~ ~ \ ;,,~ ~/'" ~ -~~~ C{/)j.. ' \"':_\ ' h 1 1:.iiVm1:..i\~'" TECHNICAL DOCUMENTS OF PRE-QUALIFICATION FOR INSULATOR (MANUFACTURER/TYPE/MODEL) OF TRANSMISSION LINE EGAT'S TRANSMISSION SYSTEM DEVELOPMENT Electricity Generating Authority of Thailand (EGAT) hereby announces the Technical Documents of Pre-Qualification for Insulator (Manufacturerffype/Model) of Transmission Line. ELECTRICITY GENERATING AUTHORITY OF THAILAND December 26, 2016 ~ i\~~ Oso~pl'-tvDI~,~ (Mrs. Nilanate Osotpavapusit) Chief, Transmission System Development Area Foreign Procurement Department Remarks The Technical Documents of Pre-Qualification for Insulator (Manufacturer/Type/Model) of Transmission Line has been announced on October 11, 2016 and revised on December 26, 2016.
TECHNICAL DOCUMENTS OF PRE-QUALIFICATION FOR INSULATOR (MANUFACTURER/TYPE/MODEL) OF TRANSMISSION LINE (REVISION 1) EGAT'S TRANSMISSION SYSTEM DEVELOPMENT
Drawings and Documents to be Furnished: Insulator for 115 & 230 kv Single & Twin bundled conductor and 230 kv Four-bundled conductor.--\ ; 1. Filled-in Supply Record Form. 2. Name of manufacturers and countries of origin. 3. Sufficient drawings, catalogs, leaflets, material specifications, and other identifying and descriptive literature to clearly demonstrate that the Equipment offered meet all the requirements of the Bidding Documents and the Specifications. 4. Sufficient references describing at least three (3) consecutive years of successful operation/use of the insulators of the same ANSI class specified in this Invitation in similar transmission line project. The references shall clearly demonstrate name of the transmission line and its operating voltage; month and year of delivery completion and operation; quantity of operated insulators; and names of the utility, including the names of utility representatives, their titles, addresses, and telephone and facsimile numbers for further communication. 5. Previous test reports of the insulators of the same ANSI class required in this Contract Documents demonstrating that the offered insulators meet or exceed the technical requirements of Specifications No.C-2 (Revision 6) and Specifications No. TL-01 : Additional Specification of Insulator Tests. The tests must be performed in accordance with ANSI C29.2 by the method of ANSI C29.1, which consist of: a) Design tests b) Quality conformance tests c) Steep front wave test d) Power arc test The acceptance criteria for the tests shall be in accordance with the requirements specified in EGAT's Specifications. Moreover, the reports shall be of the tests carried out no longer than ten (10) years before the bid opening date. Such previous test must be witnessed and the test report must be certified by a representative of an internationally-recognized testing laboratory, or inspection firm, or an institute, or a client inspector which is clearly not aligned with the manufacturer. Insulator for 500 kv 1. Filled-in Supply Record Form. 2. Name of manufacturers and countries of origin. 3. Sufficient drawings, catalogs, leaflets, material specifications, and other identifying and descriptive literature to clearly demonstrate that the Equipment offered meet all the requirements of the Bidding documents and the Specifications. 4. Sufficient reference describing the technical experience of the manufacturers in the design, manufacture and testing of same or similar type of insulators, number of years of experience. 6 l
5. Records of past successful supply, of not less than 5 years of the same or equivalent type of insulators and their use in extra-high voltage projects including the supplied quantity. 6. Previous test reports of the same ANSI class 52-8 and 52-11 suspension insulators demonstrating that the insulators offered meet or exceed the technical requirements of paragraph C [except subparagraph (3)) of Article D-7, Specifications No. L-500 kv: Construction of 500 kv Transmission Lines. The tests shall be performed in accordance with ANSI C29.2 by the method of ANSI C29.1, which consist of: a) Design tests b) Quality conformance tests c) Power arc test d) Steep front wave test The acceptance criteria for all tests shall be in accordance with the requirements specified in EGAT's specifications. Such previous tests shall have been witnessed and the test report certified by a representative of an internationally recognized testing laboratory or inspection firm, or an institute or client inspector who is clearly not aligned with the manufacturer. Bidders who fail to submit the required insulator test reports may be rejected. 7. Detailed information of the test station describing the technical experience in testing of complete conductor insulator and hardware assemblies including number of years of experience in conducting electrical performance tests and also including experience in conducting tests at the 500 kv voltage level. 8. Sufficient references demonstrating the following record for the following equipment in similar transmission line project: successful operation/use of the insulators of the same ANSI class as specified in this Invitation for at least three (3) consecutive years. These references shall clearly demonstrate name of the transmission line and its operating voltage; month and year of delivery completion and operation; quantity of operated insulators; and names of the utility, including the names of utility representatives, their titles, addresses, and telephone and facsimile numbers for further communication. 7 'l.
