and the
proto type sample approved by this office .For acceptance tests samples from the offered quantity
for inspection shall be selected by inspecting officer as per provisions of IS:14772/2000 (Latest
amended).

e) The inspection may be carried out by the purchaser's representative at any stage of manufac-
ture/before dispatch as per relevant standard. Inspection and acceptance of any material under the
specification by the purchaser, shall not relieve the manufacturer of his obligation of furnishing
material in accordance with the specification & shall not prevent subsequent rejectionif the mate-
rial is found to be defective. The manufacturer shall keep the purchaser informed in advance, about
manufacturing program so that arrangements can be made for inspection.

f) The purchaser reserves the right to insist for witnessing the acceptance /routine testing of the
bought out items. The manufacturer shall give 15 days advance intimation to enable the purchaser
to depute his representative for witnessing the acceptance and routine tests. The inspection charges
would be to the purchaser's account.

489
8.0 DRAWING

The manufacturer shall furnish drawings of HT & MIP meter boxes enclosed with the specification
duly signed on each along with the tender , failing which the offer is likely to be ignored.

9.0 GUARANTEED TECHNICAL AND OTHER PARTICULARS :

The guaranteed technical and other particulars shall be given in the Performa as per ANNEXURE-
(A&B). Any deviation from the specifications referred to above shall be supportedby adequate
justifications.

10.0 STAGE INSPECTION DURING MANUFACTURE :

The stage inspection/ testing during manufacture shall mean those tests which are to be carried out
during the process of manufacture and end inspection to ensure quality control such that the end
product is of the designed quality conforming to the intent of this specification. The inspection
may be carried out by the purchaser at any stage of manufacture/before dispatch as per relevant
standard.

11.0 QUALITY ASSURANCE PLAN :

11.1 The Manufacturer hereunder shall invariably furnish following information along with his offer,
failing which the offer shall be liable for rejection. Information shall be separately given for
individual type of material offered.
i) Statement giving list of important raw materials, names of sub-suppliers for the raw material, list
of standards according to which the raw materials are tested, list of tests normally carried
out on raw materials in the presence of Manufacturer's representative, and copies oftest certif-
icates.

ii) Information and copies of test certificates as in (i) above in respect of bought out items.

iii) List of manufacturing facilities available.

iv) Level of automation achieved and list of areas where manual processing exists.

v) List of areas in manufacturing process, where stage inspections are normally carried out
in quality control and details of such tests and inspections.

vi) Special features provided in the equipments to make it maintenance free.

490
vii) List of testing equipment available with the Manufacturer for final testing of equipment specified
and test plant limitation, if any, vis-a-vis the type, special, acceptance and routine tests specified
in the relevant standards. These limitations shall be very clearly brought out in schedule of
deviations from specified test requirements.

11.2 The Supplier shall within 30 days of placement of order submit the following information to
the Purchaser.

i) List of raw material as well as bought out accessories and the names of sub-suppliers selected
from those furnished along with the offer.

ii) Type test certificates of the raw material and bought out
accessories.

iii) Quality Assurance Plan (QAP) with hold points for Purchaser's inspection. The QAP and Pur-
chaser's hold points shall be discussed between the Purchaser and the Supplier before the QAP is
finalized.

11.3 The Supplier shall submit the routine test certificates of bought out items and raw material
at the time of routine testing of the equipments.

12.0 TEST REPORTS :

i) All records of routine test reports shall be maintained by the Supplier at his works for
periodic inspection by the Purchaser.

ii) All test reports of tests conducted during manufacture shall be maintained by the Supplier.
These shall be produced for verification as and when requested for by the Purchaser.

13.0 PACKING & FORWARDING :

The HT and MIP meter boxes shall be suitably packed in order to avoid damage during transit and
handling.

DRAWINGS:

1. MIP METER BOX

491
ANNEXURE-I DRAWING of front elevation with front door closed
ANNEXURE-II DRAWING of front elevation with front door removed
ANNEXURE-III DRAWING of Panel’s side view
ANNEXURE-IV DRAWING of Panel’s plan
ANNEXURE-V DRAWING of Panel’s window door, bus bar cleat

ANNEXURE-B
STATEMENT OF GUARANTEED TECHNICAL PARTICULARS AND
OTHER DETAILS FOR MIP METER BOXES

S. No. Particulars

1 (a) Name & address of / firm / manufacturer.

b) Work's complete address of manufacture

2 Dimensions of Box in mm
3 Thickness of M.S.Sheet in mm
a) For three sides, top & door
b) For bottom.
4 Dimensions of Bakelite/ Acrylic sheet in mm.
a) Sheet for mounting meter.
b) Sheet for cleats
5 Window/window door details :
a) Inner dimension of window
b) Wndow door dimension.
c) Viewing window dimension.
d) Toughened/triplex glass
e) Metal frame for fixing acrylic Sheet
i) Inner dimensions.
ii) Outer dimensions.
6 Dimensions of sealing/earthing bolts in mm.
a) Door sealing bolts.
b) Earthing bolts.
7 Approximate weight of complete Box in Kgs.
8 Details of painting.

492
9 Shade No. of colour/paint.
10 Tolerance in fabrication :
a) In overall dimension.
b) Rolling tolerance.
Dimensions of fixing brackets As per drawings in
11
mm.
JVVNL
Trade mark of manufacturer
12 Embossing details. TN-
Sign of danger
MIP meter box
13 Dimensions of felt lining to make box dust proof.
14 Details of Bus bar cleats
15 Details of drawing

493
TECHNICAL SPECIFICATION OF P.G. CLAMPS FOR DOG, RABBIT
3.01 SCOPE

This specification covers the manufacture, testing before despatch and delivery at our Stores/ Site of
P.G. Clamps for ACSR Panther, Dog, Rabbit, weasel Conductor and T-clamp for Panther Conductor as
detailed hereunder:-

3.03 MATERIAL:-

All material used shall conform to the relevant ISS. All aluminum and aluminum alloy used in the
manufacture of the connector(s) shall conform to designation `A6’ of IS:617 (1975) Latest amended and
IS:1367 (latest amended). Non ferrous alloy bolts, nuts and spring washers shall conform to the relevant
Standards.

The material used in the manufacture of clamps shall be Aluminum alloy 4600 of IS:617-1994 as amended
and shall be gravity die casting process only.

Steel Bolts and Nuts shall conform to IS:1368-1992 & IS:1367/1979-80 (with latest amendment, if any)

All ferrous metal parts intended for outdoor use except those made of stainless steel shall be protected by
hot dip galvanizing in accordance with IS:2633-1986.

The temperature rise of power connectors above a reference ambient temperature of 40 Deg. C when
carrying rated current as above shall not exceed 45 Deg. C to fulfill the requirement of Cl.6
IS:5561(1970).

3.04 GENERAL REQUIREMENTS:-

The power connectors shall be smooth and free from cavities, blow-holes and other defects and such
adverse effects like sharp radii of curvature, ridges & excrescence which might lead to localized pressure
or damage to conductor in service. Power connectors shall be so designed and proportioned that they are
capable of safely withstanding stresses to which they may be subjected (including these due to short
circuit and climatic conditions) and that the effect of vibrations, both on the conductor and the connector
itself are minimized. 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 be evenly
distributed by the use of pressure plates, washers or suitable saddles of adequate area & thickness.

3.05 LIMITS OF TEMPERATURE : The limits of temperature rise specified are based on the following
reference ambient temperatures:-

a) Maximum ambient air temp : 50 Deg. C.

494
b) Maximum daily average ambient : 32.5 Deg. C.
temp
c) Maximum yearly average : 32 Deg. C.
ambient temp.

3.06 DIMENSIONAL REQUIREMENT FOR P.G.CLAMPS :-

s.no PARTICU PG CLAMPS FOR

LARS
ACSR DOG TO DOG ACSR
Rabbit to
Rabbit
TYPE `A’ TYPE `B’
a.) CONDUCTOR:-
1 No. of Al. 6/ Al. 6/ Al.6/
strands in
4.72 mm 4.72 mm 3.35 mm
Conductor
Steel 7/ Steel 7/ Steel 1/
1.57 mm 1.57 mm 3.35 mm
2. Conductor
dia 14.15mm 10.05mm
14.15mm
b.)CLAMPS
1 Length
(Min.) 125mm 90mm 75mm

2 Thickness of
Metallic 10mm 10mm 8mm
Parts (Min.)
s.no PARTICU PG CLAMP FOR
LARS
ACSR DOG TO DOG ACSR
Rabbit to
Rabbit
TYPE A TYPE B
3. No. of Bolts
along with
lock nuts 3 2 2
plain
washer and

495
spring
washers
(Min.)
4. Size of
Bolts Dia X 12mm x 12mm x 8mm x
Length 50mm 50mm 35mm
(Min.)
5. Short cir-
cuit level
for 1 Sec. 16 kA 16 kA 12.5 kA

6. Rated
current
400 400 200
Amps.

Note:- Manufacturers are requested to quote alternative prices for P.G. Clamps suitable for ACSR Dog to
Dog for the Type `A’ & Type `B’.

3.07 TYPE TESTS:-

a) The manufacturer shall furnish valid and authenticated type test certificate from a Govt. approved/ a
Govt. recognized/ NABL accredited laboratory/ ILAC i.e. International Laboratory Accredited labora-
tory / ILAC i.e International Laboratory Accrediation Corporation ( In case of foreign laboratory)of sim-
ilar rating and design of tendered material. Such type test certificates should not be older than three years
as on the date of bid opening. For this purpose date of conducting type tests will be considered.

b) The type test certificates by in house laboratory of biding firm even if it is a Govt approved/ Govt
recognized/ NABL accredited Laboratory / ILAC accredited, shall not be accepted, in case of their own
bid. This will not apply if biding firm is Govt. Company/ Public Sector Undertaking.

c) The manufacturer should furnish documentary evidence in support of the laboratory whose type test
have been furnished, that the said laboratory is a Govt/ a Govt. approved/ a Govt. recognized/ NABL
accredited laboratory/ ILAC accredited ( in case of foreign laboratory)

d) The type test certificates shall be furnished either in original or duly attested by notary.

e) Following type test shall be conducted on Clamps :-

496
a) Tensile test
b) Temperature test.
c) Resistance test.
d) Dimensional test.
e) Galvanizing test
f) Short circuit test

The short circuit test shall be accompanied with the detailed dimensional drawing duly signed by the
testing agency.

3.08 INSPECTION AND TESTING

i) The material shall be tested and inspected by an authorized inspecting officer of the Nigam before
despatch. Samples shall be drawn for inspection/ testing as per provisions of relevant ISS/Purchase Order.
The purchaser reserves the right to get the material tested in any testing laboratory before despatch.

The suppliers should satisfy themselves that the stores are in accordance with the terms of the contract and
fully confirm to required specifications by carrying out a thorough pre-inspection of each quota before
tendingthe same for inspecting to the inspecting officer nominated by the purchaser. Such pre-inspection
on the part of the suppliers would minimize the chances of rejection in inspection. The following shall
constituteAcceptance Tests:-
i) Tensile Test.
ii) Resistance Test.
iii) Dimensional Check.
iv) Galvanizing Test, where applicable.

In the event of order temperature rise test shall be carried out once on one Clamp of each type from the
first offered lot in the presence of Purchaser’s representative without extra charges.

The following shall constitute Routine Tests:-

i) Visual inspection.
ii) Dimensional check.

3.10 TEST CHECKING OF MATERIAL AT STORES:-

The material received in the Stores of the Nigam shall be subjected to the test checking at Stores
before final acceptance of the material. The procedure for the same shall be as under:-
A) Sampling:-
One sample out of each sub lot/ lot of 1,000 Nos. or part thereof from each inspected lot of each
type of clamp received at Stores shall be selected for test checking of material & shall be got
tested. The selection of sample from the material received at stores shall be done as soon as
497
material is received in stores without the presence of the representative of the supplier. However,
testing of sample(s) at CTL shall be carried out in the presence of representative of the supplier
after identification / confirmation by him that sample so selected belongs to them.

B) Tests:-
The following tests shall be carried out on the above items:-

Visual Examination, Verification of Dimension, weight and marking as per ISS/

Specification.
a. Tensile Test
b. Resistance Test
c. Galvanizing test

Testing of the material shall be got done at the test laboratory of the NIGAM i.e. at CTL
in the presence of the representative of the supplier.
For witnessing of testing, clear 7 days notice shall be given to the supplier by fax / speed post stating
date, time & place where the test is to be conducted. In case the supplier do not attend for witnessing the
testing, the testing shall be proceeded and completed and action be taken as per the contract.

The Officer Incharge of Central Testing Lab (CTL) Jaipur shall send copies of test reports to the
purchaser, consignees and the supplier.

C) CRITERIA FOR ACCEPTANCE

a) Visual Examination, Verification of Dimension, weight and marking:
As per ISS/ Specification
b) Tensile Test
c) Resistance Test:-

In case of failure of sample in Tensile Test & Resistance test, the material contained in the lot/ sub-lot to
which the sample belongs shall be rejected. The rejected material shall have to be replaced by the supplier
free of cost.

d) Galvanizing Test:
i) The sample(s) shall be first tested for (n-2) number of dips where(n) is specified number of
dips in the contract. If the sample(s) does not pass the uniformity of Galvanization Test for (n-2)
dips, the material shall be rejected and the material relating to relevant lot/ sub-lot to which sample(s)
pertains shall have to be replaced by the supplier free of cost.
ii) If the sample has passed the uniformity of Galvanization Test for (n-2) dips, then it shall be
tested for (n-1) dips. If the sample has not passed the uniformity of Galvanization Test with (n-1)
dips, then material pertaining to relevant lot/ sub-lot shall be accepted with a deduction @ 10% of
cost of material.

iii) If the sample has passed the uniformity of Galvanization Test with (n-1) dips, then
sample shall be tested for last one dip of one minute to complete the test for `n’ dips. If the sample
does not pass the uniformity of Galvanization Test with `n’ dips, then the material pertaining to
relevant lot/sub-lot shall be accepted with a deduction @ 5% of cost of material.

D) TEST CHARGES :

3.11 MARKING

The items to be supplied shall be indelibly marked with suitable marks so as to identify the same. The
Clamps shall be marked with `Rated Normal Current' and name of the `Conductor' for which the same
is suitable viz. Panther to Panther, Dog to Dog, Rabbit to Rabbit and weasel to Weasel.

3.12 PACKING
You shall pack the material in the suitable double gunny bag or double HDPE bags so that the
material may not be damaged in the transit

3.13 GUARANTEED TECHNICAL & OTHER PARTICULARS.

The manufacturer shall furnish complete guaranteed technical particulars and other particulars of material
offered by him in schedule-V.(A), V(B) and V(C)

3.14 DRAWING :
The successful manufacturer will submit the full dimensional drawings on A-3 size paper in triplicate
for our approval before commencement of supply. If the successful manufacturer manufacture the equip-
ment without obtaining approval of drawing, the purchaser will not be responsible if any partis not as
per required dimensions. Approval of drawings/work by Purchaser shall not relieve the Supplier of his
responsibility and liability for ensuring correctness and correct interpretation of the latest revision of
applicable standards, rules and codes of practices.

3.15 DEPARTURE FROM SPECIFICATION

499
Should the manufacturer wish to depart from the specification in any respect, he should clearly state such
departures indicating the reasons thereof. Unless this is done, the departmental specification will hold
good and shall be binding on the supplier unless the departures have been approved in writing by the
purchaser.

3.16 TENDERS:

Manufacturer shall furnish complete particulars of the material offered by them in regard to the specifi-
cation and submit the same with their tender. Failure to do so or any incomplete entry therein may prevent
a tender from being considered.

The tenders received without complete details required as per enclosed forms/ schedules are liable tobe
rejected.

SCHEDULE-A
GUARANTEED TECHNICAL PARTICULARS FOR P.G. CLAMPS FOR ACSR DOG, & RABBITCONDU-
CRTOR

S. DESCRIPTION FOR DOG FOR RABBIT

NO CONDUCTOR CONDUCTOR
1 Maker's name and
Address

2 Works Address

3 Reference of ISS to
which the material
shall confirm.

4 Drawing Number of
material .

5 Breaking load in Kg.

6 Electrical resistance in
Ohms

7. Short time current.

500
8. Particulars of material
of PG Clamp

9. Temperature rise
above ambient
temperature of 40 de-
gree C, when carrying
normal
current
10. Rated normal current .

11. Complete weight of

one PG clamp. (With
nut ,bolt and washers)
a) Wt. of aluminium
portion.

b) Wt of steel nut , Bolt

and washers.
c) Complete weight of
PG clamp assembly.

12 Dimensions of PG
clamps.

13. Details of Packing:

14. Details of marking.

15. Galvanizing of Nuts

and Bolts.
16. Any other information.

(Signature)
Name and designation with seal.

SCHEDULE-B

501
TECHNICAL SPECIFICATION FOR HEAT SHRINKABLE TYPE CABLE JOINTING ANDTERMI-
NATION KITS FOR LT ARMOURED PVC/ XLPE ALUMINIUM CABLES

3.01. SCOPE:
This specification covers the design, manufacturing, testing and supply of Heat-Shrinkable type
cable straight-through joints and cable end termination kits as per IS:13573(Pt.1)/2011 suitable for use
with and installation on LT armoured PVC/ XLPE aluminium/ conductor cables .

3.01.1 The cable accessories specified in this specification i.e., cable end terminations, either indooror
outdoor, and straight- through, shall be complete in all respects. Such complete set of accessories shall
be termed as kit hereinafter in this specification.

3.01.2 Termination and jointing kits shall be heat-shrinkable type of 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 skill, with minimum tools at site.

3.02 TYPE

3.02.1 Termination Kits & Joints shall be heat shrinkable type for LT armoured PVC/ XLPE aluminium/
conductor suitable for Outdoor and Indoor Cable End Terminations and Straight Through Joints
3.02.2 It is not the intent to specify completely herein all the details of the design, manufacture & as-
sembly of cable accessories; however, cable accessories shall confirm in all respects to a high standardof
design & workmanship and be capable of performing in continuous commercial operation upto manufac-
turers guarantee in a manner acceptable to the purchaser, who will interpret the meanings of thedrawings
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 troublefree operations. Such components shall be deemedto be within the scope of
supplier's supply irrespective of whether they are specifically brought out in this specification and/
or in the commercial order or not.

3.03 SYSTEM PARAMETERS

1. Nominal operating voltage 440 V rms

2. Maximum system voltage : 1.1 kV rms
3 Frequency (Hz.): 50 +/- 1.5

4. Number of Phases 3
5. Type of Earthing Solid

502
6. Environmental conditions Humid Tropical Climate with pol-
luted atmosphere ,and/or , direct
burial in
water- logged ground.

3.04 SERVICE CONDITIONS

(A) The cable accessories to be supplied against this specifications shall be suitable for continuous
& satisfactory operation under climatic conditions listed below:

S.No. Particulars
i) Peak ambient air temperature in shade (C) 50C
ii) Minimum ambient air temperature (C) 0C
iii) Maximum avg. ambient temp. over 24 Hrs. in shade ((C) 40C

iv) Maximum temperature attainable by an object 60C

V0 Maximum relative humidity (%) 100 %
vi) Maximum altitude above mean sea level 1000 mtrs
vii) Maximum wind pressure (Kg./Sq.Mtr.) 100
viii) Number of months of tropical monsoon conditions 4 months
ix) Average No. of rainy days per annum 100
x) Average Annual Rainfall in cms. 10 to 100

(B) The kits shall be provided with protection against rodent and termite attacks.

3.05 APPLICATION

The cable accessories shall be use on armoured, PVC/XLPE, LT, Aluminium cables installed in sub-
stations for power distribution system and LT consumers.

3.06 APPLICABLE STANDARDS

1554 (Part 1)/1988 PVC insulated (heavy duty) electric cables: Part 1 For working voltages up to and
including 1100 V
2071 (Part 1) /1993: High voltage test techniques:Part 1 General definitions and test

503
IEC 60-1 1989 requirements
7098 (Part 1)/1988 : Specification for cross linked polyethylene insulated PVC sheathed cable: Part 1 For
working voltages up to and including 1100 V
8130 : 1984 Conductors for insulated electric cables and flexible cords
8308 : 1993 Compression type tubular in-line connectors for aluminium conductors of insulated cables
IS-13573 (Part –I):2011 – for working voltage upto 1.1kV (E) - Test methods and requirements.
8309 : 1993 Compression type tubular terminal ends for aluminium conductors of
insulated cables
8337 : 1976 Performance requirements of compression joints of aluminium conductors in insulated cables
14255 : 1995 Aerial bunched cables for working voltages up to and including 1100
volts — Specification
IEC: 60502-04/ 2005 VDE 0278 – Standard for cable accessories.
IEEE48 –for terminations of cable.

ESI-09-13 standards – for components used in the Kit

The specification given in this documents supersedes the relevant clauses of IS-13573:2011 (Part-I)
wherever applicable.

3.07 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 LT 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 manufacturer shall furnish details of the technique employed by them for stress control in cable- end
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. Full details of the method of discharge preven-
tion shall be indicated by the manufacturer in their offer.

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.

504
iv) All Outdoor End Termination kits as well as LT Indoor End Termination kits shall be provided with
rain (weather) sheds or creepage-extending petticoats. These shall be non-tracking, weather resistant, hy-
drophobic and have smooth surface to deflect any water/ dirt etc. The design of these rain (weather) sheds
or creepage-extending petticoats shall avoid any shed to shed conducting path under heavy rain condi-
tions.

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.

3.08 GENERAL TECHNICAL REQUIREMENT

Material used for construction of a joint/termination shall perfectly match with the di-electric,
chemical and physical characteristics of the associated cable. The material and design concepts shall in-
corporate a high degree of operating compatibility between the cable and joints.

The Straight through joint kit or termination shall be complete with all accessories, jointing material,
insulating stress control and sealing material, lugs, nuts, bolts etc. as well as an instruction booklet ex-
plaining the method of using the kit. In case of heat shrinkable type kit, the joint shall include a heat
shrinkable dual wall tubing which shall be insulating from inside and semi conductive from outside.

Detailed sectional views of the assemblies shall be submitted along with the offer.
The straight through joints should be absolutely impervious to the entry of water. The manufacturer shall
use the proven technologies and design to ensure a construction which will prevent entry of water or any
other liquid inside the straight through joint and cable.

The cable termination kit shall be suitable for terminating the cable on indoor or outdoor installation as
per requirement. The type of cable will be armoured PVC / XLPE insulated L.T Cable.
The Straight - through joints shall be suitable for Buried / Over Head application.The heat shrinkable
component shall be light in weight and shall be made of specially formulated cross linked polymeric
material with excellent tracking & erosion resistance characteristic.

Environmentally sealed system for splicing dielectric shielded power cables.

The design of joint and termination shall be such that on completion of work, the cable can be charged
immediately The joint/termination shall have range taking feature. The Connector/ferrule used shall be
range taking, Moisture entry into conductor shall be protected by providing special mastic The termination

505
kit offered shall provide for total environmental sealing of the cable crutch and at the lug end. The details
of the same shall be submitted alongwith the offer.

Indoor Termination: jointing kit should be designed to withstand high humidity and surface contamination
under electrical stress caused due to condensation and dust in indoor conditions.

Outdoor Terminations: The LT Terminations should be designed to withstand exposure to extreme cli-
matic variations & surface contamination, UV rays from sunlight and electrical stress caused due to heavy
pollution & dust in external conditions.
The sizes generally used in JVVNL network.

300 Sqmm O/D

185 Sqmm O/D
120 Sqmm O/D
95 Sqmm O/D
400 Sqmm STJ
300 Sqmm STJ
185 Sqmm STJ
120 Sqmm STJ
95 Sqmm STJ

3.09 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 strained state to a temperature above the shrink temperature resulting
in the material recovering or shrinking to its original shape.

ii) (a) The stress control tubes used in heat shrinkable cable accessories shall have volume resistivity
as per Standard with latest amendments for both terminations & straight through joints. The relative per-
mittivity shall be as per Standard with latest amendments. Manufacturer shall furnish documentary evi-
dence confirming adherence to these along with the offer. Further, impedance of stress control tubes shall
not change over a range of temperature from 0 C to 125 C. The stress control tubes must havea
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) Manufacturer must submit graph showing effect on the impedance value of stress control tube due to
effects of stress, temperature variations and thermal ageing of as per Standard with latest amendments
with the offer.

c) Copies of test reports on the critical components used in the joints & terminations be furnished as per
as per IS:13573(Pt.1)/2011, be furnished along with the offer.

i) 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 hydro-phobic
in nature. A heat-shrinkable flexible polymeric tubing, preferably coloured black, 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 para-
graph above. Copies of test reports, confirming the non-tracking tubes and rain-sheds (skirts) meetingthe
above requirements shall be furnished along with the offer.

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. Documentary evidence shall
be furnished in this regard along with the offer.

iii) All cuts/ nicks inadvertently occurred to XLPE insulation must be rendered discharge free
by using suitable discharge suppression compound.

iv) The heat shrinkable tubes may be either extruded or moulded type.

vi) The higher wall-thickness of heat shrinkable tubes / sleeves shall be preferred to counter the effect
of erosion due to pollution.

3.10 OTHER REQUIREMENTS

i) The kit shall be suitable for storage without deterioration at a temperature upto 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 of-
fered by means of proven methods, details of which shall be elaborated in the offer. Detailed sectional
view of assemblies shall be submitted along with the offer.

