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Volume - II Technical Specifications
Document Code: DC-TPGL-SPTL-05
This document is meant for the exclusive purpose of bidding against this specification and shall not be transferred, reproduced or otherwise used for purpose other than that for which it is specifically issued.
VOLUME - II
GENERAL INFORMATION AND SCOPE TECHNICAL SPECIFICATION FOR ACSR ʹMOOSEʹ CONDUCTOR
Clause No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
TECHNICAL SPECIFICATIONS SECTION‐I CONTENTS Description General Information Scope Weights and Measures General Technical Conditions Technical Description Test and Standards Technical Particulars Technical Information Service Condition
Page No. 1 1 1 1 6 6 7 8 8
TECHNICAL SPECIFICATIONS SECTION‐I General Information The material covered in this specification shall be used in following Transmission Line. Package Line length i) 400 kV D/C Transmission Line Sugen to Pirana B: ACSR MOOSE Conductor 210 km(approx.)
Scope The material to be supplied on final destination at site basis as covered in this volume shall be designed, manufactured and tested as per the requirements specified. Final Destination shall mean the stores established by the Contractor of the Owner along the Transmission Lines. The materials covered here under this specification shall be supplied complete in all respects, including all components, fittings and accessories which are necessary or are usual for their efficient performance and satisfactory maintenance under the various operating and atmospheric conditions. Such parts shall be deemed to be within the scope of the Contract, whether specifically included or not in the Specification or in the Contract Schedules. The Supplier shall not be eligible for any extra charges for such fittings, etc. The details of the materials required for the Conductor package under this Specification are mentioned in the bidding documents. Weights and Measures All weights and measures shall be in System International (S.I.) units. All fasteners shall be of Metric size only. General Technical Conditions The following provisions shall supplement all the detailed technical specifications and requirements brought out in the accompanying Technical Specifications. The Bidder’s proposal shall be based on the use of equipment and materials complying fully with the requirements, specified herein. The Bidder shall furnish clause‐by‐clause commentary (with detailed technical data as required) on the Technical Specifications demonstrating the goods substantial responsiveness to the specifications or deviations and exceptions to the provisions of the Technical Specification. Equipment Performance Guarantee
3. 4. 4.1
The performance requirements of the items are detailed separately in this Specification. These guarantees shall supplement the general performance guarantee provisions covered under General Terms and Conditions of Contract in clause entitled ‘Guarantee’. Liquidated damages for not meeting specified performance shall be assessed and recovered from the Supplier. Such liquidated damages shall be without any limitation whatsoever and shall be in addition to damages, if any payable under any other clause of Conditions of Contract. Engineering Data The furnishing of engineering data by the Supplier shall be in accordance with the appropriate Schedule appended to this document. The review of these data by the Owner will cover only general conformance of the data to the specifications and drawings. This review by the Owner may not indicate a thorough review of all dimensions, quantities and details of the equipment, materials, any devices or items indicated or the accuracy of the information submitted. This review and/or approval by the Owner shall not be considered by the Supplier, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these Specifications and documents. All engineering data submitted by the Supplier after final process including review and approval by the Owner shall form part of the Contract Document and the entire works performed under these Specifications shall be performed in strict conformity, unless otherwise expressly requested by the Owner in writing. Drawings All drawings submitted by the Supplier including those submitted at the time of bid shall be in sufficient detail to indicate the type, size, arrangement, dimensions, material description, Bill of Materials, weight of each component, break‐up for packing and shipment, fixing arrangement required, the dimensions required for installation and any other information specifically requested in the Specifications. Each drawing submitted by the Supplier shall be clearly marked with the name of the Owner, the unit designation, the Specification title, the Specification number and the name of the Project. All titles, noting, markings and in writings on the drawing shall be in English. All the dimensions should be to the scale and in metric units. The drawings submitted by the Supplier shall be reviewed by the Owner as far as practicable within four (4) weeks and shall be modified by the Supplier if any modifications and/or corrections are required by the Owner in compliance with Specifications. The Supplier shall incorporate such modifications and or corrections and submit the final drawings for approval. Any delays arising out of failure by the
