TECHNICAL SPECIFICATION FOR ACSR CONDUCTORS 1.

00 This section of the specification covers manufacture, testing at manufacturers works and supply of ACSR conductors indicated in the schedule of requirement. 2.0 The basic technical and other. Particulars of the equipment and the various components are specified in the following sections and tender schedule. 3.0 ACSR CONDUCTOR: The conductor shall comply in all respects with the latest edition of ISS-398 (Part-II) 1976 with its latest amendment. a) The aluminium strands shall be hard drawn from electrolytic aluminium rods of EC grade having purity not less than 99.5% and a copper content not exceeding 0.04%. They shall have the same properties and characteristics as prescribed in IEC:889-1987. The Aluminium wires used in the manufacture of the conductor shall be of the highest electrical quality and free from scratches, die marks and other surface imperfections. b) They shall be reinforced with a central core of galvanized steel wire drawn from high carbon steel wire rods produced by either the acid or the basic open-hearth process, or the electric furnace process, or the basic oxygen process and shall conform to the following requirements as to the chemical composition IS 398 (Pt. II) 1996: Element Carbon Manganese Phosphorous Sulphur Silicon % Composition 0.50 to 0.85 0.50 to 1.10 Not more than 0.035 Not more than 0.045 0.10 to 0.35 as prescribed in

The steel wire shall not be subject to any heat treatment after being galvanized. The zinc coating of steel wires shall be smooth and of uniform thickness. There shall be no bare spots owing to adherence of scales or other causes. 4.0 JOINTS IN WIRES: Joints in the individual Aluminium, wires are permitted but no two such joints shall be within 15 meters apart in the complete stranded conductors. There should be no joints in the galvanized steel wire

except those made in the base rod or wire before final drawing forming the core of steel reinforced Aluminium. 5.0 The resistance of the individual Aluminium wire shall be determined separately before stranding by means of standard tests on sample wires. The test samples shall be of sufficient length to give an accuracy of atleast one part in a thousand. 6.0 The ACSR conductor size and standard lengths shall be as per IS 398 (Part-II) 1976 with its latest amendments and is indicated in the schedule of material specification. 7.0 STANDARD SIZES OF WIRES : The Aluminium wire and galvanized steel wire for the standard construction of conductors have diameter specified as shown below,as per Tables 1&2 Section of IS 398 (Part-II). TABLE-1: Aluminium Wire used in the construction Conductors Galvanized Steel Reinforced. Cross Sectional area of nominal dia wire 5.269 mm2 8.814 mm2 Mass Resistance at 200 C max/Km. of Aluminium

Diameter in mm Nomi Minim Maxi nal um mum

Breaking load Before After stranding stranding

2.59 3.35

2.56 3.32

2.62 3.38

14.24 Kg/Km 23.82 Kg/Km.

5.527 3.286

0.89 KN 1.43 KN

0.85 KN 1.36 KN

TABLE-2:

Steel wire used in the construction of Aluminium conductors galvanized steel reinforced. Cross Sectional area of nominal dia wire 5.269 mm2 8.814 mm2 Mass Resistance at 200 C max/Km. Breaking load Before After stranding stranding

Diameter in mm Nomi Minim Maxi nal um mum

2.59 3.35

2.54 3.28

2.64 3.42

41.09 Kgs/Km 68.75 Kgs/Km

6.92 KN 11.58 KN

6.57 KN 11.0 KN

8.0

LAY RATIO: Ratio of the axial length of a complete turn of the helix formed by the individual wire in a standard conductor to the external diameter of the helix. The lay ratio shall be as shown below. TABLE-3: Lay Ratios Reinforced. of Aluminium Conductor, Galvanized Steel

