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    15 ETI PSI 72-9-85(Connectors)

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    psi draw

    Copyright:

    © All Rights Reserved
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    107 views19 pages

    15 ETI PSI 72-9-85 (Connectors)

    Uploaded by

    Nisha Santosh
    psi draw

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 19
    CARRIAGE DIRECTORATE COMPUTER WING COVERING LETTER SUBJECT: SCANNING/DIGITISATIONANDEXING OF OFFIGIALDOCUMENTS OF DIFFERENT DIRECTORATES OF 050 i] NAME OF THE DIRECTORATE oes 2 NAME OF THE SUB- | DIRECTORATE/SECTION Dec- coll — NAME & DESIGNATION OF THe SCANNING- = ORDINATION OFFICERISTAFF mhawergp Sivestove (THs NAME OF THE RECORD/FILE/ wba G. EF! | ey DOCUMENTISPECIFICATION ete. AND ITS Monel oa A Errol ne rq | VOLUME/VERSION &. a 5 | TOTAL NO OF PAGES/IMAGES [6 _ | NAME, SIGNATURE AND QESIGNATION OF 7 -THE HANDING OVER RDSO OFFICIAL 7 NAME,SIGNATURE AND DESIGNATION OF DOCUMENT _ | 11 | NAME, SIGNATURE AND DESIGNATIONOF | ‘THE RDSO OFFICAL RECEIVING BACK ‘THE DOCUMENT AFTER SCANNING (No of papers to be checked by department) 2 | REMARKS/FEEDBACK IF ANY | ==] (vay of documents to be ‘checked by : THE TAKING OVER.CMC OFFICIAL 1 DATE OF HANDING OVER FILE/DOCUMENT et. 9 FIELDS FOR INDEXING a 1 1] Type of Document (File? ~y oS | DRAWING/TECHNICAL CIRCULAR/MODIFICATION Spee 1 SHEET/SPECIFICATIONINP) _ { Document No. i | SuBsECT — = + 3 SUB-SUBJECT ” Afee. a | 6 | VOLUE | 6 [Sr.No _ 7m | | 7 DATE OF CREATION OF FILE | 11 C ) b- | eee eee a | | 8 I Dealer [ ome | 10 | DATE OF RECEIVING BACK THE VSTe) fe _ | i { 'A) COMPUTER GENERATED GOOD QUALITY 8) COMPUTER GENERATED (DOT MATRIX) C) TYPE WRITTEN {| D) HANDWRITTEN 7 | Orarae ec oF, REFERENCE COPY Specification Wo, BIT/PSI/72(9/85) SPECIFICATION FOR ELECTRIC POWER CONNECTORS FOR 4.C. TRACTION POWER SUPPLY SYST | oocczies TRACTION INSTALLATION: DIRECTORATE RESEARCH 1JESIGNS & STADARDS ORGANISATION MINIS\IRY OF Par GOvERIMENT OF +MAMAK TAGAR, ‘LUCEROW W326 ol 1.2.4 1.3 Government of India Ministry of Reilwaye Research Designs & “Standards Organisation. Specification No, BTI/PS1/72(9/85) SPECIFICATION FOR ELECTRIC POWER CONNECTORS’ FOR 3. TON -POWETC uy SYSTat Scone. This specification covers the desl gn,manufacture and testing of electric power connectors for outdoor use for horizontal and vertical. take-off between t he con- ductors: (strung/rigia busbar) and equipment(like power transformer; circuit breakers booster trans- formers, instrument’ transformers etd.) to establish ejectrical connection between them, The:connectors are generally composed of metale such a8‘ Munindum-bronze, tin-bronze, Aluminium alloys inclusiveof Aluminlum-copper strip and fasteners, The materiale of the connectors, clamps etc.are specified ont he relevant standard drawings of the purchaser, ; a There are three types of connectors generally usef At Traction sub-stations, switching stations and -boo, s, transformer stations, viz. ls i oo 41) Rigid-type connector designed for the purposes of connecting together equipment / terminal ead 5 busber .or connecting ‘two condictors, with ‘no ‘ allowance for the relative movement between the conductors. : - 11). Expansion type connector designed for the pur- pose of connecting together equipment terminal and busbar or connecting two conductors,with ample allowance. for the relative movemett between the conductors, 441). Bimetallic connector designed-for ‘the purpose “ of connecting together. two conductors having dissimilar materlals« (generally copper and » gluminium ¢onductors)for prévdnting electro- lyticcorrosion, ‘Bime'tallic conhectors can be of rigid: type or’ expansion type. 3.1 444) HS:2061-1953 2 Governing specifications * Agaistance les been. taced’ from the following Indian gn British Stondaras in preperation of this speci cation: 41) I8:6561-1970 Specification for electric power connectors, 41). 