Technical Specification
Technical Specification
INSULATOR
September 2017
Engineering Department
1. SCOPE :
2. STANDARD :
The Post and Disc Insulators shall comply in all respect with the provisions of the following
Standards as amended up-to-date unless otherwise specified hereinafter and also as per
relevant IEC’s.
Normally the offer should be as per Technical Specification without any deviation. But any
deviation felt necessary to improve performance, efficiency and utility of the Post/Disc insulator
and insulator hardware fittings must be mentioned in the Deviation Schedule with reasons duly
supported by documentary evidence. Such deviation suggested may or may not be accepted.
Deviation not mentioned in ‘Deviation Schedule’ will not be considered.
A. DISC INSULATOR :
(i) The insulator discs shall be cap and ball pin type with Ball and Socket coupling suitable for
use in suspension or tension strings. Insulators shall be interchangeable and shall be
suitable for forming either suspension or tension string. Normal type disc insulator with
Ball and Socket coupling is not acceptable. Anti fog type disc insulator is to be supplied
only.
(ii) The porcelain shall be uniform brown colour, non-porous having high dielectric mechanical
and thermal strength, free from internal stresses, blisters, laminations, voids, foreign
matters, imperfections or other defects, which might in any way render it unsuitable as
insulator shells. Porcelain shall be smoothly glazed to remain unaffected by climatic
condition, Ozone, acids, alkalies, zinc or dust.
(iii) The glaze shall have bright Luster, smooth surface, a good performance under extreme
weather condition of tropical climate and dust resistant. The glaze shall not crack or chip
due to ageing under normal service condition or while handling during transit or erection.
(iv) Cement used in the construction of insulators shall not cause fracture by expansion or
loosening by contraction and must have high compressive and shearing strength and free
from change in volume due to ageing and temperature change. The cement shall not give
rise to chemical reaction with metal fittings. Rapid hardening cement with special sand
shall be used for assembly of metal parts. When operating at normal rated voltage there
shall be no electric discharge between insulator and conductor, which would cause
corrosion or injury to conductor and insulator by the formation of substance due to
chemical action.
(v) The caps and ball pins of Disc Insulator shall be hot dip galvanised in accordance with the
latest edition of IS : 2629 and mechanically strong. The Zn used for galvanising shall be of
grade Zn 99.95 as per IS : 209. The Zinc. Coating shall be uniform, adherent, smooth
reasonably bright, continuous and free from imperfection such as flux, ash, rust stains
bulky white deposits and blisters. The ball pins shall move freely in the cap socket, but
shall be so designed that they do not disengage while in service. The caps shall be made
of heat treated malleable cast iron. These shall be free from cracks, shrinks, air holes,
burrs and rough edges. All load bearing surfaces shall be smooth and uniform so as to
distribute loading stress evenly.
(vi) The ball pins shall be of forged steel and so designed that they will not yield or distract
under loaded conditions. The ball and socket insulators shall be provided with ‘R’ clip to
prevent uncoupling of insulator units from each other. The ‘R’ clip shall be made of
phosphor bronze or stainless steel to safe guard against corrosion.
(vii) The electrical and mechanical characteristic of the Disc Insulator shall conform to specific
technical parameters of this specification and relevant Indian Standards. Each Insulator
shall have rated strength markings on porcelain printed and applied before firing.
B. POST INSULATOR :
(i) The porcelain used shall be homogeneous, free from lamination, cavities thoroughly verified
smoothly glazed and type of post insulator shall be solid core. The glaze shall be of uniform
brown in colour. The glaze shall cover the exposed porcelain parts of the insulator. Glazing
shall be free from blisters, burrs etc.
(ii) The post insulator shall be designed and manufactured to avoid stresses due to expansion and
contraction which may lead to deterioration, stress concentration due to direct engagement of
porcelain with metal fittings and shapes which do not facilitate cleaning by normal methods.
(iii) Cement used in the construction of insulators shall not cause fracture by expansion or
loosening by contraction and must have high compressive and shearing strength and free from
change in volume due to ageing and temperature change. The cement shall not give rise to
chemical reaction with metal fittings. Rapid hardening cement with special sand shall be used
for assembly of metal parts. When operating at normal rated voltage there shall be no electric
discharge between insulator and conductor, which would cause corrosion or injury to
conductor and insulator by the formation of substance due to chemical action.
