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Guidelines For Rationalised Use Of

High Performance Conductors
Guidelines For Rationalised Use Of High
Performance Conductors

By
Power System Engineering & Technology Division
Central Electricity Authority
 CENTRAL ELECTRICITY AUTHORITY

CONTENTS

S. No. Clause No./ Title Page

Annexure No.
1. 1.0 Introduction 1

2. 2.0 Options for Increasing Transmission Capacity 4

3. 3.0 Description of High Performance Conductors 7

4. 4.0 Ampacity comparision of various High Performance 16

Conductors
5. 5.0 Application areas for High Performance Conductors 21

6. 6.0 Issues to be considered before installation of High 23

Performance Conductors
7. 7.0 Cost-benefit analysis 25

8. 8.0 Criteria for technical evaluation of bids for different 27

types of High Performance Conductors
9. 9.0 Use of High Performance Conductors by various 29
utilities
10. 10.0 Conductor accessories for various types of High 29
Performance Conductors
11. 11.0 Manufacturing facility for High Performance 30
Conductors in India
12. 12.0 Testing facility 30

13. 13.0 Recommendations of the Committee 31

14. Annexure-I List of Test Facilities in India 34

15. Annexure-II Technical specification for High Performance 38

Conductors
16. Annexure-III Technical specification for hardware fitting and 79
accessories
17. Annexure-IV Guaranteed Technical Particulars/Technical Data 133
Sheets
18. Annexure-V Office order for constitution of the Committee 155

19. References 157

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1.0 INTRODUCTION:

1.1 Indian power sector is growing at a very rapid pace both in supply
and demand side. Transmission capacity needs to be enhanced to
commensurate with the rapid urbanization and consequent increase
in demand. The most common way to raise transmission capacity
is to construct new lines. However, increased environmental
constraints and public opposition to new overhead lines has made it
very difficult to get Right of Way (RoW) for new lines and the cost of
RoW is also escalating due to rapid urbanization. Apart from
addition of new transmission system, there is urgent need of
enhancement of the capacity of the existing transmission system to
cater to the increase in demand. The problem in getting RoW has
necessitated to utilize existing RoW in more efficient way to enhance
quantum of power in the same RoW. Wherever transmission
constraints are felt and enhancement in power transmission
capacity in existing corridor becomes necessity, alternative means
such as use of higher size conductor, voltage increase technologies,
circuit addition, HVDC, dynamic line rating etc. need to be explored.
One such emerging technology is the use of new generation High
Performance Conductors (HPC), which include High Temperature
(HT) conductors and High Temperature Low Sag (HTLS) conductors,
and these conductors have been proven successful globally.

1.2 In India, ACSR and AAAC conductors are commonly used for
transmission of power on overhead lines for transmission and
distribution system. Conductors constitutes about 30% to 40% of
total cost of overhead EHV transmission lines and type of conductors
plays an important role in quantum of power flow, Transmission &
Distribution (T&D) losses, height & design of towers, span length, ,
and hence cost of the transmission line. HPC conductors are being
used by several Indian utilities, however, there is need to adopt such
conductors rationally to suit India’s Transmission and Distribution
Sector requirement. These HPC conductors could help electric power
delivery system to meet the desired objective. Apart from its use in
enhancement of power transmission capacity in existing corridor,
such conductors could also be used in new lines where higher power
flow is required which otherwise is not possible through ACSR or
AAAC conductors. As such, a judicious decision is needed while
selecting a particular type of New Generation conductor for new lines
as well as for uprating the existing corridors in Transmission and
Distribution segment keeping in mind the techno-economic benefits.

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1.3 The conventional ACSR and AAAC conductors are currently

designed to operate at maximum temperature of 85o C and 95o C
respectively. The thermal limit of the conductor is established by the
fact that further heating anneals the conductor. The ordinary hard
drawn aluminium used in conventional ACSR starts annealing and
losing strength at above 93oC and is not suitable for use at
temperature above this. Thus, the ampacity of these conductors is
restricted by above mentioned temperature and further
enhancement of ampacity is not possible. Ampacity in the same
transmission line can be enhanced by use of either higher size
conductor or High Performance Conductors (HPC). Each option
needs to be thoroughly evaluated including requirement of changes
to be made in existing infrastructure.

1.4 High Performance Conductors are designed to operate continuously

at temperature of at least 150o C. Some of these conductors can
continuously operate at temperature as high as 250o C without any
degradation in mechanical or electrical properties. Because of their
operation at high temperature, these conductors can carry higher
current (typically 1.5 to 2 times that of ACSR) without exceeding size
& weight of existing conductor and offering similar or better tensile
strength, hence allowing use of same structure without any or with
minimal modification resulting into short erection period.

1.5 In India, for last few years, the need of use of High Performance
Conductors in some corridors has been felt. The power flow in these
corridors has increased and congestion has been reduced by using
such conductors. Such conductor would be required where the
power transfer over the line is constrained due to consideration of
thermal loading.

1.6 High Performance Conductors can be considered for reconductoring

of existing lines and can also be used in new lines. Depending on the
type of conductor, the cost of such conductor may vary between 1.5
to 5 times the cost of conventional ACSR/ AAAC conductors. Other
than the cost of power conductor, cost of additional ohmic loss at
elevated temperature, conductor accessories, insulator hardware,
de-stringing of conventional power conductor, re-stringing &
installation of High Performance Conductors are to be considered
before deciding whether installation of High Performance
Conductors is economically justifiable. The terminal equipment
rating at substations also needs to be examined for enhancement of
power transfer in a line. Moreover, for new lines, proper system
studies need to be carried out to identify the corridors for use of such

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conductor. The use of HPC conductors need to be considered on case

to case basis based on techno-economic analysis over the life cycle.
After considering the life-cycle cost, the overall project costs may, in
some cases, be less even after higher cost of the conductor and
accessories.

1.7 A Technical Committee comprising representatives from CEA, CPRI,

IEEMA, PGCIL, State utilities, and conductor manufacturers was
constituted under the Chairmanship of Chief Engineer, Power
System Engineering & Technology Development Division of CEA vide
order No. CEA/SETD/323/2016/23 dated 18.01.2016 to “Discuss
and rationalize the effective use of new generation High Performance
Conductor (HPC) [High Temperature / High Temperature Low Sag
(HTLS) Conductor] in Indian Transmission & Distribution System”.
Office order vide which the Committee was constituted is enclosed
at Annexure-V.

1.8 The first meeting of the Committee was held on 29.01.2016. Second
meeting was held on 12.05.2017 in which the comments on draft
document were discussed. Based on deliberations in these meetings
and information collected from utilities, conductor manufacturers
and other sources, this document has been prepared. As the
technology of High Performance Conductors (HPC) [High
Temperature / High Temperature Low Sag (HTLS) Conductor] are
ever evolving and improvements are being made due to improved
metallurgy of conducting part as well as core material, the technical
parameters indicated in this document may experience changes or
new type of conductors get introduced, which may not be covered in
this document. As such, at the time of procurement of such
conductors, utilities have to make their own assessment of need and
techno-economic benefits.

1.9 Manufacturing of new generation High Performance Conductors is

still evolving and newer core materials & conductors are being
introduced by the manufacturers. Only few High Performance
Conductors which are being used in India have been discussed in
this document. Description of various conductors has been provided
based on information gathered from utilities, manufacturers,
publications etc.

1.10 Some of the scenarios where uprating by use of High Performance

Conductors may be adopted and the scenarios where use of High
Performance Conductors may not be a good option as compared to
other technological options have been included in the document for
the reference of the utilities. However, utilities may carry out their

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own analysis and make a decision as per their requirement to use

any conductor which has or has not been mentioned in this
document.

1.11 A sample technical specification for HTLS conductor and hardware

accessories has been provided as Annexure- II & III respectively for
the guidance to utilities. The values of parameters have been left
blank and the same may be filled and technical specification may be
modified by the utilities as per their requirement.

1.12 Correct assessment of current in various conditions needs to be

made over life cycle be made and levelized accordingly for the
purpose of loss loadings, alternatively time percentages of nominal
expected current may be considered. However, the loss loading
should not consider unrealistic flows as it can potentially disturb the
inter-se ranking of bidders and utility may ultimately have to incur
higher cost.

1.13 The list of tests required to be conducted on HPC conductors is

included in the technical specification and technical data sheets to
be filled by bidders has been provided at Annexure-IV. Some tests
will be common for all HPC conductors while some tests will be
exclusive for any specific conductor because of their specific
metallurgical/electro-mechanical properties.

1.14 The purpose of this document is to provide basic information

about High Performance Conductors to the utilities and create
awareness so as to empower them to rationalize the effective
use of such conductors in Indian Transmission & Distribution
System. This document, by no means, promote or endorse any
particular type of conductor or manufacturer.

2.0 Options for Increasing Transmission Capacity

As transmission capacity (MVA) is a product of voltage (kV) and

current (kA), the increase in capacity could be achieved by either
increasing voltage or current or both of them. Various methods are
available to increase the rating of an existing overhead line, each of
these have unique cost-benefit ratio and the utility has to make
studies before arriving at alternative best suited to them. Some of
the options available for increasing the transmission capacities are
as under:

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(a) Use of higher size conductor: The most obvious method to

improve ampacity of existing line is to replace the existing
conductor with a higher size conductor that will run at the same
operating temperature. However, size increase may warrant
strengthening or replacement of the support structure. This
approach is considered to be one step short of a wholesale
replacement of the line and it can be considered that all that is
salvaged by the change is the right-of-way itself.

(b) Circuit addition: Another solution for delivering more power

between terminals is the addition of a circuit to a line. However,
it is rare to find space on existing structures that would allow
the addition of another circuit without serious revision to the
structures. The most promising situation is the conversion of a
single circuit line of vertical or delta configuration to a double
circuit configuration. Conversion of an existing single circuit
framing to a double circuit framing requires that enough
spacing for phase to phase and phase to ground clearance is
available so that after conversion regulatory and technical
requirement of clearances is met.

(c) Voltage Increase Technologies: Wherever site situation

permits, operation of an overhead line at a higher voltage level
is a very effective way to increase the transmission capacity.
Changing to a higher voltage level will increase the line capacity
by the direct ratio of the voltage change and would reduce the
energy losses by the voltage ratio squared. However, this
approach requires either the presence of voltage options at the
line ends (stations), or it requires a considerable expenditure on
this end equipment replacement to accept the new line voltage.
Additionally, to increase the lines voltage significantly, the
structures also need revision. Also, to install longer insulators
while maintaining the required clearances for the higher
voltages, additional space would be needed which may not be
available on structures.

Newer technologies like providing insulated cross-arms in

existing towers provide advantages in maintaining the
conductor swing and electrical clearances, thereby possibility
of employing next higher voltage in existing lines with
appropriate modifications. The ROW calculations with

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insulated cross arm also show space advantages. By changing

both transmission voltages to next level and also replacing
existing conventional conductor to HTLS conductor, the power
transfer capacity of transmission line could increase multifold.
These options may be explored by utilities in case substantial
increase in power transfer capability of transmission line is
required in a given corridor, while retaining the basic structure.

Often, conductor size may limit voltage uprating, as it may be

necessary to replace existing conductors with larger diameter
or additional conductors per bundle while increasing the
voltage because of Corona effect, thereby further increasing the
power transfer capability of line.

Voltage uprating is especially suited to converting a double

circuit line into a single circuit line. Also, the phase to phase
distance can be easily obtained by the conversion of a double
circuit line into a single circuit line.

(d) Use of HVDC : Another technology for quantum increase in

power transfer capability is the deployment of HVDC. However,
the planning of such lines is an intricate and rigorous exercise.
This option may prove to be very costly considering requirement
of converters at both ends and associated DC network.

(e) Capacity increase by Real Time Monitoring Systems &

Dynamic Line Ratings (DLR): Applying dynamic ratings based
on real-time monitoring of weather conditions or conductor
properties to determine (by calculations or direct measurement)
the ground clearance at any time can allow higher power
capacities in 'beneficial' weather conditions. Enhancement of
ampacity can also be obtained from the difference between the
ambient temperature used for the line design (e.g. 45°C) and
the average ambient temperature of the region (e.g. 25°C). On
an average, the increase in the thermal rating of lines using real
time systems is about 10 to 15%.

(f) High Surge Impedance Lines: There are technologies that

apply almost exclusively to long EHV lines, as power transfer
capacity of these types of lines are generally limited by surge
impedance. One such method involves reshaping of the line’s

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physical configuration to revise its natural surge impedance to

the advantage of its capacity. It provides a higher Surge
Impedance Loading (SIL) than conventional line configurations
offer. The HSIL lines concept can be applied either to new lines
or to existing lines. In practice, this can be done by:
 Adding sub-conductors per phase
 Increasing the bundle size for each phase (Expanded
Bundle Technology (EXB)
 The use of asymmetric bundles
 Decreasing the phase to phase distance

(g) HPC conductor: Reconductoring an existing line with HPC

conductor is yet another alternative. Since HPC conductors are
more expensive than conventional aluminum stranded
conductors, they are not suitable in every uprating situation.
Reconductoring with HPC conductors is not economically
justified in each & every case of capacity enhancement and the
decision shall be made by the concerned utility based on their
specific requirement, system study and techno-economic
analysis. Some scenarios where uprating by HPC Conductor
may or may not be used are provided in para 3.8.

When increasing the ampacity of a circuit, it is important to

check that all components of the circuit are appropriate for the
new ampacity and if necessary change some of them (e.g. circuit
breakers, current transformers, joints and clamps).
Additionally, requirement of safe level of electric and the
magnetic field beneath lines and RoW needs to be ensured.

3.0 Description of High Performance Conductors

3.1 As mentioned earlier, the ordinary hard drawn aluminium used in

conventional ACSR starts annealing and losing strength at above
93oC and not suitable for long term use at temperature above this.
To avoid annealing, two options are used in conductor design. One
option is to anneal the conductor’s aluminum intentionally in the
factory before purchase and installation. The other option is to alloy
the aluminum with zirconium in varying degrees to produce TAL,
ZTAL/UTAL and XTAL designated alloys. Alloying of aluminium
slightly increases the resistivity whereas annealing of aluminium
lowers resistivity thereby having better conductivity.

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3.2 High Performance Conductors are manufactured using any of the

above two options and are designed to operate continuously at
temperature of 150o C and higher. Some of these conductors can be
operated at as high as 250o C. High Performance Conductor is
stranded with combination of annealed aluminium or aluminium
alloy wires for conductivity, and reinforced by core wires. Al-Zr alloy
wires have similar conductivity and tensile strength as ordinary
Electrical Conductor (EC) Grade aluminium wire but can operate
continuously at temperatures up to 150oC – 200oC. Fully annealed
aluminium wires are chemically identical to ordinary hard drawn
aluminum and have much reduced tensile strength, but can operate
indefinitely at temperatures even higher than 250oC without any
change in mechanical properties of aluminium. As shown in Table-
I, the wire materials used for High Performance Conductors are
capable of continuous operation at temperatures in excess of 1000C
with stable electrical and mechanical properties.

Table-I

Type Aluminium Tensile Conductivity Maximum Emergency

Conductor strength (% IACS) continuous operating
(MPa) operating temperature
temperature (°C) (<10
(°C) hrs. per
year)
Fully 1350-O 42 to 98 61.8 200 250
Annealed (Fully
annealed)

Thermal TAL or 60 159 to 60 150 180

Resistant TAL (AT1) 169

HS KTAL 225 to 55 150 180

Thermal (AT2) 248
Resistant

Ultra ZTAL or 159 to 60 210 240

Thermal UTAL 176
Resistant (AT3)

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Extra XTAL 159 to 58 230 260

Thermal (AT4) 169
Resistant

3.3 The core material used in High Performance Conductors include

galvanized steel, aluminium cladded steel, mischmetal steel, INVAR
steel (Fe-Ni alloy), high strength steel, metal matrix composites and
polymer matrix composites (e.g. carbon fiber composite). For High
Performance Conductors with annealed aluminum strands, the
conductor stiffness and breaking strength is largely determined by
the core. For High Performance Conductors with Zirconium
aluminum strands, the composite conductor strength and stiffness
depends on both the reinforcing core and the aluminum strand
layers. Properties of various core materials have been shown in
Table-II.
Table-II

Description Modulus of Tensile Coefficient Unit weight

Elasticity Strength of (mg/mm3)
(GPa) (MPa) Expansion
(x10-6/°C)

HS Steel 200 1379-1448 11.5 7.778

EHS Steel 200 1517 11.5 7.778

EXHS Steel, 200 1965 11.5 7.778

Galfan coated

Aluminum clad 162 1103-1345 13 6.588

20.3% IACS

Galvanized Invar 162 1034-1069 1.5-3.0 7.778

alloy

Aluminum clad 152 932-1080 3.7 - 10.8 7.1

Invar

Mischmetal (Std, 200(I) - 1379-1448 11.5 7.778

HS) 186(F)
1517-1620

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Metal Matrix 215 1310 6.0 3.322

Polymer Matrix 112.3 2158 1.6 1.88

3.4 An High Performance Conductor can be manufactured by using any

of the following combinations:

(a) Steel/ coated steel/ steel alloy core with an envelope of thermal-
resistant aluminium alloys
(b) Steel/ coated steel/ steel alloy core with an envelope of
annealed aluminium
(c) Metal-matrix composite (MMC) core with an envelope of
thermal-resistant aluminium alloys
(d) Polymer-matrix composite (PMC) core with an envelope of
annealed aluminium/ thermal-resistant aluminium alloy

3.5 A combination of the properties of the envelope and the reinforcing

core decides the operating temperature limit of a High Performance
Conductor. Normally, a compromise between the operating
temperature limits and loss of tensile strength of the envelope is
made. The operating temperature limitation of the conductor also
factors in the possible deterioration of the connectors and associated
hardware. So, the operating temperature limits for High Performance
Conductors are normally less than or equal to the operating
temperature limits of the individual component materials.

3.6 A brief description, which includes construction, pros & cons,

erection issues, etc., of all major type of High Performance
Conductors presently available are given in following section.

(A) Steel/ coated steel/ steel alloy core with an envelope of

thermal-resistant aluminium alloys
[Typical conductors: ZTACSR, ZTACIR (INVAR), GZTACSR]

(a) (Z)TACSR

(Z)TACSR conductor has the same construction as conventional

ACSR conductor, with galvanized steel wires for the core and TAL
(thermal-resistant aluminium alloy) wires or ZTAL (thermal-
resistant aluminium alloy wires with zirconium added) wires as
envelope. TAL and ZTAL aluminium strands have the same

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conductivity and tensile strength as ordinary electrical conductor-

grade aluminium strand but can operate continuously at
temperatures up to 150o C and 210o C, respectively, without any
loss of tensile strength over time.

(Z)TACSR is not, by design, a low-sag conductor. It has the same

thermal elongation behavior as ACSR. The main advantage of
(Z)TACSR is that its aluminium alloy wires do not anneal at
temperatures up to 150oC for TAL and 210oC for ZTAL. (Z)TACSR
can be used to uprate existing lines where some additional clearance
is available.

(b) (Z)TACIR / STACIR: (Conductor with INVAR core)

As with (Z)TACSR, (Z)TACIR/STACIR has a conventional stranded

construction identical to ACSR, making use of material innovations
to give properties allowing the conductor to be operated at high
temperatures. In place of the steel strands of (Z)TACSR, it has
galvanized or aluminium-clad invar alloy steel wires for the core and
(Z)TAL wires surrounding them. Invar is an iron-nickel alloy (Fe-
36%Ni) with a very small coefficient of thermal expansion.
Geometrically identical to conventional ACSR, with the only
differences being a slightly reduced conductivity and a much
increased maximum allowable temperature as the aluminium alloy
wires do not lose strength at high temperature.

(Z)TACIR/SATCIR has a maximum continuous operating

temperature of 210°C and can have twice the current capacity of
ACSR conductor. The coefficient of thermal expansion of invar wire
is around one-third that of galvanized or aluminium-clad steel wire.
However, tensile strength of invar wire (1080 MPa) is lower than
galvanized steel wire. Tensile strength of the conductor is about 8%
lower than normal ACSR conductor. (Z)TACIR/SATCIR Conductor
has equivalent sag-tension properties to conventional ACSR. The
installation methods and accessories for the conductor are similar
to those used for conventional ACSR. A slight lengthening of
compression type accessories is required only to satisfy increased
current carrying requirements. Pre-stressing can effectively lower
the temperature of the knee-point. Cladding may be done to improve
conductivity.

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(c) G(Z)TACSR (GAP Conductor)

G(Z)TACSR i.e. gap type conductor uses a galvanized steel core

surrounded by a thermo-resistant aluminium alloy. The wires of the
innermost layer of aluminium are always of trapezoidal shape, and
sized such that the inside diameter of the resulting tube is slightly
larger than the external diameter of the core so as to maintain slight
gap in between. The radial gap between the core and the envelope
allows independent movement between the two. The gap is filled with
heat-resistant grease (filler) to reduce friction between the steel core
and the aluminum layer and to prevent water penetration &
corrosion. The outer layers can be made trapezoidal also to maintain
compact stranding and to minimize electrical resistance and
increase the effective cross-sectional area on aluminum strands.

Gap-type conductor exhibits the same properties (corrosion,

electrical, etc.) as a TACSR and its low sag behavior will allow it to
be operated at much higher temperatures than ACSR. Knee point of
the conductor is at erection temperature which means sag of the
conductor is fully dependent on sag of steel core allowing to
maximize use of low sag properties at very high temperature.
However, if sections are erected at different temperatures (on
different days) then their sag/temperature behavior will be different
in the different sections. The expansion coefficient of the conductor
above the knee-point temperature will be that of the steel core (11.5
x10-6/ºC).

The installation of this conductor is more complex and labor

intensive than ACSR. During erection, the conductor has to be
stripped bare and hanged from the steel for 8-12 hours during
stringing. Although this special erection technique is different from
that employed with conductors of standard construction (i.e., ACSR),
the compression splices and bolted suspension clamps are similar
albeit suitable for elevated temperature.

Grease used in the gap type conductor should have elevated drop
point (at least 300o C) and oil separation point to prevent migration
of the grease to the outer surface; should retain its properties over a
specified temperature range and under varied environmental
conditions; and should comply with the requirements of relevant
standards.

Trapezoidal wires (TW) may be used for outer layer of the conductor
for snow bound areas, as these are less sensitive to snow accretion.

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(B) Steel/ coated steel/ steel alloy core with an envelope of

annealed aluminium
[Typical conductors: Aluminium Conductor Steel Supported (ACSS)
and ACSS/TW (trapezoidal wire)]

ACSS conductor consists of fully annealed strands of aluminium

around a stranded steel core. In appearance, ACSS conductors are
essentially identical to standard ACSR conductors. ACSS is typically
available in “Standard Round Strand” construction or “Trapezoidal
Aluminium Wire” construction with equal area or equal diameter to
conventional round wire construction. The steel core may be of High
Strength (HS), Extra High Strength (EHS), Ultra High Strength (UHS)
steel, mischmetal or aluminium Clad Steel core.

Annealed aluminium (61.8% IACS) has higher conductivity than

hard-drawn aluminium wires (61% IACS) used in ACSR thereby
increasing the existing current capacity of the line. However, the
tensile strength of fully annealed aluminium is lower than hard-
drawn aluminium. This may be mitigated by using high strength
steel core or higher steel core area or both. Since the tension in the
annealed aluminium wires is low, the thermal elongation is
essentially that of the steel core alone thereby providing reduced sag
up to 250°C. Also, due to low tension in the aluminium strands, it
does not creep under everyday tension loading.

Galvanizing is prone to degradation above 200oC, however,

aluminium-clad or mischmetal (Al-Zinc alloy) clad cores are more
robust against heat degradation. The Mischmetal Coating on the
steel core may also be used which can withstand up to 250oC
temperature for continuous operation. Mechanical and physical
properties of Mischmetal steel wire are similar to that of the
galvanized steel wires. Corrosion resistance of Mischmetal steel
wires are better than that of galvanized steel wires.

The reduced strength of the annealed aluminium wires results in a

relatively low knee-point for the conductor. It can be significantly
reduced by pre-stressing the conductor, which has the effect of
imparting a permanent plastic deformation to the aluminium wires,
such that an even greater proportion of stress is carried by the steel
core. This helps to reduce or prevent vibration fatigue damage in
challenging installations such as river crossings.

Although the splicing, installation, and termination is no more

complicated than for ACSR conductors, however, the annealed

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strands, being very soft, should be handled with care and should not
be dragged across the bare ground, over rocks, or fences etc. Parallel
jaw grips should be closely sized to the conductor diameter and the
clamp surface needs to be clean to minimize strand distortion. Also
because of the annealed aluminum strands, the two-stage
compression splice is somewhat longer than those designed for an
ACSR conductor. They require no special suspension clamp design,
and tension-stringing installation is straightforward. High
temperature tolerant suspension clamps must be used to allow the
maximum operating temperature that these HTLS conductors are
capable of reaching.

(C) Metal-Matrix Composite (MMC) core with an envelope of

thermal-resistant aluminium alloys
[Typical conductors: ACCR]

These conductors are made of Metal Matrix Composite (MMC) Core

with envelope of thermal-resistant aluminium alloys. The core is
made of wires composed of alumina fibers in an aluminium matrix,
forming a composite material. The core wire looks physically similar
to steel core, but it is eight times stronger than aluminum and about
the same stiffness as the steel core. Each core wire contains
thousands of small-diameter and ultra-high-strength aluminum
oxide fibers. These fibers are continuously oriented in the direction
of the wire, and fully embedded within high-purity aluminum.

Both the composite core and the outer strands contribute to the
overall conductor strength and conductivity. The composite core
material provides a substantially lower coefficient of thermal
expansion above its knee-point in comparison to steel core, thereby
significantly reducing the expansion coefficient of the conductor as
a whole. The core material is significantly lighter than steel, resulting
in a lower weight, while at the same time being both stronger and
having a higher elastic modulus. Conductivity is also significantly
greater than steel.

