NETWORK CONSTRUCTIONS AND MAINTENANCE DEPARTMENT 22, Chalkokondyll St, 104 32 Athens - Tol: +30 210 5202030, Fax: +30 210 8239301 ) PUBLIC POWER CORPORATION S.A. PPC Technical Description DKSD-287/March 2004 | SUSPENSION CLAMP FOR SELF SUPPORTING AERIAL BUNDLED CABLES 4x120 mm? Al+ 25 mm” Al FOR OVERHEAD LV NETWORKS CONTENTS 1. SCOPE 2. KEYWORDS 3, OPERATING CONDITIONS 4, NORMS ~ SPECIFICATIONS 5. DESCRIPTION 6. TESTS 7. MARKING 8. PACKING 9. ANNEXES - DRAWINGSPUBLIC POWER CORPORATION S.A. NETWORK CONSTRUCTIONS AND MAINTENANCE DEPARTMENT PPC Technical Description DKSD-287/March 2004 |SUSPENSION CLAMP FOR SELF SUPPORTING AERIAL BUND! ABLES 4x1 + 25 mm” Al ‘FOR OVERHEAD LV NETWORKS 1. SCOPE This Technical Description (TD) specifies the construction and testing requirements for the suspension clamp for self supporting aerial bundled cables 4x120 mm? Al + 25 mm? Al, used in overhead distribution networks of rated voltage 0,6/1 KV. ‘The suspension clamp is installed at sections of lines having zero or non-zero deviation angles’ using the above mentioned cables, and, combined with the suspension bracket, provides mechanical support, (suspension) of the cabies on the pole. 2 KEYWORDS Cable accessory, suspension clamp, self supporting LV aerial bundled cables, overhead distribution network, 0,6/1 KV. 3. OPERATING CONDITIONS 3.4. Environmental conditions - Installation The suspension clamp is intended for outdoor installation, at overhead LV distribution networks with self supporting aerial bundled cables. = Climatic conditions The suspension clamp shall be suitable for installation in areas where the temperature and sunlight conditions are as follows: Minimum ambient air temperature 20°C Maximum average ambient air temperature measured over a period of 24h +35°C "The maximum permitted deviation angle is limited by the mechanical strength of the assembly ‘consisted of the suspension clamp (see par. §.5) and the suspension bracket,Maximum ambient air temperature +40°C Minimum annual exposure to sunlight 2800 h + Altitude Most installations are located at altitudes not exceeding 1000 m above the sea level. Special Conditions sion clamp shall be suitable for operation in high corrosion areas (deposits of industrial pollutants, presence of moisture, water, ice). 4, NORMS - SPECIFICATIONS. 44. CENELEC! HD 626 $1/1986 + A1/1997 + A2/2002 (or its most recent amendment): ‘Overhead distribution cables of rated voltage Uo/U(Um): 0,6/1 (1,2) kV = Part 2: Additional test methods - Part 4 Section N: Bundle assembled cores for overhead distribution (Type 4N-1) 42. PPC Technical Description DMKLD-211/29.05.1997 + Supplement No 1/14.03.02: Self supporting aerial bundled cables for use in overhead LV networks. 43, PPC Technical Specification GR-278/31.03.1986; Suspension assembly for aerial bundled cables for use in overhead LV networks. 44, PPC Technical Description DKSD-268/March 2004: Tension clamp for self supporting aerial bundled cables 4x120 mm? Al + 25 mm? Al for overhead LV networks. 48. PPC Technical Description DMKLO-153/19.11.1999: Special sockets for LV aerial bundled cables (short-circuiting and earthing connectors). 46. PPC Technical Specification XK 11.02/10.03.1988: Hot dip galvanization process for iron-made or steel-made items. 47. PPC Technical Specification XK 11.03/11.11.1987: Chromium coating treatment for galvanized surfaces. 4.8. PPC Technical Specification TK 02.01/11.11.1987: Sampling procedures and tables for checking the percentage of defective items by assessments. NOTE: The text of this TD prevails and its requirements supersede any other Standard or Specification. 8. DESCRIPTION 8.4, General description The suspension clamp shall be suitable for the self supporting LV aerial bundled cables (ABC) manufactured according to PPC TD DMKLD-211/29.05.1997 (or according to the most recent amendment of HD 626-4N) and shall consist of the following parts: — Main body = Bundle retaining ring (insulating insert) — Tightening screw ‘An indicative outline of the clamp is provided in Drawing No 1 (paragraph 8.2.1), whileDrawing No 2 (paragraph 9.2.2) provides some supplementary dimensions of the main body. 5.1.1. Main body The main body shall be made of steel and shall be hot dip galvanized according to PPC Technical Specification XK 11.02/10.03.1998, with minimum galvanization thickness according to Table | of the same Specification, and with chromium treatment according to PPC Technical Specification XK 11.03/11.11.1987, exhibiting strength of 150 h under salt fog test. It shall be appropriately processed in order to be free of defects and poorly treated edges and holes. This process shall be performed prior to galvanization. it must be noted that a clamp with main body made of aluminium or aluminium alloys shall not be accepted due to inadequate resistance against coastal corrosion. At the top side, the clamp shall have a suspension hole enabling it to be suspended from the suspension bracket of Type | of Part | of PPC Technical Specification GR-278/31.03. 