TECHNICAL SPECIFICATIONS - JPPGLjaypeepowergrid.com/tenders/Insulator-GIFB/VOLUME-II/Sec... · Web viewThe Impact Test shall be carried out in accordance with ANSI-C-29.2 Clause 8.2.8

TECHNICAL SPECIFICATIONS

TECHNICAL SPECIFICATIONS

SECTION-II

1.0Technical Description of Disc Insulators

1.1Details of Disc Insulators

1.1.1The Insulator strings shall consist of Standard discs for a three phase, 50 Hz, effectively earthed 400 kV transmission system in a lightly polluted atmosphere. The discs shall be cap and pin, ball and socket type.

1.1.2Supplier may quote for disc insulator, made of either electro-porcelain or toughened glass.

1.1.3 The size of disc insulator, minimum creepage distance, the number to be used in different type of strings, their electromechanical strength and mechanical strength of insulator string alongwith hardware fittings shall be as follows :

Sl. No.

Type of string

Size of disc insulators (mm)

Minimum creepage distance of each disc (mm)

No. of disc

Electro-mechnical strength of insulator disc(KN)

Mechanical strength of insulator string along with hardware fittings (KN)

A. For 400 kV D/C (Quad Bundle) TL in Snow Zone

1.

Single ‘I’ suspension Pilot

255x145 or

280x145

315

25

120

120

2.

Quad Tension

280x170

330

4 x 25

160

4 x 160

3.

Single Tension

255x145 or

280x145

315

25

120

120

B. For 400 kV D/C (Quad Bundle) TL in Non-Snow Zone

1.

Double ‘I’ suspension

255x145 or

280x145

315

2 x 23

120

2 x 120

2.


255x145 or

280x145

315

23

120

120

3.

Quad Tension

280x170

330

4 x 23

160

4 x 160

4.

Single Tension

255x145 or

280x145

315

24

120

120

C. For 400 kV D/C (Triple Bundle) TL in Snow Zone

1.


255x145 or

280x145

315

25

120

120

2.

Double Tension

280x170

370

2 x 25

210

2 x 210

1.2Pin and Cap

1.2.1Pin and Cap shall be designed to transmit the mechanical stresses to the shell by compression and develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric, of such design that it will not yield or distort under load conditions.

1.2.2 The pin ball shall move freely in the cap socket but without danger of accidental uncoupling during erection or in position. The design of the disc should be such that stresses due to expansion or contraction in any part of the insulator shall not lead to deterioration.

1.3Security clip

1.3.1Security clip for use with ball and socket coupling shall be of R-shaped hump type which shall provide positive locking of the coupling as per IS:2486-(Part-Ill)/IEC : 372. The legs of the security clips shall be spread after installation to prevent complete withdrawal from the socket. The locking device should be resilient, corrosion resistant and of suitable mechanical strength. There shall be no risk of the locking device being displaced accidentally or being rotated when in position. Under no circumstances shall locking device allow separation of insulator units or fittings.

1.3.2The hole for the security clip shall be countersunk and the clip shall be of such design that the eye of clip may be engaged by a hot line clip puller to provide for disengagement under energised conditions. The force required to pull the security clip into its unlocked position shall not be less than 50N (5 kg) or more than 500N (50 kg).

1.4Ball and Socket Designation

The dimensions of the balls and sockets shall be of 20 mm designation for 120 KN and 160 KN disc insulator & 24 mm designation for 210 KN disc in accordance with the standard dimensions stated in IS:2486 - (Part - II)/IEC:120.

1.5Dimensional Tolerance of Insulator Disc (Standard)

It shall be ensured that the dimensions of the disc insulators are within the limits specified below :

a)

Diameter of Disc (mm)

Standard

Maximum

Minimum

120 KN Disc

255/280

266/293

244/267

160 KN & 210 KN Disc

280

293

267

b)

Ball to ball spacing between discs

Standard

Maximum

Minimum

120 KN Disc

145

149

141

160 KN & 210 KN Disc

170

175

165

1.6Interchangeability

The disc insulators inclusive of the ball and socket fittings shall be of standard design suitable for use with the hardware fittings of any make conforming to relevant Indian/International Standards.

1.7Corona And RI Performance

All surfaces must be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to excessive localised pressure. The metal parts shall be so designed and manufactured that it shall not generate any Radio Interference beyond specified limit and not produce any noise generating corona under the operating conditions.

1.8Maintenance

1.8.1The disc insulators offered shall be suitable for employment of hot line maintenance techniques so that the usual hot line operations can be carried out with ease, speed and safety.

1.8.2Bidders shall indicate the methods generally used in the routine hot and dead line maintenance of EHV Lines for which similar disc insulators have been supplied by them. Bidders shall also indicate the recommended periodicity of such maintenance.

1.9Materials

1.9.1Porcelain

The porcelain used in the manufacture of shells shall be sound, free from defects thoroughly vitrified and smoothly glazed.

1.9.2Glaze

The finished porcelain shall be glazed in brown colour. The glaze shall cover all exposed parts of the insulator and shall have a good lusture, smooth surface and good performance under the extreme weather conditions of a tropical climate. It shall not crack or chip by ageing under the normal service conditions. The glaze shall have the same coefficient of expansion as of the porcelain body throughout the working temperature range.

1.9.3Toughened Glass

The glass used for the shells shall be sound, free from defects such as flaws. bubbles, inclusions etc. and be of uniform toughness over its entire surface. All exposed glass surfaces shall be smooth.

1.9.4Cement

Cement used in the manufacture of the insulator shall not cause fracture by expansion or loosening by contraction. The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as small and uniform as possible. Proper care shall be taken to correctly centre and locate individual parts during cementing.

1.9.5Pins and Caps

Pins and Caps shall be made of drop forged steel and malleable cast iron/spheriodal graphite iron/drop forges steel respectively, duly hot dip galvanised and shall not be made by jointing, welding, shrink fitting or any other process from more than one piece of material.

1.9.6Security Clips

Security clips shall be made of good quality stainless steel or phosphor bronze as per IS:1385. 2.5% extra Security clip shall be provided.

1.10Workmanship

1.10.1All the material shall be of the latest design and conform to the best modern practices adopted in the extra high voltage field. Suppliers shall offer only such insulators as are guaranteed by him to be satisfactory and suitable for 400 kV Transmission lines and will give continued good service.

1.10.2The 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 to limit corona and radio interference.

1.10.3The 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.

1.10.4Metal caps shall be free from cracks, seams, shrinks, air holes, burrs and rough edges. All surfaces of the metal parts shall be perfectly smooth with no 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.

1.10.5All ferrous parts shall be hot dip galvanised to give a minimum average coating of Zinc equivalent to 600 gm/sq.m. and shall be in accordance with the requirement of IS:2629 and shall satisfy the tests mentioned in IS:2633. The zinc used for galvanising shall be of Grade Zn 99.95 as per IS:209. The zinc coating shall be uniform, adherent, smooth, reasonably bright, continuous and free from imperfections such as flux, ash, rust stains, bulky white deposits and blisters. The galvanised metal parts shall be guaranteed to withstand atleast six successive dips each lasting for one (1) minute duration under the standard preece test.

1.10.6Before ball fittings are galvanised, all die flashing on the shank surface of the ball shall be carefully removed without reducing the dimensions below the design requirements.

1.10.7The design of the insulators shall be such that the shell shall not engage directly with hard metal. The design shall also be such that when units are coupled together there is no contact between the shell of one unit and metal of the next adjacent unit. The design of the shell ribs shall be such that the security clip of the insulator can be engaged and disengaged easily with hot stick without damaging the shell ribs.