18:1570(Pt.V) - Schedule for wrought steels - - 1972, Part-V stainless and heat resisting steele. Phosphor bronze spring washers for general engineering purposes. dv) 18306-1983 Tin bronze ingots and. castings. _ Aluminium & aluminium alloy ingots and castings for general engineering purposes. v) 18#617-1975 vi) 18:1897-1971 - Copper strip for electrical purposes, oe vii) ‘15:3091-1965 - . Aluminium bronze ingots and castings for fittings # in electrie traction. yiti) 18:2654-1977-. Method for tensile testing of ¢ copper and copper alloys. ix) 15:4027-1967_- Method of chemical analysis of . bronzes. Recommended procedure for inspection of copper based alloy and castings. x). 1821408-1968 Service conditions The connectors are interded for use in Railways! electric traction substations,switching stations and booster stations ar should be designed to provide uninterrupted ssrvice under all conditions of load and weather. The equipments in which these connectors would be used are to be installei in moist tropical climate and in areas subjected jo heavy rainfall and severe lightning in Indla, a/- 3.3 3.4 “The equipments (along with: the terminal connectors) = Gonta Maximum ambient air temperature » =. 45°C in shade not exceeding Minimum ambient: temperature = -5°C 65°c ” Maximum temperature attain- able by ‘on object exposed to sun. Maximum relative humidity, = 100%, Maximum wind pressure, = 200 kg/m? Maximum altitude. . = 1000 metres. No.of rainy days per annum. = 120 days max, Average antual raih-fall. = .1750 to 6250 mm. No.of thunder-storm days/year. = 85'days max. No.of dust-storm days/year. = 35 days max. They are also sibjected to chemical pollution from the effluent gases of chemicsl plants,exhaust of steam/ diesel locomotives and to saline atmosphere in coastal areas. 63 Vibrations of ~ are installed on stetl structures: located by the side of Railway. tracks and are subjected to vibratigig with the passage of trains, ?The amplitude of these vibrations lies*in the range of 30 to, 150 microns with instentaneous'peaks going up to 350 microns. These vibrations occur with rapidly varying time periods in the range of 15 to’70 ms. General requirenent; All parte of the connector shall be manuracturea vy the connector manufacturer at hie works. However, compo- nents such as fasteners may be obtained from the Railways! approve¢.suppliers withthe specific approval of the irdentor, All connectors shill be manufactured by gravity diecasting procesit. 4/- 4.4 4.5 4.7 4.10 4 The detailed dimensional drgs.of connectors ao per Railwoya' standard size of 210 mm x 297 mm or any integral multiple thereof, shall be eub- mitted to RDSO for approval ,before teking up the manufacture of test bars / prototype terminal connector. For the guidence of manufacturer, a list of RDSO's "drawings for terminal connector equipment- wise,is given at Annexure-B, The connectors of same identification number (3,I.No.) and materials shall have free interchangeability. The connectors shall be smooth,free from cavities, Sharp edges, blow-holes, cracke and such other defects which are likely to be detrimental to their perform ance while in service, The connectors should.withstand short-circuit forces and the loads normally expected to occur in outdoor conditions and the effect of vibration both on the conductor and the connector itself. All connectors and hardwares shall be either in- herently resistant to the atmospheric corrosion or suitably protected against corrosion both during storage and in service. Bolted jointe shall be 90 designed es to apply uniform presoure on the terminal and the conductor to provide adequate area for current transfer, and -also to. provide e mechanical strength not less than that of the conductor to which it is to be connected, Since the connectors are to be used in current carry- ing circuits, all. botts,nuts and washers shall be made of stainless steclunlees otherwise stated in the relevant drawings, The connectors and clamps are required for use.in Railways traction substation and other important locations where utmost reliability is required end as such the best material. and workmanship are to be employea.. Rating and other pa: The. various types of oulara onnectors covered by this - specification are briefly described in dnnexure-C. The rating and other particulars of the connector assembly shall be as follows? 