These conductors can be operated continuously at temperatures up

to 210°C and emergency up to 240°C with AT3 alloy wires. The
conductor is essentially all-aluminium, and the lack of a steel core
removes the possibility of galvanic corrosion. It also exhibits very
little creep. It has no undesirable magnetic properties unlike
conductors with a ferrous core which experience increase in
resistance due to magnetic effects. This magnetic effect is eliminated
in MMC core with thermal resistant aluminium alloys.

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The compression-type hardware for the dead-end assembly of these

conductors uses a modified two-part approach, as in the ACSR
conductor. One part grips the core, and then an outer sleeve grips
the aluminum strands. This approach prevents notching of the core
wires. The gripping method ensures that the core remains straight
to evenly load the wires, and also ensures that the outer aluminum
strands suffer no lag in loading relative to the core. The composite
materials are highly anisotropic, i.e., they have good tensile strength
but lower shear, transverse & torsional strength and have a more
limited ability to conform to a low bend radius than conventional
engineering metals and alloys, such as steel & aluminium. Thus
composite materials require careful handling and care needs to be
taken in choosing the correct diameter sheaves (i.e. travellers),
bullwheel sizes, pulling tension and conductor reels sizes, to prevent
excessive bending radius during installation.

(D) Polymer-matrix composite (PMC) core with an envelope of

annealed aluminium/ thermal-resistant aluminium alloy
(Carbon Composite Core (CCC) Conductor)
[Typical conductors: ACCC, CFCC, HVCRC, ACFR etc.]

The core is made of a polymer matrix composite (PMC), usually

carbon fibers in a resin or epoxy resin matrix, with annealed
aluminium or thermal resistant aluminium alloy envelope. The
polymer matrix can be made with thermoplastic or thermosetting
compounds. The core is protected against galvanic corrosion by
either an annular sleeve made up of glass fibers, all in the same resin
matrix, or protected by an aluminium alloy welded tube or other
methods while the envelope can be round, trapezoidal or Z-shaped.

PMC cores have higher tensile strength compared to steel and

compensate for the lower strength of fully annealed aluminium
wires. While the aluminum strands are fully annealed, offering the highest
degree of conductivity for any aluminum available today, the composite core offers
a very low coefficient of thermal expansion than steel core which allows for less
sag at high temperature operation. Less sag and low weight can be utilized to
have increased spans on fewer/shorter structures along with reduced line losses.
Generally, the composite core used is a solid, single-piece rod with
no interstices. However, stranded configuration does also exist. As
the core has a smooth surface and it bears the overall tensile
strength of the conductor, the dead-end assembly has been designed
to create a stronger crimp compared to that of ACSR conductor that
forms a very solid aluminum press that fits around the composite
core. The core resists degradation from vibration, corrosion,
ultraviolet radiation, corona, chemical and thermal oxidation and,

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most importantly, cyclic load fatigue. However, the core made of

multiple strands may be more susceptible to thermal oxidation.
Although CCC has significantly less thermal sag than other High
Performance Conductor designs, its core is quite elastic and
sags more than other designs under ice load. For ice loading
condition, core with higher modulus has to be designed. For very
heavy ice loading regions, extra high strength composite core should
be used to improve Sag values. This conductor requires special fittings,
such as splice and dead-end connections which are patented. The composite
materials are highly anisotropic, i.e., they have good tensile strength
but lower shear, transverse & torsional strength and have a more
limited ability to conform to a low bend radius than conventional
engineering metals and alloys, such as steel & aluminium. Thus
composite materials require careful handling and care needs to be
taken in choosing the correct diameter sheaves (i.e. travellers),
bullwheel sizes, pulling tension and conductor reels sizes, to prevent
excessive bending radius during installation. The manufacturer’s
recommendations/procedures should be adhered to during
installation so as to avoid any damage to the core of the CCC
conductor which may lead to snapping of conductor.

4.0 Ampacity comparision of various High Performance Conductors

High Performance Conductors typically consist of aluminum wires

enveloping a reinforcing core. The comparative performance of the
HPC viz-a-viz ACSR conductors depends on the degree to which the
aluminum strand and reinforcing core’s physical properties are
stable at high temperature and on the elastic, plastic and thermal
elongation of the combined HPC. As such, the current carrying
capacity/ ampacity at different operating temperature is helpful to
ensure optimum use of their advantages.

Typical values of Ampacity and AC Resistance at various

temperatures for corresponding diameter of various conductors
equivant to ACSR Moose, Panther and Zebra conductors at following
assumptions is given below in Tables III, IV and V. AAAC and Al59
conductors have also been included in the table for comparison
purpose.

Ambient temperature: 45o C

Solar radiations : 1045 W/m2
Wind Speed : 0.56 m/s
Absorption Coefficient : 0.8
Emissivity Coefficient : 0.45

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These values have been provided for reference purpose only. Values
may change depending upon material properties, size and shape of
the conductor strands, diamtere of the conductor etc. Different
manufaturers may have different sizes for any particular conductor.
Utilities should do due dilligence to arrive at ampacity, resistance
and losses of any conductor in consultation with the manufacturer.

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Table-III

Typical values of Ampacity and AC Resistance at various temperatures for ACSR Moose and Equivalent
AAAC, Al59 & High Performance Conductors
S. Conductor Dia Resistance Weight Parameter Operating Temperature
No. (mm) at 20o C (kg/km)
(Ohm/km)
75⁰C 85⁰C 95⁰C 125⁰C 150⁰C 180⁰C 200⁰C 210⁰C 250⁰C
1. ACSR 31.77 0.05552 2004 Ampacity (A) 620 794
Moose Rac (Ohm/km) 0.06906 0.07125
2. AAAC 31.95 0.0568 1666 Ampacity (A) 619 795 933
Rac (Ohm/km) 0.0694 0.0714 0.0733
3. Al59 31.77 0.0497 1648 Ampacity (A) 656 841 987
Rac (Ohm/km) 0.0617 0.0636 0.0655
4. TACSR 31.77 0.0556 1997 Ampacity (A) 620 794 931 1237 1430
Rac (Ohm/km) 0.06907 0.07131 0.0735 0.0801 0.0855
5. ACCC 31.77 0.0418 1990 Ampacity (A) 710 910 1068 1421 1644 1866
Rac (Ohm/km) 0.05265 0.05426 0.05588 0.0607 0.06477 0.06962
6. STACIR 28.95 0.0599 2001 Ampacity (A) 585 744 869 1149 1324 1499 1601 1649
Rac (Ohm/km) 0.0743 0.0766 0.079 0.08612 0.09203 0.09913 0.1037 0.10623
7. GZTACSR 29.9 0.05134 2004 Ampacity (A) 629 801 937 1242 1433 1623 1735 1787
(Gap) Rac (Ohm/km) 0.0663 0.0684 0.07052 0.0769 0.0822 0.08861 0.09287 0.09501
8. ACSS 31.77 0.0521 2000 Ampacity (A) 633 810 950 1261 1457 1652 1766 1820 2018
Rac (Ohm/km) 0.06494 0.0669 0.06903 0.07516 0.08027 0.0864 0.09049 0.09245 0.10071

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Table-IV

Typical values of Ampacity and AC Resistance at various temperatures for ACSR Zebra and Equivalent
AAAC, Al59 & High Performance Conductors
S. Conductor Dia Resistance Weight Parameter Operating Temperature
No. (mm) at 20o C (Kg/km)
(Ohm/km)
75⁰C 85⁰C 95⁰C 125⁰C 150⁰C 180⁰C 200⁰C 210⁰C 250⁰C
1. ACSR 28.62 0.06868 1621 Ampacity (A) 552 702
Zebra Rac(Ohm/km) 0.0849 0.0876
2. AAAC 28.62 0.0706 1337 Ampacity (A) 550 700 819
Rac (Ohm/km) 0.0855 0.08806 0.0905
3. Al59 28.62 0.0618 1337 Ampacity (A) 583 741 866
Rac (Ohm/km) 0.07616 0.07853 0.08089
4. TACSR 28.62 0.0685 1621 Ampacity (A) 554 703 822 1086 1253
Rac (Ohm/km) 0.0846 0.0873 0.09 0.0981 0.1048
5. ACCC 28.14 0.0536 1565 Ampacity (A) 624 792 925 1221 1408 1593
Rac (Ohm/km) 0.0662 0.0683 0.0705 0.0769 0.0822 0.0888
6. STACIR 25.4 0.0775 1587 Ampacity (A) 513 648 754 989 1138 1286 1373 1412
Rac (Ohm/km) 0.09545 0.0985 0.1016 0.1108 0.1185 0.1261 0.1338 0.1369
7. GZTACSR 27.1 0.0676 1621 Ampacity (A) 547 691 806 1063 1225 1385 1479 1523
(Gap) Rac (Ohm/km) 0.08552 0.0883 0.09105 0.09936 0.1063 0.1146 0.1202 0.12294
8. ACSS 28.04 0.0684 1619 Ampacity (A) 552 700 818 1080 1254 1409 1505 1550 1717
Rac (Ohm/km) 0.08456 0.08727 0.0899 0.09813 0.1049 0.1130 0.1185 0.1212 0.1321

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Table-V

Typical values of Ampacity and AC Resistance at various temperatures for ACSR Panther and Equivalent
AAAC, Al59 & High Performance Conductors

S. Conductor Dia Resistance Weight Parameter Operating Temperature

No. (mm) at 20o C (Kg/km)
(Ohm/km)
75⁰C 85⁰C 95⁰C 125⁰C 150⁰C 180⁰C 200⁰C 210⁰C 250⁰C
1. ACSR 21 0.139 974 Ampacity (A) 374 465
Panther Rac(Ohm/km) 0.1703 0.17588
2. AAAC 21 0.114 720 Ampacity (A) 416 518 600
Rac(Ohm/km) 0.13752 0.14163 0.1457
3. Al59 21 0.1143 720 Ampacity (A) 413 514 595
Rac(Ohm/km) 0.1394 0.1438 0.1483
4. TACSR 21 0.1386 973 Ampacity (A) 375 466 539 703 807
Rac(Ohm/km) 0.1698 0.1754 0.1809 0.1975 0.2115
5. ACCC 20.5 0.1024 834 Ampacity (A) 434 539 623 813 931 1049
Rac(Ohm/km) 0.1258 0.1299 0.134 0.146 0.1565 0.1689
6. STACIR 20.7 0.1408 966 Ampacity (A) 370 460 532 694 796 896 955 982
Rac(Ohm/km) 0.1725 0.1782 0.1835 0.2001 0.2149 0.2319 0.2432 0.2488
7. GZTACSR 20.6 0.1224 974 Ampacity (A) 397 493 570 743 852 959 1022 1051
(Gap) Rac(Ohm/km) 0.1501 0.155 0.1599 0.1745 0.1867 0.2014 0.2112 0.2161
8. ACSS 20.5 0.1355 925 Ampacity (A) 377 469 542 707 810 896 972 1000 1103
Rac(Ohm/km) 0.166 0.17144 0.1768 0.1931 0.2067 0.2203 0.2339 0.2393 0.2611

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5.0 Application areas for High Performance Conductors

(A) Some applications for reconductoring with High Performance

Conductors may involve the following scenarios:

(a) The state utilities have a large number of transmission lines of 33

kV/66 kV/132 kV etc. These lines are very old and are not able to
carry more power. Uprating of such transmission lines to carry
more power at the same voltage.
(b) If the structures and foundations are in good condition, and the
minimum increase in thermal rating in excess of 20% is required,
then High Performance Conductors are likely to be a good choice.
(c) Many of such lines which were once upon a time outside the urban
boundaries are now inside the urban boundaries due to rapid
urbanization. Changing the tower and/or foundation is almost
impossible in such crowded streets.
(d) For short lines, which experience occasional high electrical loads,
High Performance Conductors are often an excellent method of
uprating. For reconductoring short lines, increase in electrical
losses may not be significant, and the use of HPC conductors is
usually a reasonable and economic option.
(e) For longer lines, reconductoring with High Performance
Conductors may also be economic, if the frequency and duration
of high current loads are less.
(f) In Intra-State Transmission System, requirement of such
conductor is expected at 220kV, 132kV and 66kV level. The
requirement of such conductor may not be much in Inter-State
Transmission System (ISTS), which is dominated by 400kV and
765kV network. In case of ISTS lines, the High Performance
Conductors would be a good substitute to Quad bundle ACSR and
AAAC conductor, particularly at 400 kV level when line length is
short.
(g) For long river crossing spans, the valleys & major high way
crossings and in ravines, the conventional conductor will sag more
and result into excess height of tower and cost of foundation. If
new generation low sag conductors are used, situation can be
addressed.

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(h) Reconductoring existing transmission/distribution network with

HPC conductors is a viable option as it enhances the existing power
transfer capability of the line without involving RoW issues.
(i) Due to oceanic and/or industrial pollution, the existing conductors
of the line show sizable degradation. It may be necessary to replace
such conductors by new conductors, which may be resistant to
such vagaries and simultaneously can carry higher current.

(B) Similarly, some scenarios wherein an alternative method of

uprating will be more attractive than reconductoring with HTLS are
the following:

i) Structures or foundations of the existing line are in poor condition.

ii) Existing line is in good physical condition, and the rating is to be
increased by less than 20%.
iii) If the line is above 400 kV, reconductoring with HTLS conductors
is not typically required because the existing thermal rating is
already much higher than the limits on power flow related to
voltage drop and phase shift.

(C) Quad bundle ACSR conductors are being used in HVDC line not
only to meet the requirement of higher current but electric field as
well. Hence, application of High Performance Conductors is not
cost effective for HVDC system.

(D) High Performance Conductors can be considered for use in

distribution system where there is congestion, such as in urban
areas, and space is not available for addition of new overhead lines.
High Performance Conductors can also be useful, if chosen
judiciously, to get more benefits in terms of technical losses.
However, due to less electrical clearance requirement and
proximity from households/buildings, the impact of operation of
High Performance Conductors at high temperature need to be
assessed properly. The demand from distribution sector is yet to
come from utilities because of high initial investment cost,
however, the same can be recovered in a short span of time
depending on load flow and other factors.

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6.0 Issues to be considered before installation of High

Performance Conductors

6.1 The transmission conductor must meet the minimum electrical

clearance requirement, throughout the life of the line, under all
environmental conditions including high wind and/or ice loading
and high temperature. When reconductoring an existing line with
HTLS conductor, sag clearance calculations must consider the
initial sag of the replacement conductor, its plastic elongation over
time, and it elastic and thermal elongation relative to its final sag
position. The increase in sag due to thermal elongation at high
conductor temperature and elastic increase in sag due to ice or
wind load is based on the final sag not the initial. HTLS conductors
must not only elongate less in response to high temperature, they
must also be strong enough (elastic modulus) to limit elastic sag
increase under ice and wind load and they must not exhibit high
plastic elongation in response to high tension or long term
application of more modest tension.

6.2 When uprating existing lines by replacing the conductors, an

assessment must be made of the present capability of the
structures. Replacing the conductors of an existing line should
only be attempted if it has been demonstrated that the structures
are capable of supporting the required loads for the lifetime
required of the new conductor system and increased load during
pre-tensioning of conductor. In some cases, this might involve
carrying out repairs or improvements to the structures.

6.3 When replacing conductors, use of a larger conductor imposes

greater loads on the existing structures and may reduce the
reliability of the line unless the structures are reinforced. However,
by use of replacement conductor having nearly same diameter as
original conductor capable of operating at higher temperature
which remains within existing sag clearance and loss-of-strength
constraints, need for extensive reinforcement of structure can be
avoided.

6.4 When reappraising the loading criteria for an uprated line, the line
designer should consider changing the conductor design, wire
materials, and making changes in the tension limits under both
every day and extreme conditions.

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6.5 Reconductoring normally leaves the original ground level electric

field, electric induction, corona discharge levels, and audible noise
levels unchanged. However, the ground level magnetic field and
magnetic induction levels will increase if the line current increases
as a result of the higher line thermal rating.

6.6 Knee Point of operation of different types of HT/HTLS

conductors:

When the temperature of a composite conductor is increased, the

aluminium (or aluminium alloy) envelope wires usually expand at
a higher rate than the core. This expansion is accompanied by a
corresponding reduction in its share of the total tensile load on the
conductor. With increasing temperature, the aluminium will
transfer its mechanical load to the core resulting in the core
carrying most, if not all, of the mechanical load. At a given
temperature, the envelope becomes mechanically "unloaded", the
conductor being supported only by its core. This temperature is
called Knee Point. This is the point below which the conductor sag-
tension relationship is determined by the whole conductor whereas
above this point it is governed by the core. For High Temperature
conductors, since aluminium has a larger Coefficient of Thermal
Expansion (CTE) than core, the thermal elongation properties of
the core control the maximum sag of the conductor. The knee point
is different for different types of HT/HTLS conductors. It depends
on the installation conditions and for some conductor technologies,
the knee-point can be shifted to a lower temperature by pre-
tensioning. This is more effective with conductors containing
annealed aluminium. The knee-point is not a fixed value and
depends on many factors like span length, mechanical tension,
ruling conditions, conductor constituent characteristics (e.g.
proportion of envelope section over total section, coefficient of
thermal expansion, modulus of each component). It should be
further noted that creep in the conductor will also shift the
conductor knee point to lower temperatures over time, because
conductor creep is primarily driven by the aluminium constituent,
and the tensile load in the envelope shifts to the core while it
elongates (due to creep). For a HT conductor to be fully effective,
the rated temperature of the line needs to be above the knee-point
if there is to be full benefit from having a low-expansion core.

6.7 As a consequence of the use of HT conductors, higher conductor

temperatures will be reached that may affect the insulator
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performance. The conductor temperature will also influence the

temperature of the conductor clamp, links and shackles, the
insulator hardware and the insulator body itself. The extent of this
influence also depends on the specific design of the insulator.
Apart from insulator, assessment should be made for use of
conductor accessories of original conductor with replacement
conductor. If required, new accessories suitable for high
temperature operation of replacement conductor should be
installed.

6.8 If HTLS conductors with annealed aluminum strands are pre-

stressed, then their self-damping properties are good and initial
stringing sags may be quite small without causing vibration
fatigue. If not pre-stressed, high initial tension levels may lead to
premature failure from vibration fatigue unless dampers are
installed.

6.9 All transmission line source and end point connections involve
terminal equipment. The primary terminal equipment generally
consists of circuit breakers, disconnectors, current and voltage
transformers, and in some cases power line communication
coupling equipment, insulators etc. Considerations for the
uprating of transmission lines must include a review of the rating
of the terminal equipment to ensure compatibility with the line
rating.

6.10 Sometimes the power utilities in India are going for one specific
type of conductor although other types of conductors are also
available to cater to similar requirements. Moreover, it is
understood that there is a wide variation in cost of various types of
High Performance Conductors (HPC). In the process, the utilities
are not getting the product at a competitive price as competition
gets restricted and as a result the overall cost of the project gets
jacked up. Competition invariably leads to significant benefits to
consumers through reduction in capital cost and facilitate the price
to be determined competitively.

7.0 Cost-benefit analysis

7.1 In general, the use of HPC conductor is justified due to offering

increased current capacity than ACSR or AAAC conductor and in
case of re-conductoring, reduction in the cost due to minimal
modifications in the towers. There are variety of HTLS conductors,
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description of which has been provided in relevant sections of this

document, available in India. Certain replacement conductor
characteristics may be attractive, but it may not necessarily be
“cost-effective” i.e. the additional cost of the special conductor may
not be justified by the increase in line rating.

7.2 There does not appear to be a compelling reason to choose one of

the HTLS conductors over the others except possibly for cost.
Following factors should be considered for replacement of existing
conductor with HPC conductor:

 Cost of electrical losses

 Frequency and magnitude of occasional high current loads
 Purchase and labor costs of replacing the existing
conductors
 The cost of structure reinforcement
 Availability of replacement conductor
 Existing clearance buffer
 Likelihood of vibration fatigue problems
 Severity of ice and wind load conditions
 Cost/Benefit ratio of increased capacity
 Availability of additional right-of-way

7.3 When only conductor cost is considered, the cost of INVAR, ACCR
etc. is about five times the cost of conventional ACSR while the cost
of Gap type conductors is almost twice. CCC Conductors are about
3.5 times costlier, ACSS is approximately 1.5 times and TACSR is
about 1.15 times that of ACSR conductors. But other than the cost
of power conductor, cost of ohmic loss, conductor accessories,
insulator hardware, de-stringing of conventional power conductor,
re-stringing & installation of High Performance Conductors are to
be considered before deciding whether installation of High
Performance Conductors is economically justifiable.

7.4 Depending on the project and its environmental configuration, the

utility will have to compare the total life-cycle costs of conductor
replacement and reinforcement of towers to that with the building
of a new line. After considering the life-cycle cost, the overall
project costs may, in some cases, be less even after higher cost of
the conductor.

7.5 Hence, before deciding whether or not to opt High Performance

Conductors, the utilities need to have the information on the
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comparative costs to upgrade an existing line section using

different High Performance Conductors, comparative costs of
operation which shall include cost of power losses, and lifetime
costs when installing and operating networks using High
Performance Conductors with respect to conventional ACSR
conductors. Impact of new conductor types on the Sag
calculations, existing tower design and necessary engineering
changes when designing, shipping, handling, installing,
inspecting, and maintaining these conductors will have to be
examined as well. In some cases, special tools and measures like
pre-tensioning may be needed and various additional factors like
effect of erection tension and stringing have to be considered while
installing. Special handling precautions may have to be taken
when shipping conductors to a site or while on site. Cost
implication of all these requirements has to be included to evaluate
the total expenses.

8.0 Criteria for technical evaluation of bids for different types of

High Performance Conductors

8.1 Criteria for technical evaluation of bids for different types of High
Performance Conductors is based on assumption that no specific
conductor type, for reconductoring of existing transmission or
distribution line, has been specified by the utility, no change in
existing structure is envisaged, maximum sag is equal to or less
than existing sag and regulatory requirement of electrical
clearances are complied.

8.2 It needs to be checked that the data furnished by the bidder in

Guaranteed Technical Particulars/Technical Data Sheet is equal
to or better than those required as per specification.

8.3 The offered High Performance Conductor shall be capable of

carrying the current specified by the utility at a continuous
operating conductor temperature not exceeding the maximum
permissible operating temperature of the offered High Performance
Conductor without exceeding the level of permissible sag of the
existing Conductor while satisfying other specified technical
requirements/ parameters.

8.4 The calculations for Ampacity shall be based on latest edition of

IEEE Standard 738. The bidder in his bid shall furnish
calculations for the ampacity based on the above Standard for the
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proposed High Performance Conductor. These calculations should

be checked by the utility.

8.5 The utilities shall consider capitalization of average ohmic loss at

continuous operating current specified by the utility and
corresponding AC resistance. Based on the conductor parameters
guaranteed by the bidders, average ohmic losses for different type
of conductors for all three phases of one circuit of a transmission
line offered by the bidders shall be calculated as per the following
formula:

Average Ohmic loss (kW) = Loss Load Factor × 3 × Line

Length × No. of sub conductors
per bundle × (Continuous
operating current specified by
utility)2 × AC Resistance
corresponding to continuous
operating current specified by
utility

Values of various parameters of this formula shall be taken by the

utilities as per system studies and system requirement. In case,
loss load factor has not been derived by utility, the same may be
taken as 0.3. Differential price evaluation for the conductors
offered by the bidders shall be carried out considering the average
ohmic losses calculated as above and considering capitalisation
cost (₹ per kW) as specified by the utility in the bidding document.
Cost of capitalisation may vary from utility to utility depending
upon their cost of energy, cost of borrowing etc. However,
capitalisation cost normally remains in the range of ₹1.5 lac to ₹1.6
lac per kW.
The best parameter of loss (lowest ohmic loss for conductor)
corresponding to lowest AC resistance quoted among bidders by
any technically responsive and qualified bidder shall be taken as
basis and that quoted by the particular bidder shall be used to
arrive at differential price to be applied for each bid.

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9.0 Use of High Performance Conductors by various utilities

As per information available, the Central Transmission Utility

(CTU)/ PGCIL, few State Transmission Utilities like UPPTCL (UP),
MSETCL (Maharashtra), WBSETCL (West Bengal), OPTCL
(Odisha), JUSNL (Jharkhand), PTCUL (Uttarakhand), KPTCL
(Karnataka), GETCO (Gujarat), RRVPNL (Rajasthan) and some
private utilities like Tata Power, Torrent Power, CESC have already
used Gap, Invar, ACCR & ACCC conductor in transmission line
corridors which are getting overloaded / exceeding the thermal
loading limits of the existing conductor. Some more projects of re-
conductoring as well as of new lines using High Performance
Conductors are underway.

It is difficult to comment on performance of such conductor as

current / power flow in the line has not reached the level for which
it has been designed.

10.0 Conductor accessories for various types of High Performance

Conductors

The High Performance Conductor & accessories must be designed

to operate reliably in demanding conditions that combine high
temperature operation under a broad spectrum of mechanical and
electrical load. The conductor and accessories must resist wide
range of transient mechanical & thermal loads such as fault
current, lightning strikes, galloping events and ice loading. The
contact between dissimilar materials may cause excessive
corrosion in some environments. The hardware and accessories
(connected electrically and mechanically to the conductor) should
be designed and tested to ensure that conductor retain its
performance with accessories under normal as well as under
emergency conditions and are compatible for the conductor.

Some manufacturers in India have started manufacturing of

accessories for different High Performance Conductors. With
increase in demand for High Performance Conductors, few more
manufacturers may show interest to manufacture the accessories
and hardware fittings for such conductors.

