Sec II

TECHNICAL SPECIFICATIONS
SECTION-II
1.0 Technical Description of Disc Insulators
1.1 Details of Disc Insulators
1.1.1 The Insulator strings shall consist of Standard discs for a three phase, 50 Hz,
effectively earthed 400 kV transmission system in a lightly polluted
atmosphere. The discs shall be cap and pin, ball and socket type.
1.1.2 Supplier may quote for disc insulator, made of either electro-porcelain or
toughened glass.
1.1.3 The size of disc insulator, minimum creepage distance, the number to be used
in different type of strings, their electromechanical strength and mechanical
strength of insulator string alongwith hardware fittings shall be as follows :
Sl. Type of Size of disc Minimum No. Electro- Mechanical

No. string insulators creepage of mechnical strength of
(mm) distance of disc strength insulator
each disc of string along
(mm) insulator with
disc(KN) hardware
fittings (KN)
A. For 400 kV D/C (Quad Bundle) TL in Snow Zone
1. Single I 255x145 315 25 120 120
or
suspension
280x145
Pilot
2. Quad 280x170 330 4 x 160 4 x 160
Tension 25
3. Single 255x145 315 25 120 120
or
Tension
280x145
B. For 400 kV D/C (Quad Bundle) TL in Non-Snow Zone
1. Double I 255x145 315 2 x 120 2 x 120
or
suspension 23
280x145
2. Single I 255x145 315 23 120 120
or
suspension
280x145
Pilot
3. Quad 280x170 330 4 x 160 4 x 160
Tension 23
4. Single 255x145 315 24 120 120
or
SECTION-II (VOLUME-II) PAGE 1

Tension 280x145
C. For 400 kV D/C (Triple Bundle) TL in Snow Zone
1. Single I 255x145 315 25 120 120
or
suspension
280x145
Pilot
2. Double 280x170 370 2 x 210 2 x 210
Tension 25
1.2 Pin and Cap
1.2.1 Pin and Cap shall be designed to 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, of such
design that it will not yield or distort under load conditions.
1.2.2 The pin ball shall move freely in the cap socket but without danger of
accidental uncoupling during erection or in position. The design of the disc
should be such that stresses due to expansion or contraction in any part of the
insulator shall not lead to deterioration.
1.3 Security clip
1.3.1 Security clip for use with ball and socket coupling shall be of R-shaped hump
type which shall provide positive locking of the coupling as per IS:2486-(Part-
Ill)/IEC : 372. The legs of the security clips shall be spread after installation to
prevent complete withdrawal from the socket. The locking device should be
resilient, corrosion resistant and of suitable mechanical strength. There shall
be no risk of the locking device being displaced accidentally or being rotated
when in position. Under no circumstances shall locking device allow
separation of insulator units or fittings.
1.3.2 The hole for the security clip shall be countersunk and the clip shall be of
such design that the eye of clip may be engaged by a hot line clip puller to
provide for disengagement under energised conditions. The force required to
pull the security clip into its unlocked position shall not be less than 50N (5
kg) or more than 500N (50 kg).
1.4 Ball and Socket Designation
The dimensions of the balls and sockets shall be of 20 mm designation for 120
KN and 160 KN disc insulator & 24 mm designation for 210 KN disc in
accordance with the standard dimensions stated in IS:2486 - (Part -
II)/IEC:120.
1.5 Dimensional Tolerance of Insulator Disc (Standard)
It shall be ensured that the dimensions of the disc insulators are within the
limits specified below :

a) Diameter of Disc (mm)
Standard Maximum Minimum

120 KN Disc 255/280 266/293 244/267
160 KN & 210 KN 280 293 267

Disc
b) Ball to ball spacing between discs
Standard Maximum Minimum

120 KN Disc 145 149 141
160 KN & 210 KN 170 175 165

Disc
1.6 Interchangeability
The disc insulators inclusive of the ball and socket fittings shall be of standard
design suitable for use with the hardware fittings of any make conforming to
relevant Indian/International Standards.
1.7 Corona And RI Performance
All surfaces must be clean, smooth, without cuts, abrasions or projections. No

part shall be subjected to excessive localised pressure. The metal parts shall
be so designed and manufactured that it shall not generate any Radio
Interference beyond specified limit and not produce any noise generating
corona under the operating conditions.
1.8 Maintenance
1.8.1 The disc insulators offered shall be suitable for employment of hot line
maintenance techniques so that the usual hot line operations can be carried
out with ease, speed and safety.
1.8.2 Bidders shall indicate the methods generally used in the routine hot
and dead line maintenance of EHV Lines for which similar disc insulators
have been supplied by them. Bidders shall also indicate the recommended
periodicity of such maintenance.
1.9 Materials
1.9.1 Porcelain
The porcelain used in the manufacture of shells shall be sound, free from
defects thoroughly vitrified and smoothly glazed.

1.9.2 Glaze
The finished porcelain shall be glazed in brown colour. The glaze shall cover
all exposed parts of the insulator and shall have a good lusture, smooth
surface and good performance under the extreme weather conditions of a
tropical climate. It shall not crack or chip by ageing under the normal service
conditions. The glaze shall have the same coefficient of expansion as of the
porcelain body throughout the working temperature range.
1.9.3 Toughened Glass
The glass used for the shells 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.
1.9.4 Cement
Cement used in the manufacture of the insulator shall not cause fracture by
expansion or loosening by contraction. The cement shall not give rise to
chemical reaction with metal fittings and its thickness shall be as small and
uniform as possible. Proper care shall be taken to correctly centre and locate
individual parts during cementing.
1.9.5 Pins and Caps

Pins and Caps shall be made of drop forged steel and malleable cast
iron/spheriodal graphite iron/drop forges steel respectively, duly hot dip
galvanised and shall not be made by jointing, welding, shrink fitting or any
other process from more than one piece of material.
1.9.6 Security Clips
Security clips shall be made of good quality stainless steel or phosphor

bronze as per IS:1385. 2.5% extra Security clip shall be provided.
1.10 Workmanship
1.10.1 All the material shall be of the latest design and conform to the best modern
practices adopted in the extra high voltage field. Suppliers shall offer only
such insulators as are guaranteed by him to be satisfactory and suitable for
400 kV Transmission lines and will give continued good service.
1.10.2 The design, manufacturing process and material control at various stages
shall be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish and elimination of sharp edges and
corners to limit corona and radio interference.
1.10.3 The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
1.10.4 Metal caps shall be free from cracks, seams, shrinks, air holes, burrs and
rough edges. All surfaces of the metal parts shall be perfectly smooth with no
projecting points or irregularities which may cause corona. All load bearing