List of Proposed Equipment Manufacturer/ Description ANSI-Class M&E Strength LBS. Model Country Insulator for 115 kv 52-3 15,000 Single & Twin bundled 52-3 18,000 conductor 52-5 25,000 52-8 36,000 Insulator for 230 kv 52-3 15,000 Single & Twin bundled 52-3 18,000 conductor 52-5 25,000 52-8 36,000 Insulator for 230 kv 52-8 36,000 Four-Bundled conductor 52-11 50,000 Insulator for 500 kv 52-8 36,000 52-11 50,000 2 J
List of Proposed Equipment Manufacturer/ Description ANSI-Class M&E Strength LBS. Model Country Insulator for 115 kv Fog type 15,000 Single & Twin bundled Fog type 18,000 conductor Fog type 25,000 Fog type 36,000 Insulator for 230 kv Fog type 15,000 Single & Twin bundled Fog type 18,000 conductor Fog type 25,000 Fog type 36,000 Insulator for 230 kv Fog type 36,000 Four-Bundled conductor Fog type 50,000 Insulator for 500 kv Fog type 36,000 Fog type 50,000 3 q
ELIGIBILITY OF EQUIPMENT I MANUFACTURER Insulator for 115 kv Single & Twin bundled conductor 1. Proposed insulator shall be complied with the specification. 2. The manufacturer shall be a regular of excellent reputation and have significant technical knowledge and at least three (3) years experience in the design, manufacture and testing of such Equipment. Moreover, he shall have manufacturing capacity available to perform the Work properly and expeditiously within the time specified, and shall have satisfactory past experience. 3. The manufacturer shall have a record of a minimum three (3) consecutive years of successful operation/use of at least 10,000 units of insulators of the same or similar ANSI class as those required under this Invitation in any one transmission line operating in the transmission network electric utility in overseas country (not his own country) at a voltage level similar to or higher than 115 kv during the last ten years. Insulator for 230 kv Single & Twin bundled conductor 1. Proposed insulator shall be complied with the specification. 2. The manufacturer shall be a regular of excellent reputation and have significant technical knowledge and at least three (3) years experience in the design, manufacture and testing of such Equipment. Moreover, he shall have manufacturing capacity available to perform the Work properly and expeditiously within the time specified, and shall have satisfactory past experience. 3. The manufacturer shall have a record of a minimum three (3) consecutive years of successful operation/use of at least 10,000 units of insulators of the same or similar ANSI class as those required under this Invitation in any one transmission line operating in the transmission network electric utility in overseas country (not his own country) at a voltage level similar to or higher than 230 kv during the last ten years. Insulator for 230 kv Four-Bundled conductor 1. Proposed insulator shall be complied with the specification. 2. The manufacturer shall be a regular of excellent reputation and have significant technical knowledge and at least three (3) years experience in the design, manufacture and testing of such Equipment. Moreover, he shall have manufacturing capacity available to perform the Work properly and expeditiously within the time specified, and shall have satisfactory past experience. 3. The manufacturer shall have a record of three (3) consecutive years of successful operation/use of at least 100,000 units of insulator ANSI Class 52-8 or similar and at least 20,000 units of insulator ANSI Class 52-11 or similar in transmission line(s) operated in the transmission network electric utility in overseas country (not his own country) at a voltage level of 230 kv or higher during the last ten years. 4 "
