DRAFT Doc No.: SM/IS 398 (Pt.1) PRODUCT MANUAL FOR ALUMINIUM CONDUCTORS FOR OVERHEAD TRANSMISSION PURPOSES PART 1 ALUMINIUM STRANDED CONDUCTORS ACCORDING TO IS 398 (Part 1):1996 (with Amendment No.01 APR 1999) (First Issue) MANAK BHAWAN, 9, B.S. ZAFAR MARG, NEW DELHI-110 002 Date of Issue: December 2013
Amendment Sheet To ensure that this Product Manual contains a complete record of Amendments, this Amendment sheet shall be maintained in the Product Manual. AMENDMENT No. Date of Issue Page No. /Text Affected [2]
0. Foreword BIS has published Indian Standards for Aluminium Conductors for Overhead Transmission Purposes in various parts which are used for transmission of Electrical Energy covering different types of conductors. Part 1 of the Indian Standard is for Aluminium Stranded Conductors generally referred as All Aluminium Conductor - AAC. This Standard was originally published in 1953.The First licence to use Mark was granted by BIS (earlier ISI) was as per this Standard. Now this standard is equivalent to International Standard IEC 60889: 1987. Different procedures are being adopted by BIS regional and branch offices. Sometimes the scope of the product in BIS licence was also found given differently. Therefore, it was felt necessary to prepare Product Certification manual for certification of Aluminium Conductors for Stranded Conductors for uniform procedures throughout BIS. This manual also aims to bring all the guidelines issued by CMD from time to time at one place. Guidelines for Grant of BIS Certification Marks Licence to use Mark for an applicant is also given in this manual. Grouping guidelines, sample size for testing, information about laboratories where the product can be tested for the purpose of Grant of Licence, Inclusion, etc., are described in the manual for the convenience of applicants as well as existing licensees. Efforts have been made to provide applicable Scheme of Testing and Inspection (STI), type & routine tests, marking fee, typical forms of test report. Amendment No.01 APRIL 1999 has been issued and implemented for IS 398(Pt.1): 1996 Suggestions for any improvement in the manual may be sent to CMD for consideration. BIS Standard Mark for the Product is as follows: IS 398 PART 1 [3]
Prepared by: NGBO CONTENTS Item Chapter Page -- Amendment Sheet No 2 0 Foreword 3 1 Introduction/ Product description 5 2 List of referred Indian standards for raw material and test method 5 3 Check List for submission of an application for grant of licence 5 4 Raw Materials (important/basic) 5 5 Description of manufacturing process 5 6 Infrastructure for production 6 7 List of test equipment with calibration requirement 6 8 Supply of Material 6 9 Sample(s) for independent testing 6 10 Test Request 7 11 Selection of laboratory, Testing charges and time 7 12 Critical requirements of the standard 7 13 Grouping guidelines 7 14 Testing in the factory 8 15 Testing for considering grant of licence 8 16 Writing Scope of the Licence (Product Description in the Licence) 8 17 Inclusion of new varieties 8 18 Operation of Certification Marks Licence 8 19 Manner of sealing the sample 9 20 Availability of packing material in the factory at all times for 9 sealing of the samples. 21 Whether remnants of the sample are returnable/non-returnable. 9 22 Procedure to be followed for destroying the product that does not 9 meet the quality parameters during regular production 23 Scheme of Testing and Inspection 9 24 Rate of Marking Fee 9 ANNEXES A Factory Testing Report 10 B Typical Manufacturing process flow chart 11 C List of Test facilities 12 D Scheme of Testing and Inspection 13-17 E Acceptance of Rate of Marking Fee 18 [4]
Prepared by: NGBO Stranded Conductors as per IS 398(Pt.1) : 1996 1. Introduction/Product description 1.1 This Indian Standard covers the requirements of Aluminium Conductors for Stranded Conductors generally referred as All Aluminium Conductor - AAC. 1.2 IS 398(Pt.1): 1996 covers the following sizes of conductors S.No. Nominal Aluminium (mm 2 ) Stranding and Wire Diameter (mm) 1 25 7/2.21 2 50 7/3.10 3 100 7/4.39 4 150 19/3.18 5 240 19/3.99 6 300 19/4.65 2 List of referred Indian standards for raw material and test method IS Title 2: 1960 Rules for rounding of numerical values 1778: 1980 Reels and Drums for bare conductors 1885(Pt.32): 1993 Electrotechnical vocabulary-electric cables 5484: 1997 EC grade aluminium rods produced by continuous casting and rolling 4026: 2007 Aluminium ingots billets and wire bars (EC grade) 1608: 2005 Metallic materials Tensile testing 7623: 1993 Lithium base grease for industrial purposes 3 Check List for submission of an application for grant of licence No separate check-list is required for the submission of the application. The check-list, as available on the BIS website shall be used. 4. Raw Materials (important/basic) 4.1 EC grade aluminium rod conforming to IS 5484 4.2 Lithium soap grease corresponding to grade II of IS 7623 having minimum drop point not less than 180 C 5. Description of manufacturing process See the ANNEX B [5]
