TECHNICAL SPECIFICATIONS

OF
11 KV & 33kV – AL59 ACS Type
Covered Conductors Accessories

Tender No: ________________

: TECHNICAL SPECIFICATIONS:

Sr. No. Technical Specification No./Revision Date of revision

1.

2.

3.
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INDEX
CLAUSE NO CONTENTS

1.0 SCOPE
2.0 SPECIAL INSTRUCTIONS TO BIDDER
3.0 DISTRIBUTION NETWORK PARAMETERS
4.0 ATMOSPHERIC PARTICULARS
5.0 APPLICABLE STANDARDS
6.0 MATERIAL
7.0 ACCESSORIES
8.0 PRINCIPAL PARAMETERS
9.0 TESTS
10.0 INSPECTION
11.0 END SEALING
12.0 STANDARD LENGTH AND VARIOATION IN LENGTH
13.0 QUALITY ASSURANCE PLAN
14.0 PACKING AND MARKING
15.0 ANNEXURE-I
16.0 ANNEXURE-II
ANNEXURE-III

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1. SCOPE:
This specification covers design, Engineering, manufacturing, Testing, Inspection before
dispatch, Forwarding, transportation to sites, Erection, supervision, testing &
commissioning of Aluminium alloy AL-59 - Aluminium clad steel conductor with
operating temperature 95⁰C type covered conductor by replacing the existing Rabbit /
Dog conductor under ……… Utility.
The conductor should conform to latest Standards. The AL-59 ACS type covered
conductor equivalent to ACSR Rabbit/Dog shall be conforming to SS 424 08 13, SS 424
08 14 and IEC 61232 with latest amendment and the insulation conforming to
requirement given in Table 1 as below.
The AL-59 ACS type Covered conductor shall conform in all respects to highest standards
of Engineering, design, workmanship, this specification and the latest revisions of
relevant standards at the time of offer and the authorized person of utility have power
to reject any work or materials, which his judgment, is not in full accordance therewith.

2. SPECIAL INSTRUCTIONS TO BIDDER:

2.1. The Bidder shall execute the work on TURNKEY basis i.e., design, engineering,
manufacturing of Covered Conductor from core to finish in-house, testing at
manufacturer’s works, supply and delivery, erection, testing and commissioning of
atleast 50KM of AL59 ACS Type Covered Conductor on 11kV or above with relevant
accessories on Existing Distribution feeder by replacing Existing Dog conductor.
2.2. The bidder is required to impart training in view of manufacture, assembly, erection,
operation and maintenance for offered item, at his works and, to the person/s identified
by the DISCOMs, in the event of an order, free of cost. In the training session, bidder
shall confirm that he has to impart the all the aspects of Installation method with
accessories, objective of the individual components, possible defects and corrections
etc.
2.3. The bidder shall bring out all the technical deviation/s only at the specified annexure.
2.4. Before proceeding with the execution of the aforesaid work, the bidder shall require to
fully familiarize himself with the site conditions. If the existing span length between
successive two poles is found to be more than 50 MTRs then in that case the bidder
shall erect the single 8 MTR PSC Pole in the center of the span with relevant accessories
and earthing. The PSC poles with all support insulators, fabrications shall be supplied by
the buyer and successful bidder shall withdraw the material from utility designated
store.
2.5. It shall be the responsibility of the successful bidder to arrange all inputs required for
detailed engineering and execution. The Bidders are advised to visit the installation site,
may arrange the feeder survey, collect all necessary inputs and acquaint themselves
with the topography, infrastructure etc. The Successful bidder shall be fully responsible
for providing all equipment, materials, system and services specified or otherwise which
are required for complete implementation of the pilot project of installation of covered
conductor.
2.6. The bidder shall submit Quality Assurance Plan for manufacturing process and Field
Quality Plan with the technical bid.
2.7. The Bidder should be a manufacturer of covered conductors in India and must have a
minimum experience of 5 years as a manufacturer of covered conductor. (the Bidder
should have a covered conductor manufacturing facility in India for the past 5 years)

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2.8. The bidder shall have to submit all the required type test reports should not be older
than 07 years for the offered item. All the required type test of any equal or higher size
item must have been conducted in the span of one year only. However, in the event of
partial submission of reports older than specified limit, bidder must submit his
confirmation for those type test reports to be submitted in the event of an order,
without affecting delivery schedule, before commencement of supply, free of cost. In
absence of this confirmation, the evaluation shall be carried out accordingly as non-
submission of type test reports.
2.9. It is not the intent to specify completely here in all the details of design & construction
of material. However the material shall conform in all respects to high standards of
Engineering, design and workmanship operation in manner acceptable to the
purchaser, who will interpret the meanings of drawings and specification and shall have
the power to reject any work or material which in his judgment is not in accordance
therewith. The offered material shall be complete with all components necessary for
their effective and trouble free operation. Such components shall be deemed to be
within the scope of bidders supply irrespective of whether these are specifically brought
out in his specification and / or purchaser order or not.

3. SYSTEM PARTICULARS/DISTRIBUTION NETWORK PARAMETERS:

The normal system parameters of the distribution network are as below.
Network 3Phase-3wire

Max. System Voltage 12 kV & 36 kV

Nominal System Voltage 11 kV & 33 kV
No of phases Three
System Frequency 50 Hz±3%
Neutral earthing Solidly Grounded
Method of earthing Effectively earthed
Fault Level (Minimum) 20 KA For 3 sec.