Supplier to rectify the drawings in good time shall not alter the Contract completion date. 4.4.4 The drawings submitted for approval to the Owner shall be in quadruplicate. One print of such drawings shall be returned to the Supplier by the Owner marked “approved/approved with corrections”. The Supplier shall there upon furnish the Owner additional print as stipulated in Technical Specification along with one reproducible in original of the drawings after incorporating all corrections. Further work by the Supplier shall be strictly in accordance with these drawings and no deviation shall be permitted without the written approval of the Owner, if so required. All manufacturing and fabrication work in connection with the equipment/ material prior to the approval of the drawings shall be at the Supplier’s risk. The Supplier may make any changes in the design which are necessary to make the equipment conform to the provisions and intent of the Contract and such changes will again be subject to approval by the Owner. Approval of Supplier’s drawing or work by the Owner shall not relieve the Supplier of any of his responsibilities and liabilities under the Contract. Manufacturing Schedule The Supplier shall submit to the Owner his manufacturing, testing and delivery schedules of various items within thirty (30) days from the date of the Letter of Award in accordance with the delivery requirements stipulated. Schedules shall also include the materials and items purchased from outside Suppliers, if any. Reference Standards The Codes and/or Standards referred to in Specifications shall govern, in all cases wherever such references are made. In case of a conflict between such Codes and/or Standards and the specifications, latter shall govern. Such Codes and/or Standards, referred to shall mean the latest revisions, amendments/changes adopted and published by the relevant agencies. Other Internationally acceptable Standards which ensure equivalent or better performance than those specified shall also be accepted. Design Improvements The Owner or the Supplier may propose changes in the Specification of the equipment or quality thereof and if the parties agree upon any such changes, the Specification shall be modified accordingly. If any such agreed upon change is such that it affects the price and schedule of completion, the parties shall agree in writing as to the extent of any change in the
SECTION‐I (VOLUME‐II) PAGE 3
4 6 4.6.1
4.6.2 4.7 4.7.1
price and/or schedule of completion before the Supplier proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amended accordingly. 4.8 4.8.1 Quality Assurance To ensure that the equipment under the scope of this Contract whether manufactured within the Supplier’s Works or at his Sub‐Supplier’s premises is in accordance with the specifications, the Supplier shall adopt suitable Quality Assurance Programme to control such activities at all points necessary. Such programme shall be outlined by the Supplier and shall be finally accepted by the Owner after discussions before the award of Contract. A Quality Assurance Programme of the Supplier shall generally cover but not limited to the following : (a) (b) (c) (d) His organisation structure for the management and implementation of the proposed Quality Assurance Programme. Documentation control system. Qualification data for key personnel; The procedure for purchases of materials. Parts/components and selection of sub‐Supplier’s services including vendor analysis, source inspection, incoming raw material inspection, verification of material purchases etc. System for shop manufacturing including process controls. Control of non‐conforming items and system for corrective action. Control of calibration and testing of measuring and testing equipments. Inspection and test procedure for manufacture. System for indication and appraisal of inspection status. System for quality audits. System for authorising release of manufactured product to the Owner. System for maintenance of records. System for handling, storage and delivery and A Quality Plan detailing out the specific quality control procedure adopted for controlling the quality characteristics of the product.
(e) (f) (g) (h) (i) (j) (k) (I) (m) (n)
4.8.2 The Quality Plan shall be mutually discussed and approved by the Owner after incorporating necessary corrections by the Supplier as may be required. Quality Assurance Documents The Supplier shall be required to submit all the Quality Assurance Documents as stipulated in the Quality Plan at the time of Owner’s inspection of equipment/material.
The Owner or his duly authorised representatives reserves the right to carry out Quality Audit and quality surveillance of the systems and procedures of the Supplier’s/his vendor’s Quality Management and Control Activities. Owner’s Supervision To eliminate delays and avoid disputes and litigation it is agreed between the parties to the Contract that all matters and questions shall be resolved in accordance with the provisions of this document. The manufacturing of the product shall be carried out in accordance with the specifications. The scope of the duties of the Owner, pursuant to the contract, will include but not be limited to the following: (a) Interpretation of all the terms and conditions of these Documents and Specifications. (b) Review and interpretation of all the Supplier’s drawings, engineering data etc (c) Witness or authorise his representative to witness tests at the manufacturer’s works or at site, or at any place where work is performed under the Contract. (d) Inspect, accept or reject any equipment, material and work under the Contract, in accordance with the Specifications. (e) Issue certificate of acceptance and/or progressive payment and final payment certificate. (f) Review and suggest modification and improvement in completion schedules from time to time, and (g) Supervise the Quality Assurance Programme implementation at all stages of the works. Inspection, Testing & Inspection Certificate The Owner, his duly authorised representative and/or outside inspection agency acting on behalf of the Owner shall have at all reasonable times access to the Supplier’s premises and works and shall have the power at all reasonable times to inspect and examine the materials and workmanship of the product during its manufacture and if part of the product is being manufacture or assembled at other premises or works, the Supplier shall obtain from the Owner and /or his duly authorised representative permission to inspect as if the equipment/ materials were manufactured or assembled on the Supplier’s own premises or works. The Supplier shall give the Owner Inspector fifteen (15) days written notice of any material being ready for testing. Such tests shall be to the Supplier’s account except for the expenses of the Inspector. The Owner/inspector, unless witnessing of the tests is waived, will attend such tests within fifteen (15) days of the date of which the equipment is notified as being ready for test/inspection or on a mutually agreed date, failing which the Supplier may proceed with the test which shall be deemed
