Vol V KFW TR 107 16112017 PDF

MADHYA PRADESH POWER TRANSMISSION CO. LTD.
SHAKTI BHAWAN RAMPUR: JABALPUR
VOLUME –V
Part-1
Technical Book Serial No.

MPPTCL/TECH/PROC/12/JULY15
TECHNICAL SPECIFICATION FOR SUPPLY

OF MATERIALS AND CONSTRUCTION OF
220KV AND 132KV TRANSMISSION
LINES.
O/o CHIEF ENGINEER (PROCUREMENT)

MPPTCL, JABALPUR.
TABLE OF CONTENTS
PART I – Specifications & requirements for supply of

Transmission Line Materials
Section- 1 Common Technical Requirement ………………………. 1
Section- 2 Technical Specifications for Towers ………………….. 14
Section- 3 Technical Specifications for Conductor ………………. 32
Section- 4 Technical Specifications for Earth wire …..………….. 44
Section- 5 Technical Specifications for Disc Insulators …………… 51
Section- 6 Technical Specifications for Hardware fittings for

Conductor & Earth wire………………..................... 87
Section- 7 Technical Specifications for Accessories for Conductor
& Earth wire ……………………………………………. 105
Section- 8 Technical Specification for Optical Ground Wire (OPGW),
Associated Hardware & AccessoriesTechnical
Specifications for erection of transmission ……. 121
Section- 9 Technical Specifications for erection of transmission

lines ………………………………………………… 156
Annexure – 1 Technical Particulars of ACSR Conductors & Earth 177

wire
Annexure – 2 Technical Particulars of Disc Insulators 181
Annexure – 3 Technical Particulars of Hardware for conductor 183

& Earth wire
Annexure – 4 Technical Particulars of Accessories for conductor 187
& Earth wire
Annexure – 5 List of Drawings 190
Volume-V Part-1
SECTION-1
COMMON TECHNICAL REQUIREMENT
1.01 SCOPE:
1.01.01 The provisions under this section are to supplement

common requirements for supply of Transmission Line Materials
and Installation work. Section-2 to Section-9 contains technical
specification for all the Materials to be used for Construction of
Transmission Lines. The bidders shall furnish catalogues,
engineering data / technical information, drawing etc. in
conformity with the technical specification.
1.01.02 The scope of work involves fabrication, galvanizing and

delivery of 220kV & 132kV Double Circuit/ Multi circuit towers, their
body extensions, river/ line crossing structures (Gantries), Hangers, U
bolts, D Shackles, Bolts and Nuts, Spring washers, pack washers, step
bolts, tower accessories (earthing rod with clamps, Danger Boards,
Number plates, Phase plates and Anti-climbing Devices (including fixing
arrangements and barbed wire), ACSR Conductor, Earth wire, OPGW,
Disc insulators, hardware and accessories for conductor and Earth
wire/OPGW and complete erection of transmission lines including,
detailed survey/check survey, casting of foundations, tower erection,
stringing etc. and testing & commissioning of the transmission lines.
Cement and reinforcement steel for foundation of towers, extensions,
river/ line crossing structures and any such materials required for
erection work shall also be provided by the successful Bidder. The
Bidder is also required to provide required number of stub
setting templates for each installation work at his own cost.
1.01.03 This section also provides for the Design, manufacturing,

stage testing, inspection and testing before despatch, packing and
delivery of materials for use on 220kV/132kV transmission lines in the
State of Madhya Pradesh.
1.01.04 It is not the intent to specify completely herein all details of

the design and construction of Material. However, the Material shall
conform in all respects to high standards of engineering, design and
workmanship and shall be capable of performing the duties specified
herein. The Material offered shall be complete with all components
necessary for its effective and trouble free operation. Such components
shall be deemed to be within the scope of Bidder’s supply, irrespective
of whether these are specifically brought out in this specification or not.
1.01.05 If due to site condition any other type of tower (which is not
envisaged at present) is required to be provided, the same will also be
supplied by the bidder at the same rates terms and conditions.
MPPTCL/TECH/PROC/12/JULY15 Page 1 of 192

Volume-V Part-1
1.02 CLIMATIC CONDITION

The equipments and materials shall be suitable for satisfactory
continuous operation under the following climatic conditions:
1 Location in the state of MADHYA PRADESH

0
2 Maximum ambient air temperature ( C) 50
0
3 Minimum temperature in shade ( C ) 1
4 Maximum relative humidity (%) 95(sometimes
approaches
saturation)
5 Average daily ambient air temperature (0C ) 32° Centigrade
6 ISOCERANIC Level (days/year)
50
(Average number of thunder storm days)
7 Average rainfall(mm) 1250
8 Wind Zone as per IS 802(Part-I)- 1995 4
9 Max. Altitudes above mean sea level
1000
(meters)
10 Seismic level (Horizontal acceleration)(g) 0.3
NOTE: Moderately hot and humid tropical climate conducive to rust and
fungus growth. The climatic conditions are also prone to wide
variations in ambient conditions. Smoke is also present in the
atmosphere. Heavy lightening also occurs during June to
October.
1.03 STANDARDS:
1.03.01 Bidders may please note that all offered materials shall be
manufactured, tested and supplied with all guaranteed technical
particulars generally conforming to meet the requirement of technical
specification as brought out in various Sections and latest revisions of
relevant standards of international electro technical commission or
equivalent national standards of India with latest amendments of
relevant standards rules and codes. The lists of standards are specified
in relevant Sections of bid document.
1.03.02 The works covered by the specification shall be designed,

engineered, manufactured, built, tested and commissioned in
accordance with the Acts, Rules Laws and Regulations of India.
1.03.03 The Contractor shall also note that list of standards

presented in this specification is not complete. Wherever necessary the
list of standards shall be considered in conjunction with specific IS/IEC.

Volume-V Part-1
1.03.04 When the specific requirements stipulated in the

specifications exceed or differ than those required by the applicable
standards, the stipulation of the specification shall take precedence.
1.04 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS :
1.04.01 The lists of Indian standards are specified in individual

sections for various materials and Installation work of bid document.
However, the Material and Installation work meeting any other
authoritative International Standard, which ensures equal or better
quality than the Standards mentioned in bid document, shall also be
acceptable. Material for which Indian Standards are not available,
any equivalent International Standards will be applicable.
Please attach photocopy of all such Standards according to
which the material and Installation work have been offered.
1.04.02 If the material offered by the Bidder conform to any other

standards, salient points of comparison between the standards adopted
and the specific standards shall be clearly brought out in relevant
schedule of deviation. It will be sole responsibility of Bidder to prove
that the salient features of offered materials are equivalent or better
than Indian standards as indicated in Section-2 to Section- 9 of this
document.
1.04.03 The Material and Installation work conforming to standards

other than specified in individual sections for various Material and
Installation work shall be subject to Employer’s approval.
1.05 TYPE TESTS:

1.05.01 Type tests shall mean those tests, which are to be carried
out to prove the process of manufacture and general conformity of the
Material.
1.05.02 The offered Material (except Towers & Tower Accessories)
should be fully type tested as per the relevant standards. Bidder shall
invariably furnish type test reports from the reputed and approved
national/international laboratory/Government approved test houses to
prove that specifications of Material to be supplied conform to the
relevant standard. Test certificates shall clearly indicate the type and
other details etc., so that relevant details of offered Material could be
verified. While submitting the bid the details and type etc., shall be
clearly indicated. Type test reports so furnished should not pertain to
the period earlier than five years from the date of opening of Bid. In
case the type tests were carried out earlier than five years, the
manufacturer will have to conduct these tests without any extra cost to
the Employer. In both the above cases type test certificate must be
submitted with the offer. The Bidders have to submit one complete set
of Test reports for the offered Material. Further, for any change in the

Volume-V Part-1
design/type already type tested and the design/type offered against

this specification, the Employer reserves the right to demand repetition
of tests without any extra cost.
1.06 DISCREPANCY IN TECHNICAL PARTICULARS:
The bidders will have to furnish confirmation in regard to compliance of

our entire technical requirement. The bid should clearly describe
various technical particulars of the material as per this specification.
1.07 MANUFACTURER'S AUTHORISATION:

The bidders shall have to submit the documentation from the
manufacturer of the Material on the format specified in this volume that
they are authorised to supply the material indicated in their bids in the
employer's country
1.08 SCHEDULE OF QUANTITIES:
1.08.01 The requirements of various Materials and Installation work

are indicated in Price Schedules. In these schedules short description of
material has been given. The details of all such description are given in
relevant sections of this document. The bidder shall refer these detailed
descriptions for clarity.
1.08.02 Although all the quantity of Material and Installation work

have been included in the bid as mentioned in Price Schedules.
However there may be requirement of some minor nature items
required for successful erection / commissioning of transmission line
work covered under this Bid. Bidder should include all such items in
the bid proposal sheets which are not specifically mentioned but are
essential for the execution of the contract. The cost of supply of such
item which explicitly may not appear in various schedules and are
required for successful commissioning of transmission line shall deemed
to be inclusive in the bid price and shall be provided at no extra cost to
Employer.
1.09 PERFORMANCE GUARANTEE PERIOD:
All the Material & its accessories and Installation work covered under
the Bid shall guaranteed for performance and quality for a period of 24
months from the date of completion of facilities (or any part thereof).
In case after commissioning of transmission line, any operational
problem is observed in any Material/ installation work because of which
any major rectification or replacement work is done, then the guarantee
for such Material / installation work shall be extended by a period equal
to the period during which the facilities or such part can not be used by
the EMPLOYER.

Volume-V Part-1
1.10 WORKMANSHIP:
All Material shall be of the best class and quality most suitable for the
conditions of operation under the climate conditions as per clause no.
1.02 above for supply of Material. The workmanship shall be of the best
grade and the entire construction in accordance with the best modern
practice.
1.11 DRAWINGS AND DOCUMENTS:
1.11.01 In addition to those stipulated in Vol. I of bidding

document, the following also shall apply in respect of Contractor
drawings.
1.11.02 Within one month from the award of contract, the

contractor shall submit the drawing of all Material for approval. Each
drawing submitted by the Contractor shall be clearly marked with the
name of the EMPLOYER, the specification title, the specification number
and the name of the Project. All titles, noting, markings and writings
on the drawing shall be in English. All the dimensions should be to the
scale and in S.I. units.
1.11.03 The comments/ approval to drawings submitted by the

Contractor shall be conveyed by the EMPLOYER as far as practicable
within 15 days and shall be modified by the Contractor if any
modifications and/or corrections are required by the EMPLOYER. The
Contractor shall incorporate such modifications and/or corrections and
submit the final drawings for approval with 15 days from date of
EMPLOYERs comments. Any delays arising out of failure by the
Contractor to rectify the drawings in good time shall not alter the
Contractual Time Schedule.
1.11.04 The drawings submitted for approval to the EMPLOYER shall

be in quadruplicate. One print of such drawings shall be returned to
the Contractor by the EMPLOYER marked “approved/approved with
corrections”. The contractor shall there upon furnish the EMPLOYER
additional prints as may be required along with one reproducible in
original of the drawings after incorporating all corrections.
1.11.05 The work shall be performed by the Contractor strictly in

accordance with these drawings and no deviation shall be permitted
without the written approval of the EMPLOYER, if so required.
1.11.06 All manufacturing, fabrication and Installation work under

the scope of Contractor, prior to the approval of the drawings shall be
at the Contractor’s risk. The contractor may incorporate any changes in
the design, which are necessary to confirm to the provisions and intent

Volume-V Part-1
of the contract and such changes will again be subject to approval by

the EMPLOYER.
1.11.07 The approval of the documents and drawings by the

EMPLOYER shall mean that the EMPLOYER is satisfied that:
a. The Contractor has completed the part of the Works covered
by the subject documents (i.e. confirmation of progress of
work).
b. The Works appear to comply with requirements of
Specifications.
In no case the approval by the EMPLOYER of any document does imply
compliance with all technical requirements or the absence of errors in
such documents.
If errors are discovered any time during the validity of the contract,
then the Contractor shall be responsible for consequences.
1.11.08 All drawings shall be prepared using AutoCAD software.

After final approval all the drawings and documents (structural
drawings, BOMs, shop sketches, tower accessories drawings and
drawings of other materials) shall be submitted to the EMPLOYER in
CDs.
A copy of each drawing reviewed will be returned to the Contractor as
stipulated herein.
1.11.09 Copies of drawings returned to the Contractor will be in the

form of a print with the EMPLOYER’s marking.
1.11.10 All rights of the design/drawing for all Material and

Installation work drawings shall be strictly reserved with the EMPLOYER
only and any designs/drawings/data sheets submitted by the contractor
from time to time shall become the property of the EMPLOYER. Under
no circumstances, the contractor shall be allowed to user/offer above
designs/drawings/data sheets to any other authority without prior
written permission of the EMPLOYER. Any deviation to above is not
acceptable and may be a cause for rejection of the bid.
1.11.11 The manufacturing of the material shall be strictly in

accordance with the approved drawings and no deviation shall be
permitted without the written approval of the EMPLOYER. All
manufacturing and fabrication work in connection with the material
prior to the approval of the drawing shall be at Contractor’s risk.
1.11.12 Approval of drawing/works by EMPLOYER shall not relieve

the Contractor of his responsibility and liability for ensuring correctness
and correct interpretation of the latest revision of applicable standards,

Volume-V Part-1
rules and codes of practices. The plant shall conform in all respect to
high standards of engineering, design, workmanship and latest
revisions of relevant standards. EMPLOYER shall have the power to
reject any work or material, which in his judgment is not in full
accordance therewith.
1.12 QUALITY ASSURANCE PROGRAM:
1.12.01 Quality Assurance Program : To ensure that the Material

and Services under the scope of this contract whether
manufactured or performed within the Contractor's works or at his
Sub-Contractor's premises or at the EMPLOYER's site or at any other
place of work are in accordance with the Specifications, the
Contractor shall adopt suitable Quality Assurance Program (QAP) with
hold points for EMPLOYER’s inspection to control such activities at all
necessary points. Such program shall be outlined by the Contractor
and shall be finally accepted by the EMPLOYER after discussions.
1.12.02 Immediately after award of contract, the contractor shall

submit to the EMPLOYER, the quality assurance plan for all major
items of Material covering the manufacture and Installation activities of
the transmission line. The list of selected sub vendors for supply of
minor items like Bolts & Nuts, tower accessories etc. shall also be
submitted.
1.12.03 The contractor shall ensure that manufacturer must

establish that they are following the accepted quality assurance
programme for manufacture of offered equipments.
1.12.04 The contractor shall ensure that manufacturers of major

items of Material invariably furnish following information:-
(i) Statement giving list of important raw materials, names of
sub supplier for the raw material, list of standards according
to which the raw material are tested, list of tests normally
carried out on raw material in presence of manufacturers
representative, copies of test certificates.
(ii) Information and copies of test certificates as in (i) above in
respect of bought out items.
(iii) List of manufacturing facilities available.
(iv) Levels of automation achieved and list of areas where
manual processing exists.
(v) List of areas in manufacturing process, where stage
inspections are normally carried out for quality control and
details of such tests and inspection.

Volume-V Part-1
(vi) Special features provided in the equipment to make it

maintenance free.
(vii) List of testing equipment available with the manufacturer
for final testing of equipment specified and test plant
limitations, if any vis-à-vis type, special, acceptance and
routine tests specified in the relevant Indian Standards or
equivalent international standard. These limitations shall be
very clearly brought out in schedule of deviations from
specified test equipments.
1.12.05 The Contractor shall follow the accepted Quality Assurance

Plan in true spirit. If desired by the EMPLOYER, he shall give access to
all the Specifications, equipments and records so as to satisfy the
EMPLOYER that Quality Assurance Plan (QAP) is being followed
properly.
1.12.06 All Material shall be subjected to the routine and acceptance

tests before dispatch, as specified in this Specification.
1.13 INSPECTION AND TEST CERTIFICATES:

1.13.01 All Material to be supplied will be subject to inspection and
approval by the EMPLOYER's representative before despatch. Inspection
before despatch will not however relieve the contractor of his
responsibility to supply the Material strictly in accordance with the
specifications.
1.13.02 For Inspection / testing, the contractor shall intimate the
EMPLOYER at least 15 days in advance about readiness of Material as
per the scheduled delivery so that action may be taken for getting the
Material inspected. While notifying the readiness of the Material, the
factory test certificate in respect of offered Material shall invariably be
sent. The EMPLOYER will depute authorized representative for
inspection of Material or alternatively may issue waiver of inspection.
1.13.03 The contractor will submit a test certificate to the
EMPLOYER after inspection of offered Material by EMPLOYER’s
authorized representative. These test certificates should be in
accordance with latest issue of the relevant Indian Standards or as
approved by the order placing authority.
1.13.04 The Material shall not be dispatched unless the test
certificates approval and despatch instructions have been issued by the
EMPLOYER.
1.13.05 All Material shall conform to provisions of any statutory
acts such as the Indian Electricity Act, Indian Factory Act, the
Indian Boiler Act, etc. and corresponding rules and regulations as may
be applicable.

Volume-V Part-1
1.13.06 The EMPLOYER's representatives shall be entitled at all

reasonable time during manufacture to inspect, examine and test at
the contractor's premises the material and workmanship of the plant to
be supplied under this contract.
1.13.07 A copy of the accepted Quality Assurance Plan must be
available at the manufacturer’s works of the Material for reviewing by
inspecting officer of the EMPLOYER.
1.13.08 The acceptance of any quantity of plant shall in no way
relieve the Contractor of any of his responsibilities for meeting all
requirements of the specification, and shall not prevent subsequent
rejection if such plant is later found to be defective. The Contractor will
have to assume the responsibility for free replacement/rectification of
such defects.
1.13.09 Testing Expenses:
The entire cost of testing for the acceptance and routine tests and tests
during manufacture specified in the bid document shall be treated as
included in the quoted unit price of plant.
1.14 SPECIAL REQUIREMENTS:
1.14.01 EMPLOYER expects that participating bidder will take all

necessary precautions to supply best quality Material, which may
provide trouble free performance and also it is expected that the
modern practices for erection and commissioning shall be adopted to
ensure timely and trouble free commissioning of installation and also to
ensure aesthetic overall view of finished transmission line installation.
Some of the conditions which will have to be essentially accepted and

followed by the Bidders for the purpose of participating against the Bid
and also for undertaking construction activities are enumerated below
for specific confirmation by the Bidders.
1.15 STORE FOR SUPPLY OF MATERIAL:

The Contractor shall supply the Material at selected destination set up
by him along the route of the transmission line. The Contractor will set
up above site store within one month from the date of contract and
inform the EMPLOYER. The Contractor will have to supply above
materials and receive them at these places only and the rates
quoted by the Bidder should include charges for delivery of such
materials at the store set up by him, receipt and proper stacking/
stocking at the store.
1.16 COMMENCEMENT OF ACTIVITIES:

Volume-V Part-1
Commencement of following activities is subject to prior and specific

approval of the items mentioned against each:-
S. Activity Items for which prior approval

No. is necessary from Employer
1. Manufacturing of tower Inspection of Proto Assembly of
parts. each type of tower. Submission
of quality assurance plan.
2. Manufacturing of Submission of Quality Assurance
Conductors, Ground wire, Plan, approval of drawings.
Insulators, Hardware
fittings & Accessories for
Conductor and Earth
wire/ OPGW.
3. Dispatch of towers, Acceptance test and issue of test
Conductors, Earth wire, certificate approval
Insulators, Hardware
fittings & Accessories for
Conductor and Earth
wire/ OPGW.
4. Foundation work. Classification of foundation.
5. Erection of tower Quality Assurance Plan for
erection.
6. Stringing of Conductor Stringing chart and stringing
and Earth wire /OPGW. method.
1.17 RESPONSIBILITY FOR OBTAINING INFORMATION AND

TAKING ACTION IN TIME:
Whenever any information or clarifications in respect of construction
of line has to be obtained from various authorities, the Contractor shall
be responsible for taking action well in time so that there are no delays
on this account. The completion period specified in the bidding
document is deemed to include the time taken for such incidental
works. Request for extension of the completion date on such ground
will not be entertained.
1.18 PERMITS AND PRIORITIES:
1.18.01 Necessary permits, if any, required for the execution of the

contract shall be arranged by the Contractor himself. The Contractor
shall obtain the necessary license/permission as per
Central/State/local statutory bodies at his cost.

Volume-V Part-1
1.18.02 The Purchaser may, however, furnish to the Contractor such

certificates (on receipt of such written request from the Contractor) as
may be required for the necessary permits/priorities for the execution
of works, if it considers the demand as justified.
1.18.03 The Purchaser however, shall not be responsible for the delay
in execution of contract, if permits/priorities are not granted in time in
spite of issuance of such certificate.
1.19 WAY LEAVE:
The purchaser will arrange for necessary way leave and clearance of
trees. The Purchaser will pay the way leave compensation. The
purchaser will also arrange for the following: -
(i) Railway clearance

(ii) PTCC clearance
(iii) Forest clearance
(iv) Any other necessary clearance if required/requested.
The Contractor shall inform the purchaser about the places where there
is a way leave problem, sufficiently in advance (preferably 30 days) so
that required way leave can be arranged in time.
Further Contractor shall inform the employer at least 15 days in

advance, the sections of the line where he has planned to carry out the
foundation/ tower erection/stringing work so that MPPTCL may take
advance suitable actions to avoid possibility of any ROW problem.
Please note that while carrying out stringing work, if obstruction is faced
due to branches of trees, the same will be cleared by the contractor.
Further, the contractor will make all- out efforts to carry out stringing
work across Electrified Railway Track within minimum possible duration.
1.20 USE OF PRIVATE ROADS/APPROACH ROAD TO SITE:
1.20.01 The purchaser will help in getting necessary permission for

use of private/forest/canal, roads for transportation of materials and
construction personnels, wherever possible under the rules. Any
charges/tole tax etc. levied by the concerned authorities for use of such
roads etc. shall be borne by the Contractor.
1.20.02 During the erection work, if approach roads are required to be

constructed for reaching the construction sites for transportation of
men/materials, the cost of construction of such approach roads and any

Volume-V Part-1
other expenses incurred in obtaining clearance/permission shall be

borne by the Contractor.
1.21 MATERIALS TO BE ARRANGED BY THE CONTRACTOR FOR

ERECTION WORK:
1.21.01 The supply of cement for foundation work would be arranged

by the Contractor of the quality as per IS - 269 :1989 (Ordinary
Portland Cement 33 Grade) or IS – 8112 : 1987 (Ordinary Portland
Cement 43 Grade) or IS – 12269 : 1987 (Ordinary Portland Cement 53
Grade) or IS:1489 (Portland-Pozzolana Cement (PPC)). The cost of
cement shall be deemed to be included in the quoted unit rates of
concreting.
1.21.02 The cement used shall be procured from reputed manufacturer

like JP Cement, L&T, Birla Cement, ACC, Ambuja etc. The Contractor
shall submit the manufacturer’s certificate, for each consignment of
cement procured, to the Purchaser. The cement shall be arranged in
conventional Jute/HD bags each weighing 50 Kgs net with necessary IS
certification mark on it. In case of any dispute regarding quality of
cement, sample for testing may be taken jointly by contractor’s
representative and Engineer in- charge of work or any authorized
representative of the Company. The sample taken shall be tested for
standard test as per IS code in Govt. Engineering/Polytechnic College
and testing charge shall be borne by the contractor. In case the
material is found defective i.e. not as per relevant ISS, the same shall
be replaced by the contractor at his cost. The Contractor shall also have
no claim towards suspension of work due to time taken in conducting
tests in the laboratory. Changing of brand or type of cement within the
same structure shall not be permitted without the prior approval of the
Purchaser.
1.21.03 The Quantity of cement to be used per unit quantity of

consumption for different mix (nominal mix) of concrete should be as
follows:
Description Unit Quantity of minimum

S. Cement to be used per Unit
No. quantity of work(in kgs)
1 1:1.5:3 nominal mix Cu.m. 400
concrete

Volume-V Part-1
2 1:2:4 nominal mix Cu.m. 330

concrete
3 1:3:6 nominal mix Cu.m. 220
concrete
4 Random Rubble Masonry Cu.m 83
with 1:6 cement mortar
1.21.04 The Contractor shall arrange metal, sand, stone and water
required for foundation/revetment work. The transport, octroi, levy or
duty on these materials shall be borne by the Contractor himself and
the purchaser will not accept any liability on this account.
1.21.05 The Contractor will also arrange steel rods and binding wires
etc. for foundation, reinforcement and the cast incurred will be
borne by him. Materials for proper earthing of towers i.e. earthing rod,
connecting clamps and connecting wires etc. would also be
arranged by the Contractor as already specified.
***

Volume-V Part-1
SECTION-2
TECHNICAL SPECIFICATION FOR SUPPLY OF TOWERS

2.01 INDIAN STANDARDS:
The 220kV & 132kV Double Circuit/ Multi circuit towers, their body
extensions, river/ line crossing structures (Gantries) under this
specification shall conform to the requirements of the latest revisions
and amendments available at the time of placement of order of all the
relevant Indian standards/codes listed here under or equivalent
International Standards, except as modified in this document.
S. Indian standards or Title
No. equivalent
International
Standards
1 IS:209-1992 Zinc ingot- Specification.
2 IS:278-1991 Galvanized Steel Barbed Wire.
3 IS:800-1991 Code of Practice for General Building

Construction in Steel.
4 IS:802-Part-II-1990 Code of practice for use of structural
steel in overhead transmission line.
Part-II Fabrication, Galvanising,
Inspection & packing.
5 IS 808 – 1991 Dimensions for Hot Rolled Steel beam,
Column, Channel and Angle Sections.
6 IS:1363(Part-III)-1992 Specification for Hexagon head bolts,
screws and nut for product grade –
“C” Hexagon nuts of property class 5.
7 IS:1367-1992 Technical supply conditions for
threaded fasteners (1st Revision).
8 IS:1367(Part-III)-1991 Mechanical properties and test method
for bolts, screws & studs with full
loadability.
9 IS:1367(Part-VI)-1994 Mechanical properties and test method
for nuts with specified proof loads.
10 IS-1367(Part-XIII)-1983 The hot dip galvanized coating of
fasteners.
11 IS:1573-1991 Specification for electroplated coating
of zinc on Iron & steel.
12 IS:1586-1968 Methods of Rock well hardness test
(`B’ & `C’ scales) for steel (first
revision).

Volume-V Part-1

No. equivalent
International
Standards
13 IS:1852-1991 Rolling and Cutting Tolerances of Hot
Rolled Steel Products.
14 IS:2016-1992 Plain Washers.
15 IS:2062-2006 Steel for general Structural purposes –
Specification.
16 IS:2614-1969 Method for sampling of fasteners.
17 IS:2629-1990 Recommended practice for hot dip

galvanizing of iron and steel.
18 IS:2633-1992 Method of testing uniformity of coating
of zinc coated articles.
19 IS:3063-1994 Single Coil Rectangular Section spring
washers for bolts, nuts, and screws.
20 IS:3202-1972 Methods for testing local thickness of
electro plated coatings.
21 IS:3218(Part-V)-1979 Isometric screw threads “Tolerance”.
22 IS:3757-1992 High Strength Structural Bolts.
23 IS:4072-1975 Specification for steel for spring

washers (first revision).
24 IS:4218(Part-VI)-1978 Isometric screw threads limits of sizes
for commercial bolts & nuts.
25 IS:4759-1990 Specification for Hot dip Zinc coatings
on Structural Steel and other Allied
products.
26 IS:5358-1969 Hot dip galvanized coatings on
fasteners.
27 IS:5369-1991 General Requirements for Plain
Washers.
28 IS:6610-1991 Specification for Heavy Washers for
Steel Structures.
29 IS:6623-1992 High Strength Structural Nuts.
30 IS:6745-1972 Method for determination of weight of

zinc coating of zinc coated iron and
steel article.
31 IS:6821-1973 Methods for sampling of non threaded
fasteners.
32 IS:8500-1992 Specification for weldable structural

Volume-V Part-1

No. equivalent
International
Standards
steel (Medium & High Strength
Qualities).
33 IS:10238-1989 Step Bolts for Steel Structures.
34 IS:12427-1992 Specification for Transmission Tower
Bolts of property class 5.6
2.02 TYPE OF TOWERS :

2.02.1 The towers will be double circuit, self-supporting lattice
type, designed for the specified loading conditions. The following type
of towers are required: -
(A) For 220kV Lines :-
i) Tower type B-0: Tangent type tower with maximum line
deviation up to 2° to be used with
Single/Double suspension insulator strings.
ii) Tower type B-30: Medium angle tower to be used for line
deviation from 0° to 30° with Single/Double
tension insulator strings.
iii) Tower type B-60: Heavy angle tower to be used for line
deviation from 0° to 60° and also as dead
end tower with Single/Double tension
insulator strings.
iv) Gantry (type-AGT) Wherever necessary will also be required for
crossing 220/400kV transmission lines.
(B) For 132kV Lines:-
i) Tower type E-0: Tangent type tower with maximum line
deviation up to 2° to be used with
Single/Double suspension insulator strings.
ii) Tower type E-30: Medium angle tower to be used for line
tension insulator strings.
iii) Tower type E-60: Heavy angle tower to be used for line
deviation from 0° to 60° and also as dead
end tower with Single/Double tension
insulator strings.
iv) Gantry(type-3GO4):Wherever necessary will also be required
for crossing 132/220kV transmission lines.

Volume-V Part-1
2.03 EXTENSIONS:
Suitable extension of 3M, 6M and 10M height will be supplied for use
with 132 kV/220 kV towers.
2.04 TOWER TYPE JC/JCT:

River crossing tower to be used across major river crossings with
Double suspension insulator strings.
2.05 220KV MULTI CIRCUIT TOWERS:

Wherever necessary, MC-0/MC-30/MC-60 type multi circuit towers with
3/6/10 Meter extension and MCX tower may be required for
transmission lines.
2.06 132KV MULTI CIRCUIT TOWERS:

Wherever necessary, MD-0/MD-15/MD-30/ MD60 132kV Multi circuit
Towers with 5M & 10M extension may be required for transmission
lines.
2.07 STUB SETTING TEMPLATES:

The Contractor will fabricate required number of adjustable stub-
setting templates for each type of tower for carrying out the foundation
work. The templates will remain property of the contractor.
2.08 PROCUREMENT OF STEEL AND ZINC:

The following provisions shall apply in connection with the procurement
of steel and zinc by the bidder:
2.08.1 The steel used for fabrication of tower parts, extensions,
templates etc. shall be mild steel of tested quality as per Indian
Standard 2062-1992 or equivalent International Standard.
2.08.2 The bidder should take into account the fabrication wastage
while quoting the rates. The Employer shall not accept any liability in
connection with the actual wastage of steel during fabrication or
otherwise and no additional cost will be allowed on this account.
2.08.3 Substitutions, if any, of steel sections of the tower parts by
higher size, due to their non-availability or otherwise shall be to the
Bidder’s account. The Employer shall not accept any liability on this
account.
2.08.4 The steel shall generally be procured from the Main Steel
Producers. However, sections not rolled/available from the main
producers, could be procured from re-rollers as per quality conforming
to Indian Standard, provided;

Volume-V Part-1
2.08.4.1 Re-rolling of structural steel sections is done from

billets/ingots of tested quality only.
2.08.4.2 Re-rolled sections are duly tested as per relevant Indian
Standard. It may however be noted that no additional cost
shall be payable towards procurement of steel section from
re-rollers.
2.08.5 The zinc used for galvanising of fabricated material shall be
Electrolytic High Grade Zinc (99.95% purity).
2.09 MATERIAL:
2.09.1 IS Steel Sections of tested quality in conformity with IS:
2062: 2006 grade E250 (Designated Yield Strength. 250 MPa) and/ or
grade E350 (Designated Yield Strength 350 MPa) are to be used in
towers, extensions, stubs and stub setting templates. The Contractor
can use other equivalent grade of structural steel angle sections and
plates conforming to latest International Standards. However, use of
steel grade having designated yield strength more than that of EN
10025 grade S355 JR/JO (designated yield strength 355 MPa) is not
permitted, unless otherwise indicated in this specification.
2.09.2 Steel plates below 6mm size exclusively used for packing
plates/packing washers produced as per IS: 1079 -1994 (Grade -0) are
also acceptable. However, if below 6mm size plate are used as load
bearing plates viz gusset plates , joint splices etc. the same shall
conform to IS : 2062 or equivalent standard meeting mechanical
strength/metallurgical properties corresponding to grade E250 or E350
(designated yield strength not more than 355MPa), depending upon the
type of grade incorporated into design. Flats of equivalent grade
meeting mechanical strength/ metallurgical properties may also be
used in place of plates for packing plates/ packing washers. The
chequered plates shall conform to IS: 3502. SAILMA 350HI grade plate
can also be accepted in place of HT plates (EN 10025 grade S355 JR/JO
/ IS 2062:2006 – grade 350, as applicable) provide SAILMA 350HI
grade plate meet all the mechanical properties of plate as per EN 10025
grade S355 JR/JO (designated yield strength 355 MPa) / IS 2062:2006
– grade 350.
2.09.3 For designing of towers, preferably rationalised steel section
has been used. During execution of the project, if any particular section
is not available, the same shall be substituted by higher section. Any
cost on account of the same shall be borne by the Contractor. However,
design approval for such substitution shall be obtained from the
employere before any substitution and records of such substitutions
shall be maintained by the Contractor.
2.10 WEIGHTS:

Volume-V Part-1
The unit weight of each type of tower and extension including bolts and
nuts, accessories, attachments and step bolts is indicated in the Bill of
Materials which shall be supplied by the Employer to the successful
bidder. The weight of structure means the weight calculated using black
sectional (i.e. ungalvanised) weights of all steel members of the sizes
indicated in the fabrication drawings without taking into consideration
the reduction in weight due to drilling of bolts, holes, skew cuts,
chamfering etc. or increase in weight due to galvanising.
2.11 GALVANISING:
2.11.1 The tower parts, stubs and pack washers shall be hot dip
galvanized. The galvanization shall be done as per requirements of IS
4759 after all fabrication work is completed. The contractor shall also
take guidelines from the recommended practices for hot dip galvanizing
laid down in IS 2629 while deciding and implementing galvanizing
procedure. The mandatory requirements however, are specified herein.
2.11.2 Unless otherwise specified the fabricated tower parts and
stubs shall have a minimum overall zinc coating of 610 gms per sq.m.
of surface except for plates below 5mm which shall have Zinc coating of
460 gms per sq.m of surface. The average zinc coating for sections
5mm & above shall be maintained as 87 microns and that for sections
below 5mm shall be maintained as 65 microns.
2.11.3 The zinc coating shall be adherent, reasonably uniform,
smooth, continuous and free from imperfections such as black/bare
spots, ash rust strains, bulky white deposits/wet storage strains and
blisters.
2.11.4 The surface preparation for fabricated tower parts and stubs
for hot dip galvanizing shall be carried out a indicated herein below:
(i) Degreasing & Cleaning of Surface: Degreasing and cleaning of
surface, wherever required, shall be carried out in accordance
with clause 4.1 of IS 2629-1990. After degreasing the article
shall be thoroughly rinsed. However, if acidic degreasers are
used rinsing is not required.
(ii) Pickling: pickling shall be done using either hydrochloric or
sulphuric acid as recommended at clause 4.3 of IS 2629-1990.
The actual concentration of the acids and the time duration of
immersion shall be determined by the Contractor depending on
the nature of material to be pickled. Suitable inhibitors also shall
be used with the acids to avoid over pickling. The acid
concentration, inhibitors used, and maximum allowable iron
content shall form part of plant standard to be formulated and
submitted to Employer along with Quality Assurance Program.

Volume-V Part-1
(iii) Rinsing: After pickling, the material shall be rinsed, preferably in

running water to remove acid traces, iron particles or any other
impurities from the surface. Two rinse tanks are preferable, with
water cascading from the second tank to the first to ensure
thorough cleaning. Wherever single tank is employed, the water
shall be periodically changed to avoid acid contamination, and
removal of other residue from the tank.
(iv) Fluxing: The rinsed article shall be dipped in a solution of zinc
ammonium chloride. The concentration and temperature of the
flux solution shall be standardized by the contractor depending on
the article to be galvanized and individual circumstances. These
shall form part of plant standard to be formulated and submitted
to Employer along with Quality Assurance Program. The specific
gravity of the flux solution shall be periodically monitored and
controlled by adding required quantity of flux crystals to
compensate for drag-out losses. Free acid content of the flux
solution also shall be periodically checked and when it is more
than two (2) grams of free acid per litre of the solution, it shall be
neutralized. Alternatively, Ph value should be monitored
periodically and maintained between 5.0 to 5.5.
(v) Drying: When dry galvanizing is adopted the article shall be
thoroughly dried after fluxing. For the purpose of drying, the
contractor may use hot plate, air oven or any other proven
method ensuring complete drying of the article after fluxing and
prior to dipping in the molten zinc bath. The drying process shall
be such that the article shall not attain a temperature at which
the flux shall get decomposed. The article thus dried shall be
galvanized before the flux coating picks up moisture from the
atmosphere or the flux layer gets damaged or removed from the
surface. The drying procedure, time duration, temperature limits,
time lag between fluxing, drying, galvanizing etc shall form part
of plant standard to be formulated and submitted to Employer
along with Quality Assurance Program.
(vi) Quality of Zinc: Any one or combination of the grades of zinc
specified in IS 209 or IS 13229 or other comparable international
standard shall be used for galvanizing. The contractor shall
declare the grade(s) of zinc proposed to be used by them for
galvanizing. The molten metal in the zinc bath shall contain
minimum 98.5 % zinc by mass. It shall be periodically measured
and recorded. Zinc aluminium alloy shall be added as per IS
2629.
(vii) Dipping Process: The temperature of the galvanizing bath shall
be continuously monitored and controlled. The working
temperature of the galvanizing bath shall be maintained at 450 ±
10°C. The article should be immersed in the bath as rapidly as

Volume-V Part-1
possible without compromising on safety aspects. The

galvanizing bath temperature, immersion angle & time, time
duration of immersion, rate of withdrawal etc. shall be monitored
and controlled depending upon the size, shape, thickness and
chemical composition of the article such that the mass of zinc
coating and its uniformity meets the specified requirements and
the galvanized surface is free from imperfections and galvanizing
defects.
(viii) Post Treatment: The article shall be quenched in water. The
quench water is to be changed / drained periodically to prevent
corrosive salts from accumulating in it. If water quenching is not
done then necessary cooling arrangements should be made. The
galvanized articles shall be dipped in chromating solution
containing sodium dichromate and sulphuric acid or chromic acid
base additive at a predetermined concentration and kept at room
temperature to retard while rust attack. The temperature of the
chromate solution shall not exceed 65°C. The articles shall not
be stacked immediately after quenching and dichromating. It
shall be ensured that the articles are dry before any further
handling operation.
(ix) Storing, Picking and Handling: In order to prevent while rust
formation sufficient care should be exercised while storing
handling and transporting galvanized products. The articles shall
be stored in an adequately ventilated area. The articles shall be
stored with spacers in between them and kept at an inclination to
facilitate easy drainage of any water collected on the articles.
Similar care is to be taken while transporting and storing the
articles at site.
(x) The Contractor shall prepare a detailed galvanizing procedure
including Flow Chart with control parameters and all plant
standards as required above and submit to Employer for
acceptance as part of Quality Assurance Plan.
(xi) Minor defects in hot-dip galvanised members supplied at site shall
be repaired by applying zinc rich primer and two coats of enamel
paint to the satisfaction of the employer before erection, after
obtaining specific permission from Employer.
2.12 GALVANISED BOLTS, NUTS AND WASHERS:

2.12.1 The bolts and nuts to be supplied shall be mild steel hot dip
galvanized bolts (5.6 quality) and nuts (5.0 quality). The spring
washers are to be supplied for insertion under all nuts. These washers
shall be of steel, electro galvanized, and positive lock type and of
3.5mm thickness. Bolt heads and nuts shall be of hexagonal shape.

Volume-V Part-1
2.12.2 The nuts shall be forged and tapped after galvanizing and
then lubricated. The nuts shall be chamfered on one face only; the
other face shall be machined.
2.12.3 The bolts of 16mm size shall be manufactured by cold/hot
forging process and the threads shall be rolled.
2.12.4 The bolts and nuts shall be free from forging and threading
defects such as cuts, splits, burrs, bulging, taper, eccentricity, loose fit
etc.
2.12.5 The bolts shall be threaded up to standard length only as
per relevant Indian Standard and not to full length.
2.12.6 The bolts and nuts shall conform to Indian Standard1367:
1991 Part-III and Part-IV, Indian Standard12427:1992, Indian
Standard1363-1992, Indian Standard 1367 (Part-XIII)-1983 with latest
amendment or equivalent International Standards.
2.12.7 The spring washers designated as M 16-B suitable for
16mm dia galvanized bolt shall be manufactured out of rectangular
section with tolerances as per Indian Standard 3063-1994 with latest
amendments or equivalent International Standard. The spring steel
shall conform to Indian Standard:4072-1975 with latest amendments
"Specification for steel for spring washers" or equivalent International
Standard.
2.12.8 The spring washers after coiling shall be suitably heat-
treated to obtain finished washer having hardness 43 to 50 HRC when
tested in accordance with Indian Standard 1586- 1968 or equivalent
International Standard.
2.12.9 The surface of the washers shall be free of scales and burrs.
The washers shall be coiled without any kinks (except for the shape
with turned-up ends). The ends of the washer shall not abut when the
washers are compressed. The ends shall be so served as to prevent
tangling.
2.12.10 The approximate weight of 1000 pieces of spring washers
suitable for 16mm dia bolt shall be 8.91 kg. in natural black finish as
shown in Indian Standard 3063-1994 with latest amendments or
equivalent International Standard.
2.12.11 The spring washer shall be electro galvanized with
chromate passivation. The electro galvanizing of washers should
conform to ’severe’ grading service conditions incorporated in Indian
Standard 1573: 1991 or equivalent International Standard as "Service
Grade No.4", classification Fe Zn 25. The thickness of zinc coating
should be minimum 25 microns and average thickness 38 microns. It

Volume-V Part-1
should be further suitably heat-treated to avoid any danger of hydrogen

embrittlement.
2.13 STEP BOLTS :

Each tower will be provided, on one of the legs, with step-bolts of
16mm dia and 175mm long, spaced not more than 450mm and
extending from 3 meters above ground level up to the top portion of
the tower. The step bolts shall conform to Indian Standard1363-
1992, Indian Standard10238:1989 and Indian Standard 1367(Part-
XIII):1983 or equivalent International Standards.
2.14 DANGER BOARD, NUMBER PLATE AND PHASE PLATES :

Each tower will be fitted with danger board, number plate and phase
plates. The tower to be supplied shall have provision to fix these plates
at a height of about 3 meters above ground level. Necessary provision
in tower & extensions for fixing of these items shall be made. The
Danger board, number plate and phase plates shall be supplied
conforming to following technical details:-
2.14.1 The danger boards shall conform to IS-2551-1982 and their
revision, if any except where modified in this specification.
2.14.2 The danger boards, number plates and phase plates shall
conform to the drawings enclosed in this specification.
2.14.3 The colour scheme of the enamel and size of figures and
dimensions of lettering shall be as shown in the drawing as also the
overall size. The holes as indicated in the drawing shall be provided
before enamellings.
2.14.4 The thickness of the plate out of which the danger board,
number plate and phase plate will be manufactured, shall not be less
than 1.6mm.
2.14.5 The enamellings shall be done by vitreous enameling
process only.
2.14.6 All letterings shall be centrally spaced. The dimensions of
the letters, figures and their respective positions shall be as given in
drawings. The size of each letter in the word in each language and the
spacing between them for the purpose of scribing shall be so chosen
that they are uniformly written in the space earmarked for them.
2.14.7 The corners of the plate shall be rounded off. The location
of the fixing holes shall be according to drawing annexed with this
specification.
2.14.8 The plate shall be made from mild steel at least 1.6mm
thick and vitreous enameled white, with letters, figures and the

Volume-V Part-1
conventional skull and cross-bones in signal red colour on the front

side. The rear side of the plate shall also be enameled.
2.15 ANTICLIMBING DEVICE WITH BARBED WIRE :

The barbed wire type anti-climbing device shall be supplied for use at a
height of approximately 3 meters as an anti-climbing deterrent
measure, as per the details given in Indian Standard: 5613(Part-
2/Sec-I) 1985 or equivalent International Standard. The angle pieces
with notches for accommodating barbed wire shall be used for this
purpose. The towers to be supplied by the Bidder shall have provision
of suitable bolt holes on leg members for fitting the angles to fix the
barbed wire as indicated above. The details of anti-climbing device are
indicated in drawing enclosed in Annexure-6. The requirement of angle
pieces with notches and barbed wire (per set) will generally be as
under:-
(A) For 220kV Towers:-
Angle pieces - 23.57 Kgs.
Bolts & nuts - 3.41 Kgs.
Barbed wire - 25.00 Kgs.
(B) For 132kV Towers:-

Angle pieces - 24.34 Kgs.
Bolts & nuts - 2.00 Kgs.
Barbed wire - 20.00 Kgs.
2.16 EARTHING :
2.16.1 A provision shall be made in all stubs for fixing earthing
material. The stub will be provided with a hole at a distance of 250 mm
from bottom end and at a distance of 500 mm below ground level for
connection with earthing materials. The hole will be of 17.5 mm dia.
2.16.2 The Bidder shall also supply and erect the following
materials per earthing set for earthing of towers (four sets per tower): -
(i) One no. Hot dip galvanized earthing Mild Steel Rod (2 Meter
long, 25 mm diameter):
(ii) Hot dip galvanized connecting clamps (`F’ type and Ù’ type- 2
No. per set);
(iii) Hot dip galvanized stranded steel wire of size 7/4mm, Grade 5 to
be used as connecting wire conforming to Indian Standard:
2141:1992 and Indian Standard 4826: 1979 or equivalent
International Standard (5 Meter per earthing set).
2.16.3 The details of earthing rod and clamps and earthing
arrangement for towers are shown in the drawing enclosed.

Volume-V Part-1
2.16.4 The earthing rod shall be of mild steel solid rod of 2 meters
in length and 25mm in diameter with one end pointed. The rods shall
be galvanized as per relevant Indian Standard or equivalent
International Standard. The zinc coating on the rod shall not be less
than 610 gm/m² of surface area.
2.16.5 The tower end-connecting clamp shall be of flat type and
rod end connecting clamp shall be of Ù’ type. The clamps shall be of
forged steel cast iron / malleable iron. The clamps should be hot dip
galvanized as per Indian Standard: 2629:1990 or equivalent
International Standard. The zinc coating on the clamps shall not be
less than 610 gm/m² of surface area.
2.16.6 The hot dip galvanized stranded steel wire of size
7/4.00mm shall be supplied for connection between the earthing rod
and the stub. The steel wire shall conform to Indian Standard 2141:
1992 or equivalent International Standard and Indian Standard:4826:
1979 and latest revision thereof or equivalent International Standard
and shall consist of seven strands, each strand having a diameter of 4
mm and Grade-5. The galvanizing shall be done as per Indian
Standard specification2141: 1992 or equivalent International
Standard and 4826: 1979 and latest revision thereof or equivalent
International Standard for heavy zinc coating. The coating of zinc shall
not be less than 260 gm/m².
2.17 ATTACHMENT FOR INSULATOR STRING & EARTH WIRE

/OPGW CLAMPS:
2.17.1 The towers shall be provided with suitable attachment for
supporting insulator strings and Earth wire /OPGW suspension and
tension assembly.
2.17.2 The towers shall be provided with the cleats to support the
hanger.
2.17.3 The Earth wire suspension assembly has got a ‘D’ shackle.
There shall be a suitable arrangement to support the same.
2.17.4 On angle towers, strain plates shall be provided for the
purpose of attaching the tension insulator string. For fixing Earth wire
tension assembly a hole 17.5mm dia shall be provided in the strain
plate.
2.18 FABRICATION WORKMANSHIP :

2.18.1 Except where hereinafter modified, details of fabrication
shall conform to Indian Standard-802 (Part-II)-1990 or equivalent

Volume-V Part-1
2.18.2 The fabrication of towers shall be done strictly in

accordance with the drawings supplied by the Employer.
2.18.3 The tower shall be of bolted construction.
2.18.4 Normally lap splice shall be used for connecting members
of un-equal size and the inside angles of lap splice shall be rounded at
the heel to fit the fillet of the outside angle. All splices shall develop full
stress in the members connected through bolts. Butt joint as well as lap
joint splices shall be made as above and as close to the main panel as
possible.
2.18.5 Joints shall be designed and detailed to avoid eccentricity as
far as possible. The use of gusset plates for joining tower members
shall be avoided as far as possible. However, where the connections are
such that the eliminations of the gusset plates would result in eccentric
joints, gusset plates and spacer plates may be used in conformity with
modern practice.
2.18.6 The tower structures shall be accurately fabricated to bolt
together easily at site without any undue strain on the bolts.
2.18.7 No angle member shall have two leg flanges brought
together by closing the angle.
2.18.8 The diameter of the hole shall be equal to the diameter of
the bolt plus 1.5 mm.
2.18.9 All similar parts shall be made strictly
interchangeable. All steel section before any work is done on them
shall be carefully leveled, straightened and made true to detailed
drawings by methods which will not damage the materials so that when
assembled the adjacent matching surfaces are in close contact
throughout. No rough edges shall be permitted in the entire structures.
Hammering is not permitted for straightening.
2.18.10 Cutting may be done by shearing, cropping, flame
cutting or sawing. The surface so cut shall be cleaned smooth,
reasonably square and free from deformation and distortion.
2.19 BENDING :
2.19.1 Mild steel angle sections up to 75x75 mm (up to 6mm
thick) shall bent cold up to and including bend angle of 10° Angles.
Above 75x75mm (thickness up to 6mm) and up to and including
100x100 mm (thickness up to 8 mm) may also be bent cold up to the
bend angle of 5 Deg. All other angle sections and bend angles not
covered above shall be bent hot.

Volume-V Part-1
2.19.2 All plates up to 12mm thickness shall be bent cold up to a

maximum bend angle of 15 Deg. Plates of thickness more than 12mm
with bends greater than 15 Degree shall be bent hot.
2.19.3 All hot bend material shall be air-cooled. The bends shall
be of even profile and free from any surface damages.
2.20 DRILLING AND PUNCHING :

2.20.1 The holes in the member shall either be drilled or punched
with a jig; the former process will be preferred.
2.20.2 Punching may be adopted for sections upto 12 mm
thickness. For thicker sections drilling shall be done.
2.20.3 The holes shall be punched/drilled after bending
and related position of these holes shall be maintained with the use
of proper templates/jigs and fixtures.
2.20.4 The holes shall be perfectly circular and no tolerance in this
respect is permissible. The holes shall be perpendicular to the plate and
angle flanges.
2.20.5 Holes must be square with the plates or angles and have
their walls parallel.
2.20.6 All burrs left by drills or punch shall be removed completely.
When the tower members are in positions, the holes shall be truly
opposite to each other. Drilling or ramming to enlarge defective holes
shall not be permitted.
2.20.7 The minimum spacing of bolt and edge distance shall be as
under: -
(a) For 16 mm dia bolt edge distance of 20 mm from hole

center to rolled or swaned edge and 23mm from hole center
to sheared or flame cut edge, hole center to hole center
distance minimum 40mm (the hole size being 17.5mm).
(b) The gap between the edges of the connected members in

butt joint shall not be more than 6mm and less than 4mm.
(c) The bolt gauge distance in flanges of angle

sections shall generally be in accordance with
Table XXXI of SF6 (1)-1961-ISI “Hand Book for structural
Engineers-Structural Steel Sections (Revised).”
2.21 TOLERANCES :
2.21.1 The maximum allowable difference in the diameter of the hole
on the two sides of the plate or angle shall not exceed 0.8 mm on

Volume-V Part-1
diameter. The allowable taper in drilled/punched hole shall not exceed

0.8 mm on diameter.
2.21.2 The tolerance cumulative or between consecutive holes
shall be within +/-0.5mm.
2.21.3 The tolerance on the overall length of member shall be
within +/- 1.6 mm.
2.21.4 The tolerance on gauge distance shall be within +/- 0.5mm.
2.21.5 Rolling and weight tolerance of steel sections shall be as per
Indian Standard: 1852 or equivalent International Standard and Indian
Standard: 808 or equivalent International Standard.
2.22 MARKING :
Every member shall be distinctly given punch mark similar to those
given in structural drawings. The mark shall be given with marking
dies of minimum 18 mm size and this mark shall be legible. Letter
XMPTBA, XMPTBB and XMPTBC for 220kV and XMPTEA, XMPTEB and
XMPTEC for 132kV shall precede erection mark where ‘X’ stands for
manufacturer’s name, ‘MPT’ stands for Madhya Pradesh Power
Transmission Company and BA, BB & BC stands for B0, B30 & B60 type
towers and EA, EB & EC stands for E0, E30 & E60 type towers
respectively. For other types of towers, similar marking scheme shall
be followed and shall be conveyed to successful bidder.
2.23 QUALITY ASSURANCE PROGRAM :

The contractor shall submit the Quality Assurance Programme as
specified in clause 1.12 Section-1 of the biding document. A copy of the
accepted Quality Assurance Plan must be available at the
manufacturer’s works of the Plant for reviewing by inspecting officer of
the employer.
2.24 INSPECTION OF PROTOTYPES :

2.24.1 Proto type of each type of structure/extensions shall be
offered by the successful bidder for inspection within three month’s
time from the date of contract.
2.24.2 Notwithstanding any thing covered in the drawings and
other details furnished by the Employer, the successful bidder shall
make minor modifications, if any, in length, size, notching etc.
according to the proto assembly which are necessary for easy assembly
of the structure.
2.25 INSPECTION :

Volume-V Part-1
2.25.1 As specified in clause 1.13 Section-1 of the biding

document, Plant to be supplied will be subject to inspection and
approval by the Employer's representative before despatch.
2.25.2 Each consignment ready for transportation shall be offered
to the Employer for inspection before dispatch giving a minimum time
of not less than fifteen days. Only complete sets of towers/extensions
shall be offered for inspection. All materials constituting towers (Steel
parts, Bolts & nuts, spring and pack washers, earthing sets) shall be
offered simultaneously. Samples of fabricated tower materials and
accessories shall be subjected to tests as per relevant Indian Standard
or equivalent International Standard. The Employer shall be kept
informed about the source of procurement of raw-steel, particularly
through re-rollers. The Employer reserves right to inspect and get the
samples of raw-steel tested as per Indian Standard-2062 and relevant
standards or equivalent International Standard. The cost of testing
shall be borne by the bidder.
2.25.3 The Contractor shall keep the Employer informed in
advance of the time of starting and of the progress of manufacture and
fabrication of structures at various stages.
2.25.4 In case, any member of the structure is not found to
comply with the relevant drawing, it shall be liable for rejection even
after receipt.
2.25.5 Defects, which may appear during fabrication, shall be
made good. Any member once rejected shall be cut into pieces in front
of the Employer’s representative so that it is not offered again by
mistake.
2.26 GENERAL GUIDE-LINE FOR INSPECTION :

2.26.1 Fabricated Structure Members :
(i) Visual examination and quantity verification of offered lot.
(ii) Sample selection from the offered lot at a ratio of 40 MT
(or part thereof) 1 no. each for all tests.
(iii) Dimension, fabrication and trueness verification of
structure member from fabrication sketch.
(iv) Galvanising test of each sample i.e. dip test, hammer test
and mass of zinc test.
(v) Random verification of Zinc coating of galvanized surface
by Alko-meter.
(vi) Tensile test and bend test of each sample.
(vii) Chemical composition test of at least two samples per
offered lot of 50 MT for inspection.

Volume-V Part-1
(viii) Verification of manufacturer’s test certificate for mild steel

used in structure members.
2.26.2 Bolts-Nuts, Washer, Accessories, Attachments etc.: (To be
carried out at manufacturers works of these items)
(ii) Sample selection from the offered lot as per relevant Indian
Standard for each item.
(iii) Dimension, fabrication and trueness verification from
fabrication sketch.
(iv) Galvanising test of each sample.
(v) Other acceptance tests for respective items as per relevant
Indian standard.
2.26.3 The supplier shall submit the factory test certificates of
bought out accessories at the time of acceptance tests of towers.
2.26.4 Since at the time of inspection only fabricated tower
members and accessories will be verified, acceptance of any lot shall in
no way relieve the bidder of his responsibility to meet all technical
requirements of this specification for fabricated towers. In case any
shortcoming is noticed at the time of actual assembly and erection, the
Employer may reject any part or item or accessory and the contractor
will have to assume the responsibility for free replacement/rectification
of such defects.
2.27 PACKING AND MARKING ON PACKING :

2.27.1 The material shall be boxed or bundled for transport in the
following manner:
(i) Angle shall be packed in bundles securely wrapped four times
around at each end and over 900 mm with No.9 SWG steel wire
with ends twisted tightly. Gross weight of any bundle shall not
be less than 450 Kg and more than 2000 Kg. The bundle shall
be in complete Tower form only.
(ii) Cleat angles, brackets, filler plates and similar small loose pieces
shall be nested and bolted together through holes and wrapped
around at least four times with No.9 SWG wire with ends twisted
tightly or packed in wooden crates. Gross weight of each bundle
shall not exceed 200 Kg.
(iii) Correct number of bolts, nuts and washers required for
structures shall be packed in heavy gunny bags accurately
tagged in accordance with the contents and a number of bags
packed in a solid box of 22mm thick lumber with paneled ends to
be accurately nailed and further reinforced with 22 mm x 75 mm

Volume-V Part-1
Batons round the sides and at the ends with 25 mm x No.18

SWG iron band stretched entirely around the batons with ends
overlapping at least 150mm. Gross weight of each box shall not
exceed 200 Kg.
(iv) Packing list incorporating all relevant details e.g. quantity of
structures (complete sets), number and size of steel sections,
quantity of nuts, bolts, washers etc. shall be forwarded along
with each consignment.
(v) In the nutshell the packing arrangement should be such that all
lots of one particular type of structure are identifiable at site for
the purpose of allocation for a particular work. In case more than
one structure of a particular type is delivered in area store/work
site, combined packing arrangement by way of clubbing
members of similar type (for more than one structure) in a
combined package should not be done. Uniform packing
procedure for each structure should be adopted.
2.27.2 All above packing are subject to the approval of the
Employer or his appointed representatives.
2.27.3 Each bundle or packing shall have the following marks:
(i) The name of the consignee (as per dispatch instructions given by
the Employer).
(ii) Ultimate destination as required by the Employer.
(iii) The relevant marks and number of structure members or
reference or bolts, nuts and small components like gusset plats,
various attachment, etc. for easy identification.
2.27.4 The marking shall be stenciled and indelibly inked on the
top members in the bundles, on wooden boxes and also on gunny bas
containing smaller components.

Volume-V Part-1
SECTION-3
TECHNICAL SPECIFICATIONS FOR CONDUCTOR
3.01 STANDARDS:
This section provides for standard design, manufacture, stage testing,

inspection and testing before despatch, packing and delivery of Steel
Cored Aluminium Conductors specified hereunder for their satisfactory
operation. The power conductors shall conform to the following Indian
Standards, which shall mean latest revisions, amendments/changes
adopted and published, unless otherwise specified hereinbefore:
Sr. Indian Standards Title

No. or any Equivalent
International
Standard
1 IS:209 -1990 Specification for Zinc

2 IS:398 Part I to Part Specification for Aluminium
V Conductors for overhead
(as relevant) Transmission purpose
3 IS:1778 Reels and drums for Bare wires
4 IS:1521 Method of Tensile Testing of Steel

wire
5 IS:2629 -1990 Recommended practice for Hot Dip
Galvanising Iron and Steel
6 IS:2633 -1990 Method of Testing Uniformity of
Zinc coating of Zinc coated
Articles.
7 IS:4826 Galvanised coating on Round Steel
wire
8 IS:6745 -1990 Method of Determination of weight
of Zinc coating of zinc coated Iron
and Steel Articles
9 IS:8263 Method of Radio Interference Tests
10 IS:1841 EC Grade Aluminium Rod produced
by rolling
11 IS:5484 EC grade Aluminium Rod produced
by continuous casting and rolling
12 IS: 2141 -1990 Method of Elongation test of steel
wire

Volume-V Part-1
3.02 PARAMETERS :
Sr. No. Details of Stranded ACSR ACSR

Conductor Zebra Panther
3.02.01 Principal Parameters of Stranded Conductor:
a) No. of Strands Aluminium- Aluminium-

54 30
Steel –7 Steel-7
i. Steel Centre 1 1
ii. 1st Steel Layer 6 6
iii. 1st Aluminium Layer 12 12
iv. 2nd Aluminium Layer 18 18
v. 3rd Aluminium Layer 24 -
b) Sectional Area of Aluminium 428.9 212.10
(Sq.mm)
c) Total Sectional Area (Sq.mm) 484.50 261.60
d) Overall diameter(mm) 28.62 21.00
e) Approximate weight (Kg/Km ) 1621 976
f) Calculated D.C. Resistance at 0.06915 0.139
20 Deg.C (Ohm/Km)
g) Minimum UTS (kN) 130.32 89.67
h) Modulus of Elasticity 69 80
GN/SqMtr
3.02.02 The details of Aluminium Strand are as follows :
a) Minimum breaking load of 1.29 1.17

strand Before stranding (kN)
b) Minimum breaking load of 1.23 1.11
strand after stranding (kN)
c) Maximum D.C. resistance of 3.651 4.107
strand at 20 deg.C (Ohm/Km)
d) Nominal Strand Dia 3.18 3.00
e) Max. Strand Dia 3.21 3.03
f) Min. Strand Dia 3.18 3.00

Volume-V Part-1
g) Mass (Kg/Km) of Strand at 21.47 19.11

Nominal dia
3.02.03 The details of Steel Strand are as follows:
a) Minimum breaking load of 10.43 9.29

strand Before stranding (kN)
b) Minimum breaking load of 9.91 8.83
strand after stranding (kN)
c) Nominal Strand Dia 3.18 3.00
d) Maximum Strand Dia 3.24 3.06
e) Minimum Strand Dia 3.18 3.00
f) Mass (Kg/Km) of Strand at 61.95 55.18
Nom. dia
g) Zinc coating testing 3 dips of 1 3 dips of 1
min. each min.each
h) Wt. Of Zinc Coating 260gms/sq. 260gms/sq.
metre Metre
3.03 GENERAL TECHNICAL REQUIREMENTS : MATERIAL AND

WORKMANSHIP (FOR ACSR ZEBRA & ACSR PANTHER):
3.03.01 Materials:
The conductors shall be manufactured from EC grade aluminium rods

suitably hard-drawn on wire drawing machines. The aluminium rods
used shall comply with IS: 1841 and IS: 5484 or any equivalent
International Standard. The mechanical and electrical properties of
aluminium wire shall comply with the requirements given in relevant
standard.
3.03.02 Physical constants for Hard-drawn Aluminium:
3.03.02.1 Resistivity:
The resistivity of aluminium depends upon its purity and its physical
condition. For the purpose of this specification the maximum value
permitted is 0.28264 Ohm sq.mm/mt. at 20° C and this value has been
used for calculation of the maximum permissible value of resistance.
NOTE: It is not intended to check the resistivity from the measured
values of resistance.
3.03.02.2 Density:

Volume-V Part-1
At a temperature of 20° C the density of hard drawn aluminium has

been taken as 2.703 g/cm.3
3.03.02.3 Constant-Mass Temperature Co-efficient of

Resistance:
At a temperature of 20°C, the constant-mass temperature co-efficient

of resistance of hard drawn aluminium measured between two potential
points rigidly fixed to the wire, the metal being allowed to expand
freely, has been taken as 0.004 per degree Celsius.
3.03.02.4 Co-efficient of Linear Expansion:
The co-efficient of linear expansion of hard-drawn aluminium at 0° C
has been taken as 23.0 x 10 -6 per ° C. This value holds good for all
practical purposes over the range of temperature from 0 ° C to highest
safe operating temperature.
3.03.03 Galvanised steel wire shall be drawn from high carbon steel
rods produced by either acidic or basic open hearth process, electric
furnace process or basic oxygen process. The mechanical and electrical
properties of wire shall comply with the requirements given in relevant
standard. The chemical composition of high carbon steel wires is given
below for guidance only.
Element Percentage Composition
Carbon 0.5 to 0.85
Maganese 0.50 to 1.10
Phosphorous Not more than 0.035
Sulphur Not more than 0.045
Silicon 0.10 to 0.35
3.03.03.1 Physical constants for Galvanised steel wires:
3.03.03.1.1 Density :
At a temperature of 20° C, the density of galvanized steel wire is to be
taken as 7.80 g/Cm3.
3.03.03.1.2 Coefficient of Linear Expansion :
In order to obtain uniformity in calculation a value of 11.5 x 10 -6 per °
C may be taken as the value for the co-efficient of Linear Expansion of
galvanized steel wires used for the cores of steel-reinforced aluminium
conductors.
3.03.03.1.3 The zinc used for galvanizing shall be electrolytic
high-grade Zinc not less than 99.95 percent purity. It shall conform to
and satisfy all the requirements of IS: 209. Galvanising may be done
either by hot process or electrolytic process. Minimum weight of Zinc
coating shall be 260 g/sq. metre. Neutral grease may be applied
between the layers of wire.

Volume-V Part-1
3.03.03.1.4 Freedom From Defects:

The wires shall be smooth and free from all imperfections such as spills,
slag inclusion, die marks, scratches, fittings, blow-holes, projections,
looseness, overlapping of strands, chipping of aluminium layers etc. and
all such other defects which may hamper the mechanical and electrical
properties of the conductor. Special care should be taken to keep away
dirt, grit etc. during stranding.
3.04 Wire Sizes
3.04.01 Nominal Size:
The aluminium and galvanized steel wires for the stranded conductor
covered by this standard shall have diameters specified in clause
3.02.02 & 3.02.03. The diameter of the steel wires shall be measured
over the zinc coating.
3.04.02 Tolerances on Nominal Size :
Tolerance of + 1% is permitted on the nominal diameter of
Aluminium Wires of Panther and Zebra Conductor and a tolerance of +
2 % is permitted on the nominal diameter of Galvanised Steel Core
Wire.
3.05 JOINTS IN WIRES:
3.05.01 Aluminium Wires:
No joints shall be permitted in the aluminium wires in the outermost
layer of the ACSR Conductor. Joints in the inner layers are permitted, in
addition to those made in the base rod or wire before final drawing, but
no two such joints shall be less than 15 mtr. apart in the complete
stranded conductor. Such joints shall be made only by cold pressure
butt-welding. It may please be noted that Joints are not permitted in
the outermost layer of the conductor in order to ensure a smooth
conductor finish and reduce radio interference levels and corona losses
on extra high voltage lines.
3.05.02 Galvanised Steel Wires:
There shall be no joints except those made in the base rods or wires
before final drawing, in steel wires forming the core of the steel-
reinforced aluminium conductor. Joints are not permitted in the steel
wires after final drawing also in order to avoid reduction in the breaking
strength of the conductor that may occur as a result of failure of the
joints.
3.06 STRANDING :

Volume-V Part-1
3.06.01 The wires used in the construction of galvanized steel

reinforced aluminium conductor, before stranding, shall satisfy all the
relevant requirements of this specification.
3.06.02 The lay ratio of the different layers shall be within the limits
given in the Table below:-
Type of Ratio of Lay Ratios Lay Ratios for Aluminium wires (3

conductor Alu. wire of Steel Alu. Wire Layer Conductors)
diameter core 6
to steel wire layer Layer
Outermost immediately Innermost
wire layer Layer
diameter beneath
outer most
layer
Min. Max. Min. Max. Min. Max. Min. Max.
Panther
1 13 28 10 14 10 16 - -
AL -30 Wire
ST. - 7 Wire
Zebra
1 13 28 10 14 10 16 10 17
AL -54 Wire
ST. - 7 Wire
NOTE : For the purpose of calculation, the mean lay ratio shall
be taken as the arithmetic mean of the relevant
minimum and maximum values given in this table.
3.06.03 In all constructions, the successive layers shall have opposite
directions of lay, the outermost layer being right-handed. The wires in
each layer shall be evenly and closely stranded.
3.06.04 In conductors having multiple layers of aluminium wires, the
lay ratio of any aluminium layer shall not be greater than the lay ratio
of the aluminium layer immediately beneath it.
3.06.05 The finished Conductor shall have a smooth surface without
any surface cut, abrasion, scuff marks and shall be free from dirt, grit,
etc. even if the damage to conductor is acceptable from mechanical
considerations. It will not be acceptable from electrical considerations,
and full care should be taken not to supply damaged conductor.
Projections of more than 2 mils shall not be acceptable. Any such
damage shall be properly rectified or new conductor supplied.
3.06.06 Failure of any sample to meet the above requirements shall be
sufficient cause for rejection of the lengths of conductor represented by
the sample. Particular care shall, therefore, be taken during
manufacture, handling, packing and transportation of the conductor, to
see that the surface is not dented, cut or damaged in any way.
3.07 STANDARD LENGTH :

Volume-V Part-1
3.07.01 The standard length of conductor shall be 1500 metres. A

tolerance of +/-5% on the standard length offered by the Contractor
shall be permitted. All lengths outside this limit of tolerance shall be
treated as random lengths.
3.07.02 Contractor shall also indicate the maximum single length,
above the standard length, they can manufacture. This is required for
special stretches like river crossing etc.
3.08 GALVANISING:
3.08.01 All the wires of Iron & steel strand shall be galvanized in
accordance with IS-2629-1990. ‘Recommended practice for hot dip
galvanizing of Iron and Steel’ or some other authoritative equivalent
standard.
3.09 TESTS :
3.09.01 The conductor offered shall be type tested as per the relevant
standards. Further the acceptance, routine tests and tests during
manufacture shall be carried out on the conductor.
3.09.02 Acceptance tests shall mean those tests, which are to be
carried out on samples taken from each lot offered for pre-despatch
inspection, for the purpose of acceptance of that lot.
3.09.03 Routine tests shall mean those tests which are to be carried
out on each strand/spool/length of the conductor to check requirements
which are likely to vary during production.
3.09.04 Tests during manufacture shall mean those tests, which are to
be carried out during the process of manufacture and end inspection by
the Contractor to ensure the desired quality of the end product to be
supplied by him.
3.09.05 The norms and procedure of sampling for these tests will be as
per the Quality Assurance Programme to be mutually agreed to by the
Contractor and the Employer.
3.09.06 The standards to which these tests will be carried out are listed
in para 3.01. Where a particular test is a specific requirement of this
specification, the norms and procedures of the test shall be as mutually
agreed to between the Contractor and the Employer in the Quality
Assurance Programme.
3.09.07 For all type and acceptance tests, the acceptance values shall
be the values guaranteed by the Contractor in the “Technical
Questionnaire” or the acceptance value specified in this specification,
whichever is more stringent for that particular test.
3.09.08 Type Tests :
The Conductor offered shall be fully type tested for the following tests
as per the relevant International/Indian Standard and the bidder shall
furnish the report along with the offer.

Volume-V Part-1
a) UTS test on stranded conductor

b) DC resistance test on stranded conductor
c) Stress-strain test on composite conductor
3.09.09 Acceptance Tests :
a) Visual and dimensional check
b) Visual check for joints, scratches etc. and lengths of
conductor
c) Dimensional check on steel and aluminium strands
d) Check for lay ratios of various layers
e) Galvanising test on steel strands
f) Torsion and Elongation test on steel wire
g) Breaking load test on steel and aluminium strands
h) Wrap test on steel and aluminium strands
i) DC resistance test on aluminium strands
j) UTS test on welded joint of aluminium strand
NOTE: All the above tests except test mentioned at (j) shall be carried
out on aluminium and steel strands after stranding only.
3.09.10 Routine Test :
a) Check to ensure that the joints are as per specification.
b) Check that there are no cuts, fins etc. on the strands.
c) Check that drums are as per specifications.
d) All acceptance tests as mentioned in Clause 3.09.09 above
shall be carried out on each coil.
3.09.11 Tests During Manufacture :
a) Chemical analysis of zinc used for galvanizing
b) Chemical analysis of aluminium for making aluminium
strands
c) Chemical analysis of steel used for making steel strands
3.09.12 Additional Tests:
The Employer reserves the right of having at his own expenses any
other test(s) of reasonable nature carried out at Contractor’s premises,
at site, or in any other place in addition to the aforesaid type,
acceptance and routine tests to satisfy himself that the material comply
with the specification.
3.09.13 Test Reports

Volume-V Part-1
(a) Record of routine test reports shall be maintained by the

Contractor at his works for periodic inspection by the
Employer’s representative.
(b) Test Certificates of test during manufacture shall be
maintained by the Contractor. These shall be produced for
verification as and when desired by the Employer.
3.09.14 Test Facilities
The following additional test facilities shall be available at Contractor’s
Works.
(a) Calibration of various testing and measuring equipment
including tensile testing machine, resistance measurement
facilities, burette, thermometer, barometer etc.
(b) Standard resistance for calibration of resistance bridges.
(c) Finished conductor shall be checked for length verification
and surface finish on separate rewinding machine at
reduced speed (variable from 8 to 16 metres per minute).
The rewinding facilities shall have appropriate clutch system
and free of vibrations, jerks etc. with transverse layering
facilities.
3.10 QUALITY ASSURANCE PROGRAM

the employer.
3.11 INSPECTION :
3.11.01 As specified in clause 1.13 Section-1 of the biding document,

Plant to be supplied will be subject to inspection and approval by the
Employer's representative before despatch.
3.11.02 At least 5% of the total number of drums subject to minimum

of two in any lot put up for inspection, shall be selected at random to
ascertain the length of conductor by following method:
“At the works of the manufacturer the conductor shall be

transferred from one drum to another at the same time measuring its
length with the help of graduated pulley and Cyclometer. The difference
in the average length thus obtained and as declared by the Contractor
in the packing list shall be applied to all the drums if the conductor is
found short during checking”

Volume-V Part-1
3.11.03 The supplier shall submit the factory test certificates of raw
materials & bought out accessories at the time of acceptance tests of
the Conductor.
3.12 PACKING AND FORWARDING :
3.12.01 The conductor shall be supplied in non-returnable strong

wooden drums provided with lagging of adequate strength, to protect
the conductor against all damage and displacement during transit,
storage and subsequent handling and stringing operations in the field.
The drums shall generally conform to IS: 1778 except otherwise
specified hereinafter.
3.12.02 The drums shall be suitable for wheel mounting and for jetting
off the conductor under a minimum controlled tension of the order of
5kN.
3.12.03 The standard drum drawings are enclosed. However,
Contractor should submit the proposed drum drawings along with the
bid. The same shall be in line with the requirements of standard
drawings and as stated herein. The Contractor shall submit four copies
of fully dimensioned drawing of the drum he wishes to supply, for
Employer’s approval, before taking up manufacturing of conductor.
3.12.04 All wooden components shall be manufactured out of seasoned
soft wood free from such defects that may materially weaken the
component part of the drums. Preservative treatment for anti-termite
/anti-fungus (Aldrine/Aldruse) shall be applied to the entire drum with
preservatives of a quality which is not chemically harmful to the
conductor.
3.12.05 The flanges shall be of two/three ply construction with each
ply at right angles to the other and nailed together. Further the outer
face of the flange shall be reinforced with the circumferential battens,
fixing in octagonal shape. The nails shall be driven from the inside face
of flange, punched and then clenched on the outer face. The tolerance
in thickness of each ply shall be +/- 3 mm only. There shall be at least
3 nails per plank of ply with maximum nail spacing of 75 mm. Where a
slot is cut in the flange to receive the inner end of the conductor, the
entrance shall be in line with the periphery of the barrel. Spindle hole
shall be provided at the centers of the planks of the plies and spindle
plates with 102 mm dia. Holes shall be fitted on either side of both the
flanges.
3.12.06 The wooden battens used for making the barrel of the
conductor shall be of segmental type. These shall be nailed to the
barrel supports with at least two nails. The battens shall be closely
butted and shall provide a round barrel with smooth external surface.
The edges of the battens shall be rounded or chamfered to avoid
damage to the conductor.

Volume-V Part-1
3.12.07 Barrel studs shall be used for construction of drums. The

flanges shall be holed and the barrel supports slotted to receive
them. The barrel studs shall be threaded over a length on either end,
sufficient to accommodate washers, spindle plates and nuts for fixing
flanges at the required spacing. Barrel studs should be tack welded with
the nuts after tightening.
3.12.08 Normally, the nuts on the studs shall stand protrude of the
flanges. All the nails used on the inner surface of the flanges and the
drum barrel shall be counter sunk. The ends of barrel shall generally be
flushed with the top of the nuts.
3.12.09 The inner cheek of the flanges and drum barrel surface shall
be painted with bitumen based paint.
3.12.10 Before reeling, cardboard or double corrugated or thick
bituminised waterproof bamboo paper shall be secured to the drum
barrel and inside of flanges or the drum by means of a suitable
commercial adhesive material. The paper should be dried before use.
Medium grade craft paper shall be used in between the layer of the
conductor/Earth wire /OPGW. After reeling the conductor the exposed
surface of the outer layer of conductor shall be wrapped with thin
polythene sheet across the flanges to preserve the conductor from dirt,
grit and damage during transportation and handling and also to prevent
ingress of rain water during storage/transport.
3.12.11 Minimum space of 125 mm shall be provided between the
inner surface of the external protective layer and outer layer of the
conductor.
3.12.12 Each batten shall be securely nailed across grains as far as
possible to the flange edges with at least 2 nails per end. The length of
the nails shall not be less than twice the thickness of the battens. The
nail shall not protrude above the general surface and shall not have
exposed sharp edges or allow the battens to be released due to
corrosion.
3.12.13 Outside the protective layer, there shall be minimum of two
binder consisting of hoop iron/galvanized steel wire. Each protective
layer shall have two recess to accommodate the binders.
3.12.14 The conductor ends shall be properly sealed and secured with
the help of U-nails on one side of the flanges. The end securing shall be
done by taking out at least 500 mm of steel core on either ends by U-
nails. The composite conductor shall be binded by use of galvanized
steel wire/aluminum wire at three locations at least 75 mm apart or
more covered with PVC adhesive tape so as to avoid loosening of
conductor layers in transit and handling.
3.12.15 Only one length of conductor shall be wound on each drum.
3.13 MARKING :

Volume-V Part-1
Each drum shall have the following information stenciled on it in

indelible ink along with other essential data:
i. Contract
ii. Name and address of consignee
iii. Manufacturer’s name and address
iv. Drum number
v. Size of conductor
vi. Length of conductor in metres
vii. Gross weight of drum with conductor
viii. Weight of empty drum with protective lagging
ix. Arrow marking for unwinding
3.14 END SEALING:
Both the ends of each length of conductor should be provided with non-
destructive type metal crimped or epoxy capped seals with punching
embossing/ engraving of manufacturer’s monogram and drum number.
***

Volume-V Part-1
SECTION- 4
TECHNICAL SPECIFICATIONS FOR
HIGH TENSILE GALVANISED STEEL EARTH WIRE
4.01 STANDARDS:
The High Tensile Galvanised Steel Earth Wire shall conform to the
following Indian Standards, which shall mean latest revisions,
amendments/changes adopted and published, unless otherwise
specified hereinbefore.
Indian Standards
S. Title
or any Equivalent
No.
International
Standard
1 IS:209 -1992 Specification for Zinc
2 IS:2141 -1992 Specification for Earth wire for
overhead Transmission purpose
4 IS:1521 Method of Tensile Testing of Steel
wire
5 IS:2629 -1992 Recommended practice for Hot Dip
6 IS:2633 -1992 Method of Testing Uniformity of
Zinc coating of Zinc coated Articles.
7 IS:4826 Galvanised coating on Round Steel
wire
8 IS:6745 -1992 Method of Determination of weight
of Zinc coating of zinc coated Iron
and Steel Articles
9 IS: 12776 Method of Testing of Earth wire
4.02 PARAMETERS:
4.02.01 PRINCIPAL PARAMETERS OF EARTH WIRE:
The standard technical particulars of 7/3.66mm galvanized steel

earth wire shall be as follows:-
a. The details of Steel strand:

Volume-V Part-1
i. Material Steel
ii. Stranding 7
iii. Weight per Km 583 Kgs
iv. Dia. of wire 3.66 mm
v Tolerance 2%
vi Minimum elongation in 100 mm 5 mm
length
vii Minimum breaking strength per 1000 Kg
strand
viii Minimum tensile strength 95 Kg./mm2
ix D.C. resistance at 20 Deg. C 17.15 Ohms/Km
b. The details of Stranded Earth Wire :

i. Maximum Length of Lay 198
ii. Minimum Length of Lay 165
iii. Minimum breaking load 6972 Kgs
iv. Overall diameter 10.98mm
v Modulus of elasticity 1.933 x 106
2
Kg./cm
vi Co-efficient of linear expansion 11.50 x 10- 6
per Deg.C
2
vii Weight of zinc coating on wire 260 gms./ m
(Min.)
viii No. of one minute dip and half 3 one minute
minute dip respectively and 1 half
minute
ix Calculated d.c. Resistance at 20 2.5 Ohms per
Deg.C Km
4.03 GENERAL TECHNICAL REQUIREMENT : MATERIAL AND

WORKMANSHIP FOR EARTH WIRE:
4.03.01 The steel wire (strands) used in manufacture of galvanized
steel earth wire shall be drawn from steel wire rod produced by either
acid or basic open hearth process or by the electric furnace process or
basic oxygen process. The steel wire shall not have sulphur and
phosphorous contents exceeding 0.045% each. The carbon content
shall not exceed 0.55%. The steel produced by bassemer process shall
not be used for drawing of steel wire strands. The finished earth wire

Volume-V Part-1
shall have minimum brittleness as it will be subjected to continuous

vibration while in use on line.
4.03.02 The steel wire shall be hot dip galvanized and shall have
zinc coating of minimum 260 gram per sq. meter of the uncoated wire
surface. The zinc coating shall be smooth and continuous of uniform
thickness, free from imperfections not consistent with good commercial
practice and shall meet the test requirement. The zinc used in
galvanizing of earth wire shall be as per IS: 209-1992.
4.03.03 All the steel wires shall be circular, smooth, uniform and
free from imperfections, such as spills and splits, die marks scratches,
abrasions, cuts and kinks etc. drawing and after stranding.
4.03.04 The steel wires, after galvanizing shall be bright in
appearance, smooth and free from all defects like flux, ash, cross
inclusions, bare and black spots, pimples, lumpiness in runs, rust,
stains, bulky white deposits and blisters.
4.03.05 To avoid susceptibility towards wet storage stains (white
rust) the stranded earth wire shall be provided with a protective coating
of boiled linseed oil.
4.03.06 The finished earth wire shall have a smooth surface without
any surface cuts, abrasions, scuff marks and shall be free from dirt, grit
etc.
4.03.07 Failure of any sample to meet the above requirements shall
be sufficient cause for rejection of the lot of earth wire represented by
the sample, particular care shall therefore be taken during
manufacture, handling, packing and transportation of the earth wire so
that it is not dented, cut or damaged in any way.
4.04 SIZE AND PROPERTIES:

4.04.01 The earth wire size, physical properties, tolerance in
diameter of individual strands and length of lay of the strand shall be as
given above.
4.04.02 The wires shall be so stranded together that when an
evenly distributed pulls is applied at the end of completed strands,
each wire will take an equal share of the pull.
4.04.03 The earth wire shall be supplied in the standard lengths
which shall not be less than 3 Km. Not less than 95% of the total
quantity of the earth wire shall be supplied in standard lengths. The
quantity of earth wire in length shorter than standard one shall not
exceeds 5% of the total quantity to be supplied. Further, no single
earth wire length in respect of such 5% (maximum) supply in random
lengths shall be shorter than 50% of the standard length.

