TECHNICAL SPECIFICATION

COMPOSITE LONG ROD INSULATORS

FOR HVAC: 132kV, 220kV, 400kV, 765kV and
HVDC: ±500kV & ±800kV TRANSMISSION LINES

SECTION-II

ADANI ENERGY SOLUTIONS LIMITED

Section-II PAGE 1
 TECHNICAL SPECIFICATIONS
SECTION-II

TECHNICAL SPECIFICATIONS CONTENTS

Clause No. Description Page No.

Technical Description of Composite Long Rod

1.0 3
Insulators

2.0 Equipment Marking 8

3.0 Bid Drawings 9

4.0 Tests and Standards 9

Annexure-A Tests Procedure for Composite Long Rod Insulators 19

Standard Technical Particulars of Composite Long

Annexure-B 27
Rod Insulators
High voltage test on Composite insulators for
Annexure-C evaluation of defects in FRP rods and Interfaces of 38
composite insulators during acceptance test

Revision History

Revision No. Month/year Description

Rev-0 July - 2022 First Release
Rev-1 Jan-2023 Second Revision
Rev-2 Apr-2024 Third Revision
Rev-3 Oct-2024 Forth Revision

Section-II PAGE 2
1.0 Technical Description of Composite Long Rod Insulators

1.1 Details of Composite Long Rod Insulators

1.1.1 The insulators of the strings shall consist of composite long rod insulators for
a three phase, 50 Hz, effectively earthed 132kV, 220kV, 400kV and 765 kV AC
transmission system and ±500kV HVDC & ±800kV HVDC application in a very
heavily polluted environment. Couplings shall be ball and socket type.
1.1.2 Bidder shall quote such composite insulators which have proven use under
foggy/humid operational conditions in polluted industrial environment
combined with smoke and dust particles. The Bidder shall furnish evidence in
the form of certification from the power utilities that the similar type of
product supplied to them had been performing satisfactorily. The Bidder shall
also submit certified test report for an accelerated ageing test of 5000 hours
such as that described in IEC 62730 (2012).
1.1.3 Insulators shall have sheds of the “open aerodynamic profile without any
under ribs” with good self-cleaning properties. Insulator shed profile; spacing
projection etc. shall be strictly in accordance with the recommendation of
IEC-60815.
1.1.4 The size of long rod insulator, minimum creepage distance, the number to be
used in different type of strings, their electromechanical strength and
mechanical strength of insulator string along with hardware fittings shall be
as per the standard technical particulars shown in Annexure-B.

1.2 Dimensional Tolerance of Composite Insulators

The tolerances on all dimensions e.g., diameter, length shall be allowed as

follows:
± (0.04d+1.5) mm when d≤300 mm.
+(0.025d+6) mm when d>300 mm with a maximum of +10 mm.
Where, d being the dimensions in millimeters for diameter, length as the case
may be.
The tolerance in creepage distance shall be based on design dimensions and
their tolerances. However, no negative tolerance shall be applicable to
creepage distance specified in clause 1.1.4.

1.3 Interchangeability

The composite long rod insulators inclusive of the ball & socket connection
shall be standard design suitable for use with the hardware fittings of any
make conforming to relevant IEC/IS standards.

1.4 Corona and RI Performance

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No
part shall be subjected to excessive localized pressure. The insulator and
metal parts shall be so designed and manufactured that it shall avoid local
corona formation and shall not generate any radio interference beyond
specified limit under the operating conditions.
Section-II PAGE 3
1.5 Maintenance
1.5.1 The long rod insulators offered shall be suitable for employment of hot line
maintenance technique so that usual hot line operation can be carried out
with ease, speed and safety.
1.5.2 All insulators shall be designed to facilitate cleaning and they shall have the
minimum practical number of sheds and grooves. All grooves shall be so
proportioned that any dust deposit can be removed without difficulty either
by wiping with a cloth or by remote washing under live line condition.

1.6 Materials

1.6.1 Core

It shall be a glass-fiber reinforced (FRP rod) epoxy resin rod of high strength.
The rod shall be resistant to hydrolysis. Glass fibers and resin shall be
optimized. The rod shall be electrical grade corrosion resistant (ECR), boron
free glass and shall exhibit both high electrical integrity and high resistance
to acid corrosion. Glass Transition Temperature (Tg) for FRP rod to be
minimum 140° C.

1.6.2 Housing & Weather sheds

The FRP rod shall be covered by a sheath of High Temperature Vulcanized

(HTV) silicone rubber compound of a thickness of minimum 5 mm for ±320kV
& above HVDC applications and minimum 3 mm for other voltage levels and
AC applications. The housing & weather sheds should have silicon content of
minimum 30% by weight. It should protect the FRP rod against environmental
influences, external pollution, and humidity. It shall be extruded or directly
molded on the core. The interface between the housing and the core must be
uniform and without voids. The strength of the bond shall be greater than the
tearing strength of the polymer. The manufacturer shall follow non-
destructive technique (N.D.T.) to check the quality of jointing of the housing
interface with the core. The technique to be followed with detailed procedure
and sampling shall be furnished by the Supplier and finalized during
finalization of MQP.

The weather sheds of the insulators shall be of alternate shed profile. The
weather sheds shall be vulcanized to the sheath (extrusion process) or molded
as part of the sheath (injection molding process) and free from imperfections.
The vulcanization for extrusion process shall be at high temperature and for
injection molding shall be at high temperature & high pressure. Any seams /
burrs protruding axially along the insulator, resulting from the injection
molding process shall be removed completely without causing any damage to
the housing. The track resistance of housing and shed material shall be class
1A4.5 according to IEC60587. The strength of the weather shed to sheath
interface shall be greater than the tearing strength of the polymer. The
composite insulator shall be capable of high pressure washing.

Section-II PAGE 4
1.6.3 End Fittings

End fittings transmit the mechanical load to the core. They shall be made of
malleable cast iron, spheroidal graphite or forged steel. They shall be
connected to the rod by means of a controlled compression technique. The
manufacturer shall have in-process Acoustic emission arrangement or other
arrangement to ensure that there is no damage to the core during crimping.
This verification shall be in-process and done on each insulator. The system
of attachment of end fitting to the rod shall provide superior sealing
performance between housing and metal connection. The gap between
fitting and sheath shall be sealed by a flexible silicone rubber compound. The
sealing shall stick to both housing and metal end fitting. The sealing must be
humidity proof and durable with time.

End fittings shall have suitable provisions for fixing grading rings at the
correct position as per design requirements.

1.6.4 Grading Rings

Grading rings shall be used at each side of the insulators for ±800kV HVDC
Insulators (420kN & 160kN) and at line end for metallic return insulators (160
& 210kN) for reducing the voltage gradient on and within the insulator and to
reduce radio and TV noise to acceptable levels. Covered grading rings (having
minimum 2 mm thickness) shall be provided on tower side of vertical portion
(II-portion) of 420kN Insulators to be used in “Y-string” & 160kN suspension
Pilot insulator strings, of ±800HVDC lines, at cross-arm/ cold end and
designed such that to reduce deposition of bird excreta on polymer insulator
sheds.

For up to 765kV voltage level, grading rings shall be used for each composite
insulator unit as per Standard Technical particulars enclosed at Annexure-B
for reducing the voltage gradient on and within the insulator and to reduce
radio and TV noise to acceptable levels. For Covered grading rings (having
minimum 2 mm sheet thickness of the cover) shall be provided on suspension
insulator strings at cross-arm/ cold end as per Standard Technical particulars
enclosed at Annexure-B and designed such that to reduce deposition of bird
excreta on polymer insulator sheds.

The covered grading ring shall have sloped surface to facilitate natural
cleaning/ removal of any deposition on its surface. The open type grading ring
shall essentially be a round extruded Aluminum Alloy tube of minimum 50 mm
diameter, minimum wall thickness of 2.5 mm. The fixing arms of the grading
ring shall consist of a holder & a keeper. While the holder shall be either
welded or riveted on the corona ring, the keeper shall be bolted onto the
holder. To avoid the possibility of loosening/ opening of grading ring during
service, suitable additional locking measures viz. Lock nut/ bolt patch/ locking
washer etc. shall be provided by the supplier. Gap between holder & keeper
Section-II PAGE 5
 shall be kept uniformly as 32mm for up to 120kN and 36mm for 160kN &
210kN.
The size and placement of the metallic grading rings shall be designed to
eliminate dry band arcing / corona cutting / exceeding of permissible
electrical stress of material. Also, to ensure correct installation of grading
rings, a proper slot shall be provided at the outside edge of the End fittings
and on grading ring holders. The design of the grading rings shall be such that
it will only fit in the designated slot facing correct installation direction. The
position of the slots shall be at suitable distance on end fittings to ensure
acceptable levels of radio and TV noise and voltage gradient on and within
the insulator.

