Chapter 04 – GTR-HTLS Conductor 1 of 22

Chapter-04
GTR-HTLS CONDUCTOR

Description of High Temperature Low Sag Conductor (HTLS) and its Technical
Requirements

The HTLS Conductor shall be capable of providing the Ampacity of 1200 A for BEAR equivalent
HTLS conductor not exceeding the maximum permissible operating temperature for continuous
operation of the offered HTLS Conductor and without exceeding the level of maximum permissible
sag indicated at normal condition.
The physical and operating performance requirements of the transmission line with HTLS
conductor are mentioned below and the offered Conductor should be type tested.

1. Current Carrying Capacity /Ampacity Requirements

The conductor shall be capable of providing the Ampacity of 1200 A for BEAR equivalent HTLS
conductor at 50 Hz, alternating current under the ambient conditions, maximum safe operational
temperature (e.g.: 180-degree C) & maximum conductor sag specified below while satisfying
other specified technical requirements/ parameters:
i. Elevation above sea level = ranging from 80m to 100m
ii. Ambient surrounding temperature = 40 degree C
iii. Solar Absorption coefficient =0.8
iv. Solar Radiation = 1045 watt/sq.mm
v. Emissivity Constant = 0.45

Wind velocity considering angle between wind & axis of conductor as 90 degrees = 0.56m/sec
Effective angle of incidence of sun’s rays= 90 deg.

The calculations for Ampacity shall be based on IEEE Standard 738-2006 in SI units. Ratio of AC
resistance & DC resistance for HTLS conductor shall be calculated on the basis of the formulae
indicated as follows:-

Rac = Rdc X (1+ 0.00519 X (mr)n X 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 mr> 2.8 < 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+ 0.0094Xmr3
k2 = 0 for composite core type HTLS conductor
Where,
D= conductor outer diameter in meters
d = conductor inner diameter in meters
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Rdc = dc resistance of conductor at given temperature, ohms/ km

Rac=ac resistance of conductor at given temperature, ohms/ km

The calculations for the Ampacity based on the above for the proposed HTLS conductor shall be
used for comparison of Ampacity of HTLS conductors.
The design of conductor shall be suitable for operation at a steady state conductor temperature
experienced for a sub conductor AC current flow of 1200A under the normal 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.

2. Technical Particulars of HTLS Conductor

Direction of lay of outer layer should be right hand. The bidder shall guarantee the DC resistance
of HTLS conductor at 20 deg. C and AC resistance at the calculated temperature corresponding
to 50Hz alternating current flow of 1200 Amperes for BEAR equivalent HTLS conductor at
specified ambient conditions. The bidder shall also furnish along with its bid the resistance
calculation for each offered HTLS conductor at specified ambient conditions for the following:

a) AC resistance calculation at the temperature corresponding to 50Hz single Ampacity of alternating

current (i.e. 1200 Amperes for BEAR equivalent HTLS conductor).
b) AC resistance calculation at the temperature corresponding to 50Hz maximum continuous
operating temperature.
c) AC resistance calculation at the temperature corresponding to 50Hz emergency operating
temperature.
The bidders have to furnish the knee point temperature (Transition) with calculation of proposed
HTLS conductor along with bid.
Similarly, the bidders have to furnish the Ampacity calculation and Sag Tension chart for 10 0 C
interval of proposed HTLS conductor along with bid.
The HTLS conductors should have Alternating current flow capacity of 1200 Amperes for BEAR
equivalent HTLS conductor at specified ambient conditions for continuous operation.
The conductivity at 20 Deg. C (corresponding to % IACS) of aluminum or aluminum alloy used in
the offered HTLS conductor should not be less than the % IACS Conductivity of Aluminum used
in Equivalent ACSR type conductor. (IACS: International Annealed Copper Standard).

3. Sag-Tension Requirements

The HTLS conductor shall meet the following sag tension requirements for all Spans of the
existing Transmission Line:

i. Sag at maximum continuous operating temperature of offered HTLS conductor must be less than
sag of existing ACSR BEAR Conductor at 75 Deg. Cel for corresponding ruling span and tension
limits as provided in section 4.

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Detail Sag & tension calculation shall be provided for the ruling span of 628 m for BEAR
equivalent HTLS conductor.

During Sag Tension Analysis followings points shall be strictly followed:

i. Each conductor must not violate existing sag and existing tension on tower at any operating
temperature condition of individual conductors.
ii. While doing so, the factor of safety for individual conductors must be well maintained under all
operating condition.

