Specification P-176: 2007
Specification P-176: 2007
______________________________________________
PAKISTAN
WATER AND POWER DEVELOPEMNET AUTHORITY
DESIGN DEPARTMENET NTDC
CONTENTS
0. Foreword
1. Scope
2. Climatic Conditions
3. Requirements
4. Material
5. Tests
6. Packaging
7. Tender Data
8. Approval of Drawings
9. 500 kV Connectors
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SPECIFICATION P-176: 86
0 FOREWORD
1 SCOPE
1.1 This specification describes the connectors suitable for installations on 500, 220 and
132 kV Grid Stations under climatic conditions mentioned in clause 2.0.
1.2 The connectors shall be of the type described in the following clauses:
TABLE-I(A) TEE-CONNECTORS
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Tee-connector 2X484/2X484 TDMRR PDW/DF-409 2X29.6 2X29.6
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Fixed bus support for 3” pipe size
BSP3.0 PDW/DF-436 88.9
Fixed bus support for 3.5” pipe size
BSP3.5 PDW/DF-436 101.6
Fixed bus support for 5” pipe size
BSP5.0 PDW/DF-436 141.3
Expansion bus support for coupling 3” pipe size EBSP3.0 PDW/DF-434 88.9
Expansion bus support for coupling 3.5” pipe
EBSP3.5 PDW/DF-434 101.6
size
Expansion bus support for coupling 5” pipe size EBSP5.0 PDW/DF-434 141.3
The bimetallic connector shall be made of separate Copper and Aluminum alloy bodies joined
by a suitable bimetallic joint to prevent galvanic action. These shall be of the following types
and according to the drawings attached and as per Table – II (A) and II (B)
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Straight connector - 2X484/60 ODBR60 PDW/DF-397 2x29.6 60
Straight connector - 2X455/60 ODBA60 PDW/DF-397 2x27.72 60
Straight connector - 3.5/60 OBP 3.5,60 PDW/DF-428 101.6 60
2. CLIMATIC CONDITIONS
2.1 Connectors of all types shall be suitable for satisfactory operation under the
following conditions:
Maximum 500 C
Maximum mean over any 24 hours 450 C
Mean in any year 300 C
Minimum -100 C
2.3 Humidity
The relative humidity may range from 0 to 100%. The maximum values of the ambient temperature
and humidity however do not occur simultaneously. During the monsoon, high humidity may persist
for many days at a time along with temperature ranging from 300 C to 400 C.
2.4 Altitude
It may be assumed that the air is not normally heavily polluted by dust, smoke, aggressive
gases, vapors, or salt spray. At certain times of year severe dust storm may be experienced.
3 REQUIREMENTS
3.1 The connectors shall be so designed that there are no sharp corners or edges
which may damage the conductor or cause radio interference, and corona. The connector shall
not become loose due to vibrations, or temperature variations.
3.2 The connectors shall be of bolted type and should be able to develop adequate
electrical contact between the conductors and or terminals and between all wires of the stranded
conductor.
Connectors with single bolt technology may be considered for connection on tube only; if the
design of the product is submitted for approval along with type test reports giving evidence of
covering the following performances:
3.3 The temperature rise of the connector shall not exceed the temperature rise of the conductor with
which it is intended to be used.
3.4 The temperature rise of the connector, which connects conductors of varying sizes shall not
exceed the temperature rise of the conductor having highest temperature rise.
3.5 The resistance of a conductor including connectors shall not exceed the resistance of an equal
length of the identical conductor without connectors by more than 110 percent of all sizes of
conductor.
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3.6 The resistance measurement shall be made by milli volt drop, accurate resistance bridge or other
suitable means.
3.7 The condition specified in clause 3.3, 3.4 and 3.5 above, shall be for the minimum rated current
specified in Table-III.
TABLE – III
TABLE - IV
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All connectors for 3½” pipe size snap-Dragon conductor
2200
All connectors for 5” pipe size snap-Dragon conductor
3500
All connectors for 6” pipe size snap-Dragon conductor
4000
3.9 The monometallic connectors and Aluminum portion of Bimetallic connectors shall be made from
corrosion proof Aluminum alloy conforming to clause 4.1. The copper based Aluminum alloys shall
not be acceptable.
