TECHNICALSPECIFICATIONS

SECTIONII

1.0 TechnicalDescriptionofDiscInsulators

1.1 DetailsofDiscInsulators

1.1.1 TheInsulatorstringsshallconsistofStandarddiscsforathreephase,50Hz,
effectively earthed 400 kV transmission system in a lightly polluted
atmosphere.Thediscsshallbecapandpin,ballandsockettype.

1.1.2 Supplier may quote for disc insulator, made of either electroporcelain or
toughenedglass.

1.1.3 Thesizeofdiscinsulator,minimumcreepagedistance,thenumbertobeused
in different type of strings, their electromechanical strength and mechanical
strengthofinsulatorstringalongwithhardwarefittingsshallbeasfollows:

Sl. Typeof Sizeofdisc Minimum No. Electro Mechanical

No. string insulators creepage of mechnical strengthof
(mm) distanceof disc strength insulator
eachdisc of stringalong
(mm) insulator with
disc(KN) hardware
fittings(KN)
A.For400kVD/C(QuadBundle)TLinSnowZone
1. SingleI 255x145 315 25 120 120
suspension or
280x145
Pilot
2. Quad 280x170 330 4 x 160 4x160
Tension 25
3. Single 255x145 315 25 120 120
Tension or
280x145
B.For400kVD/C(QuadBundle)TLinNonSnowZone
1. DoubleI 255x145 315 2 x 120 2x120
or
suspension 23
280x145
2. SingleI 255x145 315 23 120 120
or
suspension
Pilot 280x145

3. Quad 280x170 330 4 x 160 4x160

Tension 23
4. Single 255x145 315 24 120 120
or

SECTION-II (VOLUME-II) PAGE 1

 Tension 280x145
C.For400kVD/C(TripleBundle)TLinSnowZone
1. SingleI 255x145 315 25 120 120
or
suspension
280x145
Pilot
2. Double 280x170 370 2 x 210 2x210
Tension 25

1.2 PinandCap

1.2.1 PinandCapshallbedesignedtotransmitthemechanicalstressestotheshell
by compression and develop uniform mechanical strength in the insulator.
Thecapshallbecircularwiththeinnerandoutersurfacesconcentric,ofsuch
designthatitwillnotyieldordistortunderloadconditions.

1.2.2 The pin ball shall move freely in the cap socket but without danger of
accidental uncoupling during erection or in position. The design of the disc
shouldbesuchthatstressesduetoexpansionorcontractioninanypartofthe
insulatorshallnotleadtodeterioration.

1.3 Securityclip

1.3.1 SecurityclipforusewithballandsocketcouplingshallbeofRshapedhump
typewhichshallprovidepositivelockingofthecouplingasperIS:2486(Part
Ill)/IEC:372.Thelegsofthesecurityclipsshallbespreadafterinstallationto
preventcompletewithdrawalfromthesocket.Thelockingdeviceshouldbe
resilient, corrosion resistant and of suitable mechanical strength. There shall
benoriskofthelockingdevicebeingdisplacedaccidentallyorbeingrotated
when in position. Under no circumstances shall locking device allow
separationofinsulatorunitsorfittings.

1.3.2 The hole for the security clip shall be countersunk and the clip shall be of
such design that the eye of clip may be engaged by a hot line clip puller to
providefordisengagementunderenergisedconditions.Theforcerequiredto
pullthesecurityclipintoitsunlockedpositionshall notbelessthan50N(5
kg)ormorethan500N(50kg).

1.4 BallandSocketDesignation

Thedimensionsoftheballsandsocketsshallbeof20mmdesignationfor120
KN and 160 KN disc insulator & 24 mm designation for 210 KN disc in
accordance with the standard dimensions stated in IS:2486 (Part
II)/IEC:120.

1.5 DimensionalToleranceofInsulatorDisc(Standard)

It shall be ensured that the dimensions of the disc insulators are within the
limitsspecifiedbelow:

SECTION-II (VOLUME-II) PAGE 2



a) DiameterofDisc(mm)

Standard Maximum Minimum
120KNDisc 255/280 266/293 244/267

160 KN & 210 KN 280 293 267
Disc

b) Balltoballspacingbetweendiscs

Standard Maximum Minimum
120KNDisc 145 149 141

160 KN & 210 KN 170 175 165
Disc
1.6 Interchangeability

Thediscinsulatorsinclusiveoftheballandsocketfittingsshallbeofstandard
designsuitableforusewiththehardwarefittingsofanymakeconformingto
relevantIndian/InternationalStandards.

1.7 CoronaAndRIPerformance

Allsurfacesmustbeclean,smooth,withoutcuts,abrasionsorprojections.No
part shall be subjected to excessive localised pressure. The metal parts shall
be so designed and manufactured that it shall not generate any Radio
Interference beyond specified limit and not produce any noise generating
coronaundertheoperatingconditions.

1.8 Maintenance

1.8.1 The disc insulators offered shall be suitable for employment of hot line
maintenance techniques so that the usual hot line operations can be carried
outwithease,speedandsafety.

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

1.9 Materials

1.9.1 Porcelain

The porcelain used in the manufacture of shells shall be sound, free from
defectsthoroughlyvitrifiedandsmoothlyglazed.

SECTION-II (VOLUME-II) PAGE 3

1.9.2 Glaze

Thefinishedporcelainshallbeglazedinbrowncolour.Theglazeshallcover
all exposed parts of the insulator and shall have a good lusture, smooth
surface and good performance under the extreme weather conditions of a
tropicalclimate.Itshallnotcrackorchipbyageingunderthenormalservice
conditions. The glaze shall have the same coefficient of expansion as of the
porcelainbodythroughouttheworkingtemperaturerange.

1.9.3 ToughenedGlass

Theglassusedfortheshellsshallbesound,freefromdefectssuchasflaws.
bubbles, inclusions etc. and be of uniform toughness over its entire surface.
Allexposedglasssurfacesshallbesmooth.

1.9.4 Cement

Cementusedinthemanufactureofthe insulatorshall not cause fractureby

expansion or loosening by contraction. The cement shall not give rise to
chemical reaction with metal fittings and its thickness shall be as small and
uniformaspossible.Propercareshallbetakentocorrectlycentreandlocate
individualpartsduringcementing.
1.9.5 PinsandCaps

Pins and Caps shall be made of drop forged steel and malleable cast
iron/spheriodal graphite iron/drop forges steel respectively, duly hot dip
galvanised andshall notbemade by jointing, welding,shrinkfitting or any
otherprocessfrommorethanonepieceofmaterial.
1.9.6 SecurityClips

Security clips shall be made of good quality stainless steel or phosphor

bronzeasperIS:1385.2.5%extraSecurityclipshallbeprovided.
1.10 Workmanship

1.10.1 Allthematerialshallbeofthelatestdesignandconformtothebestmodern
practices adopted in the extra high voltage field. Suppliers shall offer only
such insulators as are guaranteed by him to be satisfactory and suitable for
400kVTransmissionlinesandwillgivecontinuedgoodservice.
1.10.2 The design, manufacturing process and material control at various stages
shall be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish and elimination of sharp edges and
cornerstolimitcoronaandradiointerference.
1.10.3 Thedesignoftheinsulatorsshallbesuchthatstressesduetoexpansionand
contractioninanypartoftheinsulatorshallnotleadtodeterioration.
1.10.4 Metal caps shall be free from cracks, seams, shrinks, air holes, burrs and
roughedges.Allsurfacesofthemetalpartsshallbeperfectlysmoothwithno
projecting points or irregularities which may cause corona. All load bearing

SECTION-II (VOLUME-II) PAGE 4

 surfacesshallbesmoothanduniformsoastodistributetheloadingstresses
uniformly.
1.10.5 All ferrous parts shall be hot dip galvanised to give a minimum average
coating of Zinc equivalent to 600 gm/sq.m. and shall be in accordance with
the requirement of IS:2629 and shall satisfy the tests mentioned in IS:2633.
The zinc used for galvanising shall be of Grade Zn 99.95 as per IS:209. The
zinc coating shall be uniform, adherent, smooth, reasonably bright,
continuous and free from imperfections such as flux, ash, rust stains, bulky
whitedepositsandblisters.Thegalvanisedmetalpartsshallbeguaranteedto
withstandatleastsixsuccessivedipseachlastingforone(1)minuteduration
underthestandardpreecetest.
1.10.6 Beforeballfittingsaregalvanised,alldieflashingontheshanksurfaceofthe
ball shall be carefully removed without reducing the dimensions below the
designrequirements.

1.10.7 The design of the insulators shall be such that the shell shall not engage
directly with hard metal. The design shall also be such that when units are
coupledtogetherthereisnocontactbetweentheshellofoneunitandmetal
of the next adjacent unit. The design of the shell ribs shall be such that the
securityclipoftheinsulatorcanbeengagedanddisengagedeasilywithhot
stickwithoutdamagingtheshellribs.

