TECHNICAL SPECIFICATION OF ELECTRICAL MATERIALS · 19 8 SWG GI wire Kg 1000 NB: 1. Bidders should put their authorized signature with office seal on each page of the documents. 2.

Tech. Specification of TN No. NESCO Utility/MR Materials/18/26.11.16 Page 1

SECTION –IV

TECHNICAL SPECIFICATION

OF

ELECTRICAL MATERIALS

GROUP -A Tender Notice No. NESCO Utility/ MR Materials/ 18/13138 Dt.26.11.16


GROUP – A : Sl. No. Name of the materials Unit Quantity

1 33 KV. "V' Cross Arms (GI) No. 2000

2 11 KV "V" Cross-Arms(G.I) No 3000

3 33 KV. 3 Pole 400 A.B.Switch (H) Set 80

4 33 KV. Post Insulator. No. 300

5 11KV PIN Insulator No 5000

6 33KV Stay Insulator. No 1500

7 33 KV. Pole Top Bracket. No. 500

8 33 KV. G.I. Pin. No. 500

9 40 mm G.I. Earthing Device No 1000

10 20 mm H.T. Stay Set. Set 1500

11 16 mm L.T. Stay Set. Set 2000

12 7/12 SWG G.I. Stay Wire Kg 15000

13 7/8 SWG G.I. Stay Wire Kg 15000

14 300Amp Kitkat Fuse No. 1000

15 400Amp Kitkat Fuse No. 1000

16 33KV AB Switch Male Contact(H) No 170

17 33KV AB Switch Female Contact(H) No 170

18 6 SWG GI wire Kg 1000

19 8 SWG GI wire Kg 1000

NB: 1. Bidders should put their authorized signature with office seal on each page of the documents. 2. Bidders should put their offer in the Guaranteed particulars column furnished in the tender documents. 3. Bidders should submit samples of their quoted items for item sl. no. 1 to 3 , 7 to 11 & 14 to 17 at NESCO Utility Store, Balasore and furnished store receipt copy along with bid documents for verification . 4. Purchaser reserves the right to increase or decrease the above quantities during placement of purchase order or may cancel any item/items without assigning any reason thereof .

General Manager (C&P) NESCOUtility, Balasore, Odisha


TECHNICAL SPECIFICATION

33KV ‘V’ Cross arm (GI) 33 KV ‘V’ cross arm made out of 100x50x6 mm M.S Channel as per REC Standard M-1. The cross arm shall be fabricated out of 100x50x6 mm size channel having 9.2 Kg/Mtr. After fabrication the cross arm shall be Galvanized as per IS-2633/1972.(Latest Amendment) , IS :2629/1985 (1st. Revision)conforming to REC construction standard & drawi

Guaranteed Technical Particulars of 33 KV 'V' Cross Arm

Sl. No.

Description

Specified

Bidders Offer

1

Type of Cross Arm

ISMC 100x50

2

Channel Weight

9.2 Kg/mtr

3

Grade of Steel

FY 250

4

Steel Standard

IS:2062-1992

5

Fabrication Standard

IS:802 (part - 2) - 1978

6

Dimension

(100x50x6)mm

7 Size of M S Flat welded at both ends

50x8mm

8

Steel Tensile Strength

1500kgf/cm²

9 Galvanisation

Hot dip , as per IS-2633/1972, IS :2629/1985 (latest revision)

10

Working Load

400/ 450/ 550/600Kg

11

Total Weight

19.7 Kg (approx.)

12 Drawing enclosed

Name & Signature of Bidder with seal


11 KV ‘V’ Cross Arm (GI) : The Cross arm is to be made out of ISMC 75x40 with 50mmx6mm flat packing on top & bottom flange of the channel where the insulator pin is to be mounted conforming to REC construction standard

& drawing . Galvanized the V cross arm as per IS-2633/1972.(Latest Amendment) , IS :2629/1985 (1st. Revision).

Guaranteed Technical Particulars of 11KV 'V' Cross Arm

Sl. No.

Description

Specified

Bidders Offer

1 Type of Cross Arm ISMC 75x40

2 Channel Weight

7.14 Kg/mtr

3 Grade of Steel

FY 250

4

Steel Standard

IS:2062-1992

5

Fabrication Standard

IS:802 (part - 2) - 1978

6 Dimension

(75x40x4.8)mm

7

Size of M S Flat welded at both ends

50x8mm

8

Steel Tensile Strength

1500kgf/cm²

9

Galvanisation

Hot dip , as per IS-2633/1972, IS :2629/1985 (latest revision)

10

Working Load

200/300/350/400Kg

11

Total Weight (with tolerance per meter + 4%)

11.2 Kg (approx.)



TECHNICAL SPECIFICATION OF 33 KV 3 POLE, 400 AMP , HORIZONTAL TYPE AB SWITCH

1.0 SCOPE:- This specification covers manufacturing testing and supply of 3 Pole, 400 AMP, 50 Hz, Single break, 33 KV class Air Break switches for outdoor installations to be used at 33/11 KV Sub-stations and for incoming & outgoing Lines suitable for operation under off load conditions.

1.1 DESCRIPTION OF THE MATERIALS:-The A.B. Switch sets shall confirm to the following

parameters:-

Sl. No.

Description Parameters of AB Switch

Parameters of AB 33 KV

i) No. of poles 3

ii) Number of Post insulator per pole 4 nos. 22/24 KV class

iii) Nominal system voltage (KV) 33 iv) Highest System Voltage (KV) 36

v) Rated frequency 50HZ

vI) System earthing Effectively earthed.

vII) Rated nominal current Amp.

viii) Altitude of installation Not exceeding 1000 M

The post insulators used in the A.B. Switches shall have the following ratings

Sl.

No.

Description

Parameters P.I. of AB Switches for

33 KV

i) Power frequency withstand voltage

95

ii) Power frequency withstand voltage (wet) KV (RMS)

75

iii)

iii

Impulse withstand voltage (dry) KV

170 KV (peak)

170 iv) Power frequency puncture

1.3 times the actual dry flashover voltage of the unit


1.2 STANDARDS:- The AB Switch Set shall conform to the following standards:-

i) IS-9920 (Part-I to V.)

ii) IS-2544/1973 ( for porcelain post insulators

iii) IS-2633 (for galvanization of ferrous parts.) or its latest amendments if any.

1.3 INSULATORS:-

22 KV / 24 KV class Post Insulators complete with pedestal cap duly cemented to be used in the AB Switch Set conforming to IS-2544/1973

The bidder shall furnish the type test certificate of the post insulators from their manufacturer for reference.

The bidder shall mention make, type of insulation materials, metal fittings, Creep age distance, protected Creep age distance, tensile strength, compression strength, torsion strength and cantilever strength.

1.4 CLIMATIC CONDITIONS:-

The A.B. Switch set shall be suitable for operation under the following climatic

1.

Conditions

Maximum ambient air temperature.

45 0 C

2. Maximum daily average air temperature 35 0 C 3. Maximum yearly average ambient air temperature 30 0 C 4. Maximum temperature attainable by a body exposed to the

sun. 50 0 C

5. Minimum ambient air temperature

0 0 C

6. Maximum relative humidity. 100%

7. Minimum number of rainy days per annum 70

8. Average number of rainy days per annum 120

9. Average annual rain fall. 150 cm.

10. Number of months of tropical monsoon conditions 4

11. Maximum wind pressure. 260 Kg./ mm2

12. Degree of exposure to atmospheric pollution. Normally polluted atmosphere.

1.5 TECHNICAL DETAILS:-

1.5.1 The 33 KV A.B. Switch Set shall be gang operated (with double tandem pipe) single air

break outdoor type horizontal mounting having 4 nos. 22/24 KV post insulator per phase. The


operating mechanism shall be suitable for manual operation from the ground level and shall

be so designed that all the three phases shall open or close simultaneously. The Switches shall

be robust in construction, easy in operation and shall be protected against over travel or

straining that might adversely affect any of its parts. The required base M.S. Channel, phase

coupling rod, operating rod with intermediate guide braided with flexible electrolytic

copper, tail piece of required current carrying capacity and operating mechanism with

‗ON‘ & ‗OFF‘ positions shall be provided. The operating rod shall be medium gauge of

32mm diameter nominal bore G.I. pipe single piece 6 meters. The phase coupling rod for

gang operation shall medium gauge 25mm dia nominal bore G.I. Pipe. Rotating post

insulators shall be provided with suitable bearing mounted on a base channel with 6 mm

thick thrust collar and 6mm split pin made out of stainless steel. The operating down rod shall

be coupled to the spindle (minimum dia - 32mm) for gang operation through another suitable

bearing by two numbers 10mm dia through stainless steel bolts with double nuts. The post

insulators should be fixed with the base channel using Galvanized Nuts and Bolts.