1.10.8Insulator units after assembly shall be concentric and co-axial within limits as permitted by the relevant Indian Standards.

1.10.9The manufacturer of the insulators shall guarantee an insulator failure rate not exceeding 1 (one) per 10000 (ten thousand) per year for disc insulator per year. In case the annual failure rate during the first ten years of service exceeds the above figure, under normal operating condition, as will be determined by check to be conducted as per mutually agreed procedure and conditions upto ten years, (as permitted by the operating situation), the Supplier shall supply to the Owner free of cost spare insulators equal to 10 time the excess failure.

1.10.10The Supplier shall guarantee that there shall not be any decapping/breaking of insulators on line under normal operating conditions. In the event of any decapping/breaking and subsequent line drop, during the first ten years of service the Supplier shall have to pay Rs. 50,000/- (Rs. Fifty thousand only) per dropped string towards expenditure to be incurred by OWNER for this line repair.

2.0Technical Description of Porcelain Long Rod Insulators

2.1Details of Long Rod Insulators

2.1.1The insulators of the stings shall consist of standard long rod insulators with normal sheds for a three phase, 50 Hz, effectively earthed 400 kV transmission system in a lightly polluted atmosphere. Insulators shall be long rod type with Ball and socket connections.

2.1.2Insulators shell have normal sheds/alternate sheds with good self-cleaning properties. Insulator shed profile, spacing projection etc. shall be strictly in accordance with the recommendation of IEC-815.

2.1.3Supplier quoting for long rod insulators made of electro porcelain shall also supply intermediate ball pins and intermediate arcing horns along with long rod insulators.

The price of these items shall be considered as including in the price of long rod insulators.

2.1.4The size of long rod insulator, minimum creepage distance, the number to be used in different type of strings, their electromechanical strength and mechanical strength of insulator string alongwith hardware fittings shall be as follows :

2.1.5 Description of long rod insulator string (equivalent to standard disc insulator)

Sl. No.

Type of string

Size of long rod insulators (mm)

Minimum creepage distance of each unit (mm)

No. of individual units per string

Electro-mechanical strength of insulator disc(KN)

Mechanical strength of insulator string along with hardware fittings (KN)

A. For 400 kV D/C (Quad Bundle) TL in Snow Zone

1.


60-85

2625

1 x 3

120

120

2.

Quad Tension

75-85

2750

4 x 3

160

4 x 160

3.

Single Tension

60-85

2625

1 x 3

120

120

B. For 400 kV D/C (Quad Bundle) TL in Non-Snow Zone

1.

Double ‘I’ suspension

60-85

2415

2 x 3

120

2 x 120

2.

Single ‘I’ suspension pilot

60-85

2415

1 x 3

120

120

3.

Quad Tension

75-85

2530

4 x 3

160

4 x 160

4.

Single Tension

60-85

2415

1 x 3

120

120

C. For 400 kV D/C (Triple Bundle) TL in Snow Zone

1.


60-85

2625

1 x 3

120

120

2.

Double Tension

85-90

3084

2 x 3

210

2 x 210

Note : (i) Bidders may quote for the relevant strings.

(ii) Length of long rod insulator strings shall be matching with the corresponding disc insulator strings.

(iii) The cost of intermediate Ball pin and intermediate arcing horn shall be considered as including in the price of long rod insulators.

2.2Pin and Cap

2.2.1Pin and cap shall be designed to transmit the mechanical stresses to the shell by compression and develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric, of such design that it will not yield or distort under load conditions.

2.2.2The pin ball shall move freely in the cap socket but without danger of accidental uncoupling during erection or in position. The design of the long rod should be such that stresses due to expansion or contraction in any part of the insulator shall not lead to deterioration.

2.3Ball and Socket Designation

The dimensions of the balls and socket shall be of 20 mm designation for 120 & 160 KN for long rod insulators and 24 mm designation for 210 KN long rod insulators in accordance with the standard dimensions stated in IS 2486-(Part-II)/IEC:120.

2.4Dimensional Tolerance

The tolerance on all dimensions e.g. diameter, length and creepage distance shall be allowed as follows :

± (0.04 d + 1.5) mm when d < 300 mm.

± (0.025d + 6) mm when d > 300 mm

Where d being the dimensions in millimeters for diameter, length or creepage distance as the case may be.

However, no negative tolerance shall be applicable to creepage distance.

2.5Intermediate Ball Pin Designation

The dimensions of the intermediate ball pin shall be in accordance with the standard dimension stated in IEC:471.

2.6Intermediate Arcing Horn

2.6.1For Insulator strings with long rod insulators besides the arcing horn on tower side of hardware fittings, intermediate arcing horns along with fixtures and fasteners as shown in the specification shall also be provided.

The total effective arcing distance shall be 3050 mm (for TL in Non-snow zone) and 3340 mm (for TL in Snow zone) under nominal dimensions of insulator.

2.6.2The spark gap shall be so adjusted to ensure effective operation under actual field coordination.

2.7Inter Changeability

The long rod insulators with ball and socket connection shall be of standard design suitable for use with the hardware fittings of any make conforming to relevant IEC standards.

2.8Corona and RI Performance

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to excessive localised 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.

2.9Maintenance

2.9.1The long rod insulators offered shall be suitable for employment of hot line maintenance techniques so that usual hot line operations can be carried out with ease, speed and safety.

2.9.2All insulators shall be designed to facilitate cleaning and insulators shall have the minimum practical number of sheds and grooves. All grooves shall be so proportioned that any dust deposit can be removed without difficulty either by wiping with a cloth or by remote washing under live line condition.

2.10Materials

2.10.1Porcelain

The porcelain used in the manufacture of long rods shall be alumina type. It shall be sound, free from defects and thoroughly vitrified and smoothly glazed.

2.10.2Glaze

The finished porcelain shall be glazed in brown colour. The glaze shall cover all exposed parts of the insulator and shall have a good lusture, smooth surface and good performance under the extreme weather conditions of a tropical climate. It shall not be cracked or chipped by aging under the normal service conditions. The glaze shall have the same co-efficient of expansion as of the porcelain body throughout the working temperature range.

2.10.3Insulator Cap

The caps of long rod insulator units shall be of malleable cast iron or other suitable material, duly hot dip galvanised and shall not be made by jointing, welding, shrink fitting or any other process from more than one piece of material. The design of the unit shall be such that stresses due to expansion and contraction of any part of the insulator shall not lead to deterioration.

2.10.4Intermediate Ball Pin

The intermediate ball pin shall be made of drop forged steel, duly hot dip galvanised and shall not be made by jointly welding, shrink filling or any other process from more than one piece of material.

2.10.5Intermediate Arcing horn

Intermediate Arcing horn shall be mild steel tube.

2.10.6Cement

Cement used in the manufacture of the insulator shall not cause fracture by expansion or loosening by contraction. The cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as small and uniform as possible. Proper care shall be taken to correctly centre and locate individual parts during cementing.

2.11Workmanship

2.11.1All the materials shall be of latest design and conform to the best modern practices adopted in the extra high voltage field. Bidders shall offer only such insulators as are guaranteed by him to be satisfactory and suitable for 400 kV transmission lines and will give continued good service.

2.11.2The 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 to limit corona and radio interference.

2.11.3The 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.