3.10 The bimetallic connectors shall have separate copper and Aluminum bodies jointed by a suitable
bimetal strip joint with 2mm of thickness. The connectors employing bimetallic shims shall not be
accepted.
3.11 The copper portion of the bimetallic joints shall be made of copper alloy conforming to clause 4.3
3.12 The nuts, bolts and washers shall be conforming to clause 4.2.
3.13 The number and size for bolts nuts shall be adequate for the design of connectors to fulfill the
requirements of contact pressure, temperature rise and resistance etc.
3.14 The dimensions of the connector shall be submitted for approval. The tolerance on the dimensions
shall be plus or minus 2 percent from that of the approved one.
3.15 For connectors with flat terminals, the flat portion shall have holes drilled in it as per respective
drawing. The numbers of bolts, nuts and washers as per clause 3.13 shall be supplied with each
flat type connector. The supplier/manufacturer is required to drill four (04) Nos. holes for M16 bolts
on the terminal palm of the flat type connector for which the corresponding drawing (s) does not
show the same. These connector(s) are to be supplied with requisite number of bolts, nuts and
washers as per clause 11.3 of the Specification. The length of bolts should be enough to
accommodate the thickness of the connector, nut, washer with protuberant for 3-4 threads.
3.16 Each connector drawing should clearly indicate the grade of material being used, the weight of
copper and Aluminum parts, separately and tightening torque of bolts.
3.17 The current caring capacity of the connectors shall be more then the current rating of the
respective conductor(s) / pipe for which it is to be used. The connector should be able to withstand
the short circuit current of the network. The temperature rise of a connector shall not exceed the
temperature rise of the conductor/pipe with which it is intended to be used. The temperature rise of
the connector, which connects conductors/pipes of varying sizes, shall not exceed the temperature
rise of the conductor/pipe having the highest temperature rise.
4 MATERIAL
4.1 The material and composition of the Aluminum alloy used on monometallic
connectors and the Aluminum portion of the bimetallic connectors shall be submitted for approval.
The alloy will be properly heat treated. Additionally, keepers, components, which are subjected to
high forces during services, will be obtained by gravity die casting with following characteristics:
4.2 The bolts, nuts and washers shall be of stainless steel having following properties:
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Breaking strength, min = 65 kg/ mm2
Yield strength, min = 40 kg/mm2
Brinell hardness, min = 140 HB
Use of alternate alloys shall be permissible subject to approval, for which all relevant data such as
composition, strength characteristics and tightening torques etc. shall be submitted.
4.3 The material and composition of the copper alloy in the bimetallic connectors shall be submitted for
approval. The copper alloy will be from the Copper/Nickel base family of alloys with a minimum of
96.4% of copper in order to guarantee high conductivity properties as well as high strengths
characteristics. Copper alloy shall be heat-treated.
4.4 The copper alloy must be developed and defined in accordance with mechanical and electrical
properties indicated in clause 4.3 of P-176:2007. This copper alloy must be heat treated to reach
the electrical and mechanical requirement as per clause 4.3. The chemical composition should be
in accordance with the following standards:
Ultimate tensile strength Rm (min) = 20 kg/ mm2, (196.2) N/mm2, (196.2) MPa
Yield strength Re 0.2% min = 10 kg/mm2, (98.1) N/mm2, (98.1) MPa
Elongation (min) = 18% on 50 mm scale
Electrical conductivity at 200C = 32% IACS
(%IACS) (min)
5 TESTS
5.1.1 The following sample tests are required to be carried out on connectors:
i) visual inspection and dimension test
ii) Temperature rise test
iii) Resistance test
iv) Strength test
Each batch offered for acceptance shall be divided into lots of 500 connectors. Samples shall be
selected at random from each lot for test.
The number of connectors in the sample shall be 50 for visual inspection and
verification of dimensions.
If the number of defective connectors in any sample is three or less, the entire lot shall be
accepted. If it is more than 10, the entire lot shall be rejected.
If the number of the defective connectors is 4 to 10 inclusive, a second sample of 100 connectors
shall be selected at random from the same lot (but excluding the first sample) and these shall be
inspected and the number of the defective units in the second sample determined.