The insulator supplier shall furnish design calculations using appropriate

electric field software as per Clause 4.2 (EFM Analysis) in this specification.
The insulator supplier must provide EFM report with all limits as per criteria
mentioned in clause 4.2 (2). Any modifications to achieve the same shall be
done in Insulator string only. Grading rings shall be capable of installation and
removal with hot line tools without disassembling any other part of the
insulator assembly.

The design & supply of grading rings shall be in the scope of the composite
insulator supplier.

1.6.5 Bolts and nuts for grading rings shall be galvanized as per IS 1367 (Part 13)/ IS
2629. Fully threaded bolts confirming to relevant Indian Standard shall be
used. Dimensions of bolts / nuts shall be M10x50mm. Bolts shall be of
minimum 4.6 grade. In case bolts & nuts of other materials viz. stainless steel,
aluminum alloy, etc. are proposed to be used by the supplier, these shall
conform to relevant Indian/International standards and complete details shall
be submitted by the supplier for review & approval by the Employer.

Section-II PAGE 6
1.6.6 The details of materials for different component are listed as in Table-I
TABLE-1: (Details of Materials)

S. No. Item Material treatment Reference Material Grade

Forged Steel, Class 4 as per IS 2004
Forged Steel, EN8D as per BS970
Ball Forged Steel 41Cr4 as per ISO 683-18-1996 or
1. EN10083-3-2006
End
C40 as per EN-10083-2
Cast Steel C45 as per EN-10083-2
Forged Steel, Class 4 as per IS 2004
Forged Steel, EN8D as per BS970
Forged Steel 41Cr4 as per ISO 683-18-1996 or
EN10083- 3-2006
Socket
2. C40 as per EN-10083-2
End Cast Steel C45 as per EN-10083-2
Spheroidal
SGCI-450/10 as per IS 1865:1991
Graphite Cast Iron
Covered type:
Aluminum Casting LM6 as per BS 1490/ 4600 as per IS 617
Open type:
3. Ring High Strength Al. Alloy, 63400 as per IS
Aluminum
733, 63401 as per IS 5082
Extrusion
Mild Steel E410 as per IS-2062
C45, EN-10083-2
Cast Steel 65-35 as per ASTM A27
A 1020 ASTM A732
4. Holder/ High Strength Al. Alloy, 63400 as per IS
Keeper Aluminum Extrusion
733, 63401 as per IS 5082
Aluminum
LM6 as per BS 1490/ 4600 as per IS 617
Casting (for
(min. 8 mm thickness)
holder only)
Silicone
5.
Rubber High Temperature Vulcanized (HTV) Silicone Rubber

1.7 Workmanship

1.7.1 All the materials shall be of latest design and conform to the best modern
practices adopted in the extra high voltage field. Bidders shall offer only such
insulators as are guaranteed by him to be satisfactory and suitable for
transmission lines specified and will give continued good service.
1.7.2 The design, manufacturing process and material control at various stages
shall be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish and elimination of sharp edges and
corners to limit corona and radio interference.
1.7.3 The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
1.7.4 The core shall be sound and free of cracks, impurities and voids that may
adversely affect the insulators.

Section-II PAGE 7
1.7.5 Weather sheds/ Housing shall be uniform in quality. It shall be free from voids
and impurities. Weather sheds/Housing shall be clean, sound, smooth and free
from gross defects and excessive flashing at parting lines.
1.7.6 End fittings shall be free from cracks, seams, shrinks, air holes and rough
edges. End fittings should be effectively sealed to prevent moisture ingress,
effectiveness of sealing system must be supported by test documents. All
surfaces of the metal parts shall be perfectly smooth with the projecting
points or irregularities which may cause corona. All load bearing surfaces shall
be smooth and uniform to distribute the loading stresses uniformly.
1.7.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating
of zinc equivalent to 600 gm/m² and shall be in accordance with the
requirement of ISO:1461 (E) and shall satisfy the tests mentioned in ISO:1460
(E).

However, under marine/ extreme environment/ coastal areas, all the ferrous
parts have a minimum zinc coating of 910 gm/ sqm (equivalent to 127 microns)
of surface area. Also, in such case, stainless steel bolts/ nuts shall only be
used.

Spring washers shall be electro-galvanized. Stainless steel washer may be

used as an alternative.

The zinc used for galvanizing shall be of purity of 99.95%. The zinc coating
shall be uniform, adherent, smooth, reasonably bright continuous and free
from imperfections such as flux, ash rust stains, bulky white deposits and
blisters. The galvanized metal parts shall be guaranteed to withstand at least
six successive dips each lasting for one (1) minute duration under the
standard preece test. The galvanizing shall be carried out only after any
machining.
1.7.8 The supplier / contractor shall guarantee that there shall not be any failure/
decapping / breaking of insulators online under normal operating condition.
In the event of any failure/ decapping /breaking of insulators during the first
ten years of service, Supplier shall supply to the Owner / Purchaser free of
cost spare insulators equal to 10 times the failed insulator quantity. Further,
in case of decapping / Breaking and subsequent line drop, during the first ten
years of service, the supplier shall also have to pay Rs 1,00,000/- (Rs one lakh
only) per dropped string towards expenditure to be incurred by Owner /
Purchaser for this line repair.
2.0 Equipment Marking
2.1 Each composite long rod unit shall be legibly and indelibly marked with the
trademark of the manufacturer, name of Owner / Purchaser and month & year
of manufacture. The guaranteed combined mechanical and electrical
strength shall be indicated in kilo Newton followed by the word ‘kN’ to
facilitate easy identification and to ensure proper use. Holder of grading rings
shall be legibly and indelibly marked with trademark of the composite
insulator supplier.

Section-II PAGE 8
2.2 One 10 mm thick ring or 20 mm thick spot of suitable quality of paint shall be
marked on the cap/end fitting of each composite long rod of particular
strength for easy identification of the type of insulator. The paint shall not
have any deteriorating effect on the insulator performance. Following codes
shall be used as identification mark:

Long rod
70 kN 90 kN 120 kN 160 kN 210 kN 320 kN 420 kN
unit, kN
Colour Green Orange Yellow Blue Brown Purple black

3.0 Bid Drawings

3.1 The Bidder shall furnish full description and illustration of the material
offered.
3.2 The Bidder shall furnish along with the bid the outline drawing of each
insulator unit along with grading rings including a cross sectional view of the
long rod insulator unit. The drawing shall include but not limited to the
following information:
(a) Major Dimensions with manufacturing tolerances of insulator unit and its
all parts
(b) Number of Sheds
(c) Minimum Dry arcing distance with positive tolerances
(d) Minimum Creepage distance with positive tolerance
(e) Protected creepage distance
(f) Unit mechanical and electrical characteristics
(g) Size and weight of ball and socket parts
(h) Weight of composite long rod units
(i) Weight of all parts
(j) Materials of all items
(k) Confirming applicable standards for all items/materials
3.3 After placement of award, the Supplier shall submit full dimensioned insulator
drawings containing all the details as given in Clause No. 3.2 above, in four (4)
copies to Owner / Purchaser for approval. After getting approval from Owner
/ Purchaser, the Supplier shall submit 10 more copies of the same drawing
along with a soft copy to the Owner / Purchaser for further distribution and
field use at Owner / Purchaser's end.
3.4 After placement of award the Supplier shall also submit fully dimensioned
insulator crate drawing for different type of insulators.