surfaces shall be smooth and uniform so as to distribute the loading stresses
uniformly.
1.10.5 All ferrous parts shall be hot dip galvanised to give a minimum average
coating of Zinc equivalent to 600 gm/sq.m. and shall be in accordance with
the requirement of IS:2629 and shall satisfy the tests mentioned in IS:2633.
The zinc used for galvanising shall be of Grade Zn 99.95 as per IS:209. The
zinc coating shall be uniform, adherent, smooth, reasonably bright,
continuous and free from imperfections such as flux, ash, rust stains, bulky
white deposits and blisters. The galvanised metal parts shall be guaranteed to
withstand atleast six successive dips each lasting for one (1) minute duration
under the standard preece test.
1.10.6 Before ball fittings are galvanised, all die flashing on the shank surface of the
ball shall be carefully removed without reducing the dimensions below the
design requirements.
1.10.7 The design of the insulators shall be such that the shell shall not engage
directly with hard metal. The design shall also be such that when units are
coupled together there is no contact between the shell of one unit and metal
of the next adjacent unit. The design of the shell ribs shall be such that the
security clip of the insulator can be engaged and disengaged easily with hot
stick without damaging the shell ribs.
1.10.8 Insulator units after assembly shall be concentric and co-axial within limits as
permitted by the relevant Indian Standards.
1.10.9 The manufacturer of the insulators shall guarantee an insulator failure rate
not exceeding 1 (one) per 10000 (ten thousand) per year for disc insulator per
year. In case the annual failure rate during the first ten years of service
exceeds the above figure, under normal operating condition, as will be
determined by check to be conducted as per mutually agreed procedure and
conditions upto ten years, (as permitted by the operating situation), the
Supplier shall supply to the Owner free of cost spare insulators equal to 10
time the excess failure.
1.10.10 The Supplier shall guarantee that there shall not be any decapping/breaking
of insulators on line under normal operating conditions. In the event of any
decapping/breaking and subsequent line drop, during the first ten years of
service the Supplier shall have to pay Rs. 50,000/- (Rs. Fifty thousand only)
per dropped string towards expenditure to be incurred by OWNER for this
line repair.
2.0 Technical Description of Porcelain Long Rod Insulators
2.1 Details of Long Rod Insulators
2.1.1 The insulators of the stings shall consist of standard long rod insulators with
normal sheds for a three phase, 50 Hz, effectively earthed 400 kV
transmission system in a lightly polluted atmosphere. Insulators shall be long
rod type with Ball and socket connections.

2.1.2 Insulators shell have normal sheds/alternate sheds with good self-cleaning
properties. Insulator shed profile, spacing projection etc. shall be strictly in
accordance with the recommendation of IEC-815.
2.1.3 Supplier quoting for long rod insulators made of electro porcelain shall also
supply intermediate ball pins and intermediate arcing horns along with long
rod insulators.
The price of these items shall be considered as including in the price of long
rod insulators.
2.1.4 The size of long rod insulator, minimum creepage distance, the number to be
used in different type of strings, their electromechanical strength and
mechanical strength of insulator string alongwith hardware fittings shall be as
follows :
2.1.5 Description of long rod insulator string (equivalent to standard disc

insulator)
Sl. Type of Size of Minimum No. of Electro- Mechanical

No. string long rod creepage individ mechanical strength of
insulators distance of ual strength of insulator
(mm) each unit units insulator string along
(mm) per disc(KN) with
string hardware
fittings (KN)
A. For 400 kV D/C (Quad Bundle) TL in Snow Zone
1. Single I 60-85 2625 1x3 120 120
suspension
Pilot
2. Quad 75-85 2750 4x3 160 4 x 160
Tension
3. Single 60-85 2625 1x3 120 120
Tension
B. For 400 kV D/C (Quad Bundle) TL in Non-Snow Zone
1. Double I 60-85 2415 2x3 120 2 x 120
suspension
2. Single I 60-85 2415 1x3 120 120
suspension
pilot
3. Quad 75-85 2530 4x3 160 4 x 160
Tension
4. Single 60-85 2415 1x3 120 120
Tension
C. For 400 kV D/C (Triple Bundle) TL in Snow Zone

1. Single I 60-85 2625 1x3 120 120
suspension
Pilot
2. Double 85-90 3084 2x3 210 2 x 210
Tension
Note : (i) Bidders may quote for the relevant strings.
(ii) Length of long rod insulator strings shall be matching with the
corresponding disc insulator strings.
(iii) The cost of intermediate Ball pin and intermediate arcing horn
shall be considered as including in the price of long rod
insulators.
2.2 Pin and Cap
2.2.1 Pin and cap shall be designed to 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, of such
design that it will not yield or distort under load conditions.
2.2.2 The pin ball shall move freely in the cap socket but without danger of
accidental uncoupling during erection or in position. The design of the long
rod should be such that stresses due to expansion or contraction in any part
of the insulator shall not lead to deterioration.
2.3 Ball and Socket Designation
The dimensions of the balls and socket shall be of 20 mm designation for 120
& 160 KN for long rod insulators and 24 mm designation for 210 KN long rod
insulators in accordance with the standard dimensions stated in IS 2486-(Part-
II)/IEC:120.
2.4 Dimensional Tolerance
The tolerance on all dimensions e.g. diameter, length and creepage distance
shall be allowed as follows :
(0.04 d + 1.5) mm when d < 300 mm.
(0.025d + 6) mm when d > 300 mm
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.
2.5 Intermediate Ball Pin Designation

The dimensions of the intermediate ball pin shall be in accordance with the
standard dimension stated in IEC:471.
2.6 Intermediate Arcing Horn
2.6.1 For Insulator strings with long rod insulators besides the arcing horn on
tower side of hardware fittings, intermediate arcing horns along with fixtures
and fasteners as shown in the specification shall also be provided.
The total effective arcing distance shall be 3050 mm (for TL in Non-snow

zone) and 3340 mm (for TL in Snow zone) under nominal dimensions of
insulator.
2.6.2 The spark gap shall be so adjusted to ensure effective operation under actual
field coordination.
2.7 Inter Changeability

The long rod insulators with ball and socket connection shall be of standard
design suitable for use with the hardware fittings of any make conforming to
relevant IEC standards.
2.8 Corona and RI Performance

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No
part shall be subjected to excessive localised pressure. The insulator and
metal parts shall be so designed and manufactured that it shall avoid local
corona formation and not generate any radio interference beyond specified
limit under the operating conditions.
2.9 Maintenance
2.9.1 The long rod insulators offered shall be suitable for employment of hot line
maintenance techniques so that usual hot line operations can be carried out
with ease, speed and safety.
2.9.2 All insulators shall be designed to facilitate cleaning and insulators shall have
the minimum practical number of sheds and grooves. All grooves shall be so
proportioned that any dust deposit can be removed without difficulty either
by wiping with a cloth or by remote washing under live line condition.
2.10 Materials
2.10.1 Porcelain
The porcelain used in the manufacture of long rods shall be alumina type. It
shall be sound, free from defects and thoroughly vitrified and smoothly
glazed.
2.10.2 Glaze
The finished porcelain shall be glazed in brown colour. The glaze shall cover
all exposed parts of the insulator and shall have a good lusture, smooth
surface and good performance under the extreme weather conditions of a
tropical climate. It shall not be cracked or chipped by aging under the normal

service conditions. The glaze shall have the same co-efficient of expansion as
of the porcelain body throughout the working temperature range.
2.10.3 Insulator Cap
The caps of long rod insulator units shall be of malleable cast iron or other
suitable material, duly hot dip galvanised and shall not be made by jointing,
welding, shrink fitting or any other process from more than one piece of
material. The design of the unit shall be such that stresses due to expansion
and contraction of any part of the insulator shall not lead to deterioration.
2.10.4 Intermediate Ball Pin
The intermediate ball pin shall be made of drop forged steel, duly hot dip
galvanised and shall not be made by jointly welding, shrink filling or any
other process from more than one piece of material.
2.10.5 Intermediate Arcing horn
Intermediate Arcing horn shall be mild steel tube.