2.11.4Metal caps shall be free from cracks, seams, shrinks, air holes and rough edges. All surfaces of the metal parts shall be perfectly smooth with the 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.

2.11.5All ferrous parts shall be not dip galvanised to give a minimum average coating of zinc equivalent to 600 gm/sq. mm. and shall be in accordance with the requirement of IS: 2629 and shall satisfy the tests mentioned in IS : 2633. The zinc coating shall be uniform, adherent, smooth, reasonably bright continuous and free from imperfections such as flux, ash, rust stains, bulky white deposits and blisters. the galvanised metal parts shall be guaranteed to withstand at least six successive dips each lasting for one (1) minute duration under the standard preece test. The galvanising shall be carried out only after any machining.

2.11.6The design of the insulators shall be such that the porcelain shall not engage with hard metal.

2.11.7Insulator units after assembly shall be concentric and co-axial within limits as permitted by the relevant international standard.

2.11.8The manufacturer of the insulators shall guarantee an insulator failure rate not exceeding one per 1500 porcelain long rod units. In case the annual failure rate during the first ten years of operation exceeds the above figure under normal operating conditions, as will be determined by check to be conducted as per mutually agreed procedure and conditions upto ten years (as permitted by the operating situation). The manufacturer shall supply to the owner free of cost spare insulators (Porcelain long rod) equal to 10 times the excess failure.

2.11.9The manufacturer shall guarantee that there shall not be any decapping and breakage of insulators or line under normal operating conditions. In event of any decapping or breakage resulting in line drop during the first ten years of service the manufacturer shall have to pay Rs. 50,000/- (Rs. fifty thousand) per dropped string towards expenditure to be incurred by OWNER for this line repair.

3.0Equipment Marking

3.1Each insulator disc/long rod unit shall be legibly and indelibly marked with the trade mark of the manufacturer, name of OWNER and month & year of manufacture. The guaranteed combined mechanical and electrical strength shall be indicated in kilo Newton followed by the word ‘kN’ to facilitate easy identification and to ensure proper use.

3.2For porcelain insulator, the marking shall be on porcelain. The marking shall be printed, not impressed and shall be applied before firing. For toughened glass insulators the marking shall be on the metal parts.

3.3One 10 mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on the cap of each insulator porcelain disc/porcelain long rod of particular strength for easy identification of the type of insulator. The paint shall not have any deteriorating effect on the insulator performance. Following codes shall be used as identification mark :

For120 kN disc/ long rod unit:Yellow

For160 kN disc / long rod unit:Green

For210 kN disc / long rod unit:Blue

4.0Bid Drawings

4.1The Bidder shall furnish full description and illustration of the material offered.

4.2The Bidder shall furnish along with the bid the outline drawing (6 copies) of each insulator unit including a cross sectional view of the insulator shell. The drawing shall include but not limited to the following information :

(a)Shell diameter and ball to ball spacing with manufacturing tolerances

(b)Minimum Creepage distance with positive tolerance

(c)Protected creepage distance

(d)Eccentricity of the disc

(i)Axial run out

(ii)Radial run out

(e)Unit mechanical and electrical characteristics

(f)Size and weight of ball and socket parts

(g)Weight of unit insulator disc/long rod units

(h)Materials

(i)Identification mark

(j)Manufacturer's catalogue number

4.3 After placement of award, the Supplier shall submit full dimensioned insulator drawings containing all the details as given in Clause No. 4.11.2 above, in four (4) copies to Owner for approval. After getting approval from Owner and successful completion of all the type tests, the Supplier shall submit 20 more copies of the same drawing to the Owner for further distribution and field use at Owner's end.

4.4After placement of award the Supplier shall also submit fully dimensioned insulator crate drawing for different type of insulators.

4.5After placement of award, the Supplier shall submit full dimensioned manufacturing drawing of insulator cap, pin and insulator shell in six (6) copies to the Owner for reference and record.

5.0Tests and Standards

5.1Type Tests

The following type tests shall be conducted on a suitable number of individual standard disc insulators or long rod units, components, materials or complete strings:

5.1.1On unit disc Insulators

a)

Verification of dimensions

As per IEC :60383

b)

Thermal mechanical performance test

As per Annexure-A

c)

Power frequency voltage withstand and flashover test under (i) dry

(ii) wet condition

As per IEC : 60383

d)

Impulse voltage withstand and flashover test (dry)

As per IEC : 60383

e)

Visible Discharge test (dry)

As per IS:731, Cl. 10.2

f)

RIV test (dry)

As per IEC:60437

g)

Residual strength Test

As per Annexure-A

h)

Steep wave front Test

As per Annexure-A

i)

Impact Test

As per Annexure-A

5.1.2On Porcelain long rod Insulator units

a)


As per IEC : 60383

b)

Thermal mechanical performance test

As per Annexure-A

c)

Power frequency voltage withstand and flashover test under (i) dry

(ii) wet condition

As per IEC : 60383

d)

Impulse voltage withstand and flashover test (dry)

As per IEC : 60383

e)

Visible Discharge test (dry)

As per IS:731, Cl 10.2

f)

RIV test (dry)

As per IEC:60437

5.1.3On the complete Disc Insulator String with Hardware Fittings

a)

Power frequency voltage withstand test with corona control rings/grading ring and arcing horns under wet condition

As per IEC : 60383

b)

Switching surge voltage withstand test under wet condition

As per IEC: 60383

c)

Impulse voltage withstand test under dry condition

As per IEC : 60383

d)

Impulse voltage flash over test under dry condition

As per IEC : 60383

e)

Voltage distribution test

As per Annexure-A

f)

Corona and RIV test under dry condition

As per Annexure-A

g)

Mechanical Strength test

As per Annexure-A

h)

Vibration test

As per Annexure-A

i)

Power-Arc Test

As per Annexure-A

5.1.4On the complete Porcelain long rod Insulator string with Hardware Fittings

a)

Power frequency voltage withstand test with corona control rings/grading ring and arcing horns under wet condition

As per IEC : 60383

b)

Switching surge voltage withstand test under wet condition

As per IEC : 60383

c)

Impulse voltage withstand test under dry condition

As per IEC : 60383

d)

Impulse voltage flash over test under dry condition

As per IEC : 60383

e)

Corona and RIV test under dry condition

As per Annexure-A

f)

Mechanical Strength test

As per Annexure-A

g)

Vibration test

As per Annexure-A

h)

Power-Arc Test

As per Annexure-A

5.1.5All the type test given in Clause No. 5.1.3 for disc insulator string or Clause No. 5.1.4 for long rod porcelain insulator string shall be conducted on 400 kV Double Suspension and Quad Tension insulator strings along with hardware fittings for 400 kV (Quad Bundle) Lines. All the type test given in Clause No. 5.1.3, except clause 5.1.3 (i) for disc insulator string or Clause No. 5.1.4, except clause 5.1.4 (h) for long rod porcelain insulator string shall be conducted on 400 kV Double Tension insulator strings along with hardware fittings for 400 kV (Triple Bundle) Line.

5.1.6All the type tests given under Clause No. 5.1.3 (a) to (g) for disc insulator string or 5.1.4 (a) to (f) for porcelain long rod insulator string shall also be conducted on 400 kV Single Suspension Pilot and Single Tension Insulator strings.

5.1.7Type tests specified under Clause 5.1.3 (a) to (d) or under Clause 5.1.4 (a) to (d) shall not be required to be carried out if a valid test certificate is available for a similar design, i.e., tests conducted earlier should have either been conducted in accredited laboratory (accredited based on ISO/IEC vide 25/17025 or EN 45001 by the National accreditation body of the country where laboratory is located) or witnessed by the representative(s) of OWNER or utility. The test reports submitted shall be for the tests conducted within last 5 (five) years prior to date of bid opening.