1986. The suspension hole shall be reinforced by a ring (either metalic or made of synthetic material), in order to ensure its strength against decay due to friction with the U bolt of the suspension bracket. If the above ring is made of synthetic material, the specifications for the insulating insert and the other synthetic parts of the clamp (see per. 5.1.2) shall also apply regarding the ring's strength against environmental impacts. ‘The configuration of the bottom part of the main body shall be approximately semi-cylindrical in order to enclose the bundle retaining ring (par. 5.1.2). Tightening of the ring inside the main body shall be achieved by the tightening screw (par. 5.1.3), which shall pass through ‘two opposite points of the main body and over the ring. Drawings No 1 and No 2 (par. 9.2.1 and 9.2.2) provide limits and tolerances for certain clamp dimensions. All dimensions shall be provided by the manufacturer in the questionnaire of Annex. No 3. The clamp design shall ensure the following, during clamp's free vertical suspension from the suspension bracket: — When horizontal forces develop on the cable (wind pressure), no dangerous contact or friction of the cable cores insulation with the pole shall occur. Thus the L, dimension of the main body (see Drawing No. 2) shail not exceed 150 mm. — The axis of the bundle retaining ring shall not be incompatibly perpendicular to the axis of the pole. — The “suspension bracket - suspension clamp - cable” assembly shall not exhibit ‘eccentricities, which, in combination with the applied forces either during normal ‘operation or during the tests, may lead to failure of the materials. 5.1.2. Bundle retaining ring (insulating insert) The bundle retaining ring shail be made of suitable synthetic material in order not to damage the cable cores installed in the ring. At the same time, it shall act as insulating insert to ensure the required dielectric strength of the clamp (see par. 6.6). it shall be able to be completely separated from the main clamp body and it shall have a longitudinal cut at the top to enable insertion of the cable cores into the ring. The ring shall have internal diameter d) = 44 mm (with the screw fully tightened - see Drawing No 1) to enable the installation of all ABC 4x120 mm? Al + 25 mm* Al cores inside it, ite. the cores of the three phases, neutral, and Public Lighting (PL). The ring shall be made of synthetic material with high resistance against environmental impacts (exposure to UV radiation levels dominating in Greece, industrial pollution, salt, high or low temperatures etc.), and against impacts resulting from the cable's operation (cable warming due to loading étc.), and it shall provide reliable insulation between cable cores and metalic parts of the clamp under such conditions.All other parts of the clamp which are made of synthetic material (e.g. nut heads and suspension hole reinforcement ring, if they are made of synthetic material) shall have the above properties. 5.1.3. Tightening screw The tightening screw and its nut shall be made of the same material (steel) and they shall both have the same gaivanization and chromium treatment as the main body (see par. 5.1.1), but the galvanization thickness shall be according to Table | of PPC Technical Specification XK 11.02/10.03.1988. The screw shall be tightened by hand, using a suitable tightening handle (wing nut) made of insulating material. Alternatively, itis acceptable to perform tightening with a wrench, using & nut head made of insulating material, of a double-head nut. In any case, tightening shall be torque-measuring (i.e. either the handle or the nut head shall be “sheared-of™ when the tightening torque reaches the required value for correct installation of the clamp). Following the installation of the clamp and the breaking of the handle or nut, any subsequent disassembly of the clamp shall be carried out by using the (not ‘shear-off?) steel nut. The required tightening torque shall be marked on the nut, in order to enable re-installation of the clamp using a torque-measuring wrench. The manufacturer shall specify in his offer the required tightening torque for the nut or the breaking torque for the torque-measuring handle. The tightening screw shall be permanently attached to the main body (e.g. by a belt or other suitable method) to avoid losing the screw during clamp disassembly. Moreover, the tightening screw shall be equipped with an appropriate device (e.g. washer) to prevent its unscrewing. 5.2. Size The size of the suspension clamp, as standardized by this TD, shall be: Size 120mm* : For suspension of the seif supporting LV aerial bundled cables 4x120 mm? Al + 25 mm? Al, manufactured according to PPC TD DMKLD-211/29.05.97 (or according to the most recent amendment of HD 626-4N). . 63. Fal requi for construction materials All materials used shall be appropriately selected regarding their physical and chemical properties and their dimensions for reliable operation of the clamp under the expected conditions of the network and its environment (maximum continuous loadings, overcurrents, direct exposure to sunlight / ultraviolet radiation, dust, sait, industrial pollution, humidity, low temperatures, etc.). 