4. BEAR Equivalent HTLS conductor

a) Initial Design Conditions:

The sag tension design calculation for the ACSR BEAR sections shall be done in accordance to
the following design conditions and limitations as per previous as built drawings and old
documents.

Table: Temperature and Weather Data

S.N. Description Unit Value
o
1 Everyday Temperature C 30
o
2 Minimum Temperature C 0
o
3 Maximum Temperature Rise C 45
4 Temperature during maximum oC 28
wind pressure acting on conductor
5 Max wind pressure Kg/sq.m 168.8
6 Wind pressure at min. temperature Kg/sq.m 63.7

b) Requirements of HTLS Conductor:

The HTLS conductor shall meet the following minimum requirements:

Table: General Requirements
S.N. Description Unit Value
1 Overall diameter of conductor Mm Maximum 25,
not less than 21
2 Approx. mass of complete conductor Kg/km Less than or equal
to 1213
3 Minimum Ultimate Tensile strength of KN 100
conductor
4 Direction of lay of Outer Layer - Right Hand
5 Overall diameter of Core of HTLS Mm
More than or equal
to 7.75

The HTLS conductors shall meet the following sag tension requirements for ruling span of 628 m:
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Table: Tension Criteria

S.N. Description Value
0
1 Tension at everyday condition (30 C) Less than 25% of UTS of proposed
conductor or 27875 N whichever is
lesser
o
2 Tension at 30 C full wind Less than 40% of UTS of proposed
conductor or 42000 N whichever is
lesser
3 Tension at minimum temperature and Less than 40% of UTS of proposed
37.74% of full wind conductor or 42000 N whichever is
lesser

Note: In case of re-conductoring work, the idea is not to maintain the existing tension only, but to
maintain the individual factor of safety and stress on the new conductor as well.
Sag-Tension calculations for conductor shall be carried by using PLSCAD. Following values
should be considered for the purpose of sag-tension calculation:

i) Final values of modulus of elasticity of Aluminum/ composite core, Coefficient of Linear Expansion
of Aluminum/ composite core, Stress-Strain coefficients & Creep coefficients of aluminum/
composite core in the cable data (.wir file) should be used for calculation of sag in PLSCAD shall
be based on either of the following: -
a) Existing standard files on Power Line website
b) A file derived from existing standard file on PLS website for conductor of equivalent/near
equivalent stranding and size. However, value of Final values of modulus of elasticity of
Aluminium Alloy/ Core strands, Coefficient of Linear Expansion of Aluminium Alloy/ Core strands
shall be within the limits.
c) 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 by the bidder along
with the bid.

ii) PLSCAD Sagging criteria/conditions shall be based on the sag tension limits specified above and
should be carried out in a manner that the abovementioned sag-tension limits are met in “After
Creep” as well as in “After Load” condition.
The newly designed conductor without standard published .wir file will not be accepted. For
Proposed Design of HTLS Conductor wir file must be available on Power Line Systems website
to do sag tension working using PLS CADD software.
Various conductor parameters (viz. modulus of elasticity, coefficient of linear expansion, stress-
strain and creep, etc.) considered above in the sag tension calculation should be verified during
detailed engineering based on type tests conducted.
The sag & tensions under no wind for various temperatures starting from 0 deg. C to designed
maximum temperature in steps of 5 deg. C should be furnished.
Besides above, during detailed engineering details the creep characteristics in respect of the
offered type of HTLS conductor based on laboratory investigations/ experimentation (creep test
as per IEE1138 or IEC 61395) conducted on similar type of conductor should be furnished and
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should 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 at room temperature.

5. Workmanship

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.
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.

6. Joints in Wires

6.1 Aluminum Wires

During stranding, no Aluminum/ Alloy wire welds shall be made for the purpose of achieving the
required conductor length.
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 Aluminum. 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 Aluminum of the
completed conductor.
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.

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 complete stranded core. For composite
core wires, during the production run, splicing of the galvanic protection barrier is allowed,
provided diameter specifications are maintained.

7.1 Tolerances

Manufacturing tolerances on the dimensions to the extent of one percent (+/-1 %) shall be
permitted for individual strands and the complete conductor. For composite cores, the
manufacturing tolerance shall be +/- 0.05 mm of the stated nominal value.