4.0 Tests and Standards

4.1 Type Tests

The required type tests on composite long-rod units, components, materials
and complete strings are stipulated hereunder.
The specified type tests under the following clause shall not be required to
be carried out if a valid test certificate is available for a similar design. The
tests certificate shall be considered valid if:

Section-II PAGE 9
 i. Tests conducted earlier is either conducted in accredited laboratory
(accredited based on ISO/IEC vide 25/17025 or EN 45001 by the National
accreditation body of the country where laboratory is located) or
witnessed by the representative(s) of Owner / Purchaser or utility,

ii. Type test reports contain valid Calibration reports of the relevant testing
equipment and information pertaining to ratings, the relevant drawings,
model number, test circuit, calculations (if any), photos, acceptance
criteria/values specified in Technical Specification/relevant standards
(IS/ IEC) and compliance to the same.

iii. Tests have been conducted not prior to 5 (five) years from the date of bid
opening or as per CEA guidelines whichever is critical.

In case the test have been conducted earlier than the above stipulated period
or carried out on samples manufactured from any other manufacturing works
or in case of revision/ amendment in the provisions/ test procedure of the IS/
IEC as referred in the TS or in the event of any discrepancy in the test report
(i.e., due to non-inclusion of valid calibration certificate, desired information
etc. or any test 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 Specifications),
the tests shall be conducted by the Supplier at no extra cost to the Purchaser.

4.1.1 On complete composite Long Rod Insulator String with Hardware Fittings

Ref (latest
Strings on which test to
No Test standards to
be conducted
be referred)
(a) Power frequency / DC voltage
withstand test with corona IEC:383-
control rings/grading ring and 1993/IEC 60-1
arcing horns under wet condition
(b) Switching surge voltage
withstand test under wet IEC:383-1993
Condition (applicable for 400kV
& above voltage level) All strings that shall be used in
transmission line covered under
(c) Impulse voltage withstand test IEC:383-1993
the package.
under dry condition
(d) Corona (AC/ DC) and RIV test Annexure-A
under dry condition (applicable
for 220kV & above voltage level)
(e) Mechanical Strength test Annexure-A
(f) Vibration test Annexure-A
(g) Salt-fog pollution withstand test Annexure-A
# As indicated in Cl. no. 4.1, the bidder should have successfully completed all specified type
tests on these strings and tests indicated at 4.1.2 on applicable Insulators to be considered
technically responsive / qualified.

Note: Tests indicated at f) & g) shall not be required to be carried out on Pilot strings for all
voltage levels, DIS & DT strings of 132 & 220kV (single ZEBRA) TL and Single Tension strings of
220 kV (twin MOOSE), 400kV & 765 kV TL.

Altitude correction factor as per IEC60071-2 shall be considered in the specified voltage
withstand values for above tests.

Section-II PAGE 10
 These type tests on the insulator string assembly shall not be required to be repeated due to
use of specified size of grading rings even in case valid type test reports for the offered
composite long rod insulator strings are available with different size of grading rings.

4.1.2 On Composite Insulator Units

Tests on interfaces and connections of metal IEC: 61109-2008/

(a)
fittings IS 16784
IEC: 61109-2008/
(b) Assembled core load time test
IS 16784
Damage limit proof test and test of tightness of IEC: 61109-2008/
(c)
interface between end fittings & insulator housing. IS 16784
(d) High Pressure washing test Annexure-A
(e) Brittle fracture resistance test Annexure-A
(f) Dye penetration test IEC: 61109-2008
(g) Water diffusion test IEC: 61109-2008
(h) Tracking and erosion test IEC: 61109-2008
(i) Hardness test IEC: 61109-2008
(j) Accelerated weathering test IEC: 61109-2008
(k) Flammability test IEC: 61109-2008
(l) Silicone content test Annexure-A
(m) Recovery of Hydrophobicity test Annexure-A
(n) Torsion test Annexure-A
(o) Water diffusion test followed by pull-off test Annexure-A

Hardness test, Accelerated weathering test & Flammability test specified

under Clause No.4.1.2 above shall be conducted on housing/ weather shed of
any of the composite long rod insulator for the same type of material.

4.2 EFM Analysis

1. Below details shall be mentioned in test reports: -

a. String configuration.
b. The EFM analysis must be complied with satisfying all dimensions as
per Type test report for the same type of insulator with hardware
fittings as a whole.
c. Method & Software used for analysis with license number with image
of the same.
d. Assumptions along with Insulator dimension including arcing
distance
e. Influence factors on E-field Distribution
f. Inputs for the software:
1) Voltage & Relative Permittivity and conductivity of material i.e.
for FRP rod, silicone rubber insulator, Corona rings, ball and
socket end fittings.
Section-II PAGE 11
 2) Voltage applied on live side
3) Dielectric strength of silicone rubber
g. Reference: IEEE TRANSACTIONS ON POWER DELIVERY, VOL. 30, NO.
3, JUNE 2015.

2. Criteria:

The electric field for dry uncontaminated polymer insulators shall not be more
than following critical values:

a. The E-field on the end fitting seal / surface of the sealing should not
exceed 3.5 kV/cm (rms).
b. The E-field on the insulator sheath should not exceed 4.2 kV/cm
(rms) for more than 10mm along the insulator surface.
c. Surface E-filed magnitudes on end fittings & corona rings should not
exceed 18 kV/cm (rms).

3. The E-field stress analysis should be carried out for both live side and
tower side at highest system voltage.
4. Reports shall include images of E-field stress & it’s measured values of all
above factors taken from software.
5. The results should be provided in tabular from along with requirements.
6. Conclusion.
7. All drawings for insulator and hardware fittings used shall be submitted
along with reports and supplier shall ensure same drawings shall only be
used for on-going projects.

4.3 Acceptance Tests

4.3.1 For Composite Long Rod Insulators

a) Verification of dimensions IEC : 61109-2008

b) Galvanizing test IEC : 60383
c) Verification of end fittings IEC: 61109 -2008
d) Recovery of Hydrophobicity Annexure-A
Verification of tightness of interface between
e) end fittings and insulator housing and of IEC : 61109-2008
specified mechanical load
Tests on interfaces and connections of metal
f) IEC : 61109-2008
fittings
g) Silicone content test Annexure-A
h) Brittle Fracture Resistance Test Annexure-A
i) Dye Penetration Test IEC :61109-2008
j) Water Diffusion Test IEC : 61109-2008
As per AESL
High voltage test on Composite insulators for
procedure
k) Evaluation of Defects in FRP rods and Interfaces
(Annexure-C)
of composite insulators with IR camera

Section-II PAGE 12
 The test 4.4.1 (f) to (j) shall be carried out as an acceptance test on any one
lot of each PO. In the event of failure of the sample to satisfy the acceptance
test(s) specified in 4.3 above, the retest procedure shall be as per IEC 61109
or (IS 16784).
The test 4.3.1 (k), sampling shall be as per AESL, Standard quality plan
submitted as a part of QA requirements.

4.4 Routine Tests

4.4.1 For Composite Long Rod Insulator Units

a) Visual Examination As per IEC: 61109-2008

b) Mechanical routine test As per IEC: 61109 -2008

4.5 Tests During Manufacture

On all components as applicable

As per
a) Chemical analysis of zinc used for galvanizing
Annexure-A
Chemical analysis, mechanical, metallographic test and As per
b)
magnetic particle inspection for malleable castings. Annexure-A
Chemical analysis hardness tests and magnetic As per
c)
particle inspection for forgings Annexure-A
d) Tracking and erosion test on insulating material IEC 60587

4.6 Testing Expenses

4.6.1 As mentioned under clause 4.1 above, no type test charges shall be payable
to the supplier.
4.6.2 For Type Tests which involves the tests on the complete insulator string with
hardware fitting, standard hardware fittings similar to existing insulator
strings shall be arranged and used by the insulator supplier at his own cost.
4.6.3 In case of failure in any type test the supplier is either required to modify the
design of the material & successfully carryout all the type tests as has been
detailed out in Clause 4.1 of this specifications or to repeat that particular
type test at least three times successfully at his own expenses.
4.6.4 Bidder shall indicate the laboratories in which they propose to conduct the
type tests. They shall ensure that adequate facilities are available in the
laboratory and the tests can be completed in these laboratories within the
time schedule guaranteed by them in the appropriate schedule.
4.6.5 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.
4.6.6 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 /
Purchaser's representative shall be deducted from the contract price. Also, if
Section-II PAGE 13
 on receipt of the Supplier's notice of testing, the Owner / Purchaser's
representative does not find the material or test setup / equipment to be
ready for testing, the expenses incurred by the Owner / Purchaser for re-
deputation shall be deducted from contract price.
4.6.7 The Supplier shall intimate the Owner / Purchaser about carrying out of the
type tests along with detailed testing programme at least 3 weeks in advance
(in case of testing in India) and at least 6 weeks advance (in case of testing
abroad) of the scheduled date of testing during which the Owner / Purchaser
will arrange to depute his representative to be present at the time of carrying
out the tests.