1.10.8 Insulatorunitsafterassemblyshallbeconcentricandcoaxialwithinlimitsas
permittedbytherelevantIndianStandards.

1.10.9 The manufacturer of the insulators shall guarantee an insulator failure rate
notexceeding1(one)per10000(tenthousand)peryearfordiscinsulatorper
year. In case the annual failure rate during the first ten years of service
exceeds the above figure, under normal operating condition, as will be
determinedbychecktobeconductedaspermutuallyagreedprocedureand
conditions upto ten years, (as permitted by the operating situation), the
Supplier shall supply to the Owner free of cost spare insulators equal to 10
timetheexcessfailure.

1.10.10 TheSuppliershallguaranteethatthereshallnotbeanydecapping/breaking
ofinsulatorsonlineunder normal operating conditions. Intheevent of any
decapping/breaking and subsequent line drop, during the first ten years of
service the Supplier shall have to pay Rs. 50,000/ (Rs. Fifty thousand only)
per dropped string towards expenditure to be incurred by OWNER for this
linerepair.

2.0 TechnicalDescriptionofPorcelainLongRodInsulators

2.1 DetailsofLongRodInsulators

2.1.1 Theinsulatorsofthestingsshallconsistofstandardlongrodinsulatorswith
normal sheds for a three phase, 50 Hz, effectively earthed 400 kV
transmissionsysteminalightlypollutedatmosphere.Insulatorsshallbelong
rodtypewithBallandsocketconnections.

SECTION-II (VOLUME-II) PAGE 5

2.1.2 Insulators shell have normal sheds/alternate sheds with good selfcleaning
properties. Insulator shed profile, spacing projection etc. shall be strictly in
accordancewiththerecommendationofIEC815.

2.1.3 Supplierquotingforlongrodinsulatorsmadeofelectroporcelainshallalso
supplyintermediateballpinsandintermediatearcinghornsalongwithlong
rodinsulators.

Thepriceoftheseitemsshallbeconsideredasincludinginthepriceoflong
rodinsulators.

2.1.4 Thesizeoflongrodinsulator,minimumcreepagedistance,thenumbertobe
used in different type of strings, their electromechanical strength and
mechanical strength of insulator string alongwith hardware fittings shall be
asfollows:

2.1.5 Descriptionoflongrodinsulatorstring(equivalenttostandarddiscinsulator)

Sl. Typeof Sizeof Minimum No.of Electro Mechanical

No. string longrod creepage individ mechanical strengthof
insulators distanceof ual strengthof insulator
(mm) eachunit units insulator stringalong
(mm) per disc(KN) with
string hardware
fittings(KN)
A.For400kVD/C(QuadBundle)TLinSnowZone
1. SingleI 6085 2625 1x3 120 120
suspension
Pilot
2. Quad 7585 2750 4x3 160 4x160
Tension
3. Single 6085 2625 1x3 120 120
Tension
B.For400kVD/C(QuadBundle)TLinNonSnowZone
1. DoubleI 6085 2415 2x3 120 2x120
suspension
2. SingleI 6085 2415 1x3 120 120
suspension
pilot
3. Quad 7585 2530 4x3 160 4x160
Tension
4. Single 6085 2415 1x3 120 120
Tension
C.For400kVD/C(TripleBundle)TLinSnowZone
1. SingleI 6085 2625 1x3 120 120

SECTION-II (VOLUME-II) PAGE 6

 suspension
Pilot
2. Double 8590 3084 2x3 210 2x210
Tension

Note:(i)Biddersmayquotefortherelevantstrings.

(ii) Lengthoflongrodinsulatorstringsshallbematchingwiththe
correspondingdiscinsulatorstrings.

(iii) ThecostofintermediateBallpinandintermediatearcinghorn
shallbeconsideredasincludinginthepriceoflongrod
insulators.

2.2 PinandCap

2.2.1 Pinandcapshallbedesignedtotransmitthemechanicalstressestotheshell
by compression and develop uniform mechanical strength in the insulator.
Thecapshallbecircularwiththeinnerandoutersurfacesconcentric,ofsuch
designthatitwillnotyieldordistortunderloadconditions.

2.2.2 The pin ball shall move freely in the cap socket but without danger of
accidentaluncouplingduringerectionorin position.Thedesignofthelong
rodshouldbesuchthatstressesduetoexpansionorcontractioninanypart
oftheinsulatorshallnotleadtodeterioration.

2.3 BallandSocketDesignation

Thedimensionsoftheballsandsocketshallbeof20mmdesignationfor120
&160KNforlongrodinsulatorsand24mmdesignationfor210KNlongrod
insulatorsinaccordancewiththestandarddimensionsstatedinIS2486(Part
II)/IEC:120.

2.4 DimensionalTolerance

The tolerance on all dimensions e.g. diameter, length and creepage distance
shallbeallowedasfollows:

(0.04d+1.5)mmwhend<300mm.

(0.025d+6)mmwhend>300mm

Wheredbeingthedimensionsinmillimetersfordiameter,lengthorcreepage
distanceasthecasemaybe.

However,nonegativetoleranceshallbeapplicabletocreepagedistance.

2.5 IntermediateBallPinDesignation

The dimensions of the intermediate ball pin shall be in accordance with the
standarddimensionstatedinIEC:471.

SECTION-II (VOLUME-II) PAGE 7

2.6 IntermediateArcingHorn

2.6.1 For Insulator strings with long rod insulators besides the arcing horn on
towersideofhardwarefittings,intermediatearcinghornsalongwithfixtures
andfastenersasshowninthespecificationshallalsobeprovided.

The total effective arcing distance shall be 3050 mm (for TL in Nonsnow

zone) and 3340 mm (for TL in Snow zone) under nominal dimensions of
insulator.

2.6.2 Thesparkgapshallbesoadjustedtoensureeffectiveoperationunderactual
fieldcoordination.
2.7 InterChangeability

Thelongrodinsulatorswithballandsocketconnectionshallbeofstandard
designsuitableforusewiththehardwarefittingsofanymakeconformingto
relevantIECstandards.
2.8 CoronaandRIPerformance

Allsurfacesshallbeclean,smooth,withoutcuts,abrasionsorprojections.No
part shall be subjected to excessive localised pressure. The insulator and
metal parts shall be so designed and manufactured that it shall avoid local
corona formation and not generate any radio interference beyond specified
limitundertheoperatingconditions.
2.9 Maintenance

2.9.1 The long rod insulators offered shall be suitable for employment of hot line
maintenance techniques so that usual hot line operations can be carried out
withease,speedandsafety.
2.9.2 Allinsulatorsshallbedesignedtofacilitatecleaningandinsulatorsshallhave
theminimumpracticalnumberofshedsandgrooves.Allgroovesshallbeso
proportionedthatanydustdepositcanberemovedwithoutdifficultyeither
bywipingwithaclothorbyremotewashingunderlivelinecondition.
2.10 Materials

2.10.1 Porcelain

Theporcelainusedinthemanufactureoflongrodsshallbealuminatype.It
shall be sound, free from defects and thoroughly vitrified and smoothly
glazed.
2.10.2 Glaze

Thefinishedporcelainshallbeglazedinbrowncolour.Theglazeshallcover
all exposed parts of the insulator and shall have a good lusture, smooth
surface and good performance under the extreme weather conditions of a
tropicalclimate.Itshallnotbecrackedorchippedbyagingunderthenormal
serviceconditions.Theglazeshallhavethesamecoefficientofexpansionas
oftheporcelainbodythroughouttheworkingtemperaturerange.