Prepared by: NGBO 6. Infrastructure for production Following Machinery may be required for producing AAC a. Wire drawing machine Bull block b. Wire drawing machine to suitable sizes c. Necessary Dies of various sizes d. Pointing machine e. Spooling machine f. Stranding machine (as required) g. Electric Butt welding machine h. Weighing machine 7. List of test equipment with calibration requirement See ANNEX C (to be approved by CMD/CL) 8. Supply of Material 8.1 Unless otherwise agreed between the purchaser and the manufacturer, stranded aluminium conductors shall be supplied in the manufacturer s usual production lengths and with a permitted variation of ±5 percent in the length of any one conductor length. 8.2 Random lengths Unless otherwise agreed between the purchaser and the manufacturer, it shall be permissible to supply not more than 10percent of the lengths on any one order in random lengths; none of them shall be shorter than one-third of the nominal length. 8.3 The Conductor shall be wound on Reels or Drums and marked as per STI. 9. Sample(s) for independent testing a) Approximately 5 metres of finished Stranded Conductor. b) Approximately 5 metres of Aluminium Wire before standing. c) Approximately 1 metre of Aluminium Rod from which the conductor has been manufactured. [6]
Prepared by: NGBO 10. Test Request Test request shall clearly indicate the following: 10.1 For the Finished Conductor a) Nominal Aluminium in mm 2 with Stranding and wire diameter. b) Drum No./Lot No./Batch No. with Date of manufacture. c) Length of the Conductor 10.2 For the Aluminium Wire before stranding a) Diameter of the Wire b) Reel No with Date of manufacture. c) Length of the Wire. 10.3 For the Aluminium Rod a) Diameter of the Rod b) Batch No./Coil No. c) Length of the Rod 11. Selection of laboratory, Testing charges and time 11.1 Samples shall be tested either at BIS laboratory or BIS recognized laboratory. A list of recognized laboratories is given on BIS website. Selection of laboratory for independent testing shall be as per provisions of OMPC. 11.2 Testing charges as fixed by CL are available on BIS website. The present testing charges are as follows: Seven strands construction Rs.750/- (plus ST as applicable) Nineteen strands construction Rs. 1350/- (plus ST as applicable) 11.3 Maximum of Three days are sufficient for testing of the product. 12. Critical Requirements of the Standard (to be identified by CMD/ETD) 13. Grouping guidelines S.No. Group Nominal Aluminium (mm 2 ) [Refer Col(1),Table 2 of IS 398(Pt.1):1996] 1 A Upto and including 100 2 B Above 100 13.1 One sample from each group, preferably highest size, shall be drawn for covering entire range of sizes in the group. 13.2 Firm to declare size of conductors they intend to cover in the licence. IO may accordingly verify their manufacturing capability and availability of testing facilities to restrict size of conductors and may recommend grant of licence/inclusion. [7]
Prepared by: NGBO 14. Testing in the factory 14.1 Following tests are mandatory to do in the factory on the sample(s) selected, during preliminary visit/verification visit (simplified procedure) and during regular surveillance visits, as these are subjective in nature and cannot be done by independent laboratory. a) Freedom from defects as per clause 6 b) Joints as per clause 8 14.2 Other tests to be done during factory visit. a) Diameter, Breaking Load, Wrapping and Resistance tests on Aluminium Wires removed from the Stranded Conductor and also on the Wires before stranding (whenever available). b) Lay ratio on the Finished Stranded Conductor. See ANNEX A for format of test report. 15. Testing for considering grant of licence Grant of licence/inclusion of new varieties is based on Independent testing. However, as per the provisions of OMPC, depending on the urgency/availability of manpower BO can decide regarding Factory testing. 16 Writing Scope of the Licence (Product Description in the Licence) Aluminium Stranded Conductors for Overhead Transmission Purposes, Sizes: Up to and including mm 2 nominal Aluminium 17 Inclusion of new varieties The same similar guidelines are to be followed for inclusion of new varieties as is being followed for grant of licence and samples are to be selected as per the grouping guidelines along with raw material(s). 