2.10.6 Cement
Cement used in the manufacture of the insulator shall not cause fracture by
expansion or loosening by contraction. The cement shall not give rise to
chemical reaction with metal fittings and its thickness shall be as small and
uniform as possible. Proper care shall be taken to correctly centre and locate
individual parts during cementing.
2.11 Workmanship
2.11.1 All the materials shall be of latest design and conform to the best modern
practices adopted in the extra high voltage field. Bidders shall offer only such
insulators as are guaranteed by him to be satisfactory and suitable for 400 kV
transmission lines and will give continued good service.
2.11.2 The design, manufacturing process and material control at various stages
shall be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish and elimination of sharp edges and
corners to limit corona and radio interference.
2.11.3 The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
2.11.4 Metal caps shall be free from cracks, seams, shrinks, air holes and rough
edges. All surfaces of the metal parts shall be perfectly smooth with the
projecting points or irregularities which may cause corona. All load bearing
surfaces shall be smooth and uniform so as to distribute the loading stresses
uniformly.
2.11.5 All ferrous parts shall be not dip galvanised to give a minimum average
coating of zinc equivalent to 600 gm/sq. mm. and shall be in accordance with
the requirement of IS: 2629 and shall satisfy the tests mentioned in IS : 2633.
The zinc coating shall be uniform, adherent, smooth, reasonably bright

continuous and free from imperfections such as flux, ash, rust stains, bulky
white deposits and blisters. the galvanised metal parts shall be guaranteed to
withstand at least six successive dips each lasting for one (1) minute duration
under the standard preece test. The galvanising shall be carried out only after
any machining.
2.11.6 The design of the insulators shall be such that the porcelain shall not engage
with hard metal.
2.11.7 Insulator units after assembly shall be concentric and co-axial within limits as
permitted by the relevant international standard.
2.11.8 The manufacturer of the insulators shall guarantee an insulator failure rate
not exceeding one per 1500 porcelain long rod units. In case the annual failure
rate during the first ten years of operation exceeds the above figure under
normal operating conditions, as will be determined by check to be conducted
as per mutually agreed procedure and conditions upto ten years (as
permitted by the operating situation). The manufacturer shall supply to the
owner free of cost spare insulators (Porcelain long rod) equal to 10 times the
excess failure.
2.11.9 The manufacturer shall guarantee that there shall not be any decapping and
breakage of insulators or line under normal operating conditions. In event of
any decapping or breakage resulting in line drop during the first ten years of
service the manufacturer shall have to pay Rs. 50,000/- (Rs. fifty thousand) per
dropped string towards expenditure to be incurred by OWNER for this line
repair.
3.0 Equipment Marking

3.1 Each insulator disc/long rod unit shall be legibly and indelibly marked with
the trade mark of the manufacturer, name of OWNER and month & year of
manufacture. The guaranteed combined mechanical and electrical strength
shall be indicated in kilo Newton followed by the word kN to facilitate easy
identification and to ensure proper use.
3.2 For porcelain insulator, the marking shall be on porcelain. The marking shall
be printed, not impressed and shall be applied before firing. For toughened
glass insulators the marking shall be on the metal parts.
3.3 One 10 mm thick ring or 20 mm thick spot of suitable quality of paint shall be
marked on the cap of each insulator porcelain disc/porcelain long rod of
particular strength for easy identification of the type of insulator. The paint
shall not have any deteriorating effect on the insulator performance.
Following codes shall be used as identification mark :
For 120 kN disc/ long rod unit : Yellow
For 160 kN disc / long rod unit : Green
For 210 kN disc / long rod unit : Blue
4.0 Bid Drawings

4.1 The Bidder shall furnish full description and illustration of the material
offered.
4.2 The Bidder shall furnish along with the bid the outline drawing (6 copies) of
each insulator unit including a cross sectional view of the insulator shell. 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 and socket parts
(g) Weight of unit insulator disc/long rod units
(h) Materials
(i) Identification mark
(j) Manufacturer's catalogue number
4.3 After placement of award, the Supplier shall submit full dimensioned
insulator drawings containing all the details as given in Clause No. 4.11.2
above, in four (4) copies to Owner for approval. After getting approval from
Owner and successful completion of all the type tests, the Supplier shall
submit 20 more copies of the same drawing to the Owner for further
distribution and field use at Owner's end.
4.4 After placement of award the Supplier shall also submit fully dimensioned
insulator crate drawing for different type of insulators.
4.5 After placement of award, the Supplier shall submit full dimensioned
manufacturing drawing of insulator cap, pin and insulator shell in six (6)
copies to the Owner for reference and record.
5.0 Tests and Standards
5.1 Type Tests
The following type tests shall be conducted on a suitable number of

individual standard disc insulators or long rod units, components, materials
or complete strings:
5.1.1 On unit disc Insulators

a) Verification of dimensions As per IEC :60383

b) Thermal mechanical performance test As per Annexure-A
c) Power frequency voltage withstand and flashover As per IEC : 60383

test under (i) dry
(ii) wet condition
d) Impulse voltage withstand and flashover test (dry) As per IEC : 60383
e) Visible Discharge test (dry) As per IS:731, Cl. 10.2
f) RIV test (dry) As per IEC:60437
g) Residual strength Test As per Annexure-A
h) Steep wave front Test As per Annexure-A
i) Impact Test As per Annexure-A
5.1.2 On Porcelain long rod Insulator units

a) Verification of dimensions As per IEC : 60383
b) Thermal mechanical performance test As per Annexure-A
c) Power frequency voltage withstand and flashover test As per IEC : 60383
under (i) dry
(ii) wet condition
d) Impulse voltage withstand and flashover test (dry) As per IEC : 60383
e) Visible Discharge test (dry) As per IS:731, Cl 10.2
f) RIV test (dry) As per IEC:60437
5.1.3 On the complete Disc Insulator String with Hardware Fittings
a) Power frequency voltage withstand test with corona As per IEC : 60383
control rings/grading ring and arcing horns under
wet condition
b) Switching surge voltage withstand test under wet As per IEC: 60383
condition
c) Impulse voltage withstand test under dry condition As per IEC : 60383
d) Impulse voltage flash over test under dry condition As per IEC : 60383
e) Voltage distribution test As per Annexure-A
f) Corona and RIV test under dry condition As per Annexure-A
g) Mechanical Strength test As per Annexure-A
h) Vibration test As per Annexure-A
i) Power-Arc Test As per Annexure-A
5.1.4 On the complete Porcelain long rod Insulator string with Hardware Fittings
a) Power frequency voltage withstand test with corona As per IEC : 60383
control rings/grading ring and arcing horns under
wet condition