6.4, Life span requirements ‘The suspension clamp shall operate in a satisfactory manner for the period during which the aerial bundled cables are expected to operate in a satisfactory manner (a period of about 35 years). 6.8. Mechanical characteristics = Minimum strength against tensile loads along the vertical axis without any visible deformation (and without exceeding the material's yield point): 1000 daN (see test of par. 6.1.2.3)~ Minimum sliding load at the cable cores along the longitudinal direction for which no slippage of the cable greater than 4 mm (inside the clamp) can be observed: 60 daN (see test of par. 6.1.2.4) 5.6, Electrical characteristics — Dielectric strength of the insulating insert: 4 kV (see test of par. 6.1.2.1) — Dielectric strength between the metallic parts of the clamp and the cable cores: 30 kV (Gee test of par. 6.1.2.2) 6. TESTS The Table of Annex No 1 provides the sequence of tests and the number of samples required for each test. 6.1. Type Tests These tests are performed at the beginning of a Contract and they can be repeated in the absolute judgement of the Corporation at any time during the Contract execution period, To the discretion of the Corporation, it is possible for existing test certificates issued by the PPC/TRSC (KDEP) or other recognized laboratories to be accepted. 6.1.1. General Requirements 6.1.1.1, Samples and installation of samples ‘The tests shall be carried out on new samples. ‘The samples shall be installed on new pieces of complete self supporting ABC 4x120 mm? Al + 25 mm? Al, manufactured according to PPC TD DMKLD-211/29.08.1997 (or according to the most recent amendment of HD 626 - 4N). The cable pieces shall have sufficient length for the performance of the tests (detailed data provided in the description of each test), The screw of the samples shall be tightened until the torque-measuring handle or the torque- measuring tightening nut are sheared-off. 6.1.1.2. Preparation of the cable cores before tests The core pieces shall be conditioned prior to the tests to ensure the dimensional stabilization of their insulation. In particular, the cores shall be cut to a length suitable for the test and then they shall be stored in a closed chamber at a temperature of (120 + 2)°C for about 1 hour, and then they shall be left to cool down to the ambient temperature by opening the chamber's door. 6.1.1.3. Design approval eriteria if a failure occurs in two sample items during a Type test, the design of the suspension clamp shall be rejected. if a failure occurs in one sample item during a Type test, the test shall be repeated with twice the number of samples as specified in this TD. In this case, the test shall be considered successful if no failure occurs in the new samples, but if even one failure occurs, the design of the suspension clamp shall be rejected. tt must be noted that if, during a test, a failure in a core of the ABC is observed, which is not caused by the sample, the test shall be considered non-performed and it shall be repeated with new samples and new core pieces.6.1.2. Description of the tests - Success criteria 6.1.2.1. Dielectric test on the insulating insert of the clams 6.1.2.1.1. Test procedure ‘A sufficient length of cable (all 5 cores) is covered with copper or aluminium foil and the covered part is installed and retained in the clamp. ‘The main body of the clamp (metallic parts) is earthed, and the copper or aluminium foil is connected to a 50 Hz AC voltage generator, set to trip at a leakage current of (10 + 0,5) mA. The voltage is increased gradually, at a rate of approximately 1 kV/s, up to 4 KV, and this value is maintained for 1 min. 6.1.2.1.2. Success criterion The test is considered successful if no flashover or breakdown of the insulating insert is observed, and in general if no leakage current greater than (10 + 0,5) mA is observed (/.e. if no tripping of the generator occurs) 6.1.2.1.3. Number of samples Two (2) samples. NOTE: If the test is successful, the voltage increase continues in at least one of the samples, and at the same rate, until failure occurs, The voltage value during failure is recorded for research purposes. 6.1.2.2. Dielectric test between the metallic parts of the clamp and’the conductors of the cable 61.221. Test procedure A sufficient length of cable (all 5 cores) is placed in the clamp. A 60 Hz AC voltage Is applied between the metallic parts of the clamp and the core conductors, with the metallic parts of the clamp connected to earth. The voltage is increased gradually, at a rate of approximately 1 KV/s, up to 30 KV. 6.1.2.2.2. Success criterion ‘The test is considered successful if no failure (piercing) of the cable core insulation is observed. 6.1.2.2.3, Number of samples ‘Two (2) samples. NOTES: 1. A clamp that has successfully passed the previous test (paragraph 6.1.2.1) may also be used, provided that no subsequent failure has ocourred in the sample. 