5/- 5.2 5.3 Conta. 1) Type of connector: 41) a) Continuous current rating. b) Overload current for 16 minutes. 444). Rated frequency. dv) Rated short-time current for one second. v) Material of the connector. vi) rise when carrying rated overload current for 15 minutes with refer- ence to an ambient fegperature of 45%. The ratings given in clawe 5.2 refer to terminal connectors used. on power transformers, circuit breakers ,interruptors,current transformers and isolators, These ratiags do not refer to terminal connectors used on potential transformers and 25«V Max.permissible temp. WG 32kV_side) 200° Amps. 409 Ampe. 50 Rigid / Expansion ‘LW (25ev_si4e) 1250 Amps. 2000 Amps. Hz 50 Hz ~ 40 katrns) “e5k aA (rms) 4100 kal a) 6) ¢) * 40% peek) 62, 5k A(peak) Aluminiun-bronze/tin- bronze to the equip- ment terminal(copper or brass), Aluminium alloy to the busbar end(epider AAC or eluminium tube). 2mm ‘thick aluminium copper( ALCU) strip for bimetallic terminal connector. 40°C 20002124 booster transformers, The continuous current rating and overload ratin, connectors for’ 25k’ for 15 minutes of terminal booster transformers shall be 800Amps and’1200 Anps respectively, The other rating as given at 81 No.(il4),(iv),(v) and (vi) of clause §.2 shall also be applicable for connectors for 25kV booster transformers, 132kV potential transformere and 2&cV potential transformers, 6/- 6.1 6.1.1 6.1.2 6.1.3 6 Material specification Aluminium bronze connector Aluminium bronze alloy used for the connector body clamping piece shall conform to I$:3091-1966, The material when analysed in accordance with IS: 4027-1967 shall have the chemical composition as, givenbelow: Chemical. osition of eluminiun-bronze ingots ~ and_castings . ~ Constituent Por cent i) Aluminium . 9.0 to 11.0 ii)” Iron : 4.0 to 5.0 iti) Manganese 0,1 to 0.5 iv) Copper Remainder, The material. when tested in accordance with IS: 2664-1977 stall have the following mechanical properties: Mode of Properties, . Values. Chill cast i) Tensile strength, ~60kef/mm? or any other Min, casting : process, 41i) Elongation on 50mm 20 per cent. gauge length, Min, 441i) 0.2 per cent perma- 25kgt/mm* nent set stress, . Min, Tin-bronze connector. Tin-bronze alloy used for the connector body ana clamping p:.ece shall conform to IS:306-1983, The material when analysed in accordance with 15:4027-1957 shall have the chemical composition as given below: ‘ 2/- 6.2.2. Contd. 2 Chemical co itd ¢. Constituent. Composition per cent Tngots. Cas tings. 1) Tin : 95-105 9.5 - 105 44) Zine 1.75 = 3.25 1.5 - 3.0 414) Lead,Mexe 1.5 1.5 jv) Wickel Max. 1.0 1.0 v) Tron,Max. 0.15 0.15 vi) Aluminium,Max. 0,01 0.02 vil) Silicon ,Max. 0,02 0,02 vitd) Biemuth,Max. 0,03 0.03, ix) Total impurities Max. 0.50 0.50 (neludes iron, alu minium, areenic, anti- mony silicon, blemuth) . x) Copper Remainder. Remainder. 6.263. The material when tested in accordance with IS: 2654-1977 shall have the following mechanical properties: Mode of Tensile 0.2 per cent FBlongation per casting. strength proof stress cent on gauge MPa, Min, MPa,Min, length 5. Ae oueaee Gkeidmm?). (Kef/am’). Mine. Sand cast- 260 120 13, .-ing(separa- (26.5) (12.5) tely cast). Chill cast- 210 120 . dng (separa (21,5) (12.5) tely cast). e 0000212 6.3 Aluminium and aluminium alloy connector. 6.3.1 The aluminium alloy used for the connector body and clemping piece shall conform to grade 4600{M) of IS 617-1975. 