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4. ATMOSPHERIC PARTICULARS:
Maximum Ambient Air Temperature 50° C
Minimum Ambient Air Temperature 0° C
Maximum daily average ambient air 35°C
temperature
Maximum temperature attained by an object 70°C
exposed to sun
Maximum humidity 95%
Altitude above M.S.L. (maximum) 1000 Mtr.
Average annual rainfall (mm) 1150
Max. wind pressure(Kg/sq.m) 200
Average number of rainy days per Annum 90
Horizontal Seismic Co-efficient – (Acceleration) 0.08 g
Zone 5
Vertical Seismic Co-efficient – (Acceleration) 0.84 g
Zone 5
Iso-ceraunic level(Days per Year) 50
Average thunder storm days per annum 15
Note: The climatic conditions are prone to wide variations in ambient conditions
and hence the equipment shall be of suitable design to work satisfactorily under
these conditions.

5. APPLICABLE STANDARDS:
Sr. No Applicable IEC/IS Description
1 SS 424 08 13 All Aluminium Alloy Conductors for overhead lines
2 SS 424 08 14 Aluminium Alloy Stranded Conductors for overhead
lines AL-59 conductors
3 EN 50397-1:2006 Covered conductors for overhead lines and the related
accessories
4 EN 50397-2:2009 Accessories for Covered Conductors - Tests and
Acceptance Criteria
5 ASTM B 856 Standard Specification for Concentric-Lay-Stranded
Aluminum Conductors, Coated Steel Supported (ACSS)
6 IEC 61232:1993 Aluminum-clad steel wires for electrical purposes
All Indian Electricity Rules/ Bills amended up to date applicable for clearances, safety and
operation of the equipment

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6. TECHNICAL REQUIREMENT:

6.1. Constructional requirement:

The covered conductor shall conform in general to EN 50397-1/2006.
6.1.1. Basic features:

1- Longitudinally water tight (black compound) conductor with 95⁰C operating

Temperature
2- Extruded semi-conducting compound (Black)
3- XLPE insulation (Natural) with 95⁰C operating Temperature
4- XLPE (Black) having UV protection and anti-tracking properties with 95⁰C
operating Temperature

6.1.2 Conductor:
The material offered shall be of the best quality and workmanship. The Insulated /
Covered conductor shall be formed longitudinally watertight and constructed from
Aluminium alloy conductor AL-59 Type & Aluminium Clad Steel type Covered
conductor which have the mechanical and electrical properties specified in SS 424
08 13, SS 424 08 14, and IEC 61232. The conductor is stranded circular compacted
type.

6.1.2.1 FILLING (WATER BLOCKING):

The Stranded circular compacted Conductor shall be longitudinally water tight by
means of Water blocking material/compound Incorporated during the extrusion
process. The use of grease /water swellable tape / water swellable powder inside
or over the surface of conductor is not permitted. The water blocking material shall
be stable at maximum operating conductor temperature of 95⁰C. The Water
blocking compound shall be compatible with the conductor material as well as the
semi Conducting screen layer above it and not adversely affect its electrical or
mechanical Properties.

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6.1.2.2 Conductor screen

Conductor screen shall be semi-conducting compound suitable for continuous
operating temperature at 95⁰C and provided over conductor by extrusion.

6.1.2.3. Insulation
The insulation shall be as per Table 1 as below comprising of two layers. The
Average thickness of the covering insulation shall not be less than that stipulated in
the Technical Requirements. The physical and electrical properties of insulating
compounds shall be as specified as per below Table 1 as below & generally as per
EN 50397-1.

1- The inner Covering insulation of natural colour XLPE suitable for continuous
operating temperature 95⁰C shall be unfilled and shall not contain Carbon black.

2- The outer covering insulation which also serves as protective covering shall be
UV Stabilized, weather resistant and Track resistant XLPE Black with continuous
operating temperature 95⁰C.

Covering Thickness chart:

Voltage Inner Covering XLPE Outer Covering XLPE

Level Nom. Thickness (mm) Nom. Thickness (mm)
11 kV 1.20 1.10
33kV 2.43 1.20

The Semi Conducting Screen, Inner Insulation and Outer Insulation should be extruded in
one step i.e. triple extrusion process to ensure a good, permanent bond between the three
layers and also with the conductor.

It shall be possible to remove the Semi Conducting Screen, Inner and Outer Insulation
Layers without damage to the conductor

Properties of covering insulation material shall meet the requirements specified in below
Table-1.
Tracking resistance as per EN 50397-1 shall be applicable. Manufacturer should have
in-house test facility to conduct tracking resistance test as per EN 50397-1. This test
shall be conducted on one sample of each size of covered conductor and test report
shall be submitted.

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TABLE : 1
PROPERTIES OF XLPE INSULATION FOR 95⁰C OPERATING TEMPERATURE
Sr. No. Properties Requirements
1. Tensile Strength 12.5 N/mm², Min.
2. Elongation to break 200 percent, Min
3. Aging in air oven:
a) Treatment: Temperature: 135°C
Duration: 10 days
b) Tensile Strength variation: ±25 percent, Max
c) Elongation variation: ±25 percent, Max
4. Hot set:
a) Treatment: Temperature: 200±3°C
Time under load 15 min
Mechanical stress 20N/cm²
b) Elongation under load 175 percent, Max
c) Permanent elongation (set) 10 percent, Max
after cooling
5. Shrinkage:
a) Treatment: Temperature 150±3°C
Duration 2 hour
b) Shrinkage 4 percent, Max
6. Water absorption (Gravimetric):
a) Treatment: Temperature: 85±2°C
Duration 14 days
b) Water absorbed 1 mg/cm², Max
7. Test of Compatibility (Ageing of
complete product sample )
d) Treatment: Temperature: 115°C +/- 2°C for
Duration: 10 days
e) Tensile Strength variation: ±25 percent, Max
f) Elongation variation: ±25 percent, Max

6.1.2.4. Tolerance on normal sizes:

The tolerance in diameter of AL-59 & ACS wire used in the manufacture of Insulated
/ Covered Conductor shall be allowed as SS 424 08 13, SS 424 08 14, and IEC 61232,
amended up to date.