All the bearings shall be provided with grease nipple. All ferrous parts shall be galvanized and polished. The pipes shall be galvanized in accordance with IS-4736/1968.

1.5.2 Mounting: - The A.B. Switches shall be suitable for horizontal mounting in all type of sub-

station structures.

1.5.3 Switching Blades: - It shall be made out of electrolytic copper with silver plated. The

approximate size shall be 250mm x 50 x 8mm. The switch shall have such a spring

mechanism so as to ensure that the speed of the opening of contact is independent of speed of

manual operation.

1.5.4 Fixed Contacts:- The fixed jaw type female contracts (50x8x95 )mm shall be made of

electrolytic copper ( minimum 95 % copper composition) duly electroplated controlled by

Phosphor bronze high pressure spring housed in robust G.I. Cover.

It is essential that provision shall be made in fixed female contracts to take the shock

arising from the closing of moving contract blade without the same being transmitted to the

post insulator. The arrangement made in this regard shall be specifically shown in the drawing.

1.5.5 Arcing Horn:- As the switches are generally meant for isolating transmission line and

distribution transformers, suitable arcing horns shall be provided for breaking the

charging current horn shall be made of 10 mm dia G.I. Rod with spring assisted

operation.


1.5.6 Terminal Connectors:- Terminal connectors shall be robust in design. The size of fixed

connector shall be ( 80 x 50 x8 mm) and size of movable connector shall be of ( 80 x50) x

( 80 x 50) x 8 mm of copper casting with uniform machine finishing duly silver plated

made out of minimum 95 % copper composition with 2 nos. 12 mm dia holes provided

with suitable brass bolts and double nuts, flat washers & 2 nos. bimetallic solderless

sockets suitable up to ACSR Panther or AAAC 232 mm2 conductor.

1.5.7 Spacing:- The minimum clearance between phase to the switch shall be 1200 mm. The

operating down rod shall be at a transverse distance of 300 mm from the outer limb of the

switch. The centre spacing between two post insulators of the same phase shall be 560 mm.

In the open position of the A.B. Switches the moving blade shall rotate through anangle of

90 0 . This shall be exhibited in the drawing.

1.5.8 Drawing & Literatures:- Drawings of 33 KV 400 amp, 3 Pole, single break A.B. Switch

shall be furnished along with the tender.

The details of construction and materials of different parts of the A.B. Switches shall

clearly be indicated in the tender and illustrative pamphlet / literature for the same shall be

submitted along with the tender.

1.6 TESTS & TEST CERTIFICATE

1.6.1 Type Test:- Certificates for the following type tests conducted within five years

proceeding to the date of opening of tender on prototype set of A.B Switch in a Govt.

Approved Testing Laboratory preferably at CPRI, Bhopal/ Bangalore shall have to be

submitted for reference and scrutiny.

i. Impulse voltage dry test

ii. Power frequency voltage dry test

iii. Power frequency voltage wet test

iv. Temperature of resistance.

v. Measurement of resistance.

vi. Test to prove the capability of carrying the rated peak short circuit current and the rated short time current.

vii. Mainly active load breaking capacity test. viii. Transformer off-load breaking test.

ix. Line charging breaking capacity test.

x. Operation tests.


xi. Mechanical endurance test.

xii. Mechanical strength test for the post insulator as per IS-2544/1973.

xiii. Test for galvanization of metal (ferrous) parts as perm IS-2633/1973.

Besides, mechanical endurance test will have to be conduct on one set in the presence of our authorized person who shall be deputed to carryout acceptance tests before delivery of the materials.

1.6.2 Routine Tests: - The following routine tests shall have to be conducted on each sets and results are to be furnished for consideration of deputing inspecting officer for inspection and conducting testing of the materials.

1. Power frequency voltage dry test

2. Measurement of resistance of main circuit

3. Tests to prove satisfactory operation.

4. Dimension check

5. Galvanization test.

1.7 GUARANTEED TECHNICAL PARTICULARS:-

The Bidder shall furnish the guaranteed technical particulars duly filled in the format at

Appendix-I along with the tender.

1.8 COMPLETENESS OF EQUIPMENT:-

Any fittings, accessories for apparatus which may not have been specifically mentioned in

this specification but which are usual or necessary in equipment of similar plant shall be

deemed to be included in the specification and shall be supplied by the Tender without extra

charge. All plant and equipment shall be completed in all details whether such details are

mentioned in the specification or not.

1.9 INSPECTION:-Routine and acceptance tests shall be conducted at the place of manufacturer.

The bidder are requested to furnish details of equipment which will be used for testing along with

tender. The bidder of those manufacturers who do not have adequate testing facilities for conducting

routine and acceptance test are liable for cancellation. The successful bidder has to furnish routine test

certificate and guaranteed certificate for approval prior to offer of materials for inspection for each

consignment of offer.


GUARANTEED TECHNICAL PARTICULARS FOR 33KV, 400A, 50 HZ, 3 POLE, SINGLE BREAK TYPE AB SWITCH

Sl. No

Particulars

Desired values Bidder‘s

offer

1 2 3 4

1. Maker‘s name and country

of origin

To be specified by the tenderer

2. Type of Switch Rotating type only

3. Suitable for mounting Horizontal only

4. Number of supporting post insulators per phase

4 nos.22 KV / 24 KV Post Insulators per phase as per ISS-2544/1973.

5. No. of Breakers per phase Single Break

6. Post Insulator. a) Maker‘s name and country

of origin

Techno Ceramics / Allied Ceramic/JSI/Equivalent type test certificate to be provided along with bid.

b) Type of cementing To be quoted for original cemented only & as per IS-2544-1973 & relevant IEC.

c) One minute power frequency withstand voltage Dry

95 KV RMS.

d) One minute power frequency withstand voltage Wet

75 KV RMS.

e) Visible discharge voltage 27 KV RMS.

f) Dry Flashover Voltage To be specified by the tenderer

g) Power frequency puncture with stand voltage

1.3 times of actual dry flash over voltage

h) Impulse withstand voltage

(switch in position)

170 KV (peak)

i) Creepage distance (mm) 450 mm minimum. (actual creepage distance for which type test have been conducted is to be specified by the tenderer

7.

Impulse withstand voltage for positive and negative polarity 1.2 / 50 mircro- second wave.

a) Across the isolating distance 195 KV (peak)


b) To earth & between poles 170 KV (peak)

8. One minute power frequency withstand voltage.

a) Across the isolating distance 80 KV (RMS)

b) To earth & between poles 70 KV (RMS)

9.a) Rated normal current and rated frequency

400 amps. 50 Hz

b) Rated short time current. 16 KA ( RMS )

10. Rated short circuit making capacity

25 KA (RMS)

11. Rated peak withstand current 40 KA ( Peak )

12. Rated cable charging breaking capacity

40 KA ( RMS )

13. Rated Transformer off load breaking capacity

16 Amp (RMS)

14. Rated line charging breaking capacity

5.3 Amps ( RMS)

15. Minimum clearance between adjacent phases

a) Switch Closed ( centre to centre) 1200 mm

b) Switch Opened ( centre to edge of blade)

640 mm

16. Temperature rise

Temperature rise shall not exceed the maximum limit as specified below at an ambient temperature not exceeding in 40 0 C

b) Copper contacts in air 65 0 C

c)

Terminal of switch intended to be connected to external conductor by bolts

50 0 C

17. Vertical Clearance from top of insulator cap to mounting channel

508 mm (minimum)


18.

Type of Contact: -

a) Self aligned, high pressure jaw type fixed contacts of electrolytic copper of size 50 mm x 8 mmx95 mm duly silver plated. Each contact should be revetted with three nos. Copper rivets with a bunch (minimum 3 mm thick) consisting of copper foils, each may vary from 0.15 mm to 0.25 mm. These total thickness of copper foils per jaw should be 6 mm. Jaw assemblies are to be bolted through stainless steel bolts and nuts with stainless steel flat and spring washer.

b) Solid rectangular blade type moving contact of electrolytic copper size 250 mm x

50 mm x 8 mm duly silver plated ensuring a minimum deposit of 10 micron of silver on copper contacts or as may be prescribed under relevant ISS / IEC.

c) Pressure spring to be used in jaw contacts shall be Stainless Steel having 8 nos of turn x 28 mm height x 14.4 mm diameter with 14 SWG wire (minimum six nos springs shall be used)

19.