18 Operation of Certification Marks Licence 18.1 At least two surveillance inspections are required to be done in an operative year of a licence, as per the requirements of the BIS (Certification) Regulations, 1988. The inspections shall be planned in a manner to evenly spread over during the period of a licence s validity. 18.2 The implementation of STI shall be verified during surveillance inspection. 18.3 During surveillance visits samples of different varieties covered in the licence shall be drawn for testing in the factory as well as outside lab so that all the varieties covered in the licence are inspected and tested over a period of three years. Raw material samples need not be drawn during surveillance visits. [8]
Prepared by: NGBO 18.4 Two Market samples of the finished product shall be drawn during an operative year. Efforts also should be made to obtain Customer Feedback from the users as it is generally not possible to obtain market samples as the product is supplied to Utilities. 19 Manner of sealing the sample The sample(s) should be coiled and wrapped with Polyethylene wrapper/other suitable material wax sealed after attaching a tag with Sample code & details 20 Availability of packing material in the factory at all times for sealing of the samples. Polyethylene wrapper/other suitable material, Paper/Cloth/Metallic tags and Wax stick. 21 Whether remnants of the sample are returnable/non-returnable. Non-Returnable and are to scrapped. No special care is required for disposal of the remnants. 22 Procedure to be followed for destroying the product that does not meet the quality parameters during regular production. 22.1 Non-conforming material whether at wire drawing stage or at stranding stage shall be scrapped and disposed-off. 22.2 Separate record shall be maintained regarding the rejected material. 23 Scheme of Testing and Inspection See ANNEX D for the latest STI Doc: STI/398(Part 1)/2 July 1998 24 Rate of Marking Fee See ANNEX E for the details of the latest marking fee in the requisite proforma for taking acceptance. This Rate of Marking Fee is applicable only to the Indian manufacturers. [9]
ANNEX A Factory Testing Report as per IS 398(Pt.1): 1996 Product: Aluminium Stranded Conductors for Overhead Transmission Purposes (AAC) Nominal Aluminium and Stranding & wire diameter: Drum/Coil No. and Manufacturing date: S.No. Clause Requirement Sp.Value Ob. Value 1 11 Packing and Marking a) Source of Manufacture b) Size and Type of Conductor c) Net mass of conductor in kg d) Gross mass of conductor in kg e) Length of conductor in m 2 12.2 Diameter of Wires Before Stranding (mm) After Stranding (mm) 3 12.3 Breaking Load Test Before Stranding (kn) After Stranding (kn) 4 12.4 Wrapping Test Before Stranding After Stranding 5 12.5 Resistance test at 20 C Before Stranding (Ohms/km) After Stranding (Ohms/km) 6 12.6 & 9.4 7 12.6 & 9 Lay Ratio Outer layer Inner Layer Stranding Direction of outer layer Direction of inner layer 8 6 Freedom from defects 9 8 Joints in wires Result/Remarks: Signature: Name: Designation: Representing: BIS Applicant/Licensee [10]
ANNEX B Typical Manufacturing Process Flow Chart Aluminium ROD Drawn to Intermediate size Drawn to actual size Check as per STI of wire as required Application of neutral grease (whenever required by the customer) Stranding to actual size of conductor Roll on to Drums (or) Coiled Marking Packing Inspection and Testing as per STI Storage/Dispatch [11]
ANNEX C List of Test Facilities S.No. Test Least Count Calibration Tests used in Remarks Equipment/Chemicals & Range with clause 1 Micrometer 0.01mm Upto 25mm Yes Diameter of wire 2 Tensile testing machine With necessary grips 10N & Upto5000N Yes Breaking load Separation of jaws of the machine shall be between 25 & 100mm/min 3 Kelvin Double Bridge or Wheatstone Bridge with all accessories and connecting leads 0.2 micro- Ohms & Upto 11 Ohms 4 Digital micro-ohm Meter with connecting leads 0.01mOhms & 20.00kOhms 5 Thermometer 1 C & Upto 60 C 6 Vernier Callipers 0.02mm & Upto 150mm 7 Measuring Scale 0.5mm & Upto 300mm/ 600mm/ 1000mm Yes Resistance Alternate to S.No.4 Yes Resistance Alternate to S.No.3 Yes Resistance Yes No Lay Ratio, Sectional area, Overall Dia Lay Ratio, Resistance [12]