6.1.2.5. Stranding:
The wires used in the construction of aluminum (ACSS) & Aluminium Clad Steel
reinforced of conductor shall before stranding, satisfy all the relevant requirements
of this specification and relevant standards.

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7. TESTS (FOR ALUMINIUM ALLOY (AL59) - ALUMINIUM CLAD STEEL (ACS) TYPE COVERED
CONDUCTOR):

7.1. TESTS BEFORE DESPATCH: The Covered Aluminum Alloy ACSS & Aluminium clad steel
(ACS) reinforced HTLS Conductor shall be subjected at manufacturer’s works before
dispatch, to the tests mentioned here- under as per SS 424 08 13, SS 424 08 14, IEC
61232 & EN 50397-1:2006, with latest amended.

7.2. TYPE TESTS:

The following TYPE tests shall be conducted on each drum of the conductor by the
manufacturer at his works as per relevant standards.
1) Surface condition test.
2) Measurement of diameter of individual aluminum and Clad steel wires.
3) Measurement of lay ratio.
4) Breaking load of individual wires.
5) Wrapping test.
6) DC Resistance test.

Beside this the following type tests as per requirement of EN 50397-1:2006, with
latest amended, shall also be conducted for covered conductor.

7) High voltage test(No.1.2 of Table -2)

8) Leakage current test (No.1.4 of Table -2)
9) Tracking resistance test(No.1.5 of Table -2)
10) Rated tensile strength(No.3.1 of Table -2)
11) Mechanical properties(No.4.1 of Table -2)
a) Before ageing of sample
b) After ageing of sample
12) Carbon black content test – If applicable for UV Resistance test (No.4.2 of
Table -2)
13) Resistance to UV rays test(No.4.3 of Table -2)
14) Test of compatibility(No.5 of Table -2)
1) Ageing of complete product sample
15) Hot-set-test(No.6.2 of Table -2)
16) Shrinkage test(No.6.1 of Table -2)
17) Water absorption(No.7.1 of Table -2)
18) Test of the longitudinal water tightness(No.8 of Table -2)
19) Slippage test(No.10 of Table -2)

The bidder shall furnish valid and authenticated type test certificate from a Govt.
approved / a Govt. recognized / NABL Accredited laboratory / ILAC i.e. International
laboratory Accreditation Corporation (In case of foreign laboratory) of similar rating and
design of tendered material / equipment.

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7.3. ROUTINE TEST:

The following routine tests shall be conducted after covering as per sampling plan
of QAP/Relevant specifications of the Covered conductor by the manufacturer at his
works as per relevant standards.

1) Visual & dimensional check on drum as per specification.

2) Visual check for joints, scratches etc. and length of conductor by re-winding of
conductor on empty drum as per Specification.
3) Measurement of dia-meter of individual ACS wires only.
4) Measurement of Lay Ratio
5) Breaking load of ACS wire only.
6) DC Resistance Test of conductor

Beside this the following routine tests as per requirement of EN 50397-1:2006,

with latest amended, shall also be conducted for covered conductor.
7) Spark Test on the Covering.
8) Construction and Dimension (No. 2 of Table 2)/GTP Compliance with design
requirement (No. 2.1 of Table 2)/GTP Thickness of covering (No. 2.2 of Table
2)/GTP
9) Marking. (No. 9 of Table 2)/GTP
Content, legibility (No. 9.1 of Table 2)/GTP

7.4. ACCEPTANCE TESTS:

The following tests shall be conducted on samples taken at random from a lot as
per relevant standard in presence of purchaser’s representative.
1) Visual & dimensional check on drum as per specification.
2) Visual check for joints, scratches etc. and length of covered conductor by re-
winding of conductor on empty drum as per Specification / IS.
3) Measurement of dia-meter of individual ACS wires only.
4) Measurement of Lay Ratio
5) Breaking load of ACS wire only
6) DC Resistance Test of conductor
Beside this the following test as per requirement of EN 50397-1:2006, with latest
amended, shall also be conducted for covered conductor.
7) Conductor Resistance & High Voltage Test
8) Construction and Dimension (No. 2 of Table 2)/GTP
a. Compliance with design requirement (No. 2.1 of Table 2)/GTP
b. Thickness of covering (No. 2.2 of Table 2)/GTP
9) Construction and Mechanical Properties of the conductor
a. Rated Tensile Strength
b. Construction and Dimension

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10) Hot Set Test

11) Tracking resistance test
12) Test of the Longitudinal water tightness
13) Marking. Content, legibility
Note: Regarding Anti-tracking test, In-house NABL accredited Lab mandatory.

7.5. SAMPLING PLAN:

Samples for Acceptance Tests: Samples shall be taken 5% of offered length or as per
relevant EN 50397-1:2006 with latest version as the case may be.
Apart from the sample selected for carrying out Acceptance Tests at the works of the
firm during inspection, one more sample from offered lot also selected under re-
winding for carrying out various Acceptance Tests as per relevant SS/IEC/EN. If any of
the sample so selected from each length failed in any acceptance test the entire lot
under inspection is not acceptable.

7.6. TOLERANCE ON TEST RESULTS:

Tolerance on test results shall be allowed as per relevant IS/EN/Spec. whichever is
more stringent.