Volume-V Part-1
4.04.04 The length of the stranded wire shall be supplied without

joints in the individual wires comprising it, excluding welds made in
base rod before it is drawn.
4.04.05 Each coil be warranted to contain no welds, joints or splice
other than in the base rod before it is drawn.
4.05 GALVANISING AND OILING:

4.05.01 All the wires of the strand shall be galvanized in accordance
with IS-2629-1990. Recommended practice for Hot dip galvanizing of
Iron and Steel of some other authoritative equivalent standard.
4.05.02 The galvanized earth wire after stranding operation shall
have dipped in boiled linseed oil before winding it on drums.
4.06 TEST FOR EARTH WIRE :
4.06.01 Earth wire shall be subjected, before despatch from the
works to tests as specified in the IS-2141, IS 1521, IS 1755 & IS
4826 or any other authoritative equivalent standard.
4.06.02 All the drums of galvanized steel stranded earth wire of the
same grade, diameter and construction, manufactured under similar
condition shall be grouped to constitute one lot.
4.06.03 Samples from each lot shall be tested for ascertaining the
conformity to the requirements of the earth wire specified herein. The
drums selected shall be tested for length of the lay and diameter of
individual strands etc. The lot shall be declared conforming to the
requirement of these characteristics if all the samples are found
satisfactory. One test specimen from each wire of the strand shall now
be drawn from every selected drum and subjected to chemical analysis,
tensile tests, ductility test, elongation test and coating test. One test
specimen, of the completed strand from each drum shall be subjected
to tensile strength. The lot shall be declared conforming to the
requirements of these characteristics, if the entire test specimen
satisfies the relevant requirement.
the employer.
4.08 INSPECTION :

Volume-V Part-1

4.08.02 At least 5% of the total number of drums subject to
minimum of two in any lot put up for inspection, shall be selected at
random to ascertain the length of earth wire by following method:
“At the works of the manufacturer of the earth wire, the earth
wire shall be transferred from one drum to another at the same
time measuring its length with the help of graduated pulley and
Cyclometer. The difference in the average length thus obtained
and as declared by the Contractor in the packing list shall be
applied to all the drums if the conductor/earth wire is found
short during checking.”
the earth wire.
4.09 PACKING AND FORWARDING:
4.09.01 The earth wire shall be supplied in strong wooden drums
provided with lagging of adequate strength, to protect the
conductor/earth wire against all damage and displacement during
transit, storage and subsequent handling and stringing operations in
the field. The drums shall generally conform to IS: 1778 except
otherwise specified hereinafter.
4.09.02 The drums shall be suitable for wheel mounting and for
jetting off the conductor/earth wire under a minimum controlled
tension of the order of 5kN.
4.09.03 The standard drum drawings are enclosed. However,
Contractor should submit the proposed drum drawings along with the
bid. The same shall be in line with the requirements of standard
drawings and as stated herein. The Contractor shall submit four copies
Employer’s approval, before taking up manufacturing of earth wire.
4.09.04 All wooden components shall be manufactured out of
seasoned soft wood free from such defects that may materially
weaken the component part of the drums. Preservative treatment for
anti-termite /anti-fungus (Aldrine/Aldruse) shall be applied to the entire
drum with preservatives of a quality which is not harmful to the earth
wire.
4.09.05 The flanges shall be of two/three ply construction with each
ply at right angles to the other and nailed together. Further the outer
face of the flange shall be reinforced with the circumferential battens,
fixing in octagonal shape. The nails shall be driven from the inside face
of flange, punched and then clenched on the outer face. The tolerance

Volume-V Part-1
in thickness of each ply shall be +/- 3 mm only. There shall be at least

3 nails per plank of ply with maximum nail spacing of 75 mm. Where a
slot is cut in the flange to receive the inner end of the conductor/earth
wire, the entrance shall be in line with the periphery of the barrel.
Spindle hole shall be provided at the centers of the planks of the plies
and spindle plates with 102 mm dia. Holes shall be fitted on either side
of both the flanges.
4.09.06 The wooden battens used for making the barrel of the earth
wire shall be of segmental type. These shall be nailed to the barrel
supports with at least two nails. The battens shall be closely butted and
shall provide a round barrel with smooth external surface. The edges of
the battens shall be rounded or chamfered to avoid damage to the
earth wire.
4.09.07 Barrel studs shall be used for construction of drums. The
flanges shall be holed and the barrel supports slotted to receive
them. The barrel studs shall be threaded over a length on either end,
sufficient to accommodate washers, spindle plates and nuts for fixing
flanges at the required spacing. Barrel studs should be tack welded with
the nuts after tightening.
4.09.08 Normally, the nuts on the studs shall stand protrude of the
flanges. All the nails used on the inner surface of the flanges and the
drum barrel shall be counter sunk. The ends of barrel shall generally be
flushed with the top of the nuts.
4.09.09 The inner cheek of the flanges and drum barrel surface shall
be painted with bitumen-based paint.
4.09.10 Before reeling, cardboard or double corrugated or thick
bituminised waterproof bamboo paper shall be secured to the drum
barrel and inside of flanges or the drum by means of a suitable
commercial adhesive material. The paper should be dried before use.
Medium grade craft paper shall be used in between the layer of the
conductor/earth wire. After reeling the earth wire the exposed surface
of the outer layer of earth wire shall be wrapped with thin polythene
sheet across the flanges to preserve the conductor/earth wire from dirt,
grit and damage during transportation and handling and also to prevent
ingress of rain water during storage/transport.
4.09.11 Minimum space of 125 mm shall be provided between the
inner surface of the external protective layer and outer layer of the
earth wire.
4.09.12 Each batten shall be securely nailed across grains as far as
possible to the flange edges with at least 2 nails per end. The length of
the nails shall not be less than twice the thickness of the battens. The
nail shall not protrude above the general surface and shall not have
exposed sharp edges or allow the battens to be released due to
corrosion.

Volume-V Part-1
4.09.13 Outside the protective layer, there shall be minimum of two

binders consisting of hoop iron/galvanized steel wire. Each protective
layer shall have two recesses to accommodate the binders.
4.09.14 The earth wire ends shall be properly sealed and secured
with the help of U-nails on one side of the flanges. The end securing
shall be done by taking out at least 500 mm of steel wire on either end
by U-nails. The earth wire shall be binded by use of galvanized steel
wire/aluminum wire at three locations at least 75 mm apart or more
covered with PVC adhesive tape so as to avoid loosening of earth wire
layers in transit and handling.
4.09.15 Only one length of earth wire shall be wound on each drum.
4.10 MARKING :
Each drum shall have the following information stenciled on it
in indelible ink along with other essential data:
(i) Order Number and date.
(ii) Name and address of consignee
(iii) Manufacturer’s name and address
(iv) Drum number
(v) Size of earth wire (7/3.66mm)
(vi) Length of earth wire in meters
(vii) Gross weight of drum with earth wire
(viii) Weight of empty drum with protective lagging
(ix) Arrow marking for unwinding
4.11 END SEALING :
Both the ends of each length of earth wire should be provided with
non-destructive type metal crimped or epoxy capped seals with
punching embossing/ engraving of manufacturer’s monogram and drum
number.
***

Volume-V Part-1
SECTION- 5
Part A
TECHNICAL SPECIFICATION FOR DISC INSULATORS
5.01 STANDARDS
This section provides for the design, manufacture, stage testing and
inspection and testing before dispatch packing and delivery of disc
insulators as per technical requirements furnished in this section.
Unless otherwise specified elsewhere in this specification, the rating as
well as performance & testing of the disc insulators shall conform but
not limited to the latest revision & amendments available at the time of
placement of order of all the relevant standards as listed hereunder,
except as modified in this document.
S. Indian Title
No Standard
1 IS:209-1992 Specification for Zinc
2 IS:206-1991 Method for Chemical Analysis of Slab
Zinc
3 IS:731-1991 Porcelain insulators for overhead power
lines with a nominal voltage greater
th 1000V
4 IS:2071 Method of High Voltage Testing
Part(I)-1993
Part(II)-1991
5 IS:2121 Specification of Conductors and Earth
wire Accessories for Overhead Power
Part(I) Lines.
Armour Rods, Binding Wires & Tapes for
Conductors
6 IS:2486 Specification for insulator fittings for
overhead power lines with a nominal
voltage greater than 1000V
Part I-1993 General Requirements & Tests
Part II-1989
Dimensional Requirements
Part III -
Locking Devices
1991
7 IS:2629-1990 Recommended practice for Hot Dip
Galvanization for iron & steel
8 IS:2633-1992 Testing for Uniformity of Coating of Zinc
coated articles

Volume-V Part-1
9 IS:3188-1988 Dimensions for Disc Insulators

10 IS:6745-1990 Determination of Weight of Zinc coating
on Zinc coated iron and steel articles
11 IS : 8263-1990 Methods of RIV Test of HV Insulators
12 IS:8269-1990 Methods for Switching impulse test on
HV insulators
5.02 PRINCIPAL PARAMETERS
5.02.01 DETAILS OF DISC INSULATORS
i) The insulator strings shall consist of standard discs for a three

phase 50 Hz, effectively earthed 220KV/132KV transmission
system in a moderately polluted atmosphere. The discs shall be
cap and pin, ball and socket type.
ii) The specified values and disc dimensions, impulse and

power frequency voltages, electromechanical strength [EMS] of
individual insulator units are as under. The values given are
minimum which apply to all cases. Specified withstand and
flashover voltages are referred to standard atmospheric
condition.
5.02.02 CHARACTERISTICS OF DISC INSULATORS
The disc insulators should have the following particulars and

characteristics:
S.No Particulars Disc Insulators

70KN 90kN 160kN
EMS EMS EMS
i Diameter of the disc (mm) 255 255 280
ii Spacing of the disc (mm) 145 145 170
iii Size and designation of pin- 16 mm 16 mm 20 mm
ball shank
iv Creepage distance (mm) 320 320 330
(minimum)
v Power frequency one 70 75 75
minute dry withstand
voltage kV (rms)
vi Power frequency one 40 45 45
minute wet withstand
voltage kV (rms)
vii Power frequency puncture 120 125 125
withstand voltage kV (rms)
viii Minimum dry impulse 110 110 120

Volume-V Part-1
withstand voltage 1.2x50

micro second wave, positive
and negative Kv Peak)
ix Maximum Radio 50 50 50
interference
voltage with 10 kV RMS to
ground. (microvolts)
x Minimum corona extinction 9 9 18
voltage kV(rms)
5.03 SPECIFICATION DRAWINGS

The specification drawing in respect of the disc insulators indicated
above is attached with this specification. The specification drawing is
attached herewith for information and guidance of the Contractor only.
The drawings to be furnished by the Contractor shall be as per his own
design and manufacture and shall be distinct and separate from these
specification drawings.
The drawing shall include but not limited to the following
information:-
a) Shell diameter and ball to ball spacing with manufacturing
tolerances.
b) Minimum creepage distance with positive tolerance.
c) Protected creepage distance
d) Eccentricity of the disc
i) Axial run out
ii) Radial run out
e) Unit mechanical and electrical characteristics
f) Size and weight of ball & socket parts
g) Weight of unit insulator disc
h) Materials
i) Identification mark
j) Manufacturer’s catalogue number.
After placement of order, the Contractor shall submit full

dimensioned manufacturing drawing of insulator cap, pin &
insulator shell in six copies to the Employer for reference &
record.
5.04 GENERAL TECHNICAL REQUIREMENTS
5.04.01 Porcelain
The porcelain used in the manufacture of the shells shall be ivory white,
nonporous of high dielectric, mechanical and thermal strength, free
from internal stresses, blisters, laminations, voids, foreign matter,

Volume-V Part-1
imperfections or other defects which might render it in any way

unsuitable for insulator shells. Porcelain shall remain unaffected by
climatic conditions, ozone, acid, alkalizes, zinc or dust. The
manufacturing shall be by the wet process and impervious character
obtained by thorough verification.
5.04.02 Porcelain Glaze
Surfaces to come in contact with cement shall be made rough by sand
glazing. All other exposed surfaces shall be glazed with ceramic
materials having the same temperature coefficient of expansion as that
of the insulator shell. The thickness of the glaze shall be uniform
throughout and the colour of the glaze shall be brown. The glaze shall
have a visible luster, smooth on surface and be subject to satisfactory
performance under extreme tropical climatic weather conditions and
prevent ageing of the porcelain. The glaze shall remain under
compression on the porcelain body throughout the working temperature
range.
5.04.03 METAL PARTS
5.04.03.1 Cap and Ball Pins

Ball pins shall be made with drop forged steel and caps with malleable
cast iron. They shall be in one single piece and duly hot dip galvanized.
They shall not contain parts or pieces joined together, welded, shrink
fitted or by any other process from more than one piece of material.
The pins shall be of high tensile steel, drop forged and heat-treated.
The caps shall be cast with good quality black hearth malleable cast
iron and annealed. Galvanising shall be by the hot dip process with a
heavy coating of zinc of very high purity. The Contractor shall specify
the grade, composition and mechanical properties of steel used for caps
and pins.
5.04.03.2 Security Clips
The security clips shall be made of phosphor bronze or of stainless
steel.2.5% extra security clip shall be provided.
5.05 FILLER MATERIAL

Cement to be used as a filler material shall be quick setting, fast curing
Portland cement. It shall not cause fracture by expansion or loosening
by contraction. Cement shall not react chemically with metal parts in
contact with it and its thickness shall be as small and as uniform as
possible.
The insulator design shall be such that the insulating medium shall not
directly engage with hard metal. The surfaces of porcelain and hard
metal should be coated with resilient paint to offset the effect of
difference in thermal expansions of these materials.

Volume-V Part-1
5.06 MATERIAL DESIGN AND WORKMANSHIP
5.06.01 GENERAL
(i) All raw materials to be used in the manufacture of these

insulators shall be subject to strict raw material quality
control and to stage testing/quality control during
manufacturing stage to ensure the quality of the final end
product. Manufacturing shall conform to the best engineering
practices adopted in the field of extra high voltage
transmission. Bidders shall therefore offer insulators as are
guaranteed by them for satisfactory performance on
220KV/132KV Transmission lines.
(ii) The design, manufacturing, process and material control at

various stages be such as to give maximum working load,
highest mobility, best resistance to corrosion, good finish,
elimination of sharp edges and corners to limit corona and
radio interference voltages.
5.06.02 INSULATOR SHELL

The design of the insulator shells shall be such that stresses due to
expansion and contraction in any part of the insulator shall not lead to
deterioration. Shells with cracks shall be eliminated by temperature
cycle test followed by mallet test. Shells shall be dried under controlled
conditions of humidity and temperature.
5.06.03 METAL PARTS
(i) The pin and cap shall be designed such that it will not
transmit the mechanical stresses to the shell by
compression and develop uniform mechanical strength in
the insulator. The cap shall be circular with the inner and
outer surfaces concentric and of such design that it will not
yield or distort under loaded conditions. The head portion of
the pin ball shall be suitably designed so that when the
insulator is under tension the stresses are uniformly
distributed over the pinhole portion of the shell. The pin ball
shall move freely in the cap socket either during assembly
of a string or during erection of a string or when a string is
placed in position.
(ii) Metal caps shall be free from cracks, seams, shrinks, air
holes, blow holes and rough edges. All metal surfaces shall
be perfectly smooth with no projecting parts or

Volume-V Part-1
irregularities, which may cause corona. All load bearing

surfaces shall be smooth and uniform so as to distribute the
loading stresses uniformly. Pins shall not show any
microscopically visible cracks, inclusions and voids.
5.06.04 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the
latest edition of IS: 2629. The zinc to be used for galvanizing shall
conform to grade Zn 99.95 as per IS: 209. The Zinc coating shall be
uniform, smoothly adherent, reasonably bright, continuous and free
from impurities such as flux, ash, rust stains, bulky white deposits and
blisters. Before ball fittings are galvanized, all die flashing on the shank
and on the bearing surface of the ball shall be carefully removed
without reducing the designed dimensional requirements.
5.06.05 SECURITY CLIPS (LOCKING DEVICES)
The security clips to be used as a locking device for ball and socket
coupling shall be ‘R’ shaped hump type to provide for positive locking of
the coupling as per IS:2486 (Part IV). The legs of the security clips
shall allow for spreading after installation to prevent complete
withdrawal from the socket. The locking device shall be resilient,
corrosion resistant and of sufficient mechanical strength. There shall be
no possibility of the locking device to be displaced or be capable of
rotation when placed in position and under no circumstances shall it
allow separation of insulator units and fittings. ‘W’ type security clips
are also acceptable. The hole for the security clip could be countersunk
and the clip shall be of such design that the eye of the clip may be
engaged by a hot line clip puller to provide for disengagement under
energized conditions. The force required for pulling the clip into its
unlocked position shall not be less than 50 N (5 kgs) or more than, 500
N (50 kgs).
5.06.06 BALL AND SOCKET DESIGNATION
The dimensions of the balls and sockets for 70 KN & 90 KN discs shall
be of 16 mm and for 160KN discs shall be of 20 mm designation in
accordance with the standard dimensions stated in IS:2486 (Part II).
5.07 DIMENSIONAL TOLERANCE OF DISC INSULATOR

It shall be ensured that the dimensions of the disc insulators are within
the limits specified below:
a. Diameter of Disc (mm)
Rating Standard Maximum Minimum

160 KN Disc 280 293 267
90 KN Disc 255 266 244

Volume-V Part-1

70 KN Disc 255 266 244
b. Ball to Ball Spacing between Discs (mm)
Rating Standard Maximum Maximum
160 KN Disc 170 175 165

90 KN Disc 145 149 141
70 KN Disc 145 149 141
5.08 INTERCHANGEABILITY
The insulators inclusive of the ball and socket fittings shall be of
standard design suitable for use with hardware fittings of any make
conforming to relevant Indian Standards.
5.09 SUITABILITY FOR LIVE LINE MAINTENANCE
The insulators shall be compatible for use with hot line or live line
maintenance techniques so that usual hot line operations can be carried
out with ease, speed and safety.
Contractors shall indicate the methods generally adopted in routine hot

and cold line maintenance of EHV lines for similar insulators supplied by
them. Contractors shall also indicate the recommended periodicity of
such maintenance.
5.10 FREEDOM FROM DEFECTS
Insulators shall have none of the following defects:

i) Ball pin shake
ii) Cementing defects near the pin like small blow holes, small
hair cracks, lumps, etc.
iii) Sand fall ferro particle defects on the surface of the
insulator.
iv) Shell eccentricity
5.11 INSULATOR STRINGS:
5.11.01 TYPE AND RATING

The insulator strings shall be formed with standard discs described in
this specification for use on 3 phase, 220kV/132kV, 50Hz effectively
earthed systems in a moderately polluted atmosphere. Suspension

Volume-V Part-1
insulator strings for use with suspension towers are to be fitted with
discs of 70 kN EMS rating while tension insulator strings for use with
Anchor/Tension towers are to be fitted with discs of 90 kN & 160 kN
EMS rating.
The Bidder may also use Long Rod Porcelain Insulators String or
Long Rod Polymer Insulators in place of Disc Insulator Strings.
The Long Rod Porcelain Insulators or Long Rod Polymer
Insulators shall have technical specification equivalent to or
better than the technical specification of Disc Insulator Strings.
It may please be noted that in a particular work, the bidder will
have to use any one type of Insulators and combination of two
different types of Insulators in one particular work will not be
allowed.
5.11.02 STRING SIZE
The size of the disc insulator, the number to be used in different types
of strings and their electro-mechanical strength shall be as follows:
S. Size of No. of Electro

Type of String
No disc standard mechanical
. insulator discs strength of
(mm) insulator
string (kN)
a) Single Suspension for 220/132KV 255x145 13/9 70
b) Double Suspension for 255x145 2x13/2x9 2x70

220KV/132KV
c) Single Tension for 220KV 280x170 14 160
d) Double Tension for 220KV 280x170 2x14 2x160
e) Single Tension for 132KV 255x145 10 90
f) Double Tension for 132KV 255x145 2x10 2x90
5.11.03 STRING CHARACTERISTICS :
5.11.03.1 The characteristics of the complete string shall be as

follows :
S. Characteristics Single/Double Single/Double

NO. Suspension Suspension
220kV 132kV 220kV 132kV
1 No. of Standard Discs 1x13 1x9 1x14 1x10

2x13 2x9 2x14 2x10
2 Nominal diameter of discs 255 255 280 255
3 Power frequency 460 280 490 300

Volume-V Part-1

220kV 132kV 220kV 132kV
Withstand voltage (wet)
kV (rms)
4 Lighting impulse withstand 1200 800 1200 800
voltage (dry)(kVp)
5 Switching surge Withstand 900 350 900 350
voltage (Dry & wet) (kVp)
6 Mechanical failing Load 7000/ 7000/ 16500/ 9000/
(kgf) 14000 14000 33000 18000
7 Pollution Moderately polluted Moderately polluted

8 No deformation load (kgf) 4690/ 4690/ 11055/ 6030/
9380 9380 22110 12060
9 Corona Extinction voltage 176 - 176 -
(KV rms)
5.11.03.2 Insulator units after assembly shall be concentric and

coaxial within limits as permitted by Indian standards.
5.11.03.3 The string design shall be such that when units are
coupled together there shall be contact between the shell
of one unit and metal of the next adjacent unit.
5.12 TESTS :
5.12.01 The Disc insulators offered should be fully type tested as per
the relevant standards. The following tests shall be carried out on the
insulator string and also on unit disc insulators.
5.12.02 Acceptance Tests shall mean those tests which are to be
inspection for the purpose of acceptance of the lot.
5.12.03 Routine Tests shall mean those tests, which are to be carried
out on each insulator to check the requirements which are likely to vary
during production.
5.12.04 Stage tests during manufacture shall mean those tests which
are to be carried out during the process of manufacture to ensure
quality control such that the end product is of the designed quality
conforming to the intent of this specification.
5.12.05 The norms and procedure of sampling for the above tests
shall be as per the relevant Indian Standard or other internationally
accepted standards.
5.12.06 The standards according to which these tests are to be
carried out are listed against each test. Where a particular test is a

Volume-V Part-1
specific requirement of this specification, the norms and procedure for

the same shall be as specified in Appendix-I attached hereto or as
mutually agreed to between the Contractor and the Employer in the
Quality Assurance Programme.
5.12.07 For all type and acceptance tests, the acceptance values
shall be the value guaranteed by the Contractor in the “Technical
Questionnaire” or the acceptance value specified in this specification or
the relevant standard whichever is more stringent for that particular
test.
5.13 DETAILS OF TYPE TESTS :
5.13.01 The Disc insulators offered shall be fully type tested for the
following tests as per relevant International/Indian Standard and the
bidder shall furnish type test reports along with the offer.
a) Visible discharge test IS:731

b) Impulse voltage withstand test IS:731
c) Wet power frequency voltage IS:731
withstand test
d) Verification of dimension test IS:731
e) Temperature cycle test IS:731
f) Electro-Mechanical failing load test IS:731
g) Puncture test IS:731
h) Porosity test IS:731
i) Galvanising test IS:731
j) 24 hours mechanical failing load test IS:731
k) Metallurgical test IS:2108 &
IS:2004
5.14 DETAILS OF ACCEPTANCE AND ROUTINE TESTS :
5.14.01 All Acceptance and Routine tests as stipulated herein shall

be carried out by the Contractor in the presence of Employer’s
representative. Immediately after finalisation of the programme of
acceptance/routine testing, the Contractor shall give sufficient advance
intimation to the Employer, to enable him to depute his representative
for witnessing the test.
5.14.02 For String Insulator Units following Acceptance & Routine
tests shall be conducted:
(A) Acceptance tests:
a) Verification of dimensions IS:731

Volume-V Part-1
b) Temperature cycle test IS:731

c) Galvanising test IS:731
d) Mechanical performance test IEC:575
e) Test on locking device for ball and socket IEC:372/IS-
coupling 2486(part-IV)
f) Eccentricity test As per
Specification
g) Electro-mechanical strength test
h) Puncture test IS-731
i) Porosity test
(B) Routine tests:
a) Visual Inspection IS-731

b) Mechanical routine test
c) Electrical routine test IEC:383
5.15 Tests during Manufacture (STAGE TESTS)
On all components as applicable
a) Chemical analysis of Zinc used for

galvanizing
b) Chemical analysis, mechanical and
metallographic test and magnetic particle
inspection for malleable castings
As per this
c) Chemical analysis, hardness test and Specification
magnetic particle inspection for forgings
d) Crack detection test for metal parts
5.16 ADDITIONAL TESTS :

The Employer reserves the right for carrying out any other tests of a
reasonable nature at the works of the Contractor/laboratory or at any
other recognized laboratory / research institute in addition to the above
mentioned type, acceptance and routine tests at the cost of the
Employer to satisfy that the material complies with the intent of this
specification.
5.17 COORDINATION FOR TESTING:
For 220KV/132KV insulator strings, the Contractor is required to

produce type test reports to the satisfaction of the Employer. However,
in case the Employer desires, the Contractor shall conduct all the type
tests on the complete string with relevant hardware fittings.

Volume-V Part-1
Responsibility of arranging required hardwares for the purpose of type

testing will remain with the Contractor.

the employer.
5.19 INSPECTION :
5.19.01 As specified in clause 1.13 Section-1 of the biding document,

Plant to be supplied will be subject to inspection and approval by the
Employer's representative before despatch.
5.19.02 The acceptance of any quantity of insulators shall in no way
relieve the successful Contractor of his responsibility for meeting all the
requirement of this specification and shall not prevent subsequent
rejection, if such disc insulators are later found to be defective.
5.19.03 The Contractor shall submit the routine test certificates of
bought out items and raw material at the time of routine testing of the
insulator.
5.20 IDENTIFICATION MARKING :
i) Each disc insulator shall be legibly and indelibly marked

with the trade mark of the manufacturer, the month and
year of manufacture, the guaranteed combined mechanical
and electrical strength in kilo-newtons abbreviated by ‘KN’
to facilitate easy identification and proper use.
ii) The marking shall be on porcelain shell of insulators. The

marking shall be printed and not impressed/embossed and
same shall be applied before firing.
iii) One 10mm thick ring of good quality paint shall be marked
on the cap of each insulator of particular strength for easy
identification of the type of insulator. The paint shall not
have any deteriorating effect on the insulator performance.
Following codes shall be used as identification mark:-
For 70kN disc insulator – Green
For 90kN disc insulator – Blue
For 160kN disc insulator – Red
5.21 DOCUMENTATION

Volume-V Part-1
The Contractor shall furnish full description and illustrated

catalogues of insulators offered, alongwith the bid. The supplier
shall also furnish alongwith the bid the outline drawing of each
insulator unit including cross-sectional view of the shell. The
drawing shall include the following information :
i) Shell diameter and unit spacing with manufacturing

tolerance.
ii) Creepage distance.
iii) Unit mechanical and electrical characteristics as also for the
complete string-suspension and tension.
iv) Size and weight of ball and socket part.
v) Weight of unit insulator disc.
vi) Materials for the disc, cap and pin.
vii) Identification mark.
viii) Manufacturer’s catalogue number.
ix) Brief installation instructions.
x) Relevant technical details of significance.
5.22 PACKING & FORWARDING :
i) All disc insulators shall be packed in strong seasoned

wooden crates. The gross weight of the crates alongwith
disc insulators shall not normally exceed 100 kg. to avoid
handling problem.
ii) The packing shall be of sufficient strength to withstand
rough handling during transit, storage at site and
subsequent handling in the field.
iii) Suitable cushioning, protective padding, or dunnage or
spacers shall be provided to prevent damage or
deformation during transit and handling.
iv) All packing cases shall be marked legibly and correctly so as
to ensure safe arrival at their destination and avoid the
possibility of goods being lost or wrongly dispatched on
account of faulty packing and faulty or illegible markings.
Each wooden case/crate shall have all the markings
stenciled on it in indelible ink.

Volume-V Part-1
Appendix-I
TEST DETAILS
1. Voltage Distribution Test:

The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted into percentage and
proportionate correction be applied so as to give a total of 100%
distribution. The voltage across any disc shall not exceed 9% for
suspension insulator strings and for double tension insulator strings.
The total of the voltage distribution of all discs so computed shall be
within 95% and 105%. If not, the test shall be repeated. The
proportions correction shall be made on the values so as to give a total
of 100% distribution.
2. Mechanical Strength Test:
The complete insulator string alongwith its hardware fittings excluding
arcing horn, corona control ring/grading ring and suspension
assembly/dead end assembly shall be subjected to a load equal to 50%
of the specified minimum ultimate tensile strength (UTS) which shall be
increased at steady rate to 67% of the minimum UTS specified. The
load shall be held for five minutes and then removed. After removal of
the load, the string components shall not show any visual deformation
and it shall be possible to disassemble them by hand. Hand tools may
be used to remove cotter pins and loosen the nuts initially. The string
shall then be reassembled and loaded to 50% of UTS and the load shall
be further increased at a steady rate till the specified minimum UTS and
held for one minute. No fracture should occur during this period. The
applied load shall then be increased until the failing load is reached and
the value recorded.
3. Vibration Test:
The suspension string shall be tested in suspension mode, and tension
string in tension mode itself in laboratory span of minimum 30 metres.
In the case of suspension string a load equal to 600 kg shall be applied
along the axis of the suspension string by means of turn buckle. The
insulator string alongwith hardware fittings and two sub-conductors
(each tensioned at 4500 kg) shall be secured with clamps. The system
shall be suitable to maintain constant tension on each sub-conductors
throughout the duration of test. Vibration Dampers shall not be used on
the test span. Both the sub-conductors shall be vertically vibrated
simultaneously at one of the resonance frequencies of the insulator
string (more than 10 Hz) by means of vibration inducing equipment.
The amplitude of vibration at the antinode point nearest to the string
shall be measured and the same shall not be less than + 120/f , f
being the frequency of vibration. The insulator string shall be vibrated
for five million cycles then rotated by 90 deg. and again vibrated for 5

Volume-V Part-1
million cycles without any failure. After the test, the disc insulators
shall be examined for looseness of pins and cap or any crack in the
cement. The hardware fittings shall be examined for fatigue failure and
mechanical strength test. There shall be no deterioration of properties
of hardware components and disc insulators after the vibration test.
The disc insulators shall be subjected to the following tests as per
relevant standards:
S. Test Percentage of
No. discs to be
tested
a) Temperature cycle test followed by 60

mechanical performance test
b) Puncture test (for porcelain 40

insulator only)
If the results of the second test show a porcelain shell rupture,
the production does not comply with this specification.
4. Chemical Analysis of Zinc used for Galvanising:

Samples taken from the zinc ingot shall be chemically analysed as per
IS:209. The purity of zinc shall not less than 99.95%.
5. Tests for Forgings:
The chemical analysis, hardness tests and magnetic particle inspection
for forgings, will be as per the internationally recognized procedures for
these tests. The sampling will be based on heat number and heat
treatment batch. The details regarding test will be as discussed and
mutually agreed to by the Contractor and Employer in Quality
6. Test on Castings:
The chemical analysis, mechanical and metallographic tests and
magnetic particle inspection for castings will be as per the
internationally recognized procedures for these tests. The samplings
will be based on heat number and heat treatment batch. The details
regarding test will be as discussed and mutually agreed to by the
Contractor and Employer in Quality Assurance Programme.
7. Eccentricity Test:
The insulator shall be vertically mounted on a fixture using dummy pin
and socket. A vertical scale with horizontal slider shall be used for the
axial run out. The pointer shall be positioned in contact with the
bottom of the outermost petticot of the disc. The disc insulators shall
be rotated with reference to the fixture and the slider shall be allowed

Volume-V Part-1
to move up and down on the scale but always maintaining contact with
the bottom of the outer most petticot. After one full rotation of the
disc, the maximum and minimum position the slider has reached on the
scale can be found out. Difference between the above two readings
shall satisfy the guaranteed value for axial run out. Similarly using a
horizontal scale with vertical slider the radial run out shall be measured.
The slider shall be positioned on the scale to establish contact with the
circumference of the disc insulator and disc insulator rotated on its
fixture always maintaining the contact. After one full rotation the
maximum and minimum position of the slider reached on the scale are
found out. The difference between the above readings shall satisfy the
guaranteed value for radial run out.
8. Crack Detection Test:
Crack detection test shall be carried out on each ball and pin before
assembly of disc unit. The manufacturer shall maintain complete record
of having conducted such tests on each and every piece of ball pin. The
Contractor shall furnish full details of the equipment available with him
for crack test and also indicate the test procedure in detail.
SYSTEM PARTICUALRS
S.No. PARTICULARS Electrical System Data
1 System A.C. A.C. A.C.
3phase 3phase 3phase
2 Line voltage (kV rms) 220 132 400
3 Max.voltage (kV rms) 245 145 420
4 Frequency 50Hz. 50Hz. 50 Hz
5 Neutral grounding system effectively effectively effectively
earthed earthed earthed
6 Lightning impulse with- 1050 550 1425
stand voltage(dry &
wet)(kVp)
7 Power frequency 395 230 630
withstand voltage (wet)
(kVp)
8 Switching surge 650 325 1050
withstand voltage (wet)
(kVp)
9 Short circuit level (kA) 40 40 40
10 Minimum corona - - 320
extinction voltage at 50
Hz AC system dry
condition (Kv rms)
11 Radio interference - - 500
voltage at one MHz for
phase to earth voltage of

Volume-V Part-1
S.No. PARTICULARS Electrical System Data

266KV dry
conditions(Microvolt)
Part B
TECHNICAL SPECIFICATION FOR POLYMER
INSULATORS
5.23 STANDARDS
5.23.01 Unless otherwise specified elsewhere in this specification,

the rating as well as performance & testing of the Polymer Insulators
shall conform but not limited to the latest revision & amendments
available at the time of placement of order of all the relevant standards
as listed hereunder, except as modified in this document.
S. Indian Title International

No Standard Standard
1 IS:731 Porcelain insulators for IEC:61109-
overhead power lines with a 1992
nominal voltage greater
than 1000V
2 Verification of Dimensions of IEC:61109
Polymer Insulators
3 IS:13134 Guide for the selection of
insulators in respect of IEC : 60815
polluted conditions
4 IS:2071 Method of High Voltage IEC:60060-1
Part(I), II, III Testing
5 Characteristics of string IEC : 60433
insulator units of the long rod
type
6 IS:2486 Specification for insulator IEC-60575
fittings for overhead power IEC-60120
lines with a nominal voltage
greater than 1000V-General
Requirements , Tests,
Dimensional Requirements, IEC:60372
Locking Devices
7 Hydrophobicity classification STRI guide
guide 1.92/1
8 Standard for insulators– ANSI C29 13-
Composite-Distribution Dead- 2000

Volume-V Part-1
end type
9 IS : 8263 Methods of RIV Test of HV IEC:60487
Insulators
S. Indian Title Internation
No Standard al Standard
10 Standard specification for ASTMD 578-
glass fiber strands 05
11 Standard test method for ASTME 1131-
compositional analysis by 03
Thermo gravimetry
12 IS:8269 Methods for Switching IEC:60506
impulse test on HV insulators
13 IS:2629 Recommended practice for ISO:1461(E)
Hot Dip Galvanisation for iron
& steel
14 IS:2633 Testing for Uniformity of
Coating of Zinc coated
articles
15 IS:6745 Determination of Weight of BS:443-1969
Zinc coating on Zinc coated ISO 1460-
iron and steel articles 1973
16 IS : 4759 Hot dip zinc coatings on ISO :
structural steel & other allied 1459,ISO :
products 1461
17 IS : 4699 Specification for refined
secondary zinc
IS : 3203 Methods of testing of local ISO : 2178
18 thickness of electroplated
coatings
19 IS:209 Specification for Zinc BS:3436
20 IS:206 Method for Chemical Analysis BS:3436

of Slab Zinc
The standards mentioned above are available from:
Reference Name and Address

Abbreviation
BS British Standards,
British Standards Institution
101, Pentonvile Road,
N - 19-ND, UK

Volume-V Part-1
IEC International Electro technical Commission,

Bureau Central de la Commission,
electro Technique international,
1 Rue de verembe,
Geneva, SWITZERLAND
BIS/IS Beureau Of Indian Standards.
Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110001. INDIA
ISO International Organisation for
Standardization.
Danish Board of Standardization
Danish Standardizing Sraat,
Aurehoegvej-12
DK-2900, Heeleprup, DENMARK
STRI guide 1.92/1 STRI, Sweden, Website : www.stri.se
NEMA/ANSI C29 13- National Electric Manufacture Association,

2000 155, East 44th Street, New York, NY: 10017
U.S.A
ASTM American Society for Testing and Materials,
1916 Race St. Phelledelphia, PA19103
U.S.A.
5.23.02 Material meeting with the requirements of other

authoritative standards, which ensure equal or better performance than
the standards mentioned above, shall also be considered. When the
material offered by the bidder conforms to other standards, salient
points of difference between standards adopted & the standards
specified in this specification shall be clearly brought out in the relevant
schedules. Three copies of such standards with authentic translation in
English shall be furnished along with the bid.
5.24 CLIMATIC CONDITIONS
The insulators shall be suitable for being installed directly in air

with Power ACSR conductors of Double Circuit Double Strung
transmission lines. The materials offered shall be suitable for
operation in tropical climate & shall be subject to the sun & inclement
weather and shall be able to withstand wide range of temperature
variations. The topography & climatic conditions in general are as
under:-

2 Maximum ambient air 50

Volume-V Part-1
temperature (0C)
3 Minimum temperature in shade 1
(0C )
approaches
saturation)
5 Average daily ambient air 40° Centigrade
temperature (0C )
6 ISOCERANIC Level (days/year) 50
(Average number of thunder
storm days)
8 Maximum wind pressure ( kg/ 50
square meter)
9 Maximum Altitudes above mean 1000
sea level (meters)
10 Seismic level(Horizontal 0.3
acceleration) (g)
NOTE:- Moderately hot and humid tropical climate conducive to rust

and fungus growth. The climatic conditions are also prone to
wide variations in ambient conditions. Stroke is also present
in the atmosphere. Heavy lightening also occurs during June
to October.
5.25.01 DETAILS OF POLYMER INSULATORS
A. The Polymer insulator shall be suitable for a three phase 50 Hz,

effectively earthed 400 KV, 220 KV and 132 KV transmission
system in a moderately polluted atmosphere. They shall be ball
and socket type.
B. The specified values and dimensions, impulse and power

frequency voltages, electromechanical strength [EMS] of Polymer
insulators are as under. The values given are minimum which
apply to all cases. Specified withstand and flashover voltages are
referred to standard atmospheric condition.
S.No Particulars Value
400 KV POLYMER 220 KV POLYMER 132 KV POLYMER

INSULATORS INSULATORS INSULATORS
Suspen- Tension Suspen- Tension Suspen- Tension

sion sion sion

Volume-V Part-1
120 KN 160 KN 70KN 160 KN 70 KN 90 KN

i Size and 20 20 16 mm 20 16 mm 16 mm
designation of mm mm mm
ball & socket
ii Creep-age 13020 13020 7595 7595 4495 4495
distance (mm)
(minimum)
iii Power frequency 720 720 510 510 325 325
one minute dry
withstand voltage
kV (rms)
iv Power frequency 680 680 460 460 275 275
one minute wet
withstand voltage
kV (rms)
v Visible discharge 266 266 154 154 105 105
Test voltage kV
(rms)
vi Minimum dry 1550 1550 1050 1050 650 650
impulse withstand
voltage 1.2x50
micro second
wave, positive
and negative Kv
Peak)
vi Nominal length 3335 4080 1885 2380 1305 mm 1450
(Insulation mm mm mm mm mm
Spacing) ( mm)
C. Polymer Insulators shall have sheds with good self-cleaning

properties. Insulator shed profile, spacing, projection etc., and
selection in respect of polluted conditions shall be generally in
accordance with the recommendation of IEC-60815/IS : 13134
D. Dimensional Tolerance of Composite Insulators
The tolerances on all dimensions e.g. diameter, length and

creepage distance shall be allowed as follows in line with-IEC
61109 :
± (0.04d + 1.5)mm when d≤300mm
± (0.025d+6)mm when d>300mm
Where, d being the dimensions in millimeters for diameter, length

or creepage distance as the case may be.
However, no negative tolerance shall be applicable to creepage

distance

Volume-V Part-1
5.26.01 Core:
The core shall be glass-fiber reinforced epoxy resin rod (FRP) of
high strength. Both, glass fiber and resin shall be optimized in the FRP
rod. Glass fibers with low content in alkalies shall be boron free E glass
or Boron free electrically corrosion resistance (ECR) glass. Use of resin
with hydrolysis trend due to water penetration should be prevented i. e.
matrix of the FRP rod shall be Hydrolysis resistant. Suitability of Epoxy
matrix as well as interface between matrix and fibers is to be
considered as design parameter to prevent brittle fracture. The FRP rod
should be void free and shall be manufactured through Pultrusion
process.
5.26.02 Housing (Sheath):

The core of the Polymer insulator shall be completely covered by
a continuous housing consisting of a sheath-weathershed. For moulding
of entire weathershed structure on to the rod in a one shot moulding
process to be employed to avoid multiple interfaces. Hardware i. e.
metal fittings may be installed on the rod prior to moulding of the shed
controlling moulding lines. The base polymer shall be 100% Silicon
Rubber prior to the addition of reinforcing fillers. The thickness of
compounding material on core should be minimum 3 mm. Manufacturer
should furnish a description of its Quality Assurance Programme
including fabrication, testing and inspection for any material (i.e.
rubber), components(i.e. rod) or hardware (i.e. end fittings). The
manufacturer has had fabricated by others should also be included.
Manufacturing methods and material composition documentation will be
a part of Technical Bid to be submitted along with offer. Insulator
should have hermetically sealed structure in which the housing material
is moulded to cover the interface between the end fittings and the FRP
rod. This seal should never be broken during testing or otherwise.
5.26.03 End fittings:

The Polymer insulators shall be socket and ball type with the
necessary coupling arrangement such that pin shall move freely in the
socket but do not get disengaged while in service under various
operating and atmospheric conditions.
The socket & ball type metal end fittings shall be designed to transmit
the mechanical load to the core & the end fittings shall maintain
uniform and consistent mechanical strength Material and methods used
in the fabrication of metal parts shall be selected to provide good
toughness and ductility. Metal end fittings shall be made from a quality
malleable cast iron or forged steel or Spheroidal Graphite Iron(SGI) and
shall be hot dipped galvanized in accordance with IS 2629. Metal end
fittings shall be uniform and without sharp edges or corners and shall
be free of cracks, flakes, slivers, slag, blow-holes shrinkage defects and
localized porosity. The attachment to the FRP rod shall be performed

Volume-V Part-1
with a symmetrically controlled crimping method control by acquistic

method that compresses the metal radically onto the rod without
damage to the rod fibers or resin matrix while providing a strength
equal to or greater than the defined and specified ultimate strength to
the insulator. The material used in fittings shall be corrosion resistant.
Nominal dimensions of the pin, ball and socket interior shall be in
accordance with the standard . No joints in ball & socket or pin will be
allowed. Outer portion of ball or socket should be Zinc sleeved with
minimum 99.95% purity of electrolytic high grade Zinc. The finished
surface shall be smooth and shall have a good performance The surface
shall not crack or get chipped due to ageing effect under normal and
abnormal service conditions or while handling during transit or erection.
The design of the fittings and the insulators shall be such that there is
no local corona formation or discharges likely to cause the interference
to either sound or vision transmission.
5.26.04 GRADING RINGS

Grading rings shall be provided when system voltages are equal to or
greater than 220 KV. For 220 KV transmission, grading ring is to be
provided at the energized end only. For 400 KV transmission , grading
ring is to be provided at both ends of the insulators.
All grading rings and brackets shall be designed as an integral part of

the insulator assembly with a positive mounting system that allows
mounting in one position . The design of the grading ring shall be such
that ring can only be mounted with its orientation towards the weather
sheds for maximum RIV and
Corona control . Grading rings shall be designed in such a manner that
the rings can be readily installed and removed with hot line tools
without disassembling any other part of the insulator assembly .
Grading ring height (is the distance from the end of the end fitting to
the top of corona ring) should be so selected that maximum field
minimizes and uniformly distributed along the insulator. Manufacturer
should provide reports of successful electric field modeling testing for
the specific insulator design. The EFM should be three dimensional with
result containing drawing depicting the electric field in various colours ,
each of a different voltage level. The result of this study should show
that the voltage field surrounding the polymer insulators is optimum
along the entire length of the insulator , with the effected hot end of
the insulator being a critical location . The threshold at which corona
may or may not be present should be defined as a figure in KV/mm for
the designed insulator.
5.27 VERIFICATION OF HOUSING MATERIAL

Volume-V Part-1
The manufacturer should provide written verification about housing

material, for which base polymer shall be 100% Silicon Rubber prior to
the addition of reinforcing fillers considered will provide satisfactory
performance in the particular environment It shall meet following
requirements Be homogenous, impermeable, with no fissures, bubbles
and strange materials inclusions. Be designed in order to avoid
formation of localized discharges and to prevent interfaces humid
penetration. Be resistant to corona, UV radiation, ozone, atmospheric
contamination, water penetration and power arcs.
5.28 BALL AND SOCKET DESIGNATION
The dimensions of the Ball and Socket shall be 16mm designation for
70KN and 90KN Polymer insulators and 20 mm designation for 120
KN and 160 KN Polymer insulators in accordance with the standard
dimensions stated in IEC:60120/IS:2486(Part-II)
5.29 MARKINGS:
5.29.01 Each insulator shall be legibly and indelibly marked with the
following details as per IEC – 61109.
a. Name or trademark of the manufacturer.
b. Voltage and Type.
c. Month and year of manufacturing.
d. Minimum failing load / guaranteed mechanical strength in kilo
Newton followed by the word ‘KN’ to facilitate easy
identification.
e. Country of manufacture
5.29.02 One 10 mm thick ring of suitable quality of paint shall be

marked on the end fitting of particular strength for easy
identification of Polymer insulators. The paint shall not have
any deteriorating effect on the insulator performance.
Following codes shall be used as identification mark :
For 70KN Polymer insulator : Green
For 90KN Polymer insulator : Blue
For 120KN Polymer insulator : Yellow
For 160KN Polymer insulator : Red.
5.30.01 GENERAL
(i) All raw materials to be used in the manufacture of these

insulators shall be subject to strict raw material quality control

Volume-V Part-1
and to stage testing/quality control during manufacturing stage

to ensure the quality of the final end product. Manufacturing
shall conform to the best engineering practices adopted in the
field of high voltage transmission. Bidders shall therefore offer
insulators as are guaranteed by them for satisfactory
performance on 400KV/220 KV and 132kV Transmission lines.
(ii) The design, manufacturing, process and material control at

various stages be such as to give maximum working load,
highest mobility, best resistance to corrosion, good finish,
elimination of sharp edges and corners to limit corona and radio
interference voltages.
5.30.02 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with
the latest edition of IS:2629. The zinc to be used for
galvanizing shall conform to grade Zn 99.5 as per IS:209. The
Zinc coating shall be uniform, smoothly adherent, reasonably
bright, continuous and free from impurities such as flux, ash,
rust stains, bulky white deposits and blisters. Before ball fittings
are galvanized, all die flashing on the shank and on the bearing
surface of the ball shall be carefully removed without reducing
the designed dimensional requirements.
5.30.03 INTERCHANGEABILITY
The Polymer insulators inclusive of the ball and socket fittings

shall be of standard design suitable for use with hardware
fittings of any make conforming to relevant Indian Standards.
5.30.04 CORONA AND RADIO INTERFERENCE VOLTAGE (RIV)

PERFORMANCE
All surfaces shall be even, smooth, without cuts, abrasions or

projections. No part shall be subjected to excessive localized
pressure. The metal parts shall not produce any noise
generating corona under all operating conditions.
5.31.01 The Polymer insulators shall be compatible for use with hot
line or live line maintenance techniques so that usual hot line
operations can be carried out with ease, speed and safety.

Volume-V Part-1
5.31.02 Suppliers shall indicate the methods generally adopted in

routine hot and cold line maintenance of EHV lines for similar Polymer
insulators supplied by them. Suppliers shall also indicate the
recommended periodicity of such maintenance.
5.32 TESTS
The following tests shall be carried out on the Polymer insulator:
5.32.01 TYPE TESTS
This shall mean those tests which are to be carried out to prove
the design, process of manufacture and general conformity of the
material and product with the intents of this specification. These tests
shall be conducted on a representative number of samples prior to
commencement of commercial production.
5.32.02 ACCEPTANCE TESTS
This shall mean those tests which are to be carried out on

samples taken from each lot offered for pre-despatch inspection for the
purpose of acceptance of the lot.
5.32.03 ROUTINE TESTS

This shall mean those tests, which are to be carried out on each
Polymer insulator to check the requirements, which are likely to vary
during production.
5.32.04 STAGE TESTS DURING MANUFACTURE
Stage tests during manufacture shall mean those tests, which are
to be carried out during the process of manufacture to ensure quality
control such that the end product is of the designed quality conforming
to the intent of this specification.
5.32.05 TEST VALUES
For all type and acceptance tests, the acceptance values shall be
the value guaranteed by the Supplier in the guaranteed technical
particulars or the acceptance value specified in this specification or the
relevant standard whichever is more stringent for that particular test.
5.32.06 TEST PROCEDURES AND SAMPLING NORMS

Volume-V Part-1
5.32.06.1 The norms and procedure of sampling for the above tests
shall be as per the relevant Indian Standard or other Internationally
accepted standards. This will be discussed and mutually agreed to
between the successful Supplier and Purchaser before placement of
order. The standards and norms according to which these tests are to
be carried out are listed against each test. Where a particular test is a
specific requirement of this specification the norms and procedure for
the same shall be as mutually agreed to between the successful
supplier and purchaser in the quality assurance programme. The
supplier shall offer at least three times the quantity of material required
for conducting all the type tests for sample selection. Before sample
selection, the supplier shall be required to conduct all the acceptance
test successfully in presence of purchaser’s representative.
5.32.06.2 TYPE TESTS
(A) The following type tests shall be conducted on all types of the
Polymer insulator with hardware fittings :
a) Power frequency voltage withstand test with

corona control rings and arcing horn under
(dry/wet) conditions
b) Power frequency voltage flash over test with
corona control rings and arcing horn under
(dry/wet) conditions
c) Power frequency voltage flash over test
without corona control rings and arcing
horn under (dry/wet) conditions
d) Switching surge voltage withstand test
under wet condition.
e) Impulse voltage withstand test under dry
condition.
f) Voltage Distribution test
g) Impulse voltage flash over test under dry
condition
h) Corona and RIV Test under dry condition.
i) Mechanical strength test
j) Vibration test.
k) Power Arc Test
l) Salt fog pollution withstand Test
(B) On composite Insulator Unit:-
1. Tests on interface and connection of metal fittings

Volume-V Part-1
(a) Dry Power frequency Voltage Test

(b) Sudden Load Release Test
(c) Thermal Mechanical Test
(d) Steep Front Impulse Voltage Test
(e) Dry Power frequency Voltage Test
2. Assembled Core Load Time Test
(a) Determination of the Average failing load of the core of the

assembled unit
(b) Control of slope of the strength time curve of the insulator
3. Accelerated Ageing Test of 5000 hours

4. Flammability Test
5. Recovery of Hydrophobic Test
6. Mechanical Load Time Test
7. Brittle Fracture resistance test
8. Test of Housing, Tracking and Erosion Test
9. Test for the Core Material
- Dye Penetration Test
- Water diffusion Test
5.32.07 ACCEPTANCE AND ROUTINE TESTS
On Polymer Insulators following Acceptance & Routine tests shall

be conducted:
a) Verification of IEC:61109-1992
dimensions
b) Verification of Locking
System
c) Galvanising test IS-731
d) Verification of specified IEC:575
Mechanical Load
e) Recovery of As per annex-A
Hydrophobicity
(B) Routine tests:


Volume-V Part-1
5.32.08 Tests during Manufacture (STAGE TESTS)
a) Chemical analysis of Zinc used for galvanizing
b) Chemical analysis, mechanical and metallographic

test and magnetic particle inspection for malleable
castings
c) Chemical analysis, hardness test and magnetic

particle inspection for forgings
5.32.09 ADDITIONAL TESTS
The purchaser reserves the right for carrying out any other tests
of a reasonable nature at the works of the Supplier/laboratory or at any
other recognized laboratory / research institute in addition to the above
mentioned type, acceptance and routine tests at the cost of the
Purchaser to satisfy that the material complies with the intent of this
specification.
5.32.10 COORDINATION FOR TESTING:
For polymer insulator strings, the Supplier is required to produce

type test reports to the satisfaction of the Purchaser. However, in case
the Purchaser desires, the Supplier shall conduct all the type tests on
the complete string with relevant hardware fittings. Responsibility of
arranging required hardwares for the purpose of type testing will
remain with the insulator Supplier.
5.32.11 TEST SCHEDULE

The material offered shall be fully type tested as per this
specification and the Supplier shall furnish four sets of type test reports
alongwith the offer. These tests must not have been conducted earlier
than five years.

Volume-V Part-1
For any change in the design/type ,already type tested and the
design/type offered against this bid, the purchaser reserves the right to
demand repetition of some or all type tests without any extra cost.
5.32.11.2 ACCEPTANCE AND ROUTINE TESTS
All Acceptance and Routine tests as stipulated herein shall be

carried out by the Supplier in the presence of Purchaser’s
representative.
Immediately after finalization of the programme of

acceptance/routine testing, the Supplier shall give sufficient
advance intimation to the Purchaser, to enable him to depute
his representative for witnessing the test.
5.33 INSPECTION
i) Purchaser and its representatives shall at all times be

entitled to have access to the works and to all places of
manufactures where insulators are manufactured and the
successful Supplier shall afford all facilities to them for
unrestricted inspection of the works, inspection of material,
inspection of manufacturing process of insulators and for
conducting necessary tests as specified herein.
ii) The successful Supplier shall keep the Purchaser informed

in advance of the time of starting and progress of
manufacture of insulators in its various stages so that
arrangements could be made for inspection.
iii) No material shall be despatched from its point of

manufacture unless the material has been satisfactorily
inspected and tested.
iv) The acceptance of any quantity of insulators shall in no way

relieve the successful Supplier of his responsibility for
meeting all the requirement of this specification and shall
not prevent subsequent rejection, if such insulators are
later found to be defective.
5.34 QUALITY ASSURANCE PLAN
5.34.01 The Supplier hereunder shall invariably furnish following

information alongwith his offer, failing which the offer shall
be liable for rejection. Information shall be separately given
for individual type of material offered.

Volume-V Part-1
i) Statement giving list of important raw materials, names of

sub-suppliers for the raw material, list of standards
according to which the raw material are tested, list of tests,
normally carried out on raw material in presence of
Supplier’s representative, copies of test certificates.
ii) Information and copies of test certificates as in (i) above in

respect of bought out items.
iii) List of manufacturing facilities available.
iv) Level of automation achieved and list of areas where

manual processing exists.
v) List of areas in manufacturing process, where stage

inspections are normally carried out in quality control and
details of such test and inspections.
vi) Special features provided in Polymer insulators to make it

maintenance free.
vii) List of testing equipment available with the Supplier for final
testing of Polymer insulators specified and test plant
limitation, if any, vis-a-vis the type, special, acceptance and
routine tests specified in the relevant standards.
5.34.02 The successful Supplier shall within 30 days of placement of

order submit the following information to the Purchaser.
i) List of raw material as well as bought out accessories and

the name of material as well as bought out accessories and
the names of sub-suppliers selected from those furnished
alongwith the offer.
ii) Type test certificates of the raw material and bought out
accessories.
iii) Quality assurance plan (QAP) with hold points for

Purchaser’s inspection. The QAP and Purchaser’s hold
points shall be discussed between the Purchaser and the
Supplier before the QAP is finalized.
5.34.03 The successful Supplier shall submit the routine test

certificates of bought out items and raw material at the
time of routine testing of the insulator.\
5.35 DOCUMENTATION

Volume-V Part-1
5.35.01 The Supplier shall furnish full description and illustrated

catalogues of insulators offered, alongwith the bid. The
supplier shall also furnish alongwith the bid the outline
drawing of Polymer insulator unit including cross-sectional
view. The drawing shall include the following information:
i) Shed diameter and unit spacing with manufacturing

tolerance.
iii) Unit mechanical and electrical characteristics for the
complete string-suspension and tension. unit
v) Weight of Polymer unit.
vi) Materials for the cap and pin.
5.35.02 TEST REPORTS
i) Four copies of type test reports shall be furnished to the

Purchaser within one month of conducting the tests. One
copy will be returned duly certified by the Purchaser to the
Supplier within three weeks thereafter and on receipt of
the same Supplier shall commence with the commercial
production of the Polymer insulators.
ii) Four copies of acceptance test reports shall be furnished to

the Purchaser. One copy will be returned, duly certified by
the Purchaser and only thereafter shall the materials be
despatched.
iii) All records of routine test reports shall be maintained by the

Supplier at his works for periodic inspection by the
Purchaser.
iv) All test reports of tests conducted during manufacture shall

be maintained by the Supplier. These shall be produced for
verification as and when requested for by the Purchaser.
5.36 GUARANTEED PARTICULARS AND PERFORMANCE

GUARANTEE:

Volume-V Part-1
(i) The bidder shall furnish all relevant technical guaranteed

particulars of the long rod Polymer Insulators offered. Offers
without such details may not be considered.
(ii) The Polymer Insulators shall be guaranteed for satisfactory

performance for a period of 24 months from the date of
commissioning of line. Any defect due to faulty material or
workmanship found during guarantee period shall be rectified free
of cost to the MPPTCL. The replacement will have to be organized
expeditiously and within one month from the date of intimation.
The manufacturer shall also guarantee that there

shall not be any failure/decapping/ breaking of insulators on
line under normal operating condition. In the event of any
failure/decapping/ breaking of insulators during first ten years
of service, the manufacturer shall supply to the
owner/purchaser free of cost spare insulators equal to 10 times
the failed quantity. Further , in case of decapping/breaking and
subsequent line drop , during the first ten years of service , the
manufacturer shall also have to pay Rs. 1,00,000/-(Rs. One
Lakh only) per dropped string towards expenditure to be
incurred by MPPTCL for the line repair.
(iii) In case, the replacement of defective material is not made within

one month then apart from operating clause of Penalty, the
MPPTCL may also take suitable penal action against the
contractor, which may include encashing the Performance
Security to the extent required besides debarring the contractor
and the manufacturer from all future business with the MPPTCL
for a period which will be at the discretion of MPPTCL.
(iv) The defective/ rejected material shall be collected by the

contractor from Trans. Stores/Site within one month from the
date of intimation at your own cost.
(v) The bidder shall indicate the facilities available at the

manufacturer’s works to carry out the tests as per relevant ISS.
Supplies shall be subject to testing as per IS.
5.37 PACKING & FORWARDING
i) All Polymer insulators shall be packed in suitable

PVC/Plastic tubes/any other suitable packing. The packing
shall provide protection against rodents. The supplier shall
furnish detailed design of the packing. For marine
transportation crates shall be palleted.

Volume-V Part-1
ii) The packing shall be of sufficient strength to withstand

rough handling during transit, storage at site and
subsequent handling in the field.
iii) Suitable cushioning, protective padding, or dunnage or

spacers shall be provided to prevent damage or
deformation during transit and handling.
iv) All packing cases shall be marked legibly and correctly so as

to ensure safe arrival at their destination and avoid the
possibility of goods being lost or wrongly dispatched on
account of faulty packing and faulty or illegible markings.
Each case/crate shall have all the markings stenciled on it
in indelible ink.
v) The supplier shall guarantee the adequacy of the packing

and shall be responsible for any loss or damage during
transportation handling, storage and installation due to
improper packing indelible ink.

Volume-V Part-1
ANNEXURE-II
1.0 Tests on Complete composite Insulator with Hardware

Fittings.
1.1 Salt - fog pollution withstand test
This test shall be carried out in accordance with IEC-60507. The

salimity level for composite long rod insulators shall be 80 Kg /
m3 NACL.
2.0 Composite Long rod Insulator Units
2.1 Brittle Fracture Resistance Test.
Assembled core load time test with container that contains in-
HNO3 concentric acid this is applied at the naked rod. The rod
should be held at 80% of SML for the duration of the test. The rod
should not fail within the 96 hour test duration.
2.2 Recovery of Hydrophobicity Test
(1) The surface of selected samples shall be cleaned with isopropyl

alcohol. Allow the surface to dry and spray with water. Record the
HC classification. Dry the sample surface
(2) Treat the surface with corona discharges to destroy the

hydrophobicity. This can be done utilizing a high frequency corona
tester. Holding the electrode approximately 3 mm from the
sample surface slowly move the electrode over an area
approximately 1’’ x 1’’. Continue treating this area for 2-3
minutes, operating the tester at maximum output.
(3) Immediately after the corona treatment, spray the surface with
water and record the HC classification. The surface should be
hydrophilic with an HC value of 6 to 7. If not, dry the surface and
repeat the corona treatment for a longer time until an HC of 6 or
7 is obtained. Dry the sample surface.
(4) Allow the sample to recover and repeat the hydrophobicity

measurement at several time intervals. Silicone rubber should
recover to HC 1 – HC 2 within 24 to 48 hours, depending on the
material and the intensity of the corona treatment.
3.0 Test on All components (As applicable).

Volume-V Part-1
3.1 Chemical Analysis of Zinc used for Galvanizing.

Samples taken from the zinc ingot shall be chemically analysed as
per IS 209-1979. The purity of zinc shall not be less than
99.95%.
3.2 Tests for Forgings.
The chemical analysis hardness tests and magnetic particle

inspection for forgings, will be as per the internationally
recognized procedures for these tests. The sampling will be based
on heat number and heat treatment batch. The details regarding
test will be as discussed and mutually agreed to by the Supplier
and Owner in Quality Assurance Programme.
3.3 Tests on Castings.
The chemical analysis, mechanical and metallographic tests and

magnetic, particle inspection for castings will be as per the
internationally recognized Procedures for these tests. The
samplings will be based on heat number and heat treatment
batch. The details regarding test will be as discussed and
mutually agreed to by the Supplier and Owner in Quality
4.0 Power Arc Test:
Three insulators having any one design of end fittings shall be

tested for power arc endurance while tensioned horizontally at
3000lb. An arc shall be initiated across the insulator by means of
a Copper shorting fuse wire. The arc shall burn 15 to 30 cycles
and its current magnitude is determined by ampere- time
product(IxT) equal to a minimum of 150kA cycles. Each insulator
is only acceptable if there is no exposure of the core, no
mechanical separation of the insulator, and no cracks in the
housing .

Volume-V Part-1
SECTION- 6
TECHNICAL SPECIFICATION FOR HARDWARE FITTINGS
FOR 220/132 KV LINES
6.01 STANDARDS:
This section provides for the Design, manufacturing, stage testing,

inspection and testing before despatch, packing and delivery of
Hardware fittings for Insulator string suitable for Conductor and Earth
wire for use on 132 KV/220KV transmission lines. The material and
services under this specification shall be performed as per the
requirements of the latest revisions and amendments available at the
time of placement of order of all the relevant Indian Standards/Codes
listed here under or equivalent International Standards, except as
modified in this document:
S. Indian Title
No Standard
1 IS:209-1992 Specification for Zinc Ingot
2 IS:206 – Tee and Strap Hinges
1992
3 IS:7814- Phosphor Bronze Sheet and Strip
1985
4 IS:2071 Method of high voltage testing
5 IS:731 Porcelain Insulator for Overhead Power Lines
with a Nominal Voltage Greater than 1000 V.
6 IS:961 Structural Steel
7 IS:1385 Phosphor Bronze Rods & Bar Sheet and Strips
and Wire
8 IS:2004 Carbon Steel Forgings for General Engineering
Purpose
9 IS:2107 White Hearth Malleable Iron Castings
10 IS:2108 Black Hearth Malleable Iron Castings
11 IS:2121(Part Specification for Conductors and Earth wire
-I & II) Accessories for Overhead Power Line, Armour
Rods Binding Wires and Tapes for Conductor
12 IS:2486 Specification for Insulator Fittings for
Overhead Power Lines with a Nominal Voltage
Greater than 1000 V.
13 IS:2629 Recommended Practice for Hot Dip
Galvanization of Iron and Steel.

Volume-V Part-1
S. Indian Title
No Standard
14 IS:2633 Testing of Uniformity of Coating of Zinc coated
Articles
15 IS:3138 Hexagon Bolts and Nuts
16 IS:6639 Hexagon Bolts for Steel Structures
17 IS:6745 Determination of Weight of Zinc Coating on
Zinc Coated Iron and Steel Articles
18 IS:3188 Characteristic of String Insulators Units
19 IS:4218 ISO Metric screw Threads
20 IS:4172 Dimensions for Radii under the Heads of Bolts
& Screws
21 IS:4206 Dimensions for nominal lengths and Thread
length for Screws and Studs (with
amendment)
22 IS:4759 Hot Dip Zinc Coatings on Structural Steel and
other Allied Products
23 IS:1573 Electroplated Coatings of Zinc on Iron and Steel
24 IS: 398 Specification for Aluminium Conductor Steel
Reinforced for overhead transmission purpose.
25 IS: 1327- Methods for determination of weight of tin
1966 Coating on Tin Plates
26 IS: 4826- Hot Dip Galvanised Coating on Round Steel
1979 Wires
27 IS: 1363 Hexagon Head Bolts, Screws & Nuts.
28 IS: 1367 Technical supply conditions for threaded Steel
Fasteners
29 IS: 9708 Stockbridge Vibration Dampers for Overhead
Power lines.
30 IS: 8263 Method of Radio Interference Tests on High
Voltage Insulators.
31 IS:10162 Spacers and Spacer Dampers for twin
horizontal bundle Conductors.
32 IS: 2004 Carbon Steel Forgings for general engineering
purposes.
33 BS:970 General Instructions and Testing Procedures
(Part-I) Specific Requirements for Carbon and Carbon
Manganese Alloy and Stainless Steels.

Volume-V Part-1
6.02 PRINCIPAL PARAMETERS:
6.02.01 Details of Hardware Fittings:

The Hardware fittings shall meet the technical requirement as per
clause 6.3 and also general arrangement drawings of Hardware fittings
attached herewith. Hardware fittings shall be suitable for single/double
suspension Insulator strings and single/double tension Insulator strings.
Each Hardware fitting shall be supplied complete in all respect and shall
include all components, which are required for making complete set.
The hardware fittings for lines shall be suitable for ACSR Conductor and
Earth wire as per technical parameters indicated in Annexure-3
6.03 INSULATOR STRING CHARACTERISTICS:
6.03.01 The complete insulator string including Hardware fittings

shall have the following characteristics:

220kV 132kV 220kV 132kV
1 No. of Standard Discs 1x13 1x9 1x14 1x10

2x13 2x9 2x14 2x10
2 Nominal diameter of 255 255 280 255
discs
3 Power frequency 460 280 490 300
Withstand voltage
(wet) kV (rms)
4 Lighting impulse 1200 800 1200 800
withstand voltage
(dry)(kVp)
5 Switching surge 900 350 900 350
Withstand
voltage (Dry & wet)
(kVp)
6 Mechanical failing 7000/ 7000/ 16500/ 9000/
Load (kgf) 14000 14000 33000 18000
7 Pollution Moderately Moderately
polluted polluted
8 No deformation load 4690/ 4690/ 11055/ 6030/
(kgf) 9380 9380 22110 12060

Volume-V Part-1
9 Corona Extinction 176 - 176 -

voltage (KV rms)
6.03.02 The Insulator string Hardware fittings and Earth wire

assemblies shall comply and conform to the above requirement.
6.04 BALL AND SOCKET DIMENSIONS:

The Ball and Socket for Hardware fittings shall necessarily conform to
the dimensions as stipulated in the Indian Standards. The Ball and
Socket dimensions of the Hardware sets to be used with 7000 kg and
9100 kg Electro Mechanical strength Disc Insulators shall conform to
designation 16mm/16mm-B in accordance with IS:2486(Part-II) or
equivalent International Standard. The Ball and Socket dimension of
Hardware to be used with 11500 Kg & 16,500 kg Electro Mechanical
strength disc insulator shall conform to designation 20mm in accordance
with IS-2486:(Part-II) or equivalent International Standard. The Bidder
shall offer full detail of locking device in accordance with IS 2486:(Part-
III) or equivalent International Standard along with test reports, gauges
and adherence to Standards for Tests on Locking Devices in line with
IS:2486 (Part-IV) or equivalent International Standard.
6.05 REQUIRED GUARANTEED STRENGTH OF HARDWARE OF

INSULATOR STRINGS:
6.05.01 The Hardwares and Clamps of 132kV/220kV single

suspension and double suspension strings suitable for Panther ACSR
and Zebra ACSR for transmission line and shall have the ultimate
breaking strength of not less than 7,000 kgs.
6.05.02 The slipping strength of the suspension clamp shall not be

less than 15% and more than 20% of the Conductor strength with
which it is to be used.
6.05.03 The Hardware and Compression Clamp of single and double

tension strings suitable for Panther ACSR shall have ultimate breaking
strength of not less than 9,100 kgs. The slipping strength of
Compression Clamp shall not be less than 95% of the ultimate breaking
strength of Panther ACSR.
6.05.04 The Hardware and Compression Clamp of single & double

tension strings suitable for Zebra ACSR for 220kV transmission line
shall have ultimate breaking strength of not less than 16500 kgs. The
Compression Clamp shall have slipping strength not less than 95% of
breaking strength of Zebra ACSR.
6.05.05 Each individual Hardware component of double suspension

and double tension strings such as ball-clevis, socket clevis etc. shall

Volume-V Part-1
have minimum breaking strength as specified for respective single

suspension and tension string respectively.
6.06 PARTICULARS OF HARDWARE FITTINGS:
Each Hardware fitting for the transmission line shall be complete in all
respect and Bidder should furnish complete drawings and technical
particulars of the items of hardware fittings. The Hardware fittings
should normally comprise items conforming to enclosed drawing as
under: -
6.06.01 Single Suspension Hardware Fitting With AGS Type

Clamp:
Single suspension Hardware string shall comprise of one Ball Hook, one
Socket Eye Horn holder, one line side Arcing Horn and one Suspension
Clamp of AGS type with armour rod suitable for respective sizes of
Conductors.
6.06.02 Double Suspension String Hardware Fittings With AGS

Type Clamp:
The double suspension string Hardware fittings shall comprise of one
Ball Hook, one Socket Clevis, one Top Yoke Plate, two Ball Clevis, two
Socket Clevis, one bottom Yoke Plate, two line side Arcing Horns, one
Clevis Eye and one AGS type Suspension Clamp suitable for respective
sizes of Conductors.
6.06.03 Single Tension String Hardware Fittings:

Single tension string Hardware shall comprise of one `D’ Shackle, one
Ball Link, one Forged Steel Socket, Socket Clevis Horn holder, one line
side Arcing Horn and one Tension Clamp of compression type having
before and after compression dimensions strictly as shown in enclosed
Appendix-2.
6.06.04 Double Tension String Hardware Fittings:

The double tension string Hardware shall comprise of two `D’ shackle,
one chain link one top yoke plate, two ball clevis, two socket clevis,
one bottom yoke plate, one line side arcing horn, one clevis and a
compression type dead-end Clamp having `before and after
compression’ dimensions strictly as shown in enclosed Appendix-2.
6.07 EARTH WIRE ASSEMBLIES:

6.07.01 Earth Wire Suspension Assembly With Preformed
Armour Rods:
This shall comprise of AGS type Suspension Clamp of heat-treated

malleable iron, one Chain Link and one ‘D’ Shackle. The entire

Volume-V Part-1
assembly shall be hot dip galvanized complete with minor accessories.

The breaking strength of all the Hardware items of the assembly shall
not be less than 7000 kgs. The complete assembly of suspension
clamp shall be guaranteed for slip strength of not less han 15 KN & not
more than 19 KN. The strength of the Earth wire has been specified in
Annexure-3. The suspension assembly shall be supplied with armour
rod for Earth wire.
6.07.02 Earth Wire Tension Assembly:
The Earth wire tension assembly shall have minimum breaking strength
equal to that of the Earth Wire. The slipping strength of the
Compression Clamp shall not be less than 95% of the breaking
strength of Earth Wire. The strain assembly of the Earth wire for
transmission line shall comprise of compression type dead end Clamp
and two `D’ Shackles complete with minor accessories such as pins,
bolts & nuts etc. Strain assembly shall be hot dip galvanized and made
inherently resistant to the atmosphere corrosion. The dead end Clamp
of the assembly shall be of compression type. The tension clamp shall
be attached to the horizontal strain plate of the tower body by means
of a “D” shackle. “D” shackle shall be suitable for attaching the tension
clamp to strain plate of towers having 8mm thickness with a hole of
21.5 mm diameter. The tension clamp body shall be made out of steel
of 304 L grade or equivalent with Brinnel Hardness not exceeding 200.
The complete assembly shall also include one 12.5mm dia, 45 mm long
HRH MS Bolt hot dip galvanized with nuts and lock washers for
attaching G.I. earth bond. A detailed drawing giving dimensional details
of the complete assembly shall accompany the tender. After
compression, dimensions of the joint shall be as indicated in enclosed
Appendix-2.
6.08 DETAILS OF COMPONENTS OF HARDWARE FITTINGS:
6.08.01 Armour Grip Suspension Clamp (AGS):
AGS fitting shall consist of 2 Neoprene Halves, a set of Helical rods

made of Aluminium alloy, two Aluminium halves casting having inner
profile matching with the profile of the Armour rod cage and jointed by
supporting strap made of Aluminium alloy.
The Contractor should give complete data on the reduction of the
dynamic stresses of the Conductor at the point of AGS support
compared to that of bare clamp used with preformed types of Armour
rods.

Volume-V Part-1
The Contractor will be required to prove the comparative performance

in regard to the dynamic flexural stress pattern on the vibrating
Conductor on the tensioned span with actual tests on the AGS unit
compared to the normal bare clamp with Armour rods. Suitable curves
should be furnished for the same and also actual reports on the stress/
strain determinations. The Contractor should give the guaranteed
value of the power loss of the AGS units to be supplied by them
supported by a test certificate of any reputed laboratory of the country.
Suitable curves should be furnished for the power loss due to AGS unit
as well as with the conventional envelope type of Suspension Clamps.
The housing supports and housing straps should provide positive stop
closure. AGS unit should have low rotational inertia, strut action of the
Armour Cage, resilient cushioning of the neoprene insert, immunity
from high compressive and flexural stress and wide area support.
Manufacturer is required to guarantee minimum fatigue life of the AGS
units and this would be established under actual tests on tensioned
Conductor span. The manufacturer is required to guarantee minimum
40 years life of the complete AGS units including Neoprene cushioning
and this should be established under actual test on a tensioned
Conductor span.
The rubber used with AGS unit must be capable of withstanding desired
long out-door performance including the variation of temperature from
00C to 750C. The Contractor will have to provide certificate from
reputed manufacturers that the rubber being supplied by them is
suitable for AGS fitting and must have tensile strength of 2000 PSI and
minimum ultimate elongation 300%.
The helical retaining rods required for AGS assembly shall be made of
Aluminium alloy of HE 20 grade as per IS-6051/1970 or equivalent
International Standard duly heat treated and shall be suitable to wrap a
desired size of Conductor. The tensile strength of the retaining rod
material should not be less than 50,000 PSI and the electrical
conductivity should not be less than 40% (IACS). The minimum
slipping strength of the complete fitting shall not be less than 15% and
more than 20% of the UTS of the cable on which it is to be used. The
Clamp shall be in 2 parts made of Aluminium and will have inner profile
matching with the profile of Armour rod. This Clamp should be made
by drop forging process. AGS assembly should be provided with the
forged steel socket eye to match with the suspension string and should
have UTS not less than 7,000 kgs.
IT IS ESSENTIAL FOR THE CONTRACTOR TO HAVE SUITABLE

HEAT TREATMENT FACILITIES FOR ALUMINIUM ALLOY WIRES
IN THE ARMOUR GRIP SUSPENSION UNITS. FORMED ROD
BASED ITEMS WILL NOT BE ACCEPTABLE FROM

Volume-V Part-1
MANUFACTURERS WHO DO NOT HAVE NECESSARY TECHNOLOGY

FOR DEVELOPMENT OF ADEQUATE RESILIENCE, ELONGATION
UTS AND TWIST TEST FACILITIES BACKED WITH PROPER HEAT
TREATMENT SYSTEMS.
6.08.02 AGS Preformed Armour Rods:
The AGS Preformed Armour rods set suitable for ACSR Zebra/ Panther
conductor (as the case may be) shall be used to minimize the stress
developed in a conductor due to different static and dynamic loads
because of vibration due to wind, slipping of conductor from suspension
clamp as a result of unbalance conductor tension in adjacent span and
broken wire condition. It shall be made of Aluminium alloy of HE 20
grade as per IS-6051/1970 duly heat-treated. The aluminium alloy
wires (pre heat treated) for manufacturing of Armour rods can also be
used, however Contractor shall submit the test certificates in support of
their claim for using pre heat-treated wires. It shall also withstand
power arcs, chafing and abrasion from suspension clamp and localized
heating effects due to resistance losses of the conductor.
The pitch length of the rods shall be determined by the Contractor but
shall be less than that of the outer layer of ACSR conductor and the
same shall be accurately controlled to maintain uniformity and
consistently reproducible characteristics wholly independent of the skill
of lineman.
The preformed armour rod sets shall have right hand lay and the
inside diameter of the helices shall be less than the outside diameter of
the conductor to grip the same tightly. The surface of the armour rod
when fitted on the conductor shall be smooth and free from
projections, cuts and abrasions etc.
The length of each rod shall be as per drawing enclosed. The tolerance
in length of each rod shall be +/-25mm. The tolerance in length of the
rods in completed sets should be within 13 mm between the longest
and shortest rod. The ends of the armour rod shall be parrot billed.
The number of armour rods in each set shall be 11/12. The each rod
shall be marked in the middle with paint for easy applications on the
line.
The armour rod shall not loose their resilience even after five
applications. The conductivity of each rod of the set shall not be less
than 40% of the conductivity of International Annealed Copper
Standard (IACS). The minimum tensile strength of armour rod should
be 35 kg per sq.mm.

Volume-V Part-1
6.08.03 Strain Clamp:

The Strain Clamp shall be of the compression type for the specified size
of Conductor for 220/132KV lines. The outer sleeve of the Compression
Clamp and Jumper Terminal shall be of EC grade Aluminium 99.5%
pure tube formed by extrusion process and the inner sleeves shall be of
galvanized steel. The angle of jumper terminal to be mounted should
be 30 deg. with respect to the vertical line. The Compression Clamp
shall have slipping strength not less than 95% of the ultimate breaking
strength of Conductor with which it is to be used. The compression
dead end clamp for transmission line shall be manufactured out of
extruded Aluminium.
The resistance of the clamp when compressed on the conductor shall

not be more than 75% of the resistance of equivalent length of
conductor. Die compression line shall be clearly marked on each dead-
end assembly designed for continuous die compression and shall bear
the words “COMPRESS FIRST” suitably inscribed near the point on each
assembly where the compression begins. It shall bear identification
marks “COMPRESSION ZONE” and “NON COMPRESSION ZONE”
distinctly with arrow marks showing the direction of compressions and
knurling marks showing the ends of the Zones. Tapered aluminium
filler plugs shall also be provided at the line of demarcation between
Compression and Non-compression zone. The letters, numbers and
other marking on the finished clamp shall be distinct and legible.
6.08.04 Arcing Horn:

132/220kV Insulator strings for transmission line shall be provided with
Arcing Horns of different type as indicated in the enclosed drawings. In
case of 132 kV line, the Arcing Horn shall be made out of 25mm x 6mm
size flat. At the ends of flat, spherical ball of 38 mm dia. shall be
provided as shown in enclosed drawing. In case of 220kV Hardware
strings, the Arcing Horn shall be made out of 25mm dia steel pipe. The
dimension of the Arcing Horn shall be as indicated in the drawing.
However, the height of the Arcing Horn may be changed depending
upon the length of Socket Eye, Yoke Plate etc. Please note that Arcing
Horn shall be strictly according to above. Any other type of Arcing Horn
including graded type, may not be acceptable.
The designed fixture of the Arcing Horn with that of the string
Hardware of Yoke Plate shall be such that the possibility of relative
movement between the two, due to vibration of assembly in service is
altogether avoided. Making two bolt connections and providing a collar
to the Hardware item can achieve this. An additional nut should be
provided along with bolts and nuts to fix the Arcing Horn with Hardware
items. The provision of an additional nut will avoid the possibility of
relative movement between the Arcing Horn and the Hardware item,
due to vibration of string. The arrangement for fixing of Arcing Horn

Volume-V Part-1
shall be such that they do not get loose while in service. To achieve
this, they should have proper seat for the Arcing Horn and heat-treated
Belleville washers should be provided with the bolts.
6.08.05 Socket Eye & Ball Clevis:

The Socket Eye and Ball Clevis be made of forged steel as per the
drawing enclosed.
6.08.06 U Clevis:
These shall be made of forged steel complete with galvanised steel
rivets washer and Phosphorus Bronze/Stainless Steel pins.
6.08.07 Ball Fittings:

These shall be made of forged steel in one piece. They shall be
normalized to achieve the minimum breaking strength specified in the
respective drawings. Before galvanising of ball fittings, all die fleshing
on the shank and on the bearing surface of the ball shall be carefully
removed without reducing the dimension below the requirements. The
dimension of the ball & socket shall be 16mm/20mm designation in
accordance with standard dimensions stated in IS:2486 (Part-II).
6.08.08 Dimensions & Tolerances:
6.08.08.1 The dimensions and tolerances of pin balls and socket ends
shall conform to IS 2486 Part-II/IEC-120 and shall be checked
by the gauge therein after galvanizing.
6.08.08.2 The pin balls shall be checked with the applicable “GO”
gauges in at least two directions, one of which shall be across
the line of die flashing and the other 90 deg. to this line. “NO
GO” gauges shall not pass in any direction.
6.08.08.3 The bearing surfaces of balls and machined sockets, before
galvanizing shall not have surface roughness more than 250
micro inches.
6.08.08.4 The bearing surface of socket ends shall be uniform about

the entire circumference without depressions or high spots.
The internal contour of the socket ends shall be concentric with
the axis of fittings. The axis of the bearing surface of socket
ends shall be coaxial with the axis of fittings with no
appreciable tilting.
6.08.09 Socket Fittings:
Socket fittings shall be made of class IV steel as per IS:2004 or steel of

equivalent grade and shall be forged in one piece. They shall be
normalized to achieve the minimum breaking strength specified on the
respective drawings.