6.3.2 The chemical composition and mechanical properties of aluminium end aluminium alloy ave given below: a) _ Chemimal composition (condition-M): Alloy designation Per cent,Max, (pressure diecast : alloy). i) Copper 0.2 44) Silicon 10.0 t0.13,0 413) Megnesiun 0.10 ° 4v) Iron 0.6 v) Manganese 06 vi) Bickel O12 vii) Zine 0.1 8.1 vill) Lead O21 ix) Tia 0.05 x) Titanium 0.2 8.2 xi) Aluminium, Repainder. ‘ b) Mechanical propertigs: Mode of casting. Tensile strength Flongation(on kgf /nm? Min, 50 m gauge a> length) Min, cence. wow’, PS! 8.3 Sand cast 16.5 5 Chill cast 19.0 6.4 8.2 8.3 9 Festeners (hardvares) Stainless steel bolts,nuts and washers shall conform to Grade 04 Cr 17 Ni 12 Mog of ISt 1570(Pt.V)-1972, Tolerances, Tolerances of + 0,5 mm shall be permissible on all dimensfons unless otherwise specified onthe relevant drawing of the purchaser, Alternatively whenever not epecified on the relevant drawing furnished by the purchaser ,the following tolerances shall apply for non-mating surfaces? Dimension. Tolerances: 41) © Up to and inelud- 30.5 mm ing 35 mm, 41) Over 35 mm 41.5% iii) Wall thickness. + 1.0 m - 0.5 mn Teste _on test vars. These tests shall be carried out, as described below, on test bars before conducting type test on terminal connectors by RDSO to check the chemical composition and mechanical properties of the material used for the. termina’, connector. The supplier shall have to manufacture three numbers of cast-to shape test bars for each of the materials used for the connector, The test bar shall be made in accordance with the drawing placed at Annexure- 4, The bars shall be cast to the. dimensions,dressed or cleaned and shall be tested in the mechined condition, The test bars shall be from the same melt from which the samples of the connectors have ‘been cast. ‘One test bar shall be tested for chemical composition and mechanical proper-tiesdn azcordence ‘with clause-6 as applicable, If the bar Sails in any test,two more test bars shall. be tested. The samples shall be deemed to have passed the tests if there is no failure in the re-test. 10/- 60002126 8.4 8.5 10 10.1 10.1.1 lo If the mechanical and chemical properties of the test bars are acceptable, the terminal connector shall be subjected to all the tyre tests as per clause 10,1 in the presence of RDSO's representative. All type tests on the samples including various teste on test bars shall be arranged by the manu- facturers free of cost to the Railways in the presence of RDSO's representative. Deviations from specification Imy deviation from thie specification to inprove the pezformence,efficlency and utility of the connectors proposed by the tenderer will be. given due ‘consideration provided full particulars with justification thereof are furnished. Tests Type tests These tests are normally made before the approval of the prototype samples, but may be repeated at the discretion of RDSO,at any time. The following type tests shall be carried out on three prototype samples of termimal connectors to prove the general quality and designs: 4) Visual inspection C1... 44) Dimensional verification.C1.11.2 44i) - Electrical resistance _01.11.3 (milli-volt drop) test. iv) Slip test(tensile test) C1.11.4 v) Temperature rise test. 1.11.5 vi) Shor’ time current test. C1.11.6 : Acceptance tea’ The number of terminal connectors for acceptance teste, vo be celested at randon, shall. be twe nearest whole number £0.10 per cent of the batch offered for heeeptance, The following acceptance tests shall be carried out: ‘i i) + n/- 11 il 11 11. il. 11, n 10.2 fonta, i) Dimensional verification. C1,11.2 ii) Electrical resistance test, C1.11.3 je. CL1.4 fii) Slip test(Tensile 10.3 Routine test The following shall constitute the routine tests and shall be carried out on all the terminal connectors: 4). Visual inspection, Cl1.11.1 di) Dimensional verification.Cl.11.2 n Zegt methods 11.1 Visua: wpecti All connectors shall be examined visually for good workmanshipand smooth finish i,é, free from cavities, blow holes,hatr-line cracks and other defects. 11.2 Dimensional. verification The dimensions of the connectors shall be checked by gauges calipers and micrometers to ascertain con- ormity to the relevant approved drawing. 