to have been made in the Inspector’s presence and he shall forthwith forward to the Inspector duly certified copies of tests in triplicate. 4.10.3 The Owner/Inspector shall, within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Supplier, of any objection to any drawings and all or any equipment and workmanship which in his opinion is not in accordance with the Contract. The Supplier shall give due consideration to such objections and shall make the modifications that may be necessary to meet the said objections. When the factory tests have been completed at the Supplier’s or Sub‐Supplier’s works, the Owner inspector shall issue a certificate to this effect within fifteen (15) days after completion of tests but if the tests are not witnessed by the Owner/inspector, the certificate shall be issued within fifteen (15) days of receipt of he Supplier’s Test Certificate by the Owner/ Inspector. The completion of these tests or the issue of the certificate shall not bind the Owner to accept the equipment should it, on further tests after erection, be found not to comply with the Contract. In all cases where the Contract provides for test whether at the premises or works of, the Supplier or of any Sub‐Supplier, the Supplier except where otherwise specified shall provide free of charge such item as labour , materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Owner inspector or his authorised representative to carry out effectively such tests of the equipment in accordance with the Contract and shall give facilities to the Owner/Inspector or to his authorised representative to accomplish testing. The inspection by Owner and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Supplier in respect of the agreed Quality Assurance Programme forming a part of the Contract. Technical Description The technical description of the conductor shall be as specified in Section‐II of this Technical Specifications. Tests and Standards Tests The following type, acceptance and routine tests and tests during manufacture shall be carried‐out on the material. For the purpose of this clause: Type Tests shall mean those tests which are to be carried out to prove the process of manufacture and general conformity of the material to this Specification. These tests shall be carried out on samples prior to commencement of commercial production against the order. The Bidder shall indicate his schedule for carrying out these tests.
SECTION‐I (VOLUME‐II) PAGE 6
5. 5.1 6. 6.1 6.1.1
Acceptance Tests shall mean those tests which are to be carried out on samples taken from each lot offered for pre‐dispatch inspection, for the purposes of acceptance of that lot. Routine Tests shall mean those tests, which are to be carried out on the material to check requirements which are likely to vary during production. Tests During Manufacture shall mean those tests, which are to be carried out during the process of manufacture and end inspection by the Supplier to ensure the desired quality of the end product to be supplied by him. The norms and procedure of sampling for these tests will be as per the Quality Assurance Programme to be mutually agreed to by the Supplier and the Owner. The standards and norms to which these tests will be carried out are listed against them. Where a particular test is a specific requirement of this Specification, the norms and procedure of the test shall be as specified in Annexure‐A or as mutually agreed to between the Supplier and the Owner in the Quality Assurance Programme. For all type and acceptance tests, the acceptance values shall be the values specified in this Specification or guaranteed by the Bidder, as applicable. Technical Particulars The Standard Technical Particulars of the various items which the bidder has to guarantee (item as applicable) are specified in Section‐II of this volume. The Bidder shall furnish any other information as in their opinion is needed to give full description and details to judge the item(s) offered by them A Bidder may guarantee a value more stringent than the specification requirement. However, for testing purpose or from performance point of view, the material shall be considered performed successfully if it achieves the minimum/maximum value required as per the technical specification. No preference what so ever shall be given to the bidder offering better/more stringent values than those required as per specification.
6.1.7 7. 7.1
Technical Information Electrical System Data SL. No. a. b. c. d. e. f. Parameter Nominal Voltage Maximum system voltage BIL (Impulse) Power frequency withstand voltage (Wet) Switching surge withstand voltage (Wet) Minimum Corona extinction voltage at 50 Hz AC system under dry condition Radio interference voltage at one MHz for phase to earth voltage of 305 kV (for 400 kV line under dry condition.) kV kV kV (Peak) kV (rms) kV(peak) KV(rms) Phase to earth. Microvolts 400 kV line 400 420 1550 680 1050 320
Service Condition. Equipment/material to be supplied against this specification shall be suitable for satisfactory continuous operation under conditions as specified below: Maximum ambient temperature (Degree Celsius) Minimum ambient temperature (Degree Celsius) Relative humidity (% range) Maximum annual rainfall & snowfall (Cm) Wind zone (as per IS: 875) Maximum wind velocity (m/sec.) Maximum altitude above mean sea level (Metres) Isokeraunic level (days/years) : : : : : : : : 50 4 10‐100 as per published Meteorological/ climatological data 3 44 m/sec. for WZ‐3 (as per IS : 875) Upto 1000 m 50
Climate varies from moderately hot and humid tropical climate to cold climate.