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

507
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. The details of the environmental sealing provided shall be submitted along with the offer.

v) Provisions for effective screening over each core shall be made and the manufacturer shall cate-
gorically confirm this aspect in the offer.

vi) The materials and components not specifically stated in the specification but which are essentialfor
satisfactory operation of the cable shall be deemed to be included in the kit without any extra cost.

vii) 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.

viii) The armour / earthing arrangement shall form part of the terminations/ joints and shall be protected
from erosion either by suitable tape or tube.

ix) The terminations/ jointing kits shall have provision for shield connection and earthing whichever re-
quired.

x) The fault level as well as duration withstand capacity of termination / jointing kits should be strictly
matching with the parameters of cables for which the kits are intended to be used.

xi) 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

xii) Suitable creepage extension/ rain protection sheds for outdoor cable end terminations shall be pro-
vided.

xiii) Adequate provisions for eliminating the chances of entrapment of air at steps formed by semicon
screen shall be made.

xiv) The terminations/ joints shall be supplied in kit form. All insulation and sealing materials, consum-
able items, conductor fittings, earthing arrangements and lugs etc. should be provided .

xv) The manufacturer shall furnish the constructional features of material offered.

508
xvi) 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 kit. Various items, quantity thereof included in each kit must beindicated in the in-
struction manual / packing slip provided in the kit packing.

This specification covers design and manufacturing of cable joints suitable for 1.1 kV Armored
PVC/XLPE Al Conductor Cables.

1. The accessories shall be supplied in kit form. Each component of the kit shall
carry the manufacturer’s mark of origin.

2. The supplied joint shall have a range taking feature.

3. The kits must have unlimited shelf life.

4. The insulating tubing over the connector should be Dual Wall design sleeve
With entrapped lubricant.

5. Type tests should have been carried out to prove the general qualities and design of a given type of
jointing system. The sleeve shall be tested for ANSI C1191.1-1986 or equivalent standard. Type Test
Report for the same shall be submitted along with offer.

6. The installation of joint shall be done without use of special tools like crimping tool.

7. Conductor connection shall be achieved by use of connectors with pre-defined shear off bolt head
design. The connector should be range taking which can be used for both copper & Aluminium cables.

8. Armour Connectivity shall be maintained by using Tinned copper braid.

9. Armour Wrap to be provided for mechanical protection of joint body.

10. The design of joint shall be such that on completion of joint the cable can be charged immediately.

3.11 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 at clause 3.08 , then the manufacturer shall furnish the details of kit number and corre-
sponding cable sizes for which the kit is suitable.

509
3.12 CIRCULAR SHAPED CONDUCTOR:-

The terminations/ jointing kits offered shall be suitable to be used on circular compacted XLPE
cable conductor.

3.13 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.

3.14 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.

3.15 EARTHING

Earthing shall be as per relevant standards and the details of the earthing arrangement offered for the cable
accessories shall be submitted along with the offer.

3.16 FIRE RESISTANCE

The cable end terminations and straight-through joints shall be fire resistant. The components
of kits shall have flame retardant property.
3.17 INTERCHANGEABILITY

The components of different size of the kits shall be interchangeable between more than one cable
sizes in case the need so arises. Manufacturers should indicate the range / limits of such interchangeability.

3.18 EASY INSTALLATION

The manufacturer shall offer complete material and components for each kit so as to make one
termination/ joint complete in all respects. The manufacturer shall indicate the list of the material/

510
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 verifi-
cation by the purchaser's inspecting officer and at Nigam's stores / site.

ii) All components shall 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.

3.19 MARKING and LABELLING

As per the IS 13573 (Part-I):2011 all kits shall be marked and labelled suitably for identification.

a. Manufacturer’s name or logo and the name of components wherever feasible;

b. Type of jointing materials, the application;
c. Batch number(s), where relevant;
d. Product reference;
e. Defined storage conditions and expiry date, if any;
f. If relevant, the manufacturing date;
g. Health and safety marking and handling instructions, where
relevant; and
h. Reference to compliance with this standard

3.20 GUARANTEED & OTHER TECHNICAL PARTICULARS

(A) The manufacturer shall furnish the guaranteed and other technical particulars of the kits offeredby
him in schedule-V attached with the bid specifications. The particulars which are subject to guarantee
shall be clearly indicated. The manufacturer shall furnish the length of the tube used in the kitsin the GTP
attached. The complete drawings indicating such length of tubing must be also enclosed alongwith the type
test reports duly authenticated by the testing agency. Without schedule of GTP completely filled in, the
bid offer may be ignored.

(B) The manufacturer shall highlight the various technical aspects and salient features of the kits offered
by them.

3.21 GUARANTEE

511
The cable end terminations and straight through joints shall bear guarantee for five and half years
from dt. of last consignment or five years from dt. of installation. Any defect noticed in the kit, same shall
be replaced ( only for LT ) free of cost, if required otherwise the same will be arranged at the supplier's
risk and cost. The successful manufacturer shall furnish manufacturer's warranty on Rajasthan Non-judi-
cial stamp paper worth Rs.500/-.

3.22 TESTS

1) TYPE TESTS
a) The manufacturer shall furnish valid and authenticated type test certificate as per IS:13573(Pt.1)/2011
from a Govt. approved/ a Govt. recognized/ NABL accredited laboratory/ ILAC i.e. International Labor-
atory Accredited laboratory / ILAC i.e International Laboratory Accrediation Cooperation ( In caseof for-
eign laboratory)

b) The manufacturer should furnish documentary evidence in support of the laboratory whose type test
have been furnished, that the said laboratory is a Govt/ a Govt. approved/ a Govt. recognized/ NABL
accredited laboratory/ ILAC accredited ( in case of foreign laboratory)

c) Such type test certificates should not be older than Seven years as on the date of bid opening.

The test sequence shall be in the order given in Tables 3 to 5, of IS 13573 (Part 1) : 2011 as appropriate
for the accessory being tested

2) ACCEPTANCE TESTS

All acceptance and routine tests as stipulated in the relevant standards, latest amended shall be
carried out by the supplier in presence of purchaser’s representative , and the sampling plan shall be 1%
subject to minimum of one No. of assorted size/type for each voltage rating i.e. LT separately.
Further tests mentioned below shall be conducted as acceptance tests at supplier’s works or any approved
test laboratory preferably at place where supplies work is situated; which will be arranged by the supplier
at his own cost:

a) Visual Inspection. The offered kits should be free from any visible defects

b) Physical verification of contents - all the contents shall be checked as per kit contents list enclosed by
the supplier

c) Electric Strength test for insulation tubing

d)Elongation tests for all types of tubing

e)Wall thickness ratio in expanded condition

f)Longitudinal change after full recovery

g)Tensile strength

3) ROUTINE TESTS
The manufacturer must specify the details of the routine tests being conducted at their Works
along with the standards applicable in their offer.

3.23 INSPECTION
The supplier shall provide the facilities to carry out the prescribed acceptance tests on selected samples
from the lot offered at one or more testing laboratories. The samples from the lot shall be selected by the
inspecting officer or the person authorized by purchaser.

All the tests shall be arranged and carried out as per the procedures laid down in respective speci-
fications as per latest amendment in the presence of purchaser's nominee.

The suppliers should satisfy themselves that the material offered are in accordance with the term of
contract and fully confirms to the required specifications by carrying out a thorough pre-inspection of
each lot before offering the same for inspection to the purchaser. Such pre-inspection on the part of the
supplier shall minimize the chances of rejection during inspection.

3.24 lnspection & Testing

lnspection of material shall be done as per clause (6). Relevant documents including certificate of
compliance regarding import / inflow of materials / tubing, test reports under type approval and quality
assurance shall be made available to the inspection team for its checking and verification.

3.25 TRAINING

If required by the Purchaser, the manufacturer shall arrange for demonstration / training on the use /
proper installation of the kits ordered by the Purchaser, free of cost at Circle Headquarters of Jaipur Dis-
com for getting acquainted with the joining method. The kits used in the training shall be provided by
Jaipur Discom

3.26 LIST OF KIT CONTENTS

The manufacturer shall furnish the lists of kit contents and shall also confirm unlimited shelf-life of
the kits.

513
3.27 PREFERENCE

The offer of standard make & directly from the manufacturers quoting shorter delivery period shall
be preferred.

3.28 DEPARTURE FROM THE SPECIFICATION

Should the manufacturer wish to depart from the specification in any respect, he should clearly state
such departures indicating the reasons thereof. Unless this is done, the departmental specification will
hold good and shall be binding on the supplier unless the departures have been approved in writing by the
purchaser.

514
515
516
TECHNICAL SPECIFICATION FOR HEAT SHRINKABLE TYPE CABLE JOINTING ANDTERMI-
NATION KITS FOR 11 KV XLPE CABLES

1.01. SCOPE:

This specification covers the design, manufacturing, testing and supply of Heat-Shrinkable type
cable straight-through joints and cable end termination kits as per IS:13573(Pt.2)/2011 suitable for use
with and installation on 33 KV and 11 KV XLPE aluminum conductor cables .

1.01.1 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 kit hereinafter in this specification.

1.01.2 Termination and jointing kits shall be heat-shrinkable type of proven make and of a design and
type which have already been extensively used and fully type tested. The offered kits shall be easyin
handling and simple to install without much skill , with minimum tools at site.

3.02 TYPE

3.02.1 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

3.02.2 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 upto manu-
facturers guarantee in a manner acceptable to the purchaser, who will interpret the meanings of the draw-
ings and specifications and shall have the power to reject any works or material which in hisjudgment are
not in accordance therewith. The cable accessories offered shall be complete with all components neces-
sary for the effective and troublefree operations. Such components shall be deemed to be within the
scope of supplier's supply irrespective of whether they are specifically brought outin this specification
and/ or in the commercial order or not.

3.03 SYSTEM PARAMETERS

1. Nominal operating voltage 33 kV rms 11 kV rms

2. Maximum system voltage : 33 kV rms 12 kV rms
3 Frequency (Hz.): 50 +/- 1.5 50 +/- 1.5

518
4. Number of Phases 3 3
5. Type of Earthing Solid Solid
6. Environmental conditions Humid Tropical Climate with polluted atmosphere ,and/or ,
direct burial in water- logged ground.
7. Basic Insulation Level 170 kV (Peak) 75 kV (Peak)

3.04 SERVICE CONDITIONS

(A) The cable accessories to be supplied against this specifications shall be suitable for continuous
& satisfactory operation under climatic conditions listed below:

S.No. Particulars
i) Peak ambient air temperature in shade (C) 50C
ii) Minimum ambient air temperature (C) 0C
iii) Maximum avg. ambient temp. over 24 Hrs. in shade ((C) 40C

iv) Maximum temperature attainable by an object 60C

v) Maximum relative humidity (%) 100 %
vi) Maximum altitude above mean sea level 1000 mtrs
vii) Maximum wind pressure (Kg./Sq.Mtr.) 100
viii) Number of months of tropical monsoon conditions 4 months
ix) Average No. of rainy days per annum 100
x) Average Annual Rainfall in cms. 10 to 100

(B) The kits shall be provided with protection against rodent and termite attacks.

3.05 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.

519
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 manufacturer shall furnish details of the technique employed by them for stress control in cable- end
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.

iv) All Outdoor End Termination kits as well as 33 kV Indoor End Termination kits shall be provided
with rain (weather) sheds or creep age-extending petticoats. These shall be non-tracking , weather re-
sistant, hydrophobic and have smooth surface to deflect any water/ dirt etc. The design of these rain
(weather) sheds or creep age-extending petticoats shall avoid any shed to shed conducting path under
heavy rain conditions.

vi) The lugs and ferrules provided should be suitable for compacted conductors and should withstand
thermal short circuit of 250 deg. centigrade.

3.06 GENERAL REQUIREMENT FOR CABLE END TERMINATIONS / STRAIGHT-THROUGH

JOINTS.

ii) (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 permittiv-
ity shall be minimum 15. Manufacturer shall furnish documentary evidence confirming adherence to these
along with the offer. Further, impedance of stress control tubes shall not change over a range of tem-
perature from 0 C to 125 C. The stress control tubes must have a thermal enduranceequivalent to 35 years
life. The impedance should also remain constant in spite of the difference in stress

520
which will exist within the sleeve due to heating effect within the conductor and the temperature of theenviron-
ment.

a) Manufacturer 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.

b) Copies of test reports on the critical components used in the joints & terminations be furnished as per
as per IS:13573(Pt.2)/2011, be furnished along with the offer.

i) 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 hydro-phobic
in nature. A heat-shrinkable flexible polymeric tubing, preferably coloured red, and possessing non-track-
ing erosion and weather resistant properties shall work as an external covering for the cable covers.

iii) All cuts/ nicks inadvertently occurred to XLPE insulation must be rendered discharge free
by using suitable discharge suppression compound.

iv) The heat shrinkable tubes may be either extruded or moulded type.

v) The higher wall-thickness of heat shrinkable tubes / sleeves shall be preferred to counter the effectof
erosion due to pollution.

3.07 OTHER REQUIREMENTS

i) The kit shall be suitable for storage without deterioration at a temperature upto 50 Deg. C and shall
have unlimited shelf life. Conducting paints having limited shelf life are not acceptable.

521
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.

v) Provisions for effective screening over each core shall be made and the manufacturer shall categor-
ically confirm this aspect in the offer.

vii) 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.

viii) The armour / earthing arrangement shall form part of the terminations/ joints and shall be protected
from erosion either by suitable tape or tube.

ix) The terminations/ jointing kits shall have provision for shield connection and earthing whichever re-
quired.

x) The fault level as well as duration withstand capacity of termination / jointing kits should be strictly
matching with the parameters of cables for which the kits are intended to be used.

xii) Suitable creepage extension/ rain protection sheds for outdoor cable end terminations shall be pro-
vided.

xiii) Adequate provisions for eliminating the chances of entrapment of air at steps formed by semicon
screen shall be made.

xiv) The terminations/ joints shall be supplied in kit form. All insulation and sealing materials, consum-
able items, conductor fittings, earthing arrangements and lugs etc. should be provided .

522
xv) The manufacturer shall furnish the constructional features of material offered.

xvi) 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 kit. Various items, quantity thereof included in each kit must be indicated in the in-
struction manual / packing slip provided in the kit packing.

3.08 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 at clause 3.06 , then the manufacturer shall furnish the details of kit number and corre-
sponding cable sizes for which the kit is suitable.

3.09 CIRCULAR SHAPED CONDUCTOR:-

The terminations/ jointing kits offered shall be suitable to be used on circular compacted XLPE
cable conductor.

3.10 LUGS/ FERRULES

3.11 EARTH/SCREEN CONTINUITY

i) Screen continuity by using tinned copper mesh and earth continuity by tinned copper braids ofappro-
priate 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.

3.12 EARTHING

Earthing shall be as per relevant standards and the details of the earthing arrangement offered for the
cable accessories shall be submitted along with the offer.

3.13 FIRE RESISTANCE

523
The cable end terminations and straight-through joints shall be fire resistant. The components
of kits shall have flame retardant property.

3.14 INTERCHANGEABILITY

3.15 EASY INSTALLATION

The manufacturer shall offer complete material and components for each kit so as to make one
termination/ joint complete in all respects. The manufacturer shall indicate the list of the material/ com-
ponents 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 verifi-
cation by the purchaser's inspecting officer and at Nigam's stores / site.

3.16 SUPERVISORY ERECTION & COMMISSIONING

The successful manufacturer shall provide free services of a trained jointer / foreman / erector (
hereinafter referred to as jointer ) for installation / jointing all 33 kV cable end terminations and straight-
through joints. The jointer of the supplier shall be duly trained and certified by the manufacturer for su-
pervision of installation of the cable accessories. The jointer shall direct the sequence of installation. The
jointer shall correct in the field any errors, omissions on the part of the manufacturer, in order to make
the equipment and material perform properly in accordance with the intent of this specification. The jointer
shall be responsible for any damage to the accessory during his work as well as for any damageresulting
from faulty or improper installation. The purchaser shall provide adequate number of skilled / semi-
skilled workers as well as all ordinary tools and consumable T&P items used in the work such as LPG
gas / kerosene. The purchaser shall not be responsible for any other expenses such as erector's insurance
against personal injuries to the jointer etc. Special tools such as LPG torch, if required for jointing, erec-
tion and commissioning , shall be provided by the supplier at his cost.

3.17 GUARANTEED & OTHER TECHNICAL PARTICULARS

524
(A) The manufacturer shall furnish the guaranteed and other technical particulars of the kits offeredby
him in schedule-V attached with the bid specifications. The particulars which are subject to guarantee
shall be clearly indicated. The manufacturer shall furnish the length of the tube used in the kitsin the GTP
attached. The complete drawings indicating such length of tubing must be also enclosed alongwith the type
test reports duly authenticated by the testing agency. Without schedule of GTP completely filled in, the
bid offer may be ignored.

(B) The manufacturer shall highlight the various technical aspects and salient features of the kits of-
fered by them.

3.18 GUARANTEE

The cable end terminations and straight through joints shall bear guarantee for five and half years from
dt. of last consignment or five years from dt. of installation. Any defect noticed in the kit shall be attended
by the supplier immediately but not later than 24 hours in Jaipur city and not later than 3 days in other
places in the area of Jaipur Discom on receiving the complaint, and if required, the kit shall bereplaced
and installed ( only for 33 kV ) free of cost; otherwise the same will be arranged at the supplier'srisk and
cost. The successful manufacturer shall furnish manufacturer's warranty on Rajasthan Non- judicial stamp
paper worth Rs.500/-

3.19 TESTS

1) TYPE TESTS

a) The manufacturer shall furnish valid and authenticated type test certificate as per IS:13573(Pt.2)/2011
from a Govt. approved/ a Govt. recognized/ NABL accredited laboratory/ ILAC i.e. International Labor-
atory Accredited laboratory / ILAC i.e International Laboratory Accreditation Cooperation ( In caseof for-
eign laboratory)

c) Such type test certificates should not be older than Ten years as on the date of bid opening.

2) ACCEPTANCE TESTS

A) The following tests shall constitute as Acceptance tests:

(i) Visual examination
(ii) Verification of bill of material / kit contents.
(iii) Dimensional check including verification of lengths of tubes as given in the GTP.
(iv) Tensile strength
(v) Ultimate Elongation
(vi) Longitudinal shrinkages
(vii) Dielectric strength
(viii) Volume Resistivity
(ix) Torchability / Recovery -as per manufacturer’s standard
(x) Tracking Resistance ( as per ASTM 2303 )

The above tests shall be carried out in the presence of the Purchaser's representative as per rele-
vant prescribed standards , latest amended and the sampling plan shall be 1% subject to minimum ofone
No. of assorted size/type for each voltage rating i.e. 33 kV and 11 kV separately.

3) ROUTINE TESTS

The manufacturer must specify the details of the routine tests being conducted at their Works
along with the standards applicable in their offer.

3.20 INSPECTION

The supplier shall provide the facilities to carry out the prescribed acceptance tests on selected samples
from the lot offered at one or more testing laboratories. The samples from the lot shall be selected by
the inspecting officer or the person authorized by purchaser.

All the tests shall be arranged and carried out as per the procedures laid down in respective speci-
fications as per latest amendment in the presence of purchaser's nominee.

The suppliers should satisfy themselves that the material offered are in accordance with the term
of contract and fully confirms to the required specifications by carrying out a thorough pre- inspection of
each lot before offering the same for inspection to the purchaser. Such pre-inspection on the part of the
supplier shall minimize the chances of rejection during inspection.

3.21 TRAINING

526
Discom for getting acquainted with the joining method. The kits used in the training shall be provided by
Jaipur Discom.

3.22 LIST OF KIT CONTENTS

The manufacturer shall furnish the lists of kit contents and shall also confirm unlimited shelf-life
of the kits.

3.23 PREFERENCE

The offer of standard make & directly from the manufacturers quoting shorter delivery period shall
be preferred.

3.24 DEPARTURE FROM THE SPECIFICATION

Schedule – A

GUARANTEED TECHNICAL PARTICULARS OF CABLE END TERMINATION & STRAIGHT

THROUGH JOINTS

S.No PARTICULARS TO BE FURNISHED BY

THE MANUFACTURER
1. Name of the manufacturer
2. Trade Name of Kits
3. Is the kit fully or partly imported
4. If the kit /Component is / are imported. Specifycoun-
try (IES) of origin
5. Is the production in India is supported by anycol-
laboration?
6. If so. Name and address of the principle
7. Location & address of the manufacturer’s work in
India for indigenous components.

527
S.No PARTICULARS TO BE FURNISHED BY
THE MANUFACTURER
8. Indicate the standard to which components of kit have
been tested. If yes, furnish copy of test reports.
9. Method of cross linking for Heat shrinkable Tube.
10 Whether the copies of test certificate(s) confirming
compliance to IS:13573(Pt.2)/2011 with latest
amendment, if any have been enclosed.
11. Whether dimensional drawing indicating the clear-
ance etc. and bill of material (as per type tested draw-
ing duly authenticated by the testing agency) foreach
kit is furnished along with the offer.
12. Whether type approval and quality assurance pro-
gramme for basic materials, Tubings, Sealentsetc. are
enclosed with the offer of the manufacturer orthe sub
vendor.
13. Volume resistivity of the material of stress control
tubing (enclose documentary evidence)
14. Relative permittivity ( min) of the material of stress
control tubing ( enclose documentary evidence)
15. Minimum permittivity of stress grading mastic.
16. Volume resistivity of stress grading mastic.
17. Total creepage distance per phase in mm.
18. Material of non-tracking tubes .
19. Type of kit.(whether termination or strength through)
20. a) Shelf Life of the Kit(Years)
b) Design Life of the Kit (Years)
21. Guarantee of the Kit
22. Net Dimensions of the kit(Length X Breadth X Width
and Weight)
23. Craft sensitivity and reliability
24. Time required to prepare a joint termination
25. Time require for energisation after completing the
termination and joints.(Curing Period)

528
S.No PARTICULARS TO BE FURNISHED BY
THE MANUFACTURER
26. Special Storage Condition, if any. Upto an ambient
temperature of 50 deg. C.
27. Whether provision made for
a.) Stress Relief
b.)Track Resistance
c.) Sealing
28. Whether any additional support is required for kit if
so, give details.
29. Make, type & material of Lugs Provided with kits
30. Class of Kits

529
TECHNICAL SPECIFICATION FOR THE SUPPLY OF DANGER LABEL/PLATES

3.01 SCOPE

This specification covers the fabrication, manufacture, testing, checking & supply of Danger Label/ plates
for 33/11KV & 11/0.4 KV Sub-Stations. Before despatch of material, the inspection testing & check-
ing will be witnessed by the representative of the purchaser.

3.02 SPECIFICATIONS & STANDARDS:

The relevant ISS to which this material shall conform are indicated as below:-

S.NO. Bureau of Indian Standards Title

a) IS:2551-1982 ( Latest amended) For general checking
b) IS-5-1978 ( Latest amended) For colours for ready mixed paints an enamels.
c) i. IS:3972 (Pt.2/Sec.1):1985 For resistance to citric acid at room temperature
and boiling temperature.
ii) IS:3972 (Pt.2/Sec.1)1985 For low & high voltage tests for detecting and
locating defects.
iii) IS:3972 (Pt.1)Sec.1):1982 For production of Specimen for testing.

3.03 DIMENSIONS:-

S. Items Nominal thick- Other dimension as per ISS

No. ness of M.S. Length Width
Plate (Min.) in mm in mm.

1. Danger 1.6mm 250 200

Plates IS-2551/1982 (latest amended)
for 33/11 KV &
11/0.4 KV
Sub-stations.

530
3.04 GUARANTEED TECHNICAL & OTHER PARTICULARS.

The GTP of Danger Label/ plate should be given in the tender technical particulars and other
particulars of material in Schedule-V.

3.04.1 Material

The Danger plates shall be made from mild steel sheet of at least 1.6mm thick and vitreous enam-
elled white with letters, figures and conventional skull and cross bones in signal red colour conforming
to IS-5-1978 on the front side and rear side should be enameled black. The edges & rear side should be
enamelled black. Holders for fixing the plates should be drilled not punched.

3.05 TESTS:-

In order to ensure that Danger plates conform to the specification the following tests are to be carried
out:-

a) Visual Examination.
b) Dimensional check including checking of thickness of M.S. Plate and weight.
c) Test for weather prootfness.
d) Checking of thickness of enamel.
e) Resistance to citric acid at room temperature.
f) Low & high voltage tests for detecting and locating defects.

3.06 INSPECTION:- Before dispatch of material, the inspection testing & checking will be witnessed
by the representative of the purchaser

The number of samples of danger plates selected at random from the lot shall be in accordance with the
table given below:-
Lot First sample sample size for Permissible Second Permissible
size for tests a,b,c, checking of Rejection sampling. Rejection
d,e & f. thickness of steel number. number
plate & enamelling.
a) Upto 500 5 1 0 2
b) 501 to 800 7 2 0 3
c) 801 to 1300 10 4 0 3

531
d) 1301 to 3200 15 6 1 4
e) 3201 to 8000 25 8 2 5
f) 8001 & above 35 10 2 7

The checking of the thickness of M.S. plates and enamelling on the plates number of samples as per
Column 3 is acceptable provided the rejection of the samples is not more than the number mentioned in
column 4.

In the event of rejection being more than the number in Column 4 double the sampling as per Column
5 be done. Incase of rejection of samples is beyond the number mentioned at 6, the lot shall be considered
rejected.

On inspection/ testing/checking, if the material is found acceptable as per above criteria the purchaser's
representative shall seal the material, before dispatch.