(iv) All ferrous metal parts except those of stainless steel shall be hot dip galvanised and uniform
zinc coating shall satisfy the requirement of IS:2633. The Zinc used for galvanising shall be
grade Zn 99.95 as per IS:209. The zinc coating shall be uniform, adherent smooth, reasonably
bright, continuous and free from imperfection.
(v) The tapped holes suitable for bolts with threads shall have anti-corrosion protection. The
effective length of the thread shall not be less than the nominal diameter of the bolt.
(vi) The electrical and mechanical characteristics of post insulator shall conform to the specific
technical parameters of this specification and relevant Indian Standards.
(vii) Post Insulator shall be suitable for upright mounting on steel structures.
(i) General design of hardware fittings shall be such as to ensure uniformity, high strength, and
freedom from corona formation and high resistance against corrosion.
(ii) The materials of the fittings shall be so selected that yield strength of the material shall not be
less than maximum working load.
(iii) All shackles, fasteners, eyes, suspension and tension clamp and other fittings for attaching
insulators to the Gantry tower, A-frame & other sub-station structure with conductor shall be so
designed as to reduce any damage to conductor, insulator & hardware fittings. Anchor shackles,
Ball hook, Ball eye, Ball clevis, Ball link, Socket clevis, Yoke plates, Arcing horn, turnbuckle,
jumper cone. Comp. Dead end assembly Bolted type suspension clamp etc. shall be supplied as
per requirement.
(v) All forgings and castings shall be of good finish and free from flaws and other defects. The
edges on the outside of fittings such as the eye, clevis and holes shall be rounded.
(vi) All parts of different fittings which provide the inter connection shall be made such that sufficient
clearance is provided at the connection point to ensure free movement and suspension of the
insulator string assembly. Suspension clamps shall be so designed that the effects of vibration
both on conductors and fitting itself are minimised. The clamp shall permit the conductor to slip
before the failure of the conductor occurs. The fitting shall have sufficient contact surface to
minimise damage due to fault current.
(vii) The Hardware fittings for Suspension and Tension string shall be supplied complete in all
respect.
(viii) The suspension hardware is to be used with normal (B-type) disc insulator having Electro-
mechanical Strength of 70 KN for all voltage classes except 400KV and tension hardware are to
be used with normal. (B-type) disc insulator having Electro-mechanical Strength of 120 KN for
220 KV, 132 KV & 33 KV voltage class & 160KN for 400KV voltage class. For 400KV suspension
string Disc insulator with normal (B) type disc insulator having electro mechanical strength of
120KN shall be used.
(ix) Suspension and tension hardware shall be suitable for insulator with nominal pin shank diameter
of either 16 mm. or 20 mm. as per approved 12KV Class Disc insulator to be utilised at sub-
station. Unless specifically mentioned the tension clamps shall be of compression dead end type
and shall have a steel sleeve to be compressed on the steel core end of the conductor.
(x) Sag compensating spring shall be within the scope of supply by the Contractor for 400 KV Main
I, Main II and Transfer Bus. Design calculation of the springs are to be submitted during detailed
Engineering
(xii) Design of fittings shall be such as to avoid local corona formation or discharges and shall have
smooth finished surface of all parts.
Each suspension and tension hardware set shall comprise of the following components.
SINGLE SUSPENSION & DOUBLE SUSPENSION HARDWARE SET FOR 132KV, 220KV
SINGLE TENSION & DOUBLE TENSION HARDWARE SET FOR 132KV, 220KV
(xiv) All necessary hardwares for following type of 400KV String insulators shall be within the scope of
supply.
a) 400KV Double Tension string insulator with double anchoring point suitable for Quad
ACSR Moose Conductor.
b) 400KV Double Tension String insulator with double anchoring point suitable for Twin
ACSR Moose Conductor.
c) 400KV Single Suspension String insulator suitable for Quad ACSR Moose Conductor.
d) 400KV Single Suspension String insulator suitable for Twin ACSR Moose Conductor.
(i) Twisted Eye Link (ii) Turn Buckle (iii) Yoke Plate
(iv) Clevis Clevis (v) Corona ring (vi) H-H Ball Link
(vii) Anchor Shackle (viii) Corona ring (ix) Turn Buckle
(x) Tension Clamp (xi) Socket Clevis
Any other hardware components not mentioned above but necessary for Double tension string
shall be within the scope of supply of Contractor.