If the total number of defective units from the first and second sample together is 10 or less, the
entire lot shall be accepted. If it is more than 10 than the entire lot shall be rejected.
Individual items shall be visually examined for thee defects given below:
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Sr.No. Examination Defects
1. Construction i. Not of proper dimensions
ii. Nor of correct material
iii. Any crack on the material
2. Finish i. Not free from roughness, sharp edges and
projections which will interfere with the proper
use of the article
ii. Corner edges not rounded
Connectors of each type being offered shall be subject to temperature rise test. For this purpose a
circuit diagram/loop containing at least two connectors of each type shall be formed by using the
relevant conductor/tube.
The test shall be performed according to NEMA CC1.
The temperature rise of the connectors shall not exceed the temperature rise of the conductor with
which it is intended to be used.
The temperature rise of the connectors, which connects conductors of varying sizes, shall not
exceed the temperature rise of the conductor having highest temperature rise.
The resistance of each connector shall not exceed 110% of the reference conductor resistance.
5.2.1 The following type tests shall be carried out on connector bodies, bolts, nuts and washers.
5.2.2 Subject to approval, the type test reports can be submitted in lieu of actual tests. Copies in English
Language of appropriate test methods shall be submitted with the type test report.
6 PACKING
6.1 Each connector shall be packed in a polythene bag. Nuts, bolts and washers supplied as per
clause 3.15 shall also be packed therein.
6.2 The connector shall be packed in wooden cases with 100 connectors in each case. The wooden
cases shall be strong e4nough to withstand the rigors of transportation. Each package shall have
marked on two sides the connector types designations as per clause 1.2.
7 TENDER DATA
The manufacturer shall submit with the tender the following information:
a) The details of materials, its composition and materials, its composition and
mechanical characteristics.
b) Manufacturer catalogue number alongwith the catalogues.
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c) Copies of type test reports on the connectors alongwith English version of
the relevant specifications, to which the connectors are manufactured and
tested.
d) Fully dimensioned drawings of the connectors.
8. APPROVAL DRAWINGS.
Four sets of the drawings and one set of reproducible shall be submitted for approval. The
drawings shall show all dimensions, alloy designation and catalogue number.
500 kV CONNECTOR
9 SCOPE
The aim of this specification is to provide technical recommendations for selection of clamps and
connectors used in 500 kV substations for transmission systems. HV connectors need to be
selected carefully as they are one of the most critical functions within the substation and by
consequence for the grid.
This document covers all connection functions as well as mechanical support and spacers required
for phase conductors (cables and tubes).
10 QUALITY REQUIREMENTS
Clamps and connectors when manufactured by casting process are produced with aluminum alloys
first melt with new ingots. Ingots will be delivered to the casting plant with its certificate of
conformity as per the relevant standard requirement. Alloys and applicable standards are listed in
the hereunder paragraphs.
Traceability from the components to the poured alloy will be provided by the supplier through his
quality system, which has to be ISO 9001 (Edition 2000) certified.
Number of
Conductor type Number of Bolts
Keepers
Stranded conductor 3 minimum 6 minimum
Connectors with single bolt technology are permitted for connection on tube only; but the design of
the product must be submitted to approval with type test reports evidence covering the following
performances:
11.3 Bolts and washers will be made in stainless steel grade A2-70 minimum as
per the ISO 3506 standard.
Applicable
Item Technical characteristics Requirements
standard
Applicable
Item Technical characteristics Requirements
standard
Rp0.2 190 N/mm²
Casting Aluminum alloys
Rm Mini 230 N/mm² EN 1706
AC 42100
Conductivity mini 38 % IACS
12 TYPE TEST
The connectors shall be subjected to the type test and meet the requirements given below.
Ageing cycling test ANSI C119.4 (edition 2004) 125 Cycles minimum
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40kA/1Sec
63 kA/1Sec
Short Circuit test IEC 60694 (edition 1996)
No cracks and no melt on the tested connectors.
T° Max < 200°C after testing.
R.I.V test IEC 60694 (edition 1996) 2500µV at Un
Corona test IEC 60694 (edition 1996) Extinction at Un
EN 60068-2-11 (edition
Corrosion test 500 Hours in Salt fog
1999)
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