saa efor ehraron feo ftrerzor fororer UITAR DAKSHIN HARYANA SLJLI VITRAN NIGAM BVN Specification No. CSC-112/UH/DH/P&D/2015-2016 TECHNICAL SPECIFICATION FOR ACSR CONDUCTOR 105 SQMM INSULATED Issue Month: March 2016 Common Specification Committee (CSC Approval date 08012016 ) UHBVN & DHBVN &saa efit efteron feo fraqor fare UTTAR DAKSHIN HARYANA SLILI VITRAN NIGAM iBVN CONTENTS |. SCOPE . APPLICABLE STANDARDS . SERVICE CONDITIONS }. GENERAL TECHNICAL REQUIREMENT . GENERAL INSTRUCTIONS . NAME PLATE & MARKING . ROUTINE AND ACCEPTANCE TESTS . TYPE TEST . TYPE TEST CERTIFICATS: 10. TENDER SAMPLE 11. PACKING 12. GUARANTEED TECHNICAL PARTICULARS 13. INSPECTION AND TESTING 14. QUALITY ASSURANCE PLAN:- 15. GUARANTEE / WARRANTY:- 16. CHALLENGE CLAUSE 17. GURANTEED TECHNICAL PARTICULARS FOR ACSR CONDUCTOR 105 SQMM INSULATED 18. SCHEDULE OF DEVIATIONS SPrnNeneawn a TECHNICAL SPECIFICAIONS FOR ACSR CONDUCTOR 105 MM? INSULATED 1. SCOPE:Ge saa efaror efteron fio ferarzor feo Es UTTAR DAKSHIN HARYANA SULT VITRAN NIGAM BVN UHEMN This specification covers the design manufacture, shop testing, loading, Transportation and delivery at departmental stores of ACSR CONDUCTOR 105 MMP INSULATED under Specified Climatic Conditions. 2. APPLICABLE STANDARDS: The conductor shall comply in all respects with the latest edition of the following Bureau of Indian Standards (IS) 1s 209 Zinc ingot 1S 2633 Methods for testing uniform of coating of Zinc coated articles 1S 4826 Hot dipped galvanized coatings on round steel wires. 18.6745 Method for determination of mass of Zinc coating on zinc coated Iron & steel articles. 1S 1778 Reels and drums for bare conductors. 1S 398 (Part II) Aluminum conductors for overhead transmission. Purpose: Aluminum conductors galvanized steel. 3. SERVICE CONDITIONS:- The ACSR Conductor 105 Mm? Insulated to be supplied against this specification shall be suitable for satisfactory operation under the following climatic Conditions. i__| Maximum ambient temperature ((C) 60 ii isoceraunic level 45 ii__| Minimum ambient air temperature (°C) Ge HAQHATE | iv__ | Maximum average daily ambient temperature(°C) 40 v__| Maximum yearly weighed average ambient temperature (°C) _| 32 vi__ | Maximum altitude above mean sea level (m) 1000 vii_| Minimum Relative Humidity (%) 26 vili_| Maximum Relative Humidity (%) 95 ix | Average no of Rainy days/ year 120 x__| Average annual rainfall ‘900mm xi | Maximum wind pressure 195 kgim sq Xii_| Pollution Moderate The equipment shall be for safe operation in moderately hot and humid tropical climate, conducive to rust and fungus growth. 4. GENERAL TECHNICAL REQUIREMENT: 4.1 MATERIALS:saa eferor sferon fit feraraor fret UTTAR DAKSHIN HARYANA SULI VITRAN NIGAM (BVN Materials shall be as per clauses 6.0 of IS 398(Part-Il) the Aluminum conductor strands shall be drawn from 99.5% pure electrolytic EC grade Aluminum rods whose physical constants shall be as per IS 398 (Part-II) clause 4.0 and sub clause thereof. The galvanized steel wire to be used shall be manufactured from the acidic or basic open hearth or by electric arc process and its physical constants shall conform to IS 398 (Part-l) clause 5.0 .No steel wire drawn from Bessemer process shall be used. The steel wire shall not contain sulphur and phosphorus exceeding 0.05% and the total sulphur and phosphorus shall not exceed 0.085%. The steel wire shall not be subject to any heat treatment after being galvanized. The Zinc coating of the steel wires shall be smooth and of uniform thickness and shall conform to IS 209, IS 4826and satisfy test as per IS 2633 & IS 6745. There shall be no bare spots owing to adherence of scales or other causes, The resistance of the individual Aluminum wires shall be determined separately before stranding by means of tests on samples of wires to an accuracy of one part in a thousand. The test samples shall be of sufficient length to give the required accuracy. 