7.2 Materials

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

7.3 Outer layer

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The material of outer layer of HTLS conductor shall be of fully annealed aluminum with aluminum
strands of trapezoidal/ Z-shaped. The strands shall be manufactured through appropriate
manufacturing process to ensure consistent electrical, mechanical and metallurgical properties
under continuous high temperature operation.

7.4 Core
The core should be Carbon Fiber Composite Core type and shall be either of High Strength grade
or extra high strength grade as per ASTM B987. The offered composite core must have non-
conductive Galvanic Protection Barrier Layer. The materials shall be of such proven quality that
its properties are not adversely influenced by the normal operating conditions of a 132 kV
transmission line in tropical environment conditions of the site as mentioned in the bid. 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 along with
the bid.

8. Standard Length

8.1 The standard length of the conductor shall be indicated by the bidder 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 m. All lengths
outside this limit of tolerance shall be treated as random lengths.

8.2 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 any point, the cumulative quantity supplied of such random lengths shall not 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.

8.3 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.

9. Evaluation of Ohmic Losses & Differential Price Loading

Based on the conductor parameters guaranteed by the bidders, average ohmic losses for different
type of conductors offered by the bidders shall be calculated as per the following formula:

Average Ohmic loss (kW) = Line Length x No. of phases x No. of sub-conductors X (Continuous
operating current under normal condition) ^2 X AC Resistance corresponding to continuous
operating current.

Average Ohmic loss (kW) = L x (1200) ^2 x Rac /1000

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Where Rac is the AC resistance per km guaranteed by the bidder at temperature corresponding
to the continuous operating current of 1200 A under normal condition for BEAR conductor .

Differential price evaluation for the conductors offered by the bidders shall be carried out
considering the average ohmic losses calculated as above and considering US $ 2962.00 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.

10. Tests and Standards

10.1 Design validation test on composite core

In case of composite core type conductors, composite Core manufacturer must have
successfully performed design validation tests prior to bid submission as per ASTM B987
on the class of core being offered and it must be witnessed by the representative (s) of
Utility or witnessed by representative of a Laboratory which is accredited to ISO/IEC
17025 (different than that of laboratory where tests were performed).
Design Validation test classification
 Tensile Test
 Glass Transition Temperature
 Density
 Dimensions
 Heat Exposure
 Heat/Stress Test
 Bending Test
 Dye Penetrant after Bending Test
 Tensile Test after Bending Test
 Galvanic Protection Barrier Layer Thickness Test

10.2 Type Tests

10.2.1 Type Tests on Stranded Conductor/ Stranded wire
The following tests shall be conducted once on sample/samples of conductor from
each manufacturing facility:
(i) On complete Conductor
a) DC resistance test on stranded conductor : As per Annexure-A
b) UTS test on stranded conductor : As per Annexure-A
c) Radio interference voltage test (dry) : As per Annexure-A
d) Corona extinction voltage test (dry) : As per Annexure-A
e) Stress- Strain test on stranded conductor and core at room : IEC 61089
temperature

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f) Stress-strain test on stranded conductor and core at : As per Annexure-A

elevated temperature
g) High temperature endurance & creep test on stranded : As per Annexure-A
conductor
h) Sheaves Test : As per Annexure-A
i) Axial Impact Test : As per Annexure-A
j) Radial Crush Test : As per Annexure-A
k) Torsional Ductility Test : As per Annexure-A
l) Aeolian Vibration Test : As per Annexure-A
m) Temperature Cycle Test : As per Annexure-A
(ii) On Conductor Strand/core
a) Coefficient of linear expansion on core wire : As per Annexure-A
b) Strand Brittle fracture test (for Carbon Fibre composite core : As per Annexure-A
only)
c) Bending test on composite core (for Carbon Fibre : As per ASTM B987
composite core only)

10.2.2 Type tests specified under Clause 10.2.1 shall not be required to be carried out if a valid test
certificate is available for the offered 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) and shall be
witnessed by the representative (s) of NEA and/or Consultant (if required by the employer). The
accreditation shall be by an agency that is certified to ISO/IEC 17011 with an ILAC-mutual
recognition agreement.

In the case of composite core conductors, the tests specified under Clause 10.2.1 shall be carried
out before stranding on as-manufactured samples.

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
noncompliance with the requirement stipulated in the Technical Specification) or type test has not
performed on offered design in that case the tests shall be conducted by the Contractor with his
own cost.