Connectors:-

Terminal connectors for both movable and fixed should be of copper flats of same size similar to that of moving contact blades (minimum 95% copper composition). The fixed connector shall of size 80 mm x 50 x 8 mm and the size of movable connector shall be size 80 x 50 x 8 mm with machine finishing duly silver plated with 2 nos. of 3/8‖ stainless steel bolts, nuts, plain washers & spring washers should be provided along with 2 nos solder less bimetallic sockets for each connector suitable sockets for each connector suitable up to 232 mm² AAA conductor.

20.

Moving Contacts supports:-

Movable contact is to be supported by galvanized angle of 50 x 50 x 5 mm in each phase and the moving contact are to be bolted through 2 no stainless steel bolts and nuts with suitable stainless steel flat and spring washers.


21. Galvanization a) Iron parts shall be dip galvanized as per

IS-2633/1972.

b) b) The pipe shall be galvanized as per IS-

4736/1968.

22.

Details of Phase

a)

Coupling Rod 25 mm nominal bore G.I. pipe medium gauge.

b)

Operating Rod

32 mm nominal bore G.I. pipe medium gauge single length 6 mtrs. The detailed dimension of the G. I. pipe as per IS-1239 (Pt. I) as mentioned below :-

Nominal base (mm)

Outside

diameter

Diameter thickness (mm)

Max Min

25

34.2 33.3 3.25

32

42.9 42 3.25

c) Arcing Horns 10 mm dia G.I. rod with spring assisted operation.

d) Force of Fixed contact spring To be specified by the tenderer.

e)

Copper braided flexible tapes:-

450 mm long 2 nos. of flexible electrolytic copper tape or braided chord (with tin coated) having minimum weight 450 gms per meter and both ends shall be crimped with copper sockets through brass bolts and nuts with brass flat washers. Two nos of suitable copper sockets shall be used at both ends. The minimum no. of flexible wires should be 1536 of 36 SWG for each flexible chord.

f) Quick break device Lever mechanism.

g)

Bearings

4 nos. self lubricated bearing to be provided with grease nipple including 4th bearing being a thrust bearing.

h) Locking arrangement Pad Lock & Key arrangement at both ‗ON‘

& ‗OFF‘ position.

i) Earth Terminal: To be provided at base channels.


23. Supporting Channels 100 x 50x5 mm M.S. Channel hot dip galvanized.

24. Weight of each pole complete

To be specified by the tender

25. Detailed drawing To be submitted by the bidder

NB- Every AB Switch should bear the marking of manufacturer’s name ,Purchaser’s name , P.O. No., Sl. No. etc.


33KV 400 Amp. AB Switch Male contact(H) & Female contact(H)

Requirement Bidders Offer

a) Self aligned high pressure jaw type fixed contacts of electrolytic copper of size 50mm x 8 mm x95mm duly silver plated .Each contact should be riveted with three nos. copper rivets with a bunch ( minimum 3 mm thick) of copper strips /foil each may vary from 0.15 mm to 0.25 mm to and total thickness of copper foil per jaw should be 6 mm . Jaw assembles are to be bolted through brass bolts and nuts with spring washer.

b) Solid rectangular blade type moving contact of electrolytic copper of size 250mmx50 mm X 8 mm duly silver plated ensuring a minimum deposit of silver 10 micron on copper contacts or as may be prescribed under relevant ISS / IEC .

c) Pressure springs are to be used in each jaw contacts should be phosphorous bronze having 8nos. of turns x 28mm heights X14.4mm diameter with 14 SWG wire ( minimum six nos. springs shall be used).



TECHNICAL SPECIFICATIONS OF 33 KV POST TYPE INSULATOR

1.Scope of Work: This Specification covers design, engineering, manufacture, assembly, stage testing, inspection & testing before supply and delivery at site of the 33 KV post type insulator

2.0 INSULATORS 2.1 General Requirements

2.1.1 The Porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. 2.1.2 Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelain parts of the insulator except those areas which serve as supports during firing or are left unglazed for the purpose of assembly. 2.1.3 The design of the insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal. 2.1.4 Cement used in the construction of the insulator shall not cause fracture by expansion or loosening by contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fittings, and its thickness shall be as uniform as possible.

3.0 Tests: The insulators shall comply with the following tests as per IS:2544-1973 & IS: 5350(PT – III)-1971.

3.1 Type tests

a) Visual examination b) Verification of dimensions c) Visible discharge test d) Impulse voltage withstand test. e) Wet power-frequency voltage withstand test. f) Temperature cycle test. g) Electro-mechanical failing load test. h) Mechanical failing load test (for those of type B strin insulator units to which electro

mechanical failing load test (g) is not applicable. i) Twenty four hours mechanical strength test (for string insulators only when specified

by the purchaser). j) Puncture test k) Porosity test and l) Galvanising test.

3.2 Acceptance Tests The test samples after having withstood the routine tests shall be subjected to the following acceptance test in the rder indicated below:

a) Verification of dimensions. b) Temperature cycle test. c) Twenty four hours mechanical strength test(for string insulator units only when specified by

the purchaser) d) Electro-Mechanical failing load test. e) Puncture test


f) Porosity test and g) Galvanising test.

3.3 Routine Test

a) Visual examination. b) Mechanical routine test(for string insulator units only) and c) Electrical routine test(for string insulator units only)

3.4 Marking

3.4.1 Each Insulator shall be legibly and indelibly marked to show the following.

a) Name and trade mark of the manufacturer. b) Month and year of manufacture c) Minimum failing load in Newtons d) Country of the manufacturer and e) ISI Certification mark, if any. f) Specific Parameters & Layout Conditions.

3.4.2 Marking on porcelain shall be printed and shall be applied before firing. 3.5 Packing

All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail transport. Where more than one insulator are packed in a crate, wooden separators shall be fixed between the insulators to keep individual insulators in position without movement within the crate.

GUARANTEED TECHNICAL PARTICULARS FOR 33 KV POST INSULATOR

Slno. Description Unit Specified Bidder’s Offer UNIT STACK

1

Manufacture Name

To be Submitted by Bidder

2

Address of Manufacture

To be Submitted by Bidder

3

Reference Standard (s) of Insulator

IS: 2544-1973 & IS:5350(PT-III)-1971

4 Height mm 254 508

5 Insulating Part Diameter mm

192

192

6 Pitch Circle Diameter

a) Top Metal Fitting mm

76

76

b) Bottom Metal Fitting mm

76

76

7

Minimum creepage Distance

mm 450

900

8 Cantilever Strength


a) Upright Kgf

900

459

b) Inverted Kgf

700

340

9 Tensile Strength Kgf

3060

3060

10 Torsional Strength Kgfm 70 70

10 Compression Strength Kgf

4600

4600

11 Nominal System Voltage KV(rms) 22 33

12

Highest System Voltage

KV(rms) 24

36

13 Power frequency withstand

voltage (Dry)

KV(rms)

75

140

14 Power frequency withstand

voltage (Wet)

KV(rms)

55

90

15

Impulse-withstand test voltage(1.2x50 microsecond wave)

Caps Padestal

a)

Positive

KVP

125

190

b)

Negative

KVP

125

190

16 Material of Cap Aluminium Alloy Cap

17 Drawing & Sample

To be submitted by bidder

NB- Every insulator should bear the marking of manufacturer’s name & Purchaser’s name and ISI mark.


11 KV PIN INSULATOR:

1.SCOPE :

The specification cover the manufacture, testing at works supply and delivery of Porcelain insulators for overhead power lines with a nominal voltage below 12KV . Both Pin and Shackle type insulators are covered. 2.APPLICABLE STANDARDS:

Except when they conflict with the specific requirements of this specification, the insulators shall

comply with IS : IS:731 & IS: 3188 or the latest version thereof.

3.GENERAL REQUIREMENTS:

The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. The design

of the insulators shall be such that the stresses due to expansion and contraction in any part of the

insulator shall not lead to its deterioration. The glaze shall be brown in color for insulators. The glaze


shall cover the entire porcelain surface parts except those areas that serve as supports during firing.

The insulators shall be suitable for use with all Aluminum Conductor or Copper conductor or ACSR

upto 100 sq.mm. The insulators should withstand the conductor tension the reversible wind load as

well as the high frequency vibrations set due to wind.

4.SYSTEM CONDITIONS: Frequency : 50 Hz

Nominal System Voltage : 11KV Maximum System Voltage LT System : 12KV Minimum LT Voltage : 11KV

Power frequency one minute withstand Voltage(wet) : 35KV

5. TYPE OF INSULATORS:

The standard Pin insulators shall be of designation Type –B of IS : 731 or its latest revision.