4.2 SURFACE CONDITIONS: Surface conditions of the conductor shall be generally as per clause 7.0 of IS 398 (Part Il). The conductor surface shall be free from points, sharp edges, abrasions or other departures smoothness on uniformity of surface contour that would increase radio interference and corona losses. When subjected to tension up to 50% of the ultimate strength of the conductor, the surface shall not depart from the cylindrical form on any part of the compartment, parts or ‘strands, more relative to each other in such a way as to get out of place and disturb the longitudinal smoothness of the conductor. 4.3 STANDARD SIZES: * Size of wires shall be as per clause 8.0 and sub clauses thereof of IS 398 (Part I). * Tolerance on Aluminum and steel wires shall be as per clauses 8.1.2.1 and 8.1.2.2 of IS 398 part II. However, negative tolerance on Aluminum wire is not permitted. The tolerance shall be when connected to standard temperature. Further negative tolerance on standard weight /Km of conductor is also not permitted 4.4 JOINTS IN WIRES: Joints shall be generally as per clause 9.0 and sub clause thereof as per IS-398(Part-I). 4.5STRANDING: Stranding of wire shall be generally as per clause 10.0 and sub clause thereof as per IS 398 (Part I). 5. GENERAL INSTRUCTIONS: ‘The conductors should be generally constructed as per IS 398 (Part-II)/1996. The steel strands shall have Grease applied between the strands as snit corrosive agent, 6. NAME PLATE & MARKING Packing and marking shall be as per clause 12.0 and sub clauses thereof as per |S 398(Part II). The conductor shall be wound on non-retumable wooden reels or drums conforming to the latest edition of IS: 1778. The weight of the empty reel, including that of the circumferential lagging shall also be marked along with the total weight of the reel with the conductor. be7. ROUTINE ° ©0000 8. Type test BO@PNAMRYN= 0. saa efor eftaron ferorcit ftreror forever UTTAR DABSHIN HARYANA BLILI VITRAN NIGAM IBVN AND ACCEPTANCE TESTS SELECTION OF TEST SAMPLES: Test samples shall be selected as per clause 13.1.1 to 13.1.3 of IS 398(Part Il). However test shall also be conducted and samples of wire to be taken from length of standard conductors as per clause of Is: 398, BREAKING LOAD TEST : Breaking load test shall be conducted as per clause 13.1 and 13.3.1 of IS 398 ( Part Il).The minimum ultimate tensile strength , Minimum breaking load, Minimum average ultimate tensile strength in a complete conductor shall not be less than the value specified in the data sheet DUCTILITY TEST : This shall be conducted based on the torsion test as per clause 13.4.1 of IS 398 ( Part Il). WRAPPING TEST : This shall be conducted on Aluminium and steel wire separately as per clause 13.5.1 and 13.5.2 of IS 398( Part I). RESISTANCE TEST: This shall be as per clause 13.6 of IS 398 (Part Il). The resistance corrected at 20 deg C. Shall not more than the maximum value specified in the data sheet GALVANIZING TEST: Galvanizing test shall be as per clause 13.7 and sub clause thereof as per IS 398 (Part-I). Sampling of test pieces shall be as per clause 3.2.1 and 3.2.2 of IS 6745 and 2.1.2 of 82633. The sample shall be cleaned as per clause 4.1 of 1S 6745 and 2.2 of IS 2633. The test procedure shall bethat outlined in clause 5.0 and sub clause thereof as is applicable for galvanized wires as per IS 6745 and clause 2.4 and 2.5 of IS 2633. The mass of coating on wire shall be determined as per clause 6.0 and sub clause thereof of IS 2633. The test values shall not be less than those specified in data sheet. Rejection & Retest: Rejection and retest procedures shall be as per clause 15.1, 15.2 of IS 398(Part II) TEST ON COMPLETE CONDUCTOR: Theresistance, mass of the conductor lay ration and calculated breaking load of the conductor shall be based as per IS 398 (Part I!) Measurement of lay ratio for all wire & conductors. Diameter measurement of individual wires (for AL & Stee!) and complete conductor. Surface Finish Test Uniformity of zinc coating & weight of