All the tests (as mentioned at Clause 6.1.2) and Inspection shall be made at the place of manufacturer
unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The
manufacturer shall afford the inspection officer(s) representing the purchaser all reasonable facilities with-
out charges, to satisfy him that the material is being furnished in accordance with this specification. The
purchaser has the right to have the tests carried out at his own cost by an independent agency whenever
there is a dispute regarding the quality of supply.

The Inspection may be carried out by the purchaser at any stage of manufacture/ before dispatch as per
relevant standard.

Inspection and acceptance of any material under the specification by the purchaser, shall not relieve the
manufacturer 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. The Manufacturer shall keep the
purchaser informed in advance, about manufacturing program so that arrangements can be made for in-
spection.

The purchaser reserves the right to insist for witnessing the acceptance/ routine testing of the bought out
items.

The Manufacturer shall give 15 days( for local supplies) / 30 days ( in case of foreign manufacturer) ad-
vance intimation to enable the purchaser to depute his representative for witnessing the acceptance and
routine tests. The inspection charges would be to the purchaser's account.

3.07 MARKING
The essential information that would be necessary to identify the manufacture of Danger Plates such
as JVVNL, Purchase Order No. & Date shall be marked in such a manner & position on the plates that it
does not interfere with the other information and should be of permanent nature.

3.08 DRAWING

The dimensions of Danger plate shall be confirm to the following drawings & our specification
(copy enclosed)

Drawing for Drawing No.

33/11 KV S/S SE(MM-I)/SPO-III/TN-

11/0.4 KV S/S SE(MM-I)/SPO-III/TN-

3.09 TEST CHECKING OF MATERIAL AT TESTING LABORATORY:

The material received in stores of nigam shall be subjected to the test checking at testing laboratory before
final acceptance of material. The procedure for testing shall be as under:

i) SAMPLING

One sample out of each sub lot/ lot of (1000 Nos.) thousand Nos. or part thereof from each inspected lot
received in stores shall be selected from each store for test checking of material and shall be got tested.
The selection of sample from the material received at stores shall be done as soon as material is received
in stores without the presence of the representative of the supplier. However, testing of sample(s) at CTL
or else where as arranged by the JVVNL shall be carried out in the presence of representative of the
supplier after identification / confirmation by him that samples so selected belong to them.

ii) TESTS

The following test shall be carried out on the above samples :

a) Visual examination , verification of dimensions, weight and marking as perGTP/ISS/Specifica-

tion/ approved drawing.

For witnessing of the testing, clear 3 (Three) days notice shall be given to the supplier by fax/
speed post stating date, time & place where the test is to be conducted. In case the supplier do not

533
attend for witnessing the testing, the testing shall be proceeded and completed and action be taken as
per the contract.

The Officer Incharge of Central Testing Lab (CTL) Jaipur shall send copies of test reports to
the purchaser, consignees and the supplier.

iii) CRITERIA FOR ACCEPTANCE

a) Visual Examination, verification of dimensions, weight and marking.

As per Specification/ GTP/ ISS/approved drawing.

iv) TEST CHARGES :

All test charges incurred towards test checking of the material received in our stores shall

3.10 PACKING

You shall pack the material in the suitable wooden cases so that the material may not be
damaged in the transit and also remain protected from the atmosphere.

3.11 DEPARTURE FROM SPECIFICATION

Should the manufacturer depart from the specification in any respect, he should clearly state such
departures indicating the reasons thereof. Unless this is done, the departmental specification
will hold good and shall be binding on the supplier unless the departures have been approved in writing by
the purchaser.

3.12 TENDERS:

Manufacturer shall furnish complete particulars of the material offered by them in regard to the spec-
ification and submit the same with their tender. Failure to do so or any incomplete entry therein may
prevent a tender from being considered.

The tenders received without complete details required as per enclosed forms/ schedules are liable
to be rejected.

534
SCHEDULE-V-A

GUARANTEED AND OTHER TECHNICAL PARTICULARS OF DANGER PLATE

(To be filled in by the manufacturer and sent along with bid)

S.NO PARTICULARS
1. MAKER’S NAME & ADDRESS
2. PLACE OF MANUFACTURE
3. IDENTIFICATION MARK
4. SPECIFICATION & STANDARDS:
I) GENERAL CHECKING
II) COLOUR ENAMELLING
III) RESISTANCE TO CITRIC ACID
A) AT ROOM TEMPERATURE
B) BOILING TEMPERATURE:
IV) LOW & HIGH VOLTAGE TEST FOR
DETECTING AND LOCATIANG DEFECTS.

V) PRODUCTION OF SPECIMEN FOR TESTING

.
5. THICKNESS OF M.S.PLATE
I) WITHOUT ENAMELLING
II) WITH ENAMELLING
6. DIAMETER OF HOLES
7. COLOUR ENAMELLS
8. MARKING
9. PACKING DETAILS
I) WEIGHT OF WOODEN CASE
II) NO. OF PLATES IN ONE CASE
III) GROSS WT. OF ONE CASE

Signature
Name & Designation with seal of the firm
TECHNICAL SPECIFICATION FOR ALUMINUM LUGS

1.0 SCOPE :

This specification covers the design, manufacture, inspection and testing before dispatch, supply and
delivery at our stores/ site of Aluminum Lugs (Aluminum terminal ends) specified herein for their satis-
factory operation in Distribution lines in Jaipur Discom.

2.0 GENERAL TECHNICAL REQUIREMENTS :

Terminal end or lug connective device with barrel accommodating respective conductor size of electrical
cable should have a fixing arrangement of termination by means of a bolt fixing in terminal type terminal
block and screwing the aluminium lugs/ terminal end shall conform to IS:8309/1993 with latest amend-
ments.

The material of terminal end/ lug shall be of Aluminum of grade IE of IS: 5082/1969 “Specification for
wrought Al. & Al. alloys, bars, rods, tubes and section for electrical purpose”.

The inside of barrel shall either be suitably rough end throughout the crimping length of terminal end or
provided with a suitable grease based compound with abrasive action.
Edges and corners shall be free from burrs and sharp edges.

The dimensions &tolerences for “Compression type tubular terminal ends for aluminum conductors of
insulated cables” shall be as per table 1 (clause 5 & 6) of IS:8309/ 1993.

3.0 GURANTEED TECHNICAL AND OTHER PARTICULARS

The manufacturer shall furnish complete Guaranteed Technical& Other Particulars(GTP) of material of-
fered by him in Schedule-V-A in absence of which the bid is liable to be rejected.

4.0 DRAWING: The manufacturer shall furnish the drawing & weight with details of dimensions.

5.0 INSPECTION AND TESTING:

5.1 The material shall be tested and inspected by an authorized inspecting officer of the Nigam before
dispatch. Sample(s) shall be drawn for inspection/ testing as per provisions of relevant ISS/ Purchase
Order. The Purchase reserves the right to get the material tested in any testing laboratory for dispatch.
5.2 The suppliers should satisfy themselves that the stores are in accordance with the terms of the
contract and fully confirm to required specifications by carrying out a thorough pre- inspection of each
quota before tending the same for inspecting to the inspecting officer nominated by the Purchaser. Such
pre-inspection on the part of the suppliers would minimize the chances of rejection in inspection.
536
5.3 Tensile Strength, flattening test report from independent test house and manufacturers material test
report for aluminium etc. be furnished along with tender documents.

6.0 TEST CHECKING OF MATERIAL AT STORES:

The material received in the stores of the NIGAM shall be subjected to the checking of dimensions as per
approved drawing from 1% of the supply received and the same shall be reported to the SuperintendingEn-
gineer(Proc).

7.0 PREFERENCES:

7.1 All other things being equal, the ISI marking material will be preferred.
7.2 The offers of Standard make and directly from the manufacturer quoting
shorter delivery period shall be preferred.

8.0 MARKING: Marking on Aluminum lugs shall be as per IS:8309/1993 along with

SCHEDULE-A
GUARANTEED TECHNICAL & OTHER PARTICULARS OF COMPRESSION TYPETUBU-
LAR TERMINAL ENDS OF ALUMINUM CONDUCTOR OF INSULATED CABLES.
(To be filled in by the manufacturer and sent alongwith bid)

S.N. Description Particulars

1) Manufacturer's Name & address.
2) Make of Aluminium Lugs/ Terminal End
3) Type of Aluminium Lugs/ Terminal End
4) Size of Aluminium Lugs/ Terminal End
5) Aluminium Lugs/ Terminal End conforms to IS:8309/1993 with latest
Amendments
6) Material of Terminal End/ Lug Aluminum of Grade IE of
IS:5082/1969

7) Edges and corners shall be free From burrs Yes

and sharp edges
8) Inside of Barrel shall be
a) Rough & throughout the crimping length of
terminal End
537
b) Provided with a suitable grease based
compound with abrasive action
9) Dimensions & Tolerances for Compression As per table 1 of
Type Terminal Ends IS:8309/1993

10) Marking As per IS:8309/1993 &

Also have JVVNL & TN NO.
11) Testing facilities are available as per ISS
12) Tensile Strength & Flattening Test report
from independent test house furnished with
the tender
13) Manufacturer’s material test report for Al. etc
14) Offered material is ISI marked or not
15) Other details/informations

Signature
Name & Designation with seal of the firm

538
SECTION- (PART-A)

TECHNICAL SPECIFICATION FOR 12 KV OUTDOOR VACUUM CIRCUIT

BREAKER KIOSKS.

1.0 SCOPE

This specification is intended to cover the design manufacture, assembly, testing at manufacturer's
works, supply, delivery of 12 kV Vacuum Circuit breaker Kiosks with current transformers,
Potential transformers, protection relays, metering instruments etc. Complete with all accessories
and Installation & Commissioning by the supplier as per Schedule-III (Part-B) for efficient &
trouble free operation (Separate price for Installation & Commissioning and Civil works).

1.1 It is not the intent to specify completely herein all details of the design and construction of equip-
ments. However, the equipment shall conform in all respects to high standards of engineering,
design and workmanship and shall be capable of performing in continuous commercial operation
upto the Manufacturer's guarantee in a manner acceptable to the Purchaser, who will interpret the
meanings of drawings and specifications and shall have thepower to reject any work or material
which in his judgment is not in accordance therewith. The offered equipment shall be complete
with all components necessary for its effective and trouble free operation along with associated
equipments, interlocks, protection schemes etc. Such components shall be deemed to be within
the scope of supply, irrespective of whether those are specially brought out in this specification
and/or the commercial order or not.

2.0 STANDARDS

The 12 KV vacuum circuit breaker Kiosks shall conform to latest revisions with amendments of
standards as under unless specified otherwise. Equipment meeting any other authoritative standard
which ensure equal or better quality than the standard mentioned above will also be acceptable.
In such cases a copy of standard (English version) adopted, should be enclosed with the tender.

IEC62271/100-200 High Voltage Switchgear & Control gears.

IS:13118/IS-3427 Circuit Breaker/ metal enclosed Switchgear
and control gear.
IS: 3156 Voltage transformers.
IS: 2705 Current transformers.
IS: 3231 Electrical Relays for power system.
IEC: 60255 Electrical Relays
IS:1248 Meters and Instruments
IS:14697-1999 Specification for AC static transformer operated watt hour
and VAR hour meters class 0.2 S & 0.5 S.
IEC-62053-22-2003 Specification for AC Static Watt hour Meters, class 0.2 S &
0.5 S.
IEC-62052-11-2003
CBIP Technical Report Specification for AC Static Electrical Energy Meter.
No.88 revised July, 1996
read with amendment is-
sued (April,99,
September,99 and also any
other amendment
thereafter).
IEC 60255: Measuring relays and protection equipment

IEC61000: Electromagnetic compatibility (EMC)

IEC 60068: Environment testing
IS:13703-1 LV Fuses for voltages not exceeding 1000 volt AC or 1500
Volt DC
IEC:60279 Low Voltage Power Fuses
IS-2147 or IS-13947 Part-1 Verification of degree of protection IP-55 of
or IEC 60947-1-2004 (with enclosure/cubicle/control cabinet
latest amendments)

3.0 CLIMATIC CONDITIONS:

Equipment to be supplied against this specification shall be suitable for satisfactory continuous
operation under the following tropical conditions :-

i) Peak ambient air temperature 50 DEG Cin

shade.
ii) Minimum ambient air temperature (-) 5 DEG C
in shade
iii) Maximum relative humidity. 95 %
iv) Minimum relative humidity 10 %

v) Dust storms are liable to occur from the period March to July

vi) Height above mean sea level less than 1000M

vii) Average number of thunder 40 DAYS
storms days per annum.

540
viii) Average annual rainfall 10-100 cm
(Depending on area)

ix) Number of months of tropical 4

monsoon conditions p.a.

4.0 PRINCIPAL PARAMETERS OF CIRCUIT BREAKERS

4.1 TYPE AND RATING 12 kV

4.1.1 Type Vacuum circuit breaker

4.1.2 Service Outdoor

4.1.3 Pole 3

4.1.4 Rated voltage 11/12 kV(nominal/max.)

4.1.5 Rated frequency 50 HZ

4.1.6 System Neutral Effectively grounded.earth-

ing

4.1.7 INSULTATION LEVEL

4.1.7.1 Impulse withstands 75 kVp

4.1.7.2 One minute power As per relevant standards.

frequency withstand
voltage.

4.1.8 Rated Current

4.1.8.1 Continuous at 50 C. 630 A

541
4.1.8.2 Short time current 16 kA
for 3 Sec.

4.1.9 Rated Breaking Capacity

4.1.9.1 Symmetrical 16 kA

4.1.9.2 Asymmetrical As per relevant standard

4.1.10 Rated making capacity 2.50X16 KA

4.1.11 Rated short time with- 16 KA

stand current 3 secs.

4.1.12 Total break time 3 cycles (Max.)

Closing time 4 cycles (Max.)

4.1.13 Creepage distance 300 mm or more

4.1.14 Protection class of kiosk IP-55 as per

IEC 529

4.1.15 Operating duty

For gang operation O-0.3 Sec-CO-3min-CO

4.1.16 Operating Mechanism motor operated spring charged closing

mechanism or Magnetic Actuator.

4.1.17 Spring charging Motor 220V-240V

4.1.17.1 Heater/Lamp/Socket. 240V AC

4.1.18 Terminal Connector

542
4.1.18.1 Type Bimetallic clamp type/ Al. alloy.

4.1.18.2 Suitable for 10% Panther and 90%

ACSR conductor Dog Conductor

4.2 System details

4.2.1 H.V. System

Voltage (Nominal/Max.) 11/12 kV

Phases 3

System Neutral Effectively earthed.

Fault level 16 KA r.m.s. Symmetrical

4.2.2 Auxiliary power Supply

4.2.2.1 A.C. Supply 1. 415 volts 3 ph 4 W 50 Hz

2. 240V 1 Ph 2 W 50 Hz

5. GENERAL TECHNICAL REQUIREMENTS: -

5.1 DESIGN CRITERIA

The manufacturer shall quote 12 KV Outdoor VCB Kiosks conforming to M-2 class only. The
equipment will be used in high voltage system having characteristics as listed in the specification.
The equipment will be installed outdoor in a hot, humid and tropical atmosphere. All equipment,
accessories and wiring shall have tropical protection, involving special treatment of metal and
insulation against fungus, insects and corrosion.
The maximum temperature in any part of the equipment at specified rating shall not exceed the
permissible limits as stipulated in the relevant standards.

The equipment shall be capable of withstanding the dynamic and thermal stresses of listed
short circuit current without any damage or deterioration.

The safety clearances of all live parts of the equipment shall be as per relevant standards.

The cowling provision shall be provided on the roof of 12 KV outdoor VCB Kiosk to avoid direct
inception of water at any joint.

5.2 SPECIFIC REQUIREMENTS

5.2.1 The vacuum circuit breaker kiosk shall be for outdoor installation. The duty of the circuit breaker
shall involve satisfactory interruption of short circuit currents as listed in the specification. The
breaker shall be capable of interruption of low reactive current (lagging/leading) without undue
over voltage.

5.2.2 CONSTRUCTIONAL FEATURE

5.2.2.1

a) The circuit breakers shall be triple pole horizontal fixed type enclosed in Kiosk of CRCA sheet
steel of 3 mm thickness for load bearing members and 2 mm thickness for non-load bearingmem-
bers and shall comply with latest edition of IS:13118/3427/IEC-56. The Kiosk shall be vermin
proof and dust tight. The switchgears and Control gears shall be complete with all
necessary supporting frame works, Nuts and bolts etc. for securing the same to the floor.
The operating mechanism shall operate (close/open) all the three phases simultaneously. The op-
erating mechanism links etc. should be accessible for maintenance. The circuit breakers and its
operating mechanism shall be fully interlocked to prevent mal- operation. All the breakers shall
be supplied with necessary clamps and connectors suitable for appropriate current ratings.
Rigid type bimetallic/Al.alloy terminal connectorsof
630 Amps. current rating form part of supply. Suitable arrangement of earthing the switchgears
shall be provided. All the connecting bus bars shall be made of copper.
b) Hinges of door shall be concealed type to avoid rusting and obstructive opening of the door.
c) The quality of welding shall be good and there should not be any lumps and splatters on the panel.
d) All the connecting bus bar and current carrying parts shall be made of copper.
e) All the gasket shall be of chemically treated neoprene.
f) Hole & Pin locking (Check nut) arrangement should also be provided while fixing the vacuum
interrupter at bottom side.

544
5.2.2.2 Switchgear (Vacuum Circuit breakers etc.)and control gear (CTs.,PTs, relays etc.)shall be
mounted on the same Kiosk. Bus bars shall be air insulated with PVCinsu-
lation/sleeves on electrostatic powder coating. The bus bars should be of electrolytic copper
with permissible limits of current density. Size of the bus bars and current density should be
specified in the tender. The bus bars conductor shall conform to Indian standard 8084 and 3427
and shall be rated for 630 A,STC 16 KA for 3 sec.

5.2.2.3 All the meters, instruments, relays etc. shall be mounted on the switchgear kiosk. The outdoor
circuit breakers Kiosk shall be suitable for AC shunt tripping arrangement.

5.2.2.4 The Kiosk shall have an arrangement for emergency shunt tripping from remote place in
addition to arrangement for local emergency tripping(Mechanical). The kiosk shall also have a
system to check the "Trip circuit healthy check" in all the three phases. Necessary tripand
closing coils shall be provided for operation of the breakers.

5.2.2.5 All the six terminals shall be brought out through appropriate class bushings.

5.2.2.6 The arcing contacts shall be made of homogeneous special alloy so that surge voltage
are reduced to negligible level & multiple reignition is eliminated.

5.2.2.7 The circuit breaker kiosk shall be electrically and mechanically trip free under various
conditions.

5.2.2.8 The provision shall be kept on the kiosk roof and roof bushing assembly to adopt arcing
horns.

5.2.2.9 The lifting arrangement shall not cause any effective loss of creepage distance/ phase to
earth clearances as specified in the ISS/IEC.

5.2.3 MAIN CONTACTS

The main contacts shall have adequate area and contact pressure for carrying rated continuous and
short time current without excessive heating liable to cause pitting and welding.

The breakers may be provided with silver plated contacts, if necessary, to meet the requirement of
IS:13118/IEC56 where higher temperature rise is permitted with silver plated contacts. The quan-
tity of silver facing shall be such that after carrying out one tenth of total number of operationsspec-
ified for mechanical endurance tests, there is still continuous layer of silver on contacts.

5.2.4 NUMBER & TYPE OF SPARE, AUXILIARY CONTACTS/ SWITCHES :

545
Adequate number of spare auxiliary switches/contacts both of normally open & normally close type
but not less than four each shall be provided on the circuit breaker for use in the indication and
controlling scheme of circuit breakers.

5.2.5 INTERLOCK

All electrical and mechanical interlocks which are necessary for safe and satisfactory operation
of the circuit breaker shall be provided .

5.2.6 BUSHINGS FOR CIRCUIT BRAKER KIOSK

a) The out door circuit breakers shall be metal enclosed fitted with weather proof/ suitable type bushing
conforming to IS:2099 and shall be designed to have the necessary mechanical strength and rigidity
required and shall be free from objectionable interference and external and internal corona. The porce-
lain shall be of the wet process type, homogeneous, free from laminations and cavities or other flaws
which could effect its chemical & mechanical strength and shall not be injuriously stressed by tem-
perature change. The porcelain shall be thoroughly vitrified tough and impervious to moisture and
shall be evenly glazed. The glazing shall be free from blisters or burrs. The bushing shall be designed
manufactured & tested in accordance with latest edition of IS:2099. The type and characteristic data
bushing shall be clearly specified.

b) The bushing shall not be subjected to direct point loading. They shall be provided with neck around
clamps for evenly distributed pressure.
c) The bushing shall be mounted using suitable clamps and gasket arrangement to provide required
degree of protection.
d) The bushing assembly shall be provided with lock nut and check nut which will be non-magnetic and
non-corrosive.

5.2.7 OPERATING MECHANISM

Characteristics of Operating mechanism of circuit breaker and associated equipments :

Method of operation: The circuit breaker shall be equipped with power operated mechanism to
operate all three phases simultaneously using 220/240 V AC Motor operated spring closing
mechanism or magnetic actuator type. It shall be electrically & mechanically trip free under
various conditions. Kiosk shall also be provided with hand operated spring charging closing mech-
anism. Operation counter and mechanically ON-OFF indicator shall be provided.

5.2.8 VACUUM CIRCUIT BREAKER

The three phase vacuum circuit breaker will have three vacuum interrupters (one interrupter per
phase) mounted on same carriage. The interrupters shall be air insulated with epoxy resin /
546
insulated phase barriers. Each interrupter shall have fixed and moving contacts in sealed envelops
having vacuum below 10-6 torr. The metallic bellow shall permit axial movementof moving
contact and act as vacuum seal. The contacts shall have requisite mechanical strength and good
electrical and thermal conductivity and shall be made of copper chromium alloy. Complete litera-
ture of vacuum bottles shall be furnished with the tender.

In order to have safe operation under fetal conditions, the vacuum interrupter should be housed in
epoxy pole unit and make of Vacuum Interrupter will be as “BEL, CGL, SIEMENS, ABB, AL-
STOM, AREVA, MEGAWIN”.

Any other equivalent make of V.I. shall also be acceptable subject to prior approval of S.E. (MM-
II), JVVNL, Jaipur.

5.2.9 VOLTAGE TRANSFORMERS

i) Highest equipment voltage : 12 KV

ii) No. of phases. : 3 Nos. single
phase VTs
iii) Insulation level.
a) Impulse withstand voltage : 75 KVP
b) One minute power frequency
withstand voltage on :
i) Primary winding : As per relevant standard.
ii) Secondary winding : 2 KV rms
iv) Frequency. : 50 Hz.
v) Transformation ratio. : 11000/110 V
vi) Rated output. : 100VA/Phase
vii) Accuracy class. : 0.5
viii) Rated voltage factor. : 1.2 continuous &
1.5 for 30 sec.
ix) Type of insulation : Resin cast.

VTs, shall be provided with HRC type fuses on the secondary side. The VT fuses on primary side
shall also be provided with all safety precautions. One of the secondary terminals of theVTs, shall
be solidly earthed. Three numbers single phase voltage transformer of this rated

547
output will be required for each circuit breaker kiosk. Voltage transformers shall be fixed type
and shall be suitable for single phasing.

5.2.10 CURRENT TRANSFORMERS

i) Rated voltage. : 12 KV

ii) Insulation level.

a) Impulse withstand voltage : 75 KVP

b) One minute power frequency

withstand voltage on :

i) Primary winding : As per relevant standard.

ii) Secondary winding : 2 KV rms

iii) Frequency. : 50 Hz.

iv) Rated continuous thermal current: 120% of rated

primary current
v) Short time thermal rating
and its duration. : 16 KA for 3 sec.

vi) Transformation ratio of : Core-I Core.II

CTs 400-200-100/5-5A ----------------
a) Rated output 15 VA 15 VA
b) Class of accuracy 5P 0.5S
c) Accuracy limit factor. 15 -
d) Purpose Relaying Metering

vii) Max.instrument security :- 5

factor.
548
12 KV current transformers shall be single phase. The core shall be of grade non ageing laminated
silicon steel of low hysteresis loss and high permeability to ensure high accuracy at both normal
and fault current.

5.2.11 The rating of secondary winding shall be 5 Amps. Required transformers ratio can be achieved in
any manner, However, the current transformers will have to satisfy the requirement of rated
VA burden, Class of accuracy , accuracy limit factor and short time thermal rating as have been
specified above at all transformation ratio.

The rating of current transformers of all classes regarding ratio error, knee point voltage, resistance
of secondary winding etc. shall have to be co-ordinate with the requirement of protective relays
and protection scheme without any extra cost.

5.2.12 The manufacturer shall also furnish along with the tender, complete general arrangement, sche-
matic and outline diagrams indicating the mounting arrangement and position of current trans-
formers, potential transformer, terminal block etc. Type of current transformers and potential
transformers employed shall also be clearly stated.

5.2.13 INDICATING AND INTERGRATING METERS/INSTRUMENTS:

All indicating instruments shall be of switch board type, back connected suitable for flush mounting
and provided with dust and vermin proof cases for tropical use and finished in suitable colour. All
instruments shall have practical laboratory means of adjustment of accuracy. The limits of errors
for ammeters/voltmeter shall be permissible for class 1.5 instruments as per IS:1248. The amme-
ters and voltmeters shall be suitable scaled to indicate the current for all theratings of current/volt-
age transformers. A phase selector switch with four/six positions shall be used to measure the
current/voltage of each phase. The meter shall be located at eye level to facilitate observation
of readings correctly.

Any alarm scheme shall have both audio-visual annunciations in redundancy of each other and
appropriate accept and reset push buttons shall be part of alarm scheme.