Clause No. 1.0 2.0
TECHNICAL SPECIFICATIONS SECTION‐II CONTENTS Description Technical Description of ACSR Conductor Tests and Standards Annexure‐A : Tests on Conductor Annexure‐B : Standard Technical Particulars Drum Drawing
Page No. 1 4 13 16 18
TECHNICAL SPECIFICATIONS SECTION‐II Technical Description of ACSR Conductor Details of Conductor The ACSR Conductor shall generally conform to IEC: 1089/ IS: 398 except where otherwise specified herein. The salient parameters of the ACSR Conductor are indicated below. a) b) c) d) e) 1.1.3 18.104.22.168 ACSR MOOSE Conductor
1. 1.1 1.1.1 1.1.2
Stranding and wire diameter 54/3.53mmAl +7/3.53 mm steel Number of Strands Steel core 1st steel layer 2nd steel layer 1st Aluminium layer 2nd Aluminium layer 3rd Aluminium layer Sectional area of Aluminium Total sectional area Overall diameter (mm) 1 6 12 18 24 528.5 597.0 31.77
Standard Technical Particulars The Standard Technical Particulars (STP) of the ACSR conductor are enclosed at Annexure‐B of this section. The values indicated in the STP are the minimum and/or maximum values required to be met by the Supplier. Workmanship All the Aluminium and steel strands shall be smooth, uniform and free from all imperfections, such as spills and splits, die marks, scratches, abrasions, etc., after drawing and also after stranding. The finished conductor shall be smooth, compact, uniform and free from all imperfections including kinks (protusion of wires), wire cross over, over riding, looseness (wire being dislocated by finger/hand pressure and/or unusual bangle noise on tapping), material inclusions, white rust, powder formation or black spot (on account of reaction with trapped rain water etc.), dirt, grit etc.
The steel strands shall be hot dip galvanised and shall have a minimum zinc coating as indicated in the STP. The zinc coating shall be smooth, continuous, of uniform thickness, free from imperfections and shall withstand number of dips in standard Preece test as indicated in STP. The steel wire rods shall be of such quality and purity that, when drawn to the size of the strands specified and coated with zinc, the finished strands and the individual wires shall be of uniform quality and have the same properties and characteristics as prescribed in IEC: 888. The steel strands shall be preformed and post formed in order to prevent spreading of strands in the event of cutting of composite core wire. Care shall be taken to avoid, damages to galvanisation during pre‐forming and post‐ forming operation. Joints in Wires Aluminium Wires During stranding, no aluminium wire welds shall be made for the purpose of achieving the required conductor length. No joints shall be permitted in the individual wires in the outer most layer of the finished conductor. However joints are permitted in the inner layer of the conductor unavoidably broken during stranding, provided such breaks are not associated with either inherently defective wire or with the use of short lengths of aluminium wires. Such joints shall not be more than four (4) per conductor length and shall not be closer than 15 meters from joint in the same wire or in any other aluminium wire of the completed conductor. Joints shall be made by cold pressure butt welding and shall withstand a stress of not less than the breaking strength of individual strand guaranteed. Steel Wires There shall be no joint of any kind in the finished wire entering into the manufacture of the strand. There shall also be no strand joints or strand splices in any length of the completed stranded steel core of the conductor. Tolerances The manufacturing tolerances to the extent indicated in the STP shall be permitted in the diameter of individual aluminium and steel strands and lay‐ ratio of the conductor
1.3 1.3.1 22.214.171.124 126.96.36.199
Materials Aluminium The aluminium strands shall be hard drawn from electrolytic aluminium rods having purity not less than 99.5% and a copper content not exceeding 0.04%. They shall have the same properties and characteristics as prescribed in IEC: 889. Steel The steel wire strands shall be drawn from high carbon steel wire rods produced by either the acid or the basic open‐hearth process, the electric furnace process, or the basic oxygen process and shall conform to the chemical composition indicated in the STP. The Steel wire strands shall have the same properties and characteristics as prescribed for regular strength steel wire in IEC : 888. Zinc The zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity as per IS209. It shall conform to and satisfy all the requirements of IS:209. Standard Length The standard length of the conductor shall be as indicated in the STP. All lengths outside this limit of tolerance shall be treated as random lengths. Random lengths will be accepted provided no length is less than 70% of the standard length and the total quantity of such random lengths shall not be more than 10% of the total quantity ordered. When one number random length has been manufactured at any time, five (5) more individual lengths each equivalent to the above random length with a tolerance of +/‐ 5% shall also be manufactured and all the above six random lengths shall be despatched in the same shipment. At no point, the cumulative quantity supplied of such random lengths shall not be more than 12.5% of the total cumulative quantity supplied including such random lengths. However, the last 20% of the quantity ordered shall be supplied only in standard lengths as specified. The Owner reserves the right to place orders for the lengths above the standard length on the same terms and conditions applicable for the standard lengths during the pendency of the Contract.