zinc. Check for joints on conductor Surface finish test Ultimate breaking load on stranded conductor. Stress strain test. Measurement of diameter of individual aluminum & Steel wire. Measurement of lay ratio Breaking load of individual wires, Ductility test Resistance test Wrapping test Galvanizing testsaq efaror sftaron fort ftrraor ferret UITAR DAKSHIN HARYANA SLILI VITRAN NIGAM BVN 9. TYPE TEST CERTIFICATS: Certificates for the type tests conducted within five years precedingto the date of opening of tender on Samples in a Govt. Approved Testing Laboratory shall be submitted alongwith the tender. 10. TENDER SAMPLE Bidder shall have to submit the sample of material with the offer (in case of first supply to DHBVN). 11. PACKING The conductor shall be supplied in the standard length of 2.00 km. not less than 95% of the conductor shall be supplied in the standard lengths and the remaining 5% required to be supplied in the pieces shall not be less than 500 meters .The no. of pieces if in the drums shall be indicated on conductor drum. 12, GUARANTEED TECHNICAL PARTICULARS The bidders are required to furnish the guaranteed technical particulars duly filled in along with the tender. Format is attached 13. INSPECTION AND TESTING Manufacturer shall_have testing facilities for routine & acceptance test mentioned, Materialshallbeinspectedandtestedbythepurchaserorhisauthorizedagent_beforedispatch as per technical specifications of the Nigam unlessdispensedwithinwritingbythepurchaser. TheSuppliershall givetothepurchaser (Chief Engineer /MM) atleast20daysadvancenoticeforsuchinspectionandtest. The vendor /supplier shall also provide a copy of approved QAP, drawings along with the inspection call. Vendor / supplier should give it in writing that he is ready for the inspection Onreceiptoftheadvancenoticefromthesupplierofferingthematerialforinspection the purchasing authority will get + the = material__~—s inspected + and ~—sissue _thedispatch authorizationwithin20days. IncasetheInspectingOfficerfindsonarrivalatthesupplier's premisesthatthematerialwasnotreadyforinspectionandthatthenoticegivenbythe supplierwasinfructuous, theexpenditureincurredbytheNigamonarrangingforsuchinspectionwillbedebit edtothefirm'saccount Besidesthisaletterofwamingshallbe issuedanditshallbecountedtowardstheirperformanceforallintentsandpurposes. ‘TheContractorshallberesponsibletopaypenaltyofRs.20,000/-foreachoccasionat whichthefakeinspectioncallhasbeenmadeorthematerialisrejectedduringtesting/ inspectionbytheauthorizedagency/representativeoftheNigam. Thispenaltywould beinadditiontotheexpensesincurredbytheNigamindeputingthelnspectingOfficer, carryingoutsuchinspection. In case the material offered for inspection fails in Ist inspection, the Nigam will have the right to levy a penalty at 0.1 % of the order value. In case the material offered for inspection fail during the 2" inspection, the Nigam will have the right to increase the penalty to 0.25% of the order value. In case, the material offered fails during the 3 and final inspection also, the firm will be liable for penal action encashment of BG, debarring/ blacklisting in future and no further opportunity for inspection would be provided to the supplier firm.saa efor efteron ferorct ftrraor fororar UITAR DAKSHIN HARYANA BLILI VITRAN NIGAM IBVN LHEWN, NigamintendstopurchaseonlyHighQualitymaterial.Forthispurposesamplefrom lotofthematerialsuppliedshouldbesent to NABL LaboratoryforTestingatNigam’sCost Anylotshallbe finallyacceptedonlywhenthesampleispassedbytheNABL Laboratory. 