Principal Technical Parameters for Buspost Insulator and Disc Insulator:

1.0 Bus Post Insulators:

1.0 The Bus Post Insulators (BPI) shall be suitable for outdoor service and it shall
be solid core. The insulator shall be made of homogeneous and vitreous
porcelain of high mechanical and di-electric strength. Glazing of the porcelain
shall be of uniform brown or dark brown color, with a smooth surface arranged
to shed away rain water.

1.2 The Bus Post Insulators shall be provided with a completely galvanized steel
base designed for mounting on the support structure. The base and mounting
shall be such that the insulator will be rigid and self supporting, and no guying
or cross- bracings between phases shall be necessary. All the ferrous (metal)
parts shall be duly hot dip galvanized.

1.3 The Bus Post Insulators shall be provided with cap of high grade malleable
steel casting. It shall be machine-faced and hot dip galvanized. The casting
shall be free from blow holes, cracks and other defects.

1.4 All necessary nuts, bolts, washers, etc. required for the assembly of the
insulator stack shall be supplied alogwith the insulator. All these fasteners
shall be hot dip galvanized.

1.6 The basic technical parameters of Bus Post Insulators are as follows:

Sr. Particulars 400 KV 220 KV 132/100 33 KV

No KV
.
1) Voltage Rating 420 KV 245 KV 145 KV 36 KV
2) Height 3650 mm 2300 mm 1500 mm 508 mm
3) Min.Nominal Creepage 10500 mm 6125 mm 3625 mm 840 mm
Distance
4) Bending Strength (min.) 8 KN 6 KN 4 KN 4 KN
5) Torsional Strength 600 Kgm 460 Kgm 460 Kgm 460 Kgm
(min.)
6) Impulse Withstand 1425 KVp 1050 KVp 650 KVp 170 KVp
Voltage
7) No. of Tapped holes 4/8 4/4 4/4 4/4
(Top / Bottom).
8) Tapped Dia. (Top) M16 M16 M16 M16
9) Hole Dia. (Bottom) 18 mm 18 mm 18 mm M16
10) PCD (Top/Bottom) 127/300 127/200 127/184 127/184
mm mm mm mm (for bus
support
insulator)
76/76 mm
(for isolator)

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2.0 Disc Insulators

2.1 The insulator strings shall consist of standard Porcelain or Glass discs for a
three phase 50 Hz, effectively earthed 400 KV/220 KV/132 KV/33 KV system
The discs shall be cap and pin, ball and socket type. All the disc insulators
shall be of antifog type.

2.2 The number of insulators to be used for suspension and tension locations,
their electromechanical strength alongwith hardware fitting shall be as follows:

Sr. Particulars System Voltage

No. 33 KV 132 KV 220 KV 400 KV
1 EMS of Insulators for
a Tension String 120 KN 120 KN 120 KN 120 KN
b Suspension string 70 KN 70 KN 70 KN 70 KN
2 No. of Insulators for
a Tension String 4 10 15 24
b Suspension string 4 9 14 23

2.3 The size of disc insulator, minimum creepage distance shall be as follows:

Sr. EMS of Type of Size of Disc insulator Min. Creepage

No. insulator insulator (mm) distance (mm)
(Dia. x Height)
1 70 KN N 255 x 145 320
AF 280 x 145 430
2 120 KN N 255 x 145 320
AF 280 x 145 430
3 160 KN N 280 x 170 320
AF 305 x 170 430
NOTE: Details applicable for items covered in BOM only be considered.

2.4 All raw materials to be used in the manufacture of 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.

2.5 The porcelain used for manufacturing the porcelain discs shall be ivory white,
non-porous and having very high dielectric, mechanical and thermal strength.
The porcelain shall remain unaffected by climatic conditions, ozone, acid,
alkali, zinc or dust. The manufacturing shall be by wet process, and
impervious character obtained by thorough vitrification.
2.6 The glass used for manufacturing the shells of Glass disc insulator shall be
sound, free from defects such as flaws. bubbles, inclusions etc. and be of
uniform toughness over its entire surface. All exposed glass surfaces shall be
smooth.
2.7 The insulator surfaces that come in contact with cement shall be made rough
by sand glazing. All other exposed surfaces shall be brown glazed. The
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 thickness of the glaze shall be uniform throughout the working temperature
range.

2.8 The insulator caps shall be made of good quality malleable cast iron and shall
be annealed. Ball-pins shall be made of drop-forged steel. The ferrous parts
(caps, pins, etc.) shall be duly hot dip galvanized. The security clips shall be
made of phosper bronze or stainless steel.

2.9 Cement used as a filler material shall be quick setting, fast curing, port land
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.

2.10 The dimensions of Ball & Socket for 70 KN disc shall be 16 mm and of
120/160 KN disc 20 mm in accordance with the standard dimensions stated in
IS-2486(II).

3.0 IDENTIFICATION MARK:

3.1 The shell of insulator shall be legibly and indelibly marked with the trade
mark/name of the manufacturer, the month and year of manufacture, country
of manufacture, guaranteed electro-mechanical strength in Kilo-Newton’s
abbreviated by 'KN' to facilitate easy identification and proper use. The
marking shall be printed and not impressed and the same shall be applied
before firing.

3.2 The metal cap of each disc insulator shall bear the name of manufacturer by
embossing. The identifying letters shall be at least 5 mm high. The characters
shall be distinct, durable, and conspicuous after galvanizing.

4.0 Type Tests:

4.1 All the type tests as specified for Buspost insulators and Disc insulators
(unit/string) in MSETCL Technical Specification for the respective items and
conducted within last 5 years from the date of opening of tender shall be
submitted.

4.2 In case, the tests have been conducted earlier than 5 years or if there is any
change in the manufacturing process, material or design in the equipment
since after earlier passing of the type tests, the respective type test(s) shall be
carried out by the successful tenderer, after award of contract, in presence of
purchaser's representative, free of cost.

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5.0 Acceptance Tests:

The following acceptance tests shall be conducted on 70 KN, 120 KN and 160
KN disc insulators in presence of purchasers representative for the purpose of
acceptance of a lot:

Sr. Particulars of test Reference

No. Standard
a) Visual examination } IS:731

b) Verification of dimensions } IS:731

c) Temperature cycle test } IS:731

d) Galvanising test } IS:731

e) Mechanical performance test } IEC:60575

f) Test on locking device for } IS:2486(IV)

ball and socket coupling }

g) Eccentricity test (Axial & Radial } IEC:60383/60168

Runout)

h) Electro-mechanical strength test } IS: 731

i) Puncture test } IS: 731

(Only for Porcelain Disc insulators)

j) Porosity test } IS: 731

(Only for Porcelain Disc insulators)

k) Thermal shock test } IEC:60383

(Only for Glass Disc insulators)

l) Steep wave front test/Puncture test } As per MSETCL

(Only for Glass Disc insulators) } specification

m) Mechanical failing load Test } As per MSETCL

(Only for Glass Disc insulators) } specification

n) Power frequency voltage } IEC: 60383

withstand test (Dry) }

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6.0 Routine Tests:

The following routine tests shall be conducted on each insulator and results
certified by the manufacturer:
Sr. Particulars of test Reference
No. Standard
a) Visual Inspection } IS: 731
b) Mechanical routine test } IS: 731
c) Electrical routine test } IEC: 60383

d) Thermal shock routine test } IEC: 60383

(for glass insulator only)
e) Polarised Light Inspection } As per MSETCL
(for glass insulator only) specification

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