Volume-V Part-1
6.08.10 Security clip for Socket fittings:
6.08.10.1 Socket fittings shall be provided with R-shaped security clip

in accordance with IS:2486 (Part-III) to provide positive
locking against unintentional disengagement of socket from
the ball of the insulator. The security clip shall be humped to
maintain the clip in the locked position and shall have both
prongs spread to prevent complete withdrawal from the
socket. The clip end shall not project outside the recess of
socket when the clip is in locked position.
6.08.10.2 The hole for the security clip shall be on the side of the
socket opposite to the socket opening . The hole for the clip
shall be counter sunk. The clip eye shall be of such design
that the same may be engaged by a hotline clip puller to
provide for disengagement under energized conditions.
6.08.10.3 The force required to pull the clip to its unlocked position
shall not be less than 50 N or more than 500N.
6.08.10.4 The security clip shall be made of stainless steel of type
AISI 302 or 304 or phosphor bronze as per IS:7814.
6.08.11 Clevis-Eye:
These shall be forged steel of malleable cast iron and shall be complete
with galvanised pin with flat washer and split pin of Phosphorus
Bronze/Stainless Steel.
6.08.12 Yoke Plate:
6.08.12.1 The yoke plates/link plate shall be made of mild steel plate
as per IS: 2062 or equivalent standards. Shearing/cutting of
the plates shall be clean without drawn or ragged edges. If
the plates are flame cut, mechanical guides shall be used. It
shall be ensured that the grain flow of the yoke plate shall be
in the direction of the tensile load.
6.08.12.2 Holes shall be cylindrical clean cut and perpendicular to the
plane of the material. The periphery of the holes shall be free
from burrs.
6.08.12.3 All the corners and edges should be rounded off with a
radius of at least 3mm.
6.08.12.4 Design calculation is for bearing and tensile strength for
deciding the dimensions of yoke plate shall be furnished by the
Contractor. The holes provided for bolts in the yoke plate
should satisfy shear edge condition as per IS:800.

Volume-V Part-1
6.09 IMPORTANT CONDITIONS:

6.09.01 All Hardware items shall be complete with minor items such
as security clip, bolts, nuts, washer, split pins and inners etc.
6.09.02 Enclosed drawings show the attachment proposed to be
fitted on the towers. The Contractor shall be responsible for satisfying
him that the Insulator fittings offered are entirely suitable for the
proposed attachments and for the sizes of the Conductor specified.
6.09.03 All ferrous fittings (except those specified otherwise) shall
be hot dip galvanized, after all machining and fitting has been
completed, in accordance with relevant Indian Standard. All Hardware
items (other than clamps) and those specified otherwise should be
made of Drop Forged Steel. Socket items in forged steel must be
forged. All forgings supplied should be stress relieved and this
treatment should be done at the Contractor works. Forgings, which are
not stress relieved, will not be acceptable. The items like Yoke Plate,
Arcing Horn, Bolts and Nuts shall be of mild steel and rest of the items
shall be of forged steel.
6.09.04 All Bolts, Nuts and Screw heads shall have only wide worth
standard thread and of sizes indicated in the enclosed drawing. Bolts
head and Nuts shall be hexagonal. Where required, nuts shall be locked
in approved manner. The thread in Nuts shall be over tapped after
galvanizing and shall be cut before galvanizing. The threads shall not be
under cut. The Nuts should be tapped such that they are fit on the bolt
threads i.e. these should not have loose fitting.
6.10 LENGTH OF STRINGS:

6.10.01 The clearance to the tower steel parts under service
conditions of Insulator have been decided on the basis that the overall
length of 9 Disc for 132kV line and 13 Disc for 220kV line (both of 7000
kgs EMS for single suspension string) will not exceed the length as
indicated in the attached drawings. The dimension of the Disc for Ball
and Socket type will be 255mm (dia) x145mm (height) for 7000 kgs
EMS to be used with suspension strings on 132kV and 220kV lines.
6.10.02 In case of 132kV tension strings, 10 Disc insulators of 9100
kg EMS of size 255mm (dia) x 145mm (height) will be used. In case of
220kV tension strings, 14 Disc insulators of 16,500 kgs EMS of size
280mm (dia) x 170mm (height) will be used.
6.11 GALVANISING:
6.11.01 Hot dip galvanizing shall conform to Indian Standard
specification IS-2633 or equivalent International Standard. Galvanising
shall be uniform, free from blisters, and shall not peel off due to
abrasion, Zinc coating shall be thick enough to withstand 6 one minute

Volume-V Part-1
dips in Copper Sulphate solution (precee test) for all ferrous parts
except for threaded portions which shall withstand at least 4 one
minute dips.
6.11.02 The Contractor must emboss/engrave their name in each
forged steel item and Aluminium castings such as Ball Hook, Yoke Plate,
Socket Clevis, Clevis Eye, Clevis-Clevis, Anchor Shackle/D-Shackle,
Chain Link, Suspension Clamps of AGS type, Tension Clamps and Arcing
Horns.
6.12 TESTS :
6.12.01 The hardware fittings offered shall be type tested as per the
relevant standards. Further the acceptance, routine tests and tests
during manufacture shall be carried out on the conductor.
out on each and every product so as to check with requirements which
are likely to vary during production.
6.12.04 Tests during manufacture shall mean those tests, which are
to be carried out during the process of manufacture and end inspection
by the Contractor to ensure the desired quality of the end product to be
supplied by him.
6.12.05 The norms and procedure of sampling for these tests will be
as per the Quality Assurance Programme to be mutually agreed to by
the Contractor and the Employer.
6.12.06 The standards to which these tests will be carried out are
listed in para 6.01. Where a particular test is a specific requirement of
this specification, the norms and procedures of the test shall be as
shall be the values guaranteed by the Contractor in the “Technical
6.13 ACCEPTANCE TEST/SAMPLE TESTS:
6.13.01 On both suspension and tension hardware fittings:

a. Visual Examination IS:2486 (Part-I)
b. Verification of dimensions IS:2486 (Part-I)
c. Galvanising test/Electroplating As per this
specification.

Volume-V Part-1
d. Mechanical strength test of welded joint As per this

specification.
e. Mechanical strength test for corona control BS:3288(Part-I)
rings.
f. Test on locking devices for ball & socket IEC:372(2)
coupling.
g. Mechanical strength test of each components As per this
excluding corona control ring and arcing horn. specification.
6.13.02 On suspension Hardware fittings only:

a. Clamp slip strength vs torque test for As per this
suspension clamp. specification.
b. Shore hardness test of elastomer cushion for
AG suspension clamp.
c. Bend test for armour rod set.
d. Re silence test for armour rods set. IS:2121 (Part-I)
e. Conductivity test for armour rods set
6.13.03 On tension hardware fittings only

a. Slip strength test for dead end assembly IS:2486 (Part-I)
6.13.04 Suspension hardware for Earth wire.

a. Visual examination
b. Dimensional verification.
c. Slip strength test.
d. Mechanical strength test on each component
e. Galvanising test
f. Mechanical strength test of welded joint
6.13.05 Tension hardware for Earth wire

d. Electrical resistance test .
6.13.06 Test during manufacture.

a. On all components as applicable.
b. Chemical analysis of zinc used for galvanizing
c. Chemical analysis, hardness test grain size
inclusion rating and magnetic particle
inspection for forgoing/castings.

Volume-V Part-1
d. Chemical analysis and proof load test

fabricated hardware.
e. Tests on malleable castings forgings and
fabricated hardware’s.
6.14 MATERIALS AND WORKMANSHIP:
6.14.01 All the materials shall be of the latest design and conform
to the best modern practice adopted in the extra high voltage field. The
manufacturer shall supply only such material as guaranteed by him to
be satisfactory and suitable for 220/132kV Transmission lines.
6.14.02 The design, manufacturing process and quality control of all
the materials shall be such as to give maximum factor of safety,
maximum possible working load, highest mobility, elimination of sharp
edges and corners, best resistance to corrosion and a good finish.
6.14.03 All ferrous parts shall be hot dip galvanised, after all
machining has been completed. Nuts may, however, be tapped
(threaded) after galvanising and the threads oiled. Spring washers
shall be electro galvanised. The bolts threads shall be under cut to take
care of increase in diameter due to galvanising. Galvanising shall be
done in accordance with IS:2629-1990 or equivalent International
Standard and satisfy the tests mentioned in IS:2633-1992 or equivalent
International Standard. Fasteners shall withstand four dips while spring
washers shall be guaranteed to withstand at least six dips each lasting
one minute under the standard precee test for galvanising.
6.14.04 The Zinc coating shall be perfectly adhere, of uniform
thickness, smooth, reasonably bright, continuous and free from
imperfections such as flux, ash, rust stains, bulky while deposits and
blisters. The Zinc used for galvanising shall be grade Zn. 99.95 as per
IS: 209-1992 or equivalent International Standard.
6.14.05 In case of castings, the same shall be free from all internal
defects like shrinkage, inclusion, blowholes, cracks etc.
6.14.06 All current carrying parts shall be so designed and
manufactured that contact resistance is reduced to minimum.
6.14.07 No item which would produce high electrical and mechanical
stresses in normal working shall have sharp ends or edges, abrasions or
projections and shall not cause any damage to the Conductor in any
way during erection or during continuous operation. The design of
adjacent metal parts and mating surfaces shall be such as to prevent
corrosion of the contact surface and no maintain good electrical contact
under service conditions.
6.14.08 Particular care shall be taken during manufacturing and
subsequent handling to ensure smooth surface free from abrasion or
dents.

Volume-V Part-1
6.14.09 The fasteners shall conform to the requirement of IS: 6639-

1972 or equivalent International Standard. All fasteners and clamps
shall have locking arrangements to guard against vibration loosening.
6.15 IDENTIFICATION MARKING:

The main component of the material covered in the specification shall
be legibly and indelibly marked with the trademark of the
manufacturer, the month and year of manufacture, the guaranteed
combined mechanical and electrical strength in kilo-Newton
abbreviated by ‘kN’ to facilitate easy identification and proper use.
Marks shall be forged or stamped with a steel die before Galvanizing.
The marks shall be distinct, durable and conspicuous.
Embossing/Engraving should be done at the time of manufacturing
process itself, but before Galvanizing. Smaller component like bolts &
nuts, split pin and washers etc. may be excluded from this
requirement.

the employer.
6.16.01 INSPECTION :As specified in clause 1.13 Section-1 of the

biding document, Plant to be supplied will be subject to inspection and
6.16.02 The acceptance of any quantity of material shall in no way
relieve the Contractor of his responsibility for meeting all the
requirement of this specification and shall not prevent subsequent
rejection, if such materials are later found to be defective.
the material covered in the specification.
6.17 DOCUMENTATION & LIST OF DRAWINGS:
6.17.01 The detailed drawings of each component assembly
drawings and descriptive literature of the Hardware assembly shall be
submitted for approval of EMPLOYER. The detailed dimension drawings
for each and all-individual Hardware items such as clamps, U Clevis,
Socket Eye, Yoke Plate and Socket Clevis etc. shall also be submitted
separately. Test certificates for different tests conducted as per relevant
ISS, for all the offered items must also be submitted essentially.

Volume-V Part-1
6.17.02 The bidder shall furnish full description, illustrated

catalogues and dimensional drawings, along with the bid. The drawing
shall include the following information:
(i) General outline & assembly drawings of all the items
/material covered in the specification.
(ii) Dimensions, unit spacings
(iii) Unit mechanical and electrical characteristics as also for the
complete assembly/set .
(iv) Weight of each component.
(v) Identification mark.
(vi) Material designation used for different components with
reference to Standards.
(vii) Fabrication details such as welds, finishes and coatings
(viii) Manufacturer’s catalogue number.
(ix) Brief installation instructions.
(x) Reference of type testing.
(xi) Relevant technical details of significance.
6.18 PACKING:
6.18.01 The material shall be packed in strong wooden boxes with

steel straps. The gross weight of packing shall be in range of 50 kgs to
200 kgs to avoid handling problem. The packing shall be strong
enough to withstand rough handling during transit or storage in the
field. All the packing cases shall be legibly marked to avoid possibility
of loss in transit. The Contractor shall be responsible for any damage
during transit due to improper and inadequate packing and handling.
6.18.02 Each consignment shall be accompanied by a detailed
packing list showing following details:-
(i) The name of the consignees
(ii) Details of consignment.
(iii) Destination.
(iv) Total weight of consignment.
(v) Handling and unpacking instrumentation.
(vi) Bill of material indicating content of each
package.

Volume-V Part-1
APPENDIX-2
BEFORE AND AFTER COMPRESSION DIMENSIONS OF

COMPRESSION TYPE DEAD-END CLAMPS AND REPAIR SLEEVE
FOR CONDUCTOR AND EARTH WIRE
Dimension before
Dimension after Length of sleeve Length of sleeve
compression (Rod
compression (Flat before after compression
Sl. cross section)
to flat distance of compression
Particular
No. hexagon)
Panth Zebr G/ W Panth Zebra G/ W Panth Zebr G/ W Panth Zebr G/ W
er a er er a er a
A Aluminium sleeve
a Inner 23 31 - - - -
dimension
(mm)
b Outer 38 48 - 32 40 - 610 711 - 660 763 -
dimension
(mm)
B Steel sleeve
a Inner 9.35 9.95 11.5 - - -
dimension
(mm)
b Outer 18 19.2 21 15 16.1 17.5 203 241 230 233 270 262
dimension
(mm)
C Repair sleeve
Outer 38 48 20.8 32 46 17.5 241 279 150 270 310 175
dimension
(mm)

Volume-V Part-1
SECTION- 7
TECHNICAL SPECIFICATION FOR ACCESSORIES FOR
220/132kV LINES
7.01 INDIAN STANDARDS/EQUIVALENT INTERNATIONAL

STANDARD:
This section provides for the Design, manufacturing, stage testing,
inspection and testing before despatch, packing and delivery of
Accessories suitable for Conductor and Earth wire for use on 132/220kV
transmission lines. The material and services under this specification
shall be performed as per the requirements of the latest revisions and
amendments available at the time of placement of order of all the
relevant Indian Standards/Codes listed here under or equivalent
International Standards, except as modified in this document:
S.No Indian Title
Standard/equivalent
International Standards
2 IS:206 –1992 Tee and Strap Hinges
3 IS:7814-1985 Phosphor Bronze Sheet and Strip
4 IS:2071 Part-I, II & III Method of high voltage testing
5 IS:731 Porcelain Insulator for Overhead Power
Lines with a Nominal Voltage Greater
than 1000 V.
7 IS:1385 Phosphor Bronze Rods & Bar Sheet and
Strips and Wire
8 IS:2004 Carbon Steel Forgings for General
Engineering Purpose
11 IS:2121(Part-I & II) Specification for Conductors and Earth
wire Accessories for Overhead Power Line,
Armour Rods Binding Wires and Tapes for
Conductor
12 IS:2486 Specification for Insulator Fittings for
Overhead Power Lines with a Nominal
Voltage Greater than 1000 V.
Part-I General Requirements and Tests
Part-II Dimensional Requirements
Part-III Locking Devices
Part-IV Tests for Locking Devices
13 IS:2629 Recommended Practice for Hot Dip

Volume-V Part-1
S.No Indian Title

Standard/equivalent
14 IS:2633 Testing of Uniformity of Coating of Zinc
coated Articles
17 IS:6745 Determination of Weight of Zinc Coating
on Zinc Coated Iron and Steel Articles
19 IS:4218 Part-I to VI Isometric screw Threads
20 IS:4172 Dimensions for Radii under the Heads of
Bolts & Screws
21 IS:4206 Dimensions for nominal lengths and
Thread length for Screws and Studs
(with amendment)
22 IS:4759 Hot Dip Zinc Coatings on Structural Steel
and other Allied Products
23 IS:1573-1986 Electroplated Coatings of Zinc on Iron and
Steel
24 IS: 398 (Part-II & III) Specification for Aluminium Conductor
Steel Reinforced for overhead
transmission purpose.
25 IS: 1327-1966 Methods for determination of weight of tin
Coating on Tin Plates
26 IS: 4826-1979 Hot Dip Galvanised Coating on Round
Steel Wires
27 IS: 1363 Part-I to III Hexagon Head Bolts, Screws & Nuts.
28 IS: 1367 Technical supply conditions for threaded
Steel Fasteners.
IS: 1367 (Part-I) Introduction and General Information.
IS: 1367 (Part-II) Product Grades and Tolerances.
IS: 1367 (Part-III) Mechanical Properties and Test Methods
for Bolts, Screws and Studs with full
Load ability.
29 IS: 9708 Stockbridge Vibration Dampers for
Overhead Power lines.
30 IS: 8263 Method of Radio Interference Tests on
High Voltage Insulators.
32 IS: 2004 Carbon Steel Forgings for general
engineering purposes.
33 BS:970 (Part-I) General Instructions and Testing
Procedures Specific Requirements for
Carbon and Carbon Manganese Alloy and

Volume-V Part-1
S.No Indian Title

Standard/equivalent
Stainless Steels.

7.02.01 Bidders will have to furnish confirmation in regard to
compliance of our entire technical requirement. The bid should clearly
describe various technical particulars of the material as per details
given in this section. Based on above information all details required
should be furnished so that we may be able to examine whether the bid
submitted is technically acceptable or not.
7.02.02 Details of Accessories:
i. The Conductor Accessories shall be suitable for ACSR
Conductor as per technical parameters furnished in
Annexure-1.
ii. The Earth wire accessories shall be suitable for Earth wire
as per technical parameters furnished in Annexure-1.
7.03 GENERAL TECHNICAL REQUIREMENTS FOR ACCESSORIES:
The technical requirements of the individual Accessories are as
under:
7.03.01 Mid Span Joints and Repair Sleeves:

i. The Mid Span Joints for Conductor & Earth wire shall be
compression type.
ii. The Conductor Mid Span Joints shall comprise of Aluminium
and Steel Sleeves. The Earth wire Mid Span Joints and Steel
Sleeves of Conductor Mid Span Joints shall be Hot dip
Galvanized. Sleeves shall be of circular shape suitable for
compression into hexagonal shape. The detailed drawing
showing the length of Sleeves, inner and outer cross sectional
dimension, before compression for Aluminium corresponding
dimensions of hexagon after compression for Aluminium and
Steel Sleeve shall be indicated. The Aluminium Sleeve shall be
of extruded Aluminium. The material of the Steel Sleeve shall
be specified.
iii. The Repair Sleeve of Conductor shall be in two halves
preferably of same shape, and this should be of extruded
Aluminium. The Repair Sleeve for Earth wire shall be single
piece and Hot dip Galvanized. Its material shall be specified.
The Repair Sleeves shall be of circular shape suitable for
compression into hexagonal shape.

Volume-V Part-1
iv. The steel and Aluminium Sleeves for Mid Span Joints as well
as Aluminium Repair Sleeves and Steel Repair Sleeves shall
have their outer dia tapered towards the two ends. Also the
inside of the Sleeves shall be well rounded off, so that there is
no sharp edge, which can cut the strands.
v. The compression type of Joints and Repair Sleeves shall be
circular shape suitable for compression into hexagonal shape.
The length of Sleeves before compression & cross-sectional
dimensions after compression and the cross sectional
dimensions between the flats of the opposite sides of the
hexagon & other dimensions are indicated in Appendix-2,
Section-6 in Volume-II of bid document.
vi. Other dimensions are indicated in the enclosed drawing.
vii. The Joints and Repair Sleeves shall conform to IS:2121/1981
or equivalent International Standard.
viii. The conductor compressed with mid span joint or with repair
sleeve shall not permit slipping of, damage to or failure of
complete conductor or any part thereof at a load of not less
than 95% of the ultimate tensile strength of the conductor.
ix. The electrical resistance of the joint/repaired portion of the
conductor shall not exceed 75% of the measured resistance of
equivalent length of conductor.
7.03.02 4R-VIBRATION DAMPERS FOR PANTHER & ZEBRA
ACSR:
7.03.02.1 Only Vibration Dampers having 4-resonance frequency
characteristic commonly called 4R Dampers shall be offered.
The Damper shall eliminate fatigue on the Conductor due to
vibration and damp-out the vibrations effectively, so that no
damage due to vibration is caused to Conductor and string.
7.03.02.2 The Dampers are to be used at all tension locations and
suspension locations. One or more Dampers are proposed to
be used on tension/suspension locations depending upon the
span. The Damper shall be such as to effectively damp out the
vibration on the conductor, so that the dynamic strain at the
suspension point with conventional type of Suspension Clamp
‘U’ bolt and keeper pieces, shall not exceed 150 micro strains.
Contractor shall recommend the number of Dampers required
to effectively damp out the vibration of the Conductor, so that
the dynamic strain at the suspension point with conventional
Suspension type Clamp shall not exceed 150 micro strains.
7.03.02.3 The requirement indicated in Schedule-I Ais based on use of
two Vibration Dampers per Conductor per span. However,

Volume-V Part-1
final requirement will depend upon Bidder’s recommendations

duly supported by literature. Contractor shall also recommend
the number of Dampers required to effectively damp out
Conductor vibration for different values of span lengths and
the distance for fixation. While working out Damper
Characteristics, it may be kept in view that on suspension
locations, preformed Armour rods are also to be fitted on the
conductor. Contractor shall given full details of the damper
characteristics and energy dissipation curves of the Damper
and shall also guarantee their effectiveness for damping
design.
7.03.02.4 The messenger cable shall be made of high strength steel
strands of spring steel with a minimum strength of 136 Kg/sq.
mm and preformed in order to prevent subsequent dropping of
weights in service. The Contractor shall indicate full technical
particulars of the messenger cable. The keeper pieces shall
have proper curvature and edges be rounded off so that it
shall have proper grip over the conductor without any damage
to conductor strands. Clamping bolts shall be provided with
self-locking nuts designed to prevent corroding of the threads
or loosening during service ensuring that no slippage occurs up
to specified longitudinal force on clamp along the conductor.
All ferrous parts including the messenger cable shall be
effectively sealed to prevent corrosion.
7.03.02.5 The collar for fixing the bolt shall be designed in such a way
that sufficient space is available for tightening the bolt through
spanner. Further bolt length be maintained in such a way that
it should not come out completely while affixing the clamp on
Conductor.
7.03.02.6 The Contractor shall specify the material used for the
Damper weight and shall confirm and explain, how constant
design characteristics will be maintained during production.
Fixing of the masses to the messenger cable shall be done by
pressing Aluminium Sleeves at each end of the messenger
cable under pressure. Each end should be sealed properly so
as to achieve prefect joint. The molten metal filling method
for attachment of messenger cable to counter weight is not
acceptable.
7.03.02.7 The Dampers shall meet the test requirements
specified hereunder:
The effectiveness of the Vibration Dampers shall be to reduce
the amplitude of vibration, when tested for span of 320 meters
for Panther and 335 meters for Zebra ACSR, tension taken as
25% of ultimate tensile strength in such a order that it limits
the dynamic strain in the Conductor below 150 micro strains

Volume-V Part-1
for 0 to 15 miles per hour wind condition in general and 2 to

10 miles per hour wind condition in particular condition,
conforming to as close as possible to the optimum damping
force requirement which the Contractor can predict and
furnish for the ranges of wind velocity and the conductor
tension.
7.03.02.8 The Contractor shall furnish the recommended spacing and
the basis including wind velocity range for selecting the
spacing. The results of the analysis shall account for the
following:
i. Prediction of (a) Amplitude (b) Frequency and (c) Vibration
energy levels of Aeolian vibration on Panther and Zebra
ACSR for spans of 50, 100, 150, 200, 250, 300, 350, 400,
450 and 500 meters.
ii. Test results for various frequency response characteristics
of Vibration Dampers such as vibration amplitude and phase
angle including power dissipation measured from its
hysteretic loops.
7.03.02.9 Maximum residual vibration must be of such an order that
the strain level does not exceed 150 micro strains.
7.03.02.10 The Vibration Dampers and their attachments shall have
smooth surface so that corona and radio interference voltage
levels are within specified limits.
7.03.02.11 All Ferrous parts shall be fully galvanized..
7.03.02.12 The Vibration Damper shall be capable of being installed
and removed from energized line by means of hot line tools
without completely separating components. The Damper
Assembly shall be electrically conductive. The transmission line
details are as under:-
S. Description Technical Particulars
No. 220kV 132 kV
1 Configuration Single ACSR Single ACSR
Zebra Panther
2 Span length in meters:
i. Ruling design span 350 350
ii. Maximum span 500 M 500 M
iii. Minimum span 100 100
3 Tensile load in Kg:
i. At minimum temp. of 0o C 4064 2794
and still air

Volume-V Part-1
S. Description Technical Particulars

No. 220kV 132 kV
ii. At every day temp. of 32o C 3329 2282
iii. At 0o C and 2/3rd full wind 4360 3050
4 Nature of terrain Partly hilly, partly flat with
cultivated fields
5 Armour rods/AGS clamp AGS clamps
6 Maximum wind load 45 Kg/m2 Acting on full
projected area.
7 Max permissible dynamic 150 micro strains
strains
The Contractor shall recommend the number of vibration dampers of

the type offered and their points of fixation for spans of 100M to 1000M
in steps of 50M.
7.03.02.13 The other important features of vibration dampers as
regards to materials test, etc., are as under: -
Material:
i. Dampers - As per IS-9708/1993 or equivalent
ii. Clamp - Aluminium alloy
iii. Messenger cable - High strength steel wire with a
strength (kg/sq. mm) not less than the
strength of steel core of power
Conductor/Earth Wire.
iv. Weight - Cast Iron (Hot dip Galvanized)
Galvanising:
i. Spring washers - Electro Galvanized.
ii. Other Ferrous parts - Hot Dip Galvanized.

iii. Casting - As per IS:729-1961 or equivalent
iv. Wires - As per IS:326-1968 or equivalent
v. Bolts & Nuts - As per IS:5358-1969 or equivalent
Slip strength of Clamp:

Volume-V Part-1
i. Not less than 250 kg. When an untested Vibration Damper

is installed on Panther and Zebra ACSR Conductor.
ii. Not less than 200 kg. After conducting the fatigue test.
Maximum permissible dynamic strain - 150 micro strains.
on the Conductor with the Damper
Minimum number of cycles for fatigue - 10 millions
Performances.
Amplitude for fatigue test - ±1 mm at the highest
Resonant frequency.
Radio interference voltage at - Less than 500
microvolts.
266 kV (rms) phase to ground.
7.04 4R VIBRATION DAMPERS FOR 7/3.66MM 95 Kg PER MM2

QUALITY EARTH WIRE:
7.04.01 The design and general particulars of Vibration Damper for
Earth wire shall be the same as described for Dampers for Conductor,
Preformed Armour Rods will be used at Earth wire suspension locations.
The dynamic strain at suspension point shall not exceed 150 micro
strains.
7.04.02 The entire test as described for Vibration Dampers for
Conductor shall be carried out except for Magnetic Power Loss Test.
7.05 FLEXIBLE G.I. EARTH BONDS:
The flexible G.I. MS earth bond shall be made of flexible MS wire of size
37/7/0.417 with 9.81mm dia and area equivalent to 34 sq.mm. The
length of MS wire shall not be less than 500mm. Two steel connecting
lugs shall be press jointed to the either ends of the flexible MS cable.
One end of the lug shall have hole of 17.5mm size and another of
14.5mm. The complete assembly shall also include one 16mm dia
40mm long HRH M.S.Bolt hot dip galvanized with nut and lock washer.
7.06 TECHNICAL PARTICULARS FOR “ CLAMPS ”
7.06.01 All the current carrying parts shall be designed and
manufactured to have minimum contact resistance. There shall not be
any sharp edges which may lead to accumulation of charge & electrical
breakdown. All corners/ edges shall be rounded.
7.06.02 The clamps shall be liberally designed and certain minimum
contact surface shall be provided.
7.06.03 The clamps and fittings shall be designed so that insulators
shall not be subject to any abnormal stresses due to thermal changes in
conductor.

Volume-V Part-1
7.06.04 All the clamps & fittings shall enable the connection to be as
short as possible. Wherever possible the clamps shall be two separate
halves. No “U” bolts shall be used. All components of like design shall
be inter-changeable
7.06.05 All nuts, bolts & washers shall be made of Hot dip
galvanized Mild Steel conforming to relevant ISS only.
7.06.06 The clamp in all respect shall incorporate highest quality of
modern engineering design and workmanship. The specification is
merely for the guidance of the Contractor as has been clearly stated
earlier and it is not the intention to specify the details of design and
workmanship. The clamps shall be designed and manufactured in
accordance with the Contractor’s standard practices, when such
practices do not conflict with this specification.
7.06.07 The materials offered shall be complete with all components
and accessories which are necessary or useful for their satisfactory
performance and efficient maintenance. Such parts shall be deemed to
be within the scope of this specification whether specifically included or
not.
7.06.08 The design should be such that adequate clamping pressure
is obtained with the tightening of the nuts and the pressure should be
maintained throughout the service of the connector. In order to provide
for creep of Aluminium under pressure, it is essential that only Belleville
washers are used. This should be specifically confirmed and should also
indicate tightening torque required.
7.06.09 All clamps shall be suitable to carry safely the maximum
allowable current in the associated conductor and to withstand the
maximum loads occurring under adverse circumstances and operating
conditions. The maximum fault current is 40 KA rms for a period of 3
seconds. The temperature of the clamps and fittings shall never exceed
that of the associated conductor.
7.06.10 Fittings intended to connect two dissimilar metals shall be
designed to avoid harmful bimetallic corrosion under service condition,
by way of provision of best quality bimetallic strips.
7.06.11 The short circuit current shall be of the order of 40 KA for 3
seconds. The clamps should be suitable to withstand the short circuit
forces corresponding to this current.
7.06.12 The design of clamps should be such that proper space for
movement of normal quality single head spanner during tightening is
available. This is an important requirement and should be confirmed by
the Contractor.
7.07 Materials:
7.07.01 The Clamps & Connectors/Spacers shall be made of
materials listed below: -

Volume-V Part-1
i. For connecting ACSR conductor Aluminium alloy casting

conforming to designation A6 of IS:617.(Redesignation 4600)
ii. Bolts, Nuts, plain washers and spring washers for above
items shall be made of hot dip galvanized Mild Steel
conforming to relevant IS only.
The Contractor shall ensure that the Alloy used assures good
stability and sound casting by proper fluidity. Proper
mechanical and physical strength characteristics should be
obtained corresponding to the standard requirements of the
Alloy specified.
7.07.02 The Contractor shall ensure that the Alloy used assures
good stability and sound casting by proper fluidity. Proper mechanical
and physical strength characteristics should be obtained corresponding
to the standard requirements of the Alloy specified.
7.07.03 The clamps bodies shall be made by gravity die-casting only
and thereafter given the appropriate heat treatment and precipitation
treatment. Clamps bodies made by sand casting shall not be accepted
in any case.
7.08 CASTINGS:
All casting shall be free from blow holes, surface, Blisters and shall be
rounded off.
7.09 CONSTRUCTIONAL DETAILS:

7.09.01 All sharp edges and corners shall be blurred and rounded
off.
7.09.02 Thickness of the clamps shall not be less than 12mm
7.09.03 Bolts and nuts shall have hexagonal heads and threads as
per Indian Standard.
7.09.04 Flexible connectors, braids or laminated straps shall be
made from tinned copper strips or aluminium laminates depending
upon the clamp.
7.09.05 Size of terminal / conductor for which the clamps is suitable
shall be embossed on each component of the clamp.
7.09.06 Casting should be such that adequate free space for
placement and movement of spanners for tightening of nuts is
available.
7.10 BOLTS, NUTS & WASHERS:

These shall be as per Indian Standard and shall have tensile strength
and elongation as per grade 5.6. The Contractor should ensure proper
tightening either by use of Belleville or by the use of torque wrenches.

Volume-V Part-1
7.11 GALVANISING:
Hot dip galvanizing shall conform to Indian Standard specification IS-
2633 or equivalent International Standard. Galvanising shall be
uniform, free from blisters, and shall not peel off due to abrasion, Zinc
coating shall be thick enough to withstand 6 one minute dips in Copper
Sulphate solution (precee test) for all ferrous parts except for threaded
portions which shall withstand at least 4 one minute dips.
7.12 TESTS:
7.12.01 The hardware fittings offered shall be type tested as
per the relevant standards. Further the acceptance, routine tests
and tests during manufacture shall be carried out on the conductor.
out on each and every product so as to check with requirements which
are likely to vary during production.
7.12.04 Tests during manufacture shall mean those tests, which are
to be carried out during the process of manufacture and end inspection
by the Contractor to ensure the desired quality of the end product to be
supplied by him.
7.12.05 The norms and procedure of sampling for these tests will be
as per the Quality Assurance Programme to be mutually agreed to by
the Contractor and the Employer.
7.12.06 The standards to which these tests will be carried out are
listed in para 6.01. Where a particular test is a specific requirement of
this specification, the norms and procedures of the test shall be as
shall be the values guaranteed by the Contractor in the “Technical
7.13 TYPE TESTS:
7.13.01 Flexible G.I. Bond for Earth wire:

Slip strength test
7.13.02 Mid span compression joint for conductor & Earth

wire.

Volume-V Part-1
i. Slip strength test

ii. Electrical Resistance test
Iii Healing cycle test
iv. Corona Extinction voltage As per IS 2121,2633
test dry. 6745
v. Radio interference voltage
test Dry.
vi. Galvanising test
7.13.03 Repair Sleeve for conductor:
i Electrical Resistance test.
ii. Corona Extinction Voltage test. As per IS 2121
iii. Radio Interference voltage test dry.
7.13.04 Vibration Damper for conductor & Earth wire
a. Chemical analysis of material
b. Dynamic Characteristic Test.
c. Vibration Analysis.
d. Clamp Slip test.
e. Fatigue Test.
f. Magnetic power loss test.
g. Corona extinction voltage test (Dry).
h. Radio interference voltage test (Dry).
i. Damper efficiency test.
NOTE: Tests mentioned at (f)(g)&(h) are not applicable to dampers

for Earth wire.
7.13.05 Clamps
(i) Tensile Test
(ii) Resistance Test
(iii) Temperature rise Test As per IS:5561
(iv) Short time current Test
(v) Dimensional Check
(vi) Galvanising Test
7.14 ACCEPTANCE TEST:
7.14.01 FLEXIBLE G.I. BOND:

a. Visual examination IS:2121
b. Dimensional verification
7.14.02 Midspan Compression Joint for Power

Conductor & Earth wire

Volume-V Part-1
i. Visual examination
ii. Dimensional verification.
iii. Galvanising Test
iv. Hardness test.
v. Failing load test (test to be
conducted after 24 hours of
compression).
7.14.03 Repair Sleeves for Conductor.
7.14.04 Vibration Damper for power conductor/ Earth
wire.
iv. Verification of resonance
frequencies
v. Clamp slip test
vi. Clamp bolt torque test
vii. Strength of messenger cable.
viii. Mass pull off test.
7.14.05 Clamps
i. Tensile Test
ii. Resistance Test
iii. Dimensional Check
iv. Galvanising Test
7.14.06 Test during manufacture.
i. On all components as applicable.
ii. Chemical analysis of zinc used for
galvanizing
iii. Chemical analysis, hardness test
grain size inclusion rating and
magnetic particle inspection for
forgoing/castings.
iv. Chemical analysis and proof load
test.
v. Tests on malleable castings
forgings and fabricated
hardware’s.
7.15 MATERIAL AND WORKMANSHIP:
7.15.01 All the materials shall be of the latest design and conform
to the best modern practice adopted in the extra high voltage field.

Volume-V Part-1
The Contractor shall offer only such equipment as guaranteed by him to

be satisfactory and suitable for 220/132kV Transmission lines.
7.15.02 The design, manufacturing process and quality control of all
the materials shall be such as to give maximum factor of safety,
maximum possible working load, highest mobility, elimination of sharp
edges and corners, best resistance to corrosion and a good finish.
7.15.03 All ferrous parts shall be hot dip galvanised, after all
machining has been completed. Nuts may, however, be tapped
(threaded) after galvanising and the threads oiled. Spring washers
shall be electro galvanised. The bolts threads shall be under cut to take
care of increase in diameter due to galvanising. Galvanising shall be
done in accordance with IS:2629-1966 or equivalent International
Standard and satisfy the tests mentioned in IS:2633-1972 or equivalent
International Standard. Fasteners shall withstand four dips while spring
washers shall be guaranteed to withstand at least six dips each lasting
one minute under the standard precee test for galvanising.
7.15.04 The Zinc coating shall be perfectly adhere, of uniform
thickness, smooth, reasonably bright, continuous and free from
imperfections such as flux, ash, rust stains, bulky while deposits and
blisters. The Zinc used for galvanising shall be grade Zn. 99.95 as per
IS: 209-1966 or equivalent International Standard.
7.15.05 In case of castings, the same shall be free from all internal
defects like shrinkage, inclusion, blowholes, cracks etc.
7.15.06 All current carrying parts shall be so designed and
manufactured that contact resistance is reduced to minimum.
7.15.07 No item which would produce high electrical and mechanical
stresses in normal working shall have sharp ends or edges, abrasions or
projections and shall not cause any damage to the Conductor in any
way during erection or during continuous operation. The design of
adjacent metal parts and mating surfaces shall be such as to prevent
corrosion of the contact surface and no maintain good electrical contact
7.15.08 Particular care shall be taken during manufacturing and
subsequent handling to ensure smooth surface free from abrasion or
dents.
7.15.09 The fasteners shall conform to the requirement of IS: 6639-
1972 or equivalent International Standard. All fasteners and clamps
shall have locking arrangements to guard against vibration loosening.
The main component of the material covered in the specification shall
be legibly and indelibly marked with the trademark of the
manufacturer, the month and year of manufacture, the guaranteed
combined mechanical and electrical strength in kilo-Newton

Volume-V Part-1
abbreviated by ‘kN’ to facilitate easy identification and proper use.

Marks shall be forged or stamped with a steel die before Galvanizing.
The marks shall be distinct, durable and conspicuous.
Embossing/Engraving should be done at the time of manufacturing
process itself, but before Galvanizing. Smaller component like bolts &
nuts, split pin and washers etc. may be excluded from this
requirement.

the employer.
7.18 INSPECTION :

7.18.02 At least 5% of the total number of drums subject to
minimum of two in any lot put up for inspection, shall be selected at
random to ascertain the length of conductor by following method:
“At the works of the manufacturer the conductor shall be
transferred from one drum to another at the same time measuring its
length with the help of graduated pulley and Cyclometer. The difference
in the average length thus obtained and as declared by the Contractor
in the packing list shall be applied to all the drums if the conductor is
found short during checking”
the Conductor.
7.19 DOCUMENTATION & LIST OF DRAWINGS
7.19.01 The Contractor shall submit the detailed drawings of the

Accessories offered and descriptive literature. The dimensional drawings
for compression type Mid Span Joint (Aluminium & Steel Sleeve),
compression type Repair Sleeve Preformed Armour rods for Conductor
& Earth wire and 4R Vibration Dampers etc. must be submitted. Test
certificates for different tests conducted as per relevant ISS, for all the
offered items must also be submitted essentially.

Volume-V Part-1
7.19.02 The bidder shall furnish full description, illustrated

catalogues and dimensional drawings of offered items ,along with the
bid.. The drawing shall include the following information:
(i) General outline & assembly drawings of all the items
/material covered in the specification.
(ii) Dimensions, unit spacing
(iii) Unit mechanical and electrical characteristics as also for the
complete assembly/set .
(iv) Weight of each component.
(v) Identification mark.
(vi) Material designation used for different components with
reference to Standards.
(vii) Fabrication details such as welds, finishes and coatings
(viii) Manufacturer’s catalogue number.
(ix) Brief installation instructions.
(x) Reference of type testing
(xi) Relevant technical details of significance.
7.20 PACKING:
7.20.01 The material shall be packed in strong wooden boxes with

steel straps. The gross weight of packing shall be in range of 50 kgs to
200 kgs to avoid handling problem. The packing shall be strong enough
to withstand rough handling during transit or storage in the field. All
the packing cases shall be legibly marked to avoid possibility of loss in
transit. The bidder shall be responsible for any damage during transit
due to improper and inadequate packing and handling.
7.20.02 Each consignment shall be accompanied by a detailed
packing list showing following details:-
(ii) The name of the consignees
(iii) Details of consignment.
(iv) Destination.
(v) Total weight of consignment.
(vi) Handling and unpacking instrumentation.
(vii) Bill of material indicating content of each package.

Volume-V Part-1
SECTION- 8
TECHNICAL SPECIFICATION FOR OPTICAL GROUND WIRE
(OPGW), ASSOCIATED HARDWARE & ACCESSORIES
8 STANDARDS:
8.01 Unless otherwise mentioned in the specification the offered
Optical Ground wire (OPGW) and associated Hardware shall be
manufactured, tested and supplied with all guaranteed technical
particulars generally confirming to meet the requirement of the
latest revisions of relevant standard of International Electro-
Technical Commission or equivalent National Standards of India.
S.
STANDARD TITLE
NO.
1 IEEE 1138 Standard Construction of Composite Fiber Optic
Ground wire (OPGW) for use on Electric Utility
Power Lines
2 ITUT G.652 For Optical Fibers
3 IEC 1396 Requirements and test methods for Optical
Ground wires (OPGW)
4 IEC 1089 Overhead electrical standard conductors
5 IS 2486 Metal fittings of Insulator for overhead power

lines with a nominal voltage greater than 1000V
6 IS 802 Code of practice for use of structural steel in

overhead transmission line
7 IS 875 Code of practice for design load for building &
structural
8 IEC794-1- Test Procedure
C10
9 IS 1804 Fibre cores for steel wire ropes
8.02 Tenderer shall clearly state the standards to which the equipment
offered by them conforms. In the event of offering of equipment
conforming to standards other than IS, the salient points of
comparison between standards adopted and the relevant IS shall
be indicated in the proposal alongwith copies of adopted
standards. It will be sole responsibility of the Tenderer to prove
that the salient features of offered equipment are equivalent or
better than standards specified above.
8.03 GENERAL REQUIREMENT FOR OPGW:

Volume-V Part-1
8.03.01 Fiber and Cladding

Each optical fiber shall consist of a core made of fused silica and the
cladding intimately surrounding the core shall be also fused silica. The
properties of optical fiber are shown in Annexure ‘D’.
8.03.02 Fiber Coating

The clad fiber core shall be coated with UV cured urethane acrylate
resin.
8.03.03 Optical Fiber Unit

OPGW cable construction shall comply with IEEE-1138, 2009. The cable
provided shall meet both the construction and performance
requirements such that the ground wire function, the optical fibre
integrity and optical transmission characteristics are suitable for the
intended purpose. The cable shall consist of optical fibre units as
defined in this specification. There shall be no factory splices within the
cable structure of a continuous cable length.
The composite fibre optic overhead ground wire shall be made up of
multiple buffer tubes embedded in a water tight aluminium/aluminium
alloy/stainless steel with aluminium coating protective central fibre optic
unit surrounded by concentric-lay stranded metallic wires in single or
multiple layers. Each buffer tube shall have maximum 12 no. of fibres.
The dual purpose of the composite cable is to provide the electrical and
physical characteristics of conventional overhead ground wire while
providing the optical transmission properties of optical fibre.
All optical fibre cabling including fibre itself and all associated installation
hardware shall have a minimum guaranteed design life span of 25 years.
Documentary evidence in support of guaranteed life span of cable and
fibre shall be submitted by the Contractor during detailed engineering.
8.03.04 Physical Characteristics

Dual-Window Single mode (DWSM), G.652D optical fibres shall be
provided in the fibre optic cables. DWSM optical fibres shall meet the
requirements defined in Table below.
8.03.05 Attenuation
The attenuation coefficient for wavelengths between 1525 nm and 1575
nm shall not exceed the attenuation coefficient at 1550 nm by more
than 0.05 dB/km. The attenuation coefficient for wavelengths between
1285 nm and 1330 nm shall not exceed the attenuation coefficient at
1310 nm by more than 0.05 dB/km. The attenuation of the fibre shall
be distributed uniformly throughout its length such that there are no
point discontinuities in excess of 0.10 dB. The fibre attenuation
characteristics specified in table below shall be "guaranteed" fibre
attenuation of any and every fibre reel.

Volume-V Part-1
The overall optical fibre path attenuation shall not be more than
calculated below:
Maximum attenuation 0.21 dB/km x total km + 0.05 dB/splice x no.
@ 1550nm : of splices + 0.5 dB/connector x no. of
connectors
Maximum attenuation 0.35dB/km x total km + 0.05 dB/splice x no.
@ 1310nm: of splices + 0.5 dB/connector x no. of
connectors
DWSM OpticalFibre
Characteristics
Fibre Description: Dual-Window Single-Mode
Mode Field Diameter: 8.6 to 9.5 µm (± 0.6µm )
Cladding Diameter: 125.0 µm ± 1 µm
Mode field concentricity ≤ 0.6µm
error
Cladding non-circularity ≤ 1%
Cable Cut-off ≤ 1260 nm
Wavelength A,cc
1550 nm loss As per G.652 D
performance
Proof Test Level ≥ 0.69 Gpa
Attenuation Coefficient: @ 1310 nm ≤ 0.35 dB/km
@ 1550 nm ≤ 0.21 dB/km
Chromatic Dispersion; 18 ps/(nm x km) @ 1550 nm
Maximum: 3.5 ps/(nm x km) @ 1288-1339nm
5.3 ps/(nm x km) @ 1271-1360nm
Zero Dispersion 1300 to 1324nm
Wavelength: Zero 0.092 ps/(nm2xkm) maximum
Dispersion Slope:
½
Polarization mode < 0.2 ps/km^
dispersion coefficient
Temperature Induced attenuation < 0.05 dB (-60°C to
Dependence: +85°C )
Bend Performance: @ 1310 nm (75±2 mm dia Mandrel), 100
turns; Attenuation Rise ≤ 0.05 dB
@ 1550 nm (30±1 mm radius Mandrel),
100 turns; Attenuation Rise ≤ 0.05 dB @
1550 nm (32±0.5 mm dia Mandrel, 1 turn;
Attenuation Rise ≤ 0.50 dB
8.03.06 Fibre Optic Cable Construction

Overhead Fibre Optic Cables shall be OPGW (Optical Ground Wire). The
OPGW cable is proposed to be installed on the 132kV and 220kV EHV
transmission lines spread across the State of Madhya Pradesh in India.

Volume-V Part-1
The design of cable shall account for the varying operating and
environmental conditions that the cable shall experience while in
service. The OPGW cable to be supplied shall be designed to meet the
overall requirements of all the transmission lines. Normally the tower
span of the lines shall not exceed 525 m; however, some of the spans
may be up to around 1000 m or more. To meet the overall requirement
of all the transmission lines, the contractor may offer more than one
design without any additional cost, in case one type of offered OPGW
does not meet the requirements for using on spans more than 525m.
8.03.07 Optical Fibre Cable Link Lengths

The estimated optical fibre link lengths shall be as per transmission line
route length. However, the Contractor shall supply and install the
optical fibre cable as required based on detailed site survey to be
carried out by the Contractor during the project execution. The
Contractor shall verify the transmission line route length during the
survey and the Contract price shall be adjusted accordingly.
For the purpose of payment, the optical fibre link lengths are defined as
transmission line route lengths from Gantry at one terminating station
to the Gantry in the other terminating station. The actual cable lengths
to be delivered shall take into account various factors such as sag,
service loops, splicing, working lengths and wastage etc. and no
additional payment shall be payable in this regard. The unit rate for FO
cable quoted in the Bid price Schedules shall take into account all such
factors.
8.03.08 Optical Fibre Identification

Individual optical fibres within a fibre unit and fibre units shall be
identifiable in accordance with EIA/TIA 598 or IEC 60304 or Bellcore
GR-20 colour-coding scheme.
Colouring utilized for colour coding optical fibres shall be integrated into
the fibre coating and shall be homogenous. The colour shall not bleed
from one fibre to another and shall not fade during fibre preparation for
termination or splicing.
Each cable shall have traceability of each fibre back to the original fibre
manufacturer's fibre number and parameters of the fibre. If more than
the specified number of fibers is included in any cable, the spare fibers
shall be tested by the cable manufacturer and any defective fibres shall
be suitably bundled, tagged and identified at the factory by the vendor.
8.03.09 Buffer Tube

Loose tube construction shall be implemented. The individually coated
optical fibre(s) shall be surrounded by a buffer for protection from
physical damage during fabrication, installation and operation of the

Volume-V Part-1
cable. The fibre coating and buffer shall be strippable for splicing and
termination. Buffer tubes shall be filled with a water-blocking gel.
8.03.10 Optical Fibre Strain

The fibre optic cable shall be designed such that the optical fibres
experience no strain under all loading conditions defined in IS 802. No
fibre strain condition shall apply even after a 25 year cable creep.
For the purpose of these specifications, the following definitions shall

apply:
• Maximum Working Tension (MWT) is defined as the maximum

cable tension at which there is no fibre strain.
• The no fibre strain condition is defined as fibre strain of less
than or equal to 0.05%, as determined by direct measurements
through IEC/ ETSI (FOTP) specified optical reflectometry
techniques.
• The Cable strain margin is defined as the maximum cable strain
at which there is no fibre strain.
• The cable Maximum Allowable Tension (MAT) is defined as the
maximum tension experienced by the Cable under the worst
case loading condition as defined in IS 802.
• The cable max strain is defined as the maximum strain
experienced by the Cable under the worst case loading
condition as defined in IS 802.
• The cable Every Day Tension (EDT) is defined as the maximum
cable tension on any span under normal conditions viz at 32 °C
and no wind.
• The Ultimate /Rated Tensile Strength (UTS/ RTS/ breaking
strength) is defined as the maximum tensile load applied and
held constant for one minute at which the specimen shall not
break.
While preparing the Sag-tension charts for the OPGW cable the
following conditions shall be met:
• The Max Allowable Tension (MAT) / max strain shall be less

than or equal to the MWT/ Strain margin of the cable.
• The sag shall not exceed the earth wire sag in all conditions.
• The Max Allowable Tension shall also be less than or equal to
0.4 times the UTS of OPGW. However, Max Allowable Tension
up to 0.5 times the UTS of OPGW may be accepted, subject to
no fibre strain.
• The 25 year creep at 25% of UTS (creep test as per IEEE 1138)
shall be such that the 25 year creep plus the cable strain at Max
Allowable Tension (MAT) is less than or equal to the cable strain
margin.

Volume-V Part-1
• The everyday tension (EDT) shall not exceed 20% of the UTS for
the OPGW cable.
The Sag-tension chart indicating the maximum tension, cable strain and
sag shall be submitted for the following conditions as specified in IS
802:1977/1995:-
a. 53 oC, no wind, no ice

b. 32 oC, no wind, no ice
c. 0 oC, no wind, no ice
d. 32 oC, full wind, no ice
e. 0 oC, 2/3rd / 36% of full wind (IS 802:1977/1995)
However, the same shall not be exceeding the limiting values as

under:-
S.N Particulars E Series B Series

o. (132 kV Towers) (220 kV Towers)
1. Wind Load 189 Kg/meter2 194 Kg/meter2
2. Design Span 350 meter 350 meter
3. Sag at 0°C with Nil Wind 4.835 meter 5.508 meter
4. Max Sag at 53°C with Full
6.19 meter 6.91 meter
Wind
5. Max Tension at 32°C with
3400 Kg 3300 Kg
Full Wind
The above cases shall be considered for the spans from 100 m to 525 M
or higher span length in the range of 50 m spans.
8.03.11 Cable Materials

The materials used for optical fibre cable construction, shall meet the
following requirements:
8.03.12 Filling Materials

The interstices of the fibre optic unit and cable shall be filled with a
suitable compound to prohibit any moisture ingress or any water
longitudinal migration within the fibre optic unit or along the fibre optic
cable. The water tightness of the cable shall meet or exceed the test
performance criteria as per IEC-60794-1-F-5.
The filling compound used shall be a non-toxic homogenous

waterproofing compound that is free of dirt and foreign matter, non-
hygroscopic, electrically nonconductive and non-nutritive to fungus. The
compound shall also be fully compatible with all cable components it
may come in contact with and shall inhibit the generation of hydrogen
within the cable.

Volume-V Part-1
The filling compound shall remain stable for ambient temp. between -
20°C and +65°C and shall not drip, flow or leak with age or at high
temperatures during short duration lightning strikes and short circuit
currents The filling compound shall meet the requirements of “Seepage
of Filling Compound test” as per EIA/TIA 455-81.
The waterproofing filling materials shall not affect fibre coating, colour
coding, or encapsulant commonly used in splice enclosures, shall be
dermatologically safe, non-staining and easily removable with a non-
toxic cleaning solvent.
8.03.13 Metallic Members

When the fibre optic cable design incorporates metallic elements in its
construction, all metallic elements shall be electrically continuous.
8.04 COMPLETED OPGW

The optical fiber unit shall be surrounded with a number of strands of
aluminium-clad steel wires. The direction of outermost layer shall be
left-handed (S direction).
8.04.01 Optical Ground Wire (OPGW)

OPGW cable construction shall comply with IEEE-1138-2009 and IEC
publication 1396. The cable provided shall meet both the construction
and performance requirements such that the ground wire function, the
optical fibre integrity and optical transmission characteristics are
suitable for the intended purpose.
The composite fibre optic overhead ground wire shall be made up of
buffered optical fibre units embedded in a water tight
aluminium/aluminium alloy/stainless steel protective central fibre optic
unit surrounded by concentric-lay stranded metallic wires in single or
multiple layers. However, other material may be accepted subject to
meeting the cable type-testing requirements as specified in the
technical specifications. The dual purpose of the composite cable is to
provide the electrical and physical characteristics of conventional
overhead ground wire while providing the optical transmission
properties of optical fibre.
8.04.02 Central Fibre Optic Unit

The central fibre optic unit shall be designed to house and protect
multiple buffered optical fibre units from damage due to forces such as
crushing, bending, twisting, tensile stress and moisture. The central
fibre optic unit and the outer stranded metallic conductors shall serve
together as an integral unit to protect the optical fibres from
degradation due to vibration and galloping, wind and ice loadings, wide

Volume-V Part-1
temperature variations, lightning and fault current, as well as

environmental effects which may produce hydrogen. The OPGW design
of dissimlar materials for stranded wires and tubes are not
allowed.Central fibre optic unit may be of aluminium/ aluminium alloy /
stainless steel tube. There shall be no exposed areas of tubing that can
make electrical contact either directly or indirectlly through moisture,
contamination, protrusions, etc with the surroundings stranded
wires.The tube may be fabricated as a seamless tube, seam welded, or
a tube without a welded seam.
8.04.03 Basic Construction

The cable construction shall conform to the applicable requirements of
Technical Specification, applicable clauses of IEC 61089 related to
stranded conductors and Table 8.04.05 OPGW Mechanical and
Electrical Characteristics. In addition, the basic construction shall
include bare concentric-lay-stranded metallic wires with the outer layer
having left hand lay. The wires may be of multiple layers with a
combination of various metallic wires within each layer. The direction of
lay for each successive layer shall be reversed.
The Wires shall be so stranded that when the complete OPGW is cut,
the indivisual wires can be readily regrouped and then held in place by
one hand.
8.04.04 Breaking Strength

The rated breaking strength of the completed OPGW shall be taken as
no more than 90 percent of the sum of the rated breaking strengths of
the individual wires, calculated from their nominal diameter and the
specified minimum tensile strength.
The rated breaking strength shall not include the strength of the optical
unit. The fibre optic unit shall not be considered a load bearing tension
member when determining the total rated breaking strength of the
composite conductor.
8.04.05 Electrical and Mechanical Requirements

Table below provides OPGW Electrical and Mechanical Requirements for
the minimum performance characteristics. Additionally, the OPGW
mechanical & electrical characteristics shall be similar to the electrical &
mechanical characteristics of the earthwire being replaced such that
there is no or minimal consequential increase in stresses on towers. The
existing earthwire parameters are listed in appendices. For the
purposes of determining the appropriate Max Working Tension limit for
the OPGW cable, IS 802:1995 and IS 875: 1987 shall be applied.
However the OPGW sag & tension charts shall be based on IS 802. For
the OPGW cable design selection and preparation of sag tension charts,
the limits specified in this section shall also be satisfied. The Bidder
shall submit sag-tension charts for the above cases with their bids.

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Table 8.04.05
OPGW Electrical and Mechanical Requirements
1 Everyday Tension at ≤ 20% of UTS of OPGW

32ºC, no wind:
2 D.C. Resistance at 20ºC: < 1.0 ohm/Km
Short Circuit Current: ≥6.32 kA for 1.0 second(for 220 kV
3 & above line)
≥5.6 kA for 1.0 second (for 132 kV &
above line)
8.04.06 Operating conditions

Since OPGW shall be located at the top of the EHV transmission line
support structure, it will be subjected to Aeolian vibration, Galloping
and Lightning strikes. It will also carry ground fault currents. Therefore,
its electrical and mechanical properties shall be the same or similar as
those required of conventional ground conductors.
8.04.07 Live Line Installation Suitability

OPGW shall be suitable for installation under live line condition, i.e. with
all circuits charged to the rated line voltage as specified in this section.
8.05 SPECIFIC REQUIREMENTS FOR OPGW

ACCESSORIES:
Assemblies and Line Accessories
a. General
The OPGW assemblies and line accessories shall consist of the

hardware indicated herein. All hardware and accessories shall be
made of aluminium, aluminium alloy, malleable iron, steel (metal
mould of drop forging process), stainless steel, or non-ferrous metal,
unless otherwise specified. In addition, all hardware and accessories
shall have an ultimate tensile strength equal to or exceeding the
rated ultimate tensile strength of the overhead ground wire. All
metal shall be free from burrs, sharp edges, lumps and dross, and
shall be smooth, so that interconnecting parts will fit properly, and
so that the parts may be assembled and readily.
Unless otherwise specified, all ferrous metal shall be galvanized in

accordance with ASTM A153. Bolts and nuts shall be galvanized after
being threaded, and excessive zinc shall be removed; they shall run
freely (hand fit) for the entire length of the thread. Re-tapping of

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nuts after galvanizing is permitted. Each piece of hardware shall be

permanently marked by casting or die-forging.
All bolts and other fasteners shall be installed according to
manufacturer’s recommendations. Materials not specifically covered
herein by detailed specifications shall be of standard commercial
quality suitable for the intended use. The Contractor shall determine
the most suitable type of clamp to be used at each and every
transmission tower location.
b. Suspension Assembly Clamps
Preformed armour grip suspension clamps and aluminum alloy

armour rods/reinforcing rods shall be used. The suspension clamps
shall ne designed to carry a vertical load of not less than 25KN. The
suspension clamps slippage shall occur between 12kN and 17kN as
measured.
The Contractor shall supply all the components of the suspension

assembly including shackles, bolts, nuts, washers, split pins, etc. the
total drop of the suspension assembly shall not exceed 150mm
(measured from the centre point of attachment to the centre point of
the OPGW). The design of the assembly shall be such that the
direction of run of the OPGW shall be the same as that of the
conductor.
c. Tension Clamps
All dead end clamp assemblies shall preferably be of performed

armoured grip type and shall include all necessary hardware for
attaching the assembly to the tower strain plates. Dead end clamps
shall allow the OPGW to pass through continuously without cable
cutting. The slip strength shall be rated not less than 95% of the
rated tensile strength of the OPGW.
d. Vibration dampers
Stockbridge type vibration dampers, suitable for use on the OPGW

shall be supplied. The dampers shall have an aluminum clamping
bolt, or other suitable device, on the galvanized wire between the
weights, and be suitable for attachment to the OPGW. The damper
clamp shall be designed to permit installation and removal using hot
line tools. Each damper weight, subject to the accumulation of
moisture, shall be provided with one drain hole positioned at the
bottom of the weight when the damper is installed in the vertical

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plane. Damper weights shall be made of hot dip galvanized cast iron
or steel.
The Vibration analysis of the system, with and without damper and
dynamic characterstics of the damper as detailed in Technical
specification, shall have to be submitted. The Technical paticulars for
vibration analysis and damping design of the system are as follows:-
S.No. Description Technical Particulars

Span Lengths in meters
(i) Ruling design span: 350 meters
(ii) Maximum span: 1100 meters
(iii) Minimum Span: 100 meters
Cofiguration: As per Specifications
Tensile load in each: As per sag tension
calculations
Armour rods used: Standard performed
armour rods / AGS
Maximum Permissible dynamic +/- 150 micro strains
strain:
e. Armour Rods
The armor rods for the OPGW shall be of the preformed type. They
shall be smooth and free from corrosion, splitting, cracking, or any
other defects. They shall be designed to effectively protect the
OPGW from fatigue caused by vibration.
f. Down Lead Clamp
The tenderer should offer Down Lead Clamp suitable for OPGW & the
offered clamps should meet requirement stipulated in the relevant
standard. Details of Down Lead Clamp including drawing shall be
submitted with the offer.
g. Joint Box
The joint box shall be air-tight, water-proof. The cover shall be

securely fastened to the case by non-loosening fasteners. Both the
case and the cover shall be made of non-corrosive aluminum alloy or
hot dip galvanized steel or approved materials. The joint box shall be
sufficiently rugged and sturdy to withstand outdoor climatic and
environmental conditions. The joint box shall accommodate sheath
protected arc-fusion splices and up to 1.5 m of additional fiber on
each side of the splice; guides shall be provided to keep the extra
fiber well above the allowable bending radius of the fiber. The spliced

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parts of the optical fiber within the joint box shall be reinforced and
free from tension after completion of the splicing.
The Supplier shall provide one set of terminating materials with

every joint box for optical fiber connection.
1. Way Joint Box for OPGW

This type of joint box shall be used to straight joint OPGW to
OPGW, or OPGW to approach cable. It shall be used at all
locations requiring such a device except those specified otherwise
in the text or drawings elsewhere in this specification.
2. Way Joint Box for OPGW and approach cable

This type of joint box shall be used to spur joint all fibers
contained in two OPGW cables to OPGW or one multi-core optical
fiber cable at each terminal station, repeater station, or other
location, as detailed in the text or drawings elsewhere in this
Specification.
h. Earth Bond
The Tenderer should offer Earth Bonds suitable for OPGW & the
offered Earth Bonds should meet requirement stipulated in the
relevant standard. Details of Earth Bonds including drawing shall be
submitted with the offer.
i. In-Line Fibre Optic Splice Enclosures
All in-line splices shall be encased in In-Line Fibre Optic Splice

Enclosures. Suitable splice enclosures shall be provided to encase
the optical cable splices in protective, moisture and dust free
environment. In line splice enclosures shall comply to ingress
protection class IP 66 or better. The splice enclosures shall be
designed for the storage and protection of 48 optical fibre splices
and equipped with sufficient number of splice trays for splicing all
fibres in the cable. In-line splice enclosures shall be suitable for
outdoor use with each of the cable types provided under this
contract. Splice enclosures shall be appropriate for mounting on EHV
transmission towers above anti-climb guard levels at about 10
metres from the ground level and shall accommodate pass-through
splicing. The properties of required for Splice Enclosures are shown
in Annexure ‘F’.
8.06 TEST FOR OPGW

TYPE TESTING/ FACTORY ACCEPTANCE TESTS REQUIREMENTS

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Wherever the referenced test procedures or the technical specifications

call for visual inspection for damage, the test report shall include a full
description of observed status of the sample. (Visually inspected
samples shall also be colour photographed and copies of colour
photographs shall be included in type test report)
8.06.01 Type Tests for Optical Fibres

The type tests listed below in Table 4.2 shall be conducted on DWSM
fibres. The tests specific to the cable type are listed in subsequent
sections.
Table 4.2
Type Tests For Optical Fibres
S. Test Name Acceptance Test

No. Criteria procedure
1 Attenuation
2 Attenuation Variation with

Wavelength
3 Attenuation at Water Peak
Temp. Cycling
4 (Temp dependence of
Attenuation)
5 Attenuation With Bending AS per AS per

(Bend Performance) Tender Tender
Specification Specification
6 Mode Field dia.
7 Chromatic Dispersion
8 Cladding Diameter
9 Point Discontinuities of
attenuation
10 Core -Clad concentricity error
11 Fibre Tensile Proof Testing
8.06.02 Type Tests For OPGW Cables

The type tests to be conducted on the OPGW cable are listed in Table
4.3: Type Tests for OPGW Cables. Unless specified otherwise in the
technical specifications or the referenced standards, the optical
attenuation of the specimen, measured during or after the test as
applicable, shall not increase by more than 0.05 dB/Km.
Table 4.3
Type tests for OPGW Cable

Volume-V Part-1
S.No. Test Name Test Test Procedure

Description
1 Water IEEE 1138 IEEE 1138, Section 5.1.1.1
Ingress Test Section 4.1.1.1 (IEC 794-1-F5 /EIA/TIA 455-82B)
IEEE 1138, Section 5.1.1.1
(IEC 794-1-F5 /EIA/TIA 455-82B),
Test duration : 24 hours
2 Seepage of IEEE 1138 IEEE 1138 Preconditioning period : 72

filling Section 4.1.1.2 Section 5.1.1.2 hours. Test duration : 24
compound (EIA/TIA 455- hours.
81B)
Short Circuit IEEE 1138 IEEE 1138 Fibre attenuation shall be
Test Section 4.1.1.3 Section 5.1.1.3 continuously monitored and
recorded through a digital
Or data logging system or
equivalent means.
A suitable temperature
sensor such as thermocouple
shall be used to monitor and
record the temperature
inside the OPGW tube in
addition to monitoring &
recording the temperatures
between the strands and
between optical tube and the
strand as required by IEEE
1138.
Test shall be conducted
with the tension clamps
proposed to be supplied. The
cable and the clamps shall be
visually inspected for
mechanical damage and
photographed after the test.
IEC 60794-1-2 Initial temperature during

(2003) the test shall be greater than
Method H1 or equal to ambient field
temperature. However,
maximum temperature
recorded on any component
of OPGW cable shall not
exceed the Short Circuit
transient peak temperature
guaranteed by the
Contractor during design.
4 Aeolian IEEE 1138 IEEE 1138 Fibre attenuation shall be
Vibration Section 4.1.1.4 Section 5.1.1.4 continuously monitored and
Test recorded through a digital
data logging system or
equivalent means.
The vibration frequency and

amplitude shall be monitored
and recorded continuously.
All fibres of the test cable

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sample shall be spliced

together in serial for
attenuation monitoring.
Test shall be conducted with
the tension/suspension
clamps proposed to be
supplied. The cable and the
clamps shall be visually
inspected for mechanical
damage and photographed
after the test.
5 Galloping test IEEE 1138 IEEE 1138 Test shall be conducted with
Section 4.1.1.5 Section 5.1.1.5 the tension/suspension
supplied. The cable and
after the test. All fibres of
the test cable sample shall
be spliced together in serial
for attenuation monitoring.
6 Cable Bend Procedure 2 in IEC:794-1-E11 The short-term and long-
Test term bend tests shall be
conducted in accordance with
Procedure 2 in IEC:794-1-
E11 to determine the
minimum acceptable radius
of bending without any
increase in attenuation or
any other damage to the
fibre optic cable core such as
bird caging, deformation,
kinking and crimping.
Fibre attenuation shall be
7 Sheave Test IEEE 1138 IEEE 1138 continuously monitored &
Section 4.1.1.6 Section 5.1.1.6 recorded through a digital
IEC 60794-1-2 equivalent means. The
(2003) Sheave dia. Shall be based
on the pulling angle and the
Method E18B
minimum pulley dia
employed during installation.
8 Crush Test IEEE 1138 IEEE 1138 The crush test shall be
Section 4.1.1.7 Section 5.1.1.7 carried out on a sample of
approximately one (1) metre
(IEC 794-1-E3/ long in accordance with
EIA/TIA 455- IEC:794-1-E3. A load equal
41B) to 1.3 times the weight of a
400-metre length of fibre
optic cable shall be applied
for a period of 10 minutes. A

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permanent or temporarily
increase in optical
attenuation value greater
than 0.1dB change in sample
shall constitute failure. The
load shall be further
increased in small
increments until the
measured attenuation of the
optical waveguide fibres
increases and the failure load
recorded along with results.
9 Impact Test IEEE 1138 IEEE 1138, The impact test shall be
Section 4.1.1.7 Section 5.1.1.7 carried out in accordance
(IEC 794-1-E4/ with IEC:794-1-E4. Five
EIA/TIA 455- separate impacts of 0.1-
25B) 0.3kgm shall be applied. The
radius of the intermediate
piece shall be the reel drum
radius ± 10%. A permanent
or temporary increase in
optical attenuation value
greater than 0.1 dB/km
change in sample shall
constitute failure.
10 Creep Test IEEE 1138 IEEE 1138 As per Aluminium Association
Section 4.1.1.8 Section 5.1.1.8 Method , the best-fit straight
line shall be fitted to the
recorded creep data and
shall be extrapolated to 25
years. The strain margin of
the cable at the end of 25
years shall be calculated. The
time when the creep shall
achieve the strain margin
limits shall also be
calculated.
IEEE 1138 IEEE 1138
11 Fibre Strain
Section 4.1.1.9 Section 5.1.1.9
Test
12 Strain Margin IEEE 1138 IEEE 1138
Test Section Section 5.1.1.10
4.1.1.10
13 Stress strain IEEE 1138 IEEE 1138
4.1.1.11
14 Cable Cut-off IEEE 1138 IEEE 1138
wavelength Section Section 5.1.1.12
Test 4.1.1.12
15 Temperature IEEE 1138 IEEE 1138
Cycling Test Section Section 5.1.1.13
4.1.1.13
16 Corrosion EIA/TIA 455-16A
(Salt Spray)
Test

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17 Tensile IEC 794-1-E1 / The test shall be conducted on a sample of

Performance EIA/TIA 455- sufficient length in accordance with IEC:794-1-
Test 33A E1. The attenuation variation shall not exceed
0.05 dB/kM up to 90% of RTS of fibre optic
cable.
The load shall be increased at a steady rate up
to rated tensile strength and held for one (1)
minute. The fibre optic cable sample shall not
fail during the period. The applied load shall
then be increased until the failing load is
reached and the value recorded.
18 Fault IEEE Std. 4- Tension equal to 20% of the OPGW RTS shall be
Current/ 1978 applied to a sample with minimum length of 15
lightning Test m of cabled fibres and two separate 4/10 micro
second current impulses each having a peak
value of 150 KA and a negative polarity shall be
applied through a 1 cm gap. The attenuation
during the tests shall be continuously measured.
After the tests the same shall be visually
inspected. Any increase in optical waveguide
fibres attenuation measured at 1550 nm shall
constitute failure.
Fibre attenuation shall be continuously

monitored and recorded through a digital data
logging system or equivalent means.
The tensile performance test shall be repeated
on the sample subjected to the lightning arc
test.
IEC 60794-1- The cable construction shall be tested in
2(2003) accordance with Method H2
19 DC On a fibre optic cable sample of minimum 1 metre length, two

Resistance contact clamps shall be fixed with a predetermined bolt torque.
Test The resistance shall be measured by a Kelvin double bridge by
placing the clamps initially zero metre and subsequently one
metre apart. The tests shall be repeated at least five times and
the average value recorded after correcting at 20 C.
8.07 Type Test on OPGW Cable Fittings

The type tests to be conducted on the OPGW Cable fittings and
accessories are listed below:
8.07.01 Mechanical Strength Test for Suspension/Tension

Assembly
Applicable Standards: IS: 2486 / IEC: 61284 :1997.
8.07.01.1 Suspension Assembly

The armour rods /reinforcement rods are assembled on to the approved
OPGW using the Installation Instructions to check that the assembly is
correctly fitted and is the same that will be carried out during
installations.

Volume-V Part-1
Part 1:
The suspension assembly shall be increased at a constant rate up to a
load equal to 50% of the specified minimum Failure Load increased and
held for one minute for the test rig to stabilise. The load shall then be
increased at a steady rate to 67% of the minimum Failure Load and
held for five minutes. The angle between the cable, the Suspension
Assembly and the horizontal shall not exceed 16o. This load shall then
be removed in a controlled manner and the Protection Splice
disassembled. Examination of all the components shall be made and
any evidence of visual deformation shall be documented.
Part 2:
The Suspension clamp shall then be placed in the testing machine. The
tensile load shall gradually be increased up shall gradually be increased
up to 50% of the specified Minimum Failure Load of the Suspension
Assembly and held for one minute for the Test Rig to stabilise and the
load shall be further increased at a steady rate until the specified
minimum Failure Load is reached and held for one minute. No
fracture should occur during this period. The applied load shall then be
increased until the failing load is reached and the value shall be
documented.
8.07.01.2 Tension Assembly

The Tension Assembly is correctly fitted and is the same that will be
carried out during installations.
Part 1:
The tension assembly (excluding tension clamp) shall be increased at a
constant rate up to a load equal to 50% of the specified minimum
Failure Load increased at a constant rate and held for one minute for
the test rig to stabilise. The load shall then be increased at a steady
rate to 67% of the minimum Failure Load and held for five minutes.
This load shall then removed in a controlled manner and the Tension
Assembly disassembled. Examination of the Tension Dead-End and
associated components shall be made and any evidence of visual
deformation shall be documented.
Part 2:
The Tension Dead-End and associated components shall then be
reassembled and bolts tightened as before. The tensile load shall
gradually be increased up shall gradually be increased up to 50% of the
specified Minimum Failure Load of the Tension Assembly and held for
one minute for the Test Rig to stabilise and the load shall be further
increased at a steady rate until the specified minimum Failure Load is
reached and held for one minute. No fracture should occur during this
period. The applied load shall then be increased until the failing load is
reached and the value shall be documented.

Volume-V Part-1
Acceptance Criteria:
- No evidence of binding of the Nuts or Deformation of components at

end of part 1 of Test.
- No evidence of Fracture at the end of one minute at the minimum

failure load during Part 2 of the Test.
Any result outside these parameters shall constitute a failure.
8.07.02 Clamp Slip Strength Test for Suspension Assembly

The suspension assembly shall be vertically suspended by means of a
flexible attachment. A suitable length fibre optical cable shall be fixed in
the clamps. Once the Suspension Clamp has been assembled, the test
rig is tensioned to 1 kN and the position scale on the recorder ‘zeroed’.
The test rig is then tensioned to 2.5 kN and the relative positions of the
Reinforcing Rods, Armour Rods and Suspension Clamp shall be marked
by a suitable means to confirm any slippage after the test has been
completed. The relative positions of the helical Armour Rods and
associated Reinforcing Rods at each end shall be marked and also 2
mm relative position between clamp body and Armour Rods shall be
marked on one side. The load shall be increased to 12 kN at a loading
rate of 3 kN/min and held for one minute. At the end of this one minute
period, the relative displacement between clamp body and the armour
rods shall be observed. If the slippage is 2 mm or above, the test shall
be terminated. Otherwise, at the end of one minute the position of the
clamp body and 2 mm. relative positions between clamp body and
armour rods shall be marked on the other side. After the one minute
pause, the load shall be further increased at a loading rate of 3 kN/min,
and recording of load and displacement shall continue until either the
relative Position displacement between clamp body and armour rods
reaches more than 2 mm.or the load reaches the maximum slip load of
17 kN. On reaching either of the above values the test is terminated.
Visual examination of all paint marks shall be recorded, and a
measurement of any displacement recorded in the Table of Results.
Acceptance Criteria :
The Suspension Clamp has passed the Slip Test if the following
conditions are met :
• No slippage* shall occur at or below the specified minimum slip
load.
* Definition of no slippage in accordance with IEC 61284:1997 :-

Any relative movement less than 2 mm is accepted. The possible
couplings or elongations produced by the cable as a result of the
test itself are not regarded as slippage.
• Slippage shall occur between the specified maximum and minimum

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slip load of 12 - 17 kN.

• There shall be no slippage of the Reinforcing Rods over the cable,
and no slippage of the Armour Rods over the Reinforcing Rods.
• The relative movement (i.e. more than 2 mm between Armour
Rods & Clamp body) between minimum 12 kN and maximum slip
17 kN, shall be considered as slip.
• The Armour Rods shall not be displaced from their original lay or
damaged**.
** Definition of no damage in accordance with convention

expressed in IEC 61284 : 1997 no damage, other than surface
flattening of the strands shall occur.
Any result outside these parameters is a failure.
8.07.03 Slip Strength Test of Tension Clamp

Tension clamps shall be fitted on a 8 m length of fibre optic cable on
both ends. The assembly shall be mounted on a tensile testing machine
and anchored in a manner similar to the arrangement to be used in
service. A tensile load shall gradually be applied up to 20 % of the RTS
of OPGW. Displacement transducers shall be installed to measure the
relative movement between the OPGW relative to the Reinforcing Rods
and Tension Dead -End relative to Reinforcing Rods. In addition,
suitable marking shall be made on the OPGW and Dead-End to confirm
grip. The load shall be gradually increased at a constant rate up to 50
% of the UTS and the position scale of the recorder is zeroed. The load
shall then gradually increased up to 95 % of the UTS and maintained
for one minute. After one minute pause, the load shall be slowly
released to zero and the marking examined and measured for any
relative movement.
- No movement* shall occur between the OPGW and the Reinforcing

Rods, or between the Reinforcing Rods and the Dead-End assembly.
- No failure or damage or disturbance to the lay of the Tension Dead-
End, Reinforcing Rods or OPGW.
* Definition of no movement as defined in IEC 61284 : Any relative
movement less than 2 mm is accepted. The possible couplings or
elongations produced by the conductor as a result of the test itself are
not regarded as slippage.
8.07.04 Grounding Clamp and Structure Mounting Clamp Fit Test

For structure mounting clamp, one series of tests shall be conducted
with two fibre optic cables installed, one series of tests with one fibre
optic cable installed in one groove, and one series of tests with one
fibre optic cable in the other groove. Each clamp shall be installed

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including clamping compound as required on the fibre optic cable. The

nut shall be tightened on to the bolt by using torque wrench with a
torque of 5.5 kgm or supplier's recommended torque and the tightened
clamp shall be held for 10 minutes. After the test remove the fibre optic
cable and examine all its components for distortion, crushing or
breaking. Also the fibre optic cable shall be checked to ensure free
movement within the core using dial callipers to measure the diameter
of the core tube. The material shall be defined as failed if any visible
distortion, crushing, cracking or breaking of the core tube is observed
or the fibre optic cable within the core tube is not free to move, or
when the diameter of the core tube as measured at any location in the
clamped area is more than 0.5 mm larger or smaller of the core
diameter as measured outside the clamped area.
8.07.05 Structure Mounting Clamp Strength Test

The clamp and mounting assembly shall be assembled on a vertical 200
mm x 200 mm angle and a short length of fibre optic cable installed. A
vertical load of 200 kg shall be applied at the end of the mounting
clamp and held for 5 minutes. Subsequently, the load shall be increased
to 400 kg and held for 30 seconds. Any visible distortion, slipping or
breaking of any component of the mounting clamp or assembly shall
constitute failure.
8.07.05.1 Type Test on Vibration Damper
8.07.05.2 Dynamic Characteristic Test

The damper shall be mounted with its clamp tightened with torque
recommended by the manufacturer on shaker table capable of
simulating sinusoidal vibrations for Critical Aeolian Vibration frequency
band as determined through vibration analysis of undamped OPGW..
The damper assembly shall be vibrated vertically with a ±1 mm
amplitude from 5 to 15 Hz frequency and beyond 15 Hz at 0.5 mm to
determine following characteristics with the help of suitable recording
instruments.
(a) Force Vs frequency
(b) Phase angle Vs frequency
(c) Power dissipation Vs frequency
The Force Vs frequency curve shall not show steep peaks at resonance
frequencies and deep troughs between the resonance frequencies. The
resonance frequencies shall be suitably spread within the Aeolian
vibration frequency-band between the lower and upper dangerous
frequency limits determined by the vibration analysis of fibre optic cable
without dampers.
The above dynamic characteristics test shall be conducted on five
dampers. The variations between the samples tested shall conform to
the sample test limits.

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8.07.05.3 Vibration Analysis

The vibration analysis of the fibre optic cable shall be done with and
without damper installed on the span. The vibration analysis shall be
done on a digital computer using energy balance approach. The
following parameters shall be taken into account for the purpose of
analysis.
(a) The analysis shall be done for single fibre optic cable without
armour rods. The tension shall be taken as max Permissible
Every Day Tension (20% of UTS), for a span ranging from
100 m to 1100 m.
(b) The self damping factor and flexural stiffness (EI) for fibre
optic cable shall be calculated on the basis of experimental
results. The details to experimental analysis with these data
shall be furnished.
(c) Examine the Aeolian Vibration level of the fibre optic cable
with and without vibration damper installed at the
recommended location or wind velocity ranging from 0 to 30
Km per hour, predicting amplitude, frequency and vibration
energy input.
(d) From vibration analysis of fibre optic cable without damper,

antinode vibration amplitude and dynamic strain levels at
clamped span extremities as well as antinodes shall be
examined and thus lower and upper dangerous frequency
limits between which the Aeolian vibration levels exceed the
specified limits shall be determined.
(e) From vibration analysis of fibre optic cable with damper(s)

installed at the recommended location, the dynamic strain
level at the clamped span extremities, damper attachment
point and the antinodes on the fibre optic cable shall be
determined. In addition to above damper clamp vibration
amplitude and antinodes vibration amplitudes shall also be
examined.
(f) The dynamic strain levels at damper attachment point,

clamped span extremities and antinodes shall not exceed the
specified limits. The damper clamp vibration amplitude shall
not be more than that of the specified fatigue limits.
8.07.05.4 Vibration Damper Clamp Slip and Fatigue Tests
8.07.05.4.1 Test Set Up

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The clamp slip and fatigue tests shall be conducted on a laboratory set
up with a minimum effective span length of 30m. The fibre optic cable
shall be tensioned at 15kN & shall not be equipped with protective
armour rods at any point.
Constant tension shall be maintained within the span by means of lever
arm arrangement. After the fibre optic cable has been tensioned,
clamps shall be installed to support the fibre optic cable at both ends
and thus influence of connecting hardware fittings are eliminated from
the free span. The clamps shall not be used for holding the tension on
the fibre optic cable. There shall be no loose parts, such as suspension
clamps, U bolts, on the test span supported between clamps mentioned
above. The span shall be equipped with vibration inducing equipment
suitable for producing steady standing vibration. The inducing
equipment shall have facilities for step less speed control as well as
step less amplitude arrangement. Equipment shall be available for
measuring the frequency, cumulative number of cycles and amplitude
of vibration at any point along the span.
8.07.05.4.2 Clamp Slip Test

The vibration damper shall be installed on the test span. The damper
clamp, after tightening with the manufacturer's specified tightening
torque, when subjected to a longitudinal pull of 2.5kN parallel to the
axis of fibre optic cable for a minimum duration of one minute shall not
slip, i.e., the permanent displacement between fibre optic cable and
clamp measured after removal of the load shall not exceed 1.0 mm.
The load shall be further increased until the clamp starts slipping. The
load at which the clamp slips shall not be more than 5kN.
8.07.05.4.3 Fatigue Test

The vibration damper shall be installed on the test span with the
manufacturer's specified tightening torque. It shall be ensured that the
damper shall be kept minimum three loops away from the shaker to
eliminate stray signals influencing damper movement.
The damper shall then be vibrated at the highest resonant frequency of
each damper mass. For dampers involving torsional resonant
frequencies, tests shall be done at torsional modes also in addition to
the highest resonant frequencies at vertical modes. The resonance
frequency shall be identified as the frequency at which each damper
mass vibrates with the maximum amplitude on itself. The amplitude of
vibration of the damper clamp shall be maintained not less than ±25/f
mm where f is the frequency in Hz.
The test shall be conducted for minimum ten million cycles at each
resonant frequency mentioned above. During the test, if resonance shift
is observed, the test frequency shall be tuned to the new resonant
frequency.