14. QUALITY ASSURANCE PLAN:- 14.1 SUBMISSION OF QUALITY ASSURANCE PROCEDURE The Vendor / Contractor at the time of submission of the drawings for approval from DHBVN/UHBVN js also required to submit a Quality Assurance Procedure (QAP) of the materials to be supplied for review and approval. In this QAP, the vendor / contractor shall clearly indicate the quality measures being taken by the manufacturer to maintain the quality of the finished product. The drawings/QAP once approved shall not be required to be submitted for approval again. QAP will indicate the following details:- i) Tests being performed on the raw material purchased by manufacturer for manufacturing of the finished product. ii) Tests being conducted during manufacturing of the product (In process testing). illTests which shall be done on the finished product at the time of pre-dispatch inspection. iv)Test results assured by the vendor. v) Tests procedure followed for the inspection with full details of test setup ete The Inspection shall be carried out on the basis of the approved QAP. Alll the details provided by the vendor / contractor shall be verified by Nigam / Third Party during the inspection and if any deviation is found from the approved documents, it will be noted in the inspection report. 14.2 INSPECTION CALL RAISED BY VENDOR / CONTRACTOR The vendor / contractor will give inspection call notice 20 days in advance of date of readiness of material or as provided in the NIT to the below mentioned agencies: © For Work Orders issued by PD&C: CE / PD&C © For Purchase Order issued by MM : CE / MM © For work order issued by Field offices: SE/OP (Concemed)/Const. The vendor / contractor shall also provide a copy of approved QAP, drawings along with the inspection call. Vendor / contractor should give it in writing that he is ready for the inspection and in case of any default on his part, appropriate action in form of penalty will be taken by DHBVN/UHBVN. 14.3 MATERIAL INSPECTION AT DHBVN/UHBVN STORES FOR NIGAM PURCHASE Checking of material received at DHBVN/UHBVN store shall be carried out as under: a) A team of 2 XENs to be nominated by CE/MM will carry out random checking to ensure quality and quantity of material received in Nigam’s stores. b) The team will draw sample from each lot received in anyone of the stores to carry out checking as under:- © Genuineness of seals provided during inspection ‘© Workmanship of material received in store ‘© Quantity of material inspected viz-a-viz received quantity © Quality of material received in the store cesax efor eferon fact feaaor foro UTTAR DAKSHIN HARYANA BULI VITRAN NIGAM iBVN ©) The above said inspection / checking would be carried out to check all physical parameters as per approved technical specifications of the Nigam / Engineering Design / Drawings d) The above said team would also draw samples randomly for any material for its testing from any NABL accredited testing lab as approved by the Nigam e) A committee of two XENs to be constituted by Director/Projects at random may also draw sample from any lot for cross checking as per (b) & (d) above. f) The material received at the store shall not be issued to field offices before the test reports from NABL accredited lab is received by DHBVN/UHBVN. However, in case of any urgency to issue material in the field, an undertaking may be obtained from the Vendor stating that in case the material fails in the NABL Lab, the cost of replacement of material including its erection and dismantling at site, transport of material from store of DHBVN/UHBVN etc. shall be borne by the vendor. The whole LOT of material shall be considered as rejected in such case. 15. GUARANTEE / WARRANTY:- The supplier shall be responsible to replace, free of cost, with no transportation or insurance cost to the Purchaser, up to destination, the whole or any part of the material which in normal and proper use Proves the defective in quality or workmanship, subject to the condition that the defect is noticed within 78 months from the date of receipt of material in stores or 72 months from the date of commissioning whichever period may expire earlier. The consignee or any other officer of Nigam actually using the material will give prompt notice of each such defect to the supplier. The feplacement shall be effected by the supplier within a reasonable time, but not, in any case, exceeding 45 days. The supplier