ANNEX D Doc:STI/398 (Part 1)/2 July 1998 SCHEME OF TESTING AND INSPECTION FOR CERTIFICATION OF ALUMINIUM CONDUCTORS FOR OVERHEAD TRANSMISSION PURPOSES ACCORDING TO IS 398 (Part 1):1996 (Third Revision) 1. LABORATORY: A laboratory shall be maintained, which shall be suitably equipped and staffed, where different tests shall be carried out in accordance with the methods given in the specification. 1.1 All inspection, measuring and test equipments shall be periodically calibrated at least every year and records of such calibrations shall be maintained. 2. TEST RECORDS: All records of tests and inspections shall be kept in suitable forms approved by BIS. 2.1 Copies of any records or charts that may be required by BIS shall be made available at any time on request. 3.0 QUALITY CONTROL: It is recommended that as far as possible, Statistical Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme (See IS:397 (Part I):1972, IS:397 (Part 2):1985 and IS:397 (Part 3):1980). 3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with the Quality System Modules as per IS/ISO 9001 or IS/ISO 9002 or IS/ISO 9003 as appropriate to the activities of the organization. 4.0 The manufacturer s label attached to each coil of conductor as also each real or drum on which conductor is coiled shall carry the standard mark as given in column 1 of the First Schedule of the license, provided always that the conductor to which this Mark is thus applied conforms to every requirement of the specification. 5.1 MARKING: In addition, the drum/labels shall contain the following information: a) Manufacturer s Name and/or his recognized trade mark, if any; b) Size of conductor; c) Length of conductor; d) Drum number or identification in code or otherwise to enable the date and lot of manufacture to be traced back to factory records; e) Made in India, if required. [13]
Doc:STI/398 (Part 1)/2 July 1998 5.2 The standard Mark shall be applied in such a manner that as far as possible, the empty reels do not retain the Standard Mark intact, as otherwise these might be fraudulently used by any person so as to deceive that his product coiled on the reels carried the Standard Mark and thus conforms to the specification. 6. LEVELS OF CONTROL: The tests and inspection, as indicated in Table 1 attached and at the levels of control specified therein, shall be carried out on whole production of the factory covered by the license and appropriate records and charts maintained in accordance with paragraph 2 above. On the basis of test results decision regarding conformity or otherwise of the control unit shall be taken. All the production which conforms to the Indian Standard and covered by the license shall be marked with Certification Mark of the Bureau. 6.1 On the basis of test and inspection results, decision regarding conformity or otherwise of the lot as a whole with the requirements of the specification shall be made as follows: 6.1.1 Each of the samples taken for test shall satisfy the requirements of the specification for acceptance of each coil. 6.2 In respect of all other clauses of the specification and at all stages of manufacture, the factory shall maintain appropriate control and checks to ensure that their product conform to various requirements of the specification. 6.3 In case any failure is observed, the future production of that particular type shall not be marked until the results of further tests on that type indicate conformity with the requirements of the specification. 7.0 REJECTIONS: A separate record shall be maintained giving information relating to the rejection of conductors which do not conform to the specification and of the method of their disposal. Such conductors shall, in no case be stored together with those conforming to the specification. 8.0 SAMPLES: The licensee shall supply, free of charge, the samples required in accordance with the Bureau of Indian Standards (Certification) Regulations, 1988, as subsequently amended from the factory or godowns. The samples so supplied would be returned to the licensee after the tests have been carried out. The transport charges shall be borne by the licensee. The Bureau shall pay for the samples taken by it from the open market. 9.0 REPLACEMENT: Whenever a complaint is received soon after the goods with Standard Marks have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods or their components shall be replaced free by the licensee in case the complaint s is proved to be genuine and the warranty period (where applicable) has not expired. The final authority to judge conformity of the product to the Indian Standard shall be with the Bureau. [14]