6. TESTS: 6.1 Type tests:

a) Visual examination

b) Verification of dimensions

c) Temperature cycle test

d) Dry one minute power frequency withstand test

e) Wet one minute power frequency withstand test

f) Mechanical strength test

g) Porosity test 6.2 Acceptance test:

The insulators, after having withstood the routine test shall be subjected to the following

acceptance tests in the order given below:

a) Verification of Dimensions.

b) Temperature cycle test

c) Mechanical strength test

d) Porosity test

6.3 Routine tests:

ii) Visual examination

7.TESTING FACILITIES: a. The Bidder must clearly indicate what testing facilities are available in the works of the

manufacturer and whether the facilities, are adequate to carry out all the routine as well as type tests.

These facilities should be made available to Purchaser‟s Engineers if deputed to carry out or witness

the tests. If any tests cannot be carried out at the manufacturer‟s works, the reasons should be clearly


stated in the tender.

b. The Bidder shall furnish detailed type test reports of the offered 11KV Pine insulator as per

clause 6.1 of this specification. All the above Type Tests shall be carried out at laboratories, which are

accredited, by the National Accreditation Board of Testing and Calibration Laboratories (NABL) of

Government of India to prove that the insulators offered meet the requirements of the specification.

These Type Tests should have been carried out within five years prior to the date of opening of this

tender.

c. There offered L.T. shackle Insulators & pin insulators are already fully Type Tested at Laboratories

accredited by the National Accreditation Board of Testing and Calibration Laboratories (NABL) within

five years prior to the date of opening of the tender.

There is no change in the design of Type tested L.T. shackle Insulators and those offers against this

tender.

8. Drawings :

The tender shall be accompanied with the detailed drawings showing the dimensions of the

individual insulator, giving all the design dimensions of various component parts. Generally it

shall be as per IS.

9. MARKING:

a. Each insulator shall be legibly and indelibly marked to show the

following:

i) Name of Purchaser- NESCO

ii)Name or trade mark of the manufacturer

iii) Year of manufacturer

iv) ISI certificate, mark, if any.

b. Marking on porcelain shall be applied before firing.

10. Packing :

All insulators shall be packed in crates or boxes suitable for rough handling. Packing shall be marked with the strength and voltage rating.


GUARANTEED TECHNICAL PARTICULARS 11 KV PIN INSULATOR

Sl. No.

Description Specific Requirement Bidders offer

Name of Manufacturer. & Address To be specified by the bidder

Location of type testing To be specified by the bidder

Applicable standard IS: 731,IS 3188 or the latest version thereof

1 Normal working voltage 11 Kv (rms) 2 High system voltage. 12 Kv (rms) 3 Visible Discharge voltage dry PF. 9 Kv (rms) 4 1 Minute withstand voltage wet PF. 65 Kv (rms) 5 1 Minute withstand voltage................. 35 Kv (rms) 6 PF puncture withstand voltage. 110 Kv (rms) 7 Impulse withstand voltage :

(+ ve) 80 Kv peak (- ve) 80 Kv peak 8 Impulse flashover voltage :

(+ ve) 90 Kv peak (- ve) 120 Kv peak 9 Minimum failing load. 5 KN. 10 Minimum creepage distance. 240 mm. 11 Colour of glaze. Brown. 12 Weight per unit. 1.4 Kg. (Apprx.) 13 Size of insulator. (Height) 125 mm.

(Diameter) 125 mm. 14 Material of thimble. Lead. 15 Steel head. Small head. 16 Standard. IS : 731/1971. 17 Tolerance. Tolerance will be allowed as per IS : 731/1971

or latest amendments if any. 18 Drawing To be submitted

19 Conforming standard As per IS

NB- Every insulator should bear the marking of manufacturer’s name & Purchaser’s name and ISI mark.



TECHNICAL SPECIFICATION OF 33KV STAY INSULATOR

TECHNICAL SPECIFICATION OF HT GUY STRAIN INSULATORS (STAY INSULATORS)

1. SCOPE:

The specification covers porcelain guy strain insulators for use in HT distribution system.

1. APPLICABLE STANDARDS:

Except when they conflict with the specific requirements of this specification, the

insulators shall comply with IS: 5300-1969 or the latest version thereof. 3.GENERAL REQUIREMENTS:

The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.

The design of the insulators shall be such that the stresses due to expansion and

contraction in any part of the insulator shall not lead to its deterioration. The glaze shall

be brown in color for insulators. The glaze shall cover the entire porcelain surface parts

except those areas that serve as supports during firing.

4. SYSTEM CONDITIONS: HT

Frequency : 50 Hz

Nominal System Voltage : 33 KV Maximum System Voltage HT System : 36 KV Power frequency one minute withstand (Dry) : 75KV (rms)

Power frequency one minute withstand (wet) : 45KV(rms)

Neutral Earthing arrangement LT System : Solidly Earthed Solidly Earthed

5. TYPE OF INSULATORS:

The standard guy strain insulators shall be of designation as per IS: 5300/1969 or its latest

revision. The recommended type of guy strain insulators for use on guy wires of 33KV

overhead line .

6. TESTS: 6.1 Type tests:

a) Visual examination b) Verification of dimensions c) Temperature cycle test d) Dry one minute power frequency withstand test e) Wet one minute power frequency withstand test

f) Mechanical strength test g) Porosity test

6.2 Acceptance test:

The insulators, after having withstood the routine test shall be subjected to the


following acceptance tests in the order given below: a) Verification of Dimensions. b) Temperature cycle test c) Mechanical strength test d) Porosity test

6.3 Routine tests:

i) Visual examination

7. TESTING FACILITIES:

a. The Bidder must clearly indicate what testing facilities are available in the works of the manufacturer and whether the facilities, are adequate to carry out all the routine as well as type tests. These facilities should be made available to Purchaser‟s Engineers if deputed to carry out or witness the tests. If any tests cannot be carried out at the manufacturer‟s works, the reasons should be clearly stated in the tender. b. The Bidder shall furnish detailed type test reports of the offered HT Stay Insulators as per clause 6.1 of this specification. All the above TypeTests shall be carried out at laboratories, which are accredited, by the National Accreditation Board of Testing and Calibration Laboratories(NABL) of Government of India to prove that the insulators offered meet the requirements of the specification. These Type Tests should have been carried out within five years prior to the date of opening of this tender. c. There offered HT Stay Insulators are already fully Type Tested at Laboratories accredited by the National Accreditation Board of Testing and Calibration Laboratories (NABL) within five years prior to the date of opening of the tender.

8. Drawings :

The tender shall be accompanied with the detailed drawings showing the dimensions

of the individual insulator, giving all the design dimensions of various component

parts. Generally it shall be as per IS.

9. MARKING:

a. Each insulator shall be legibly and indelibly marked to show the following:

i) Name of the Purchaser : ‘NESCO Utility’ ii) Name or trade mark of the manufacturer iii) Year of manufacturer

iv) ISI certificate, mark, if any b. Marking on porcelain shall be applied before firing.

10. Packing :

All insulators shall be packed in crates or boxes suitable for rough handling. Packing

shall be marked with the strength and voltage rating.


33KV STAY INSULATOR GURANTEED TECHNICAL PARTICULARS (To be submitted along with Bidder’s offer) Sl. no. Description Unit 33KV Stay Insulator 1 Manufacturer’s name

2 Address of manufacturer

3 Location of type testing

4 Applicable standard & Type

5 Type of insulator (Porcelain or toughened glass)

6 Dry impulse withstand voltage

7 Wet power frequency, 1 minute, withstand voltage

8 Dry, Critical Impulse Flashover Voltage

9 Dry, power frequency, Critical Flashover

Voltage

10 Wet, power frequency, Critical Flashover

Voltage

11 Power frequency Puncture Voltage

12 Safe Working Load

13 Minimum Failing Load

14 Creepage Distance

15 Protected Creepage Distance

16 Type and Grade of Materials : Insulator

17 Colour of Insulator

18 Weight of Insulator

19 Number of Insulators per Crate

20 Type of semi conducting Glaze

21 Minimum dia of Stay wire hole

22 Whether drawing showing dimensional

details have been furnished along with Bid

23 Whether Type Test Certificate have been furnished

24 Other particulars (if any)



33 KV F Clamp/ Pole top Bracket (GI) : 33 KV line pole top bracket made out of 65 mm long 100x50x6 mm M.S channel welded with 65x65x6

mm M.S Angle & hot dip galvanize as per IS-2633/1972.(Latest Amendment) , confirming to REC

Construction Standard.M-4 & drawing .