5.2.14 RELAYS :

The circuit breaker shall be fitted with numerical relay having shunt trip coil for operation on 3
over current & one earth fault element. The numerical relay to be provided with the 12 KV Outdoor
VCB Kiosk, should be so designed so as to operate/ trip on earth fault as well as on over current
faults but should not operate on unbalance load conditions during single phasing (which can be
achieved through residual voltage control or otherwise).
The circuit breaker shall have suitable arrangement for power supply of relay and breaker opera-
tion through shunt trip coil using power pack. The power pack should be suitable for 6 Nos.closing/
tripping operations and for future remote communication as well as breaker testing duringlong time
power failure. The output voltage may be as per manufacturer’s design. The charging ofPower pack
shall be through 230 V A.C. supply available at Sub-Station.

The make, model No., type and Technical specification of the relay as well as power pack are
required to be mentioned in the bid.

The Relay & Power Pack arrangement system should be warranted for 5 years (in line with war-
ranty of breaker).

The numerical relays shall have following features:-

i. Self Diagnosis.
ii. Minimum last five abnormal events recording (over current & earth fault) including fault level and
phase along with date & time.
iii. On-line display of current.
iv. Communicable with open Protocol having RS-485 port.
v. The relay should contain four shots, three phase, programmable & auto reclose control feature.

Relay should be numerical in design and flush mounted on the panel board. The relay should
be rated for 110V AC as well as DC & 5 Ampere CT secondary. The relay should conform to
latest IEC specifications. The tenders shall furnish the detailed type test in this regard along with
the offer.

Relay TTB shall have trip bypass arrangement.

All the relays shall be provided with test blocks in panel so designed that the relays may be tested at site. The
relays should have provision of testing either through test block or test plug easily accessible by injecting the
voltage / current/frequency (as applicable) from external testing instruments /source without first disconnect-
ing/ re-energizing the primary electrical circuit protected by the relays. Facilities for isolating the tripping
circuit during such testing shall also be provided.

The requirement of test block shall not be applicable in case of drawout type relays which can be
tested by using test plug without removing the relay from its casing.

The testing facilities provided in the relays shall be specifically stated in the bid. Necessary test
plug etc. as may be required for proper testing shall be included in the contractor’s scope of supply.
One test plug with five panels or part thereof are to be supplied.

The technical suitability of relays/schemes may also be examined by Protection Wing of Discoms
& acceptability will be judged appropriately.
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Relay should have following additional features in addition to above mentioned protections:
1. Relay should have two group settings. Group switching (From 1st group (Three phase
condition) to 2nd group (Single phase) and vice versa) based on single phase and three phase load
condition. E.g. If three phase load detected then relay should be in 1st group and when single phase
load detected, there should be auto switching from 1st group to 2nd group.

2. Neutral displacement protection (NDR) blocking should be available during single phase
load conditions. Relay should only trip on earth fault if actual value of NDR voltage increases
beyond pre-set value till time earth fault should be block.

The manufacturer must furnish type test reports as per relevant ISS/ IEC along with bid to suit the envi-
ronmental conditions of our State, in respect of the relay (of the type and design offered)
which should have been type tested in NABL accredited test laboratory in respectof such
tests for which the lab has been accredited (for Indian make Relays)/ CPRI/ Nationally
accredited testing laboratory (for Foreign make Relays).These type test reportsshould not
be older than Ten years from the date of opening of bid.

Further, the type test reports which could not be revalidated due to COVID pandemic, since
23.03.2020 will be considered valid up to 30.09.2022.

The Following makes of Relays are acceptable:-

a. Areva.
b. ABB.
c. Easun Reyrolle
d. C&S
e. JVS
f. SEL
g. ASHIDA
h. MEGAWIN
i. STELMEC
j. CGL
Any other equivalent make of relays shall also be acceptable subject to prior approval of S.E.
(MM-II), JVVNL, Jaipur.

5.2.15 WIRING :

All wiring shall be of switch board type consisting of copper conductor of 2.5 sq.mm cross section
insulated with polyvinyl chloride insulation suitable for 660V service and in accordancewith rel-
evant IS:732. Polyvinyl chloride used shall have excellent resistance against burning, moisture,
oil and vermin and shall be finished with clear colour. Rubber insulated wiring shall not be ac-
ceptable. Manufacturers shall furnish the details of method being adopted by them for joint/ con-
nections.
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All instruments and panel wiring shall be of heat resisting and self extinguishing type in compliance
with British Standard Practice/IS. Plastic or porcelain cleats of the limited compression type shall
be used for holding wiring runs. All wires shall be suitable for bending to meet the terminal studs
at right angles. Metal cases of all apparatus mounted on kiosk shall be separately earthed by means
of copper wire or strips. The following colour schemes of the wiring shall be used as per IS:375.

a) AC three phase circuits :

i) No.1 phase : Red

No.2 phase : Yellow
No.3 phase : Blue

ii) Neutral conductor : Black

iii) Connection to earth : Green

5.2.16 TERMINAL BLOCKS :

Terminal blocks shall be 650 V grade, box clamp type ELMEX 10 sq.mm or approved equal. Not
more than two wires shall be connected to any terminal. Spare terminals equal in number to 20%
of active terminals shall be furnished.

Terminal blocks shall be located to allow easy access. Wiring shall be so arranged that individual
wires of an external cable can be connected to consecutive terminals.

5.2.17 TEST TERMINAL BLOCK :

Two Nos. test terminal blocks shall be provided one for testing of relays and other for testing meters.
They shall be of switch board type back connected for front of panel mounting. The test blocks
shall provide complete isolation of meters, instruments etc. and the arrangement shall be such
that testing power could be connected at the test block from any external source or may be taken
from the instrument transformers. Provision shall be made for short circuiting current transform-
ers. Suitable sealing arrangement shall be provided in test terminal blocks.

5.2.18 INDICATING LAMPS :

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Indicating lamps shall be provided on the control board to indicate the following:

i) Visual indication of ON and OFF position of each circuit breaker.

ii) PT supply indication.

Each lamp body shall be of moulded insulation and shall be able to withstand a high voltage test
of appropriate value. All lamps shall be suitable for 240 V AC supply and shall have low power
consumption and shall provide a wide angle of illumination of sufficient intensity for comfortable
viewing. A glass of appropriate colour shall be screwed into the front of lamp body. The design
of indication lamp shall be such as to facilitate replacement of burnt lamps. An engraved label
indicating the purpose of the lamp shall be provided with each lamp.

5.2.19 FERRULES :

Ferrules engraved/printed with the same numbers, of symbols as indicated in the connections and
wiring diagram shall be provided on the terminal ends of all wires for identification of circuits
for inspection and maintenance. Ferrules shall be of strong and flexible insulating material with
glossy finish to prevent adhesion. They shall be engraved/ printed and clearly marked and
shall not be effected by dampness. Ferrule numbering shall be in accordance with IS:375. The
same ferrules number shall not be used on wires in different circuitson a panel.

5.2.20 HT TVM:-

3 phase 4 wire A.C. Static H.T. Trivector meter of accuracy class 0.5S for measurement of
energy as per latest specification of JVVNL, shall be provided on each Outdoor VCB Kiosks.

Following makes of HT TVMs are acceptable:

i) Secure
ii) L&T
iii) ABB/Elster
iv) Schlumberger
v) Genus Infra
vi) Genus Power
vii) HPL

Any other make being procured by Nigam shall also be acceptable.

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5.2.21 All interiors and exteriors of switchgear enclosure, breaker mechanism etc shall be finished
and painted to produce a neat, fire resistant and durable surface which would prevent rusting
and corrosion. Sheet metal component shall be pre-treated using 7 tank phosphating process
consisting of de-greasing, acid pickling, de-rusting, phosphating and passivation including re-
peated rinsing in between. On completion of the passivation of the components, they shall be
preheated and then epoxy powder coated or treated with one coat of primer & zinc chromateand
finished with two coats of light gray enamel paint of shade 631 of IS 5 and stoved to achieve
excellent anti-rusting and scratch resistance properties. The thickness of painting shallbe around
60 microns.

5.3 SCHEDUOLE OF EQUIPMENTS, FITTING & ACCESSORIES :

12 KV 630 Amps Vacuum circuit breakers kiosks for outdoor installation :

5.3.1 1 No. - 12 KV 630 Amp. Vacuum Circuit Breaker horizontal fixed type with provision of manual
tripping by means of push button and emergency shunt tripping.

Electrically operated through 230 V AC. A lockable Local/ Remote switch shall be provided, apart
from Trip-Neutral-Close (TNC switch) control switch to select local/ remote operation of the
switchgear. The breaker control switch shall have Trip-Neutral-Close position spring return se-
quence locking mechanism. The breaker control switch and selector switch shall be mounted onthe
front side of cubicle and located at a convenient height for easy operation.

5.3.2 1 No. - AC Motor charged spring operated closing mechanism or magnetic actuator type closing
mechanism.

5.3.3 1 No. - Shunt tripping arrangement/ Coil for operation on over current (load) and earth fault by
relays along with emergency shunt tripping from remote place in addition to local emergencytrip-
ping(Mech.) One additional shunt trip coil, fitted very near to the original coil (which will be
unwired) is also required to be provided.

5.3.4 3 Nos. - Single phase 12 KV Current Transformer ratio 400-200-100/5-5A suitable for metering
and protection. The class of accuracy shall be 0.5 for metering and 5P15 for protection. Rated
burden (output) shall be 15 VA for each secondary winding and it should not be less than suitable
for tripping arrangement provided. Instrument security factor for metering core shall not be exceed
5.

5.3.5 6 Nos. - Rigid type bimetallic/ aluminium alloy terminal connector suitable for ACSR (10% Pan-
ther and 90% Dog Conductor) for both horizontal/ vertical take-off.

5.3.6 1 No. - Mechanical ON/OFF indicator.

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5.3.7 1 No. - Operating handle for independent manual closing mechanism.
5.3.8 1 No. - Red indicating lamp for ON indication.
5.3.9 1 No. - Green indicating lamp for OFF indication.
5.3.10 Spare auxilliary contacts/switch having minimum 4 NO + 4 NC
5.3.11 1 No. - Flush mounting pattern 96x96 sq.mm Moving Iron ammeter of class 1.5 accuracy
suitable scaled for 5 Amps. CT secondary.
5.3.12 1 No. - Ammeter selector switch to indicate phase current in all three phases and with OFF
position.
5.3.13 1 No. – Numerical 3 O/C + E/F relay.
5.3.14 1 No. HT TVM of accuracy class 0.5S as per latest specification of JVVNL.
5.3.15 2 Nos. - 240 V AC single phase 80 or 100 watt anti condensation heaters with thermostat and
switch.
5.3.16 1 No. - Automatic door illumination lamp with switch.
5.3.17 3 Nos. - 11000/110 V single phase voltage transformers each having 100 VA/phase burden &
class of accuracy 0.5 suitably connected to meters and indicating instruments etc.

5.3.18 1 No. - Flush pattern switch board mounting pattern 96x96 sq. mm moving iron AC voltmeter
of class 1.5 accuracy suitable for 110 V phase to phase secondary suitably scaled.

5.3.19 1 No. - Voltmeter selector switch to indicate phase to phase & phase to neutral voltage of all
the three phases.

5.3.20 3 Nos. - Indicating lamps coloured Red,Amber Blue for PT supply.

5.3.21 2 Nos. - Test terminal blocks to test meters and relays with sealing arrangement.

5.3.22 1 No. - Blank lable on the front of kiosks at the top.

5.3.23 Door locks with keys for all doors.

5.3.24 Pair of base channel for grouting in floor.

5.3.25 Arrangement to check healthy trip circuit in all three phases (separate lamps for R phase, Y
phase and B phase) be provided.

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5.3.26 1 set - Self auxiliary plug and socket.

5.3.27 1 No. - ground bus system, size 50x6mm copper may be provided and the earthing stud shall be
capable of withstanding rated short circuit current and stud design shall be as per IS-133427 or
IEC -200.

5.3.28 1 No. - Audio-Visual Annunciations.

5.3.29 1 No. - Operation counter.

5.3.30 1 No. - Name plate at front and back of each kiosk.
5.3.31 1 set - 3 phase air insulated main copper bus bar of 630 amp. continuous current rating having
maximum current density 1.5 Amp./ MM2 with minimum cross sectional area 600 MM2
with PVC insulation or sleeves, STC rating 16 KA for 3 sec.
5.3.32 1 Set -Power Pack arrangement system as specified in cl. No. 5.2.14.
5.3.33 1 No. -Spring Charge Indication Lamp.

The busses within the cubical shall be of high conductivity electrolyte grade copper. The
Bus bar joints shall be silver plated and bolted in such a manner that initial contact pressure
around the square headed high tensile bolt will remain substantially undiminished at all
temperature upto rated full load temperature. The Bus support and bushings shall be of
epoxy resin cast type. All drop off from main bus to VCB and VCB to bushing terminations
shall be suitable for current rating of circuit breaker . All the bus bar shall be sleeved with
heat shrinkable sleeves of 12 KV voltage level (Insulated for a service voltage of 12 KV)
and bus bar shall be shrouded wherever possible. All the bus bar joints shall be shrouded
and where shrouding is not possible, it shall be taped with HV self amalgamation tape. All
the tap off bus bar connections inside panel and PT jumpers shall be sleeved with HT heat
shrinkable sleeves. Special care shall be taken in the design of bus bar system to provide
for thermal expansion and to minimize the chances of bus fault. Bimetallic washers shall
be provided at the joints of two different metal surfaces.
The bus supports and bushings shall be non hygroscopic non aging glass reinforced poly-
mer.

5.4 MAKE AND TYPE OF BOUGHT OUT ITEMS :

Make / type of each relay, indicating instruments, integrating instruments, control switch
for Circuit Breaker/Trip Transfer, selector switch for Voltmeter/Ammeter, Semaphore Indicator,
indicating lamps, annunciator, Push Button, A.C. Hooter/Bell, D.C. Hooter, Heater, Link Type
Test Terminal Block for testing of TVM, CFL Tube, 2/3 Pin Socket with Switch etc. shall be
clearly and invariably indicated in the GTP (Guaranteed Technical Particulars), bill of material
and unit price list. Only specific make accessories shall be indicated. The word "EQUIVA-
LENT/REPUTED MAKE" will not be given for consideration.

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The other makes of all bought out items shall be acceptable if it is of "ISI Marked" or type tested
for which manufacturer shall furnish attested Photostat copies of ISI Certificate/type test reports
not older than Ten years for the respective make offered, subject to prior approval of SE(MM-
II), JVVNL, Jaipur.

Further, the type test reports which could not be revalidated due to COVID pandemic, since
23.03.2020 will be considered valid up to 30.09.2022.

Other standard accessories which are not specifically mentioned but are required to be supplied
with circuit breaker kiosk of similar type and rating for efficient and trouble-free operation.

5.5 TEMPERATURE RISE :

The max. temperature rise of various parts of the circuit breakers when tested under rated condition
shall not exceed the specified values at a peak ambient temperature of 50 deg.C . The breaker may
be provided with silver plated contacts if necessary to meet the requirement of IS:13118/IEC:56
where higher temperature rise is permitted with silver plated contacts. The quantity of silver facing
shall be such that after carrying out one tenth of the total number of operations specified for mech.
Endurance test, there is a still continuous layer of silver on the contacts. The temperature rise
of CTs and PTs shall also not exceed the permissible values as per relevant Indian standards when
corrected for max. ambient temperature at site.

6. 0 TESTS :

6.1 TEST BEFORE DESPATCH : The 12 KV vacuum circuit breakers and accessories shall besub-
jected at maker's works before despatch, to the following tests as per relevant IS/IEC.

A) ROUTINE TESTS ON EACH UNIT AS PER RELEVANT STANDARDS :

(i) One minute power frequency voltage withstand dry

test on main circuit.
(ii) Voltage withstand test on control & auxiliary
circuits.
(iii) Measurement of the resistance of main circuit.
(iv) Mechanical operating test.
(v) Design and visual checks.

B) The following type tests shall be conducted on the material as per relevant standards:

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(i) Dielectric tests.
a) Lightning Impulse Voltage Test.
b) One Minute Power Frequency Test (Wet & Dry).
(ii) Short time withstand current and peak withstand current test.
(iii) Basic short circuit duties test.
(iv) Single phase short circuit test.
(v) Mechanical Operation test as per M-2 class.
(vi) Out of phase making & breaking test.
(vii) Capacitive Current Switching Test.
a) Cable Charging Test.
b) Single Capacitor Bank Current Switching Test.
(viii) Measurement of resistance of main circuit.
(ix) Temp. rise test.
(x) IP-55 Test (For cubicle/control cabinet).
(xi) Any other type tests not specified above but
covered as per amendment/latest edition of rele-
vant IS/IEC.

C) The type test reports of Circuit Breakers, Current Transformers, Potential Transformers,
Relays, Meters etc. shall be complete in all respect as per relevant IEC/ISS.

6.2 TYPE TESTS :

The 12 KV vacuum circuit breaker kiosk offered shall be fully type tested as per relevant
standards.

The manufacturer must furnish type test reports as per the qualification requirement of the Tender
Specification.

Where permitted in the relevant standard, a test specimen for type test may be a representative
sub-assembly/ a representative functional unit. An individual type test is acceptable for a change
of constructional detail, for any change in the design/type of type test report and the design/type
of offered against this specification, if the manufacturer can demonstrate and purchaser is satisfied
that this change does not influence the result of the individual type test. The manufacturer may
bring out in their offer all such changes made in components, materials, design etc. as the case
may be. The purchaser will interpret the meanings of drawings and specifications and shall have

558
the power to accept/reject any type test report which in his judgment is/is not in a manner accepta-
ble to him. The decision of Purchase Committee in this matter shall be final and binding to all.

However, the purchaser reserves the right to demand repetition of some or all the type tests
in presence of purchaser's representative. For this purpose, the manufacturer should indicate unit
rates for carrying out such type tests. These test charges shall not be taken into consideration for
bid evaluation.

Further, Type and Make for Vacuum Interrupter as well as for Breaker should be same for all type
tests and same shall be in the supply.

6.3 TEST ON BOUGHT OUT ITEMS :

Tests are not required to be performed on bought out equipments/items like motor, terminal con-
nector, etc. at the works of manufacturer. Furnishing Test Certificate of these items from the orig-
inal equipment manufacturers shall be deemed to be satisfactory evidence. Inspection of the tests
at Sub-contractors works will be arranged by the supplier whenever required.

6.4 ROUTINE/ACCEPTANCE TESTS :

(i) The following acceptance and routine tests shall be got conducted in presence of purchaser's
representative as per stipulation of the relevant standards, on each unit.
a) One minute power frequency voltage withstand dry test on main circuit.
b) Voltage withstand test on control & auxiliary circuits.
c) Measurement of the resistance of main circuit.
d) Mechanical operating test.
e) Design and visual checks

(ii) Inspection & tests on control gear.

In addition to the above tests at 6.4 (i) above specified by IEC, the following shall also be performed
at manufacturer's works in presence of purchaser's representative after completely assembling the
kiosk.

a) Checking wiring of circuits and their contacts.

b) Insulation resistance of complete wiring, circuit by circuit with all equipment mounted on the
panels.
c) Checking of operational protective schedule , instruments and meters.
d) Checking of phase faults between R&Y, Y&B and B&R phases. Kiosk should trip under
all three conditions.
(iii) Temp. rise test on one No. Kiosk in the first offered lot shall also be done in thepres-
ence of the purchaser's representative.
(iv) Any other tests not specified above but covered as per amendment/latest edition of
relevant IS/IEC.

6.5 TOLERANCE ON TEST RESULTS :

As per relevant standards/specification.

6.6 TEST AT SITE :

The purchaser reserves the right to conduct all tests on 12 KV circuit breakers after arrival at site
and the contractor shall guarantee test certificate figures under actual service conditions.

7.0 INSPECTION :

All the tests (as mentioned at Clause 6.4) and Inspection shall be made at the place of manufacturer
unless otherwise especially agreed upon by the manufacturer and purchaser at thetime of purchase.
The manufacturer shall afford the inspection officer(s) representing the purchaser all reasonable
facilities without charges, to satisfy him that the material is being furnished in accordance with
this specification. The purchaser has the right to have the tests carried out at his own cost by an
independent agency whenever there is a dispute regarding the quality of supply.

The Inspection may be carried out by the purchaser at any stage of manufacture/ before despatch
as per relevant standard.

Inspection and acceptance of any material under the specification by the purchaser, shall not relieve
the manufacturer 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. The Manufacturer
shall keep the purchaser informed in advance, about manufacturing programme so that arrange-
ments can be made for inspection.

The purchaser reserves the right to insist for witnessing the acceptance/ routine testing of the bought
out items.
The Manufacturer shall give 15 days advance intimation to enable the purchaser to depute his
representative for witnessing the acceptance and routine tests.

8.0 QUALITY ASSURANCE PLAN

1) The Manufacturer shall invariably furnish following information along with his offer,
failing which the offer shall be liable for rejection. Information shall be separately given
for individual type of equipment offered.
i) Statement giving list of important raw materials, names of sub-suppliers for the raw materi-
als, list of standards according to which the raw material are tested, list of tests
normally carried out on raw material in the presence of Supplier's representative,
copies of test certificates.
ii) Information and copies of test certificates as in (i) above in respect of bought out items.
iii) List of manufacturing facilities available.
iv) Level of automation achieved and list of areas where manual processing exists.
v) List of areas in manufacturing process, where stage inspections are normally carried
out for quality control and details of such tests and inspections.
vi) Special features provided in the equipment to make it maintenance free.
vii) The manufacturer should have adequate facilities to carryout accurately all required tests
during manufacturing and routine/acceptance tests as per relevant ISS/IEC standards at the
final end routine/acceptance. The supplier will ensure that all testing/measuring instru-
ments/apparatus are calibrated at regular periodicity from reputed test house as per relevant
standards and a certificate of testing authority is made available to purchaser's inspector at
the time of inspection. Such calibration certificates, in any case shall not beolder than one
year on the date of such tests".

viii) List of testing instruments and apparatus along with their last date of calibration, available
with the Manufacturer for testing of equipment specified and test plant limitation, if
any, vis-a-vis the type, special, acceptance and routine tests testing during manufacture
specified in the relevant standards. These limitations shall be very clearly brought out in
"Schedule of Deviations".

2) The Supplier shall also submit the following information to the Purchaser, along with draw-
ings/GTPs/BOM of ordered material, within 15 days of placement of order for purchaser’s
approval:-
i) Name of the raw material as well as bought out accessories and the names of sub- suppliers
selected from those furnished along with the offer.
ii) Type test certificates of the raw material and bought out accessories/items.
iii) Quality Assurance Plan (QAP) withhold points for Purchaser's inspection. The QAP and
Purchaser's hold points shall be discussed between the Purchaser and the Supplier before
the QAP is finalized.

3) The Supplier shall submit the routine test certificates of bought out items and raw material at
the time of routine testing of the fully assembled equipment.

9.0 DOCUMENTATION

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9.1 All drawings shall conform to International Standards Organization (ISO) `A', series of drawing
sheet/Indian Standards specification IS:13118/IEC-56. All drawings shall be in ink and suitable
for micro filming. All dimensions and data shall be in S. I Units.

9.2 List of drawings and documents

The manufacturer shall furnish four sets of following drawings along with his offer.

a) General outline and assembly drawings of the equipment i.e. breaker, CTs,PTs etc.

b) Graphs showing the performance of equipments in regard to magnetization characteristics.

c) Sectional views showing -

i) General Constructional features.
ii) the materials/ gaskets /sealings used.
iii) the insulation, the winding arrangements, method of connection of the primary/secondary
winding to the primary /secondary terminals etc.
iv) porcelain used and its dimensions along with the mechanical and electrical characteristics.

d) arrangement of terminal's and details of connection studs provided.

e) Name Plate

f) Schematic drawing

g) Type test reports in case the equipment has already been type tested.

h) Test reports, literature, pamphlets of the bought out items, and raw material.

9.3 The successful tender shall, within 2 weeks of placement of order, submit three sets of final versons
of all the above said drawings for purchaser's approval. The purchaser shall communicatehis com-
ments/approval on the drawings to the supplier within four weeks. The supplier shall,if neces-
sary, modify the drawings and resubmit three copies of the modified drawings for owners approval
with in two weeks from the date of owner's comments. After receipt of owner's approval, the
supplier shall within two weeks, submit 12 prints and two good quality reproducibles of the ap-
proved drawings for purchasers use.

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9.4 Six sets of the type test reports, duly approved by the purchaser, shall be submitted by the supplier
for distribution before commencement of supply. Adequate copies of acceptance and routine test
certificate, duly approved by the purchaser shall accompany the despatch consignment.

9.5 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 purchaser. All manufac-
turing and fabrication work in connection with the equipment prior to the approval of thedrawing
shall be at the supplier's risk.
9.6 16 sets of nicely printed and bound volumes of operation, maintenance and erection manuals in
English language, for each type and rating of equipment supplied shall be submitted by the supplier
for distribution, prior to the despatch of the equipment. The manual shall contain all the drawings
and information required for erection, operation and maintenance of the circuit breaker. The man-
ual shall also contain a set of all the approved drawings, type test reports etc.

9.7 Approval of drawings/work by purchaser shall not relieve the supplier of his responsibility and
liability for ensuring correctness and correct interpretation of the drawings for meeting the require-
ment of the latest revision of applicable standards, rules and codes of practices. The equipment
shall conform in all respects to high standards of engineering, design, workmanship and latest re-
visions of relevant standards at the time of ordering and purchaser shall have the powerto reject any
work or materials which, in his judgement is not in full accordance therewith.