SECTION-II (VOLUME-II) PAGE 8

2.10.3 InsulatorCap

The caps of long rod insulator units shall be of malleable cast iron or other
suitablematerial,dulyhotdipgalvanisedandshallnotbemadebyjointing,
welding, shrink fitting or any other process from more than one piece of
material.Thedesignof theunit shallbesuchthat stressesduetoexpansion
andcontractionofanypartoftheinsulatorshallnotleadtodeterioration.
2.10.4 IntermediateBallPin

The intermediate ball pin shall be made of drop forged steel, duly hot dip
galvanised and shall not be made by jointly welding, shrink filling or any
otherprocessfrommorethanonepieceofmaterial.
2.10.5 IntermediateArcinghorn

IntermediateArcinghornshallbemildsteeltube.
2.10.6 Cement

Cementusedinthemanufactureofthe insulatorshall not cause fractureby

expansion or loosening by contraction. The cement shall not give rise to
chemical reaction with metal fittings and its thickness shall be as small and
uniformaspossible.Propercareshallbetakentocorrectlycentreandlocate
individualpartsduringcementing.
2.11 Workmanship

2.11.1 All the materials shall be of latest design and conform to the best modern
practicesadoptedintheextrahighvoltagefield.Biddersshallofferonlysuch
insulatorsasareguaranteedbyhimtobesatisfactoryandsuitablefor400kV
transmissionlinesandwillgivecontinuedgoodservice.
2.11.2 The design, manufacturing process and material control at various stages
shall be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish and elimination of sharp edges and
cornerstolimitcoronaandradiointerference.
2.11.3 Thedesignoftheinsulatorsshallbesuchthatstressesduetoexpansionand
contractioninanypartoftheinsulatorshallnotleadtodeterioration.
2.11.4 Metal caps shall be free from cracks, seams, shrinks, air holes and rough
edges. All surfaces of the metal parts shall be perfectly smooth with the
projecting points or irregularities which may cause corona. All load bearing
surfacesshallbesmoothanduniformsoastodistributetheloadingstresses
uniformly.
2.11.5 All ferrous parts shall be not dip galvanised to give a minimum average
coatingofzincequivalentto600gm/sq.mm.andshallbeinaccordancewith
therequirementofIS:2629andshallsatisfythetestsmentionedinIS:2633.
The zinc coating shall be uniform, adherent, smooth, reasonably bright
continuous and free from imperfections such as flux, ash, rust stains, bulky
whitedepositsandblisters.thegalvanisedmetalpartsshallbeguaranteedto
withstandatleastsixsuccessivedipseachlastingforone(1)minuteduration

SECTION-II (VOLUME-II) PAGE 9

 underthestandardpreecetest.Thegalvanisingshallbecarriedoutonlyafter
anymachining.
2.11.6 Thedesignoftheinsulatorsshallbesuchthattheporcelainshallnotengage
withhardmetal.

2.11.7 Insulatorunitsafterassemblyshallbeconcentricandcoaxialwithinlimitsas
permittedbytherelevantinternationalstandard.
2.11.8 The manufacturer of the insulators shall guarantee an insulator failure rate
notexceedingoneper1500porcelainlongrodunits.Incasetheannualfailure
rate during the first ten years of operation exceeds the above figure under
normaloperatingconditions,aswillbedeterminedbychecktobeconducted
as per mutually agreed procedure and conditions upto ten years (as
permitted by the operating situation). The manufacturer shall supply to the
ownerfreeofcostspareinsulators(Porcelainlongrod)equalto10timesthe
excessfailure.
2.11.9 Themanufacturershallguaranteethatthereshallnotbeanydecappingand
breakageofinsulatorsorlineundernormaloperatingconditions.Ineventof
anydecappingorbreakageresultinginlinedropduringthefirsttenyearsof
servicethemanufacturershallhavetopayRs.50,000/(Rs.fiftythousand)per
dropped stringtowards expenditureto be incurred by OWNERforthisline
repair.
3.0 EquipmentMarking

3.1 Eachinsulatordisc/longrodunitshallbelegiblyandindeliblymarkedwith
thetrademarkofthemanufacturer,nameofOWNERandmonth&yearof
manufacture. The guaranteed combined mechanical and electrical strength
shallbeindicatedinkiloNewtonfollowedbythewordkNtofacilitateeasy
identificationandtoensureproperuse.
3.2 Forporcelaininsulator,themarkingshallbeonporcelain.Themarkingshall
be printed, not impressed and shall be applied before firing. For toughened
glassinsulatorsthemarkingshallbeonthemetalparts.

3.3 One10mmthickringor20mmthickspotofsuitablequalityofpaintshallbe
marked on the cap of each insulator porcelain disc/porcelain long rod of
particular strength for easy identification of the type of insulator. The paint
shall not have any deteriorating effect on the insulator performance.
Followingcodesshallbeusedasidentificationmark:

For 120kNdisc/longrodunit : Yellow

For 160kNdisc/longrodunit : Green

For 210kNdisc/longrodunit : Blue

4.0 BidDrawings

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

SECTION-II (VOLUME-II) PAGE 10

4.2 TheBiddershallfurnishalongwiththebidtheoutlinedrawing(6copies)of
eachinsulatorunitincludingacrosssectionalviewoftheinsulatorshell.The
drawingshallincludebutnotlimitedtothefollowinginformation:

(a) Shelldiameterandballtoballspacingwithmanufacturingtolerances

(b) MinimumCreepagedistancewithpositivetolerance

(c) Protectedcreepagedistance

(d) Eccentricityofthedisc

(i) Axialrunout

(ii) Radialrunout

(e) Unitmechanicalandelectricalcharacteristics

(f) Sizeandweightofballandsocketparts

(g) Weightofunitinsulatordisc/longrodunits

(h) Materials

(i) Identificationmark

(j) Manufacturerscataloguenumber

4.3 After placement of award, the Supplier shall submit full dimensioned
insulator drawings containing all the details as given in Clause No. 4.11.2
above,infour(4)copiestoOwnerforapproval.Aftergettingapprovalfrom
Owner and successful completion of all the type tests, the Supplier shall
submit 20 more copies of the same drawing to the Owner for further
distributionandfielduseatOwnersend.

4.4 After placement of award the Supplier shall also submit fully dimensioned
insulatorcratedrawingfordifferenttypeofinsulators.

4.5 After placement of award, the Supplier shall submit full dimensioned
manufacturing drawing of insulator cap, pin and insulator shell in six (6)
copiestotheOwnerforreferenceandrecord.

5.0 TestsandStandards

5.1 TypeTests

The following type tests shall be conducted on a suitable number of

individual standard disc insulators or long rod units, components, materials
orcompletestrings:

5.1.1 OnunitdiscInsulators

a) Verificationofdimensions AsperIEC:60383

b) Thermalmechanicalperformancetest AsperAnnexureA

SECTION-II (VOLUME-II) PAGE 11

 c) Power frequency voltage withstand and flashover AsperIEC:60383
testunder(i)dry
(ii)wetcondition
d) Impulsevoltagewithstandandflashovertest(dry) AsperIEC:60383

e) VisibleDischargetest(dry) AsperIS:731,Cl.10.2

f) RIVtest(dry) AsperIEC:60437

g) ResidualstrengthTest AsperAnnexureA

h) SteepwavefrontTest AsperAnnexureA

i) ImpactTest AsperAnnexureA

5.1.2 OnPorcelainlongrodInsulatorunits

a) Verificationofdimensions AsperIEC:60383

b) Thermalmechanicalperformancetest AsperAnnexureA

c) Powerfrequencyvoltagewithstandandflashovertest AsperIEC:60383
under(i)dry
(ii)wetcondition
d) Impulsevoltagewithstandandflashovertest(dry) AsperIEC:60383

e) VisibleDischargetest(dry) AsperIS:731,Cl10.2

f) RIVtest(dry) AsperIEC:60437

5.1.3 OnthecompleteDiscInsulatorStringwithHardwareFittings

a) Power frequency voltage withstand test with corona AsperIEC:60383

control rings/grading ring and arcing horns under
wetcondition

b) Switching surge voltage withstand test under wet AsperIEC:60383

condition

c) Impulsevoltagewithstandtestunderdrycondition AsperIEC:60383

d) Impulsevoltageflashovertestunderdrycondition AsperIEC:60383

e) Voltagedistributiontest AsperAnnexureA

f) CoronaandRIVtestunderdrycondition AsperAnnexureA

g) MechanicalStrengthtest AsperAnnexureA

h) Vibrationtest AsperAnnexureA

i) PowerArcTest AsperAnnexureA

5.1.4 OnthecompletePorcelainlongrodInsulatorstringwithHardwareFittings

a) Power frequency voltage withstand test with corona AsperIEC:60383

control rings/grading ring and arcing horns under
wetcondition
b) Switching surge voltage withstand test under wet AsperIEC:60383
condition

SECTION-II (VOLUME-II) PAGE 12

 c) Impulsevoltagewithstandtestunderdrycondition AsperIEC:60383

d) Impulsevoltageflashovertestunderdrycondition AsperIEC:60383

e) CoronaandRIVtestunderdrycondition AsperAnnexureA

f) MechanicalStrengthtest AsperAnnexureA

g) Vibrationtest AsperAnnexureA

h) PowerArcTest AsperAnnexureA


5.1.5 AllthetypetestgiveninClauseNo.5.1.3fordiscinsulatorstringorClause
No.5.1.4forlongrodporcelaininsulatorstringshallbeconductedon400kV
DoubleSuspensionandQuadTensioninsulatorstringsalongwithhardware
fittingsfor400kV(QuadBundle)Lines.AllthetypetestgiveninClauseNo.
5.1.3,exceptclause5.1.3(i)fordiscinsulatorstringorClauseNo.5.1.4,except
clause5.1.4(h)forlongrodporcelaininsulatorstringshallbeconductedon
400kVDoubleTensioninsulatorstringsalongwithhardwarefittingsfor400
kV(TripleBundle)Line.