Insulator for 500 kv 1. Proposed insulator shall be complied with the specification. 2. The manufacturer shall be a regular of excellent reputation and have significant technical knowledge and at least three (3) years experience in the design, manufacture and testing of such Equipment. Moreover, he shall have manufacturing capacity available to perform the Work properly and expeditiously within the time specified, and shall have satisfactory past experience. 3. The manufacturer shall have a record of three (3) consecutive years of successful operation/use of at least 100,000 units of insulator ANSI Class 52-8 or similar and at least 20,000 units of insulator ANSI Class 52-11 or similar in transmission line(s) operated in the transmission network electric utility in overseas country (not his own country) at a voltage level of 380 kv or higher during the last ten years. 5 b
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SPECIFICATIONS NO. C-2 (REVISION 6) SECTION D INSULATOR ASSEMBLIES D-1. General. The insulator assemblies shall consist of the indicated number of insulator discs, hardware, suspension clamps, compression type dead end clamps or strain clamps and arcing horn (if specified). The details are as shown on the drawings and shall meet the requirements hereafter described. An insulator assembly complete with hardware shall not exhibit excessive corona formation at voltages less than the flashover voltage. The design of the insulators and hardware shall be made to minimize the effect of local corona formation and discharges likely to cause radio interference. D-2. Insulators. The insulator discs shall be of the cap and pin, ball and socket type, radio interference free. Each insulator disc shall be in accordance with the ANSI C29.2 for Wet Process Porcelain (Suspension Type) and shall have the characteristics as specified hereunder and shown on the drawing No. TP-126. a. Porcelain Insulator Shells. The insulator shells shall be made of the highest grade, dense, homogeneous, wet-process porcelain, cylindrical headed with sanded surface, completely and uniformly vitrified throughout to produce uniform mechanical and electrical strength and long life service. The porcelain shall be free from warping, roughness, cracks, blisters, laminations, projecting points, foreign matters and other defects, except those within the limits of accepted standard practice. All porcelain surfaces exposed to the weather shall be glazed with reasonably uniform color as specified on the drawing No. TP-126. The glaze shall be smooth, hard, dense, and properly fitted to the porcelain and shall be unaffected by the weather, ozone, nitric acid, nitric oxides, alkali, dust, or sudden changes in temperature within the atmosphere range. b. Cap and Pin. The cap and pin shall be of such design that it will not yield or distort under the specified mechanical load in such a manner as to change the relative spacing of the insulators or add other stresses to the shells. The insulator caps shall be of the socket type, provided with non-ferrous metal or stainless steel cotter key. The cap shall be made of good commercial grade malleable iron or open hearth or electric furnace steel, hot-dip galvanized. The cap shall be truly circular, with the inner and outer surfaces concentric, and shall be free from cracks, shrinks, air holes, burrs, and rough edges, to minimize field concentrations and radio disturbances. The insulator pins shall be made of malleable iron or drop-forged or machine steel free from cracks and airholes. All bearing surfaces shall be smooth and uniform so as to distribute the loading stresses evenly. The cap and pin shall have practical hot-line maintenance capability. - 01 - Specifications No. C-2 (Revision 6) ).