4.7 Sample Batch for Type Testing

4.7.1 The Supplier shall offer material for sample selection for type testing only
after getting Quality Assurance Programme approved by the Owner /
Purchaser. The Supplier shall offer at least three times the quantity of
materials required for conducting all the type tests for sample selection. The
sample for type testing will be manufactured strictly in accordance with the
Quality Assurance Programme approved by the Owner / Purchaser.
4.7.2 Before sample selection for type testing, the Supplier shall be required to
conduct all the acceptance tests successfully in presence of Owner /
Purchaser's representative.
However, those acceptance tests, which are also required to be carried out
afresh as type test, shall not be required to be carried out as acceptance test
for sample selection for type testing.

4.8 Schedule of Testing

4.8.1 The Bidder has to indicate the schedule of following activities in their bids:
a) Submission of drawing for approval.
b) Submission of Quality Assurance Programme for approval.
c) Offering of material for sample selection for type tests.
d) Type testing.

4.9 Additional Tests

4.9.1 The Owner / Purchaser reserves the right of having at his own expenses any
other test(s) of reasonable nature carried out at Supplier's premises, at site,
or in any other place in addition to the aforesaid type, acceptance and routine
tests to satisfy himself that the material complies with the Specifications.
4.9.2 The Owner / Purchaser 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 center. In case of
evidence of non-compliance, it shall be binding on the part of the Supplier to
prove the compliance of the items to the technical specifications by repeat
tests or correction of deficiencies or replacement of defective items, all
without any extra cost to the Owner / Purchaser.

4.10 Guarantee
Section-II PAGE 14
 The Supplier of insulators shall guarantee overall satisfactory performance of
the insulators.

4.11 Test Reports

4.11.1 Copies of type test reports shall be furnished in at least six (6) copies along
with one original. One copy shall be returned duly certified by the Owner
4.11.2 Purchaser only after which the commercial production of the concerned
material shall start.
4.11.3 Copies of acceptance test reports shall be furnished in at least six (6) copies.
One copy shall be returned duly certified by the Owner / Purchaser, only after
which the material shall be dispatched.
4.11.4 Record of routine test reports shall be maintained by the Supplier at his works
for periodic inspection by the Owner / Purchaser’s representative.
4.11.5 Test certificates of test during manufacture shall be maintained by the
Supplier. These shall be produced for verification as and when desired by the
Owner / Purchaser.

4.12 Inspection

4.12.1 The Owner / Purchaser’s representative shall at all times be entitled to have
access to the works and all places of manufacture, where insulator, and its
component parts shall be manufactured and the representatives shall have
full facilities for unrestricted inspection of the Supplier’s and sub-Supplier’s
works, raw materials, manufacture of the material and for conducting
necessary test as detailed herein.
4.12.2 The material for final inspection shall be offered by the Supplier only under
packed condition as detailed in clause No.4.13 of the specification. The
Owner / Purchaser shall select samples at random from the packed lot for
carrying out acceptance tests. The lot should be homogeneous and should
contain insulators manufactured in 3-4 consecutive weeks.
4.12.3 The Supplier shall keep the Owner / Purchaser informed in advance of the
time of starting and the progress of manufacture of material in their various
stages so that arrangements could be made for inspection.
4.12.4 No material shall be dispatched from its point of manufacture before it has
been satisfactorily inspected and tested unless the inspection is waived off
by the Owner / Purchaser in writing. In the latter case also, the material shall
be dispatched only after satisfactory testing for all tests specified herein have
been completed.
4.12.5 The acceptance of any quantity of material shall be no way relieve the
Supplier of his responsibility for meeting all the requirements of the
specification and shall not prevent subsequent rejection if such materials are
later found to be defective.

4.13 Packing and Marking

Section-II PAGE 15
4.13.1 All insulators shall be packed in suitable wooden pallets. For any other
packaging for specific requirement of project/transmission line, OEM shall
have to take approval from Engineering/QA team. The packing shall provide
protection against rodents. The Supplier shall furnish detailed design of the
packaging for approval. For marine transportation, crates shall be palleted.
Further, last 20% quantity or said spare quantity of insulators shall be packed
in suitable PVC / plastic tubes of at least 3 mm thickness or water-resistant
packing material and the packaging shall not break during storage &
transportation even in overhang condition during transportation (this is used
to ensure long storage of about 5 years).
4.13.2 The packing shall be of sufficient strength to withstand rough handling during
transit, storage at site and subsequent handling in the field.
4.13.3 Suitable cushioning, protective padding or dunnage or spacers shall be
provided to prevent damage or deformation during transit and handling.
4.13.4 All packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and to avoid the possibility of goods being lost or
wrongly dispatched on account of faulty packing and faulty or illegible
markings. Each case/crate shall have all the markings stenciled on it in
indelible ink.
4.13.5 The Supplier shall guarantee the adequacy of the packing and shall be
responsible for any loss or damage during transportation, handling, storage
and installation due to improper packing.
4.13.6 To prevent birds from pecking the insulators installed on transmission lines
before charging, removable plastic/ polyethylene/ polypropylene covers for
10% of the insulators of each rating shall be supplied by the manufacturer.
These covers should have provisions/ attachments for easy removal from the
installed insulators and is in addition to the normal packing provided by the
manufacturer.
(# Clause 4.13.6, not applicable for insulator replacement/ AM packages)

4.14 Standards

The insulator strings and its components shall conform to the following
Indian/International Standards which shall mean latest revision, with
amendments/changes adopted and published, unless specifically stated
otherwise in the Specification.

4.14.1 In the event of supply of insulators conforming to standards other than

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

Sl. Indian Standard Title International

No. Standard
1. IS:209-1992 Specification for zinc BS:3436
2. IS:406-1991 Method of Chemical Analysis of Slab Zinc BS:3436

Section-II PAGE 16
 Sl. Indian Standard Title International
No. Standard
3. IS:731-1991 Porcelain insulators for overhead Power lines with a BS:137- (I&II)
nominal voltage greater than 1000 V IEC:60383
4. IS:2071 Methods of High Voltage Testing IEC:60060-1
Part (I) – 1993
Part (II)- 1991
Part (III)- 1991
5. IS:2486 Specification for Insulator fittings for Overhead
Power Lines with a nominal voltage greater than
1000V
Part- I-1993 General Requirements and Tests BS:3288
Part- II-1989 Dimensional Requirements IEC:60120
Part-III-1991 Locking Devices IEC:60372
6. IS:2629-1990 Recommended Practice for Hot, Dip Galvanization ISO-1461 (E)
for iron and steel
7. IS:2633-1992 Testing of Uniformity of Coating of zinc coated
articles
8. IS:6745-1990 Determination of Weight of Zinc Coating on Zinc BS:433-1969
coated iron and steel articles ISO:1460-1992
9. IS:8263-1990 Methods of RI Test of HV insulators IEC:60437
NEMA Publi-
cation No.07/
1964/ CISPR
10. IS:8269-1990 Methods for Switching Impulse test on HV IEC:60506
insulators
11. Thermal Mechanical Performance test and IEC: 60575
mechanical performance test on string insulator
units
12. Salt Fog Pollution Voltage Withstand Test IEC:60507
13. Composite insulators for A.C. Overhead lines with IEC 61109
nominal voltage greater than 1000V – Definitions,
test methods and acceptance criteria
14. Selection and dimensioning of high voltage IEC:60815-3
insulators intended for use in polluted conditions:
Polymer Insulators for AC systems
15. Tests on insulators of Ceramic material or glass or IEC:60383
glass for overhead lines with a nominal voltage
greater than 1000V
16. Composite string insulator units for overhead lines IEC 61466-1
with a nominal voltage above 1000V: Standard
strength classes and end fittings
17. Composite string insulator units for overhead lines IEC 61466-2
with a nominal voltage above 1000V: Dimensional
and electrical characteristics
18 Electrical Insulating materials used under severe IEC 60587
ambient conditions –Test methods for evaluating
resistance to tracking and erosion
19 Polymeric insulators for indoor and outdoor use IEC 62217
with nominal voltage greater than 1000V- General
definitions, tests, methods and acceptance criteria.