2 If the test is successful, the voltage increase continues at one of the samples, at least, ‘and at the same rate, until failure occurs. The voltage value during failure is recorded for research purposes.6.1.2.3. Mechanical strenath test 6.1.2.3.1. Test procedure ‘The sample is connected to a tensioning machine according to the arrangement of Drawing No 3 (paragraph 9.2.3). A tensioning force F; is applied to the clamp gradually, at an increase rate between 100 and 500 daN/min, up to a value of 1000 daN. This value is maintained for 1 min and then the sample is unloaded gradually, at approximately the same rate. NOTE: Instead of the metallic bar mentioned in Drawing No 3, a device similar to the one mentioned in PPC Technical Specification GR-278/31.03.1986, Part ll, par. 3.1.2.1, may also be used, ie., it is permitted to use a steel wire rope of appropriate diameter (44 mm, equal to the diameter of the cable bundle), covered with plastic tape. 6.1.2.3.2, Success criterion The test is considered successful if, on the one hand, no breaking of the clamp is observed during its loading and, on the other hand, no permanent deformation is observed at its metalic parts after unloading, 6.1.2.3.3. Number of samples Two (2) samples, 1. A clamp that has been successfully submitted to one or both of the previous tests (par. 6.1.2.1 and 6.1.2.2) may also be used, provided that no subsequent failure occurred to the sample. 2. If the test is successful, at least one of the samples shall be submitted again to tensioning, at the same increase rate of the tensioning force, until failure (breaking) of the sample, and the failure tensioning force shall be recorded for research purposes. 6.1.24. Cable slip test 6.1.24.1. Test procedure A sufficient length of cable (all 5 cores) is placed in the clamp. All four (4) load carrying cores (3 phases and neutral) of the cable are subjected to tensioning, as illustrated in Drawing No 4 (paragraph 9.2.4). The PL core is not subjected to tensioning, The tensioning force is increased at a rate between 10 and 50 daN/min up to the value of Fa = 50 daN, and this value is maintained for 1 min (where F; is the total tensioning force at all 4 cores). Appropriate provisions shall be taken so that the applied force is uniformly distributed among the 4 tensioned cores (e.g. by using an tension clamp). 6.1.2.4.2. Success criterion The test is considered successful if, using the loading described in paragraph 6.1.2.4.1, no slippage of the cable greater than 4 mm is observed at the clamp. In case of failure (slippage more than 4 mm), the results are recorded and evaluated. 6.1.2.4.3, Number of samples ‘Two (2) samples.NOTE if the test is successful, the increasing cable tensioning force is maintained in at least one of the samples, at the same rate, until failure occurs, and the failure tensioning force is recorded for research purposes. As failure is considered any initiation of cable's slippage inside the clamp or loosening of the cable's strain at its tensioned end (which can be established by using a dynamometer at that end). 6.1.2.5. Climatic ageing test 6.1.2.5.1. Samples The samples which have been successfully submitted to the cable slip test (paragraph 6.1.2.4) are used for the climatic ageing test (2 items - without cable lengths) NOTE: Clamps that failed during the above test - i.e. a cable slippage was observed - may also be used, provided that no visible damage has been caused to the insulating insert of the clamp. 6.1.2,5.2. Test procedure ‘The samples (suspension clamps) are subjected to climatic ageing using 6 weekly cycles of 468 hours each, with an ageing procedure according to paragraphs 6.1.1.3 up to 6.1.1.6 of PPC TD DMKLD-211/29.05.1997 (see also HD 626 S1:1996/Part 2, paragraph 2.5.1 and Table 2.5.1.1). Ageing is performed in a special chamber at (maximum) temperature (70#2)°C. During the test, suitable measures shall be taken to ensure that the samples exposure to the source of radiation is as uniform as possible (see also PPC TD DMKLD-153/19.11.1989, paragraph 6.1.2.7.1). 6.1.2.5.3. Success criteria Following the climatic ageing procedure, the samples are left at the environment of the laboratory for at least 24 and up to 72 h. Then the samples are subjected successively to the following tests: 6.1.2.5.3.1. Dielectric test on the insulating insert of the clamp (paragraph 6.1.2.1) The success criterion is the one mentioned in paragraph 6.1.2.1.2. In case of failure, the failure voltage values are recorded and the results are evaluated. 