8. INSPECTION:
8.1. The Covered conductor shall be manufactured in accordance with latest edition of
generally as per EN 50397- 1:2006 & GTP with all subsequent amendments issued
from time to time for AL-59 ACS type Covered Conductor. All the tests as laid down in
the above mentioned specification on covered conductor. The testing shall also
include the tests on manufactured finished conductor. Moreover the supplier shall
also furnish test certificate(s) of raw materials to the inspecting officer at the time of
inspection.
8.2. The Manufacturer shall provide all adequate facilities at his works for inspection of at
least one number covered conductor drum or 5% covered conductor drums offered
for inspection whichever is higher selected at random by the authorized
representative of the purchaser for checking / verification of conductor length/
manufacturing defects by transferring the conductor from one drum to the another
empty drum and at the same time measuring the length and lay ratio of each
conductor length so transferred by means of the standard calibrated and sealed
meter.
8.3. The supplier shall provide adequate facilities for weighment of all the drums offered
for inspection.
8.4. The supplier shall present the latest Calibration Certificate(s) of testing instruments /
equipment’s to be used for the testing of the material covered in the Purchase Order
to the authorized inspecting officer / inspecting agency of the purchaser. The testing
instruments / meters/ apparatus etc. should be got calibrated by the supplier from
time to time from Govt. Lab or Independent test laboratory / house having valid
accreditation from National Accreditation Board for Testing and Calibrating
Laboratories for the testing equipment or original manufacturer having traceability to NABL /
NPL or equivalent accredited lab.
8.5. The calibration certificate(s) should not in any case be older than one year at the time
of presenting the same to the inspecting officer / inspecting agency of the purchaser.

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The testing instruments / equipment should be duly sealed by the Calibrating Agency
and mention thereof shall be indicated in the calibration certificate(s).
8.6. All tests and inspections shall be made at the place of manufacturer unless otherwise
specifically agreed upon by the purchaser. The manufacturers shall afford the
Inspector representing the purchaser all reasonable facilities, without charge, to
satisfy him that the material is being furnished in accordance with this specification.
The purchaser has the right to have the tests carried out at his own cost by an
independent agency whenever in dispute regarding the quality of supply.
8.7. The supplier shall furnish the following documents as proof of purchase of RAW
material along with each inspection offer.
a) Invoice of the supplier b) Supplier Test Certificate c) Packing List d) Bill of Landing e)
Description of material, electrical analysis, physical inspection, certificate of surface
defects, thickness and width of material wherever applicable.

9. End Sealing:
Heat Shrinkable end Caps with sealant shall be used for effectively sealing the end
terminals of the covered conductor. The inner diameter range of the cap shall be such
that it shall tightly fit to the covered conductors to prevent moisture ingress.

10.Standard length & variation in lengths:

The Covered conductor Aluminium alloy AL-59 ACS reinforced conductor shall be
supplied in the standard length of 1000 /2500 Mtr. The tolerance on standard length of
covered Conductor with (+/-) 5% shall be acceptable.

Short length(s), if any shall not measure less than 80% of standard length as specified
above in any case. The total quantity of such short length(s) shall not exceed 5% of the
quantity of the lot offered for inspection. The maximum permissible length per drum
shall be as under subject to condition that the manufacturer while packing the conductor
in drum shall ensure that after winding complete quantity of conductor in drum a
uniform space of not less than 100 mm. remains between outer layer of conductor and
inner surface of the external protective lagging of the drum. This is essential to ensure
that the conductor does not get closer to the lagging and to avoid damaged during
transportation/ reeling / unreeling or rolling on the undulated ground / fields.

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11.QUALITYASSURANCEPLAN:
The successful bidder shall submit following information along with the bid:
11.1. Test certificates of the raw materials and bought out accessories.
11.2. Statement giving list of important raw material, their grades along with names of
sub- suppliers for raw materials, list of standards according to which the raw
materials are tested. List of tests normally carried out on raw materials in presence
of bidder’s representative.
11.3. List of manufacturing facilities available.
11.4. Level of automation achieved and lists of areas where manual processing exists.
11.5. List of areas in manufacturing process, where stage inspections are normally
carried out for quality control and details of such tests and inspections.
11.6. List of testing equipment available with the bidder for final testing of equipment
along with valid calibration reports.
11.7. The manufacturer shall submit Manufacturing Quality Assurance Plan
(QAP) for approval & the same shall be followed during manufacture and testing.
11.8. The successful bidder shall submit the routine test certificates of bought out raw
materials/accessories and central excise passes for raw material at the time of
inspection.
11.9. The Company may at its option order the verification of these plans at
manufacturer's works as a pre-qualification for technically accepting the bid.
During verification if it is found that the firm is not meeting with the quality
assurance plan submitted by the firm, the offer shall be liable for rejection.
11.10. The material for final inspection shall be offered by the Supplier only under packed
condition. The owner shall select samples at random from the packed lot for
carrying out acceptance tests.
11.11. The Supplier shall keep the Owner 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.
11.12. No material shall be dispatched from its point of manufacture before it has been
satisfactorily inspected and tested unless the owner in writing waives off the
inspection. In the later case also the material shall be dispatched only after
satisfactory testing specified here in has been completed.

12.PACKING AND MARKING:

12.1. The packing shall have to be done as per standard practice worthy of road transport.
The covered conductor shall be wound in strong wooden drums so as to withstand
all stresses due to transportation, handling and stringing operation so that the
conductor surface is not cut, dented, scratched or damaged in any way during
manufacture, Transport & Stringing. The wooden drums shall be non-returnable and shall
generally conform IS: 10418/1982 with latest amendments. The packing of accessories shall
be sufficient to withstand, without limitation, rough handling during transit and exposure
to extreme temperatures, salt and precipitation during transit, and open storage.
12.2. The covered conductor drum should be suitable for wheel mounting, before reeling,
the cardboard or other suitable material shall be secured to the drum and inside
flanges of the drums. After reeling, the exposed surface area of conductor shall be
nearly wrapped with suitable soft material to protect the conductor from dirt and
grit.