1.6 1.6.1 1.6.2
Tests and Standards Type Tests The following tests shall be conducted once on a sample/samples of conductor for every 1500 Kms. of production from each manufacturing facility: a) DC resistance test on stranded conductor As per Annexure‐A b) UTS test on stranded conductor c) d) Radio interference voltage test (dry) Corona extinction voltage test (dry)
Acceptance Tests a) b) c) d) e) f) g) h) i) j) Visual and dimensional check on drum Visual check for joints scratches etc. and length measurement of conductor by rewinding Dimensional check on steel and aluminium strands Check for lay‐ratios of various layers Galvanizing test on steel strands Torsion and Elongation tests on steel strands Breaking load test on steel and Aluminium strands Wrap test on steel & Aluminium strands DC resistance test on Aluminium strands IEC : 888 & 889 IEC : 889
As per Annexure‐A
k) Note : All the above tests except (j) shall be carried out on Aluminium and steel strands after stranding only. Routine Test a) b) c) d) Check to ensure that the joints are as per Specification Check that there are no cuts, fins etc., on the strands. Check that drums are as per Specification All acceptance test as mentioned above to be carried out on each coil/ drum (as applicable)
Procedure qualification test on welded joint of Annexure‐A Aluminium strands Barrel Batten strength test Annexure‐A
Tests During Manufacture a) b) Chemical analysis of zinc used for galvanizing Chemical analysis of Aluminium used for making Aluminium strands Chemical analysis of steel used for making steel strands
As per Annexure‐A
c) 2.5 2.5.1 2.5.2
Testing Expenses The break‐up of the testing charges for the type tests specified shall be indicated separately. Bidder shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that adequate facilities are available in the laboratories and the tests can be completed in these laboratories within the time schedule guaranteed by them. In case of failure in any type test the Supplier is either required to manufacture fresh sample lot and repeat all the test successfully once or repeat that particular type test three times successfully on the sample selected from the already manufactured lot at his own expenses. In case a fresh lot is manufactured for testing then the lot already manufactured shall be rejected. The entire cost of testing for the acceptance and routine tests and Tests during manufacture specified herein shall be treated as included in the quoted unit price of conductor, except for the expenses of the inspector/Ownerʹs representative. In case of failure in any type test, if repeat type tests are required to be conducted, then all the expenses for deputation of Inspector/Ownerʹs representative shall be deducted from the contract price. Also if on receipt of the Supplierʹs notice of testing, the Ownerʹs representative does not find ʹplantʹ to be ready for testing the expenses incurred by the Owner for re‐ deputation shall be deducted from contract price. Additional Tests The 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 materials comply with the Specifications. The 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 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. 2.7 2.7.1 Sample Batch For Type Testing The Supplier shall offer material for selection of samples for type testing only after getting Quality Assurance Plan approved from Owner’s Quality Assurance Deptt. The sample shall be manufactured strictly in accordance with the Quality Assurance Plan approved by Owner. The Supplier shall offer at least three drums for selection of sample required for conducting all the type test. The Supplier is required to carry out all the acceptance tests successfully in presence of Owner’s representative before sample selection. Test Reports Copies of type test reports shall be furnished in at least six copies alongwith one original. One copy will be returned duly certified by the Owner only after which the commercial production of the material shall start. Record of routine test reports shall be maintained by the Supplier at his works for periodic inspection by the Owner’s representative. Test Certificates of tests during manufacture shall be maintained by the Supplier. These shall be produced for verification as and when desired by the Owner. Inspection The Owner’s representative shall at all times be entitled to have access to the works and all places of manufacture, where conductor shall be manufactured and representative shall have full facilities for unrestricted inspection of the Supplier’s works, raw materials and process of manufacture for conducting necessary tests as detailed herein. The Supplier shall keep the Owner informed in advance of the time of starting and of the progress of manufacture of conductor in its various stages so that arrangements can be made for inspection. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested, unless the inspection is waived off by the Owner in writing. In the latter case also the conductor shall be dispatched
2.7.2 2.7.3 2.8 2.8.1