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11.0 Manufacturing facility for High Performance Conductors in

India

Various conductor manufacturers have set up facility for

manufacturing of different High Performance Conductors. The
INVAR core and polymer composite matrix core of CCC conductor
are presently being imported, although, envelope of these
conductors is manufactured indigenously. Some manufacturers
in India have started manufacturing of accessories for different
High Performance Conductors. Many manufacturers such as M/s
Apar Industries, M/s Sterlite Power, M/s Gupta Power, M/s
Hindustan Urban Infrastructure Ltd., M/s JSK Industries, M/s
Shashi Cables Ltd., M/s Lumino Industries etc. have indigenous
facility for supply of High Performance Conductors. It is noted
that every manufacturer may not necessarily have all types of
High Performance Conductors in their product portfolio. Some of
these manufacturers have not supplied some types of High
Performance Conductors, however, those conductors have been
type tested and facility to manufacture them is available with
these manufacturers. Some manufacturers have supplied High
Performance Conductors for transmission lines of various utilities
which are in operation and some manufacturers are in process of
supply.

12.0 Testing facility

The constituent materials used in High Performance Conductors

vary; some cores are common steel strands coated with zinc
(galvanized), zinc alloy or aluminium (aluminium clad,
aluminium-5% mischmetal). Other conductors utilize relatively
new materials such as fiber reinforced aluminium composites or
fiber reinforced polymer composites. The required tests and test
methods will differ depending on materials. Presently facility for
all type test is not available in India and many of the type tests
are being carried out outside the country which adds to the cost
of project. However, ERDA and CPRI are in the process of
establishing testing facilities for High Performance Conductors.
List of all tests for which facilities are available in CPRI and ERDA
and list of tests for which facilities are being developed is given at
Annexure-I. Some manufacturers also have NABL accredited test
laboratories. However, information regarding test facilities
available at these labs is not available. M/s Tag Corporation,

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Chennai, also has some testing facilities for conductor

accessories.

13.0 Recommendations of the Committee

Based on the deliberations, the recommendations of the

Committee are as follows:

13.1 High Performance Conductors can address issues like growing

congestion in existing corridor of transmission / distribution
network and can help in enhancement of power flow per unit
Right of Way (RoW).

13.2 High Performance Conductors should be considered in those

corridors where the power transfer over the line is constrained
due to thermal loading of conductor. In Intra-state transmission
system, requirement of such conductor is expected at 220kV,
132kV and 66kV level. However, application of High Performance
Conductors may not be cost effective for HVDC system and for
765kV voltage level.

13.3 The power utilities should invite bids without specifying type of
High Performance Conductor as several types of such conductors
are available and could bring techno-economic benefits. Also,
generic name of conductor like CCC, GAP conductor etc. should
only be specified by the power utilities instead of patented names
of manufacturer or conductor.

13.4 High Performance Conductors can be considered for

reconductoring of existing lines and can also be used in new lines.
The terminal equipment rating at substations needs to be
examined for enhancement of power flow in a line. However, for
new lines, proper system studies need to be carried out to identify
the corridors for use of such conductor.

13.5 The use of High Performance Conductors need to be considered

on case to case basis based on techno-economic analysis over the
life cycle.

13.6 High Performance Conductors may also be considered for use in

distribution system where utility can get more benefits in terms
of technical loss although initial investment cost will be high.

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13.7 Testing facilities for some of the type tests required for high
performance conductors are not available in the country. These
needs to be established on priority.

13.8 The erection of High Performance Conductors should be carried

out under the supervision of conductor supplier / manufacturer.
The manufacturers’ recommendation should be followed during
erection and commissioning of High Performance Conductors.

13.9 The state utilities should go for vendor development program for
manufacturers who want to develop manufacturing facility for
high performance conductors for promoting complete
indigenization of the product and its hardware.

13.10 The core of High Performance Conductors is presently being

imported by almost all the manufacturers, however other
processes in making the finished product including the envelope
are carried out within the country.

13.11 It is observed that even though some manufacturers have proper

manufacturing & testing facility for making HPC and also got their
product type tested from accredited labs are not able to
participate in the bidding process due to lack of supply or relevant
experience of in-service operation of High Performance
Conductors thereby do not meet qualifying requirement specified
by the utilities. In such a scenario only few manufacturers
compete and utilities do not get the competitive price. The
utilities should devise a mechanism to allow such experienced
manufacturers to participate, without compromising their
interest and quality of the product.

13.12 Environment impact assessment of HPC lines passing through

forest areas needs to be done.

*************************************************************************

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ANNEXURE-I

LIST OF TEST FACILITES IN INDIA

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Annexure-I

Test Facilities presently available for HT/HTLS Conductor and

accessories in India

Sr. No. Test Facility

i) On Complete Conductor

1. D.C. Resistance test on stranded conductor

2. UTS test on stranded conductor

3. Lay ratio & Lay direction

Stress-Strain test on stranded conductor and core at

4.
room temperature

5. Salt Spray Test

6. Radio interference voltage test (dry)

7. Corona extinction voltage test (dry)

8. Aeolian Vibration test

9. Galloping test

10. Corona resistance test on conductor and strands

11. Fault current test

12. Dye penetration test

ii) On Individual Wire/Strand

1. Measurement of the diameter of the individual wire

2. Breaking load test on individual wire

3. Elongation test on individual wire (steel)

4. Torsion Test

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5. Wrapping test

6. Galvanizing Test

7. Radial Crush Test

8. Grass transition temperature test

9. Heat resistance test on aluminium alloy strands or core

10. Coefficient of linear expansion on core and core strands

11. Flexural strength on composite core

12. Strand Brittle Fracture test

iii) Accessories

1. Visual & verification of dimension

2. Galvanizing & electroplating

3. Wet power frequency voltage withstand test

4. Impulse voltage withstand test

5. Mechanical strength

6. Ozone test on elastomeric

7. Electrical resistance

8. Clamp slip / torque / slip strength

9. Hardness / grain size / inclusion ratings / NDT

10. Shore hardness for elastomeric

11. Bend test / resilience test

12. Vibration damper tests

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Test facilities being developed

Sr. No. Test Facility

1 Stress-strain test at controlled temperature

2 Stress-strain test at elevated temperature

3 Creep test at controlled temperature

4 Creep test at elevated temperature

5 Sheaves Test

6 Axial Impact Test

7 Torsional Ductility Test

8 Temperature Cycle Test

9 Bending Test on Composite core

10 Resistance Test

11 Grease drop test

12 Magnetic power loss test

13 Glass transition temperature of core

14 UTS test on complete conductor at elevated temperature

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ANNEXURE-II

TECHNICAL SPECIFICATION FOR HIGH

PERFORMANCE CONDUCTORS

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Annexure-II

TECHNICAL SPECIFICATION FOR HT/HTLS CONDUCTOR

1.0 Description of High Temperature (HT)/ High Temperature

Low Sag (HTLS) Conductor and its Technical Requirements
1.1 The offered HT/HTLS Conductor shall be capable of carrying the
minimum specified Current (--- Amp. e.g. 1574 Amps.) at a
continuous operating conductor temperature not exceeding the
maximum permissible operating temperature of the offered HT/
HTLS Conductor without exceeding the level of maximum
permissible sag of the existing ..….Conductor (e.g. ACSR
MOOSE) as indicated in Cl. 1.2.1.
The physical and operating performance requirements of the
transmission line with HT/ HTLS conductor are mentioned
below. The bidder shall offer HT/ HTLS conductor complying
with the specified requirements. The Bidder shall indicate
particulars of the proposed conductor in the relevant GTP
schedule along with calculations to establish compliance with
the specified requirements.
1.2 Current Carrying Capacity /Ampacity Requirements
1.2.1 Each conductor / sub conductor in the bundle of HT/ HTLS
conductor shall be suitable to carry minimum specified 50 Hz
alternating current (--- Amps. e.g. 1574Amps.) under the
ambient conditions and maximum conductor sag specified below
while satisfying other specified technical requirements/
parameters:
Elevation above sea level -----------m

Ambient temperature ---------- oC (e.g. 45 oC)

Solar Absorption coefficient 0.8

Solar Radiation 1045 watt/sq.m

Emissivity Constant 0.45

Wind velocity 0.56 m/sec

Effective angle of incidence of 90 degree

sun’s rays
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Maximum permissible Conductor sag for ----m (e.g. 400m for

400kV line) span at steady state conductor temperature and nil
wind corresponding to specified 50 Hz alternating current (---
Amps. e.g. 1574Amps.) per conductor / sub conductor under
ambient conditions specified above shall be ---- m (e.g. 13.26 m
for 400kV)
The calculations for Ampacity shall be based on latest edition of
IEEE Standard 738. The bidder in his bid shall furnish
calculations for the ampacity based on the above Standard for
the proposed HT/ HTLS conductor. The AC resistance and DC
resistance for HT/ HTLS conductor shall be calculated as
follows:
Rac = Rdc × ( 1+ 0.00519 X (mr)n × k1 + k2) where,
mr = 0.3544938/ (Rdc) ½
if mr < 2.8, then n = 4- 0.0616 + 0.0896 X mr – 0.0513 X(mr)2
if 2.8 < mr < 5.0, then n = 4+ 0.5363 -0.2949X mr +0.0097
X(mr)2
k1 = {cos (90 (d/D)P)}2.35 where,
p = 0.7 + 0.11Xmr – 0.04Xmr2 + 0.0094Xmr 3
k2 = 0.15 for single aluminium layer INVAR type HTLS conductor
= 0.03 for three aluminium layer INVAR type HTLS conductor
= 0.003 for two or four aluminium layer INVAR type HTLS conductor
= 0 for carbon fiber composite core type HTLS conductor
where,
D= conductor outer diameter in meters
d = conductor inner diameter in meters
Rdc = dc resistance of conductor at given temperature, ohms/ km
Rac = ac resistance of conductor at given temperature, ohms/ km
The bidder in his bid shall furnish calculations for the ampacity
based on the above for the proposed HT/ HTLS conductor.
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1.2.2 The design of conductor shall be suitable for operation at a

steady state conductor temperature experienced for a sub-
conductor for specified AC current flow (----Amps. e.g.
1574Amps.) under the above ambient conditions based on
ampacity calculations mentioned above. The bidder shall also
indicate the maximum permissible conductor temperature for
continuous operation without any deterioration of its electrical,
mechanical & metallurgical properties. The bidder shall also
furnish the maximum permissible conductor temperature for
short term operations including permissible duration of such
short term operation. The UTS of conductor at ambient
temperature and maximum continuous operating temperature
shall be declared in the GTP. Further, UTS of conductor achieved
at maximum continuous operating temperature shall not be less
than 80% of UTS at ambient temperature declared in the GTP.
1.3 Technical Particulars of HTLS Conductor

The HTLS conductor shall meet the following minimum

requirements:
Overall diameter of complete Not exceeding existing
conductor conductor overall diameter (--
mm e.g. 31.77mm for 400kV
line) and Not less than (----
mm e.g. 28.62 mm)

Approx. mass of complete Less than or equal to existing

conductor (kg/km) conductor weight per unit
length (-----kg/km e.g.
2004kg/km for ACSR MOOSE)

Direction of lay of outer layer Right Hand

The bidder shall indicate the technical particulars and details of

the construction of the conductor in the relevant schedule of
GTP. The bidder shall also guarantee the DC resistance of
conductor at 20 deg C and AC resistance at the calculated
temperature corresponding to 50Hz specified alternating current
flow (--- Amps. e.g. 1574 Amps.) per sub conductor at specified
ambient conditions (maximum continuous operating
temperature).

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The bidder shall submit the supporting calculations for the AC

resistance indicating details & justifications of values of
temperature coefficient of resistance & DC to AC resistance
conversion factor(s) with due reference to construction /
geometry of the conductor.
1.4 Sag-Tension Requirements

1.4.1 The HTLS conductor shall meet the following sag tension
requirements for ruling span of ---- meters (e.g. 400m for
400kV line)

Particulars Limiting value

Tension at every day Not exceeding 25% of UTS of
condition (32°C, no wind) proposed conductor

Sag at maximum continuous ≤---- meters

operating temp (e.g. 13.26 m)
(corresponding to specified
current --- Amps. e.g. 1574
Amps. per conductor / sub-
conductor and ambient
conditions specified at 1.2.1)
Tension at 32°C, full wind (- ≤ ----kgs and not exceeding 70%
--- kg/m2 e.g. 203.2 kg / of UTS of proposed conductor
m2) (e.g. 9421 kgs for 400kV line)
Tension at designed Not exceeding 25% of UTS at
maximum temperature and designed maximum
no wind condition temperature

Tension at designed ≤ --- kgs and not exceeding 70%

maximum temperature and of UTS at designed maximum
full wind temperature of proposed
conductor
Tension at knee point Not exceeding 40% of UTS of
temperature & no wind core* of proposed conductor

*UTS of core shall be equal to the Breaking strength of individual core

wires after stranding X no. of wires in the core of offered conductor.

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Sag-Tension calculation for HTLS conductor can be carried out

by using PLSCAD. Following values shall be considered for the
purpose of sag-tension calculations:-

(i) Final values of modulus of elasticity of Aluminium/

Aluminium alloy/core, Coefficient of Linear Expansion of
Aluminium/ Aluminium alloy/ core, Stress-Strain
coefficients & Creep coefficients of aluminium/ Aluminium
alloy/ core in the cable data (.wir file) used for calculation of
sag in PLSCAD shall be based on either of the following:

a) Existing ‘.wir’ files for offered conductor as available on PLS

website.
b) A file derived from existing standard file for conductor of
equivalent/ near equivalent stranding.
c) A file derived from type test conducted on conductor of same
stranding.

In each of the above cases, proper justification in the form of test

reports/ calculations/ print out of ‘.wir’ file as available on PLS
website, etc. shall be required to be submitted during detailed
engineering.

(ii) PLSCAD Sagging criteria/conditions shall be based on the

sag tension limits specified above at Clause 1.4.1 and shall
be carried out in a manner that the above mentioned sag-
tension limits are met in ‘After Creep’ as well as in ‘After Load’
condition.

However, for INVAR type HTLS conductor, following

conventional methodology may also be adopted for sag-tension
calculations.

This methodology is illustrated at Appendix-B to the section.

Following values shall be considered for the purpose of sag
tension calculation:

i) Modulus of Elasticity of Thermal resistant Al alloy strands:

55 GPa to 61.8 GPa (one value from the above specified range
to be selected conforming to the Al alloy strands in the
offered conductor)

ii) Modulus of Elasticity of INVAR core strands: 155 Gpa

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iii) Coefficient of Linear Expansion of Thermal resistant Al.

Alloy: 23 X 10-6/oC

iv) Coefficient of Linear Expansion of INVAR core strands (max):

3.7 X 10-6/oC

v) Initial temperature in manufacturing conductor- not less

than 15oC. In case the bidder proposes the coefficient of
linear expansion of INVAR core strands less than 3.7 X 10-
6/ oC, proper justification in the form of test reports,
documents, etc. shall be submitted during detailed
engineering.

1.4.2 Various conductor parameters (viz. modulus of elasticity,

coefficient of linear expansion, stress-strain and creep, etc.)
considered above in the sag tension calculation shall be verified
during detailed engineering based on type tests conducted.
1.4.3 The Contractor shall also furnish sag & tensions under no wind
for various temperatures starting from 0oC to designed
maximum temperature in steps of 5oC during detailed
engineering
1.4.4 After award of the contract, the Supplier shall submit Sag-
Tension calculations corresponding to various conditions given
above for all the spans as per detailed survey and spans ranging
from 100 m to 1100 m in intervals of 50 m.
1.4.5 Besides above, the Supplier shall also furnish details of creep
characteristics in respect of HTLS conductor based on laboratory
investigations/ experimentation (creep test as per IEEE1138 or
IEC 61395) conducted on similar type of conductor and shall
indicate creep strain values corresponding to 1 month, 6
months, 1 year 10 years & 20 years creep at everyday tension
and at maximum continuous operating temperature as well as
room temperature.
1.5 Workmanship

1.5.1 All the conductor strands shall be smooth, uniform and free from
all imperfections, such as spills and splits, cracks, die marks,
scratches, abrasions, rust etc.

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1.5.2 The finished conductor shall be smooth, compact, uniform and

free from all imperfections including kinks (protrusion of wires),
wire cross over, over riding, looseness (wire being dislocated by
finger/hand pressure and/or unusual bangle noise on tapping),
material inclusions, white rust, powder formation or black spot
(on account of reaction with trapped rain water etc.), dirt, grit
etc.
1.6 Joints in Wires
1.6.1 Aluminium Alloy Wires
1.6.1.1 During stranding, no Aluminium Alloy wire welds shall be made
for the purpose of achieving the required conductor length.
1.6.1.2 No joints shall be permitted in the individual wires in the outer
most layer of the finished conductor. However, joints are
permitted in the inner layer(s) of the conductor unavoidably
broken during stranding provided such breaks are not
associated with either inherently defective wire or with the use
of short lengths of Aluminium Alloy wires. Such joints shall not
be more than four (4) per conductor length and shall not be
closer than 15 meters from joint in the same wire or in any other
Aluminium Alloy wire of the completed conductor. A record of
such joints for each individual length of the conductor shall be
maintained by the Contractor for Owner’s review.
1.6.1.3 Joints shall be made by cold pressure butt welding and shall
withstand a stress of not less than the breaking strength of
individual strand guaranteed.
1.6.2 Core Wires
There shall be no joint of any kind in the finished wire entering
into the manufacture of the strand. There shall also be no joints
or splices in any length of the completed solid or stranded core

1.7 Tolerances
Manufacturing tolerances on the dimensions to the extent of one
percent (+/- 1%) shall be permitted for individual strands and
the complete conductor.

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1.8 Materials
The materials used for construction of the conductor shall be
such that the conductor meets the specified technical and
performance requirements.

1.8.1 Outer layer

1.8.1.1 The material of outer layer of HTLS conductor shall be of high
temperature resistant aluminum alloy added with zirconium or
any other suitable element(s) etc. to electrolytic aluminium
having purity not less than 99.5% and a copper content not
exceeding 0.04%. The strands shall be manufactured through
appropriate manufacturing process to ensure consistent
electrical mechanical and metallurgical properties under
continuous high temperature operation. Bidder shall guarantee
the chemical composition in the schedule GTP of BPS and also
furnish description of the manufacturing process in the Bid.
1.8.1.2 In case of fully annealed type (0 tempered) aluminium / alloy
strands round/ trapezoidal /Z-shaped wire shall be accepted.
1.8.2 Core
The core wire strand(s) shall be of galvanized steel wires/
aluminium clad steel wires / Zinc – 5% Aluminium – Misch
metal alloy coated invar wire / galvanized invar wires/
aluminium clad invar wires/ composite materials etc. and shall
have properties conforming to the technical performance
requirements of the finished conductor. In case, the designed
maximum temperature of the offered HTLS conductor exceeds
180 deg C, ordinary zinc coating/ galvanizing of the Steel/Invar
core wires shall not be accepted and only aluminium clad or
Misch metal coated wires shall be permitted. Bidder shall
furnish properties and composition of the core wire strand(s)in
the GTP.

The zinc used for galvanizing in case of steel /invar core shall be
electrolytic High Grade Zinc of 99.95% purity. It shall conform
to and satisfy all the requirements of IS:209. The minimum mass
of zinc coating shall be as per requirements of Class-1 coating
as per IEC-888. Zinc – 5% Aluminium – Misch metal alloy
coating if used, shall conform to all requirements of ASTM B803
/ B 958.

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The aluminium cladding of invar/ steel wires shall be with

aluminum having purity not less than 99.5 % and shall be
thoroughly bonded to the core wire strand(s). The minimum
thickness of aluminium cladding shall be 0.07mm to achieve a
minimum conductivity of 14% of IACS.

Where composite material for core is offered, the material shall

be either of High strength grade or extra high strength grade as
per ASTM B987. The materials shall be of shall be of such proven
quality that its properties are not adversely influenced by the
normal operating conditions of a ---- kV transmission line in
tropical environment conditions as experienced by the existing
line. The bidder shall provide adequate details including
specifications/test reports/operating experience
details/performance certificates etc. in support of the suitability
of the offered materials.

1.9 Conductor Length

1.9.1 The standard length of the conductor shall be indicated in the
guaranteed technical particulars of offer. A tolerance of +/-5%
on the standard length offered by the Bidder shall be permitted.
Standard Length shall not be more than 2500 meters. All lengths
outside this limit of tolerance shall be treated as random lengths.
1.9.2 Random lengths will be accepted provided no length is less than
70% of the standard length and the total quantity of such
random lengths shall not be more than 10% of the total quantity
ordered. At no point, the cumulative quantity supplied of such
random lengths shall be more than 12.5% of the total cumulative
quantity supplied including such random lengths. However, the
last 20% of the quantity ordered shall be supplied only in
standard lengths as specified.
1.9.3 Bidder shall also indicate the maximum single length, above the
standard length, he can manufacture in the guaranteed
technical particulars of offer. This is required for special
stretches like river crossing etc. The Employer reserves the right
to place orders for the above lengths on the same terms and
conditions applicable for the standard lengths during the
pendency of the Contract.

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1.10 Evaluation of Ohmic Losses and Differential Price Loading

1.10.1 Based on the conductor parameters guaranteed by the bidders,
average ohmic losses for different type of conductors for all three
phases of one circuit of a transmission line offered by the bidders
shall be calculated as per the following formula:

Average Ohmic loss (kW) = Loss Load Factor × 3 × Line

Length × No. of sub conductors
per bundle × (Continuous
operating current specified by
utility)2 × AC Resistance
corresponding to continuous
operating current specified by
utility

Differential price evaluation for the conductors offered by the

bidders shall be carried out considering the average ohmic
losses calculated as above and considering capitalisation
cost………..₹ per kW.
The best parameter of loss (lowest ohmic loss for conductor)
corresponding to lowest AC resistance quoted among bidders
by any technically responsive and qualified bidder shall be
taken as basis and that quoted by the particular bidder shall
be used to arrive at differential price to be applied for each bid.
2.0 Tests and Standards

2.1 Type Tests

2.1.1 Type Tests on Stranded Conductor/ Stranded wire

The following tests shall be conducted once on sample/samples
of conductor from each manufacturing facility:

On complete Conductor
a) DC resistance test on stranded
As per Appendix-A
conductor
b) UTS test on stranded conductor at As per Appendix-A

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i) Room temperature
ii) Elevated temperature

c) Radio interference voltage test

As per Appendix-A
(dry) [for 400kV line]
d) Corona extinction voltage test
As per Appendix-A
(dry) [for 400kV line]
e) Stress- Strain test on stranded
: IEC 1089
conductor and core at room
temperature
f) Stress-strain test on stranded
conductor and core at elevated As per Appendix-A
temperature
g) High temperature endurance &
As per Appendix-A
creep test on stranded conductor
h) Sheaves Test As per Appendix-A
i) Axial Impact Test As per Appendix-A
j) Radial Crush Test As per Appendix-A
k) Torsional Ductility Test As per Appendix-A
l) Aeolian Vibration Test As per Appendix-A
m) Temperature Cycle Test As per Appendix-A
On Conductor Strand/core
a) Heat resistance test on Aluminium
As per Appendix-A
Alloy strands or core
b) Bending test on core As per Appendix-A
c) Compression test on core As per Appendix-A
d) Coefficient of linear expansion on
As per Appendix-A
core/ core strands
e) Strand Brittle fracture test (for
As per Appendix-A
polymer composite core only)

Type tests specified above shall not be required to be carried

out if a valid test certificate is available for the offered design.
The tests conducted earlier should have been conducted in
accredited laboratory (accredited based on ISO/IEC guide
25/17025 or EN 45001 by the National Accreditation body of
the country where laboratory is located) or witnessed by the
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representative (s) of a Utility. In the event of any discrepancy in

the test report (i.e., any test report not applicable due to any
design / material/manufacturing process change including
substitution of components or due to non-compliance with the
requirement stipulated in the Technical Specification) the tests
shall be conducted by the Contractor at no extra cost to the
Employer/ Purchaser.
2.2 Acceptance Tests

a) Visual and dimensional As per Appendix-A

check on drum

b) Visual check for joints As per Appendix-A

scratches etc. and length
measurement of conductor
by rewinding

c) Dimensional check on core As per Appendix-A

strands/ composite core and
Aluminium Alloy strands

d) Check for lay-ratios of As per Appendix-A

various layers

e) Galvanizing test on core As per Appendix-A

strands (if applicable)

f) Thickness of aluminum on As per Appendix-A

aluminium clad wires

g) Torsion and Elongation tests As per Appendix-A

on core strands/composite
core

h) Breaking load test on core As per Appendix-A

strands and Aluminium /
Aluminium Alloy strands

i) Wrap test on core strands As per IEC:888 and

and Aluminium Alloy IEC:889
strands

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j) Resistivity test on thermal As per IEC : 889

resistant Aluminium
Alloy/Aluminium strands

k) Procedure qualification test As per Appendix-A

on welded joint of
Aluminium
Alloy/Aluminium strands

l) Heat resistance test on As per Appendix-A

Aluminium Alloy strands

m) Ageing test on filler (if As per Appendix-A

applicable)

n) Resistivity test on aluminium As per Appendix-A

clad core strands

o) Glass transition temperature As per Appendix-A

test (For Polymer Composites
only)

p) Flexural Strength test (For As per Appendix-A

Polymer Composites only)

q) Bending test on polymer As per Appendix-A

composite core

r) Galvanic Protection Barrier As per ASTM B987

Layer Thickness test (on
polymer composite core)

s) Coating Test on Zinc – 5% Al As per ASTM B803/

-Mischmetal alloy Coating (if B958
applicable)

t) Adherence of Coating Test : As per ASTM B803/

on Zinc – 5% Al - B958
Mischmetal alloy Coating (if
applicable)

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Note: All the above tests except (k) shall be carried out on
Aluminium /Aluminium Alloy and core strands after stranding
only.