Volume-V Part-1
The clamp slip test as mentioned herein above shall be repeated after
fatigue tests without retorquing or adjusting the damper clamp, and the
clamp shall withstand a minimum load equal to 80% of the slip strength
for a minimum duration of one minute.
After the above tests, the damper shall be removed from fibre optic
cable and subjected to dynamic characteristics test. There shall not be
any major deterioration in the characteristics of the damper. The
damper then shall be cut open and inspected. There shall not be any
broken, loose, or damaged part. There shall not be significant
deterioration or wear of the damper. The fibre optic cable under clamp
shall also be free from any damage.
For purposes of acceptance, the following criteria shall be applied:
a) There shall not be any frequency shift by more than

±2Hz for frequencies lower than 15Hz & ±3Hz for
frequencies higher than 15Hz.
b) The force response curve shall generally lie within
guaranteed % variation in reactance after fatigue test in
comparison with that before fatigue test by they
Supplier.
c) The power dissipation of the damper shall not be less
than guaranteed % variation in power dissipation before
fatigue test by the Supplier. However, it shall not be less
than minimum power dissipation which shall be governed
by lower limits of reactance and phase angle indicated in
the envelope.
8.07.06 Type Tests for In Line Splice Enclosures

Following Type tests shall be demonstrated on the In Line Splice
Enclosure(s) (Splice Enclosure/Box). For certain tests, lengths of the
fibre optic cable shall be installed in the splice box, and the fibres must
be spliced and looped in order to simulate conditions of use. The
attenuation of the fibres shall be measured, during certain tests, by
relevant Fibre Optic Test Procedures (IEC 794-1 procedures).
8.07.06.1 Temperature Cycling Test

FO cable is installed in the splice enclosure and optical fibres spliced
and looped. The box must be subjected to 5 cycles of temperature
variations of -40°C to +65°C with a dwell time of at least 2 hours on
each extreme.
Fibre loop attenuation shall be measured in accordance with IEC 794-1-
C10. The variation in attenuation shall be less than ±0.05dB. The final
humidity level, inside the box, shall not exceed the initial level, at the
closing of the box.

Volume-V Part-1
8.07.06.2 Humid Heat test

The sealed splice enclosure, with fibres spliced and looped inside, must
be subjected to a temperature of +55°C ±2°C with a relative humidity
rate of between 90% and 95% for 5 days. The attenuation variation of
the fibres during the duration of the test shall be less than ±0.05dB,
and the internal humidity rate measured, less than 2%.
8.07.06.3 Rain Withstand Test

The splice enclosure with optical fibres cable installed and fibres spliced
fixed, shall be subjected to 24 hours of simulated rain in accordance
with IEC 60 testing requirements. No water seepage or moisture shall
be detected in the splice enclosure. The attenuation variation of the
fibres after the test shall be less than ±0.05dB.
8.07.06.4 Vibration Test

The splice enclosure, with fibres united inside, shall be subjected to
vibrations on two axes with a frequency scanning of 5 to 50 Hz. The
amplitude of the vibrations shall be constant at 0.450mm, peak to
peak, for 2 hours, for each of the vibrations' axes. The variation in
attenuation, of the fibres, shall be less than ±0.05dB. The splice
enclosure shall be examined for any defects or deformation. There shall
be no loosening or visible damage of the FO cable at the entry point.
8.07.06.5 Bending and Torsion test

The splice enclosure, with fibres spliced inside, shall be firmly held in
place and be subjected to the following sequence of mechanical
stresses on the cable:
a) 3 torsion cycles of ±180° shall be exercised on the cable. Each
cycle shall be less than one minute.
b) 3 flexure cycles of the cable, of ±180° with one cycle less than one
minute.
The variation in the attenuation, of the fibres, shall be less than
±0.05dB. The cables connection ring shall remain securely fixed to the
box with the connection maintained firmly. No defects/fissures shall be
noted on the joint ring or on the splice enclosure
8.07.06.6 Tensile test

The splice enclosure with cable fixed to the boxes shall be subjected to
a minimum tension of 448 N for a period of two minutes. No fissure
shall be noted in the connections or on the box.
8.07.06.7 Drop Test

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With 2 lengths of 10 metres of cable fixed to the box, it shall be

dropped five times from a height of 11 metres. There shall be no
fissure, at all, of the box, and the connections shall remain tight. The
test shall be carried out in accordance with procedure described in IEC-
68-2-32.
8.07.07 Factory Acceptance Tests on Fibre Optic Cables

As specified in technical specifications, the Factory acceptance tests
shall be conducted on random sampling of fibre optic cable to be
supplied for the present procurement, prior to any shipment.
8.07.07.1 FAT On Fibre : Optical Acceptance Tests

The Optical acceptance tests listed in Table 4.5.1 below are applicable
for the fibres of all types of Fibre Optic Cables i.e. OPGW and approach
cable to be supplied. The listed tests follow testing requirements set
forth in IEEE standard 1138 section 4.2.2.1 and section 5.2.2.1. The
referenced sections specify the detailed test description. The
acceptance norm shall be as specified in the above mentioned IEEE
standards unless specified otherwise in the technical specifications.
Table 4.5.1
Factory Acceptance Tests for Fibres of all FO cables: Optical Tests
S. Acceptance Test
Test Name
1 Attenuation Coefficient
Point Discontinuities of
2
attenuation
AS per
3 Attenuation at Water Peak AS per
Technical
Technical
4 Chromatic Dispersion Specificatio
Specification
n
5 Core – Clad Concentricity Error
6 Cladding diameter
The test reports for the above tests for all types of the fibres carried out
by the Fibre Manufacturer and used in the OPGW cables and approach
cable shall be shown to the inspector during OPGW cable FAT and shall
be submitted along with the OPGW cable FAT report.
8.07.08 Factory Acceptance Test On OPGW Cable

Volume-V Part-1
The factory acceptance tests for OPGW cable specified below in Table
4.6 follow the requirements set forth in section 4.1.2 and section
5.1.2 of IEEE standard 1138. The FAT shall be carried out on 10% of
offered drums in each lot as specified in technical specifications and the
optical tests shall be carried out in all fibers of the selected sample
drums. The Rated Tensile Strength test shall be carried out on one
sample in each lot.
Table 4.6
Factory Acceptance Tests On OPGW
Applicable standard: IEEE 1138
S. No. Factory Acceptance Test on Manufactured OPGW
1 Attenuation Co-efficient at 1310 nm and 1550 nm
2 Point discontinuities of attenuation
Visual Material verification and dimensional checks as per approved

3
DRS/Drawings
4 Rated Tensile Strength
5 Lay Length Measurements
8.07.09 Factory Acceptance Test On OPGW Fittings
The factory acceptance tests for OPGW Fittings as specified below in

Table 4.7. The sampling plan shall be as per IS 2486:
Table 4.7
Factory Acceptance Tests On OPGW Fittings
S. No. Factory Acceptance Test

Suspension Assembly
1 UTS/Mechanical Strength of the assembly
2 Clamp Slip Test
3
DRS/Drawings
4 Mechanical strength of each component
Tension Assembly
5 Clamp Slip Strength test
6
DRS/Drawings
Vibration Damper
8 Galvanising test on damper, masses and messenger wires
9 Damper response (resonant frequencies)
10 Clamp Slip test
11 Strength of messenger wires

Volume-V Part-1
12 Mass pull off test

13
DRS/Drawings
Structure Mounting Clamp
14 Clamp fit test
15 Clamp Strength test
16
DRS/Drawings
8.07.10 Factory Acceptance Test on In Line Splice Enclosures

The factory acceptance tests for In Line Splice Enclosures as specified
below in Table 4.8:
Table 4.8
Factory Acceptance Tests on In Line Splice Enclosures
Visual check Kit Quantities and Specific Component Number for each
1 component of In Line Splice Enclosure and dimensional checks against the
approved drawings.
8.08 PACKING AND MARKING -

All conductors for export shipment are generally shipped on best
commercial practice non-returnable steel reels having suitable
dimension for winding a specified length.
Each length of cable shall be wound on a separate cable reel and the
cable ends shall be securely fastened to the reel to prevent the cable
from becoming loose in transit or during placing operations. Both ends
of the cable shall be sealed with a suitable plastic cap to prevent the
entry of moisture during shipping, handling and storage. Spare plastic
cap shall be provided with each drum.
The cable shall be shipped on reels designed to prevent damage to the
cable during shipment and installation. The wooden lagging will be
given a preventive treatment from termite and wood preservative
treatment.The construction of reels and markings shall be as per
approved documents.
The wire shall be furnished on reels of sufficiently sturdy construction to
withstand normal shipping, hauling and field erection. The size, length,
weight, manufacturer’s name or trade mark, date of manufacturer
direction of rolling for each drum, and contract number shall be clearly
marked on the outside of each drum. The wire shall be packed to
protect it from moisture, salt, or any other impurities which may cause
rust or other harmful effects.
The packing and shipping requirements for overhead galvanized steel
wire hardware shall be applied for assemblies and line accessories for
OPGW.

Volume-V Part-1
Each package shall be clearly, legibly and durably marked on both sides
as follows:-
a. Name & designation of the consignee (to be furnished
by the purchaser.)
b. Ultimate destination (as required by the purchaser).
c. Items and respective quantities contained in the
package to be furnished by the purchaser.)
d. Net and gross weight of the material.
e. Gross weight of each package.
8.09 DESIGN AND DRAWING DETAILS
The design, manufacture and performance of OPGW and accessories

shall comply with all the requirements of the latest editions of
International codes and standards applicable. Nothing in this
specification shall be construed to relieve the vendor of this
responsibility.
The design and workmanship shall be in accordance with best
engineering practices to ensure satisfactory performance and long
service life and shall be such as has been proved to be suitable for the
intended purpose.
The equipment offered shall be robust and durable. It shall be generally
possible to set up and assemble the equipment without the use of
special tools but in case special tools are required for installation the
same shall be provided free cost basis with the supply of OPGW.
The equipment offered shall require minimum maintenance.All relevant
requirements of data and drawings for galvanized steel wire and its
hardware shall be applicable for OPGW and joint boxes.
8.10 INSTALLATION OF OPGW
The Supplier shall provide a complete description of all procedures and

methods to be used during installation of the OPGW.
The installation methods and tools required for OPGW shall be similar to
those of conventional overhead ground wire. The OPGW shall be strung,
sagged and clipped before phase conductors are strung. The OPGW
shall be connected to the transmission tower for grounding at every
location
8.11 OVERHEAD GROUND WIRE WITH OPTICAL FIBER

CONNECTIONS

Volume-V Part-1
The jointing of overhead ground wires shall be performed using joint

boxes located on tension towers. All overhead ground wire connections
shall be of the underpass variety.
8.11.01 OPTICAL FIBER CONNECTIONS
The jointing of optical fiber shall be performed using arc-fusion splicing.

All cores shall be spliced at every locations, fiber identification shall be
matched and maintained for the entire length of the installation.
The optical fiber splicing loss shall not be more than 0.10 dB for any
one joint, and shall average no more than 0.05 dB per joint on any
given repeater span. Splicing loss shall be measured immediately after
the splice has been made, and if the splice does not meet minimum
standards above, it shall be replaced.
All successful splices shall be protected using a heat shrink protection
sleeve with integrated reinforcement, or some other material/process
providing equivalent protection.
An additional slack of 1 to 1.5 m shall be provided on each side of each
splice, and stored securely in the joint box.
8.11.02 COMPLETENESS OF EQUIPMENT AND BOUGHT OUT

ITEMS
8.11.02.1 Offered material shall be complete in all respects and shall

include all minor component, accessories, small wiring etc., not
specifically mentioned in this order, specifications etc; but essential
for the completeness of the system. Supplier shall not be eligible for
extra charges in respect of such minor components, accessories, small
wiring etc., though not included specifically in this Tender but requires
for satisfactory operation of equipment offered.
8.11.02.2 It is obligatory on the part of supplier to ensure that supply

of all accessories along with Main equipment are simultaneously
delivered to avoid any holdups. Responsibility for obtaining timely
supplies of bought out items will rest on the supplier.
8.11.02.3 It may be noted that in case of damages/shortages

due to improper packing or any other negligence ,replenishment
shall be arranged within one months time. For bought out items,
responsibility for guarantee and obtaining immediate
replacement in case any defects are noticed and also in case
defective supply of any item is reported, will rest on the
suppliers.

Volume-V Part-1
ANNEXURE -A
OPGW TECHNICAL SPECIFICATION

(To be submitted by manufacturer)
Configuration : To be filled by bidder.
Guaranteed value
Description Unit
48 fibers
Applicable standard - IEEE std. 1138:2009
Number of fiber
No. 48
Aluminium-clad steel wire To be filled by Bidder

Aluminium alloy wire
Structure No/dia
Stainless steel tube -do-
Lay direction of outer layer

- (Left-hand (S)
Ratio of length of lay or a layer to nominal

Times To be filled by Bidder
outside diameter of that layer
Outer diameter mm -do-
Aluminium-clad steel wire -do-
2
(*) Cross Aluminium alloy wire mm -do-
section
Steel tube -do-
(*) Approximate weight Kg/km -do-
Rated tensile strength (RTS) (min)

-do-
Ultimate tensile strength (UTS) (min) Kg
2
(*) Modules of elasticity Kg/mm -do-
(*) Co-efficient of linear expansion /deg C -do-
D.C. resistance at 20 deg C (max) ohm/km -do-
Short circuit current capacity for 1 second

(Initial temperature : 40 ° C) KA 6.32
Assumed maximum temperature under short

circuit current deg C To be filled by Bidder
Remark – (*) means data for information only.

Volume-V Part-1
ANNEXURE-B
PROPERTIES OF INDIVIDUAL WIRE

Guaranteed value
Description Unit
48 fibers
Type of individual wire - ACS Wires Al-alloy
Applicable standard -
To be filled To be filled
by bidder by bidder
Standard diameter mm -do- -do-
Tolerance of diameter mm -do- -do-

2
Minimum tensile strength Kg/mm -do- -do-
Minimum elongation in 250 mm % -do- -do-
Minimum conductivity %ACS -do- -do-
Minimum number of twisting

No. -do- -do-
(100 x dia)
Minimum thickness of Aluminium mm -do- -do-
-do-
Properties of wrapping % -do-
ANNEXURE – C
PROPERTIES OF OPTICAL FIBER UNIT

Guaranteed
Description Unit value 48
Fibers
Loose type
(Stainless Steel Tube
Buffer type - type preffered)
Number of Loose tube No. To be filled by bidder
Total No.of Fibers No 48
(*) Diameter Mm To be filled by bidder
Number of empty tube Nos. To be filled by bidder
Loose tube
To be filled by bidder
(*) Material -
Remark : (*) means data for information only.

Volume-V Part-1
ANNEXURE - D
PROPERTIES OF OPTICAL FIBER
Description Unit Guaranteed value

Applicable standard - ITU-TG 652 D
Cladding diameter µm 125±1
Core concentricity error µm ≤ 0.6
Cladding non-circularity % ≤ 1.0
Mode field diameter at 1310 mm (8.6-9.5)+0.6
µm
Attenuation coefficient at 1310 mm dB/km ≤ 0.4
at 1550 mm dB/km ≤ 0.3

Attenuation at water peak at 1383±3 nm dB/km ≤ 0.4
Bend performance
dB/km ≤ 0.05 at 1310 nm
@1310 nm (75±2mm diameter mandrel),
100 turns, Attenuation Rise
dB/km ≤ 0.10 at 1550 nm
@1550 nm (32±0.5mm diameter
mandrel), 1turn
dB/km ≤ 0.50 at 1550 nm
Temperature dependence (-60°C ̃+

dB/km ≤ 0.05 dB
85°C)
Cutoff wavelength for cabled fiber (λ) nm ≤ 1260 nm
Chromatic dispersion
@ 1288 nm ̃1339 nm ps/(nm.km) ≤ 3.5
@ 1271 nm ̃1360 nm ps/(nm.km) ≤ 5.3
@ 1550 nm ps/(nm.km) ≤ 18
Zero dispersion wavelength Nm 1300 to 1324
2
Zero dispersion Slope Ps/Nm .km ≤0.093
½
Polarization mode dispersion (PMD) ps/km ≤0.2
Point discontinuities of attenuation dB ≤0.1@1310&1550 nm
Proof-test level Gpa ≥ 0.69
ANNEXURE-E
COLOR CODE OF OPTICAL FIBER UNIT

Loose Tube : To be filled by bidder.
Fiber Colors(12 No;s)
Blue,Orange,Green,Brown,Slate,white,Red,Black,Yellow,Violet,Pink and Aqua

Volume-V Part-1
ANNEXURE-F
DATA REQUREMENT SHEETS FOR INLINE SPLICE ENCLOSURE
S.
Parameter Unit Particulars
No.
1. Dimensions HWD mm To be filled by bidder
2. Weight Kg To be filled by bidder
3. Color and Finish Stainless Steel AISI 304
4. Cable Glanding & Fixing Mechanical clamp
Stainless Steel AISI 304
5. Construction materials & Gauge
(1.0 - 3.0 )mm
6. Locking arrangements Bolts and nuts
Installation Clearances:
Front access: N/A
7.
Rear access: 2 N/A
Cm To be filled by bidder
Top*Bottom*Slides
8. IP Protection Code IP 68
9. Total number of optical couplings n* To be filled by bidder
10. Provision of pass through splicing Yes/No Yes
Whether filled with suitable
11. Yes/No To be filled by bidder
encapsulant
Method(s) for mounting with the
12. Mechanical
tower
Optical Fiber Cable Accommodations
13. Cable Glanding Cable Blocking

Maximum number of cables that can
14. n* To be filled by bidder
be accommodated
Diameter(s) of cables that can be
15. mm To be filled by bidder
accommodated :
Details of Splice Trays :
Dimension: Mm To be filled by bidder
Material/Gauge: ABS/1 mm
17.
Weight: kg To be filled by bidder
Color & Finish: RAL 7035
Method of mounting: Release
18. Maximum number of splices per tray n* To be filled by bidder
19. Number of splices per tray n* To be filled by bidder
Provision of maximum splice
organizers
Do splice trays require a separate
Yes/No To be filled by bidder
enclosure?
If so:
Manufacturer:
21.
Dimensions: H*W*D Cm
Weight: kg
Color and Finish:
Method(s) of Mounting:

Volume-V Part-1
Construction Materials & Gauge:

Locking arrangements
Front Access:
m
Rear Access:
Top*Bottom*Slides:
22. Excess length of Fiber service loops m 1.5 + 1.5

Volume-V Part-1
SECTION- 9
TECHNICAL SPECIFICATION FOR ERECTION OF 220KV
AND 132KV TRANSMISSION LINES
9.01 INDIAN STANDARDS/CODE :

The material and services under this section shall conform to the
requirements of the latest revisions and amendments available at the
time of placement of order of all the relevant Indian standards/codes
listed here under or equivalent International Standards, except as
modified in this document.
S.N Indian standards Title

o.
1. IS:5613-1995 Code of practice for design, installation
(part-II) and maintenance of overhead power
lines.
Sec.-1 - Designs.
Sec.-2 - Installation &
Maintenance
2. IS:269-1967 Ordinary rapid hardening and low heat

Portland cement.
3. IS:456-2000 Code of practice for plain and

reinforced concrete
4. IS:1786-1966 Cold twisted steel bars for concrete

reinforcements
5. IS:4091-1967 Code of practice for design &

construction of foundation for
transmission line towers & poles
9.02 LINE MATERIALS:

9.02.01 Conductor:
The conductor used in the132kV line will be single ACSR Panther

Conductor and the conductor size is 30/3.00mm A1. + 7/3.00 mm steel
and the conductor used in the 220kV line will be single ACSR Zebra
Conductor and the conductor size is 54/3.18mm A1. + 7/3.18 mm steel.
9.02.02 Earth wire :

Volume-V Part-1
The Earth wire to be used on the line shall be 7/3.66 mm; 95

kg/mm2 quality galvanized steel stranded wire.
9.02.03 Insulator Strings with Hardware Fittings:
(A) For 220kV lines

(i) Single suspension and single tension strings will be used on
the line as under:
a. At suspension locations:
13 disc single suspension strings having 70KN E&MS of
255x145 mm size disc insulators with AGS type clamps
will be used.
b. At tension locations :
14-disc single tension strings with 160 KN E&MS disc
insulators of 280x170 mm size disc insulators will be used
with compression type dead end clamp.
(ii) In the cases of Railway/Road/River/Other transmission line
crossing, double suspension/double tension insulator strings
will be used.
(B) For 132kV lines
(i) Single suspension and single tension strings will be used on
the line as under:
a. At suspension locations:
9 disc single suspension strings having 70KN E&MS of
255x145 mm size disc insulators with AGS type clamps
will be used.
b. At tension locations :
(ii) 10-disc single tension strings with 90 KN E&MS disc insulators
of 255x145 mm size disc insulators will be used with
compression type dead end clamp.
(iii) In the cases of Railway/Road/River/Other transmission line
crossing, double suspension/double tension insulator strings
will be used.
9.02.04 Conductor Accessories:
(i) AGS type suspension clamps shall be used with
suspension strings.
(ii) Vibration Dampers (4-R type) shall be used for Conductors.
9.02.05 Miscellaneous Items:
Enameled Number Plates, Phase Plates and Danger Board, Bolts

and Nuts, Spring washers, Pack washers and other tower

Volume-V Part-1
accessories like ‘D’ Shackle, Hanger, U-Bolts and fasteners etc.,

shall be provided with the tower.
9.03 DETAILED SURVEY/CHECK SURVEY:

The contractor will have to carry out detailed survey of the line for which
route map indicating the proposed alignment of the transmission line
will be handed over by the Employer. If the detailed survey is already
conducted by the Employer for some portion of the line, the profiles for
such portion will be handed over to the Contractor for check survey. It
may please be noted that no check survey is required to be conducted
for the portion of line for which detail survey is conducted by the
contractor himself.
9.03.01 Detailed Survey:-
(d) At the starting point of the commencement of route survey, an

angle iron spike 65 x 65 x 1000mm shall be driven firmly into the
ground to show only 150mm above the ground level. A punch
mark on the top section of the angle iron shall be made to
indicate location of the surveying instrument. Teak wood pegs 50
x 50 x 650 mm shall be driven at prominent positions at intervals
of not more than 750 meter along the transmission line to be
surveyed up to the next angle point. 125 mm wire nails should
be fixed on the top of these pegs to show the location of
instrument. The pegs shall be driven firmly into the ground to
show only 100 mm above ground level. At angle positions,
stones shall be put up for easy identification. Paint mark in
white lead paint shall be put in, about 300 mm squares with a
direction indication, on nearby boulders, rocks, or trees, along
the complete line alignment. At peg position, identification marks
giving the peg position, with reference to painting marks, shall
be given. The white lead paint mark shall indicate to the
individual the direction of alignment from either direction.
(e) Routing/Re-routing of transmission line through
protected/reserved forest area should be avoided. In case it is
not possible to avoid the forests or areas having large trees
completely, then keeping in view of the overall economy, the
route should be aligned in such a way that cutting of trees is
minimum.
(f) The route should have minimum crossings of Major river, Railway
lines, National/State highways, overhead EHV power line and
communication lines.
(g) The number of angle points shall be kept to minimum.
(h) The distances between the terminal points specified shall be kept
shortest possible, consistent with the terrain that is encountered.

Volume-V Part-1
(i) Marshy and low lying areas, river beds and earth slip zones shall
be avoided to minimize risk to the foundations.
(j) It would be preferable to utilize level ground for the alignment.
(k) Crossing of power lines shall be minimum. Alignment will be kept
at a minimum distance of 300 m from power lines to avoid
induction problems on the lower voltage lines.
(l) Crossing of communication line shall be minimized and it shall be
preferably at right angle. Proximity and parallelism with telecom
lines shall be eliminated to avoid danger of induction to them
(m) Areas subjected to flooding such as nalah shall be avoided.
(n) Restricted areas such as civil and military airfield shall be
avoided. Care shall also be taken to avoid aircraft landing
approaches.
(o) All alignment should be easily accessible both in dry and rainy
seasons to enable maintenance throughout the year.
(p) Certain areas such as quarry sites, tea, tobacco and saffron fields
and rich plantations, gardens and nurseries which will present the
Employer problems in acquisition of right of way and way leave
clearance during construction and maintenance should be
avoided.
(q) Angle points should be selected such that shifting of the point
within 100 m radius is possible at the time of construction of the
line.
(r) The line routing should avoid large habitations, densely populated
areas, Forests, Animal/Bird sanctuary, reserve coal belt areas, oil
pipe line/underground inflammable pipe lines etc to the extent
possible.
(s) The areas requiring special foundations and those prone to
flooding should be avoided.
(t) From the field book entries, the route plan and level profile shall
be plotted and prepared to the scales of 1=2000 horizontal and
1=200 vertical on 1 mm/5 mm/1 cm square paper.
(u) If the difference in levels be too high, the chart may be broken up
according to requirement. A 400 meter overlap shall be shown
on each following sheet. The chart shall progress from left to
right. For convenience in handling, the sheet size may be limited
to 594x841 mm (Al) size.
(v) After completing the detail survey, profiles shall be submitted to
the Employer duly spotted with tower for approval. While
submitting the profiles after conducting the detail survey, the

Volume-V Part-1
contractor will also submit a copy of route alignment on the route

map indicating the surveyed route.
9.03.02 Check Survey:-
The Contractor shall conduct the check survey only for such
portion of line for which detailed survey has been done by the Employer
after the profiles are handed over to the Contractor. The check survey
shall include checking of deviation angles, checking of levels at critical
points. After completing the check survey, profiles shall be re-submitted
to the Employer duly spotted with tower for approval.
9.03.03 The requirement of tower site leveling and revetment work, if
required, shall also be marked by the Contractor on the
profiles while carrying out the detail or check survey work.
9.03.04 If due to site conditions any change in the tower
location/provision of extension is considered necessary
compared to approve profiles, the contractor shall bring the
same to the knowledge of the Employer well in time and get
revised approval of the profile before setting the stubs.
The revised approval shall be conveyed to the Contractor by
the Employer.
9.04 APPROVED PROFILE:
(Applicable for check survey only)
9.04.01 The detailed survey may be conducted by the Employer for
some portion of the transmission line and in such case, the
profiles will be handed over to contractor for carrying out
check survey and marking of towers on the profiles. The
profile will be prepared on cm. graph paper on scale 1:2000
horizontal and 1:200 vertical. The profile will be submitted
along with the route map showing the route followed by the
contractor during check survey.
9.04.02 The route alignment surveyed by the Employer shall be
marked at angle points. At angle points concrete blocks shall
be provided and in the straight alignment marking will be done
by pegs.
9.04.03 The Contractor will be responsible for the correct setting of
towers as shown in approved profiles. If towers after erection
are found to be out of the approved alignment/position in the
profile, the Contractor will dismantle and re-erect them
correctly fully at his own cost and without extension of time.
9.04.04 Soil Resistivity:-
While carrying out detailed/ check survey work, the Soil

Resistivity values will have to be measured at convenient points along

Volume-V Part-1
the route, not exceeding 2.50 Km between adjacent points. The Soil
Resistivity wiil be measured using 4 electrod method with an inter
electrod spacing of 50 M . The following formula shall be used :
P=2πaR
Where a = Interelectrod spacing = 50M
R = Earth resistance measured in Ohms
P = Soil Resistivity in Ohm- m
The soil resistivity values shall be submitted duly marked on the
route map and also in the form of statement. The quoted rates for
detailed survey/ check survey work shall be inclusive of cost of
measuring soil resistivity values along the proposed route and the
contractor will not be paid separately for this work.
9.05 EXCAVATION:
9.05.01 Except as specifically otherwise provided, all excavation for
footing shall be made to the lines and grades of the foundation. The
excavation walls shall be vertical and the pit dimensions shall be such
as to allow a clearance of 150mm on all sides from the foundation pit,
where form boxes are used. In undercut/stepped (slab type)
foundations where form box is not required to be used at the base, the
pit dimensions should be as per the standard drawings. All excavation
shall be protected so as to maintain a clean sub-grade, until the footing
is placed, by using timbering, shoring or casing, if necessary. Any
sand, mud, silt or other undesirable materials which may have
accumulated in the excavation shall be removed by the Contractor
before placing concrete.
9.05.02 The Soil to be excavated for tower foundations shall be
classified as under for the purpose of payment of excavation for
tower site leveling and building stone revetment:
(a) Normal Dry Soil : Soil removable by means of ordinary pick
axes and shovels (Normal Soil, intermediate Soil fall
under this category).
(b) Wet Soil : Soil as per (a) above, where the sub Soil water
table is encountered within the range of foundation
depth, the Soil below the water table and that at
locations where pumping or bailing out of water is
required due to presence of surface water, will be
treated as wet Soil.
(c) Black cotton (Dry/Wet) :To be used at locations where soil is
clayey type, not necessarily black in colour, which
shrinks when dry and swells when wet, resulting in
differential movement extending to a maximum depth
of about 3.5 meter below ground level.

Volume-V Part-1
(d) Soft Rock: This will mean fissured rock i.e. decomposed rock,
hard gravel, kankar, limestone, laterite or any other Soil
of similar nature which can be excavated with pick axe,
crow bar etc. However, if required, light blasting may be
resorted to for loosening the material but this will not in
any way entitle the excavation to be classified as hard
rock.
(e) Hard Rock: Hard rock will be that which requires chiseling or
drilling and blasting.
9.05.03 No extra charges shall be admissible for the removal
the fallen earth in the pits when once excavated.
9.05.04 If water is encountered in the foundation pit, de-
watering will have to be done. The cost of dewatering shall be
deemed to be included in the unit rates of excavation for
foundation work.
9.05.05 For excavation of foundation in rock, where blasting is
unavoidable, care should be taken to minimize the volume of concrete
necessary for filling up the blasted area. The blasted area shall be
reduced to the minimum possible so that the specified form for the
foundation could be obtained. No extra payment for excavation in hard
rock shall be allowed if the excavated area exceeds the designed
excavation volumes. Similarly, no extra payment shall be made if
concrete volume exceeds the designed volume due to excessive
blasting.
9.05.06 The payment for excavation shall be made as per actual
type of soil encountered at the time of excavation, but the total
payment for excavation portion shall not exceed the amount as payable
for excavation considering the foundation as classified for that location.
9.05.07 The Contractor shall arrange requisite blasting material,
excavation and drilling equipment, necessary license etc., at his own
cost and the quoted rates shall be deemed to be inclusive of all such
costs.
9.05.08 The decision of the owner shall be final and binding with
respect to classification of soil and foundation.
9.06 CLASSIFICATION OF FOUNDATIONS :
9.06.01 The foundation designs shall depend upon the type of

Soil, sub-Soil water level and the presence of surface water which
have been classified as follows:
(A) For 132 kV Double Circuit /220kV Double Circuit/ 220kV
Multi Circuit lines:-

Volume-V Part-1
(i) Normal dry : To be used for locations where normal

dry cohesive or non-cohesive soils are
met.
(ii) Wet : To be used for locations :
(a) Where sub-soil water is met at
1.5meter or more below the ground level.
(b)Which are in surface water for long
periods with water penetration not
exceeding one meter below the ground
level e.g. the paddy fields.
(iii) Partially Submerged: To be used at locations where sub-soil
water level is met between 0.75 meter to
1.5 meter below the ground level.
(iv) Fully Submerged : To be used at locations where sub-soil
water level is met less than 0.75 meter
below ground level.
(v) Black cotton(Dry/Wet): To be used at locations where soil is
clayey type, not necessarily black in
colour, which shrinks when dry and
swells when wet, resulting in differential
movement extending to a maximum depth
of about 3.5meter below ground level.
(vi) Dry Fissured rock: To be used at locations where decomposed
or fissured rock, hard gravel, kanker,
limestone, laterite or any other soil of
similar nature is met. Under cut type
foundation is to be used for fissured rock
locations.
(vii) Submerged Fissured rock: In case of fissured rock locations
where water level is met at 1.5meter or
more below ground level, submerged
fissured rock foundations shall be adopted.
If after soil investigation, water level is
encountered at less than 1.5meter below
ground level, a separate foundation shall be
developed.
(viii) Hard rock : The locations where chiseling, drilling and

blasting is required for excavation, hard
rock type foundations are to be used.
(B) For 132kV M/C lines:-
(i) Normal dry : To be used for locations where normal

dry cohesive or non-cohesive soils are
met.

Volume-V Part-1
(ii) Black cotton(Dry/Wet):To be used at locations where soil is

clay type, not necessarily black in colour,
which shrinks when dry and swells when
wet, resulting in differential movement
extending to a maximum depth of about
3.5 meter below ground level.
(iii) Dry Fissured rock: To be used at locations where decomposed
or fissured rock, hard gravel, kanker,
limestone, laterite or any other soil of
similar nature is met. Under cut type
foundation is to be used for fissured rock
locations.
(iv) Composite soil: To be used at location where soil is clay
type up to 1 meter depth from top and
balance is Normal/Intermediate soil.
9.07 SHORING OF PITS:

Shoring of pits with shuttering on the internal walls surrounding the
vertical facing of approved dimensions of the pit shall be done when
the Soil condition is so bad that there is likelihood of accident due to
falling of surrounding earth in foundation pit. The cost of carrying out
shoring & shuttering shall be deemed to be included in the unit rate of
excavation for foundation work and no extra payment shall be made on
this account.
9.08 TOWER SITE LEVELLING:
In case of foundations located on sloping ground, it may be necessary
to level the ground for locating the tower. In leveling the tower site,
only excavation will be allowed. The Contractor shall quote separate
rates for excavation for purpose of site leveling for dry Soil, wet Soil,
soft and hard rock in respective Schedule. The requirement of tower
site leveling will be decided by the Employer’s site Engineer and will be
marked by the Contractor in the profiles while carrying out the check
survey work.
9.09 SETTING OF STUBS:
9.09.01 The Contractor shall be responsible for correct setting of
stubs. Discrepancies, if any, shall be brought to the notice of Employer
and final approval shall be taken before execution of work. The stub
shall be set correctly in accordance with approved method at the exact
locations and alignment and imprecisely correct levels. The stub
setting Templates shall be used for proper setting of stubs. Stubs shall
be set in the presence of Employer’s representative available at site
whenever required and for which the contractor shall give adequate
advance intimation to the site Engineer.

Volume-V Part-1
9.09.02 The foundations are to be made as per designs and

drawings approved by the Employer. Extent of the work as defined by
such drawings shall not be exceeded except in very exceptional cases
where the prior approval of Employer has been obtained.
9.09.03 The setting of stubs in hard rock foundation may require
cutting of stubs depending on depth at which hard rock is encountered.
The cutting of stubs and drilling of new holes for fixing cleats etc. shall
be considered inclusive in the rate of foundation of towers in hard rock.
However, the cut pieces of stubs shall be returned to EMPLOYER.
9.09.04 Setting of stub at each location shall be approved by the
Employer’s site Engineer. This approval shall not however, absolve the
Contractor of his responsibility of correct setting of stubs and casting of
foundations, who will be required to rectify the faulty work at his own
expense.
9.10 PLACEMENT OF REINFORCEMENT:
9.10.01 Some of the tower foundations may be designed with steel
reinforcement so as to achieve better foundation strength with lesser
space. The cost of placing of reinforcement steel, binding etc. in the
foundation pit shall be paid as per rate to be quoted in the price
schedule.
9.10.02 The Contractor shall arrange foundation reinforcement steel
etc. at their cost which shall be deemed to be included in the quoted
rate of placement of reinforcement steel. The reinforcement bars will
have to be properly cut, bent in required shape and placed in the
foundation in approved manner after due cleaning of oil, grease or
organic matter. The reinforcement shall be properly tied by binding
wire.
9.11 CONCRETE:
9.11.01 The cement concrete used for the foundation shall be of
1:2:4 mix ratio (M150) with 20mm nominal size stone metal for
chimney portion and 40mm nominal size stone metal for pyramid or
slab portions. 1:3:6 mix ratios (M 100) shall be used for base padding
(lean pad). For RCC, the aggregates shall preferably be of 20mm
nominal size.
9.11.02 The cement required for the purpose of foundations,
building revetment walls etc. shall be arranged by the Contractor at
his own cost, which shall be deemed to be included in the cost of
foundations.
9.11.03 The sand used for the concrete shall be arranged by the
Contractor at his own cost including necessary license etc., which shall
be deemed to be included in the cost of foundations. The sand shall be
composed of hard silicate materials. It shall be clean and of a

Volume-V Part-1
sharp angular grit type and free from earthy or organic matter and
deleterious salts.
9.11.04 The aggregate shall be arranged by the contractor at his
own cost including necessary license etc, which shall be deemed to be
included in the cost of foundations. The aggregate shall be of clean
broken hard granite or other stone specified or approved by the
Employer. It shall be of hard and coarse-grained quality. It shall also
be as far as possible cube like, preferably angular, but not flaky,
perfectly clean and free from earth, organic or other deleterious
matter. 40mm aggregate shall be of size as will pass through a mesh of
40 mm measured in the clear and 20 mm aggregate through 20mm
square mesh measured in clear.
9.11.05 The water used for mixing concrete shall be arranged by
the contractor at his own cost including necessary license etc, which
shall be deemed to be included in the cost of foundations. The water
used shall be fresh, clean and free from oil, acid and alkali, organic
materials or other deleterious substances. Salty/Saline or brackish
water should not be used. Potable water is generally satisfactory.
9.11.06 The concrete shall be mixed in a mechanical mixer.
However in case of locations not accessible for concrete mixers, hand
mixing may be permitted at the discretion of our site Engineer.
9.11.07 Mixing shall be continued until there is uniform
distribution of materials and the mixing is uniform in colour and
consistency but in no case the mixing is done for less than two
minutes. Normally mixing shall be done close to the foundation, but in
case it is not possible, the concrete may be mixed at the nearest
convenient place. The concrete shall be transported from the place of
mixing to the place of final deposit as rapidly as practicable by
methods, which shall prevent the segregation or loss of any ingredient.
The concrete shall be placed and compacted before setting
commences. The transportation cost of these materials shall be
deemed to be included in the cost of foundations.
9.11.08 The concrete should be mixed as stiff as per the
requirements of placing the concrete in the form boxes, with ease and
the degree to which the concrete resists segregation. Hence the
quantity of water used should not be too much.
9.11.09 Proper form boxes adequately braced to retain proper
shape while concreting should be used for chimney or pyramid and slab
portions. The form boxes should be made water tight so that cement
cream may not come out leaving only sand and jelly consequently
forming of honeycombing in the concrete. The form boxes shall be
cleaned and oiled before these are used for concreting.

Volume-V Part-1
9.11.10 The concrete shall be laid in 150mm layers and

consolidated well so that the cement cream works up to the top and
no honeycombing is left in the concrete. Concreting is to be done
continuously so that the subsequent layers are laid before the initial
setting of the bottom layer begins. The consolidation of concrete shall
normally be done by using vibrators.
9.11.11 After concreting the chimney portion up to the
required height, the top surface should be finished smooth, with
slight slope towards the outer edge, to drain off the rainwater falling
on the coping.
9.11.12 In wet locations, the site must be kept completely de-
watered both during the placing of the concrete and up to 24 hours
after completion. There should be no spilling to concrete by water
during this period.
9.11.13 The form boxes shall be removed only after at least 24
hours after the completion of concreting. After removal of the forms
and boxes the concreted surface wherever required shall be repaired
with a mixture of rich cement and sand mortar in the shortest possible
time.
The cost of carrying out concreting of shall be payable as per unit
rates quoted by the Bidder.
9.12 BACKFILLING AND REMOVAL OF STUB TEMPLATE:
9.12.01 Following opening of form work and removal of
shoring and shuttering, if required, backfilling shall be started after
24 hours of casting repairs, if any, to the foundation concrete.
Backfilling shall normally be done with the excavated Soil, unless it
consists of large boulders, which shall be broken to a maximum size of
80mm.
9.12.02 The backfill materials should be clean and free from
organic or other foreign materials The earth shall be deposited in
maximum 200mm layers, leveled, and wetted and rammed
properly before another layer of earth is deposited. Care shall be
taken that the back filling is started from the foundation end only in the
pits towards the outer end.
9.12.03 The backfilling and grading shall be carried to an elevation
of about 150mm above the finished ground level to drain out water.
After backfilling, 50mm high earthen embankment (bandh) will be
made along the sides of excavated pits and sufficient water will be
poured in the backfilled earth for at least next 24 hours.
9.12.04 The stub setting Templates shall be opened only after the
completion of back-filling.

Volume-V Part-1
9.12.05 After completing stringing work, if level of backfilling of

some of the locations gets settled and it is required to backfill the
locations again, the same would be done by the contractor at no extra
cost.
9.12.06 No extra charge is admissible for carrying out
backfilling of foundation pit (including backfilling from borrowed
earth if required) and the cost of backfilling shall be deemed to be
included in the cost of excavation quoted by the bidder in the price
schedule.
9.13 CURING:
The concrete, after it is 24 hours old, shall be cured by keeping the
concrete wet continuously for a period of 14 days after laying. The
pit may be backfilled with selected earth sprinkled with necessary
amount of water and well consolidated in layers not exceeding
200mm of consolidated thickness after a minimum period of 24
hours and thereafter both the backfilled earth and exposed chimney
top shall be kept wet for the remainder of the prescribed time of 14
days. The uncovered concrete chimney above the backfilled earth shall
be kept wet by providing empty cement bags dipped in water fully
wrapped around the concrete chimney for curing duly ensuring that the
bags are kept wet by frequent pouring of water on them. The
Contractor may use anti curing paint. However no extra payment
shall be made on this account.
9.14 BUILDING STONE REVETMENT:
Stone revetment in 1:5 cement mortars shall be constructed by the
Contractor at specified locations. The detailed proposal in consultation
with the site Engineer, for carrying out revetment work shall be
submitted to the concerned Superintending Engineer, EHT
Construction and approval shall be obtained before carrying out
revetment work. The top seal cover of revetment work shall be done
with 1:2:4 normal mixes. All materials including cement shall be
provided by the contractor and cost of building revetment shall be
deemed to include cost of such materials also i.e. Cement, sand, metal
and stone. Curing of revetment shall be done as specified for tower
foundation. The back filling of the inside of the revetment wall with
Soil/borrowed earth will be paid for extra on per m³ basis and shall
include its compacting and watering. The excavation for revetment
foundation shall be paid at the rates as indicated by the bidder in Price
Schedule. The revetment work, wherever necessary, shall have to be
completed before taking up final tensioning work in the Section.
9.15 TOWER EARTHING:
9.15.01 For the purpose of earthing, necessary earthing rods
(25mm dia, 2 meter long) connecting clamps, and connecting

Volume-V Part-1
wire will be provided by the contractor. The earthing rods are to be

hammered preferably in the side wall of foundation pits and connected
to stub by 7/4.00mm Earth wire and with necessary connecting clamps
before concreting the foundation. If it is not possible to tie the rods in
the foundation pit i.e. in rocky location, they shall be
buried near the foundation pit and connected to the stubs. The earthing
rods are to be provided in every leg of the tower. Each tower shall be
earthed before the foundation is casted.
9.15.02 The tower footing resistance of all towers shall be
measured in dry whether after the erection and before the stringing of
Earth wire. The counterpoise earthing shall be resorted to, in
accordance with the instructions of the site Engineer, in case the tower
footing resistance (TFR) exceeds the specified value. It shall be
ensured that the tower footing resistance is less than 10 ohms. Each
tower footing resistance shall be intimated (along with the tower
location number) while submitting the progress report of tower
erection.
9.15.03 Counterpoise Earthing :
In case of high resistivity, counterpoise earthing shall be provided

which consists of four lengths of galvanized steel stranded wires,
7/4.00mm fitted with each leg of the tower with proper clamps for
connection to the tower leg at one end. The counterpoise will be laid
radially away from the tower and will normally be 15 meters in length,
buried to the depth of 600mm below the ground level. The length of
counterpoise wire may be increased if the resistance requirements are
not met. Connecting clamps shall be buried in the chimney portion
of the foundation. Contractor shall quote for the laying of counterpoise
earthing on per running meter basis, excluding cost of all materials.
The scope of work of connecting the counterpoise to the tower legs
shall be deemed to be included in the cost of laying of counterpoise.
The counterpoise shall preferably be laid through soft soil areas if
available. The planning of laying counterpoise shall be done as per
approval of site Engineer. The cost of laying of counterpoise shall be
inclusive of excavation and backfilling work also.
The Contractor shall have to provide rod earthing at the end of each
counterpoise wire and this may lead to T.F.R. values within specified
limits. This work of additional rod earthing shall be paid extra on per
location basis as per the rates indicated in Price Schedule.
9.16 TOWER ERECTION/ ASSEMBLY:
Towers shall be erected after the foundation concrete is at least 14
days old, but a gap of 24 days shall be preferred. The method followed
for the erection of towers, shall ensure the points mentioned below:

Volume-V Part-1
(i) Straining of the members shall not be permitted for bringing

them into position. It may, however, be necessary to match
hole positions at joints and to facilitate this, Tommy bars not
more than 450mm long may be used.
(ii) Before starting erection of an upper section, the lower section of
tower shall be completely braced and all bolts provided in
accordance with approved drawings.
(iii) All plan diagonals relevant to a section of tower shall be placed in
position before assembly of upper section is taken up.
(iv) The bolt positions in assembled towers shall be as per IS: 5613
(Part-II/Sec.2), 1995 with latest amendments.
(v) Tower shall be fitted with Number, Phase and Danger Plates
which shall be arranged by the Contractor.
(vi) Anti-climbing Devices:
Barbed wire will be used at a height of approx. 3 meters and
above as an anti-climbing measure, which shall be arranged by
the Contractor. At every location three layers of Barbed wires
will be provided each inside and outside the tower in horizontal
plane. Spacing between the layers with fixing arrangements shall
be provided as per the provisions of IS:5613 (Part-II/Sec.1)-
1976 with latest amendments. The galvanized angle pieces with
notches for accommodating Barbed wire with Bolts Nuts etc.
shall be supplied by the Contractor. After the Barbed wire is
placed in position in the notches, the notch opening shall be
welded to avoid the theft of Barbed wire and anti-corrosive
treatment with cold galvanizing paint shall be given, as also in
the case of bolts to be welded below bottom cross arm level.
Suitable locking arrangement (pad-lock) shall also be provided.
(vii) All blank holes, if any left, after complete erection of the tower,
are to be filled up by bolts and nuts of proper size.
9.17 TIGHTENING PUNCHING AND WELDING
OF BOLTS AND NUTS:
9.17.01 All nuts shall be tightened properly using correct size of

spanners. Before tightening, it will be seen that packing washers and
plates are placed in relevant gaps between members, bolts of proper
size and length are provided and one spring washer is used under each
nut and in case of step bolts, spring washers shall be placed under the
outer nut.
9.17.02 The tightening shall progressively be carried out from the
top to downwards, care being taken that all bolts at every level are
tightened simultaneously. The threads of bolts projecting outside
the nuts shall be punched at three positions on the periphery to

Volume-V Part-1
ensure that the nuts are not loosened in course of time. If during
tightening a nut is found to be slipping or running over the bolt
threads, the bolt together with the nut shall have to be replaced.
9.17.03 The threads of all the bolts projected outside the nuts shall
be welded around the periphery of nut & bolts. The welding of bolt
projections as above shall be provided from ground level to bottom
cross arm level in all towers and also on extensions up to 10M except
in case of special river crossing tower in which case welding shall be
done up to 20 meter height from ground level.
9.17.04 After welding, cold galvanized paint having at least 90%
zinc content shall be applied on the welded portion. At least two coats
of the paint shall be applied. The cost of such paint and welding etc.,
including application of paint etc., shall be deemed to be included in the
quoted erection rates.
9.18 INSULATOR HOISTING:
Suspension insulator strings shall be used on suspension towers and
tension insulator strings on angle and dead end towers. They shall
be fixed on all the towers just prior to the stringing. Damaged
Insulators and fittings, if any, shall not be used in the assemblies.
Before hoisting, all Insulators shall be cleaned in a manner that will
not spoil, injure or scratch the surface of the Insulator, but in no case
shall any oil be used for the purpose. Security clips shall be fitted in
position for the Insulators before hoisting. Arcing Horns shall be fitted
in an approved manner. Torque wrench shall be used for fixing
different line materials and their components, like suspension clamps
etc. for Conductor and Earth wire etc.
9.19 HANDLING OF CONDUCTOR AND EARTH WIRE:
9.19.01 The Contractor shall be entirely responsible for any damage
caused to the towers or Conductors during stringing. While running
out the Conductors, proper care shall be taken ensuring that the
Conductors do not touch and rub against the ground or objects which
could cause scratches or damage to the Conductor strands. The
Conductors shall be run out of the drums from the top in order to avoid
damage due to chafing. The drum stand shall be provided with a
suitable braking device to avoid damage, loose running out and
kinking of Conductor. The Conductor will be pulled by pull cable and
consequently pass over the running out blocks. The groove of the
running out blocks will be of such a design that the seat is semi-
circular and larger than the diameter of the Conductor and it does
not slip over or rub against the sides. The grooves shall be lined with
hard rubber or neoprene to avoid damage to Conductor and shall be
mounted on properly lubricated bearings.
9.19.02 The running blocks shall be suspended in a manner to suit
the design of the cross arm. All running out blocks especially
those at the tensioning end, will be fitted on the cross arm with jute

Volume-V Part-1
cloth wrapped over the steel work and under the slings to avoid
damage to the slings as well as to the protective surface finish of the
steel work. The Conductor shall be continuously observed for loose or
broken strands or any other kind of damage. When approaching
towards end of a drum length, at least three coils shall be left when
the stringing operations are to be stopped. These coils are to be
removed carefully if another length is required to be run out, new
length may be joined to the length already run out by the compression
joint in approved manner.
9.19.03 The Conductor joints and clamps shall be erected in such a
manner that no bird caging, over tensioning of individual wires or
layers or other deformities or damage to the conductor shall occur.
Clamps or bracing devices shall under erection conditions allow no
relative movement of strands or layers of the conductors.
9.19.04 Repairs of Conductors, in the event of damage being
caused to isolated strands of a conductor during the course of
erection, if necessary, shall be carried out during the running out
operations, with repair sleeves. Repairing of Conductor surface with
repair sleeve shall be done only in case of minor damage, scuff marks
etc., keeping in view both electrical and mechanical safety
requirements. The final Conductor surface shall be clean, smooth and
shall be without any projections, sharp points, cuts, abrasions etc.
Repair sleeves may be used when the damage is limited to the
outermost layer of the Conductor and is equivalent to the severance
of not more than one third of the strands of the outermost layer. No
repair sleeve shall be fitted within 30 m of tension or suspension clamp
or fittings. Further, more than one repair sleeve per Conductor shall
not be normally used in any single span.
9.19.05 Conductor splices shall be so made that they do not crack
or get damaged in the stringing operation. The Contractor shall
use only such equipment/methods during Conductor stringing which
ensures complete compliance in this regard.
9.19.06 Derricks shall be used where roads, rivers, canals,
telecommunication or overhead power lines, railway lines, fences
or walls have to be crossed during stringing operations. It shall
be seen that normal services are not interrupted and no damage is
caused to property. Shut down shall be obtained when working at
crossing of overhead power lines.
9.19.07 The sequence of running out shall be from
top to downwards, i.e. the Earth wire shall be run out first followed
by the Conductors in succession. Imbalances of loads on towers shall
be avoided as far as possible i.e. both Earth wires, then both bundles of
top Conductor and then both bundles of middle Conductor followed by
both bundle Conductors of bottom Cross-arm should be strung.

Volume-V Part-1
9.19.08 The proposed transmission line may run parallel for certain
distance with the existing 400/220/132KV lines which will remain
energized during the stringing period. As a result there is a possibility
of dangerous voltage build up due to electromagnetic and electrostatic
coupling in the pulling cables, Conductors and Earth wires, which
although comparatively small in magnitude during normal operations,
can be severe during switching and ground fault conditions on the
energised lines. It shall be the Contractor's responsibility to take
adequate safety precautions to protect his employees and others from
this potential danger.
9.20 STRINGING OF CONDUCTOR AND EARTH WIRE:
The contractor shall give complete details of the stringing methods,
which he proposes to follow. At least one month in advance of the
commencement of stringing, the contractor will submit the
stringing charts for the conductors and earth wire showing the
initial and final sags and tension for various temperatures and
spans, alongwith equivalent spans in the lines, for the approval of
the Employer. The stringing shall be carried out as per
the stringing charts approved by the Employer and in accordance
with relevant IS. All the tolerances for the line shall conform to IS
5613 (Part-2/Sec-2) 1995
9.21 JOINTING:
9.21.01 The number of joints in Conductor/Earth wire shall be kept
to minimum possible by properly selecting the drums from available
lot of respective drums. All the joints on the Conductor and Earth wire
shall be of compression type. Each part of the joint shall be cleaned
by wire brush to make it free of rust or dirt etc. and properly
greased with anti-corrosive compound, as approved by our
Engineer before the final compression is done with the compressors.
The cost of such grease etc. used for joints shall not be paid extra
and shall be deemed to be included in the stringing rates.
9.21.02 All joints shall be made at least 30 meter away from the
structures. No joints shall be made in the spans crossing over the
main roads, railways, rivers etc. Not more than one joint per Conductor
shall be allowed in one span. Care shall be taken to mark the
conductor for properly centering the compression clamp before
compressing. During compression operation, the conductor shall be
handled in such a manner as to prevent lateral or vertical bearing
against the dies. After pressing the joint the aluminum sleeve
shall have all corners rounded, burrs and sharp edges removed and
smoothened.
9.21.03 Suitable protector shall be used during stringing of
Conductor to avoid any damage to the joint while it passes over the
traveler.
9.22 SAGGING IN OPERATION:

Volume-V Part-1
9.22.01 The Conductors shall be pulled up to the desired sag and

left in running block for at least one hour after which the sag shall be
rechecked and adjusted, if necessary, before transferring the conductor
from the running out blocks to the suspension clamps. The
Conductors shall be clamped within 36 hours of sagging in.
9.22.02 The sag will be checked in the first and the last span of the
section in case of sections up to eight spans and in one intermediate
span also for sections with more than eight spans. The sag shall also
be rechecked when the Conductor have been drawn up and
transferred from running blocks to the insulator clamps.
9.22.03 The running out blocks, when suspended from
the transmission structure for sagging shall be so adjusted that the
Conductors on running out blocks will be at the same height as that of
the suspension clamps to which it is to be secured.
9.22.04 At sharp vertical angles, the sags and tensions shall be
checked on both sides of the angle. The Conductor and Earth wire shall
be checked on the running out blocks for equality of tension on both
sides. The suspension insulator assemblies will normally assume
vertical positions when the Conductor is clamped.
9.22.05 Tensioning and sagging operations shall be carried out in
calm weather, when rapid changes in temperature are not likely to
occur.
9.23 TENSIONING & SAGGING OF CONDUCTOR AND EARTH
WIRE:
The tensioning and sagging shall be done in accordance with the
approved stringing charts before the Conductor and Earth wire is
finally attached to the towers through the insulator strings for the
Conductor and Earth wire clamps for the Earth wire Dynamometers
shall be used for measuring tension in the Conductor and Earth wire.
9.24 CLIPPING IN:
9.24.01 Clipping of the Conductors in position shall be done in
accordance with the method approved by our Engineer. At suspension
location free center type suspension clamp with Armour rod set or AGS
type suspension clamp shall be used.
9.24.02 The jumpers at the section and angle towers shall be
formed to parabolic shape to ensure maximum clearance
requirements. Pilot suspension insulator string shall be used, if
necessary, to restrict the jumper swings to the design values. Jumper
connections of transposition towers shall be so made that adequate
clearances are available from tower body as well as phase conductors.
9.24.03 Fasteners in all fittings and accessories shall be secured in
position. The security clip shall be properly opened and sprung into
position.

Volume-V Part-1
9.25 FIXING OF CONDUCTORS AND EARTH WIRE

ACCESSORIES :
Vibration dampers (4-R type) and other Conductor and Earth wire
Accessories supplied by the Employer shall be installed by the
Contractor as per the design/drawing requirement and as per
instructions of the Engineer. While installing the Conductor and Earth
wire Accessories, proper care shall be taken to ensure that the surfaces
are clean and smooth and no damage shall occur to any part of the
Accessories.
9.26 MAINTENANCE:
9.26.01 For a period of 12 (twelve) calendar months
commencing immediately upon the satisfactory completion of the
final tests at site and taking over of the line, the Contractor's
liability shall be limited to the replacement (supply and re-erection)
of any defective parts that may develop on line of his own
manufacture or those of his Sub-Contractors approved by the Employer
under the conditions provided for by the contract under proper use
and arising solely from faulty materials, or workmanship.
9.26.02 If it becomes necessary for the Contractor to replace or
renew any defective portions of the line under this clause, the
provisions of this clause shall apply to the portions of the line so
replaced or renewed until the expiration of six months from the date
of such replacement or renewal or until the end of the above
mentioned period of twelve months whichever may be the later.
9.26.03 If any defects be not remedied within a reasonable time,
the Employer may proceed to do the work at the Contractor's risk and
expense, but without prejudice to any other rights which the Employer
may have against the Contractor in respect of such defects. The
Contractor shall bear reasonable cost of minor repairs carried out on
his behalf at site. At the end of the maintenance period the
Contractor’s liability ceases.
In respect of plant not covered by the first paragraph of this clause, the
Employer shall be entitled to the benefit of any guarantee given to the
Contractor by the original Contractor or manufactures of such plant.
9.27 REPLACEMENT:
If any replacements are to be effected after stringing and
tensioning or during maintenance, members and bracing shall not be
removed without reducing the tension on the tower with proper
guying or releasing the Conductor. If the replacement of cross arms
becomes necessary after stringing, the Conductor shall be suitably tied
to the tower at tension points or transferred to suitable roller pulleys at
suspension points.
9.28 PRE-COMMISSIONING:

Volume-V Part-1
After completion of the works, final checking of the line shall be done
by the Contractor to ensure that all the foundation works, tower
erection, and stringing have been done strictly in accordance with the
specification and as approved by the Employer. All the works shall
be thoroughly inspected keeping in view the following main points:
9.28.01 Sufficient back-filled earth is lying over each foundation pit
and it is adequately compacted.
9.28.02 Concrete chimneys and their copings are in good finely
shaped conditions.
9.28.03 All the tower members are correctly used, strictly according
to approved drawing and are free from defects or damages,
whatsoever.
9.28.04 All bolts are properly tightened and punched/tack welded
as per this specification.
9.28.05 The stringing of the Conductors and Earth wire has been
done as per the approved sag and tension charts and desired
clearances are clearly available.
9.28.06 All Conductor and Earth wire Accessories are properly
installed.
9.28.07 All other requirements to complete the work like fixing of
Danger Plate, Phase Plate, Number Plate, Anti-climbing devices,
Aviation Signal (wherever required) etc. are properly installed and the
painting has been done wherever required as per Aviation Rules.
9.28.08 It should be ensured that revetment is provided, wherever
required.
9.29 COMMISSIONING:-
9.29.01 The line insulation is tested by the Contractor by providing
his own equipment labour etc. to the satisfaction of the Employer to
ascertain the insulation condition of the line.
9.29.02 Conductor continuity test is carried out to verify that each
Conductor of the overhead line is properly connected electrically also.
The line may be charged at a low value of Power Frequency Voltage
for the purpose of testing and commissioning.
9.30 TAKING OVER:
When all performance tests called for by the Specification have
been successfully carried out, the transmission line shall be accepted
and taken over when it has been satisfactorily put into operation on
site, or within one month of its being ready to be put into
operation, whichever shall be the earlier and the Engineer shall
forthwith issue a taking over certificate. The Engineer shall not delay
the issue of any taking over certificate contemplated by this clause

Volume-V Part-1
on account of minor defects in the plant which do not materially effect

the commercial use thereof, provided that the Contractor shall
undertake to make good the same in due course.

Volume-V Part-1
ANNEXURE- 1
GUARANTEED TECHNICAL PARTICULARS OF CONDUCTOR &

EARTH WIRE
[A] ACSR CONDUCTOR
S. Description ZEBRA PANTHER

No.
1. Particulars of ACSR Conductor
i. Standard nominal Copper area (sq. 260 130
mm)
ii. Stranding, lay and wire dia (mm) 54/7/3.1 30/7/3.00
8
iii. Diameter of complete conductor (mm) 28.62 21.00
iv. Overall diameter when wrapped with 44.36 33.78
preformed Armour Rod (mm)
v. Weight (kg/km)
a. Steel Section (kg) 436 586
b. Aluminium Section (kg) 1185 390
c. Conductor (kg) 1621 976
2. Guaranteed ultimate tensile strength of 130.32 89.67
conductor in KN
3. Calculated D.C. resistance/km of 0.06915 0.139
conductor when corrected to standard
weight at 20oC
4. Standard Cross Sectional Area of 7.942 7.069
i. Aluminium strand in sq. mm
ii. Standard Cross Sectional Area of Steel 7.942 7.069
strand in sq. mm
iii. Standard Cross Sectional Area of 484.5 261.60
conductor in sq. mm.
5. Modulus of elasticity of Conductor 69 80
(GN/M2 )
6. Co-efficient of liner expansion per oC of
a. Aluminium strand Kg/sq.cm 23X10-6 23X10-6
b. Steel strand Kg/sq.cm 11.5X10- 11.5X10-6
6
c. ACSR Conductor Kg/sq.cm 19.3X10- 17.8X10-6

6

Volume-V Part-1

No.
7. Mean Lay-ratio
i. First layer 13-28 13-28
ii. Second layer 10-17 10-16
iii. Third layer 10-16 10-14
iv. Fourth layer 10-14
8. Continuous maximum current rating of 750 427
i. conductor in still air at 40 oC ambient
temperature (amp)
ii. Temperature rise for the above current 35 oC 30 oC
(oC)
9. Standard length of conductor (km.) 1.5 1.5
i.
ii. Tolerance in length (in percent) +/- 5% +/- 5%
10. Particulars of strands
i. Aluminiu Aluminiu
Minimum ultimate tensile strength in
m/ St eel m/ St eel
kg/sq.mm.
a. Aluminimum strand 16.56 16.02
b. Steel strand 134 127.41
ii. Nominal strand Dia 3.18/3.18 3.0/3.0
a. Maximum (mm) 3.21/3.24 3.03/3.06
b. Minimum (mm0 3.18/3.18 3.0/3.0
iii Mass (kg/Km) of strand at Nominal Dia 21.47 19.11
of Aluminium
iv. Mass (kg/Km) of strand at Nominal Dia 61.95 55.18
of Steel
v. Minimum breaking load in KN for
a. Aluminium strand
i) Before stranding 1.29 1.17
ii) After stranding 1.23 1.11
b. Steel strand
i) Before stranding 10.43 9.29
ii) After stranding 9.91 8.83
c. Approximate breaking load of conductor 13316 9127
in kgs
vi. Zinc coating

Volume-V Part-1

No.
a. Uniformity of coating, number and 3 dips 1 3 dips 1
duration of dips(according to Preece min. min.
test)
b. Minimum weight of coating 260 260
(gms/sq.meter)
c. Purity of zinc and the standard to which 99.95% 99.95%
it will conform IS:209 IS:209

Volume-V Part-1
[B] HTGS EARTH WIRE
S.N. Particulars HTGS EARTH WIRE

1 Particulars of single steel wire before
stranding
a) No. of wires 7
b) Diameter (mm) 3.66 mm
c) Tolerance 2%
Plus 3.74
Minus 3.58
d) Minimum elongation in 100 mm
5 mm
length
e) Breaking load (Kg.)
Standard/Minimum 1179/1000
f) Minimum ultimate tensile stress
95
(Kg/mm2)
g) D.C. resistance at 20 deg. C
17.57(Max.)
(Ohm/Km)
2 Stranded Wire
a) Length of lay (mm)
Maximum 198
Minimum 165
b) Overall diameter of Earth wire(mm) 10.98
c) Area of cross section of Earth wire
73.64
(sq. mm.)
d) Breaking load (Kg.)
e) Resistance in Ohms per Km. at 20
2.5
deg. C.
f) Modulus of elasticity of Earth Wire
19 x10 5Kg/cm2
(Kg/cm2)
g) Weight of Earth wire (Kg/Km) 583
h) Co-efficient of linear expansion (per
11.5x10-6 /deg. C
deg. C)
3 Quality of zinc used (Specify the
Zn - 99.95 %
grading and percentage)
4 Coating of zinc on wires In Gms. per
260
sq. mtrs.
5 Nos. of Dip 3,one minute&1, half
minute
6 Oiling/greasing on Earth wire Boiled Linseed Oil
7 Tolerance in standard length Plus/Minus 5%

Volume-V Part-1
ANNEXURE-2
GUARANTEED TECHNICAL PARTICULARS OF DISC INSULATORS
S. Description 70 kN EMS 90kN EMS 160kN EMS

No. Single Double Single Double Single Double
Suspensio Suspensi Tension Tensio Tension Tension
n on n
1. Size and designation of 16 mm 16 mm 20 mm
Ball & Socket and
standard to which it will
conform (mm)
2. No. of insulator discs 9/132KV 2x9/132KV 10 2X10 14 2X14
per string 13/220K 2x13/220K
V V
3. Outside dia. of the disc 255 255 280
– mm
4. Spacing - mm 145 145 170
5. Creepage distance of 320 320 340
the single disc-mm
6. Electro-mechanical 7000 9178 16500
strength of single disc –
kg.
7. Withstand voltage of
single disc-kVp
7.1 Power frequency
a) Dry – kV (rms) 70 75 75
b) Wet – kV (rms) 40 45 45
7.2 Impulse voltage
1.2/50 microsecond
a) Positive – kV 110 110
b) Negative - kV 110 115 120
120
8. Withstand voltage for
the complete string
8.1 Power frequency (with
and without Corona
ring) 280 400/405
a) Dry – kV (rms) 280 300/305
b) Wet – kV (rms) 490/690
490/690
8.2 Lightning Impulse
voltage 1.2/50
microsecond (With and
.
without Corona ring) 800/805
550
a) Positive – kVp 805/810 1050/1425
550
b) Negative – kVp 1050/1425
9. Flashover voltage for
the disc
9.1 Power frequency
a) Dry – kV (rms)
b) Wet – kV (rms) 75 80 85
45 50 55

Volume-V Part-1
S. Description 70 kN EMS 90kN EMS 160kN EMS

No. Single Double Single Double Single Double
Suspensio Suspensi Tension Tensio Tension Tension
n on n
9.2 Lightning impulse
voltage 1.2/50
microsecond
115 115
a) Positive – kVp 130
115 120
b) Negative – kVp 130
10. Flashover voltage for
the complete string
10. Power frequency (with
1 Corona ring)
a) Dry – kV (rms) 415/420
290 470 310/315 500
b) Wet – kV (rms) 290 470 500
10. Lightning Impulse
2 voltage 1.2/50
microseconds (with and
without Corona ring)
a) Positive – kVp 560 1060 825/830 1050
b) Negative – kVp 560 1060 830/835 1050
11. Max. voltage (%) across
any disc in the string
9% 13% 14%
(with and without
Corona ring)
12. P.F. Puncture Voltage of
each disc insulator 110 125 125
KV(rms)
13. Maximum RIV with 10
KV(RMS) of each disc
50 50 50
insulator (microvolts)
14. Weight of each disc

5.2 5.2 9.5
(kgs)
15. Electromechanical
strength of complete 7000 14000 9178 18356 16500 33000
string (kgs.)

Volume-V Part-1
ANNEXURE-3
GUARANTEED TECHNICAL PARTICULARS OF HARDWARE

FITTINGS FOR ACSR ZEBRA/PANTHER AND EARTH WIRE FOR
LINE
S. Particulars Panther ACSR Zebra ACSR Earth Wire

No. (7/3.66) mm
A) Conventional Type
Hardware Sets:
1 Length of single suspension
strings with 9 Disc Insulators
and 13 Disc Insulators of size
1551 2171 185
255 mm (Dia.) x 145 mm
(Height) respectively for
Panther & Zebra ACSR. In mm
2 Length of double suspension
strings 9x2 Disc Insulators &
13x2 Disc Insulators of 255mm
1873 2429 NA
(Dia) x 145 mm (height) size
respectively for Panther and
Zebra ACSR.
3 Length of single tension strings
with 10 Disc Insulator of 255
mm(Dia)x145 mm (Height) size
for Panther and 14 Disc 1728 2679 375
Insulator of 280 mm (Dia) x170
mm (Height) size for Zebra
Conductor.
4 Length of double tension strings
with 10x2 Disc insulator of 255
mm x 145 mm size for Panther
2069 3202 NA
and 14x2 disc insulators of size
280 mm x 170 mm for Zebra
ACSR.
5 Minimum breaking strength of
suspension strings Hardware.
(i) Single 7000kgf 7000kgf 7000kgf
(ii) Double 2x7000kgf 2x7000kgf
6 Minimum slipping strength of 25% of UTS
15to20% of UTS of Conductor
suspension clamp. of Wire
7 Minimum breaking strength of
tension strings Hardware.
(i) Single 9000kgf 16500kgf 7000kgf
(ii) Double 2x9000kgf 2x16500kgf
8 Minimum slipping strength of 95% of UTS 95% of UTS of 95% of UTS
tension clamp. of Conductor Conductor of wire
9 Ball & Socket designation of
Hardware items for Tension 16mm 16mm NA

Volume-V Part-1

No. (7/3.66) mm
Type of strings.
10 Ball & Socket designation of

Hardware items for suspension 16mm 16mm NA
strings.
11 Unit weight of Single
Suspensions String Hardware 6.4kg appox. 11kg appox. 2.9kg appox.
sets(without Disc Insulators)
12 Unit weight of double
24.5kg 29.32kg
suspension string Hardware NA
appox. appox.
sets(without Disc Insulators)
13 Unit weight of single tension
string Hardware sets (without 6.6kg appox. 9.8kg appox. 2.3kg appox.
Disc Insulators).
14 Unit weight of double tension
Hardware sets (without Disc 21kg appox. 31.7kg appox. NA
Insulators).
15 Type of suspension clamp.
AGS Type AGS Type AGS Type
16 Material used for suspension
Al. Alloy Al. Alloy MCI
Clamp giving reference of ISS
17 Type of tension clamp. Compression
Type
18 Material used for tension Clamp Extruded Al. Extruded Al.
Mild Steel
giving reference of ISS Alloy Alloy
19 Unit weight and material used
for each of the following
Hardware items in Kg.
a. Ball hook 0.775kg 0.775kg
NA
appox. appox.
b. Socket type horn holder 0.920kg 0.920kg
NA
appox. appox.
c. `D’ Shackle 0.450/ 0.950/
0.450kg
0.950kg 2.000kg
appox.
appox. appox.
d. Ball link 0.375kg 0.750kg
NA
appox. appox.
e. Socket clevis 0.650kg 0.650/1.275kg
NA
appox. appox.
f. Ball clevis 0.300kg 0.300/0.600kg
NA
appox. appox.
g. Clevis Eye 0.650kg 0.650kg
NA
appox. appox.
h. Chain Link 0.600kg 1.500kg 0.350kg
appox. appox. appox.
i. Suspension Clamp 3.0kg appox. 6.0kg appox. 2.0kg appox.

Volume-V Part-1

No. (7/3.66) mm
j. Tension Clamp with Jumper
2.4kg appox. 4.5kg appox. 1.0kg appox.
Sleeves.
20 Power loss in Aluminium alloy 100 Milli
143 Milli Watt NA
Suspension Clamp at 400 amps. Watt
21 Power loss in extruded NA
Aluminum Tension Clamp at Insignificant
400 amps.
22 Type of arcing horn
(i) 132 kV Flat type NA NA
(ii) 220 kV Pipe type Pipe type NA
B) AGS Type Suspension
Assembly:
1 Type of material used for
Al.Alloy of HE 20 Grade as per
retaining rod for AGS assembly NA
IS:6051
giving reference of ISS
2 Minimum tensile strength of
35kg/sq. mm NA
retaining rod material.
3 Chemical composition of
As per IS:733 NA
retaining rod material.
4 Electrical conductivity of Armour
Rod material (in percentage of
the conductivity of IACS i.e. Not less than 40% of the IACS NA
International Annealed Copper
Standard)
5 Slipping strength of cushioned
15to20% of UTS of Conductor NA
suspension assembly
6 Breaking strength of cushioned
7000 kgf NA
suspension assembly
7 Physical properties of synthetic
rubber:
a. Minimum tensile strength 2000PSI NA
b. Minimum ultimate elongation 300% NA

8 Details of the retaining rods
of AGS assembly:
a. Length of Armour Rod (mm) 1550 2080 -
b. Diameter of Armour Rod(mm) 6.35 7.87 3.00
c. Number of Armour Rod/set 11 12 12
d. Wt. of each Armour Rod(gm) 150 292 -
e. Tolerance in diameter of each

Armour Rod
i. Maximum (mm) NA
+/- 1% +/- 1%

Volume-V Part-1

No. (7/3.66) mm
ii. Minimum (mm) +/- 1% +/- 1% NA
f. Tolerance in flattening Max. +/- 0.08 +/- 0.08 NA
(mm)
g. Pitch length of the helix (mm) 190.5 260.4 NA
h. Tolerance in pitch length
i. Maximum (mm) NA
+/- 6 +/- 6
ii. Minimum (mm) +/- 6 +/- 6 NA
i. Tolerance in internal diameter of
helix.
i. Maximum (mm) NA
+/- 0.2 +/- 0.2
ii. Minimum (mm) +/- 0.2 +/- 0.2 NA
j. Tolerance in outer diameter of
helix
i. Maximum (mm) NA
+/- 0.2
ii. Minimum (mm) NA
9 Power loss at 400 Amp. Current 200 Milli 501.50 Milli
NA
AGS suspension assembly Watt Watt

Volume-V Part-1
ANNEXURE-4
GUARANTEED TECHNICAL PARTICULARS FOR

ACCESSORIES FOR ZEBRA/PANTHER ACSR & EARTH
WIRE FOR LINES

No. (7/3.66) mm
A MIDSPAN JOINTS (Compression Type)
1 Breaking strength. 95% of UTS of 95% of UTS of 95% of UTS of
Conductor Conductor Earth wire
2 Slipping strength. 95% of UTS of 95% of UTS of 95% of UTS of
Conductor Conductor Earth wire
3 Conductivity. 100% of eqvt. 100% of eqvt. 100% of eqvt.
Length of Length of Length of Earth
conductor conductor wire
4 Before and after
compression dimensions in
mm Al. Steel Al. Steel Al. Steel
OD 38.0 18.0 48.0 19.20 NA 21.0
23.0 9.35 31.0 9.95 NA 11.5
ID
37.0 17.40 46.0 18.80 NA 20.20
Across Corner 32.0 15.10 40.0 16.10 NA 17.50
Across Flat
5 Material from which
following is made. Also give
reference to ISS for the
same.
a. Aluminium sleeve. Extruded Extruded
NA
Aluminium. Aluminium.
b. Steel sleeve. Mild Steel Mild Steel Mild Steel
Galvanised Galvanised Galvanised
6 Unit weight of:
a. Aluminium sleeve. 1.15 1.91 Appox. NA
b. Steel sleeve. 0.28 Appox. 0.41 Appox. 0.470 Appox.
7 Length of steel and
Aluminium sleeve in mm
Before compression Al. Steel Al. Steel Al. Steel
610 203 711 241 NA 230
Tolerance
+/-5 +/-5 +/-5 +/-5 NA +/-5
After compression 660 233 763 273 NA 252
Tolerance +/-5 +/-5 +/-5 +/-5 NA +/-5
B REPAIR SLEEVE (Compression Type)
1 Breaking strength of cable 95% of UTS of 95% of UTS of 95% of UTS of
with sleeve compressed. Conductor Conductor Earth wire
2 Conductivity of cable with 100% of eqvt. 100% of eqvt. 100% of eqvt.
Length of Length of Length of Earth

Volume-V Part-1

No. (7/3.66) mm
sleeve compressed. conductor conductor wire conductor
3 Before and after
compression dimensions in
mm
OD 38.0 48.0 20.8
ID 23.0 31.0 41.3
4 Material from which sleeve
Mild Steel
is made with IS for the Extruded Extruded
Galvanised
same. Aluminium. Aluminium.
5 Unit weight of repair sleeve. 0.40 appx. 0.740 appx. 0.400 kg appx.
6 Length of repair sleeve in
mm Before compression 241 +/- 0.5 279 +/- 5 254 +/- 5
After compression. 270 +/- 5.0 310 +/- 5 280 +/- 5
C 4R VIBRATION DAMPER
1 Type 4R Type
2 Suitable for conductor size. 21 28.62 10.98
3 Material used for :
a. Clamp Al. Alloy GDC
b. Messenger cable. H T G S IS:4826
4 Number of strands and dia. 19/2.11 19/2.59 19/2.11
of each wire used in
messenger cable.
5 Over all dia. of messenger 10.55 mm appox. 12.95mm appox. 10.55mm
cable. appox.
6 Weight per Km of - - -
messenger cable.
7 Slipping strength of 2.5 KN 2.5 KN 2.5 KN
messenger cable.
8 Total weight of each damper 3.4 kg +/- 5% 6.5 kg +/- 5% 2.3 kg +/- 5%
with tolerance.
9 Weight of each counter
weight with tolerance.
a. Heavier mass. 2.4 kg +/- 5% 3.3 kg +/- 5% 1.150 kg +/-
5%
b. Lighter mass. 1.750 kg +/- 2.4 kg +/- 5% 0.950 kg +/-
5% 5%
10 Natural frequencies of 12+/-1 18.5+/-1 8+/-1 12+/-1 12+/-1 18.5+/-1
damper. 30+/-2 46+/-2 17.5+/-2 30+/-2 46+/-2
30+/-2
11 Clamping torque (Kg 6.5 7.5 6
meter).
12 a. Minimum fatigue test 10 Million cycles 10 Million cycles 10 Million cycles
at the highest resonant
frequency.

Volume-V Part-1

No. (7/3.66) mm
b. Amplitude of fatigue test +/- 1 +/- 1 +/- 1
of the resonant
frequency.
13 Slip strength of clamp. 2.5 KN 2.5 KN 2.5 KN
14 Maximum magnetic power

loss of damper at 500 Less than 1Watt Less than 1Watt Less than 1Watt
Amps, 50 Hz, AC current.
15 Wind velocity range for Max. Wind load Max. Wind load Max. Wind load
which damper will be 45 kg/sq. m 45 kg/sq. m 45 kg/sq. m
effective.
16 Maximum dynamic strain on
the conductor with the 150 Micro strain 150 Micro strain 150 Micro strain
damper at clamping points.
17 Standard to which material
will be manufactured and IS:9708 IS:9708 IS:9708
tested.

Volume-V Part-1
ANNEXURE-5
LIST OF DRAWINGS
S.No Particulars
1. Details of earthing arrangement.
2. Number plate for 220 kV Transmission line.
3. Phase plate for 220 kV Transmission line.
4. Danger Board for 220 kV Transmission line.
5. Anticlimbing device for 220kV towers
6. Number plate for 132 kV Transmission line.
7. Phase plate for 132 kV Transmission line.
8. Danger Board for 132 kV Transmission line.
9. Anticlimbing device for 132kV towers.
10. Flexible GI Bond for earth wire.
11. Drum for Zebra conductor
12. Drum for Panther conductor
13. Drum for Earth Wire
14. 220kV Single & Double suspension insulator string hardware for Zebra
ACSR conductor
15. 220kV Single & Double tension insulator string hardware for Zebra ACSR
conductor
16. 132kV Single & Double suspension insulator string hardware for Panther
ACSR conductor
17. 132kV Single & Double tension insulator string hardware for Panther
ACSR conductor
18. Hardware fittings for Earth wire
19. Mid span compression joint for Zebra ACSR Conductor

20. Vibration damper for Zebra ACSR Conductor
21. Repair sleeve for Zebra ACSR
22. Mid span compression joint for Panther ACSR
23. Vibration damper for Panther ACSR Conductor
24. Repair sleeve for Panther ACSR
25. Mid span compression joint for Earth Wire
26. Vibration damper for Earth Wire

27. Repair sleeve for Earth Wire
28. Disc Insulators of Ball & Socket type

29. Armour Rods for Conductor and Earthwire suspension clamps

Volume-V Part-1

MADHYA PRADESH POWER TRANSMISSION CO. LTD.
SHAKTI BHAWAN RAMPUR: JABALPUR
VOLUME –V(Part-2)
Technical Book Serial No.