b) Switching surge voltage withstand test under wet As per IEC : 60383
condition
c) Impulse voltage withstand test under dry condition As per IEC : 60383
d) Impulse voltage flash over test under dry condition As per IEC : 60383
e) Corona and RIV test under dry condition As per Annexure-A
f) Mechanical Strength test As per Annexure-A
g) Vibration test As per Annexure-A
h) Power-Arc Test As per Annexure-A
5.1.5 All the type test given in Clause No. 5.1.3 for disc insulator string or Clause
No. 5.1.4 for long rod porcelain insulator string shall be conducted on 400 kV
Double Suspension and Quad Tension insulator strings along with hardware
fittings for 400 kV (Quad Bundle) Lines. All the type test given in Clause No.
5.1.3, except clause 5.1.3 (i) for disc insulator string or Clause No. 5.1.4, except
clause 5.1.4 (h) for long rod porcelain insulator string shall be conducted on
400 kV Double Tension insulator strings along with hardware fittings for 400
kV (Triple Bundle) Line.
5.1.6 All the type tests given under Clause No. 5.1.3 (a) to (g) for disc insulator
string or 5.1.4 (a) to (f) for porcelain long rod insulator string shall also be
conducted on 400 kV Single Suspension Pilot and Single Tension Insulator
strings.
5.1.7 Type tests specified under Clause 5.1.3 (a) to (d) or under Clause 5.1.4 (a) to
(d) shall not be required to be carried out if a valid test certificate is available
for a similar design, i.e., tests conducted earlier should have either been
conducted in accredited laboratory (accredited based on ISO/IEC vide
25/17025 or EN 45001 by the National accreditation body of the country where
laboratory is located) or witnessed by the representative(s) of OWNER or
utility. The test reports submitted shall be for the tests conducted within last 5
(five) years prior to date of bid opening.
In case the test have been conducted earlier than the above stipulated period
or in the event of any discrepancy in the test report (i.e., any test not
applicable due to any design/manufacturing change including substitution of
components or due to non-compliance with the requirement stipulated in the
Technical Specifications), the tests shall be conducted by the Supplier at no
extra cost to the Owner.
5.2 Acceptance Tests
5.2.1 For Disc Insulators (Both porcelain and glass)

a) Visual examination As per IEC : 60383

b) Verification of dimensions As per IEC : 60383
c) Temperature cycle test As per IEC : 60383
d) Galvanising test As per IEC : 60383
e) Mechanical performance test As per IEC:60575Cl 4.0
f) Test on locking device for ball and socket As per IEC:60372

coupling
g) Eccentricity test As per IEC:60383
h) Residual Strength Test As per IEC:797

Clause 4.4 & 4.5
i) Metallurgical Test (For metal fittings only in black As per Annexure-A

condition)
i) Grain size
ii) Inclusion rating
iii) Chemical analysis
iv) Microstructure
j) Chemical analysis of Zinc Sleeve As per Annexure-A
k) IR Measurement As per Annexure-A
l) Impact Test As per Annexure-A
m) Steep Wave front test As per Annexure-A
n) Thermal Mechanical performance test As per Annexure-A
Note : Tests specified under Clause 5.2.1 (m) & (n) above shall be performed
as acceptance tests once for every supply of 25,000 nos. of a particular rating.
5.2.2 For Porcelain disc Insulators Only

a) Electro-mechanical strength test As per Annexure-A
b) Porosity test As per IEC : 60383
c) Puncture test As per IEC : 60383
5.2.3 For Glass Insulators Only

a) Thermal shock test As per IEC : 60383
b) Steep wave front test/Puncture test As per Annexure-A
c) Mechanical failing load Test As per Annexure-A
5.3 For Porcelain Long rod Insulators

a) Visual examination As per IEC : 60383
b) Verification of dimensions As per IEC : 60383
c) Temperature cycle test As per IEC : 60383

d) Galvanising test As per IEC : 60383
e) Mechanical performance test As per IEC:60575

Clause 4.0
f) Test on locking device for ball and socket coupling As per IEC:60372
g) Eccentricity test As per IEC : 60383-1
h) Mechanical failing load test As per IEC : 60383-1
i) Porosity test As per IEC : 60383
j) Metallurgical Test (For metal fittings only in black As per Annexure-A

condition)
i) Grain size
ii) Inclusion rating
iii) Chemical analysis
iv) Microstructure
k) Thermal Mechanical performance test As per Annexure-A
Note : The test specified under 5.3 (k) above shall be performed as acceptance
test once for every supply of 3260 nos. long rod insulator units of a particular
rating.
5.4 Routine Tests
5.4.1 For Disc Insulators

a) Visual Inspection As per IS:731, Cl. 10.13
b) Mechanical routine test As per IS:731 Cl. 10.14
c) Electrical routine test (for porcelain disc insulator As per IS:731 Cl. 10.15
only)
d) Thermal shock routine test (for glass insulator only) As per IEC:60383
e) Polarised Light Inspection (for glass insulator only) As per Annexure-A
5.4.2 For Porcelain Long Rod Insulator Units

a) Visual Inspection As per IEC:60383
b) Mechanical routine test) As per IEC:60383
5.5 Tests During Manufacture
On all components as applicable

a) Chemical analysis of zinc used for galvanising As per Annexure-A
b) Chemical analysis, mechanical, metallographic test As per Annexure-A

and magnetic particle inspection for malleable
castings.
c) Chemical analysis hardness tests and magnetic As per Annexure-A
particle inspection for forgings

d) Hydraulic Internal Pressure tests on disc insulator As per Annexure-A
shells
e) Autoclave Test on Cement As per Annexure-A
5.6 Testing Expenses
5.6.1 Testing charges for the type test specified shall be indicated separately in the
prescribed schedule.
5.6.2 Bidder shall indicate unit type test charges for all type tests covered under
Clause 5.1.1/5.1.2 and 5.1.3 (e) to (i)/5.1.4 (e) to (h) separately, in the relevant
schedule of Prices as applicable. Charges for each type tests shall be
separately indicated.
5.6.3 For Type Tests which involves the tests on the complete insulator string with
hardware fitting the Contractor of hardware fittings shall supply the
necessary number of sets of hardware fittings at the place of testing free of
cost.
5.6.4 In case of failure in any type test the bidder whose material has failed is either
required to modify the design of the material & successfully carryout all the
type tests as has been detailed out in Clause 5.1.3 or 5.1.4 of this specifications
or to repeat that particular type test at least three times successfully at his
own expenses. Incase of failure of the complete string in any type test, the
manufacturer whose product has failed in the use shall get the test repeated at
his cost. The Supplier whose material has not failed in the test shall be
required to supply the requisite quantity of material (that is insulator or
hardware fittings as the case may be) required for repeat testing at the place of
testing and the cost of supply shall be borne by the Supplier whose material
has failed in testing.
5.6.5 Supplier shall indicate the laboratories in which they propose to conduct the
type tests. They shall ensure that adequate facilities are available in the
laboratory and the tests can be completed in these laboratories within the time
schedule guaranteed by them in the appropriate schedule.
5.6.6 The entire cost of testing for acceptance and routine tests and tests during
manufacture specified herein shall be treated as included in the quoted Ex-
works/CIF Price.
5.6.7 In case of failure in any type test, if repeat type tests are required to be
conducted, then all the expenses for deputation of Inspector/ Owner's
representative shall be deducted from the contract price. Also if on receipt of
the Supplier's notice of testing, the Owner's representative does not find
material or test facilities to be ready for testing the expenses incurred by the
Owner for redeputation shall be deducted from contract price.
5.6.8 The Supplier shall intimate the Owner about carrying out of the type tests
alongwith detailed testing programme at least 3 weeks in advance (in case of
testing in India) and at least 6 weeks advance (in case of testing abroad) of the

scheduled date of testing during which the Owner will arrange to depute his
representative to be present at the time of carrying out the tests.
5.7 Sample Batch for Type Testing
5.7.1 The Supplier shall offer material for sample selection for type testing only
after getting Quality Assurance Programme approved by the Owner. The
Supplier shall offer at least three times the quantity of materials required for
conducting all the type tests for sample selection. The sample for type testing
will be manufactured strictly in accordance with the Quality Assurance
Programme approved by the Owner.
5.7.2 Before sample selection for type testing, the Supplier shall be required to
conduct all the acceptance tests successfully in presence of Owner's
representative.
5.8 Schedule of Testing
5.8.1 The Bidder has to indicate the schedule of following activities in their
bids :
a) Submission of drawing for approval.