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

5.1.7 TypetestsspecifiedunderClause5.1.3(a)to(d)orunderClause5.1.4(a)to
(d)shallnotberequiredtobecarriedoutifavalidtestcertificateisavailable
for a similar design, i.e., tests conducted earlier should have either been
conducted in accredited laboratory (accredited based on ISO/IEC vide
25/17025orEN45001bytheNationalaccreditationbodyofthecountrywhere
laboratory is located) or witnessed by the representative(s) of OWNER or
utility.Thetestreportssubmittedshallbeforthetestsconductedwithinlast5
(five)yearspriortodateofbidopening.

Incasethetesthavebeenconductedearlierthantheabovestipulatedperiod
or in the event of any discrepancy in the test report (i.e., any test not
applicableduetoanydesign/manufacturingchangeincludingsubstitutionof
componentsorduetononcompliancewiththerequirementstipulatedinthe
Technical Specifications), the tests shall be conducted by the Supplier at no
extracosttotheOwner.

5.2 AcceptanceTests

5.2.1 ForDiscInsulators(Bothporcelainandglass)

a) Visualexamination AsperIEC:60383

b) Verificationofdimensions AsperIEC:60383

SECTION-II (VOLUME-II) PAGE 13

 c) Temperaturecycletest AsperIEC:60383

d) Galvanisingtest AsperIEC:60383

e) Mechanicalperformancetest AsperIEC:60575Cl4.0

f) Testonlockingdeviceforballandsocket AsperIEC:60372
coupling

g) Eccentricitytest AsperIEC:60383

h) ResidualStrengthTest AsperIEC:797
Clause4.4&4.5

i) MetallurgicalTest (Formetalfittingsonlyinblack AsperAnnexureA

condition)
i) Grainsize
ii) Inclusionrating
iii) Chemicalanalysis
iv) Microstructure
j) ChemicalanalysisofZincSleeve AsperAnnexureA

k) IRMeasurement AsperAnnexureA

l) ImpactTest AsperAnnexureA

m) SteepWavefronttest AsperAnnexureA

n) ThermalMechanicalperformancetest AsperAnnexureA

Note:TestsspecifiedunderClause5.2.1(m)&(n)aboveshallbeperformed
asacceptancetestsonceforeverysupplyof25,000nos.ofaparticularrating.

5.2.2 ForPorcelaindiscInsulatorsOnly

a) Electromechanicalstrengthtest AsperAnnexureA

b) Porositytest AsperIEC:60383

c) Puncturetest AsperIEC:60383

5.2.3 ForGlassInsulatorsOnly

a) Thermalshocktest AsperIEC:60383

b) Steepwavefronttest/Puncturetest AsperAnnexureA

c) MechanicalfailingloadTest AsperAnnexureA

5.3 ForPorcelainLongrodInsulators

a) Visualexamination AsperIEC:60383

b) Verificationofdimensions AsperIEC:60383

c) Temperaturecycletest AsperIEC:60383

d) Galvanisingtest AsperIEC:60383

SECTION-II (VOLUME-II) PAGE 14

 e) Mechanicalperformancetest AsperIEC:60575
Clause4.0
f) Testonlockingdeviceforballandsocketcoupling AsperIEC:60372

g) Eccentricitytest AsperIEC:603831

h) Mechanicalfailingloadtest AsperIEC:603831

i) Porositytest AsperIEC:60383

j) MetallurgicalTest(Formetalfittingsonlyinblack AsperAnnexureA
condition)
i) Grainsize
ii) Inclusionrating
iii) Chemicalanalysis
iv) Microstructure

k) ThermalMechanicalperformancetest AsperAnnexureA

Note:Thetestspecifiedunder5.3(k)aboveshallbeperformedasacceptance
testonceforeverysupplyof3260nos.longrodinsulatorunitsofaparticular
rating.

5.4 RoutineTests

5.4.1 ForDiscInsulators

a) VisualInspection AsperIS:731,Cl.10.13
b) Mechanicalroutinetest AsperIS:731Cl.10.14
c) Electrical routine test (for porcelain disc insulator AsperIS:731Cl.10.15
only)

d) Thermalshockroutinetest(forglassinsulatoronly) AsperIEC:60383

e) PolarisedLightInspection(forglassinsulatoronly) AsperAnnexureA

5.4.2 ForPorcelainLongRodInsulatorUnits
a) VisualInspection AsperIEC:60383

b) Mechanicalroutinetest) AsperIEC:60383

5.5 TestsDuringManufacture

Onallcomponentsasapplicable

a) Chemicalanalysisofzincusedforgalvanising AsperAnnexureA

b) Chemicalanalysis,mechanical,metallographictest AsperAnnexureA
andmagneticparticleinspectionformalleable
castings.
c) Chemicalanalysishardnesstestsandmagnetic AsperAnnexureA
particleinspectionforforgings

SECTION-II (VOLUME-II) PAGE 15

 d) HydraulicInternalPressuretestsondiscinsulator AsperAnnexureA
shells
e) AutoclaveTestonCement AsperAnnexureA

5.6 TestingExpenses

5.6.1 Testingchargesforthetypetestspecifiedshallbeindicatedseparatelyinthe
prescribedschedule.

5.6.2 Bidder shall indicate unit type test charges for all type tests covered under
Clause5.1.1/5.1.2and5.1.3(e)to(i)/5.1.4(e)to(h)separately,intherelevant
schedule of Prices as applicable. Charges for each type tests shall be
separatelyindicated.

5.6.3 ForTypeTestswhichinvolvesthetestsonthecompleteinsulatorstringwith
hardware fitting the Contractor of hardware fittings shall supply the
necessary number of sets of hardware fittings at the place of testing free of
cost.

5.6.4 Incaseoffailureinanytypetestthebidderwhosematerialhasfailediseither
requiredtomodifythe designofthematerial&successfullycarryoutallthe
typetestsashasbeendetailedoutinClause5.1.3or5.1.4ofthisspecifications
or to repeat that particular type test at least three times successfully at his
own expenses. Incase of failure of the complete string in any type test, the
manufacturerwhoseproducthasfailedintheuseshallgetthetestrepeatedat
his cost. The Supplier whose material has not failed in the test shall be
required to supply the requisite quantity of material (that is insulator or
hardwarefittingsasthecasemaybe)requiredforrepeattestingattheplace
of testing and the cost of supply shall be borne by the Supplier whose
materialhasfailedintesting.

5.6.5 Suppliershallindicatethelaboratoriesinwhichtheyproposetoconductthe
type tests. They shall ensure that adequate facilities are available in the
laboratoryandthetestscanbecompletedintheselaboratorieswithinthetime
scheduleguaranteedbythemintheappropriateschedule.

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

5.6.7 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/ Owners
representativeshallbedeductedfromthecontractprice.Alsoifonreceiptof
the Suppliers notice of testing, the Owners representative does not find
materialortestfacilitiestobereadyfortestingtheexpensesincurredbythe
Ownerforredeputationshallbedeductedfromcontractprice.

5.6.8 The Supplier shall intimate the Owner about carrying out of the type tests
alongwithdetailedtestingprogrammeatleast3weeksinadvance(incaseof
testinginIndia)andatleast6weeksadvance(incaseoftestingabroad)ofthe

SECTION-II (VOLUME-II) PAGE 16

 scheduleddateoftestingduringwhichtheOwnerwillarrangetodeputehis
representativetobepresentatthetimeofcarryingoutthetests.

5.7 SampleBatchforTypeTesting

5.7.1 The Supplier shall offer material for sample selection for type testing only
after getting Quality Assurance Programme approved by the Owner. The
Suppliershallofferatleastthreetimesthequantityofmaterialsrequiredfor
conductingallthetypetestsforsampleselection.Thesamplefortypetesting
will be manufactured strictly in accordance with the Quality Assurance
ProgrammeapprovedbytheOwner.

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

5.8 ScheduleofTesting

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

a) Submissionofdrawingforapproval.
b) SubmissionofQualityAssuranceProgrammeforapproval.
c) Offeringofmaterialforsampleselectionfortypetests.
d) Typetesting.

5.9 RepeatE&MStrengthTest

5.9.1 E&Mteston20nos.fordiscinsulatoror3nos.forPorcelainlongrodinsulator
of samples for every lot of 10,000 nos. or 1500 nos. for Porcelain longrod
receivedatsiteshallbeconducted.Testingexpenseshavetobebornebythe
Supplier and shall be included in quoted Exworks/CIF price. Incase of
failure, it will be repeated on double no. of samples and if it again fails, the
whole lot should be rejected and shall be replaced by the Supplier. The
sampleshavetobetakenatrandomaftersegregatinginsulatorsdamagedin
transportationorotherwise.