MPPTCL/TECH/PROC/13/JULY15
TECHNICAL SPECIFICATION FOR SUPPLY

OF MATERIALS AND CONSTRUCTION OF
400KV TRANSMISSION LINES.
O/o CHIEF ENGINEER (PROCUREMENT)

MPPTCL, JABALPUR.
TABLE OF CONTENTS
PART I – Specifications & requirements for supply of

Transmission Line Materials
Section- 1 Common Technical Requirement ………………………. 1
Section- 2 Technical Specifications for Towers ………………….. 12
Section- 3 Technical Specifications for Conductor ………………. 27
Section- 4 Technical Specifications for Earth wire …..………….. 41
Section- 5 Technical Specifications for Disc Insulators …………… 47
Section- 6 Technical Specifications for Hardware fittings and

accessories for Conductor & Earthwire…....................77
Section- 7 Technical Specifications for Optical Ground wire 104

(OPGW), associated hardware & accessories
Section- 8 Technical Specifications for erection of transmission

lines……………………........................................... 133
Annexure – 1 Technical Particulars of ACSR Conductors & Earth 150

wire
Annexure – 2 Technical Particulars of Disc Insulators 153
Annexure – 3 List of Sample Drawings 157

Volume-V (Part-2)
SECTION-1
COMMON TECHNICAL REQUIREMENT
1.1 SCOPE:
1.1.1 The provisions under this section are to supplement common

requirements for supply of Transmission Line Materials and
Installation work. Section-2 to Section-8 contains technical
specification for all the Materials to be used for Construction of
Transmission Lines. The bidders shall furnish catalogues, engineering
data / technical information, drawing etc. in conformity with the
technical specification.
1.1.2 The scope of work involves fabrication, galvanizing and delivery of 400kV
Double Circuit towers, their body extensions, river crossing Towers, Hangers,
U bolts, D Shackles, Bolts and Nuts, Spring washers, pack washers, step
bolts, tower accessories (earthing rod with clamps, Danger Boards, Number
plates, Phase plates and Anti-climbing Devices (including fixing arrangements
and barbed wire), ACSR Conductor, Earth wire, Disc insulators, hardware and
accessories for conductor and Earth wire and complete erection of
transmission lines including, detailed survey/check survey, casting of
foundations, tower erection, stringing etc. and testing & commissioning of the
transmission lines. Cement and reinforcement steel for foundation of towers,
extensions, river/ line crossing structures and any such materials required for
erection work shall also be provided by the successful Bidder. The Bidder is
also required to provide required number of stub setting templates for
each installation work at his own cost.
1.1.3 This section also provides for the Design, manufacturing, stage testing,
inspection and testing before despatch, packing and delivery of materials for
use on 400kV transmission lines in the State of Madhya Pradesh.
1.1.4 It is not the intent to specify completely herein all details of the design and
construction of Material. However, the Material shall conform in all respects to
high standards of engineering, design and workmanship and shall be capable
of performing the duties specified herein. The Material offered shall be
complete with all components necessary for its effective and trouble free
operation. Such components shall be deemed to be within the scope of
Bidder’s supply, irrespective of whether these are specifically brought out in
this specification or not.
1.1.5 If due to site condition any other type of tower (which is not envisaged at
present) is required to be provided, the same will also be supplied by the
bidder at the same rates terms and conditions.
1.2 CLIMATIC CONDITION

The equipments and materials shall be suitable for satisfactory
continuous operation under the following climatic conditions:

2 Maximum ambient air temperature (0C) 50
3 Minimum temperature in shade (0C ) 1
approaches
saturation)
5 Average daily ambient air temperature (0C ) 32° Centigrade

Volume-V (Part-2)

8 Wind Zone as per IS 802(Part-I)- 1995 4
9 Max. Altitudes above mean sea level (meters) 1000
1 Seismic level (Horizontal acceleration) (g) 0.3
0
fungus growth. The climatic conditions are also prone to wide
variations in ambient conditions. Smoke is also present in the
atmosphere. Heavy lightening also occurs during June to October.
1.3 STANDARDS:
1.3.1 Bidders may please note that all offered materials shall be manufactured,
tested and supplied with all guaranteed technical particulars generally
conforming to meet the requirement of technical specification as brought out
in various Sections and latest revisions of relevant standards of international
electro technical commission or equivalent national standards of India with
latest amendments of relevant standards rules and codes. The lists of
standards are specified in relevant Sections of bid document.
1.3.2 The works covered by the specification shall be designed, engineered,

manufactured, built, tested and commissioned in accordance with the Acts,
Rules Laws and Regulations of India.
1.3.3 The Contractor shall also note that list of standards presented in this
specification is not complete. Wherever necessary the list of standards shall
be considered in conjunction with specific IS/IEC.
1.3.4 When the specific requirements stipulated in the specifications exceed or

differ than those required by the applicable standards, the stipulation of the
specification shall take precedence.
1.4 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS :
1.4.1 The lists of Indian standards are specified in individual sections for various
materials and Installation work of bid document. However, the Material and
Installation work meeting any other authoritative International Standard,
which ensures equal or better quality than the Standards mentioned in bid
document, shall also be acceptable. Material for which Indian Standards
are not available, any equivalent International Standards will be
applicable. Please attach photocopy of all such Standards according to
which the material and Installation work have been offered.
1.4.2 If the material offered by the Bidder conform to any other standards, salient
points of comparison between the standards adopted and the specific
standards shall be clearly brought out in relevant schedule of deviation. It will
be sole responsibility of Bidder to prove that the salient features of offered
materials are equivalent or better than Indian standards as indicated in
Section-2 to Section- 8 of Volume-V(Part-2) of bid document.
1.4.3 The Material and Installation work conforming to standards other than
specified in individual sections for various Material and Installation work shall
be subject to Employer’s approval.

Volume-V (Part-2)
1.5 TYPE TESTS:
1.5.1 Type tests shall mean those tests, which are to be carried out to prove the
process of manufacture and general conformity of the Material.
1.5.2 The offered Material (except Towers & Tower Accessories) should be fully type
tested as per the relevant standards. Bidder shall invariably furnish type test
reports from the reputed and approved national/international
laboratory/Government approved test houses to prove that specifications of
Material to be supplied conform to the relevant standard. Test certificates
shall clearly indicate the type and other details etc., so that relevant details of
offered Material could be verified. While submitting the bid the details and
type etc., shall be clearly indicated. Type test reports so furnished should not
pertain to the period earlier than five years from the date of opening of Bid.
In case the type tests were carried out earlier than five years, the
manufacturer will have to conduct these tests without any extra cost to the
Employer. In both the above cases type test certificate must be submitted
with the offer. The Bidders have to submit one complete set of Test reports
for the offered Material. Further, for any change in the design/type already
type tested and the design/type offered against this specification, the
Employer reserves the right to demand repetition of tests without any extra
cost.
1.6 DISCREPANCY IN TECHNICAL PARTICULARS:

The bidders will have to furnish confirmation in regard to compliance of our
entire technical requirement. The bid should clearly describe various technical
particulars of the material as per this specification.
1.7 MANUFACTURER'S AUTHORISATION:

The bidders shall have to submit the documentation from the manufacturer of
the Material on the format specified in this volume that they are authorised to
supply the material indicated in their bids in the employer's country
1.8 SCHEDULE OF QUANTITIES:
1.8.1 The requirements of various Materials and Installation work are indicated in
Price Schedules. In these schedules short description of material has been
given. The details of all such description are given in relevant sections of
Volume-V(Part-2) of bid document. The bidder shall refer these detailed
descriptions for clarity.
1.8.2 Although all the quantity of Material and Installation work have been included
in the bid as mentioned in Price Schedules. However there may be
requirement of some minor nature items required for successful erection /
commissioning of transmission line work covered under this Bid. Bidder
should include all such items in the bid proposal sheets which are not
specifically mentioned but are essential for the execution of the contract. The
cost of supply of such item which explicitly may not appear in various
schedules and are required for successful commissioning of transmission line
shall deemed to be inclusive in the bid price and shall be provided at no extra
cost to Employer.
1.9 PERFORMANCE GUARANTEE PERIOD:

All the Material & its accessories and Installation work covered under the Bid
shall guaranteed for performance and quality for a period of 24 months from
the date of completion of facilities (or any part thereof). In case after
commissioning of transmission line, any operational problem is observed in

Volume-V (Part-2)
any Material/ installation work because of which any major rectification or

replacement work is done, then the guarantee for such Material / installation
work shall be extended by a period equal to the period during which the
facilities or such part can not be used by the EMPLOYER.
1.10 WORKMANSHIP:
All Material shall be of the best class and quality most suitable for the
conditions of operation under the climate conditions as per clause no. 1.02
above for supply of Material. The workmanship shall be of the best grade and
the entire construction in accordance with the best modern practice.
1.11 DRAWINGS AND DOCUMENTS:
1.11.1 In addition to those stipulated in Vol. I of bidding document, the following also
shall apply in respect of Contractor drawings.
1.11.2 With in one month from the award of contract, the contractor shall submit the
drawing of all Material for approval. Each drawing submitted by the Contractor
shall be clearly marked with the name of the EMPLOYER, the specification
title, the specification number and the name of the Project. All titles, noting,
markings and writings on the drawing shall be in English. All the dimensions
should be to the scale and in S.I. units.
1.11.3 The comments/ approval to drawings submitted by the Contractor shall be

conveyed by the EMPLOYER as far as practicable within 15 days and shall be
modified by the Contractor if any modifications and/or corrections are
required by the EMPLOYER. The Contractor shall incorporate such
modifications and/or corrections and submit the final drawings for approval
with 15 days from date of EMPLOYERs comments. Any delays arising out of
failure by the Contractor to rectify the drawings in good time shall not alter
the Contractual Time Schedule.
1.11.4 The drawings submitted for approval to the EMPLOYER shall be in

quadruplicate. One print of such drawings shall be returned to the Contractor
by the EMPLOYER marked “approved/approved with corrections”. The
contractor shall there upon furnish the EMPLOYER additional prints as may be
required along with one reproducible in original of the drawings after
incorporating all corrections.
1.11.5 The work shall be performed by the Contractor strictly in accordance with
these drawings and no deviation shall be permitted without the written
approval of the EMPLOYER, if so required.
1.11.6 All manufacturing, fabrication and Installation work under the scope of
Contractor, prior to the approval of the drawings shall be at the Contractor’s
risk. The contractor may incorporate any changes in the design, which are
necessary to confirm to the provisions and intent of the contract and such
changes will again be subject to approval by the EMPLOYER.
1.11.7 The approval of the documents and drawings by the EMPLOYER shall mean
that the EMPLOYER is satisfied that:
a. The Contractor has completed the part of the Works covered by the
subject documents (i.e. confirmation of progress of work).
b. The Works appear to comply with requirements of Specifications.

Volume-V (Part-2)
In no case the approval by the EMPLOYER of any document does imply

compliance with all technical requirements or the absence of errors in such
documents.
If errors are discovered any time during the validity of the contract, then the
Contractor shall be responsible for consequences.
1.11.8 All drawings shall be prepared using AutoCAD software. After final approval
all the drawings and documents (structural drawings, BOMs, shop sketches,
tower accessories drawings and drawings of other materials) shall be
submitted to the EMPLOYER in CDs.
A copy of each drawing reviewed will be returned to the Contractor as

stipulated herein.
1.11.9 Copies of drawings returned to the Contractor will be in the form of a print
with the EMPLOYER’s marking.
1.11.10 All rights of the design/drawing for all Material and Installation work
drawings shall be strictly reserved with the EMPLOYER only and any
designs/drawings/data sheets submitted by the contractor from time to time
shall become the property of the EMPLOYER. Under no circumstances, the
contractor shall be allowed to user/offer above designs/drawings/data sheets
to any other authority without prior written permission of the EMPLOYER.
Any deviation to above is not acceptable and may be a cause for rejection of
the bid.
1.11.11 The manufacturing of the material shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written
approval of the EMPLOYER. All manufacturing and fabrication work in
connection with the material prior to the approval of the drawing shall be at
Contractor’s risk.
1.11.12 Approval of drawing/works by EMPLOYER shall not relieve the Contractor of

his responsibility and liability for ensuring correctness and correct
interpretation of the latest revision of applicable standards, rules and codes
of practices. The plant shall conform in all respect to high standards of
engineering, design, workmanship and latest revisions of relevant standards.
EMPLOYER shall have the power to reject any work or material, which in his
judgment is not in full accordance therewith.
1.12 QUALITY ASSURANCE PROGRAM:
1.12.1 Quality Assurance Program : To ensure that the Material and Services
under the scope of this contract whether manufactured or performed
within the Contractor's works or at his Sub-Contractor's premises or at
the EMPLOYER's site or at any other place of work are in accordance
with the Specifications, the Contractor shall adopt suitable Quality
Assurance Program (QAP) with hold points for EMPLOYER’s inspection to
control such activities at all necessary points. Such program shall be
outlined by the Contractor and shall be finally accepted by the EMPLOYER
after discussions.
1.12.2 Immediately after award of contract, the contractor shall submit to the
EMPLOYER, the quality assurance plan for all major items of Material
covering the manufacture and Installation activities of the transmission line.
The list of selected sub vendors for supply of minor items like Bolts & Nuts,
tower accessories etc. shall also be submitted.

Volume-V (Part-2)
1.12.3 The contractor shall ensure that manufacturer must establish that they are
following the accepted quality assurance programme for manufacture of
offered equipments.
1.12.4 The contractor shall ensure that manufacturers of major items of Material
invariably furnish following information:-
(i) Statement giving list of important raw materials, names of sub
supplier for the raw material, list of standards according to which the
raw material are tested, list of tests normally carried out on raw
material in presence of manufacturers representative, copies of test
certificates.
(ii) Information and copies of test certificates as in (i) above in respect of
bought out items.
(iv) Levels of automation achieved and list of areas where manual
processing exists.
(v) List of areas in manufacturing process, where stage inspections are
normally carried out for quality control and details of such tests and
inspection.
(vi) Special features provided in the equipment to make it maintenance
free.
(vii) List of testing equipment available with the manufacturer for final
testing of equipment specified and test plant limitations, if any vis-à-
vis type, special, acceptance and routine tests specified in the relevant
Indian Standards or equivalent international standard. These
limitations shall be very clearly brought out in schedule of deviations
from specified test equipments.
1.12.5 The Contractor shall follow the accepted Quality Assurance Plan in true spirit.
If desired by the EMPLOYER, he shall give access to all the Specifications,
equipments and records so as to satisfy the EMPLOYER that Quality
Assurance Plan (QAP) is being followed properly.
1.12.6 All Material shall be subjected to the routine and acceptance tests before
dispatch, as specified in this Specification.
1.13 INSPECTION AND TEST CERTIFICATES:
1.13.1 All Material to be supplied will be subject to inspection and approval by the
EMPLOYER's representative before despatch. Inspection before despatch will
not however relieve the contractor of his responsibility to supply the
Material strictly in accordance with the specifications.
1.13.2 For Inspection / testing, the contractor shall intimate the EMPLOYER at least
15 days in advance about readiness of Material as per the scheduled delivery
so that action may be taken for getting the Material inspected. While
notifying the readiness of the Material, the factory test certificate in respect
of offered Material shall invariably be sent. The EMPLOYER will depute
authorized representative for inspection of Material or alternatively may
issue waiver of inspection.
1.13.3 The contractor will submit a test certificate to the EMPLOYER after inspection
of offered Material by EMPLOYER’s authorized representative. These test
certificates should be in accordance with latest issue of the relevant Indian
Standards or as approved by the order placing authority.
Volume-V (Part-2)
1.13.4 The Material shall not be dispatched unless the test certificates approval and
despatch instructions have been issued by the EMPLOYER.
1.13.5 All Material shall conform to provisions of any statutory acts such as the
Indian Electricity Act, Indian Factory Act, the Indian Boiler Act, etc. and
corresponding rules and regulations as may be applicable.
1.13.6 The EMPLOYER's representatives shall be entitled at all reasonable time

during manufacture to inspect, examine and test at the contractor's
premises the material and workmanship of the plant to be supplied under
this contract.
1.13.7 A copy of the accepted Quality Assurance Plan must be available at the
manufacturer’s works of the Material for reviewing by inspecting officer of
the EMPLOYER.
1.13.8 The acceptance of any quantity of plant shall in no way relieve the Contractor
of any of his responsibilities for meeting all requirements of the specification,
and shall not prevent subsequent rejection if such plant is later found to be
defective. The Contractor will have to assume the responsibility for free
replacement/rectification of such defects.

during manufacture specified in the bid document shall be treated as included
in the quoted unit price of plant.
1.14 SPECIAL REQUIREMENTS:
1.14.1 EMPLOYER expects that participating bidder will take all necessary precautions
to supply best quality Material, which may provide trouble free performance
and also it is expected that the modern practices for erection and
commissioning shall be adopted to ensure timely and trouble free
commissioning of installation and also to ensure aesthetic overall view of
finished transmission line installation.
1.14.2 Some of the conditions which will have to be essentially accepted and
followed by the Bidders for the purpose of participating against the Bid and
also for undertaking construction activities are enumerated below for specific
confirmation by the Bidders.
1.15 STORE FOR SUPPLY OF MATERIAL:
The Contractor shall supply the Material at selected destination set up by him along
the route of the transmission line. The Contractor will set up above site store within
one month from the date of contract and inform the EMPLOYER. The Contractor will
have to supply above materials and receive them at these places only and the
rates quoted by the Bidder should include charges for delivery of such materials at
the store set up by him, receipt and proper stacking/ stocking at the store.
1.16 COMMENCEMENT OF ACTIVITIES:
Commencement of following activities is subject to prior and specific approval of the

items mentioned against each:-

Volume-V (Part-2)
S. Activity Items for which prior approval is

No. necessary from Employer
1. Manufacturing of tower parts. Inspection of Proto Assembly of each type
of tower. Submission of quality
assurance plan.
2. Manufacturing of Conductors, Submission of Quality Assurance Plan,
Ground wire, Insulators, approval of drawings.
Hardware fittings &
Accessories for Conductor and
Earth wire.
3. Dispatch of towers, Acceptance test and issue of test certificate
Conductors, Earth wire, approval
Insulators, Hardware fittings
& Accessories for Conductor
and Earth wire.
4. Foundation work. Classification of foundation.
5. Erection of tower Quality Assurance Plan for erection.
6. Stringing of Conductor and Stringing chart and stringing method.
Earth wire.
1.17 RESPONSIBILITY FOR OBTAINING INFORMATION AND TAKING

ACTION IN TIME:
Whenever any information or clarifications in respect of construction of line
has to be obtained from various authorities, the Contractor shall be
responsible for taking action well in time so that there are no delays on this
account. The completion period specified in the bidding document is deemed
to include the time taken for such incidental works. Request for extension of
the completion date on such ground will not be entertained.
1.18 PERMITS AND PRIORITIES:
1.18.1 Necessary permits, if any, required for the execution of the contract shall
be arranged by the Contractor himself. The Contractor shall obtain the
necessary license/permission as per Central/State/local statutory bodies
at his cost.
1.18.2 The Purchaser may, however, furnish to the Contractor such certificates (on
receipt of such written request from the Contractor) as may be required for
the necessary permits/priorities for the execution of works, if it considers the
demand as justified.
1.18.3 The Purchaser however, shall not be responsible for the delay in execution of
contract, if permits/priorities are not granted in time in spite of issuance of
such certificate.
1.19 WAY LEAVE:
The purchaser will arrange for necessary way leave and clearance of trees. The
Purchaser will pay the way leave compensation. The purchaser will also arrange
for the following: -
(i) Railway clearance

(ii) PTCC clearance
(iii) Forest clearance
(iv) Any other necessary clearance if required/requested.
Volume-V (Part-2)
The Contractor shall inform the purchaser about the places where there is a way
leave problem, sufficiently in advance (preferably 30 days) so that required way
leave can be arranged in time.
Further Contractor shall inform the employer at least 15 days in advance, the
sections of the line where he has planned to carry out the foundation/ tower
erection/stringing work so that MPPTCL may take advance suitable actions to
avoid possibility of any ROW problem.
Please note that while carrying out stringing work, if obstruction is faced due to
branches of trees, the same will be cleared by the contractor. Further, the
contractor will make all- out efforts to carry out stringing work across Electrified
Railway Track within minimum possible duration.
1.20 USE OF PRIVATE ROADS/APPROACH ROAD TO SITE:

1.20.1 The purchaser will help in getting necessary permission for use of
private/forest/canal, roads for transportation of materials and construction
personnels, wherever possible under the rules. Any charges/tole tax etc.
levied by the concerned authorities for use of such roads etc. shall be borne
by the Contractor.
1.20.2 During the erection work, if approach roads are required to be constructed for
reaching the construction sites for transportation of men/materials, the cost
of construction of such approach roads and any other expenses incurred in
obtaining clearance/permission shall be borne by the Contractor.
1.21 MATERIALS TO BE ARRANGED BY THE CONTRACTOR FOR

ERECTION WORK:
1.21.1 The supply of cement for foundation work would be arranged by the
Contractor of the quality as per IS - 269 :1989 (Ordinary Portland Cement
33 Grade) or IS – 8112 : 1987 (Ordinary Portland Cement 43 Grade) or IS
– 12269 : 1987 (Ordinary Portland Cement 53 Grade) or IS:1489 (Portland-
Pozzolana Cement (PPC)). The cost of cement shall be deemed to be
included in the quoted unit rates of concreting.
1.21.2 The cement used shall be procured from reputed manufacturer like JP
Cement, L&T, Birla Cement, ACC, Ambuja etc. The Contractor shall submit
the manufacturer’s certificate, for each consignment of cement procured, to
the Purchaser. The cement shall be arranged in conventional Jute/HD bags
each weighing 50 Kgs net with necessary IS certification mark on it. In case
of any dispute regarding quality of cement, sample for testing may be taken
jointly by contractor’s representative and Engineer in- charge of work or any
authorized representative of the Company. The sample taken shall be tested
for standard test as per IS code in Govt. Engineering/Polytechnic College
and testing charge shall be borne by the contractor. In case the material is
found defective i.e. not as per relevant ISS, the same shall be replaced by
the contractor at his cost. The Contractor shall also have no claim towards
suspension of work due to time taken in conducting tests in the laboratory.
Changing of brand or type of cement within the same structure shall not be
permitted without the prior approval of the Purchaser.
1.21.3 The Quantity of cement to be used per unit quantity of consumption for
different mix (nominal mix) of concrete should be as follows:
S. Description Unit Quantity of minimum

No. Cement to be used per
Volume-V (Part-2)
Unit quantity of work(in

kgs)
1 1:1.5:3 nominal mix concrete Cu.m. 400
2 1:2:4 nominal mix concrete Cu.m. 330
3 1:3:6 nominal mix concrete Cu.m. 220
4 Random Rubble Masonry Cu.m 83
with 1:6 cement mortar
1.21.4 The Contractor shall arrange metal, sand, stone and water required for
foundation/revetment work. The transport, octroi, levy or duty on these
materials shall be borne by the Contractor himself and the purchaser will not
accept any liability on this account.
1.21.5 The Contractor will also arrange steel rods and binding wires etc. for
foundation, reinforcement and the cast incurred will be borne by him.
Materials for proper earthing of towers i.e. earthing rod, connecting clamps
and connecting wires etc. would also be arranged by the Contractor as
already specified.
***

Volume-V (Part-2)
SECTION-2
TECHNICAL SPECIFICATIONS FOR TOWERS
Clause No. Name of Clause

2.01 INDIAN STANDARDS/CODE
2.02 TYPE OF TOWERS
2.03 EXTENSIONS
2.04 STUB SETTING TEMPLATES
2.05 DESIGN
2.06 GALVANIZING PASSIVATION AND PAINTING
2.07 MATERIAL
2.08 WEIGHTS
2.09 BOLTS AND NUTS AND WASHERS:
2.10 STEP BOLTS
2.11 DANGER BOARD, NUMBER PLATE AND PHASE PLATES
2.12 ANTICLIMBING DEVICE WITH BARBED WIRE:
2.13 EARTHING
2.14 ATTACHMENT FOR INSULATOR STRING & GROUNDWIRE CLAMPS
2.15 FABRICATION WORKMANSHIP
2.16 BENDING
2.17 DRILLING AND PUNCHING
2.18 TOLERANCES
2.19 MARKING

Volume-V (Part-2)
SECTION-2
TECHNICAL SPECIFICATIONS FOR TOWERS

The material and services under this specification shall be performed as per
the requirements of the latest revisions and amendments available at the
time of placement of order of all the relevant Indian standards/codes listed
here under or equivalent International Standards , except as modified in this
document.
S.No. Indian standards Title

1. IS:209-1992 Zinc ingot- Specification.
2. IS:278-1991 Galvanized Steel Barbed Wire.
3. IS:800-1991 Code of Practice for General Building
Construction in Steel.
4. IS:802 -1990 ( Part-II) Code of practice for use of structural
steel in over-head Transmission Line :
Fabrication, Galvanising, Inspection &
packing.
5. IS:802 -1990 ( Part-III) Code of practice for use of structural
steel in over-head Transmission Line
Towers: Testing
6. IS:808-1991 Dimensions for Hot Rolled
Steel Beam, Column, Channel
and Angle Sections.
7. IS:1363(Part-III)-1992 Specification for Hexagon head bolts,
screws and nut for product grade – “C”
Hexagon nuts of property class 5.
8. IS:1367-1979 Technical supply conditions for threaded
fasteners (1st Revision).
9. IS:1367(Part-III)-1991 Mechanical properties and test method
for bolts, screws & studs with full
loadability.
10. IS:1367(Part-VI)-1994 Mechanical properties and test method
for nuts with specified proof loads.
11. IS-1367(Part-XIII)-1983 The hot dip galvanized coating of
fasteners.
12. IS:1573-1991 Specification for electroplated coating of
zinc on Iron & steel.
13. IS:1586-1968 Methods of Rock well hardness test (`B’
& `C’ scales) for steel (first revision).
14. IS:1852-1991 Rolling and Cutting Tolerances of Hot
Rolled Steel Products.
15. IS:2016-1992 Plain Washers.
16. IS:2062-1992 Steel for general Structural purposes –

Specification.
17. IS:2614-1969 Method for sampling of fasteners.
18. IS:2629-1990 Recommended practice for hot dip
galvanizing of iron and steel.
19. IS:2633-1992 Method of testing uniformity of coating of
zinc coated articles.
Volume-V (Part-2)

20. IS:3063-1994 Single Coil Rectangular Section spring
washers for bolts, nuts, and screws.
21. IS:3202-1972 Methods for testing local thickness of
electro plated coatings.
22. IS:3218(Part-V)-1979 Isometric screw threads “Tolerance”.
23. IS:3757-1992 High Strength Structural Bolts.
24. IS:4072-1975 Specification for steel for spring washers
(first revision).
25. IS:4218(Part-VI)-1978 Isometric screw threads limits of sizes for
commercial bolts & nuts.
26. IS:4759-1990 Specification, for Hot dip Zinc coatings on
Structural Steel and other Allied
products.
27. IS:5358-1969 Hot dip galvanized coatings on fasteners.
28. IS:5369-1991 General Requirements for Plain Washers.
29. IS:5613-1995 (part-II) Code of practice for design, installation
and maintenance of overhead power
lines.
Sec.-1 - Designs.
Sec.-2 - Installation &
Maintenance
30. IS:6610-1991 Specification for Heavy Washers for Steel
Structures.
31. IS:6623-1992 High Strength Structural Nuts.
32. IS:6745-1972 Methods for determination of weight of
zinc coating of zinc coated iron and steel
articles.
33. IS:6821-1973 Methods for sampling of non threaded
fasteners.
34. IS:8500-1992 Specification for weldable structural steel
(Medium & High Strength Qualities).
35. IS:10238-1989 Step Bolts for Steel Structures.
36. IS:12427-1992 Specification for Transmission Tower
Bolts of property class 5.6
37. IS:269-1967 Ordinary rapid hardening and low heat
Portland cement.
38. IS:456-2000 Code of practice for plain and
reinforced concrete
39. IS:1786-1966 Cold twisted steel bars for concrete
reinforcements
40. IS:4091-1967 Code of practice for design & construction
of foundation for transmission line towers
& poles
2.02 TYPE OF TOWERS:
The towers are self supporting lattice type, designed for the specified
loading conditions. There will generally be following type of towers:-

Volume-V (Part-2)
a. Tower type NNFD-0: Tangent type tower with maximum line deviation
up to 2° to be used with Single/Double
suspension insulator strings.
b. Tower type NNFD-30/NNFDT: Medium angle tower to be used for line

tension insulator strings. NFD-30 type tower is
also used as Transposition tower with modified
cross arms.
c. Tower type NNFD-60: Heavy angle tower to be used for line deviation
from 0° to 60° and also as dead end tower with
Single/Double tension insulator strings.
d. River Crossing Towers:- The Bidder will have to supply River Crossing
Towers for crossing major river. Similarly for
crossing 400kV line if NFD60+ 30/35M extension
tower is required, the same will have to be
supplied by the contractor after approval of the
Purchaser.
2.03 EXTENSIONS:
Suitable extension of 3M, 6M, 10M height shall be supplied for use with the
NFD-0, NFD-30 and NFD-60 type towers. 18/25M extension shall be supplied
for NFD-0 type tower depending upon the requirement intimated by the
Purchaser.
2.04 STUB SETTING TEMPLATES:
The stub setting template shall be required for each type of tower and its
respective extensions and shall be supplied by the Bidder for each type of
tower and its respective extensions. The template shall be of adjustable
type i.e. for use with normal towers as well as extensions.
2.05 DESIGN:
2.05.1 400kV Towers/extensions to be supplied are designed as per IS 802(Part-

I)-1977.
2.05.2 The towers have square base with twin MOOSE ACSR conductor per phase in
vertical formation and two ground-wires of 7/3.66 mm galvanized stranded
steel wire of 95kg/sq.mm grade placed on the top of the towers. .
2.06 GALVANIZING PASSIVATION AND PAINTING:

The tower parts, stubs and pack washers shall be hot dip galvanized. The
galvanization shall be done as per requirements of IS 4759 after all
fabrication work is completed. The contractor shall also take guidelines
from the recommended practices for hot dip galvanizing laid down in IS
2629 while deciding and implementing galvanizing procedure. The
mandatory requirements however, are specified herein.
Unless otherwise specified the fabricated tower parts and stubs shall have a
minimum overall Zinc coating of 610 gms per sq. m of surface except for
plates & sections below 5mm which shall have Zinc coating of 460 gms per
sq. m of surface. The average zinc coating for all sections and plates 5mm &
Volume-V (Part-2)
above shall be maintained as 87 microns and that for plates and sections
below 5mm shall be maintained as 65 microns.
The zinc coating shall be adherent, reasonably uniform, smooth,

continuous and free from imperfections such as black/bare spots, ash rust
strains, bulky white deposits/wet storage strains and blisters.
The surface preparation for fabricated tower parts and stubs for hot
dip galvanizing shall be carried out a indicated herein below:
(i) Degreasing & Cleaning of Surface: Degreasing and cleaning of surface,

wherever required, shall be carried out in accordance with clause 4.1 of IS
2629-1985. After degreasing the article shall be thoroughly rinsed. However,
if acidic degreasers are used rinsing is not required.
(ii) Pickling: pickling shall be done using either hydrochloric or sulphuric acid as
recommended at clause 4.3 of IS 2629-1985. The actual concentration of the
acids and the time duration of immersion shall be determined by the
Contractor depending on the nature of material to be pickled. Suitable
inhibitors also shall be used with the acids to avoid over pickling. The acid
concentration, inhibitors used, and maximum allowable iron content shall
form part of plant standard to be formulated and submitted to MPPTCL along
with Quality Assurance Program.
(iii) Rinsing: After pickling, the material shall be rinsed, preferably in running
water to remove acid traces, iron particles or any other impurities from the
surface. Two rinse tanks are preferable, with water cascading from the
second tank to the first to ensure thorough cleaning. Wherever single tank is
employed, the water shall be periodically changed to avoid acid
contamination, and removal of other residue from the tank.
(iv) Fluxing: The rinsed article shall be dipped in a solution of zinc ammonium
chloride, The concentration and temperature of the flux solution shall be
standardized by the contractor depending on the article to be galvanized and
individual circumstances. These shall form part of plant standard to be
formulated and submitted to MPPTCL along with Quality Assurance Program.
The specific gravity of the flux solution shall be periodically monitored and
controlled by adding required quantity of flux crystals to compensate for drag-
out losses. Free acid content of the flux solution also shall be periodically
checked and when it is more than two (2) grams of free acid per litre of the
solution, it shall be neutralized. Alternatively, Ph value should be monitored
periodically and maintained between 5.0 to 5.5.
(v) Drying: When dry galvanizing is adopted the article shall be thoroughly
dried after fluxing. For the purpose of drying, the contractor may use hot
plate, air oven or any other proven method ensuring complete drying of the
article after fluxing and prior to dipping in the molten zinc bath. The drying
process shall be such that the article shall not attain a temperature at which
the flux shall get decomposed. The article thus dried shall be galvanized
before the flux coating picks up moisture from the atmosphere or the flux
layer gets damaged or removed from the surface. The drying procedure, time
duration, temperature limits, time lag between fluxing, drying, galvanizing etc
shall form part of plant standard to be formulated and submitted to MPPTCL
along with Quality Assurance Program.
(vi) Quality of Zinc: Any one or combination of the grades of zinc specified in IS
209 or IS 13229 or other comparable international standard shall be used for
Volume-V (Part-2)
galvanizing. The contractor shall declare the grade(s) of zinc proposed to be

used by them for galvanizing. The molten metal in the zinc bath shall contain
minimum 98.5 % zinc by mass. It shall be periodically measured and
recorded. Zinc aluminium alloy shall be added as per IS 2629.
(vii) Dipping Process: The temperature of the galvanizing bath shall be

continuously monitored and controlled. The working temperature of the
galvanizing bath shall be maintained at 450 ± 10°C. The article should be
immersed in the bath as rapidly as possible without compromising on safety
aspects. The galvanizing bath temperature, immersion angle & time, time
duration of immersion, rate of withdrawal etc. shall be monitored and
controlled depending upon the size, shape, thickness and chemical
composition of the article such that the mass of zinc coating and its
uniformity meets the specified requirements and the galvanized surface is
free from imperfections and galvanizing defects.
(viii) Post Treatment: The article shall be quenched in water. The quench water
is to be changed / drained periodically to prevent corrosive salts from
accumulating in it. If water quenching is not done then necessary cooling
arrangements should be made. The galvanized articles shall be dipped in
chromating solution containing sodium dichromate and sulphuric acid or
chromic acid base additive at a predetermined concentration and kept at
room temperature to retard while rust attack. The temperature of the
chromate solution shall not exceed 65°C. The articles shall not be stacked
immediately after quenching and dichromating. It shall be ensured that the
articles are dry before any further handling operation.
(ix) Storing, Picking and Handling: In order to prevent while rust formation
sufficient care should be exercised while storing handling and transporting
galvanized products. The articles shall be stored in an adequately ventilated
area. The articles shall be stored with spacers in between them and kept at
an inclination to facilitate easy drainage of any water collected on the articles.
Similar care is to be taken while transporting and storing the articles at site.
(x) The Contractor shall prepare a detailed galvanizing procedure including Flow
Chart with control parameters and all plant standards as required above and
submit to Purchaser for approvals as part of Quality Assurance Plan.
(xi) Minor defects in hot-dip galvanised members shall be repaired by applying

zinc rich primer and two coats of enamel paint to the satisfaction of the
Owner before erection.
2.07 MATERIAL :
2.07.1 IS Steel Sections of tested quality in conformity with IS:2062 : 2006 grade
E250 (Designated Yield Strength. 250 MPa) and/ or grade E350 (Designated
Yield Strength 350 MPa) are to be used in towers, extensions, stubs and stub
setting templates. The Contractor can use other equivalent grade of structural
steel angle sections and plates conforming to latest International Standards.
However, use of steel grade having designated yield strength more than that
of EN 10025 grade S355 JR/JO (designated yield strength 355 MPa) is not
permitted, unless otherwise indicated in this specification.
2.07.2 Steel plates below 6mm size exclusively used for packing plates/packing
washers produced as per IS : 1079 -1994 (Grade -0) are also acceptable.
However, if below 6mm size plate are used as load bearing plates viz gusset
plates , joint splices etc. the same shall conform to IS : 2062 or equivalent

Volume-V (Part-2)
standard meeting mechanical strength/metallurgical properties corresponding

to grade E250 or E350 (designated yield strength not more than 355MPa),
depending upon the type of grade incorporated into design. Flats of
equivalent grade meeting mechanical strength/ metallurgical properties may
also be used in place of plates for packing plates/ packing washers. The
chequered plates shall conform to IS : 3502. SAILMA 350HI grade plate can
also be accepted in place of HT plates (EN 10025 grade S355 JR/JO / IS
2062:2006 – grade 350, as applicable) provide SAILMA 350HI grade plate
meet all the mechanical properties of plate as per EN 10025 grade S355
JR/JO (designated yield strength 355 MPa) / IS 2062:2006 – grade 350.
2.07.3 For designing of towers, preferably rationalised steel sections has been used.
During execution of the project, if any particular section is not available, the
same shall be substituted by higher section. Any cost on account of the same
shall be borne by the Contractor. However, design approval for such
substitution shall be obtained from the Owner before any substitution and
records of such substitutions shall be maintained by the Contractor.
2.08 WEIGHTS :
The unit weight of each type of tower and extension including bolts and
nuts, accessories, attachments and step bolts is indicated in the Bill of
Materials which shall be supplied by the Employer to the successful Bidder.
The weight of structure means the weight calculated using black sectional
(i.e. ungalvanised) weights of all steel members of the sizes indicated in the
fabrication drawings without taking into consideration the reduction in
weight due to drilling of bolts, holes, skew cuts, chamfering etc. or increase
in weight due to galvanising. The weight of gusset plates shall mean the
weight of its circumscribing rectangle, without taking into considerations the
reductions in weight due to holes, notches etc.
2.09 GALVANISED BOLTS AND NUTS AND WASHERS :
2.09.1 The design of the towers and extensions are based on use of HRH mild steel
hot dip galvanized bolts (5.6 quality) and nuts (5.0 quality). The connections
are designed on the basis of use of 16mm dia bolts. The spring washers shall
be provided for insertion under all nuts.
2.09.2 The nuts shall be forged and tapped after galvanizing and then lubricated.
The nuts shall be chamfered on one face only, the other face shall be
machined.
2.09.3 The Bolts up to M16 and having length up to 10 times the diameter of the bolt
should be manufactured by cold forging and thread rolling process to obtain
good and reliable mechanical properties and effective dimensional control.
The shear strength of bolts for 5.6 grade should be 310 MPa minimum as per
IS:12427. Bolts should be provided with washer face in accordance with
IS:1363 (Part-I) to ensure proper bearing.
2.09.4 Nuts for hexagonal bolts should be double chamfered as per the requirement
of IS:1363 Part-III. It should be ensured by the manufacturer that nuts
should not be over tapped beyond 0.4mm oversize on effective diameter for
size up to M16.
2.09.5 Fully threaded bolts shall not be used. The length of bolts shall be such that
the threaded portion will not extend into the place of contact of the members
2.09.6 All bolts shall be threaded to take the full depth of the nuts and threaded for
enough to permit firm gripping of the members, but not further. It shall be
Volume-V (Part-2)
ensured that the threaded portion of each bolt protrudes not less than 3mm
and not more than 8mm when fully tightened. All nuts shall fit tight to the
point where the shank of the bolt connects to the head.
2.09.7 Flat and tapered washers shall be provided wherever necessary. Spring
washers shall be provided for insertion under all nuts. These washers shall be
steel electrogalvanised, positive lock type and 3.5mm in thickness for 16mm
dia bolt and 4.5mm for 24mm bolt.
2.09.8 To avoid bending stress in bolts or to reduce it to minimum, no bolt shall

connect aggregate thickness of members more than three (3) times its
diameter.
2.09.9 The bolt positions in assembled towers shall be as per structural drawing.
2.09.10 Bolts at the joints shall be so staggered that nuts shall be tightened with
spanners without fouling.
2.09.11 To ensure effective in-process Quality control it is desirable that the

manufacturer should have in house testing facility for all tests like weight
of zinc coating, shear strength and other tests etc. The manufacturer
should also have proper Quality Assurance System which should be in line
with the requirement of this specification and IS:14000 series Quality
System Standard
2.09.12 The bolts and nuts shall be free from forging and threading defects such
as cuts, splits, burrs, bulging, taper, eccentricity, loose fit etc.
2.09.13 The bolts shall be threaded up to standard length only as per relevant
Indian Standard and not to full length.
2.09.14 The bolts and nuts shall confirm to IS 1967-1971 Part-III and Part-IV, IS
12427, IS 1363-92, IS 1367 Part-XIII with latest amendment.
2.09.15 The spring washers designated as M 16-B suitable for 16mm dia
galvanized bolt shall be manufactured out of rectangular section with
tolerances as per IS 3063-1994 with latest amendments. The spring
steel shall conform to IS- 4072-1975 with latest amendments
"Specification for steel for spring washers".
2.09.16 The spring washers after coiling shall be suitably heat treated so as to
result in the finished washer having hardness 43 to 50 HRC when tested in
accordance with IS 1586- 1968.
2.09.17 The surface of the washers shall be free of scales and burrs. The
washers shall be coiled without any kinks (except for the shape with
turned-up ends). The ends of the washer shall not abut when the
washers are compressed. The ends shall be so served as to prevent
tangling.
2.09.18 The approximate weight of 1000 pieces of spring washers suitable for
16mm dia bolt shall be 8.91 kg. in natural black finish as shown in IS
3063-1972 with latest amendments.
2.09.19 The spring washer shall be electro galvanized with chromate passivation.
The electro galvanizing of washers should conform to 'severe’ grading
service conditions incorporated in IS 1573-1986 as "Service Grade

Volume-V (Part-2)
No.4", classification Fe Zn 25. The local thickness of zinc coating should

be minimum 25 microns and average thickness 38 microns. It should
be further suitably heat treated to avoid any danger of hydrogen
embrittlement.
2.10 STEP BOLTS :

Each tower will be provided, on one of the legs, with step-bolts of 16mm dia
and 175mm long, spaced not more than 450mm and extending from 3
meters. approx. above ground level up to the top portion of the tower. The
step bolts shall be confirm to IS 1363-1992, IS 10238:1989 and IS
1367(Part-XIII): 1983.
2.11 DANGER BOARD, NUMBER PLATE AND PHASE PLATES :

Each tower will be fitted with danger board, number plate and phase plates.
The tower to be supplied shall have provision to fix these plates at a height of
about 3 meters above ground level. Necessary provision in tower & extensions
for fixing of these items shall be made. The Danger board, number plate and
phase plates shall be supplied conforming to following technical details:-
2.11.1 The danger boards shall conform to IS-2551-1982 and their revision, if any
except where modified in this specification.
2.11.2 The danger boards, number plates and phase plates shall conform to the
drawings enclosed in this specification.
2.11.3 The colour scheme of the enamel and size of figures and dimensions of
lettering shall be as shown in the drawing as also the overall size. The holes
as indicated in the drawing shall be provided before enamellings.
2.11.4 The thickness of the plate out of which the danger board, number plate and
phase plate will be manufactured, shall not be less than 1.6mm.
2.11.5 The enamellings shall be done by vitreous enameling process only.
2.11.6 All letterings shall be centrally spaced. The dimensions of the letters, figures
and their respective positions shall be as given in drawings. The size of each
letter in the word in each language and the spacing between them for the
purpose of scribing shall be so chosen that they are uniformly written in the
space earmarked for them.
2.11.7 The corners of the plate shall be rounded off. The location of the fixing holes
shall be according to drawing annexed with this specification.
2.11.8 The plate shall be made from mild steel at least 1.6mm thick and vitreous
enameled white, with letters, figures and the conventional skull and cross-
bones in signal red colour on the front side. The rear side of the plate shall
also be enameled.
2.11.9 The corners of the danger, number and circuit plates shall be rounded off to
remove sharp edges.
2.11.10 The letters of number and phase plates shall be red enameled with white
enameled background.

Volume-V (Part-2)
2.12 ANTICLIMBING DEVICE WITH BARBED WIRE :
The barbed wire type anticlimbing device shall be used at a height of

approximately 3 meters as an anticlimbing deterrent measure, as per the
details given in IS:5613(Part- 2/Sec-I)1985. The towers to be supplied by the
Bidder shall have provision to fix the barbed wire as indicated above.
Thus the angle pieces with notches for accommodating barbed wire shall be
supplied with the towers alongwith with provision for suitable bolt holes on
leg members for fitting the angles. It should have the facility of the locking
arrangement. The Barbed wire shall confirm to IS:278/1978 with latest
amendment and shall be type 'A-3'.
The Barbed wire shall be made of Hot dip Galvanised MS solid wire of size
2.5mm dia (for line wire) and 2.0 mm dia (for point wire). The barbs shall
have four points and shall be formed by twisting 2 point wires, each two
turns, tightly around both line wires making altogether four complete turns.
The wire shall be galvanised by Hot dip process as per IS:2629/1966 (with
latest amendment). The galvanised wire shall confirm to the requirement as
per IS:4826/1971 with latest amendment in all respect. IS:2633/1972 and IS
6745/1972 for testing of uniformity & mass of zinc coating. The zinc coating
shall be medium type on line wire and light type on point wire i.e. having zinc
coating minimum 110 gm/m² on line wire and 70 gm/m² on point wire.
2.13 EARTHING :
2.13.1 A provision shall be made in the stub for fixing earthing material. The stub
will be provided with a hole at a distance of 250 mm from bottom end and at
a distance of 500 mm below ground level for connection with earthing
materials. The hole will be of 17.5 mm dia.
2.13.2 The Bidder shall also supply the following materials per earthing set for
earthing of towers (four sets per tower): -
(i) One no. Hot dip galvanized earthing Mild Steel Rod (2 Meter long, 25 mm
diameter):
(ii) Hot dip galvanized connecting clamps (`F’ type and Ù’ type- 2 Nos. per
set);
(iii) Hot dip galvanized stranded steel wire of size 7/4.00mm, Grade 5 to be
used as connecting wire conforming to Indian Standard:2141:1992 and
Indian Standard 4826: (5 Meter per earthing set).
2.13.3 The details of earthing rod and clamps and earthing arrangement for towers
are shown in the drawing enclosed.
2.13.4 The earthing rod shall be of mild steel solid rod of 2 meters in length and
25mm in diameter with one end pointed. The rods shall be galvanized as per
relevant Indian Standard . The zinc coating on the rod shall not be less than
610 gm/m² of surface area.
2.13.5 The tower end-connecting clamp shall be of flat type and rod end connecting
clamp shall be of Ù’ type. The clamps shall be of forged steel cast iron /

Volume-V (Part-2)
malleable iron. The clamps should be hot dip galvanized as per Indian
Standard:2629:1990 . The zinc coating on the clamps shall not be less than
610 gm/m² of surface area.
2.13.6 The hot dip galvanized stranded steel wire of size 7/4.00mm shall be supplied
for connection between the earthing rod and the stub. The steel wire shall
conform to Indian Standard 2141: 1992 and Indian Standard:4826: 1979
and latest revision thereof and shall consist of seven strands, each strand
having a diameter of 4 mm and Grade-5. The galvanizing shall be done as
per Indian Standard specification2141: 1992 and 4826: 1979 and latest
revision thereof for heavy zinc coating. The coating of zinc shall not be less
than 260 gm/m².
2.14 ATTACHMENT FOR INSULATOR STRING & GROUNDWIRE CLAMPS:
2.14.1 The towers shall be provided with suitable attachment for supporting
insulator strings and ground-wire suspension and tension assembly.
2.14.2 The towers shall be provided with the cleats to support the hanger. The
details of hanger are shown in the drawing enclosed.
2.14.3 The ground-wire suspension assembly has got a 'D’ shackle. There shall be
a suitable arrangement to support the same.
2.14.4 On angle towers, strain plates shall be provided for purpose of attaching
the tension insulator string. For fixing ground-wire tension assembly
a hole 17.5mm dia shall be provided in the strain plate.
2.15 FABRICATION WORKMANSHIP :
2.15.1 Except where hereinafter modified, details of fabrication shall conform to

IS-802(Part-II)-1990.
2.15.2 The fabrication of towers shall be done strictly in accordance with the
drawing supplied by the Employer.
2.15.3 The towers shall be of bolted construction.
2.15.4 Normally lap splice shall be used for connecting members of un-equal size
and the inside angles of lap splice shall be rounded at the heel to fit the
fillet of the outside angle. All splices shall develop full stress in the
members connected through bolts. Butt-joint as well as lap joint splices
shall be made as above and as close to the main panel as possible.
2.15.5 Joints are designed and detailed to avoid eccentricity as far as possible.
The use of gusset plates for joining tower members shall be avoided as far
as possible. However, where the connections are such that the eliminations
of the gusset plates would result in eccentric joints, gusset plates and spacer
plates may be used in conformity with modern practice.
2.15.6 The tower structures shall be accurately fabricated to bolt together easily at
site without any undue strain on the bolts.
2.15.7 No angle member shall have two leg flanges brought together by closing the
angle.
2.15.8 The diameter of the hole shall be equal to the diameter of the bolt plus 1.5
mm.

Volume-V (Part-2)
2.15.9 All similar parts shall be made strictly interchangeable. All steel
section before any work is done on them shall be carefully leveled,
straightened and made true to detailed drawings by methods which will not
injure the materials so that when assembled the adjacent matching
surfaces are in close contact throughout .No rough edges shall be
permitted in the entire structures. Hammering is not permitted for
straightening.
2.15.10 Cutting may done by shearing, cropping, flame cutting or sawing .

The surface so cut shall be cleaned smooth , reasonably square and free
from deformation and distortion.
2.16 BENDING :
2.16.1 Mild steel angle sections up to 75x75 mm (up to 6mm thick) shall bent cold
up to and including bend angle of 10° Angles. Above 75x75mm (thickness up
to 6mm) and up to and including 100x100 mm (thickness up to 8 mm) may
also be bent cold up to the bend angle of 5 Deg. All other angle sections and
bend angles not covered above shall be bent hot.
2.16.2 All plates up to 12mm thickness shall be bent cold up to a maximum bend
angle of 15 Deg. Plates of thickness more than 12mm with bends greater
than 15 Degree shall be bent hot.
2.16.3 All hot bend material shall be air-cooled. The bends shall be of even profile
and free from any surface damages.
2.17 DRILLING AND PUNCHING :
2.17.1 The holes in the member shall either be drilled or punched with a jig , the
former process will be preferred.
2.17.2 Punching may be adopted for sections upto 12 mm thickness. For thicker
sections drilling shall be done.
2.17.3 The holes shall be punched/drilled after bending and related position of
these holes shall be maintained with the use of proper
templates/jigs and fixtures .
2.17.4 The holes shall be perfectly circular and no tolerance in this respect is
permissible. The holes shall be perpendicular to the plate and angle
flanges.
2.17.5 Holes must be square with the plates or angles and have their walls parallel.
2.17.6 All burrs left by drills or punch shall be removed completely. When the tower
members are in positions, the holes shall be truly opposite to each other.
Drilling or ramming to enlarge defective holes shall not be permitted.
2.17.7 The minimum spacings of bolt and edge distance shall be as under :-
a. For 16 mm dia bolt edge distance of 20 mm from hole center to rolled or

swaged edge and 23mm from hole center to sheared or flame cut edge,
hole center to hole center distance minimum 40mm (the hole size being
17.5mm).
b. The gap between the edges of the connected members in butt joint
shall not be more than 6mm and less than 4mm.
Volume-V (Part-2)
c. The bolt gauge distance in flanges of angle sections shall generally be in

accordance with Table XXXI of SF6(1)-1961-ISI “Hand Book for
structural Engineers-Structural Steel Sections (Revised).”
d. The bolt gauge distance in flanges of angle sections shall

generally be in accordance with Table XXXI of SF6(1)-1961-ISI “
Hand Book for structural Engineers-Structural Steel Sections
(Revised).”
2.18 TOLERANCES :
2.18.1 The maximum allowable difference in the diameter of the hole on the two
sides of the plate or angle shall not exceed 0.8 mm on diameter. The
allowable taper in drilled/punched hole shall not exceed 0.8 mm on diameter.
2.18.2 The tolerance cumulative or between consecutive holes shall be within

+/- 0.5mm.
2.18.3 The tolerance on the overall length of member shall be within +/- 1.6 mm.
2.18.4 The tolerance on gauge distance shall be within +/- 0.5mm.
2.18.5 Rolling and weight tolerance of steel sections shall be as per Indian Standard:
1852 and Indian Standard: 808.
2.19 MARKING :
All members shall be distinctly given punch mark similar to those given in
structural drawings. The mark shall be given with marking dies of minimum
18 mm size and this mark shall be legible. Letter XMPTNFD0,
XMPTNFD30 and XMPTNFD60 shall precede erection mark where ‘X’ stands for
manufacturer’s name, ‘MPT’ stands for Madhya Pradesh Power Transmission
Company and NFD0, NFD30 & NFD60 stands for type towers.
The contractor shall submit the Quality Assurance Programme as specified in

clause 1.12 Section-1 of the biding document. A copy of the accepted Quality
Assurance Plan must be available at the manufacturer’s works of the Plant for
reviewing by inspecting officer of the employer.
2.21 INSPECTION OF PROTOTYPES :
2.21.1 Proto type of each type of structure/extensions shall be offered by the

successful bidder for inspection within three month’s time from the date of
contract.
2.21.2 Notwithstanding any thing covered in the drawings and other details furnished
by the Employer, the successful bidder shall make minor modifications, if any,
in length, size, notching etc. according to the proto assembly which are
necessary for easy assembly of the structure.
2.22 INSPECTION :
2.22.1 As specified in clause 1.13 Section-1 of the biding document, Plant to be

supplied will be subject to inspection and approval by the Employer's
representative before despatch.

Volume-V (Part-2)
2.22.2 Each consignment ready for transportation shall be offered to the Employer
for inspection before dispatch giving a minimum time of not less than fifteen
days. Only complete sets of towers/extensions shall be offered for inspection.
All materials constituting towers (Steel parts, Bolts & nuts, spring and pack
washers, earthing sets) shall be offered simultaneously. Samples of fabricated
tower materials and accessories shall be subjected to tests as per relevant
Indian Standard or equivalent International Standard. The Employer shall be
kept informed about the source of procurement of raw-steel, particularly
through re-rollers. The Employer reserves right to inspect and get the
samples of raw-steel tested as per Indian Standard-2062 and relevant
standards or equivalent International Standard. The cost of testing shall be
borne by the bidder.
2.22.3 The Contractor shall keep the Employer informed in advance of the time of
starting and of the progress of manufacture and fabrication of structures at
various stages.
2.22.4 In case, any member of the structure is not found to comply with the relevant
drawing, it shall be liable for rejection even after receipt.
2.22.5 Defects, which may appear during fabrication, shall be made good. Any
member once rejected shall be cut into pieces in front of the Employer’s
representative so that it is not offered again by mistake.
2.23 GENERAL GUIDE-LINE FOR INSPECTION :
2.23.1 Fabricated Structure Members :
(ii) Sample selection from the offered lot at a ratio of 40 MT (or part thereof) 1
no. each for all tests.
(iii) Dimension, fabrication and trueness verification of structure member from

fabrication sketch.
(iv) Galvanising test of each sample i.e. dip test, hammer test and mass of zinc
test.
(v) Random verification of Zinc coating of galvanized surface by Alko-meter.
(vi) Tensile test and bend test of each sample.
(vii) Chemical composition test of at least two samples per offered lot of 50 MT
for inspection.
(viii) Verification of manufacturer’s test certificate for mild steel used in structure
members.
2.23.2 Bolts-Nuts, Washer, Accessories, Attachments etc.: (To be carried out at

manufacturers works of these items)
(ii) Sample selection from the offered lot as per relevant Indian Standard for each
item.
(iii) Dimension, fabrication and trueness verification from fabrication sketch.

Volume-V (Part-2)
(iv) Galvanising test of each sample.
(v) Other acceptance tests for respective items as per relevant Indian standard.
2.23.3 The supplier shall submit the factory test certificates of bought out
accessories at the time of acceptance tests of towers.
2.23.4 Since at the time of inspection only fabricated tower members and
accessories will be verified, acceptance of any lot shall in no way relieve the
bidder of his responsibility to meet all technical requirements of this
specification for fabricated towers. In case any shortcoming is noticed at the
time of actual assembly and erection, the Employer may reject any part or
item or accessory and the contractor will have to assume the responsibility for
free replacement/rectification of such defects.
2.24 PACKING AND MARKING ON PACKING :
2.24.1 The material shall be boxed or bundled for transport in the following manner:
(i) Angle shall be packed in bundles securely wrapped four times around at each
end and over 900 mm with No.9 SWG steel wire with ends twisted tightly.
Gross weight of any bundle shall not be less than 450 Kg and more than 2000
Kg. The bundle shall be in complete Tower form only.
(ii) Cleat angles, brackets, filler plates and similar small loose pieces shall be
nested and bolted together through holes and wrapped around at least four
times with No.9 SWG wire with ends twisted tightly or packed in wooden
crates. Gross weight of each bundle shall not exceed 200 Kg.
(iii) Correct number of bolts, nuts and washers required for structures shall be
packed in heavy gunny bags accurately tagged in accordance with the
contents and a number of bags packed in a solid box of 22mm thick lumber
with paneled ends to be accurately nailed and further reinforced with 22 mm x
75 mm Batons round the sides and at the ends with 25 mm x No.18 SWG iron
band stretched entirely around the batons with ends overlapping at least
150mm. Gross weight of each box shall not exceed 200 Kg.
(iv) Packing list incorporating all relevant details e.g. quantity of structures
(complete sets), number and size of steel sections, quantity of nuts, bolts,
washers etc. shall be forwarded along with each consignment.
(v) In the nutshell the packing arrangement should be such that all lots of one
particular type of structure are identifiable at site for the purpose of allocation
for a particular work. In case more than one structure of a particular type is
delivered in area store/work site, combined packing arrangement by way of
clubbing members of similar type (for more than one structure) in a combined
package should not be done. Uniform packing procedure for each structure
should be adopted.
2.24.2 All above packing are subject to the approval of the Employer or his
appointed representatives.
2.24.3 Each bundle or packing shall have the following marks:
(i) The name of the consignee (as per dispatch instructions given by the
Employer).
(ii) Ultimate destination as required by the Employer.

Volume-V (Part-2)
(iii) The relevant marks and number of structure members or reference or bolts,
nuts and small components like gusset plats, various attachment, etc. for
easy identification.
2.24.4 The marking shall be stenciled and indelibly inked on the top members in the
bundles, on wooden boxes and also on gunny bas containing smaller
components.
***

Volume-V (Part-2)
SECTION-3
TECHNICAL SPECIFICATIONS FOR CONDUCTOR
3.1 SCOPE :
3.1.1 This specification provides for standard design, manufacture, stage

testing, inspection and testing before despatch, packing and delivery
of Steel Cored Aluminium Conductor specified hereunder for their
satisfactory operation in various lines and sub-stations of the State.
The Conductor is to be used as power conductor on double circuit
transmission lines.
3.1.2 Bidders are required to quote for supply of all materials as detailed in the
specification. The bidder shall furnish full particulars as called for in various
clauses, in addition to filling and completing the schedules annexed to this
specification.
3.1.3 The unit rate quoted shall be inclusive of deployment of all plant, equipment,
men, material, skilled & unskilled labors etc. essential for satisfactory supply
of ACSR Moose.
3.1.4 All the raw materials for supply of ACSR Moose shall be included in the
Bidder’s scope of supply. Bidder shall inform the sources from where he
proposes to procure the raw materials.
3.2 STANDARDS:
3.2.1 The power conductor shall conform to the following Indian Standards, which
shall mean latest revisions, amendments/changes adopted and published,
unless otherwise specified hereinbefore.
Sl. No. Indian Standards Title

or any Equivalent
International
Standard
1 IS:209 Specification for Zinc
2 IS:398 Part I to Specification for Aluminium Conductors
Part V (as relevant) for overhead Transmission purpose.
4 IS:1521 Method of Tensile Testing of Steel wire
5 IS:2629 Recommended practice for Hot Dip
6 IS:2633 Method of Testing Uniformity of Zinc

coating of Zinc coated Articles.
7 IS:4826 Galvanised coating on Round Steel wire
8 IS:6745 Method of Determination of weight of Zinc
coating of zinc coated Iron and Steel
Articles
9 IS:8263 Method of Radio Interference Tests
10 IS:1841 EC Grade Aluminium Rod produced by
Volume-V (Part-2)
rolling
11 IS:5484 EC grade Aluminium Rod produced by
continuous casting and rolling
12 IS: 2141 Method of Elongation test of steel wire
3.2.2 Acceptance of Other Authoritative Standards :

In the paragraph above, relevant Indian standards have been mentioned.
However, the ACSR Moose meeting any other authoritative international
standard, which ensures equal or better quality than the standards,
mentioned above shall also be acceptable. Please attach photocopy of all such
standards according to which the, ACSR Moose have been offered.
In this bid, the Bidders will have to furnish confirmation in regard to

compliance of our entire technical requirement. The bid should clearly
describe various technical particulars of the, ACSR Moose as per details given
in this specification.
3.3 CLIMATIC CONDITIONS :
3.3.1 The ACSR conductor shall be suitable for being installed directly in air
supported with suspension insulator strings or anchored through tension
insulator strings supported with hanger/suspension clamp or tension clamp at
the cross arms of single circuit and double circuit transmission line towers.
The conductor shall be therefore suitable for satisfactory continuous operation
under the following climatic conditions:

2 Maximum ambient air temperature (0C) 50.
3 Minimum temperature in shade (0C ) 1.
4 Maximum relative humidity (%) 95(sometimes approaches
saturation)
5 Average daily ambient air temperature (0C 40° Centigrade
)
8 Maximum wind pressure (kg/ square metre) 150
9 Max. Altitudes above mean sea level 1000
(metres)
10 Seismic level (Horizontal acceleration) (g) 0.3
fungus growth. The climatic conditions are also prone to wide variations in
ambient conditions. Stroke is also present in the atmosphere. Heavy
lightening also occurs during June to October.
3.4 PARAMETERS :

Volume-V (Part-2)
3.4.1 Principal Parameters of Stranded Conductor:
Sr. No. Details of Stranded Conductor ACSR

Moose
a) No. of Strands Aluminium-54

Steel –7
i. Steel Centre 1
ii. 1st Steel Layer 6
iii. 1st Aluminium Layer 12
iv. 2nd Aluminium Layer 18
v. 3rd Aluminium Layer 24
b) Sectional Area of Aluminium (Sq.mm) 528.5
c) Total Sectional Area (Sq.mm) 597.0
d) Overall diameter(mm) 31.77 mm
e) Approximate weight (Kg/Km ) 2004
f) Calculated D.C. Resistance at 20 Deg.C 0.05552
(Ohm/Km)
g) Minimum UTS (kN) 161.2
h) Modulus of Elasticity kg/cm2 0.703x106
3.4.1.1 The details of aluminium strand are as follows :
Sr. Details of Aluminium Strands ACSR

No. Moose
a) Minimum breaking load of strand Before stranding 1.57
(kN)
b) Minimum breaking load of strand after stranding 1.49
(kN)
c) Maximum D.C. resistance of strand at 20 deg.C 2.921
(Ohm/Km)
d) Nominal Strand Dia 3.53
e) Max. Strand Dia 3.55
f) Min. Strand Dia 3.53
g) Mass (Kg/Km) of Strand at Nominal dia 21.47
3.4.1.2 The details of steel strand are as follows:
Sr. Details of Steel Strands ACSR Moose

No
p) Minimum breaking load of strand Before 12.86
stranding (kN)

Volume-V (Part-2)
q) Minimum breaking load of strand after stranding 12.22

(kN)
r) Nominal Strand Dia 3.53
s) Maximum Strand Dia 3.60
t) Minimum Strand Dia 3.53
u) Mass (Kg/Km) of Strand at Nom. dia 76.34
v) Zinc coating testing 3 dips of 1
min. each
w) Wt. of Zinc Coating (gms/sq. metre) 260
3.5 GENERAL TECHNICAL REQUIREMENTS : MATERIAL AND

WORKMANSHIP (FOR ACSR MOOSE):
3.5.1 Materials:
3.5.1.1 The conductors shall be manufactured from EC grade aluminium rods suitably
hard-drawn on wire drawing machines. The aluminium rods used shall comply
with IS: 1841 and IS: 5484 or any equivalent International Standard. The
mechanical and electrical properties of aluminium wire shall comply with the
requirements given in relevant standard.
3.5.1.2 Physical constants for Hard-drawn Aluminium:
i. Resistivity:
The resistivity of aluminium depends upon its purity and its physical condition.
For the purpose of this specification the maximum value permitted is 0.28264 Ohm
sq.mm/mt. at 20° C and this value has been used for calculation of the maximum
permissible value of resistance.
NOTE : It is not intended to check the resistivity from the measured values of
resistance.
ii. Density:
At a temperature of 20° C the density of hard drawn aluminium has been
taken as 2.703 g/cm.3
iii. Constant-Mass Temperature Co-efficient of Resistance:
At a temperature of 20°C, the constant-mass temperature co-efficient of
resistance of hard drawn aluminium measured between two potential points rigidly
fixed to the wire, the metal being allowed to expand freely, has been taken as 0.004
per degree Celsius.
iv. Co-efficient of Linear Expansion:
The co-efficient of linear expansion of hard-drawn aluminium at 0° C has been

taken as 23.0 x 10 -6 per ° C. This value holds good for all practical purposes over the
range of temperature from 0 ° C to highest safe operating temperature.
Galvanised steel wire shall be drawn from high carbon steel rods produced by
either acidic or basic open hearth process, electric furnace process or basic oxygen
process. The mechanical and electrical properties of wire shall comply with the

Volume-V (Part-2)
requirements given in relevant standard. The chemical composition of high carbon

steel wires is given below for guidance only.
Element Percentage Composition
Carbon 0.5 to 0.85

Maganese 0.50 to 1.10
Phosphorous Not more than 0.035
Sulphur Not more than 0.045
Silicon 0.10 to 0.35
3.5.1.3 Physical constants for Galvanised steel wires:
i. Density :
At a temperature of 20° C, the density of galvanized steel wire is to be taken

as 7.80 g/Cm3.
ii. Coefficient of Linear Expansion :

In order to obtain uniformity in calculation a value of 11.5 x 10 –6 ° C may be
taken as the value for the co-efficient of Linear Expansion of galvanized steel wires
used for the cores of steel-reinforced aluminium conductors.
iii. The zinc used for galvanizing shall be electrolytic high-grade Zinc not less than 99.95
percent purity. It shall conform to and satisfy all the requirements of IS: 209.
Galvanising may be done either by hot process or electrolytic process. Minimum
weight of Zinc coating shall be 260 g/sq. metre. Neutral grease may be applied
between the layers of wire.
iv. Freedom From Defects:

The wires shall be smooth and free from all imperfections such as spills, slag
inclusion, die marks, scratches, fittings, blow-holes, projections, looseness,
overlapping of strands, chipping of aluminium layers etc. and all such other defects
which may hamper the mechanical and electrical properties of the conductor. Special
care should be taken to keep away dirt, grit etc. during stranding.
3.5.2 Wire Sizes
3.5.2.1 Nominal Size:
The aluminium and galvanized steel wires for the stranded conductor covered by
this standard shall have diameters specified in clause 3.4.1.1 & 3.4.1.2. The diameter
of the steel wires shall be measured over the zinc coating.
3.5.2.2 Tolerances on Nominal Size :
Tolerance of + 1% is permitted on the nominal diameter of Aluminium Wires of

Moose Conductor and a tolerance of + 2 % is permitted on the nominal diameter of
Galvanised Steel Core Wire.
3.5.3 Joints in Wires:
3.5.3.1 Aluminium Wires:
No joints shall be permitted in the aluminium wires in the outermost layer of the
ACSR Conductor. Joints in the inner layers are permitted, in addition to those made in
the base rod or wire before final drawing, but no two such joints shall be less than 15
Volume-V (Part-2)
mtr. apart in the complete stranded conductor such joints shall be made only by cold
pressure butt-welding. It may please be noted that Joints are not permitted in the
outermost layer of the conductor in order to ensure a smooth conductor finish and
reduce radio interference levels and corona losses on extra high voltage lines.
3.5.3.2 Galvanised Steel Wires:
There shall be no joints except those the base rods or wires before final drawing, in
steel wires forming the core of the steel-reinforced aluminium conductor. Joints are
not permitted in the steel wires after final drawing also in order to avoid reduction in
the breaking strength of the conductor that may occur as a result of failure of the
joints.
3.5.4 Stranding:
3.5.4.1 The wires used in the construction of galvanized steel reinforced aluminium
conductor, before stranding, shall satisfy all the relevant requirements of this
specification.
3.5.4.2 The lay ratio of the different layers shall be within the limits given in the
Table below:-
LAY RATIO OF ALUMINIUM CONDUCTORS GALVANISED STEEL-REINFORCED

(Moose Aluminium-54 Wire Steel - 7 Wire)
Ratio Lay Ratios Lay Ratios for Aluminium wires (3 Alu.

of Alu. of Steel Wire Layer Conductors)
wire core 6 wire
diamet layer
er to Outermost Layer Innermost
steel layer immediatel Layer
wire y beneath
diamet outer most
er layer
Min. Max. Min. Max. Min. Max. Min Max.
.
1 16 18 10 12 11 13 12 14
NOTE : For the purpose of calculation, the mean lay ratio shall be taken as the
arithmetic mean of the relevant minimum and maximum values given in this table.
3.5.4.3 In all constructions, the successive layers shall have opposite directions of lay,
the outermost layer being right-handed. The wires in each layer shall be
evenly and closely stranded.
3.5.4.4 In conductors having multiple layers of aluminium wires, the lay ratio of any
aluminium layer shall not be greater than the lay ratio of the aluminium layer
immediately beneath it.

Volume-V (Part-2)
3.5.4.5 The finished Conductor shall have a smooth surface without any surface cut,
abrasion, scuff marks and shall be free from dirt, grit, etc. even if the damage
to conductor is acceptable from mechanical considerations. It will not be
acceptable from electrical considerations, and full care should be taken not to
supply damaged conductor. Projections of more than 2 mils shall not be
acceptable. Any such damage shall be properly rectified or new conductor
supplied.
3.5.4.6 Failure of any sample to meet the above requirements shall be sufficient
cause for rejection of the lengths of conductor represented by the sample.
Particular care shall, therefore, be taken during manufacture, handling,
packing and transportation of the conductor, to see that the surface is not
dented, cut or damaged in any way.
3.5.5 Standard Length :
3.5.5.1 The standard length of conductor shall be 1500 metres. A tolerance of +/-5%
on the standard length offered by the supplier shall be permitted. All lengths
outside this limit of tolerance shall be treated as random lengths.
3.5.5.2 Random lengths will be accepted provided no length is less than 70% of the
standard length specified and the total quantity of such random lengths shall
not be more than 5% of the total quantity ordered.
3.5.5.3 Supplier shall also indicate the maximum single length, above the standard
length, they can manufacture in the guaranteed technical particulars. This is
required for special stretches like river crossing etc. The purchaser reserves
the right to place orders for the above length to the 5% of the total ordered
quantity on the same terms and conditions applicable for the standard lengths
during the pendency of the contract.
3.5.6 Galvanising:
3.5.6.1 All the wires of Iron & steel strand shall be galvanized in accordance with IS-
2629-1966. ‘Recommended practice for hot dip galvanizing of Iron and Steel’
or some other authoritative equivalent standard.
3.5.6.2 Specific technical requirements for galvanizing and relevant tests quoted in
clause-6 of this specification for guidance shall be complied.
3.6 TESTS :
3.6.1 The conductor offered shall be type tested as per the relevant standards.
Further the acceptance, routine tests and tests during manufacture shall be
carried out on the conductor.
3.6.2 Type tests shall mean those tests, which are to be carried out to prove the
process of manufacture and general conformity of the material to this
specification.
3.6.3 All the materials offered shall be fully type tested as per the relevant
standards and the supplier shall furnish four sets of type test reports along
with the offer. These tests must not have been conducted earlier than five
Volume-V (Part-2)
years, prior to the date of opening of bid. For any change in the design/type
already type tested and the design/type offered against this specification, the
purchaser reserves the right to demand repetition of tests without any extra
cost.
3.6.4 Acceptance tests shall mean those tests, which are to be carried out on
samples taken from each lot offered for pre-despatch inspection, for the
purpose of acceptance of that lot.
3.6.5 Routine tests shall mean those tests which are to be carried out on each
strand/spool/length of the conductor to check requirements which are likely
to vary during production.
3.6.6 Tests during manufacture shall mean those tests, which are to be carried out
during the process of manufacture and end inspection by the supplier to
ensure the desired quality of the end product to be supplied by him.
3.6.7 The norms and procedure of sampling for these tests will be as per the
Quality Assurance Programme to be mutually agreed to by the Supplier and
the Purchaser as per relevant clause of General Conditions of Contract.
3.6.8 The standards and norms to which these tests will be carried out are listed in
para 2.0. Where a particular test is a specific requirement of this specification,
the norms and procedures of the test shall be as mutually agreed to between
the Supplier and the Purchaser in the Quality Assurance Programme.
3.6.9 For all type and acceptance tests, the acceptance values shall be the values
guaranteed by the Supplier in the ‘Guaranteed Technical Particulars’ of his
proposal or the acceptance value specified in this specification, whichever is
more stringent for that particular test.
3.6.10 Type Tests :
The Conductor offered shall be fully type tested as per the relevant
International/Indian Standard and the bidder shall furnish the report along with the
offer. These tests must not have been conducted earlier than 5 years prior to the date
of opening of bid. For any change in the design/type, already type tested and the
design/type offered against this bid, the purchaser reserves the right to demand
repetition of some or all type tests without any extra cost.
The above said test reports submitted with the offer shall not be older than five
years, prior to the date of opening of bid.
a) UTS test on stranded conductor

b) DC resistance test on stranded conductor
c) Stress-strain test on composite conductor
3.6.11 Acceptance Tests :
a) Visual and dimensional check
b) Visual check for joints, scratches etc. and lengths of conductor

Volume-V (Part-2)
d) Dimensional check on steel and aluminium strands
d) Check for lay ratios of various layers
e) Galvanising test on steel strands
f) Torsion and Elongation test on steel wire
g) Breaking load test on steel and aluminium strands
h) Wrap test on steel and aluminium strands
i) DC resistance test on aluminium strands
j) UTS test on welded joint of aluminium strand
NOTE: All the above tests except test mentioned at (j) shall be carried out on aluminium
and steel strands after stranding only.
3.6.12 Routine Test :
a) Check to ensure that the joints are as per specification.
b) Check that there are no cuts, fins etc. on the strands.
c) Check that drums are as per specifications.
d) All acceptance tests as mentioned in Clause 6.1.10 above shall be

carried out on each coil.
3.6.13 Tests During Manufacture :
a) Chemical analysis of zinc used for galvanizing
b) Chemical analysis of aluminium for making aluminium strands
c) Chemical analysis of steel used for making steel strands
during manufacture specified herein shall be treated as included in the quoted unit
price of conductor, except for the expenses of the inspection/Purchaser’s
representative.
3.6.15 Additional Tests:
The Purchaser reserves the right of having at his own expenses any other test(s) of
reasonable nature carried out at Supplier’s premises, at site, or in any other place in
addition to the aforesaid type, acceptance and routine tests to satisfy himself that the
material comply with the specification.

Volume-V (Part-2)
3.6.16 Sample Batch for Type Testing
(a) The bidder shall offer at least three (3) drums for selection of samples required for
conducting all the type tests, in case of change in design/type already tested and
the design type offered against this specification, for which the purchaser reserves
the right to demand carrying out type test without any extra cost.
(b) The bidder is required to carry out all the acceptance tests successfully in the
presence of Purchaser’s representative before despatch of conductor.
3.6.17 Test Reports

(a) Record of routine test reports shall be maintained by the Supplier at his works for
periodic inspection by the Purchaser’s representative.
(b) Test Certificates of test during manufacture shall be maintained by the Supplier.
These shall be produced for verification as and when desired by the Purchaser.
3.6.18 Test Facilities
The following additional test facilities shall be available at Bidder’s Works.
(a) Calibration of various testing and measuring equipment including tensile testing
machine, resistance measurement facilities, burette, thermometer, barometer etc.
(b) Standard resistance for calibration of resistance bridges.
(c) Finished conductor shall be checked for length verification and surface finish on
separate rewinding machine at reduced speed (variable from 8 to 16 metres per
minute). The rewinding facilities shall have appropriate clutch system and free of
vibrations, jerks etc. with transverse layering facilities.
3.7 INSPECTION :
3.7.1 The purchaser’s representative shall at all times be entitled to have access to
the works and all places of manufacture where conductor shall be
manufactured and the representative shall have full facilities for unrestricted
inspection of the Supplier’s works, raw materials and process of manufacture
for conducting necessary tests as detailed herein.
3.7.2 The Supplier shall keep the Purchaser informed in advance of the time of
starting and of the progress of manufacture of conductor in its various stages
so that arrangements can be made for inspection.
3.7.3 No material shall be despatched from its point of manufacture before it has
been satisfactorily inspected and tested, unless the inspection is waived off by
the purchaser in writing. In the later case also, the conductor shall be
despatched only after satisfactory testing for all tests specified herein has
been completed.

Volume-V (Part-2)
3.7.4 The acceptance of any quantity of material shall in no way relieve the
Supplier of any of his responsibilities for meeting all requirements of the
specification, and shall not prevent subsequent rejection if such material is
3.7.5 At least 5% of the total number of drums subject to minimum of two in any
lot put up for inspection, shall be selected at random to ascertain the length
of conductor by following method:
“At the works of the manufacturer the conductor shall be transferred from one
drum to another at the same time measuring its length with the help of graduated
pulley and Cyclometer. The difference in the average length thus obtained and as
declared by the supplier in the packing list shall be applied to all the drums if the
conductor is found short during checking”
3.8 QUALITY ASSURANCE PLAN :
3.8.1 The Supplier shall invariably furnish following information along with his offer,
failing which his offer may be liable for rejection. Information shall be
separately given for individual type of equipment offered.
(i) Statement giving list of important raw materials names of sub supplies for the
raw materials, list of standards according to which the raw materials are
tested, list of tests normally carried out on raw materials in presence of
(ii) Information and copies of test certificates as in (i) above in respect of bought
out accessories.
(iv) Level of automation achieved and list of areas where manual process exists.
(v) List of areas in manufacturing process, where stage inspections are normally
carried out for quality control and details of such tests and inspections.
(vi) Special features provided in the equipment to make it maintenance free.
(vii) List of testing equipments available with the Supplier for final testing of
material specified and test plant limitation. If any, vis-a-vis the type, special,
acceptance and routine tests specified in the relevant standards. These
limitations shall be very clearly brought out in schedule of deviation from
specified test requirements.
3.8.2 The successful Supplier shall within 30 days of placement of order, submit
following information to the purchaser.
(i) List of raw materials as well as bought out accessories and the names
of sub-suppliers selected from those furnished along with offer.
(ii) Type test certificates of the raw material and bought out accessories.
(iii) Quality assurance plan (QAP) with hold points for Purchaser’s
inspection. The quality assurance of plan and Purchaser’s hold points
shall be discussed between the Purchaser and Supplier, before QAP is
finalized.
3.8.3 The successful Supplier shall submit the routine test certificates of bought out
accessories and central excise passes for raw material viz. oil, copper,
Volume-V (Part-2)
aluminium, conductor’s insulating materials, core material at the time of

routine testing of the Conductor.
3.9 DOCUMENTATION :
3.9.1 Six sets of type test reports, duly approved by the Purchaser shall be
submitted by the supplier for distribution, before commencement of supply.
Adequate copies of acceptance and routine test certificates, duly approved by
the Purchaser shall accompany with despatched consignments.
approval of the Purchaser. All manufacturing and fabrication work in
Supplier’s risk.
3.9.3 Approval of drawing/work by Purchaser shall not relieve the Supplier of his
responsibility and liability for ensuring correctness and correct interpretation
of the latest revision of applicable standards, rules and codes of practices.
The material shall conform in all respect to high standards of engineering,
design, workmanship and latest revisions of relevant standards at the time of
ordering. Purchaser shall have the power to reject any work or material,
which in his judgment is not in full accordance therewith.
3.10 PACKING AND FORWARDING :
3.10.1 The conductor shall be supplied in non-returnable strong wooden drums

provided with lagging of adequate strength, to protect the conductor against
all damage and displacement during transit, storage and subsequent handling
and stringing operations in the field. The drums shall generally conform to IS:
1778 except otherwise specified hereinafter.
3.10.2 The drums shall be suitable for wheel mounting and for jetting off the
conductor under a minimum controlled tension of the order of 5kN.
3.10.3 The standard drum drawings are enclosed however, supplier should submit
the proposed drum drawings along with the bid. The same shall be in line with
the requirements of standard drawings and as stated herein. After placement
of the letter of Award, the supplier shall submit four copies of fully
dimensioned drawing of the drum he wishes to supply, for Purchaser’s
approval, before taking up manufacturing of conductor. After getting approval
from the Purchaser, Supplier shall submit 30 more copies of the approved
drawing to Purchaser for further distribution and field use at Purchaser’s end.
3.10.4 All wooden components shall be manufactured out of seasoned soft wood free
from such defects that may materially weaken the component part of the
drums. Preservative treatment for anti-termite /anti-fungus (Aldrine/Aldruse)
shall be applied to the entire drum with preservatives of a quality which is not
chemically harmful to the conductor.
3.10.5 The flanges shall be of two/three ply construction with each ply at right
angles to the other and nailed together. Further the outer face of the flange
shall be reinforced with the circumferential battens, fixing in octagonal shape.
Volume-V (Part-2)
The nails shall be driven from the inside face of flange, punched and then
clenched on the outer face. The tolerance in thickness of each ply shall be +/-
3 mm only. There shall be at least 3 nails per plank of ply with maximum
nail spacing of 75 mm. Where a slot is cut in the flange to receive the inner
end of the conductor, the entrance shall be in line with the periphery of the
barrel. Spindle hole shall be provided at the centers of the planks of the plies
and spindle plates with 102 mm dia. Holes shall be fitted on either side of
both the flanges.
3.10.6 The wooden battens used for making the barrel of the conductor shall be of
segmental type. These shall be nailed to the barrel supports with at least two
nails. The battens shall be closely butted and shall provide a round barrel with
smooth external surface. The edges of the battens shall be rounded or
chamfered to avoid damage to the conductor.
3.10.7 Barrel studs shall be used for construction of drums. The flanges shall be
holed and the barrel supports slotted to receive them. The barrel studs shall
be threaded over a length on either end, sufficient to accommodate washers,
spindle plates and nuts for fixing flanges at the required spacing. Barrel studs
should be tack welded with the nuts after tightening.
3.10.8 Normally, the nuts on the studs shall stand protrude of the flanges. All the
nails used on the inner surface of the flanges and the drum barrel shall be
counter sunk. The ends of barrel shall generally be flushed with the top of the
nuts.
3.10.9 The inner cheek of the flanges and drum barrel surface shall be painted with a
bitumen based paint.
3.10.10 Before reeling, cardboard or double corrugated or thick bituminised

waterproof bamboo paper shall be secured to the drum barrel and inside of
flanges or the drum by means of a suitable commercial adhesive material.
The paper should be dried before use. Medium grade craft paper shall be used
in between the layer of the conductor/earth wire. After reeling the conductor
the exposed surface of the outer layer of conductor shall be wrapped with thin
polythene sheet across the flanges to preserve the conductor from dirt, grit
and damage during transportation and handling and also to prevent ingress of
rain water during storage/transport.
3.10.11 Minimum space of 125 mm shall be provided between the inner surface of the
external protective layer and outer layer of the conductor.
3.10.12 Each batten shall be securely nailed across grains as far as possible to the
flange edges with at least 2 nails per end. The length of the nails shall not be
less than twice the thickness of the battens. The nail shall not protrude above
the general surface and shall not have exposed sharp edges or allow the
battens to be released due to corrosion.
3.10.13 Outside the protective layer, there shall be minimum of two binder consisting
of hoop iron/galvanized steel wire. Each protective layer shall have two recess
to accommodate the binders.
3.10.14 The conductor ends shall be properly sealed and secured with the help of U-
nails on one side of the flanges. The end securing shall be done by taking out
at least 500 mm of steel core on either ends by U-nails. The composite
conductor shall be binded by use of galvanized steel wire/aluminum wire at
three locations at least 75 mm apart or more covered with PVC adhesive tape
so as to avoid loosening of conductor layers in transit and handling.