b) Submission of Quality Assurance Programme for approval.
c) Offering of material for sample selection for type tests.
d) Type testing.
5.9 Repeat E&M Strength Test
5.9.1 E&M test on 20 nos. for disc insulator or 3 nos. for Porcelain longrod insulator
of samples for every lot of 10,000 nos. or 1500 nos. for Porcelain longrod
received at site shall be conducted. Testing expenses have to be borne by the
Supplier and shall be included in quoted Ex-works/CIF price. Incase of
failure, it will be repeated on double no. of samples and if it again fails, the
whole lot should be rejected and shall be replaced by the Supplier. The
samples have to be taken at random after segregating insulators damaged in
transportation or otherwise.
5.9.2 The Owner 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 Specifications.
5.9.3 The Owner also reserves the right to conduct all the tests mentioned in this
specification at his own expense on the samples drawn from the site at
Supplier's premises or at any other test centre. In case of evidence of non
compliance, it shall be binding on the part of the Supplier to prove the
compliance of the items to the technical specifications by repeat tests or
correction of deficiencies or replacement of defective items, all without any
extra cost to the Owner.
5.10 Co-ordination for Testing

The Supplier shall have to co-ordinate testing of insulators with hardware
fittings to be supplied by other Supplier and shall have to guarantee overall
satisfactory performance of the insulators with the hardware fittings.
5.11 Guarantee
The Supplier of insulators shall guarantee overall satisfactory performance of
the insulators with the hardware fittings.
5.12 Test Reports
5.12.1 Copies of type test reports shall be furnished in at least six (6) copies along
with one original. One copy shall be returned duly certified by the Owner
only after which the commercial production of the concerned material shall
start.
5.12.2 Copies of acceptance test reports shall be furnished in at least six (6) copies.
One copy shall be returned duly certified by the Owner, only after which the
material shall be dispatched.
5.12.3 Record of routine test reports shall be maintained by the Supplier at his works
for periodic inspection by the Owners representative.
5.12.4 Test certificates of test during manufacture shall be maintained by the
Supplier. These shall be produced for verification as and when desired by the
Owner.
5.13 Inspection
5.13.1 The Owners representative shall at all times be entitled to have access to the
works and all places of manufacture, where insulator, and its component
parts shall be manufactured and the representatives shall have full facilities
for unrestricted inspection of the Suppliers and sub-Suppliers works, raw
materials, manufacture of the material and for conducting necessary test as
detailed herein.
5.13.2 The material for final inspection shall be offered by the Supplier only under
packed condition as detailed in clause No.5.14 of the specification. The
Owner shall select samples at random from the packed lot for carrying out
acceptance tests. Insulators shall normally be offered for inspection in lots not
exceeding 10,000 nos. for disc / 650 units for long rod insulator. The lot should
be homogeneous and should contain insulators manufactured in 3-4
consecutive weeks.
5.13.3 The Supplier shall keep the Owner informed in advance of the time of starting
and the progress of manufacture of material in their various stages so that
arrangements could be made for inspection.
5.13.4 No material shall be dispatched from its point of manufacture before it has
been satisfactorily inspected and tested unless the inspection is waived off by
the Owner in writing. In the latter case also the material shall be dispatched
only after satisfactory testing for all tests specified herein have been
completed.

5.13.5 The acceptance of any quantity of material shall be no way relieve the
Supplier of his responsibility for meeting all the requirements of the
specification and shall not prevent subsequent rejection, if such material are
later found to be defective.
5.14 Packing and Marking
5.14.1 All insulators shall be packed in strong seasoned wooden crates. The gross
weight of the crates along with the material shall not normally exceed 200 Kg
to avoid handling problem. For marine transportation crates shall be
palleted.
5.14.2 The packing shall be of sufficient strength to withstand rough handling

during transit, storage at site and subsequent handling in the field.
5.14.3 Suitable cushioning, protective padding, or dunnage or spacers shall be

provided to prevent damage or deformation during transit and handling.
5.14.4 All packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and to 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 stencilled on it
in indeliable ink.
5.15 Standards
The insulator strings and its components shall conform to the following
lndian/ International Standards which shall mean latest revision, with
amendments/
changes adopted and published, unless specifically stated otherwise in the
Specification.
5.15.1 In the event of supply of insulators conforming to standards other than

specified, the Bidder shall confirm in his bid that these standards are
equivalent to those specified. In case of award, salient features of comparison
between the standards proposed by the Bidder and those specified in this
document will be provided by the Supplier to establish equivalence.
Sl. Indian Title International

No. Standard Standard
1. IS:209-1992 Specification for zinc BS:3436
2. IS:406-1991 Method of Chemical Analysis of Slab Zinc BS:3436
3. IS:731-1991 Porcelain insulators for overhead Power BS:137- (I&II)
lines with a nominal voltage greater than IEC:60383
1000 V
4. IS:2071 Methods of High Voltage Testing IEC:60060-1
Part (I) 1993
(Part(II)- 1991
Part(III)- 1991
5. IS:2486 Specification for Insulator fittings for
Overhead Power Lines with a nominal

voltage greater than 1000V
Part- I-1993 General Requirements and Tests BS:3288
Part- II-1989 Dimensional Requirements IEC:60120
Part-III-1991 Locking Devices IEC:60372
6. IS:2629-1990 Recommended Practice for Hot, Dip ISO-1461 (E)
Galvanisation for iron and steel
7. IS:2633-1992 Testing of Uniformity of Coating of zinc
coated articles
8. IS:3188-1988 Dimensions for Disc Insulators IEC:60305
9. IS:6745-1990 Determination of Weight of Zinc Coating on BS:433-1969
Zinc coated iron and steel articles ISO:1460-1973
10. IS:8263-1990 Methods of RI Test of HV insulators IEC:60437
NEMA Publi-
cation No.07/
1964/ CISPR
11. IS:8269-1990 Methods for Switching Impulse test on HV IEC:60506
insulators
12. Thermal Mechanical Performance test and IEC: 60575
mechanical performance test on string
insulator units
13. Salt Fog Pollution Voltage Withstand Test IEC:60507
14. Residual Strength of String Insulator Units IEC:60797
of Glass or Ceramic Material for Overhead
Lines after Mechanical Damage of the
Dielectric
15. Guide for the selection of insulators in IEC:60815
respect of polluted conditions
16. Tests on insulators of Ceramic material or IEC:60383
glass or glass for overhead lines with a
nominal voltage greater than 1000V
17. Characteristics of string insulator units of IEC : 60433
the long rod type
18. Standard Test Method for Autoclave ASTM C151-93-
Expansion of Portland Cement a
19. American National Standard for Insulators ANSI C29-2-
wet process porcelain and toughened glass 1992
suspension type
The standards mentioned above are available from:
Reference Abbreviation Name and Address
BS British Standards,
British Standards Institution
101, Pentonvile Road,
N - 19-ND, UK
IEC/CISPR 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.
NEMA 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 USA
A. STANDARD TECHNICAL PARTICULARS OF NORMAL INSULATOR