10.3 Acceptance Tests

Test shall be conducted in presence of the NEA representative in the Manufacturer
premises and following test shall be conducted along with test of above clause 3.5.2.2
Type Tests on Stranded Conductor/ Stranded wire:
a) Visual and dimensional check on drum : As per Annexure-A

b) Visual check for joints scratches etc. and : As per Annexure-A

length measurement of conductor by
rewinding

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c) Dimensional check on core or core strands : As per Annexure-A

d) Check for lay-ratios of various layers : As per Annexure-A

e) Galvanising test on core strands(if : As per Annexure-A
applicable)
f) Coating Test on Zinc-5% Al-Mischmetal : As per ASTM B803/B
alloy coating (if applicable) 958
g) Adherence of Coating Test on Zinc-5% Al- : As per ASTM B803/B
Mischmetal alloy coating (if applicable) 958
h) Torsion and Elongation tests on core : As per Annexure-A
strands
i) Ageing test on filler (if applicable) : As per Annexure-A
j) Glass transition temperature test For : As per Annexure-A
Carbon fibre-composite core only
k) Flexural Strength test For Carbon : As per Annexure-A
Fibre-composite core only
l) Galvanic layer thickness test for Carbon : As per ASTM B987
fibre composite core only
m) Bending test on composite core for Carbon : As per ASTM B987
fibre-composite core only
Note For composite core the tests
specified under Clause 3.5.3 shall be
carried out before stranding on as-
manufactured samples
10.4 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
10.5 Tests During Manufacture
a) Chemical analysis of zinc used for galvanizing : As per Annexure-A

b) Chemical analysis of Aluminium alloy used for : As per Annexure-A

making Aluminium Alloy strands
c) Chemical analysis of core strands/composite : As per Annexure-A
core (not on polymer composite core)

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10.6 Testing Expenses

As indicated in Clause 10.2.2, no type test /inspection/acceptance test charges shall be payable
to the Contractor.

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 manufactured for testing then the lot already manufactured shall be rejected.

Bidder shall indicate the laboratories in which they propose to conduct the type tests, if required.
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.

The entire cost of testing for the acceptance and routine tests and Tests during manufacture as
well as type tests, if required, specified herein shall be treated as included in the quoted unit price
of conductor, except for the expenses of the inspector/Employer's representative.

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/Employer's representative shall be deducted from the
contract price. Also if on receipt of the Supplier's notice of testing, the Employer's representative
does not find material/ testing facilities to be ready for testing the expenses incurred by the
Employer for re-deputation shall be deducted from contract price.

The Supplier shall intimate the Employer 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
in advance (in case of testing abroad) of the schedule date of testing during which the Employer
will arrange to depute his representative to be present at the time of carrying out the tests.

10.7 Additional Tests

The Employer 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.

The Employer 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 Employer.

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11. Sample Batch For Type Testing

a) The Supplier shall offer material for selection of samples for type testing only after getting Quality
Assurance Plan approved from Employer’s Quality Assurance Department. The sample shall be
manufactured strictly in accordance with the Quality Assurance Plan approved by Employer.
b) The Supplier shall offer at least three drums for selection of sample required for conducting all
the type test.
c) The Supplier is required to carry out all the acceptance tests successfully in presence of
Employer’s representative before sample selection.

12. Test Reports

a) 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 Employer only after which the commercial production of
the material shall start.
b) Record of routine test reports shall be maintained by the Supplier at his works for periodic
inspection by the Employer’s representative.
c) Test Certificates of tests during manufacture shall be maintained by the Supplier. These shall be
produced for verification as and when desired by the Employer.

13. Inspection
a) The Employer’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.
b) The Supplier shall keep the Employer 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.
c) 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 Employer in writing. In the latter
case also the conductor shall be dispatched only after satisfactory testing for all tests specified
herein have been completed.
d) 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.

14. Test Facilities

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

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15. Packing
a) 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. As an alternative to wooden drum Bidder may also supply
the conductors in returnable painted steel drums or returnable wood-Steel hybrid drums. 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. Wooden/Steel drum/Wood-Steel hybrid drum will be treated at par
for evaluation purpose and accordingly the Bidder should quote in the package.
b) After completion of stringing works, the supplier shall take back or dispose off the empty drums
on his own, except for the drums of spare conductor, if any, which shall be kept by the Owner.
c) 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.
d) The Bidder should submit their proposed drum drawings along with the bid.
e) One conductor length only shall be wound on each drum.
f) 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.
g) 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
(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.
(m) Gross weight of drum after putting lagging.
(n) Tear weight of the drum without lagging.
(o) Net weight of the conductor in the drum.
(p) CIP/MICC No.
The above should be indicated in the packing list also.