Number of Wires Aluminium 6 Steel 1

Ratio of Aluminium wire dia to Steel wire dia 1.00

Lay ratio for steel core Minimum Maximum -

Lay ratio for Alumini-um outside layer Minimum Maximum 10 14

Note: For the purpose of calculation, the mean lay ratio shall be taken as the arithmetic mean of the relevant minimum and maximum values given in this table. 9.0 TESTS & INSPECTION OF RAW MATERIAL AT SUPPLIERS WORKS: Within two weeks of receipt of each consignment of raw materials viz., steel, Electrolytic Aluminium rods, etc., at the manufacturers works, the contractor shall furnish to the purchaser in triplicate the raw material manufacturers certificates. 10.0 The test certificates shall cover all tests on required number of samples as stipulated in clause 12.1 of ISS. (Part-II) 1976 with latest amendments if any. 10.1 The manufacturer shall not commence manufacturing the conductor ordered prior to purchasers approval of the test certificate for raw materials. 10.2 Similarly test certificates in triplicate for tests on the finished ACSR conductor shall be submitted. The suppliers shall furnish along with RCs, the number of pieces of conductor in each reel and the length of individual pieces. 10.3 All tests as detailed in clause 12 of ISS-398 (Part-II) 1976 with its latest amendments shall be carried out on conductors covered by this specification and shall be submitted by the contractor for purchasers approval within four weeks of the acceptance of the letter of intent of the purchaser. No change in the schedule of tests, unless desired by the purchaser shall be subsequently

made by the contractor or his sub-contractors of the manufacturers without prior consent of the purchaser. 10.4 The purchaser may at any time call for any tests that are laid down in the specification as optional tests. The contractor shall arrange to carry out such tests expeditiously and it his own cost. The certificates for such optional tests shall be submitted to the purchaser for approval. 10.5 The contractor shall notify the purchaser, at least fifteen days in advance, the time of manufacture so that inspection of materials during manufacture and or witnessing of the tests can be arranged. If the purchaser waives inspection he will advice the contractor accordingly. Inspection shall also include method of packing and stacking of finished materials in the works. 11.0 Packing: Drawing of the reels/drums shall be enclosed with tenders. The ACSR conductor reels shall be of dimensions approved by the purchaser and made of seasoned wood sufficient strong and in sound condition to ensure that the reels shall reach the site intact with lagging end free from damage due to transport hazards by rail and over land. These reels shall conform to IS 1778/1961 with latest amendments if any. a) The standard length of the ACSR conductor shall be as per schedule of materials specification. Longer lengths are acceptable. However, short lengths not less than one Km. each are acceptable to the minimum extent of 5% of the quantity ordered. b) The contractor shall submit in duplicate detailed packing specification for the conductors for the purchasers approval at least fifteen days prior to commencement of dispatch. Finally approved specification shall be furnished along with the dispatch documents. REEL OR DRUM SHALL BEAR THE FOLLOWING INFORMATION a) Reel or drum number b) Size and description of contents c) Length of each piece of conductor (on reels) d) No. of pieces in each package/reel e) Gross weight

f) Net weight g) Purchase order No. & Date h) Place and designation of consignee The above details shall be legibly and indelibly marked.

SCHEDULE OF MATERIAL SPECIFICATION FOR WEASEL AND RABBIT ACSR CONDUCTORS: Code Name of Conductor Nominal Aluminium area Dia of wires in mm Appx. Calculat ed breakin g load in KN 11.12 18.25 Appx. Over all dia (mm) 7.77 10.05 Standard length in Mtrs. App. Mass Kg./ Km. 127.7 213.6

Aluminium Weasel Rabbit 30 Sq.mm. 50 Sq.mm. 6/2.59 6/3.35

Steel 1/2.59 1/3.35

2000 1400

12.0 2.1 2.1.1

Quantity tolerance 5% tolerance shall be allowed on the ordered quantity on each category of ACSR separately. Details of conductor : The contractor shall conform to IS : 398 (part V) 1982 except where other wise specified herein.