only after satisfactory testing for all tests specified herein have been completed. 2.9.4 The acceptance of any quantity of material shall in no way relieve the Supplier of any of his responsibilities for meeting all requirements of the Specification, and shall not prevent subsequent rejection it such material is later found to be defective. Test Facilities The following additional test facilities shall be available at the Supplier’s works: a) Calibration of various testing and measuring equipment including tensile testing machine, resistance measurement facilities, burette, thermometer, barometer , digital ohm metre etc. b) Standard resistance for calibration of resistance bridges. c) Finished conductor shall be checked for length verification and surface finish on separate rewinding machine at reduced speed (variable from 8 to 16 meters per minute). The rewinding facilities shall have appropriate clutch system and free of vibrations, jerks etc. with traverse laying facilities. Packing The conductor shall be supplied in non‐returnable, strong, wooden drums provided with lagging of adequate strength, constructed to protect the conductor against all damage and displacement during transit, storage and subsequent handling and stringing operations in the field. The Supplier shall be responsible for any loss or damage during transportation handling and storage due to improper packing. The drums shall generally conform to IS:1778, except as otherwise specified hereinafter. The drums shall be suitable for wheel mounting and for letting off the conductor under a minimum controlled tension of the order of 5 KN. The general outline of the drum for conductor shall be as in the annexed drawings. The Bidder should submit their proposed drum drawings along with the bid. For conductor, one standard length shall be wound on each drum. All wooden components shall be manufactured out of seasoned soft wood free from defects that may materially weaken the component parts of the
drums. Preservative treatment shall be applied to the entire drum with preservatives of a quality which is not harmful to the conductor. 2.11.6 The flanges shall be of two ply construction with each ply at right angles to the adjacent ply and nailed together. The nails shall be driven from the inside face flange, punched and then clenched on the outer face. The thickness of each ply shall not vary by more than 3mm from that indicated in the figure. There shall be at least 3 nails per plank of ply with maximum nail spacing of 75mm. Where a slot is cut in the flange to receive the inner end of the conductor the entrance shall be in line with the periphery of the barrel. The wooden battens used for making the barrel of the conductor shall be of segmental type. These shall be nailed to the barrel supports with at least two nails. The battens shall be closely butted and shall provide a round barrel with smooth external surface. The edges of the battens shall be rounded or chamfered to avoid damage to the conductor. Barrel studs shall be used for the construction of drums. The flanges shall be holed and the barrel supports slotted to receive them. The barrel studs shall be threaded over a length on either end, sufficient to accommodate washers, spindle plates and nuts for fixing flanges at the required spacing. Normally, the nuts on the studs shall stand protruded of the flanges. All the nails used on the inner surface of the flanges and the drum barrel shall be counter sunk. The ends of barrel shall generally be flushed with the top of the nuts. The inner cheek of the flanges and drum barrel surface shall be painted with a bitumen based paint. Before reeling, card board or double corrugated or thick bituminised water‐ proof bamboo paper shall be secured to the drum barrel and inside of flanges of the drum by means of a suitable commercial adhesive material. After reeling the conductor, the exposed surface of the outer layer of conductor shall be wrapped with water proof thick bituminised bamboo paper to preserve the conductor from dirt, grit and damage during transport and handling. A minimum space of 75 mm for conductor shall be provided between the inner surface of the external protective tagging and outer layer of the conductor. Each batten shall be securely nailed across grains as far as possible to the flange, edges with at least 2 nails per end. The length of the nails shall not be less than twice the thickness of the battens. The nails shall not protrude above the general surface and shall not have exposed sharp, edges or allow the battens to be released due to corrosion.
The nuts on the barrel studs shall be tack welded on the one side in order to fully secure them. On the second end, a spring washer shall be used. A steel collar shall be used to secure all barrel studs. This collar shall be located between the washers and the steal drum and secured to the central steel plate by welding. Outside the protective lagging, there shall be minimum of two binder consisting of hoop iron/galvanised steel wire. Each protective lagging shall have two recesses to accommodate the binders. The conductor ends shall be properly sealed and secured on the side of one of the flanges to avoid loosening of the conductor layers during transit and handling. As an alternative to wooden drum Bidder may also supply the conductors in non‐returnable painted steel drums. After preparation of steel surface according to IS:9954, synthetic enamel paint shall be applied after application of one coat of primer. Wooden/Steel drum will be treated at par for evaluation purpose and accordingly the Bidder should quote in the package. Marking Each drum shall have the following information stenciled on it in indelible ink along with other essential data : (a) (b) (c) (d) (e) (f) (g) (h) (i) (k) (l) (m) (n) Contract/Award letter number. Name and address of consignee. Manufacturer’s name and address. Drum number Size of conductor Length of conductor in meters Arrow marking for unwinding Position of the conductor ends Distance between outer‐most Layer of conductor and the inner surface of lagging. Barrel diameter at three locations & an arrow marking at the location of the measurement. Number of turns in the outer most layer. Gross weight of drum after putting lagging. Tear weight of the drum without lagging.
(o) (p) 2.13
Net weight of the conductor in the drum. CIP/MICC No.