16. Verification of Conductor Length

The Employer 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.

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17. Payment for Conductors

Payment for the supply and delivery for the contract item, conductors will be made at the unit bid
price. Therefore, in the Price Schedule, the unit bid price shall include full compensation for all
the costs incurred in furnishing all materials, equipment, inspection & factory test, labors and all
other operations related to conductor and accessories fabrication, delivery etc.

18. Standards
18.1 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.
18.2 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.

Sl.
Title International Standard
No.
1 Specification for zinc BS:3436-1986
Specification for Aluminium
IEC:1089-1991 BS:215-
2 Conductors for Overhead
1970
Transmission Purposes
Reels and Drums for Bare
3 BS:1559-1949
Conductors

Method of Testing Uniformity of

4
Coating on Zinc Coated Articles

Method of Radio Interference Tests IEC:437-1973

5
on High Voltage Insulators
NEMA:107-1964 CISPR
Hard drawn Aluminium wire for
6 IEC : 889-1987
overhead line conductors

Method of measurement of
7 IEC:468
resistivity of metallic materials

8 Ampacity IEEE738

Carbon Fiber Thermoset Polymer

Matrix Composite Core (CFC) for
9 ASTM B987
use in Overhead Electrical
Conductors

The standards mentioned above are available from:

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Reference Abbreviation Name and Address

BS British Standards,
British Standards Institution
101, Pentonvile Road,
N - 19-ND
UK

IEC/CISPR International Electro technical

Commission,
Bureau Central de la Commission,
electro Technique international,
1 Rue de verembe,
Geneva
SWITZERLAND
BIS/IS Beureau Of Indian Standards.
ManakBhavan,
9, Bahadur Shah ZafarMarg,
New Delhi - 110001.
INDIA

ISO International Organisation for

Standardization.
Danish Board of Standardization
Danish Standardizing Sraat,
Aurehoegvej-12
DK-2900, Heeleprup,
DENMARK.
NEMA National Electric Manufacture
Association,
155, East 44th Street.
New York, NY 10017
U.S.A.
ASTM ASTM International:
100 Barr Harbor Drive, PO Box C700,
West Conshohocken, PA, 19428-2959
USA

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Annexure-A
1.0 Tests on Conductor

1.1 UTS Test on Stranded Conductor

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 subconductors 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.

1.3 Radio Interference Voltage Test

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 154 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 metre and subsequently
one metre 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 20deg C as per IS:398-(Part-IV)/(Part-V).
The resistance corrected at 20deg C shall conform to the requirements of this Specification.

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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 70% 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 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 conducted 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 22 % 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 / ASTM B987
section 14. Dye penetrant exposure time shall be 30 +1/-0 minutes.

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1.8 Axial Impact Test

The conductor sample shall be suspended vertically and load applied by dropping a 650 Kg from
an elevation of 4 meters above the sample. The impact velocity shall be not be less than 8 m/sec.
with an intial 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 platens. Load shall be held at
350 Kgs for 1 minute and then released. Core/ core strands shall be subsequently disassembled
and tensile tested. Core/ core strands shall exhibit full strength retentionvis-a-vis guaranteed
breaking strength of core wires (after stranding).

1.10 Torsional Ductility Test

The conductor sample of 10-15 m or 1500 times core diameter shall be loaded to 20% of UTS
and then rotated in increasing steps of +/-180 deg. In case of INVAR type HTLS conductor, the
entire conductor shall withstand atleast 16 such rotation and there shall not be any damage to
Aluminium Alloy or core wires.
In case of carbon-fibrecomposite 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 upto 16 rotations. The composite core shall withstand upto 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 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 (peak-to-peak) 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.