DISCS
S.N. DESCRIPTION UNIT 120 KN 160KN
1.0 GENERAL
Size and designation of ball and 20.0as per 20.0as per
(a) socket mm IS2486/IEC120 IS2486/IEC120
2.0 DIMENSIONS
(a) Disc insulator diameter mm 255.0 or 280.0 280.0
11.0(for
255.0)/13.0(for
(b) Tolerance of dia. mm 280.0) 13.0
(c) Ball to ball spacing between disc mm 145.0 170.0
(d) Tolerance of spacing mm 4.0 5.0
Minimum Creepage distance of
(e) single disc mm 315.0 330.0
Colour of glaze of finished porcelain

3.0 insulator NA Brown Brown
ELECTRO-MECANICAL
4.0 STRENGTH KN 120.0 160.0
5.0 MINIMUM ELECTRICAL VALUES

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

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

6.0 PUNCTURE VOLTAGE ) 120.0 125.0
MIN VISIBLE DISCHARGE kV

7.0 VOLTAGE OF SINGLE (rms) 18.0 18.0
DISC(DRY)
8.0 MAX RIV AT 1MHz and 10 KV(rms) V 50.0 50.0
9.0 No. of dips in standard preece test Nos (6 dips of 1min) (6 dips of 1min)
10.0 ECCENTRICITY OF DISC

7.65(for
255.0)/8.40(for
(a) Max radial runout mm 280.0) 8.4
10.20(for
255.0)/11.20(for
(b) Max axial runout mm 280.0) 11.2
MINIMUM MASS OF ZINC gm/sq.

11.0 COATING m. 600 600
MINIMUM ZINC PURITY USED

12.0 FOR GALVANIZING % 99.95% 99.95%
S.N. DESCRIPTION UNIT 210KN
1.0 GENERAL
Size and designation of ball and 24.0as per
(a) socket mm IS2486/IEC120
2.0 DIMENSIONS
(a) Disc insulator diameter mm 280.0
(b) Tolerance of dia. mm 13.0
(c) Ball to ball spacing between disc mm 170.0
(d) Tolerance of spacing mm 5.0
Minimum Creepage distance of
(e) single disc mm 370.0
3.0 Colour of glaze of finished porcelain NA Brown

insulator
ELECTRO-MECANICAL
4.0 STRENGTH KN 210.0

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

6.0 PUNCTURE VOLTAGE ) 125.0
MIN VISIBLE DISCHARGE kV

7.0 VOLTAGE OF SINGLE (rms) 18.0
DISC(DRY)
8.0 MAX RIV AT 1MHz and 10 KV(rms) V 50.0
9.0 No. of dips in standard preece test Nos (6 dips of 1min)
10.0 ECCENTRICITY OF DISC

(a) Max radial runout mm 8.4
(b) Max axial runout mm 11.2
MINIMUM MASS OF ZINC gm/sq.

11.0 COATING m. 600
MINIMUM ZINC PURITY USED

12.0 FOR GALVANIZING % 99.95%
B. STANDARD TECHNICAL PARTICULARS OF NORMAL LONGROD

INSULATOR UNITS

S.N. DESCRIPTION UNIT 120 KN 160 KN
Size and designation of ball and 20.0as per 20.0as per

1.0 socket assembly mm IS2486/IEC120 IS2486/IEC120
2.0 Core diameter (d) mm 60 to 85 75 to 85
3.0 Tolerance on Core diameter mm (0.04d +1.5) (0.04d +1.5)
4.0 Minimum Creepage distance mm 2415*/2625# 2530*/2750#

5.0 insulator NA Brown Brown
6.0 Mechanical strength KN 120.0 160.0

a (dry) Kv(rms) 270.0 290.0
b voltage(wet) kV(rms) 240.0 250.0
c (dry) peak 550.0 550.0
d (dry) peak 570.0 570.0
E voltage(dry) Kv(rms) 250.0 270.0
F voltage(wet) Kv(rms) 230.0 230.0
Impulse withstand voltage positive
G (dry) Kv(rms) 500.0 500.0
Impulse withstand voltage negative
H (dry) Kv(rms) 510.0 510.0
No. of one minute dips which the

8.0 end fittings can withstand Nos. 6.0 6.0
in standard preece test
Max axial/radial runout(as per 1.2% of 1.2% of

9.0 pointer B) mm insulator length insulator length
10.0 Maximum Angular displacement degree 15.0 15.0
Minimum purity of Zinc used for

11.0 galvanizing % 99.95 99.95
gm/sq.
12.0 Minimum mass of zinc coating m. 600.0 600.0

- For 400 kV Non-snow Zone TL ; # - For 400 kV Snow Zone TL
S.N. DESCRIPTION UNIT 210 KN
Size and designation of ball and 24.0as per

1.0 socket assembly mm IS2486/IEC120
2.0 Core diameter (d) mm 85 to 90
3.0 Tolerance on Core diameter mm (0.04d +1.5)
4.0 Minimum Creepage distance mm 3084

5.0 insulator NA Brown
6.0 Mechanical strength KN 210.0

a (dry) Kv(rms) 290.0
b voltage(wet) kV(rms) 250.0
c (dry) peak 550.0
d (dry) peak 570.0
E voltage(dry) Kv(rms) 270.0
F voltage(wet) Kv(rms) 230.0
Impulse withstand voltage positive
G (dry) Kv(rms) 500.0
Impulse withstand voltage negative
H (dry) Kv(rms) 510.0
No. of one minute dips which the

8.0 end fittings can withstand Nos. 6.0
in standard preece test
Max axial/radial runout(as per 1.2% of

9.0 pointer B) mm insulator length
10.0 Maximum Angular displacement degree 15.0

Minimum purity of Zinc used for
11.0 galvanizing % 99.95
gm/sq.
12.0 Minimum mass of zinc coating m. 600.0
C. STANDARD TECHNICAL PARTICULARS OF NORMAL INSULATOR

STRINGS (WITH DISC INSULATORS) ALONGWITH HARDWARE
FITTINGS
S.N. DESCRIPTION UNIT FOR 400 KV QUAD BUNDLE LINE IN SNOW ZONE
Single Single Quad Tension

Suspension Tension string string
pilot string
(1 x 25) (1 x 25) (4 x 25)
1.0 Power frequency kV(rms) 680 680 680

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

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

voltage(dry)
Min. Impulse
4.0 flashover
voltage(dry)*
(a) Positive kV(peak) More than 1800 More than 1800 More than 1800
(b) Negative kV(peak) More than 1800 More than 1800 More than 1800
5.0 Minimum Corona kV(rms) 320 320 320

extinction voltage
under dry condition

RIV at 1MHZ when
6.0 the Microvolt 1000(max.) 1000(max.) 1000(max.)
string is energized at
305 Kv(rms) under
dry
Condition
Mechanical strength
7.0 of kN 120 120 4 X 160
complete insulator
string alongwith hard-
ware fittings
8.0 Maximum voltage % 9 10 10

distribution across
any
disc of line to earth
Voltage
* As per IEC 60-1
S.N. DESCRIPTION UNIT FOR 400 KV QUAD BUNDLE LINE IN NON-SNOW