In case the test have been conducted earlier than the above stipulated period or in the event of any discrepancy in the test report (i.e., any test not applicable due to any design/manufacturing change including substitution of components or due to non-compliance with the requirement stipulated in the Technical Specifications), the tests shall be conducted by the Supplier at no extra cost to the Owner.

5.2Acceptance Tests

5.2.1For Disc Insulators (Both porcelain and glass)

a)

Visual examination

As per IEC : 60383

b)


As per IEC : 60383

c)

Temperature cycle test

As per IEC : 60383

d)

Galvanising test

As per IEC : 60383

e)

Mechanical performance test

As per IEC:60575Cl 4.0

f)

Test on locking device for ball and socket coupling

As per IEC:60372

g)

Eccentricity test

As per IEC:60383

h)

Residual Strength Test

As per IEC:797

Clause 4.4 & 4.5

i)

Metallurgical Test (For metal fittings only in black condition)

As per Annexure-A

i)

Grain size

ii)

Inclusion rating

iii)

Chemical analysis

iv)

Microstructure

j)

Chemical analysis of Zinc Sleeve

As per Annexure-A

k)

IR Measurement

As per Annexure-A

l)

Impact Test

As per Annexure-A

m)

Steep Wave front test

As per Annexure-A

n)

Thermal Mechanical performance test

As per Annexure-A

Note : Tests specified under Clause 5.2.1 (m) & (n) above shall be performed as acceptance tests once for every supply of 25,000 nos. of a particular rating.

5.2.2For Porcelain disc Insulators Only

a)

Electro-mechanical strength test

As per Annexure-A

b)

Porosity test

As per IEC : 60383

c)

Puncture test

As per IEC : 60383

5.2.3For Glass Insulators Only

a)

Thermal shock test

As per IEC : 60383

b)

Steep wave front test/Puncture test

As per Annexure-A

c)

Mechanical failing load Test

As per Annexure-A

5.3For Porcelain Long rod Insulators

a)

Visual examination

As per IEC : 60383

b)


As per IEC : 60383

c)

Temperature cycle test

As per IEC : 60383

d)

Galvanising test

As per IEC : 60383

e)

Mechanical performance test

As per IEC:60575

Clause 4.0

f)

Test on locking device for ball and socket coupling

As per IEC:60372

g)

Eccentricity test

As per IEC : 60383-1

h)

Mechanical failing load test

As per IEC : 60383-1

i)

Porosity test

As per IEC : 60383

j)

Metallurgical Test (For metal fittings only in black condition)

As per Annexure-A

i)

Grain size

ii)

Inclusion rating

iii)

Chemical analysis

iv)

Microstructure

k)

Thermal Mechanical performance test

As per Annexure-A

Note : The test specified under 5.3 (k) above shall be performed as acceptance test once for every supply of 3260 nos. long rod insulator units of a particular rating.

5.4Routine Tests

5.4.1For Disc Insulators

a)

Visual Inspection

As per IS:731, Cl. 10.13

b)

Mechanical routine test

As per IS:731 Cl. 10.14

c)

Electrical routine test (for porcelain disc insulator only)

As per IS:731 Cl. 10.15

d)

Thermal shock routine test (for glass insulator only)

As per IEC:60383

e)

Polarised Light Inspection (for glass insulator only)

As per Annexure-A

5.4.2For Porcelain Long Rod Insulator Units

a)

Visual Inspection

As per IEC:60383

b)

Mechanical routine test)

As per IEC:60383

5.5Tests During Manufacture

On all components as applicable

a)

Chemical analysis of zinc used for galvanising

As per Annexure-A

b)

Chemical analysis, mechanical, metallographic test and magnetic particle inspection for malleable castings.

As per Annexure-A

c)

Chemical analysis hardness tests and magnetic particle inspection for forgings

As per Annexure-A

d)

Hydraulic Internal Pressure tests on disc insulator shells

As per Annexure-A

e)

Autoclave Test on Cement

As per Annexure-A

5.6Testing Expenses

5.6.1Testing charges for the type test specified shall be indicated separately in the prescribed schedule.

5.6.2Bidder shall indicate unit type test charges for all type tests covered under Clause 5.1.1/5.1.2 and 5.1.3 (e) to (i)/5.1.4 (e) to (h) separately, in the relevant schedule of Prices as applicable. Charges for each type tests shall be separately indicated.

5.6.3For Type Tests which involves the tests on the complete insulator string with hardware fitting the Contractor of hardware fittings shall supply the necessary number of sets of hardware fittings at the place of testing free of cost.

5.6.4In case of failure in any type test the bidder whose material has failed is either required to modify the design of the material & successfully carryout all the type tests as has been detailed out in Clause 5.1.3 or 5.1.4 of this specifications or to repeat that particular type test at least three times successfully at his own expenses. Incase of failure of the complete string in any type test, the manufacturer whose product has failed in the use shall get the test repeated at his cost. The Supplier whose material has not failed in the test shall be required to supply the requisite quantity of material (that is insulator or hardware fittings as the case may be) required for repeat testing at the place of testing and the cost of supply shall be borne by the Supplier whose material has failed in testing.

5.6.5Supplier shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that adequate facilities are available in the laboratory and the tests can be completed in these laboratories within the time schedule guaranteed by them in the appropriate schedule.

5.6.6The entire cost of testing for acceptance and routine tests and tests during manufacture specified herein shall be treated as included in the quoted Ex-works/CIF Price.

5.6.7In case of failure in any type test, if repeat type tests are required to be conducted, then all the expenses for deputation of Inspector/ Owner's representative shall be deducted from the contract price. Also if on receipt of the Supplier's notice of testing, the Owner's representative does not find material or test facilities to be ready for testing the expenses incurred by the Owner for redeputation shall be deducted from contract price.

5.6.8The Supplier shall intimate the Owner about carrying out of the type tests alongwith detailed testing programme at least 3 weeks in advance (in case of testing in India) and at least 6 weeks advance (in case of testing abroad) of the scheduled date of testing during which the Owner will arrange to depute his representative to be present at the time of carrying out the tests.

5.7Sample Batch for Type Testing

5.7.1The Supplier shall offer material for sample selection for type testing only after getting Quality Assurance Programme approved by the Owner. The Supplier shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. The sample for type testing will be manufactured strictly in accordance with the Quality Assurance Programme approved by the Owner.

5.7.2Before sample selection for type testing, the Supplier shall be required to conduct all the acceptance tests successfully in presence of Owner's representative.

5.8Schedule of Testing

5.8.1The Bidder has to indicate the schedule of following activities in their bids :

a)Submission of drawing for approval.

b)Submission of Quality Assurance Programme for approval.

c)Offering of material for sample selection for type tests.

d)Type testing.

5.9Repeat E&M Strength Test

5.9.1E&M test on 20 nos. for disc insulator or 3 nos. for Porcelain longrod insulator of samples for every lot of 10,000 nos. or 1500 nos. for Porcelain longrod received at site shall be conducted. Testing expenses have to be borne by the Supplier and shall be included in quoted Ex-works/CIF price. Incase of failure, it will be repeated on double no. of samples and if it again fails, the whole lot should be rejected and shall be replaced by the Supplier. The samples have to be taken at random after segregating insulators damaged in transportation or otherwise.