Section-II PAGE 17
 Sl. Indian Standard Title International
No. Standard
20 IS 16784:2018 Insulators for Overhead Lines —
Composite Suspension and Tension
Insulators for a.c. Systems with a
Nominal Voltage Greater Than
1 000 V — Definitions, Test Methods and
Acceptance Criteria

The standards mentioned above are available from:

Reference Name and Address

Abbreviation
BS British Standards,
British Standards Institution, 101, Pentonvile Road, N- 19-ND, UK
IEC/CISPR International Electro technical Commission,
Bureau Central de la Commission,
électro Technique international, 1 Rue de verembe,
Geneva, SWITZERLAND
BIS/IS Bureau Of Indian Standards.
Manak Bhavan,
9, Bahadur Shah ZafarMarg, New Delhi - 110001.INDIA
ISO International Organization for Standardization.
Danish Board of Standardization
Danish Standardizing Sraat, Aurehoegvej-12
DK-2900, Heeleprup, DENMARK
NEMA National Electric Manufacture Association,
155, East 44th Street. New York, NY 10017U.S.A.
ASTM American Society for Testing and Materials,
1916 Race St. Philadelphia, PA19103 USA

4.15 Quality Assurance - Special Requirements

4.15.1 Bidder is requested to fill the type test details as required in the attached
annexure - 1 and submit as a part of bidding documents.
4.15.2 Bidder should submit the separate type test detail excel sheet for each type
of insulator string configuration and Hardware fittings and accessories.
4.15.3 To fill all the columns of excel sheet is mandatory.
4.15.4 Successful bidder shall submit the detail type test reports prior to kick of
meeting for Owner / Purchaser engineering team for review. If any test reports
are found invalid, then bidder shall do the type test without any cost & time
implication to Owner / Purchaser.
4.15.5 Bidder shall acknowledge the attached SQP (Annexure-2) as an acceptance
and submit as a part of bidding documents.
4.15.6 In the case of any observation/deviation for SQP, Bidder shall provide their
feedback in attached formats (Annexure -3) with SQP or else the same shall
be deems as acceptable to Bidder in all respect without any deviation.
Section-II PAGE 18
4.15.7 No further deviations will be agreed post bid on SQPs.
4.15.8 QA Coordination Procedure shall be discussed with Successful Bidders and
same shall be followed during the Project Execution.
4.15.9 The QA Coordination procedure will consist of Methodology of Inspection
management for equipment through SIMS (Source Inspection Management
System) Procedure, communication Procedure & various documentation
requirements.
4.15.10 The submission of type test details and acceptance of SQP are mandatory for
bidding documents.
4.15.11 Bidder should submit the combination test charges as optional for Owner /
Purchaser along with bidding documents if asked in inquiry documents.

Section-II PAGE 19
 ANNEXURE-A
1.0 Tests on Complete Strings with Hardware Fittings

1.1 Corona Extinction Voltage Test (Dry)

The sample assembly consisting of complete insulator string when subjected
to power frequency/ DC voltage shall have a corona extinction voltage of not
less than the requirement stipulated in the table below: -

Maximum Height of the Min. Corona extinction

Voltage Level
conductor above ground (m) voltage (kV)
400 kV 8.84 320 (305 for RIV test)
15 (or as per specific
765 kV 510
requirement)
Such that voltage gradient is
±500kV HVDC 550
not less than 22kV/cm
Such that voltage gradient is
±800kV HVDC 880
not less than 22kV/cm

There shall be no evidence of corona on any part of the sample. The

atmospheric condition during testing shall be recorded and the test results
shall be accordingly corrected with suitable correction factor as stipulated in
IEC: 60383.
1.2 RIV Test (Dry)
Under the conditions as specified under (1.1) above, the insulator string along
with complete hardware fittings shall have a radio interference voltage level
below 1000 micro volts at one MHz. The test procedure shall be in accordance
with IS: 8263/ IEC 60437.

1.3 Mechanical Strength Test

1.3.1 Mechanical Strength Test for insulator strings.

The complete insulator string along with its hardware fitting excluding arcing
horn, corona control ring, grading ring and suspension assembly/dead end
assembly shall be subjected to a load equal to 50% of the specified minimum
ultimate tensile strength (UTS) which shall be increased at a steady rate to
67% of the minimum UTS specified. The load shall be held for five minutes and
then removed. After removal of the load, the string components shall not
show any visual deformation and it shall be possible to disassemble them by
hand. Hand tools may be used to, remove cotter pins and loosen the nuts
initially. The string shall then be reassembled and loaded to 50% of UTS and
the load shall be further increased at a steady rate till the specified minimum
UTS and held for one minute. No fracture should occur during this period. The
applied load shall then be increased until the failing load is reached, and the
value recorded.

The complete insulator string along with its hardware fitting excluding arcing
horn, corona control ring, grading ring and suspension assembly/dead end
assembly shall be loaded to reproduce design conditions. The testing program
varies with string and tower types according to the following table.
Section-II PAGE 20
 String Type Total Test Direction** of Duration of Sequence of
Load* (kN) Load Load (Min.) Testing ***
132kV (SINGLE PANTHER)
Double I 94 1 5 1
Suspension 140 1 1 2
F**** 1 - 3
Single I 60 1 5 1
Suspension 90 1 1 2
F**** 1 - 3
Single Tension 60 1 5 1
90 1 1 2
F**** 1 - 3
Double 120 1 5 1
Tension 180 1 1 2
F**** 1 - 3
220 kV (SINGLE ZEBRA)
Single I 60 1 5 1
Suspension 90 1 1 2
F**** 1 - 3
Single I 60 1 5 1
Suspension 90 1 1 2
Pilot F**** 1 - 3
Double I 120 1 5 1
Suspension 180 1 1 2
F**** 1 - 3
Single Tension 80 1 5 1
120 1 1 2
F**** 1 - 3
Double 160 1 5 1
Tension 240 1 1 2
F**** 1 - 3
220 kV (TWIN MOOSE)
Single I 80 1 5 1
Suspension 120 1 1 2
F**** 1 - 3
Single I 80 1 5 1
Suspension 120 1 1 2
Pilot F**** 1 - 3
Single Tension 80 1 5 1
120 1 1 2
F**** 1 - 3
Double 214 1 5 1
Tension 320 1 1 2
F**** 1 - 3
400kV (TWIN MOOSE/ HTLS)
Single V 80 2 5 1
60 1 5 2
90 1 1 3
F**** 1 _ 4

Section-II PAGE 21
 Single I 80 1 5 1
Suspension 120 1 1 2
(120kN) F**** 1 - 3
Single I 107 1 5 1
Suspension 160 1 1 2
(160kN) F**** 1 - 3
Single I 80 1 5 1
Suspension 120 1 1 2
Pilot F**** 1 - 3
(120kN)
Single I 107 1 5 1
Suspension 160 1 1 2
Pilot F**** 1 - 3
(160 kN)
Single Tension 80 1 5 1
(120 kN) 120 1 1 2
F**** 1 - 3
Single Tension 107 1 5 1
(160 kN) 160 1 1 2
F**** 1 - 3
Single Tension 214 1 5 1
(320 kN) 320 1 1 2
F**** 1 - 3
Double 214 1 5 1
Tension 320 1 1 2
(2X160kN) F**** 1 - 3
Double 280 1 5 1
Tension 420 1 1 2
(2X210kN) F**** 1 - 3
400kV (TRIPLE SNOWBIRD)
Double I 161 1 5 1
Suspension 240 1 1 2
F**** 1 - 3
Single I 80 1 5 1
Suspension 120 1 1 2
Pilot F**** 1 - 3
Single Tension 80 1 5 1
120 1 1 2
F**** 1 - 3
Double 281 1 5 1
Tension 420 1 1 2
F**** 1 - 3
400kV (QUAD MOOSE)
Double I 161 1 5 1
Suspension 240 1 1 2
F**** 1 - 3
Single I 80 1 5 1
Suspension 120 1 1 2
Pilot F**** 1 - 3
Single Tension 80 1 5 1
120 1 1 2
F**** 1 - 3
Section-II PAGE 22
 Quad Tension 429 1 5 1
640 1 1 2
F**** 1 - 3
±500kV HVDC (QUAD BERSIMIS)
Single V 155 2 5 1
130 3 5 2
130 4 5 3
210 3 1 4
F**** 3 - 5
Quadruple 429 1 5 1
Tension (160 640 1 1 2
kN) F**** 1 - 3
±500kV HVDC (QUAD LAPWING)
Single V 155 2 5 1
130 3 5 2
130 4 5 3
210 3 1 4
F**** 3 - 5
Quadruple 560 1 5 1
Tension (210 840 1 1 2
kN) F**** 1 - 3
765kV S/C (QUAD BERSIMIS)
Double I 160 1 5 1
240 1 1 2
F**** 1 1 3
Single V 155 2 5 1
130 3 5 2
130 4 5 3
210 3 1 4
F**** 3 - 5
Double V 280 2 5 1
260 3 5 2
260 4 5 3
420 3 1 4
F**** 3 - 5
Single Tension 80 1 5 1
120 1 1 2
F**** 1 - 3
Quadruple 540 1 5 1
Tension 840 1 1 2
F**** 1 - 3
Single I & V 80 1 5 1
Pilot 120 1 1 2
F**** 1 - 3
765kV D/C (HEXA ZEBRA)
Double I 214 1 5 1
Suspension 320 1 1 2
(2X160kN) F**** 1 - 3
Double I 280 1 5 1
Suspension 420 1 1 2