The above should be indicated in the packing list also. Verification of Conductor Length The Owner reserves the right to verity the length of conductor after unreeling. The quantity for verification shall be between a minimum of five percent (5%) to a maximum of ten percent (10%)of the drums in a lot offered for inspection. The actual quantity will be discussed and mutually agreed to by the Supplier & Owner in the Quality Assurance Programme. Standards The conductor shall conform to the following Indian/International Standards, which shall mean latest revisions, with amendments/changes adopted and published, unless specifically stated otherwise in the Specification. In the event of the supply of conductor conforming to standards other than specified, the Bidder shall confirm in his bid that these standards are equivalent to those specified. In case of award, salient features of comparison between the standards proposed by the Supplier and those specified in this document will be provided by the Supplier to establish their equivalence.
Sl. Indian Standard No. 1. IS: 209‐1992 2. IS: 398 Part‐I ‐ 1996 IS:398 Part‐II ‐ 1996 IS:398 Part‐V ‐ 1992 IS : 1778‐1980 IS : 1521‐1991 IS : 2629‐1990 IS : 2633‐1992 IS : 4826‐1992 IS : 6745‐1990 Title Specification for zinc Specification for Aluminium Conductors for Overhead Transmission Purposes Aluminum Conductor Galvanised Steel Reinforced Aluminum Conductor Galvanised Steel‐ Reinforced For Extra High Voltage (400 KV) and above Reels and Drums for Bare Conductors Method of Tensile Testing of Steel Wire Recommended Practice for Hot Dip Galvanising of Iron and Steel Method of Testing Uniformity of Coating on Zinc Coated Articles Galvanised Coating on Round Steel Wires Methods of Determination of Weight of Zinc Coating of Zinc Coated Iron and Steel Articles Method of Radio Interference Tests on High Voltage Insulators Zinc Coated steel wires for stranded Conductors Hard drawn Aluminium wire for overhead line conductors International Standard BS:3436‐1986 IEC:1089‐1991 BS:215‐1970 BS;215‐1970 IEC:1089‐1991 IEC:1089‐1991 BS:215‐1970 BS:1559‐1949 ISO 6892‐1984 IEC : 888‐1987 BS:443‐1969 BS:433‐1969 ISO 1460 ‐ 1973 IEC:437‐1973 NEMA:107‐1964 CISPR IEC : 888‐1987 IEC : 889‐1987
5. 6. 7. 8. 9. 10.
IS : 8263‐1990
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 Beureau Of Indian Standards. Manak Bhavan, 9, Bahadur Shah Zafar Marg, New Delhi ‐ 110001. INDIA International Organisation for Standardization. Danish Board of Standardization Danish Standardizing Sraat, Aurehoegvej‐12 DK‐2900, Heeleprup, DENMARK. National Electric Manufacture Association, 155, East 44th Street. New York, NY 10017 U.S.A.
ANNEXURE‐A 1. 1.1 Tests on Conductor UTS Test on Stranded Conductor Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor of minimum 5 m length between fixing arrangement suitably fixed on a tensile testing machine. The load shall be increased at a steady rate upto 50% of minimum specified UTS and held for one minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter the load shall be increased at steady rate to 100% of the UTS of conductor and held for one minute. The Conductor sample shall not fail during this period. The applied load shall then be increased until the failing load is reached and this value shall be recorded. Corona Extinction Voltage Test The sample assembly with each conductor of 5 m length shall be strung as per the configuration shown in the Table below. Line Configuration No of conductor Spacing Maximum Height of the conductor samples per (mm) above ground (m) Bundle 400kV with twin Two 450 8.84 ACSR MOOSE 400kV with Quad Four 457 8.84 ACSR MOOSE The sample assembly when subjected to power frequency voltage shall have a corona extinction voltage of not less than that indicated in the STP. There shall be no evidence of corona on any part of the samples. The test should be conducted without corona control rings. However, small corona control rings may be used to prevent corona in the end fittings. The voltage should be corrected for standard atmospheric conditions. Radio Interference Voltage Test Under the conditions as specified under (1.2) above, the conductor samples shall have radio interference voltage as indicated in the standard technical particulars enclosed at Annexure‐B of this section. This test may carried out with corona control rings and arcing horns. The test procedure shall be in accordance with IEC‐437 D.C. Resistance Test on Stranded Conductor On a conductor sample of minimum 5m length two contact‐clamps shall be fixed with a predetermined bolt torque. The resistance shall be measured by a
Kelvin double bridge or digital ohm‐metre of sufficient accuracy by placing the clamps initially zero metre and subsequently one metre apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 200C as per IS:398. The resistance corrected at 200C shall conform to the requirements indicated in the STP. 1.4 Chemical Analysis of Aluminium and Steel Samples taken from the Aluminium and steel ingots/coils/strands shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this Specification.