2.3 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 Specification

d) All acceptance tests as mentioned above to be carried out on

10 % of drums

2.4 Tests During Manufacture

a) Chemical analysis of zinc used for As per Appendix-A

galvanizing
b) Chemical analysis of Aluminium alloy As per Appendix-A
used for making Aluminium Alloy strands

c) Chemical analysis of core strands (not on As per Appendix-A

polymer composite core)

2.5 Testing Expenses

2.5.1 No type test charges shall be payable to the supplier.
2.5.2 Bidder shall indicate the laboratories in which they propose to
conduct the type tests. They shall ensure that adequate
facilities are available in the laboratories and the tests can be
completed in these laboratories within the time schedule
guaranteed by them.
2.5.3 In case of failure in any type test the Supplier is either required
to manufacture fresh sample lot and repeat the entire test
successfully once or repeat that particular type test three times
successfully on the sample selected from the already
manufactured lot at his own expenses. In case a fresh lot is

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manufactured for testing then the lot already manufactured

shall be rejected.
2.5.4 The entire cost of testing for the acceptance and routine tests
and Tests during manufacture specified herein shall be treated
as included in the quoted unit price of conductor, except for
the expenses of the inspector/Owner's representative.
2.5.5 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/
testing facilities to be ready for testing the expenses incurred
by the Owner for re-deputation shall be deducted from contract
price.
2.5.6 The Supplier shall intimate the Owner about carrying out of the
type tests along with detailed testing program at least 3 weeks
in advance (in case of testing in India) and at least 6 weeks in
advance (in case of testing abroad) of the schedule date of
testing during which the Owner will arrange to depute his
representative to be present at the time of carrying out the
tests.
2.6 Additional Tests
2.6.1 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 materials comply with the Specifications.
2.6.2 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 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.
2.7 Sample Batch for Type Testing
2.7.1 The Supplier shall offer material for selection of samples for
type testing only after getting Quality Assurance Plan approved
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from Owner’s Quality Assurance Deptt. The sample shall be

manufactured strictly in accordance with the Quality
Assurance Plan approved by Owner.
2.7.2 The Supplier shall offer at least three drums for selection of
sample required for conducting all the type test.
2.7.3 The Supplier is required to carry out all the acceptance tests
successfully in presence of Owner’s representative before
sample selection.
2.8 Test Reports
2.8.1 Copies of type test reports shall be furnished in at least three
copies along with one original. One copy will be returned duly
certified by the Owner only after which the commercial
production of the material shall start.
2.8.2 Record of routine test reports shall be maintained by the
Supplier at his works for periodic inspection by the Owner’s
representative.
2.8.3 Test Certificates of tests during manufacture shall be
maintained by the Supplier. These shall be produced for
verification as and when desired by the Owner.
2.9 Inspection
2.9.1 The Owner’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 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.
2.9.2 The Supplier shall keep the Owner 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.
2.9.3 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 conductor shall be dispatched only after
satisfactory testing for all tests specified herein have been
completed.

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2.9.4 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 it such material is later found to be
defective.
2.10 Test Facilities
2.10.1 The following additional test facilities shall be available at the
Supplier’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 meters per minute).
The rewinding facilities shall have appropriate clutch
system and free of vibrations, jerks etc. with traverse laying
facilities.
2.11 Packing
2.11.1 The conductor shall be supplied in non-returnable, strong,
wooden/painted steel/hybrid (painted steel cum wood) drums
provided with lagging of adequate strength, constructed to
protect the conductor against all damage and displacement
during transit, storage and subsequent handling and stringing
operations in the field. The Supplier shall select suitable drums
for supply of conductor and shall be responsible for any loss or
damage to conductor and/or drum during transportation
handling and storage due to improper selection of drum or
packing.
2.11.2 The drums shall be suitable for wheel mounting and for letting
off the conductor under a minimum controlled tension of the
order of 5 kN.
2.11.3 The Bidder should submit their proposed drum drawings along
with the bid.
2.11.4 One standard length only shall be wound on each drum.

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2.11.5 The conductor ends shall be properly sealed and secured on

the side of one of the flanges to avoid loosening of the conductor
layers during transit and handling.
2.11.6 All wooden components shall be manufactured out of seasoned
soft wood free from defects that may materially weaken the
component parts of the drums. Preservative treatment shall be
applied to the entire drum with preservatives of a quality which
is not harmful to the conductor.
2.11.7 The flanges shall be of two ply construction with each ply at
right angles to the adjacent ply and nailed together. The nails
shall be driven from the inside face flange, punched and then
clenched on the outer face. The thickness of each ply shall not
vary by more than 3mm from that indicated in the figure. There
shall be at least 3 nails per plank of ply with maximum nail
spacing of 75mm. 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.
2.11.8 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.
2.11.9 Barrel studs shall be used for the 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.
2.11.10 Normally, the nuts on the studs shall stand protruded 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.
2.11.11 The inner cheek of the flanges and drum barrel surface shall
be painted with a bitumen based paint.
2.11.12 Before reeling, card board or double corrugated or thick
galvanized water-proof bamboo paper shall be secured to the
drum barrel and inside of flanges of the drum by means of a
suitable commercial adhesive material. After reeling the
conductor, the exposed surface of the outer layer of conductor
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shall be wrapped with water proof thick galvanized bamboo

paper to preserve the conductor from dirt, grit and damage
during transport and handling.
2.11.13 A minimum space of 75 mm for conductor shall be provided
between the inner surface of the external protective tagging and
outer layer of the conductor.
2.11.14 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 nails shall not protrude above the general
surface and shall not have exposed sharp, edges or allow the
battens to be released due to corrosion.
2.11.15 The nuts on the barrel studs shall be tack welded on the one
side in order to fully secure them. On the second end, a spring
washer shall be used.
2.11.16 A steel collar shall be used to secure all barrel studs. This collar
shall be located between the washers and the steel drum and
secured to the central steel plate by welding.
2.11.17 Outside the protective lagging, there shall be a minimum of two
binders consisting of hoop iron/ galvanized steel wire. Each
protective lagging shall have two recesses to accommodate the
binders.
2.11.18 As an alternative to wooden drum, Bidder may also supply the
conductors in returnable/ non-returnable painted steel drums.
After preparation of steel surface according to IS:9954,
synthetic enamel paint shall be applied after application of one
coat of primer. Wooden/Steel drum will be treated at par for
evaluation purpose and accordingly the Bidder should quote in
the package.
2.11.19 In case of returnable steel drums for conductor, following
clauses shall apply:
(a) The ownership of the empty conductor drums shall lie
with the conductor supplier who shall ultimately take
back the empty conductor drum from the Project site(s)
from the erection contractor’s designated stores after the
running out of conductor from the drum.
(b) The erection contractor shall intimate the Conductor
supplier and Employer regarding empty steel drums at
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their designated stores. Necessary coordination for

taking back the empty steel drums in this regard shall be
done by the Conductor Supplier with the erection
Contractor.
(c) The empty drum shall be taken back by the conductor
supplier from the stores of erection contractor as & when
these are available after usage of conductor. Conductor
supplier shall be required to take back the empty steel
drum within a period of one month from date of
information by erection contractor regarding availability
of the drums at erection contractor stores. However, 2%
of the total drums shall not be returned to the conductor
supplier as these may be used for storage of spare
conductor by the Purchaser.
(d) The steel drums may get damage and wear & tear due to
transportation, normal handling & operation at site,
which shall be rectified by the conductor supplier before
re-use. However, 2% of the total drums shall not be
returned on account of damages / wastage for which no
compensation will be payable. The wastage beyond 2%
shall be reimbursed by Erection Contractor. Thus, 4% of
total drums shall not be returnable to the conductor
supplier.
2.11.20 As an alternative to outer wooden lagging, in case of
returnable/ non-returnable steel drums, solid polypropylene
sheet (of min 5mm thickness) can be used for outer covering of
conductor. In case of PP sheets are proposed to be used by the
supplier, the conductor supplier shall supply two nos.
additional binders per drum for re-wrapping PP sheet with each
lot of conductor and 5 nos. crimping machines with the first lot
of conductor for crimping the binders at site.
2.11.21 Marking
Each drum shall have the following information stenciled on it
in indelible ink along with other essential data:
(a) Contract/Award letter number
(b) Name and address of consignee
(c) Manufacturer’s name and address
(d) Drum number
(e) Size of conductor
(f) Length of conductor in meters
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(g) Arrow marking for unwinding

(h) Position of the conductor ends
(i) Distance between outer-most Layer of conductor and the
inner surface of lagging.
(j) Barrel diameter at three locations & an arrow marking at
the location of the measurement.
(k) Number of turns in the outer most layer.
(l) Gross weight of drum after putting lagging.
(m)Tear weight of the drum without lagging.
(n) Net weight of the conductor in the drum.
(o) CIP/MICC No.

The above should be indicated in the packing list also.

2.12 Verification of Conductor Length
The Owner reserves the right to verify the length of conductor
after unreeling at least ten (10) percent of the drums in a lot
offered for inspection.
2.13 Standards
2.13.1 The conductor shall conform to the following
Indian/International Standards, which shall mean latest
revisions, with amendments/changes adopted and published,
unless specifically stated otherwise in the Specification.
2.13.2 In the event of the supply of conductor 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 Supplier and those specified in this document
will be provided by the Supplier to establish their equivalence.

S.no. Indian/ Title

International
Standard
1. IS: 209-1992 Zinc Ingot- Specification

2. IS: 398-1982 Aluminium Conductors for Overhead

Transmission Purposes- Specification
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3. IS:398-1990 Aluminum Conductor Galvanized Steel Reinforced

Part-II
4. IS:398-1992 Aluminum Conductor - Galvanized Steel-
Part-V Reinforced For Extra High Voltage (400 kV and
above)
5. IS : 1778-1980 Specification for Reels and Drums for Bare
Conductors
6. IS : 1521-1991 Method for Tensile Testing of Steel Wire

7. IS : 2629-1990 Recommended Practice for Hot Dip Galvanizing of

Iron and Steel
8. IS : 2633-1992 Method for Testing Uniformity of Coating on Zinc
Coated Articles
9. IS : 4826-1992 Specification for hot-dipped galvanized coatings
on round steel wires
10. IS : 6745-1990 Methods for Determination of Weight of Zinc
Coating on Zinc Coated Iron and Steel Articles
11. IS : 8263-1990 Method for Radio Interference Tests on High
Voltage Insulators
12. IS : 9997-1988 Aluminium Alloy Redraw Rods for electrical
purposes- Specification
13. IEC : 888-987 Zinc Coated steel wires for stranded Conductors

14. IEC : 889- Hard drawn Aluminium wire for overhead line
1987 conductors
15. IS:398 Aluminium alloy stranded conductors
(Part-IV) (aluminium-magnesium-silicon type) -
specification
16. IEC:1232 Aluminium clad steel wires for electrical purposes

17. IEC:468 Method of measurement of resistivity of metallic

materials
18. IEEE738 Standard for Calculating the Current-
Temperature Relationship of Bare Overhead
Conductors
19. IEC 62004 Thermal-resistant aluminium alloy wire for
overhead line conductor
20. ASTM B498 Standard Specification for Zinc-Coated
(Galvanized) Steel Core Wire for Use in Overhead
Electrical Conductors

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21. ASTM B606 Standard Specification for High-Strength Zinc-

Coated (Galvanized) Steel Core Wire for Aluminum
and Aluminum-Alloy Conductors, Steel Reinforced
22. ASTM B502 Standard Specification for Aluminum-Clad Steel
Core Wire for Use in Overhead Electrical
Aluminum Conductors
23. ASTM B388 Standard Specification for Thermostat Metal Sheet
and Strip
24. ASTM B753 Standard Specification for Thermostat Component
Alloys
25. ASTM A856 Standard Specification for Zinc-5% Aluminum-
Mischmetal Alloy-Coated Carbon Steel Wire
26. ASTM A857 Standard Specification for Steel Sheet Piling, Cold
Formed, Light Gage
27. ASTM B230 Standard Specification for Aluminum 1350–H19
Wire for Electrical Purposes
28. ASTM B398 Standard Specification for Aluminum-Alloy 6201-
T81 and 6201-T83 Wire for Electrical Purposes
29. ASTM B609 Standard Specification for Aluminum 1350 Round
Wire, Annealed and Intermediate Tempers, for
Electrical Purposes
30. SS 424 0813 Aluminium alloy wire for stranded conductors for
overhead lines – Al 59 wire
31. SS 424 0814 Aluminium alloy stranded conductors for
overhead lines – Al 59 wire
32. BS EN 50540 Conductors for overhead lines. Aluminium
conductors steel supported (ACSS)
33. ASTM B 941 Standard Specification for Heat Resistant
Aluminum-Zirconium Alloy Wire for Electrical
Purposes
34. ASTM B 957 standard Specification for Extra-High-Strength
and Ultra-High-Strength Zinc-Coated (Galvanized)
Steel Core Wire for Overhead Electrical
Conductors
35. ASTM B 802 Standard Specification for Zinc–5 % Aluminum-
Mischmetal Alloy-Coated Steel Core Wire for
Aluminum Conductors, Steel Reinforced (ACSR)
36. ASTM B 958 Standard Specification for Extra-High-Strength
and Ultra-High-Strength Class A Zinc–5%
Aluminum-Mischmetal Alloy-Coated Steel Core
Wire for Use in Overhead Electrical Conductors
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37. ASTM B 976 Standard Specification for Fiber Reinforced

Aluminum Matrix Composite (AMC) Core Wire for
Aluminum Conductors, Composite Reinforced
(ACCR)
38. ASTM B987- Standard Specification for Carbon Fiber
17 Thermoset Polymer Matrix Composite Core (CFC)
for use in Overhead Electrical Conductors

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Appendix-A
1. Tests on Conductor
1.1 UTS Test on Stranded Conductor at a) room temperature b)
elevated temperature
a) UTS Test on Stranded Conductor at room temperature
Circles perpendicular to the axis of the conductor shall be
marked at two places on a sample of conductor of minimum 5
m length between fixing arrangement suitably fixed by
appropriate fittings on a tensile testing machine. The load shall
be increased at a steady rate up to 50% of minimum specified
UTS and held for one minute. The circles drawn shall not be
distorted due to relative movement of strands. Thereafter the
load shall be increased at steady rate to minimum UTS and
held for one minute. The Conductor sample shall not fail during
this period. The applied load shall then be increased until the
failing load is reached and the value recorded.
*The test is to be conducted at ambient temperature, between
minimum and maximum ambient temperature of 0 deg C and
50 deg C respectively.
b) UTS Test on Stranded Conductor at elevated
temperature
UTS Test on Stranded Conductor shall be conducted as per
clause no. 1.1(a) specified above keeping conductor
temperature at the designed maximum temperature.
1.2 Corona Extinction Voltage Test [for 400kV System]
Two samples of conductor of minimum 5 m length each shall
be strung in horizontal twin bundle configuration with spacing
of 450 mm between sub-conductors at a height not exceeding
8.84m above ground. The twin bundle assembly when
subjected to 50 hz power frequency voltage shall have a corona
extinction voltage of not less than 320 kV (rms) line to ground
under dry condition. There shall be no evidence of corona on
any part of the samples. The test should be conducted without
corona control rings. However, small corona control rings may
be used to prevent corona in the end fittings. The voltage
should be corrected for standard atmospheric conditions.

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1.3 Radio Interference Voltage Test [for 400kV System]

Under the conditions as specified under (1.2) above, the
conductor samples shall have radio interference voltage level
below 1000 microvolts at one MHz when subjected to 50 Hz AC
voltage of 305 kV line to ground under dry conditions. This test
may be carried out with corona control rings and arcing horns.
1.4 D.C. Resistance Test on Stranded Conductor
On a conductor sample of minimum 5m length two contact-
clamps shall be fixed with a predetermined bolt torque. The
resistance shall be measured by a Kelvin double bridge or using
micro ohm meter of suitable accuracy by placing the clamps
initially zero meter and subsequently one meter apart. The test
shall be repeated at least five times and the average value
recorded. The value obtained shall be corrected to the value at
20oC as per IS:398-(Part-IV)/(Part-V). The resistance corrected
at 20deg C shall conform to the requirements of this
Specification.
1.5 Stress-strain test at elevated temperature
Stress-strain test as per IEC-61089 shall be conducted keeping
conductor temperature at designed maximum temperature.
UTS for this test shall be 80% of the UTS guaranteed in the
GTP.

1.6 High Temperature endurance & creep test

Two conductor samples of length equal to at least 100 X d + 2
X a (where, d is the conductor diameter and a is the distance
between the end fitting and the gauge length) shall be strung
at tension equal to 25 % of conductor UTS. The distance, a,
shall be at least 25 % of the gauge length or 2 m whichever is
the smaller. The conductor samples shall be subjected to tests
as indicated below:
(i) On one of the conductor samples, the conductor
temperature shall be maintained at 20 deg C for 1000
hours. The elongation/creep strain of the conductor during
this period shall be measured and recorded at end of 1
hour, 10 hour, 100 hour and subsequently every 100 hour
up to 1000 hours time period.
(ii) On other conductor sample, the conductor temperature
shall be increased to designed maximum temperature in
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steps of 20 deg. C and thermal elongation of the conductor

sample shall be measured & recorded at each step. The
temperature shall be held at each step for sufficient
duration for stabilization of temperature. Further, the
temperature of the conductor shall be maintained at
designed maximum temperature +10 Deg. C for 1000
hours. The elongation/creep strain of the conductor during
this period shall be measured and recorded at end of 1
hour,
10 hour, 100 hour and subsequently every 100 hour upto
1000 hours time period. After completion of the above, the
core of the conductor sample shall be subjected to UTS test
as mentioned above at clause 1.1. The conductor core shall
withstand a load equivalent to 95 % of UTS. In case of
polymer composite core conductor, the flexural strength &
glass transition temperature of the core shall also be
evaluated and the same shall not be degraded by more than
10 % over the initial value. The supplier shall plot the
thermal elongation with temperature.
The supplier shall furnish details of creep characteristic in
respect of the conductor based on laboratory test and other
laboratory investigations/experimental conducted on similar
type of conductor and shall indicate creep strain values
corresponding to 1 month, 6 month, 1 year, 10 year & 20
year creep at everyday tension & designed maximum
temperature as well as room temperature.
1.7 Sheaves Test
The conductor sample of minimum length of 35 meter shall
be tensioned at 25 % of the UTS and shall be passed through
pulleys having diameter of 32 times that of the conductor
with angle of 20 deg. between the pulleys. The conductor
shall be passed over the pulleys 36 times a speed of 2 m/sec.
After this test UTS test on the conductor shall be carried out
as mentioned above at clause 1.1. In case of polymer
composite core conductors, the core shall be inspected for
any sign of damage or cracking through dye penetration test
as per ASTM D5117.
1.8 Axial Impact Test
The conductor sample shall be suspended vertically and load
applied by dropping a 650 kgs from an elevation of 4 meters

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above the sample. The impact velocity shall be not be less than
8 m/sec. with an initial pre-tension of 200 kgs. The curve for
load vs time shall be recorded and recorded load of failure for
core shall not be less than UTS of core.

1.9 Radial Crush Test

A section of conductor is to be crushed between two six-inch
steel plates. Load shall be held at 350 kgs for 1 minute and
then released. All the strands shall be subsequently
disassembled and tensile tested. All the strands shall exhibit
full strength retention

1.10 Torsional Ductility Test

The conductor sample of 10-15 m shall be loaded to 20% of
UTS and then rotated in increasing steps of +/-180 deg. The
entire conductor shall withstand at least 16 such rotation and
there shall not be any damage to Aluminium Alloy or core
wires. In case of composite core conductors, after 4 rotations
or after separation of aluminium strands, the aluminium
wires shall be cut and removed from the conductor and the
exposed core shall be twisted and shall withstand up to 16
rotations.

1.11 Aeolian Vibration Test

The conductor and supporting hardware shall be loaded to

_25% of UTS. A dynamometer, load cell, calibrated beam or
other device shall be used to measure the conductor tension.
Some means should be provided to maintain constant tension
to allow for temperature fluctuations during the testing. The
overall span between system terminations shall be a
minimum of 30 m. The span shall be supported at a height
such that the static sag angle of the cable to horizontal is (1.5
+ 0.5) deg in the active span. Means shall be provided for
measuring and monitoring the mid-loop (antinode) vibration
amplitude at a free loop, not a support loop. An electronically
controlled shaker shall be used to excite the conductor in the
vertical plane. The shaker armature shall be securely fastened
to the conductor so it is perpendicular to the conductor in the
vertical plane. The shaker should be located in the span to
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allow for a minimum of six vibration loops between the

suspension assembly and the shaker.

The test shall be carried out at one or more resonance

frequencies (more than 10 Hz) . The amplitude at the antinode
point shall be one third of conductor diameter. The assembly
shall be vibrated for not less than 10 million cycles without
any failure. After the test, the conductor should not exhibit
any damage (broken strands). The conductor shall be tested
to demonstrate that it retains at least 95% UTS.

1.12 Temperature Cycle Test

The purpose of this test is verification of degradation

characteristics of metallic and non-metallic material when
subjected to thermal cycling temperature cycling can create
large internal stresses due to thermal expansion mismatch
between constituents.
Test Methods:-
- Mechanical tension, 20 % UTS, marks on the conductor at
the edge of the conductor
-100 cycles from room temperature up to designed maximum
temperature. Hold at designed maximum temperature + 2.5
deg. C for 5 minutes.
- After the above mentioned 100 cycle, Mechanical tension
shall be increased up to 70 % UTS at room temperature and
kept at this tension for 24 hours. Thereafter, release to 20%
UTS.
- This cycling test shall be repeated 5 times.
- During the test, temperature of connectors, conductor and
resistance are recorded according to ANSI C 119.
- A breaking load test is applied at the end of the test.
Conductor strength has to be higher than 95 % UTS.
- In case of polymer composites, the flexural strength should
not degrade by more than 10 % and the Glass Transition
temperature shall not degrade by more than 10 % after

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thermal cycling. Flexural strength shall be obtained on the

basis of test procedure indicated at 1.32 below.

1.13 Heat Resistance test on Aluminium Alloy wire

Breaking load test as per clause 1.25 below shall be carried
out before and after heating the sample in uniform heat
furnace at following temperature for one hour. The breaking
strength of the wire after heating shall not be less than the
90% of the breaking strength before heating:

Maximum continuous operating Test Temperature

temperature of the conductor
Upto 150 deg. C 230 degC (+5/-3
degC)
More than 150 deg. C & up to 210 280 degC (+5/-3
deg. C degC)
More than 210 deg. C & up to 230 400 degC (+5/-3
deg. C degC)

1.14 Bending test on aluminium clad core strand

A sample of aluminium clad invar strand measuring 30 cm in
length shall be subject to bending with help of a vise. The vised
length of wire should be 5 cm and radius of bend 4.8 mm. The
bending should be first 90 degrees left and 90 degree right.
After this operation the strand should cut at the bending
point. There should be no separation of core and aluminium
at the bending point after this operation.

1.15 Compression test on aluminium clad strand

A sample of aluminium clad core strand 10 mm in length is to
be compressed by a plate with a load of 3600 kgs. The
aluminium and core strand should not break.

1.16 Coefficient of linear expansion for core/core strands

The temperature and elongation on a sample shall be
continuously measured and recorded at interval of
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approximately 15 degree C from 15 degree C to maximum

continuous operating temperature corresponding to rated
current (------e.g. 1574 A) by changing the temperature by
suitable means. Coefficient of linear expansion shall be
determined from the measured results.

1.17 Strand Brittle fracture test (for polymer composite core

only)

The sample shall be tensioned to approx. 25% of UTS with

simultaneous application of 1N-HNO3 acid directly in contact
with naked polymer composite core. The contact length of acid
shall not be less than 40mm and thickness around the core
not less than 10mm.The rod shall withstand 80% of SML for
96 hours.

1.18 Visual and Dimensional Check on Drums

The drums shall be visually and dimensionally checked to
ensure that they conform to the approved drawings.

1.19 Visual Check for Joints, Scratches etc.

Conductor drums shall be rewound in the presence of the
Owner. The Owner shall visually check for scratches, joints
etc. and that the conductor generally conform to the
requirements of this Specification. Ten percent (10%) drums
from each lot shall be rewound in the presence of the Owner's
representative.

1.20 Dimensional Check on Core Strands and Aluminium Alloy

Strands
The individual strands shall be dimensionally checked to
ensure that they conform to the requirement of this
Specification.

1.21 Check for Lay-ratios of Various Layers

The lay-ratios of various layers shall be checked to ensure that
they conform to the guaranteed values furnished by the
Contractor.
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1.22 Galvanizing Test

The test procedure shall be as specified in IEC: 888. The
material shall conform to the requirements of this
Specification. The adherence of zinc shall be checked by
wrapping around a mandrel four times the diameter of steel
wire.

1.23 Aluminum thickness on aluminum clad wires

The thickness of aluminium of the specimen shall be
determined by using suitable electrical indicating instruments
operating on the permeameter principle, or direct
measurement. Measurements shall be read to three decimal
places, and number rounded to two decimal places is
considered as measured thickness. For reference purposes,
direct measurement shall be used to determine aluminium
thickness on specimens taken from the end of the coils.

1.24 Torsion and Elongation Tests on Core wires/composite

core
The test procedures for Torsion and Elongation Tests on Core
wires shall be as per clause No. 6.3.3 and 6.3.2 b) of IEC
61232 respectively. In torsion test, the number of complete
twists before fracture shall not be less than the value specified
in the GTP on a length equal to 100 times the standard
diameter of the strand. In case test sample length is less or
more than 100 times the stranded diameter of the strand, the
minimum number of twists will be proportioned to the length
and if number comes in the fraction then it will be rounded
off to next higher whole number. In elongation test, the
elongation at fracture of the strand shall not be less than the
value specified in the GTP for a gauge length of 250 mm. In
case of composite core HTLS conductor, the following
procedure shall be applicable:
(i) Elongation Test: The elongation of the composite core
sample at shall be determined using extensometer. The
load along the core shall be gradually increased. The
elongation achieved on reaching the tensile strength of

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the core shall not be less than the value guaranteed in

the GTP.
(ii) Torsion Test : The purpose of the test is to determine
the resilience of the composite core to twisting and to
show that after the composite core has experienced the
prescribed twisting, it will not crack or have a loss in
tensile strength due to the twisting. A sample length
that is 170 times the diameter of the composite core
being tested is mounted in the gripping fixtures. One
grip shall then be fixed so that it does not twist and the
other end shall be twisted a full 360 degrees and then
fixed in this position for 2 minutes. Once the twist time
is completed, the core is untwisted and inspected for
any crazing or other damage. If no damage is observed,
the composite core is then tensile tested to failure and
the final load recorded. For the test to be accepted, the
composite core must withstand at least 100% of its
rated tensile strength. Two samples need to be
completed in order to satisfy the testing requirement.