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12.3. However, use of seasoned wood shall not be insisted, provided wood used should
be of good quality to withstand transportation hazards. The drums shall be having
inside flanges painted with Aluminium Paint and with Ordinary White Enamel paint
from outside. The conductor on each drum shall be securely fastened at each end.
The outer end of the covered conductor shall be fastened inside the drum against
one of the sides of the flanges while it is under tension and shall be such that no
looseness is transmitted to the internal layers. The covered conductor shall be
snugly, tightly and uniformly spooled on the drums. The wrapping of covered
conductor on the drums shall be laid snugly against side of the preceding wrap and
the first and last wrap in each layer shall fit snugly against the sides of the flanges.
Covered conductor shall be covered with PP sheet in wooden drum. The wooden
drums after covering by PP sheet shall be fastened by two steel tapes over the
covering on the two sides of adequate size to keep the drum intact and to prevent
the drum from crushing/ damage.
12.4. Although the various dimension of the drums such as flanges, stretches, traverse
and barrel diameter shall depend on the quantity of covered conductor as offered
and agreed upon, on one drum. The manufacturer while packing the covered
conductor in drum shall ensure that after winding complete quantity of covered
conductor in drum a uniform space of not less than 100 mm. remains between outer
layer of covered conductor and inner surface of the external protective PP sheet of
the drum.
12.5. Following details of identification shall be printing at interval of length of one Meter
of outer covering of covered conductor.
(a) Name of Manufacturer
(b) Year of Manufacture
(c) Voltage Grade
(d) AL-59 ACS
(e) 95⁰C Operating Temperature
(f) Name of Purchaser “ ---------- “.
(g)Generally as per EN 50397-1: 2020

12.6. The drums shall be marked clearly in block letters with water proof mark having the
marking attached to them so that there is no possibility of goods being lost or
wrongly dispatched due to faulty marking. The marking shall constitute the
following:-
i. Name & full address of the consignee.
ii. Destination station.
iii. Serial number of drum.
iv. Size of covered conductor
v. Total length of Conductor in drum, with individual length (s).
vi. Number of length(s) in each drum.
vii. Gross mass of drum including the tare mass of drum.
viii. Net mass of conductor.
ix. Name of the supplier.
x. Purchase order reference/TN number.
Besides above, an arrow shall be put on the drum so as to indicate the direction in
which the drum can be unwound.

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Beside this covered conductor shall also carry marking/printing at regular interval
as below:
Name of Manufacture or Trade Mark, Voltage Grade Covered AL-59 Aluminum
Alloy & ACS Conductor size in sq. mm. Year of Mfg., Standard EN 50397-1

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13.Annexure –I
Guaranteed technical particulars
To be submitted along with Tender documents in triplicate as per format annexed herewith
Technical characteristic shall be guaranteed by the bidder. In case of failure of materials to
meet the GTPs, the Purchaser shall have right to reject the material.
Sr. No Parameter Name Parameter Value / Name

1. GENERAL:
1.1 Brand Name or Trade Mark
1.2 Manufacturer‘s Name & Address
1.3 Size of the Conductor
1.4 Lists of Standard applicable for conductor and
Covered Conductor.
1.5 Manufactured as per reference standards
(Yes/No)
2. BASE CONDUCTOR:
2.1 Material of strands & Chemical composition
2.2 Applicable standard
2.3 Nos of strands of aluminium alloy
2.3 Nos of strands of ACS wire
2.4 Diameter of strand-mm- aluminium alloy (before
stranding) (After stranding not measurable being
compacted conductor.)
A) Nominal
B) Max
C) Min
Diameter of strand-mm- ACS
A) Nominal
B) Max
C) Min
2.5 Cross section area aluminium alloy strand-mm2
2.6 Cross section area ACS strand-mm2
2.7 Overall Diameter of Conductor (mm)
2.8 Minimum thickness of aluminium covering on
ACS wire
2.9 Minimum thickness of aluminium covering on
ACS wire confirms IEC 61232? (Yes/No)
2.10 Conductivity of ACS wire (IACS)
2.11 Cross section area of Conductor(mm2)
2.12 Conductor Type
2.13 Nominal cross section area of conductor (mm
Sq.)
2.14 Maximum DC resistance at 20o C Ohm /KM of
conductor

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Sr. No Parameter Name Parameter Value / Name

2.15 Maxi Inductive reactance OHM /KM of

conductor
2.16 Lay ratio of most outer layer Min
Max
2.17 Maximum allowable Continuous Conductor
Temperature (in 0C)
2.18 Maximum allowable Short time Conductor
Temperature (in 0C)
2.19 Breaking Load of conductor (KN)
2.20 Approximate Weight (Kg/Km)
2.21 Longitudinally water tight Conductor (Yes/No)
2.22 Assumed Conditions for Calculations : As per CEA
Conditions
Ambient Temp = 45°C ,
Continuous operating Temp. = 95°C
Solar Absorption coefficient =0.8,
Emissivity Coefficient = 0.45,
Intensity of Solar Radiation = 1045 W/m2,
Wind Speed = 0.56 m/s. Elevation = 0 m
2.23 Assumed Conditions for Calculations : As per CEA
Conditions
Ambient Temp = 45°C ,
Continuous operating Temp. = 105°C
Solar Absorption coefficient =0.8,
Emissivity Coefficient = 0.45,
Intensity of Solar Radiation = 1045 W/m2,
Wind Speed = 0.56 m/s. Elevation = 0 m
3. CONDUCTOR SCREENING:
3.1 Material
3.2 Nominal thickness (mm)
4. INSULATION:
4.1 Insulation Material (Inner Layer)
4.2 Insulation Material (Outer Layer)
4.3 Nominal thickness–Inner layer(mm)
4.4 Nominal thickness Outer Layer (mm)
4.5 Tolerance on thickness (Inner/Outer)
4.6 Color of Insulation (Inner/Outer)
4.7 Method of application of Insulation