6. GUARANTEE :
In the event of placement of Letter of Award the contractor shall submit six (6) copies of the
following drawings and catalogue/manuals for approval :
(i) Dimensional general arrangement drawing showing all fittings and accessories, sectional
drawing etc. of individual disc and post insulator with all technical parameters and G.T.P.
(ii) Dimensional general arrangement drawings of insulator string (Tension and Suspension)
along with all fittings and accessories, technical parameters of the string and drawing of
individual hardware components along with G.T.P.
Four (4) sets of approved drawings, G.T.P. and four (4) copies of Catalogue / Manual both in
hard and soft copy shall be submitted for our record and distribution to site.
All routine and acceptance tests of Disc insulator, Post insulator and Disc Insulator string, and
hardware components shall be carried out at the works of the manufacturer as per relevant
Indian Standards & IEC in presence of representative of WBSETCL.
All acceptance tests shall be carried out at the manufacturer’s works on every lot offered for
inspection as per relevant Indian Standards. Selection of samples for acceptance test as well as
rejection and re-testing shall be guided by relevant IS and IEC. The entire cost of acceptance
and routine tests that are to be carried out as per relevant IS shall be treated as included in
quoted price of Disc and Post insulator, Disc Insulator string and hardware accessories. Three
(3) copies of test reports shall be submitted for approval and distribution to site.
An advance notice of 15 (fifteen) days shall be given by the contractor to Chief Engineer, Engg.
Deptt. intimating the actual date of tests and details of all inspection that are to be carried out.
Contractor has to co-ordinate among disc insulator manufactures and insulator hardware
manufactures for conducting all acceptance test of disc insulator string as per relevant IS &IEC.
Only type tested Disc Insulators , Post insulator & Insulator Hardware are to be offered
conforming to our technical specification, and relevant IS and IEC. Disc Insulators , Post
insulator & Insulator Hardware offered should be similar with ones on which type testing has
been carried out as per relevant IS and IEC. Three sets of complete type test reports carried
out in Govt. recognized Test House or Laboratory /NABL accreditated laboratory shall have to
be submitted by successful bidder positively alongwith submission of drawings during detailed
Engineering. Successful bidder may require to produce original copies of type test reports at the
time of detail Engineering if asked by WBSETCL.
Each type test report shall comply the following information with test result
i) Compete identification, date and serial no.
ii) Relevant drawings as documented with test report.
iii) Method of application, Where applied, duration and interpretation of each test.
19 Bus-bar Conductor Quadruple Moose Twin Moose for Twin Moose for Twin Moose
for main I & II, Main I&11 Bus Main 1&11 Bus & for Main Bus
Twin Moose for Single Moose for Single Moose For & Single
Transf Bus for Transf Bus for Transf Bus for Moose For
400/220/132/33K 400/220/132/33K 400/220/132/33K Transf Bus
V S/stn. V &220/132/33KV V S/stn.& Twin FOR
S/stn. Moose for Main 220/132/33K
Bus & Single V&
Moose For Transf 132/33KV
Bus for S/stn.
220/132/33KV &
132/33KV S/stn.
The disc of 255 mm dia. with electromechanical strength of 70 KN for 220 KV , 132 KV & 33 KV
Switchyard. Distance between centre of unit shall be 145mm for 400KV, 220KV, 132KV & 33KV. The
minimum number of disc per suspension string for 400KV, 220 KV, 132 KV, & 33 KV shall be 24nos.,
15 nos., 10 nos and 3 nos. respectively. The disc of 280 mm. Dia with electro-mechanical strength of
120KN shall be used for suspension insulator string for 400KV.
Post Insulator :
SNO DESCRIPTION TECHNICAL PARAMETERS
400KV 220 KV 132 KV 33 KV
1 Rated Voltage (KV) 400 220 132 33
2 Highest System Voltage (KV) 420 245 145 36
If corona extinction voltage is to be achieved with the help of corona ring or any other similar device,
the same shall be deemed to be included in the scope of the contractor.
i) a) Type of insulators
(1) Ball and socket :
(2) Conventional / Antifog :
b) Size & designation of ball and socket:
with standard to which it will conform
iii) Dimensions
a) Porcelain disc diameter (mm) :
b) Unit spacing (mm) :
c) Creepage distance (mm) of each
disc (min.) :
v) Mechanical Values
a) Electro mechanical strength (KN) :
b) Mechanical failing load (KN) :
Suspension Tension
Insulator String Insulator String
Single / Double Single / Double
2. Applicable Standard :
4. Electro-mechanical strength of
Complete string (Kgf) :