2.7.6 The details of the conductor are tabulated below : Drake 26/4.442 mm Al + 7.3.454 mm steel 402.9 mm sq. 468.4 mm sq. 28.13 mm 1622 kg/km Lynx .. 30/7.29 mm + 7/7.29 mm steel 183.4 mm sq. 19.53 844 kg/km Coyote 26/2.54 mm Al + 7/1.91 mm steel 131.7 mm sq. 15.89 521 Rabbit 6/3.35 mm All + 1/3.3.5 mm steel 52.9 10.0 214

a) Stranding & wire diameter b) Sectional area of Aluminum c) Total sectional area d) Overall diameter e) Approximate

weight f) Calculated DC resistance at 20 deg. C g) Minimum UTS

0.0715 ohm/km 141.75 KN

0.1610 ohm/km -

0.2246 ohm/km -

0.5524 ohm/km -

2.8 3.1.2

WORKMANSHIP The finished conductor shall be smooth, compact from uniform and free from all imperfections including spills, die marks, scratches, abrasions, scuff marks, kinks (protrusion of wires), dents, press marks, cut marks, wire cross over, over riding, looseness (wire being dislocated by finger/hand pressure and/or unusual bangle noise on tapping), material inclusions, while rust powder formation or black spots (on account of erection with trapped rain water etc.,) dirt, grit etc., All the aluminum and steel strands shall be smooth, uniform and free from all innerfections such as spills and splits, die marks, scratches abrasions and kinks after drawing. The steel strands shall be hot dip galvanized and shall have a minimum zinc coating of 260 gm/sq. mm after stranding of the uncoated wire surface. The zinc coating shall be smooth, continuous and of uniform thickness, free from imperfection and shall with stand minimum three dips after stranding in standard prerce test. The finished stands and the individual wire shall be of uniform quality and have the same property and the characteristics as prescribed in ASTM designation : B498-74 and relevant IS. The steel strands shall be preformed and post formed in order to prevent the spreading of the strands in the event of cutting of composite core wire. Care shall be taken to avoid damage to galvanization during performing and post forming operation. Joints in wires Aluminum wires No joints shall be permitted in the individual wire in the outermost layer of a finished conductor. However joints in the 12 wire and 18 wire inner layers of the conductor shall be allowed but these joints shall be made by cold pressure but twelding shall and be such that no such joints are within 15 Mtr. of each other in the complete stranded conductor. Steel wire There shall be no joints of any kind in the finished wire entering into the manufacture of the strand. There shall also be no strand splices in any length of the completed stranded steel core of the conductor. Tolerance

3.1.3

3.1.4

3.1.5

3.2 3.2.2

3.2.3

3.3

The manufacturing tolerance tot eh extent of the following limits only shall be permitted in the diameter of individual aluminum and steel strands and lay-ratio of the conductor : 3 Diameter of Aluminum and steel strands : Standard Maximum Aluminum 3.53 mm 3.55 mm Steel 3.53 mm 3.50 mm Lay ratio of conductor : Maximum Steel Aluminum 7 wire layer 12 wire layer 18 wire layer 26 wire layer 18 14 13 12 12 11 10 Minimum 3,51 mm 3.46 mm Minimum 16

3.4 3.4.2

Materials Aluminum The aluminum strands shall be hard drawn from electrolytic aluminum rods having purity not less than 99.5% and a copper content not exceeding 0.01% Steel The steel wire strands shall be drawn from high carbon steel wire rods and shall conform to the following chemical composition : Element Carbon Manganese Phosphorous : Sulphur Silicon : : : : : % composition 0.50 to 0.85 0.50 to 1.10 not more than 0.035 not more than 0.045 0.10 to 0.35

3.4.3

3.4.4

Zinc : The zinc used for galvanizing shall be electrolytic high grades zinc of 99.95% purity. It shall conform to and satisfy all the requirements of IS 209 -1979. Standard length : The conductor shall be supplied in standard length of 1500 1800 meters as required. No joint shall be allowed within a single span of stringing. Tests : The following type acceptance & routine tests and tests during manufacturing shall be carried out On the conductor. Type tests The following type tests shall be conducted on samples of connection. The testing charges for the type test shall be charged separately in the prescribed schedule of the Bid.