1.25 Breaking load test on Aluminium Alloy & Core strands and
DC Resistance test on Aluminium Alloy wire
The above tests shall be carried out as per IEC: 888/889 and
the results shall meet the requirements of the specification.

1.26 Wrap test on Core wires (Applicable for steel/Al clad

Steel/invar core only)
The wrap test on steel strands shall meet the requirements of
IEC: 888. In case of aluminium clad core wire, the same shall
be wrapped around a mandrel of diameter of five times that of
the strand to form a helix of eight turns. The strand shall be
unwrapped. No breakage of strand shall have occurred.

1.27 Resistivity test on thermal resistant aluminium alloy

strands

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Resistivity test as per IEC-468/IEC 889 shall be conducted to

confirm minimum conductivity as per specification
requirement.

1.28 Procedure Qualification test on welded Aluminium Alloy

strands.
Two Aluminium Alloy wire shall be welded as per the approved
quality plan and shall be subjected to tensile load. The
breaking strength of the welded joint of the wire shall not be
less than the guaranteed breaking strength of individual
strands.

1.29 Ageing Test on Filler (if applicable)

The test shall be done in accordance with Grease drop point
test method. The specimen should be drop as a droplet when
kept at a temperature 40 deg. C above designed maximum
operating temperature of the conductor for 30 minutes. The
temperature shall then be increase till one droplet drops and
the temperature recorded.

1.30 Resistivity test on aluminium clad wire

Resistivity test as per IEC-468 shall be conducted to confirm
minimum conductivity as per specification requirement.

1.31 Glass Transition Temperature Test (for polymer

composite core only)
Test shall be conducted as per ASTM B987. The minimum
glass transition temperature shall be either (i) the design
maximum continuous operating temperature of the offered
HTLS conductor + 35 deg C or (ii) minimum glass transition
temperature as per ASTM B987 i.e.180 deg. C + 25 deg C ;
Whichever is lower.
In case, the design maximum continuous operating
temperature of the offered HT/HTLS conductor is more than
the minimum glass transition temperature as per ASTM B987
i.e. more than 180 deg. C then, the test shall be conducted as
per ASTM B987 & the minimum glass transition temperature
shall be the design maximum continuous operating
temperature of the offered HTLS conductor + 25 deg C.
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1.32 Flexural Strength Test (for polymer composite core only)

Test method shall be as per ASTM D7264, ASTM D4475 or

ISO 14125. The flexural strength shall not be less than the
value guaranteed in the GTP.
1.33 Chemical Analysis of Aluminium Alloy and Core

Samples taken from the Aluminium and core coils/strands

shall be chemically/spectrographically analyzed. The same
shall be in conformity to the particulars guaranteed by the
bidder so as to meet the requirements stated in this
Specification.
1.34 Chemical Analysis of Zinc
Samples taken from the zinc ingots shall be chemically/
spectrographically analyzed. The same shall be in conformity
to the requirements stated in the Specification.
1.35 Bending test on polymer composite core (Type test):

Bending test on polymer composite core (CFC) before

stranding shall be performed as per ASTM B987/B987M-17
on polymer composite core samples taken from composite core
at conductor manufacturing unit before stranding of
conductor. Alternatively Bending test on polymer composite
core (CFC) before stranding may be performed at the core
manufacturing unit on the samples taken from the same reel
being supplied to conductor manufacturer subject to proper
traceability of the same at the conductor manufacturers
works.

Bending test on polymer composite core (CFC) shall also be

performed as per ASTM B987/B987M-17 on polymer
composite core samples taken from stranded conductor. For
test after stranding the diameter of cylindrical mandrel shall
be as following:
1) For high strength grade CFC – 60 times the diameter of
CFC
2) For Extra high strength grade CFC – 70 times the
diameter of CFC
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1.36 Bending test on polymer composite core (Acceptance test):

Bending test on polymer composite core (CFC) shall be
performed as per ASTM B987/B987M-17 on polymer
composite core samples taken from stranded conductor. For
test after stranding the diameter of cylindrical mandrel shall
be as following:
1) For high strength grade CFC – 60 times the diameter of
CFC
2) For Extra high strength grade CFC – 70 times the diameter
of CFC

Appendix-B

Calculation of sag and tension for INVAR type HTLS conductor

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Definitions of symbols are as follows:-

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Sample Calculation

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ANNEXURE-III

TECHNICAL SPECIFICATION
FOR
HARDWARE FITTINGS ANDACCESSORIES

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Annexure-III
TECHNICAL SPECIFICATION FOR HARDWARE FITTINGS AND
ACCESSORIES

1. Technical Description of Hardware Fittings

1.1 General
This section details technical particulars of fittings viz. suspension
clamps and compression type dead end clamps for the HTLS
Conductor to be supplied by the bidder. Each fitting shall be
supplied complete in all respects.
1.2 The fittings shall be suitable for attachment to suspension and
tension insulator strings along with hardware fittings and shall
include 2.5 % extra fasteners and Aluminum filler plugs. The
supplier shall be responsible for satisfactory performance of
complete conductor system along with fittings offered by them for
continuous operation at the designed maximum temperature
specified by them for the conductor.
1.3 Corona and RI Performance [for 400kV]
Sharp edges and scratches on all the hardware fittings shall be
avoided. All surfaces must be clean, smooth, without cuts and
abrasions or projections. The Supplier shall be responsible for
satisfactory corona and radio interference performance of the
materials offered by him.
1.4 Maintenance
1.4.1 The hardware fittings offered shall be suitable for employment of
hot line maintenance technique so that usual hot line operations
can be carried out with ease, speed and safety. The technique
adopted for hot line maintenance shall be generally bare hand
method & hot stick method.
1.5 Split Pins
1.5.1 Split pins shall be used with bolts & nuts.
1.6 Suspension Assembly
1.6.1 The suspension assembly shall be suitable for the HTLS
Conductor, the bidder intends to supply. The technical details of
the conductor shall be as proposed by the bidder.

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1.6.2 The suspension assembly shall include either free center type
suspension clamp along with standard preformed armour rods or
armour grip suspension clamp.
1.6.3 The suspension clamp along with standard preformed armour rods
set shall be designed to have maximum mobility in any direction
and minimum moment of inertia so as to have minimum stress on
the conductor in the case of oscillation of the same.
1.6.4 The suspension clamp suitable for various type of Conductor along
with standard preformed armour rods/armour grip suspension
clamp set shall have a slip strength in conformity with relevant
Indian/ International standards.
1.6.5 The suspension clamp shall be designed for continuous operation
at the temperature specified by the bidder for conductor.
1.6.6 The suspension assembly shall be designed, manufactured and
finished to give it a suitable shape, so as to avoid any possibility of
hammering between suspension assembly and conductor due to
vibration. The suspension assembly shall be smooth without any
cuts, grooves, abrasions, projections, ridges or excrescence which
might damage the conductor.
1.6.7 The suspension assembly/clamp shall be designed so that it shall
minimize the static & dynamic stress developed in the conductor
under various loading conditions as well as during wind induced
conductor vibrations. It shall also withstand power arcs & have
required level of Corona/RIV performance.
1.6.9 Free Centre Type Suspension Clamp
For the Free Centre Suspension Clamp seat shall be smoothly
rounded and curved into a bell mouth at the ends. The lip edges
shall have rounded bead. There shall be at least two U-bolts for
tightening of clamp body and keeper pieces together.
1.6.10 Standard Preformed Armour Rod Set
1.6.10.1 The Preformed Armour Rods Set shall be used to minimize the
stress developed in the sub-conductor due to different static and
dynamic loads because of vibration due to wind, slipping of
conductor from the suspension clamp as a result of unbalanced
conductor tension in adjacent spans and broken wire condition. It
shall also withstand power arcs, chafing and abrasion from
suspension clamp and localized heating effect due to magnetic

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power losses from suspension clamps as well as resistance losses

of the conductor.
1.6.10.2 The preformed armour rods set shall have right hand lay and the
inside diameter of the helics shall be less than the outside diameter
of the conductor to have gentle but permanent grip on the
conductor. The surface of the armour rod when fitted on the
conductor shall be smooth and free from projections, cuts and
abrasions etc.
1.6.10.3 The pitch length of the rods shall be determined by the Bidder but
shall be less than that of the outer layer of conductor and the same
shall be accurately controlled to maintain uniformity and
consistently reproducible characteristic wholly independent of the
skill of linemen.
1.6.10.4 The length and diameter of each rod shall be furnished by the
bidder in the GTP. The tolerance in length of the rods between the
longest and shortest rod in complete set should be within the limits
specified in relevant Indian/International Standards. The ends of
armour rod shall be parrot billed.
1.6.10.5 The length and diameter of each rod shall be specified in the GTP.
The tolerance in length of the rods in complete set should be within
13 mm between the longest and shortest rod. The ends of armour
rod shall be parrot billed.
1.6.10.6 The number of armour rods in each set shall be supplier’s design
to suit HTLS conductor offered Standards. Each rod shall be
marked in the middle with paint for easy application on the line.
1.6.10.7 The armour rod shall not lose their resilience even after five
applications.
1.6.10.8 The conductivity of each rod of the set shall not be less than 40%
of the conductivity of the International Annealed Copper Standard
(IACS).
1.6.11 Armour Grip Suspension Clamp
1.6.11.1 The armour grip suspension clamp shall comprise of retaining
strap, support housing, elastomer inserts with aluminium
reinforcements and AGS preformed rod set.
1.6.11.2 Elastomer insert shall be resistant to the effects of temperature up
to designed maximum conductor temperature guaranteed by the
bidder corresponding to peak current, Ozone, ultraviolet radiations
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and other atmospheric contaminants likely to be encountered in

service. The physical properties of the elastomer shall be of
approved standard. It shall be electrically shielded by a cage of
AGS performed rod set. The elastomer insert shall be so designed
that the curvature of the AGS rod shall follow the contour of the
neoprene insert.
1.6.11.3 The supplier shall submit relevant type/performance test
certificates as per applicable standard/product specifications for
elastomer to confirm suitability of the offered elastomer for the
specified application.
1.6.11.4 The AGS preformed rod set shall be as detailed in clause 1.6.10.4
to 1.6.10.7 in general except for the following.
1.6.11.4 The length of the AGS preformed rods shall be such that it shall
ensure sufficient slipping strength as detailed under clause 1.6.4
and shall not introduce unfavorable stress on the conductor under
all operating conditions. The length of the AGS preformed rods
shall be indicated in the GTP.
1.7 Envelope Type Suspension Clamp
1.7.1 The seat of the envelope type suspension clamp shall be smoothly
rounded & suitably curved at the ends. The lip edges shall have
rounded bead. There shall be at least two U-bolts for tightening of
clamp body and keeper pieces together. Hexagonal bolts and nuts
with split-pins shall be used for attachment of the clamp.
1.8 Dead end Assembly
1.8.1 The dead end assembly shall be suitable for the offered HTLS
Conductor.
1.8.2 The dead end assembly shall be of compression type with provision
for compressing jumper terminal at one end. The angle of jumper
terminal to be mounted (including angle of pad) should be 30° with
respect to the vertical line. The area of bearing surface on all the
connections shall be sufficient to ensure positive electrical and
mechanical contact and avoid local heating due to I2R losses. The
resistance of the clamp when compressed on Conductor shall not
be more than 75% of the resistance of equivalent length of
Conductor.
1.8.3 Die compression areas shall be clearly marked on each dead-end
assembly designed for continuous die compressions and shall bear

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the words ‘COM PRESS FIRST’ suitably inscribed near the point
on each assembly where the compression begins. If the dead end
assembly is designed for intermittent die compressions 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 end of
the zones. Tapered aluminium filler plugs shall also be provided at
the line of demarcation between compression & non-compression
zone. The letters, number and other markings on the finished
clamp shall be distinct and legible. The dimensions of dead end
assembly before & after compression along with tolerances shall
be guaranteed in the relevant schedules of the bid and shall be
decided by the manufacturer so as to suit the conductor size &
conform to electrical & mechanical requirement stipulated in the
specification. These shall be guaranteed in the relevant schedules
of bid.
1.8.4 The assembly shall not permit slipping of, damage to, or failure of
the complete conductor or any part thereof at a load less than 95%
of the ultimate tensile strength of the conductor.
1.8.5 Jumper bolting arrangement between jumper terminal/cone and
terminal pad/plate of dead end assembly of tension hardware
fittings shall be designed to suit the specification requirement of -
----A current and shall conform to the relevant
Indian/International standards
1.8.6 For composite core HTLS conductor, dead end assembly shall
inter-alia include collets, collet housing, inner sleeve etc., suitable
for the offered design of HTLS conductor
1.9 Fasteners: Bolts, Nuts and Washers
1.9.1 All bolts and nuts shall conform to IS 6639. All bolts and nuts shall
be galvanized as per IS 1367 (Part-13)/IS 2629. All bolts and nuts
shall have hexagonal heads, the heads being forged out of solid
truly concentric, and square with the shank, which must be
perfectly straight.
1.9.2 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 bolt for 5.6
grade should be 310 MPa minimum as per IS 12427. Bolts should

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be provided with washer face in accordance with IS 1363 (Part-1)

to ensure proper bearing.
1.9.3 Nuts should be double chamfered as per the requirement of IS
1363 Part-III 1984. It should be ensured by the manufacturer that
nuts should not be over tapped beyond 0.4 mm oversize on
effective diameter for size up to M16.
1.9.4 Fully threaded bolts shall not be used. The length of the bolt shall
be such that the threaded portion shall not extend into the place
of contact of the component parts.
1.9.5 All bolts shall be threaded to take the full depth of the nuts and
threaded enough to permit the firm gripping of the component
parts but no further. It shall be ensured that the threaded portion
of the bolt protrudes not less than 3 mm and not more than 8 mm
when fully tightened. All nuts shall fit and tight to the point where
shank of the bolt connects to the head.
1.9.6 Flat washers and spring washers shall be provided wherever
necessary and shall be of positive lock type. Spring washers shall
be electro-galvanized. The thickness of washers shall conform to
IS:2016.
1.9.7 The Contractor shall furnish bolt schedules giving thickness of
components connected, the nut and the washer and the length of
shank and the threaded portion of bolts and size of holes and any
other special details of this nature.
1.9.8 To obviate bending stress in bolt, it shall not connect aggregate
thickness more than three time its diameter.
1.9.9 Bolts at the joints shall be so staggered that nuts may be tightened
with spanners without fouling.
1.9.10 To ensure effective in-process Quality control it is essential that
the manufacturer should have all the testing facilities for tests like
weight of zinc coating, shear strength, other testing facilities etc.,
in-house. The
manufacturer should also have proper Quality Assurance system
which should be in line with the requirement of this specification
and IS-.14000 services Quality System standard.
1.9.11 Fasteners of grade higher than 8.8 are not to be used and
minimum grade for bolt shall be 5.6.

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1.10 Materials
The materials of the various components shall be as specified
hereunder. The Bidder shall indicate the material proposed to be
used for each and every component of hardware fittings stating
clearly the class, grade or alloy designation of the material,
manufacturing process & heat treatment details and the reference
standards.
1.10.1 The details of materials for different component are listed as in
Table No-1.
1.11 Workmanship
1.11.1 All the equipment shall be of the latest design and conform to the
best
modern practices adopted in the Extra High Voltage field. The
Bidder shall offer only such equipment as guaranteed by him to be
satisfactory and suitable for ---kV transmission lines and will give
continued good performance. For employer’s review of the offered
design of clamps/ fittings, the supplier shall submit
document/design details of similar type of clamps/ fittings used
in past for similar type of HTLS conductor application
1.11.2 High current, heat rise test shall be conducted by the supplier to
determine the maximum temperature achieved in different
components of fittings under simulated service condition
corresponding to continuous operation of conductor at designed
maximum temperature. The material of the components should be
suitable for continued good performance corresponding to these
maximum temperatures. The supplier shall submit relevant
type/performance test certificates as per applicable
standards/product specifications to confirm suitability of the
offered material.
1.11.3 The design, manufacturing process and quality control of all the
materials shall be such as to give the specified mechanical rating,
highest mobility, elimination of sharp edges and corners to limit
corona and radio-interference, best resistance to corrosion and a
good finish.
1.11.4 All ferrous parts including fasteners shall be hot dip galvanized,
after all machining has been completed. Nuts may, however, be
tapped (threaded) after galvanizing and the threads oiled. Spring
washers shall be electro galvanized. The bolt threads shall be
undercut to take care of the increase in diameter due to
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galvanizing. Galvanizing shall be done in accordance with IS 2629

/ IS 1367 (Part-13) and shall satisfy the tests mentioned in IS
2633. Fasteners shall withstand four dips while spring washers
shall withstand three dips of one minute duration in the standard
Preece test. Other galvanized materials shall have a minimum
average coating of zinc equivalent to 600 gm/sq.m., shall be
guaranteed to withstand at least six successive dips each lasting
one (1) minute under the standard preece test for galvanizing.
1.11.5 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 dimensions below the design requirements.
1.11.6 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 galvanizing shall be grade Zn 99.95 as per
IS:209.
1.11.7 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 90o to this line. "NO GO" gauges shall not
pass in any direction.
1.11.8 Socket ends, before galvanizing, shall be of uniform contour. The
bearing surface of socket ends shall be uniform about the entire
circumference without depressions of high spots. The internal
contours of socket ends shall be concentric with the axis of the
fittings as per IS:2486/IEC : 120.
The axis of the bearing surfaces of socket ends shall be coaxial
with the axis of the fittings. There shall be no noticeable tilting of
the bearing surfaces with the axis of the fittings.
1.11.7 In case of casting, the same shall be free from all internal defects
like shrinkage, inclusion, blow holes, cracks etc. Pressure die
casting shall not be used for casting of components with thickness
more than 5 mm.
1.11.8 All current carrying parts shall be so designed and manufactured
that contact resistance is reduced to minimum.
1.11.9 No equipment shall have sharp ends or edges, abrasions or
projections and cause any damage to the conductor in any way
during erection or during continuous operation which would
produce high electrical and mechanical stresses in normal

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working. The design of adjacent metal parts and mating surfaces

shall be such as to prevent corrosion of the contact surface and to
maintain good electrical contact under service conditions.
1.11.9 All the holes shall be cylindrical, clean cut and perpendicular to
the plane of the material. The periphery of the holes shall be free
from burrs.
1.11.10 All fasteners shall have suitable corona free locking arrangement
to guard against vibration loosening.
1.11.11 Welding of aluminium shall be by inert gas shielded tungsten arc
or inert gas shielded metal arc process. Welds shall be clean,
sound, smooth, uniform without overlaps, properly fused and
completely sealed. There shall be no cracks, voids incomplete
penetration, incomplete fusion, under-cutting or inclusions.
Porosity shall be minimized so that mechanical properties of the
aluminium alloys are not affected. All welds shall be properly
finished as per good engineering practices.
1.12 Bid Drawings
1.12.1 The Bidder shall furnish full description and illustrations of
materials offered.
1.12.2 Fully dimensioned drawings of the hardwares and their component
parts shall be furnished --- copies along with the bid. Weight,
material and fabrication details of all the components should be
included in the drawings.
1.12.3 All drawings shall be identified by a drawing number and contract
number. All drawings shall be neatly arranged. All drafting &
lettering shall be legible. The minimum size of lettering shall be 3
mm. All dimensions & dimensional tolerances shall be mentioned
in mm.
The drawings shall include:
(i) Dimensions and dimensional tolerance.
(ii) Material, fabrication details including any weld details & any
specified finishes & coatings. Regarding material
designation & reference of standards are to be indicated.
(iii) Catalogue No.
(iv) Marking
(v) Weight of assembly
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(vi) Installation instructions

(vii) Design installation torque for the bolt or cap screw.
(viii) Withstand torque that may be applied to the bolt or cap
screw without failure of component parts.
(vi) Installation instructions
(ix) The compression die number with recommended
compression pressure.
(x) Placement charts for spacer/spacer damper and damper
(xi) All other relevant technical details
1.12.4 After placement of award, the Contractor shall submit fully
dimensioned drawing including all the components in ----- copies
to the Owner for approval. After getting approval from the Owner
and successful completion of all the type tests, the Contractor shall
submit ------ more copies of the same drawings to the Owner for
further distribution and field use at Owner’s end.

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TABLE-1
(Details of Materials)
Sl. Name of Material Process of Reference Remarks
No. item treatment Standard

1. Security Stainless - AISI 302 or

Clips Steel/ 304-L/ IS-
Phospher 1385
Bronze
2. For Free Centre /Envelope type clamps
(a) Clamp Body, High Strength Casted or IS:617or
Keeper Piece Al. Alloy 4600/ forged & Heat ASTM-
LM-6 or treated B429
6061/65032

(b) Cotter Mild Steel Hot dip As per IS-

bolts/ galvanized 226
Hangers, or IS-2062
Shackles,
Brackets
(c) U Bolts Stainless Steel Forged & & AISI 302 or
or High Heat treated 304-L
Strength Al ASTM-
alloy 6061/ B429
65032
(d) P. A. Rod High Strength Heat ASTM- Min.
Al. Alloy 4600/ treatment B429 tensile
LM-6 or during strength
6061/65032 manufacturin of 35
g kg/mm2
3. For AGS type clamp
(a) Supporting High Strength Casted or IS:617or
House Corrosion forged & Heat ASTM-
resistant Al. treated B429
Alloy 4600/
LM-6 or
6061/65032
(b) Al insert & High Strength Casted or IS:617or High
Retaining Al. Alloy 4600/ forged & Heat ASTM- Strength
strap LM-6 or treated B429 Al. Alloy
6061/65032 4600/
LM-6 or
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6061/650
32

(c) Elastomer Moulded on Al.

reinforcement

4. For Dead End Assembly

(a) Outer EC grade Al of
Sleeve purity not less
than 99.50%

(b) Steel Sleeve Mild Steel Hot Dip IS:226/

Galvanized IS-2062
5. Ball & Class-IV Steel Drop forged & As per IS:
Socket normalized 2004
Fittings, Hot dip
galvanized
6. Yoke Plate Mild Steel Hot dip As per IS-
galvanized 226
or IS-2062

7. Sag Mild Steel Hot dip As per IS-

Adjustment galvanized 226
plate or IS-2062

8(a) Corona High Strength Heat treated ASTM- Mechanical

Control Al. Alloy tube Hot dip B429 or as strength of
ring/ (6061/ galvanized per IS welded
Grading ring 6063/1100 joint shall
type or not be less
65032/ 63400 than 20
Type) kN
8(b) Supporting High Strength Heat treated ASTM-
Brackets & Al Alloy 7061/ Hot dip B429 or as
Mounting 6063/ galvanized per IS:226
Bolts 65032/63400 or IS:2062
Type) or Mild
Steel