GUARANTEED TECHNICAL PARTICULARS FOR 11KV POLE TOP BRACKET

Sl.No. Constructional Features Specified Bidders

Offer

1. Material used 65x65x6 mm MS Angle &

100x50x6 mm MS Channel

2. Overall height 380 mm

3. Flange Width (one welded &

65 mm

4. Spacing between two flanges 100mm

5. Spacing of 2 nos of 18 mm holes

for fixing on pole top

100mm

6. C/L Distance of 2nos of 25mm

holes on top flanges of the bracket

40mm from edge

of the flange

7. Galvanization Hot dip

8. ISS 2062 ,2633

9. Drawing enclosed



33 KV GI Pin : 33 KV GI Pin conforming to IS 2486 (part –II)/74 and suitable for 33 KV Pin Insulator having stalk

length of 300 mm & shank length 150 mm with minimum failing load of 10 KN & provision of double

nuts & a spring washer. The threading shall good finish & with standard galvanization.

GUARANTEED TECHNICAL PARTICULARS FOR 33KV G.I PIN

Sl no. Description Specified Bidder’s Offer 1 Manufacture Name & Address 2 Standard applicable specification IS 2486 3 Minimum failing load 10KN 4 Dimensions (mm) a) Length 450mm b) Shank length 150mm c) Stalk length 300mm 5 Type of Threads

6

Threads per inch 8-9 threads per

inch

7 Type of galvanization of pin & nuts Hot Dip 8 Mass of Zinc (minimum) 690 gm/m2 9 Applicable specification IS 2633

10

No. of Nuts with each pin & its size To be submitted

by the bidder

11

No. of spring washer with each pin & its size To be submitted

by the bidder

12 Packing Details a) Type of packing Heasian Bag

b)

Weight of each pin approx.(with nut & washers)

c) No. of pins in each packing (Kg)

15 Pcs

13

Tolerance in weight

±3%

14

I.S.I Certificate License number

16 Manufacture's Trade mark with each GI Pins

17

Drawing & Sample

To be submitted by

bidder



40mm dia GI Earthing Device: 1. Scope :-

This specification provides for design, manufacturing, testing before dispatch, supply & delivery of Earthing Device (Heavy Duty) (for use in Sub-station earthing).

2. APPLICABLE STANDARDS :-

The Earthing Device must be made out of 40 mm nominal Bore & 3.2 mm (Medium Gauge- No minus Tolerance allowed) wall thickness Hot Dip G.I. Pipe (as per IS ;- 1239,m Part-1, 1990 & REC construction Standard –J-2) , ISI marked of reputed Make & 2.5 mtrs length tapered finished smooth at one end for a length of 75 mm & Clamp at the other end.

Staggered drills hole of 12 mm Dia of interval of 150mm shall be made before galvanization.

The GI Earthing Clamp/ Strip (C- Clamp Type) is to be of 50mm width, 6mm thickness & flange length of 65 mm in each side. This should be suitable for termination of 4 nos of GI Flat earth electrodes. The Clamp/ Strip & Earthing pipe after fabrication will be hot dip galvanized confirming to IS: 2629/85 with latest amendments. The clamp shall have two holes in both sides suitable for 5/8 x 2” Bolt & provided with two GI bolts& Nuts in each side of 12mm dia 50mm long half threaded with spring washer as per IS: 3043/1982.The galvanization tests are to be conducted as per IS: 2633/72 & IS: 6745/72 & its latest amendments.

Guaranteed Technical Particulars of Earthing Device (To be submitted along with Offer)

Particu

Bidder’s Offer

1. Location of Factory or Place of Manufacture

2. Maker’s Name, Address & Country

3. Size of

a Pipe

b Earthing Strips

4. Length

5. Thickness of Pipe

6. Galvanization Process

7. Galvanization thickness

a For Earthing device

b For Connecting Flat

8. Galavanization tests to be conducted as per ISS

9. Any other Particulars ( like details of Clamp/ G.I. Bolts)

10. Details of Drawings submitted



20mm HT GI Stay Set : 16mm LT Stay Set:

TECHNICAL SPECIFICATION OF LT AND HT STAY SET

SCOPE:This specification covers design, manufacture, testing and dispatch of LT Stay Sets of 16 mm and HT stay sets 20 mm dia.

GENERAL REQUIREMENTS

16 mm Dia Stay sets (Galvanized) – LT Stay Set

This stay sets (Line Guy set) will consist of the following components:-

Anchor Rod with one washer and Nut

Overall length of rod should be 1800 mm to be made out of 16 mm dia GI Rod, one end threaded up to 40 mm length with a pitch of 5 threads per cm and provided with one square GI washer of size 40X40x1.6mm and one GI hexagonal nut conforming to IS:1367:1967 & IS:1363:1967. Both washer and nut to suit threaded rod of 16 mm dia. The other end of the rod to be made into a round eye having an inner dia of 40mm with best quality welding.

Anchor Plate Size 200 x 200 x6 mm

To be made out of GI plate of 6 mm thickness. The anchor plate should have at its centre 18 mm dia hole.

Turn Buckle & Eye Bolt with 2 Nuts

To be made of 16 mm dia GI Rod having an overall length of 450mm, one end of the rod to be threaded up to 300 mm length with a pitch of 5 threads per cm and provided with two GI Hexagonal nuts of suitable size conforming toIS:1363:1967 & IS:1367:1967. The other end of rod shall be rounded into a circular eye of 40mm inner dia with proper and good quality welding.

Bow with Welded Angle

To be made out of 16mm dia GI rod. The finished bow shall have an over all length of 995 mm and eight of 450 mm, the apex or top of the bow shall be bent at an angle of 10 R. The other end shall be welded with proper and good quality welding to a GI angle 180 mm long having a dimension of 50x50x6mm. The angle shall have 3 holes of 18 mm dia each.

Thimble

To be made on 1.5 mm thick GI sheet into a size of 75x22x40mm and shape as per standard shall be supplied.

Average Weight of Finished 16mm Stay Sets shall be at least 7.702 KG (Minimum) (Excluding Nuts Thimbles and Washer) 8.445 Kg. (Maximum)


20 mm Dia Stays Sets for 33 Kv,11 KV Lines (Galvanized) HT Stay Set The Stay Set (Line Guy Set) will consist of the following components: Anchor Rod with one Washer and Nut Overall length of Rod should be 1800mm to be made out of 20 mm dia GI rod one end threaded up to 40 mm length with a pitch of threads per cm. And provided with one square G.I Washer of Size 50x50x1.6mm and one GI Hexagonal nut conforming to IS: 1363:1967 & IS:1367:1967. Both washer and nut to suit the threaded rod of 20mm. The other end of the rod to be made into a round eye having an inner dia of 40mm with best quality of welding. Dimensional and other details are indicated and submitted by bidders for owner‟s approval before start of manufacturing. Anchor Plate Size 300 x 300 x 8 mm

To be made out of G.S. Plate of 8 mm thickness. The anchor plate to have at its centre 22mm

dia hole.

Turn Buckle, Eye Bolt with 2 Nuts.

To be made of 20 mm dia G.I Rod having an overall length of 450 mm. One end of the rod to be threaded up to 300 mm length with a pitch of 4 threads per cm. The 20 mm dia bolt so made shall be provided with two G.I Hexagonal nuts of suitable size conforming to IS: 1363:1967 & IS: 1367:1967.The other end of the rod shall be rounded into a circular eye of 40mm inner dia with proper and good quality of welding. Welding details are to be indicated by the bidder separately for approval.

Bow with Welded Channel:

To be made out of 16mm dia G.I Rod. The finished bow shall have and overall length of 995 mm ad height of 450 mm. The apex or top of the bow shall be bent at an angle of 10R. he other end shall be welded with proper and good quality welding to a G.I Channel 200 mm long having a dimension of 100x50x4.7 mm. The Channel shall have 2 holes of 18 mm dia and 22 dia hole at its centre as per drawing No.3 enclosed herewith.

Thimble 2 Nos.

To be made of 1.5 mm thick G.Isheet into a size of 75x22x40mm and shape as per standard.

Galvanizing

The complete assembly shall be hot dip galvanized.

Welding

The minimum strength of welding provided on various components of 16mm and 20 mm dia stay sets shall be 3100 kg & 4900 kg respectively. Minimum 6mm filet weld or its equivalent weld area should be deposited in all positions of the job i.e. at any point of the weld length. The welding shall be conforming to relevant IS: 823/1964 or its latest amendment.

Threading

The threads on the Anchor Rods, Eye Bolts and Nuts shall be as per specification IS;4218:1967 (ISO Metric Screw Threads). The Nuts shall be conforming to the requirements of IS:

1367:1967 and have dimension as per IS 1363:1967. The mechanical property requirement of fasteners


shall confirm to the properly clause 4.6 each for anchor rods and Eye bolt and property clause 4 for nuts as per IS: 1367:1967.Average weight of finished 20 mm Stays Set: 14.523 Kg.(Min) (Excluding Nuts Thimble & Washer) :15.569 Kg.(Max.)