10. PACKING AND FORWARDING

10.1 The equipments shall be packed in crates suitable for vertical/horizontal transport as the case may
be, and suitable to withstand handling during transport and outdoor storage during transit. The
supplier 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 symbol. Wherever necessary, proper arrangement for lifting, such
as lifting hooks etc. shall be provided. Any material found short inside the packing cases shall
be supplied by supplier without any extra cost.

10.2 Each consignment shall be accompanied with a detailed packing list containing the following infor-
mation :

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.
g) Bill of material indicating contents of each package.

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10.3 The supplier shall ensure that the packing list and bill of material are approved by the purchaser
before despatch.

11.0 Optional Spares

The manufacturer shall also recommend optional spares that will be required for breakers along
with their total and unit prices. However, the prices of operation spares will not be considered for
bid evaluation.

12.0 PERFORMANCE WARRANTY PERIOD :

The performance warranty period shall be 5 (Five) years from the date of receipt of equipment
along with its all accessories.

The amount of performance security shall be 2.5 percent of the amount of supply order in case of
procurement of goods and services. In case of Small Scale Industries of Rajasthan it shall be 0.5
percent of the amount of quantity ordered for supply of goods and in case of sick industries, other
than Small Scale Industries, whose cases are pending before the Board of Industrial and Financial
Reconstruction (BIFR), it shall be one percent of the amount of supply order, which is required to
be valid for 5 years.

Successful manufacturer shall attend the complaint within 30 days from the date of receipt of
complaint. The date of receipt of complaint shall be treated as the date of E-mail/ FAX of com-
plaint by the field officer/ stores/ Purchaser. If the supplier fails to attend the complaint within30
days from the date of receipt of complaint intimated by the field officer/ purchaser then penalty
@1/4% per week or part thereof for first 4 weeks in case delay is exceeds more than 4 weeks then
@1/2% per week or part thereof shall be charged for entire delay, subject to a maximum of 10%
of the breaker. This penalty will be in addition to the penalty leviable delay in delivery of material.

In case firm fails to attend the complaint within 120 days from the date of intimation, the cost of
the VCB shall be withheld from firm’s financial hold.

Further to this, in case of emergency, breaker can be get rectified by the sub-divisional officers/
M&P officers (as authorized by Nigam) at the risk & cost of the supplier firm, by obtaining quo-
tation from three firms, for same item/equipment, meeting the general requirement of specifica-
tion. The rectification of breaker means satisfactory performance report duly signed by the sub-
divisional officers/ M&P officers (as authorized by Nigam) i.e. in-charge of 33/11 KV Sub-Sta-
tion.

564
SECTION- (PART-B)
1 SCOPE

This specification is intended to cover the installation & commissioning of 12 KV Outdoor Vac-
uum Circuit Breaker (Kiosks), complete in all respect at various 33/11 KV Sub-Stations underJai-
pur Discom/Ajmer Discom/Jodhpur Discom.

2.0 INSTALLATION & COMMISSIONING OF VCB

The 12 KV Outdoor Vacuum Circuit Breaker Kiosks supplied shall be installed & commissioned
by the successful manufacturer, at various 33/11 KV Sub-Stations under Jaipur Discom/ Ajmer
Discom/ Jodhpur Discom. The name of 33/11 KV Sub-Stations shall be intimated at the time of
despatch instructions/ stores.

3.0 ACTIVITY

The following main activities are to be carried out by the supplier for installation & commissioning
of 12 KV Outdoor Vacuum Circuit Breaker Kiosks:-

a) Foundation of Bolts along with grouting.

b) Installation & Commissioning of Kiosk.
c) Laying & connection of control cables from breaker to Control & Relay panel (Control
cables shall be supplied by Nigam).
d) Connection of Earthing of breaker from the earth mesh of the GSS. Providing M.S. flat
shall be in the scope of supplier.
e) All Civil works related with foundation and installation & commissioning of 12 KV
Outdoor VCB Kiosks.

Note:- The M.S. Earthing & Foundation bolts required for Installation & Commissioning
shall be provided in a packet and shall put up in each breaker.

4.0 CIVIL FOUNDATION WORK:-

The foundation & grouting work along with all civil works required for installation of 12 KV
outdoor vacuum circuit breaker kiosk shall be carried out by the supplier. The foundation drawing
shall be furnished by the successful manufacturer(s), which shall be approved by SE(MM) in con-
sultation with SE(Civil).

5.0 INSTALLATION & COMMISSIONING OF KIOSK

Installation & commissioning of 12 KV Outdoor Vacuum Circuit Breaker Kiosks complete with
accessories including use of special tools & conducting all pre-commissioning tests before ener-
gisation shall be carried out by the supplier. PG/T-Clamps of required size to connect
565
incoming & outgoing terminals of VCB to main bus bar shall be arranged by the supplier, however,
required ACSR conductor for jumpers shall be arranged by the Nigam.

The agency should engage team of experienced Engineers & skilled staff for the purpose of In-
stallation & Commissioning of 12 KV Outdoor Vacuum Circuit Breaker Kiosks.

Mainly following pre-commissioning tests shall be carried out:-

a) Visual inspection.
b) Cleaning
c) Testing of relays/ CTs/PTs.
d) Testing of current circuitry by primary injection
e) Testing of breaker by primary injection.
f) IR value.
g) Checking of various equipments viz. Ammeter, Voltmeter, Energy meter etc. and alarms/
flags/ trip circuit healthiness etc.

A) SCHEDULE OF EQUIPMENTS, FITTING & ACCESSORIES :

12 KV 630 Amps Vacuum circuit breakers kiosks for out door installation :

5.3.1 1 No. - 12 KV 630 Amp. Vacuum Circuit Breaker horizontal fixed type with provision of manual
tripping by means of push button and emergency shunt tripping.

5.3.2 1 No. - AC Motor charged spring operated closing mechanism or magnetic actuator type closing
mechanism.

5.3.4 3 Nos. - Single phase 12 KV Current Transformer ratio 400-200-100/5-5A suitable for metering
and protection. The class of accuracy shall be 0.5 for metering and 5P15 for protection. Rated
burden (output) shall be 15 VA for each secondary winding and it should not be less than suitable
566
for tripping arrangement provided. Instrument security factor for metering core shall not be
exceed 5.

5.3.5 6 Nos. - Rigid type bimetallic/ aluminium alloy terminal connector suitable for ACSR (10%
Panther and 90% Dog Conductor) for both horizontal/ vertical take-off.

5.3.6 1 No. - Mechanical ON/OFF indicator.

5.3.7 1 No. - Operating handle for independent manual closing mechanism.

5.3.8 1 No. - Red indicating lamp for ON indication.
5.3.9 1 No. - Green indicating lamp for OFF indication.
5.3.10 Spare auxilliary contacts/switch having minimum 4 NO + 4 NC
5.3.11 1 No. - Flush mounting pattern 96x96 sq.mm Moving Iron ammeter of class 1.5 accuracy
suitable scaled for 5 Amps. CT secondary.
5.3.12 1 No. - Ammeter selector switch to indicate phase current in all three phases and with OFF
position.
5.3.13 1 No. – Numerical 3 O/C + E/F relay.
5.3.14 1 No. HT TVM of accuracy class 0.5S as per latest specification of JVVNL.
5.3.15 2 Nos. - 240 V AC single phase 80 or 100 watt anti condensation heaters with thermostat and
switch.
5.3.16 1 No. - Automatic door illumination lamp with switch.
5.3.17 3 Nos. - 11000/110 V single phase voltage transformers each having 100 VA/phase burden &
class of accuracy 0.5 suitably connected to meters and indicating instruments etc.

5.3.18 1 No. - Flush pattern switch board mounting pattern 96x96 sq. mm moving iron AC voltmeter
of class 1.5 accuracy suitable for 110 V phase to phase secondary suitably scaled.

5.3.19 1 No. - Voltmeter selector switch to indicate phase to phase & phase to neutral voltage of all
the three phases.

5.3.20 3 Nos. - Indicating lamps coloured Red,Amber Blue for PT supply.

5.3.21 2 Nos. - Test terminal blocks to test meters and relays with sealing arrangement.

5.3.22 1 No. - Blank lable on the front of kiosks at the top.

567
5.3.23 Door locks with keys for all doors.

5.3.24 Pair of base channel for grouting in floor.

5.3.25 Arrangement to check healthy trip circuit in all three phases (separate lamps for R phase, Y phase
and B phase) be provided.

5.3.26 1 set - Self auxiliary plug and socket.

5.3.28 1 No. - Audio-Visual Annunciations.

5.3.29 1 No. - Operation counter.

568
SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS OF 12 KV OUT-
DOOR VCBKIOSKS

Sl. To be furnished by the

PARTICULARS
No. Manufacturer
CIRCUIT BREAKERS
NAME OF MANUFACTURER &
1
COLLABORATOR, IF ANY

(A) OFFICE ADDRESS OF MANUFACTURER

(B) WORKS ADDRESS

2 CONSTRUCTION TYPE OF BREAKER

3 NO. OF POLES
4 CLASS
5 RATED VOLTAGE
6 RATED INSULATION LEVEL
LIGHTENING IMPULSE WITHSTAND
(a)
VOLTAGE
ONE MIN. POWER FREQ. WITHSTAND TEST
(b)
VOLTAGE KV (rms)
ONE MIN. POWER FREQ. WITHSTAND TEST
(c)
VOLTAGE FOR AUXILIARY CIRCUITS KV (rms)
7 RATED FREQUENCY
8 RATED NORMAL CURRENT
RATED SHORT CIRCUIT BREAKING CURRENT/
9
CAPACITY
RATED SHORT TIME WITHSTAND CURRENT
10
AND ITS DURATION
RATED TRANSIENT RECOVERY VOLTAGE
11
FOR TERMINAL FAULTS
12 RATED SHORT CIRCUIT MAKING CURRENT
13 RATED OPERATING SEQUENCE
14 FIRST POLE TO CLEAR FACTOR
15 (a) OPENING TIME

569
15 (b) CLOSING TIME
TOTAL BREAK TIME MEASURED FROM THE
16
INSTANT OF TRIP CIRCUIT ENERGISATION
(a) AT 10% BREAKING CAPACITY
(b) AT 100% BREAKING CAPACITY
17 PROTECTION CLASS OF KIOSK
18 CONTACT TRAVEL
(a) LENGTH OF TRAVEL

(b) RATE OF TRAVEL

19 MAKE TIME
20 SPRING CHARGING TIME
21 DEGREE OF VACUUM PROVIDED IN VCB

22 OPERATING MECHANISM OF CIRCUIT

BREAKER AND ITS ASSOCIATED EQUIPMENT
22.1 TYPE OF CLOSING MECHANISM
WHETHER THE CIRCUIT BREAKER IS TRIP
22.2 FREE OR FIXED TRIP AND WHETHER IT IS
WITH LOCKOUT PREVENTING CLOSING
RATED SUPPLY VOLTAGE OF CLOSING
22.3
MECHANISM
CURRENT REQUIRED AT RATED SUPPLY
22.4
VOLTAGE TO CLOSE THE CIRCUIT BREAKER
RATED SUPPLY VOLTAGE OF SERIES/ SHUNT
22.5
OPENING RELEASE
CURRENT REQUIRED AT RATED VOLTAGE
22.6
FOR SERIES/ SHUNT OPENING RELEASE
NO. AND TYPE OF SPARE AUXILIARY
22.7
SWITCHES/ CONTACTS

CURRENT REQUIRED AT RATED SUPPLY

22.8
VOLTAGE BY OTHER AUXILIARIES

23 OTHER INFORMATION
23.1 (a) TYPE OF BREAKER (DRAWOUT/ FIXED)
(b) TYPE OF ISOLATION (VERTICAL/
HORIZONTAL)
23.2 TYPE OF ARC CONTROL DEVICE
23.3 CONTACTS
(a) MAIN
(I) TYPE
(II) MATERIAL
(III) SILVER FACING PROVIDED

(iv) DESIGN CONTACT PRESSURE

(b) ARCING CONTACTS

(I) TYPE

(II) MATERIAL
(III) SILVER FACING PROVIDED
(IV) DESIGN CONTACT PRESSURE
23.4 LIFE
(I) MECHANICAL OPERATIONS
(II) ELECTRICAL OPERATIONS
(III) SHORT CIRCUIT OPERATIONS

MAXIMUM TEMPERATURE RISE OVER AN

23.5
AMBIENT TEMPERATURE OF 50° C

23.6 TRANSIENT BEHAVIOUR DETAILS

(a) PF RECOVERY VOLTAGE BETWEEN PHASES
(b) PEAK TRANSIENT RECOVERY VOLTAGE
© RATE OF RISE OF RECOVERY VOLTAGE
WHETHER THE CIRCUIT BREAKER IS
23.7
RESTRIKE FREE
23.8 DETAILS OF INTERLOCKS PROVIDED
DERATING FACTOR FOR SPECIFIED 50 DEG. C.
23.9 AMBIENT TEMPERATURE AND SITE
CONDITION, IF ANY
23.10 MAXIMUM CHOPPING CURRENT
23.11 VACUUM INTERRUPTED DETAILS
MAKE AND CODE NUMBER OF VACUUM
(a)
BOTTLE
(b) PRESSURE INSIDE INTERRUPTER
MANUFACTURER'S CODE NO. / REFERANCE
(C)
STANDARD
23.12 CONTACT WEAR INDICATION
MAX. OVER VOLTAGE ON SWITCHING
23.13
TRANSFORMER ON NO LOAD.

24 THICKNESS OF SHEET STEEL

25 WHETHER COLD ROLLED OR HOT ROLLED

11 KV VOLTAGE TRANSFORMER

1 MANUFACTURER'S NAME

2 TYPE DESIGNATION
3 HIGHEST EQUIPMENT VOLTAGE
4 NO. OF PHASES
5 SYSTEM EARTHING
6 INSULATION LEVEL
ONE MINUTE POWER FREQUENCY
(a)
WITHSTAND VOLTAGE
(I) PRIMARY WINDING
(II) SECONDARY WINDING
(b) IMPULSE WITHSTAND VOLTAGE
7 FREQUENCY
TRANSFORMATION RATIO
RATED OUTPUT
ACCURACY CLASS
WINDING CONNECTION
RATED VOLTAGE FACTOR
13 TYPE
13.1 RESIN CAST OR OIL FILLED
13.2 WHETHER SINGLE PHASE OR THREE PHASE
13.3 TYPE OF FUSES PROVIDED
(a) PRIMARY
(b) SECONDARY
© MAKE
CURRENT TRANSFORMERS

1 MANUFACTURER'S NAME

572
2 TYPE DESIGNATION
3 RATED VOLTAGE
TYPE OF INSULATION WHETHER OIL FILLED
4
OR RESIN CAST
5 INSULATION LEVEL
ONE MINUTE POWER FREQUENCY
5.1
WITHSTAND VOLTAGE
5.2 IMPULSE WITHSTAND VOLTAGE
5.3 PF WITHSTAND VOLTAGE FOR SECONDARY
6 FREQUENCY
7 TRANSFORMATION RATIO
8 RATED OUTPUT

9 CLASS OF ACCURACY

10 INSTRUMENT SECURITY FACTOR

SHORT TIME THERMAL CURRENT AND ITS
11
DURATION
12 SECONDARY WINDING RISE AT 75 DEG.C
13 KNEE POINT VOLTAGE
14 MAXIMUM EXCITING CURRENT IN RMS
RELAYS

1 MANUFACTURER'S NAME

2 TYPE DESIGNATION
3 RATED CT SECONDARY CURRENT.

4 TAP RANGE

5 VA BURDEN
1) HIGHEST TAP
2) LOWEST TAP
6 RATED VOLTAGE OF COIL FOR OPERATION.
WHETHER RELAY IS ABLE TO STORE AMINI-
MUM OF FIVE FAULT VALUES INCLUDING
7
FAULT LEVEL AND PHASE WITH DATE &
TIME.
WHETHER RELAY IS MOUNTED IN FLUSH
8
PATTERN ON THE PANEL BOARD.

573
WHETHER TEST BLOCKS PROVIDED AS PER
9
SPEC.
WHETHER NUMERICAL RELAY IS WITH
COMMUNICATION FACILITY AND STANDARD
10
OPEN PROTOCOL / SCADA COMPATIBILITY
ALONGWITH IED FOR PURPOSE OF SCADA
WHETHER COMMUNICATION ON RS-485 PORT
11
PROTOCOL PROVIDED.
12 TYPE OF CHARACTERISTIC
13 DESCRIPTIVE LEAFLET ATTACHED OR NOT
14 ACCURACY CLASS OF CT NEEDED
RANGE OF SETTING FOR OVER CURRENT
15
AND EARTH FAULT PROTECTION.
16 WHETHER DRAWOUT TYPE

MEMORY TYPE STATIC HT TVM ENERGY

METER

1 NAME OF MANUFACTURER
2 TYPE OF METER
3 CLASS OF ACCURACY

4 REFERENCE VOLTAGE

5 BASIC CURRENT
6 MAXIMUM CONTINUOUS CURRENT
WHEATHER SEALING ARRANGEMENT
PROVIDED ON FRONT SIDE OF METER FOR
7 METER BODY/ TERMINAL COVER / MD RESET
BUTTON/ COMMUNICATION PORT.

PROGRAMMED INTO METER MEMORY FOR

8
IDENIFICATION THROUGH CMRI
BURDEN AND WATT LOSS OF VOLTAGECIR-
9
CUIT PER PHASE.
PUSH BUTTON MODE AS PER SPECIFICATIONS
10
PROVIDED OR NOT
MEMORY NON- VOLATILE OR BATTERY
11
BACKED

574
WHETHER ENERGY METER CONFIRMING TO
12 IS AND HAVING ALL THE PARAMETER
REQUIRED AS PER LATEST SPEC. OF JVVNL.
INDICATING AND INTEGRATING
INSTRUMENTS
(I)
1 MANUFACTURER'S NAME
2 TYPE DESIGNATION
3 ACCURACY CLASS
THE VA BURDEN AT NORMAL CURRENT AND
4
OR NOMINAL VOLTAGE
(a) CURRENT COIL
(b) POTENTIAL COIL
TRANSFORMATION RATIO OF INSTRUMENT
TRANSFORMER FOR WHICH THE INSTRU-
5
MENT HAS BEEN ADJUSTED, IF RELEVANT

6 SIZE
WHETHER SUITABLE FOR SHEET STEEL
7
MOUNTING
8 COLOUR FINISH
9 SHORT DURATION OVER LOAD CAPACITY
MAKE AND TYPE OF SELECTOR SWITCH FOR
10
AMMETER/ VOLTMETER
(ii) CONTROL SWITCHES
1 MANUFACTURER'S NAME
2 TYPE DESIGNATION
3 TYPE OF HANDLE PROVIDED
4 NO. OF POSITION
5 NO. OF CONTACTS
(a) NORMALLY CLOSED
(b) NORMALLY OPENED
6 MAKING/ BREAKING CAPACITY
WHETHER SPRING RETURNED TO NORMAL
7
OR STAY PUT TYPE
8 TYPE OF LOCK PROVIDED
(iii) INDICATING LAMPS

575
1 MANUFACTURER'S NAME
2 TYPE DESIGNATION
3 OPERATING VOLTAGE
4 SIZE OF LAMP
5 WATTAGE OF LAMPS
6 COLOUR OF LAMP BODY
(IV) SWITCH BOARD WIRING
1 INSULATION OF WIRING
2 SIZE OF WIRING CONDUCTOR FOR
(a) CT CIRCUITS
(b) PT CIRCUITS
© AC SUPPLY CIRCUITS
(d) OTHER CIRCUITS
SIZE OF EARTHING BAR FOR SAFETY
3
EARTHING
4 TYPE OF TERMINALS PROVIDED ON WIRING
5 CONDUCTOR MATERIAL
6 COLOUR USED
(a) AC CIRCUITS
(I) I PHASE
(II) II PHASE
(III) III PHASE
(IV) NEUTRAL
(V) EARTH
(b) DC CIRCUITS
7 IDENTIFICATION OF SUFFIX USED FOR
a) METERING CIRCUITS
(b) O/C AND E/F INDICATION
8 AC AUXILIARY CIRCUITS
MICELLANEOUS INFORMATION

1 BUSHINGS

(a) MAKE AND DRAWING NO.

(b) TYPE OF BUSHING
( c) CREEPAGE DISTANCE

576
(I) TOTAL

(ii) PROTECTED

ONE MINUTE POWER FREQUENCY

(d)
WITHSTAND VOLTAGE FOR BUSHING
DRY
WET
(e) IMPULSE WITHSTAND VOLTAGE
(f) REFERENCE STANDARD
PERMISSIBLE SAFE CANTILEVER LOADING
(g)
ON BUSHING
CATALOGUE NO. OF BUSHING OFFERED AND
(h)
ITS MECHANICAL STRENGTH
2 MOTOR
a) MAKE
(b) WATTAGE
( c) RATED VOLTAGE
(d) PROTECTION EQUIPMENT
(e) CLOSING CONTACTOR
3 TERMINAL CONNECTORS
a) MAKE/ MATERIAL
(b) RATED CONTINUOUS CURRENT
( c) RATED SHORT TIME CURRENT FOR 3 SEC.
MAXIMUM TEMPERATURE RISE OF
TERMINAL CONNECTOR OVER AMBIENT
(d)
TEMPERATURE OF 50 DEG. C AND MAXIMUM
TEMPERATURE ATTAINED.
4 PAINT SHADE OF OUTDOOR KIOSK
5 MAIN BUS BAR
a) SIZE
(b) MATERIAL (COPPER ONLY)
( c) RATED SHORT TIME CURRENT FOR 3 SEC.
(d) CURRENT DENSITY
6 INTER CONNECTING BUS BAR
a) SIZE
(b) MATERIAL (COPPER ONLY)

577
( c) RATED SHORT TIME CURRENT FOR 3 SEC.
(d) CURRENT DENSITY
7 CT WINDINGS
(a) PRIMARY
(i) NO. OF TURNS
(ii) CROSS SECTIONAL AREA
(iii) MATERIAL
(b) SECONDARY
(i) NO. OF TURNS
(ii) CROSS SECTIONAL AREA
(iii) MATERIAL
8 LIST OF INTERLOCKS
(a) MECHANICAL
(b) ELECTRICAL
9 OVERALL DIMENSIONS
FOR VACUUM CIRCUIT BREAKER KIOSK
9.1
COMPLETE
9.2 CIRCUIT BREAKERS
IMPACT FOR FOUNDATION DESIGN TO
INCLUDE DEAD LOAD PLUS IMPACT VALUE
9.3
ON OPENING AT MAXIMUM INTERACTING
RATING IN DEAD LOAD
10 CONSTRUCTIONAL FEATURES
MASS OF COMPLETE CIRCUIT BREAKER WITH
(a)
MECHANISM AND VACUUM BOTTLE
(b) MASS OF VACUUM BOTTLE
( c) NO. OF BREAKERS IN SERIES PER POLE.
(d) MINM. CLEARANCE IN AIR.
(I) BETWEEN POLES
(ii) TO EARTH
11 ARRANGEMENT PROVIDED
POLE DISCREPANCY
(a) TRIP FREE / FIXED TRIP
(b) ANTI PUMPING
12 CONNECTION FOR CT
(a) SIZE

578
(b) MATERIAL
13 CONNECTION FOR PTs
(a) SIZE
(b) MATERIAL

Name of Firm
Signature of Manufacturer
Designation & Seal
Date
TECHNICAL SPECIFICATION FOR PURCHASE OF MS FLAT OF SIZE 50X6MM

1. SCOPE:-

1.1 This specification covers for design, manufacture, stage testing, inspection & testing before
dispatch, pac king supply and delivery of steel plates, strips, section, flats, bars etc. for use
in structural work.
1.2 These sections shall be suitable for welded, bolted and riveted structures and for general
engineering purposes.
1.3 Where welding is employed for fabrication and guaranteed weld-ability is required,
welding procedure should be as specified in IS:9595:1980.

2.0 Standards:

Except as modified in this specification, the material, and purpose of material cov-
ered under “SCOPE” clause 1.1 to 1.3 shall confirm to the latest revis ion with amend-
ments thereof the following bureau of Indian Standard & where the relevant ISSis not
available, the material/equipment should comply the latest B.S.S.

S.No. Bureau Title

o
f Indian
Standards.
IS No.
1 2062 Steel for General structural purpose (Fifth revision)
2 228 Method of chemical analysis of steel (second revis ion)
3 1608/1995 Mechanic al testing of metals- Tensile testing (Second
Revision)
4 1757/1988 Method for charpy impact test (V notch) for metallic material
(second revision)
5 3803 Part.I/ Steel-convers ion of elongation values Part.I Carbon & alloy
1989 Steels (Second revis ion)
6 8910/1978 Ground technical delivery requirements for steel & steel
products.
7 10842/1984 Testing & evaluation procedure for Y groove crackability test.
8 1786/1985 High Strength Deformed Steel Bars and wires for concrete
reinforcement.
9 1599/1985 Method for bend test(second revision)
10 1052/1985 Rolling and cutting tolerances for hot rolled steel products
(Third Revision).