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Note : Alternate materials conforming to other national standards of other

countries also may be offered provided the properties and compositions of these
are close to the properties and compositions of material specified. Bidder should
furnish the details of comparison of material offered viz a viz specified in the bid
or else the bids are liable to be rejected.
2.0 Accessories for the HTLS Conductor
2.1 General
2.1.1 This portion details the technical particulars of the accessories for
Conductor.
2.1.2 2.5% extra fasteners, filler plugs and retaining rods shall be
provided.
2.1.3 The supplier shall be responsible for satisfactory performance of
complete conductor system along with accessories offered by him
for continuous operation at temperature specified for the HTLS
Conductor.
2.2 Mid Span Compression Joint
2.2.1 Mid Span Compression Joint shall be used for joining two lengths
of conductor. The joint shall have a resistively less than 75% of
the resistivity of equivalent length of conductor. The joint shall not
permit slipping off, damage to or failure of the complete conductor
or any part thereof at a load less than 95% of the ultimate tensile
strength of the conductor. It must be able to withstand the
continuous design temperature of conductor.
2.2.2 The dimensions of mid span compression joint before & after
compression along with tolerances shall be shall be guaranteed in
the relevant schedules of the bid and shall be decided by the
manufacturer so as to suit the conductor size & conform to
electrical & mechanical requirement stipulated in the
specification. For composite core conductor, suitable sleeve,
collets, collet housing shall be used for core jointing.
2.3 Repair Sleeve
Repair Sleeve of compression type shall be used to repair
conductor with not more than two strands broken in the outer
layer. The sleeve shall be manufactured from 99.5% pure
aluminium / aluminium alloy and shall have a smooth surface. It
shall be able to withstand the designed maximum operating
temperature of conductor. The repair sleeve shall comprise of two
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pieces with a provision of seat for sliding of the keeper piece. The
edges of the seat as well as the keeper piece shall be so rounded
that the conductor strands are not damaged during installation.
The dimensions of Repair sleeve along with tolerances shall be
guaranteed in the relevant schedules of the bid and shall be
decided by the manufacturer so as to suit the conductor size &
conform to electrical & mechanical requirement stipulated in the
specification.
2.4 Vibration Damper
2.4.1 Vibration dampers of 4R-stockbridge type with four (4) different
resonances spread within the specified Aeolian frequency band
width corresponding to wind speed of 1 m/s to 7 m/s are installed
in the existing line at suspension and tension points on each
conductor in each span along with bundle spacers to damp out
Aeolian vibration as well as sub- span oscillations. One damper
minimum on each side conductor / sub-conductor in a bundle for
suspension points and one / two dampers minimum on each side
conductor / sub-conductor in a bundle for tension points has been
used for a ruling design span of --- meters.
2.4.2 The bidder shall offer damping system including Stockbridge type
dampers and bundle spacers for HTLS conductor for its
protection from wind induced vibrations which could cause
conductor fatigue /strand breakage near a hardware attachment,
such as suspension clamps.
Alternate damping systems with proven design offering equivalent
or better performance also shall be accepted provided the
manufacturer meets the qualifying requirements stipulated in the
Specifications. Relevant technical documents including type test
reports to establish the technical suitability of alternate systems
shall be furnished by the Bidder along with the bid.
The damper shall be designed to have minimum 4 nos of resonance
frequencies to facilitate dissipation of vibration energy through
inter-strand friction of the messanger cable and shall be effective
in reducing vibration over a wide frequency range (depending upon
conductor dia) or wind velocity range specified above. The vibration
damper shall meet the requirement of frequency or wind velocity
range and also have mechanical impedence closely matched with
the offered HTLS conductor. The vibration dampers shall be
installed at suitable positions to ensure damping effectiveness
across the frequency range. The power dissipation of the vibration
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dampers shall exceed the wind power so that the vibration level on
the conductor is reduced below its endurance limit i.e. 150 micro
strain. The bidder shall clearly indicate the method for evaluating
performance of dampers including analytical and laboratory test
methods. The bidder shall indicate the type tests to evaluate the
performance of offered damping system.
2.4.5 The clamp of the vibration damper shall be made of high strength
aluminium alloy of type LM-6. It shall be capable of supporting the
damper and prevent damage or chafing of the conductor during
erection or continued operation. The clamp shall have smooth and
permanent grip to keep the damper in position on the conductor
without damaging the strands or causing premature fatigue failure
of the conductor under the clamp. The clamp groove shall be in
uniform contact with the conductor over the entire clamping
surface except for the rounded edges. The groove of the clamp body
and clamp cap shall be smooth, free from projections, grit or other
materials which could cause damage to the conductor when the
clamp is installed. Clamping bolts shall be provided with self-
locking nuts and designed to prevent corrosion of threads or
loosening in service.
2.4.6 The messenger cable shall be made of high strength galvanized
steel/stain less steel with a minimum strength of 135 kg/sqmm.
It shall be of preformed and postformed quality in order to prevent
subsequent drop of weight and to maintain consistent flexural
stiffness of the cable in service. The number of strands in the
messenger cable shall be 19. The messenger cable other than
stainless steel shall be hot dip galvanized in accordance with the
recommendations of IS:4826 for heavily coated wires.
2.4.7 The damper mass shall be made of hot dip galvanized mild
steel/cast iron or a permanent mould cast zinc alloy. All castings
shall be free from defects such as cracks, shrinkage, inclusions
and blowholes etc. The surface of the damper masses shall be
smooth.
2.4.8 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
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effectively sealed to prevent corrosion. The damper mass made of

zinc alloy shall be casted over the messenger cable and have
sufficient and permanent grip on the messenger cable under all
service conditions.
2.4.9 The damper assembly shall be so designed that it shall not
introduce radio interference beyond acceptable limits.
2.4.10 The vibration damper shall be capable of being installed and
removed from energized line by means of hot line technique. in
addition, the clamp shall be capable of being removed and
reinstalled on the conductor at the designated torque without
shearing or damaging of fasteners.
2.4.11 The contractor must indicate the clamp bolt tightening torque to
ensure that the slip strength of the clamp is maintained between
2.5 kN and 5 kN. The clamp when installed on the conductor shall
not cause excessive stress concentration on the conductor leading
to permanent deformation of the conductor strands and premature
fatigue failure in operation.
2.4.12 The vibration analysis of the system, with and without damper and
dynamic characteristics of the damper as detailed under
Appendix-I, shall have to be submitted. The technical particulars
for vibration analysis and damping design of the system are as
follows:

Sl. Description Technical particulars

No.
1. Span length in meters
i) Ruling design span ---meters (e.g. 400m)
ii) Maximum span 1100 meters
iii) Minimum span 100 meters
2. Configuration ----[e.g. Double Circuit twin
bundle conductor per phase
in vertical configuration]

3. Tensile load in Conductor As per Sag – tension

at temperature of calculations
minimum temperature and
still air

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4. Armour rods used Standard preformed armour

rods/AGS
5. Maximum permissible +/- 150 micro strains
dynamic strain i.e.
endurance limit.

2.4.14 The damper placement chart shall be submitted for spans ranging
from 100m to 1100m. Placement charts should be duly supported
with relevant technical documents and sample calculations.
2.4.15 The damper placement charts shall include the following
(1) Location of the dampers for various combinations of spans and
line tensions clearly indicating the number of dampers to be
installed per conductor per span.
(2) Placement distances clearly identifying the extremities between
which the distances are to be measured.
(3) Placement recommendation depending upon type of
suspension clamps (viz Free center type/Armour grip type etc.)
(4) The influence of mid span compression joints, repair sleeves
and armour rods (standard and AGS) in the placement of dampers.

2.5 Bundle Spacer

2.5.1 Armour grip bundle spacers shall be used to maintain the spacing
of 450 mm between the sub-conductors [for 400kV] of each bundle
under all normal working conditions.
2.5.2 Spacers offering equivalent or better performance shall also be
accepted provided offer meets the qualifying requirements
stipulated in the Specification.
2.5.3 The offer shall include placement charts recommending the
number of spacers per phase per span and the sub span lengths
to be maintained between the spacers while installing on the
bundle conductors.
2.5.3.1 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 30 km/hr. and to avoid clashing
of sub conductors. The placement shall ensure bundle stability
under all operating conditions.
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2.5.3.2 The placement chart shall be provided for spans ranging from 100
m to 1100m. The number of spacers recommended for a ruling
design span of 400m [for 400kV] shall however be seven with no
sub-span greater than 70m and no end sub-span longer than 40m.
2.5.3.3 The Bidder may offer more number of spacers per ruling design
span than the specified. However, in such case, suitable price
compensation shall be considered for evaluation. For the purpose
of price compensation, all the spans shall be assumed to be ruling
design spans.
2.5.3.4 The Bidder shall also furnish all the relevant technical
documents in support of their placement charts along with the
bid.
2.5.4 Jumpers at tension points shall also be fitted with spacers so as
to limit the length of free conductor to 3.65 m and to maintain the
sub conductor spacing of 450 mm [for 400kV] for bundle
conductors. Bidder shall quote for rigid spacer for jumper. It shall
meet all the requirements of spacer used in line except for its
vibration performance. Spacers requiring retaining rods shall not
be quoted for jumpers.
2.5.5 The spacer offered by the Bidder shall satisfy the following
requirements.
2.5.5.1 Spacer shall restore normal spacing of the sub-conductors after
displacement by wind, electromagnetic and the electrostatic forces
under all operating conditions including the specified short circuit
level without permanent deformation damage either to conductor
or to the assembly itself. They shall have uniform grip on the
conductor
2.5.5.2 For spacer requiring retaining rods, the retaining rods shall be
designed for the specified conductor size. The preformed rods shall
be made of high strength, special aluminium alloy of type
6061/65032 and shall have minimum tensile strength of 35
kg/sq.mm. The ends of retaining rods should be ball ended. The
rods shall be heat-treated to achieve specified mechanical
properties and give proper resilience and retain the same during
service.
2.5.5.3 Four number of rods shall be applied on each clamps to hold the
clamp in position. The minimum diameter of the rods shall be 7.87
+ 0.1 mm and the length of the rods shall not be less than 1100
mm.
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2.5.5.4 Where elastomer surfaced clamp grooves are used, the elastomer
shall be firmly fixed to the clamp. The insert should be forged from
aluminium alloy of type 6061/65032. The insert shall be duly heat
treated and aged to retain its consistent characteristics during
service.
2.5.5.5 Any nut used shall be locked in an approved manner to prevent
vibration loosening. The ends of bolts and nuts shall be properly
rounded for specified corona performance or suitably shielded.
2.5.5.6 Clamp with cap shall be designed to prevent its cap from slipping
out of position when being tightened.
2.5.5.7 The clamp grooves shall be in uniform contact with the conductor
over the entire surface, except for rounded edges. The groove of the
clamp body and clamp cap shall be smooth and free of projections,
grit or other material which cause damage to the conductor when
the clamp is installed.
2.5.5.8 For the spacer involving bolted clamps, the manufacturer must
indicate the clamp bolt tightening torque to ensure that the slip
strength of the clamp is maintained between 2.5 kN and 5 kN. The
clamp when installed on the conductor shall not cause excessive
stress concentration on the conductor leading to permanent
deformation of the conductor strands and premature fatigue
failure in operation.
2.5.5.9 Universal type bolted clamps, covering a range of conductor sizes,
will not be permitted.
2.5.5.10 No rubbing, other than that of the conductor clamp hinges or
clamp swing bolts, shall take place between any parts of the
spacer. Joint incorporating a flexible medium shall be such that
there is no relative slip between them.
2.5.5.11 The spacer shall be suitably designed to avoid distortion or damage
to the conductor or to themselves during service.
2.5.5.12 Rigid spacers shall be acceptable only for jumpers.
2.5.5.13 The spacer shall not damage or chafe the conductor in any way
which might affect its mechanical and fatigue strength or corona
performance.
2.5.5.14 The clamping system shall be designed to compensate for any
reduction in diameter of conductor due to creep.
2.5.5.15 The spacer assembly shall not have any projections, cuts,
abrasions etc. or chattering parts which might cause corona or
RIV.
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2.5.5.16 The spacer tube shall be made of aluminium alloy of type

6061/65032. If fasteners of ferrous material are used, they shall
conform to and be galvanized conforming to relevant Indian
Standards.
2.5.5.17 Elastomer, if used, shall be resistant to the effects of temperature
up to the designed maximum temperature specified for the
conductor, ultraviolet radiation and other atmospheric
contaminants likely to be encountered in service. It shall have good
fatigue characteristics. The physical properties of the elastomer
shall be of approved standard. The supplier shall submit relevant
type/ performance test certificate as per applicable standard/
product specification for elastomer to confirm suitability of the
offered elastomer for the specified application.
2.5.5.18 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 be suitably selected
by the manufacturers to ensure satisfactory electrical performance
and to avoid deterioration of elastomer under all service
conditions.
2.5.5.19 The spacer assembly shall have complete ease of installation and
shall be capable of removal/reinstallation without any damage.
2.5.5.20 The spacer assembly shall be capable of being installed and
removed from the energized line by means of hot line technique.
2.6 Spacer Damper (Alternative to Vibration Damper & Bundle
Spacer)
2.6.1 Suitable spacer dampers for HTLS conductor can be offered as an
alternative to the combination of Vibration Damper and Bundle
Spacer. The spacer damper covered by this specification shall be
designed to maintain the bundle spacing of 450 mm under all
normal operating conditions and to effectively control Aeolian
vibrations as well as sub span oscillation and to restore conductor
spacing after release of any external extraordinary load. The
nominal sub conductor spacing shall be maintained within ±5 mm.
2.6.2 The spacer damper shall restore the normal sub-conductor
spacing due to displacement by wind, electromagnetic and
electrostatic forces including the specified short circuit level
without permanent deformation or damage either to bundle
conductors or to spacer damper itself.

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2.6.3 The design offered shall be presented as a system consisting of

spacer dampers and their staggering scheme for spans ranging
from 100 m to 1100 m.

2.6.4 Under the operating conditions specified, the spacer damper

system shall adequately control Aeolian vibrations throughout the
life of the transmission line with wind velocity ranging from 0 to 30
km per hour in order to prevent damage to conductor at
suspension clamps, dead end clamps and spacer damper clamps.

2.6.5 The spacer damper system shall also control the sub-span
oscillations in order to prevent conductor damage due to chaffing
and severe bending stresses at the spacer damper clamps as well
as suspension and dead end clamps and to avoid wear to spacer
damper components.

2.6.6 The spacer damper shall consist of a rigid central body called the
frame linked to the conductor by two articulated arms terminated
by suitable clamping system. The articulation shall be designed to
provide elastic and damping forces under angular movement of the
arms. The dynamic characteristics of the articulations shall be
maintained for the whole life of the transmission line.

2.6.7 The clamping system shall be designed to provide firm but gentle
and permanent grip while protecting the conductor against local
static or dynamic stresses expected during normal operating
conditions. The clamping system shall be designed to compensate
for any reduction of conductor diameter due to creep.

2.6.8 Bolted type clamps shall allow installation without removal of the
bolts or the clamps from clamp body. Locking mechanism shall be
suitable to prevent bolt loosening. Clamp locking devices with
small loose components shall not be accepted. Nut cracker, hinged
open or boltless type clamps are acceptable provided adequate grip
can be maintained on the conductor.

2.6.9 Bolts and nuts shall be of mild steel, stainless steel, or high
strength steel in accordance with the design of the spacer damper.

2.6.10 Where elastomer surfaced clamps are used, the elastomer

elements shall be firmly fixed to the clamp. The insert should be
forged from aluminium alloy of type 6061 or equivalent aluminium
alloy having minimum tensile strength of 25 kg/mm2. The insert
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shall be moulded on the insert surface. The insert shall be duly

heat treated and aged to retain its consistent characteristics
during service. The grain flow of the forged insert shall be in the
direction of the maximum tension and compression loads
experienced.

2.6.11 If clamps involving preformed rods are used, these rods shall be
designed for specific conductor size. They shall be made of high
strength aluminium alloy of type 6061 or equivalent aluminium
alloy having a minimum tensile strength of 35 kg/mm3. The rods
shall be ball ended. The rods shall be heat treated and aged to
achieve specified mechanical properties and to retain the same
during service. The length of the rods shall be such that the ends
fall inside the imaginary square whose sides are vertical and
horizontal outer tangents to the conductor sections.

2.6.12 The spacer damper body shall be cast/ forged from suitable high
strength corrosion resistant aluminum alloy. The aluminium alloy
shall be chosen in relation with the process used.

2.6.13 The rubber components involved in the design such as damping

elements shall be made with rubber compound selected
specifically for that particular application. The Contractor shall
submit a complete list of physical and mechanical properties of the
elastomer used. This list shall make reference to all applicable
ASTM standards.

2.6.14 The rubber components used shall have good resistance to the
effects of temperature up to the designed maximum temperature
of the conductor and to ultraviolet radiation, ozone and other
atmospheric contaminants. The rubber shall have good wear and
fatigue resistance and shall be electrically semi-conductive.

2.6.15 The spacer damper involving ferrous material shall not have
magnetic power loss more than 1 watt.

2.6.16 The spacer damper assembly shall have electrical continuity. The
electrical resistance between the sub-conductors across the
assembly in case of spacer damper involving elastomer surfaced
clamps shall be suitably selected by the manufacturer to ensure
satisfactory electrical performance and avoid deterioration of
elastomer under service conditions.

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2.6.17 The spacer damper assembly shall have complete ease of

installation and shall be capable of removal/reinstallation without
any damage.

2.6.18 The spacer damper assembly shall be capable of being installed

and removed from the energized line by means of hot line
techniques. The Bidder shall supply with the bid the complete
description of the installation, removal and reinstallation
procedure.

2.6.19 The Bidder shall recommend the staggering scheme for installation
of spacer dampers on the line which shall ensure most satisfactory
fatigue performance of the line as specified. The scheme shall
indicate the number of spacer dampers per phase per span and
the sub span lengths to be maintained between spacer dampers
while installing on the bundle conductors.

2.6.20 The staggering scheme shall be provided for spans ranging from
100 m to 1100 m. The number of spacer dampers for a nominal
ruling span of 400 m [for 400kV] shall not be less than six.

2.6.21 No sub span shall be greater than 70 m and no end sub span shall
be longer than 40 m.

2.6.22 The staggering scheme shall be such that the spacer dampers be
unequally distributed along the span to achieve sufficient detuning
of adjacent subs pans for oscillations of sub span mode and to
ensure bundle stability for wind speeds up to 60 km/hr.

2.6.23 The manufacturer / supplier shall supply free of cost 25 number

fixed setting torque wrench ( of torque as per spacer damper
design) along with 1st batch of supply of spacer dampers for
installation of spacer damper on the line by the tower contractors.

2.6.24 The Bidder shall furnish all the relevant technical documents in
supports of the staggering scheme recommended for the spacer
damper.

2.7 Material and Workmanship

2.7.1 All the equipment shall be of the latest proven design and conform
to the best modern practice adopted in the extra high voltage field.
The Bidder shall offer only such equipment as guaranteed by him
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to be satisfactory and suitable for --- kV transmission line

application with / without bundle conductors and will give
continued good performance at all service conditions. For
employer’s review of the offered design of accessories, the supplier
shall submit document/design details of similar type of
accessories used in past for similar type of HTLS conductor
application
2.7.2 The design, manufacturing process and quality control of all the
materials shall be such as to achieve requisite factor of safety for
maximum working load, highest mobility, elimination of sharp
edges and corners, best resistance to corrosion and a good finish.
2.7.3 High current, heat rise test shall be conducted by the supplier to
determine the maximum temperature achieved in different
components of fittings/ accessories under simulated service
condition corresponding to continuous operation of conductor at
designed maximum temperature. The material of the components
should be suitable for continued good performance corresponding
to these maximum temperatures. The supplier shall submit
relevant type/ performance test certificates as per applicable
standards/product specifications to confirm suitability of the
offered material.
2.7.4 All ferrous parts shall be hot dip galvanized, after all machining
has been completed. Nuts may, however, be tapped (threaded) after
galvanizing and the threads oiled. Spring washers shall be electro
galvanized as per grade 4 of IS-1573. The bolt threads shall be
undercut to take care of increase in diameter due to galvanizing.
Galvanizing shall be done in accordance with IS:2629/ IS-1367
(Part-13) and satisfy the tests mentioned in IS-2633. Fasteners
shall withstand four dips while spring washers shall withstand
three dips. Other galvanized materials shall have a minimum
average coating of Zinc equivalent to 600 gm/sq.m and shall be
guaranteed to withstand at least six dips each lasting one minute
under the standard Preece test for galvanizing unless otherwise
specified.
2.7.5 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 galvanizing shall be of grade Zn 99.95 as per
IS:209.
2.7.6 In case of castings, the same shall be free from all internal defects
like shrinkage, inclusion, blow holes, cracks etc.
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2.7.7 All current carrying parts shall be so designed and manufactured

that contact resistance is reduced to minimum and localized
heating phenomenon is averted.
2.7.8 No equipment 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 which
would produce high electrical and mechanical stresses in normal
working. The design of adjacent metal parts and mating surfaces
shall be such as to prevent corrosion of the contact surface and to
maintain good electrical contact under all service conditions.
2.7.9 Particular care shall be taken during manufacture and subsequent
handling to ensure smooth surface free from abrasion or cuts.
2.7.10 The fasteners shall conform to the requirements of IS:6639-1972.
All fasteners and clamps shall have corona free locking
arrangement to guard against vibration loosening.
2.8 Compression Markings
Die compression areas shall be clearly marked on each equipment
designed for continuous die compressions and shall bear the
words ‘COMPRESS FIRST’ ‘suitably inscribed on each equipment
where the compression begins. If the equipment is designed for
intermittent die compressions, it shall bear the identification
marks ‘COMPRESSION ZONE’ and ‘NON-COMPRESSION ZONE’
distinctly with arrow marks showing the direction of compression
and knurling marks showing the end of the zones. The letters,
number and other markings on finished equipment shall be
distinct and legible.
3.0 Tests and Standards
3.1 Type Tests
3.1.1 On Suspension Clamp
a) Magnetic power loss test : As per Appendix-I
b) Clamp slip strength Vs torque test : As per Appendix-I
c) Ozone Test on elastomer : As per Appendix-I
d) Vertical damage load & Failure load : IEC:61284
test
3.1.2 On Dead end Tension Assembly

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a) Electrical resistance test for dead end : As per IS:2486-

Assembly (Part-I)
b) Heating cycle test for dead end : As per Appendix-I
Assembly
c) Slip strength test for dead end : As per Appendix-I
assembly
d) Ageing test on filler (if applicable) : As per Appendix-I

3.1.3 Mid Span Compression Joint for Conductor

a) Chemical analysis of materials : As per Appendix-I
b) Electrical resistance test :As per IS:2121
(Part-II)
c) Heating cycle test : As per Appendix-I
d) Slip strength test : As per Appendix-I
e) Corona extinction voltage test (dry)[for : As per Appendix-I
400kV]
f) Radio interference voltage test (dry) : As per Appendix-I
[for 400kV]

3.1.4 Repair Sleeve for Conductor

a) Chemical analysis of materials : As per Appendix-I
b) Corona extinction voltage test (dry) : As per Appendix-I
[for 400kV]
c) Radio interference voltage test (dry) : As per Appendix-I
[for 400kV]
3.1.5 Vibration Damper for Conductor
a) Chemical analysis of materials : As per Appendix-I
b) Dynamic characteristics test* : As per Appendix-I
c) Vibration analysis : As per Appendix-I
d) Clamp slip test : As per Appendix-I

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e) Fatigue tests : As per Appendix-I

f) Magnetic power loss test : As per Appendix-I
g) Corona extinction voltage test (dry) : As per Appendix-I
[for 400kV]
h) Radio interference voltage test (dry) : As per Appendix-I
[for 400kV]
i) Damper efficiency test : As per IS:9708
* Applicable for 4 R Stockbridge dampers. For alternate type of
vibration dampers (permitted as per clause 2.4.2), as an
alternative to dynamic characteristic test, damper efficiency test
as per IEEE-664 may be proposed/ carried out by the supplier.
3.1.6 Bundle Spacer for line
a) Chemical analysis of materials : As per Appendix-I
b) Clamp slip : As per Appendix-I
test
c) Vibration Test : As per Appendix-I
(i) Vertical vibration : As per Appendix-I
ii) Longitudinal vibration : As per Appendix-I
iii) Sub-span oscillation : As per Appendix-I
d) Magnetic power loss test (if applicable) : As per Appendix-I
e) Compressive and Tension Test : As per Appendix-I
f) Corona extinction voltage test (dry) : As per Appendix-I
[for 400kV]
g) Radio interference voltage test (dry) : As per Appendix-I
[for 400kV]
h) Ozone test on elastomer : As per Appendix-I

3.1.7 Rigid spacer for jumper

a) Chemical analysis of materials : As per Appendix-I

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b) Clamp slip : As per Appendix-I

test
c) Magnetic power loss test (if applicable) : As per Appendix-I

d) Tension-compression Test : As per Appendix-I

e) Corona extinction voltage test (dry) [for : As per Appendix-I

400kV]
f) Radio interference voltage test (dry) [for : As per Appendix-I
400kV]

3.1.8 Spacer Damper (Alternative to combination of Vibration

Damper & Bundle spacer)
a) Chemical analysis of materials : As per Appendix-I
b) Clamp slip : As per Appendix-I
test
c) Vibration Test : As per Appendix-I
(i) Vertical Vibration : As per IS 10162
(ii) Longitudinal Vibration : As per IS 10162
(iii)Sub-span oscillation : As per IS 10162
d) Dynamic characteristics test : As per Appendix-I

e) Fatigue tests : As per Appendix-I

d) Magnetic power loss test (if applicable) : As per Appendix-I
e) Compressive and Tension Test : As per Appendix-I
f) Corona extinction voltage test (dry) [for : As per Appendix-I
400kV]
g) Radio interference voltage test (dry) [for : As per Appendix-I
400kV]
h) Ozone test on elastomer : As per Appendix-I
k) Log decrement test : As per Appendix-I

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Type tests specified above shall not be required to be carried out if a valid test
certificate is available for a same design, i.e., tests conducted earlier should
have been conducted in accredited laboratory (accredited based on ISO/IEC
guide 25/17025 or EN 45001 by the National Accreditation body of the country
where laboratory is located) or witnessed by the representative (s) of a Utility.

In the event of any discrepancy in the test report (i.e., any test report not
applicable due to any design / material/manufacturing process change
including substitution of components or due to non-compliance with the
requirement stipulated in the Technical Specification) the tests shall be
conducted by the Contractor at no extra cost to the Employer/ Employer/
Purchaser.

3.2 Acceptance Tests

3.2.1 On Both Suspension Clamp and Tension Assembly
a) Visual Examination : As per IS:2486-(Part-I)
b) Verification of dimensions : As per IS:2486-(Part-I)
c) Galvanizing/Electroplating test : As per IS:2486-(Part-I)
d) Mechanical strength test of each : As per Appendix-I
component
e) Mechanical Strength test of welded joint : As per Appendix-I
f) Chemical analysis, hardness tests, grain : As per Appendix-I
size, inclusion rating & magnetic
particle inspection for forgings/castings

3.2.2 On Suspension Clamp only

a) Clamp Slip strength Vs Torque test for : As per Appendix-I
suspension clamp
b) Shore hardness test of elastomer : As per Appendix-I
cushion for AG suspension clamp
c) Bend test for armour rod set : As per IS:2121(Part-I),
Clause 7.5,7,10 & 7.11
d) Resilience test for armour rod set : As per IS:2121(Part-I),
Clause 7.5,7,10 & 7.11
e) Conductivity test for armour rods set : As per IS:2121(Part-I),
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Clause 7.5,7,10 & 7.11

3.2.3 On Tension Hardware Fittings only

a) Slip strength test for dead end assembly : As per Appendix-I
d) Ageing test on filler (if applicable) : As per Appendix-II

3.2.4 On Mid Span Compression Joint for Conductor

a) Visual examination and dimensional : As per IS:2121
verification (Part-II), Clause 6.2,
6.3 7 6.7
b) Galvanizing test : As per Appendix-II
c) Hardness test : As per Appendix-II
d) Ageing test on filler (if applicable) : As per Appendix-II
3.2.5 Repair Sleeve for Conductor
a) Visual examination and dimensional : As per IS:2121(Part-II)
verification Clause 6.2, 6.3

3.2.6 Vibration Damper for Conductor

a) Visual examination and dimensional : As per IS:2121(Part-II)
verification Clause 6.2, 6.3 7 6.7
b) Galvanizing test : As per Appendix-II
(i) On damper masses : As per Appendix-II
ii) On messenger cable : As per Appendix-II
c) Verification of resonance frequencies : As per Appendix-II
d) Clamp slip test : As per Appendix-II
e) Clamp bolt torque test : As per Appendix-II
f) Strength of the messenger cable : As per Appendix-II
g) Mass pull off test : As per Appendix-II
h) Dynamic characteristics test* : As per Appendix-II
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* Applicable for 4 R Stockbridge dampers. For alternate type of vibration

dampers (permitted as per clause 2.4.2), as an alternative to dynamic

characteristic test, damper efficiency test as per IEEE-664 may be
proposed/ carried out by the supplier.