5.9.2The Owner reserves the right of having at his own expenses any other test(s) of reasonable nature carried out at Supplier's premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the material comply with the Specifications.

5.9.3The Owner also reserves the right to conduct all the tests mentioned in this specification at his own expense on the samples drawn from the site at Supplier's premises or at any other test centre. In case of evidence of non compliance, 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 Owner.

5.10Co-ordination for Testing

The Supplier shall have to co-ordinate testing of insulators with hardware fittings to be supplied by other Supplier and shall have to guarantee overall satisfactory performance of the insulators with the hardware fittings.

5.11Guarantee

The Supplier of insulators shall guarantee overall satisfactory performance of the insulators with the hardware fittings.

5.12Test Reports

5.12.1Copies of type test reports shall be furnished in at least six (6) copies along with one original. One copy shall be returned duly certified by the Owner only after which the commercial production of the concerned material shall start.

5.12.2Copies of acceptance test reports shall be furnished in at least six (6) copies. One copy shall be returned duly certified by the Owner, only after which the material shall be dispatched.

5.12.3Record of routine test reports shall be maintained by the Supplier at his works for periodic inspection by the Owner’s representative.

5.12.4Test certificates of test during manufacture shall be maintained by the Supplier. These shall be produced for verification as and when desired by the Owner.

5.13Inspection

5.13.1The Owner’s representative shall at all times be entitled to have access to the works and all places of manufacture, where insulator, and its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection of the Supplier’s and sub-Supplier’s works, raw materials, manufacture of the material and for conducting necessary test as detailed herein.

5.13.2The material for final inspection shall be offered by the Supplier only under packed condition as detailed in clause No.5.14 of the specification. The Owner shall select samples at random from the packed lot for carrying out acceptance tests. Insulators shall normally be offered for inspection in lots not exceeding 10,000 nos. for disc / 650 units for long rod insulator. The lot should be homogeneous and should contain insulators manufactured in 3-4 consecutive weeks.

5.13.3The Supplier shall keep the Owner informed in advance of the time of starting and the progress of manufacture of material in their various stages so that arrangements could be made for inspection.

5.13.4No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the Owner in writing. In the latter case also the material shall be dispatched only after satisfactory testing for all tests specified herein have been completed.

5.13.5The acceptance of any quantity of material shall be no way relieve the Supplier of his responsibility for meeting all the requirements of the specification and shall not prevent subsequent rejection, if such material are later found to be defective.

5.14Packing and Marking

5.14.1All insulators shall be packed in strong seasoned wooden crates. The gross weight of the crates along with the material shall not normally exceed 200 Kg to avoid handling problem. For marine transportation crates shall be palleted.

5.14.2The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and subsequent handling in the field.

5.14.3Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent damage or deformation during transit and handling.

5.14.4All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings. Each wooden case/crate shall have all the markings stencilled on it in indeliable ink.

5.15Standards

The insulator strings and its components shall conform to the following lndian/ International Standards which shall mean latest revision, with amendments/changes adopted and published, unless specifically stated otherwise in the Specification.

5.15.1In the event of supply of insulators conforming to standards other than specified, the Bidder shall confirm in his bid that these standards are equivalent to those specified. In case of award, salient features of comparison between the standards proposed by the Bidder and those specified in this document will be provided by the Supplier to establish equivalence.

Sl. No.

Indian Standard

Title

International Standard

1.

IS:209-1992

Specification for zinc

BS:3436

2.

IS:406-1991

Method of Chemical Analysis of Slab Zinc

BS:3436

3.

IS:731-1991

Porcelain insulators for overhead Power lines with a nominal voltage greater than 1000 V

BS:137- (I&II) IEC:60383

4.

IS:2071 Part (I) – 1993 (Part(II)- 1991 Part(III)- 1991

Methods of High Voltage Testing

IEC:60060-1

5.

IS:2486

Part- I-1993

Part- II-1989

Part-III-1991

Specification for Insulator fittings for Overhead Power Lines with a nominal voltage greater than 1000V

General Requirements and TestsDimensional Requirements

Locking Devices

BS:3288

IEC:60120

IEC:60372

6.

IS:2629-1990

Recommended Practice for Hot, Dip Galvanisation for iron and steel

ISO-1461 (E)

7.

IS:2633-1992

Testing of Uniformity of Coating of zinc coated articles

8.

IS:3188-1988

Dimensions for Disc Insulators

IEC:60305

9.

IS:6745-1990

Determination of Weight of Zinc Coating on Zinc coated iron and steel articles

BS:433-1969 ISO:1460-1973

10.

IS:8263-1990

Methods of RI Test of HV insulators

IEC:60437

NEMA Publi- cation No.07/ 1964/ CISPR

11.

IS:8269-1990

Methods for Switching Impulse test on HV insulators

IEC:60506

12.

Thermal Mechanical Performance test and mechanical performance test on string insulator units

IEC: 60575

13.

Salt Fog Pollution Voltage Withstand Test

IEC:60507

14.

Residual Strength of String Insulator Units of Glass or Ceramic Material for Overhead Lines after Mechanical Damage of the Dielectric

IEC:60797

15.

Guide for the selection of insulators in respect of polluted conditions

IEC:60815

16.

Tests on insulators of Ceramic material or glass or glass for overhead lines with a nominal voltage greater than 1000V

IEC:60383

17.

Characteristics of string insulator units of the long rod type

IEC : 60433

18.

Standard Test Method for Autoclave Expansion of Portland Cement

ASTM C151-93-a

19.

American National Standard for Insulators wet process porcelain and toughened glass suspension type

ANSI C29-2-1992

The standards mentioned above are available from:

Reference Abbreviation

Name and Address

BS

British Standards,

British Standards Institution

101, Pentonvile Road,

N - 19-ND, UK

IEC/CISPR

International Electro technical Commission,

Bureau Central de la Commission,

electro Technique international,

1 Rue de verembe,

Geneva, SWITZERLAND

BIS/IS

Beureau Of Indian Standards.

Manak Bhavan,

9, Bahadur Shah Zafar Marg,

New Delhi – 110001, INDIA

ISO

International Organisation for Standardization.

Danish Board of Standardization

Danish Standardizing Sraat,

Aurehoegvej-12

DK-2900, Heeleprup, DENMARK.

NEMA

National Electric Manufacture Association,

155, East 44th Street.

New York, NY 10017, U.S.A.

ASTM

American Society for Testing and Materials,

1916 Race St. Phelledelphia, PA19103 USA

A.STANDARD TECHNICAL PARTICULARS OF NORMAL INSULATOR DISCS

S.N.

DESCRIPTION

UNIT

120 KN

160KN

1.0

GENERAL

(a)

Size and designation of ball and socket

mm

20.0as per IS2486/IEC120


2.0

DIMENSIONS

(a)

Disc insulator diameter

mm

255.0 or 280.0

280.0

(b)

Tolerance of dia.