3.0 CLIM ATIC CONDITIONS:

The steel sections covered under this specification are to be used for fabrication of various
structures to be erected in the state of Rajasthan and shall be suitable for the climatic
580
conditions prevailing in the area as per details given below:-

Location In the State of Rajasthan

Max. ambient air temperature (deg.C) 50
Min. ambient air temperature (deg.C) -2.5
Average daily ambient air temperature (deg.C) 32.2

Max. relative humidity (%) 100

Min. relative humidity (%) 50
Average rainfall per annum (mm) 150 to 1000
No. of rainy days per annum 70
Max. altitude above mean sea level (metres) 100-1000
Max. wind pressure (kg per sq.m) 195
Isoceraunic level (days per annum) 25 (Thunder Storm)
Seismic Level (horizontal acceleration) 0.08 g

Note:- Moderately hot and humid tropical climate, conductive to rust and fungus growth. The
climatic conditions are also prone to wide variations in ambient conditions. Smoke is also pre-
sent in the atmosphere, heavy lightning also occurs during June to October.

4.0 REQUIREMENT

The approximate quantity required of various steel sections are indicated in the Schedule-I
(schedule of requirement along with approximate weight).

The quantities mentioned in the schedule of requirement (Schedule-I) are provisional. How-
ever, the net quantity shall be determined later-on at the time of finalization of the tender. The
purchaser reserves the right to increase or decrease the tendered quantity/ weight of structure.
The purchaser also reserves the right to split the quantity and to entrust the orderfor the
supply on one or more Suppliers. The manufacturer shall agree to supply part quantity ordered
on him at the rates/ prices mentioned in the tender or accepted by the purchaser.

5.0 GENERAL TECHNICAL REQUIREMENT

The technical, parameters to which the steel sections shall confirm are as under:-

5.1 MECHANICAL PROPERTIES:

a Grade A
b. Designation Fe 410 W A
c. Tensile strength min., mpa 410
d. Yield strength min., mpa <20, 20-40 >40
mm mmmm
250 240 230
e. Elongation percent, min.(at gauge length 23
5.65xSQRT (So)
f. Internal Diameter of Bend min. 3t
g. Charpy V Notch Impact energy J, min.

581
5.2 CHEMICAL COMPOSITION
a Grade A
b. Designation Fe 410 W A
c. Ladle Analys is, percent, Max. C- 0.23
Mn- 1.50
S - 0.050
P - 0.050
Si - 0.40

d. Supply condition. As rolled

e. Carbon equivalent (CE) Max. 0.42
f. De-oxidation mode

5.3 MASS & STANDARD LENGTH

S.No Name of the Steel Size in mm Mass in Kg. Required length

Sections Per Metre in metre
(Standard
length)
1 M.S. Flat 50x6 As per ISS 8-11

5.4 TOLERANCE IN ST ANDARD LENGTH:- ±5% for all sections

5.5 TOLERANCE IN DIMENSIONS:- As per relevant IS

5.6 PACKING AND MARKING:-

a) Packing As per ISS
b) Marking The steel sections shall be marked with colour
code as per IS and each product shall carry a tag
or be marked with the manufacturer name or trade
mark.

5.7 WORKMANSHIP

i) All finished steel shall be well and clearly rolled to dimensions, sections and masses specified.
The finished material, shall be reasonably free from surface flows, laminations, rough/jagged
and imperfect edges and other harmful defects.
ii) Minor surface defects may be removed by the manufacturer.

582
6.0 IDENTIFICAT ION MARKING:

Each product shall carry a tag or be marked with the name or trade mark of the manufacturer.
Designation of steel should also be marked on the product tag.

The ends of the rolled product shall be painted with a colour code “Green” for Grade ‘A’.

7.0 QUALITY ASSURANCE PLAN:

The manufacturer shall invariably furnish the following information along-with his offer, fail-
ing which the offer shall be liable for rejection. Information shall be separately given forindi-
vidual type of steel section.

i) Statement giving lis t of important raw materials, names of sub-supplier for the raw
material, lis t of standards according to which the raw material are tested, list of tests
normally carried out on raw material in presence of manufacturers representatives,
copies of tests certificates.
ii) Information and copies of test certificates as in (i) above in respect of bought out
items.
i) List of manufacturing facilities available
iv) Level of automation achieved and list of areas where manual processing exists.
v) List of areas in manufacturing process, where stage inspections are normallycar-
ried out for quality control and details of such tests and inspections.

The supplier shall submit the routine test certificates of bought out items and raw material at
the time of routine testing.

8.0 PACKING & FORWARDING

The various sections of steel shall be packed in such a manner so that same should be able
to resist hazard involved in transportation, unloading, stacking etc.

9.0 TESTS

Tests before dispatch:- The various steel sections before dispatch shall be subject tofollow-
ing tests as per IS:2062 at the maker’s works.

ROUTINE TEST/ACCEPTANCE TEST:

(i) Dimensional checking & visual inspection.
(ii) Weight checking
(iii) Chemical composition test
(iv) Mechanical properties tests

10. INSPECTION

The inspection shall be carried out on each lot separately. The following number of

583
pieces selected at random shall be subjected to inspection/ testing and checking.

a) Workmanship and dimension checking: 1 samples from each 50 MT or

part thereof.

b) Chemical test : One sample of each section from the entire lot of
material offered for
inspection.

c) Tensile test : One sample from every 50 MT or

part thereof of each section.
d) Bend test : One sample from every 50 MT or
part thereof of each section.

All the tests (as mentioned at clause 9) and inspection shall be carried out at the place of man-
ufacturer unless otherwise especially agreed upon by the manufacturer and purchaser at the
time of purchase. The manufacturer shall afford all reasonable facilities without charges forthe
inspecting officer(s), to satisfy him that the material is being furnished in accordance with
this specification. The purchaser has the right to have the tests carried out at his own cost by
an independent agency whenever there is a dispute regarding the quality of supply.

The inspection may be carried out by the purchaser at any stage of manufacture/ beforedis-
patch as per relevant standard.

Inspection and acceptance of any material under the specification by the purchaser, shall not
relieve the manufacturer of his obligation of furnishing material in accordance with the specifi-
cation and shall not prevent subsequent rejection if the material is found to be defective.The
manufacturer shall keep the purchaser informed in advance, about manufacturing programme
so that arrangements can be made for inspection.

The test for chemical and mechanical properties shall have to be arranged in presence of
Inspecting officer at recognized Lab.

11. FINANCIAL RESOURCES AND EXPERIENCE :

The manufacturer shall submit along with the tender, the details regarding his previous experi-
ence in performing similar comparable work, the technical strength and manufacturingfacili-
ties available and also financial capability. The manufacturer is further requested to furnish the
information, particularly on the following points :-

a. Standing of the firm as manufacturer or authorized dealer/sole selling agent/ sole

distributor
b. Approximate tonnage, fabricated so far at his works on monthly basis.
c. Testing facilities available at their works.

584
TECHNICAL SPECIFICATION FOR SUPPLY OF M.S.BOLTS & NUTS OF ASSORTED SIZE

1. SCOPE

The specification covers the manufacture, design, inspection, testing before dispatch, marking, packing and delivery
at the consignees headquarter of M.S. Bolts & Nuts for 33 KV & 11 KV Sub-transmission line/sub-station, and
operation & LT maintenance work.

2. CLIMATIC CONDITIONS

I. Peak ambient temperature 50 Degree C

II. Maximum average ambient temperature 40 Degree C

III. Maximum temperature attainable 60 Degree C

IV. Maximum relative humidity 100 %

V. Minimum relative humidity 50 %

VI. Average number of thunder storm days per annum 40

VII. Average number of rainy days per annum 100

VIII. Average annual rainfall 10-100 cm

IX. Maximum wind pressure 100 Kg/sq.m

X. Altitudes not exceeding 1000 mtrs

3. REQUIREMENT:

The tendered quantity of MS Bolts & Nuts for each size is as under:

S.No. Particulars of material required Qty. in MT

1 M.S. Bolts & Nuts
a) M16x65 N(2.5”) 50
b) M16x100 N(4”) 57
c) M16x150 N(6”) 50
d) M16x200 N(8”) 50

Total 207.00

The above tendered quantity is provisional. However, net quantity shall be determined later-on at the time
of finalization of this tender. The purchaser also reserves the right to increase or decrease the tendered
quantity. The purchaser also reserves the right to split the quantity and to entrust the order for the supply
on one or more suppliers. The manufacturer shall agree to supply part quantity ordered on him at the rates/
prices mentioned in the tender or accepted by the purchaser.

4. . STANDARDS

The relevant Indian Standard Specification(latest amended) to which the material shall conform are as follows:-

S.No. Particulars For M.S. Bolts & Nuts

1 Grade Grade ”C” as specified in IS-1367(Part-2)/2002.
2 Dimension Nominal dia-16 mm length of bolt(IS-1363 Pt-I-1992
100,150, 200, 250,300 mm Length of Nut-15 mm
(IS-1363-Part-III/1992 (with latest amendments)
3 Raw material Low or medium carbon steel.
4 Tolerance As per (IS:1367 Part-II)
5 Chemical composition For Bolt:IS:1367 Part(Pt.III/1991)
For Nut: IS:1367 (Pt.VI)/1980
6 Testing For Bolt:IS:1367 Part(Pt.III/1991)
For Nut: IS:1367 (Pt.VI /1980)
7 Sampling IS:2614-1969 for Bolts & Nuts

5. FINANCIAL RESOURCES AND EXPERIENCE

a. Standing of the firm as manufacturer/supplier

b. Approximate qty., manufacture/supplied so far at his works on monthly basis.
c. Testing facilities available at his works
6. WORKMANSHIP

The characteristic and properties of finished product required are as detailed below:-

For Bolts & Nuts: (Properties class)

i) Properties class for bolts required. : 4.6 as specified in IS:1367-Part-II

ii) Properties class for nuts required : 5 as specified in IS:1367-Part-III/1980

CHEMICAL COMPOSITION

i) For Bolts: (IS-1367 Part-III) 1991 Car-

bon % max. 0.55

Phosphorous % max. 0.05
Sulphur % max. 0.06

ii) For Nuts:

Carbon % max. 0.50

Phosphorous % max. 0.12
Sulphur % max. 0.34
MECHANICAL PROPERTIES:

i) For Hexagonal Bolts: (IS-1367 Part-III)1991

a) Tensile strength(to be arranged on

size 150 mm & above) : N/mm sq. 400 (min)

b) Stress under proof load. : N/mm sq. 225 (min)

c) Brinell Hardness : HB 114(min) to 238 max.

d) Rockwell hardness : HRB-Max. 67(min.) to 99.5 max.

e) Vickers harness : HV 120 (min) to 250 max.

f) Elongation after fracture : 3 Min. 22%

g) Strength under wedge loading

(to be arranged on size above 40 mm) : N/mm sq. 400 (min)

h) Head soundness : No fracture

ii) For Hexagonal Nuts(IS:1367 Part-VI/1980 Table4)

a) Proof stress. : N/mm sq. 610 (min)

b) Vicker Hardness : HV-Min. 130 HV-Max. 302

7. ISI CERTIFICATION AND TYPE TEST CERTIFICATE

The manufacturer should furnish the copy of valid BIS License along with BIS License No. with the
technical bid

The manufacturer shall furnish valid and authenticated type test certificates from a Govt. approved / Govt.
Recognized / NABL Accredited laboratory / ILAC i.e. International Accreditation Corporation (in case
of foreign laboratory) of same size or higher size (higher size means same dia with longer length ) i.e. if
manufacturer furnishes valid and authenticated type test certificates for M16x300N or higher, then it will
be qualified for M16x100N ,M16x150N, M16x200N and M16x250N i.e. for lower sizes of Bolts & Nuts.

Such type test certificates should not be older than 5 years as on the date of Techno-commercial bid
opening. For this purpose date of conducting type test will be considered.

The type test certificate by in house laboratory of bidding firms even if it is Govt. approved / Govt. Rec-
ognized / NABL Accredited laboratory / ILAC accredited, shall not be accepted, in case of their ownbid.
This will not apply if bidding firm is Govt. Company / Public sector undertaking.

The manufacturer should furnish documentary evidence in support of laboratory whose type test have
been furnished, that the said laboratory is a Govt. / Govt. approved / Govt. Recognized / NABL Accredited
laboratory / ILAC accredited (in case of foreign laboratory). The type test certificate shall befurnished
either in original or copy duly attested by Notary.

8. QUALITY ASSURANCE PLAN

588
The supplier shall invariably furnish the following information along-with his offer, failing which his
offer shall be liable for rejection.

(ii) Information and copies of test certificates as in (i) above in respect of bought out material.

(iii) List of manufacturing facilities available.

(iv) Level of automation achieved and list of areas where manual processing exists.

(v) List of areas in manufacturing process, where stage inspections are normally carried out for quality
control and details of such test and inspection.

(vi) List of testing equipments available with the supplier for final testing of G.S. stay wire and test
plant limitation if any vis-à-vis the type, special acceptance and routine tests specified in the rele-
vant standards. These limitations shall be very clearly brought out in schedule of deviation from
specified test requirements.

9. INSPECTION, TESTING & CHECKING BEFORE DISPATCH:-

All the tests and Inspection shall be made at the works of manufacturer unless otherwise specifically
agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall provide
the inspecting officer(s) representing the purchaser all reasonable facilities without charges, to satisfy him
that the material is being furnished in accordance with this specification. The purchaser has the right to
have the tests carried out at his own cost by an independent agency whenever there is a dispute regarding
the quality of supply.

The inspection may be carried out by the purchaser at any stage of manufacture/ before dispatch as per
relevant standard.

Inspection and acceptance of any material under the specification by the purchaser, shall not relieve the
manufacturer from his obligation of furnishing material in accordance with the specification and shall not
prevent subsequent rejection if the material is found to be defective. The manufacturer shall keep the
purchaser informed in advance, about manufacturing programme so that arrangements can be made for
inspection.

The purchaser reserves the right to insist for witnessing the acceptance/routine testing of the bought out
items.

589
The manufacturer shall give atleast 15 days advance intimation to enable the purchaser to depute his
representative for witnessing the acceptance and routine tests.

TYPE TESTS

The following tests shall constitute the type tests and shall be carried out as per relevant IS:1367 Part-III.
1) Chemical Composition Test

2) Test for Mechanical Properties for Hexagonal Bolts

a) Tensile strength
b) Yield stress
c) Stress under proof load
d) Brinell Hardness or Rockwell Hardness or Vickers Hardness
e) Elongation after Fracture
f) Strength under Wedge loading

3) Test for Mechanical Properties for Hexagonal Nuts.

a) Proof Stress
b) Vickers Hardness ROU-

TINE/ACCEPTANCE TEST

The following tests shall be got conducted in presence of purchasers representative as per relevant IS:1367
Part-III/1991 with latest amendment for Bolts and IS:1367 Part-VI/1980 with latest amendment for Nuts
on the samples taken from the offered lot material for the purpose of acceptance of that lot of material.

1) Chemical Composition Test.

2) Test for Mechanical properties for Hexagonal Bolts:

a) Tensile strength
b) Yield stress
c) Stress under proof load
d) Brinell Hardness or
e) Rockwell Hardness
f) Vickers Hardness
g) Elongation after Fracture
h) Strength under wedge loading
i) Head soundness

3) Test for Mechanical Properties for Hexagonal Nuts:

a) Proof stress
b) Vickers Hardness

10. MARKING
590
The bolts shall be marked with the following symbols on the top surface of the bolt head, either embossed
or Indented, as given below:-

(a) The Manufacturer’s identification symbol

(b) Property class
(c) The material shall be marked as per the requirement of IS-1367 (Pt. XVIII)/ 1979 for Bolts & Nuts.

11. PACKING AND FORWARDING

The packing of material shall be made in two bags one HDP bag (inner) and one gunny bag (outer) or in
double gunny bag, containing 50 Kg weight of Bolts & Nuts(Net wt.). The packing should capable to bear
transportation hazards. The packing shall be such as to protect the material from the atmospheric effect
like rains, humidity etc. The packing shall bear the marking as under:-

a) Certification regarding ISI

b) Particulars of material(s)
c) Quantity
d) Manufacturer’s identification mark
e) Complete dispatch details like name of the consignee and destination etc.

12. TESTING OF MATERIAL AT CTL

The material received in stores shall be subject to test checking at CTL of Nigam before finalac-
ceptance of material. The procedure for the same shall be as under:-

(i) Sampling:-
5 samples out of 1 MT Nuts and Bolts of assorted size or part thereof from each inspected lot received
in stores shall be selected for test checking of material and shall be got tested. The sample selection shall
be done as soon as material is received in stores without the presence of representative of supplier.
However testing of sample(s) at CTL shall be carried out in presence of representative of supplier after
identification of sample by supplier’s representative.

(ii) Tests

The following tests shall be carried out on the above items:-

(a) Visual examination
(b) Verification of dimension as per specification/ GTP/IS.

Testing shall be got done at the test laboratory of the Nigam i.e. CTL. For witnessing of the testing clear
7 days notice shall be given to the supplier stating date, time and place where the test is to be conducted.
In case the supplier do not attend for witnessing the testing, the testing shall be proceeded and com-
pleted and action taken as per the contract.

13. CRITERIA FOR ACCEPTANCE

591
The material received in the stores shall finally be accepted provided the selected samples passes the test
in CTL. The sample(s) shall be subject to verification of dimension as per specification/GTP and will
be accepted as per tolerances specified in specification/ relevant IS: The material will be accepted as per
GTP/IS.

The Executive Engineer (CTL) shall send copies of test reports to the purchaser, consignees and the
supplier.

STATEMENT OF GUARANTEED TECHNICAL PARTICULARS AND OTHER PERFORMANCE

DATAS FOR SUPPLY OF M.S.BOLTS AND NUTS

1. General :

Manufacturer’s name &address :

Place of manufacture :
Identification mark :

2. Specification and standards : As per specification

I) M.S. bolts & nuts :

3. Property class- For bolt :

For nut :

4. Size :

5. Tolerance :

6. Raw material
Grade. :
Type of steel used. :

7. Chemical Composition (%)

i) For Hexagonal Bolts
Carbon % max
Phosphorous % max.

592
Sulphur. % max.

ii) For Hexagonal Nuts :

Carbon % max. :
Phosphorous % max. : Sul-
phur. % max. :

8. Mechanical Properties :

i) For Hexagonal Bolts :

a) Tensile strength. N/mm sq. :

b) Stress under proof load N/mm sq. :
c) Brinell Hardness. HB-Min. :
d) Rockwell hardness. HRB Max. :
e) Vickers hardness. HV-Min. :
f) Elongation after fracture 3 Min :
g) Strength under wedge loading N/mm sq. :
h) Head soundness. -

ii) For Hexagonal Nuts :

a) Proof stress. N/mm sq. :

b) Vicker Hardness HV-Max. :

9. Sampling process
(Bolts & Nuts)
Mention specification etc.

10. Packing details

i) No. of bolts & nuts in a bag (size wise) :

11. ISI certification mark, if any.

593
12. BIS License No.
(Please attach copy if available)

Signature of Manufacturer
Name

Designation

seal of Manufacturer.

594
TECHNICAL SPECIFICATION FOR SUPPLY OF FABRICAT ED STEEL ITEMS
(NON-WELDED) I.E. (A) SUB-STAT ION STRUCTURE FOR MOUNTING OF 11/0.4
KV TRANSFORMERS ON DOUBLE POLE (B) 33 KV LINE DP (C) 11 KV LINE DP
(D) 1.8 METRE LONG MS CHANNEL BRACKET WITH CLAMP (E) 1.4 METRE
LONG MS CHANNEL BRACKET WITH CLAM P (F) 33/11 KV SUB-STATION
STRUCTURE (RURAL)

1. SCOPE

This specification covers fabrication, testing & delivery of fabricated steel items as a
complete pac kage, complete in all respect as per GTP/Drawings (to be provided by
the purchaser to the successful manufacturer). The steel sections generally used, tenta-
tive unit weight & BOM of fabricated item is enclosed at Schedule-I. The finalbill of
material for the purpose of payment shall be prepared and submitted by the supplier
after approval of model assembly by the purchaser.

2. CLIMATIC CONDITIONS

I. Peak ambient temperature 50 Degree C

3. REQUIREMENT

The approximate quantity required of finished fabricated items are indicated in the
Schedule-I (schedule of requirement along with approximate weight).

The quantities mentioned in the schedule of requirement (Schedule-I) are provisional. How-
ever, the net quantity shall be determined later-on at the time of finalization of the tender.
The purchaser reserves the right to increase or decrease the tendered quantity/ weightof
structure. The purchaser also reserves the right to split the quantity and to entrust the or-
der for the supply on one or more Suppliers. The manufacturer shall agree to supply part
quantity ordered on him at the rates/ prices mentioned in the tender or accepted by the pur-
chaser.

595
4. STANDARDS :

All materials and equipments shall comply in all respect with the requirements of the
latest edition of the relevant Indian Standard Specification(s) except as modified in this
specification. Where the relevant ISS is not available, the material / equipment should
comply the latest BSS. All the items should be made / fabricated/tested from steel sec-
tions conforming to IS:2062 (latest amended).

5. FINANCIAL RESOURCES AND EXPERIENCE

The manufacturer shall furnish the details regarding his previous experienc e in perform-
ing same or similar comparable work, the technical strength and manufacturing facilities
available and also financial capability along with the tender. The manufacturer isalso re-
quired to furnish the following information.

a. Standing of the firm as manufacturer/Supplier

b. Approximate qty, fabricated so far at his works on monthly basis.
c. Testing facilities available at his works.

6. MATERIAL:

The Supplier shall make his own arrangement for the procurement of steel sections before
commencement of work. The purchaser shall be at liberty to have samples of steel used,
tested / checked in any laboratory at his own cost and reject the supply, if it is found below
the required standard.

All the material required for fabrication shall be stocked in adequate quantity by the Supplier
to ensure the progress of the work is not jeopardized. No relaxation in the delivery time shall
be allowed on the pretext of non- availability or short supply of raw materials.

7. WORKMANSHIP:

The fabrication shall be done in such a way that there is a good finish of the fabricated struc-
tures. The steel structure shall be fabricated accurately adhering to dimensions as perthe
approved drawings. All the steel sections shall be carefully leveled/ straightened and made
true to method which shall not injure the material so that when assembled the adjacent sur-
face are in close contract through out. No rough edges shall be permitted anywhere through-
out the work. Holes must be perfectly circular. The tolerance(s) as per drawing/ clause here-
under is permissible. All burrs left by drills or punches shall be removed completely. No
bolts holes shall be more than 1.5 mm bigger than the corresponding bolt diameter.

8. DRAWING & MODEL ASSEMBLY :

3 sets of drawing shall be furnished by the successful manufacturer based on JVVNL

drawing for according approval of the purchaser before commencement as per clause
No.1.12.1 of GCC(Section-II).

596
The Supplier shall offer one set of model assembly (proto type) for the respective structureas
per the drawings provided to him for checking/ approval of the purchaser before commence-
ment of supplies. The firm who have already supplied same item under previous TNs as per
same drawing/design and specification in any DISCOM (Jaipur, Ajme r & Jodhpur) during last
three ye ars from the date of opening of Techno-Commercial Bid shall beexempted from ap-
proval of model assembly.

In case any deviation is detected, during the process of preparing the model assembly, the
Supplier shall intimate the purchaser or his authorized representative at the time of inspec-
tion of model assembly. The final bill of material shall be as per approved bill
of material.

The Supplier shall take-up the mass fabrication of the structure(s) only after the purchaser
has approved the model assembly along with bill of material.

No extra time shall be allowed in commencement period in getting the prototype approval.

9. MARKING

Each individual structure / section shall carry a code number conforming to component
number given to it in the drawing / Bill of material. The code number of approved size
shall be stamped with a metal dye of 16 mm size on the member and shall be legible. The
name of manufacturers in suitable code and the word “JPD” & “TN No” shall also be
stamped / punched on each individual section with metal dye of not less than 16 mm size.

If the above marking is not found on the material received in the stores, the receipted Challan
shall not be given by the concerned stores. The Challan shall only be issued after verification
of material by the Store officer.

10. INSPECTION, TESTING & CHECKING :

The finished product before acceptance shall be subject to inspection in respect of workman-
ship, checking of dimension/weight & testing as per requirement of relevant IS:2062 (latest
amended), approved drawings and bill of material, at the suppliers works if not supported by
test certificates of main producers viz. SAIL/TISCO/RINL. The certificatefor type test
(chemical composition & mechanical properties test) issued by prime producer(s) shall be
furnished along with the inspection call to the SE(Proc.), otherwise testing shall be arranged
at independent Lab on the cost of supplier. The certificate and relevant invoices shall be in
the name of the firm on whom the order is placed by the Nigam. In case manufacturer use
the steel sections manufactured by prime producers then the inspecting officer shall verify
and record in the inspection report regarding stamping and mark of prime producers. The
certificate(s) in the name of other parties/ sources shall not be accepted and in such cases
the tests for chemical and mechanical properties shall haveto be arranged in the presence of
inspecting officer(s) at recognized lab / any independent lab / test house having the testing
equipments (used in the testing), calibrated by NABL/NPLAccredited calibration laborato-
ries or equivalent.

The supplier shall present the latest Calibration Certificate(s) of testing instruments/ equip-
ments 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/ me-
ters/ apparatus etc. should be got calibrated by the supplier from time to time from independent
test laboratory/ house having valid accreditation from National/ AccreditationBoard for testing
and calibrating laboratories for testing equipments/ original manufacturer having trace ability to
NABL/NPL or equivalent.

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 test-
ing instruments/equipments should be duly sealed by the Calibrating agency and be indi-
cated in the calibration certificate(s).

The following facilities are to be provided by the supplier at his own cost to theinspect-
ing officer of JVVNL.

(a) Suitable accommodation.