6.1.2.5.3.2. Mechanical strength test (paragraph 6.1.2.3) The mechanical strength test is performed using a force F, up to 750 daN. The success criterion is the one mentioned in paragraph 6.1.2.3.2. In case of failure, the failure tensioning force values are recorded and the results are evaiuated 6.1.2.6, Endurance test under mechanical oscillations, 6.1.2.6.1. Samples The samples (2 items) which have been successfully submitted to the climatic ageing test (paragraph 6.1.2.5) are used for this test.6.1.2.6.2 General During the test, the cable installed in the suspension clamp is subjected to mechanical stress and at the same time the suspension clamp is subjected to oscillation stress. For this purpose, a tension clamp is placed at the ends of each cable section (of approximate length of 12 m). The tension clamps used for this test must be new samples whose type has been successfully subjected to the endurance test under combined thermal and mechanical stresses, as specified in paragraph 6.1.2.5 of PPC TD DKSD-288/March 2004, ‘A suspension assembly (i.e. the tested suspension clamp, attached to a suspension bracket of Type | according to PPC Technical Specification GR-278/Part 1/31.03.86) is installed in the middle of the above mentioned cable section. All 5 cores of the cable are placed inside the clamp. tt On both sides of the suspension clamp and at a distance of 1,20 m from its vertical ‘symmetry plane, a weight is hung. The two weights create an angie between the longitudinal axis of the suspension clamp and the cable. The weights shail be rigidly fixed to the cable (see Drawing No 5 of paragraph 8.2.5). The value of each load (weight), including its fixing system, shall be between 40 and 50 daN. 61.263. Test procedure 500 cycles of combined mechanical and thermal stresses to the cable as well as oscillation stress to the suspension clamp, with a duration of 90 min each, are applied as follows (Drawing No 6 in paragraph 9.2.6 provides a graph of the stress cycles): 6.1.2.6.3.1, Mechanical stress During the first 75 min of the cycle. a constant tensioning force is applied to the cable, with a value equal to-20% of its specified breaking load (i.e. the total minimum specified breaking Joad of the 4 carrying cores - see PPC TD DMKLD-211/29.05.1997). During the last 15 min of the cycle, the tensioning force value is increased to 40% of the minimum specified breaking load of the cable. The applied overloading shall be progressive and it shall not be performed in less than 5 s. 6.1.2.6.3.2. Oscillation stress During the first 75 min of the cycle (i.e. while the cable is subjected to tensioning load equal to 20% of its minimum specified breaking load), the suspension clamp performs swings so that its shifting angie is (40 + 2) degrees at both sides of the longitudinal vertical plane (see Drawing No § in paragraph 9.2.5). This movement (oscillation) can be caused by a system similar to the one described in ‘Supplement No 1/21.07.1986 of PPC Technical Specification GR-278/Part 1! (paragraph 3.1.5.2) ‘The number of side pushing actions on the suspension clamp during the first 75 min of the cycle is 128 (i.e. 64 movements towards one direction and 64 movements towards the opposite direction of the clamp’s side pushing system). During the last 15 min of the cycle no oscillations are performed. 6.1.2.6.3.3. Thermal stress (UNDER STUDY) During the first 45 min of the cycle, cable warming is caused by intermittent current passing through the cable's 4 carrying conductors (phases and neutral), with a density between 3 and 4 A/mm’, The temperature of each conductor is maintained at (60 + 3)°C. During the last 45 min, the cable conductors are left to naturally cool to ambient temperature and then their temperature is maintained until the end of the cycle.6.1.2.6.4, Success criteria ‘The test is considered successful if all the following criteria are simuttaneously met: — No slippage of the cable greater than 4 mm is observed inside the clamp. — No wear of the main body around the suspension hole is observed during the test. (However, wear of the hoie reinforcement ring is permitted to occur - see par. 5.2.1) — The cable and the clamp together are immersed in water and the dielectric test at 10 kV AC is performed, according to paragraph 6.2.5 of PPC TD DMKLD-211/29.05. 1997. — If the above test is successful, then the dielectric test between the metallic parts of the clamp and the core conductors is performed (paragraph 6.1.2.2) and the samples are checked for compliance to the criterion of paragraph 6.1.2.2.2. — One of the suspension clamps is subjected to the mechanical strength test of paragraph 6.1.2.3. In order for this part of the test to be considered successful, no breaking or permanent deformation shall occur to the clamp for a value of F; equal to 750 daN. 6.1.2.7. Metal and metakalloy analysis test This test is used to check the conformity of the metais and metal-alloys used for the metallic parts of the clamp (retaining arms, bolts, nuts, etc.) to the metals and alloys that have been stated by the manufacturer. It is performed on two (2) samples for each size. 6.1.2.8. Test of the insulating material of the bundle retaining ring (insulating insert) 61.281. Test procedure This test is used to check the conformity of the insulating material of the bundle retaining ring (insulating insert) of the clamp to the material that has been stated by the manufacturer. The check shall be performed according to the Norm / Standard mentioned in the manufacturer's offer 6.1.2.8.2. Number of samples Two (2) samples per size. 6.1.2.9. Test for quality check of the printed mar This test is performed/on clamps whose marking or part of that marking is printed. It is not applied to clamps whose marking is completely embossed or notched. 