Volume-V (Part-2)
3.10.15 Only one length of conductor shall be wound on each drum.
3.11 MARKING :
Each drum shall have the following information stenciled on it in indelible

ink along with other essential data:
i. Contract/Award letter number
ii. Name and address of consignee
iii. Manufacturer’s name and address
iv. Drum number
v. Size of conductor
vi. Length of conductor in metres
vii. Gross weight of drum with conductor
viii. Weight of empty drum with protective lagging
ix. Arrow marking for unwinding
3.12 END SEALING :
Both the ends of each length of conductor should be provided with non-destructive
type metal crimped or epoxy capped seals with punching embossing/ engraving of
manufacturer’s monogram and drum number.
3.13 CHECK MEASUREMENT
3.13.1 At least 5% of the total number of drums in any lot put up for inspection shall
be selected at random to ascertain the length of conductor by rewinding
method. The % shortage if any in the length thus obtained and as declared
by the supplier in the packing list, shall be applied to all the drums if the
conductor is found short during checking.
3.13.2 The length of conductor shall also be verified at the consignees end. Where
length measurement machines are not available the length will be verified by
the weighment basis. The determining factor will be length weight ratio of
the sample drums verified at the firm’s premises of the Lot of which the drum
under measurement at the consignees end forms a part.

Volume-V (Part-2)
SECTION-4
TECHNICAL SPECIFICATIONS FOR

HIGH TENSILE GALVANISED STEEL EARTH WIRE
4.01 STANDARDS:
The high Tensile Steel Galvanised Earth Wire shall conform to the following
Indian Standards, which shall mean latest revisions, amendments/changes
adopted and published, unless otherwise specified hereinbefore.
Sl. Indian Standards or any Title
No. Equivalent International
Standard
1 IS:209 Specification for Zinc
2 IS:2141 Specification for Earth wire for overhead
Transmission purpose
4 IS:1521 Method of Tensile Testing of Steel wire
5 IS:2629 Recommended practice for Hot Dip Galvanising
Iron and Steel
6 IS:2633 Method of Testing Uniformity of Zinc coating of
Zinc coated Articles.
7 IS:4826 Galvanised coating on Round Steel wire
8 IS:6745 Method of Determination of weight of Zinc
coating of zinc coated Iron and Steel Articles
9 IS: 12776 Method of Testing of Ground wire
4.02 PARAMETERS :
4.02.1 PRINCIPAL PARAMETERS OF EARTH WIRE:

The standard technical particulars of 7/3.66mm galvanized steel earth wire
shall be as follows :-
(A) The details of Steel strand:
Sr. No. Details of steel strands Earth Wire
a) Material Steel
b) Stranding 7
c) Weight per Km 583 Kgs
d) Dia. of wire 3.66 mm
e) Tolerance 2%
f) Minimum elongation in 100 mm length 5 mm
g) Minimum breaking strength per strand 1000 Kg
h) Minimum tensile strength 95 Kg./mm2
i) D.C. resistance at 20 Deg. C 17.15 Ohms/Km

Volume-V (Part-2)
(B) The details of Stranded Earth Wire :

Sr. No. Details of Stranded Earth Wire Earth Wire
i. Maximum Length of Lay 198

ii. Minimum Length of Lay 165
iii. Minimum breaking load 6972 Kgs
iv. Overall diameter 10.98mm
v Modulus of elasticity 1.933 x 106 Kg./cm2
vi Co-efficient of linear expansion 11.50 x 10- 6
per
Deg.C
vii Weight of zinc coating on wire 260 gms./ m 2 (Min.)
viii No. of one minute dip and half minute 3 one minute and
dip respectively 1 half minute
ix Calculated d.c. Resistance at 20 Deg.C 2.5 Ohms per Km
4.03 GENERAL TECHNICAL PARTICULARS : MATERIAL AND WORKMANSHIP

FOR EARTH WIRE:
4.03.1 The steel wire (strands) used in manufacture of galvanized steel earth wire
shall be drawn from steel wire rod produced by either acid or basic open
hearth process or by the electric furnace process or basic oxygen process.
The steel wire shall not have sulphur and phosphorous contents exceeding
0.045% each. The carbon content shall not exceed 0.55%. The steel
produced by bassemer process shall not be used for drawing of steel wire
strands. The finished earth wire shall have minimum brittleness as it will be
subjected to continuous vibration while in use on line.
4.03.2 The steel wire shall be hot dip galvanized and shall have clause ‘A’ (heavy)
zinc coating of minimum 260 gram per sq. meter of the uncoated wire
surface. The zinc coating shall be smooth and continuous of uniform
thickness, free from imperfections not consistent with good commercial
practice and shall meet the test requirement. The zinc used in galvanizing of
earth wire shall be as per IS: 209-1966.
4.03.3 All the steel wires shall be circular, smooth, uniform and free from
imperfections, such as spills and splits, die marks scratches, abrasions, cuts
and kinks etc. drawing and after stranding.
4.03.4 The steel wires, after galvanizing shall be bright in appearance, smooth and
free from all defects like flux, ash, cross inclusions, bare and black spots,
pimples, lumpiness in runs, rust, stains, bulky white deposits and blisters.
4.03.5 To avoid susceptibility towards wet storage stains (white rust) the stranded
earth wire shall be provided with a protective coating of boiled linseed oil.
4.03.6 The finished earth wire shall have a smooth surface without any surface
cuts, abrasions, scuff marks and shall be free from dirt, grit etc.
4.03.7 Failure of any sample to meet the above requirements shall be sufficient
cause for rejection of the lot of earth wire represented by the sample,
particular care shall therefore be taken during manufacture, handling,
packing and transportation of the earth wire so that it is not dented, cut or
damaged in any way.

Volume-V (Part-2)
4.04 Size and Properties:

4.04.1 The earth wire size, physical properties, tolerance in diameter of individual
strands and length of lay of the strand shall be as given above.
4.04.2 The wires shall be so stranded together that when an evenly distributed
pulls is applied at the end of completed strands, each wire will take an
equal share of the pull.
4.04.3 The earth wire shall be supplied in the standard lengths which shall not be
less than 3 Km. and such lengths will be specifically indicated in the tender.
Not less than 95% of the total quantity of the earth wire shall be supplied in
standard lengths. The quantity of earth wire in length shorter than
standard one shall not exceeds 5% of the total quantity to be supplied.
Further, no single earth wire length in respect of such 5% (maximum)
supply in random lengths shall be shorter than 50% of the standard length.
4.04.4 The length of the stranded wire shall be supplied without joints in the
individual wires comprising it, excluding welds made in base rod before it is
drawn.
4.04.5 Each coil be warranted to contain no welds, joints or splice other than in the
base rod before it is drawn.
4.05 GALVANISING AND OILING:

4.05.1 All the wires of the strand shall be galvanized in accordance with IS-2629-
1966. Recommended practice for Hot dip galvanizing of Iron and Steel of
some other authoritative equivalent standard.
4.05.2 The galvanized earthwire after stranding operation shall have dipped in
boiled linseed oil before winding it on drums.
4.06 TEST FOR EARTH WIRE :

4.06.1 Earth wire shall be subjected, before despatch from the works to tests as
specified in the IS-2141, IS 1521, IS 1755 & IS 4826 or any other
authoritative equivalent standard.
4.06.2 All the drums of galvanized steel stranded earth wire of the same grade,
diameter and construction, manufactured under similar condition shall be
grouped to constitute one lot.
4.06.3 Samples from each lot shall be tested for ascertaining the conformity to the
requirements of the earth wire specified herein. The drums selected shall be
tested for length of the lay and diameter of individual strands etc. The lot
shall be declared conforming to the requirement of these characteristics if all
the samples are found satisfactory. One test specimen from each wire of the
strand shall now be drawn from every selected drum and subjected to
chemical analysis, tensile tests, ductility test, elongation test and coating
test. One test specimen, of the completed strand from each drum shall be
subjected to tensile strength. The lot shall be declared conforming to the
requirements of these characteristics, if the entire test specimen satisfies
the relevant requirement.
4.07 INSPECTION :
4.07.1 The purchaser’s representative shall at all times be entitled to have access
to the works and all places of manufacture where earth wire shall be
manufactured and the representative shall have full facilities for unrestricted
inspection of the Supplier’s works, raw materials and process of
manufacture for conducting necessary tests as detailed herein.

Volume-V (Part-2)
4.07.2 The Supplier shall keep the Purchaser informed in advance of the time of
starting and of the progress of manufacture of earth wire in its various
stages so that arrangements can be made for inspection.
4.07.3 No material shall be despatched from its point of manufacture before it has
been satisfactorily inspected and tested, unless the purchaser in writing
waives off the inspection. In the later case also, the earth wire shall be
despatched only after satisfactory testing for all tests specified herein has
been completed.
4.07.4 The acceptance of any quantity of material shall in no way relieve the
Supplier of any of his responsibilities for meeting all requirements of the
specification, and shall not prevent subsequent rejection if such material is
4.07.5 At least 5% of the total number of drums subject to minimum of two in any
lot put up for inspection, shall be selected at random to ascertain the length
of earth wire by following method:
“At the works of the manufacturer of the earth wire, the earth wire shall be
transferred from one drum to another at the same time measuring its length
with the help of graduated pulley and Cyclometer. The difference in the
average length thus obtained and as declared by the supplier in the packing
list shall be applied to all the drums if the conductor/earth wire is found
short during checking”
4.08 DOCUMENTATION:
4.08.1 Six sets of type test reports, duly approved by the Purchaser shall be
submitted by the supplier for distribution, before commencement of supply.
Adequate copies of acceptance and routine test certificates, duly approved
by the Purchaser shall accompany with despatched consignments.
approval of the Purchaser. All manufacturing and fabrication work in
Supplier’s risk.
4.08.3 Approval of drawing/work by Purchaser shall not relieve the Supplier of his
responsibility and liability for ensuring correctness and correct interpretation
of the latest revision of applicable standards, rules and codes of practices.
The equipment shall conform in all respect to high standards of engineering,
design, workmanship and latest revisions of relevant standards at the time
of ordering. Purchaser shall have the power to reject any work or material,
which in his judgment is not in full accordance therewith.
4.09 PACKING AND FORWARDING:

4.09.1 The earth wire shall be supplied in strong wooden drums provided with
lagging of adequate strength, to protect the conductor/earth wire against all
damage and displacement during transit, storage and subsequent handling
and stringing operations in the field. The drums shall generally conform to
IS: 1778 except otherwise specified hereinafter.
4.09.2 The drums shall be suitable for wheel mounting and for jetting off the
conductor/earth wire under a minimum controlled tension of the order of
5kN.
4.09.3 After placement of the letter of Award, the supplier shall submit four copies
Purchaser’s approval, before taking up manufacturing of earth wire. After
getting approval from the Purchaser, Supplier shall submit 30 more copies
Volume-V (Part-2)
of the approved drawing to Purchaser for further distribution and field use at
Purchaser’s end.
4.09.4 All wooden components shall be manufactured out of seasoned soft wood
free from such defects that may materially weaken the component part of
the drums. Preservative treatment for anti-termite /anti-fungus
(Aldrine/Aldruse) shall be applied to the entire drum with preservatives of a
quality which is not harmful to the earth wire.
4.09.5 The flanges shall be of two/three ply construction with each ply at right
angles to the other and nailed together. Further the outer face of the flange
shall be reinforced with the circumferential battens, fixing in octagonal
shape. The nails shall be driven from the inside face of flange, punched and
then clenched on the outer face. The tolerance in thickness of each ply shall
be +/- 3 mm only. There shall be at least 3 nails per plank of ply with
maximum nail spacing of 75 mm. Where a slot is cut in the flange to receive
the inner end of the conductor/earth wire, the entrance shall be in line with
the periphery of the barrel. Spindle hole shall be provided at the centers of
the planks of the plies and spindle plates with 102 mm dia. Holes shall be
fitted on either side of both the flanges.
4.09.6 The wooden battens used for making the barrel of the earth wire shall be of
segmental type. These shall be nailed to the barrel supports with at least
two nails. The battens shall be closely butted and shall provide a round
barrel with smooth external surface. The edges of the battens shall be
rounded or chamfered to avoid damage to the earth wire.
4.09.7 Barrel studs shall be used for construction of drums. The flanges shall be
holed and the barrel supports slotted to receive them. The barrel studs
shall be threaded over a length on either end, sufficient to accommodate
washers, spindle plates and nuts for fixing flanges at the required spacing.
Barrel studs should be tack welded with the nuts after tightening.
4.09.8 Normally, the nuts on the studs shall stand protrude of the flanges. All the
nails used on the inner surface of the flanges and the drum barrel shall be
counter sunk. The ends of barrel shall generally be flushed with the top of
the nuts.
4.09.9 The inner cheek of the flanges and drum barrel surface shall be painted with
bitumen-based paint.
4.09.10 Before reeling, cardboard or double corrugated or thick bituminised

waterproof bamboo paper shall be secured to the drum barrel and inside of
flanges or the drum by means of a suitable commercial adhesive material.
The paper should be dried before use. Medium grade craft paper shall be
used in between the layer of the conductor/earth wire. After reeling the
conductor/earth wire the exposed surface of the outer layer of
conductor/earth wire shall be wrapped with thin polythene sheet across the
flanges to preserve the conductor/earth wire from dirt, grit and damage
during transportation and handling and also to prevent ingress of rain
water during storage/transport.
4.09.11 Minimum space of 125 mm shall be provided between the inner surface of
the external protective layer and outer layer of the conductor/earth wire.
4.09.12 Each batten shall be securely nailed across grains as far as possible to the
flange edges with at least 2 nails per end. The length of the nails shall not
be less than twice the thickness of the battens. The nail shall not protrude
above the general surface and shall not have exposed sharp edges or allow
the battens to be released due to corrosion.

Volume-V (Part-2)
4.09.13 Outside the protective layer, there shall be minimum of two binders
consisting of hoop iron/galvanized steel wire. Each protective layer shall
have two recesses to accommodate the binders.
4.09.14 The earth wire ends shall be properly sealed and secured with the help of
U-nails on one side of the flanges. The end securing shall be done by taking
out at least 500 mm of steel wire on either end by U-nails. The earth wire
shall be binded by use of galvanized steel wire/aluminum wire at three
locations at least 75 mm apart or more covered with PVC adhesive tape so
as to avoid loosening of earth wire layers in transit and handling.
4.09.15 Only one length of earth wire shall be wound on each drum.
4.10 MARKING :
Each drum shall have the following information stenciled on it in indelible
ink along with other essential data:
x. Order Number and date.
xi. Name and address of consignee
xii. Manufacturer’s name and address
xiii. Drum number
xiv. Size of earth wire (7/3.66mm)
xv. Length of earth wire in meters
xvi. Gross weight of drum with earth wire
xvii. Weight of empty drum with protective lagging
xviii. Arrow marking for unwinding

4.11 END SEALING :
Both the ends of each length of earth wire should be provided with non-destructive
type metal crimped or epoxy capped seals with punching embossing/ engraving of
manufacturer’s monogram and drum number.
***

Volume-V (Part-2)
SECTION-5
TECHNICAL SPECIFICATIONS FOR DISC INSULATORS
5.01 STANDARDS
5.01.1 Unless otherwise specified elsewhere in this specification, the rating as well as
performance & testing of the disc insulators shall conform but not limited to the
latest revision & amendments available at the time of placement of order of all the
relevant standards as listed hereunder, except as modified in this document.
S. No Indian Standard Title

1 IS:209-1992 Specification for Zinc
2 IS:206-1991 Method for Chemical Analysis of Slab Zinc
3 IS:731-1991 Porcelain insulators for overhead power
lines with a nominal voltage greater
than 1000V
4 IS:2071 Method of High Voltage Testing

Part(I)-1993
Part(II)-1991
Part(III)-1991
5 IS:2121 Specification of Conductors and Earth wire
Accessories for Overhead Power Lines.
Part(I) Armour Rods, Binding Wires & Tapes for

Conductors
6 IS:2486 Specification for insulator fittings for
overhead power lines with a nominal
voltage greater than 1000V
Part I-1993 General Requirements & Tests

Part II-1989 Dimensional Requirements
Part III -1991 Locking Devices
7 IS:2629-1990 Recommended practice for Hot Dip
Galvanization for iron & steel
8 IS:2633-1992 Testing for Uniformity of Coating of Zinc
coated articles
9 IS:3188-1988 Dimensions for Disc Insulators
10 IS:6745-1990 Determination of Weight of Zinc coating
on Zinc coated iron and steel articles
11 IS : 8263-1990 Methods of RIV Test of HV Insulators
12 IS:8269-1990 Methods for Switching impulse test on HV
insulators
5.01.2 Material meeting with the requirements of other authoritative standards, which
ensure equal or better performance than the standards mentioned above, shall
also be considered. When the material offered by the bidder conforms to other
standards, salient points of difference between standards adopted & the standards
Volume-V (Part-2)
specified in this specification shall be clearly brought out in the relevant

schedules. Three copies of such standards with authentic translation in English
shall be furnished along with the bid.
5.02.1DETAILS OF DISC INSULATORS
5.02.1.1 The insulator strings shall consist of standard discs for a three phase 50 Hz,
effectively earthed 400KV transmission system in a moderately polluted
atmosphere. The discs shall be cap and pin, ball and socket type.
5.02.1.2 The specified values and disc dimensions, impulse and power frequency
voltages, electromechanical strength [EMS] of individual insulator units are as
under. The values given are minimum which apply to all cases. Specified
withstand and flashover voltages are referred to standard atmospheric condition.
5.02.2CHARACTERISTICS OF DISC INSULATORS
The disc insulators should have the following particulars and characteristics:
S.No Particulars Disc Insulators

120kN EMS 160kN EMS
i Diameter of the disc (mm) 255 280
ii Spacing of the disc (mm) 145 170
iii Size and designation of pin-ball 20 mm 20 mm
shank
iv Creepage distance (mm) (minimum) 320 330
v Power frequency one minute dry 75 75
vi Power frequency one minute wet 45 45
vii Power frequency puncture withstand 125 125
voltage kV (rms)
viii Minimum dry impulse withstand 110 120

voltage 1.2x50 micro second wave,
positive and negative Kv Peak)
ix Maximum Radio interference 50 50
voltage with 10 kV RMS to ground.
(microvolts)
x Minimum corona extinction voltage 18 18
kV(rms)
5.03 SPECIFICATION DRAWINGS
The specification drawing in respect of the disc insulators indicated above is

attached with this specification. The specification drawing is attached herewith for
information and guidance of the Supplier only. The drawings to be furnished by the
Supplier shall be as per his own design and manufacture and shall be distinct and
separate from these specification drawings.
The drawing shall include but not limited to the following information :-
a) Shell diameter and ball to ball spacing with manufacturing tolerances.

Volume-V (Part-2)
b) Minimum creepage distance with positive tolerance.

c) Protected creepage distance
d) Eccentricity of the disc
i) Axial run out
ii) Radial run out
e) Unit mechanical and electrical characteristics

f) Size and weight of ball & socket parts
g) Weight of unit insulator disc
h) Materials
i) Identification mark
j) Manufacturer’s catalogue number.
After placement of award, the supplier shall submit full dimensioned
manufacturing drawing of insulator cap, pin & insulator shell in six copies to the
purchaser for reference & record.
5.04.1Porcelain
The porcelain used in the manufacture of the shells shall be ivory white, nonporous
of high dielectric, mechanical and thermal strength, free from internal stresses,
blisters, laminations, voids, foreign matter, imperfections or other defects which
might render it in any way unsuitable for insulator shells. Porcelain shall remain
unaffected by climatic conditions, ozone, acid, alkalizes, zinc or dust. The
manufacturing shall be by the wet process and impervious character obtained by
thorough verification.
5.04.2Porcelain Glaze
Surfaces to come in contact with cement shall be made rough by sand glazing. All
other exposed surfaces shall be glazed with ceramic materials having the same
temperature coefficient of expansion as that of the insulator shell. The thickness of
the glaze shall be uniform throughout and the colour of the glaze shall be brown.
The glaze shall have a visible luster, smooth on surface and be subject to satisfactory
performance under extreme tropical climatic weather conditions and prevent ageing
of the porcelain. The glaze shall remain under compression on the porcelain body
throughout the working temperature range.
5.04.3METAL PARTS
5.04.3.1 Cap and Ball Pins

Ball pins shall be made with drop forged steel and caps with malleable cast iron.
They shall be in one single piece and duly hot dip galvanized. They shall not contain
parts or pieces joined together, welded, shrink fitted or by any other process from
more than one piece of material. The pins shall be of high tensile steel, drop forged
and heat-treated. The caps shall be cast with good quality black hearth malleable
cast iron and annealed. Galvanising shall be by the hot dip process with a heavy
coating of zinc of very high purity. The Supplier shall specify the grade, composition
and mechanical properties of steel used for caps and pins.
5.04.3.2 Security Clips

The security clips shall be made of phosphor bronze or of stainless steel. 2.5% extra
security clip shall be provided.
5.05 FILLER MATERIAL

Volume-V (Part-2)
Cement to be used as a filler material shall be quick setting, fast curing Portland
cement. It shall not cause fracture by expansion or loosening by contraction.
Cement shall not react chemically with metal parts in contact with it and its thickness
shall be as small and as uniform as possible.
The insulator design shall be such that the insulating medium shall not directly
engage with hard metal. The surfaces of porcelain and hard metal should be coated
with resilient paint to offset the effect of difference in thermal expansions of these
materials.
5.06.1 GENERAL
(i) All raw materials to be used in the manufacture of these insulators shall be
subject to strict raw material quality control and to stage testing/quality control
during manufacturing stage to ensure the quality of the final end product.
Manufacturing shall conform to the best engineering practices adopted in the field of
extra high voltage transmission. Bidders shall therefore offer insulators as are
guaranteed by them for satisfactory performance on 400KV Transmission lines.
(ii) The design, manufacturing, process and material control at various stages be
such as to give maximum working load, highest mobility, best resistance to
corrosion, good finish, elimination of sharp edges and corners to limit corona and
radio interference voltages.
5.06.2 INSULATOR SHELL
The design of the insulator shells shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration. Shells with
cracks shall be eliminated by temperature cycle test followed by mallet test. Shells
shall be dried under controlled conditions of humidity and temperature.
5.06.3 METAL PARTS

(i) The pin and cap shall be designed such that it will not transmit the
mechanical stresses to the shell by compression and develop uniform mechanical
strength in the insulator. The cap shall be circular with the inner and outer surfaces
concentric and of such design that it will not yield or distort under loaded conditions.
The head portion of the pin ball shall be suitably designed so that when the insulator
is under tension the stresses are uniformly distributed over the pinhole portion of the
shell. The pin ball shall move freely in the cap socket either during assembly of a
string or during erection of a string or when a string is placed in position.
(ii) Metal caps shall be free from cracks, seams, shrinks, air holes, blow holes
and rough edges. All metal surfaces shall be perfectly smooth with no projecting
parts or irregularities, which may cause corona. All load bearing surfaces shall be
smooth and uniform so as to distribute the loading stresses uniformly. Pins shall not
show any microscopically visible cracks, inclusions and voids.
5.06.4 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the latest edition of
IS:2629. The zinc to be used for galvanizing shall conform to grade Zn 99.5 as per
IS:209. The Zinc coating shall be uniform, smoothly adherent, reasonably bright,
continuous and free from impurities such as flux, ash, rust stains, bulky white
deposits and blisters. Before ball fittings are galvanized, all die flashing on the shank
and on the bearing surface of the ball shall be carefully removed without reducing
the designed dimensional requirements.
5.06.5 SECURITY CLIPS (LOCKING DEVICES)

Volume-V (Part-2)
The security clips to be used as a locking device for ball and socket coupling shall be
‘R’ shaped hump type to provide for positive locking of the coupling as per IS:2486
(Part IV). The legs of the security clips shall allow for spreading after installation to
prevent complete withdrawal from the socket. The locking device shall be resilient,
corrosion resistant and of sufficient mechanical strength. There shall be no
possibility of the locking device to be displaced or be capable of rotation when placed
in position and under no circumstances shall it allow separation of insulator units and
fittings. ‘W’ type security clips are also acceptable. The hole for the security clip
could be countersunk and the clip shall be of such design that the eye of the clip may
be engaged by a hot line clip puller to provide for disengagement under energized
conditions. The force required for pulling the clip into its unlocked position shall not
be less than 50 N (5 kgs) or more than, 500 N (50 kgs).
5.06.6 BALL AND SOCKET DESIGNATION

The dimensions of the balls and sockets for 120KN discs shall be of 20 mm
designation in accordance with the standard dimensions stated in IS:2486 (Part II).
5.07 DIMENSIONAL TOLERANCE OF DISC INSULATOR
It shall be ensured that the dimensions of the disc insulators are within the limits
specified below:
a. Diameter of Disc (mm)

120 KN Disc 255 266 244
160 KN Disc 280 293 267
b. Ball to Ball Spacing between Discs (mm)

120 KN Disc 145 149 141
160 KN Disc 170 175 165
5.08 INTERCHANGEABILITY
The insulators inclusive of the ball and socket fittings shall be of standard design
suitable for use with hardware fittings of any make conforming to relevant Indian
Standards.
5.09 CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) PERFORMANCE

All surfaces shall be even, smooth, without cuts, abrasions or projections. No part
shall be subjected to excessive localized pressure. The metal parts and porcelain
shall not produce any noise generating corona under all operating conditions.
5.10.1The insulators shall be compatible for use with hot line or live line maintenance
techniques so that usual hot line operations can be carried out with ease, speed
and safety.

Volume-V (Part-2)
5.10.2Suppliers shall indicate the methods generally adopted in routine hot and cold line
maintenance of EHV lines for similar insulators supplied by them. Suppliers shall
also indicate the recommended periodicity of such maintenance.
5.11 FREEDOM FROM DEFECTS
Insulators shall have none of the following defects:
i) Ball pin shake

ii) Cementing defects near the pin like small blow holes, small hair cracks,
lumps, etc.
iii) Sand fall ferro particle defects on the surface of the insulator.
iv) Shell eccentricity
5.12 INSULATOR STRINGS
5.12.1 TYPE AND RATING
The insulator strings shall be formed with standard discs described in this
specification for use on 3 phase, 400kV, 50Hz effectively earthed systems in a
moderately polluted atmosphere. Suspension insulator strings for use with
suspension towers are to be fitted with discs of 120KN EMS rating .Tension insulator
strings for use with Anchor/Tension towers are to be fitted with discs of 160 kN EMS
rating.
5.12.2 STRING SIZE

The size of the disc insulator, the number to be used in different types of strings and
their electro-mechanical strength shall be as follows:
S.No. Type of String Size of No.of Electro

disc standard mechanical
insulator discs strength of
(mm) insulator
string (kN)
a) Single Suspension for 400KV 255 X145 23 120
b) Double Suspension for 400KV 255 x145 2x23 2x120
c) Single Tension for 400KV 280x170 24 160
d) Double Tension for 400KV 280x170 2x24 2x160
5.12.3STRING CHARACTERISTICS
5.12.3.1 The characteristics of the complete string shall be as follows :
S.No Particulars Single / Double Single /Double

Suspension Tension
400KV 400KV
i. Switching surge withstand 1050 1050
Volume-V (Part-2)
voltage(dry & wet) KV peak

ii Lightening Impulse withstand 1600 1700
voltage (dry) KV peak
iii Power frequency withstand voltage 680 690
(wet) KV r.m.s
iv Mechanical failing Load-kgf 11500/23000 16500/ 33000
v No deformation load-kgf 7705/ 15410 11055/ 22110
vi. Corona Extinction Voltage KV rms 320 320
vii. Max.RIV for complete string at 500 500
266KV(rms) line to ground voltage
(micro volt)
viii. Max.voltage across any disc 9% 9%
5.12.3.2 Insulator units after assembly shall be concentric and coaxial within limits as
permitted by Indian standards.
5.12.3.3 The string design shall be such that when units are coupled together there
shall be contact between the shell of one unit and metal of the next adjacent
unit.
5.13 TESTS
The following tests shall be carried out on the insulator string and also on unit disc
insulators.
5.13.1 TYPE TESTS

This shall mean those tests which are to be carried out to prove the design, process
of manufacture and general conformity of the material and product with the intents
of this specification. These tests shall be conducted on a representative number of
samples prior to commencement of commercial production. The successful supplier
shall indicate his schedule for carrying out these tests. For any change in the
design/type already type tests and the design/type offered against this specification ,
the purchaser reserves the right to demand repetition of test without extra cost

This shall mean those tests which are to be carried out on samples taken from each
lot offered for pre-despatch inspection for the purpose of acceptance of the lot.

This shall mean those tests, which are to be carried out on each insulator to check
the requirements which are likely to vary during production.
Stage tests during manufacture shall mean those tests which are to be carried out
during the process of manufacture to ensure quality control such that the end
product is of the designed quality conforming to the intent of this specification.
5.13.5 TEST VALUES

Volume-V (Part-2)
For all type and acceptance tests, the acceptance values shall be the value
guaranteed by the Supplier in the guaranteed technical particulars or the acceptance
value specified in this specification or the relevant standard whichever is more
stringent for that particular test.
5.13.6TEST PROCEDURES AND SAMPLING NORMS

The norms and procedure of sampling for the above tests shall be as per the
relevant Indian Standard or other Internationally accepted standards. This
will be discussed and mutually agreed to between the successful Supplier
and Purchaser before placement of order. The standards and norms
according to which these tests are to be carried out are listed against each
test. Where a particular test is a specific requirement of this specification,
the norms and procedure for the same shall be as specified in Appendix-I
attached hereto or as mutually agreed to between the successful Supplier
and the Purchaser in the Quality Assurance Programme. The supplier shall
offer at least three times the quantity of materials required for conducting
all the type tests for sample selection. Before sample selection, the supplier
shall be required to conduct all the acceptance tests successfully in
presence of Purchaser’s representative.
5.13.7 DETAILS OF TYPE TESTS
5.13.7.1 The material offered shall be fully type tested as per this specification and the
Supplier shall furnish four sets of type test reports alongwith the offer. These
tests must not have been conducted earlier than five years.
5.13.7.2 TYPE TESTS
(A) The following type tests shall be conducted on all types of the complete
insulator string with hardware fittings :
a) Power frequency voltage withstand test with corona control

rings and arcing horn under (dry/wet) conditions
b) Power frequency voltage flash over test with corona control
rings and arcing horn under (dry/wet) conditions
c) Power frequency voltage flash over test without corona
control rings and arcing horn under (dry/wet) conditions
d) Switching surge voltage withstand test under wet condition.
e) Impulse voltage withstand test under dry condition.
g) Impulse voltage flash over test under dry condition
j) Vibration test.
(B) Following type tests shall be conducted on string insulators/unit disc insulators
a) Visible discharge test IS:731

b) Impulse voltage withstand test IS:731
c) Wet power frequency voltage withstand IS:731
test
d) Verification of dimension test IS:731

Volume-V (Part-2)
e) Temperature cycle test IS:731

f) Electro-Mechanical failing load test IS:731
g) Puncture test IS:731
h) Porosity test IS:731
i) Galvanising test IS:731
j) 24 hours mechanical failing load test IS:731
k) Metallurgical test IS:2108 &
IS:2004
5.13.8 DETAILS OF ACCEPTANCE AND ROUTINE TESTS
5.13.8.1 All Acceptance and Routine tests as stipulated herein shall be carried out by the
Supplier in the presence of Purchaser’s representative.Immediately after
finalisation of the programme of acceptance/routine testing, the Supplier shall
give sufficient advance intimation to the Purchaser, to enable him to depute his
representative for witnessing the test.
5.13.8.2 For String Insulator Units following Acceptance & Routine tests shall be
conducted:
a) Verification of dimensions IS:731
b) Temperature cycle test IS:731
c) Galvanising test IS:731
d) Mechanical performance test IEC:575
e) Test on locking device for ball and IEC:372/IS-2486(part-IV)

socket coupling
f) Eccentricity test As per Specification
g) Electro-mechanical strength test
h) Puncture test IS-731
i) Porosity test
(B) Routine tests:

5.13.8.3 Tests during Manufacture (STAGE TESTS)

a) Chemical analysis of Zinc used for

galvanizing

Volume-V (Part-2)
b) Chemical analysis, mechanical and

metallographic test and magnetic
particle inspection for malleable
castings
As per this
c) Chemical analysis, hardness test and
Specification
magnetic particle inspection for
forgings
The purchaser reserves the right for carrying out any other tests of a
reasonable nature at the works of the Supplier/laboratory or at any other recognized
laboratory / research institute in addition to the above mentioned type, acceptance
and routine tests at the cost of the Purchaser to satisfy that the material complies
with the intent of this specification.
For 400KV insulator strings, the Supplier is required to produce type test reports to
the satisfaction of the Purchaser. However, in case the Purchaser desires, the
Supplier shall conduct all the type tests on the complete string with relevant
hardware fittings. Responsibility of arranging required hardwares for the purpose of
type testing will remain with the insulator Supplier.
5.14 INSPECTION
i) Purchaser and its representatives shall at all times be entitled to have access
to the works and to all places of manufactures where insulators are manufactured
and the successful Supplier shall afford all facilities to them for unrestricted
inspection of the works, inspection of material, inspection of manufacturing process
of insulators and for conducting necessary tests as specified herein.
ii) The successful Supplier shall keep the Purchaser informed in advance of the time of
starting and progress of manufacture of insulators in its various stages so that
iii) No material shall be dispatched from its point of manufacture unless the material
has been satisfactorily inspected and tested.
iv) The acceptance of any quantity of insulators shall in no way relieve the successful
Supplier of his responsibility for meeting all the requirement of this specification and
shall not prevent subsequent rejection, if such disc insulators are later found to be
defective.
5.15 IDENTIFICATION MARKING
5.15.1 Each disc insulator shall be legibly and indelibly marked with the trade mark of
the manufacturer, the month and year of manufacture, the guaranteed
combined mechanical and electrical strength in kilo-newtons abbreviated by
‘KN’ to facilitate easy identification and proper use.

Volume-V (Part-2)
5.15.2 The marking shall be on porcelain shell of insulators. The marking shall be
printed and not impressed/embossed and same shall be applied before firing.
5.15.3 One 10mm thick ring of good quality paint shall be marked on the cap of each
insulator of particular strength for easy identification of the type of insulator.
The paint shall not have any deteriorating effect on the insulator performance.
Following codes shall be used as identification mark:-
For 120KN disc insulator- Yellow
For 160kN disc insulator – Red
5.16.1 The Supplier hereunder shall invariably furnish following information alongwith
his offer, failing which the offer shall be liable for rejection. Information shall be
separately given for individual type of material offered.
i) Statement giving list of important raw materials, names of sub-suppliers for the raw
material, list of standards according to which the raw material are tested, list of
tests, normally carried out on raw material in presence of Supplier’s representative,
copies of test certificates.
ii) Information and copies of test certificates as in (i) above in respect of bought out
items.
iv) Level of automation achieved and list of areas where manual processing exists.
v) List of areas in manufacturing process, where stage inspections are normally carried
out in quality control and details of such test and inspections.
vi) Special features provided in the insulators to make it maintenance free.
vii) List of testing equipment available with the Supplier for final testing of insulators
specified and test plant limitation, if any, vis-a-vis the type, special, acceptance and
routine tests specified in the relevant standards.
5.16.2 The successful Supplier shall within 30 days of placement of order submit the
following information to the Purchaser.
i) List of raw material as well as bought out accessories and the name of material as
well as bought out accessories and the names of sub-suppliers selected from those
furnished alongwith the offer.
ii) Type test certificates of the raw material and bought out accessories.
iii) Quality assurance plan (QAP) with hold points for Purchaser’s inspection. The QAP
and Purchaser’s hold points shall be discussed between the Purchaser and the
Supplier before the QAP is finalized.
items and raw material at the time of routine testing of the insulator.
5.17 DOCUMENTATION
5.17.1 The Supplier shall furnish full description and illustrated catalogues of
insulators offered, alongwith the bid. The supplier shall also furnish alongwith
the bid the outline drawing of each insulator unit including cross-sectional view
of the shell. The drawing shall include the following information :
i) Shell diameter and unit spacing with manufacturing tolerance.

Volume-V (Part-2)
iii) Unit mechanical and electrical characteristics as also for the complete string-
suspension and tension.
v) Weight of unit insulator disc.
vi) Materials for the disc, cap and pin.
5.17.2 TEST REPORTS
i) Four copies of type test reports shall be furnished to the Purchaser within one
month of conducting the tests. One copy will be returned duly certified by the
Purchaser to the Supplier within three weeks thereafter and on receipt of the
same Supplier shall commence with the commercial production of the
insulators.
ii) Four copies of acceptance test reports shall be furnished to the Purchaser.
One copy will be returned, duly certified by the Purchaser and only thereafter
shall the materials be despatched.
iii) All records of routine test reports shall be maintained by the Supplier at his
works for periodic inspection by the Purchaser.
iv) All test reports of tests conducted during manufacture shall be maintained by
the Supplier. These shall be produced for verification as and when requested
for by the Purchaser.
i) All disc insulators shall be packed in strong seasoned wooden crates. The
gross weight of the crates alongwith disc insulators shall not normally exceed
100 kg. to avoid handling problem.
ii) The packing shall be of sufficient strength to withstand rough handling during
transit, storage at site and subsequent handling in the field.
iii) Suitable cushioning, protective padding, or dunnage or spacers shall be

provided to prevent damage or deformation during transit and handling.
iv) All packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and avoid the possibility of goods being lost or
wrongly dispatched on account of faulty packing and faulty or illegible
markings. Each wooden case/crate shall have all the markings stenciled on it
in indelible ink.

Volume-V (Part-2)
Appendix-I
TEST DETAILS
1. Voltage Distribution Test:
The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted into percentage and proportionate
correction be applied so as to give a total of 100% distribution. The voltage across any
disc shall not exceed 9% for suspension insulator strings and for double tension
insulator strings. The total of the voltage distribution of all discs so computed shall be
within 95% and 105%. If not, the test shall be repeated. The proportions correction
shall be made on the values so as to give a total of 100% distribution.
2. Mechanical Strength Test:
The complete insulator string alongwith its hardware fittings excluding arcing
horn, corona control ring/grading ring and suspension assembly/dead end assembly
shall be subjected to a load equal to 50% of the specified minimum ultimate tensile
strength (UTS) which shall be increased at steady rate to 67% of the minimum UTS
specified. The load shall be held for five minutes and then removed. After removal of
the load, the string components shall not show any visual deformation and it shall be
possible to disassemble them by hand. Hand tools may be used to remove cotter pins
and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of
UTS and the load shall be further increased at a steady rate till the specified minimum
UTS and held for one minute. No fracture should occur during this period. The applied
load shall then be increased until the failing load is reached and the value recorded.
3. Vibration Test:
The suspension string shall be tested in suspension mode, and tension string
in tension mode itself in laboratory span of minimum 30 metres. In the case of
suspension string a load equal to 600 kg shall be applied along the axis of the
suspension string by means of turn buckle. The insulator string alongwith hardware
fittings and two sub-conductors (each tensioned at 4500 kg) shall be secured with
clamps. The system shall be suitable to maintain constant tension on each sub-
conductors throughout the duration of test. Vibration Dampers shall not be used on the
test span. Both the sub-conductors shall be vertically vibrated simultaneously at one of
the resonance frequencies of the insulator string (more than 10 Hz) by means of
vibration inducing equipment. The amplitude of vibration at the antinode point nearest
to the string shall be measured and the same shall not be less than + 120/f , f being
the frequency of vibration. The insulator string shall be vibrated for five million cycles
then rotated by 90 deg. and again vibrated for 5 million cycles without any failure.
After the test, the disc insulators shall be examined for looseness of pins and cap or any
crack in the cement. The hardware fittings shall be examined for fatigue failure and
mechanical strength test. There shall be no deterioration of properties of hardware
components and disc insulators after the vibration test. The disc insulators shall be
subjected to the following tests as per relevant standards:
Test Percentage
of discs to
be tested
Temperature cycle test followed by 60
mechanical performance test
Puncture test (for porcelain 40

Volume-V (Part-2)
insulator only)
If the results of the second test show a porcelain shell rupture, the production does
not comply with this specification.
4. Chemical Analysis of Zinc used for Galvanising:
Samples taken from the zinc ingot shall be chemically analysed as per IS:209. The purity
of zinc shall not less than 99.95%.
5. Tests for Forgings:
The chemical analysis, hardness tests and magnetic particle inspection for
forgings, will be as per the internationally recognized procedures for these
tests. The sampling will be based on heat number and heat treatment
batch. The details regarding test will be as discussed and mutually agreed
to by the Supplier and Purchaser in Quality Assurance Programme.
6. Test on Castings:
The chemical analysis, mechanical and metallographic tests and magnetic

particle inspection for castings will be as per the internationally recognized procedures
for these tests. The samplings will be based on heat number and heat treatment batch.
The details regarding test will be as discussed and mutually agreed to by the Supplier
and Purchaser in Quality Assurance Programme.
7. Eccentricity Test:
The insulator shall be vertically mounted on a fixture using dummy pin and socket. A
vertical scale with horizontal slider shall be used for the axial run out. The pointer
shall be positioned in contact with the bottom of the outermost petticot of the disc.
The disc insulators shall be rotated with reference to the fixture and the slider shall
be allowed to move up and down on the scale but always maintaining contact with
the bottom of the outer most petticot. After one full rotation of the disc, the
maximum and minimum position the slider has reached on the scale can be found
out. Difference between the above two readings shall satisfy the guaranteed value
for axial run out. Similarly using a horizontal scale with vertical slider the radial run
out shall be measured. The slider shall be positioned on the scale to establish
contact with the circumference of the disc insulator and disc insulator rotated on its
fixture always maintaining the contact. After one full rotation the maximum and
minimum position of the slider reached on the scale are found out. The difference
between the above readings shall satisfy the guaranteed value for radial run out.
8. Crack Detection Test:
Crack detection test shall be carried out on each ball and pin before assembly
of disc unit. The manufacturer shall maintain complete record of having conducted such
tests on each and every piece of ball pin. The supplier shall furnish full details of the
equipment available with him for crack test and also indicate the test procedure in
detail.

Volume-V (Part-2)
SYSTEM PARTICUALRS
S.No PARTICULARS Electrical

. System Data
1 System A.C.
3phase
2 Line voltage (kV rms) 400
3 Max.voltage (kV rms) 420
4 Frequency 50 Hz
5 Neutral grounding system effectively earthed
6 Lightning impulse with-stand voltage(dry 1425
& wet)(kVp)
7 Power frequency withstand 630
voltage (wet) (kVp)
8 Switching surge withstand 1050
voltage (wet) (kVp)
9 Short circuit level (kA) 40
10. Minimum corona extinction voltage at 320
50 Hz AC system dry condition (Kv rms)
11. Radio interference voltage at one MHz 500
for phase to earth voltage of 266KV dry
conditions(Microvolt)

Volume-V (Part-2)
Part B
TECHNICAL SPECIFICATION FOR POLYMER INSULATORS
5.19 STANDARDS
5.19.1 Unless otherwise specified elsewhere in this specification, the rating as well as
performance & testing of the Polymer Insulators shall conform but not limited to
the latest revision & amendments available at the time of placement of order of all
the relevant standards as listed hereunder, except as modified in this document.

1 IS:731 Porcelain insulators for overhead IEC:61109-1992
power lines with a nominal voltage
greater than 1000V
2 Verification of Dimensions of IEC:61109

Polymer Insulators
3 IS:13134 Guide for the selection of insulators

in respect of polluted conditions IEC : 60815
4 IS:2071 Method of High Voltage Testing IEC:60060-1

Part(I), II, III
5 Characteristics of string insulator IEC : 60433

units of the long rod type
6 IS:2486 Specification for insulator fittings IEC-60575

for overhead power lines with a IEC-60120
nominal voltage greater than
1000V-General Requirements ,
Tests,
Dimensional Requirements, IEC:60372
Locking Devices
7 Hydrophobicity classification guide STRI guide
1.92/1
8 Standard for insulators–Composite- ANSI C29 13-
Distribution Dead-end type 2000
9 IS : 8263 Methods of RIV Test of HV IEC:60487
Insulators

10 Standard specification for glass ASTMD 578-05
fiber strands
11 Standard test method for ASTME 1131-03
compositional analysis by Thermo
gravimetry

Volume-V (Part-2)
12 IS:8269 Methods for Switching impulse test IEC:60506

on HV insulators
13 IS:2629 Recommended practice for Hot Dip ISO:1461(E)
Galvanisation for iron & steel
14 IS:2633 Testing for Uniformity of Coating of
Zinc coated articles
15 IS:6745 Determination of Weight of Zinc BS:443-1969
coating on Zinc coated iron and ISO 1460-1973
steel articles
16 IS : 4759 Hot dip zinc coatings on structural ISO : 1459,ISO
steel & other allied products : 1461
17 IS : 4699 Specification for refined secondary
zinc
IS : 3203 Methods of testing of local ISO : 2178
18 thickness of electroplated coatings
19 IS:209 Specification for Zinc BS:3436
20 IS:206 Method for Chemical Analysis of BS:3436

Slab Zinc
The standards mentioned above are available from:
Reference Name and Address

Abbreviation
BS British Standards,
British Standards Institution
101, Pentonvile Road,
N - 19-ND, UK
IEC International Electro technical Commission,
Bureau Central de la Commission,
electro Technique international,
1 Rue de verembe,
Geneva, SWITZERLAND
BIS/IS Beureau Of Indian Standards.
Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110001. INDIA
ISO International Organisation for Standardization.
Danish Board of Standardization
Danish Standardizing Sraat,
Aurehoegvej-12
DK-2900, Heeleprup, DENMARK
STRI guide 1.92/1 STRI, Sweden, Website : www.stri.se
NEMA/ANSI C29 13-2000 National Electric Manufacture Association, 155, East

44th Street, New York, NY: 10017 U.S.A
ASTM American Society for Testing and Materials, 1916

Race St. Phelledelphia, PA19103 U.S.A.
5.19.2Material meeting with the requirements of other authoritative standards, which

ensure equal or better performance than the standards mentioned above, shall also
be considered. When the material offered by the bidder conforms to other
standards, salient points of difference between standards adopted & the standards
specified in this specification shall be clearly brought out in the relevant schedules.
Volume-V (Part-2)
Three copies of such standards with authentic translation in English shall be

furnished along with the bid.
5.20.1 DETAILS OF POLYMER INSULATORS
A. The Polymer insulator shall be suitable for a three phase 50 Hz, effectively earthed
400 KV, 220 KV and 132 KV transmission system in a moderately polluted
atmosphere. They shall be ball and socket type.
B. The specified values and dimensions, impulse and power frequency voltages,
electromechanical strength [EMS] of Polymer insulators are as under. The values
given are minimum which apply to all cases. Specified withstand and flashover
voltages are referred to standard atmospheric condition.
S.No Particulars Value
400 KV POLYMER 220 KV POLYMER 132 KV POLYMER

INSULATORS INSULATORS INSULATORS
Suspen- Tension Suspen- Tension Suspen- Tension

sion sion sion
120 KN 160 KN 70KN 160 KN 70 KN 90 KN
i Size and 20 20 16 mm 20 16 mm 16 mm
designation of mm mm mm
ball & socket
ii Creep-age 13020 13020 7595 7595 4495 4495
distance (mm)
(minimum)
iii Power frequency 720 720 510 510 325 325
one minute dry
withstand voltage
kV (rms)
iv Power frequency 680 680 460 460 275 275
one minute wet
withstand voltage
kV (rms)
v Visible discharge 266 266 154 154 105 105
Test voltage kV
(rms)
vi Minimum dry 1550 1550 1050 1050 650 650
impulse withstand
voltage 1.2x50
micro second
wave, positive
and negative Kv
Peak)
vi Nominal length 3335 4080 1885 2380 1305 mm 1450
(Insulation mm mm mm mm mm
Spacing) ( mm)

Volume-V (Part-2)
C. Polymer Insulators shall have sheds with good self-cleaning properties. Insulator
shed profile, spacing, projection etc., and selection in respect of polluted conditions
shall be generally in accordance with the recommendation of IEC-60815/IS : 13134
D. Dimensional Tolerance of Composite Insulators
The tolerances on all dimensions e.g. diameter, length and creepage distance shall
be allowed as follows in line with-IEC 61109 :
± (0.04d + 1.5)mm when d≤300mm
± (0.025d+6)mm when d>300mm
Where, d being the dimensions in millimeters for diameter, length or creepage

distance as the case may be.
However, no negative tolerance shall be applicable to creepage distance
5.01.01 Core:
The core shall be glass-fiber reinforced epoxy resin rod (FRP) of high strength. Both,
glass fiber and resin shall be optimized in the FRP rod. Glass fibers with low content in
alkalies shall be boron free E glass or Boron free electrically corrosion resistance (ECR)
glass. Use of resin with hydrolysis trend due to water penetration should be prevented i. e.
matrix of the FRP rod shall be Hydrolysis resistant. Suitability of Epoxy matrix as well as
interface between matrix and fibers is to be considered as design parameter to prevent
brittle fracture. The FRP rod should be void free and shall be manufactured through
Pultrusion process.
5.01.02 Housing (Sheath):

The core of the Polymer insulator shall be completely covered by a continuous housing
consisting of a sheath-weathershed. For moulding of entire weathershed structure on to the
rod in a one shot moulding process to be employed to avoid multiple interfaces. Hardware i.
e. metal fittings may be installed on the rod prior to moulding of the shed controlling
moulding lines. The base polymer shall be 100% Silicon Rubber prior to the addition of
reinforcing fillers. The thickness of compounding material on core should be minimum 3
mm. Manufacturer should furnish a description of its Quality Assurance Programme
including fabrication, testing and inspection for any material (i.e. rubber), components(i.e.
rod) or hardware (i.e. end fittings). The manufacturer has had fabricated by others should
also be included. Manufacturing methods and material composition documentation will be a
part of Technical Bid to be submitted along with offer. Insulator should have hermetically
sealed structure in which the housing material is moulded to cover the interface between
the end fittings and the FRP rod. This seal should never be broken during testing or
otherwise.
5.01.03 End fittings:

The Polymer insulators shall be socket and ball type with the necessary coupling
arrangement such that pin shall move freely in the socket but do not get disengaged while
in service under various operating and atmospheric conditions.
The socket & ball type metal end fittings shall be designed to transmit the mechanical load
to the core & the end fittings shall maintain uniform and consistent mechanical strength
Material and methods used in the fabrication of metal parts shall be selected to provide
good toughness and ductility. Metal end fittings shall be made from a quality malleable cast
iron or forged steel or Spheroidal Graphite Iron(SGI) and shall be hot dipped galvanized in
accordance with IS 2629. Metal end fittings shall be uniform and without sharp edges or
corners and shall be free of cracks, flakes, slivers, slag, blow-holes shrinkage defects and
Volume-V (Part-2)
localized porosity. The attachment to the FRP rod shall be performed with a symmetrically
controlled crimping method control by acquistic method that compresses the metal radically
onto the rod without damage to the rod fibers or resin matrix while providing a strength
equal to or greater than the defined and specified ultimate strength to the insulator. The
material used in fittings shall be corrosion resistant. Nominal dimensions of the pin, ball and
socket interior shall be in accordance with the standard . No joints in ball & socket or pin will
be allowed. Outer portion of ball or socket should be Zinc sleeved with minimum 99.95%
purity of electrolytic high grade Zinc. The finished surface shall be smooth and shall have a
good performance The surface shall not crack or get chipped due to ageing effect under
normal and abnormal service conditions or while handling during transit or erection. The
design of the fittings and the insulators shall be such that there is no local corona formation
or discharges likely to cause the interference to either sound or vision transmission.
5.01.04 GRADING RINGS

Grading rings shall be provided when system voltages are equal to or greater than 220
KV. For 220 KV transmission, grading ring is to be provided at the energized end only. For
400 KV transmission , grading ring is to be provided at both ends of the insulators.
All grading rings and brackets shall be designed as an integral part of the insulator assembly
with a positive mounting system that allows mounting in one position . The design of the
grading ring shall be such that ring can only be mounted with its orientation towards the
weather sheds for maximum RIV and
Corona control . Grading rings shall be designed in such a manner that the rings can be
readily installed and removed with hot line tools without disassembling any other part of the
insulator assembly .
Grading ring height (is the distance from the end of the end fitting to the top of corona ring)
should be so selected that maximum field minimizes and uniformly distributed along the
insulator. Manufacturer should provide reports of successful electric field modeling testing
for the specific insulator design. The EFM should be three dimensional with result
containing drawing depicting the electric field in various colours , each of a different voltage
level. The result of this study should show that the voltage field surrounding the polymer
insulators is optimum along the entire length of the insulator , with the effected hot end of
the insulator being a critical location . The threshold at which corona may or may not be
present should be defined as a figure in KV/mm for the designed insulator.
5.02 VERIFICATION OF HOUSING MATERIAL
The manufacturer should provide written verification about housing material, for which base
polymer shall be 100% Silicon Rubber prior to the addition of reinforcing fillers considered
will provide satisfactory performance in the particular environment It shall meet following
requirements Be homogenous, impermeable, with no fissures, bubbles and strange
materials inclusions. Be designed in order to avoid formation of localized discharges and to
prevent interfaces humid penetration. Be resistant to corona, UV radiation, ozone,
atmospheric contamination, water penetration and power arcs.
5.03 BALL AND SOCKET DESIGNATION
The dimensions of the Ball and Socket shall be 16mm designation for 70KN and 90KN
Polymer insulators and 20 mm designation for 120 KN and 160 KN Polymer insulators in
accordance with the standard dimensions stated in IEC:60120/IS:2486(Part-II)
5.04 MARKINGS:
5.04.01 Each insulator shall be legibly and indelibly marked with the following details
as per IEC – 61109.
Volume-V (Part-2)
a. Name or trademark of the manufacturer.

b. Voltage and Type.
c. Month and year of manufacturing.
d. Minimum failing load / guaranteed mechanical strength in kilo
Newton followed by the word ‘KN’ to facilitate easy identification.
e. Country of manufacture
5.04.02 One 10 mm thick ring of suitable quality of paint shall be marked on the end
fitting of particular strength for easy identification of Polymer insulators. The
paint shall not have any deteriorating effect on the insulator performance.
Following codes shall be used as identification mark :
For 70KN Polymer insulator : Green
For 90KN Polymer insulator : Blue
For 120KN Polymer insulator : Yellow
For 160KN Polymer insulator : Red.
5.05.01 GENERAL
(i) All raw materials to be used in the manufacture of these insulators shall be subject
to strict raw material quality control and to stage testing/quality control during
manufacturing stage to ensure the quality of the final end product. Manufacturing
shall conform to the best engineering practices adopted in the field of high voltage
transmission. Bidders shall therefore offer insulators as are guaranteed by them
for satisfactory performance on 400KV/220 KV and 132kV Transmission lines.
(ii) The design, manufacturing, process and material control at various stages be such
as to give maximum working load, highest mobility, best resistance to corrosion,
good finish, elimination of sharp edges and corners to limit corona and radio
interference voltages.
5.05.02 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the latest
edition of IS:2629. The zinc to be used for galvanizing shall conform to grade Zn
99.5 as per IS:209. The Zinc coating shall be uniform, smoothly adherent,
reasonably bright, continuous and free from impurities such as flux, ash, rust
stains, bulky white deposits and blisters. Before ball fittings are galvanized, all die
flashing on the shank and on the bearing surface of the ball shall be carefully
removed without reducing the designed dimensional requirements.
5.05.03 INTERCHANGEABILITY
The Polymer insulators inclusive of the ball and socket fittings shall be of
standard design suitable for use with hardware fittings of any make conforming to
relevant Indian Standards.
5.05.04 CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) PERFORMANCE
All surfaces shall be even, smooth, without cuts, abrasions or projections. No

part shall be subjected to excessive localized pressure. The metal parts shall not
produce any noise generating corona under all operating conditions.

Volume-V (Part-2)
5.06.01 The Polymer insulators shall be compatible for use with hot line or live line
maintenance techniques so that usual hot line operations can be carried out with ease,
speed and safety.
5.06.02 Suppliers shall indicate the methods generally adopted in routine hot and cold
line maintenance of EHV lines for similar Polymer insulators supplied by them. Suppliers
shall also indicate the recommended periodicity of such maintenance.
5.07 TESTS
The following tests shall be carried out on the Polymer insulator:
5.07.01 TYPE TESTS
This shall mean those tests which are to be carried out to prove the design, process
of manufacture and general conformity of the material and product with the intents of this
specification. These tests shall be conducted on a representative number of samples prior
to commencement of commercial production.
This shall mean those tests which are to be carried out on samples taken from each
lot offered for pre-despatch inspection for the purpose of acceptance of the lot.

This shall mean those tests, which are to be carried out on each Polymer insulator to
check the requirements, which are likely to vary during production.
Stage tests during manufacture shall mean those tests, which are to be carried out
during the process of manufacture to ensure quality control such that the end product is of
the designed quality conforming to the intent of this specification.
5.07.05 TEST VALUES
guaranteed by the Supplier in the guaranteed technical particulars or the acceptance value
specified in this specification or the relevant standard whichever is more stringent for that
particular test.
5.07.06 TEST PROCEDURES AND SAMPLING NORMS
5.07.06.1 The norms and procedure of sampling for the above tests shall be as per
the relevant Indian Standard or other Internationally accepted standards. This will be
discussed and mutually agreed to between the successful Supplier and Purchaser before
placement of order. The standards and norms according to which these tests are to be
carried out are listed against each test. Where a particular test is a specific requirement of
this specification the norms and procedure for the same shall be as mutually agreed to
between the successful supplier and purchaser in the quality assurance programme. The
Volume-V (Part-2)
supplier shall offer at least three times the quantity of material required for conducting all
the type tests for sample selection. Before sample selection, the supplier shall be required
to conduct all the acceptance test successfully in presence of purchaser’s representative.
(A) The following type tests shall be conducted on all types of the Polymer insulator
with hardware fittings :
a) Power frequency voltage withstand test with corona

control rings and arcing horn under (dry/wet)
conditions
b) Power frequency voltage flash over test with corona
control rings and arcing horn under (dry/wet)
conditions
c) Power frequency voltage flash over test without
corona control rings and arcing horn under (dry/wet)
conditions
d) Switching surge voltage withstand test under wet
condition.
e) Impulse voltage withstand test under dry condition.
g) Impulse voltage flash over test under dry condition
j) Vibration test.
k) Power Arc Test
l) Salt fog pollution withstand Test
(B) On composite Insulator Unit:-
1. Tests on interface and connection of metal fittings
(a) Dry Power frequency Voltage Test

(b) Sudden Load Release Test
(c) Thermal Mechanical Test
(d) Steep Front Impulse Voltage Test
(e) Dry Power frequency Voltage Test
2. Assembled Core Load Time Test
(a) Determination of the Average failing load of the core of the assembled unit
(b) Control of slope of the strength time curve of the insulator
3. Accelerated Ageing Test of 5000 hours

4. Flammability Test
5. Recovery of Hydrophobic Test
6. Mechanical Load Time Test
7. Brittle Fracture resistance test
8. Test of Housing, Tracking and Erosion Test
9. Test for the Core Material
- Dye Penetration Test
- Water diffusion Test
5.07.07 ACCEPTANCE AND ROUTINE TESTS

Volume-V (Part-2)
On Polymer Insulators following Acceptance & Routine tests shall be conducted:
a) Verification of dimensions IEC:61109-1992

b) Verification of Locking System
c) Galvanising test IS-731
d) Verification of specified IEC:575
Mechanical Load
e) Recovery of Hydrophobicity As per annex-A
(B) Routine tests:

5.07.08 Tests during Manufacture (STAGE TESTS)
a) Chemical analysis of Zinc used for galvanizing
b) Chemical analysis, mechanical and metallographic test and

magnetic particle inspection for malleable castings
c) Chemical analysis, hardness test and magnetic particle

inspection for forgings
The purchaser reserves the right for carrying out any other tests of a reasonable
nature at the works of the Supplier/laboratory or at any other recognized laboratory /
research institute in addition to the above mentioned type, acceptance and routine tests at
the cost of the Purchaser to satisfy that the material complies with the intent of this
specification.
For polymer insulator strings, the Supplier is required to produce type test reports
to the satisfaction of the Purchaser. However, in case the Purchaser desires, the Supplier
shall conduct all the type tests on the complete string with relevant hardware fittings.
Responsibility of arranging required hardwares for the purpose of type testing will remain
with the insulator Supplier.
5.07.11 TEST SCHEDULE

Volume-V (Part-2)
The material offered shall be fully type tested as per this specification and the
Supplier shall furnish four sets of type test reports alongwith the offer. These tests must
not have been conducted earlier than five years.
For any change in the design/type ,already type tested and the design/type offered
against this bid, the purchaser reserves the right to demand repetition of some or all type
tests without any extra cost.
5.07.11.2 ACCEPTANCE AND ROUTINE TESTS
All Acceptance and Routine tests as stipulated herein shall be carried out by the
Supplier in the presence of Purchaser’s representative.
Immediately after finalization of the programme of acceptance/routine

testing, the Supplier shall give sufficient advance intimation to the Purchaser, to
enable him to depute his representative for witnessing the test.
5.08 INSPECTION
i) Purchaser and its representatives shall at all times be entitled to have

access to the works and to all places of manufactures where insulators are
manufactured and the successful Supplier shall afford all facilities to them for
unrestricted inspection of the works, inspection of material, inspection of
manufacturing process of insulators and for conducting necessary tests as
specified herein.
ii) The successful Supplier shall keep the Purchaser informed in advance of the
time of starting and progress of manufacture of insulators in its various
stages so that arrangements could be made for inspection.
iii) No material shall be despatched from its point of manufacture unless the
material has been satisfactorily inspected and tested.
iv) The acceptance of any quantity of insulators shall in no way relieve the
successful Supplier of his responsibility for meeting all the requirement of this
specification and shall not prevent subsequent rejection, if such insulators are
5.09.01 The Supplier hereunder shall invariably furnish following information alongwith
his offer, failing which the offer shall be liable for rejection. Information shall
be separately given for individual type of material offered.
i) Statement giving list of important raw materials, names of sub-suppliers for

the raw material, list of standards according to which the raw material are
tested, list of tests, normally carried out on raw material in presence of
ii) Information and copies of test certificates as in (i) above in respect of bought
out items.
iv) Level of automation achieved and list of areas where manual processing
exists.

Volume-V (Part-2)
v) List of areas in manufacturing process, where stage inspections are normally

carried out in quality control and details of such test and inspections.
vi) Special features provided in Polymer insulators to make it maintenance free.
vii) List of testing equipment available with the Supplier for final testing of
Polymer insulators specified and test plant limitation, if any, vis-a-vis the
type, special, acceptance and routine tests specified in the relevant
standards.
5.09.02 The successful Supplier shall within 30 days of placement of order submit the
following information to the Purchaser.
i) List of raw material as well as bought out accessories and the name of
material as well as bought out accessories and the names of sub-suppliers
selected from those furnished alongwith the offer.
ii) Type test certificates of the raw material and bought out accessories.
iii) Quality assurance plan (QAP) with hold points for Purchaser’s inspection. The
QAP and Purchaser’s hold points shall be discussed between the Purchaser
and the Supplier before the QAP is finalized.
items and raw material at the time of routine testing of the insulator.\
5.10 DOCUMENTATION
5.10.01 The Supplier shall furnish full description and illustrated catalogues of
insulators offered, alongwith the bid. The supplier shall also furnish alongwith
the bid the outline drawing of Polymer insulator unit including cross-sectional
view. The drawing shall include the following information:
i) Shed diameter and unit spacing with manufacturing tolerance.

iii) Unit mechanical and electrical characteristics for the complete string-
suspension and tension. unit
v) Weight of Polymer unit.
vi) Materials for the cap and pin.
5.10.02 TEST REPORTS
i) Four copies of type test reports shall be furnished to the Purchaser within one
month of conducting the tests. One copy will be returned duly certified by the
Purchaser to the Supplier within three weeks thereafter and on receipt of the
same Supplier shall commence with the commercial production of the Polymer
insulators.
Volume-V (Part-2)
ii) Four copies of acceptance test reports shall be furnished to the Purchaser.
One copy will be returned, duly certified by the Purchaser and only thereafter
shall the materials be despatched.
iii) All records of routine test reports shall be maintained by the Supplier at his
works for periodic inspection by the Purchaser.
iv) All test reports of tests conducted during manufacture shall be maintained by
the Supplier. These shall be produced for verification as and when requested
for by the Purchaser.
5.11 GUARANTEED PARTICULARS AND PERFORMANCE GUARANTEE:
(i) The bidder shall furnish all relevant technical guaranteed particulars of the long rod
Polymer Insulators offered. Offers without such details may not be considered.
(ii) The Polymer Insulators shall be guaranteed for satisfactory performance for a period
of 24 months from the date of commissioning of line. Any defect due to faulty
material or workmanship found during guarantee period shall be rectified free of cost
to the MPPTCL. The replacement will have to be organized expeditiously and within
one month from the date of intimation.
The manufacturer shall also guarantee that there shall not be any
failure/decapping/ breaking of insulators on line under normal operating
condition. In the event of any failure/decapping/ breaking of insulators during
first ten years of service, the manufacturer shall supply to the owner/purchaser
free of cost spare insulators equal to 10 times the failed quantity. Further , in case
of decapping/breaking and subsequent line drop , during the first ten years of
service , the manufacturer shall also have to pay Rs. 1,00,000/-(Rs. One Lakh
only) per dropped string towards expenditure to be incurred by MPPTCL for the
line repair.
(iii) In case, the replacement of defective material is not made within one month then
apart from operating clause of Penalty, the MPPTCL may also take suitable penal
action against the contractor, which may include encashing the Performance Security
to the extent required besides debarring the contractor and the manufacturer from
all future business with the MPPTCL for a period which will be at the discretion of
MPPTCL.
(iv) The defective/ rejected material shall be collected by the contractor from Trans.
Stores/Site within one month from the date of intimation at your own cost.
(v) The bidder shall indicate the facilities available at the manufacturer’s works to carry
out the tests as per relevant ISS. Supplies shall be subject to testing as per IS.
i) All Polymer insulators shall be packed in suitable PVC/Plastic tubes/any other

suitable packing. The packing shall provide protection against rodents. The
supplier shall furnish detailed design of the packing. For marine transportation
crates shall be palleted.
ii) The packing shall be of sufficient strength to withstand rough handling during
transit, storage at site and subsequent handling in the field.
iii) Suitable cushioning, protective padding, or dunnage or spacers shall be

provided to prevent damage or deformation during transit and handling.

Volume-V (Part-2)
iv) All packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and avoid the possibility of goods being lost or
wrongly dispatched on account of faulty packing and faulty or illegible
markings. Each case/crate shall have all the markings stenciled on it in
indelible ink.
v) The supplier shall guarantee the adequacy of the packing and shall be
responsible for any loss or damage during transportation handling, storage
and installation due to improper packing indelible ink.

Volume-V (Part-2)
ANNEXURE-II
1.0 Tests on Complete composite Insulator with Hardware Fittings.
1.1 Salt - fog pollution withstand test
This test shall be carried out in accordance with IEC-60507. The salimity level for
composite long rod insulators shall be 80 Kg / m3 NACL.
2.0 Composite Long rod Insulator Units
2.1 Brittle Fracture Resistance Test.
Assembled core load time test with container that contains in-HNO3 concentric acid
this is applied at the naked rod. The rod should be held at 80% of SML for the
duration of the test. The rod should not fail within the 96 hour test duration.
2.2 Recovery of Hydrophobicity Test
(1) The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the
surface to dry and spray with water. Record the
HC classification. Dry the sample surface
(2) Treat the surface with corona discharges to destroy the hydrophobicity. This can be
done utilizing a high frequency corona tester. Holding the electrode approximately 3
mm from the sample surface slowly move the electrode over an area approximately
1’’ x 1’’. Continue treating this area for 2-3 minutes, operating the tester at
maximum output.
(3) Immediately after the corona treatment, spray the surface with water and record the
HC classification. The surface should be hydrophilic with an HC value of 6 to 7. If not,
dry the surface and repeat the corona treatment for a longer time until an HC of 6 or
7 is obtained. Dry the sample surface.
(4) Allow the sample to recover and repeat the hydrophobicity measurement at several
time intervals. Silicone rubber should recover to HC 1 – HC 2 within 24 to 48 hours,
depending on the material and the intensity of the corona treatment.
3.0 Test on All components (As applicable).
3.1 Chemical Analysis of Zinc used for Galvanizing.

Samples taken from the zinc ingot shall be chemically analysed as per IS 209-1979.
The purity of zinc shall not be less than 99.95%.
3.2 Tests for Forgings.
The chemical analysis hardness tests and magnetic particle inspection for forgings,
will be as per the internationally recognized procedures for these tests. The sampling
will be based on heat number and heat treatment batch. The details regarding test
will be as discussed and mutually agreed to by the Supplier and Owner in Quality
3.3 Tests on Castings.
The chemical analysis, mechanical and metallographic tests and magnetic, particle
inspection for castings will be as per the internationally recognized Procedures for
these tests. The samplings will be based on heat number and heat treatment batch.

Volume-V (Part-2)
The details regarding test will be as discussed and mutually agreed to by the
Supplier and Owner in Quality Assurance Programme.
4.0 Power Arc Test:
Three insulators having any one design of end fittings shall be tested for power arc
endurance while tensioned horizontally at 3000lb. An arc shall be initiated across the
insulator by means of a Copper shorting fuse wire. The arc shall burn 15 to 30 cycles
and its current magnitude is determined by ampere- time product(IxT) equal to a
minimum of 150kA cycles. Each insulator is only acceptable if there is no exposure
of the core, no mechanical separation of the insulator, and no cracks in the housing .

Volume-V (Part-2)
SECTION -6
TECHNICAL SPECIFICATIONS FOR HARDWARE FITTINGS & ACCESSORIES

FOR 400 kV LINES
6.01 SCOPE:
6.01.1 This section provides for manufacturing, stage testing, inspection and testing before
despatch, packing and delivery of Hardware fittings for Insulator string and
accessories suitable for Conductor and Ground wire for use on 400KV transmission
line.
6.01.2 It is not the intent to specify completely herein all details of the design and
construction of material. However, the material shall conform in all respects to high
standards of engineering, design and workmanship and shall be capable of
performing the duties specified herein. The material offered shall be complete with
all components necessary for its effective and trouble free operation. Such
components shall be deemed to be within the scope of Bidder’s supply, irrespective
of whether these are specifically brought out in this specification or not.
6.02 STANDARDS:
6.02.1 The material and services under this specification shall be performed as per the
requirements of the latest revisions and amendments available at the time of
placement of order of all the relevant Indian Standards/Codes listed here under
except as modified in this document:
S.No Indian Standard Title
2 IS:206 –1992 Tee and Strap Hinges
3 IS:7814-1985 Phosphor Bronze Sheet and Strip
4 IS:2071 Part-I, II & III Method of high voltage testing
Porcelain Insulator for Overhead Power Lines

5 IS:731
with a Nominal Voltage Greater than 1000 V.
Phosphor Bronze Rods & Bar Sheet and

7 IS:1385
Strips and Wire
Carbon Steel Forgings for General Engineering
8 IS:2004
Purpose
Specification for Conductors and Ground wire

11 IS:2121(Part-I & II) Accessories for Overhead Power Line, Armour
Rods Binding Wires and Tapes for Conductor
Specification for Insulator Fittings for
IS:2486 Overhead Power Lines with a Nominal
12 Voltage Greater than 1000 V.
Part-I General Requirements and Tests

Volume-V (Part-2)
Part-II Dimensional Requirements

Part-III Locking Devices
Part-IV Tests for Locking Devices
Recommended Practice for Hot Dip
13 IS:2629
Testing of Uniformity of Coating of Zinc
14 IS:2633
coated Articles
Determination of Weight of Zinc Coating on

17 IS:6745
Zinc Coated Iron and Steel Articles
19 IS:4218 Part-I to VI ISO Metric screw Threads
Dimensions for Radii under the Heads of

20 IS:4172
Bolts & Screws
Dimensions for nominal lengths and Thread
21 IS:4206 length for Screws and Studs (with
amendment)
Hot Dip Zinc Coatings on Structural Steel and
22 IS:4759
other Allied Products
Electroplated Coatings of Zinc on Iron and
23 IS:1573-1986
Steel
Specification for Aluminium Conductor Steel
24 IS: 398 (Part-II & III) Reinforced for overhead transmission
purpose.
Methods for determination of weight of tin
25 IS: 1327-1966
Coating on Tin Plates
Hot Dip Galvanised Coating on Round Steel
26 IS: 4826-1979
Wires
27 IS: 1363 Part-I to III Hexagon Head Bolts, Screws & Nuts.
Technical supply conditions for threaded
IS: 1367
Steel Fasteners.
28 Introduction and General Information.
IS: 1367 (Part-I)
Product Grades and Tolerances.
IS: 1367 (Part-II)
Mechanical Properties and Test Methods for
IS: 1367 (Part-III)
Bolts, Screws and Studs with full Load ability.
29 Stockbridge Vibration Dampers for Overhead
IS: 9708
Power lines.
30 Method of Radio Interference Tests on High
IS: 8263
Voltage Insulators.
Volume-V (Part-2)

32 Carbon Steel Forgings for general
IS: 2004
engineering purposes.
General Instructions and Testing Procedures
33 BS:970 (Part-I) Specific Requirements for Carbon and Carbon
Manganese Alloy and Stainless Steels.
6.02.2 In the paragraph 2.1 above, relevant Indian Standards have been mentioned.
However, the Hardware fittings meeting any other authoritative international
standard, which ensures equal or better quality than the Standards, mentioned
above shall also be acceptable. Please attach photocopy of all such Standards
according to which the Hardware fittings have been offered.
6.03 TOPOGRAPHY AND CLIMATIC CONDITIONS:
The material to be supplied against this specification shall be suitable for

satisfactory operation under the tropical climatic conditions as under:
2 Maximum ambient air temp. 50 0C

3 Minimum temperature in shade 1 0C.
95%(sometimes approaches
4 Maximum relative humidity
Saturation)
5 Average daily ambient air temp. 40 0C
Isoceraunic Level (Average number of
6 50 days per year
thunder storm days)
7 Average rainfall 1250 mm
8 Max. Altitudes above mean sea level 1000 meter
9 Seismic level (Horizontal acceleration) 0.3 g
NOTE:- Moderately hot and humid tropical climate conducive to rust and fungus
growth. The climatic conditions are also prone to wide variations in ambient
conditions. Stroke is also present in the atmosphere. Heavy lightening also occurs
during June to October.
6.04.1 DETAILS OF HARDWARE FITTINGS:
(a) The Hardware fittings shall meet the technical requirement as per specification
and also general arrangement drawings of Hardware fittings attached herewith.
Hardware fittings shall be suitable for single/double suspension Insulator strings,
single/double tension Insulator strings and single suspension-pilot insulator strings.
Each Hardware fitting shall be supplied complete in all respect and shall include all
components, which are required for making complete set.
(b) The hardware fittings for lines shall be suitable for ACSR Moose Conductor and
Groundwire as per technical parameters indicated below:-
S.N Particulars Moose ACSR Ground Wire
o
1. Material ACSR Steel
2. Size 325 mm² Cu. eq. --

Volume-V (Part-2)
3. Nominal Aluminium area 515.70 mm² --

4. Stranding and wire diameter 54/3.53 Alu.+ 7/3.66mm.
(no./mm) 7/3.53 steel.
5. Number of strands in each layer.
Central core 1 of steel 1 of steel
1st layer 6 of steel 6 of steel
2nd layer 12 of Alu.
3rd layer 18 of Alu.
4th layer 24 of Alu.
6. Sectional area of Alu. 515.70 --
7. Total sectional area 597 mm² --
8. Approximate overall diameter 31.77 mm 10.98 mm
9. Overall diameter when wrapped with - 18.30 mm
preformed Armour Rod
10 Approximate weight 2004 Kg per Km 583Kg per Km
11 Calculated D.C. resistance at 20º C 0.0551 2.5 Ohm/km
Ohm/km
12 Approximate Breaking Load 16250 Kgs. 6972 kgs
13 Co-efficient of Linear Expansion 19.53 x 10-6 11.5 x 10-6
per ºC per ºC
14 Final Modulus of Elasticity 0.686 X 106 1.931X106
kg/cm² kg/cm²
6.05 INSULATOR STRING CHARACTERISTICS:
(a) The complete insulator string including Hardware fittings shall have the following
characteristics:
Single/ Single/
S.
Characteristics Double Double
No
Suspension Tension
1 1x23 1x24
No. of Standard Discs
2x23 2x24
2 Nominal diameter of discs 280 280
3 Power frequency Withstand voltage (wet)
680 690
kV (rms)
4 Lighting impulse withstand voltage
1600 1700
(dry)(kVp)
5 Switching surge Withstand voltage (Dry &
1050 1050
wet) (kVp)
6 Mechanical failing Load (kgf) 11500/23000 16500/33000
7 Pollution Moderately Moderately
polluted polluted
8 Corona Extinction voltage (KV rms) 320 320
(b) The Insulator string Hardware fittings shall comply and conform to the above
requirement.
6.06 BALL AND SOCKET DIMENSIONS:
The Ball and Socket for Hardware fittings shall necessarily conform to the
dimensions as stipulated in the Indian Standards. The Ball and Socket dimension of
Hardware to be used with 11500 Kg & 16,500 kg Electro Mechanical strength disc
insulator shall conform to designation 20mm in accordance with IS-2486:(Part-II).