(b) Local conveyanc e between arrival point, place of stay, works and departure point.
(c) The supplier shall assist in arranging return tic ket and reservation on the request
of the inspecting officer for which the payment shall be made by the inspecting of-
ficer. In case of joint inspection, single or shared double room accommodation shall
be provided.

11. TESTS

Test before dispatch:- The various steel section/structure before dispatch shall be subject to
following test as per IS:2062( latest amendment) at the manufacturer’s works
Routine test/acceptance test
(i) Dimensional checking and visual inspection
(ii) Weight chec king
(iii) Chemical composition test
(iv) Mechanical property test

12. SAMPLING:

The inspection shall be carried out on each lot separately. The following number of
pieces selected at random shall be subject to inspection/ testing and checking.

a) Workmanship and dimension checking : 3 % samples from finished item.

b) Chemical test : One sample of each steel section
from the entire lot of material of-
fered for inspection.
c) Tensile test : One sample of each steel section
from every 50 MT or Part thereof.
d) Bend test : One sample of each steel section
from every 50 MT or Part thereof.
13. TOLERANCE IN DIMENSIONS :
The tolerance(s) shall be permissible as per IS: 1852: (latest amended). Further the
following tolerance(s) on fabricated items will also be allowed.
i) Tolerance in over all length ± 3mm

598
ii) Tolerance in edge dimensions (centre of hole to end) ±2mm
i) Tolerance in hole centre ±2mm
iv) Circular holes No tolerance
v) Weight Tolerance +2% to (-) 4%

14. GUARANTEED TECHNICAL PARTICULARS :

The manufacturer shall furnish the guaranteed technical particulars of the material as
required in the schedule-V by mentioning specific figures therein. Any item of the GTP
left unfilled or simply written as per ISS etc. shall be considered as incomplete GTP and
such tender is liable to be rejected.

15. PACKING AND FORWARDING

The finished items complete in all respect dully inspected and cleared for dispatch, shall
have to be delivered in Nigam's stores located anywhere in Jaipur Discom by Road.
Unloading of material at store(s) is Suppliers responsibility.

16. CRITERIA FOR ACCEPT ANCE

The inspected material should be strictly in accordance to the GTP of the specificationother-
wise the material shall be treated as rejected and shall not be accepted.

17. WEIGHT

The weight of structure shall mean the weight of structures calculated by using standard sec-
tional weights of all steel structural members of the sizes indicated in the fabrication drawings
and/or subsequently revis ed drawings and bill of material without taking into consideration
the reduction in weight due to drilling of bolt-holes, s kew cuts, chamferingetc. or the in-
crease in weight due to galvanization.

The material shall be acceptable if found within permissible tolerance limit

i.e. +2% and (-) 4%.

SCHEDULE OF REQUIREMENT FOR FABRICAT ED STEEL ITEMS (NON-WELDED)

I.E. (A) SUB-ST ATION STRUCTURE FOR MOUNTING OF 11/0.4 KV TRANSFO
RMERS ON DOUBLE POLE (B) 33 KV LINE DP (C) 11 KV LINE DP (D) 1.8 METRE
LONG MS CHANNEL BRACKET WITH CLAMP (E) 1.4 METRE LONG MS CHANNEL
BRACKET WITH CLAMP (F) 33/11 KV SUB-STATION STRUCTURE (RURAL)

S.No. Type of structure Unit wt. in Provisional Total wt. General sections
Kg.(approx) qty. in sets in MT involved
(A) SUB-ST MS Channel 100x50
ATION STRUC- MS Channel 75x40
1 TURE FOR 166.746 5002.38 MS Angle 75x75x6
MOUNTING OF 30000 MS Flat 50x6
11/0.4 KV

599
TRANSFORMERS
ON DOUBLE POLE

MS Channel 100x50
MS Angle 75x75x6
2 (B) 33 KV LINE DP 142.314 1000 142.314 MS Angle 50x50x6
MS Flat 50x10
MS Flat 50x6
MS Channel 100x50
3 © 11 KV Line DP 101.383 101.383 MS Angle 65x 65x6
1000 MS Angle 50x 50x6
MS Flat 50X6
(D) 1.8 METRE MS Channel 100x50
4 LONG MS 19.271 19.271 MS Flat 50x 8
CHANNEL 1000
BRACKET WITH
CLAMP
(E) 1.4 METRE MS Channel 100x50
5 LONG MS 14.526 435.78 MS Flat 50x 6
CHANNEL 30000
BRACKET WITH
CLAMP
(F) 33/11 KV SUB- MS Channel 100x50
6 STATION STRUC- 4086.879 204.343 MS Flat 50x6
TURE 50
MS Sheet
(RURAL)
Total 5905.471
TECHNICAL SPECIFICATION FOR SUPPLY OF 33 KV SINGLE CIRCUIT UN- GAL-
VANISED STEEL LATTICE STRUCTURES 36’ LONG ALONG WITH ONE 33 KV
CROSS ARMS (CHANNEL) ONE TOP HAMPER & 48 NOS. MS BOLTS WITH NUTS

1. SCOPE

This specification covers fabrication, testing & delivery of fabricated steel items as a complete pack-
age, complete in all respect as per GTP/Drawings (to be provided by the purchaser to the successful
manufacturer). The steel sections generally used, tentative unit weight & BOM of fabricated item is
enclosed at Schedule-I. The final bill of material for the purpose of payment shall be prepared and
submitted by the supplier after approval of model assembly by the purchaser.

2. CLIMATIC CONDITIONS

XI. Peak ambient temperature 50 Degree C

XII. Maximum average ambient temperature 40 Degree C
XIII. Maximum temperature attainable 60 Degree C
XIV. Maximum relative humidity 100 %
XV. Minimum relative humidity 50 %
XVI. Average number of thunder storm days per annum 40
XVII. Average number of rainy days per annum 100
XVIII. Average annual rainfall 10-100 cm
XIX. Maximum wind pressure 100 Kg/sq.m
XX. Altitudes not exceeding 1000 mtrs.
3. REQUIREMENT

The approximate quantity required of finished Structure is indicated in the Schedule-I (schedule of require-
ment along with approximate weight).

The quantities mentioned in the schedule of requirement (Schedule-I) are provisional. However, the net
quantity shall be determined later-on at the time of finalization of the tender. The purchaser reserves the
right to increase or decrease the tendered quantity/ weight of structure. The purchaser also reserves the
right to split the quantity and to entrust the order for the supply on one or more Suppliers. The manufacturer
shall agree to supply part quantity ordered on him at the rates/ prices mentioned in the tender or accepted
by the purchaser.

5. STANDARDS :

All materials and equipments shall comply in all respect with the requirements of the latest edition of the
relevant Indian Standard Specification(s) except as modified in this specification. Where the relevant ISS
is not available, the material / equipment should comply the latest BSS. All the items should be made /
fabricated/tested from steel sections conforming to IS:2062 (latest amended).

601
6. FINANCIAL RESOURCES AND EXPERIENCE

The manufacturer shall furnish the details regarding his previous experience in performing same or similar
comparable work, the technical strength and manufacturing facilities available and also financial capability
along with the tender. The manufacturer is also required to furnish the following information.

a. Standing of the firm as manufacturer/Supplier

b. Approximate qty, fabricated so far at his works on monthly basis.
c. Testing facilities available at his works.

7. MATERIAL:

The Supplier shall make his own arrangement for the procurement of steel sections before commencement
of work. The purchaser shall be at liberty to have samples of steel used, tested / checked in any laboratory
at his own cost and reject the supply, if it is found below the required standard.

All the material required for fabrication shall be stocked in adequate quantity by the Supplier to ensure the
progress of the work is not jeopardized. No relaxation in the delivery time shall be allowed on the pretext
of non- availability or short supply of raw materials.

8. WORKMANSHIP:

The fabrication shall be done in such a way that there is a good finish of the fabricated structures. The steel
structure shall be fabricated accurately adhering to dimensions as per the approved drawings. All the steel
sections shall be carefully leveled/ straightened and made true to method which shall not injure the material
so that when assembled the adjacent surface are in close contract through out. No rough edges shall be
permitted anywhere throughout the work. Holes must be perfectly circular. The tolerance(s) as perdrawing/
clause hereunder is permissible. All burrs left by drills or punches shall be removed completely.No bolts
holes shall be more than 1.5 mm bigger than the corresponding bolt diameter.
In general all fabrication work shall conform to provision of IS-802 (part-I) 1978 latest amended. However
the details given in this specification shall prevail in specified items. The overlapping of the M.S.Flat on
M.S.angle shall be minimum 30 mm.

The holes near the bend lines of absent member, on both sides of bent lines shall be punched/ drilled after
bending and relative position of these holes, shall be maintained with the use of proper templates/jigsand
fixtures.

Punched holes must be square to the plates and the wall of the holes parallel. The following maximum
tolerance of accuracy of punched holes is permissible.

602
a) Holes must be perfectly circular and no tolerance in this respect is permissible.
b) The maximum allowable difference in diameter of the holes on the two sides of plates or angle is
0.8mm i.e. the allowable taper in punched holes should not exceed 0.8 mm on diameter.
c) Holes must be square with the plates or angles and slant holes will not be permitted.

All burrs left by drills or punches shall be removed completely. Drifting or riming to enlarge defective
holes shall not be permitted. Minimum edges distance from the centre of any bolt holes shall not be less
than what has been indicated hereunder

Dia of Min. flange Min.rolled Min. sheared

bolts width of sec. edge distance edge distance
in mm tion in mm in mm in mm

16 45 20 23

9. DRAWING & MODEL ASSEMBLY :

3 sets of drawing shall be furnished by the successful manufacturer based on JVVNL drawing for according
approval of the purchaser before commencement

The Supplier shall offer one set of model assembly (proto type) for the respective structure as per the
drawings provided to him for checking/ approval of the purchaser before commencement of supplies. The
firm who have already supplied same item under previous TNs as per same drawing/design and specifica-
tion in any DISCOM (Jaipur, Ajmer & Jodhpur) during last three years from the date of openingof Techno-
Commercial Bid shall be exempted from approval of model assembly.

In case any deviation is detected, during the process of preparing the model assembly, the Supplier shall
intimate the purchaser or his authorized representative at the time of inspection of model assembly. The
final bill of material shall be as per approved bill of material.

After inspection and checking of the model assembly of lattice structure(s), the same shall be type tested
for Radiography inspection (X-rays) of welding joint at any independent NABL Accredited Laboratory or
CPRI/Govt. approved lab.

603
The Supplier shall take-up the mass fabrication of the structure(s) only after the purchaser has approved
the model assembly along with bill of material.

Any period taken beyond 30 days for approval of model assembly shall be to manufacturers account. No
extra time shall be allowed in commencement period in getting the prototype approval.

10. MARKING

Each individual structure / section shall carry a code number conforming to component number given to it
in the drawing / Bill of material. The code number of approved size shall be stamped with a metal die of
16 mm size on the member and shall be legible. The name of manufacturers in suitable code and the word
“JPD” & “TN No” shall also be stamped / punched on each individual section with metal die of not less
than 16 mm size.

If the above marking is not found on the material received in the stores, the receipted challan shall not be
given by the concerned stores. The challan shall only be issued after verification of material by the Store
officer.

11. INSPECTION, TESTING & CHECKING :

The finished product before acceptance shall be subject to inspection in respect of workmanship, checking
of dimension/weight & testing as per requirement of relevant IS:2062 (latest amended), approved drawings
and bill of material, at the suppliers works if not supported by test certificates of main producersviz.
SAIL/TISCO/RINL. The certificate for type test (chemical composition & mechanical properties test)is-
sued by prime producer(s) shall be furnished along with the inspection call to the SE(MM-I), otherwise
testing shall be arranged at independent Lab on the cost of supplier. The certificate and relevant invoices
shall be in the name of the firm on whom the order is placed by the Nigam. In case manufacturer use the
steel sections manufactured by prime producers then the inspecting officer shall verify and record in the
inspection report regarding stamping and mark of prime producers. The certificate(s) in the name of other
parties/ sources shall not be accepted and in such cases the tests for chemical and mechanical properties
shall have to be arranged in the presence of inspecting officer(s) at recognized lab / any independent lab
/ test house having the testing equipments (used in the testing), calibrated by NABL/NPL Accredited cali-
bration laboratories or equivalent.

The supplier 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/ meters/ apparatus etc. should be got calibrated by the
supplier from time to time from independent test laboratory/ house having valid accreditation from Na-
tional/ Accreditation Board for testing and calibrating laboratories for testing equipments/ original manu-
facturer having trace ability to NABL/NPL or equivalent.

604
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/equipments
should be duly sealed by the Calibrating agency and be indicated in the calibration certificate(s).

The following facilities are to be provided by the supplier at his own cost to the inspecting officer of
JVVNL.

(c) Suitable accommodation.

(d) Local conveyance between arrival point, place of stay, works and departure point.
(e) The supplier shall assist in arranging return ticket and reservation on the request of the inspect-
ing officer for which the payment shall be made by the inspecting officer. In case of jointinspec-
tion, single or shared double room accommodation shall be provided.

12. TESTS

Test before dispatch:-

The various steel section/structure before dispatch shall be subject to following test as per IS:2062( latestamend-
ment) at the manufacturer’s works
Routine test/acceptance test

(i) Visual inspection and checking of Dimension

(ii) Weight checking
(iii) Chemical composition test
(iv) Mechanical property test
(v) Checking of welding

13. SAMPLING:

The inspection shall be carried out on each lot separately. The following number of pieces selected atran-
dom shall be subject to inspection/ testing and checking.

a) Workmanship and dimension checking : 3 % samples from finished item.

b) Chemical test : One sample of each steel section

from the entire lot of material
offered for inspection.

c) Tensile test : One sample of each steel section

from every 50 MT or Part thereof.

605
d) Bend test : One sample of each steel section
from every 50 MT or Part thereof.
14. TOLERANCE IN DIMENSIONS :

The tolerance(s) shall be permissible as per IS: 1852-1985 (latest amended). Further the followingtoler-
ance(s) on fabricated items will also be allowed.

i) Tolerance in over all length ± 3mm

ii) Tolerance in edge dimensions (centre of hole to end) ±2mm
iii) Tolerance in hole centre ±2mm
iv) Circular holes No tolerance
v) Weight Tolerance +2% to (-) 4%

15. GUARANTEED TECHNICAL PARTICULARS :

The manufacturer shall furnish the guaranteed technical particulars of the material as required in the sched-
ule-V by mentioning specific figures therein. Any item of the GTP left unfilled or simply written asper ISS
etc. shall be considered as incomplete GTP and such tender is liable to be rejected.

16. PACKING AND FORWARDING

The finished items complete in all respect dully inspected and cleared for dispatch, shall have to be deliv-
ered in Nigam's stores located anywhere in Jaipur Discom by Road. Unloading of material at store(s) is
Suppliers responsibility.

17. CRITERIA FOR ACCEPTANCE

The inspected material should be strictly in accordance to the GTP of the specification otherwise the ma-
terial shall be treated as rejected and shall not be accepted.

18. WEIGHT

The weight of structure shall mean the weight of structures calculated byusing standard sectional weights
of all steel structural members of the sizes indicated in the fabrication drawings and/or subsequently revised
drawings and bill of material without taking into consideration the reduction in weight due to drilling of
bolt-holes, skew cuts, chamfering etc. or the increase in weight due to galvanization.

606
The material shall be acceptable if found within permissible tolerance limit
i.e. +2% and (-) 4%.

(B) SCHEDULE OF REQUIREMENT FOR 33 KV SINGLE CIRCUIT UN-GALVANISED STEEL

LATTICE STRUCTURES 36’ LONG ALONG WITH ONE 33 KV CROSS ARMS (CHANNEL) ONE
TOP HAMPER & 48 NOS. MS BOLTS WITH NUTS.

Item Section Length of Members and Weight

No.
Length Qty. Sect. Wt. Total Weight Kg.
MM No. Kg. / M.
1. LEG L 50x50x6 MM 5500 8 4.5 198.00
2. Belt L 50x50x6 MM 710 4 4.5 12.78
3. Belt L 50x50x6 MM 645 4 4.5 11.61
4. Belt L 50x50x6 MM 580 4 4.5 10.44
5. Belt L 50x50x6 MM 505 4 4.5 9.09
6. Belt L 50x50x6 MM 455 4 4.5 8.19
7. Flat 50x10 MM 410 2 3.93 3.22
8. Flat 50x10 MM 350 2 3.93 2.75
9. Flat 50x10 MM 280 2 3.93 2.20
Belt Flat 50x10 MM 265 2 _ 2.08
10. Bracing Flat 50x6 MM 470 4 2.36 4.44
11. Bracing Flat 50x6 MM 475 4 2.36 4.48
12. Bracing Flat 50x6 MM 535 4 2.36 5.05
13. Bracing Flat 50x6 MM 535 4 2.36 5.05
14. Bracing Flat 50x6 MM 535 4 2.36 5.05
15. Bracing Flat 50x6 MM 550 4 2.36 5.19
16. Bracing Flat 50x6 MM 585 4 2.36 5.52
17. Bracing Flat 50x6 MM 660 4 2.36 6.23
18. Bracing Flat 50x6 MM 665 4 2.36 6.27
19. Bracing Flat 50x6 MM 705 4 2.36 6.65
20. Bracing Flat 50x6 MM 850 4 2.36 8.02
21. Bracing Flat 50x6 MM 860 4 2.36 8.12

607
22. Bracing Flat 50x6 MM 875 4 2.36 8.26
23. Bracing Flat 50x6 MM 960 4 2.36 9.06
24. Bracing Flat 50x6 MM 960 4 2.36 9.06
25. Bracing Flat 50x6 MM 960 4 2.36 9.06
26. Bracing Flat 50x6 MM 1145 4 2.36 10.81
27. Bracing Flat 50x6 MM 1150 4 2.36 10.86
28. Belt Angle 50x50x6 MM 800 4 4.50 14.40
29. Butt Joint L 65x65x5 MM 462 4 4.90 9.05
30. Butt Joint Flat 50x6 MM 462 4 2.36 4.36
31. Butt Joint Flat 50x6 MM 196 4 2.36 1.85
Wt. of Tower only 417.20
32. X-Arms Channel 100x50 MM 2320 1 9.56 22.18
33. Top Hampers Flat 50x10 MM 1015 1 3.93 3.99
34. MS Bolts & Nuts M 16x45 48 0.135 6.48
Total weight in Kg. 449.85

608
TECHNICAL S PECIFICATIO N FOR SUPPLY OF FABRICATED STEEL ITEMS
(WELDED) I.E. (A) 33 KV CROSS ARM (ANGLE) WITH CL AMP AND TOP HAM-
PER (B) 11 KV CROS S ARM(AN GLE) WITH CLAMPAN D TOP HAMPER
(C) L.T.CROSS ARM (120 0 MM) WITH CLAMP (D) L .T.CROSS ARM (60 0 MM)
WITH CLAMP

1. SCOPE

2. CLIMATIC CONDITIONS

I. Peak ambient temperature 50 Degree C

3. REQUIREMENT

The approximate quantity required of finished fabricated items are indicated in the
Schedule-I (schedule of requirement a with approximate weight).

The quantities mentioned in the schedule of requirement (Schedule-I) are provisional. How-
ever, the net quantity shall be determined later-on at the time of finalization of the tender.
The purchaser reserves the right to increase or decrease the tendered quantity/ weightof
structure. The purchaser also reserves the right to split the quantity and to entrust theor-
der for the supply on one or more Suppliers. The manufacturer shall agree to supply part
quantity ordered on him at the rates/ prices mentioned in the tender or accepted by the pur-
chaser.

4. STANDARDS :

All materials and equipments shall comply in all respect with the requirements of the latest
edition of the relevant Indian Standard Specification(s) exc ept as modified in this specifica-
tion. Where the relevant ISS is not available, the material / equipment should comply the
latest BSS. All the items should be made / fabricated/tested from steel sectionsconforming
to IS:2062 (latest amended).

609
5. FINANCIAL RESOURCES AND EXPERIENCE

The manufacturer shall furnish the details regarding his previous experienc e in perform-
ing same or similar comparable work, the technical strength and manufacturing facilities
available and also financial capability a with the tender. The manufacturer is alsorequired
to furnish the following information.

a. Standing of the firm as manufacturer/Supplier

b. Approximate qty, fabricated so far at his works on monthly basis.
c. Testing facilities available at his works.

6. MATERIAL:

7. WORKMANSHIP:

8. DRAWING & MODEL ASSEMBLY:

3 sets of drawing shall be furnished by the successful manufacturer based on JVVNLdraw-

ing for according approval of the purchaser before commencement

The Supplier shall offer one set of model assembly (proto type) for the respective
structure as per the drawings provided to him for checking/ approval of the purchaser
before commencement of supplies. The firm who have already supplied same item under
previous TNs as per same drawing/design and specification in any DISCOM (Jaipur,
Ajme r & Jodhpur) during last three ye ars from the date of opening of Techno-Commer-
cial Bidshall be exempted from approval of model assembly.

In case any deviation is detected, during the process of preparing the model as-
sembly, the Supplier shall

610
intimate the purchaser or his authorized representative at the time of inspec-
tion of model assembly.

The final bill ofmaterial shall be as per approved bill of material.

The Supplier shall take-up the mass fabrication of the structure(s) only after the pur-
chaser has approved the modelassembly a with bill of material.

No extra time shall be allowed in commencement period in getting the prototype approval.

9. MARKING

Each individual structure / section shall carry a code number conforming to compo-
nent number given to it in the drawing / Bill of material. The code number of ap-
proved size shall be stamped with a metal dye of 16 mm size on themember and shall
be legible. The name of manufacturers in suitable code and the word “JPD” & “TN
No” shall also be stamped / punched on each individual section with metal dye of
not less than 16 mm size.

If the above marking is not found on the material received in the stores, the re-
ceipted challan shall not be given by theconcerned stores. The challan shall only be
issued after verification of material by the Store officer.

10. INSPECTION, TESTING &CHECKING :

The finished product before acceptance shall be subject to inspection in respect of

workmanship, checking of dimension/weight & testing as per requirement of relevant
IS:2062 (latest amended), approved drawings and bill of material, at the suppliers
works if not supported by test certificates of main producers viz. SAIL/TISCO/RINL.
The certificate for type test (chemical composition & mechanical properties test) issued
by prime producer(s) shall be furnisheda with the inspection call to the SE(MM-I), oth-
erwise testing shall be arranged at independent Lab on the cost of supplier.

The certificate and relevant invoices shall be in the name of the firm on whom the
order is placed by the Nigam. In case manufacturer use the steel sections manufac-
tured by prime producers then the inspecting officer shall verify and record in the in-
spection report regarding stamping and mark of prime producers. The certificate(s) in
the name of otherparties/ sources shall not be accepted and in such cases the tests
for chemical and mechanical properties shall have to be arranged in the presence
of inspecting officer(s) at recognized lab/ any independent lab /test house having the
testing equipments (used in the testing), calibrated by NABL/NPL Accredited cali-
bration laboratories or equivalent.

The supplier shall present the latest Calibration Certificate(s) of testing instruments/
equipments to be used for the testingof the material covered in the purchase order to
the authorized inspecting officer/inspecting agency of the purchaser. Thetesting in-
struments/ meters/ apparatus etc. should be got calibrated by the supplier from time to
time from independent test laboratory/ house having valid accreditation from Na-
tional/ Accreditation Board for testing and calibrating laboratories for testing equip-
ments/ original manufacturer having trace ability to NABL/NPL or equivalent.

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 pur-
chaser. The testing instruments/equipments should be duly sealed by theCalibrating
agency and be indicated in the calibration certificate(s).

The following facilities are to be provided by the supplier at his own cost to the in-
specting officer of JVVNL.

(a) Suitable accommodation.

(b) Local conveyance between arrival point, place of stay, works and departure point.
(c) The supplier shall assist in arranging return tic ket and reservation on the re-
quest of the inspecting officer for which the payment shall be made by the
inspecting officer. In case of joint inspection, single or shared double room
accommodation shall be provided.

11. TESTS

Test before dispatch: - The various steel section/structure before dispatch shall be
subject to following test as perIS:2062(latest amendment) at the manufacturer’s
works
Routine test/acceptance test
(i) Dimensional checking and visual inspection
(ii) Weight checking
(iii) Chemical composition test

(iv) Mechanical property test

12. SAMPLING:

The inspection shall be carried out on each lot separately. The following
number of pieces selected at randomshall be subject to inspection/ testing and
checking.

a) Workmanship and dimension checking: 3 % samples from finished item.

b) Chemical test : One sample of each steel
section from the entire lot of
materialoffered for inspec-
tion.
c) Tensile test : One sample of each steel
section from every 50 MT
or Partthereof.
d) Bend test : One sample of each steel sectionfrom.
612
13. TOLERANCE IN DIMENSIONS :
The tolerance(s) shall be permissible as per IS: 1852: (latest amended). Further the
following tolerance(s) on fabricateditems will also be allowed.
i) Tolerance in over all length ± 3mm
ii) Tolerance in edge dimensions (centre of hole to end) ±2mm
iii) Tolerance in holecentre ±2mm
iv) Circular holes No tolerance
v) Weight Tolerance +2% to (-) 4%
14. GUARANTEED TECHNICAL PARTICULARS :

The manufacturer shall furnish the guaranteed technical particulars of the ma-
terial as required in the schedule-Vbymentioning specific figures therein. Any
item of the GTP left unfilled or simply written as per ISS etc. shall be considered
as incomplete GTP and such tender is liable to be rejected.