Section-II PAGE 23
 (2X210kN) F**** 1 - 3
Single I 107 1 5 1
Suspension 160 1 1 2
Pilot F**** 1 - 3
(1X160kN)
Single I 140 1 5 1
Suspension 210 1 1 2
Pilot F**** 1 - 3
(1X210kN)
Single Tension 107 1 5 1
(1X160kN) 160 1 1 2
F**** 1 - 3
Single Tension 140 1 5 1
(1X210kN) 210 1 1 2
F**** 1 - 3
Quad Tension 560 1 5 1
(4X210kN) 840 1 1 2
F**** 1 - 3
Quad Tension 856 1 5 1
(4X320kN) 1280 1 1 2
F**** 1 - 3
±800kV HVDC
Single ‘Y’ 340 2 5 1
suspension 250 3 5 2
250 4 5 3
420 3 1 4
F**** 3 - 5
Triple 845 1 5 1
Tension 1260 1 1 2
String F**** 1 - 3
Single I Pilot 108 1 5 1
160 1 1 2
F**** 1 - 3
132kV Metallic Return Strings
Single I 108 1 5 1
160 1 1 2
F**** 1 - 3
Double 242 1 5 1
Tension 420 1 1 2
F**** 1 - 3
Notes:
*  The total test must be established gradually at a steady rate.
**  Direction of load:
1. Following string axis.
2. Following bisector of string angle.
3. Following with respect to vertical, half the string angle, along
the axis of one of the arm of the V-string.
4. Following with respect to vertical, half the string angle +15 deg,
along the axis of one of the arm of the V-string.

Section-II PAGE 24
 ***  The insulator string must be completely unloaded & examined, then
the proper direction of loading established before proceeding to
the next sequence of test.
****  F denotes Failure load.

The insulator string shall be deemed acceptable if, for all tests loads except
failure load, the string components do not show any visual signs of
deformation or fracture, and the same components may be disassembled by
hand, except for removal of cotter pins and initial loosening of the nuts. The
failure load shall be recorded and must be greater than all previous tests
loads.

1.4 Vibration Test

The suspension string shall be tested in suspension mode, and tension string
in tension mode itself in laboratory span of minimum 30 meters. In the case
of suspension string, a load equal to 600 kg shall be applied along the axis of
the suspension string by means of turn buckle. The insulator string along with
hardware fittings and each sub-conductors tensioned at 25% of conductor
UTS shall be secured with clamps. The system shall be suitable to maintain
constant tension on each sub-conductors throughout the duration of the test.
Vibration dampers shall not be used on the test span. All the sub-conductors
shall be vertically vibrated simultaneously at one of the resonance
frequencies of the insulators string (more than 10 Hz) by means of vibration
inducing equipment. The peak to peak displacement in mm of vibration at the
antinode point, nearest to the string, shall be measured and the same shall
not be less than 1000/f1.8 where f is the frequency of vibration in cycles/sec.
The insulator string shall be vibrated for not less than 10 million cycles
without any failure. After the test, the insulators shall be examined for
looseness of pins and cap or any crack. The hardware shall be examined for
looseness, fatigue failure and mechanical strength test. There shall be no
deterioration of properties of hardware components and insulators after the
vibration test. The insulators shall be subjected to the Mechanical
performance test followed by mechanical strength test as per relevant
standards.
1.5 AC Salt-fog pollution withstand test

This test shall be carried out in accordance with IEC:60507. The salinity level
for composite long rod insulators shall be 160kg/m3 NACL.
1.6 DC pollution withstand test
This test shall be carried out as per IEC 61245 with solid layer method. The
D.C. pollution withstand voltage (negative) shall be 500kV for ±500kV HVDC
insulators as applicable at average ESDD of 0.1 mg / sq cm.
For ±800kV HVDC, the D.C. pollution withstand voltage (negative) shall be
800 kV as applicable at average ESDD of 0.1 mg / sq. cm. The test is to be
performed on Single suspension ‘Y’ String and Triple tension string preferably
Section-II PAGE 25
 in the same configuration. However, in case of laboratory limitations to carry
out the test in tension mode for Triple tension strings,
2.0 Composite Longrod Insulator Units
2.1 Brittle Fracture Resistance Test
The test arrangement shall be according to Damage limit proof test with
simultaneous application of 1N-HNO3 acid directly in contact with naked FRP
rod. 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
(specified mechanical load) for 96 hours.

2.2 Recovery of Hydrophobicity Test

(1) The surface of selected samples shall be cleaned with isopropyl alcohol.
Allow the surface to dry and spray with water. Record the HC classification.
Dry the sample surface.
(2) Treat the surface with corona discharges to destroy the hydrophobicity. This
can be done utilizing a high frequency corona tester, Holding the electrode
approximately 3mm from the sample surface, slowly move the electrode over
an area approximately 1” x 1”. Continue treating this area for 2 – 3 minutes,
operating the tester at maximum output.
(3) Immediately after the corona treatment, spray the surface with water and
record the HC classification. The surface should be hydrophilic, with an HC
value of 6 or 7. If not, dry the surface and repeat the corona treatment for a
longer time until an HC of 6 or 7 is obtained. Dry the sample surface.
(4) Allow the sample to recover and repeat the hydrophobicity measurement at
several time intervals. Silicone rubber should recover to HC 1 – HC 2 within
24 to 48 hours, depending on the material and the intensity of the corona
treatment.

2.3 Silicone content test

Minimum content of silicone as guaranteed by supplier shall be verified
through FT-IR spectroscopy & TGA analysis or any other suitable method
mutually agreed between Owner / Purchaser & Supplier in Quality Assurance
Programme. Owner / Purchaser may take rating wise samples from each lot
received at site and send to NABL approved laboratory at supplier cost for
silicone content test.

2.4 High Pressure washing test

The washing of a complete insulator of each E&M rating is to be carried out
at 3800kPa with nozzles of 6mm diameter at distance of 3m from nozzles to
the insulator, The washing shall be carried out for 10minutes. There shall be
no damage to the sheath or metal fitting to housing interface. The verification
shall be 1 minute wet power frequency withstand test at 460kV r.m.s. for
220kV, 680kV r.m.s for 400KV and 830 kV r.m.s. for 765kV Lines and 1 minute
DC withstand test at -500 kV DC for ±500 kV HVDC & -800 kV DC for ±800kV
HVDC insulators.

2.5 Torsion Test

Three complete insulators of each E&M rating shall be subjected to a torsional
load of 55 Nm. The torsional strength test shall be made with test specimen
Section-II PAGE 26
 adequately secured to the testing machine. The torsional load shall be applied
to the test specimen through a torque member so constructed that the test
specimen is not subjected to any cantilever stress. The insulator after torsion
test must pass the Dye Penetration Test as per IEC 61109 / IS 16784.

2.6 Water diffusion test followed by pull-off test

The same test samples should be used for water diffusion and for pull-off
tests. Samples with rubber housing and one shed are to be cut approximately
perpendicular to the axis of the insulator with a diamond-coated circular saw
blade under running cold water. Three samples with one shed, per insulator,
cut from the top, middle and bottom sections are to be used.