ZONE
Double 'I' Single Single Quad
Suspension Suspension Tension Tension
string pilot string string string
(2 x 23) (1 x 23) (1 x 24) (4 x 23)
1.0 Power frequency kV(rms) 680 680 680 680

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

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

voltage(dry)
Min. Impulse
4.0 flashover
voltage(dry)*

5.0 Minimum Corona kV(rms) 320 320 320 320
extinction voltage
under dry condition
RIV at 1MHZ when

6.0 the Microvolt 1000(max.) 1000(max.) 1000(max.) 1000(max.)
305 Kv(rms) under
dry
condition
Mechanical strength
7.0 of kN 2 x 120 120 120 4 X 160
complete insulator
ware fittings
8.0 Maximum voltage % 9 9 10 10

distribution across
any
voltage
* As per IEC 60-1
S.N. DESCRIPTION UNIT FOR 400 KV TRIPLE BUNDLE LINE IN SNOW

ZONE
Single Double Tension

Suspension pilot string
string
(1 x 25) (2 x 25)
1.0 Power frequency kV(rms) 680 680

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

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

voltage(dry)

Min. Impulse
4.0 flashover
voltage(dry)*
(a) Positive kV(peak) More than 1800 More than 1800
(b) Negative kV(peak) More than 1800 More than 1800
5.0 Minimum Corona kV(rms) 320 320

extinction voltage
under dry condition
RIV at 1MHZ when

6.0 the Microvolt 1000(max.) 1000(max.)
305 Kv(rms) under
dry
Condition
Mechanical strength
7.0 of kN 120 2 X 210
complete insulator
ware fittings
8.0 Maximum voltage % 9 10

distribution across
any
Voltage
* As per IEC 60-1
D. STANDARD TECHNICAL PARTICULARS OF NORMAL INSULATOR

STRINGS (WITH LONGROD INSULATORS) ALONGWITH
HARDWARE FITTINGS
FOR 400 KV QUAD BUNDLE LINE IN SNOW ZONE
S.N. DESCRIPTION UNIT Single I Single Quad

Suspension Tension Tension
Pilot string String String
(1 x 3) (1 x 3) (4 x 3)
1.0 Length
Nominal length of
(a) insulator string mm 3625 3625 4250
Tolerance on nominal
(b) length +/-mm 100 100 125
2.0 Power frequency kV(rms) 680 680 680

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

3.0 Switching surge
withstand voltage(wet)

Voltage(dry)
5.0 Min. Impulse flashover

Voltage(dry)*
(a) Positive kV(peak) More than 1800 More than 1800 More than 1800
(b) Negative kV(peak) More than 1800 More than 1800 More than 1800
6.0 Minimum Corona kV(rms) 320 320 320

extinction voltage
under dry condition
7.0 RIV at 1MHZ when the Microvolt 1000(max.) 1000(max.) 1000(max.)

305 Kv(rms) under dry
condition
8.0 Mechanical strength of kN 120 120 4 X 160

complete insulator
ware fittings
*As per IEC 60-1
FOR 400 KV QUAD BUNDLE LINE IN NON - SNOW

ZONE
S.N. DESCRIPTION UNIT Double I Single I Single Quad
Suspension Suspension Tension Tension
String Pilot string String String
(2 x 3) (1 x 3) (1 x 3) (4 x 3)
1.0 Length
Nominal length of
(a) insulator string mm 3335 3335 3335 3910
(b) length +/-mm 92 92 92 115
2.0 Power frequency kV(rms) 680 680 680 680

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


Voltage(dry)

Voltage(dry)*
6.0 Minimum Corona kV(rms) 320 320 320 320

extinction voltage
under dry condition
7.0 RIV at 1MHZ when the Microvolt 1000(max.) 1000(max.) 1000(max.) 1000(max.)
condition
8.0 Mechanical strength of kN 120 120 120 2 X 160

complete insulator
ware fittings
*As per IEC 60-1
FOR 400 KV TRIPLE BUNDLE LINE IN SNOW

ZONE
S.N. DESCRIPTION UNIT Single I Double

Suspension Tension
Pilot string String
(1 x 3) (2 x 3)
1.0 Length
Nominal length of
(a) insulator string mm 3625 4250
(b) length +/-mm 100 125
2.0 Power frequency kV(rms) 680 680

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



Voltage(dry)

Voltage(dry)*
(a) Positive kV(peak) More than 1800 More than 1800
(b) Negative kV(peak) More than 1800 More than 1800
6.0 Minimum Corona kV(rms) 320 320

extinction voltage
under dry condition
7.0 RIV at 1MHZ when the Microvolt 1000(max.) 1000(max.)

condition
8.0 Mechanical strength of kN 120 2 X 210

complete insulator
ware fittings
*As per IEC 60-1

ANNEXURE-A
1. Tests on Complete Strings with Hardware Fittings

1.1 Voltage Distribution Test (For Disc Insulators only)
The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted into percentage. The voltage
across any disc shall not exceed 9% for 400 kV suspension insulator strings,
10% for 400 kV tension insulator strings.
1.2 Corona Extinction Voltage Test (Dry)

The sample assembly when subjected to power frequency voltage shall have a
corona extinction voltage of not less than 320 kVrms (for 400 kV) line to
ground under dry condition. There shall be no evidence of corona on any part
of the sample. The atmospheric condition during testing shall be recorded and
the test results shall be accordingly corrected with suitable correction factor as
stipulated in IEC : 383.
1.3 RIV Test (Dry)

Under the conditions as specified under (1.2) above, the insulator string along
with complete hardware fittings shall have a radio interference voltage level
below 1000 micro volts at one MHz when subjected to 50 Hz AC voltage of
305 kV line to ground under dry condition. The test procedure shall be in
accordance with IS:8263/IEC : 437.
1.4 Mechanical Strength Test

The complete insulator string along with its hardware fitting 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 a 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.
1.5 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 along with
hardware fittings and four/three (as the case may be) sub-conductors each
tensioned at 25 % of conductor UTS shall be secured with clamps. The system
shall be suitable to maintain constant tension on each sub-conductors

throughout the duration of the test. Vibration dampers shall not be used on
the test span. The sub-conductors shall be vertically vibrated simultaneously
at one of the resonance frequencies of the insulators string (more than 10 Hz)
by means of vibration inducing equipment. The peak to peak displacement in
mm of vibration at the antinode point, nearest to the string, shall be measured
and the same shall not be less than 1000/f 1.8 where f is the frequency of
vibration in cycles/sec. The insulator string shall be vibrated for not less than
10 million cycles without any failure. After the test the insulators shall be
examined for looseness of pins and cap or any crack in the cement. The
hardware shall be examined for looseness, fatigue failure and mechanical
strength test. There shall be no deterioration of properties of hardware
components and insulators after the vibration test. The insulators shall be
subjected to the following tests as per relevant standards :
Tests Percentage of Percentage of units to be tested
Disc insulators Long rod
insulators
a) Temperature cycle test followed 60 100
by mechanical performance test
b) Puncture test/steep wave front 40 -

test
1.6 Power - Arc Test

This test shall be performed on the complete string in accordance with IEC
Technical Report IEC : 61467-1997 with the following test series :
Test circuit Short circuit current Number and duration of test

B In = Isys = 40 KA Two of tn = 0.2s and one of tn = 0.5s
The acceptance criteria after the completion of test series shall be following.
a) Insulator separation not permitted.

b) Burning/melting of metal components, breakage of insulator sheds,
glaze removal are permitted.
c) The complete insulator string alongwith its hardware fitting
excluding arching horn, corona control ring/grading ring shall
withstand 80% of UTS.