4.8 Type of curing of XLPE Insulation.

4.9 Outer insulation layer is UV Protected, Weather
resistance and tracking resistance
XLPE(Yes/No)

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Sr. No Parameter Name Parameter Value / Name

4.10 Method of UV Stabilization of Outer layer of

insulation (Carbon Black or Other material)?
5. Complete Covered Conductor:
5.1 Maximum operating voltage of the Cable
5.2 Rated Voltage of the Cable
5.6 Maximum short circuit current for 1 Sec. (KA)
5.7 Approximate overall diameter of cable(mm)
5.8 Approximate overall cross section area of cable
(mm2)
5.9 Approximate Total weight of cable
KG / KM.
5.10 Approx. Breaking load of Conductor (KN)
5.11 Allowable sag as a percentage of span length at
40oC ambient temperature & permissible span
length for 8 meter PSC pole and with planting
length of 1.5 MTR
5.11 Permissible maximum span length in MTR with
above allowable sag calculations for 8 MTR
PSC pole network
5.12 Marking on Cable (Write text)
5.13 Max. continuous operating conductor
temperature (˚C)
5.15 Max. Leakage current (mA)
6. DRUM:
6.1 Standard drum length (Mtr.) & tolerance of each
Drum
6.2 Dimension of Drum
6.3 Shipping Weight.
6.4 Bending radius of the cable
6.5 Overall quantity tolerance
6.6 Drum material

14.PRINCIPAL PARAMETERS:
14.1. The details of Insulated / Covered AL 59 ACS Dog conductor are tabulated below:

Sr no. Particulars Unit Value

1 Stranding and diameter of - 6/4.72
aluminium Alloy AL59
2 Stranding and diameter of - 1/4.72
Aluminum Coated steel wire
3 Sectional area of aluminium mm2 105
alloy

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Sr no. Particulars Unit Value

4 Total sectional area mm2 122.48
5 Approximate diameter mm 14.16
6 Approximate mass(without Kg/km 403/680
insulation)/with insulation
7 Calculated resistance at 20°C Ω 0.2740
(max)
8 Approximate breaking load KN 41.60
(without insulation)

14.2. The details of Insulation are as follows:

Sr no. Particulars Unit value

1 Nominal thickness of conductor mm 0.30
screen
2 Nominal thickness of XLPE mm 2.30
insulation inner Layer
3 Nominal thickness of insulation mm 1.10
outer layer(UV Stabilized,
weather Resistant & Tracking
Resistant Black XLPE)

14.3. The lay ratio of the different layers shall be within the limits given

Sr no. Particulars Unit value

1 Number of wires Aluminium Nos 6
Clad Steel 1
2 Lay ratio of Al. wire Outer Min - 10
most layer
max 14
3 Ratio of aluminium wire 1.0
diameter to steel wire
diameter

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15.ACCESSORIES:
The Accessories of Medium Voltage Covered Conductor (MVCC) are specified below
and shall consist of the following:

Sl. No Description Application

1 Tension Assembly (TA) For fitting onto a pole for tensioning at the beginning or
end of a length of MVCC, or for anchoring while a major
change in direction.
The Tension assembly consists of one wedge type Tension
/ anchoring clamp and one Tracking protection IPC.
2 Insulator Clamp / Tie (IC) For supporting and aligning MVCC at an intermediate pole
in a length, with small angle of deviation.
The Insulator Clamp hold the MVCC in its position on top
of the pin or post insulator. Insulator Tie consists of either
an “Insulated Plastic” or “Metallic helical” Type for Line
Alignment.
3 Suspension Clamp (SC) For supporting a length of MVCC at an intermediate pole
in a length, with large angle of deviation with a disc
insulator.
The suspension clamp consists of an “Assembly with one
locking type Suspension clamp with provision to fix in
Insulators.
4 Insulation Piercing For main (Bare) to main (MVCC) networking connection.
Connector for “Bare to This connector is to ensure the electrical characteristics
Covered interconnection” with in the required limits, while ensuring necessary
(IPC – Type 1) insulation protection against tracking and water
penetration on MVCC.
5 Insulation Piercing For main (MVCC) to main (MVCC) networking or branching
Connector for of MVCC to another MVCC Or Branch Cable or Looping for
Networking / Branching transformer junctions.
/Looping This connector is to ensure the electrical characteristics
(IPC – Type 2) with in the required limits, while ensuring necessary
insulation protection against tracking and water
penetration on MVCC.
6 Insulation Piercing For Temporary Earthing Provision from MVCC Cable for
Connector with maintenance purpose.
Aluminum Bail for This connector is to ensure the electrical characteristics
earthing with in the required limits, while ensuring necessary
(IPC – Type 3) insulation protection against tracking and water
penetration on MVCC.
7 Tension Joints (TJ) Mid-span tension joints for jointing MVCC over a span
8 Lightning / Surge Arrestor Protection for the Network and transformer under lighting
Kit (with provision to condition.
connect with Covered

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Conductor)

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15.1. INSULATION PIERCING CONNECTORS:

15.1.1. Piercing Connectors (IPC) are used for making Tee / Tap-off/ connections to an
MVCC / Bare Overhead Line. The main purpose of a connector is to transmit
electricity from one conductor to another. From the electrical point of view the
connector should transmit electricity with smallest possible losses. From the
mechanical point of view the connector should be able to hold conductors together
without causing damages to them and sustain climatic loading. Connectors shall be
UV Resistant, corrosion resistant and inert to bimetallic electrochemical reactions.
It endures varying mechanical tensions and other forces detrimental to the
connection. Connectors shall be capable of carrying the load current, and fault
current if any.
15.1.2. The connector shall be water proof and the water tightness shall be ensured by
appropriate elastomer materials and not by grease, gel or paste alone.
15.1.3. Insulation Piercing Connector should have a design such that there is no stripping
of insulation on the covered conductor. It shall be able to get the lowest contact
resistance& Superior insulation as well as sealing performance.
15.1.4. The superior material and process technology ensure operation regularity in
corrosive environment.
15.1.5. Material of Insulation Piercing Connector should withstand for all routine &
acceptance test as per NFC 33 020- listed below:
1. Flashover - 15 kV for 1 min in water.
2. Short circuit test,
3. Heat cycle test
15.1.6. The following type tests shall be conducted on connector as per relevant standard
EN 50397-2:2008, with latest amended.
1) Electrical ageing test
2) Water tightness test
3) Mechanical tightening test
4) Environment test
 Corrosion test
 Climate ageing test
15.1.7. The following routine/acceptance tests shall be conduct on connector as per
relevant standard EN 50397-2:2008, with latest amended.
5) Visual examination
6) Dimension and material verification.

15.2.Alignment Ties:
The Alignment ties shall be designed suitably to hold the MVCC in its position on top of
the insulator. The Clamps is preferred to be made of Insulating Plastic materials or
protected with Insulating Plastic material to ensure tracking resistance and to avoid any
insulation damage to covered conductor due abrasion while mechanical or wind induce
vibration.

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15.2.1. The following type tests shall be conducted on Alignment Ties as per relevant
standard EN 50397-2:2008, with latest amended.
1) Mechanical and failure load test
2) Slip Load Test
3) Lift / Side Load Test
4) Thermal Test under load
5) Environmental tests
a. Corrosion test
b. Climate ageing test
6) Resistance against Tracking in heavy Polluted Areas

15.2.2. The following routine/acceptance tests shall be Alignment Ties on connector as

per relevant standard EN 50397-2:2008, with latest amended.
7) Visual examination
8) Dimension and material verification.

15.3.Suspension Clamps:
The Suspension Clamps shall be made of Insulating Plastic to ensure tracking resistance
and to avoid any insulation damage to covered conductor due abrasion while mechanical
or wind induce vibration.

15.3.1. The following type tests shall be conducted on Suspension clamp as per
relevant standard EN 50397-2:2008, with latest amended.
1) Mechanical and failure load test
2) Slip Load Test
3) Lift / Side Load Test
4) Thermal Test under load

15.3.2. The following routine/acceptance tests shall be Tension clamp on connector as

per relevant standard EN 50397-2:2008, with latest amended.
5) Visual examination
6) Dimension and material verification.

15.4. Tension Clamp

Tension clamp used For the purpose of terminating covered conductors over the
covering fitting shall include, but are not limited to, the following:
Wedge type clamp:
The fittings shall be able to withstand the specific minimum failure load (SMFL), shall not
damage the covering, and shall be designed to prevent the ingress of moisture during
service.
15.4.1. The following type tests shall be conducted on Tension clamp as per relevant
standard EN 50397-2:2008, with latest amended.

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1)Damage and failure load test

2)Tensile test at ambient temperature
3)Tensile test at low temperature
4)Tensile test at high temperature
5)Shear head function test
6)Water tightness test
7)Environmental tests for clamps
 Corrosion test
 Climate ageing test
15.4.2. The following routine/acceptance tests shall be Tension clamp on connector as
per relevant standard EN 50397-2:2008, with latest amended.
8) Visual examination.
9) Dimension and material verification.
10) Tensile Test at Ambient Temperature
11) Slippage Test at Ambient Temperature.
12) Check for Permanent Marking.

15.5. Tension Joints (Mid Span Jointing Sleeves)

The mid span Insulated jointing sleeves should be Pre-Insulated type. Sleeve should be
made of Aluminum and their current rating shall not be less than that of the covered
conductors, insulated with an Anti-UV black thermoplastic tube hermetically sealed two
ends with 2 flexible rings. Strip length, Hexagonal crimping die reference and size to be
marked on the outer surface of plastic sleeve Reference standard, type test and design
requirements as per NFC 33 021.The tensile strength of the mid span jointing sleeve after
crimping/compression shall not be less than 95% of the strength of the covered
conductors.
15.5.1 The following type tests shall be conducted on Suspension clamp as per
relevant standard NFC 33 021, with latest amended.
1) Voltage Test
2) Water Tightness Test
3) Climatic Ageing Test
4) Corrosion Test

15.5.2 The following routine/acceptance tests shall be Tension clamp on connector

as per relevant standard NFC 33 021, with latest amended.
1) Visual examination
2) Dimension and material verification.

15.6 Lightning / Surge Arrestors:

The surge arresters shall be capable of discharging over voltages occurring due to
switching on unloaded transformer, reactors and long lines. The reference current of
surge arresters shall be high enough to eliminate the influence of grading and stray
capacitance on the measured reference voltage. Values and calculations shall be
furnished with offer. The surge arrester shall be fully stabilized thermally to give a life
expectancy of one hundred (100) years under site conditions and take care of effect of
direct solar radiation. The surge arresters shall protect transformers and cable with
insulation level specified in the specifications. The surge arresters shall be capable of

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withstanding meteorological and short circuit forces under site conditions.