11.3 x c. istance test 11.3.1 The largest conductor / busbar which the connector vil acccumodate shall be used during the resistance eat. 11.3.2. The resistance measurement shell be made by milli- volt drop withtne help of an accurate resistance bridge or other approved method. 11.3.3 dabtent temperature shall also be recorded during tle eat, 11.3.4 The resistance of 1,25 m of a conductor, inclusive of one connector assembly. shall not exceed the resistarse of 1.25m of the identical conductor without connector.:assembly, by more than 10 per cent. The resistance measurement stall be taken from 4 to B, Cito Diand A to D as shown in Fig. A below. The resistance measured from 4 to D 1a/- b0002127 11.3.4 11.4 eggs 12 shall be withinll0g cf the sum of resistances of. 6.625 m length of one conductcr and 0,625 m length of another conductor,which are to be connected through the terminal’ connector under test. The resistance measured between A and B shall be withingi0 peroent of half of tle resistance of 1.25 m of the particular conductor to which it is connected, And similarly the resistance between C and D shall be within4l0 per cent of half of the resist- ance of 1,25 m of the another. conductor to which it is Slip tee+(Tensile test) a) The connecter with a suitable length of the conductor with which it is intended to be used shall bé mounted. vertically in a tensile machine and anchored suitably in such a way that the tests lcad is epplied in the direction of the conénetor. The assembly sill be tightened to the required torque. L b) If the nominal breaking loed of the conductor is 1100 tg or nore, a tensile load of 55kg shall be applied initially atd the conductor shail be marked in such a way that movement “relative to tae ¢ cen easily be detected. nu Tae value of t weish the conductor in tho connecter cody begins to slip shall be. . : noted, out any subsequent adjustment on the connestor,ihe load shall be steedily increased to 110 kgs. This load shall be maintained for = one mimite, Lanyl- vol c) There shall be no movement of the conductor the relative to the connector due to slip during at this one-minute period and no faiure of the connector. : 13/- 13 11.5. - Temperatuze rise te aN a) »b) ) 4) 11.6 Short: a) Zany suitable Voltage & with the connector at any The current applied during the temperature rise test shell be the rated current assigned to the connector, The temperature rise test for power connectors ehall be made with alternating current at an average frequency not below 95% of the rated frequency. e The connector shall be assembled indoorson con ductors of size and type with which it ia to be used, Air shall be freely circulated around the assembly, but no draughts shall be allowed, Fach test shall be made over a period of time sufficient for the temperature to reach a con - stant value (for practical purposes, this condi- tion is gttained when the variation does not exceed 1°C per hour), After steady state the current shall be increased and overload currents flown in the test piece for a time as speciried in Clause 5.Q(3i)(b). Temperature shall be recorded immediately after the specified over- load time is over, Temperature measurements shail te made veing either thermocouples or meters.There shell be two spere thermo- meters for measuring exbient temperature and the seme shall be protected from any air Greugnt /abnormal heat radiations, The temperature risg of the eonnectar assembly shall not excecd 40°C over a reference anbient air temperature of 45°C. If the ambient tenpera- ture exceuds 45°C, the pemissizle temperature rise shall be redticed by an equal to the excess ambient terporature, the test be arranged,as far ae practicable, to produce conditions equivalent to those within nian would be obtained in service,when the connector under test carries yault current.The tess may be made at / / convenient temperature, The snert time curreht shall be sppliod for the speoivied time end its rms valuc shall be determined as specified in Appendix A of 1 5561-1970. The procedure of the tests shall be in accordance with Clause 13 of 15:5561-1970. 