2. On Disc Insulator Units / Porcelain long rod units (as applicable)
2.1 Steep Wave Front Test (For Disc Insulator only)
Test following test shall be performed on 10 insulator units in case of disc
insulators selected at random from the lot offered for selection of sample for
type test.
a) Each insulator unit shall be subjected to five successive positive and
negative impulse flashovers with a wave having minimum effective
rate of rise of 2500 kV per microseconds.
b) Each unit shall then be subjected to three dry power frequency
voltage flashovers.
Acceptance Criteria
An insulator shall be deemed to have met the requirement of this test if,
having been successfully subjected to the ten impulse flashovers, the
arithmetic mean of the three subsequent dry/power frequency voltage
flashover values equals or exceeds 95% of the rated dry power frequency
flashover voltage.
An insulator shall be deemed to have failed to meet the requirement of above
testing if,
(a) It has not flash over when the oscillogram or peak voltage indicator
shows a marked reduction in voltage.
or
(b) Any one of the subsequent three dry power frequency voltage
flashover value is less than 80% of the value specified.
Failure of any one unit either in the steep wave front or subsequent low
frequency voltage test shall cause for testing on double number of units.
2.2 Polarised Light Inspection (only for Glass Disc Insulator)

The disc insulator shall be held over a polarised light source and the stress
lines viewed thereon. There shall be no uneven stress distribution in the
toughened glass insulators. This shall be carried out on 100% glass shells.
2.3 Hydraulic Internal Pressure Test on Shells (only for Disc Insulator)
The test shall be carried out on 100% shells before assembly. The details
regarding test will be as discussed and mutually agreed to by the Supplier
and Owner in Quality Assurance Programme.
2.4 Thermal Mechanical Performance Test

Thermal Mechanical Performance Test shall be performed in accordance with
IEC-60383-1 Clause 20 with the following modifications :
(1) The applied mechanical load during this test shall be 70% of the rated
electromechanical or mechanical value.

(2) The acceptance criteria shall be
(a) X greater than or equal to R + 3S.
Where
X = Mean value of the individual mechanical failing load.
R = Rated electro-mechanical / mechanical failing load.
S = Standard deviation.
(b) The minimum sample size shall be taken as 20 for disc
insulator units and 5 units for long rod units.
(c) The individual electromechanical failing load shall be at least
equal to the rated value. Also puncture shall not occur before
the ultimate fracture.
2.5 Electromechanical/Mechanical Failing Load Test

This test shall be performed in accordance with clause 18 and 19 of IEC 383
with the following acceptance
(i) X greater than or equal to R + 3S
Where
X = Mean value of the electro-mechanical/mechanical/ failing load.
R = Rated electro-mechanical / mechanical failing load.
S = Standard deviation.
(ii) The minimum sample size shall be taken as 20 for disc insulators units
and 5 for long rod units. However, for larger lot size, IEC 591 shall be
applicable.
(iii) The individual electro-mechanical/mechanical failing load shall be at
least equal to the rated value. Also electrical puncture shall not occur
before the ultimate fracture.
2.6 Residual Strength Test (For Disc Insulators only)

The above test shall be performed as per clause 4.4 and 4.5 of IEC 797
preceded by the temperature cycle test, on both glass and porcelain disc
insulators. The Sample size shall be 25 and the evaluation of the results and
acceptance criteria shall be as per clause No. 4.6 of IEC:797.
2.7 Chemical Analysis of Zinc Sleeve

The purity of the zinc used in zinc sleeve shall be tested as per IS:209. The
purity of zinc shall not be less than 99.8%.
2.8 IR Measurements
IR measurement shall be carried out by the instrument operating at 1 kV DC.
IR value when measured under fair weather condition, shall not be less than
50 M-ohm.

2.9 Impact Test
The Impact Test shall be carried out in accordance with ANSI-C-29.2 Clause
8.2.8 with the following modification.
The breaking point of the pendulum shall be so adjusted that, when released
the copper nose will strike the outer rim of the shell or the most protuded rim
of the shell squarely in a direction parallel to the axis of the unit and towards
the cap.
The test specimen shall receive an impact of 7 N-m for 120 kN Disc & 10N-m
for 160 kN & 210 kN Disc by releasing the pendulum.
3. Tests 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 recognised 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 recognised
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 Assurance
Programme.
3.4 Autoclave Test

For cement used in the assembly of the insulators six samples from different
batches shall be tested in accordance with ASTM C-151. The cement shall have
an expansion less than 0.12%.

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TECHNICAL SPECIFICATIONS

1.0 Technical Description of Disc Insulators

1.1 Details of Disc Insulators

Sl. Type of Size of disc Minimum No. Electro- Mechanical

SECTION-II (VOLUME-II) PAGE 1

1.2 Pin and Cap

1.3 Security clip

1.4 Ball and Socket Designation

1.5 Dimensional Tolerance of Insulator Disc (Standard)

SECTION-II (VOLUME-II) PAGE 2

Standard Maximum Minimum

160 KN & 210 KN 280 293 267

b) Ball to ball spacing between discs

Standard Maximum Minimum

160 KN & 210 KN 170 175 165

1.7 Corona And RI Performance

All surfaces must be clean, smooth, without cuts, abrasions or projections. No

SECTION-II (VOLUME-II) PAGE 3

1.9.3 Toughened Glass

1.9.5 Pins and Caps

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

SECTION-II (VOLUME-II) PAGE 4

2.0 Technical Description of Porcelain Long Rod Insulators

2.1 Details of Long Rod Insulators

SECTION-II (VOLUME-II) PAGE 5

2.1.5 Description of long rod insulator string (equivalent to standard disc

Sl. Type of Size of Minimum No. of Electro- Mechanical

SECTION-II (VOLUME-II) PAGE 6

Note : (i) Bidders may quote for the relevant strings.

2.2 Pin and Cap

2.3 Ball and Socket Designation

2.4 Dimensional Tolerance

(0.04 d + 1.5) mm when d < 300 mm.

(0.025d + 6) mm when d > 300 mm

Where d being the dimensions in millimeters for diameter, length or creepage

However, no negative tolerance shall be applicable to creepage distance.

2.5 Intermediate Ball Pin Designation

SECTION-II (VOLUME-II) PAGE 7

2.6 Intermediate Arcing Horn

The total effective arcing distance shall be 3050 mm (for TL in Non-snow

2.7 Inter Changeability

2.8 Corona and RI Performance

SECTION-II (VOLUME-II) PAGE 8

2.10.3 Insulator Cap

Intermediate Arcing horn shall be mild steel tube.

SECTION-II (VOLUME-II) PAGE 9

3.0 Equipment Marking

For 120 kN disc/ long rod unit : Yellow

For 160 kN disc / long rod unit : Green

For 210 kN disc / long rod unit : Blue

4.0 Bid Drawings

SECTION-II (VOLUME-II) PAGE 10

(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 and socket parts

(g) Weight of unit insulator disc/long rod units

(i) Identification mark

(j) Manufacturer's catalogue number

5.0 Tests and Standards