61.2.9.1. Test procedure ‘The printed marking of the sample is rubbed for 15 min with a cloth soaked in water. Then it is rubbed for 15 min with a cloth soaked in petroleum solvent. The cloth motion is performed by hand. NOTE: As ‘petroleum solvent’ is defined the aliphatic hexane solvent with aromatic hydrocarbon content up to 0,1% by volume, Kauri-butanol value of 28, initial boiling point of 85°C, vaporization point of 69°C, and specific gravity of 0,68 g/cm*. 6.1.29.2. Success criterion The test is considered successful if the marking is readable after the above procedure. 106.1.2.9.3, Number of samples Two (2) samples. 6.1.2.10. Corrosion test (UNDER STUDY) 6.1.2.10,1. Test procedure The clamp is suspended from a suspension bracket of Type | according to PPC Technical Specification GR-278/Part |/31.03.1986. All 5 cores of a cable section of 30 cm long are placed inside the clamp. At the same time, a weight equal to (1 + 0,1) daN is suspended from the clamp'so that the weight comes in contact with the metallic part of the clamp {main body) potentially causing galvanic corrosion due to dissimilar metals. The above assembly is subjected to 4 cycles of exposure to corrosive agents, each lasting 14 days, as described in paragraph 6.1.2.9.1 of PPC TD DMKLD-153/19.11.1999 (corrosion test for special sockets for LV aerial bundied cables). 61.2.10.2. Success criteria Following the end of the exposure cycles, the samples are left in the environment of the laboratory for at least 24 and up to 72h. Then the clamp is subjected to the following tests: 6.1.2.10.2.1. Mechanical strength test (paragraph 6.1.2.3) The success criterion is the ‘one mentionied in paragraph 6.1.2.3.2. In case of failure, the failure tensioning force values are recorded and the results are evaluated. 6.1.2.10.2.2. Visual check The clamp is visually checked to establish that none of its metallic parts (either covered or exposed) has visible traces of rust. Moreover, the clamp marking shall remain readable when examined by normal or corrected vision, without magnification. 6.1.2.10.3. Number of samples Two (2) samples. 6.2. Sample tests (Batch acceptance tests) From each "to be accepted” batch of a Contract, two (2) SAMPLES shall be collected using the following sampling program, according to PPC Technical Specification TK 02.01/11.11.87: Double sampling, Special check level S4 for normal check and AQL = 1,5%. The 1" SAMPLE shall be subjected to the test of paragraphs 6.2.1 and 6.2.6 and the 2” SAMPLE shall be subjected to the tests of paragraphs 6.2.2, 6.2.3, and 6.2.4. 6.2.1. Visual check During this test, the following checks are performed: = Check of the clamps dimensions for compliance with the Contract drawings, and the proper cooperation with the suspension bracket. "— Check of the clamps for compliance with the general requirements of this TD (dimensions, thickness, treatments, materials, etc.) — Visual check of the clamps to investigate whether they have surface irregularities, pores, ete. ~ Visual check of the marking (check for compliance with the provisions of the Contract). 6.2.2. Dielectric test on the insulating insert of the clamp ‘As defined in paragraph 6.1.2.1 of this TD (without causing failure to the sample, as mentioned in the relevant note). 62.3. Dielectric test be 1e metallic parts of the clamp ar conductor cable" ‘As defined in paragraph 6.1.2.2 of this TD (without causing failure to the sample, as mentioned in note 2). 6.2.4, Mechanical strenath test As defined in paragraph 6.1.2.3 of this TD. 6.2.5. Cable slip test As defined in paragraph 6.1.2.4 of this TD. 7. MARKING 7.4, Suspension clamp marking Each suspension clamp shali have a marking with the following data, which shall be distinguishable and shall not deteriorate, taking into account the conditions of transport, storage and installation at the distribution networks: (1) Name or trademark of the manufacturer (2) On the bundle retaining ring, the number and cross-section of the cores that are instalied in it. in particular, it shall read: ~ 4x120 + 25 (3) On the nut of the tightening bolt, the value of its required tightening torque or the “shear- off’ torque for the torque-measuring tightening handie (in Nm) (4) SEH © Year of manufacture (© "CE" marking This data shall be preferably embossed or notched (paying attention not to weaken the insulation). Recommended typeface sizes: 6 mm high and 3 mm wide, except characters 1 or. 127.2, Packing marking The rigid crates in which the clamps shall be packed (see paragraph of this TD) shall have a metallic plate with the following data: (1) "Eqiyeripes Avapmons Euveotpappévou KahwOiou XT 4x120 mm® Al + 25 mm? Al Aurogepéyevou Torrou" (2) Contract number / Year of manufacture (3) QEH (4) Number of items / Net weight (8) Name of the manufacturer & PACKING Each clamp (connected as required for normal operation) shall be placed inside a resistant, transparent nyion bag. Alternatively, itis permitted to pack a small number of clamps (e.g. in pairs, in groups of 5, etc.) in a cardboard box with external transparent wrapping (e.g. nylon bag) that prevents entrance of water or moisture into the box. The above units shall be placed in reinforced crates (made of wood). For each crate the following shall apply: ~The number of contained units shall be a multiple of 10, = Gross weight of crate and content < 40 kg = Sufficient strength and safety under conditions of transport and stacking of crates up to a height of 2,5 m. The above crates shall be delivered packed on EU palettes ("europalettes") and the total weight of each palette shall not exceed 550 kg. 9. ANNEXES - DRAWINGS 941. List of annexes This TD is accompanied by the following annexes: 9.1.1. Anne 4 Table of performed tests and sample sizes. 9.1.2. Annex No 2 Verification of the competency of bidders - Configuration of tenders 9.1.3. Annex No 3 Questionnaire 139.2. List of drawings This TD is accompanied by the following drawings: 9.2.1. Drawing No 4 Indicative drawing of the suspension clamp. 9.2.2. Drawing No2 Required dimensions of the main body. 9.2.3. Drawing No 3 ‘Arrangement for the mechanical strength test of suspension clamp. 9.2.4. Drawing No 4 Performance of the slip test on suspension clamp. 925. Drawing No§ Placement and way of attachment of the suspended weights on the cable. 9.2.8. Drawing No6 Mechanical, thermal and oscillation stress cycles. 14sh (NEP 052) € “ON 158 - (AX 06) Z ON 182 -| (s2109 ¢ 112) {91M UT “ULL OF Bunioddns jos JO} A OL 388} 99/010 -| ‘SuoMe|oso yeoUE YoU} fy tu SZ + Fly WL OZ EXP z fuozL wu p > aBeddys -| a gzr9o Jepun 189} soueunpus| 9 elie owes “pasn ae (syy6u9} ayy YIM ‘paunioyed ‘2\qe0 au INOW) F “ON ISA} 0} PanNwANs aue (NEP OSZ = '4 Ayrysseoons ueaq aney yey) seKdwes eu. um) € ‘ON PUE L 'ON S1S2L 1 stro 380] BureGe onewN| ($0109 ¢ He) Bumioddns yes ‘uu | JO} NEP OS = 74 40} Ty wu Gz + By WY ORLY Zz uN OZ wu » 5 eBeddis i v719 ys0} dis a1geD|_ > (se109 ¢ 1e) Ut | 10} NEP 0001 = '4 Bumioddns yas Joy UoneWHOJ@p sey wnbuans| ty uu Gz + Ty pull OZ LX z uauogt_| swaueued 40 Gurjeaig ON 1 evr fequeyaw| € WOHEIASU! 3103 ‘eraeo| (sa109 ¢ 11e) s,a\qeo 34 jo Guroietd ON 94} Jo suo}anpUOD ayy pUue| Buypioddns yes SIAM | 9101 duseyo oxy yo syed omjeseuu| fy Wu GZ + fy Zt OZ LX z uw ozt (2H 05 ‘OV) AN.OE i TZO__| eM vEaMyeq ise) ONIeIG] Z (sauc9 ¢ tre) ‘UMOp}e21q ON, due Buryoddns yos SIAM | 218 ‘ay jo vast Gugejnsur |_fv 2m Gz + fy WRU OZ XY z un OZ} nu | 10) (ZH OS ‘OV) AN i xa) ay) uo 389} ONDE/eIC| due sedues ‘ayy ul paged aoaid oay | josequinn | ezis dwei Tasej odf} § 104) weibod Buydures 10 uonesyissetg | GL sso ‘ON (6180) adAy | 30)) sejdues jo JoqWN eueW S81 udesbered 3s0 Jo WEN hse. 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(ans ¥3QNn)| ty us Sz + ty pu OZ Ex z Jans OZ ‘s9jofo ainsodxe 1 oz 1893 UOISOLIOD| OL ‘aiqepear si Bupyew ayL “quanjos wnjoujad ul payeos| Suppeu poyuud au et z (wn OZ yop yum Bulgqny ui SI 4 6z19 Jo yoyo Ayenb 1051821] 6 yeMpeNUEG oun Aq parers jeueyew (vesur Bunemsu) ey} 0} jeuoyew Guneinsul Buy Burureyes ejpung ayn 40 - z__ | oer ‘a4j Jo eUEWOJUOD 4 e719 | reverew Sunemsuijoyse| @ sainjpenuew ayy £q = an esouy 0} sfoye-teieu! so} sisfjeue = z gunugzl _|_ 8 SIeaUL Jo eoUeWUO;UOD L 2zv9 Aoje-teyeu pue even) L cures serduies eu ul paced aoad ogy _| Jo sequinn_| ez1s duet, Taisey edi} § 103) urerBoid Buydies 16 uogesyissetg | aL simso ON (s1s@} 2dAj 1 403) sojduies Jo Jaquinn eyed BOL udes6ered 389 Jo OWEN 1881 |a %S T= TOW "ys lana] yoayp jepedg ‘Buydures aiqnoq: UU | 40) NEP Og =F 40} "29 LV'SL/.0720 ML: TAS uuu py 5 aBeddiig s sz9 sar dys aigeo| St %S'1=1OV ‘wus 5 404 NEP OOOL = + “YS fena) yoaup jenedg ‘Buydues ajqnog Jo} uoneUuoyep 380) yybua.ns| 'L9" LE LL/L0ZO UL 2 STANWS quoueuuiad 10 Gupjeesq ON s ¥z9 feoweyoow|_ pb woeinsul e103 ‘jae9} %S'L=TOV $,9\qe9 up Jo Suiard on ‘uy Jo suoyonpuco “ys Jone) yelp jenadg ‘Buydwes aiqnog SIAM | 212 duseyo ayy yo sped “28°LY F110 20 MLZ F1dWS. (2H 05 '92) AX Of 8 £79 __| em ueomjag yse omnsajaid} Eb ques sejdures aug ut pened aoaid ogy | _josequnn _| azis dwelo, Tisai edt § 10)) wresBoud Buydwes 10 vonesyissei | aL siayo “ON (sie) adh) 4 404) saidwes Jo soquNN usw, S91. udesBeseg 380 jo WEN S01,tification of tt com Configuration of ‘The houses that participate in the procurement Tender for suspension clamps, shall be able to prove their competency regarding the construction of the materials in question. For this purpose, they shall submit — Type test certifications for the offered materials. = Information regarding the manufacturing plant (postal address, personnel, ability to perform tests, etc.). — Sales catalog for the offered materials (where the quantities, years of sale and the purchasers shall be mentioned) and references for satisfactory operation, which shall prove that the manufacturing house has at least 3-year experience in manufacturing of the