Volume-V (Part-2)
The Bidder shall submit full detail of locking device in accordance with IS
2486:(Part-III) or equivalent International Standard along with test reports, gauges
and adherence to Standards for Tests on Locking Devices in line with IS:2486 (Part-
IV) or equivalent International Standard.
6.07 REQUIRED GUARANTEED STRENGTH OF HARDWARE OF INSULATOR STRINGS:
6.07.1 The slipping strength of the suspension clamp shall not be less than 15% and more
than 20% of the Conductor strength with which it is to be used.
6.07.2 The Hardware and Compression Clamp of single & double tension strings suitable for
Moose ACSR for 400KV transmission line shall have ultimate breaking strength of not
less than 16500 kgs. The Compression Clamp shall have slipping strength not less
than 95% of breaking strength of Moose ACSR.
6.07.3 Each individual Hardware component of double suspension and double tension
strings such as ball-clevis, socket clevis etc. shall have minimum breaking strength
as specified for respective single suspension and tension string respectively.
6.08 PARTICULARS OF HARDWARE FITTINGS:
Each Hardware fitting shall be complete in all respect and Bidder should
furnish complete drawings and technical particulars of the items quoted. The
Hardware fittings should normally comprise items conforming to enclosed drawing
as under: -
6.08.1 Single Suspension Hardware Fitting with AGS Type Clamp:
Single suspension Hardware string shall comprise of one Anchor Shackle,
Horn holder Ball eye, line side arcing horn, yoke plate, corona control ring and two
Suspension Clamps of AGS type with armour rod as per enclosed drawing.
6.08.2 Double Suspension String Hardware Fittings with AGS Type Clamp:
The double suspension string Hardware fittings shall comprise of one Anchor
Shackle, one Top Yoke Plate, two Ball Clevis, two Socket Clevis, corona control ring,
one bottom Yoke Plate, two line side Arcing Horns, two Clevis Eye and two AGS type
Suspension Clamps with armour rod as per enclosed drawing.
6.08.3 Single suspension Pilot string for Moose ACSR:
The single suspension pilot string for Moose ACSR shall comprise of one
Anchor Shackle, one Horn holder Ball eye, one line side arcing horn, one yoke plate,
corona control ring and two envelope type suspension clamps as per enclosed
drawing.
6.08.4 Single Tension String Hardware Fittings:
Single tension string Hardware shall comprise of one `D’ Shackle, one Ball
Link, one Forged Steel Socket, Socket Clevis Horn holder, one line side Arcing Horn
and one Tension Clamp of compression type having before and after compression
dimensions strictly as shown in Clause 7.10 below.
6.08.5 Double Tension String Hardware Fittings:
The double tension string Hardware shall comprise of two Anchor shackle, one
chain link one top yoke plate, two ball clevis, two socket clevis, one bottom yoke
plate, one arcing horn, two socket clevis, two clevis eye and two compression type
dead-end Clamps having `before and after compression’ dimensions strictly as
shown in Clause 7.10 below.
6.09 GROUNDWIRE ASSEMBLIES:
6.09.1 Ground Wire Suspension Assembly With Preformed Armour Rods:

This shall comprise of envelope type Suspension Clamp of heat-treated
malleable iron, one Chain Link and one ‘D’ Shackle. The entire assembly shall be hot
Volume-V (Part-2)
dip galvanized complete with minor accessories. The breaking strength of all the
Hardware items of the assembly shall not be less than 7000 kgs. The complete
assembly of suspension clamp shall be guaranteed for slip strength of not less than
15 KN & not more than 19 KN. The strength of the Ground wire has been specified
in Clause 7.04.01. The suspension assembly shall be supplied with armour rod for
groundwire.
6.09.2 Ground Wire Tension Assembly:
The Ground wire tension assembly shall have minimum breaking strength
equal to that of the Ground Wire. The slipping strength of the Compression Clamp
shall not be less than 95% of the breaking strength of Ground Wire. The Ground
wire tension assemblies shall be of two types as under: -
The strain assembly of the Ground wire shall comprise of compression type
dead end Clamp and two `D’ Shackles complete with minor accessories such as
pins, bolts & nuts etc. Strain assembly shall be hot dip galvanized and made
inherently resistant to the atmosphere corrosion. The dead end Clamp of the
assembly shall be of compression type. The tension clamp shall be attached to the
horizontal strain plate of the tower body by means of a “D” shackle. “D” shackle
shall be suitable for attaching the tension clamp to strain plate of towers with a hole
of 21.5 mm diameter. The tension clamp body shall be made out of steel of 304 L
grade or equivalent with Brinnel Hardness not exceeding 200. The complete
assembly shall also include one 12.5mm dia, 45 mm long HRH MS Bolt hot dip
galvanized with nuts and lock washers for attaching copper earth bond. A detailed
drawing giving dimensional details of the complete assembly shall accompany the
tender. After compression, dimensions of the joint shall be as indicated in Clause
4.10 below.
6.10 BEFORE AND AFTER COMPRESSION DIMENSIONS OF COMPRESSION TYPE DEAD-
END CLAMPS FOR CONDUCTOR AND GROUND WIRE
Dimension Dimension Length of Length of
before after sleeve sleeve after
compressioncompression before compression
Sr. (Rod cross (Flat to flat compression
Particular
No. section) distance of
hexagon)
G/ W Moose G/ W Moose G/ W Moose G/ W Moose
A Aluminium clamp
a Inner dimension - 34 -
(mm)
b Outer dimension (mm) - 54 - 46 - 735 - 785
B Steel clamp
a Inner dimension 11.5 11.1 -
(mm)
b Outer dimension (mm) 21 21 17.5 17.5 230 250 262 285
6.11 DETAILS OF COMPONENTS OF HARDWARE FITTINGS:

6.11.1Suspension Assembly for twin Moose:
a) The suspension assembly suitable for twin ACSR “Moose Conductor for 400KV
Lines shall include two armour-grip suspension clamps except for pilot insulator
string for which two suitable Envelope type suspension clamps shall be used.
b) The suspension clamp alongwith standard preformed armour rods set shall be
designed to have maximum mobility in any direction and minimum moment of

Volume-V (Part-2)
inertia so as to have minimum stress on the conductor in the case of oscillation of

the same.
c) The suspension clamp alongwith standard preformed armour rods shall have slip
strength between 20 to 29KN.
d) The suspension assembly shall be smooth without any cuts, grooves, abrasions,
projections, ridges or excrescence, which might damage the conductor.
6.11.2Armour Grip Suspension Clamp (AGS):
(a) AGS fitting shall consist of 2 Neoprene Halves, a set of Helical rods made of
Aluminium alloy, two Aluminium halves casting having inner profile matching with
the profile of the Armour rod cage and jointed by supporting strap made of
Aluminium alloy.
(b) The Bidder should give complete data on the reduction of the dynamic stresses of
the Conductor at the point of AGS support compared to that of bare clamp used
with preformed types of Armour rods.
(c) The Bidder will be required to prove the comparative performance in regard to
the dynamic flexural stress pattern on the vibrating Conductor on the tensioned
span with actual tests on the AGS unit compared to the normal bare clamp with
Armour rods. Suitable curves should be furnished along with the bid for the same
and also actual reports on the stress/ strain determinations. The Bidder should
give the guaranteed value of the power loss of the AGS units offered by them
supported by a test certificate of any reputed laboratory of the country. Suitable
curves should be furnished along with the bid for the power loss due to AGS unit
as well as with the conventional envelope type of Suspension Clamps.
(d) The housing supports and housing straps should provide positive stop closure.
AGS unit should have low rotational inertia, strut action of the Armour Cage,
resilient cushioning of the neoprene insert, immunity from high compressive and
flexural stress and wide area support. Manufacturer is required to guarantee
minimum fatigue life of the AGS units and this would be established under actual
tests on tensioned Conductor span. The manufacturer is required to guarantee
minimum 40 years life of the complete AGS units including Neoprene cushioning
and this should be established under actual test on a tensioned Conductor span.
(e) The rubber used with AGS unit must be capable of withstanding desired long out-
door performance including the variation of temperature from 0°C to 75°C. The
Bidder will have to provide certificate from reputed manufacturers that the rubber
being supplied by them is suitable for AGS fitting and must have tensile strength
of 2000 PSI and minimum ultimate elongation 300%.
(f) The helical retaining rods required for AGS assembly shall be made of Aluminium
alloy of HE 20 grade as per IS-6051/1970 or equivalent International Standard
duly heat treated and shall be suitable to wrap a desired size of Conductor. The
tensile strength of the retaining rod material should not be less than 50,000 PSI
and the electrical conductivity should not be less than 40% (IACS). The minimum
slipping strength of the complete fitting shall not be less than 15% and more
than 20% of the UTS of the cable on which it is to be used. The Clamp shall be in
2 parts made of Aluminium and will have inner profile matching with the profile of
Armour rod. This Clamp should be made by drop forging process. AGS assembly
should be provided with the forged steel socket eye to match with the suspension
string and should have UTS not less than 7,000 kgs.
IT IS ESSENTIAL FOR THE MANUFACTURER TO HAVE SUITABLE HEAT

TREATMENT FACILITIES FOR ALUMINIUM ALLOY WIRES IN THE ARMOUR GRIP
SUSPENSION UNITS. FORMED ROD BASED ITEMS WILL NOT BE ACCEPTABLE FROM
MANUFACTURERS WHO DO NOT HAVE NECESSARY TECHNOLOGY FOR DEVELOPMENT

Volume-V (Part-2)
OF ADEQUATE RESILIENCE, ELONGATION UTS AND TWIST TEST FACILITIES BACKED

WITH PROPER HEAT TREATMENT SYSTEMS.
6.11.3AGS Preformed Armour Rods:
(a) The AGS Preformed Armour rods set suitable for ACSR Moose conductor shall be
used to minimize the stress developed in a conductor due to different static and
dynamic loads because of vibration due to wind, slipping of conductor from
suspension clamp as a result of unbalance conductor tension in adjacent span
and broken wire condition. It shall be made of Aluminium alloy of HE 20 grade as
per IS-6051/1970 duly heat-treated. The aluminium alloy wires (pre heat
treated) for manufacturing of Armour rods can also be used, however Bidder
should submit the test certificates in support of their claim for using pre heat-
treated wires. It shall also withstand power arcs, chafing and abrasion from
suspension clamp and localized heating effects due to resistance losses of the
conductor.
(b) The pitch length of the rods shall be determined by the supplier but shall be less
than that of the outer layer of ACSR conductor and the same shall be accurately
controlled to maintain uniformity and consistently reproducible characteristics
wholly independent of the skill of lineman.
(c) The preformed armour rod sets shall have right hand lay and the inside diameter
of the helices shall be less than the outside diameter of the conductor to grip the
same tightly. The surface of the armour rod when fitted on the conductor shall
be smooth and free from projections, cuts and abrasions etc.
(d) The length of each rod shall be as per drawing enclosed. The tolerance in length
of each rod shall be +/-25mm. The tolerance in length of the rods in completed
sets should be within 13 mm between the longest and shortest rod. The ends of
the armour rod shall be parrot billed.
(e) The number of armour rods in each set shall be 11/12. The each rod shall be
marked in the middle with paint for easy applications on the line.
(f) The armour rod shall not loose their resilience even after five applications. The
conductivity of each rod of the set shall not be less than 40% of the conductivity
of International Annealed Copper Standard (IACS). The minimum tensile strength
of armour rod should be 35 kg per sq.mm.
6.11.4Strain Clamp:
(a) The Strain Clamp shall be of the compression type for the specified size of
Conductor for 400KV lines. The outer sleeve of the Compression Clamp and
Jumper Terminal shall be of EC grade Aluminium 99.5% pure tube formed by
extrusion process and the inner sleeves shall be of galvanized steel. The angle of
jumper terminal to be mounted should be 30 deg. with respect to the vertical
line. The Compression Clamp shall have slipping strength not less than 95% of
the ultimate breaking strength of Conductor with which it is to be used. The
compression dead end clamp for transmission line shall be manufactured out of
extruded Aluminium.
(b) The resistance of the clamp when compressed on the conductor shall not be more
than 75% of the resistance of equivalent length of conductor. Die compression
line shall be clearly marked on each dead-end assembly designed for continuous
die compression and shall bear the words “COMPRESS FIRST” suitably inscribed
near the point on each assembly where the compression begins. It shall bear
identification marks “COMPRESSION ZONE” and “NON COMPRESSION ZONE”
distinctly with arrow marks showing the direction of compressions and knurling
marks showing the ends of the Zones. Tapered aluminium filler plugs shall also
be provided at the line of demarcation between Compression and Non-
compression zone. The letters, numbers and other marking on the finished clamp
shall be distinct and legible.

Volume-V (Part-2)
6.11.5Socket Eye & Ball Clevis:

The Socket Eye and Ball Clevis be made of forged steel as per the drawing
enclosed.
6.11.6U Clevis:
These shall be made of forged steel complete with galvanised steel rivets
washer and Phosphorus Bronze/Stainless Steel pins.
6.11.7Ball Fittings:
These shall be made of forged steel in one piece. They shall be normalized to
achieve the minimum breaking strength specified in the respective drawings. Before
galvanising of ball fittings, all die fleshing on the shank and on the bearing surface
of the ball shall be carefully removed without reducing the dimension below the
requirements. The dimension of the ball & socket shall be 20mm designation in
accordance with standard dimensions stated in IS:2486 (Part-II).
6.11.8Dimensions & Tolerances:
(a) The dimensions and tolerances of pin balls and socket ends shall conform to IS
2486 Part-II/IEC-120 and shall be checked by the gauge therein after
galvanizing.
(b) The pin balls shall be checked with the applicable “GO” gauges in at least two
directions, one of which shall be across the line of die flashing and the other 90
deg. to this line. “NO GO” gauges shall not pass in any direction.
(c) The bearing surfaces of balls and machined sockets, before galvanizing shall not
have surface roughness more than 250 micro inches.
(d) The bearing surface of socket ends shall be uniform about the entire
circumference without depressions or high spots. The internal contour of the
socket ends shall be concentric with the axis of fittings. The axis of the bearing
surface of socket ends shall be coaxial with the axis of fittings with no appreciable
tilting.
6.11.9Socket Fittings:
Socket fittings shall be made of clause IV steel as per IS:2004 or steel of equivalent
grade and shall be forged in one piece. They shall be normalized to achieve the
minimum breaking strength specified on the respective drawings.
6.11.10 Security clip for Socket fittings:
(a) Socket fittings shall be provided with R-shaped security clip in accordance with
IS:2486 (Part-III) to provide positive locking against unintentional
disengagement of socket from the ball of the insulator. The security clip shall be
humped to maintain the clip in the locked position and shall have both prongs
spread to prevent complete withdrawal from the socket. The clip end shall not
project outside the recess of socket when the clip is in locked position.
(b) The hole for the security clip shall be on the side of the socket opposite to the
socket opening. The hole for the clip shall be counter sunk. The clip eye shall be
of such design that the same may be engaged by a hotline clip puller to provide
for disengagement under energized conditions.
(c) The force required to pull the clip to its unlocked position shall not be less than
50 N or more than 500N.
(d) The security clip shall be made of stainless steel of type AISI 302 or 304 or
phosphor bronze as per IS:7814.
6.11.11 Clevis-Eye:
These shall be forged steel of malleable cast iron and shall be complete with
galvanised pin with flat washer and split pin of Phosphorus Bronze/Stainless Steel.
Volume-V (Part-2)
6.11.12 Yoke Plate:

(a) The yoke plates/link plate shall be made of mild steel plate as per IS:2062 or
equivalent standards. Shearing/cutting of the plates shall be clean without drawn
or ragged edges. If the plates are flame cut, mechanical guides shall be used. It
shall be ensured that the grain flow of the yoke plate shall be in the direction of
the tensile load.
(b) Holes shall be cylindrical clean cut and perpendicular to the plane of the material.
The periphery of the holes shall be free from burrs.
(c) All the corners and edges should be rounded off with a radius of at least 3mm.
(d) Design calculation is for bearing and tensile strength for deciding the dimensions
of yoke plate shall be furnished by the Bidder. The holes provided for bolts in the
yoke plate should satisfy shear edge condition as per IS:800.
6.11.13 Corona Control Ring :
(a) The corona control ring shall be provided with hardware fittings and shall be of
such design that it should cover at-least one disc insulator in disc insulator
strings so that they will reduce the voltage across the insulator units. It shall also
improve corona and radio interference performance of the complete insulator
string alongwith hardware fittings.
(b) The corona control rings shall conform to the specification drawings. The same
shall be made of aluminium alloy tube of minimum 2.5mm wall thickness of type
6063 or equivalent. The same shall be heat treated to maintain consistency in
material properties during service.
(c) Welding of corona control ring shall be done with Argon welding. The welded
locations shall be suitably grinded and shall not allow penetration of water inside
the tube during service. The mechanical strength of welded joint shall not be less
than 20kN.
(d) The corona control ring shall be buffed and have a brushed satin finish. No
blemish shall be seen or felt while rubbing a hand over the surface.
6.11.14 Sag Adjustment Device:
(a) The sag adjustment devices to be provided with double tension hardware fittings
shall be of three plate type. The sag adjustment device shall be provided with a
safety locking arrangement.
(b) Sag adjuster plates shall be made from high qualify mild steel plate as per
IS:2062. The grain flow shall not be in a direction transverse to the tensile load.
Cutting/shearing and drilling of holes shall be similar to those for yoke plate
mentioned under clause 10.13.2 & 10.13.4.
(c) The maximum length of the sag adjustment plate from the connecting part of the
rest of the hardware fittings shall be 520 mm. The details of the minimum and
maximum adjustment possible and the steps of adjustment shall be clearly
indicated in the drawing. An adjustment of 150mm maximum at the interval of
6mm shall be possible with the sag adjustment plate.
6.12 IMPORTANT CONDITIONS:
6.12.1 All Hardware items shall be complete with minor items such as security clip, bolts,
nuts, washer, split pins and inners etc.
6.12.2 Enclosed drawings show the attachment proposed to be fitted on the towers. The
Bidder shall be responsible for satisfying him that the Insulator fittings offered are
entirely suitable for the proposed attachments and for the sizes of the Conductor
specified.
6.12.3 All ferrous fittings (except those specified otherwise) shall be hot dip galvanized,
after all machining and fitting has been completed, in accordance with relevant
Volume-V (Part-2)
Indian Standard. All Hardware items (other than clamps) and those specified
otherwise should be made of Drop Forged Steel. Socket items in forged steel must
be forged. All forgings supplied should be stress relieved and this treatment should
be done at the Bidder works. Forgings, which are not stress relieved, will not be
acceptable. The items like Yoke Plate, Arcing Horn, Bolts and Nuts shall be of mild
steel and rest of the items shall be of forged steel.
6.12.4 All Bolts, Nuts and Screw heads shall have only wide worth standard thread and of
sizes indicated in the enclosed drawing. Bolts head and Nuts shall be hexagonal.
Where required, nuts shall be locked in approved manner. The thread in Nuts shall
be over tapped after galvanizing and shall be cut before galvanizing. The threads
shall not be under cut. The Nuts should be tapped such that they are fit on the bolt
threads i.e. these should not have loose fitting.
6.13 LENGTH OF STRINGS:
6.13.1 The clearance to the tower steel parts under service conditions of Insulator have
been decided on the basis of length of string that the overall length of the 23 Disc for
400KV line will not exceed the length as indicated in the attached drawings. The
dimension of the Disc for Ball and Socket type will be 280mm x145mm for 11500
kgs EMS to be used with suspension strings.
6.13.2 In case of 400kV tension strings, 24 Disc insulators of 16500 kg EMS of size 280mm
(dia) x 170mm (height) will be used.
6.14 GENERAL TECHNICAL REQUIREMENT FOR ACCESSORIES
Details of Accessories:
i. The Conductor Accessories shall be suitable for ACSR Moose Conductor as per
technical parameters furnished in Clause 7.04.
ii. The Ground wire accessories shall be suitable for Ground wire as per technical
parameters furnished in Clause 7.04.
The technical requirements of the individual Accessories are as under:
6.14.1MID SPAN JOINTS AND REPAIR SLEEVES:

(a) The Mid Span Joints for Conductor & Ground wire shall be compression type.
(b) The Conductor Mid Span Joints shall comprise of Aluminium and Steel Sleeves.
The Ground wire Mid Span Joints and Steel Sleeves of Conductor Mid Span Joints
shall be Hot dip Galvanized. Sleeves shall be of circular shape suitable for
compression into hexagonal shape. The detailed drawing showing the length of
Sleeves, inner and outer cross sectional dimension, before compression for
Aluminium corresponding dimensions of hexagon after compression for Aluminium
and Steel Sleeve shall be indicated. The Aluminium Sleeve shall be of extruded
Aluminium. The material of the Steel Sleeve shall be specified.
(c) The Repair Sleeve of Conductor shall be in two halves preferably of same shape,
and this should be of extruded Aluminium. . The sleeve shall be manufactured
from 99.5% pure aluminium and shall have a smooth surface The Repair Sleeve
for Ground wire shall be single piece and Hot dip Galvanized. Its material shall be
specified. The Repair Sleeves shall be of circular shape suitable for compression
into hexagonal shape.
(d) The steel and Aluminium Sleeves for Mid Span Joints as well as Aluminium Repair
Sleeves and Steel Repair Sleeves shall have their outer dia tapered towards the
two ends. Also the inside of the Sleeves shall be well rounded off, so that there is
no sharp edge, which can cut the strands. A dimensional drawing must be
enclosed with the bid.

Volume-V (Part-2)
(e) The compression type of Joints and Repair Sleeves shall be circular shape suitable
for compression into hexagonal shape. The length of Sleeves before compression
& cross-sectional dimensions after compression and the cross sectional dimensions
between the flats of the opposite sides of the hexagon shall be as under:-
Dimension Dimension Length of Length of

before after sleeve sleeve after
compressioncompression before compression
Sr. (Rod cross (Flat to flat compression
Particular
No. section) distance of
hexagon)
G/ W Moose G/ W Moose G/ W Moose G/ W Moose
A Aluminium Sleeves
a Inner dimension - 34 -
(mm)
b Outer dimension (mm) - 54 - 46 - 735 - 785
B Steel Sleeves
a Inner dimension 11.5 11.1 -
(mm)
b Outer dimension (mm) 21 21 17.5 17.5 230 250 262 285
2 REPAIR SLEEVES
Outer dimension (mm) 20.8 54 17.5 46 254 305 280 330
(f) Other dimensions are indicated in the enclosed drawing. The Bidder shall indicate
the elongation of the above sleeves after compression.
(g) The Joints and Repair Sleeves shall conform to IS:2121/1981 or equivalent
(h) The conductor compressed with mid span joint or with repair sleeve shall not
permit slipping of, damage to or failure of complete conductor or any part thereof
at a load of not less than 95% of the ultimate tensile strength of the conductor.
(i) The electrical resistance of the joint/repaired portion of the conductor shall not
exceed 75% of the measured resistance of equivalent length of conductor.
6.14.24R-VIBRATION DAMPERS FOR MOOSE ACSR:
(a) Only Vibration Dampers having 4-resonance frequency characteristic commonly
called 4R Dampers shall be offered. The Damper shall eliminate fatigue on the
Conductor due to vibration and damp-out the vibrations effectively, so that no
damage due to vibration is caused to Conductor and string.
(b) The Dampers are to be used at all tension locations and suspension locations. One
or more Dampers are proposed to be used on tension/suspension locations
depending upon the span. The Damper shall be such as to effectively damp out
the vibration on the conductor, so that the dynamic strain at the suspension point
with conventional type of Suspension Clamp ‘U’ bolt and keeper pieces, shall not
exceed 150 micro strains. The manufacturer shall recommend the number of
Dampers required to effectively damp out the vibration of the Conductor, so that
the dynamic strain at the suspension point with conventional Suspension type
Clamp shall not exceed 150 micro strains.
(c) The requirement indicated in Price Schedule is based on use of two Vibration
Dampers per Conductor per span. However, final requirement will depend upon
Manufacturer’s recommendations duly supported by literature. Manufacturer shall

Volume-V (Part-2)
also recommend the number of Dampers required to effectively damp out

Conductor vibration for different values of span lengths and the distance for
fixation. While working out Damper Characteristics, it may be kept in view that on
suspension locations, preformed Armour rods are also to be fitted on the
conductor. Manufacturer shall give full details of the damper characteristics and
energy dissipation curves of the Damper and shall also guarantee their
effectiveness for damping design.
(d) The messenger cable shall be made of high strength steel strands of spring steel
with a minimum strength of 136 Kg/sq. mm and preformed in order to prevent
subsequent dropping of weights in service. The Manufacturer shall indicate full
technical particulars of the messenger cable. The keeper pieces shall have proper
curvature and edges be rounded off so that it shall have proper grip over the
conductor without any damage to conductor strands. Clamping bolts shall be
provided with self-locking nuts designed to prevent corroding of the threads or
loosening during service ensuring that no slippage occurs up to specified
longitudinal force on clamp along the conductor. All ferrous parts including the
messenger cable shall be effectively sealed to prevent corrosion.
(e) The collar for fixing the bolt shall be designed in such a way that sufficient space
is available for tightening the bolt through spanner. Further bolt length be
maintained in such a way that it should not come out completely while affixing the
clamp on Conductor.
(f) The Bidder shall specify the material used for the Damper weight and shall confirm
and explain, how constant design characteristics will be maintained during
production. Fixing of the masses to the messenger cable shall be done by pressing
Aluminium Sleeves at each end of the messenger cable under pressure. Each end
should be sealed properly so as to achieve prefect joint. The molten metal filling
method for attachment of messenger cable to counter weight is not acceptable.
The Bidder should specifically bring out the procedure for attachment in the bid.
(g) The Dampers shall meet the test requirements specified hereunder:
The effectiveness of the Vibration Dampers shall be to reduce the amplitude of
vibration, when tested for span of 400 meters for Moose ACSR, tension taken as
25% of ultimate tensile strength in such a order that it limits the dynamic strain
in the Conductor below 150 micro strains for 0 to 15 miles per hour wind
condition in general and 2 to 10 miles per hour wind condition in particular
condition, conforming to as close as possible to the optimum damping force
requirement which the Bidder can predict and furnish for the ranges of wind
velocity and the conductor tension.
(h) The Bidder shall furnish the recommended spacing and the basis including wind
velocity range for selecting the spacing. The results of the analysis shall account
for the following:
i. Prediction of (a) Amplitude (b) Frequency and (c) Vibration energy levels of
Aeolian vibration on Moose ACSR for spans of 100m to 1100m.
ii. Test results for various frequency response characteristics of Vibration
Dampers such as vibration amplitude and phase angle including power
dissipation measured from its hysteretic loops.
(i) Maximum residual vibration must be of such an order that the strain level does
not exceed 150 micro strains.
(j) The Vibration Dampers and their attachments shall have smooth surface so that
corona and radio interference voltage levels are within specified limits.
(k) All Ferrous parts shall be fully galvanized.
(l) The Vibration Damper shall be capable of being installed and removed from
energized line by means of hot line tools without completely separating

Volume-V (Part-2)
components. The Damper Assembly shall be electrically conductive. The

transmission line details are as under:-
S.N Description Technical Particulars

1 Configuration Twin ACSR Moose
2 Span length in meters:
i. Ruling design span 400m
ii. Maximum span 1100m
iii. Minimum span 100m
3 Tensile load in Kg:
i. At minimum temp. of 0o C and still air 4145 Kg.
o
ii. At every day temp. of 32 C 3614 Kg.
iii. At 0o C and 2/3rd full wind 4477 Kg.
4 Nature of terrain Partly hilly, partly flat with cultivated

fields
5 Armour rods/AGS clamp AGS clamps
6 Maximum wind load 45 Kg/m2 .
7 Max permissible dynamic strains 150 micro strains
The Bidder shall recommend the number of vibration dampers of the type offered
and their points of fixation for spans ranging from 100M to 1100M in steps of
50M .
(m) The other important features of vibration dampers as regards to materials
test, etc., are as under: -
Material:
i. Dampers - As per IS-9708/1993 or equivalent International Standard.
ii. Clamp - Aluminium alloy
iii. Messenger cable - High strength steel wire with a strength (kg/sq. mm) not less than
the strength of steel core of power Conductor/Ground Wire.
iv. Weight - Cast Iron (Hot dip Galvanized)
Galvanising:
i. Spring washers - Electro Galvanized.

ii. Other Ferrous parts- Hot Dip Galvanized.
iii. Casting - As per IS:729-1961 or equivalent International Standard.
iv. Wires - As per IS:326-1968 or equivalent International Standard.
v. Bolts & Nuts - As per IS:5358-1969 or equivalent International Standard.
Slip strength of Clamp:
The damper clamp shall be casted over the messenger cable and offer sufficient
and permanent grip on it. The messenger cable shall not slip out of the grip at a
load less than the mass pull-off value of the damper. The damper masses made
of material other-than zinc alloy shall be fixed to the messenger cable in a
suitable manner in order to avoid excessive stress concentration on the
messenger cables which shall cause premature fatigue failure of the same. The
messenger cable ends shall be suitably and effectively sealed to prevent
corrosion. The damper mass made of zinc alloy shall be casted over the

Volume-V (Part-2)
messenger cable and have sufficient and permanent grip on the messenger cable
under all service conditions
Maximum permissible dynamic strain on - 150 micro strains.
the Conductor with the Damper
Minimum number of cycles for fatigue - 10 millions Performances.
Amplitude for fatigue test - ±1 mm at the highest Resonant
frequency.
Radio interference voltage at 266 KV (rms) - Less than 500 microvolts.
phase to ground.
6.14.34R VIBRATION DAMPERS FOR 7/3.66MM 95 Kg PER MM2 QUALITY GROUND

WIRE:
a) The design and general particulars of Vibration Damper for Ground wire shall be
the same as described for Dampers for Conductor, Preformed Armour Rods will
be used at Ground wire suspension locations. The dynamic strain at suspension
point shall not exceed 150 micro strains.
b) All the test as described for Vibration Dampers for Conductor shall be carried out
except for Magnetic Power Loss Test.
6.14.4LINE SPACERS AND JUMPER SPACERS :

a) Line spacers shall be used for maintaining the intra phase spacing of 450mm
between conductors of each bundle under all normal working conditions. The
supplier shall indicate the number of spacers required per phase per span, for
spans ranging from 100M to 1100M with the longitudinal spacing recommended
for the spacers offered by them for giving the best possible performance. The
supplier shall also furnish all the relevant technical documents in support of their
placement chart alongwith the bid.
b) Jumpers at tension points shall also be fitted with line spacers so as to limit the
length of free conductor to 3.65M and to maintain the intra phase spacing of
450mm. The supplier may quote for rigid line spacer for the jumper. Spacers for
jumpers shall meet all the requirements of spacers used along the line except on
its performance for vibration and movement. Spacers requiring retaining rods
shall not be quoted for jumpers.
c) The spacer offered by the supplier shall satisfy the following requirements:-
Spacers shall restore normal spacing of the sub-conductor after displacement due
to wind, electromagnetic and electrostatic forces under all operating conditions
including the specified short circuit level without permanent deformation/damage
either to the conductor or the assemblies themselves. They shall maintain as
uniform firm grip on the conductors. They shall also have long life without fatigue
or wear. The clamp shall grip the conductor efficiently to prevent the tortional
movement of conductor. The clamping shall be designed to compensate for any
reduction due to conductor creep.
d) They shall preferably be of one piece construction and shall not have separate
small components. All fasteners shall be captive and need not be removed in
order to fit the spacer to the sub-conductor.
e) For spacers requiring retaining rods, the retaining rods shall be designed for the
specified conductor size. The rods shall be made of high strength special
aluminium alloy of type 6061 or equivalent material having minimum tensile
strength of 35 Kg/sq.mm. The ends of retaining rods shall be properly terminated
(parrot billed/ball end). The retaining rods (Armour rods) shall be of preformed
type. The rods shall be heat-treated to give proper resilience and retain the same
during service. The dimensions shall be generally as follows:-

Volume-V (Part-2)
i. Length of each rod: About 1086 ± 15mm

ii. Diameter of each rod: 7.87 ± 0.1mm
The conductivity of the rods shall not be less than 40% IACS (International
Annealed Copper Standards). Direction of lay shall preferably be of right
hand. Number of rods in the set shall be about 8. The center line of the rod
shall be suitably marked for ease of installation.
f) Where elastomer surfaced clamp grooves are used, the elastomer shall be firmly
fixed to the clamp.
g) Any nut used, shall be locked in an approved manner against loosening caused
by vibrations. The ends of bolts and nuts shall be properly rounded off for
specified corona performance.
h) Nut cracker, hinged open and or boltless type clamps are acceptable provided
adequate grip can be maintained on the conductor. Designs requiring clamping
bolt cap screw on lock pin shall utilize a single captive fastener.
i) Clamp with cap shall be designed to prevent its cap from slipping out of position
when being tightened.
j) The clamp grooves shall be in uniform contact with the conductor over the entire
clamping surface, except for rounded edges. The groove of the clamp body and
clamp cap shall be smooth and free from projections, dirt or other material,
which may cause damage to the conductor when the clamp is installed.
k) Universal type bolted clamps, covering a range of conductor sizes will not be
permitted.
l) No rubbing, other than that of the conductor clamp hinges or clamp swing bolts
shall take place between any part of the spacer. All joints shall have a flexible
medium such that there is no relative slip between them.
m) The spacers shall be flexible enough so as to avoid distortion or damage to the
conductor or to themselves. Rigid spacers are acceptable only for jumpers.
n) The spacer shall not damage or chafe the conductor in any way which might
affect its mechanical strength or corona performance. The spacer clamp shall not
damage the conductor under any condition.
o) The spacer assembly shall not have any projection, cut abrasion etc., or
chattering part which might cause corona.
p) The material used in the spacer shall be corrosion resistant. As far as possible,
the spacer shall be made of aluminium alloy of the type 6061. If iron or steel
parts are used, they shall be galvanized conforming to relevant Indian Standard
and shall have magnetic power loss of not more than one watt for, 600 amps
50Hz alternating current.
q) Elastomer, if used, shall be resistant to the effects of ozone, ultraviolet radiation
and other atmospheric contaminants likely to be encountered in service, at
temperatures upto 75ºC. It shall have good fatigue resistant characteristics. The
physical properties of the elastomer shall be indicated in the offer. These shall be
discussed and finalized with the successful supplier at the time of quality plan
approval.
r) The spacer assembly shall have electrical continuity. The electrical resistance
between the sub-conductor across the assembly. In case of spacer having
elastomer clamp grooves, shall lie between 0.1 and 0.01 mega ohm in order to
ensure satisfactory electrical performance under service conditions.
s) The spacer assembly shall be easy in installation/removal and reinstallation
without any damage.

Volume-V (Part-2)
t) The spacer assembly shall be capable of being installed and removed from the
energized line by means of hot line techniques.
i. The offer shall include placement charts recommending number of spacers
per phase per span and the sub span lengths to be maintained between the
spacers while installing on the twin bundle conductors.
ii. The placement of spacers shall be in such a way that adjacent sub spans are
sufficiently detuned and the critical wind velocity of each sub span shall be
kept more than 60Km/hr. The placement shall ensure bundle stability under
all operating conditions.
iii. The placement chart shall be provided for spans ranging from 100m to
1100m.
iv. The supplier shall also furnish all the relevant technical documents in support
of their placement charts alongwith the bid.
6.14.5FLEXIBLE COPPER EARTH BONDS:

The flexible copper earthing bond shall be made of flexible copper cable of size
37/7/0.417 with 9.81mm dia and copper area equivalent to 34 sq.mm. The length of
copper cable shall not be less than 500mm. Two steel connecting lugs shall be press
jointed to the either ends of the flexible copper cable. One end of the lug shall have
hole of 17.5mm size and another of 14.5mm. The complete assembly shall also
include one 16mm dia 40mm long HRH M.S.Bolt hot dip galvanized with nut and lock
washer.
6.14.6T-CONNECTOR
T-Connector of compression type shall be used for jumper connection at
transposition tower . It shall be manufactured out of 99.5% pure aluminium and shall
be strong enough to withstand normal working loads. The T-connector shall have a
resistivity across jumper less than 75% resistivity of equivalent length of conductor.
The T-connector shall not permit slipping off, damage to or failure of complete
conductor . The welded portions shall be designed for 30 kN axial tensile load. Leg
sleeve of T-connector should be kept at an angle of 15 deg. from vertical and
horizontal plane of the conductor in order to minimise jumper pull at the welded
portion . The dimensions and dimensional tolerances of T-connector shall be as per
Standard Technical Particulars.
6.14.7HANGER SHACKLE:
This shall comprise of one anchor shackle, one long bolt with washer and split pin.
The breaking strength of the hanger shackle assembly shall not be less than 11500
kg.
6.14.8TECHNICAL PARTICULARS FOR “CLAMPS” & “SPACERS”

a) All the current carrying parts shall be designed and manufactured to have
minimum contact resistance. The maximum tension per conductor is expected to
be 2000 Kgs. There shall not be any sharp edges which may lead to accumulation
of charge & electrical breakdown. All corners/ edges shall be rounded.
b) The clamps shall be liberally designed and certain minimum contact surface shall
be provided.
c) The clamps and fittings shall be designed so that insulators shall not be subject to
any abnormal stresses due to thermal changes in conductor.

Volume-V (Part-2)
d) All the clamps & fittings shall enable the connection to be as short as possible.
Wherever possible the clamps shall be two separate halves. No “U” bolts shall be
used. All components of like design shall be inter-changeable
e) Spacer shall prevent clashing of the “T” clamps and minimize effects of short
circuit forces between bundle conductors on structures. They shall be capable of
withstanding electro-magnetic and electrostatic forces during short circuit without
deformation or damage to the conductor or spacer.
f) Spacers shall permit the relative axial and torsional movement of sub-conductors
and maintain their correct separation without lubrication or maintenance.
g) All nuts, bolts & washers shall be made of Hot dip galvanized Mild Steel
conforming to relevant ISS only.
h) The clamp in all respect shall incorporate highest quality of modern engineering
design and workmanship. The specification is merely for the guidance of the
Bidder as has been clearly stated earlier and it is not the intention to specify the
details of design and workmanship. The clamps shall be designed and
manufactured in accordance with the Bidder’s standard practices, when such
practices do not conflict with this specification.
i) The materials offered shall be complete with all components and accessories which
are necessary or useful for their satisfactory performance and efficient
maintenance. Such parts shall be deemed to be within the scope of this
specification whether specifically included or not.
j) The design should be such that adequate clamping pressure is obtained with the
tightening of the nuts and the pressure should be maintained throughout the
service of the connector. In order to provide for creep of Aluminium under
pressure, it is essential that only Belleville washers are used. This should be
specifically confirmed and should also indicate tightening torque required.
k) All clamps shall be suitable to carry safely the maximum allowable current in the
associated conductor and to withstand the maximum loads occurring under
adverse circumstances and operating conditions. The maximum fault current is 40
KA rms for a period of 3 seconds. The temperature of the clamps and fittings shall
never exceed that of the associated conductor.
l) Fittings intended to connect two dissimilar metals shall be designed to avoid
harmful bimetallic corrosion under service condition, by way of provision of best
quality bimetallic strips.
m) The short circuit current shall be of the order of 40 KA for 3 seconds. The clamps
should be suitable to withstand the short circuit forces corresponding to this
current.
n) The design of clamps should be such that proper space for movement of normal
quality single head spanner during tightening is available. This is an important
requirement and should be confirmed by the Bidder.
6.14.9Materials:
The Clamps & Connectors/Spacers shall be made of materials listed below: -
a) For connecting ACSR conductor Aluminium alloy casting conforming to designation

A6 of IS:617.(Redesignation 4600)
b) Bolts, Nuts, plain washers and spring washers for above items shall be made of
hot dip galvanized Mild Steel conforming to relevant IS only.
c) The Bidder shall ensure that the Alloy used assures good stability and sound
casting by proper fluidity. Proper mechanical and physical strength characteristics
should be obtained corresponding to the standard requirements of the Alloy
specified.

Volume-V (Part-2)
d) The Bidders shall ensure that the Alloy used assures good stability and sound
casting by proper fluidity. Proper mechanical and physical strength characteristics
should be obtained corresponding to the standard requirements of the Alloy
specified.
e) The clamps bodies shall be made by gravity die-casting only and thereafter given
the appropriate heat treatment and precipitation treatment. Clamps bodies made
by sand casting shall not be accepted in any case.
6.15 CASTINGS:
All casting shall be free from blow holes, surface, Blisters and shall be rounded off.
6.16 CONSTRUCTIONAL DETAILS:

a) All sharp edges and corners shall be blurred and rounded off.
b) Thickness of the clamps shall not be less than 12mm.
c) Bolts and nuts shall have hexagonal heads and threads as per Indian Standard.
d) Flexible connectors, braids or laminated straps shall be made from tinned copper
strips or aluminium laminates depending upon the clamp.
e) Size of terminal / conductor for which the clamps is suitable shall be embossed on
each component of the clamp.
f) Casting should be such that adequate free space for placement and movement of
spanners for tightening of nuts is available.
6.17 BOLTS, NUTS & WASHERS:

These shall be as per Indian Standard and shall have tensile strength and elongation
as per grade 5.6. Further details are indicated in Section-5.
6.18 GALVANISING:
a) Hot dip galvanizing shall conform to Indian Standard specification IS-2633 or
equivalent International Standard. Galvanising shall be uniform, free from blisters,
and shall not peel off due to abrasion, Zinc coating shall be thick enough to
withstand 6 one minute dips in Copper Sulphate solution (precee test) for all
ferrous parts except for threaded portions which shall withstand at least 4 one
minute dips.
b) The zinc coating shall be perfectly adherent, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash rust,
stains, bulky white deposits and blisters. The zinc used for galvanising shall be Zinc
of any grade in IS: 209:1992 ingot (fourth revision) or IS:13229:1991.
6.18.1 The Bidder must emboss/engrave their name in each forged steel item and
Aluminium castings such as Ball Hook, Yoke Plate, Socket Clevis, Clevis Eye, Clevis-
Clevis, Anchor Shackle/D-Shackle, Chain Link, Suspension Clamps of AGS type,
Tension Clamps and Arcing Horns. This is very essential. If the Bidder will not agree
with this condition, their offer will be treated as non-responsive.
6.19 TESTS :
The following Type Tests, Stage Tests, Routine Tests and Acceptance Test shall be
carried out on power Conductor & Ground wire Hardware fittings & Accessories.
a) Type Tests
The material supplied shall be fully Type Tested as per this specification and the
Bidder shall furnish two sets of Type Test reports before taking up the supplies..
These tests must not have been conducted earlier than five years. For any change in
Volume-V (Part-2)
the design/type already Type Tested and the design/type offered against this
specification, the purchaser reserves the Rights to demand repetition of test without
any extra cost.
b) Stage Tests:
Stage Tests during manufacturing shall mean those test required to be carried out
during the process of manufacturing to ensure quality control such that last product is
of the designed quality conforming to the intent of this specification.
c) Routine Tests:
Routine Tests are those tests, which required to be carried out on each and every
finished product so as to check with requirements that are likely to vary during
production.
d) Acceptance Tests:
Acceptance Tests shall mean those tests, which required to be carried out on samples
taken from each lot offered for pre-despatch inspection for purposes of acceptance of
that lot.
e) Test Values:
guaranteed by the Bidder in the guaranteed technical particulars or the acceptance
value specified in this specification, the relevant Indian Standard or equivalent
f) Test Procedures And Sampling Norms:
The norms and procedure of sampling for the above tests shall be as per the relevant
Indian Standard or other internationally accepted Standards. This will be discussed
and mutually agreed to between the successful Bidder and Purchaser before
placement of order.
6.20 TYPE TESTS FOR HARDWARE FITTINGS
6.20.1 On the complete insulator string with hardware fittings
a. Power frequency voltage withstand and
flashover test with corona control grading BS:137 (Part-I)
ring under dry/wet condition.
b. Switching surge voltage withstand test
IEC:383
under wet condition.
c. Impulse voltage withstand test under dry
IEC:383
condition
d. Impulse voltage flashover test under dry
IEC:383
condition
e. Voltage distribution test

f. Corona and RIV test under dry condition. As per specification
g. Mechanical strength test for complete
As per specification
string
h. Vibration test
NOTE: For electrical tests, the insulator string shall be mounted on a
stimulated tower.
6.20.2 On Suspension Hardware fittings only.

Volume-V (Part-2)
a. Magnetic power loss test for suspension As per

b. Clamp bl
slip strength for AGS clamp specification
Clamp slip strength Vs torque test for suspension

c.
clamp
d. Test on neoprene As per specification
e. Ozone test.
f. Heat resistance test.
6.20.3 On Tension Hardware Fittings only
a. Electrical resistance test for dead end assembly.
b. Heating cycle test for dead end assembly IS:2486(Part-I)
c. Slip strength test for dead end assembly.
d. Mechanical strength test. As per specification
6.20.4 All the type tests given under clause no 7.20.1 above shall be conducted separately
on single/double suspension and tension insulator string alongwith hardware fittings.
6.20.5 The tests specified under clause no. 7.20.1 (e) & (f) (i.e. the voltage distribution test
and corona/RIV Dry test) shall also be conducted on single suspension pilot double
suspension and single tension insulator string alongwith hardware fittings.
6.20.6 The mechanical strength test given under clause no. 7.20.1 (g) above shall also be
conducted on single suspension pilot, double suspension and single tension insulator
string alongwith hardware fittings.
6.20.7 The magnetic power loss test specified under 7.20.2 (a) shall be conducted on single
suspension, single suspension pilot and double suspension assembly.
6.21 ACCEPTANCE TEST/SAMPLE TESTS:
6.21.1On both suspension and tension hardware fittings:
a. Visual Examination IS:2486 (Part-I)
b. Verification of dimensions IS:2486 (Part-I)
c. Galvanising test/Electroplating As per this specification.
d. Mechanical strength test of welded joint As per this specification.
Mechanical strength test for corona
e. BS:3288(Part-I)
control rings.
Test on locking devices for ball & socket
f. IEC:372(2)
coupling.
Mechanical strength test of each
g. components excluding corona control As per this specification.
ring and arcing horn.
6.21.2 On suspension Hardware fittings only:
Clamp slip strength vs torque test for
a.
suspension clamp.
As per this specification.
Shore hardness test of elastomer
b.
cushion for AG suspension clamp.
c. Bend test for armour rod set. IS:2121 (Part-I)

Volume-V (Part-2)
d. Re silence test for armour rods set.

e. Conductivity test for armour rods set
6.21.3 On tension hardware fittings only:
a. Slip strength test for dead end assembly IS:2486 (Part-I)
6.21.4 On Suspension hardware for groundwire
Mechanical strength test on each
d.
component
e. Galvanising test
f. Mechanical strength test of welded joint
6.21.5 On Tension hardware for groundwire:

d. Electrical resistance test.
6.21.6 Test during manufacture:

a. On all components as applicable.
Chemical analysis of zinc used for

b.
galvanizing
Chemical analysis, hardness test grain
c. size inclusion rating and magnetic
particle inspection for forgoing/castings.
Chemical analysis and proof load test
d.
fabricated hardware.
Tests on malleable castings forgings and
e.
6.22 TYPE TESTS FOR ACCESSORIES
6.22.1Flexible Copper Bond for Ground wire:

Slip strength test:
6.22.2Spacer/Rigid Spacer for power conductor.

i. Visual examination As per
ii. Dimensional verification. IS:2121
iii. Galvanising test this

Volume-V (Part-2)
Movement test (except for spacer for specification,

iv.
jumpers
IS:2633
v. Compressive and Tensile test
& IS:6745
vi. Clamp slip Test
vii. Clamp bolt torque test
viii. Assembly torque test
ix. Hardness test for neoprene
6.22.3Mid span compression joint for conductor & groundwire.
i. Slip strength test

ii. Electrical Resistance test
iii. Healing cycle test
As per IS 2121,2633 6745
iv. Corona Extinction voltage test dry.
v. Radio interference voltage test Dry.
vi. Galvanising test
6.22.4Repair Sleeve for conductor:

i. Electrical Resistance test.
ii Corona Extinction Voltage test. As per IS 2121
iii Radio Interference voltage test dry.
6.22.5Vibration Damper for conductor & groundwire

a. Chemical analysis of material
b. Dynamic Characteristic Test.
c. Vibration Analysis.
d. Clamp Slip test.
e. Fatigue Test.
f. Magnetic power loss test.
g. Corona extinction voltage test (Dry).
h. Radio interference voltage test (Dry).
i. Damper efficiency test.
NOTE: Tests mentioned at (f), (g) & (h) are not applicable to dampers for groundwire.
6.22.6Clamps
i. Tensile Test
ii. Resistance Test
iii. Temperature rise Test (As per IS:5561)
iv. Short time current Test
v. Dimensional Check
vi. Galvanising Test

Volume-V (Part-2)
6.23 ACCEPTANCE TEST

(A) FLEXIBLE COPPER BOND:
a. Visual examination IS:2121
b. Dimensional verification
(B) SPACERS/ RIGID SPACER FOR POWER CONDUCTOR:
a. Visual examination.
c. Galvanising Test.
d. Clamp slip test
e. Movement test (except for spacers for
f. jCompressive
) & Tensil test.
g. Clamp bolt torque test
h. Assembly torque test
i. Hardness test for neoprene
(C) Midspan Compression Joint for Power Conductor & Groundwire
iv. Hardness test.
Failing load test (test to be conducted after 24
v.
hours of compression).
(D) Repair Sleeves for Conductor.
(E) Vibration Damper for power conductor/ groundwire.
iv. Verification of resonance frequencies
v. Clamp slip test
vi. Clamp bolt torque test
vii. Strength of messenger cable.
viii. Mass pull off test.
(F) Clamps
i. Tensile Test
ii. Resistance Test
iii. Dimensional Check
iv. Galvanising Test

Volume-V (Part-2)
(G) Test during manufacture.

i. On all components as applicable.
ii. Chemical analysis of zinc used for galvanizing
Chemical analysis, hardness test grain size
iii. inclusion rating and magnetic particle
inspection for forgoing/castings.
iv. Chemical analysis and proof load test.
v. Tests on malleable castings forgings and

6.24 DRAWING AND LITERATURE:

The detailed drawings of each component assembly of the Hardware assembly &
Accessories and descriptive literature shall be submitted before taking up supplies.
The detailed dimension drawings for each and all-individual Hardware items such as
clamps, U Clevis, Socket Eye, Yoke Plate and Socket Clevis etc. shall also be
submitted separately. The dimensional drawings for compression type Mid Span Joint
(Aluminium & Steel Sleeve), compression type Repair Sleeve Preformed Armour rods
for Conductor & Ground wire and 4R Vibration Dampers etc. must be submitted. Test
certificates for different tests conducted as per relevant ISS, for all the offered items
must also be submitted essentially.
6.25 MATERIALS AND WORKMANSHIP:

6.25.1 All the materials shall be of the latest design and conform to the best modern
practice adopted in the extra high voltage field. The Bidder shall supply only such
equipment as guaranteed by him to be satisfactory and suitable for 400 KV
Transmission line.
6.25.2 The design, manufacturing process and quality control of all the materials shall be
such as to give maximum factor of safety, maximum possible working load, highest
mobility, elimination of sharp edges and corners, best resistance to corrosion and a
good finish.
6.25.3 All ferrous parts shall be hot dip galvanised, after all machining has been completed.
Nuts may, however, be tapped (threaded) after galvanising and the threads oiled.
Spring washers shall be electro galvanised. The bolts threads shall be under cut to
take care of increase in diameter due to galvanising. Galvanising shall be done in
accordance with IS:2629 or equivalent International Standard and satisfy the tests
mentioned in IS:2633 or equivalent International Standard. Fasteners shall
withstand four dips while spring washers shall be guaranteed to withstand at least
six dips each lasting one minute under the standard precee test for galvanising.
6.25.4 The Zinc coating shall be perfectly adhere, of uniform thickness, smooth, reasonably
bright, continuous and free from imperfections such as flux, ash, rust stains, bulky
while deposits and blisters. The Zinc used for galvanising shall be grade Zn. 99.95%
as per IS: 209:1992 ingot (fourth revision) or IS:13229:1991.
6.25.5 In case of castings, the same shall be free from all internal defects like shrinkage,
inclusion, blowholes, cracks etc.
6.25.6 All current carrying parts shall be so designed and manufactured that contact
resistance is reduced to minimum.
6.25.7 No item which would produce high electrical and mechanical stresses in normal
working shall have sharp ends or edges, abrasions or projections and shall not cause
any damage to the Conductor in any way during erection or during continuous
operation. The design of adjacent metal parts and mating surfaces shall be such as

Volume-V (Part-2)
to prevent corrosion of the contact surface and no maintain good electrical contact
6.25.8 Particular care shall be taken during manufacturing and subsequent handling to
ensure smooth surface free from abrasion or dents.
6.25.9 The fasteners shall conform to the requirement of IS: 6639-1972 or equivalent
International Standard. All fasteners and clamps shall have locking arrangements to
guard against vibration loosening.
6.26 INSPECTION:
6.26.1 Purchaser and its representatives shall at all times be entitled to have access to the
works and to all places of manufacturing and the Supplier shall afford all facilities to
them for unrestricted inspection of the works, inspection of material, inspection of
manufacturing process and for conducting necessary tests as specified herein.
6.26.2 The successful Bidder shall keep the Purchaser informed in advance of the time of
starting and progress of manufacturing of material in its various stages so that
6.26.3 No material shall be despatched from its point of manufacturing unless the material
has been satisfactorily inspected and tested.
6.26.4 The acceptance of any quantity of material shall in no way relieve the successful
Bidder of his responsibility for meeting all the requirement of this specification and
shall not prevent subsequent rejection, if such materials are later found to be
defective.
The main component of the material covered in the specification shall be
legibly and indelibly marked with the trademark of the manufacturer, the month and
year of manufacture, the guaranteed combined mechanical and electrical strength in
kilo-Newton abbreviated by ‘kN’ to facilitate easy identification and proper use.
Words “MPPTCL” shall also be embossed/engraved on the main components. Marks
shall be forged or stamped with a steel die before Galvanizing. The marks shall be
distinct, durable and conspicuous. Embossing/Engraving should be done at the time
of manufacturing process itself, but before Galvanizing. Smaller component like bolts
& nuts, split pin and washers etc. may be excluded from this requirement.
6.28 PACKING:
6.28.1 The material shall be packed in strong wooden boxes with steel straps. The gross
weight of packing shall be in range of 50 kgs to 200 kgs to avoid handling problem.
The packing shall be strong enough to withstand rough handling during transit or
storage in the field. All the packing cases shall be legibly marked to avoid possibility
of loss in transit. The Bidder shall be responsible for any damage during transit due
to improper and inadequate packing and handling.
6.28.2 Each consignment shall be accompanied by a detailed packing list showing following
details:-
i. The name of the consignees
ii. Details of consignment.
iii. Destination.
iv. Total weight of consignment.
v. Handling and unpacking instrumentation.
vi. Bill of material indicating content of each package.
6.29 STANDARD AND TESTS:
6.29.1 The original or attested photocopy of test certificates for material for the test
conducted at Govt. Laboratory are required to be submitted giving results of sample

Volume-V (Part-2)
test as per technical values given above respectively in support of compliance of

materials to the specification in the quality, performance and composition.
6.29.2 The materials offered shall conform to relevant Indian Standard. The material shall
be tested before dispatch. The MPPTCL may at its option, depute its representative
for inspection and witnessing of test. The test as specified shall be carried out and
the test report shall be submitted for an approval before dispatch.
6.29.3 Further, the MPPTCL reserves the right to carry out test as mentioned above from
bulk quantity received at the cost of supplier to ascertain the quality of the material
supplied. The supply should strictly as per our specification. The MPPTCL at its
discretion for ensuring that material supplied are conforming to specified quality and
composition may get it tested from National Laboratory by drawing samples from the
lot after the same is received by consignees. If the test result do not conform to
specified quality, the lot will be rejected and replacement shall be made free of cost
and testing charges will be to the account of supplier. If some material is already
used by time the results are received, the MPPTCL may accept such material which
has been used at the reduced cost as may be fixed at its discretion. The test as
specified shall be carried out and the test report shall be submitted for an approval
before dispatch.

Volume-V (Part-2)
SECTION- 7
TECHNICAL SPECIFICATION FOR OPTICAL GROUND WIRE (OPGW), ASSOCIATED
HARDWARE & ACCESSORIES
7 STANDARDS:
7.01 Unless otherwise mentioned in the specification the offered Optical

Ground wire (OPGW) and associated Hardware shall be manufactured,
tested and supplied with all guaranteed technical particulars generally
confirming to meet the requirement of the latest revisions of relevant
standard of International Electro-Technical Commission or equivalent
National Standards of India.
S
.
STAN
N TITLE
DARD
O
.
1 IEEE Standard Construction of Composite Fiber
1138 Optic Ground wire (OPGW) for use on
Electric Utility Power Lines
2 ITUT For Optical Fibers
G.652
3 IEC Requirements and test methods for Optical
1396 Ground wires (OPGW)
4 IEC Overhead electrical standard conductors
1089
5 IS Metal fittings of Insulator for overhead
2486 power lines with a nominal voltage greater
than 1000V
6 IS 802 Code of practice for use of structural steel
in overhead transmission line
7 IS 875 Code of practice for design load for
building & structural
8 IEC794 Test Procedure
-1-C10
9 IS Fibre cores for steel wire ropes
1804
7.02 Tenderer shall clearly state the standards to which the equipment
offered by them conforms. In the event of offering of equipment
conforming to standards other than IS, the salient points of
comparison between standards adopted and the relevant IS shall be
indicated in the proposal alongwith copies of adopted standards. It will
be sole responsibility of the Tenderer to prove that the salient features

Volume-V (Part-2)
of offered equipment are equivalent or better than standards specified

above.
7.03 GENERAL REQUIREMENT FOR OPGW:
7.03.01 Fiber and Cladding

Each optical fiber shall consist of a core made of fused silica and the cladding intimately
surrounding the core shall be also fused silica. The properties of optical fiber are shown in
Annexure ‘D’.
7.03.02 Fiber Coating

The clad fiber core shall be coated with UV cured urethane acrylate resin.
7.03.03 Optical Fiber Unit

OPGW cable construction shall comply with IEEE-1138, 2009. The cable provided shall meet
both the construction and performance requirements such that the ground wire function,
the optical fibre integrity and optical transmission characteristics are suitable for the
intended purpose. The cable shall consist of optical fibre units as defined in this
specification. There shall be no factory splices within the cable structure of a continuous
cable length.
The composite fibre optic overhead ground wire shall be made up of multiple buffer tubes
embedded in a water tight aluminium/aluminium alloy/stainless steel with aluminium
coating protective central fibre optic unit surrounded by concentric-lay stranded metallic
wires in single or multiple layers. Each buffer tube shall have maximum 12 no. of fibres. The
dual purpose of the composite cable is to provide the electrical and physical characteristics
of conventional overhead ground wire while providing the optical transmission properties of
optical fibre.
All optical fibre cabling including fibre itself and all associated installation hardware shall
have a minimum guaranteed design life span of 25 years. Documentary evidence in support
of guaranteed life span of cable and fibre shall be submitted by the Contractor during
detailed engineering.
7.03.04 Physical Characteristics

Dual-Window Single mode (DWSM), G.652D optical fibres shall be provided in the fibre optic
cables. DWSM optical fibres shall meet the requirements defined in Table below.
7.03.05 Attenuation
The attenuation coefficient for wavelengths between 1525 nm and 1575 nm shall not
exceed the attenuation coefficient at 1550 nm by more than 0.05 dB/km. The attenuation
coefficient for wavelengths between 1285 nm and 1330 nm shall not exceed the attenuation
coefficient at 1310 nm by more than 0.05 dB/km. The attenuation of the fibre shall be
distributed uniformly throughout its length such that there are no point discontinuities in
excess of 0.10 dB. The fibre attenuation characteristics specified in table below shall be
"guaranteed" fibre attenuation of any and every fibre reel.
The overall optical fibre path attenuation shall not be more than calculated below:
Maximum attenuation @ 0.21 dB/km x total km + 0.05 dB/splice x no. of splices
1550nm : + 0.5 dB/connector x no. of connectors
Maximum attenuation @ 0.35dB/km x total km + 0.05 dB/splice x no. of splices
1310nm: + 0.5 dB/connector x no. of connectors
DWSM OpticalFibre
Characteristics
Fibre Description: Dual-Window Single-Mode

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Mode Field Diameter: 8.6 to 9.5 µm (± 0.6µm )
Cladding Diameter: 125.0 µm ± 1 µm
Mode field concentricity error ≤ 0.6µm
Cladding non-circularity ≤ 1%
Cable Cut-off Wavelength A,cc ≤ 1260 nm
1550 nm loss performance As per G.652 D
Proof Test Level ≥ 0.69 Gpa
Attenuation Coefficient: @ 1310 nm ≤ 0.35 dB/km

@ 1550 nm ≤ 0.21 dB/km
Chromatic Dispersion; 18 ps/(nm x km) @ 1550 nm
Maximum: 3.5 ps/(nm x km) @ 1288-1339nm
5.3 ps/(nm x km) @ 1271-1360nm
Zero Dispersion Wavelength: 1300 to 1324nm
Zero Dispersion Slope: 0.092 ps/(nm2xkm) maximum
Polarization mode dispersion < 0.2 ps/km^ ½
coefficient
Temperature Dependence: Induced attenuation < 0.05 dB (-60°C to +85°C )
Bend Performance: @ 1310 nm (75±2 mm dia Mandrel), 100 turns;

Attenuation Rise ≤ 0.05 dB
@ 1550 nm (30±1 mm radius Mandrel), 100 turns;
Attenuation Rise ≤ 0.05 dB @ 1550 nm (32±0.5
mm dia Mandrel, 1 turn; Attenuation Rise ≤ 0.50 dB
7.03.06 Fibre Optic Cable Construction

Overhead Fibre Optic Cables shall be OPGW (Optical Ground Wire). The OPGW cable is
proposed to be installed on the EHV transmission lines spread across the State of Madhya
Pradesh in India. The design of cable shall account for the varying operating and
environmental conditions that the cable shall experience while in service. The OPGW cable
to be supplied shall be designed to meet the overall requirements of all the transmission
lines. Normally the tower span of the lines shall not exceed 525 m; however, some of the
spans may be up to around 1000 m or more. To meet the overall requirement of all the
transmission lines, the contractor may offer more than one design without any additional
cost, in case one type of offered OPGW does not meet the requirements for using on spans
more than 525m.
7.03.07 Optical Fibre Cable Link Lengths

The estimated optical fibre link lengths shall be as per transmission line route length.
However, the Contractor shall supply and install the optical fibre cable as required based on
detailed site survey to be carried out by the Contractor during the project execution. The
Contractor shall verify the transmission line route length during the survey and the Contract
price shall be adjusted accordingly.
For the purpose of payment, the optical fibre link lengths are defined as transmission line
route lengths from Gantry at one terminating station to the Gantry in the other terminating
station. The actual cable lengths to be delivered shall take into account various factors such
as sag, service loops, splicing, working lengths and wastage etc. and no additional payment
shall be payable in this regard. The unit rate for FO cable quoted in the Bid price Schedules
shall take into account all such factors.

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7.03.08 Optical Fibre Identification

Individual optical fibres within a fibre unit and fibre units shall be identifiable in accordance
with EIA/TIA 598 or IEC 60304 or Bellcore GR-20 colour-coding scheme.
Colouring utilized for colour coding optical fibres shall be integrated into the fibre coating
and shall be homogenous. The colour shall not bleed from one fibre to another and shall not
fade during fibre preparation for termination or splicing.
Each cable shall have traceability of each fibre back to the original fibre manufacturer's fibre
number and parameters of the fibre. If more than the specified number of fibers is included
in any cable, the spare fibers shall be tested by the cable manufacturer and any defective
fibres shall be suitably bundled, tagged and identified at the factory by the vendor.
7.03.09 Buffer Tube

Loose tube construction shall be implemented. The individually coated optical fibre(s) shall
be surrounded by a buffer for protection from physical damage during fabrication,
installation and operation of the cable. The fibre coating and buffer shall be strippable for
splicing and termination. Buffer tubes shall be filled with a water-blocking gel.
7.03.10 Optical Fibre Strain

The fibre optic cable shall be designed such that the optical fibres experience no strain
under all loading conditions defined in IS 802. No fibre strain condition shall apply even
after a 25 year cable creep.
For the purpose of these specifications, the following definitions shall apply:
• Maximum Working Tension (MWT) is defined as the maximum cable tension at

which there is no fibre strain.
• The no fibre strain condition is defined as fibre strain of less than or equal to
0.05%, as determined by direct measurements through IEC/ ETSI (FOTP) specified
optical reflectometry techniques.
• The Cable strain margin is defined as the maximum cable strain at which there is
no fibre strain.
• The cable Maximum Allowable Tension (MAT) is defined as the maximum tension
experienced by the Cable under the worst case loading condition as defined in IS
802.
• The cable max strain is defined as the maximum strain experienced by the Cable
under the worst case loading condition as defined in IS 802.
• The cable Every Day Tension (EDT) is defined as the maximum cable tension on
any span under normal conditions viz at 32 °C and no wind.
• The Ultimate /Rated Tensile Strength (UTS/ RTS/ breaking strength) is defined as
the maximum tensile load applied and held constant for one minute at which the
specimen shall not break.
While preparing the Sag-tension charts for the OPGW cable the following conditions shall be
met:
• The Max Allowable Tension (MAT) / max strain shall be less than or equal to the
MWT/ Strain margin of the cable.
• The sag shall not exceed the earth wire sag in all conditions.
• The Max Allowable Tension shall also be less than or equal to 0.4 times the UTS of
OPGW. However, Max Allowable Tension up to 0.5 times the UTS of OPGW may be
accepted, subject to no fibre strain.
• The 25 year creep at 25% of UTS (creep test as per IEEE 1138) shall be such that
the 25 year creep plus the cable strain at Max Allowable Tension (MAT) is less than
or equal to the cable strain margin.
• The everyday tension (EDT) shall not exceed 20% of the UTS for the OPGW cable.

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The Sag-tension chart indicating the maximum tension, cable strain and sag shall be
submitted for the following conditions as specified in IS 802:1977/1995:-
a. 53 oC, no wind, no ice

b. 32 oC, no wind, no ice
c. 0 oC, no wind, no ice
d. 32 oC, full wind, no ice
e. 0 oC, 2/3rd / 36% of full wind (IS 802:1977/1995)
However, the same shall not be exceeding the limiting values as under:-
S.N Particulars E Series B Series

o. (132 kV Towers) (220 kV Towers)
1. Wind Load 189 Kg/meter2 194 Kg/meter2
2. Design Span 350 meter 350 meter
3. Sag at 0°C with Nil Wind 4.835 meter 5.508 meter
4. Max Sag at 53°C with Full Wind 6.19 meter 6.91 meter
5. Max Tension at 32°C with Full
3400 Kg 3300 Kg
Wind
The above cases shall be considered for the spans from 100 m to 525 M or higher span
length in the range of 50 m spans.
7.03.11 Cable Materials

The materials used for optical fibre cable construction, shall meet the following
requirements:
7.03.12 Filling Materials

The interstices of the fibre optic unit and cable shall be filled with a suitable compound to
prohibit any moisture ingress or any water longitudinal migration within the fibre optic unit
or along the fibre optic cable. The water tightness of the cable shall meet or exceed the test
performance criteria as per IEC-60794-1-F-5.
The filling compound used shall be a non-toxic homogenous waterproofing compound that is
free of dirt and foreign matter, non-hygroscopic, electrically nonconductive and non-
nutritive to fungus. The compound shall also be fully compatible with all cable components it
may come in contact with and shall inhibit the generation of hydrogen within the cable.
The filling compound shall remain stable for ambient temp. between -20°C and +65°C and
shall not drip, flow or leak with age or at high temperatures during short duration lightning
strikes and short circuit currents The filling compound shall meet the requirements of
“Seepage of Filling Compound test” as per EIA/TIA 455-81.
The waterproofing filling materials shall not affect fibre coating, colour coding, or
encapsulant commonly used in splice enclosures, shall be dermatologically safe, non-
staining and easily removable with a non-toxic cleaning solvent.
7.03.13 Metallic Members

When the fibre optic cable design incorporates metallic elements in its construction, all
metallic elements shall be electrically continuous.
7.04 COMPLETED OPGW

The optical fiber unit shall be surrounded with a number of strands of aluminium-clad steel
wires. The direction of outermost layer shall be left-handed (S direction).

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7.04.01 Optical Ground Wire (OPGW)

OPGW cable construction shall comply with IEEE-1138-2009 and IEC publication 1396. The
cable provided shall meet both the construction and performance requirements such that
the ground wire function, the optical fibre integrity and optical transmission characteristics
are suitable for the intended purpose.
The composite fibre optic overhead ground wire shall be made up of buffered optical fibre
units embedded in a water tight aluminium/aluminium alloy/stainless steel protective
central fibre optic unit surrounded by concentric-lay stranded metallic wires in single or
multiple layers. However, other material may be accepted subject to meeting the cable
type-testing requirements as specified in the technical specifications. The dual purpose of
the composite cable is to provide the electrical and physical characteristics of conventional
overhead ground wire while providing the optical transmission properties of optical fibre.
7.04.02 Central Fibre Optic Unit

The central fibre optic unit shall be designed to house and protect multiple buffered optical
fibre units from damage due to forces such as crushing, bending, twisting, tensile stress and
moisture. The central fibre optic unit and the outer stranded metallic conductors shall serve
together as an integral unit to protect the optical fibres from degradation due to vibration
and galloping, wind and ice loadings, wide temperature variations, lightning and fault
current, as well as environmental effects which may produce hydrogen. The OPGW design of
dissimlar materials for stranded wires and tubes are not allowed.Central fibre optic unit may
be of aluminium/ aluminium alloy / stainless steel tube. There shall be no exposed areas of
tubing that can make electrical contact either directly or indirectlly through moisture,
contamination, protrusions, etc with the surroundings stranded wires.The tube may be
fabricated as a seamless tube, seam welded, or a tube without a welded seam.
7.04.03 Basic Construction

The cable construction shall conform to the applicable requirements of Technical
Specification, applicable clauses of IEC 61089 related to stranded conductors and Table
8.04.05 OPGW Mechanical and Electrical Characteristics. In addition, the basic construction
shall include bare concentric-lay-stranded metallic wires with the outer layer having left
hand lay. The wires may be of multiple layers with a combination of various metallic wires
within each layer. The direction of lay for each successive layer shall be reversed.
The Wires shall be so stranded that when the complete OPGW is cut, the indivisual wires
can be readily regrouped and then held in place by one hand.
7.04.04 Breaking Strength

The rated breaking strength of the completed OPGW shall be taken as no more than 90
percent of the sum of the rated breaking strengths of the individual wires, calculated from
their nominal diameter and the specified minimum tensile strength.
The rated breaking strength shall not include the strength of the optical unit.
The fibre optic unit shall not be considered a load bearing tension member
when determining the total rated breaking strength of the composite
conductor.
7.04.05 Electrical and Mechanical Requirements

Table below provides OPGW Electrical and Mechanical Requirements for the minimum
performance characteristics. Additionally, the OPGW mechanical & electrical characteristics
shall be similar to the electrical & mechanical characteristics of the earthwire being replaced
such that there is no or minimal consequential increase in stresses on towers. The existing
earthwire parameters are listed in appendices. For the purposes of determining the
appropriate Max Working Tension limit for the OPGW cable, IS 802:1995 and IS 875: 1987
shall be applied. However the OPGW sag & tension charts shall be based on IS 802. For the
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OPGW cable design selection and preparation of sag tension charts, the limits specified in
this section shall also be satisfied. The Bidder shall submit sag-tension charts for the above
cases with their bids.
Table 8.04.05
OPGW Electrical and Mechanical Requirements
1 Everyday Tension at ≤ 20% of UTS of OPGW

32ºC, no wind:
D.C. Resistance at < 1.0 ohm/Km
2
20ºC:
Short Circuit Current: ≥6.32 kA for 1.0 second(for 220 kV
3 & above line)
≥5.6 kA for 1.0 second (for 132 kV &
above line)
7.04.06 Operating conditions

Since OPGW shall be located at the top of the EHV transmission line support structure, it will
be subjected to Aeolian vibration, Galloping and Lightning strikes. It will also carry ground
fault currents. Therefore, its electrical and mechanical properties shall be the same or
similar as those required of conventional ground conductors.
7.04.07 Live Line Installation Suitability

OPGW shall be suitable for installation under live line condition, i.e. with all circuits charged
to the rated line voltage as specified in this section.
7.05 SPECIFIC REQUIREMENTS FOR OPGW ACCESSORIES:

Assemblies and Line Accessories
a. General
The OPGW assemblies and line accessories shall consist of the hardware indicated
herein. All hardware and accessories shall be made of aluminium, aluminium alloy,
malleable iron, steel (metal mould of drop forging process), stainless steel, or non-
ferrous metal, unless otherwise specified. In addition, all hardware and accessories shall
have an ultimate tensile strength equal to or exceeding the rated ultimate tensile
strength of the overhead ground wire. All metal shall be free from burrs, sharp edges,
lumps and dross, and shall be smooth, so that interconnecting parts will fit properly, and
so that the parts may be assembled and readily.
Unless otherwise specified, all ferrous metal shall be galvanized in accordance with
ASTM A153. Bolts and nuts shall be galvanized after being threaded, and excessive zinc
shall be removed; they shall run freely (hand fit) for the entire length of the thread. Re-
tapping of nuts after galvanizing is permitted. Each piece of hardware shall be
permanently marked by casting or die-forging.
All bolts and other fasteners shall be installed according to manufacturer’s
recommendations. Materials not specifically covered herein by detailed specifications
shall be of standard commercial quality suitable for the intended use. The Contractor
shall determine the most suitable type of clamp to be used at each and every
transmission tower location.
b. Suspension Assembly Clamps
Preformed armour grip suspension clamps and aluminum alloy armour rods/reinforcing
rods shall be used. The suspension clamps shall ne designed to carry a vertical load of

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not less than 25KN. The suspension clamps slippage shall occur between 12kN and 17kN
as measured.
The Contractor shall supply all the components of the suspension assembly including
shackles, bolts, nuts, washers, split pins, etc. the total drop of the suspension assembly
shall not exceed 150mm (measured from the centre point of attachment to the centre
point of the OPGW). The design of the assembly shall be such that the direction of run of
the OPGW shall be the same as that of the conductor.
c. Tension Clamps
All dead end clamp assemblies shall preferably be of performed armoured grip type and
shall include all necessary hardware for attaching the assembly to the tower strain
plates. Dead end clamps shall allow the OPGW to pass through continuously without
cable cutting. The slip strength shall be rated not less than 95% of the rated tensile
strength of the OPGW.
d. Vibration dampers
Stockbridge type vibration dampers, suitable for use on the OPGW shall be supplied. The
dampers shall have an aluminum clamping bolt, or other suitable device, on the
galvanized wire between the weights, and be suitable for attachment to the OPGW. The
damper clamp shall be designed to permit installation and removal using hot line tools.
Each damper weight, subject to the accumulation of moisture, shall be provided with
one drain hole positioned at the bottom of the weight when the damper is installed in
the vertical plane. Damper weights shall be made of hot dip galvanized cast iron or
steel.
The Vibration analysis of the system, with and without damper and dynamic
characterstics of the damper as detailed in Technical specification, shall have to be
submitted. The Technical paticulars for vibration analysis and damping design of the
system are as follows:-
S Description Technical
. Particulars
N
o
.
Span Lengths in meters
(i) Ruling design span: 350 meters
(ii) Maximum span: 1100 meters
(iii) Minimum Span: 100 meters
Cofiguration: As per Specifications
Tensile load in each: As per sag tension
calculations
Armour rods used: Standard performed
armour rods / AGS
Maximum Permissible dynamic +/- 150 micro strains
strain:
e. Armour Rods
The armor rods for the OPGW shall be of the preformed type. They shall be smooth and
free from corrosion, splitting, cracking, or any other defects. They shall be designed to
effectively protect the OPGW from fatigue caused by vibration.

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f. Down Lead Clamp
The tenderer should offer Down Lead Clamp suitable for OPGW & the offered clamps
should meet requirement stipulated in the relevant standard. Details of Down Lead
Clamp including drawing shall be submitted with the offer.
g. Joint Box
The joint box shall be air-tight, water-proof. The cover shall be securely fastened to the
case by non-loosening fasteners. Both the case and the cover shall be made of non-
corrosive aluminum alloy or hot dip galvanized steel or approved materials. The joint
box shall be sufficiently rugged and sturdy to withstand outdoor climatic and
environmental conditions. The joint box shall accommodate sheath protected arc-fusion
splices and up to 1.5 m of additional fiber on each side of the splice; guides shall be
provided to keep the extra fiber well above the allowable bending radius of the fiber. The
spliced parts of the optical fiber within the joint box shall be reinforced and free from
tension after completion of the splicing.
The Supplier shall provide one set of terminating materials with every joint box for
optical fiber connection.
1. Way Joint Box for OPGW

This type of joint box shall be used to straight joint OPGW to OPGW, or OPGW to
approach cable. It shall be used at all locations requiring such a device except those
specified otherwise in the text or drawings elsewhere in this specification.
2. Way Joint Box for OPGW and approach cable

This type of joint box shall be used to spur joint all fibers contained in two OPGW
cables to OPGW or one multi-core optical fiber cable at each terminal station,
repeater station, or other location, as detailed in the text or drawings elsewhere in
this Specification.
h. Earth Bond
The Tenderer should offer Earth Bonds suitable for OPGW & the offered Earth Bonds
should meet requirement stipulated in the relevant standard. Details of Earth Bonds
including drawing shall be submitted with the offer.
i. In-Line Fibre Optic Splice Enclosures
All in-line splices shall be encased in In-Line Fibre Optic Splice Enclosures. Suitable
splice enclosures shall be provided to encase the optical cable splices in protective,
moisture and dust free environment. In line splice enclosures shall comply to ingress
protection class IP 66 or better. The splice enclosures shall be designed for the storage
and protection of 48 optical fibre splices and equipped with sufficient number of splice
trays for splicing all fibres in the cable. In-line splice enclosures shall be suitable for
outdoor use with each of the cable types provided under this contract. Splice enclosures
shall be appropriate for mounting on EHV transmission towers above anti-climb guard
levels at about 10 metres from the ground level and shall accommodate pass-through
splicing. The properties of required for Splice Enclosures are shown in Annexure ‘F’.
7.06 TEST FOR OPGW
TYPE TESTING/ FACTORY ACCEPTANCE TESTS REQUIREMENTS

Wherever the referenced test procedures or the technical specifications call for visual
inspection for damage, the test report shall include a full description of observed status of
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the sample. (Visually inspected samples shall also be colour photographed and copies of
colour photographs shall be included in type test report)
7.06.01 Type Tests for Optical Fibres

The type tests listed below in Table 4.2 shall be conducted on DWSM fibres. The tests
specific to the cable type are listed in subsequent sections.
Table 4.2
Type Tests For Optical Fibres
S. Acceptance
Test Name Test procedure
No. Criteria
1 Attenuation
2 Attenuation Variation with Wavelength
3 Attenuation at Water Peak
Temp. Cycling
4
(Temp dependence of Attenuation)
Attenuation With Bending

5
(Bend Performance) AS per Tender AS per Tender
Specification Specification
6 Mode Field dia.
7 Chromatic Dispersion
8 Cladding Diameter
9 Point Discontinuities of attenuation
10 Core -Clad concentricity error
7.06.02 Type Tests For OPGW Cables

The type tests to be conducted on the OPGW cable are listed in Table 4.3: Type Tests for
OPGW Cables. Unless specified otherwise in the technical specifications or the referenced
standards, the optical attenuation of the specimen, measured during or after the test as
applicable, shall not increase by more than 0.05 dB/Km.
Table 4.3
Type tests for OPGW Cable
S.No. Test Name Test Test Procedure

Description
1 Water IEEE 1138 IEEE 1138, Section 5.1.1.1
Ingress Test Section 4.1.1.1 (IEC 794-1-F5 /EIA/TIA 455-82B)
IEEE 1138, Section 5.1.1.1
(IEC 794-1-F5 /EIA/TIA 455-82B),
Test duration : 24 hours
2 Seepage of IEEE 1138 IEEE 1138 Preconditioning period : 72

filling Section 4.1.1.2 Section 5.1.1.2 hours. Test duration : 24
compound (EIA/TIA 455- hours.
81B)

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Short Circuit IEEE 1138 IEEE 1138 Fibre attenuation shall be

Test Section 4.1.1.3 Section 5.1.1.3 continuously monitored and
recorded through a digital
equivalent means.
A suitable temperature
sensor such as thermocouple
shall be used to monitor and
record the temperature
inside the OPGW tube in
addition to monitoring &
recording the temperatures
between the strands and
between optical tube and the
strand as required by IEEE
1138.
Test shall be conducted
with the tension clamps
proposed to be supplied. The
cable and the clamps shall be
visually inspected for
mechanical damage and
photographed after the test.
IEC 60794-1-2 Initial temperature during

(2003) the test shall be greater than
Method H1 or equal to ambient field
temperature. However,
maximum temperature
recorded on any component
of OPGW cable shall not
exceed the Short Circuit
transient peak temperature
guaranteed by the
Contractor during design.
4 Aeolian IEEE 1138 IEEE 1138 Fibre attenuation shall be
Vibration Section 4.1.1.4 Section 5.1.1.4 continuously monitored and
Test recorded through a digital
data logging system or
equivalent means.
The vibration frequency and

amplitude shall be monitored
and recorded continuously.
Test shall be conducted with
the tension/suspension
supplied. The cable and the
after the test.
5 Galloping test IEEE 1138 IEEE 1138 Test shall be conducted with
Section 4.1.1.5 Section 5.1.1.5 the tension/suspension
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supplied. The cable and

after the test. All fibres of
the test cable sample shall
be spliced together in serial
for attenuation monitoring.
6 Cable Bend Procedure 2 in IEC:794-1-E11 The short-term and long-
Test term bend tests shall be
conducted in accordance with
Procedure 2 in IEC:794-1-
E11 to determine the
minimum acceptable radius
of bending without any
increase in attenuation or
any other damage to the
fibre optic cable core such as
bird caging, deformation,
kinking and crimping.
Fibre attenuation shall be
7 Sheave Test IEEE 1138 IEEE 1138 continuously monitored &
Section 4.1.1.6 Section 5.1.1.6 recorded through a digital
IEC 60794-1-2 equivalent means. The
(2003) Sheave dia. Shall be based
on the pulling angle and the
Method E18B
minimum pulley dia
employed during installation.
8 Crush Test IEEE 1138 IEEE 1138 The crush test shall be
Section 4.1.1.7 Section 5.1.1.7 carried out on a sample of
approximately one (1) metre
(IEC 794-1-E3/ long in accordance with
EIA/TIA 455- IEC:794-1-E3. A load equal
41B) to 1.3 times the weight of a
400-metre length of fibre
optic cable shall be applied
for a period of 10 minutes. A
permanent or temporarily
increase in optical
attenuation value greater
than 0.1dB change in sample
shall constitute failure. The
load shall be further
increased in small
increments until the
measured attenuation of the
optical waveguide fibres
increases and the failure load
recorded along with results.
9 Impact Test IEEE 1138 IEEE 1138, The impact test shall be
Section 4.1.1.7 Section 5.1.1.7 carried out in accordance
(IEC 794-1-E4/ with IEC:794-1-E4. Five
EIA/TIA 455- separate impacts of 0.1-
Volume-V (Part-2)
25B) 0.3kgm shall be applied. The

radius of the intermediate
piece shall be the reel drum
radius ± 10%. A permanent
or temporary increase in
optical attenuation value
greater than 0.1 dB/km
change in sample shall
constitute failure.
10 Creep Test IEEE 1138 IEEE 1138 As per Aluminium Association
Section 4.1.1.8 Section 5.1.1.8 Method , the best-fit straight
line shall be fitted to the
recorded creep data and
shall be extrapolated to 25
years. The strain margin of
the cable at the end of 25
years shall be calculated. The
time when the creep shall
achieve the strain margin
limits shall also be
calculated.
IEEE 1138 IEEE 1138
11 Fibre Strain
Section 4.1.1.9 Section 5.1.1.9
Test
12 Strain Margin IEEE 1138 IEEE 1138
4.1.1.10
13 Stress strain IEEE 1138 IEEE 1138
4.1.1.11
14 Cable Cut-off IEEE 1138 IEEE 1138
wavelength Section Section 5.1.1.12
Test 4.1.1.12
15 Temperature IEEE 1138 IEEE 1138
Cycling Test Section Section 5.1.1.13
4.1.1.13
16 Corrosion EIA/TIA 455-16A
(Salt Spray)
Test
17 Tensile IEC 794-1-E1 / The test shall be conducted on a sample of
Performance EIA/TIA 455- sufficient length in accordance with IEC:794-1-
Test 33A E1. The attenuation variation shall not exceed
0.05 dB/kM up to 90% of RTS of fibre optic
cable.
The load shall be increased at a steady rate up
to rated tensile strength and held for one (1)
minute. The fibre optic cable sample shall not
fail during the period. The applied load shall
then be increased until the failing load is
reached and the value recorded.