The water diffusion test shall be carried out on samples as prepared above as
per Clause no. 9.4.2 of IEC 62217, except that the current during the whole
test shall not exceed 0.1mA (r.m.s).

The Pull-off test shall be performed at 4 locations per shed (separated radially
by 90°), for each of the 3 test samples taken from the insulator. A sample for
the pull-off test shall be prepared from the shed by first making two cuts
through the rubber shed and sheath along the axis of the insulator using a
knife. The separation between the two parallel cuts should be 8±3 mm at the
surface of the core. Thereafter two parallel cuts, perpendicular to the
insulator axis and separated 15±5 mm apart, should be made above and below
the shed. In this way a rectangular sample surface is created at the interface
between rubber and core materials. The ultimate force required to pull off the
rubber sample from the core should be recorded using a tensile machine,
applying a fixed rate of elongation of 50 mm/min. The force should be applied
perpendicular to the insulator axis by clamping one terminal of the equipment
to the shed of the housing sample while keeping the rest of the insulator part
fixed. After the separation, the actual rectangular cross-section area of the
sample interface between the housing and the rod should be measured using
a sliding caliper. The ultimate breaking stress should be calculated as
maximum applied force divided by material cross section area at housing-core
interface. The test is passed if the average stress is more than 1.5 N/mm2 (for
each sample). The fracture after each test shall be photographed with a note
if the fracture was adhesive (in the interface) or cohesive (inside the rubber
housing).

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.

Section-II PAGE 27
 The details regarding test will be as discussed and mutually agreed to by the
Supplier and Owner / Purchaser in Quality Assurance Programme.

3.3 Tests on Castings

The chemical analysis, mechanical and metallographic tests and magnetic,
particle inspection for castings will be as per the internationally recognized
procedures for these tests. The samplings will be based on heat number and
heat treatment batch. The details regarding test will be as discussed and
mutually agreed to by the Supplier and Owner / Purchaser in Quality
Assurance Programme.

Section-II PAGE 28
 ANNEXURE-B

A) Standard Technical Particulars of Composite Long Rod Insulator unit:

1. For Transmission Line up to 400 kV

132 kV 132 kV 220 kV AC 220 kV AC

400kV
Sl. AC AC (Single ZEBRA) (Twin MOOSE)
Description Unit
No.
70 kN 90 kN 70 kN 120 kN 120 kN 160 kN 90 kN 120 kN 160 kN 210 kN
Size and Designation
16 mm 16 mm 16 mm 16mm
1. of Ball & Socket mm 20 mm 20 mm 20 mm 20 mm 20 mm 24 mm
(Alt-B) (Alt-B) (Alt-B) (Alt-B)
assembly
2. Core diameter* mm 20 20 20 20 20 24 20 20 24 24
3. Nominal length mm 1305 1450 2030 2175 2030 2210 3335 3335 3910 3910
Minimum Creepage
4. mm 4495 4495 7595 7595 7595 7595 13020 13020 13020 13020
distance
No. of grading rings
5. Nos. 1 1 1 1 1 1 2 2 2 2
(min.)
Nominal Outer Diameter
6.
of grading ring
a) Covered ring *** mm NA NA NA NA NA NA 300 300 300 300
b) Other rings (Open type) mm 200 200 200 200 200 200 300 300 300 300
Depth of grading ring 105-
7. mm 105-125 105-125 105-125 105-125 105-125 140-150 105-125 140-150 140-150
(open type) 125

Section-II PAGE 29
 2. For Transmission Line above 400 kV

Metallic return for

Sl. 765kV ± 500kV HVDC ± 800kV HVDC
Description Unit ± 800kV HVDC
No.
120 kN 160 kN 210 kN 320 kN 160 kN 210 kN 160 kN 420 kN 160 kN 210 kN
Size and Designation of Ball & 20
1. mm 20 mm 20 mm 24mm 24 mm 20 mm 24mm 28mm 20 mm 24mm
Socket assembly mm
2. Core diameter* mm 20 24 24 32** 24 24 24 40** 24 24
3485/
3. Nominal length mm 2900 2975 2975 2975 3485 4560 4560 2550 2550
3230
4. Minimum Creepage distance mm 2x12400 2x12400 2x12400 2x12400 2x13750 2x13750 2x16800 2x16800 8000 8000

5. No. of grading rings (min.) Nos. 2 2 2 2 2 2 2 2 2 2

Nominal Outer Diameter of
6.
grading ring
As per Manufacturers’
a) Covered ring *** mm 300 300 300 300 300 300
specification
As per Manufacturers’
b) Other rings (Open type) mm 370 370 370 370 370 370
specification
Depth of grading ring (open 125- 125- 140-
7. mm As per Manufacturers’ specification
type) (may vary to meet EFM) 155 155 155

Note:
* The core diameter of composite insulators mentioned at Row No.2 is for indicative purpose. The bidder shall offer composite long rod
insulators of suitable core diameter not less than the value specified above, to meet specified E&M and torsion strength requirements.

** For offered core diameter less than indicated in table above, the bidder shall submit documentary evidence of past supplies &
satisfactory operation of the same for minimum period of three years. However, the overall string length shall be within the limits
specified in the drawing.

*** Covered ring shall be required for Single I/ Double I suspension insulator strings only.

Section-II PAGE 30
B) Standard Technical Particulars of Insulator Strings

1. For 132 kV Transmission Line

Standard Technical Particular Value

Sl. Single ‘I’ Double ‘I’ Single Double
No. Description Unit suspension suspension Tension Tension
string string string string
No. of Insulator
1.0 Units Nos. 1x1 2x1 1x1 2x1

pf withstand voltage kV
2.0 275
under wet condition (rms)
Impulse withstand
3.0
voltage (dry)
a) Positive kVp 650
b) Negative kVp 650
4.0 Dry Arcing distance mm 1200
5.0 Mechanical strength kN 70 2 x 70 90 2 x 90

Section-II PAGE 31
 2. For 220 kV Transmission Line

a) For 220 kV Transmission Line with single ZEBRA/HTLS conductor

Standard Technical Particular Value

Sl. Single ‘I’ Single ‘I’ Double ‘I’ Single Double
No. Description Unit suspension suspension suspension Tension Tension
string Pilot string string string string
No. of Insulator
1.0 Units Nos. 1x1 1x1 2x1 1x1 2x1

pf withstand
kV 460
2.0 voltage under wet
condition (rms)

Impulse withstand
3.0 voltage (dry)

a) Positive kVp 1050

b) Negative kVp 1050

Dry Arcing
4.0 distance mm 1800

Mechanical
5.0 strength kN 90 90 2 X 90 120 2 x 120

b) For 220 kV Transmission Line with twin MOOSE conductor

Standard Technical Particular value

Sl. Single ‘I’
Description Unit Single ‘I’ Single Double
No. Suspension
Suspension Tension Tension
Pilot
No. of Insulator
1.0 Nos. 1x1 1x1 1x1 2x1
Units
pf withstand
voltage kV
2.0 460
under wet (rms)
condition
Impulse withstand
3.0
voltage (dry)
a) Positive (Peak) kVp 1050
b) Negative (Peak) kVp 1050
4.0 Dry Arcing distance mm 1800
Mechanical
5.0 kN 120 120 120 2 x 160
strength

Section-II PAGE 32
 3. For 400 kV Transmission Line

a) 400 kV Transmission Line with twin MOOSE/ HTLS Conductor

Standard Technical Particular Value

Sl. Single ‘I’
Single V Single ‘I’ Single Double
No. Description Unit Suspension Tension Tension
Suspension Suspension
Pilot
1.0 No. of Insulator Units Nos. 2x1 1x1 1x1 1x1 2x1
pf withstand voltage kV
2.0 680
under wet condition (rms)
3.0 Switching withstand voltage (dry)
a) Positive (Peak) kVp 1050
b) Negative (Peak) kVp 1050
4.0 Impulse withstand voltage (dry)
a) Positive (Peak) kVp 1550
b) Negative (Peak) kVp 1550
5.0 Dry Arcing distance mm 3050
120/ 120/ 120/ 2 x160/
6.0 Mechanical strength kN 90
160 160 160 2 x 210

b) 400 kV Transmission Line with twin ACSR LAPWING Conductor

Standard Technical Particular Value

Sl. Single ‘I’
Single ‘I’ Single Double
No. Description Unit Suspension
Suspension Tension Tension
Pilot
1.0 No. of Insulator Units Nos. 1x1 1x1 1x1 2x1
pf withstand voltage kV
2.0 680
under wet condition (rms
3.0 Switching withstand voltage (dry)
a) Positive (Peak) kVp 1050
b) Negative (Peak) kVp 1050
4.0 Impulse withstand voltage (dry)
a) Positive (Peak) kVp 1550
b) Negative (Peak) kVp 1550
5.0 Dry Arcing distance mm 3050
6.0 Mechanical strength kN 160 160 160 2 x 210