c. Cementing. In cementing the insulator shell to the cap and pin, high quality Portland cement shall be used. d. Marking. Each insulator unit shall bear legible and indelible symbols identifying the manufacturer, the year of manufactur and the rated combined mechanical and electrical strength. Marking on porcelain shall be printed, not impressed, and shall be applied before firing. e. Tests. The manufacturer shall make adequate tests to demonstrate that the insulators meet the requirements of this Specification. All requirements for sampling, inspections and tests of ANSI C29.2 made by the method of ANSI C29.1 and the requirements of thermal-mechanical performance test in accordance with IEC Publication 575 shall be met. EGAT reserves the right to require the design tests, only for new designs in ANSI C29.2 and IEC Publication 575, if insulators of the same manufacture and design are not presently in general use in EGA T system. The Contractor shall furnish four certified copies of all tests whether or not inspection is waived. For the purposes of sampling for quality conformance tests, the lot size shall be 3,000 units or fraction thereof. The cost of all tests and certificates shall be borne by the Contractor. - 02 - Specifications No. C-2 (Revision 6) y
AMENDMENT NO. 3 SPECIFICATIONS NO. C-2 (REVISION 6) CONSTRUCTION OF TRANSMISSION LINES JANUARY 1987 The following amendment shall be made with the entitled specifications. 1. Section D. Insulator Assemblies, on page 01, Article D-2. Insulators, delete this article in its entity and replace with the following. " D-2. Insulators. The insulator discs shall be of the cap and pin, ball and socket type, radio interference free. Each insulator disc shall be in accordance with the ANSI C29.2 for Wet Process Porcelain and Toughened Glass - Suspension Type, and shall have the characteristics as specified hereunder and shown on the drawing No. TP-126. a. Porcelain Insulator Shells. The porcelain insulator shells shall be made of the highest grade, dense, homogeneous, wet-process porcelain, cylindrical headed with sanded surface, completely and uniformly vitrified throughout to produce uniform mechanical and electrical strength and long life service. The porcelain shall be free from warping, roughness, cracks, blisters, laminations, projecting points, foreign matters and other defects, except those within the limits of accepted standard practice. All porcelain surfaces exposed to the weather shall be glazed with reasonably uniform color as specified on the drawing No. TP-126. The glaze shall be smooth, hard, dense, and properly fitted to the porcelain and shall be unaffected by the weather, ozone, nitric acid, nitric oxides, alkali, dust, or sudden changes in temperature within the atmosphere range. b. Toughened Glass Insulator Shells. The toughened glass insulator shells shall be made of the highest grade, dense, homogeneous, toughened glass, completely and uniformly vitrified throughout to produce uniform mechanical and electrical strength and Jong life service. The glass surface shall be smooth, hard and dense and shall be unaffected by the weather, ozone, nitric acid, nitric oxides, alkali, dust, or sudden changes in temperature within the atmosphere range. c. Cap and Pin. The cap and pin shall be of such design that it will not yield or distort under the specified mechanical load in such a manner as to change the relative spacing of the insulators or add other stresses to the shells. The insulator caps shall be of the socket type, provided with non-ferrous metal or stainless steel cotter key. The cap shall be made Amendment No. 3 to Specifications No. C-2-1 -
of good commercial grade malleable iron or open hearth or electric furnace steel, hot-dip galvanized. The cap shall be truly circular, with the inner and outer surfaces concentric, and shall be free from cracks, shrinks, air holes, burrs, and rough edges, to minimize field concentrations and radio disturbances. The insulator pins shall be made of malleable iron or drop-forged or machine steel free from cracks and air-holes. All bearing surfaces shall be smooth and uniform so as to distribute the loading stresses evenly. The cap and pin shall have practical hot-line maintenance capability. d. Cementing. High quality cement shall be used for cementing the insulator body to the cap and pin. e. Marking. Each insulator unit shall bear legible and indelible symbols identifying the manufacturer, the year of manufacture and the rated combined mechanical and electrical strength. Marking on porcelain shall be