5.9.2 TheOwnerreservestherightofhavingathisownexpensesanyothertest(s)
ofreasonablenaturecarriedoutatSupplierspremises,atsite,orinanyother
placeinadditiontotheaforesaidtype,acceptanceandroutineteststosatisfy
himselfthatthematerialcomplywiththeSpecifications.

5.9.3 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
Suppliers premises or at any other test centre. In case of evidence of non
compliance, it shall be binding on the part of the Supplier to prove the
compliance of the items to the technical specifications by repeat tests or
correction of deficiencies or replacement of defective items, all without any
extracosttotheOwner.

5.10 CoordinationforTesting

SECTION-II (VOLUME-II) PAGE 17

 The Supplier shall have to coordinate testing of insulators with hardware
fittingstobesupplied byotherSupplier andshall havetoguarantee overall
satisfactoryperformanceoftheinsulatorswiththehardwarefittings.
5.11 Guarantee

TheSupplierofinsulatorsshallguaranteeoverallsatisfactoryperformanceof
theinsulatorswiththehardwarefittings.
5.12 TestReports

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

5.12.3 RecordofroutinetestreportsshallbemaintainedbytheSupplierathisworks
forperiodicinspectionbytheOwnersrepresentative.
5.12.4 Test certificates of test during manufacture shall be maintained by the
Supplier.Theseshallbeproducedforverificationasandwhendesiredbythe
Owner.
5.13 Inspection

5.13.1 TheOwnersrepresentativeshallatalltimesbeentitledtohaveaccesstothe
works and all places of manufacture, where insulator, and its component
parts shall be manufactured and the representatives shall have full facilities
for unrestricted inspection of the Suppliers and subSuppliers works, raw
materials, manufacture of the material and for conducting necessary test as
detailedherein.
5.13.2 ThematerialforfinalinspectionshallbeofferedbytheSupplieronlyunder
packed condition as detailed in clause No.5.14 of the specification. The
Owner shall select samples at random from the packed lot for carrying out
acceptancetests.Insulatorsshallnormallybeofferedforinspectioninlotsnot
exceeding10,000nos.fordisc/650unitsforlongrodinsulator.Thelotshould
be homogeneous and should contain insulators manufactured in 34
consecutiveweeks.

5.13.3 TheSuppliershallkeeptheOwnerinformedinadvanceofthetimeofstarting
and the progress of manufacture of material in their various stages so that
arrangementscouldbemadeforinspection.

5.13.4 No material shall be dispatched from its point of manufacture before it has
beensatisfactorilyinspectedandtestedunlesstheinspectioniswaivedoffby
theOwnerinwriting.Inthelattercasealsothematerialshallbedispatched
only after satisfactory testing for all tests specified herein have been
completed.

SECTION-II (VOLUME-II) PAGE 18

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

5.14 PackingandMarking

5.14.1 All insulators shall be packed in strong seasoned wooden crates. The gross
weightofthecratesalongwiththematerialshallnotnormallyexceed200Kg
to avoid handling problem. For marine transportation crates shall be
palleted.

5.14.2 The packing shall be of sufficient strength to withstand rough handling

duringtransit,storageatsiteandsubsequenthandlinginthefield.

5.14.3 Suitablecushioning,protectivepadding,ordunnageorspacersshallbe
providedtopreventdamageordeformationduringtransitandhandling.

5.14.4 All packing cases shall be marked legibly and correctly so as to ensure safe
arrivalattheirdestinationandtoavoidthepossibilityofgoodsbeinglostor
wrongly dispatched on account of faulty packing and faulty or illegible
markings.Eachwoodencase/crateshallhaveallthemarkingsstencilledonit
inindeliableink.

5.15 Standards

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

5.15.1 In the event of supply of insulators conforming to standards other than

specified, the Bidder shall confirm in his bid that these standards are
equivalenttothosespecified.Incaseofaward,salientfeaturesofcomparison
between the standards proposed by the Bidder and those specified in this
documentwillbeprovidedbytheSuppliertoestablishequivalence.

Sl. Indian Title International

No. Standard Standard
1. IS:2091992 Specificationforzinc BS:3436
2. IS:4061991 MethodofChemicalAnalysisofSlabZinc BS:3436
3. IS:7311991 Porcelaininsulatorsfor overheadPower BS:137(I&II)
lineswithanominalvoltagegreaterthan IEC:60383
1000V
4. IS:2071 MethodsofHighVoltageTesting IEC:600601
Part(I)1993
(Part(II)1991
Part(III)1991
5. IS:2486 SpecificationforInsulator fittingsfor
OverheadPowerLineswithanominal

SECTION-II (VOLUME-II) PAGE 19

 voltagegreaterthan1000V
PartI1993 GeneralRequirementsandTests BS:3288
PartII1989 DimensionalRequirements IEC:60120
PartIII1991 LockingDevices IEC:60372
6. IS:26291990 RecommendedPracticeforHot,Dip ISO1461(E)
Galvanisation forironandsteel
7. IS:26331992 TestingofUniformityofCoatingofzinc
coated articles
8. IS:31881988 DimensionsforDisc Insulators IEC:60305
9. IS:67451990 DeterminationofWeightof ZincCoatingon BS:4331969
Zinccoatedironandsteelarticles ISO:14601973
10. IS:82631990 MethodsofRITestofHVinsulators IEC:60437
NEMAPubli
cationNo.07/
1964/CISPR
11. IS:82691990 MethodsforSwitchingImpulsetestonHV IEC:60506
insulators
12. ThermalMechanicalPerformancetestand IEC:60575
mechanicalperformancetestonstring
insulatorunits
13. SaltFogPollutionVoltage WithstandTest IEC:60507
14. ResidualStrengthofString InsulatorUnits IEC:60797
ofGlassor CeramicMaterialforOverhead
LinesafterMechanical Damageofthe
Dielectric
15. Guidefortheselectionofinsulatorsin IEC:60815
respect ofpollutedconditions
16. TestsoninsulatorsofCeramicmaterialor IEC:60383
glassorglassforoverheadlineswitha
nominalvoltagegreaterthan1000V
17. Characteristicsofstringinsulatorunitsof IEC:60433
thelong rodtype
18. StandardTestMethodforAutoclave ASTMC15193
ExpansionofPortlandCement a
19. AmericanNationalStandardforInsulators ANSIC292
wetprocessporcelainandtoughenedglass 1992
suspensiontype

Thestandardsmentionedaboveareavailablefrom:

ReferenceAbbreviation NameandAddress

BS BritishStandards,
BritishStandardsInstitution
101,PentonvileRoad,
N19ND,UK
IEC/CISPR InternationalElectrotechnicalCommission,
BureauCentraldelaCommission,
electroTechniqueinternational,
1Ruedeverembe,
Geneva,SWITZERLAND

SECTION-II (VOLUME-II) PAGE 20

 BIS/IS BeureauOfIndianStandards.
ManakBhavan,
9,BahadurShahZafarMarg,
NewDelhi110001,INDIA
ISO InternationalOrganisationforStandardization.
DanishBoardofStandardization
DanishStandardizingSraat,
Aurehoegvej12
DK2900,Heeleprup,DENMARK.
NEMA NationalElectricManufactureAssociation,
155,East44thStreet.
NewYork,NY10017,U.S.A.
ASTM AmericanSocietyfor TestingandMaterials,
1916RaceSt.Phelledelphia,PA19103USA

A. STANDARD TECHNICAL PARTICULARS OF NORMAL INSULATOR

DISCS

S.N. DESCRIPTION UNIT 120 KN 160KN

1.0 GENERAL
Size and designation of ball and 20.0as per 20.0as per
(a) socket mm IS2486/IEC120 IS2486/IEC120

2.0 DIMENSIONS
(a) Disc insulator diameter mm 255.0 or 280.0 280.0
11.0(for
255.0)/13.0(for
(b) Tolerance of dia. mm 280.0) 13.0
(c) Ball to ball spacing between disc mm 145.0 170.0
(d) Tolerance of spacing mm 4.0 5.0
Minimum Creepage distance of
(e) single disc mm 315.0 330.0

Colour of glaze of finished porcelain

3.0 insulator NA Brown Brown

ELECTRO-MECANICAL
4.0 STRENGTH KN 120.0 160.0

5.0 MINIMUM ELECTRICAL VALUES

Power frequency flashover voltage
(a) (dry) kV(rms) 75.0 78.0
Power frequency flashover
(b) voltage(wet) kV(rms) 45.0 48.0
Impulse flashover voltage positive kV
(c) (dry) peak 115.0 120.0
Impulse flashover voltage negative kV
(d) (dry) peak 120.0 125.0
Power frequency withstand
(e) voltage(dry) kV(rms) 70.0 72.0

SECTION-II (VOLUME-II) PAGE 21

 Power frequency withstand
(f) voltage(wet) kV(rms) 40.0 42.0
Impulse withstand voltage positive kV
(g) (dry) peak 110.0 115.0
Impulse withstand voltage negative kV
(h) (dry) peak 110.0 115.0
Steepness of impulse voltage(steep
(i) wave front test) Kv/s 2500.0 2500.0

POWER FREQUENCY
6.0 PUNCTURE VOLTAGE kV(rms) 120.0 125.0

MIN VISIBLE DISCHARGE kV

7.0 VOLTAGE OF SINGLE (rms) 18.0 18.0
DISC(DRY)

8.0 MAX RIV AT 1MHz and 10 KV(rms) V 50.0 50.0

9.0 No. of dips in standard preece test Nos (6 dips of 1min) (6 dips of 1min)

10.0 ECCENTRICITY OF DISC

7.65(for
255.0)/8.40(for
(a) Max radial runout mm 280.0) 8.4
10.20(for
255.0)/11.20(for
(b) Max axial runout mm 280.0) 11.2

MINIMUM MASS OF ZINC gm/sq.