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18 Fault IEEE Std. 4- Tension equal to 20% of the OPGW RTS shall be
Current/ 1978 applied to a sample with minimum length of 15
lightning Test m of cabled fibres and two separate 4/10 micro
second current impulses each having a peak
value of 150 KA and a negative polarity shall be
applied through a 1 cm gap. The attenuation
during the tests shall be continuously measured.
After the tests the same shall be visually
inspected. Any increase in optical waveguide
fibres attenuation measured at 1550 nm shall
constitute failure.
Fibre attenuation shall be continuously

monitored and recorded through a digital data
logging system or equivalent means.
The tensile performance test shall be repeated
on the sample subjected to the lightning arc
test.
IEC 60794-1- The cable construction shall be tested in
2(2003) accordance with Method H2
19 DC On a fibre optic cable sample of minimum 1 metre length, two

Resistance contact clamps shall be fixed with a predetermined bolt torque.
Test The resistance shall be measured by a Kelvin double bridge by
placing the clamps initially zero metre and subsequently one
metre apart. The tests shall be repeated at least five times and
the average value recorded after correcting at 20 C.
7.07 Type Test on OPGW Cable Fittings

The type tests to be conducted on the OPGW Cable fittings and accessories are listed below:
7.07.01 Mechanical Strength Test for Suspension/Tension Assembly

Applicable Standards: IS: 2486 / IEC: 61284 :1997.
7.07.01.1 Suspension Assembly

The armour rods /reinforcement rods are assembled on to the approved OPGW using the
Installation Instructions to check that the assembly is correctly fitted and is the same that
will be carried out during installations.
Part 1:
The suspension assembly shall be increased at a constant rate up to a load equal to 50% of
the specified minimum Failure Load increased and held for one minute for the test rig to
stabilise. The load shall then be increased at a steady rate to 67% of the minimum Failure
Load and held for five minutes. The angle between the cable, the Suspension Assembly and
the horizontal shall not exceed 16o. This load shall then be removed in a controlled manner
and the Protection Splice disassembled. Examination of all the components shall be made
and any evidence of visual deformation shall be documented.
Part 2:
The Suspension clamp shall then be placed in the testing machine. The tensile load shall
gradually be increased up shall gradually be increased up to 50% of the specified Minimum
Failure Load of the Suspension Assembly and held for one minute for the Test Rig to
stabilise and the load shall be further increased at a steady rate until the specified
minimum Failure Load is reached and held for one minute. No fracture should occur
during this period. The applied load shall then be increased until the failing load is reached
and the value shall be documented.
Volume-V (Part-2)
7.07.01.2 Tension Assembly

The Tension Assembly is correctly fitted and is the same that will be carried out during
installations.
Part 1:
The tension assembly (excluding tension clamp) shall be increased at a constant rate up to
a load equal to 50% of the specified minimum Failure Load increased at a constant rate and
held for one minute for the test rig to stabilise. The load shall then be increased at a
steady rate to 67% of the minimum Failure Load and held for five minutes. This load shall
then removed in a controlled manner and the Tension Assembly disassembled. Examination
of the Tension Dead-End and associated components shall be made and any evidence of
visual deformation shall be documented.
Part 2:
The Tension Dead-End and associated components shall then be reassembled and bolts
tightened as before. The tensile load shall gradually be increased up shall gradually be
increased up to 50% of the specified Minimum Failure Load of the Tension Assembly and
held for one minute for the Test Rig to stabilise and the load shall be further increased at a
steady rate until the specified minimum Failure Load is reached and held for one minute.
No fracture should occur during this period. The applied load shall then be increased until
the failing load is reached and the value shall be documented.
Acceptance Criteria:
- No evidence of binding of the Nuts or Deformation of components at end of part 1 of Test.
- No evidence of Fracture at the end of one minute at the minimum failure load during Part
2 of the Test.
7.07.02 Clamp Slip Strength Test for Suspension Assembly

The suspension assembly shall be vertically suspended by means of a flexible attachment. A
suitable length fibre optical cable shall be fixed in the clamps. Once the Suspension Clamp
has been assembled, the test rig is tensioned to 1 kN and the position scale on the recorder
‘zeroed’. The test rig is then tensioned to 2.5 kN and the relative positions of the Reinforcing
Rods, Armour Rods and Suspension Clamp shall be marked by a suitable means to confirm
any slippage after the test has been completed. The relative positions of the helical Armour
Rods and associated Reinforcing Rods at each end shall be marked and also 2 mm relative
position between clamp body and Armour Rods shall be marked on one side. The load shall
be increased to 12 kN at a loading rate of 3 kN/min and held for one minute. At the end of
this one minute period, the relative displacement between clamp body and the armour rods
shall be observed. If the slippage is 2 mm or above, the test shall be terminated. Otherwise,
at the end of one minute the position of the clamp body and 2 mm. relative positions
between clamp body and armour rods shall be marked on the other side. After the one
minute pause, the load shall be further increased at a loading rate of 3 kN/min, and
recording of load and displacement shall continue until either the relative Position
displacement between clamp body and armour rods reaches more than 2 mm.or the load
reaches the maximum slip load of 17 kN. On reaching either of the above values the test is
terminated. Visual examination of all paint marks shall be recorded, and a measurement of
any displacement recorded in the Table of Results.
The Suspension Clamp has passed the Slip Test if the following conditions are met :
• No slippage* shall occur at or below the specified minimum slip load.

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* Definition of no slippage in accordance with IEC 61284:1997 :- Any relative

movement less than 2 mm is accepted. The possible couplings or elongations
produced by the cable as a result of the test itself are not regarded as slippage.
• Slippage shall occur between the specified maximum and minimum slip
load of 12 - 17 kN.
• There shall be no slippage of the Reinforcing Rods over the cable, and
no slippage of the Armour Rods over the Reinforcing Rods.
• The relative movement (i.e. more than 2 mm between Armour Rods &
Clamp body) between minimum 12 kN and maximum slip 17 kN, shall
be considered as slip.
• The Armour Rods shall not be displaced from their original lay or
damaged**.
** Definition of no damage in accordance with convention expressed in IEC 61284 :

1997 no damage, other than surface flattening of the strands shall occur.
Any result outside these parameters is a failure.
7.07.03 Slip Strength Test of Tension Clamp

Tension clamps shall be fitted on a 8 m length of fibre optic cable on both ends. The
assembly shall be mounted on a tensile testing machine and anchored in a manner similar
to the arrangement to be used in service. A tensile load shall gradually be applied up to 20
% of the RTS of OPGW. Displacement transducers shall be installed to measure the relative
movement between the OPGW relative to the Reinforcing Rods and Tension Dead -End
relative to Reinforcing Rods. In addition, suitable marking shall be made on the OPGW and
Dead-End to confirm grip. The load shall be gradually increased at a constant rate up to 50
% of the UTS and the position scale of the recorder is zeroed. The load shall then gradually
increased up to 95 % of the UTS and maintained for one minute. After one minute pause,
the load shall be slowly released to zero and the marking examined and measured for any
relative movement.
- No movement* shall occur between the OPGW and the Reinforcing Rods, or between the
Reinforcing Rods and the Dead-End assembly.
- No failure or damage or disturbance to the lay of the Tension Dead-End, Reinforcing Rods
or OPGW.
* Definition of no movement as defined in IEC 61284 : Any relative movement less than 2
mm is accepted. The possible couplings or elongations produced by the conductor as a
result of the test itself are not regarded as slippage.
7.07.04 Grounding Clamp and Structure Mounting Clamp Fit Test

For structure mounting clamp, one series of tests shall be conducted with two fibre optic
cables installed, one series of tests with one fibre optic cable installed in one groove, and
one series of tests with one fibre optic cable in the other groove. Each clamp shall be
installed including clamping compound as required on the fibre optic cable. The nut shall be
tightened on to the bolt by using torque wrench with a torque of 5.5 kgm or supplier's
recommended torque and the tightened clamp shall be held for 10 minutes. After the test
remove the fibre optic cable and examine all its components for distortion, crushing or
breaking. Also the fibre optic cable shall be checked to ensure free movement within the
core using dial callipers to measure the diameter of the core tube. The material shall be
defined as failed if any visible distortion, crushing, cracking or breaking of the core tube is
observed or the fibre optic cable within the core tube is not free to move, or when the
diameter of the core tube as measured at any location in the clamped area is more than 0.5
mm larger or smaller of the core diameter as measured outside the clamped area.
Volume-V (Part-2)
7.07.05 Structure Mounting Clamp Strength Test

The clamp and mounting assembly shall be assembled on a vertical 200 mm x 200 mm
angle and a short length of fibre optic cable installed. A vertical load of 200 kg shall be
applied at the end of the mounting clamp and held for 5 minutes. Subsequently, the load
shall be increased to 400 kg and held for 30 seconds. Any visible distortion, slipping or
breaking of any component of the mounting clamp or assembly shall constitute failure.
7.07.05.1 Type Test on Vibration Damper
7.07.05.2 Dynamic Characteristic Test

The damper shall be mounted with its clamp tightened with torque recommended by the
manufacturer on shaker table capable of simulating sinusoidal vibrations for Critical Aeolian
Vibration frequency band as determined through vibration analysis of undamped OPGW..
The damper assembly shall be vibrated vertically with a ±1 mm amplitude from 5 to 15 Hz
frequency and beyond 15 Hz at 0.5 mm to determine following characteristics with the help
of suitable recording instruments.
(a) Force Vs frequency
(b) Phase angle Vs frequency
(c) Power dissipation Vs frequency
The Force Vs frequency curve shall not show steep peaks at resonance frequencies and
deep troughs between the resonance frequencies. The resonance frequencies shall be
suitably spread within the Aeolian vibration frequency-band between the lower and upper
dangerous frequency limits determined by the vibration analysis of fibre optic cable without
dampers.
The above dynamic characteristics test shall be conducted on five dampers. The variations
between the samples tested shall conform to the sample test limits.
7.07.05.3 Vibration Analysis

The vibration analysis of the fibre optic cable shall be done with and without damper
installed on the span. The vibration analysis shall be done on a digital computer using
energy balance approach. The following parameters shall be taken into account for the
purpose of analysis.
(a) The analysis shall be done for single fibre optic cable without armour rods. The
tension shall be taken as max Permissible Every Day Tension (20% of UTS), for
a span ranging from 100 m to 1100 m.
(b) The self damping factor and flexural stiffness (EI) for fibre optic cable shall be
calculated on the basis of experimental results. The details to experimental
analysis with these data shall be furnished.
(c) Examine the Aeolian Vibration level of the fibre optic cable with and without
vibration damper installed at the recommended location or wind velocity ranging
from 0 to 30 Km per hour, predicting amplitude, frequency and vibration energy
input.
(d) From vibration analysis of fibre optic cable without damper, antinode vibration
amplitude and dynamic strain levels at clamped span extremities as well as
antinodes shall be examined and thus lower and upper dangerous frequency
limits between which the Aeolian vibration levels exceed the specified limits
shall be determined.
(e) From vibration analysis of fibre optic cable with damper(s) installed at the
recommended location, the dynamic strain level at the clamped span
Volume-V (Part-2)
extremities, damper attachment point and the antinodes on the fibre optic cable
shall be determined. In addition to above damper clamp vibration amplitude and
antinodes vibration amplitudes shall also be examined.
(f) The dynamic strain levels at damper attachment point, clamped span extremities
and antinodes shall not exceed the specified limits. The damper clamp vibration
amplitude shall not be more than that of the specified fatigue limits.
7.07.05.4 Vibration Damper Clamp Slip and Fatigue Tests
7.07.05.4.1 Test Set Up

The clamp slip and fatigue tests shall be conducted on a laboratory set up with a minimum
effective span length of 30m. The fibre optic cable shall be tensioned at 15kN & shall not be
equipped with protective armour rods at any point.
Constant tension shall be maintained within the span by means of lever arm arrangement.
After the fibre optic cable has been tensioned, clamps shall be installed to support the fibre
optic cable at both ends and thus influence of connecting hardware fittings are eliminated
from the free span. The clamps shall not be used for holding the tension on the fibre optic
cable. There shall be no loose parts, such as suspension clamps, U bolts, on the test span
supported between clamps mentioned above. The span shall be equipped with vibration
inducing equipment suitable for producing steady standing vibration. The inducing
equipment shall have facilities for step less speed control as well as step less amplitude
arrangement. Equipment shall be available for measuring the frequency, cumulative number
of cycles and amplitude of vibration at any point along the span.
7.07.05.4.2 Clamp Slip Test

The vibration damper shall be installed on the test span. The damper clamp, after tightening
with the manufacturer's specified tightening torque, when subjected to a longitudinal pull of
2.5kN parallel to the axis of fibre optic cable for a minimum duration of one minute shall not
slip, i.e., the permanent displacement between fibre optic cable and clamp measured after
removal of the load shall not exceed 1.0 mm. The load shall be further increased until the
clamp starts slipping. The load at which the clamp slips shall not be more than 5kN.
7.07.05.4.3 Fatigue Test

The vibration damper shall be installed on the test span with the manufacturer's specified
tightening torque. It shall be ensured that the damper shall be kept minimum three loops
away from the shaker to eliminate stray signals influencing damper movement.
The damper shall then be vibrated at the highest resonant frequency of each damper mass.
For dampers involving torsional resonant frequencies, tests shall be done at torsional modes
also in addition to the highest resonant frequencies at vertical modes. The resonance
frequency shall be identified as the frequency at which each damper mass vibrates with the
maximum amplitude on itself. The amplitude of vibration of the damper clamp shall be
maintained not less than ±25/f mm where f is the frequency in Hz.
The test shall be conducted for minimum ten million cycles at each resonant frequency
mentioned above. During the test, if resonance shift is observed, the test frequency shall be
tuned to the new resonant frequency.
The clamp slip test as mentioned herein above shall be repeated after fatigue tests without
retorquing or adjusting the damper clamp, and the clamp shall withstand a minimum load
equal to 80% of the slip strength for a minimum duration of one minute.
After the above tests, the damper shall be removed from fibre optic cable and subjected to
dynamic characteristics test. There shall not be any major deterioration in the
characteristics of the damper. The damper then shall be cut open and inspected. There shall
not be any broken, loose, or damaged part. There shall not be significant deterioration or
wear of the damper. The fibre optic cable under clamp shall also be free from any damage.

Volume-V (Part-2)
For purposes of acceptance, the following criteria shall be applied:
a) There shall not be any frequency shift by more than ±2Hz for frequencies lower
than 15Hz & ±3Hz for frequencies higher than 15Hz.
b) The force response curve shall generally lie within guaranteed % variation in
reactance after fatigue test in comparison with that before fatigue test by they
Supplier.
c) The power dissipation of the damper shall not be less than guaranteed %
variation in power dissipation before fatigue test by the Supplier. However, it
shall not be less than minimum power dissipation which shall be governed by
lower limits of reactance and phase angle indicated in the envelope.
7.07.06 Type Tests for In Line Splice Enclosures

Following Type tests shall be demonstrated on the In Line Splice Enclosure(s) (Splice
Enclosure/Box). For certain tests, lengths of the fibre optic cable shall be installed in the
splice box, and the fibres must be spliced and looped in order to simulate conditions of use.
The attenuation of the fibres shall be measured, during certain tests, by relevant Fibre Optic
Test Procedures (IEC 794-1 procedures).
7.07.06.1 Temperature Cycling Test

FO cable is installed in the splice enclosure and optical fibres spliced and looped. The box
must be subjected to 5 cycles of temperature variations of -40°C to +65°C with a dwell time
of at least 2 hours on each extreme.
Fibre loop attenuation shall be measured in accordance with IEC 794-1-C10. The variation in
attenuation shall be less than ±0.05dB. The final humidity level, inside the box, shall not
exceed the initial level, at the closing of the box.
7.07.06.2 Humid Heat test

The sealed splice enclosure, with fibres spliced and looped inside, must be subjected to a
temperature of +55°C ±2°C with a relative humidity rate of between 90% and 95% for 5
days. The attenuation variation of the fibres during the duration of the test shall be less
than ±0.05dB, and the internal humidity rate measured, less than 2%.
7.07.06.3 Rain Withstand Test

The splice enclosure with optical fibres cable installed and fibres spliced fixed, shall be
subjected to 24 hours of simulated rain in accordance with IEC 60 testing requirements. No
water seepage or moisture shall be detected in the splice enclosure. The attenuation
variation of the fibres after the test shall be less than ±0.05dB.
7.07.06.4 Vibration Test

The splice enclosure, with fibres united inside, shall be subjected to vibrations on two axes
with a frequency scanning of 5 to 50 Hz. The amplitude of the vibrations shall be constant
at 0.450mm, peak to peak, for 2 hours, for each of the vibrations' axes. The variation in
attenuation, of the fibres, shall be less than ±0.05dB. The splice enclosure shall be
examined for any defects or deformation. There shall be no loosening or visible damage of
the FO cable at the entry point.
7.07.06.5 Bending and Torsion test

Volume-V (Part-2)
The splice enclosure, with fibres spliced inside, shall be firmly held in place and be subjected
to the following sequence of mechanical stresses on the cable:
a) 3 torsion cycles of ±180° shall be exercised on the cable. Each cycle shall be less than
one minute.
b) 3 flexure cycles of the cable, of ±180° with one cycle less than one minute.
The variation in the attenuation, of the fibres, shall be less than ±0.05dB. The cables
connection ring shall remain securely fixed to the box with the connection maintained
firmly. No defects/fissures shall be noted on the joint ring or on the splice enclosure
7.07.06.6 Tensile test

The splice enclosure with cable fixed to the boxes shall be subjected to a minimum tension
of 448 N for a period of two minutes. No fissure shall be noted in the connections or on the
box.
7.07.06.7 Drop Test

With 2 lengths of 10 metres of cable fixed to the box, it shall be dropped five times from a
height of 11 metres. There shall be no fissure, at all, of the box, and the connections shall
remain tight. The test shall be carried out in accordance with procedure described in IEC-
68-2-32.
7.07.07 Factory Acceptance Tests on Fibre Optic Cables

As specified in technical specifications, the Factory acceptance tests shall be conducted on
random sampling of fibre optic cable to be supplied for the present procurement, prior to
any shipment.
7.07.07.1 FAT On Fibre : Optical Acceptance Tests

The Optical acceptance tests listed in Table 4.5.1 below are applicable for the fibres of all
types of Fibre Optic Cables i.e. OPGW and approach cable to be supplied. The listed tests
follow testing requirements set forth in IEEE standard 1138 section 4.2.2.1 and section
5.2.2.1. The referenced sections specify the detailed test description. The acceptance norm
shall be as specified in the above mentioned IEEE standards unless specified otherwise in
the technical specifications.
Table 4.5.1
Factory Acceptance Tests for Fibres of all FO cables: Optical Tests
S. Acceptance Test
Test Name
1 Attenuation Coefficient
Point Discontinuities of
2
attenuation
AS per
3 Attenuation at Water Peak AS per
Technical
Technical
4 Chromatic Dispersion Specificatio
Specification
n
5 Core – Clad Concentricity Error
6 Cladding diameter

Volume-V (Part-2)
The test reports for the above tests for all types of the fibres carried out by the Fibre
Manufacturer and used in the OPGW cables and approach cable shall be shown to the
inspector during OPGW cable FAT and shall be submitted along with the OPGW cable FAT
report.
7.07.08 Factory Acceptance Test On OPGW Cable

The factory acceptance tests for OPGW cable specified below in Table 4.6 follow the
requirements set forth in section 4.1.2 and section 5.1.2 of IEEE standard 1138. The FAT
shall be carried out on 10% of offered drums in each lot as specified in technical
specifications and the optical tests shall be carried out in all fibers of the selected sample
drums. The Rated Tensile Strength test shall be carried out on one sample in each lot.
Table 4.6
Factory Acceptance Tests On OPGW
Applicable standard: IEEE 1138
S. No. Factory Acceptance Test on Manufactured OPGW
1 Attenuation Co-efficient at 1310 nm and 1550 nm
2 Point discontinuities of attenuation

3
DRS/Drawings
4 Rated Tensile Strength
5 Lay Length Measurements
7.07.09 Factory Acceptance Test On OPGW Fittings
The factory acceptance tests for OPGW Fittings as specified below in Table 4.7. The sampling plan
shall be as per IS 2486:
Table 4.7
Factory Acceptance Tests On OPGW Fittings

Suspension Assembly
1 UTS/Mechanical Strength of the assembly
2 Clamp Slip Test
3
DRS/Drawings
Tension Assembly
5 Clamp Slip Strength test
6
DRS/Drawings
Vibration Damper
8 Galvanising test on damper, masses and messenger wires
9 Damper response (resonant frequencies)

Volume-V (Part-2)
10 Clamp Slip test

11 Strength of messenger wires
12 Mass pull off test
13
DRS/Drawings
Structure Mounting Clamp
14 Clamp fit test
15 Clamp Strength test
16
DRS/Drawings
7.07.10 Factory Acceptance Test on In Line Splice Enclosures

The factory acceptance tests for In Line Splice Enclosures as specified below in Table 4.8:
Table 4.8
Factory Acceptance Tests on In Line Splice Enclosures
Visual check Kit Quantities and Specific Component Number for each
1 component of In Line Splice Enclosure and dimensional checks against the
approved drawings.
7.08 PACKING AND MARKING -

All conductors for export shipment are generally shipped on best commercial practice non-
returnable steel reels having suitable dimension for winding a specified length.
Each length of cable shall be wound on a separate cable reel and the cable ends shall be
securely fastened to the reel to prevent the cable from becoming loose in transit or during
placing operations. Both ends of the cable shall be sealed with a suitable plastic cap to
prevent the entry of moisture during shipping, handling and storage. Spare plastic cap shall
be provided with each drum.
The cable shall be shipped on reels designed to prevent damage to the cable during
shipment and installation. The wooden lagging will be given a preventive treatment from
termite and wood preservative treatment.The construction of reels and markings shall be as
per approved documents.
The wire shall be furnished on reels of sufficiently sturdy construction to withstand normal
shipping, hauling and field erection. The size, length, weight, manufacturer’s name or trade
mark, date of manufacturer direction of rolling for each drum, and contract number shall be
clearly marked on the outside of each drum. The wire shall be packed to protect it from
moisture, salt, or any other impurities which may cause rust or other harmful effects.
The packing and shipping requirements for overhead galvanized steel wire hardware shall
be applied for assemblies and line accessories for OPGW.
Each package shall be clearly, legibly and durably marked on both sides as
follows:-
a. Name & designation of the consignee (to be furnished by
the purchaser.)
b. Ultimate destination (as required by the purchaser).
c. Items and respective quantities contained in the package
to be furnished by the purchaser.)
d. Net and gross weight of the material.

Volume-V (Part-2)
e. Gross weight of each package.
7.09 DESIGN AND DRAWING DETAILS
The design, manufacture and performance of OPGW and accessories shall comply with all
the requirements of the latest editions of International codes and standards applicable.
Nothing in this specification shall be construed to relieve the vendor of this responsibility.
The design and workmanship shall be in accordance with best engineering practices to
ensure satisfactory performance and long service life and shall be such as has been proved
to be suitable for the intended purpose.
The equipment offered shall be robust and durable. It shall be generally possible to set up
and assemble the equipment without the use of special tools but in case special tools are
required for installation the same shall be provided free cost basis with the supply of OPGW.
The equipment offered shall require minimum maintenance.All relevant requirements of
data and drawings for galvanized steel wire and its hardware shall be applicable for OPGW
and joint boxes.
7.10 INSTALLATION OF OPGW
The Supplier shall provide a complete description of all procedures and

methods to be used during installation of the OPGW.
The installation methods and tools required for OPGW shall be similar to those of
conventional overhead ground wire. The OPGW shall be strung, sagged and clipped before
phase conductors are strung. The OPGW shall be connected to the transmission tower for
grounding at every location
7.11 OVERHEAD GROUND WIRE WITH OPTICAL FIBER

CONNECTIONS
The jointing of overhead ground wires shall be performed using joint boxes located on
tension towers. All overhead ground wire connections shall be of the underpass variety.
7.11.01 OPTICAL FIBER CONNECTIONS

The jointing of optical fiber shall be performed using arc-fusion splicing. All cores shall be
spliced at every locations, fiber identification shall be matched and maintained for the entire
length of the installation.
The optical fiber splicing loss shall not be more than 0.10 dB for any one joint, and shall
average no more than 0.05 dB per joint on any given repeater span. Splicing loss shall be
measured immediately after the splice has been made, and if the splice does not meet
minimum standards above, it shall be replaced.
All successful splices shall be protected using a heat shrink protection sleeve with integrated
reinforcement, or some other material/process providing equivalent protection.
An additional slack of 1 to 1.5 m shall be provided on each side of each splice, and stored
securely in the joint box.
7.11.02 COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS
7.11.02.1 Offered material shall be complete in all respects and shall

include all minor component, accessories, small wiring etc., not
Volume-V (Part-2)
specifically mentioned in this order, specifications etc; but essential for the
completeness of the system. Supplier shall not be eligible for extra charges
in respect of such minor components, accessories, small wiring etc., though
not included specifically in this Tender but requires for satisfactory
operation of equipment offered.
7.11.02.2 It is obligatory on the part of supplier to ensure that supply of all

accessories along with Main equipment are simultaneously delivered to avoid
any holdups. Responsibility for obtaining timely supplies of bought out items
will rest on the supplier.
7.11.02.3 It may be noted that in case of damages/shortages due to

improper packing or any other negligence ,replenishment shall be
arranged within one months time. For bought out items,
responsibility for guarantee and obtaining immediate replacement in
case any defects are noticed and also in case defective supply of any
item is reported, will rest on the suppliers.

Volume-V (Part-2)
ANNEXURE -A
OPGW TECHNICAL SPECIFICATION

Configuration : To be filled by bidder.
Guaranteed value
Description Unit
48 fibers
Applicable standard - IEEE std. 1138:2009
Number of fiber
No. 48
Aluminium-clad steel wire To be filled by Bidder

Aluminium alloy wire
Structure No/dia
Stainless steel tube -do-
Lay direction of outer layer

- (Left-hand (S)
Ratio of length of lay or a layer to nominal

Times To be filled by Bidder
outside diameter of that layer
Outer diameter mm -do-
Aluminium-clad steel wire -do-
2
(*) Cross Aluminium alloy wire mm -do-
section
Steel tube -do-
(*) Approximate weight Kg/km -do-
Rated tensile strength (RTS) (min)

-do-
Ultimate tensile strength (UTS) (min) Kg
2
(*) Modules of elasticity Kg/mm -do-
(*) Co-efficient of linear expansion /deg C -do-
D.C. resistance at 20 deg C (max) ohm/km -do-
Short circuit current capacity for 1 second

(Initial temperature : 40 ° C) KA 6.32
Assumed maximum temperature under short

circuit current deg C To be filled by Bidder
Remark – (*) means data for information only.

Volume-V (Part-2)
ANNEXURE-B
PROPERTIES OF INDIVIDUAL WIRE

Guaranteed value
Description Unit
48 fibers
Type of individual wire - ACS Wires Al-alloy
Applicable standard -
To be filled To be filled
by bidder by bidder
Standard diameter mm -do- -do-
Tolerance of diameter mm -do- -do-

2
Minimum tensile strength Kg/mm -do- -do-
Minimum elongation in 250 mm % -do- -do-
Minimum conductivity %ACS -do- -do-
Minimum number of twisting

No. -do- -do-
(100 x dia)
Minimum thickness of Aluminium mm -do- -do-
-do-
Properties of wrapping % -do-
ANNEXURE – C
PROPERTIES OF OPTICAL FIBER UNIT

Guaranteed
Description Unit value 48
Fibers
Loose type
(Stainless Steel Tube
Buffer type - type preffered)
Number of Loose tube No. To be filled by bidder
Total No.of Fibers No 48
(*) Diameter Mm To be filled by bidder
Number of empty tube Nos. To be filled by bidder
Loose tube
To be filled by bidder
(*) Material -
Remark : (*) means data for information only.

Volume-V (Part-2)
ANNEXURE - D
PROPERTIES OF OPTICAL FIBER
Description Unit Guaranteed value

Applicable standard - ITU-TG 652 D
Cladding diameter µm 125±1
Core concentricity error µm ≤ 0.6
Cladding non-circularity % ≤ 1.0
Mode field diameter at 1310 mm (8.6-9.5)+0.6
µm
Attenuation coefficient at 1310 mm dB/km ≤ 0.4
at 1550 mm dB/km ≤ 0.3

Attenuation at water peak at 1383±3 nm dB/km ≤ 0.4
Bend performance
dB/km ≤ 0.05 at 1310 nm
dB/km ≤ 0.10 at 1550 nm
@1550 nm (32±0.5mm diameter
mandrel), 1turn
dB/km ≤ 0.50 at 1550 nm
Temperature dependence (-60°C ̃+

dB/km ≤ 0.05 dB
85°C)
Cutoff wavelength for cabled fiber (λ) nm ≤ 1260 nm
Chromatic dispersion
@ 1288 nm ̃1339 nm ps/(nm.km) ≤ 3.5
@ 1271 nm ̃1360 nm ps/(nm.km) ≤ 5.3
@ 1550 nm ps/(nm.km) ≤ 18
Zero dispersion wavelength Nm 1300 to 1324
2
Zero dispersion Slope Ps/Nm .km ≤0.093
½
Polarization mode dispersion (PMD) ps/km ≤0.2
Point discontinuities of attenuation dB ≤0.1@1310&1550 nm
Proof-test level Gpa ≥ 0.69
ANNEXURE-E
COLOR CODE OF OPTICAL FIBER UNIT

Loose Tube : To be filled by bidder.
Fiber Colors(12 No;s)
Blue,Orange,Green,Brown,Slate,white,Red,Black,Yellow,Violet,Pink and Aqua

Volume-V (Part-2)
ANNEXURE-F
DATA REQUREMENT SHEETS FOR INLINE SPLICE ENCLOSURE
S.
Parameter Unit Particulars
No.
1. Dimensions HWD mm To be filled by bidder
2. Weight Kg To be filled by bidder
3. Color and Finish Stainless Steel AISI 304
4. Cable Glanding & Fixing Mechanical clamp
Stainless Steel AISI 304
5. Construction materials & Gauge
(1.0 - 3.0 )mm
6. Locking arrangements Bolts and nuts
Front access: N/A
7.
Rear access: 2 N/A
Cm To be filled by bidder
Top*Bottom*Slides
8. IP Protection Code IP 68
9. Total number of optical couplings n* To be filled by bidder
10. Provision of pass through splicing Yes/No Yes
Whether filled with suitable
11. Yes/No To be filled by bidder
encapsulant
Method(s) for mounting with the
12. Mechanical
tower
Optical Fiber Cable Accommodations
13. Cable Glanding Cable Blocking

Maximum number of cables that can
be accommodated
Diameter(s) of cables that can be
15. mm To be filled by bidder
accommodated :
Details of Splice Trays :
Dimension: Mm To be filled by bidder
Material/Gauge: ABS/1 mm
17.
Weight: kg To be filled by bidder
Color & Finish: RAL 7035
Method of mounting: Release
18. Maximum number of splices per tray n* To be filled by bidder
19. Number of splices per tray n* To be filled by bidder
Provision of maximum splice
organizers
Do splice trays require a separate
Yes/No To be filled by bidder
enclosure?
If so:
Manufacturer:
Dimensions: H*W*D Cm
21.
Weight: kg
Color and Finish:
Method(s) of Mounting:
Construction Materials & Gauge:
Locking arrangements
Volume-V (Part-2)
Front Access:
m
Rear Access:
Top*Bottom*Slides:
22. Excess length of Fiber service loops m 1.5 + 1.5

Volume-V (Part-2)
SECTION-8
TECHNICAL SPECIFICATIONS FOR ERECTION OF TRANSMISSION LINES
The material and services under this section shall conform to the requirements of the
latest revisions and amendments available at the time of placement of order of all
the relevant Indian standards/codes listed here under or equivalent International
Standards, except as modified in this document.

1 IS:5613-1995 (part- Code of practice for design, installation
II) and maintenance of overhead power lines.
Sec.-1 - Designs.
Sec.-2 - Installation & Maintenance
2 IS:269-1967 Ordinary rapid hardening and low heat
Portland cement.
3 IS:456-2000 Code of practice for plain and
reinforced concrete
4 IS:1786-1966 Cold twisted steel bars for concrete
reinforcements
IS:4091-1967 Code of practice for design & construction
of foundation for transmission line towers
& poles
8.02 LINE MATERIALS:
8.02.1 Conductor:
The Conductor used in the line will be single ACSR Moose Conductor. The
Conductor size is 54/3.53mm A1. + 7/3.53 mm Steel.
8.02.2 Ground-wire :
The Ground-wire to be used on the line shall be 7/3.66 mm; 95 kg/mm2
quality galvanized steel stranded wire.
8.02.3 Insulator Strings with Hardware Fittings:
(i) Single suspension and double tension strings will be used on the line as under:
(a) At Suspension Locations:

23 Disc single suspension strings having 120KN E&MS of 255x145 mm size
Disc Insulators with AGS type clamps will be used.
(b) At Tension Locations :
24 Disc double tension strings with 160 KN E&MS Disc insulators of 280x170
mm size Disc Insulators will be used with compression type dead end clamp.
(ii) Pilot strings will be used at deep angle tower locations for restraining the
swing of jumpers.
(iii) In cases of Railway/Road/River/Other transmission line crossings, double
suspension insulator strings will be used.
Volume-V (Part-2)
8.02.4 Conductor Accessories:

(i) AGS type suspension clamps shall be used with suspension strings.
(ii) Vibration Dampers (4-R type) and Spacers or Spacer-Dampers shall be used
for Conductors.
8.02.5 Miscellaneous Items:

Enameled Number Plates, Phase Plates and Danger Board, Bolts and Nuts,
Spring washers, Pack washers and other tower accessories like ‘D’ Shackle,
Hanger, U-Bolts and fasteners etc., shall be provided with the tower by the
Contractor. The Contractor shall supply anticlimbing device (including Barbed
wire) separately. Copper earth bond will be used for connecting Ground wire
suspension and tension clamp with tower body, which shall also be provided by
the Contractor.
8.03 DETAILED SURVEY/CHECK SURVEY:

The contractor will have to carry out detailed survey of the line for which
route map indicating the proposed alignment of the transmission line will be
handed over by the Employer. If the detailed survey is already conducted by
the Employer for some portion of the line, the profiles for such portion will be
handed over to the Contractor for carrying out check survey. It may please be
noted that no check survey is required to be conducted for the portion of line
for which detail survey is conducted by the contractor himself.
8.03.1 Detailed Survey:-

(a) At the starting point of the commencement of route survey, an angle iron
spike 65 x 65 x 1000mm shall be driven firmly into the ground to show only
150mm above the ground level. A punch mark on the top section of the angle
iron shall be made to indicate location of the surveying instrument. Teak wood
pegs 50 x 50 x 650 mm shall be driven at prominent positions at intervals of
not more than 750 meter along the transmission line to be surveyed up to the
next angle point. 125 mm wire nails should be fixed on the top of these pegs
to show the location of instrument. The pegs shall be driven firmly into the
ground to show only 100 mm above ground level. At angle positions, stones
shall be put up for easy identification. Paint mark in white lead paint shall be
put in, about 300 mm squares with a direction indication, on nearby
boulders, rocks, or trees, along the complete line alignment. At peg
position, identification marks giving the peg position, with reference to
painting marks, shall be given. The white lead paint mark shall indicate to the
individual the direction of alignment from either direction.
(b) Routing/Re-routing of transmission line through protected/reserved forest area
should be avoided. In case it is not possible to avoid the forests or areas
having large trees completely, then keeping in view of the overall economy,
the route should be aligned in such a way that cutting of trees is minimum.
(c) The route should have minimum crossings of Major river, Railway lines,
National/State highways, overhead EHV power line and communication lines.
(d) The number of angle points shall be kept to minimum.
(e) The distances between the terminal points specified shall be kept shortest
possible, consistent with the terrain that is encountered.
(f) Marshy and low lying areas, river beds and earth slip zones shall be avoided to
minimize risk to the foundations.
(g) It would be preferable to utilize level ground for the alignment.

Volume-V (Part-2)
(h) Crossing of power lines shall be minimum. Alignment will be kept at a

minimum distance of 300 m from power lines to avoid induction problems on
the lower voltage lines.
(i) Crossing of communication line shall be minimized and it shall be preferably at
right angle. Proximity and parallelism with telecom lines shall be eliminated to
avoid danger of induction to them
(j) Areas subjected to flooding such as nalah shall be avoided.
(k) Restricted areas such as civil and military airfield shall be avoided. Care shall
also be taken to avoid aircraft landing approaches.
(l) All alignment should be easily accessible both in dry and rainy seasons to
enable maintenance throughout the year.
(m) Certain areas such as quarry sites, tea, tobacco and saffron fields and rich
plantations, gardens and nurseries which will present the Employer problems
in acquisition of right of way and way leave clearance during construction and
maintenance should be avoided.
(n) Angle points should be selected such that shifting of the point within 100 m
radius is possible at the time of construction of the line.
(o) The line routing should avoid large habitations, densely populated areas,
Forests, Animal/Bird sanctuary, reserve coal belt areas, oil pipe
line/underground inflammable pipe lines etc to the extent possible.
(p) The areas requiring special foundations and those prone to flooding should be
avoided.
(q) From the field book entries, the route plan and level profile shall be plotted
and prepared to the scales of 1=2000 horizontal and 1=200 vertical on 1
mm/5 mm/1 cm square paper.
(r) If the difference in levels be too high, the chart may be broken up according to
requirement. A 400 meter overlap shall be shown on each following sheet.
The chart shall progress from left to right. For convenience in handling, the
sheet size may be limited to 594x841 mm (Al) size.
(s) After completing the detail survey, profiles shall be submitted to the Employer
duly spotted with tower for approval. While submitting the profiles after
conducting the detail survey, the contractor will also submit a copy of route
alignment on the route map indicating the surveyed route.
8.03.2 Check Survey:
(a) The Contractor shall conduct the check survey after the profiles are handed over
to the Contractor. The check survey shall include checking of deviation angles,
checking of levels at critical points. After completing the check survey the tower
spotting shall be carried out by the Contractor and profiles shall be submitted to
the purchaser for final approval. The Contractor shall be responsible for correct
setting of stubs. Discrepancies, if any, shall be brought to the notice of
purchaser and final approval shall be taken before execution of work.
(b) The requirement of tower site leveling and revetment work, if required, shall
also be marked by the Contractor on the profiles while carrying out the detail or
check survey work.
(c) If due to site conditions any change in the tower location/provision of

extension is considered necessary compared to approve profiles, the
contractor shall bring the same to the knowledge of the purchaser well in time
and get revised approval of the profile before setting the stubs. The revised
approval shall be conveyed to the Contractor by the Purchaser.
Volume-V (Part-2)
8.03.3 Soil Resistivity:-
While carrying out detailed/ check survey work, the Soil Resistivity values
will have to be measured at convenient points along the route, not
exceeding 2.50 Km between adjacent points. The Soil Resistivity wiil be
measured using 4 electrod method with an inter electrod spacing of 50 M .
The following formula shall be used :
P=2πaR
Where a = Interelectrod spacing = 50M
R = Earth resistance measured in Ohms
P = Soil Resistivity in Ohm- m
The soil resistivity values shall be submitted duly marked on the route map
and also in the form of statement. The quoted rates for detailed survey/
check survey work shall be inclusive of cost of measuring soil resistivity
values along the proposed route and the contractor will not be paid
separately for this work.
8.04 APPROVED PROFILE:
(Applicable for check survey only)
8.04.1 The detailed survey has been conducted by the Purchaser or any other
agency appointed by the Purchaser and the profiles shall be handed over
to Contractor progressively for carrying out check survey and submission of
profiles for approval of the purchaser. The profiles shall be prepared on cm.
graph paper on scale 1:2000 horizontal and 1:200 vertical.
8.04.2 The route alignment surveyed by the Purchaser shall be marked at angle
points. At angle points concrete blocks shall be provided and in the straight
alignment marking will be done by pegs.
8.04.3 The Contractor will be responsible for the correct setting of towers as shown
in approved profiles. If towers after erection are found to be out of the
approved alignment/position in the profile, the Contractor will dismantle and
re-erect them correctly fully at his own cost and without extension of time.
8.05 EXCAVATION:
8.05.1 Except as specifically otherwise provided, all excavation for footing shall be
made to the lines and grades of the foundation. The excavation walls shall be
vertical and the pit dimensions shall be such as to allow a clearance of
150mm on all sides from the foundation pit, where form boxes are used. In
undercut/stepped (slab type) foundations where form box is not required to
be used at the base, the pit dimensions should be as per the standard
drawings. All excavation shall be protected so as to maintain a clean sub-
grade, until the footing is placed, by using timbering, shoring or casing, if
necessary. Any sand, mud, silt or other undesirable materials which may
have accumulated in the excavation shall be removed by the Contractor
before placing concrete.
8.05.2 The Soil to be excavated for tower foundations shall be classified as under
for the purpose of payment of excavation for tower site leveling and
building stone revetment:
(a) Dry Soil : Soil removable by means of ordinary pick axes and shovels
(Normal Soil, intermediate Soil and black cotton Soil fall under
this category).
Volume-V (Part-2)
(b) Wet Soil : Soil as per (a) above, where the sub Soil water table is
encountered within the range of foundation depth, the Soil below
the water table and that at locations where pumping or bailing
out of water is required due to presence of surface water, will
be treated as wet Soil.
(c) Soft Rock: This will mean fissured rock i.e. decomposed rock, hard gravel,
kankar, limestone, laterite or any other Soil of similar nature
which can be excavated with pick axe, crowbar etc. However, if
required, light blasting may be resorted to for loosening the
material but this will not in any way entitle the excavation to be
classified as hard rock
(d) Hard Rock : Hard rock will be that which requires chiseling or drilling and
blasting.
8.05.3 No extra charges shall be admissible for the removal the fallen earth in
the pits when once excavated.
8.05.4 If water is encountered in the foundation pit, de-watering will have to be

done. The cost of dewatering shall be deemed to be included in the
unit rates of excavation for foundation indicated by the Bidder in the offer.
8.05.5 For foundation in rock, where blasting is unavoidable, care should be

taken to minimize the volume of concrete necessary for filling up the
blasted area. The blasted area shall be reduced to the minimum possible so
that the specified form for the foundation could be obtained. No extra
payment for excavation in hard rock shall be allowed if the excavated area
exceeds the designed excavation volumes. Similarly, no extra payment shall
be made if concrete volume exceeds the designed volume due to excessive
blasting.
This is to specify here that during excavation, if hard rock soil is
encountered but keeping in view the soil strata actually
encountered, soft rock foundation is adopted then the rates for
excavation for hard rock shall be limited to the extent of approved
rate for excavation in soft rock.
8.05.6 The Contractor shall arrange requisite blasting material, excavation and
drilling equipment, necessary license etc., at his own cost and the quoted
rates shall be deemed to be inclusive of all such costs.
8.05.7 The decision of the owner shall be final and binding with respect to
classification of soil and foundation.
8.06 CLASSIFICATION OF FOUNDATIONS :
8.06.1 The foundation designs have been carried out depending upon the type of
Soil, sub-Soil water level and the presence of surface water as follows:
(ii) Dry Soil : To be used for locations where normal dry cohesive or non-
cohesive Soils are met.
(iii) Wet Soil : To be used for locations :
(a) Where sub-Soil water is met at 1.5meter or more below the ground
level.
(b) Which are in surface water for long periods with water penetration
not exceeding one meter below the ground level e.g. the paddy fields.

Volume-V (Part-2)
(iv) Partially Submerged: To be used at locations where sub-soil water level is

met between 0.75 meter to 1.5 meter below the ground
level.
(v) Fully Submerged : To be used at locations where sub-soil water level is met
less than 0.75 meter below ground level.
(vi) Black cotton(Dry/Wet): To be used at locations where Soil is clayey type, not
necessarily black in colour, which shrinks when dry and swells when wet,
resulting in differential movement extending to a maximum depth of about
3.5meter below ground level.
(vii) Dry Fissured rock: To be used at locations where decomposed or fissured

rock, hard gravel, kanker, limestone, laterite or any other soil of similar
nature is met. Under cut type foundation is to be used for fissured rock
locations.
(viii) Submerged Fissured rock: In case of fissured rock locations where water
level is met at 1.5meter or more below ground level, submerged fissured
rock foundations shall be adopted. If after soil investigation, water level is
encountered at less than 1.5meter below ground level, a separate foundation
shall be developed.
(ix) Hard rock : The locations where chiseling, drilling and blasting is required for
excavation, hard rock type foundations are to be used.
8.06.2 The foundation of towers will be classified as per above soil strata and as per
the instructions of Executive Engineer (EHT-C) and Superintending Engineer
(EHT-C) concerned and circulars issued by this office. The decision of MPPTCL
in the regard shall be final and binding on the contractor.
8.07 SHORING OF PITS:

Shoring of pits with shuttering on the internal walls surrounding the vertical
facing of approved dimensions of the pit shall be done when the Soil condition
is so bad that there is likelihood of accident due to falling of surrounding earth
in foundation pit. The cost of carrying out shoring & shuttering shall be
deemed to be included in the unit rate of excavation of tower and no extra
payment shall be made on this account.
8.08 TOWER SITE LEVELLING:
In case of foundations located on sloping ground, it may be necessary to level
the ground for locating the tower. In leveling the tower site, only excavation
will be allowed. The Contractor shall quote separate rates for excavation for
purpose of site leveling for dry Soil, wet Soil, soft and hard rock in respective
Schedule. The requirement of tower site leveling will be decided by the
Purchaser’s site Engineer and will be marked by the Contractor in the profiles
while carrying out the check survey work.
8.09 SETTING OF STUBS:
8.09.1 The stub shall be set correctly in accordance with approved method at the
exact locations and alignment and imprecisely correct levels. The stub setting
Templates shall be used for proper setting of stubs. Stubs shall be set in the
presence of purchaser’s representative available at site whenever required
and for which the contractor shall give adequate advance intimation to the
site Engineer.

Volume-V (Part-2)
8.09.2 The foundations are to be made as per designs and drawings approved by
the purchaser. Extent of the work as defined by such drawings shall not be
exceeded except in very exceptional cases where the prior approval of
purchaser has been obtained.
8.09.3 Each tower shall be provided with suitable foundation based on the
approved designs after classification of Soil. The Soil classification shall be
done after digging minimum section of all foundation pits of a tower up to full
depth (excluding hard rock locations). The Soil should be classified strictly as
per the details of Soil encountered in the foundation pit. For example, dry Soil
foundation should be adopted at the locations where dry Soil is encountered
in the full depth of foundation. Similarly the wet type foundation should be
adopted at the locations where water level is met at level of 1.5meter or
more, below the ground level or in paddy fields or other places, which remain
in surface water for long periods with water penetration not exceeding one
meter below the ground level. Deviations, if any, from the
approved/specified conditions shall be brought to the notice of C.E.
(EHT:C&M) through site Engineer before taking up the work and his
decision shall be final in this regard and communicated through site
Engineer. If at a later date, it is found that the works carried out by the
Contractor are not according to the specifications and are without specific
approval, the entire payments made to the Contractor for carrying out such
works shall be recovered and the Contractor will have to rectify the same at
the rates indicated in the order for carrying out such work and without
extension of time.
8.09.4 The setting of stubs in hard rock foundation may require cutting of stubs
depending on depth at which hard rock is encountered. The cutting of stubs
and drilling of new holes for fixing cleats etc. shall be considered inclusive in
the rate of foundation of towers in hard rock. However, the cut pieces of
stubs shall be returned to MPPTCL.
8.09.5 Setting of stub at each location shall be approved by the purchaser’s site
Engineer. This approval shall not however, absolve the Contractor of his
responsibility of correct setting of stubs and casting of foundations, who will
be required to rectify the faulty work at his own expense.
8.10 PLACEMENT OF REINFORCEMENT:
8.10.1 Some of the tower foundations may be designed with steel reinforcement so
as to achieve better foundation strength with lesser space. The Contractor will
indicate in relevant schedules, the details of reinforcement to be provided
alongwith the weight and size of reinforcement rods. The cost of placing of
reinforcement steel, binding etc. in the foundation pit shall be deemed to be
included in the quoted rates of foundations of towers.
8.10.2 The Contractor shall arrange foundation reinforcement steel etc. at their cost
which shall be deemed to be included in the quoted cost of foundations. The
reinforcement bars will have to be properly cut, bent in required shape and
placed in the foundation in approved manner after due cleaning of oil, grease
or organic matter. The reinforcement shall be properly tied by binding wire.
8.10.3 Reinforcement shall conform to IS:1786 for deform and cold twisted bars (Fe
500). Thermo Mechanically Treated (TMT) bars (equivalent grade ) in place
of cold twisted bars are also accepted. Hard drawn steel wire shall conform to
IS:432.

Volume-V (Part-2)
8.11 CONCRETE:
8.11.1 The cement concrete used for the foundation shall be of 1:2:4 mix ratio
(M150) with 20mm nominal size stone metal for chimney portion and 40mm
nominal size stone metal for pyramid or slab portions. 1:3:6 mix ratios
(M 100) shall be used for base padding (lean pad). For RCC, the aggregates
shall preferably be of 20mm nominal size.
8.11.2 Concrete aggregates shall confirm to IS:383
8.11.3 The cement required for the purpose of foundations, building revetment
walls etc. shall be arranged by the Contractor at his own cost, which shall be
deemed to be included in the cost of concreting.
8.11.4 The sand used for the concrete shall be arranged by the Contractor at his own
cost including necessary license etc., which shall be deemed to be included in
the cost of concreting. The sand shall be composed of hard silicate
materials. It shall be clean and of a sharp angular grit type and free from
earthy or organic matter and deleterious salts.
8.11.5 The aggregate shall be arranged by the contractor at his own cost including
necessary license etc, which shall be deemed to be included in the cost of
concreting. The aggregate shall be of clean broken hard granite or other
stone specified or approved by the purchaser. It shall be of hard and coarse-
grained quality. It shall also be as far as possible cube like, preferably
angular, but not flaky, perfectly clean and free from earth, organic or other
deleterious matter. 40mm aggregate shall be of size as will pass through a
mesh of 40 mm measured in the clear and 20 mm aggregate through 20mm
square mesh measured in clear.
8.11.6 The water used for mixing concrete shall be arranged by the contractor at his
own cost including necessary license etc, which shall be deemed to be
included in the cost of concreting. The water used shall be fresh, clean and
free from oil, acid and alkali, organic materials or other deleterious
substances. Salty/Saline or brackish water should not be used. Potable
water is generally satisfactory.
8.11.7 The concrete shall be mixed in a mechanical mixer. However in case of

locations not accessible for concrete mixers, hand mixing may be permitted at
the discretion of our site Engineer.
8.11.8 Mixing shall be continued until there is uniform distribution of materials and
the mixing is uniform in colour and consistency but in no case the mixing is
done for less than two minutes. Normally mixing shall be done close to
the foundation, but in case it is not possible, the concrete may be mixed at
the nearest convenient place. The concrete shall be transported from the
place of mixing to the place of final deposit as rapidly as practicable by
methods, which shall prevent the segregation or loss of any ingredient. The
concrete shall be placed and compacted before setting commences. The
transportation cost of these materials shall be deemed to be included in the
cost of concreting.
8.11.9 The concrete should be mixed as stiff as per the requirements of placing
the concrete in the form boxes, with ease and the degree
to which the concrete resists segregation. Hence the quantity of water used
should not be too much.

Volume-V (Part-2)
8.11.10 Proper form boxes adequately braced to retain proper shape while
concreting should be used for chimney or pyramid and slab portions. The
form boxes should be made water tight so that cement cream may not come
out leaving only sand and jelly consequently forming of honeycombing in the
concrete. The form boxes shall be cleaned and oiled before these are used
for concreting.
8.11.11 The concrete shall be laid in 150mm layers and consolidated well
so that the cement cream works up to the top and no honeycombing is left
in the concrete. Concreting is to be done continuously so that the subsequent
layers are laid before the initial setting of the bottom layer begins. The
consolidation of concrete shall normally be done by using vibrators.
8.11.12 After concreting the chimney portion up to the required height,

the top surface should be finished smooth, with slight slope towards the
outer edge, to drain off the rainwater falling on the coping.
8.11.13 In wet locations, the site must be kept completely de-watered both
during the placing of the concrete and up to 24 hours after completion. There
should be no spilling to concrete by water during this period.
8.11.14 The form boxes shall be removed only after at least 24 hours after the
completion of concreting. After removal of the forms and boxes the concreted
surface wherever required shall be repaired with a mixture of rich cement and
sand mortar in the shortest possible time.
8.11.15 The cost of carrying out concreting of foundations in all respect,

shall be deemed to be included in the unit rates of foundations of tower
in different type of Soils quoted by the Bidder.
8.12 BACKFILLING AND REMOVAL OF STUB TEMPLATE:
8.12.1 Following opening of form work and removal of shoring and shuttering,
if required, backfilling shall be started after 24 hours of casting repairs, if
any, to the foundation concrete. Backfilling shall normally be done with
the excavated Soil, unless it consists of large boulders, which shall be
broken to a maximum size of 80mm.
8.12.2 The backfill materials should be clean and free from organic or other
foreign materials The earth shall be deposited in maximum
200mm layers, leveled, and wetted and rammed properly before
another layer of earth is deposited. Care shall be taken that the back filling is
started from the foundation end only in the pits towards the outer end.
8.12.3 The backfilling and grading shall be carried to an elevation of about 150mm
above the finished ground level to drain out water. After backfilling, 50mm
high earthen embankment (bandh) will be made along the sides of excavated
pits and sufficient water will be poured in the backfilled earth for at least next
24 hours.
8.12.4 The stub setting Templates shall be opened only after the completion of back-
filling.
8.12.5 After completing stringing work, if level of backfilling of some of the

locations gets settled and it is required to backfill the locations again, the
same would be done by the contractor at no extra cost.

Volume-V (Part-2)
8.12.6 No extra charge is admissible for carrying out backfilling of foundation

pit (including backfilling from borrowed earth if required) and the cost of
backfilling including cost of materials shall be deemed to be included in the
cost of excavation of towers quoted by the in the bid.
8.13 CURING:
The concrete, after it is 24 hours old, shall be cured by keeping the
concrete wet continuously for a period of 14 days after laying. The pit may
be backfilled with selected earth sprinkled with necessary amount of water
and well consolidated in layers not exceeding 200mm of consolidated
thickness after a minimum period of 24 hours and thereafter both the
backfilled earth and exposed chimney top shall be kept wet for the remainder
of the prescribed time of 14 days. The uncovered concrete chimney above the
backfilled earth shall be kept wet by providing empty cement bags dipped in
water fully wrapped around the concrete chimney for curing duly ensuring that
the bags are kept wet by frequent pouring of water on them. The Contractor
may use anti curing paint. However no extra payment shall be made on this
account.
8.14 BUILDING STONE REVETMENT:
Stone revetment in 1:6 cement mortars shall be constructed by the Contractor
at specified locations. The detailed proposal in consultation with the site
Engineer, for carrying out revetment work shall be submitted to the
O/o. CHIEF ENGINEER (Procurement), Jabalpur through concerned
Superintending Engineer, EHT Construction and approval shall be obtained
before carrying out revetment work. The top seal cover of revetment work
shall be done with 1:2:4 normal mix. All materials including cement shall be
provided by the contractor and cost of building revetment shall be deemed to
include cost of such materials also i.e. Cement, sand, metal and stone. Curing
of revetment shall be done as specified for tower foundation. The back filling of
the inside of the revetment wall with Soil/borrowed earth will be paid for
extra on per m³ basis and shall include its compacting and watering.
The excavation for revetment foundation shall be paid at the rates as indicated
by the Bidder in Price Schedule. The revetment work, wherever necessary,
shall have to be completed before taking up final tensioning work in the
Section.
8.15 TOWER EARTHING:
8.15.1 For the purpose of earthing, necessary earthing rods (25mm dia, 2
meter long) connecting clamps, and connecting wire will be provided by
the Contractor. The earthing rods are to be hammered preferably in the
foundation pits and connected to stub by 7/4.00mm earth-wire and
with necessary connecting clamps before concreting the foundation. If it is not
possible to tie the rods in the foundation pit i.e. in rocky location, they shall
be buried near the foundation pit and connected to the stubs. The earthing
rods are to be provided on diagonally opposite legs of the tower. Each tower
shall be earthed before the foundation is casted.
8.15.2 The tower footing resistance of all towers shall be measured in dry whether
after the erection and before the stringing of Ground-wire. The counterpoise
earthing shall be resorted to, in accordance with the instructions of the site
Engineer, in case the tower footing resistance (TFR) exceeds the specified
value. It shall be ensured that the tower footing resistance is less than 10
ohms. Each tower footing resistance shall be intimated (along with the tower
location number) while submitting the progress report of tower Erection.

Volume-V (Part-2)
8.15.3 Counterpoise Earthing :

(a) In case of high resistivity, counterpoise earthing shall be provided which
consists of four lengths of galvanized steel stranded wires, 7/4.00mm
fitted with each leg of the tower with proper clamps for connection to the
tower leg at one end. The counterpoise will be laid radially away from the
tower and will normally be 15 meters in length, buried to the depth of
600mm below the ground level. The length of counterpoise wire may
be increased if the resistance requirements are not met. Connecting clamps
shall be buried in the chimney portion of the foundation. Contractor shall
quote for the laying of counterpoise earthing on per running meter basis,
including cost of all materials. The scope of work of connecting
the counterpoise to the tower legs shall be deemed to be included in the
cost of laying of counterpoise (with cost of materials). The counterpoise
connecting wire and clamps will be arranged by the Contractor. The
counterpoise shall preferably be laid through soft soil areas if available.
The planning of laying counterpoise shall be done as per approval of site
Engineer. The cost of laying of counterpoise shall be inclusive of excavation
and backfilling work also.
(b) The Contractor shall have to provide rod earthing at the end of each
counterpoise wire and this may lead to T.F.R. values within specified limits.
This work of additional rod earthing shall be paid extra on per location basis
as per the rates indicated in Price Schedule. Which shall include the cost of
providing such earthing and cost of materials i.e. earthing rods (4 Nos. for
counterpoise earthing i.e. additional earthing of towers) and connecting
arrangements for one tower.
8.16 TOWER ERECTION/ ASSEMBLY:
8.16.1 Towers shall be erected after the foundation concrete is at least 14 days old,
but a gap of 24 days shall be preferred. The method followed for the erection
of towers, shall ensure the points mentioned below:
8.16.2 Straining of the members shall not be permitted for bringing them into
position. It may, however, be necessary to match hole positions at joints
and to facilitate this, Tommy bars not more than 450mm long may be used.
8.16.3 Before starting erection of an upper section, the lower section of tower shall
be completely braced and all bolts provided in accordance with approved
drawings.
8.16.4 All plan diagonals relevant to a section of tower shall be placed in position
before assembly of upper section is taken up.
8.16.5 The bolt positions in assembled towers shall be as per IS: 5613 (Part-
II/Sec.2), 1995 with latest amendments.
8.16.6 Tower shall be fitted with Number, Phase and Danger Plates which shall be
arranged by the Contractor.
8.16.7 Anti-climbing Devices:
Barbed wire will be used at a height of approx. 3 meters and above as an

anti-climbing measure, which shall be arranged by the Contractor. At every
location three layers of Barbed wires will be provided each inside and outside
Volume-V (Part-2)
the tower in horizontal plane. Spacing between the layers with fixing
arrangements shall be provided as per the provisions of IS:5613 (Part-
II/Sec.1)-1976 with latest amendments. The galvanized angle pieces with
notches for accommodating Barbed wire with Bolts Nuts etc. shall be supplied
by the Contractor. After the Barbed wire is placed in position in the notches,
the notch opening shall be welded to avoid the theft of Barbed wire and
anti-corrosive treatment with cold galvanizing paint shall be given, as
also in the case of bolts to be welded below bottom cross arm level.
Suitable locking arrangement (pad-lock) shall also be provided.
8.16.8 All blank holes, if any left, after complete erection of the tower, are to be
filled up by bolts and nuts of proper size.
8.17 TIGHTENING PUNCHING AND WELDING OF BOLTS AND NUTS:
8.17.1 All nuts shall be tightened properly using correct size of spanners. Before
tightening, it will be seen that packing washers and plates are placed in
relevant gaps between members, bolts of proper size and length are provided
and one spring washer is used under each nut and in case of step bolts,
spring washers shall be placed under the outer nut.
8.17.2 The tightening shall progressively be carried out from the top to downwards,
care being taken that all bolts at every level are tightened simultaneously.
The threads of bolts projecting outside the nuts shall be punched at
three positions on the periphery to ensure that the nuts are not loosened in
course of time. If during tightening a nut is found to be slipping or running
over the bolt threads, the bolt together with the nut shall have to be
replaced.
8.17.3 The threads of all the bolts projected outside the nuts shall be welded all
around the periphery of nut-bolts. The welding of nut-bolts as above shall be
carried out from ground level to bottom cross arm level in all towers upto
+6M extensions. In case of +10M/18M/25M extension towers and special
river crossing towers, nut-bolts welding shall be done up to 25 meter height
from ground level.
8.17.4 After welding, cold galvanized paint having at least 90% zinc content shall
be applied on the welded portion. At least two coats of the paint shall be
applied. The cost of such paint and welding etc., including application of paint
etc., shall be deemed to be included in the quoted erection rates.
8.18 INSULATOR HOISTING:

Suspension insulator strings shall be used on suspension towers and tension
insulator strings on angle and dead end towers. They shall be fixed on all
the towers just prior to the stringing. Damaged Insulators and fittings, if
any, shall not be used in the assemblies. Before hoisting, all Insulators shall
be cleaned in a manner that will not spoil, injure or scratch the surface of the
Insulator, but in no case shall any oil be used for the purpose. Security
clips shall be fitted in position for the Insulators before hoisting. Arcing Horns
shall be fitted in an approved manner. Torque wrench shall be used for fixing
different line materials and their components, like suspension clamps etc. for
Conductor and Ground-wire etc.
8.19 HANDLING OF CONDUCTOR AND EARTHWIRE:

Volume-V (Part-2)
8.19.1 The Contractor shall be entirely responsible for any damage caused to the
towers or Conductors during stringing. While running out the Conductors,
proper care shall be taken ensuring that the Conductors do not touch and rub
against the ground or objects which could cause scratches or damage to the
Conductor strands. The Conductors shall be run out of the drums from the
top in order to avoid damage due to chafing. The drum stand shall be
provided with a suitable braking device to avoid damage, loose running out
and kinking of Conductor. Proper care shall be taken to avoid injury to
Conductor while making it pass over the bull wheel of tensioner. After the
tensioner, the Conductor will be pulled by pull cable and consequently pass
over the running out blocks. The groove of the running out blocks will be of
such a design that the seat is semi-circular and larger than the diameter
of the Conductor and it does not slip over or rub against the sides. The
grooves shall be lined with hard rubber or neoprene to avoid damage to
Conductor and shall be mounted on properly lubricated bearings.
8.19.2 The running blocks shall be suspended in a manner to suit the design of
the cross arm. All running out blocks especially those at the tensioning end,
will be fitted on the cross arm with jute cloth wrapped over the steel work
and under the slings to avoid damage to the slings as well as to the
protective surface finish of the steel work. The Conductor shall be
continuously observed for loose or broken strands or any other kind of
damage. When approaching towards end of a drum length, at least three
coils shall be left when the stringing operations are to be stopped. These coils
are to be removed carefully if another length is required to be run out,
new length may be joined to the length already run out by the compression
joint in approved manner.
The Conductor joints and clamps shall be erected in such a manner that no
bird caging, over tensioning of individual wires or layers or other deformities
or damage to the conductor shall occur. Clamps or bracing devices shall
under erection conditions allow no relative movement of strands or layers of
the conductors.
8.19.3 Repairs of Conductors, in the event of damage being caused to isolated

strands of a conductor during the course of erection, if necessary, shall be
carried out during the running out operations, with repair sleeves.
Repairing of Conductor surface with repair sleeve shall be done only in case
of minor damage, scuff marks etc., keeping in view both electrical and
mechanical safety requirements. Number of damaged strands shall not
exceed 1/6th of the total strands in the outer layer. The final Conductor
surface shall be clean, smooth and shall be without any projections, sharp
points, cuts, abrasions etc. Repair sleeves may be used when the damage
is limited to the outermost layer of the Conductor and is equivalent to the
severance of not more than one third of the strands of the outermost layer.
No repair sleeve shall be fitted within 30 m of tension or suspension clamp or
fittings. Further, more than one repair sleeve per Conductor shall not be
normally used in any single span.
8.19.4 Conductor splices shall be so made that they do not crack or get damaged in
the stringing operation. The Contractor shall use only such equipment/
methods during Conductor stringing which ensures complete compliance in
this regard.
8.19.5 Derricks shall be used where roads, rivers, canals, telecommunication or

overhead power lines, railway lines, fences or walls have to be crossed
during stringing operations. It shall be seen that normal services are not

Volume-V (Part-2)
interrupted and no damage is caused to property. Shut down shall be

obtained when working at crossing of overhead power lines.
8.19.6 The sequence of running out shall be from top to downwards, i.e. the
Ground-wire shall be run out first followed by the Conductors in succession.
Imbalances of loads on towers shall be avoided as far as possible i.e. both
Ground-wires, then both bundles of top Conductor and then both bundles of
middle Conductor followed by both bundle Conductors of bottom Cross-arm
should be strung.
8.19.7 The proposed transmission line may run parallel for certain distance with the
existing 400/220/132KV lines which will remain energized during the stringing
period. As a result there is a possibility of dangerous voltage build up due
to electromagnetic and electrostatic coupling in the pulling cables,
Conductors and Ground-wires, which although comparatively small in
magnitude during normal operations, can be severe during switching and
ground fault conditions on the energised lines. It shall be the Contractor's
responsibility to take adequate safety precautions to protect his employees
and others from this potential danger.
8.20 STRINGING OF CONDUCTOR AND EARTHWIRE:
8.20.1 The stringing of the Conductor shall be done by control in tension method by
means of tension stringing equipments. The equipments shall be capable of
maintaining a continuous tension. The maximum tension imposed on a
conductor during stringing operations shall not exceed than that necessary to
clear obstructions on the ground. The contractor shall indicate in their offer,
the sets of tension stringing equipment he is having in his possession and the
sets of stringing equipment he would deploy exclusively for this work.
8.20.2 After being pulled, the Conductor/Ground-wire shall not be allowed to hang in
the stringing blocks for more than 96 hours before being pulled to the
specified sag.
8.20.3 The Contractor shall give complete details of the stringing methods, which he
proposes to follow. At least one month in advance of the commencement
of stringing, the Contractor will submit the stringing charts for the
Conductors and Ground-wire showing the initial and final sags and tension
for various temperatures and spans, alongwith equivalent spans in the
lines, for the approval of the purchaser. The stringing shall be carried out
as per the stringing charts approved by the purchaser and in accordance
with relevant IS. All the tolerances for the line shall conform to IS :5613
(Part-2/Sec-2) 1995.
8.20.4 In hilly terrain and thick forest, where deployment of tension stringing
machine is not possible, manual stringing may be adopted after getting
approval of Purchaser’s site Engineer. The contractor shall deploy appropriate
tools/equipments/machinery to ensure that the stringing operation is carried
out without causing damage to conductor/earth wire and conductor/earth wire
is installed at the prescribed sag-tension as per the approved stringing charts.
8.21 JOINTING:
8.21.1 The number of joints in Conductor/Ground-wire shall be kept to minimum

possible by properly selecting the drums from available lot of respective
drums. All the joints on the Conductor and Ground-wire shall be of
compression type. Each part of the joint shall be cleaned by wire brush to
make it free of rust or dirt etc. and properly greased with anti-corrosive

Volume-V (Part-2)
compound, as approved by our Engineer before the final compression is

done with the compressors. The cost of such grease etc. used for joints
shall not be paid extra and shall be deemed to be included in the stringing
rates.
8.21.2 All joints shall be made at least 30 meter away from the structures. No joints
shall be made in the spans crossing over the main roads, railways, rivers etc.
Not more than one joint per Conductor shall be allowed in one span. Care
shall be taken to mark the conductor for properly centering the compression
clamp before compressing. During compression operation, the conductor shall
be handled in such a manner as to prevent lateral or vertical bearing
against the dies. After pressing the joint the aluminum sleeve shall
have all corners rounded, burrs and sharp edges removed and smoothened.
8.21.3 Suitable protector shall be used during stringing of Conductor to avoid any
damage to the joint while it passes over the traveler.
8.22 SAGGING IN OPERATION:
8.22.1 The Conductors shall be pulled up to the desired sag and left in running
block for at least one hour after which the sag shall be rechecked and
adjusted, if necessary, before transferring the conductor from the running out
blocks to the suspension clamps. The Conductors shall be clamped within
36 hours of sagging in.
8.22.2 The sag will be checked in the first and the last span of the section in case of
sections up to eight spans and in one intermediate span also for sections with
more than eight spans. The sag shall also be rechecked when the
Conductor have been drawn up and transferred from running blocks to the
insulator clamps.
8.22.3 The running out blocks, when suspended from the transmission
structure for sagging shall be so adjusted that the Conductors on running out
blocks will be at the same height as that of the suspension clamps to which it
is to be secured.
8.22.4 At sharp vertical angles, the sags and tensions shall be checked on both
sides of the angle. The Conductor and Ground-wire shall be checked on the
running out blocks for equality of tension on both sides. The suspension
insulator assemblies will normally assume vertical positions when the
Conductor is clamped.
8.22.5 Tensioning and sagging operations shall be carried out in calm weather,
when rapid changes in temperature are not likely to occur.
8.23 TENSIONING & SAGGING OF CONDUCTOR AND EARTHWIRE:
The tensioning and sagging shall be done in accordance with the

approved stringing charts before the Conductor and Ground-wire is finally
attached to the towers through the insulator strings for the Conductor and
Ground-wire clamps for the Ground-wire Dynamometers shall be used for
measuring tension in the Conductor and Ground-wire.
8.24 CLIPPING IN:
8.24.1 Clipping of the Conductors in position shall be done in accordance with the
method approved by our Engineer. At suspension location free center type

Volume-V (Part-2)
suspension clamp with Armour rod set or AGS type suspension clamp shall be
used.
8.24.2 The jumpers at the section and angle towers shall be formed to parabolic
shape to ensure maximum clearance requirements. Pilot suspension
insulator string shall be used, if necessary, to restrict the jumper swings to
the design values. Jumper connections of transposition towers shall be so
made that adequate clearances are available from tower body as well as
phase conductors.
8.24.3 Fasteners in all fittings and accessories shall be secured in position. The
security clip shall be properly opened and sprung into position.
8.25 FIXING OF CONDUCTORS AND EARTHWIRE ACCESSORIES :

Spacers, spacer dampers, Vibration dampers (4-R type) and other Conductor
and Ground-wire Accessories supplied by the purchaser shall be installed by
the Contractor as per the design/drawing requirement and as per instructions
of the Engineer. Spacers shall be fitted within 24 hours of the Conductor
clamping. While installing the Conductor and Ground-wire Accessories, proper
care shall be taken to ensure that the surfaces are clean and smooth and no
damage shall occur to any part of the Accessories.
8.26 REPLACEMENT:
If any replacements are to be effected after stringing and tensioning or
during maintenance, members and bracing shall not be removed without
reducing the tension on the tower with proper guying or releasing the
Conductor. If the replacement of cross arms becomes necessary after
stringing, the Conductor shall be suitably tied to the tower at tension points or
transferred to suitable roller pulleys at suspension points.
8.27 FINAL CHECKING TESTING AND COMMISSIONING:

After completion of the works, final checking of the line shall be done by the
Contractor to ensure that all the foundation works, tower erection, and
stringing have been done strictly in accordance with the specification and
as approved by the purchaser. All the works shall be thoroughly inspected
keeping in view the following main points:
(a) Sufficient back-filled earth is lying over each foundation pit and it is
adequately compacted.
(b) Concrete chimneys and their copings are in good finely shaped conditions.
(c) All the tower members are correctly used, strictly according to approved
drawing and are free from defects or damages, whatsoever.
(d) All bolts are properly tightened and punched/tack welded as per this
specification.
(e) The stringing of the Conductors and Ground-wire has been done as per the
approved sag and tension charts and desired clearances are clearly available.
(f) All Conductor and Ground-wire Accessories are properly installed.
(g) All other requirements to complete the work like fixing of Danger Plate,
Phase Plate, Number Plate, Anti-climbing devices, Aviation Signal
(wherever required) etc. are properly installed and the painting has been
done wherever required as per Aviation Rules.
(h) It should be ensured that revetment is provided, wherever required.

Volume-V (Part-2)
(i) The line insulation is tested by the Contractor by providing his own
equipment labour etc. to the satisfaction of the purchaser to ascertain the
insulation condition of the line.
(j) Conductor continuity test is carried out to verify that each Conductor of the
overhead line is properly connected electrically also.
The line may be charged at a low value of Power Frequency Voltage for the
purpose of testing.
***

Volume-V (Part-2)
ANNEXURE- 1
GUARANTEED TECHNICAL PARTICULARS OF CONDUCTOR & EARTH WIRE
(A) ACSR MOOSE CONDUCTOR.
S.NO. PARTICULARS ACSR MOOSE

1 ACSR MOOSE– Stranding and Size in mm 54/7/3.53
2 Stranding and wire dia in mm
a) Aluminium 54/3.53
b) Steel 7/3.53
3 Standard nominal copper area in sq.mm 325
4 Actual aluminium area in sq.mm. 528.5

5 Standard area of cross section in sq.mm.
a) Aluminium strand 9.787
b) Steel strand 9.787
c) Conductor 597
6 Diameter of complete conductor in mm. 31.77
7 Minimum ultimate tensile stress in Kg./sq.mm.

a) Aluminium strand 16.38
b) Steel strand 134
8 Guaranteed ultimate tensile strength of Min. 161.20
Conductor in Kg.
9 Min. breaking load in KN for

a) Aluminium strand
i) Before stranding 1.57
ii) After Stranding 1.49
b) Steel strand
i) Before standing 12.86
After stranding 12.22

ii)
10 Zinc coating of steel strand
a) Number and duration of dips 3 dips 1 min.
b) Minimum weight of coating in gms./sq.mtr. 260
11 No. of standard length in one reel One

12 Weight in Kg./Km. (Approx.)
a) Aluminium 1465
b) Steel 539
c) Conductor 2004

Volume-V (Part-2)
S.NO. PARTICULARS ACSR MOOSE

13 Resistance in ohms per km at 20 deg. C 0.0552
14 a) Continuous max. current rating of conductor in 900
still air at 40 deg. C ambient temperature
Amps.
b) Temperature rise for the above current deg. C. 35 Deg. C
15 Lay Ratio
Steel core : 6 wire layer 16-18
Aluminium: 12 wire layer 12-14
18 wire layer 11-13
24 wire layer 10-12
16 Modulus of elasticity of 0.703x106
Conductor Kg/Sq.mm
17 Co-efficient of linear expansion per degree
centigrade of:
a) Aluminium strand Kg./sq.cm 23x10-6
b) Steel strand Kg./Sq.cm 11.5x10-6

c) Conductor Kg./sq.cm. 19.3x10-6
18 Percentage of carbon in steel wire 0.50-0.85
19 Standard length of each piece in Km. 1.5
20 Tolerance, if any, on standard length +/- 5%
The conductor should conform strictly to the “Guaranteed Technical

Particulars” as detailed above. The conductor shall conform to IS:398 Part-II –
1996 & as amended up-to-date.
(B) HTGS EARTH WIRE

1 Particulars of single steel wire before
stranding
a) No. of wires 7
b) Diameter (mm) 3.66 mm
c) Tolerance 2%
Plus 3.74
Minus 3.58
d) Minimum elongation in 100 mm length 5 mm
e) Breaking load (Kg.)
f) Minimum ultimate tensile stress (Kg/mm2) 95
g) D.C. resistance at 20 deg. C (Ohm/Km) 17.57(Max.)
2 Stranded Wire
a) Length of lay (mm)

Volume-V (Part-2)

Maximum 198
Minimum 165
b) Overall diameter of Earth wire(mm) 10.98
c) Area of cross section of Earth wire (sq. mm.) 73.64
d) Breaking load (Kg.)
e) Resistance in Ohms per Km. at 20 deg. C. 2.5
f) Modulus of elasticity of Earth Wire (Kg/cm2) 19 x10 5Kg/cm2
g) Weight of Earth wire (Kg/Km) 583
h) Co-efficient of linear expansion (per deg. C) 11.5x10-6 /deg. C
3 Quality of zinc used (Specify the grading and
Zn - 99.95 %
percentage)
4 Coating of zinc on wires In Gms. per sq.
260
mtrs.
5 Nos. of Dip 3,one minute&1, half
minute
6 Oiling/greasing on Earth wire Boiled Linseed Oil
7 Tolerance in standard length Plus/Minus 5%

Volume-V (Part-2)
ANNEXURE-2
GUARANTEED TECHNICAL PARTICULARS OF DISC INSULATORS
(A) GUARANTEED TECHNICAL PARTICULARS

FOR 120KN EMS DISC INSULATORS.
S.N. Description 120 KN DISC

Single Double
Suspension Suspension
1 Maker’s name, address and country
2 Size and designation of Ball & Socket and 20 mm IS: 2486

standard to which it will conform (mm) (Pt.II)1989
3 No. of insulator discs per string 23 2*23
4 Outside dia. of the disc – mm 255 255
5 Spacing – mm 145 145
6 Creepage distance of the single disc-mm 320mm 320mm
7 Electro-mechanical strength of single disc
– kg. 12237 12237
8 Withstand voltage of single disc-kVp
8.1 Power frequency
a) Dry – kV (rms) 75 75
b) Wet – kV (rms) 45 45
8.2 Impulse voltage 1.2/50
microsecond
b) Negative - kV 115 115
9 Withstand voltage for
the complete string
9.1 Power frequency (with and without
Corona ring)
a) Dry – kV (rms) 720 & 725 720 & 725
b) Wet – kV (rms) 680 & 685 680 & 685
9.2 Lightning Impulse voltage 1.2/50
microsecond (With and without Corona
ring)
a) Positive – kVp 1600 & 1605 1600 & 1605
b) Negative – kVp 1610 & 1615 1610 & 1615
10 Flashover voltage for the disc
10.1 Power frequency (with and without
Corona ring)
a) Dry – kV (rms) 80 80
b) Wet – kV (rms) 50 50
10.2 .Lightning impulse voltage 1.2/50
microsecond

Volume-V (Part-2)
S.N. Description 120 KN DISC

Single Double
Suspension Suspension
a) Positive – kVp 115 115

b) Negative – kVp 120 120
11. Flashover voltage for complete string.
11.1 Power frequency (with and
a) Dry – kV (rms) 745 & 750 745 & 750
b) Wet – kV (rms) 705 & 710 705 & 710
11.2 .Lightning impulse voltage
1.2/50 microsecond
a) Positive – kVp 1650 & 1655 1650 & 1655
b) Negative – kVp 1660 & 1665 1660 & 1665
12 Max. voltage (%) across any disc in the
string (with and without Corona ring) 9% 9%
13 P.F. Puncture Voltage of each disc
insulator KV(rms) 125 125
14 Minimum corona extinction voltage of
each disc insulator KV(rms) 18 18
15 Max. RIV with 10 KV (rms) of each disc
insulators (Micro volts) 50 50
15 Weight of each disc (Kgs) (approx) 6 6
(B) GUARANTEED TECHNICAL PARTICULARS

FOR 160KN EMS DISC INSULATORS.
S.N. Description 160 KN DISC INSULATORS

ON 400 KV
Single Double
Tension Tension
1 Maker’s name, address and

country
2 Size and designation of Ball & 20 mm IS: 2486(Pt.II)1989
Socket and standard to which
it will conform (mm)
3 No. of insulator discs per
1*24 2*24
string
4 Outside dia. of the disc – mm 280 280
5 Spacing - mm 170 170
6 Creepage distance of the
330 330
single disc-mm
7 Electro-mechanical strength of
16500 16500
single disc – kg.
8 Withstand voltage of single
disc-kVp
8.1 Power frequency
a) Dry – kV (rms) 75 75
Volume-V (Part-2)

ON 400 KV
Single Double
Tension Tension
b) Wet – kV (rms) 45 45
8.2 Impulse voltage 1.2/50
microsecond
b) Negative - kV 120 120
9 Withstand voltage for
the complete string
and without Corona ring)
a) Dry – kV (rms) 720 720
b) Wet – kV (rms) 690 690
9.2 Lightning Impulse voltage
1.2/50 microsecond (With and
10 Flashover voltage for the disc
a) Dry – kV (rms) 80 80
b) Wet – kV (rms) 50 50
10.2 .Lightning impulse
voltage 1.2/50 microsecond
Flashover voltage for
11.
complete string.
a) Dry – kV (rms) 740 740
b) Wet – kV (rms) 710 710
11.2 .Lightning impulse
voltage 1.2/50 microsecond
12 Max. voltage (%) across any
disc in the string (with and 9 9
13 P.F. Puncture Voltage of
each disc insulator 125 125
KV(rms)
14 Minimum corona extinction
18 18
voltage of each disc insulator

Volume-V (Part-2)

ON 400 KV
Single Double
Tension Tension
KV(rms)
15 Max. RIV with 10 KV (rms)
of each disc insulators (Micro 50 50
volts)
15 Weight of each disc (Kgs) 8 8
16 Electromechanical strength
16500 2 x 16500
of complete string (kgs.)

Volume-V (Part-2)
ANNEXURE-3
LIST OF SAMPLE DRAWINGS
S.No. Particulars
Outline drawing of 400kV 23 unit single suspension insulator

1
string.
Outline drawing of 400kV 2x23 unit double suspension

2
insulator string.
Outline drawing of 400kV 1x24 unit single tension insulator

3
string.
Outline drawing of 400kV 2x24 unit double tension insulator

4
string.
5 Central Hanger shackle
6 Details of earthing arrangement for towers
7 Armour Grip Type Spacer for conductor
8 Rigid Spacer for Jumper
9 Midspan joints
10 Repair sleeve
11 Vibration damper
12 T-Connector
Groundwire Accessories:
13 Suspension Clamp Assembly
14 Tension Clamp
15 Midspan joint
16 Vibration damper for earthwire
17 Copper earth bond
18 Number plate for 400kV transmission line

Volume-V (Part-2)
19 Phase plate for 400kV transmission line
20 Danger Board for 400kV transmission line
21 Anticlimbing Device for 400kV Towers.

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MADHYA PRADESH POWER TRANSMISSION CO. LTD.

SHAKTI BHAWAN RAMPUR: JABALPUR

Technical Book Serial No.

TECHNICAL SPECIFICATION FOR SUPPLY

O/o CHIEF ENGINEER (PROCUREMENT)

PART I – Specifications & requirements for supply of

Section- 1 Common Technical Requirement ………………………. 1

Section- 2 Technical Specifications for Towers ………………….. 14

Section- 3 Technical Specifications for Conductor ………………. 32

Section- 4 Technical Specifications for Earth wire …..………….. 44

Section- 5 Technical Specifications for Disc Insulators …………… 51

Section- 6 Technical Specifications for Hardware fittings for

Section- 9 Technical Specifications for erection of transmission

Annexure – 1 Technical Particulars of ACSR Conductors & Earth 177

Annexure – 3 Technical Particulars of Hardware for conductor 183

1.01.01 The provisions under this section are to supplement

1.01.02 The scope of work involves fabrication, galvanizing and

1.01.03 This section also provides for the Design, manufacturing,

1.01.04 It is not the intent to specify completely herein all details of

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1.02 CLIMATIC CONDITION

1 Location in the state of MADHYA PRADESH

1.03.02 The works covered by the specification shall be designed,

1.03.03 The Contractor shall also note that list of standards

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1.03.04 When the specific requirements stipulated in the

1.04.01 The lists of Indian standards are specified in individual

1.04.02 If the material offered by the Bidder conform to any other

1.04.03 The Material and Installation work conforming to standards

1.05 TYPE TESTS:

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design/type already type tested and the design/type offered against

1.06 DISCREPANCY IN TECHNICAL PARTICULARS:

The bidders will have to furnish confirmation in regard to compliance of

1.07 MANUFACTURER'S AUTHORISATION:

1.08 SCHEDULE OF QUANTITIES:

1.08.01 The requirements of various Materials and Installation work

1.08.02 Although all the quantity of Material and Installation work

1.09 PERFORMANCE GUARANTEE PERIOD:

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1.11 DRAWINGS AND DOCUMENTS:

1.11.01 In addition to those stipulated in Vol. I of bidding

1.11.02 Within one month from the award of contract, the

1.11.03 The comments/ approval to drawings submitted by the

1.11.04 The drawings submitted for approval to the EMPLOYER shall

1.11.05 The work shall be performed by the Contractor strictly in

1.11.06 All manufacturing, fabrication and Installation work under

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of the contract and such changes will again be subject to approval by

1.11.07 The approval of the documents and drawings by the

1.11.08 All drawings shall be prepared using AutoCAD software.

1.11.09 Copies of drawings returned to the Contractor will be in the

1.11.10 All rights of the design/drawing for all Material and

1.11.11 The manufacturing of the material shall be strictly in

1.11.12 Approval of drawing/works by EMPLOYER shall not relieve

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1.12 QUALITY ASSURANCE PROGRAM:

1.12.01 Quality Assurance Program : To ensure that the Material

1.12.02 Immediately after award of contract, the contractor shall