3.2.7 Bundle Spacer for line / Rigid spacer for Jumper for conductor
a) Visual examination and dimensional : As per IS:2121(Part-II)
verification Clause 6.2, 6.3 7 6.7
b) Galvanizing test : As per Appendix-II
c) Movement test (except for spacer : As per Appendix-II
jumpers)
d) Clamp slip test : As per Appendix-II
e) Clamp bolt torque test : As per Appendix-II
f) Compression-tension test : As per Appendix-II
g) Assembly torque test : As per Appendix-II
h) Hardness test for elastomer ( if : As per Appendix-II
applicable)
3.2.8 Spacer Damper for Conductor/ Rigid spacer for Jumper
a) Visual examination and dimensional : As per IS:2121(Part-II)
verification Clause 6.2, 6.3 7 6.7
b) Galvanizing test : As per Appendix-II
c) Movement test (except for spacer : As per Appendix-II
jumpers)
d) Clamp slip test : As per Appendix-II
e) Clamp bolt torque test : As per Appendix-II
f) Compression-tension test : As per Appendix-II
g) Assembly torque test : As per Appendix-II
h) Hardness test for elastomer ( if : As per Appendix-II
applicable)

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3.3 Routine Tests

3.3.1 For Hardware Fittings
a) Visual examination IS:2486-(Part-I)
b) Proof Load Test : As per Appendix-I
3.3.1 For conductor accessories
a) Visual examination and dimensional : As per IS:2121(Part-II)
verification Clause 6.2, 6.3 7 6.7
3.4 Tests During Manufacture on all components as applicable
a) Chemical analysis of Zinc used for IS:2486-(Part-I)
galvanizing
b) Chemical analysis mechanical : As per Appendix-I
metallographic test and magnetic
particle inspection for malleable castings
c) Chemical analysis, hardness tests and : As per Appendix-I
magnetic particle inspection for forging
3.5 Testing Expenses
3.5.1 Testing charges for the type test specified shall be indicated
separately in the prescribed schedule.
3.5.2 Bidder shall indicate charges for all type tests covered under
Clause No. 3.1.1 to 3.1.7 separately. The charges for each type test
shall be separately indicated.
3.5.6 Bidder shall indicate the laboratories in which they propose to
conduct the type tests. They shall ensure that adequate facilities
for conducting the tests 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.
3.5.7 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.
3.5.8 In case of failure in any type test, 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 Contractor's notice of testing, the Owner’s
representative/Inspector does not find material & facilities to be
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ready for testing the expenses incurred by the Owner’s for re-
deputation shall be deducted from contract price.
3.5.9 The Contractor shall intimate the Owner about carrying out of the
type tests along with detailed testing program 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.
3.6 Sample Batch For Type Testing
3.6.1 The Contractor shall offer material for sample selection for type
testing only after getting Quality Assurance Programme approved
by the Owner. The Contractor 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.
3.6.2 Before sample selection for type testing the Contractor shall be
required to conduct all the acceptance tests successfully in
presence of Owner’s representative.
3.7 Schedule of Testing and Additional Tests
3.7.1 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.
3.7.2 The Owner reserves the right of having at his own expense 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 specifications.
3.7.3 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 Contractor’s premises or at any other test
centre. In case of evidence of non-compliance, it shall be binding
on the part of Contractor to prove the compliance of the items to

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the technical specifications by repeat tests, or correction of

deficiencies, or replacement of defective items, all without any
extra cost to the Owner.
3.8 Test Reports
3.8.1 Copies of type test reports shall be furnished in at least six 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.
3.8.2 Copies of acceptance test report shall be furnished in at least six
copies. One copy shall be returned, duly certified by the Owner,
only after which the materials will be dispatched.
3.8.3 Record of routine test report shall be maintained by the Contractor
at his works for periodic inspection by the Owner’s representative.
3.8.4 Test certificates of tests during manufacture shall be maintained
by the Contractor. These shall be produced for verification as and
when desired by the Owner.
3.9 Inspection
3.9.1 The Owner’s representative shall at all times be entitled to have
access to the works and all places of manufacture, where the
material and/or its component parts shall be manufactured and
the representatives shall have full facilities for unrestricted
inspection of the Contractor’s, sub-Contractor’s works raw
materials. manufacturers of all the material and for conducting
necessary tests as detailed herein.
3.9.2 The material for final inspection shall be offered by the Contractor
only under packed condition as detailed in clause 4.11 of this part
of the Specification. The engineer shall select samples at random
from the packed lot for carrying out acceptance tests.
3.9.3 The Contractor shall keep the Owner informed in advance of the
time of starting and of the progress of manufacture of material in
its various stages so that arrangements could be made for
inspection.
3.9.4 Material shall not 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 all tests specified
herein have been satisfactorily completed.
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3.9.5 The acceptance of any quantity of material shall in no way relieve

the Contractor 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.
3.10 Packing and Marking
3.10.1 All material shall be packed in strong and weather resistant
wooden cases/crates. The gross weight of the packing shall not
normally exceed 200 Kg to avoid handling problems.
3.10.2 The packing shall be of sufficient strength to withstand rough
handling during transit, storage at site and subsequent handling
in the field.
3.10.3 Suitable cushioning, protective padding, dunnage or spacers shall
be provided to prevent damage or deformation during transit and
handling.
3.10.4 Bolts, nuts, washers, cotter pins, security clips and split pins etc.
shall be packed duly installed and assembled with the respective
parts and suitable measures shall be used to prevent their loss.
3.10.5 Each component part shall be legibly and indelibly marked with
trade mark of the manufacturer and year of manufacture.
3.10.6 All the 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 stenciled on it in indelible
ink.
3.11 Standards
3.11.1 The Hardware fittings; conductor and earthwire accessories shall
conform to the following Indian/International Standards which
shall mean latest revisions, with amendments/changes adopted
and published, unless specifically stated otherwise in the
Specification.
3.11.2 In the event of the supply of hardware fittings; conductor and
earthwire accessories 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 Contractor
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and those specified in this document will be provided by the

Contractor to establish their equivalence.

Sl. Indian Title International

No. Standard Standard
1. IS: 209-1992 Specification for zinc BS:3436-
1986

2. IS:398 Aluminum Conductor IEC:1089-

Galvanized Steel- Reinforced 1991
For Extra High Voltage BS:215-1970
3. IS 1573 Electroplated Coating of Zinc
on iron and Steel
4. IS : 2121 Specification for Conductor
(Part-II) and Earthwire Accessories for
Overhead Power lines:

Mid-span Joints and Repair

Sleeves for Conductors
5. IS:2486 Specification for Insulator
(Part-I) Fittings for Overhead power
Lines with Nominal Voltage
greater than 1000 V:

General Requirements and

Tests
6. IS:2629 Recommended Practice for Hot
Dip Galvanizing of Iron and
Steel
7. IS:2633 Method of Testing Uniformity
of Coating on Zinc Coated
Articles
8. Ozone test on Elastomer ASTM- D1 171
9. Tests on insulators of Ceramic IEC:383-1993
material or glass for overhead
lines with a nominal voltage
greater than 1000V
10. IS:4826 Galvanized Coating on Round ASTM A472-
Steel Wires 729
BS:443-1969
11. IS:6745 Methods of Determination of BS:433
Weight of Zinc Coating of Zinc ISO : 1460 (E)
Coated Iron and Steel Articles
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12. IS:8263 Method of Radio Interference IEC:437

Tests on High Voltage NEMA:107
Insulators CISPR
13. IS:6639 Hexagonal Bolts for Steel ISO/R-272
Structures
14. IS:9708 Specification for Stock Bridge
Vibration Dampers for
Overhead Power Lines
15. IS:10162 Specification for Spacers
Dampers for Twin Horizontal
Bundle Conductors

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Appendix - I
1.0 Tests on Hardware Fittings
1.1 Magnetic Power Loss Test for Suspension Assembly

Two hollow aluminium tubes of 32 mm diameter for the conductor shall

be placed 450 mm (for 400kV) apart. An alternating current over the
range of 1200 to 1800 amps shall be passed through each tube. One
hollow aluminium tubes of 29mm diameter for the conductor shall be
used for 132kV. An alternating current over the range of 300 - 700 amps
shall be passed through the tube. The reading of the wattmeter with and
without suspension assemblies along with line side yoke plate, clevis eye
shall be recorded. Not less than three suspension assemblies shall be
tested. The average power loss for suspension assembly shall be plotted
for each value of current. The value of the loss corresponding to ---A (at
steady state conductor temperature) shall be read off from the graph and
the same shall be limited to the value guaranteed by the supplier.
1.2 Galvanizing/Electroplating Test

The test shall be carried out as per Clause no. 5.9 of IS: 2486-(Part-1)
except that both uniformity of zinc coating and standard preecee test shall
be carried out and the results obtained shall satisfy the requirements of
this specification.
1.3 Mechanical Strength Test of Each Component

Each component shall be subjected to a load equal to 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. The component shall then again be
loaded to 50% of UTS and the load shall be further increased at a steady
rate till the specified UTS and held for one minute. No fracture should
occur. The applied load shall then be increased until the failing load is
reached and the value recorded.
1.4 Mechanical Strength Test of Welded Joint

The welded portion of the component shall be subjected to a Load of 2000

kgs for one minute. Thereafter, it shall be subjected to die-penetration/
ultrasonic test. There shall not be any crack at the welded portion.
1.5 Clamp Slip Strength Vs Torque Test for Suspension Clamp

The suspension assembly shall be vertically suspended by means of a

flexible attachment. A suitable length of conductor shall be fixed in the
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clamp. The clamp slip strength at various tightening torques shall be

obtained by gradually applying the load at one end of the conductor. The
Clamp slip strength vs torque curve shall be drawn. The above procedure
is applicable only for free center type suspension clamp. For AG
suspension clamp only clamp slip strength after assembly shall be found
out. The clamp slip strength at the recommended tightening torque shall
be as indicated in the GTP. [e.g. for 400kV: more than 20 kN but less than
29 kN.]
1.6 Heating Cycle Test

Heating cycle test shall be performed in accordance with IS 2486 (Part-I)

with following modifications:
i) Temperature of conductor during each cycle: 40 deg. C above
designed maximum operating temperature of the conductor, but not
exceeding the emergency temperature of the conductor.
ii) Number of cycle: 100
iii) Slip strength test shall also be carried out after heating cycle test.
1.7 Slip strength test for dead end assembly

The test shall be carried out as per IS:2486 (Part-I) except that the load
shall be steadily increased to 95% of minimum ultimate tensile strength
of conductor/earthwire and retained for one minute at this load.
1.8 Ageing Test on Filler (if applicable)

The test shall be done in accordance with Grease drop point test method.
The specimen should be drop as a droplet when kept at a temperature 40
deg. C above designed maximum operating temperature of the conductor
for 30 minutes. The temperature shall then be increase till one droplet
drops and the temperature recorded.
1.9 Shore Hardness Test for Elastomer Cushion for AG Suspension
Assembly

The shore hardness at various points on the surface of the elastomer

cushion shall be measured by a shore hardness meter and the shore
hardness number shall be between 65 to 80.
1.10 Proof Load Test

Each component shall be subjected to a load equal to 50% of the specified

minimum ultimate tensile strength which shall be increased at a steady
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rate to 67% of the UTS specified. The load shall be held for one minute
and then removed. After removal of the load the component shall not
show any visual deformation.
1.11 Tests for Forging Casting and Fabricated Hardware

The chemical analysis, hardness test, grain size, inclusion rating and
magnetic particle inspection for forging, castings and chemical analysis
and proof load test for fabricated hardware shall 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 in the Quality Assurance programme.
1.12 Ozone Test for Elastomer

This test shall be performed in accordance with ASTM D-1171 by the

Ozone chamber exposure method (method B). The test duration shall be
500 hours and the ozone concentration 50 PPHM. At the test completion,
there shall be no visible crack under a 2 x magnification.
2.0 Tests on Accessories for Conductor
2.1 Mid Span Compression Joint for Conductor

(a) Slip Strength Test

The fitting compressed on conductor shall not be less than one metre in
length. The test shall be carried out as per IS:2121 (Part-ii)-1981 clause
6-4 except that the load shall be steadily increased to 95% of minimum
ultimate tensile strength of conductor/earthwire and retained for one
minute at this load. There shall be no movement of the conductor/
earthwire relative to the fittings and no failure of the fit tings during this
one minute period.
(b) Heating Cycle Test
Heating cycle test shall be performed in accordance with IS 2121 (Part-
II-1981 ) with following modifications:-
i) Temperature of conductor during each cycle: 40 deg. C above
designed maximum operating temperature of the conductor.
ii) Number of cycle: 100
iii) Slip strength test shall also be carried out after heating cycle test.

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2.2 Vibration Damper for Conductor

(a) Dynamic Characteristics 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 Aeolian vibration frequency band ranging from
0.18/d to 1.4/d where d is the conductor diameter in meters. The damper
assembly shall be vibrated vertically with a + 1 mm amplitude from 5 to
15 Hz frequency and beyond 15 Hz at ± 0.5mm to determine following
characteristics with the help of suitable recording instruments:
(i) Force Vs frequency
(ii) Phase angle Vs frequency
(iii) 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 conductor
without dampers.
Acceptance criteria for vibration damper:
(i) The above dynamic characteristics test on five damper shall be
conducted.
(ii) The mean reactance and phase angle Vs frequency curves shall be
drawn with the criteria of best fit method.
(iii) The above mean reactance response curve should lie within 0.191 f to
0.762 f Kgf/mm limits where f is frequency in Hz.
(iv) The above mean phase angle response curve shall be between 25o to
130o within the frequency range of interest.
(v) If the above curve lies within the envelope, the damper design shall
be considered to have successfully met the requirement.
(vi) Visual resonance frequencies of each mass of damper is to be recorded
and to be compared with the guaranteed values.

(b) Vibration Analysis

The vibration analysis of the conductor 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:
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(i) The analysis shall be done for single conductor without armour rods
as per the parameters given under clause 2.5.13 and 3.3.8 of this part
of the Specification. The tension shall be taken from Sag & Tension
calculation (0 deg. C & no wind condition and -----m ruling span) for
a span ranging from 100 m to 1100.
(ii) The self-damping factor and flexural stiffness (El) for conductor shall
be calculated on the basis of experimental results. The details for
experimental analysis with these data should be furnished.
(iii) The power dissipation curve obtained from Dynamic Characteristics
Test shall be used for analysis with damper.
(iv) Examine the aeolian vibration level of the conductor 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.
(v) From vibration analysis of conductor without damper, anti-node
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.
(vi) From vibration analysis of conductor with damper/dampers installed
at the recommended location, the dynamic strain level, at the clamped
span extremities, damper attachment point and the antinodes on the
conductor shall be determined. In addition to above damper clamp
vibration amplitude and anti-node vibration amplitudes shall also be
examined.
The dynamic strain levels at damper attachment points, 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.
(c) Clamp Slip and Fatigue Tests

(i) Test Set Up

The clamp slip and fatigue tests shall be conducted on a laboratory set
up with a minimum effective span length of 30 m. The conductor shall be
tensioned at tension corresponding to minimum temperature & no wind
condition and ruling span ----m from sag –tension calculation and 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 conductor has been tensioned, clamps shall be
installed to support the conductor at both ends and thus influence of
connecting hardware fittings are eliminated from the free span. The
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clamps shall not be used for holding the tension on the conductor. 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 stepless speed control as well as stepless amplitude arrangement.
Equipment shall be available for measuring the frequency, cumulative
number of cycles and amplitude of vibration at any point along the span.
(ii) 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 2.5 kN parallel to the axis
of conductor for a minimum duration of one minute shall not slip i.e. the
permanent displacement between conductor and clamp measured after
removal of the load shall not exceed 1.0 mm. The load shall be further
increased till the clamp starts slipping. The load at which the clamp slips
shall not be more than 5 kN.
(iii) 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 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 hereinabove shall be repeated after
fatigue test without re-torquing 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.

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After the above tests, the damper shall be removed from conductor and
subjected to dynamic characteristics test. There shall not be any major
deterioration in the characteristic 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 conductor under clamp shall also be free from any damage.
For the purpose of acceptance, the following criteria shall be applied.
I. There shall not be any frequency shift by more than
+2 Hz for frequencies lower than 15 Hz and ± 3 Hz for frequencies
higher than 15 Hz.
II. The force response curve shall generally lie within guar anteed %
variation in reactance after fatigue test in comparison with that
before fatigue test by the Contractor.
III. The power dissipation of the damper shall not be less than
guaranteed % variation in power dissipation before fatigue test by the
Contractor. 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.

2.3 Spacer/ Spacer Damper

(a) Vibration Tests

The test set up shall be as per Clause No. 2.2(c) (i) of Appendix-I. The
spacer/spacer damper assembly shall be clamped to conductor. During
the vibration tests the axis of the clamp of sample shall be maintained
parallel to its initial static position by applying a tension (Tension form
sag-tension calculation at minimum temperature & no wind condition
and 400 m ruling span). The spacer/spacer damper assembly shall be
free to vibrate and shall not be re-torqued or adjusted between the tests.
All the vibration tests mentioned hereunder shall be conducted on the
same sample on the same test span. The samples shall withstand the
vibration tests without slipping on the conductor. loosening, damage or
failure of component parts. After each vibration test, clamp slip test shall
be carried out as per the procedure given in Clause No 2.4 (b) below:
(a) Longitudinal Vibration Test

The stationary conductor and the vibrating conductor/equivalent

diameter of aluminium alloy tube shall be restrained by fixed clamps. The
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displacement of the vibrating conductor shall be 25 mm minimum on

either side. The longitudinal movement shall be parallel to the conductor
at frequency not less than 2 Hz for minimum one million cycles.
(b) Vertical Vibration Test

The spacer/spacer damper shall be installed in the middle of the test span
and the frequency chosen so as to get an odd number of loops. The shaker
shall be positioned at least two loops away from the test specimen to allow
free movement of the conductor close to the test specimen. One conductor
shall be connected to the shaker and vibrated to an amplitude such that
f1.8 Ymax > 1000 mm/sec.
Where Ymax being the antinode displacement (mm) and f is the test
frequency (Hz). The test frequency shall be greater than 24 Hz and the
total number of cycles shall be more than 10 million.
(c) Sub-span Oscillation Test

The test shall be conducted for oscillation in horizontal plane at frequency

higher than 3 Hz for minimum one million cycles. The amplitude for
oscillation shall be kept equivalent to an amplitude of 150 mm for a full
sub-span of 80m. Both the conductor shall be vibrated 180 deg. out of
phase with the above minimum amplitude.
(b) Clamp Slip Test

The spacer assembly shall be installed on test span of twin conductor

bundle string at a tension of tension at 0 deg. C & No wind. In case of
spacer for jumper, the. clamp of sample shall be tightened with a specified
tightening torque. One of the sample clamps, when subjected to a
longitudinal pull parallel to the conductor axis for a minimum duration
of one minute, shall not slip on the conductor i.e. the permanent
displacement between the conductor and the clamp of the sample
measured after removal of the load shall not exceed specified values. The
minimum slip under longitudinal pull varies with clamp type according
to the following table:

Clamp Type Longitudinal Maximum Slip

Load (kN) (mm)
Metal-Metal bolted 6.5 1
Rubber loaded 2.5 2.5
Clamp using 2.5 12
Preformed rods
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(c) Compressive and tensile test

This test shall be conducted on 3 (three) nos samples The spacer assembly
shall withstand ultimate compressive load of 14 kN and tensile load of 7.0
kN applied between sub-conductor bundle and held for one minute
without failure. Line distance between clamps shall be recorded during
each of the compression and tension test. Measurement shall be recorded
at (i) no load (ii) with load (iii) after release of load. The center line distance
under load shall be within ± 100 mm of the nominal design spacing. After
release of load it shall be possible to retain the clamps at their original
position using only slight hand pressure. There shall be no deformation
or damage to the spacer assembly which would impair its function of
maintaining the normal spacing.

(d) Dynamic Characteristic Test (for Spacer Damper only)

The purpose of this test is to obtain quantitative information regarding

the dynamic characteristics of the spacer damper. The values obtained
during this test will serve as references to evaluate the behavior of the
same spacer damper under the fatigue test.
The test will consist in the application of sinusoidal movement of the
spacer-damper articulation and measuring the force (F), displacement (X)
and phase angle (Ø) between these two, from these values, the stiffness
(K) and the damping factor (n) will be calculated.
F
K = ——— Cos Ø; n = Tan Ø
X
The test frequency shall not be higher than 3 Hz. The test shall be
performed at five different displacement amplitudes. The amplitudes shall
be selected to reproduce 10, 20, 40, 60 and 90 percent of the maximum
displacement permitted by the spacer-damper design.
The test shall be performed on three samples.
(e) Fatigue Test (for Spacer Damper only)

The purpose of this test is to evaluate the capacity of the spacer damper
to sustain without damage the cyclic movements which can be induced
by vibrations.

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The spacer damper articulation shall be subjected to cyclic motions for a

total of 10 million cycles. The test frequency shall be between 2 and 3 Hz.
The amplitude of motion shall be established on the following basis :
I. the load applied on the spacer damper clamp shall not be less than ±
300 N.
II. the clamp displacement under the applied load shall not be less than
60% of the maximum displacement permitted by the design.
III. if the 300 N load generates movement exceeding the maximum
permitted displacement, the load can be reduced to limit the movement
to 95% of the maximum displacement.
IV. After the test, the sample shall be subjected to a second dynamic
characteristic test. This test shall be performed at two amplitudes, 10%
and 60% of the maximum displacement.
V. The spacer damper shall show no signs of cracks or deterioration,
loosening of bolts or abnormal wear.

The dynamic characteristics (k and n) shall not be less than 60% of the
values measured before the fatigue test. The test shall be performed on
three samples.
(f) Ozone Test

The test shall be performed in accordance with ASTM D-1171 by the ozone
chamber exposure method (method B). The test duration shall be 500
hours and the ozone concentration 50 PPHM. At the test completion, there
shall be no visible crack under a 2xmagnification.
(g) Log Decrement test (for spacer damper only)

The spacer damper assembly shall be mounted on test span of conductor

bundle at a tension of 0 deg. C and no wind and ruling span of 400 m.
The test span shall be instrumented to continuously monitor and record
the horizontal motion of the sub-conductor in the sub-span between
suspension point and the fist sample.
The log decrement test shall be made with an initial peak to peak
amplitude of four to six times the conductor diameter in the middle of the
sub-span being considered. The conductor shall be excited in a horizontal
one loop per sub-span resonant mode with a slow and steady buildup of
amplitude that minimizes harmonics and other distortions. After
achieving a steady state motion, the conductor excitation shall be
discontinued leaving the conductor undisturbed. The motion shall be
recorded until it reduces to an amplitude of half of the conductor
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diameter. The logarithmic (log) decrement shall be the value for a

minimum reduction of 80 % in amplitude. The minimum acceptable log
decrement average for five or more excitation shall be 0.04 based upon
the following formula for decay.
An 1 A0
Loge = Loge
An+1 n A
Where A0 is the initial amplitude and An is the amplitude ‘n’ cycles later

2.4 Magnetic Power Loss Test for Spacer

The sample involving ferrous parts shall be tested in a manner to simulate

service conditions for 50 Hz pure sine-wave. The test should be carried
out at various currents ranging from 1200 to 1800 amperes per sub-
conductor (for 400kV) the magnetic power loss at various currents should
be specified in tabulated graphical form. The difference between the
power losses without and with sample at room temperature shall be
limited to value guaranteed by the supplier for --- Amperes current (rms)
[at steady state conductor temperature]. The losses shall be determined
by averaging the observations obtained from at least four samples.
2.5 Corona Extinction Voltage Test (Dry) [for 400kV]

The sample when subjected to power frequency voltage shall have a

corona extinction voltage of not less than 320 kV rms 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 IS:731- 1971.
2.6 Radio Interference Voltage Test (Dry) [for 400kV]

Under the conditions as specified under (3.8) above, the sample shall have
a radio interference voltage level below 1000 microvolts at one MHz when
subjected to 50 Hz AC voltage of 305 kV rms line to ground under dry
condition. The test procedure shall be in accordance with IS:8263.
2.7 Chemical Analysis Test

Chemical analysis of the material used for manufacture of items shall be

conducted to check the conformity of the same with Technical
Specification and approved drawing.

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3.0 Tests on All components (As applicable)

3.1 Chemical Analysis of Zinc used for Galvanizing
Samples taken from the zinc ingot shall be chemically analyzed 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 Contractor 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 Contractor and Owner in
Quality Assurance Programme.

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Appendix-II
Acceptance Tests
1. Mid Span Compression Joint for Conductor

(a) Hardness Test

The Brinnel hardness at various points on the steel sleeve of conductor

core and tension clamp shall be measured.
2. Vibration Damper for Conductor

(a) Verification of Resonance Frequencies

The damper shall be mounted on a shaker table and vibrate at damper

clamp displacement of +/-0.5 mm to determine the resonance
frequencies. The resonance shall be visually identified as the frequency
at which damper mass vibrates with maximum displacement on itself.
The resonance frequency thus identified shall be compared with the
guaranteed value. A tolerance of ± 1 Hz at a frequency lower than 15 Hz
and ± 2 Hz at a frequency higher than 15 Hz only shall be allowed.
(b) Clamp Slip Test

Same as Clause 2.2 (c) (ii) of Appendix-I.