Visual and Dimensional Check on Drums The drums shall be visually and dimensionally checked to ensure that they conform to the requirements of this Specification. Visual Check for Joints, Scratches etc. Conductor drums shall be rewound in the presence of the Owner. The Owner shall visually check for scratches, joints etc. and that the conductor generally conform to the requirements of this Specification. Five percent (5%) to ten percent (10%) drums from each lot shall be rewound in the presence of the Ownerʹs representative. The actual quantity will be discussed and mutually agreed to by the Supplier & Owner in the Quality Assurance Programme. Dimensional Check on Steel and Aluminium Strands The individual strands shall be dimensionally checked to ensure that they conform to the requirement of this Specification. Check for Lay‐ratios of Various Layers The lay‐ratios of various layers shall be checked to ensure that they conform to the requirements of this Specification. Procedure Qualification test on welded Aluminium strands Two Aluminium wire shall be welded as per the approved quality plan and shall be subjected to tensile load. The breaking strength of the welded joint of the wire shall not be less than the breaking strength of individual strands. Chemical Analysis of Zinc Samples taken from the zinc ingots shall be chemically/ spectrographically analyzed. The same shall be in conformity to the requirements stated in the Specification.
1.7 1.8 1.9
Galvanizing Test The test procedure shall be as specified in IEC : 888. The material shall conform to the requirements of this Specification. The adherence of zinc shall be checked by wrapping around a mandrel four times the diameter of steel wire. Torsion and Elongation Tests on Steel Strands The test procedures shall be as per clause No. 10.3 of IEC : 888. In torsion test, the number of complete twists before fracture shall not be less than that indicated in the STP. In case test sample length is less or more than 100 times the stranded diameter of the strand, the minimum number of twists will be proportioned to the length and if number comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the elongation of the strand shall not be less than 4% for a gauge length of 250 mm. Check on Barrel Batten strength of Drums The details regarding barrel batten strength test will be discussed and mutually agreed to by the Supplier & Owner in the Quality Assurance Programme.
Annexure‐B STANDARD TECHNICAL PARTICULARS OF ACSR MOOSE CONDUCTOR
Sl. Description Unit Guaranteed Values
1.0 1.1 1.1
Raw Materials Steel Wire / Rods Aluminium
% % % % % % % .% mm mm mm KN KN Ohm mm mm mm KN KN
99.50 0.04 0.50 to 0.85 0.50 to 1.10 Not more than 0.035 Not more than 0.045 0.10 to 0.35 (Max.) 99.95 3.53 3.55 3.51 1.57 1.49 0.002921 3.53 3.59 3.47 12.63 11.99
a) Minimum purity of Aluminium b) Maximum copper content 1.2 Steel wires/ rods
a) Carbon b) Manganese c) Phosphorous d) Sulphur e) Silicon 1.3 Zinc
a) Minimum purity of Zinc 2.0 2.1 Aluminum strands after stranding Diameter
a) Nominal b) Maximum c) Minimum 2.2 Minimum breaking load of strand
a) Before stranding b) After stranding 2.3 Maximum resistance of 1 m length of strand at 20 deg. C 3.0 Steel strand after stranding 2.1 Diameter
a) Nominal b) Maximum c) Minimum 3.2 Minimum breaking load of strand
a) Before stranding b) After stranding
STANDARD TECHNICAL PARTICULARS OF ACSR MOOSE CONDUCTOR
Sl. Description Unit Guaranteed Values
250 2 dips of one minute & 1 dip of half minute 16
a) Minimum weight of zinc coating per sq.m. b) Minimum number of dips that the galvanised strand can withstand in the standard preece test c) Min. No. of twists in guage length equal 100 times the dia. of wire which the strand can withstand in the torsion test (after stranding) 4. Stranded Conductor 4.1 4.2 UTS of the conductor Lay length of outer steel layer
kN mm mm mm mm mm ohm/km kV (rms) Micto Volts m % kg/km kg/km kg/km
161.20 (Min.) Max 18 14 13 12 0.05552 320 Below 1000 1800 (+/‐) 5 Right Hand 2004 1969 2040 Min 16 12 11 10
a) Outer Steel layer b) 12 wire Aluminium layer c) 18 wire Aluminium layer d) 4.3 4.4 4.5 4.6 4.7 4.8 4.9 24 wire Alumimium Layer DC resistance of the conductor at 20°C Minimum corona Extinction Voltage (line to phase) under Dry condition RIV at 1 Mhz at 305 Amp (line to phase) under Dry condition Standard length of the conductor Tolerance on Standard length Direction of lay of outer layer Linear mass of the conductor
a) Standard b) Minimum c) Maximum
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