TESTS

The contractor shall be required to conduct testing of materials at Govt./Recognized testing laboratory during pre-dispatch inspection for Tensile Load of 3100 Kg/4900Kg. applied for one minute on the welding and maintained for one minute for 16 mm and 20mm dia stay sets respectively.

IDENTIFICATION MARK

All stay sets should carry the identification mark of the Purchaser (NESCO) applicable.

This should be engraved on the body of stay rods to ensure proper identification of the materials. The nuts should be of a size compatible with threaded portion of rods and there should be not play or slippage of nuts.

Welding wherever required should be perfect and should not give way after erection.

TOLERANCES

The tolerances for various components of the stay sets are indicated below subject to the condition that the average weight of finished stay sets of 16mm dia excluding nuts, thimbles and washers shall not be less than the weight specified above.

GURANTEED TECHNICAL PARTICULARS (To be submitted along with Offer)

Sl

No.

Item

Description

Specified Parameters Bidder’s Offer

Section

Tolerances

Fabrication

Tolerances

Material

1 Anchor

Plate

6mm thick +2.5%- 5%

8mm thick +2.5%-5%

200x200mm+1%

300x300mm+1%

GI Plate 6 mm thick

GI Plate 8 mm thick

LT Stay Set

HT Stay Set

2

Anchor Rod

16mm dia +5%-3% 20mm dia +3%- 2%

Length 1800mm+0.5% Rounded Eye 40 mm inside dia + 3% Threading 40mm+11%-5% Length 1800mm+0.5% Round Eye 40mm inside dia +3%.

GI Round 16mm dia GI Round 16mm dia GI Round 20mm dai GI Round 20mm dia

LT Stay Set HT Stay Set


Threading 40mm+11%-5%

3

Turn Buckle Bow

16mm dia +5%-3% 20mm dia +3%- 2%

Length 995mm+1% 16mm dia Length180mm+1% 50x50x6mm Channel length 200mm + 1% 100x50x4.7m m

GI Round 16mm dia. GI Angle G I Channel

LT Stay Set HT Stay Set

4

Eye Bolt

Rod

16mm dia +5%-3% 20mm dia +3% - 2%

Length 450mm + 1% Threading 300mm+1% Round Eye 40mm inside dia +3% Length450mm +1% Threading 300mm+1% Round Eye 40mm inside dia +3%

GI Round 16 mm dia GI Round 20mm dia.

LT Stay Set

HT Stay Set

5 Galvanisation

thickness

All galvanization shall be carried out in accordance with IS: 2629 . The weight of

Zinc deposited shall be in accordance with IS: 2629 and shall not less than 0.61 kg/m² with a minimum thickness of 86 microns for items of thickness more than 5 mm, 0.46kg/m²(64 microns) for items of thickness between 2 mm & 5 mm& 0.33kg/m²(47 microns) for items less than 2 mm thickness.

a Anchor Plate

b Anchor Rod

c TurnBuckle Bow

d Eye Bolt Rod

6 Thimble 2 nos. to be made of 1.5 mm thick G.S Sheet into a size 75x22x40 mm & shape as per standard.

7 One G.S Hexagonal Nut confirming to IS:1363 & 1367 with one square washer of size 50x50x6 mm (G.S) along with Anchor Rod.

8 Two G.S Hexagonal Nuts of suitable size along with Eye Bolt Rod.

Name & Signature of the bidder with seal


7/8 GI Stay Wire : 7/12 GI Stay Wire :

TECHNICAL SPECIFICATIONS 7/8 SWG and 7/12 SWG STAY WIRE)

1. Application Standards

Except when they conflict with the specific requirements of this specification, the G.I Stay Stranded Wires shall comply with the specific requirements of IS: 2141- 1979. IS: 4826-1979 & IS: 6594-1974 or the latest versions thereof.

2. Application and Sizes

a) The G.I. stranded wires covered in this Specification are intended for use on the overhead power line poles, distribution transformer structures etc.

b) The G.I stranded wires shall be of 7/8 SWG( 7/4.0 mm for 33KV lines) and 7/12 SWG (7/2.5 mm for LT lines) standard sizes.

3. Materials

The wires shall be drawn from steel made by the open hearth basic oxygen or electric furnace process and of such quality that when drawn to the size of wire specified and coated with zinc, the finished strand and the individual wires shall be of uniform quality and have the properties and characteristics as specified in this specification. The wires shall not contain sulphur and phosphorus exceeding 0.060% each.

3.1 Tensile Grade

The wires shall be of tensile grade 4, having minimum tensile strength of 700 N/mm² conforming to 1S:2141.

3.2 General Requirements

a) The outer wire of strands shall have a right-hand lay. b) The lay length of wire strands shall be 12 to 19 times the strand diameter.

3.3 Minimum Breaking Load & Galvanising

The minimum breaking load of the wires before and after stranding shall be as follows:

No. of Wires & Const.

Wire Dia (mm)

Min. breaking load of the Single wire

before stranding (KN)

Min. breaking load of the standard wire

(KN) 7 (6/1) 2.5 3.44 21.40

7 (6/1) 3.15 5.46 34.00

7 (6/1) 4.0 8.80 54.90


Minimum weight of

zinc coating before

stranding

490 gm/mm2

490 gm/mm2

490 gm/mm2

Minimum weight of

zinc coating before

stranding

475 gm/mm2

475 gm/mm2

475 gm/mm2

4. Construction

a) The galvanized stay wire shall be of 7-wire construction. The wires shall be so stranded together that when an evenly distributed pull is applied at the ends of completed strand, each wire shall take an equal share of the pull.

b) Joints are permitted in the individual wires during stranding but such joints shall

not be less than 15 metres apart in the finished strands.

c) The wire shall be circular and free from scale, irregularities, imperfection, flaws, splits and other defects.

5. Tolerances A tolerance of (+) 2.5% on the diameter of wires before stranding shall be permitted.

6. Sampling Criteria

The sampling criteria shall be in accordance with IS :2141.

7. Tests on Wires before Manufacture i) The wires shall be subjected to the following tests in accordance with IS :2141. a) Ductility Test

b) Tolerance on Wire Diameter

ii) Tests on Completed Strand

The completed strand shall be tested for the following tests in accordance with IS:2141. a) Tensile and Elongation Test: The percentage elongation of the

stranded wire shall not be less than 6%. b) Chemical analysis c) Galvanizing Test

The Zinc Coating shall conform to "Heavy Coating" as laid down in 1S:4826 8. Marking

Each coil shall carry a metallic tag, securely attached to the inner part of the coil bearing the following information:

a) Manufacturers name or trade mark b) Lot number and coil number c) Size d) Construction e) Tensile Designation f) Lay g) Coating h) Length i) Mass


j) ISI certification mark, if any 9. Packing

The wires shall be supplied in 75-100 Kg. coils. The packing should be done in accordance with the provisions of IS:6594.

GURANTEED TECHNICAL PARTICULARS STAY WIRE (7/8 SWG)

Sl. No.

Description Specified Bidder’s offer

1. Manufacturer’s name & address To be specified by the Bidder

2 Nominal diameter of wire in mm 4.0 3 Tolerance in diameter in mm + 2.5% 4 Minimum breaking load in Kg 5960.26 5 Tensile strength Kgf/mm² 71.40 6 Overall diameter of stranded wire in mm 12.0 7 Sectional Area (in mm².) 113.14 8 Coating Test a Type of zinc coating whether heavy or light Heavy b Weight of coating in g/m² 476

9 a Length of wire in each coil in mtr. 117

b Tolerance + 5% 10 No. of dips the coating is able to withstand

as 18 ± 20ºC 3 dip in min.

11 Adhesion Test (Wrap Test at 1 turn per second coiling while stress not exceeding % nominal tensile strength)

a Min. complete turn of wrap To be specified by bidder

b Dia of mandrel on which wrapped - do - 12 Bend Test a Angle - do - b Dia round a format to be bent - do -

13 Freedom from defect - do - 14 Chemical composition the MS Wire used

shall not exceed

a Sulphur 0.060% - do - b Phosphorous 0.065% - do -

15 a Weight of each coil in Kg 70 to 100

b Tolerance + 5%

16 a Weight of wire in Kg/Km 750 b Tolerance + 5%

17 Standard according to which the solid wire is manufactured and tested

ISS: 2141/1992 & ISS: 4826/1979



GURANTEED TECHNICAL PARTICULARS STAY WIRE (7/12 SWG)

Sl. No.