3.5 3.5.2

3.6 3.6.2 3.6.3

UTS test on stranded Conductor b)DC resistance test on standard conductor 3.6.4 Acceptance Tests a) Visual check, for joints ) scratches etc., and length of conductor b) Dimension checks on steel and Aluminum strands c) Check for lay ratios of various layers ) ) ) -do) ) ) ) As per Annexure - A The no of sample shall be mutually agreed between contractor and owner As per Annexure A.

d) Galvanizing test on steel ) strands e) Torsion and Elongation test on steel strands ) )

f) Breaking load test on steel and aluminum g) Wrap test on steel aluminum strands h) DC resistance test aluminum strands i) UTS test on welded joints ) of aluminum strands )

) ) ) ) ) ) As per Annexure A. IS : 398 (part V) 1982 clause 12.5.2, 12.7 & 12.8

NOTE : All the above tests except test mentioned at (i) shall be carried out on Aluminum and steel strands after stranding only. 3.6.5 Routine Tests : a) Check to ensure that the joints are as per specification. b) Check that there are no cuts, fins etc., on the strands. c) All acceptance test as mentioned in clause 2.7.3 above to be carried on each coil. 2.7.5 Tests during manufacture

a) Chemical analysis of zinc ) used for galvanizing ) b) Chemical analysis of aluminum used for making ) Aluminum strands. ) c) Chemical analysis of steel & used for making steel strands ) i. ) As per Annexure A. )

Sample batch for type testing

The contractor shall offer material fro selection of sample For type testing. Only after getting quality assurance plans from owners quality assurance dept The samples shall be manufactured strictly in accordance with the quality assurance plan approved by owner. TECHNICAL DATA SHEET FOR ACSR CONDUCTOR Name of the Supplier 1 Code Word Makers Name, Address & Country a) Aluminium rods 2 b) Stele wire/rods c) Complete Conductor Stranding and Wire Diameter (mm) 3 a) Aluminium b) Steel 4 Nominal Aluminium area in Sq.mm. Sectional Area of Aluminium Strands 5 in Sq.m.m. Total Sectional area in Sq.mm. 6 Cross sectional area of nominal diameter wire in Sq.mm. 7 a) Aluminium wire b) Steel Wire Overall diameter of conductor in 8 mm. 9 Breaking load of conductor in Kg. Minimum breaking load in Kg. for 10 a) Aluminium wire b) Steel Wire Zinc coating of steel wire a) Uniformity of coating No. and duration of dips (Process test with 11 stood I min. X Nos.) b) Minimum weight of coating (grm./Sq.mm.) 12 Mass in Kg. per Km. a) Aluminium wire b) Steel Wire

13

14 15

16

17

18 19 20 21 22 23 24 25 26 27

c) Conductor Resistance in Ohms per Km. at 20 Deg.C. a) Continuous maximum current rating of conductor (Amps) in still air or 45 Deg.C ambient temperature. b) Temperature rise for the above current Deg. C. Purity of Aluminium Rods Maximum working tension for complete conductor Kg. Modulus of Elasticity (Kg/mm2) a) Aluminium b) Steel c) Conductor Co-efficient of linear expansion per degree a) Aluminium b) Steel c) Conductor Standard length of each piece in Km. Tolerance, if any on standard length No. of standard lengths in one reel Approximate dimensions of the reel in Cms. Mass of the conductor in one reel in Kg. Gross mass of the reel including mass of the conductor. Mass of the reel in Kg. Standard according to which the conductor will be manufactured and tested. Date of commencement of production of conductor. Other Particulars

Signature of Vendor with Seal, Name and Address