14/- — 00002129 14 11.6 ° »b) The rms value of the shorttime current shall be thon the rated short time current and ac valve of the major current loop during the firet eyele-of the test should be not less then the corresponding values as speci~ fied in Cleuse 5.Q(iv). c) The shorttime current’ shell rot produce any mechae nical damage,euch e8 permanett distortion or burning of parts, and shall not cause a tempera- ture rics. that added to the maximum temperature atteined at rated current would damage the current: carrying parts. 12 Merkings 12.1 The neue / initials / trade mark of the manufacturer, - Rallwaya identifica tion No,(R,I,No.)end any other information required by the purchaser shall be cast on each connector, 13 Dreyings 13.1 The manufecturer shallbe required to subzit in triplicate,the detailca dimensional drawings showing all the three views (elevation, plan end side} y> gy waetever neccesary ,schrdule of mater= cross-Fect tals trsiz spesifications etc.aa per Railways! standanis sizes of 220 wn x £97 mn or any integral multiple threo? for approval. A copy of the standard ma (Forne3) is agtached at Aonexure-D for, pro f gudda 13.2 After the drawings ere’ finally ap’ prints and one i dy the sui roved by RDSO,oix spreaneivle t: ceceind manufacturer “to purchaser. Particuiers of Connectors in vse atthe Rutiveys' traction sub- statiors ,oyltchin: tions, end boos ter sformprs are given in Arnexure-B attached. NOTE: ANNEXURE-A INDIAN RESEARCH DESIGNS AND RAILWAYS STANDARDS ORGANISATICN TRSTALCATION CIRECTORATE. = 80 fl 4o Lo = Gauoe LencTH AiG. 1- ALUMINIUM- BRONZE CASTING .(1§:091: 1965) (THETEST BAR SHALL BE MADE FOR EACH LOT AND IDENTIFIED WiTH LOT & DATE OF MELT) p25 R=20 220 E1G.2- TIN BRONZE CASTING (THE TEST BAR SHALL BE ACCORDING TO ONE OF THE APPROPRIATE TYPES DESCRIBED IN 1S: 140B- 1968 ) a im ip H-k ; 1 0000212 ROSS -SECTIONAL, ‘AREA §0= 100 mm FIG. 3- ALUMINIUM-ALLOY CASTING (THE TEST BAR SHALL BE PREPARED FROM TEST SAMPLES ‘SHALL BE MACHINED JO THE DIMENSIONS OF THE STANDARQ. UND TEST PIECE & THOSE PREPARED FROM CHILL MOULDS AS FtR is. NOTE I~ a [ALL DIMENSIONS ARE IN MILLIMETRES. CAST TO SHAPE TEST PIECES eTI|PSi] 5K] 299 SCALE: NTS Anny -Liat of connectors ueed/on the terminals of different electrical equipments is given bejowt SNo. Bymipment. 12 :13%&V side of 12,5MVa traction transformer, 132 «V current trans- former & 13a potential trans- former. 2 25kV side of 13.5 MVA trace tion traneformer, 2&kV circuit ; breaker ,26kV interruptor. 3 132kV circuit: breaker and 1BzcV ‘Lsolatr. 4 25«V current trars former. 25kV booster “ transformer, 6 26k¥ isolator. 7 ~~ QrVi isolator (ae a bu coupler) 8 27 potential transformer fyposle Type of ~oaanector, Rigid. Fxpansion. Rigid. a)Rigia b) Zxpension Expansion. Rigid. Expansion, Rigide Rigid. ide Drg./R.I. No. BTI/PST/P/6800 ETI/PS1/P/6570. ETI/PSI/P/6830 ee ETI/PS1/P/6850 ETI/PSI/P/6480, ELI/PS1/P/6430-1 EYI/PS1/6530 -FIT/PS1/P/6830 S = EPT/PST/P/C510 oe BRISPS GAS A a0 o < = ails ipment Terminals and Terms tore. ‘BNo.—"Byuipment. Description of Myuipaent to urier descrip equipment be connected tion of termir. 1 terminal. to. connector. oe Bae cower e tone Le 1 Power transformer 25 30m dla 36mm o,d. Continuous curre t KV side,25kV CBs,25 copper stud, aluminium rating 1250Ajex- KV interrupters (ex- bus. pansion/rigid cept few makes of types interruptora) ,25«V current transformers, ' 2 25kV SP & DP iso- Square pa Beg 36m 0,4, Continuous, current lators,few makes of cop] aluminium ratinj interruptors, alumin: ra bus. rigi eee on ~ types 3 .Power transformer 30mm da 20mm(AAC) Kontinuous current- 132kV side, 132&V copper stud, spider rating 200A. * current transfor- conductor, _ mer. 4° 132kV CBs, 132kV Square pad 20 mm (AMC) Continuous current isolators. of aluminium spider rating 200A, alloy/copper. conductor. 5 25kV potential

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