Description Specified Bidder’s offer

1. Manufacturer’s name & address To be specified by the Bidder

2 Nominal diameter of wire in mm 2.50 3 Tolerance in diameter in mm + 2.5% 4 Minimum breaking load in Kg 2331.07 5 Tensile strength Kgf/mm² 71.40 6 Overall diameter of stranded wire in mm 7.50 7 Sectional Area (in mm².) 44.19 8 Coating Test a Type of zinc coating whether heavy or light Heavy b Weight of coating in g/m² 476

9 a Length of wire in each coil in mtr. 298

b Tolerance + 5% 10 No. of dips the coating is able to withstand

as 18 ± 20ºC 3 dip in min.

11 Adhesion Test (Wrap Test at 1 turn per second coiling while stress not exceeding % nominal tensile strength)

a Min. complete turn of wrap To be specified by bidder

b Dia of mandrel on which wrapped - do - 12 Bend Test a Angle - do - b Dia round a format to be bent - do -

13 Freedom from defect - do - 14 Chemical composition the MS Wire used

shall not exceed

a Sulphur 0.060% - do - b Phosphorous 0.065% - do -

15 a Weight of each coil in Kg 70 to 100

b Tolerance + 5%

16 a Weight of wire in Kg/Km 310 b Tolerance + 5%

17 Standard according to which the solid wire is manufactured and tested

ISS: 2141/1992 & ISS: 4826/1979



300Amp Kit Kat Fuse : 400 Amp Kit Kat Fuse: Kit Kat Fuse unit with porcelain base & carrier of reputed brand complete with extended terminals as per relevant ISS : 2086/1993, Amendment-I:

1. SCOPE This application cover the manufacture, testing at works and supply of porcelain rewireable kit kat fuses suitable for AC 3 phase 415 V 50 HZ solidly grounded neutral system. 2. WEATHER CONDITION: The material used in construction of the fuse unit shall be suitable for use under following weather condition:- I) Temp. Range 0 to 50 C ii) Relative humidity 2% to 100% iii) Altitude-upto 1000 Meters iv) Use Outdoor, in dist. box or indoor in consumers premises. 3. RATED VOLTAGE AND FREQUENCY. The fuses shall be suitable for continuous operation at AC 415 V and frequency 50 Hz. 4. RATED CURRENTS: The rated currents of fuses units shall be 300 Amps / 400 Amps. 5. APPLICATION STANDARDS: I) IS: 2086/1993 with latest amendment for fuses upto 100 A &This specification. ii) This specification for 300 A/400A kit kat fuses. 6. GENERAL CONSTRUCTION REQUIREMENT OF KIT KAT FUSES: 6.1 MATERIALS: This rewireable fuses units shall be made of ceramic which shall be of sand fine grain homogenous non-porous chemically insert and high electrical and mechanical strength and shall be thoroughly verified and smoothly glazed. It shall be non-ignitable/ The porcelain and glaze shall be white or cream in colour. The glaze shall cover at least those surfaces which are exposed when the ,fuses have been mounted in the intended manner. Themounting surface may be left unglazed. The materials should not have any defect such as – i) Crazing : A hairline crack in glaze of ceramic material. ii) Dunt : A hair line fracture extending through the body and the glaze and caused by strains set-up in the process of manufacture of ceramics materials. iii) Projection : A raised imperfection, projecting more than 0.75 mm above the Surface of the ceramic


material. iv) Water : The ceramics material shall not absorb more than absorption 2% of its weight of water when broken and tested for. 6.2 The design and dimension of the fuses shall be either in accordance with r relevant IS – 2086 -1993 6.3 PROTECTION: The carrier and fuse base when installed in the intended manner shall have all live parts so protected as to prevent inadvertent contact with such live parts. 6.4 HANDLING GRIP: The fuse carrier shall be provided with a handle or grip and shall be shaped in acceptable manner so that it will be easy to withdraw the carrier without use of any tools and without danger to any L.M. or operator. 6.5 METAL PARTS: All metal parts shall be protected against corrosion by suitable methods. 6.6 FUSE BASE: 6.6.1. The fuses base shall be provided with two fixing holes for fixing the fuse base by means of screwier bolts. 6.6.2. The fuse base shall have contacts for suitably engaging with the contacts of the fuse carrier rigidly under any condition. The contacts shall be made out of such a metal which will not lose its electricity due to heating of the contracts on full load with 20% overload current or heat generated and required pressure is maintained even after repeated engagements and disengagement. The contact for rating 63 A and above will also have extended strips for fixing cable lugs by means of bolt. 6.6.3. Live parts on the underside of the fuse base for surface mounting shall be either covered by a shield or barrier of insulating materials or be counter sunk not less than 3mm below the surface of the base and covered with water proof insulating sealing compound which will not deteriorate or flow at a temp. lower than 100 degree C or on full load current with 20% overload or blowing of fuse under short circuit condition or shall have clearance of not less 9mm for 100A, 200A and 300A size from the mounting surface and reliably prevented from loosening. 6.7 FUSE CARRIER: The fuse carried shall have contacts suitable for engaging with fuse base contacts. They shall be provided with suitable terminals for the connection of the fuse elements. The fuse carrier shall be so constructed that it is capable of being reversible for introduction into the fuse base. The contacts shall be made out of the metal which will not loose its elasticity on account of heating of the contacts on full load with 20% overload conditions or heating due to blowing of the fuse element due to short circuit and required pressure is maintained and even after repeated engagement and disengagement. 6.7.2 Live parts of the fuse carrier shall be covered either by a shield for barrier of insulating materials or be counter sunk not less than 3 mm below surface of the base and covered with water proof insulating sealing compound which will not deteriorated or flow at temp. lower than 100 ºC. 6.8 The asbestos cloth to be provided in fuse base shall be fire proof insulating and of sufficient length width and thickness. 6.9 SPRING FOR BASE PHOSPHOR BRONZE CONTACT (For 300 Amp/400 Amp only)


This should be round/elliptical made from high quality spring steel sufficient to maintain uniform pressure on the contact surface when fuse carrier is fitted. The spring shall be of sufficient width and having 1 mm thickness. 6.10 SCREWS: I) Screws upon which the general assembly of the fuse base and carriers terminals and contacts depend shall be prevented from loosening or backing out buy lock, washers, stacking or other reliable means. ii) If screws used in the assembly of a fuse are loosened or removed in order to install the fuse elements or to connect the fuse into a circuit they should be thread into metal and shall be provided with washers. 6.11 CURRENT CARRYING PARTS: I) Current carrying parts shall be of robust construction and capable of carrying their rated current without exceeding the temp. rise limits clause 4.2.1 of IS specification 2086-1993. i.e. 55 degree centigrade for rating 100amps & 65 degree centigrade for 300 amps/ 400 amp kit kat fuse. II) Iron and steel parts shall not be used for current carrying parts except as clamping device or pressure such as punching screws, clamps or wire binding screws and nuts. 6.12 CONTACTS: The contacts of the fuse base, fuse carrier, terminal blocks/strips shall be as under: i] Fuse carrier contacts (Male Contacts) Tinned Brass ii] Fuse Base Contacts (Female Contacts) Tinned Brass with terminal. iii] Terminal block/strips Tinned Brass The current carrying screws and washers shall be of tinned brass while the screw, washers not carrying current shall be M.S. Galvanized M.S. Electro Galvanized bolt and nut with one plain washer and one spring washer suitable for 120 mm², 185 mm² , 240 mm² / 300 mm² cable lugs shall be provided with extended strips for 300A and 400A fuse respectively. 6.13 Chemical composition of the contacts. Electrolytic copper (tinned phosphor bronze (Tinned) use for contacts of KK fuse shall confirm to various IS asstated below. a) Electrolytic Copper Copper strips used for contacts of kit kat fuse should confirm to IS:1897/1983 with latest amendments. The material shall be of electrolytic tough pitch (ETP) grade with minimum 99.9% of copper & silver as per table I of IS191 part IV. b) Phosphor Bronze The phosphor bronze used for contacts of KK fuse shall confirm to any of the grade-I, II or III given in IS: 7814/1985 (with latest amendments). The requirement of metal composition should be as per IS-7814. c) Brass It shall confirm to grade LCB1/DCB2 of IS-1264/1997 (with latest amendment)/IS 4101/1977 with latest amendment). The metal composition for casting shall be as per IS 1264 and that of brass sheet,

as per IS 410 6.14 The contact fixing screw holes in fuses shall be fitted with insulating material fully into the surface of the kit kat fuse carrier. 7. EMBOSSING : 7.1 Every fuse carrier shall be clearly and indelibly embossed with the following information. I) Rated Current ii) Rated voltage


iii) Size of fuse wire iv) Manufacturer’s name/Trade mark. v) NESCO Utility 8.0 TYPE TEST CERTIFICATES: 8.1 The firm has to submit type test certificates for test conducted on their own brand name make for reputed make fuses for all the tests as per cl.no. 9.0.3.1 of IS: 2086/1993 (with latest amendment) carried out at CPRI Bhopal/Bangalore/ERDA, Baroda/ NIBL or Govt. Recognized laboratory . 8.2. The firm has to submit chemical composition certificates for each contact used in each rating of fuses offered for sample tested at ERDA Baroda or any Govt.Recognized laboratory as per relevant ISS.