printed, not impressed, and shall be applied before firing. f. Tests. The manufacturer shall make adequate tests to demonstrate that the insulators meet the requirements of this Specification. All requirements for sampling, inspections and tests of ANSI C29.2 made by the method of ANSI C29.1 shall be met. EGAT reserves the right to require the design tests, only for new designs in ANSI C29.2, if insulators of the same manufacture and design are not presently in g~neral use in EGAT system. The Contractor shall furnish four certified copies of all tests whether or not inspection is waived. For the purposes of sampling for quality conformance tests, the lot size shall be 3,000 units or fraction thereof. The cost of all tests and certificates shall be borne by the Contractor. Amendment No. 3 to Specifications No. C-2-2 -
.,S::. STANDARD TYPE )l ~\ FOG TYPE ()1 I I i i I ( I! :l : )! :: :: co co I ::! l :: :... -, t ' :.. -~: I..' :........ ' :.. \. 'l:... -- I :. \. 'l ~ - I.. :.. I........ I ' I. : ' l.. i :.. :... I. ' I....'. '. '.... : : ' I ~T~.. - r. '.. i :. ' I I' I "A" CHARACTERISTICS., RAlING PARTICULARS STANDARD TYPE.ANSI CLASS FOG TYPE.. ~--. ~ --...,,......, 11.000lbl 25,0001~ Jl,OOOIN IA.so.coon.. DI...,. Iona Max:tnun disc dicrret..-... 273 273 273 298 311 273 273 298 no Unit apaclno a... 146 146 146 146 156 146 146 146 178 Leokooe distance... 292 292 279 279 381 430 430 430 545 ::. l.. \..... : l. "A" '. I I I J Mec:ha"I i co I Vo I ues COl!t>lned ll&cllcnlcol and electrical atrenoth kg 6.800 8.ooo 11,JOO 16.300 22.600 8.ooo 11,Joo 16.300 22.600 Meehan I co I I ll'!lact strenoth m-kg o.63 0.69 1.04 1.04 1.15 1.15 1.15 1.04 NOTE : 4,000 Tens I on proof kg 3,400 5.650 8.150 11,300 4.000 S.650 8.150 11,300 1. Pins for too type ln&ulotcrs shol I be corrosion proof type. Electrical Volues Low-frOQ.JenCy rry flo&t\over kv 80 80 80 80 80 A 80 A 80 ll 80 A so Low-froq.JOney wet f I osno..,. kv 50 50 50 50 50 A 50 so ll 50 A 5o Cr It tcol-lnt>ui se f loshover, posl t Ive kv 125 125 125 125 140 125 125 A 140 " 125 Crltlcol-lll'(lUlse flosno..,.,neootlve kv 130 130 130 130 140 130 130 I& 130 140 Low-froq.JOney PlrlCh.r& kv 110 110 110 110 125 110 110 A 125 ' 110 Rodlo-lnfluence-Vottooe Doto Low-fre<J,JenCy test vol tooe.nm to O""o.nd kv 10 10 10 10 10 10 10 10 10 Maxlnut1 riv. ot 1.000 khz uv 50 50 50 50 50 so 50 50 50 C0<.0l lno typa 8 8 J K K B J K K Glaze eel er I If porcelain insuloter era suppl ladl Brown Brown Brown Gray or Gray or BrOWl Brown Gray er Gray or Brown Brown Brown Brown Il~.. - ITIT"i'i1i P.Ol-w.W "9\llMCI eleotf"iooi YGI...- of foo t)'n l,_,lotcr ~ 0.let9 ti lood I,.._ ~.&. Add c:twro:t..-1..+1e1 o1 sz-tt ~d t')'pe cn:11 so.ooo 1b9 q -".-... == 42. Withstand voltooe of foo type at ESOO 0.06 ft9/c:m 1 1Lllfrt Ccntanlnotlcn Laval I nuat not be leas than 13.0 kv/1r1lt. _... = J,ANUCHA --~P/..6---.,,.... :'If~... ELECTRICITY GENERATING AUTHORITY OF THAILAND ~... ~.,. SUSPENSION INSULATORS,. trp4i 1~1otara. -.& & =il~~... -~J,... ~./!.9.... -- - - -- -- - - - - I TP-126 TP-126A r.tf,
SPECIFICATIONS NO. TL-01 (REV. 2) ADDITIONAL SPECIFICATIONS FOR INSULATOR TESTS 1. General In addition to those specified in Specification No. C-2 (Rev. 6), the manufacturer shall also perform Steep Front Wave Test on insulators to meet the requirements in Article 2 of this specification. Moreover, acceptance criteria for Combined Mechanical and Electrical Strength Test as required in Specification No. C-2 (Rev. 6) shall be as specified herein. 2. Steep Front Wave Impulse Test If required in the Contract, ten (10) insulator units of each type shall be selected by EGAT at random from the first lot brought forth for acceptance. These units shall be tested as follows : (a) (b) The insulator units shall be subjected to five successive positive and negative impulse flashovers with a wave having an effective rate of rise of 2,500 kv per microsecond. These insulators shall be tested singly. Each unit shall then be subjected to five flashovers of the low frequency dry flashover test of ANSI C29.1 and shall have a flashover value not less than 95% of the rated value. c) Failure of any one unit to pass either test of (a) or (b) above shall be the cause for testing another twenty (20) units in accordance with (a) and (b) above. Failure of any one unit of the second sample to pass either test shall be the cause for rejection of the entire lot brought forth for acceptance. (d) If a lot brought forth for acceptance is rejected due to (c) above, then subsequent lots brought forth for acceptance shall be tested in accordance with (a) through (c) above until a successful test sequence indicates the design of the insulators has been corrected. 3. Combined Mechanical and Electrical - Strength Tests (ANSI C29.2) The acceptance criteria is as follows : X ~ rating + 3 S Where: X S = average value obtained on the sample of the ten insulators tested = standard deviation for the ten insulators tested Each value measured shall not be lower than the specified mechanical and electrical strength. In addition, electrical puncture shall not occur before reaching ultimate failure. - TL-01.1 - December 2004 lo