Doc:STI/398 (Part 1)/2 July 1998 9.1 In the event of any damages caused by the goods bearing the Standard Mark, or claim being filed by the consumers against BIS Standard Mark and not conforming to the relevant Indian Standard, entire liability arising out of such non conforming product shall be of licensee and BIS shall not in any way be responsible in such cases. 10.0 STOP MARKING: The marking of the product shall be stopped under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of their product to the specification, or the testing equipment goes out of order. The marking may be resumed as soon as the defects are removed under intimation to Bureau. The information regarding resumption of markings shall also be sent to the Bureau. 11.0 PRODUCTION DATA: The licensee shall maintain production data as per enclosed proforma-1, which may be authenticated by a Chartered Accountant or by the licensee by giving affidavit 7 (which may be required along with renewal application). The licensee shall sent to the Bureau as per the enclosed, proforma-1 exported by him and the trade value thereof during the half year ending 30 June and 31 December. This statement is required to be forwarded to the Bureau on or before 31 st day of July and January for the preceding half year. [15]
Doc:STI/398 (Part 1)/2 July 1998 IS 398 (Part 1): 1996 ALUMINIUM CONDUCTORS FOR OVERHEAD TRANSMISSION PURPOSES (TABLE 1 LEVELS OF CONTROL) (Para 5 of the Scheme of Testing and Inspection) TEST DETAILS LEVELS OF CONTROL Clause Requirements Test Method No. of Frequency 7& Aluminium Wire Table 1 Clause Reference Samples 7.1 Diameter 12.2 & IS 398 (Part I) 1 Each bobbin of aluminium wire drawn/received 7.1 Breaking lead 12.3 -do- 1 -do- 7.1 Wrapping test 12.4 -do- 1 -do- 7.1 Resistance 12.5 -do- 1 -do- General Requirements All wires Freedom from defects. Joints in wires. 6 -do- Standard Conductor 7.2 & Size Table 2 7.2 -do- and 1 Every length of standard conductor. 7.2.2 Resistance 12.5 -do- 1 -do- 9.1 Stranding 9 -do- 1 -do- 9.2, 9.3, Lay Ratio 9.4 & Table 3 12.6 -do- 1 -do- Remarks If any sample fails, in respect of any requirement two more samples from the same coil shall be tested for that requirement and if there is any further failure in retesting, the coil shall be rejected. [16]
PROFORMA - 1 PROFORMA FOR OBTAINING PRODUCTION DETAILS Period covered Name of Licensee CM/L No. Name of Articles (s): AAC IS No. 398(Part 1): 1996 Grade/Type/Size/Variety/Class/Rating: 1.1 Brand/Trade/Name(s) of BIS Certification Marked Products 2.0 Total production of the articles(s) Licensed for certification marking 2.1 Total production of the article(s) Conforming to Indian Standard 3.0 Production covered with BIS Certification Mark a) Quantity b) Value (Rs.) 3.1 Brand Name used on production covered under BIS Certification Mark 3.2 Calculation of marking fee on unit-rate basis; Marking Fee per unit a) Unit b) Quantity covered with BIS Certification Mark c) Marking fee rounded off in whole rupees as obtained by applying unit rates given in (a) on quantity given in (b) Note: Incase a clause is not applicable, suitable remarks may be given against it. 4.0 Quantity not covered with BIS Certification Mark. If any, and the reasons for such noncoverage 4.1 Brand Name under which non certified goods were sold 5.0 Quantity Exported with BIS Standard Mark and its value 5.1 Brand Name under which BIS Certified goods are exported 6.0 Authentication by Chartered Accountant [17]
ANNEX E ACCEPTANCE OF RATE OF MARKING FEE We hereby agree to pay marking fee to Bureau of Indian Standards after grant of licence to use the Standard Mark on Aluminium Conductors for Overhead Transmission Purposes - Aluminium Stranded Conductors according to IS 398(Part 1): 1996 at the following rates and in the manner stipulated as under: i) Rate of marking fee: Rs.36.60 per UNIT for all the units with a Minimum of Rs. 34,000/- (for Large Scale manufacturers)* Minimum of Rs.29,000/- (for Small Scale manufacturers)* During an operative period of ONE year UNIT ONE Tonne ii) The marking fee is payable as follows: a) Minimum marking fee for one operative year payable in advance which will be carried over to next renewal(s). b) Actual marking fee for the first nine months of the operative period calculated on the unit rate on the production marked or the minimum fee whichever is higher shall be payable at the time of the first renewal of the licence. For subsequent renewals, the actual marking fee for 12 months period consisting of last three months of previous operative year and the first nine months of the current operative year or the minimum fee whichever is higher, shall be payable. c) Service tax @ 12.36 % as applicable shall also be payable. Signature: Name: Place: Date: Designation: Seal: [*Strike out whichever is not applicable] [18]