±mm

11.0(for 255.0)/13.0(for 280.0)

13.0

(c)

Ball to ball spacing between disc

mm

145.0

170.0

(d)

Tolerance of spacing

±mm

4.0

5.0

(e)

Minimum Creepage distance of single disc

mm

315.0

330.0

3.0

Colour of glaze of finished porcelain insulator

NA

Brown

Brown

4.0

ELECTRO-MECANICAL STRENGTH

KN

120.0

160.0

5.0

MINIMUM ELECTRICAL VALUES

(a)

Power frequency flashover voltage (dry)

kV(rms)

75.0

78.0

(b)

Power frequency flashover voltage(wet)

kV(rms)

45.0

48.0

(c)

Impulse flashover voltage positive (dry)

kV peak

115.0

120.0

(d)

Impulse flashover voltage negative (dry)

kV peak

120.0

125.0

(e)

Power frequency withstand voltage(dry)

kV(rms)

70.0

72.0

(f)

Power frequency withstand voltage(wet)

kV(rms)

40.0

42.0

(g)

Impulse withstand voltage positive (dry)

kV peak

110.0

115.0

(h)

Impulse withstand voltage negative (dry)

kV peak

110.0

115.0

(i)

Steepness of impulse voltage(steep wave front test)

Kv/µs

2500.0

2500.0

6.0

POWER FREQUENCY PUNCTURE VOLTAGE

kV(rms)

120.0

125.0

7.0

MIN VISIBLE DISCHARGE VOLTAGE OF SINGLE

kV (rms)

18.0

18.0

DISC(DRY)

8.0

MAX RIV AT 1MHz and 10 KV(rms)

µV

50.0

50.0

9.0

No. of dips in standard preece test

Nos

(6 dips of 1min)

(6 dips of 1min)

10.0

ECCENTRICITY OF DISC

(a)

Max radial runout

mm

7.65(for 255.0)/8.40(for 280.0)

8.4

(b)

Max axial runout

mm

10.20(for 255.0)/11.20(for 280.0)

11.2

11.0

MINIMUM MASS OF ZINC COATING

gm/sq. m.

600

600

12.0

MINIMUM ZINC PURITY USED FOR GALVANIZING

%

99.95%

99.95%

S.N.

DESCRIPTION

UNIT

210KN

1.0

GENERAL

(a)

Size and designation of ball and socket

mm


2.0

DIMENSIONS

(a)

Disc insulator diameter

mm

280.0

(b)

Tolerance of dia.

±mm

13.0

(c)

Ball to ball spacing between disc

mm

170.0

(d)

Tolerance of spacing

±mm

5.0

(e)

Minimum Creepage distance of single disc

mm

370.0

3.0


NA

Brown

4.0

ELECTRO-MECANICAL STRENGTH

KN

210.0

5.0


(a)


kV(rms)

78.0

(b)


kV(rms)

48.0

(c)


kV peak

120.0

(d)


kV peak

125.0

(e)


kV(rms)

72.0

(f)


kV(rms)

42.0

(g)


kV peak

115.0

(h)


kV peak

115.0

(i)

Steepness of impulse voltage(steep wave front test)

Kv/µs

2500.0

6.0

POWER FREQUENCY PUNCTURE VOLTAGE

kV(rms)

125.0

7.0

MIN VISIBLE DISCHARGE VOLTAGE OF SINGLE

kV (rms)

18.0

DISC(DRY)

8.0

MAX RIV AT 1MHz and 10 KV(rms)

µV

50.0

9.0

No. of dips in standard preece test

Nos

(6 dips of 1min)

10.0

ECCENTRICITY OF DISC

(a)

Max radial runout

mm

8.4

(b)

Max axial runout

mm

11.2

11.0

MINIMUM MASS OF ZINC COATING

gm/sq. m.

600

12.0

MINIMUM ZINC PURITY USED FOR GALVANIZING

%

99.95%

B.STANDARD TECHNICAL PARTICULARS OF NORMAL LONGROD INSULATOR UNITS

S.N.

DESCRIPTION

UNIT

120 KN

160 KN

1.0

Size and designation of ball and socket assembly

mm



2.0

Core diameter (d)

mm

60 to 85

75 to 85

3.0

Tolerance on Core diameter

±mm

(0.04d +1.5)

(0.04d +1.5)

4.0

Minimum Creepage distance

mm

2415*/2625#

2530*/2750#

5.0


NA

Brown

Brown

6.0

Mechanical strength

KN

120.0

160.0

7.0


a


Kv(rms)

270.0

290.0

b


kV(rms)

240.0

250.0

c


kV peak

550.0

550.0

d


kV peak

570.0

570.0

E


Kv(rms)

250.0

270.0

F


Kv(rms)

230.0

230.0

G


Kv(rms)

500.0

500.0

H


Kv(rms)

510.0

510.0

8.0

No. of one minute dips which the end fittings can withstand

Nos.

6.0

6.0

in standard preece test

9.0

Max axial/radial runout(as per pointer B)

mm

1.2% of insulator length


10.0

Maximum Angular displacement

degree

15.0

15.0

11.0

Minimum purity of Zinc used for galvanizing

%

99.95

99.95

12.0

Minimum mass of zinc coating

gm/sq. m.

600.0

600.0

- For 400 kV Non-snow Zone TL ; # - For 400 kV Snow Zone TL

S.N.

DESCRIPTION

UNIT

210 KN

1.0

Size and designation of ball and socket assembly

mm


2.0

Core diameter (d)

mm

85 to 90

3.0

Tolerance on Core diameter

±mm

(0.04d +1.5)

4.0

Minimum Creepage distance

mm

3084

5.0


NA

Brown

6.0

Mechanical strength

KN

210.0

7.0


a


Kv(rms)

290.0

b


kV(rms)

250.0

c


kV peak

550.0

d


kV peak

570.0

E


Kv(rms)

270.0

F


Kv(rms)

230.0

G


Kv(rms)

500.0

H


Kv(rms)

510.0

8.0

No. of one minute dips which the end fittings can withstand

Nos.

6.0

in standard preece test

9.0

Max axial/radial runout(as per pointer B)

mm


10.0

Maximum Angular displacement

degree

15.0

11.0

Minimum purity of Zinc used for galvanizing

%

99.95

12.0

Minimum mass of zinc coating

gm/sq. m.

600.0

C.STANDARD TECHNICAL PARTICULARS OF NORMAL INSULATOR STRINGS (WITH DISC INSULATORS) ALONGWITH HARDWARE FITTINGS

S.N.

DESCRIPTION

UNIT

FOR 400 KV QUAD BUNDLE LINE IN SNOW ZONE

Single Suspension pilot string

Single Tension string

Quad Tension string

(1 x 25)

(1 x 25)

(4 x 25)

1.0

Power frequency

kV(rms)

680

680

680

withstand voltage

of string with

arcing horns,

corona control

rings/grading rings

under wet condition

2.0

Switching surge

withstand voltage(wet)

(a)

Positive

kV(peak)

1175

1175

1175

(b)

Negative

kV(peak)

1175

1175

1175

3.0

Impulse withstand

voltage(dry)

(a)

Positive

kV(peak)

1800

1800

1800

(b)

Negative

kV(peak)

1800

1800

1800

4.0

Min. Impulse flashover

voltage(dry)*

(a)

Positive

kV(peak)

More than 1800

More than 1800

More than 1800

(b)

Negative

kV(peak)

More than 1800

More than 1800

More than 1800

5.0

Minimum Corona

kV(rms)

320

320

320

extinction voltage

under dry condition

6.0

RIV at 1MHZ when the

Microvolt

1000(max.)

1000(max.)

1000(max.)

string is energized at

305 Kv(rms) under dry

Condition

7.0

Mechanical strength of

kN

120

120

4 X 160

complete insulator

string alongwith hard-

ware fittings

8.0

Maximum voltage

%

9

10

10

distribution across any

disc of line to earth

Voltage

* As per IEC 60-1

S.N.