15.6.1 The following type tests shall be conducted on Earth parking device as per
relevant standard IEC 60099 -4:2014 /IS-3070 part III, with latest amended.
1) Insulation withstand test(Lightening Impulse withstand test, Dry & Wet
power frequency withstand test, Shear head function test)
2) Residual voltage test(Steep current Impulse Residual voltage test, Lightning
Impulse Residual voltage test and switching current Impulse Residual voltage
test).
3) Accelerated ageing test
4) Long duration current impulse withstand test
5) Operating duty test
6) Partial discharge test.
7) Weather Ageing Test

15.6.2 The following routine/acceptance tests shall be on each single surge

arrester in accordance with IEC 60099-4/ IS-3070 part III, with latest
amended.
1) AC Reference Voltage Test (final arrester)
2) Partial Discharge Test (final arrester including hardware/accessories)
3) Residual Voltage Test (final arrester or metal-oxide resistors)

15.7 Arc protection devices:

The arc protection devices shall be supplied to protect insulator sets and covered
conductors against damage caused by power arcs (arcing horns, arcing rings).
It shall withstand maximum short-circuit current 10 kA for 1 s (As per clause 4.2.4 of
En 50397-2:2008).
It shall withstand a mechanical load in order to support the installation strengths.
15.7.1. The following type tests shall be conducted on Arc protection as per relevant
standard EN 50397-2:2008, with latest amended.
1) Clamp bolt tightening test
2) Shear head function test
3) Hot dip galvanizing test
4) Damage to the main conductor test
5) Water tightness test
6) Short circuit test
7) Power arc test(only in connection with a complete insulation set)
8) Corrosion ageing test
15.7.2. The following routine/acceptance tests shall be arc protection device on
connector as per relevant standard EN 50397-2:2008, with latest amended.
9) Visual examination
10) Dimension and material verification.

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Earth parking Device/Insulation Piercing Connector with Aluminum Bail for

earthing:
The earth parking device shall be capable of carrying the short circuit current. The
maximum short circuit current shall be 10 kA for 1 s.
These fittings shall withstand a mechanical load in order to support the installation
strengths.

15.7.3. The following type tests shall be conducted on Earth parking device as per
relevant standard EN 50397-2:2008, with latest amended.
1) Clamp bolt tightening test
2) Shear head function test
3) Hot dip galvanizing test
4) Damage to the main conductor test
5) Water tightness test
6) Short circuit test
7) Mechanical test
8) Corrosion ageing test

15.7.4. The following routine/acceptance tests shall be Earth parking device on

connector as per relevant standard EN 50397-2:2008, with latest amended.
1) Visual examination
2) Dimension and material verification.

15.8.Marking of accessories:
All accessories mentioned above shall mark with the following:
 Manufacturer’s trade mark or logo;
 product code or reference;
 The minimum and maximum cross section for which the unit is suitable.
 Batch number & Year of manufacturing.

15.9. Acceptance criteria of accessories:

Note-Type Test Reports for 11 KV covered conductor accessories:The bidder shall

furnish valid and authenticated type test certificate from a Govt. approved / a Govt.
recognized / NABL Accredited laboratory / ILAC i.e. International laboratory
Accreditation Corporation (In case of foreign laboratory) of similar rating and design of
tendered material / equipment.

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16.ANNEXURE II: - TYPICAL GENERAL ARRANGEMENT DIAGRAM AND

DRAWINGS
1. Tension Assembly (TA) with Anchoring clamp and one Tracking protection IPC

2. Insulator Clamp / Tie (IC)

3. Suspension Clamp (SC)

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4. TYPE-1 : Insulation Piercing Connector for Networking / Branching

/Looping, TYPE -3: Insulation Piercing Connector with Aluminum Bail for earthing
and Tension Joints (TJ)

5. Insulation Piercing Connector for Bare to Covered interconnection

TYPICAL DRAWINGS
1. Tension Assembly (TA) with Anchoring clamp and one Tracking protection
IPC

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2. Insulator Clamp / Tie (IC)

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3. Suspension Clamp (SC)

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4. Insulation Piercing Connector for Bare to Covered interconnection

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5. Insulation Piercing Connector for Networking / Branching /Looping

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6. Insulation Piercing Connector with Aluminum Bail for earthing

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7. Tension Joints (TJ)

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ANNEXURE-III - Guaranteed technical particular of accessories

1. GTP for Tension Clamp

Sl. No. Description Particulars

1 Name of the Supplier

2 Type of Design

3 Weight

4 Cable Range Range to in line with this specification

5 Material

For conductor range of 50 - 70 sqmm =

20 KN
For conductor range of 70 - 120 sqmm =
6 Ultimate Tensile Strength 30 KN

For conductor range of 120 - 200 sqmm

= 30 KN

7 Installation(With/Without disassembly) Ready- to-use ( Without disassembling )

8 Marking

9 Dimensions

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2. GTP for Alignment Tie

Sl. No. Description Particulars

1 Name of the Supplier

2 Length

3 Weight

4 Cable Range Range to in line with this specification

5 Material

6 Installation(With/Without disassembly) Ready- to-use ( Without disassembling )

7 Marking

3. GTP for Suspension Clamp

Sl. No. Description Particulars

1 Name of the Supplier

2 Cable Range Range to in line with this specification

3 Material

4 Minimum Breaking Load - Vertical

5 Installation(With/Without disassembly) Ready- to-use ( Without disassembling )

6 Marking

7 Dimensions

8 Weight

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4. GTP for INSULATION PIERCING CONNECTOR

Sl No Particulars

1 Name of supplier
Bare to Covered conductor
2 Type of connection required Covered conductor to Covered
conductor
Tapping connector

3 Are torque limiting shear heads provided to

tightening bolts
4 Range of cable sizes Range to in line with this specification
accommodated for Main & Branch

5 Tightening Torque
6 Torque for establishing 70% of min torque specified
connection between main and Tap (Nm)

7 Marking and embossing on the connector

5. GTP for INSULATED MID SPAN JOINTS

Sl. No PARTICULARS

1 Name of Supplier.

2 IS manufacturer of Accessories
an ISO 9001-2000 Company?

3 Type No & Size Range Range to in line with this specification

Is any metallic part carrying

4 potential in operation exposed
during installation
5 Installation Crimping by Hexagonal Compression

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