11.0 COATING m. 600 600

MINIMUM ZINC PURITY USED

12.0 FOR GALVANIZING % 99.95% 99.95%

S.N. DESCRIPTION UNIT 210KN

1.0 GENERAL
Size and designation of ball and 24.0as per
(a) socket mm IS2486/IEC120

2.0 DIMENSIONS
(a) Disc insulator diameter mm 280.0
(b) Tolerance of dia. mm 13.0
(c) Ball to ball spacing between disc mm 170.0
(d) Tolerance of spacing mm 5.0
Minimum Creepage distance of
(e) single disc mm 370.0

3.0 Colour of glaze of finished porcelain NA Brown

SECTION-II (VOLUME-II) PAGE 22

 insulator

ELECTRO-MECANICAL
4.0 STRENGTH KN 210.0

5.0 MINIMUM ELECTRICAL VALUES

Power frequency flashover voltage
(a) (dry) kV(rms) 78.0
Power frequency flashover
(b) voltage(wet) kV(rms) 48.0
Impulse flashover voltage positive kV
(c) (dry) peak 120.0
Impulse flashover voltage negative kV
(d) (dry) peak 125.0
Power frequency withstand
(e) voltage(dry) kV(rms) 72.0
Power frequency withstand
(f) voltage(wet) kV(rms) 42.0
Impulse withstand voltage positive kV
(g) (dry) peak 115.0
Impulse withstand voltage negative kV
(h) (dry) peak 115.0
Steepness of impulse voltage(steep
(i) wave front test) Kv/s 2500.0

POWER FREQUENCY
6.0 PUNCTURE VOLTAGE kV(rms) 125.0

MIN VISIBLE DISCHARGE kV

7.0 VOLTAGE OF SINGLE (rms) 18.0
DISC(DRY)

8.0 MAX RIV AT 1MHz and 10 KV(rms) V 50.0

9.0 No. of dips in standard preece test Nos (6 dips of 1min)

10.0 ECCENTRICITY OF DISC

(a) Max radial runout mm 8.4
(b) Max axial runout mm 11.2

MINIMUM MASS OF ZINC gm/sq.

11.0 COATING m. 600

MINIMUM ZINC PURITY USED

12.0 FOR GALVANIZING % 99.95%

B. STANDARD TECHNICAL PARTICULARS OF NORMAL LONGROD

INSULATORUNITS

SECTION-II (VOLUME-II) PAGE 23

 S.N. DESCRIPTION UNIT 120 KN 160 KN

Size and designation of ball and 20.0as per 20.0as per

1.0 socket assembly mm IS2486/IEC120 IS2486/IEC120

2.0 Core diameter (d) mm 60 to 85 75 to 85

3.0 Tolerance on Core diameter mm (0.04d +1.5) (0.04d +1.5)

4.0 Minimum Creepage distance mm 2415*/2625# 2530*/2750#

Colour of glaze of finished porcelain

5.0 insulator NA Brown Brown

6.0 Mechanical strength KN 120.0 160.0

7.0 MINIMUM ELECTRICAL VALUES

Power frequency flashover voltage
a (dry) Kv(rms) 270.0 290.0
Power frequency flashover
b voltage(wet) kV(rms) 240.0 250.0
Impulse flashover voltage positive kV
c (dry) peak 550.0 550.0
Impulse flashover voltage negative kV
d (dry) peak 570.0 570.0
Power frequency withstand
E voltage(dry) Kv(rms) 250.0 270.0
Power frequency withstand
F voltage(wet) Kv(rms) 230.0 230.0
Impulse withstand voltage positive
G (dry) Kv(rms) 500.0 500.0
Impulse withstand voltage negative
H (dry) Kv(rms) 510.0 510.0

No. of one minute dips which the

8.0 end fittings can withstand Nos. 6.0 6.0
in standard preece test

Max axial/radial runout(as per 1.2% of 1.2% of

9.0 pointer B) mm insulator length insulator length

10.0 Maximum Angular displacement degree 15.0 15.0

Minimum purity of Zinc used for

11.0 galvanizing % 99.95 99.95

gm/sq.
12.0 Minimum mass of zinc coating m. 600.0 600.0

SECTION-II (VOLUME-II) PAGE 24

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

S.N. DESCRIPTION UNIT 210 KN

Size and designation of ball and 24.0as per

1.0 socket assembly mm IS2486/IEC120

2.0 Core diameter (d) mm 85 to 90

3.0 Tolerance on Core diameter mm (0.04d +1.5)

4.0 Minimum Creepage distance mm 3084

Colour of glaze of finished porcelain

5.0 insulator NA Brown

6.0 Mechanical strength KN 210.0

7.0 MINIMUM ELECTRICAL VALUES

Power frequency flashover voltage
a (dry) Kv(rms) 290.0
Power frequency flashover
b voltage(wet) kV(rms) 250.0
Impulse flashover voltage positive kV
c (dry) peak 550.0
Impulse flashover voltage negative kV
d (dry) peak 570.0
Power frequency withstand
E voltage(dry) Kv(rms) 270.0
Power frequency withstand
F voltage(wet) Kv(rms) 230.0
Impulse withstand voltage positive
G (dry) Kv(rms) 500.0
Impulse withstand voltage negative
H (dry) Kv(rms) 510.0

No. of one minute dips which the

8.0 end fittings can withstand Nos. 6.0
in standard preece test

Max axial/radial runout(as per 1.2% of

9.0 pointer B) mm insulator length

10.0 Maximum Angular displacement degree 15.0

SECTION-II (VOLUME-II) PAGE 25

 Minimum purity of Zinc used for
11.0 galvanizing % 99.95

gm/sq.
12.0 Minimum mass of zinc coating m. 600.0

C. STANDARD TECHNICAL PARTICULARS OF NORMAL INSULATOR

STRINGS (WITH DISC INSULATORS) ALONGWITH HARDWARE
FITTINGS

S.N. DESCRIPTION UNIT FOR 400 KV QUAD BUNDLE LINE IN SNOW ZONE

Single Single Quad Tension

Suspension Tension string string
pilot string

(1 x 25) (1 x 25) (4 x 25)

1.0 Power frequency kV(rms) 680 680 680

withstand voltage
of string with
arcing horns,
corona control
rings/grading rings
under wet condition

2.0 Switching surge

withstand
voltage(wet)
(a) Positive kV(peak) 1175 1175 1175
(b) Negative kV(peak) 1175 1175 1175

3.0 Impulse withstand

voltage(dry)
(a) Positive kV(peak) 1800 1800 1800
(b) Negative kV(peak) 1800 1800 1800

Min. Impulse
4.0 flashover
voltage(dry)*
(a) Positive kV(peak) More than 1800 More than 1800 More than 1800
(b) Negative kV(peak) More than 1800 More than 1800 More than 1800

5.0 Minimum Corona kV(rms) 320 320 320

extinction voltage
under dry condition

SECTION-II (VOLUME-II) PAGE 26

 RIV at 1MHZ when
6.0 the Microvolt 1000(max.) 1000(max.) 1000(max.)
string is energized at
305 Kv(rms) under
dry
Condition

Mechanical strength
7.0 of kN 120 120 4 X 160
complete insulator
string alongwith hard-
ware fittings

8.0 Maximum voltage % 9 10 10

distribution across
any
disc of line to earth
Voltage

* As per IEC 60-1

S.N. DESCRIPTION UNIT FOR 400 KV QUAD BUNDLE LINE IN NON-SNOW

ZONE
Double 'I' Single Single Quad
Suspension Suspension Tension Tension
string pilot string string string

(2 x 23) (1 x 23) (1 x 24) (4 x 23)

1.0 Power frequency kV(rms) 680 680 680 680

withstand voltage
of string with
arcing horns,
corona control
rings/grading rings
under wet condition

2.0 Switching surge

Withstand
voltage(wet)
(a) Positive kV(peak) 1050 1050 1050 1050
(b) Negative kV(peak) 1050 1050 1050 1050