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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 + 2.5deg. C for 5 minutes
-After the above mentioned 100 cycles, the mechanical tension shall be increased up to
70 % UTS at room temperature and kept at this tension for 24hrs. 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
thermal cycling. Flexural strength shall be obtained on the basis of test procedure
indicated at 1.32 below. The value of Tg after the test, shall however, in no case be less
than the design maximum temperature of conductor.
In case of carbon-fibre composites, the flexural strength should not be less than 90% of
the value guaranteed in GTP and the Glass Transition temperature shall not be less than
90% of the value guaranteed in GTP after 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 (not applicable to fully annealed
aluminum)

Breaking load test as per clause 1.21 above 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 temperature Test Temperature
of the conductor

Upto 150 deg. C 230 degC (+5/-3 degC)

More than 150 deg. C & upto 210 deg. C 280 degC (+5/-3 degC)

More than 210 deg. C & upto 230 deg. C 400 degC (+5/-3 degC)

1.14 Bending test on Aluminium clad core wire (if applicable)

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.

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1.15 Compression test on Aluminium clad wires (if applicable)

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 clad core strand should not break.

1.16 Coefficient of linear expansion for core/ core wires

The temperature and elongation on a sample shall be continuously measured and recorded at
interval of approximately 15 degree C from 15 degree C to designed maximum temperature
corresponding to rated current (1100A & 1250A) 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 carbon-fibre 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 for 96 hrs. The contact length of acid
shall not be less than 40mm and thickness around the core not less than 10mm.The rod shall
withstand UTS test after 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 Employer. The Employer 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 Employer's representative.

1.20 Dimensional Check on Core/ CoreWires and Aluminium/ Aluminium Alloy Wires

The individual strands shall be dimensionally checked to ensure that they conform to the
requirement of this Specification. Diameter of formed wires shall be determined as per Clause
6.3.1.2 of IEC 62420.

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.

1.22 Galvanising 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 (if applicable)

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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 Composite Core/ INVAR Core wires

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 carbon-fibre composite core HTLS conductor, the following procedure shall be
applicable:-

i) Elongation Test:- The elongation of the composite core sample at fracture shall be determined
using extensometer. The load along the core shall be gradually increased. The elongation
achieved on reaching the tensile strength of the core shall not be less than the value guaranteed
in the GTP.
ii) Torsion Test: The purpose of the testis 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 h ave a loss in tensile strength due to the twisting. For Standard and High Strength
Grade composite cores as per ASTM B987 Table 2, samples should be long enough to have a
gauge length between the gripping fixtures 170 times the diameter of the composite core being
tested. For core lengths less than 170 times the core OD, rotate the core to maintain the same
rotation to length ratio. For Extra High Strength Grade composite core as per ASTM B987 Table
2, samples should be long enough to have a gauge length between the gripping fixtures that is
340 times the diameter of the composite core being tested. For core lengths less than 340 times
the core OD, rotate the core to maintain the same rotation to length ratio. 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 an 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/ Aluminium Alloy &Composite core/ INVAR
Corewires and D.C Resistance test on Aluminium/ Aluminium Alloy wire

The above tests shall be carried out as per IEC: 888/889 or relevant international standards and
the results shall meet the requirements of the specification.
For composite cores, the breaking load shall be performed as described in Section 9 of ASTM
B987.

1.26 Wrap test on Corewires (Applicable for steel/Al clad Steel/invar core only)

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The wrap test on corestrands shall be meet the requirements of IEC: 888. In case of Aluminium
clad core wire, the same shall be wrapped around a mandrelof 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
occurred.

1.27 Minimum conductivity test on thermal resistant Aluminium alloy wire

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/ Aluminium Alloy wire.

Two Aluminium/ Aluminium Alloywire shall be welded as per the approved qualityplan 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 Aluminium conductivity test on Aluminium clad wire (if applicable)

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

1.31 Glass Transition Temperature Test (for carbon-fibre 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.
1.32 Flexural Strength Test (for carbon-fibre 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/Aluminium Alloy and Composite core/INVAR Core

Wires (not applicable for non-metallic composite core)

Samples taken from the Aluminium /Aluminium Alloy and core coils/strands shall be
chemically/spectrographically analysed. The same shall be in conformity to the particulars
guaranteed by the bidder so as to meet the requirements stated in this Specification.

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1.34 Chemical Analysis of Zinc

Samples taken from the zinc ingots shall be chemically/ spectrographically analysed. The same
shall be in conformity to the requirements stated in the Specification.

1.35 A. 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

B. 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.

NOTE:
The existing line structure and foundation were constructed and installed more than 20 years ago.
So the Contractor shall propose the conductor size and weight a suitable for the safe operation.
The conductor stringing shall be carried out at safe tension level such as not to damage the
structure.

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