shall, also, arrange to remove the defective within a reasonable Period, but not exceeding 45 days from the date of issue of notice in respect thereof, failing which, the purchaser reserve the right to dispose of defective material in any manner considered fit by him (Purchaser), at the sole risk and cost of the supplier. Any sale proceeds of the defective material after meeting the expenses incurred on its custody, disposal handling etc., shall however be credited to the supplier's account and set off against any outstanding dues of the purchaser against the supplier. The warranty for 72/78 months shall be onetime 16. CHALLENGE CLAUSE The material offered/received after the inspection by the authorized inspecting officer may again be subjected to the test for losses or any other parameter from any Testing House/in-house technique of the Nigam & the results if found deviating un-acceptable or not complying to approved GTP's, the bidder shall arrange to supply the replacement within thirty (30) days of such detection at his cost including to & fro transportation. In addition to this penalty @10% of cost of the inspected lot of material shall be imposed 17. GURANTEED TECHNICAL PARTICULARS FOR ACSR CONDUCTOR 105 SQMM INSULATED {Sr Description Unit DHBVN Specified GTP by No. | Bidders ACSR Conductor INSULATED DOG ( 105 M2) References Standards __| 1S 398( Part-II)/1996 bC2 saa efor sferon fir fraor free UTTAR DAKSHIN HARYANA SUILI VITRAN NIGAM BYN 22 | Density of Galvanized steel wire Gmiec [7.8 m 23 | Coefficient of linear expansion of Per | 11.5x10%6 galvanized steel Deg C 24 | Modulus of Electricity of conductor | GN/Sq_| 75 M 25 | Type of insulation PVC type ST2 of 1s:5831/1984 26 | Nominal thickness of insulation MM [16 27 | Minimum thickness of insulation MM [4.5 28 | Tensile strength of PVC insulation NiSqM_| 12.5 29 [Elongation % 150 (TO BE ENCLOSED WITH THE BI 18. SCHEDULE of Deviations: Al deviations from this specification shall be set out by the Bidders)-clause by Clause in this schedule unlessspecifically mentioned in this Schedule, the tender shall be deemed.to-confirm the purchaser's specifications: S.No. Clause No. Details of deviation with justifications We confirm that there are no deviations apart from those detailed above. = ey SE/P&D, DHBVN Cum-member Secretary CSC, UHBVN/DHBVNaA sae efor Sharon fro fear fererer UTTAR DAKSHIN HARYANA SLILI VITRAN NIGAM BYN UE Current Carrying capacity ‘Amp [278 7 [Aluminum Maximum Purity of Aluminum % 99.5 Maximum Copper Content % 0.04 2 | Stee! Wires/ Rod Carbon % 0.50 to 0.85 Manganese % 0.50to 1.10 Phosphorus % (0.035 (Max.) Sulphur % (0.045 (Max.) Silicon % (0.10 to 0.35 3 [Zine Maximum Purity of Zinc ‘% 99.95 4__| Aluminum Strands after stranding No. of strands Nos. [6 ‘Normal Diameter mm |4.72 5 ___ | Minimum Breaking load of strand KN 264 6 | Maximum Resistance of 1 km length of | Ohm/k | 1.65 strand at 20 Deg C. m 7__| Stee! Strands after stranding zi No. of strands Nos. [7 Nominal Diameter mm | 1.87 8 _| Minimum Breaking load of strand KN 2.57 9 | Galvanizing Minimum weight of zinc coating per |Gm | 190 Sq. m of uncoated wire surface Minimum no of one minute dips that | Nos. _| 2 dips of T minute each the galvanized strand can withstand in and 1 dip of half minute the standard preece test 40 | ACST Conductor | UTS of conductor KN 32.41KN 11 | DC Resistance of conductor at 20 Deg | Ohm/K | 0.279 c m 12 | Minimum Corona Extinction voltage(_| KV NA Line to. ground under dry condition) _| (rms) s see 73__[RIVat 1 Mhz ‘At 184 KV (rms) under dry condition | Microvo | NA It 14 | Standard length of conductor M 2000 wate 15, Max. length of conductor M 16 | Tolerance on standard length of % +5 conductor 17__| Direction of lay for outside layer Right Hand 18 | Approximate Mass of Conductor Standard KgikM_| 304 19 | Drum is as per specification Yes 20 | Density of hard drawn Aluminum Gmicc [2.703 m 21 | Coefficient of inear expansion Per | 238x106 Aluminum Deg C ye