3.0 Impulse withstand

voltage(dry)
(a) Positive kV(peak) 1550 1550 1550 1550
(b) Negative kV(peak) 1550 1550 1550 1550

Min. Impulse
4.0 flashover
voltage(dry)*
(a) Positive kV(peak) 1615 1615 1615 1615

SECTION-II (VOLUME-II) PAGE 27

 (b) Negative kV(peak) 1615 1615 1615 1615

5.0 Minimum Corona kV(rms) 320 320 320 320

extinction voltage
under dry condition

RIV at 1MHZ when

6.0 the Microvolt 1000(max.) 1000(max.) 1000(max.) 1000(max.)
string is energized at
305 Kv(rms) under
dry
condition

Mechanical strength
7.0 of kN 2 x 120 120 120 4 X 160
complete insulator
string alongwith hard-
ware fittings

8.0 Maximum voltage % 9 9 10 10

distribution across
any
disc of line to earth
voltage

* As per IEC 60-1

S.N. DESCRIPTION UNIT FOR 400 KV TRIPLE BUNDLE LINE IN SNOW

ZONE

Single Double Tension

Suspension pilot string
string

(1 x 25) (2 x 25)

1.0 Power frequency kV(rms) 680 680

withstand voltage
of string with
arcing horns,
corona control
rings/grading rings
under wet condition

2.0 Switching surge

withstand
voltage(wet)
(a) Positive kV(peak) 1175 1175
(b) Negative kV(peak) 1175 1175

3.0 Impulse withstand

voltage(dry)
(a) Positive kV(peak) 1800 1800

SECTION-II (VOLUME-II) PAGE 28

 (b) Negative kV(peak) 1800 1800

Min. Impulse
4.0 flashover
voltage(dry)*
(a) Positive kV(peak) More than 1800 More than 1800
(b) Negative kV(peak) More than 1800 More than 1800

5.0 Minimum Corona kV(rms) 320 320

extinction voltage
under dry condition

RIV at 1MHZ when

6.0 the Microvolt 1000(max.) 1000(max.)
string is energized at
305 Kv(rms) under
dry
Condition

Mechanical strength
7.0 of kN 120 2 X 210
complete insulator
string alongwith hard-
ware fittings

8.0 Maximum voltage % 9 10

distribution across
any
disc of line to earth
Voltage

* As per IEC 60-1

D. STANDARD TECHNICAL PARTICULARS OF NORMAL INSULATOR

STRINGS (WITH LONGROD INSULATORS) ALONGWITH
HARDWAREFITTINGS
FOR 400 KV QUAD BUNDLE LINE IN SNOW ZONE

S.N. DESCRIPTION UNIT Single I Single Quad

Suspension Tension Tension
Pilot string String String
(1 x 3) (1 x 3) (4 x 3)
1.0 Length
Nominal length of
(a) insulator string mm 3625 3625 4250
Tolerance on nominal
(b) length +/-mm 100 100 125

2.0 Power frequency kV(rms) 680 680 680

withstand voltage
of string with
arcing horns,

SECTION-II (VOLUME-II) PAGE 29

 Corona control
rings/grading rings
under wet condition

3.0 Switching surge

withstand voltage(wet)
(a) Positive kV(peak) 1175 1175 1175
(b) Negative kV(peak) 1175 1175 1175

4.0 Impulse withstand

Voltage(dry)
(a) Positive kV(peak) 1800 1800 1800
(b) Negative kV(peak) 1800 1800 1800

5.0 Min. Impulse flashover

Voltage(dry)*
(a) Positive kV(peak) More than 1800 More than 1800 More than 1800
(b) Negative kV(peak) More than 1800 More than 1800 More than 1800

6.0 Minimum Corona kV(rms) 320 320 320

extinction voltage
under dry condition

7.0 RIV at 1MHZ when the Microvolt 1000(max.) 1000(max.) 1000(max.)

string is energized at
305 Kv(rms) under dry
condition

8.0 Mechanical strength of kN 120 120 4 X 160

complete insulator
string alongwith hard-
ware fittings

*As per IEC 60-1

FOR 400 KV QUAD BUNDLE LINE IN NON - SNOW

ZONE
S.N. DESCRIPTION UNIT Double I Single I Single Quad
Suspension Suspension Tension Tension
String Pilot string String String
(2 x 3) (1 x 3) (1 x 3) (4 x 3)
1.0 Length
Nominal length of
(a) insulator string mm 3335 3335 3335 3910
Tolerance on nominal
(b) length +/-mm 92 92 92 115

2.0 Power frequency kV(rms) 680 680 680 680

withstand voltage
of string with
arcing horns,
Corona control
rings/grading rings

SECTION-II (VOLUME-II) PAGE 30

 under wet condition

3.0 Switching surge

withstand voltage(wet)
(a) Positive kV(peak) 1050 1050 1050 1050
(b) Negative kV(peak) 1050 1050 1050 1050

4.0 Impulse withstand

Voltage(dry)
(a) Positive kV(peak) 1550 1550 1550 1550
(b) Negative kV(peak) 1550 1550 1550 1550

5.0 Min. Impulse flashover

Voltage(dry)*
(a) Positive kV(peak) 1615 1615 1615 1615
(b) Negative kV(peak) 1615 1615 1615 1615

6.0 Minimum Corona kV(rms) 320 320 320 320

extinction voltage
under dry condition

7.0 RIV at 1MHZ when the Microvolt 1000(max.) 1000(max.) 1000(max.) 1000(max.)
string is energized at
305 Kv(rms) under dry
condition

8.0 Mechanical strength of kN 120 120 120 2 X 160

complete insulator
string alongwith hard-
ware fittings

*As per IEC 60-1

FOR 400 KV TRIPLE BUNDLE LINE IN SNOW

ZONE

S.N. DESCRIPTION UNIT Single I Double

Suspension Tension
Pilot string String
(1 x 3) (2 x 3)
1.0 Length
Nominal length of
(a) insulator string mm 3625 4250
Tolerance on nominal
(b) length +/-mm 100 125

2.0 Power frequency kV(rms) 680 680

withstand voltage
of string with
arcing horns,
Corona control
rings/grading rings
under wet condition

SECTION-II (VOLUME-II) PAGE 31

 3.0 Switching surge
withstand voltage(wet)
(a) Positive kV(peak) 1175 1175
(b) Negative kV(peak) 1175 1175

4.0 Impulse withstand

Voltage(dry)
(a) Positive kV(peak) 1800 1800
(b) Negative kV(peak) 1800 1800

5.0 Min. Impulse flashover

Voltage(dry)*
(a) Positive kV(peak) More than 1800 More than 1800
(b) Negative kV(peak) More than 1800 More than 1800

6.0 Minimum Corona kV(rms) 320 320

extinction voltage
under dry condition

7.0 RIV at 1MHZ when the Microvolt 1000(max.) 1000(max.)

string is energized at
305 Kv(rms) under dry
condition

8.0 Mechanical strength of kN 120 2 X 210

complete insulator
string alongwith hard-
ware fittings

*As per IEC 60-1

SECTION-II (VOLUME-II) PAGE 32

 ANNEXUREA

1. TestsonCompleteStringswithHardwareFittings
1.1 VoltageDistributionTest(ForDiscInsulatorsonly)
The voltage across each insulator unit shall be measured by sphere gap
method.Theresultobtainedshallbeconvertedintopercentage.Thevoltage
across any disc shall not exceed 9% for 400 kV suspension insulator strings,
10%for400kVtensioninsulatorstrings.

1.2 CoronaExtinctionVoltageTest(Dry)
Thesampleassemblywhensubjectedtopowerfrequencyvoltageshallhavea
corona extinction voltage of not less than 320 kVrms (for 400 kV) line to
groundunderdrycondition.Thereshallbenoevidenceofcoronaonanypart
ofthesample.Theatmosphericconditionduringtestingshallberecordedand
thetestresultsshallbeaccordinglycorrectedwithsuitablecorrectionfactoras
stipulatedinIEC:383.

1.3 RIVTest(Dry)
Undertheconditionsasspecifiedunder(1.2)above,theinsulatorstringalong
withcompletehardwarefittingsshallhavearadiointerferencevoltagelevel
below 1000 micro volts at one MHz when subjected to 50 Hz AC voltage of
305kV linetogroundunderdrycondition.Thetestprocedureshallbein
accordancewithIS:8263/IEC:437.