offered materials. — Any other information that the manufacturer considers as helpful for the verification of their competency (e.g. quality assurance certificate according to ISO 9001 or 9002 for the offered materials). ‘The bids of the houses that participate in the suspension clamp procurement Tender are required to include the following information: — Statement of compliance of the offered material with the requirements of this TD. In case of deviations, these shall be specifically defined and justified. The acceptance of deviations is up to the discretion of the Corporation, following their evaluation. = Asstatement mentioning that the material shall have the "CE" verification mark. — Detailed drawirigs of the offered material, showing the dimensions and mentioning the construction materials of the various parts and their treatments. — A statement accurately mentioning the materials used for the construction of the various parts of the suspension clamp, and a photocopy of the Norm/Standard on the basis of which their procurement is made (construction material of the Isolating gasket). — The questionnaire of Annex No 3 filled-in. — Samples of the offered materials. 18ANNEX No 3 Questionnaire This questionnaire is required for the technical evaluation of the bids. It shall accompany the bid for any size of suspension clamp and it shall be completely and explicitly filed-in. INDEX Requested information Offered 4. Main body 44. Construction material 42. Galvanization thickness 2 Bundle retaining ring (insulating insert) 24. Material 22 Material Nom/Standard 23. Resistivity p of the material (at 20°C & 80°C) 24, Method - Norm/Standard for checking 9 25. Tensioning strenath (without ageing) ssssnnenninne 26. Elongation at breaking point (without ageing) az. Ageing (°C, h) 28. Items 2.6 & 2.6 following ageing 28, Behaviour at low temperatures (410°C) 2.10. Behaviour under ultraviolet radiation 2.41. Behavior in ozone and under corrosive conditions (SO, + moisture) 19INDEX — Requested information Offered 3. Tightening screw 34 Construction material 3.2. Galvanization thickness 3.3, Is a wrench required for tightening of the screw? 34. Redquired nut tightening torque or "shearing- off torque of the tightening handle (in Nm) 35. Is the screw equipped with device for preventing loosening of its nut? YES oNO. cn 4 Dimensions According to Drawings No 1 (paragraph 9.2.1) and No 2 (paragraph 9.2.2): 44 uy 42. le 43. bs sees 44. ry : verenee MIM 45. bs 48. dy Al. & Z mm 48. ds en 49. ty mm. 4.10. te mm 444. r mm 20PPC TECHNICAL DESCRIPTION DKSD-287/March 2004 (Paragraph 9.2.1) ‘Main body (made of stee!) Bundle retaining ring (insulating insert) Tightening screw (made of steel) Nut with torque-measuring ‘shear-off tightening handle (or double-head torque~ measuring nut with one “shear-ofT head) Washer (or other appropriate device) Reinforcement ring of the suspension hole (metalic or synthetic) Bere on Note, ©The diameter dy refers to a fully tightened screw Dimensions in mm DRAWING TITLE DRAWING NO. INDICATIVE DRAWING OF THE SUSPENSION CLAMP 4PPC TECHNICAL DESCRIPTION DKSD-287/March 2004 (Paragraph 8.2.2) t_[ 40min- 55max_| [4 48 min - 22 max te 4175 max dy = i 25 max t | 3520.1) min ue 7150 max te > ts i oe 5 Noe ‘The dimensions marked with a dash (-) must be provided by the manufacturer. Dimensions in mm. DRAWING TITLE DRAWING NO. REQUIRED DIMENSIONS OF THE MAIN BODY 2PPC TECHNICAL DESCRIPTION DKSD-287/March 2004 (Paragraph 9.2.3) Tensioning machine Tensioning machine clamping devices clamping devices é peice ‘Suspension clamp Rod simutating the cable (with extemal diameter similar to the extemal diameter of the cable bundle) DRAWING TITLE DRAWING NO. ARRANGEMENT FOR THE MECHANICAL STRENGTH TEST OF THE SUSPENSION CLAMP 3PPC TECHNICAL DESCRIPTION DKSD-287/March 2004 (Paragraph 9.2.4) Fe the 4 tensioned poles (cross-section 120 mm") F< PL pole (not tensioned) ‘Suspension clamp Cable DRAWING TITLE DRAWING NO. PERFORMANCE OF SLIP TEST ON SUSPENSION 4 CLAMPPPC TECHNICAL DESCRIPTION DKSD-287/March 2004 (Paragraph 8.2.5) (402) degrees (40 + 2) degrees Suspension oT. ‘assembly Ce betr 0,45. m oe Cable (indicative length) i Tightening system | ‘on the cable : (2 plates tightened eae 4 | by bolts) ‘ \ ‘Suspended ‘ i" 420m weights ‘Swinging around the suspension plane DRAWING TITLE DRAWING NO. PLACEMENT AND WAY OF ATTACHMENT OF THE 5 ‘SUSPENDED WEIGHTS ON THE CABLEPPC TECHNICAL DESCRIPTION DKSD-287/March 2004 (Paragraph 9.2.6) Stress in daN Temperature in °C 428 swings of the suspension clamp (caused by 86 full "back and forth” movernents of the clamp's side pushing system, during the 75 min of the rocking period) e 60: A swinging period 7 min overioading 1 oycie = 80 min eEeeeeet mechanical cycle imposed on the cable ‘thermal cycie imposed on the cable (UNDER STUDY) swings imposed on the suspension clamp A- 20% of the total breaking load of the four strained cores B- 40% of the total breaking load of the four strained cores DRAWING TITLE DRAWING NO. MECHANICAL, THERMAL AND OSCILLATION STRESS 6 CYCLES