8.3 The above type test certificates and metal composition certificates shall be complete viz. for all tests and for all parts and submitted along with the offer. Incomplete/delayed test certificates and metal composition certificates shall not be considered. The tests for rewirable fuses shall be carried out as per the procedure detailed in I.S.2086-1993. However, for the guidance of the tenderer, the different type tests are mentioned below: a) Visual examination. b) Test for dimensions. c) Test for mechanical endurance. a) Test for mechanical strength. b) Test for temperature rise: - As per Clause No.9.6 of I.S. 2086/1993, temperature rise of different parts of the kitkats when tested in an ambient temperature of 40 °C, should not exceed 55 °C. c) Insulation Resistance test d) High Voltage test. e) Test for breaking capacity. f) Test for water absorption. g) Test on ceramic material. h) Ignition test (for non-ceramic materials) i) Test for withdrawal force.

9.0 ACCEPTANCE LOT: 9.1 SAMPLING CRITERIA: The Number of fuse carriers and fuse bases to be selected from the lot shall be in accordance with Appendix-B of IS: 2086/1993. However, the lot size shall constituted of all the fuse carriers and fuse bases of the same ratings. 9.2 ACCEPTANCE TEST. The fuse carriers and fuse bases selected as per 9.1 (of this specification) shall be subject to the acceptance test in following order. i) Visual examination ii) Dimensional check iii) Test for Mechanical endurance iv) Test for withdrawal force


(v) Test for temp. rise (vi) Insulation resistance test (vii) High voltage test (viii) Temp. Cycle test. N.B.: For purpose of temp. cycle test and temp. rise test one sample from every batch of 10000 (or less) for each current rating has to selected and tested. 10.0 ROUTINE TEST: The routing test certificate duly signed by the testing engineers of the firm clearly stating that the following routine tests has been conducted by him on each fuse unit, shall be kept ready and submitted to the inspecting officer prior inspection of lot offered and testing of samples. I) Visual examination ii) High voltage test. 11.0 VERIFICATIONM OF METALIC COMPOSITION OF CONTACTS: 11.1 NESCO reserves the right to draw the samples of metallic parts of kit kat fuses for verifications of metallic composition at the time of manufacture from the lot offered for inspection. In addition to this, the samples will be drawn from the lots received by the consignees for verification of metallic composition. In the event the metallic composition does not confirm to our specifications. The NESCO Utility reserves the right to cancel the order at the cost and risk of the supplier.

No.6 GI Wire: No.8 GI Wire : TECHNICAL SPECIFICATION OF GI WIRE WIRE

1. Qualification Criteria of Manufacturer:-

The prospective bidder may source GI Wire from manufacturers only who must qualify all the following requirements: a) The manufacturer must have successfully carried out Type Test of similar item from any NABL Accredited Laboratory within the last 5 years, prior to the date of submission of the bid.

b) The manufacturer should have supplied at least 500 Kgs. (all sizes taken together) to electricity supply utilities / PSUs. The bidder should enclose Performance Certificates from the above users issued in the name of the manufacturer as proof of successful operation in field.

2. SCOPE This specification covers manufacture, testing and supply of hot dip galvanized MS solid wire of sizes 6 SWG (5 MM) & 8 SWG (4 MM) diameters.

3. APPLICABLE STANDARDS ZINC


Zinc shall conform to grade Zen 98 specified in IS 209& IS: 4826-1979 with up to date amendments.

ZINC COATING Zinc coating shall be in accordance with IS: 4826-1979 for heavily coated hard uality. GALVANISING Galvanizing shall be as per IS: 2629-1966, IS 4826-1979 with up to date amendments UNIFORMITY OF ZINC COATING Uniformity of zinc coating shall be as per IS: 2633-1972 with up to date amendments TENSILE PROPERTIES The tensile strength of the wire after galvanizing shall be between 55-95 Kg/sq.mm ensuring

MS wire mechanical properties as per IS-28:1972 8.1 to 8.3 FREEDOM FROM DEFECTS As per IS: 2629-1966 & 4826-1979 & with up to date amendments be ensured

4. MATERIAL

The mild steel wire shall have chemical composition maximum sulphur- 0.055%, phosphorous -0.055%, Carbon 0.25%.

5. TESTS

During the process of manufacturer/fabrication and all tests for chemical, mechanical, galvanizing as per IS- 280-1979, IS1521-1972, IS-1755-1961, IS: 6745-1972 & 4826-1979 shall be carried out. The certificate towards, chemical composition shall be submitted for each lot offered for inspection. The following tests shall be conducted in presence of the representative of the purchaser: Visual physical inspection and measurement of specified dimension Coating test as per IS: 1755-1961, IS 2629-1966, IS: 2633-1972, IS: 4826-1969 Adhesion test as per IS: 1755-1961, IS: 2629-1966, IS: 2633-1972, IS: 4826-1969,& IS:6745-1972 Tensile strength and breaking load and elongation determined as per IS: 1521-1972 with up to date amendments.

6. PACKING & MARKING

Packing shall be as per IS: 280-1979 and each coil shall be between 50-100 kg. marking shall be as per IS:280-1972.


Guaranteed Technical Particulars for No. 6 G.I. wire Sl. No.

GENERAL TECHNICAL PARTICULARS Guaranteed

Value Bidders Offer

1 Nominal diameter of wire in mm 4.88 mm 2 Tolerance in diameter in mm + 2.5% 3 Sectional Area (in Sq. mm.) 18.7038 4 Tensile strength of wire in N/mm²/ MPa 550-900

5 Minimum breaking load (KN) 9

6 Variety Hard/Soft Soft 7 Type of Galvanizing Hot dip

heavy coating

8 Weight of Zinc coating (Gms/Sq. Mtr.) 290 9 No. of dips the coating is able to withstand as 18 ± 20ºC 3 dip in Min

10 Adhesion Test (Wrap Test at 1 turn per second coiling

while stress not exceeding % nominal tensile strength)

To be specified by

bidder

i) Min. complete turn of wrap do

ii) Dia of mandrel on which wrapped do

11 Bend Test do

i) Angle do

ii) Dia round a format to be bent do

12 Freedom from defect do

13 Chemical composition the MS Wire used shall not

exceed

do

i) Sulphur 0.060% do

ii) Phosphorous 0.065% do

14 Weight of wire in Kg/Km 148

15 Tolerance in wt. + 5%

16 Standard according to which the solid wire is

manufactured and tested

IS: 280/1978 ,

IS: 4826/1979 ,

IS: 7887/1975



Guaranteed Technical Particulars for No. 8 G.I. wire Sl. No.

GENERAL TECHNICAL PARTICULARS Guaranteed

Value Bidders

Offer 1 Nominal diameter of wire in mm 4.06 mm

2 Tolerance in diameter in mm + 2.5%

3 Sectional Area (in Sq. mm.) 12.9462

4 Tensile strength of wire in N/mm²/ MPa 550-900

5 Minimum breaking load (KN) 8.79

6 Variety Hard/Soft Soft

7 Type of Galvanizing Hot dip

heavy coating

8 Weight of Zinc coating (Gms/Sq. Mtr.) 290

9 No. of dips the coating is able to withstand as 18 ± 20ºC 3 dip in Min

10 Adhesion Test (Wrap Test at 1 turn per second coiling

while stress not exceeding % nominal tensile strength)

To be specified by

bidder

ii) Min. complete turn of wrap do ii) Dia of mandrel on which wrapped do

11 Bend Test do iii) Angle do iv) Dia round a format to be bent do

12 Freedom from defect do 13 Chemical composition the MS Wire used shall

not

do

iii) Sulphur 0.060% do iv) Phosphorous 0.065% do

14 Weight of wire in Kg/Km 103

15 Tolerance in wt. + 5%

16 Standard according to which the solid wire is

manufactured and tested

IS: 280/1978 ,

IS: 4826/1979 ,

IS: 7887/1975



TECHNICAL SPECIFICATION OF ELECTRICAL MATERIALS · 19 8 SWG GI wire Kg 1000 NB: 1. Bidders should put their authorized signature with office seal on each page of the documents. 2.

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