(c) Clamp Bolt Torque Test

The clamp shall be attached to a section of the conductor/earthwire. A

torque of 150 percent of the manufacturer’s specified torque shall be
applied to the bolt. There shall be no failure of component parts. The test
set up is as described in Clause 2.2 (c) (i), Appendix-I.
(d) Strength of the Messenger Cable

The messenger cable shall be fixed in a suitable tensile testing machine

and the tensile load shall be gradually applied until yield point is reached.
Alternatively, each strand of messenger cable may be fixed in a suitable
tensile testing machine and the tensile load shall be gradually applied
until yield point is reached. In such a case, the 95% of yield strength of
each wire shall be added to get the total strength of the cable. The load
shall be not less than the value guaranteed by the Contractor.

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(e) Mass Pull off Test

Each mass shall be pulled off in turn by fixing the mass in one jaw and
the clamp in the other of a suitable tensile testing machine. The
longitudinal pull shall be applied gradually until the mass begins to pull
out of the messenger cable. The pull off loads shall not be less than the
value guaranteed by the Contractor.
(f) Dynamic Characteristics Test

The test will be performed as acceptance test with the procedure

mentioned for type test with sampling mentioned below:
Vibration Damper :
 1 Sample for lot of 1000 Nos. & below
 3 Samples for lot above 1000 & up to 5000 nos.
 Additional 1 sample for every additional 1500 pieces above 5000.

The acceptance criteria will be as follows:

(i) The above dynamic characteristics curve for reactance & phase angle
will be done for frequency range of 5 Hz to 40 Hz.
(ii) If all the individual curve for dampers are within the envelope as
already mentioned for type test for reactance & phase angle, the lot
passes the test.
(iii) If individual results do not fall within the envelope, averaging of
characteristics shall be done.
(iv) Force of each damper corresponding to particular frequency shall be
taken & average force of three dampers at the frequency calculated.
(v) Similar averaging shall be done for phase angle.
(vi) Average force Vs frequency and average phase Vs frequency curves
shall be plotted on graph paper. Curves of best fit shall be drawn for
the entire frequency range.
(vii) The above curves shall be within the envelope specified.

3. Spacer/ Spacer Damper

(a) Test Set up

The test set up for the test described hereunder shall be as per clause 2.3
(a) of Appendix-I.

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(b) Movement Test

The spacer assembly shall be capable of the following movements without

damaging the conductor, assuming one conductor is fixed and the other
moving:
(i) Longitudinal movement ± 50 mm
parallel to the conductor
(ii) Vertical movement in a ± 25 mm
vertical direction at right
angle to the conductor
(iii) Torsional movement/angular ± 5 deg.
movement in a vertical plane
parallel to the conductor
(c) Compressive and Tensile Test

The spacer assembly shall withstand ultimate compressive load of 14 kN

and tensile load of 7.0 kN applied between sub-conductor bundle and
held for one minute without failure. Line distance between clamps shall
be recorded during each of the compression and tension test.
Measurement shall be recorded at (i) no load (ii) with load (iii) after release
of load. The center line distance under load shall be within ± 100 mm of
the nominal design spacing. After release of load it shall be possible to
retain the clamps at their original position using only slight hand
pressure. There shall be no deformation or damage to the spacer assembly
which would in pair its function of maintaining the normal spacing.
(d) Clamp Slip Test

Same as clause 2.3(b) of Appendix-I.

(e) Clamp Bolt Torque Test

The spacer assembly shall be attached to conductor. A torque of 150 per

cent of the manufacturer's specified tightening torque shall be applied to
the clamp bolts or cap screws. There shall be no failure of the component
parts.
(f) Assembly Torque Test

The spacer assembly shall be installed on conductor. The same shall not
rotate on either clamp on applying a torque of 0.04 kN in clockwise or
anti-clockwise direction.

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(g) Hardness test for Elastomer

The shore hardness at different points on the elastomer surface of

cushion grip clamp shall be measured by shore hardness meter. They
shall lie between 65 to 80.
(h) UTS of Retaining Rods

The ultimate tensile strength of the retaining rods shall be measured. The
value shall not be less than 35 kg/sq.mm.

(i) Ageing Test on filler (if applicable)

Same as clause 1.8 of Appendix-I.

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ANNEXURE-IV

GUARANTEED TECHNICAL PARTICULARS/

TECHNICAL DATA SHEET
(TO BE FILLED BY BIDDER)

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Annexure-IV

GUARANTEED TECHNICAL PARTICULARS OF HTLS CONDUCTOR

Sl. Description Unit Value

guaranteed by
the Bidder

1. Name & address of Manufacturer

2. Construction of conductor/ Designation

of conductor as per IEC:1089
3.1 PARTICULARS OF RAW MATERIALS

3.1 Outer Layers

a) Applicable Standard(if any)

b) Type of Aluminum alloy
c) Minimum purity of aluminum %
d) Maximum Copper content %
e) Zirconium content
i) Maximum %
ii) Minimum %
f) Other elements----------
i) ---------- %
ii) ---------- %
3.2 Inner Core

a) Applicable Standard(if any)

b) Material of core
c) Chemical composition of core
i) ---------- %
ii) ---------- %
3.3 Zinc used for galvanization of inner core
(if applicable)

a) Minimum purity of zinc %

3.4 Chemical Composition of Misch Metal
coating on core wires (if applicable)
i) Zinc %
ii) Aluminium %
iii) Other elements---------- %
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----------
3.5 Aluminium used for Aluminium
Cladding (if applicable)

a) Minimum purity of aluminum %

b) Maximum Copper content %
c) Other elements----------
i) ---------- %
ii)……….. %
4. STRANDS OF OUTER CONDUCTING
PART (AFTER STRANDING)
4.1 Number of outer layers Nos.
4.2 Number of strands
a) 1st Layer from core Nos.
b) 2nd Layer from core Nos.
c) 3rd Layer from core Nos.
…………………… …….
……………………….. ……..
4.2 Diameter of strands
a) Nominal mm
b) Maximum mm
c) Minimum mm
4.3 Minimum Breaking load of strand
a) Before stranding kN
b) After stranding kN
4.4 Resistance of 1m length of strand at 20 Ohm
deg. C
4.5 Final Modulus of elasticity Kg/sq.
mm
4.6 Final Coefficient of linear expansion Per 0 C
5 INNER CORE STRANDS/ INNER CORE
(AFTER STRANDING)
5.1 Number of layers in inner core
(excluding central wire)
5.2 Number of strands
a) 1st Layer from centre (excluding central Nos.
wire) Nos.
b) 2nd Layer from centre Nos.
c) 3rd Layer from centre …….
…………………… ……..
………………………..
5.3 Diameter
a) Nominal mm
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b) Maximum mm
c) Minimum mm
5.3 Minimum Breaking load of strand/Core
a) Before stranding kN
b) After stranding kN
5.4 Resistance of 1m length of strand at 20 Ohm
deg. C
5.5 Final Modulus of elasticity Kg/sq.
mm
5.6 Final coefficient of linear expansion Per 0 C
5.7 Aluminum cladding of INVAR core (if
applicable)
a) Thickness of cladding
i) Maximum mm
ii) Minimum mm
b)Minimum no. of twists in a gauge
length equal to 100 times diameter of
wire which the strands can withstand
in the torsion test
a) Before stranding Nos.
b) After stranding Nos.
c) Minimum elongation of strand for a %
gauge length of 250 mm
d) Resistance of 1m length of strand at Ohm
20 deg. C
5.8 Galvanizing/ Misch Metal coating (if
applicable)
a) Minimum mass of zinc coating per gm
sqm. of uncoated wire surface.
b) Minimum mass of Misch metal Nos.
coating per sqm. of uncoated wire
surface (if applicable).
c) Min. no. of twists which a single Nos.
strand shall withstand during
torsion test for a length equal to
100times dia of wire after
stranding.
d) Minimum elongation of strand for a %
gauge length of 250 mm
6 FILLER (if applicable)
6.1 Type & Designation of Filler
6.2 Chemical composition of Filler
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6.3 Mass of Filler Kg/km

7 COMPLETE HTLS CONDUCTOR
7.1 Cross section drawing of the offered Yes/No
conductor enclosed
7.2 Diameter of conductor
a) Nominal mm
b) Maximum mm
c) Minimum mm
7.3 UTS (minimum) of Conductor kN
7.4 Lay ratio of conductor Maxim Minim
a) 1st layer from centre (excluding um um
central wire)
b) 2nd Layer
c) 3rd Layer
d)4th Layer

7.5 DC resistance of conductor at 20oC Ohm/km

7.6 Final Modulus of elasticity
a) Upto transition temperature Kg/sq.
mm
b) Above transition temperature Kg/sq.
mm
7.7 Coefficient of linear expansion
a) Upto transition temperature Per deg
C
b) Above transition temperature Per deg
C
7.8 Calculation for transition temperature Yes/No
enclosed
7.9 Transition temperature (corresponding Deg C
to ---m ruling span and tension at ruling
condition as per 7.19)
7.10 Minimum Corona Extinction Voltage kV(rms)
(line to ground) under Dry condition
[for 400kV lines]
7.11 RIV at 1MHz and 305 kV (rms) under Micro-
dry conditions [for 400kV lines] volts
7.12 Maximum permissible conductor Deg C
temperature for continuous operation
7.13 Maximum permissible conductor Deg C
temperature for short term operation

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7.14 Permissible duration of above short term Minute

operation s
7.15 Steady state conductor temperature at
specified conductor current of -----A and
under Ambient conditions detailed in
Clause 1.2.1 of Section-IV of the
Technical Specification for HTLS
conductor
7.16 AC resistance at maximum continuous Ohm/k
operating temperature corresponding to m
specified maximum operating current (--
-A under ambient condition enclosed as
per Clause 1.2.1 of Section-IV of the
Technical Specification for HTLS
conductor)
7.17 AC resistance at continuous operating Ohm/k
temperature corresponding to specified m
operating current of ---A (under
ambient condition enclosed as per
Clause 1.2.1 of Section-IV of the
Technical Specification for HTLS
conductor)
7.18 Details of Creep characteristic for HTLS Yes/No
conductor enclosed (as per Clause 1.4.3
of Section-IV of the Technical
Specification for HTLS conductor)
7.19 Sag Tension Calculation
7.19.1 Sag Tension Calculation enclosed Yes/No
(clause 1.4.1 of Section-IV of the
Technical Specification for HTLS
conductor)
7.19.2 Tension at 32 deg. C & no wind Kg
7.19.3 Sag & tension at maximum continuous Meters
operating temperature (corresponding to & Kgs
current of 1574 A and Ambient
conditions detailed in Clause 1.4.1 of
Section-IV of the Technical Specification
for HTLS conductor)
i) Tension for following conditions:
a. 32 deg. C & full wind condition kg
b. 32 deg. C & Nil wind condition kg
c. Minimum tempt. & Nil wind condition kg

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d. Minimum tempt. & 36% of full wind

condition
e. 32 deg. C & 75% of full wind condition
7.19.4 Tension at transition temperature kg
7.20 Direction of lay for outside layer
7.21 Linear mass of the Conductor
a) Standard Kg/km
b) Minimum Kg/km
c) Maximum Kg/km
7.22 Standard length of conductor M
7.23 Maximum length of conductor that can M
be offered as single length
7.24 Tolerance on standard length of %
conductor
7.25 Drum is as per specification Yes/No
7.26 No. of cold pressure butt welding Nos.
equipment available at works

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GUARANTEED TECHNICAL PARTICULARS OF SUSPENSION HARDWARE

FITTINGS

Sl. Description Unit Value

No. guaranteed by
the Bidder
1. Name & address of Manufacturer

2. Address of Manufacturer

3. Drawing enclosed Yes/No

4. Maximum magnetic power loss of Watt

suspension clamp at conductor / sub-
conductor current of ---- amperes (at
steady state conductor temperature)
5. Slipping strength of suspension assembly kN
(c!amp torque Vs slip curve shall be
enclosed)

6. Particulars of standard/AGS Standard /

AGS preformed armour rod set for
suspension assembly
a) No. of rods per set No.

b) Direction of lay

c) Overall length after fitting on conductor mm

d) Actual length of each rod along its helix mm

e) Diameter of each rod mm

f) Tolerance in

i) Diameter of each rod ±mm

ii) Length of each rod ±mm

iii) Difference of length between the ±mm

longest and shortest rod in a set

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g) Type of Aluminium alloy used for

manufacture of PA rod set
h) UTS of each rod Kg/mm2

Particulars of Elastomer
7.
(For AGS Clamp only)
a) Supplier of elastomer

b) Type of elastomer

c) Shore hardness of elastomer

d) Temperature range for which elastomer

is designed
e) Moulded on insert

8. UTS of suspension clamp

9. Purity of Zinc used for galvanizing %

11. Minimum corona extinction voltage under kV (rms)

dry condition
[for 400kV lines]
12. Radio interference voltage at 1 Mhz for μV
phase to earth voltage of 305 kV (dry
condition)
[for 400kV lines]
13. Maximum permissible continuous
operating temperature of
i) Clamp body Deg. C
ii) Standard/AGS preformed rods Deg. C

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GUARANTEED TECHNICAL PARTICULARS OF TENSION HARDWARE

FITTINGS

Sl. Description Unit Value guaranteed

No. by the Bidder

1. Name of Manufacturer

2. Address of Manufacturer

3. Drawing enclosed Yes/ No

4. Purity of aluminum used for %

aluminum sleeve
5. Material for steel sleeve

(i) Type of material with chemical

composition
(ii) Range of Hardness of material BHN From …….to ……..
(Brinnel Hardness)
(iii) Weight of zinc coating gm/m2

Aluminium Steel
/ Alloy
6. Outside diameter of sleeve before mm
compression
7. Inside diameter of sleeve before mm
compression
8. Length of sleeve before compression

9. Dimensions of sleeve after

compression
(a) Corner to Corner
(b) Surface to Surface
10. Length of sleeve after compression

11. Weight of sleeve

(a) Aluminium/ aluminum Alloy kg

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(b) Steel kg

(c) Total kg

12. Electrical resistance of dead end %

assembly as a percentage of
equivalent length of Conductor
13. Slip strength of dead end assembly kN

14. UTS of dead end assembly kN

15. Purity of Zinc used for galvanizing %

16. Design calculation of yoke plates Yes

and sag adjustment plate enclosed. /
No

17. Minimum corona extinction voltage kV

under dry condition (rm
[for 400kV lines] s)
18. Radio interference voltage at 1 Mhz μV
for phase to earth voltage of 305 kV
(dry condition)
[for 400kV lines]
19. Maximum permissible continuous Deg
operating temperature of dead end .C
assembly

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GUARANTEED TECHNICAL PARTICULARS OF MID SPAN COMPRESSION

JOINT FOR HT/HTLS CONDUCTOR

Sl. Description Unit Value

No. guaranteed by
the Bidder
1. Name of Manufacturer

2. Address of Manufacturer

3. Drawing enclosed Yes/No

4. Suitable for conductor size mm

5. Purity of aluminium used for %

aluminium sleeve
6. Material for steel sleeve

(i) Type of material with chemical

composition
(ii) Range of Hardness of material BHN From …….to
(Brinnel Hardness) ……..
(iii) Weight of zinc coating gm/m2

Aluminium Steel
/ alloy
7. Outside diameter of sleeve before mm
compression
8. Inside diameter of sleeve before mm
compression
9. Length of sleeve before compression

10. Dimensions of sleeve after

compression
(a) Corner to Corner
(b) Surface to Surface
11. Length of sleeve after compression

12. Weight of sleeve

(a) Aluminium kg

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(b) Steel kg

(c) Total kg

13. Slip strength kN

14. Resistance of the compressed unit %

expressed, as percentage of the
resistivity of equivalent length of bare
conductor.
15. Minimum Corona extinction voltage kV
under dry condition [for 400kV lines] (rms)

16. Radio interference voltage at 1 MHz μV

for phase to earth voltage of 305 kV
under dry condition[for 400kV lines]
17. Maximum permissible continuous Deg. C
operating temperature of mid span
compression joint

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GUARANTEED TECHNICAL PARTICULARS OF REPAIR SLEEVE FOR

HT/HTLS CONDUCTOR

Sl. Description Unit Value guaranteed

No. by the Bidder
1. Name of Manufacturer

2. Address of Manufacturer

3. Drawing enclosed Yes/No

4. Suitable for conductor size mm

5. Purity of Aluminium / Al Alloy type %

6. Dimension of sleeve before
compression
mm
i) Inside diameter of sleeve
mm
ii) Outside dimensions of sleeve
mm
iii) Length of sleeve
7. Dimension of sleeve after
compression
i) Corner to Corner mm
ii) Surface to Surface mm
iii) Length of sleeve mm
8. Weight of sleeve Kg

9. Minimum Corona extinction voltage kV

under dry condition [for 400kV (rms)
lines]
10. Radio interference voltage at 1 MHz μV
for phase to earth voltage of 305 kV
dry condition) [for 400kV lines]
11. Maximum permissible continuous Deg. C
operating temperature of Repair
Sleeve

NOTE: Tolerances, wherever applicable, shall also be specified.

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GUARANTEED TECHNICAL PARTICULARS OF VIBRATION DAMPER

FOR HT/HTLS CONDUCTOR (IF APPLICABLE)

Sl. Description Unit Value guaranteed

No. by the Bidder
1. Name of Manufacturer

2. Address of Manufacturer

3 Drawing enclosed

(a) Design Drawing YES

/ NO
(b) Placement Chart YES
/ NO
4. Suitable for conductor size mm

5. Total weight of one damper kg

Right Left
6. Diameter of each damper mass mm

7. Length of each damper mass mm

8. Weight of each damper mass kg

9. Material of damper masses

10. Material of clamp

11. Material of the stranded messenger

cable
12. Number of strands in stranded
messenger cable
13. Lay ratio of stranded messenger cable

14. Minimum ultimate tensile strength of Kg/m

stranded messenger cable m2

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15. Slip strength of stranded messenger kN

cable (mass pull off)
Right Left
16. Resonance frequencies
(a) First frequency Hz
(b) Second frequency Hz

17 Designed clamping torque Kg-m

18. Slipping strength of damper clamp

(a) Before fatigue test kN

(b) After fatigue test kN

19. Magnetic power loss per vibration watts

damper watts for ---Amps, 50 Hz
Alternating Current [average
continuous operating current]
20. Minimum corona Extinction voltage kV
kV (rms) under dry condition
[for 400kV lines]
21. Radio Interference Voltage at 1 MHz μV
for phase to earth voltage of 305 kV
(rms) Microvolts under dry condition
[for 400kV lines]
22. Maximum permissible continuous Deg.
operating temperature of Vibration C
Damper
23. Percentage variation in reactance %
after fatigue test in comparison with
that . before fatigue test
24. Percentage variation in power %
dissipation after fatigue test in
comparison with that before fatigue
test

NOTE: Tolerances, wherever applicable, shall also be specified.

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GUARANTEED TECHNICAL PARTICULARS OF BUNDLE SPACER FOR

HT/HTLS CONDUCTOR (IF APPLICABLE)

Sl. Description Unit Value guaranteed

No. by the Bidder
1. Name of Manufacturer

2. Address of Manufacturer

3. Drawing enclosed

(a) Design Drawing YES / NO

(b) Placement Chart YES / NO

4 Suitable for conductor size mm

5. Material / Manufacturing process of component parts

Material Manufa
cturing
Process
(a) Insert

(b) Main body

(c) Retaining rods (if any)

6. Retaining rods (if used)

(a) Type of alloy used

(b) Number of retaining rods used for no.

each spacer
(c) Diameter mm

(d) Length mm

(e) Weight kg

7. Elastomer

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(a) Contractor
(b) Type
(c) Moulded on insert
(d) Shore hardness
(e) Thickness on insert mm
(f) Temp. range for which designed °C
Minimum ultimate tensile strength of
8. spacer
(a) Compressive load kN
(b) Tensile load kN
9. Weight of Spacer kg
Designed clamping torque(if kg.
10.
applicable) m
Before After
Vibration Vibration
11. Slipping strength of spacer clamp kN
Magnetic power loss per spacer for ----
Watt
12. A, 50 Hz Alternating Current (at
s
steady state conductor temperature)
Maximum Minimum
Electrical resistance of elastomer oh
13.
cushioned spacer m
14. Minimum corona Extinction voltage kV
kV (rms) under dry condition
[for 400kV lines]
15. Radio Interference Voltage at 1 MHz μV
for phase to earth voltage of 305 kV
(rms) Microvolts under dry condition
[for 400kV lines]
16. Maximum permissible continuous Deg.
operating temperature of Bundle C
spacer

NOTE: Tolerances, wherever applicable, shall also be specified.

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GUARANTEED TECHNICAL PARTICULARS OF RIGID SPACER FOR

JUMPER FOR HTLS CONDUCTOR

Sl. Description Unit Value guaranteed

No. by the Bidder
1. Name of Manufacturer

2. Address of Manufacturer

3. Drawing enclosed

(a) Design Drawing YES /

NO
(b) Placement Chart YES /
NO
4 Suitable for conductor size mm

5. Material of component parts

(a) Clamp
(b) Main body

6. Manufacturing process for

(a) Clamp
(b) Main body

(e) Weight kg

7. Elastomer

(a) Contractor
(b) Type
(c) Moulded on insert
(d) Shore hardness
(e) Thickness on insert mm
(f) Temp. range for which designed °C

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Minimum ultimate tensile strength of

8.
spacer
(a) Compressive load kN
(b) Tensile load kN

9. Weight of Spacer kg

10. Designed clamping torque(if kg.m

applicable)
11. Slipping strength of spacer clamp kN

12. Magnetic power loss per spacer for watt

Watts ---Amps, 50 Hz Alternating
Current (at steady state conductor
temperature)
Maximum Minimum
12. Electrical resistance of elastomer ohm ………
cushioned spacer
13. Minimum corona Extinction voltage kV
kV (rms) under dry condition (rms)
[for 400kV lines]
14. Radio Interference Voltage at 1 MHz μV
for phase to earth voltage of 305 kV
(rms) Microvolts under dry condition
[for 400kV lines]
15. Maximum permissible continuous Deg.
operating temperature of rigid C
spacer

NOTE: Tolerances, wherever applicable, shall also be specified.

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GUARANTEED TECHNICAL PARTICULARS OF SPACER DAMPER FOR

HTLS CONDUCTOR (IF APPLICABLE)

Sl. Description Unit Value

No. guaranteed by
the Bidder
1. Name of Manufacturer

2. Address of Manufacturer

3. Drawing enclosed

(a) Design Drawing YES

/ NO
(b) Placement Chart YES
/ NO
4 Suitable for conductor size mm

5. Material of component parts

(a) Clamp
(b) Main body

6. Type of Clamps

7. Type of Damping element

8. Manufacturing process for

(a) Clamp
(b) Main body

(e) Weight kg

9. Elastomer

(a) Contractor
(b) Type
(c) Moulded on insert

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(d) Shore hardness

(e) Thickness on insert mm
(f) Temp. range for which designed °C
Minimum ultimate tensile strength of
10.
spacer
(a) Compressive load kN
(b) Tensile load kN

11. Weight of Spacer kg

12. Designed clamping torque(if applicable) kg.

m
13. Slipping strength of spacer clamp kN

14. Magnetic power loss per spacer for Watts watt

1574 Amps, 50 Hz Alternating Current
Maxi Minim
mum um
15. Electrical resistance of elastomer ohm
cushioned spacer
16. Minimum corona Extinction voltage kV kV
(rms) under dry condition (rms)
[for 400kV lines]
17. Radio Interference Voltage at 1 MHz for μV
phase to earth voltage of 305 kV (rms)
Microvolts under dry condition
[for 400kV lines]
18. Maximum permissible continuous Deg.
operating temperature of spacer damper C

NOTE: Tolerances, wherever applicable, shall also be specified.

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ANNEXURE-V

OFFICE ORDER FOR CONSTITUTION OF

THE COMMITTEE

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REFERENCES

1. CIGRE 695 WG: B2.48: Experience with the mechanical performance of

non-conventional conductors, August 2017

2. EPRI’s report 1017448: Demonstration of Advanced Conductors for

Overhead Transmission Lines, July 2008

3. CIGRE 426 WG: B2.26: Guide for Qualifying High Temperature

Conductors for Use on Overhead Transmission Lines, August 2010

4. International Journal of Advance Engineering and Research

Development, Volume 2, Issue 5, May 2015, Re-conductoring scenario
and payback calculations of ACSR Moose and its equivalent conductors
for 400 kV transmission line [Thermal Uprating]

5. PGCIL’s specifications of High Performance Conductors and Accessories

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 Central eleCtriCity authority
Central Electricity Authority (CEA) is a statutory organization, originally
constituted under Section 3(1) of the replaced Electricity (Supply) Act,
1948, since substituted by section 70 of the Electricity Act, 2003. It was
established as a part-time body in 1951 and made a full-time body in 1975.
The functions and duties of CEA are delineated under Section 73 of the
Electricity Act, 2003. The ‘Office of CEA’ is an Attached Office of the
Ministry of Power.
CEA is an apex technical body facilitating overall development of the
power sector in the country with the vision to provide quality Power for all
at an affordable price. CEA advises Central Government on the matters
related to National Electricity Policy, formulates short-term and
perspective plans for development of electricity systems, specify various
technical standards for construction of the electric plans & electric lines,
grid connectivity, safety requirement for construction and O&M of
electrical plants & electric lines, installation & operation of electricity
meters, promotes & assists in timely completion of schemes & projects,
promotes measure for upgrading skills of human resource in the power
sector, collects & utilization of industry, promotes research in matters
affecting power sector, and advise the central Government, State
Governments, Electricity Regulatory Commissions & licensees on all such
matter of power Sector on which its advise is sought.

Central eleCtriCity authority

Ministry of Power, GovernMent of india
Power SyStem engineering & technology DeveloPment DiviSion
Sewa Bhawan, r. K. Puram, new Delhi - 110 066