4. Power Arc Test Three strings of insulators, each containing three units randomly selected from the first lots brought forth for acceptance, shall be assembled in a vertical configuration without conductors for each 52-3, 52-5 and 52-8 type of insulator. The strings shall be energized at the bottom and grounded at the top. The insulator strings shall be subject to a 50 hertz power arc of 12,000 amps rms sustained for 0.1 sec or 6,000 amps rms for 0.2 sec. The insulators shall be tensioned to 40 per cent of their rated strength prior to initiation of the arc and this tension shall be maintained for the duration of the arc and for five minutes following its extinction. There shall be no separation of cap and pin during this portion of the test. After arcing, each string of insulators shall be mechanically tested in accordance with paragraph 5.1 of ANSI C29.1, except that the load may be increased rapidly to only 45 per cent of the rated strength of the insulator. The rate of increase of load from 45 per cent to failure shall be as given in Table 1 of ANSI C29.1. If any insulator fails at less than 60 per cent of its rated strength, the insulator design fails to meet these specifications. - TL-01.2 - December 2004 "'
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Section D INSULATORS AND HARDWARE D-1. General This Specification covers the detail requirements for the design, manufacturing, test and shipping of insulators and hardware assemblies for use with the four bundled conductor system and shield wire. Insulators and hardware assemblies shall be furnished in accordance with the details shown on the drawings and the requirements hereafter described. The following items are covered under this specifications. Manufacturing will be permitted only after successful completion of the required type tests and corona and RIV tests. a. Insulators for conductor suspension, deadend and jumper support assemblies. b. Hardware for attaching insulators to tower and for attaching conductors to insulators. C. Insulators for shield wire suspension and deadend assemblies. d. Hardware for attaching insulators to tower and for attaching shield wire to insulators. D-2 Standards The materials covered under this Specification shall conform to the following standards and applicable standards referenced therein, except as specified herein. ANSI C29.1 Test methods for electrical power insulators ANSI C29.2 Wet-process porcelain and toughened glass suspension insulators ANSI C29.4 Wet-process porcelain Insulators (Strain type) ASTM A 153 Specification for Zinc coating on Iron and Steel Hardware IEC Pub. 575 Thermal - Mechanical Performance Test and Mechanical Performance Test on String Insulator Units. AWS D1.1 Structural Welding Code by the American Welding Society SP-L-500 kv Rev. I,i. - DI -
D-3. Detail Requirements for Insulators a. Strain Type Insulators. The strain type insulators shall be made of porcelain and shall meet all the requirements of ANSI C29.4 for Wet Process Porcelain insulators (Strain Type) except as otherwise specified herein. ANSI class Particulars Rating 54-2 Dimensions : Minimum leakage distance, mm 47 Meachanical Values : Tensile strength, kg 5,400 Electrical Values : Low - frequency dry flashover, kv Low - frequency wet flashover, kv Color of glaze 30 15 brown b. Suspension Type Insulators. The insulator discs shall be porcelain or glass with cap and pin, ball and socket type, radio interference free. Each insulator disc shall meet all of the requirements of ANSI C29.2 for Wet-Process Porcelain and Toughened Glass Insulators (Suspension Type) except as otherwise specified herein. (1) Dimensions and Characteristics. Dimensions and characteristics of each type of insulator shall be in accordance with the following : Particulars Rating ANSI class 52-4 52-8 Fog type 52-11 Dimensions: Maximum disc diameter, mm 273 298 298 311 Unit spacing, mm 146 146 146 156 Minimum leakage distance, mm 292 305 432 381 (REV.l) SP-L-500 kv Rev. I - D2 - )!