DESCRIPTION

UNIT

FOR 400 KV QUAD BUNDLE LINE IN NON-SNOW ZONE

Double 'I' Suspension string


Single Tension string

Quad Tension string

(2 x 23)

(1 x 23)

(1 x 24)

(4 x 23)

1.0

Power frequency

kV(rms)

680

680

680

680

withstand voltage

of string with

arcing horns,

corona control

rings/grading rings

under wet condition

2.0

Switching surge

Withstand voltage(wet)

(a)

Positive

kV(peak)

1050

1050

1050

1050

(b)

Negative

kV(peak)

1050

1050

1050

1050

3.0

Impulse withstand

voltage(dry)

(a)

Positive

kV(peak)

1550

1550

1550

1550

(b)

Negative

kV(peak)

1550

1550

1550

1550

4.0


voltage(dry)*

(a)

Positive

kV(peak)

1615

1615

1615

1615

(b)

Negative

kV(peak)

1615

1615

1615

1615

5.0

Minimum Corona

kV(rms)

320

320

320

320

extinction voltage

under dry condition

6.0


Microvolt

1000(max.)

1000(max.)

1000(max.)

1000(max.)



condition

7.0


kN

2 x 120

120

120

4 X 160

complete insulator


ware fittings

8.0

Maximum voltage

%

9

9

10

10



voltage

* As per IEC 60-1

S.N.

DESCRIPTION

UNIT

FOR 400 KV TRIPLE BUNDLE LINE IN SNOW ZONE


Double Tension string

(1 x 25)

(2 x 25)

1.0

Power frequency

kV(rms)

680

680

withstand voltage

of string with

arcing horns,

corona control

rings/grading rings

under wet condition

2.0

Switching surge


(a)

Positive

kV(peak)

1175

1175

(b)

Negative

kV(peak)

1175

1175

3.0

Impulse withstand

voltage(dry)

(a)

Positive

kV(peak)

1800

1800

(b)

Negative

kV(peak)

1800

1800

4.0


voltage(dry)*

(a)

Positive

kV(peak)

More than 1800

More than 1800

(b)

Negative

kV(peak)

More than 1800

More than 1800

5.0

Minimum Corona

kV(rms)

320

320

extinction voltage

under dry condition

6.0


Microvolt

1000(max.)

1000(max.)



Condition

7.0


kN

120

2 X 210

complete insulator


ware fittings

8.0

Maximum voltage

%

9

10



Voltage

* As per IEC 60-1

D.STANDARD TECHNICAL PARTICULARS OF NORMAL INSULATOR STRINGS (WITH LONGROD INSULATORS) ALONGWITH HARDWARE FITTINGS

FOR 400 KV QUAD BUNDLE LINE IN SNOW ZONE

S.N.

DESCRIPTION

UNIT

Single I

Single

Quad

Suspension

Tension

Tension

Pilot string

String

String

(1 x 3)

(1 x 3)

(4 x 3)

1.0

Length

(a)

Nominal length of insulator string

mm

3625

3625

4250

(b)

Tolerance on nominal length

+/-mm

100

100

125

2.0

Power frequency

kV(rms)

680

680

680

withstand voltage

of string with

arcing horns,

Corona control

rings/grading rings

under wet condition

3.0

Switching surge


(a)

Positive

kV(peak)

1175

1175

1175

(b)

Negative

kV(peak)

1175

1175

1175

4.0

Impulse withstand

Voltage(dry)

(a)

Positive

kV(peak)

1800

1800

1800

(b)

Negative

kV(peak)

1800

1800

1800

5.0


Voltage(dry)*

(a)

Positive

kV(peak)

More than 1800

More than 1800

More than 1800

(b)

Negative

kV(peak)

More than 1800

More than 1800

More than 1800

6.0

Minimum Corona

kV(rms)

320

320

320

extinction voltage

under dry condition

7.0


Microvolt

1000(max.)

1000(max.)

1000(max.)



condition

8.0


kN

120

120

4 X 160

complete insulator


ware fittings

*As per IEC 60-1

FOR 400 KV QUAD BUNDLE LINE IN NON - SNOW ZONE

S.N.

DESCRIPTION

UNIT

Double I

Single I

Single

Quad

Suspension

Suspension

Tension

Tension

String

Pilot string

String

String

(2 x 3)

(1 x 3)

(1 x 3)

(4 x 3)

1.0

Length

(a)


mm

3335

3335

3335

3910

(b)


+/-mm

92

92

92

115

2.0

Power frequency

kV(rms)

680

680

680

680

withstand voltage

of string with

arcing horns,

Corona control

rings/grading rings

under wet condition

3.0

Switching surge


(a)

Positive

kV(peak)

1050

1050

1050

1050

(b)

Negative

kV(peak)

1050

1050

1050

1050

4.0

Impulse withstand

Voltage(dry)

(a)

Positive

kV(peak)

1550

1550

1550

1550

(b)

Negative

kV(peak)

1550

1550

1550

1550

5.0


Voltage(dry)*

(a)

Positive

kV(peak)

1615

1615

1615

1615

(b)

Negative

kV(peak)

1615

1615

1615

1615

6.0

Minimum Corona

kV(rms)

320

320

320

320

extinction voltage

under dry condition

7.0


Microvolt

1000(max.)

1000(max.)

1000(max.)

1000(max.)



condition

8.0


kN

120

120

120

2 X 160

complete insulator


ware fittings

*As per IEC 60-1

FOR 400 KV TRIPLE BUNDLE LINE IN SNOW ZONE

S.N.

DESCRIPTION

UNIT

Single I

Double

Suspension

Tension

Pilot string

String

(1 x 3)

(2 x 3)

1.0

Length

(a)


mm

3625

4250

(b)


+/-mm

100

125

2.0

Power frequency

kV(rms)

680

680

withstand voltage

of string with

arcing horns,

Corona control

rings/grading rings

under wet condition

3.0

Switching surge


(a)

Positive

kV(peak)

1175

1175

(b)

Negative

kV(peak)

1175

1175

4.0

Impulse withstand

Voltage(dry)

(a)

Positive

kV(peak)

1800

1800

(b)

Negative

kV(peak)

1800

1800

5.0


Voltage(dry)*

(a)

Positive

kV(peak)

More than 1800

More than 1800

(b)

Negative

kV(peak)

More than 1800

More than 1800

6.0

Minimum Corona

kV(rms)

320

320

extinction voltage

under dry condition

7.0


Microvolt

1000(max.)

1000(max.)



condition

8.0


kN

120

2 X 210

complete insulator


ware fittings

*As per IEC 60-1

ANNEXURE-A

1. Tests on Complete Strings with Hardware Fittings

1.1Voltage Distribution Test (For Disc Insulators only)

The voltage across each insulator unit shall be measured by sphere gap method. The result obtained shall be converted into percentage. The voltage across any disc shall not exceed 9% for 400 kV suspension insulator strings, 10% for 400 kV tension insulator strings.

1.2Corona Extinction Voltage Test (Dry)

The sample assembly when subjected to power frequency voltage shall have a corona extinction voltage of not less than 320 kVrms (for 400 kV) line to ground under dry condition. There shall be no evidence of corona on any part of the sample. The atmospheric condition during testing shall be recorded and the test results shall be accordingly corrected with suitable correction factor as stipulated in IEC : 383.

1.3RIV Test (Dry)

Under the conditions as specified under (1.2) above, the insulator string along with complete hardware fittings shall have a radio interference voltage level below 1000 micro volts at one MHz when subjected to 50 Hz AC voltage of 305 kV line to ground under dry condition. The test procedure shall be in accordance with IS:8263/IEC : 437.