15. PACKING AND FORWARDING

The finished items complete in all respect dully inspected and cleared for dispatch, shall
have to be delivered in Nigam’s

stores located anywhere in Jaipur Discom by Road. Unloading of material at store(s) is Sup-
pliers responsibility.

16. CRITERIA FOR ACCEPT ANCE

The inspected material should be strictly in accordance to the GTP of the specifica-
tion otherwise the material shall betreated as rejected and shall not be accepted.

17. WEIGHT

The weight of structure shall mean the weight of structures calculated byusing standard
sectional weights of all steel structural members of the sizes indicated in the fabrication
drawings and/or subsequently revis ed drawings and bill of material without taking into
consideration the reduction in weight due to drilling of bolt-holes, s kew cuts, cham-
feringetc. or the increase in weight due to galvanization.

The material shall be acceptable if found within permissible tolerance

limit i.e. +2% and (-)4%.SCHEDULE OF REQUIREMEN T FORF

OLL OWING ITEMS

613
S. Type of structureUnit wt. Prov isional T otal wt. in General sections
N. in qty. in sets MT involved
Kg.(appr
ox.)
1. 33 KV CROSS ARM MS Channel 100x 50
(ANGLE) WIT H22.849 1000 22.849 MS Angle 75x75x 6
CLAMP AND TOP MS Angle 65x65x 6
HAMPER MS Flat 50x10
2. 11 KV CROSS MS Channel 100x 50
ARM (ANGLE) 12.789 150000 1918.350 MS Angle 65x65x 6
WITH CLAMP MS Flat 50x6
AND TOP
HAMPER.

3. L.T.CROSS ARM MS Angle 50x50x 6

(1200 MM) WIT H 7.383 2000 14.766 MS Flat 50x6
CLAMP
4. L.T.CROSS ARM MS Angle 50x50x 6
(600 MM) WITH 4.233 10000 42.3300 MS Flat 50x6
CLAMP
Total 1998 .295

GUARANTEED & OTHER TECHNICAL PARTICULARS FOR FABRICATED STEEL

ITEMS (WELDED) I.E. (A) 33 KV CROSS ARM (ANGLE) WITH CLAMP AND TOP
HAMPER (B) 11 KV CROSS ARM(A NGLE) WITH CLAMP AND TOP HAMPER (C ) L.T
.C ROSS ARM (1200 MM) WITH CLAMP (D) L.T.CROSS ARM (600 MM) WITH CLAMP

GENERAL:

1. Name of firm :

2. Address for correspondence:

3. Address of Works :

STANDARDS & SPECIFICATION:

1. Dimension : As per approved drawing.

2. Testing
a) Steel :As per IS:2062: (Latest amended). If not sup-
ported by test certificate of primeproducers.
TOLERANCE :

a) Steel : As per IS:1852:(Latest amended)

b) Length : +/- 3 mm
614
c) Edge dimensions : +/- 2 mm
d) Holecentre : +/- 2 mm

e) Weight tolerance : +2% to (-) 4%

D) GUARANTEED WEIGHT OFSTRUCTURE : As per BOM

E) Properties of steel (for class `A')

(a) Chemical composition:

(i) Carbon % (Max.) 0.23
(ii) Manganese % (Max.) 1.50
(iii) Sulpher % (Max.) 0.05
(iv) Phosphorus % (Max.) 0.05
(v) Silicon % (Max.) 0.40
(vi) C.E. % (Max.) 0.42
(b) Mechanical Properties :

UTS(Mpa) Min. 410

Y.S.(Mpa) Min. 240
El (%) Min. 23

615
Material Specifications for SPV

The proposed projects (installation and commissioning of solar power plants) shall be completed as per the
technical specifications given below.
The Successful Bidder is required to take approval of the specifications of materials under the scope from JVVNL
before procuring the same.
1. PARAMETERS
1.1. A project would consist of SPV array, Module mounting structure, Power Conditioning Unit (PCU)
consisting of Maximum Power Point Tracker (MPPT), charge controller (if required), Inverter, Controls &
Protections, interconnect cables and switches. PV Array should be mounted on a suitable structure.
Project should be designed with necessary features to synchronize with the grid power. Components and
parts used in the Project including the PV modules, metallic structures, cables, junction box, switches,
PCUs etc., should conform to the BIS or IEC or international specifications, wherever such specifications
are available and applicable. Specifications of the solar PV module as per below section and PCU/Inverter
as per below sections are given here for the reference of the bidder/successful bidder so that
specifications of balance of supply can be designed accordingly, also the successful bidder will have to
consider solar PV module and PCU/Inverter of same specifications during comprehensive operation and
maintenance phase of the solar power plant for 25 years as per scope of work.
2. PROJECT SHALL CONSIST OF FOLLOWING EQUIPMENT/ COMPONENTS:
2.1. Solar Photovoltaic Modules
2.1.1. The PV modules used must qualify to the latest edition of IEC PV module qualification test or
equivalent BIS standards Crystalline Silicon Solar Cell Modules IEC 61215/IS14286. In addition, the
modules must conform to IEC 61730 Part-1- requirements for construction & Part 2 – requirements
for testing, for safety qualification or equivalent IS.
2.1.2. For the PV modules to be used in a highly corrosive atmosphere throughout their lifetime, they
must qualify to IEC 61701/IS 61701.
2.1.3. The total solar PV array capacity should not be less than allocated capacity (kWp) and should
comprise of solar crystalline modules of minimum 540 Wp and above wattage. Module capacity less
than minimum 540 Wp should not be accepted.
2.1.4. Protective devices against surges at the PV module shall be provided. Low voltage drop bypass
diodes shall be provided.
2.1.5. PV modules must be tested and approved by one of the IEC authorized test centers.
2.1.6. The module frame shall be made of corrosion resistant materials, having pre-galvanized/
anodized Aluminum or superior material.
2.1.7. The Power Producer shall carefully design & accommodate requisite numbers of the modules to
achieve the rated power in its Bid.
2.1.8. Other general requirement for the PV modules and subsystems shall be the following:
a. The rated output power of any supplied module shall have tolerance of +/- 3%.
b. The peak-power point voltage and the peak-power point current of any supplied module and/or
any module string (series connected modules) shall not vary by more than 2 (two) per cent from
the respective arithmetic means for all modules and/or for all module strings, as the case may be.
c. The module shall be provided with a junction box with either provision of external screw terminal
connection or sealed type and with arrangement for provision of by-pass diode. The box shall
616
have hinged, weatherproof lid with captive screws and cable gland entry points or may be of
sealed type and IP-65 rated.
d. I-V curves at STC should be provided by Power Producer.
e. Poly Crystalline make solar module not less than 540 Wp each and having valid IEC certificate.
(Certificate to be submitted on shortlisting of successful Tenders).
2.1.9.Modules deployed must use a RF identification tag. The following information must be mentioned in
the RFID used on each modules This should be inside laminate only.
f. Name of the manufacturer of the PV module
g. Name of the manufacturer of Solar Cells.
h. Month & year of the manufacture (separate for solar cells and modules)
i. Country of origin (for solar cells)
j. I-V curve for the module Wattage, Im, Vm and FF for the module
k. Unique Serial No and Model No of the module
l. Date and year of obtaining IEC PV module qualification certificate.
m. Name of the test lab issuing IEC certificate.
n. Other relevant information on traceability of solar cells and module as per ISO 9001 and ISO
14001
2.1.10. Warranties
a) Material Warranty
i. Material Warranty is defined as: The manufacturer should warrant the Solar Module(s) to be
free from the defects and/or failures specified below for a Period not less than 5 years from
the date of sale to original customer.
ii. Defects and/or failures due to manufacturing
iii. Defects and/or failures due to quality of materials
iv. Nonconformity to specifications due to faulty manufacturing and/or inspection processes. If
the solar Module(s) fails to conform to this warranty, the manufacturer will replace the solar
module(s)
b) Performance Warranty
The predicted electrical degradation of power generated not exceeding 20% of the minimum rated
power over the twenty five (25) Year period and not more than 10% at the end of twelfth(12th) Year
of the full rated original output.
2.1.11. Protective devices against surges at the PV module shall be provided. Low voltage drop bypass
diodes shall be provided.
2.1.12. The module frame shall be made of corrosion resistant materials, having pre-galvanized/
anodized Aluminum or superior material.
2.1.13. The Successful Bidder shall carefully design & accommodate requisite numbers of the modules to
achieve the rated power in its Bid.
c) Warranties
Material Warranty

617
i. Defects and/or failures due to manufacturing
ii. Defects and/or failures due to quality of materials
3. PCU/ Inverter
a) As SPV array produce direct current electricity, it is necessary to convert this direct current into
alternating current and adjust the voltage levels to match the grid voltage. Conversion shall be achieved
using an electronic Inverter and the associated control and protection devices. All these components of
the Project are termed the “Power Conditioning Unit (PCU)”. In addition, the PCU shall also house MPPT
(Maximum Power Point Tracker), an interface between Solar PV array & the Inverter, to the PCU/inverter
should also be DG set interactive. The PCU should also have provision of charge controller in case of
systems. If necessary. Inverter output should be compatible with the grid frequency. Typical technical
features of the inverter shall be as follows:
• Switching devices: IGBT/MOSFET
• Control: Microprocessor /DSP
• Nominal AC output voltage and frequency: 415V, 3 Phase, 50 Hz (In case single phase inverters
are offered, suitable arrangement for balancing the phases must be made.)
• Output frequency: 50 Hz
• Grid Frequency Synchronization range: + 3 Hz or more
• Ambient temperature considered: -20o C to 50o C.
• Humidity: 95 % Non-condensing
• Protection of Enclosure: IP-20(Minimum) for indoor: IP-65(Minimum) for outdoor.
• Grid Frequency Tolerance range: + 3 or more
• Grid Voltage tolerance: - 20% & + 15 %
• THD: < 3%
• PF: > 0.9
b) Three phase PCU/ inverter shall be used as required.
c) Built-in meter and data logger to monitor Project performance retrievable through external computer
shall be provided.
d) The charge controller (if any) / MPPT units environmental testing should qualify IEC 60068-2(1, 2, 14,
30)/Equivalent BIS standard. The junction boxes/ enclosures should be IP 65(for outdoor)/ IP 54 (indoor)
and as per IEC 529 specifications.
e) The PCU/ inverters should be tested from the MNRE approved test centres/NABL/BIS/IEC accredited
testing-calibration laboratories. In case of imported power conditioning units, these should be approved
by international test houses.
4. Array Structure
4.1. The mounting (Rectangular pipe / square pipe / circular pipe) with requisite cross bars, nuts and bolts,
etc. shall be pre-galvanized or galvanized. The Rectangular / square /circular hollow pipe section used for
the structure should have a minimum thickness of 2.0 mm. other than above, the material thickness
should be minimum 2.5 mm. The ground clearance of the bottom most edge of solar panel shall not be
less than 1200 (+/- 100 mm).
a. Column –The minimum section (thickness) should be 80MM*50MM.

618
b. Rafter - The minimum section (thickness) should be 70MM*40MM.
c. Purlin - The minimum section (thickness) should be 70MM * 40MM.
4.2. Hot dip galvanized MS mounting structures may be used for mounting the modules/ panels/arrays. Each
structure should have angle of inclination as per the site conditions to take maximum insulation.
However, to accommodate more capacity the angle inclination may be reduced until the Project meets
the specified performance ratio requirements.
4.3. The Mounting structure shall be so designed to withstand the speed for the wind zone of the location
where a Project is proposed to be installed (for minimum wind speed of 150 km/hour). Suitable fastening
arrangement should be adopted to secure the installation against the specific wind speed. A certificate of
a structural engineer certifying the strength and stability of the mounting structure to withstand the
weight and wind speed of 150 km/hour throughout the life span of 25 years of the system, shall be
submitted by the vendors.
4.4. The mounting structure steel shall be as per latest IS 2062: 1992 and galvanization of the mounting
structure shall be complying with latest IS 4759.
4.5. Structural material shall be corrosion resistant and electrolytically compatible with the materials used in
the module frame, its fasteners, nuts and bolts. Aluminium structures also can be used, that can
withstand the wind speed of respective wind zone. Necessary protection towards rusting need to be
provided either by coating or anodization.
4.6. The fasteners used should be made up of stainless steel. The structures shall be designed to allow easy
replacement of any module. The array structure shall be so designed that it will occupy minimum space
without sacrificing the output from the SPV panels.
4.7. Regarding civil structures the Successful Bidder need to take care of the load bearing capacity of the
ground and need arrange suitable structures based on the quality of soil/ ground.
4.8. The total load of the structure (when installed with PV modules) on the ground should be less than 60
kg/m2.
4.9. The minimum clearance of the structure from the ground level should be 300 mm. Allowed as per site
feasibility.
4.10. Ballast type structures can be used only for plants for capacity more than 40 kWp.
5. Junction Boxes (JBS) Based on System Design Requirements
5.1. The junction boxes are to be provided in the PV array for termination of connecting cables. The J. Boxes
(JBs) shall be made of GRP/FRP/Powder Coated Aluminium/cast aluminium alloy with full dust, water &
vermin proof arrangement. All wires/cables must be terminated through cable lugs. The JBs shall be such
that input & output termination can be made through suitable cable glands.
5.2. Copper bus bars/terminal blocks housed in the junction box with suitable termination threads
Conforming to IP65 standard and IEC 62208 Hinged door with EPDM rubber gasket to prevent water
entry. Single / double compression cable glands with provision of earthing. It should be placed at 5 feet
or suitable height for ease of accessibility.
5.3. Each Junction Box shall have High quality Suitable capacity Metal Oxide Varistors (MOVs) / SPDs, suitable
Reverse Blocking Diodes. The Junction Boxes shall have suitable arrangement monitoring and
disconnection for each of the groups.
5.4. Suitable markings shall be provided on the bus bar for easy identification and the cable ferrules must be
fitted at the cable termination points for identification.
6. DC Distribution Board Based on System Design Requirements

619
6.1. DC Distribution panel to receive the DC output from the array field.
6.2. DC DPBs shall have sheet from enclosure of dust & vermin proof conform to IP 65 protection. The bus
bars are made of copper of desired size. Suitable capacity MCBs/MCCB shall be provided for controlling
the DC power output to the PCU along with necessary surge arrestors.

7. AC Distribution Panel Board

7.1. AC Distribution Panel Board (DPB) shall control the AC power from PCU/ inverter and should have
necessary surge arrestors. Interconnection from ACDB to mains at LT Bus bar while in grid tied mode.
7.2. All switches and the circuit breakers, connectors should conform to IEC 60947, part I, II and III/ IS60947
part I, II and III.
7.3. The changeover switches, cabling work should be undertaken by the Successful Bidder as part of the
project.
7.4. All the Panel’s shall be metal clad, totally enclosed, rigid, floor mounted, air - insulated, cubical type
suitable for operation on three phase / single phase, 415 or 230 volts, 50 Hz.
7.5. The panels shall be designed for minimum expected ambient temperature of 45 degree Celsius, 80
percent humidity and dusty weather.
7.6. All indoor panels will have protection of IP54 or better. All outdoor panels will have protection of IP65 or
better.
7.7. Should conform to Indian Electricity Act and rules (till last amendment).
7.8. All the 415 AC or 230 volts devices / equipment like bus support insulators, circuit breakers, SPDs, VTs
etc., mounted inside the switchgear shall be suitable for continuous operation and satisfactory
performance under the following supply conditions: -
Variation in supply voltage +/- 10 %
Variation in supply frequency +/- 3 Hz
8. PCU/Array Size Ratio
a) The combined DC wattage of all inverters should not be less than rated capacity of Project under STC.
b) Maximum power point tracker shall be integrated in the PCU/inverter to maximize energy drawn from
the array.
c) 10% (maximum) overloading of inverter is allowed, Subject to manufacturer’s recommendations.
9. Integration Of PV Power With Grid
9.1. For better grid interaction and functioning of Project, the following arrangement shall be ensured by the
vendor:
a) Project should have appropriate instruments installed at solar panel output, inverter and load to
facilitate minute-wise recording and storage of monthly data (voltage, current, generation,
consumption and grid injection) for twelve (12) Months of energy flow at various nodes.
b) In case of network failure, or low or high voltage, Project shall go under islanding mode but not be out
of synchronization so far as its operation with connected load is concerned. The supply from Project
to the load points would be resumed, once the DG set comes into service, Project shall again be
synchronised with DG supply and load requirement would be met to the extent of availability of
power. 4 pole isolation of inverter output with respect to the grid/ DG power connection need to be
provided.
620
10. Data Acquisition System / Project Monitoring
10.1. Data Acquisition System shall be provided for each of the solar PV Project.
10.2. Data Logging Provision for Project control and monitoring, time and date stamped system data
logs for analysis computer for data monitoring, metering and instrumentation for display of systems
parameters and status indication to be provided. Web based Online monitoring can be allowed with Data
Logging for a minimum period of 1 year.
10.3. The following parameters should be accessible via the operating interface display in real time
separately for Project:
a) AC Voltage
b) AC Output current.
c) Output Power
d) Power factor
e) DC Input Voltage
f) DC Input Current
g) Time Active
h) Time disabled
i) Time Idle
j) Power produced.
k) Protective function limits (Viz-AC Over voltage, AC Under voltage, over frequency, Under
frequency ground fault, PV starting voltage, PV stopping voltage.
10.4. All major parameters available on the digital bus and logging facility for energy auditing through
the internal microprocessor and read on the digital front panel at any time) and logging facility (the
current values, previous values for up to a Year and the average values) should be made available for
energy auditing through the internal microprocessor and should be read on the digital front panel.
10.5. String and array DC Voltage, Current and Power, Inverter AC output voltage and current (All 3
phases and lines), AC power (Active, Reactive and Apparent), Power Factor and AC energy (All 3 phases
and cumulative) and frequency shall be monitored.
10.6. The data shall be recorded in a common work sheet chronologically date wise. The data file shall
be MS Excel compatible. The data shall be represented in both tabular and graphical form.
10.7. All instantaneous data should be available through RMS.
10.8. Software shall be provided for USB download and analysis of DC and AC parametric data for
individual Project.
10.9. Provision for Internet monitoring and download of data shall be necessarily incorporated for
projects.
10.10. Remote Monitoring and data acquisition through Remote Monitoring System software with latest
software/hardware configuration and service connectivity for online/real time data monitoring/control
complete to be supplied and Comprehensive O&M/control to be ensured by the supplier. Provision for
interfacing these data on Nodal Agency server and portal in future shall be kept.
11. Transformer “If Required” & Metering

621
11.1. Dry/oil type appropriate kVA, of transformer Step up along with all protections, switchgears,
Vacuum circuit breakers, cables etc. along with required civil work.
11.2. The Successful Bidder must take approval/NOC from the concerned distribution licensee for the
connectivity, technical feasibility, and synchronization of Project with distribution network and submit
the same to Nodal Agency before Commissioning Project.
11.3. Reverse power relay shall be provided by Successful Bidder (if necessary), as per the local
distribution licensee’s requirement.
12. Power Consumption
Regarding the generated power consumption, priority needs to be given for internal consumption first and
thereafter any excess power can be exported to the distribution licensee network.
13. Protections
The Project should be provided with all necessary protections like earthing, Lightning, and grid islanding as
follows:
14. Lightning Protection
The SPV power Project shall be provided with lightning & overvoltage protection of appropriate size. The
main aim in this protection shall be to reduce the over voltage to a tolerable value before it reaches the PV or
other sub system components. The source of over voltage can be lightning, atmosphere disturbances etc. The
entire space occupying the SPV array shall be suitably protected against Lightning by deploying required
number of Lightning Arrestors. Lightning protection should be provided as per IEC 62305 standard. The
protection against induced high voltages shall be provided using metal oxide varistors (MOVs) and suitable
earthing such that induced transients find an alternate route to earth.
15. Surge Protection
Internal surge protection shall consist of three MOV type surge-arrestors connected from +ve and –ve
terminals to earth (via Y arrangement).
16. Earthing Protection

a) Each array structure of the PV yard should be grounded/earthed properly as per IS:3043-1987. In
addition, the lighting arrester/masts should also be earthed inside the array field.
b) Earth resistance shall not be more than 5 ohms. It shall be ensured that all the earthing points are bonded
together to make them at the same potential.
17. Grid Islanding
17.1. In the event of a power failure on the electric grid, it is required that any independent power-
producing inverters attached to the grid turn off in a short period of time. This prevents the DC-to-AC
inverters from continuing to feed power into small sections of the grid, known as “islands.” Powered
islands present a risk to workers who may expect the area to be unpowered, and they may also damage
grid-tied equipment. The Project shall be equipped with islanding protection. In addition to
disconnection from the grid (due to islanding protection) disconnection due to under and over voltage
conditions shall also be provided.
17.2. A manual-disconnect 4 pole isolation switch, besides automatic disconnection to grid would have
to be provided at utility end to isolate the grid connection by the utility personnel to carry out any
maintenance. This switch shall be locked by the utility personnel.
18. AC and DC Cables

622
Cables of appropriate size to be used in the Project shall have the following characteristics:
a) Shall meet IEC 60227/IS 694, IEC 60502/IS1554 standards.
b) Temp. Range: –10oC to +80oC.
c) Voltage rating 660/1000V
d) Excellent resistance to heat, cold, water, oil, abrasion, UV radiation
e) Flexible
f) Sizes of cables between array interconnections, array to junction boxes, junction boxes to Inverter etc.
shall be so selected to keep the voltage drop (power loss) of the entire Project to the minimum. The
cables (as per IS) should be insulated with a special grade PVC compound formulated for outdoor use.
g) Cable Routing/ Marking: All cable/wires are to be routed in a GI cable tray and suitably tagged and
marked with proper manner by good quality ferule or by other means so that the cable easily identified.
h) The Cable should be so selected that it should be compatible up to the life of the solar PV panels i.e.,
twenty-five (25) Operational Years.
i) The ratings given are approximately, Successful Bidder to indicate size and length as per system design
requirement. All the cables required for the Project provided by the Successful Bidder. All cable
schedules/layout drawings approved prior to installation.
j) Multi Strand, Annealed high conductivity copper/aluminum conductor PVC type ‘A’ pressure extruded
insulation or XLPE insulation. Overall PVC/XLPE insulation for UV protection Armored cable for
underground laying. All cable trays including covers to be provided. All cables conform to latest edition of
IEC/ equivalent BIS Standards as specified below: BOS item / component Standard Description Standard
Number Cables General Test and Measuring Methods, PVC/XLPE insulated cables for working Voltage up
to and including 1100 V, UV resistant for outdoor installation IS /IEC 69947.
k) The size of each type of DC cable selected shall be based on minimum voltage drop.
l) The size of each type of AC cable selected shall be based on minimum voltage drop; however, the
maximum drop shall be limited to 2 %.
m) All such external electrical works shall be required to be done as per DISCOMs SOR.
19. Connectivity
The maximum capacity for interconnection with the grid at a specific voltage level shall be as specified in the
Distribution Code/Supply Code of the State and amended from time to time. Following criteria have to be
followed for selection of voltage level in the distribution licensee’s network for ready reference of the solar
suppliers. The work should be done in compliance with respective regulations and policy.
20. Tools & Tackles and Spares
20.1. The requirement of maintaining tools, tackles, and spares at site or at service centre is left to the
discretion of the bidder with a condition that the same would be made available immediately as and
when required.
20.2. The bidders are advised to ensure a response time of 24 hours and maximum expected
turnaround time of 72 hours (under special circumstances, additional time limit may be considered).
20.3. Minimum requisite spares to be maintained by the Successful Bidder, in case of PCU/inverter
comprising of a set of control logic cards, IGBT driver cards etc. Junction Boxes, fuses, MOVs / arrestors,
MCCBs etc. shall be maintained at site or at nearest service centre for the entire period of
Comprehensive O&M.
21. Danger Boards and Signages
623
Danger boards should be provided as and where necessary as per IE Act./IE rules as amended up to date.
22. Fire Extinguishers
The firefighting system for the proposed Project for fire protection shall consist of portable fire extinguishers
in the control room for fire caused by electrical short circuits. The installation of Fire Extinguishers should
confirm to TAC regulations and BIS standards. The fire extinguishers shall be provided in the control room
housing PCUs as well as the PV Array have been installed.
23. Drawings and Manuals
23.1. Two sets of Engineering, electrical drawings and Installation and Comprehensive O&M manuals
are to be supplied. Successful Bidder shall provide complete technical data sheets for each equipment
giving details of the specifications along with make/makes in their bid with basic design of the Project
and power evacuation, synchronization as also protection equipment.
23.2. Approved ISI and reputed makes for equipment be used.
23.3. For complete electro-mechanical works, Successful Bidder shall supply complete design, details
and drawings to Nodal Agency.
24. Planning and Designing
24.1. The Successful Bidder should carry out Shadow Analysis at the site and accordingly design strings
& arrays layout considering optimal usage of space, material and labour. The Successful Bidder should
submit the array layout drawings along with Shadow Analysis Report to the designated authority of
Nodal Agency.
24.2. Nodal Agency reserves the right to modify the landscaping design, Layout and specification of
sub-systems and components at any stage as per local site conditions/requirements.
24.3. The Successful Bidder shall submit preliminary drawing for approval & based on any modification
or recommendation, if any. The Successful Bidder shall submit one sets and soft copy in CD of final
drawing for formal approval to proceed with construction work.
25. Safety Measures
The Successful Bidder shall take entire responsibility for electrical safety of the installation(s) including
connectivity with the grid and follow all the safety rules & regulations applicable as per Electricity Act, 2003
and CEA guidelines etc.
26. Transportation
The responsibility of transportation of materials would lie with the vendor. The vendor shall be responsible
for transporting all materials to the project site.

624

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