Section-II PAGE 33
 c) 400 kV Transmission Line with triple ACSR SNOWBIRD Conductor

Standard Technical Particular Value

Sl. Single ‘I’
Double ‘I’ Single Double
No. Description Unit Suspension
Suspension Tension Tension
Pilot
1.0 No. of Insulator Units Nos. 2x1 1x1 1x1 2x1
pf withstand voltage kV
2.0 680
under wet condition (rms))
3.0 sSwitching withstand voltage (dry)
a) Positive (Peak) kVp 1050
b) Negative (Peak) kVp 1050
4.0 Impulse withstand voltage (dry)
a) Positive (Peak) kVp 1550
b) Negative (Peak) kVp 1550
5.0 Dry Arcing distance mm 3050
6.0 Mechanical strength kN 2 x 120 120 120 2 x 210

d) 400 kV Transmission Line with quad MOOSE Conductor

Standard Technical Particular Value

Sl. Single ‘I’

Double ‘I’ Single Quadruple
Description Unit Suspension
No. Suspension Tension Tension
Pilot
4x
1.0 No. of Insulator Units Nos. 2x1 1x1 1x1
1
pf withstand voltage kV
2.0 680
under wet condition (rms)
3.0 Switching withstand voltage (dry)
a) Positive (Peak) kVp 1050
b) Negative (Peak) kVp 1050
4.0 Impulse withstand voltage (dry)
a) Positive (Peak) kVp 1550
b) Negative (Peak) kVp 1550
5.0 Dry Arcing distance mm 3050
6.0 Mechanical strength kN 2 x 120 120 120 4 x 160

Section-II PAGE 34
 4. For 765 kV Transmission Line

a) 765 kV Single Circuit Transmission Line

Standard Technical Particular Value

Suspension

Suspension

Suspension

Suspension

Suspension

Quadruple
Double ‘ V’
Single ‘ V’

Double ‘ I’

Single ‘ V’

Single ‘ I’

Tension

Tension
Single
Pilot

Pilot
Sl.
No. Description Unit

2x2x
1.0 No. of Insulator Units Nos. 2x2 2x2 2x2 1x2 1x2 4x2
2
pf withstand voltage kV
2.0 830
under wet condition (rms)
3.0 Switching withstand voltage (dry)
a) Positives (Peak) kVp 1550
b) Negative (Peak) kVp 1550
4.0 Impulse withstand voltage (dry)
a) Positive (Peak) kVp 2400
b) Negative (Peak) kVp 2400
7.0 Dry Arcing distance mm 2 x 2550
210 2 x 210 120
4x
Mechanical strength kN along 240 along along 120 120
8.0 210
each each each

b) 765 kV Double Circuit Transmission Line

Standard Technical Particular Value

Sl. Single ‘I’
Description Unit Double ‘I’ Single Quadruple
No. Suspensio
Suspension Tension Tension
n Pilot
1.0 No. of Insulator Units Nos. 2x2 1x2 1x2 4x2
pf withstand voltage under kV
2.0 830
wet condition (rms)
3.0 Switching withstand voltage (dry)
a) Positive (Peak) kVp 1550
b) Negative (Peak) kVp 1550
4.0 Impulse withstand voltage (dry)
a) Positive (Peak) kVp 2400
b) Negative (Peak) kVp 2400
5.0 Dry Arcing distance mm 2 x 2550
2 x 160/ 160/ 160/ 4 x 210/
6.0 Mechanical strength kN
2 x 210 1 x 210 1 x 210 4 x 320

Section-II PAGE 35
±500kV HVDC Transmission Line

a) ±500kV HVDC Line with quad ACSR BERSIMIS Conductor

Sl.
No Description Unit Standard Technical Particular Value
Single ‘V’ Suspension Quad Tension
String string
Nos
1.0 No. of Insulator Units 2x2 4x2
.
DC withstand voltage
2.0 kV 550 (negative)
under wet condition
3.0 Impulse withstand voltage (dry)
a) Positive (Peak) kVp 1800
b) Negative (Peak) kVp 1800
4.0 Switching Withstand voltage (dry)
a) Positive (Peak) kVp 1000
b) Negative (Peak) kVp 1000
5.0 Dry Arcing distance mm 2 x 3050
6.0 Mechanical strength kN 2 x 210 4 x 160

b) ±500kV HVDC Line with quad ACSR LAPWING Conductor

Sl.
No Description Unit Standard Technical Particular Value
Single ‘V’ Suspension Quad Tension
String string
Nos
1.0 No. of Insulator Units 2x2 4x2
.
DC withstand voltage 550
2.0 kV
under wet condition (negative)
3.0 Impulse withstand voltage (dry)
a) Positive (Peak) kVp 1800
b) Negative (Peak) kVp 1800
4.0 Switching Withstand voltage (dry)
a) Positive (Peak) kVp 1000
b) Negative (Peak) kVp 1000
5.0 Dry Arcing distance mm 2 x 3050
6.0 Mechanical strength kN 2 x 210 4 x 210

Section-II PAGE 36
 5. ±800kV HVDC Transmission Line

132kV Metallic
± 800kV HVDC Strings
Return Strings
Single
Sl. Single I
Description Unit Single ‘Y’ Triple ‘I’ Double
No. Suspensio
Suspension Tension Suspe Tension
n Pilot
string string nsion string
string
string
2x2
1.0 No. of Insulator Units Nos. (V-portion) & 3x3 1x3 1x1 2x1
1x2 (II-portion)
420
Mechanical strength of (along one limb
complete insulator
2.0 kN of V- portion 3 x 420 1 x 160 160 2 x 210
string along with
hardware fittings and along II
portion)
DC withstand voltage
for DC/ Power
frequency withstand
voltage for metallic
800
3.0 return of string with kV 460
arcing horns, corona (negative)
control rings/ grading
rings under wet
condition
4.0 Impulse withstand voltage (dry)
a) Positive (Peak) kVp 2250 1050
b) Negative (Peak) kVp 2250 1050
5.0 Switching Withstand voltage (dry)
a) Positive (Peak) kVp 1850 NA
b) Negative (Peak) kVp 1850 NA
Minimum corona
extinction
6.0 voltage kV 880 NA
under dry condition
Radio interference
voltage at one MHZ
when the string Micro
7.0 subjected to conductor <1000 NA
volt
surface gradient of
22kV/cm (+DC)
DC pollution withstand
8.0 kV 800 (negative) NA
voltage test

Section-II PAGE 37
 ANNEXURE-C

High voltage test on Composite insulators for Evaluation of Defects in

FRP rods and Interfaces of composite insulators during acceptance test.
1. The sample size is as per IEC 61109.
2. The test should be performed in an indoor lab.
3. Procedure for High Voltage Test.
i. Copper/Brass Fixture without Sharp edges should be used while attaching
the live/ earth wire to the Insulator Housing.
ii. Apply 250kV/Meter along the length of insulator.
iii. Capture the IR image with thermal camera before starting the test and once
started the test.
iv. Apply the High Voltage for 15 Min and Monitor the Thermal Profile along
the Length of the insulator from start of the test to end of the test.
v. The thermal camera with Min. 320x240 pixel with distance not more than
10 meters from the point of measurement.
vi. Take the image of the Insulator before and after completion of 15 Minutes
High voltage test.
vii. Analyze the images taken in Step iii and Step Vi for Temperature Difference
along the length of the insulator before and after the application of High
Voltage.
4. Evaluation of testing.
i. The insulator should withstand 250kV/Meter for 15 minutes without
tripping.

The temperature Difference between step iii and Step vi at any point along the length
of insulator should not exceed 1° centigrade.

Section-II PAGE 38