1.4Mechanical Strength Test

The complete insulator string along with its hardware fitting excluding arcing horn, corona control ring, grading ring and suspension assembly/dead end assembly shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string components shall not show any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to, remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded.

1.5Vibration Test

The suspension string shall be tested in suspension mode, and tension string in tension mode itself in laboratory span of minimum 30 metres. In the case of suspension string a load equal to 600 kg shall be applied along the axis of the suspension string by means of turn buckle. The insulator string along with hardware fittings and four/three (as the case may be) sub-conductors each tensioned at 25 % of conductor UTS shall be secured with clamps. The system shall be suitable to maintain constant tension on each sub-conductors throughout the duration of the test. Vibration dampers shall not be used on the test span. The sub-conductors shall be vertically vibrated simultaneously at one of the resonance frequencies of the insulators string (more than 10 Hz) by means of vibration inducing equipment. The peak to peak displacement in mm of vibration at the antinode point, nearest to the string, shall be measured and the same shall not be less than 1000/f1.8 where f is the frequency of vibration in cycles/sec. The insulator string shall be vibrated for not less than 10 million cycles without any failure. After the test the insulators shall be examined for looseness of pins and cap or any crack in the cement. The hardware shall be examined for looseness, fatigue failure and mechanical strength test. There shall be no deterioration of properties of hardware components and insulators after the vibration test. The insulators shall be subjected to the following tests as per relevant standards :

Tests Percentage of

Percentage of units to be tested

Disc insulators

Long rod insulators

a)

Temperature cycle test followed by mechanical performance test

60

100

b)

Puncture test/steep wave front test

40

-

1.6Power - Arc Test

This test shall be performed on the complete string in accordance with IEC Technical Report IEC : 61467-1997 with the following test series :

Test circuit

Short circuit current

Number and duration of test

B

In = Isys = 40 KA

Two of tn = 0.2s and one of tn = 0.5s

The acceptance criteria after the completion of test series shall be following.

a)Insulator separation not permitted.

b)Burning/melting of metal components, breakage of insulator sheds, glaze removal are permitted.

c)The complete insulator string alongwith its hardware fitting excluding arching horn, corona control ring/grading ring shall withstand 80% of UTS.

2.On Disc Insulator Units / Porcelain long rod units (as applicable)

2.1Steep Wave Front Test (For Disc Insulator only)

Test following test shall be performed on 10 insulator units in case of disc insulators selected at random from the lot offered for selection of sample for type test.

a)Each insulator unit shall be subjected to five successive positive and negative impulse flashovers with a wave having minimum effective rate of rise of 2500 kV per microseconds.

b)Each unit shall then be subjected to three dry power frequency voltage flashovers.

Acceptance Criteria

An insulator shall be deemed to have met the requirement of this test if, having been successfully subjected to the ten impulse flashovers, the arithmetic mean of the three subsequent dry/power frequency voltage flashover values equals or exceeds 95% of the rated dry power frequency flashover voltage.

An insulator shall be deemed to have failed to meet the requirement of above testing if,

(a)It has not flash over when the oscillogram or peak voltage indicator shows a marked reduction in voltage.

or

(b)Any one of the subsequent three dry power frequency voltage flashover value is less than 80% of the value specified.

Failure of any one unit either in the steep wave front or subsequent low frequency voltage test shall cause for testing on double number of units.

2.2Polarised Light Inspection (only for Glass Disc Insulator)

The disc insulator shall be held over a polarised light source and the stress lines viewed thereon. There shall be no uneven stress distribution in the toughened glass insulators. This shall be carried out on 100% glass shells.

2.3Hydraulic Internal Pressure Test on Shells (only for Disc Insulator)

The test shall be carried out on 100% shells before assembly. The details regarding test will be as discussed and mutually agreed to by the Supplier and Owner in Quality Assurance Programme.

2.4 Thermal Mechanical Performance Test

Thermal Mechanical Performance Test shall be performed in accordance with IEC-60383-1 Clause 20 with the following modifications :

(1)The applied mechanical load during this test shall be 70% of the rated electromechanical or mechanical value.

(2)The acceptance criteria shall be

(a)X greater than or equal to R + 3S.

Where

X = Mean value of the individual mechanical failing load.

R = Rated electro-mechanical / mechanical failing load.

S = Standard deviation.

(b)The minimum sample size shall be taken as 20 for disc insulator units and 5 units for long rod units.

(c)The individual electromechanical failing load shall be at least equal to the rated value. Also puncture shall not occur before the ultimate fracture.

2.5Electromechanical/Mechanical Failing Load Test

This test shall be performed in accordance with clause 18 and 19 of IEC 383 with the following acceptance

(i)X greater than or equal to R + 3S

Where

X = Mean value of the electro-mechanical/mechanical/ failing load.

R = Rated electro-mechanical / mechanical failing load.

S = Standard deviation.

(ii)The minimum sample size shall be taken as 20 for disc insulators units and 5 for long rod units. However, for larger lot size, IEC 591 shall be applicable.

(iii)The individual electro-mechanical/mechanical failing load shall be at least equal to the rated value. Also electrical puncture shall not occur before the ultimate fracture.

2.6Residual Strength Test (For Disc Insulators only)

The above test shall be performed as per clause 4.4 and 4.5 of IEC 797 preceded by the temperature cycle test, on both glass and porcelain disc insulators. The Sample size shall be 25 and the evaluation of the results and acceptance criteria shall be as per clause No. 4.6 of IEC:797.

2.7Chemical Analysis of Zinc Sleeve

The purity of the zinc used in zinc sleeve shall be tested as per IS:209. The purity of zinc shall not be less than 99.8%.

2.8IR Measurements

IR measurement shall be carried out by the instrument operating at 1 kV DC. IR value when measured under fair weather condition, shall not be less than 50 M-ohm.

2.9Impact Test

The Impact Test shall be carried out in accordance with ANSI-C-29.2 Clause 8.2.8 with the following modification.

The breaking point of the pendulum shall be so adjusted that, when released the copper nose will strike the outer rim of the shell or the most protuded rim of the shell squarely in a direction parallel to the axis of the unit and towards the cap.

The test specimen shall receive an impact of 7 N-m for 120 kN Disc & 10N-m for 160 kN & 210 kN Disc by releasing the pendulum.

3.Tests on All components (As applicable)

3.1Chemical Analysis of Zinc used for Galvanizing

Samples taken from the zinc ingot shall be chemically analysed as per IS:209-1979. The purity of zinc shall not be less than 99.95%.

3.2Tests for Forgings

The chemical analysis hardness tests and magnetic particle inspection for forgings, will be as per the internationally recognised procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Supplier and Owner in Quality Assurance Programme.

3.3Tests on Castings

The chemical analysis, mechanical and metallographic tests and magnetic, particle inspection for castings will be as per the internationally recognised procedures for these tests. The samplings will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Supplier and Owner in Quality Assurance Programme.

3.4Autoclave Test

For cement used in the assembly of the insulators six samples from different batches shall be tested in accordance with ASTM C-151. The cement shall have an expansion less than 0.12%.

SECTION-II (VOLUME-II)

PAGE 37

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TECHNICAL SPECIFICATIONS - JPPGLjaypeepowergrid.com/tenders/Insulator-GIFB/VOLUME-II/Sec... · Web viewThe Impact Test shall be carried out in accordance with ANSI-C-29.2 Clause 8.2.8