1.4 MechanicalStrengthTest
Thecompleteinsulatorstringalongwithitshardwarefittingexcludingarcing
horn, corona control ring, grading ring and suspension assembly/dead end
assemblyshallbesubjectedtoaloadequalto50%ofthespecifiedminimum
ultimate tensile strength (UTS) which shall be increased at a steady rate to
67% of the minimum UTS specified. The load shall be held for five minutes
andthenremoved.Afterremovaloftheload,thestringcomponentsshallnot
showanyvisualdeformationanditshallbepossibletodisassemblethemby
hand. Hand tools may be used to, remove cotter pins and loosen the nuts
initially.Thestringshallthenbereassembledandloadedto50%ofUTSand
theloadshallbefurtherincreasedatasteadyratetillthespecifiedminimum
UTS and held for one minute. No fracture should occur during this period.
Theappliedloadshallthenbeincreaseduntilthefailingloadisreachedand
thevaluerecorded.

1.5 VibrationTest
Thesuspensionstringshallbetestedinsuspensionmode,andtensionstring
intensionmodeitselfinlaboratoryspanofminimum30metres.Inthecaseof
suspensionstringaloadequalto600kgshallbeappliedalongtheaxisofthe
suspension string by means of turn buckle. The insulator string along with
hardware fittings and four/three (as the case may be) subconductors each
tensionedat25%ofconductorUTSshallbesecuredwithclamps.Thesystem
shall be suitable to maintain constant tension on each subconductors

SECTION-II (VOLUME-II) PAGE 33

 throughout the duration of the test. Vibration dampers shall not be used on
thetestspan.Thesubconductorsshallbeverticallyvibratedsimultaneously
atoneoftheresonancefrequenciesoftheinsulatorsstring(morethan10Hz)
bymeansofvibrationinducingequipment.Thepeaktopeakdisplacementin
mmofvibrationattheantinodepoint,nearesttothestring,shallbemeasured
and the same shall not be less than 1000/f1.8 where f is the frequency of
vibrationincycles/sec.Theinsulatorstringshallbevibratedfornotlessthan
10 million cycles without any failure. After the test the insulators shall be
examined for looseness of pins and cap or any crack in the cement. The
hardware shall be examined for looseness, fatigue failure and mechanical
strength test. There shall be no deterioration of properties of hardware
components and insulators after the vibration test. The insulators shall be
subjectedtothefollowingtestsasperrelevantstandards:
TestsPercentageof Percentageofunitstobetested
Discinsulators Longrod
insulators
a) Temperaturecycletest followed 60 100
bymechanical performancetest

b) Puncture test/steep wave front 40

test

1.6 PowerArcTest
This test shall be performed on the complete string in accordance with IEC
TechnicalReportIEC:614671997withthefollowingtestseries:

Testcircuit Shortcircuitcurrent Numberanddurationoftest
B In=Isys=40KA Twooftn=0.2sandoneoftn=0.5s

Theacceptancecriteriaafterthecompletionoftestseriesshallbefollowing.

a) Insulatorseparationnotpermitted.
b) Burning/melting of metal components, breakage of insulator sheds,
glazeremovalarepermitted.
c) The complete insulator string alongwith its hardware fitting
excluding arching horn, corona control ring/grading ring shall
withstand80%ofUTS.

SECTION-II (VOLUME-II) PAGE 34


2. OnDiscInsulatorUnits/Porcelainlongrodunits(asapplicable)
2.1 SteepWaveFrontTest(ForDiscInsulatoronly)
Test following test shall be performed on 10 insulator units in case of disc
insulatorsselectedatrandomfromthelotofferedforselectionofsamplefor
typetest.
a) Each insulator unitshallbesubjectedto fivesuccessive positive and
negative impulse flashovers with a wave having minimum effective
rateofriseof2500kVpermicroseconds.
b) Each unit shall then be subjected to three dry power frequency
voltageflashovers.
AcceptanceCriteria
An insulator shall be deemed to have met the requirement of this test if,
having been successfully subjected to the ten impulse flashovers, the
arithmetic mean of the three subsequent dry/power frequency voltage
flashover values equals or exceeds 95% of the rated dry power frequency
flashovervoltage.
Aninsulatorshallbedeemedtohavefailedtomeettherequirementofabove
testingif,
(a) It has not flash over when the oscillogram or peak voltage indicator
showsamarkedreductioninvoltage.
or
(b) Any one of the subsequent three dry power frequency voltage
flashovervalueislessthan80%ofthevaluespecified.
Failure of any one unit either in the steep wave front or subsequent low
frequencyvoltagetestshallcausefortestingondoublenumberofunits.

2.2 PolarisedLightInspection(onlyforGlassDiscInsulator)
The disc insulator shall be held over a polarised light source and the stress
lines viewed thereon. There shall be no uneven stress distribution in the
toughenedglassinsulators.Thisshallbecarriedouton100%glassshells.

2.3 HydraulicInternalPressureTestonShells(onlyforDiscInsulator)
The test shall be carried out on 100% shells before assembly. The details
regarding test will be as discussed and mutually agreed to by the Supplier
andOwnerinQualityAssuranceProgramme.

2.4 ThermalMechanicalPerformanceTest
ThermalMechanicalPerformanceTestshallbeperformedinaccordancewith
IEC603831Clause20withthefollowingmodifications:
(1) Theappliedmechanicalloadduringthistestshallbe70%oftherated
electromechanicalormechanicalvalue.

SECTION-II (VOLUME-II) PAGE 35

 (2) Theacceptancecriteriashallbe
(a) XgreaterthanorequaltoR+3S.
Where
X=Meanvalueoftheindividualmechanicalfailingload.
R=Ratedelectromechanical/mechanicalfailingload.
S=Standarddeviation.
(b) The minimum sample size shall be taken as 20 for disc
insulatorunitsand5unitsforlongrodunits.
(c) The individual electromechanical failing load shall be at least
equal to the rated value. Also puncture shall not occur before
theultimatefracture.

2.5 Electromechanical/MechanicalFailingLoadTest
This test shall be performed in accordance with clause 18 and 19 of IEC 383
withthefollowingacceptance
(i) XgreaterthanorequaltoR+3S
Where
X=Meanvalueoftheelectromechanical/mechanical/failingload.
R=Ratedelectromechanical/mechanicalfailingload.
S=Standarddeviation.
(ii) Theminimumsamplesizeshallbetakenas20fordiscinsulatorsunits
and5forlongrodunits.However,forlargerlotsize,IEC591shallbe
applicable.
(iii) The individual electromechanical/mechanical failing load shall be at
leastequaltotheratedvalue.Alsoelectricalpunctureshallnotoccur
beforetheultimatefracture.

2.6 ResidualStrengthTest(ForDiscInsulatorsonly)
The above test shall be performed as per clause 4.4 and 4.5 of IEC 797
preceded by the temperature cycle test, on both glass and porcelain disc
insulators. TheSamplesizeshall be 25 and the evaluationoftheresultsand
acceptancecriteriashallbeasperclauseNo.4.6ofIEC:797.

2.7 ChemicalAnalysisofZincSleeve
The purity of the zinc used in zinc sleeve shall be tested as per IS:209. The
purityofzincshallnotbelessthan99.8%.

2.8 IRMeasurements
IRmeasurementshallbecarriedoutbytheinstrumentoperatingat1kVDC.
IRvaluewhenmeasuredunderfairweathercondition,shallnotbelessthan
50Mohm.

SECTION-II (VOLUME-II) PAGE 36


2.9 ImpactTest
The Impact Testshallbecarried out in accordance with ANSIC29.2 Clause
8.2.8withthefollowingmodification.
Thebreakingpointofthependulumshallbesoadjustedthat,whenreleased
thecoppernosewillstriketheouterrimoftheshellorthemostprotudedrim
oftheshellsquarelyinadirectionparalleltotheaxisoftheunitandtowards
thecap.
Thetestspecimenshallreceiveanimpactof7Nmfor120kNDisc&10Nm
for160kN&210kNDiscbyreleasingthependulum.

3. TestsonAllcomponents(Asapplicable)
3.1 ChemicalAnalysisofZincusedforGalvanizing
Samples taken from the zinc ingot shall be chemically analysed as
perIS:2091979.Thepurityofzincshallnotbelessthan99.95%.

3.2 TestsforForgings
The chemical analysis hardness tests and magnetic particle inspection for
forgings, will be as per the internationally recognised procedures for these
tests. The sampling will be based on heat number and heat treatment batch.
Thedetailsregardingtestwillbeasdiscussedandmutuallyagreedtobythe
SupplierandOwnerinQualityAssuranceProgramme.

3.3 TestsonCastings
The chemical analysis, mechanical and metallographic tests and magnetic,
particle inspection for castings will be as per the internationally recognised
proceduresforthesetests.Thesamplingswill be basedonheatnumberand
heat treatment batch. The details regarding test will be as discussed and
mutually agreed to by the Supplier and Owner in Quality Assurance
Programme.

3.4 AutoclaveTest
Forcementusedintheassemblyoftheinsulatorssixsamplesfromdifferent
batches shall be tested in accordance with ASTM C151. The cement shall
haveanexpansionlessthan0.12%.

SECTION-II (VOLUME-II) PAGE 37