Particulars Rating Mechanical Values: Combined mechanical and electrical strength, kg 6,800 16,300 16,300 22,600 Mechanical impact strength, m-kg 0.63 1.04 1.04 1.04 Tension proof, kg 3,400 8,150 8,150 11,300 Time load, kg 4,500 10,880 10,880 13,600 Electrical Values: Low-frequency dry flashover, kv 80 80 80 80 Low-frequency wet flashover, kv 50 50 50 50 Critical impulse flashover, positive, kv 125 125 125 140 Critical impulse flashover, negative, kv 130 130 130 140 Low-frequency puncture, kv 110 110 110 125 Radio-Influence Voltage Data: Low-frequency test voltage, rms to ground, kv 10 10 10 10 Maximum RIV at 1000 khz, v 50 50 50 50 Coupling Type: - K K K Glaze Color: brown grey grey grey (if porcelain insulators are or or or supplied) brown brown brown Note: Specific glaze color shall be as specified in the Contract. (REV1) SP-L-500 kv Rev. I - D3 - 'lf>
(2) Porcelain. Where porcelain insulators are used, they shall be made of the highest grade, dense, homogeneous, wet-process procelain, cylindrical headed with sanded surface, completely and uniformly vitrified throughout to produce uniform mechanical and electrical strength and long life service. The porcelain shall be free from warping, roughness, cracks, blisters, laminations, projecting points foreign matter and other defects, except those within the limits of standard accepted practice. (3) Toughened glass. Where glass insulators are used, they shall be made of the highest grade, dense, homogeneous, toughened glass possessing uniform mechanical and electrical strength and suitable for long life service. The glass shall be free from warping, roughness, cracks, blisters, laminations, projecting points, foreign matter and other defects, except those within the limits of standard accepted practice. (4) Cap and pin. The cap and pin shall be of such design that it will not yield or distort under the specified mechanical load in such a manner as to change the relative spacing of the insulators or add other stresses to the shells. The insulator caps shall be of the socket type for ANSI Class 52-11, ANSI Class 52-8 and Fog type, and clevis type for ANSI Class 52-4, provided with stainless steel cotter pins. The cap shall be made of good commercial grade malleable iron, open hearth or electric furnace steel or ductile iron, hot-dip galvanized in accordance with ASTM A 153. The cap shall be truly circular, with the inner and outer surfaces concentric, and shall be free from cracks, shrinks, air holes, burrs, and rough edges to minimized field concentrations and radio disturbances. The insulator pins shall be made of malleable iron or drop-forged or machine steel and free from cracks and air-holes. All bearing surfaces shall be smooth and uniform so as to distribute the loading stresses evenly. Pins for fog type insulators shall be corrosion proof type. (5) Glaze. All porcelain surfaces exposed to the weather shall be glazed with reasonably uniform color as specified. The glaze shall be smooth, hard, dense, and properly fitted to the porcelain and shall be unaffected by the weather, ozone, nitric acid, nitric oxides, alkali, dust, or sudden changes in temperature within the atmospheric range. (6) Cementing. High quality cement shall be used for cementing the insulator body to the cap and pin. SP-L-500 kv Rev. I - D4 - \G
c. Insulators. All types of insulators shall be subject to test at the Contractor's expense in accordance with the following requirements: (1) Design Tests. Submission of previous test certificates of design tests in accordance with all the requirements of ANSI C29.2 and ANSI C29.4 for suspension type and strain type insulators respectively, shall be regarded as evidence of compliance except the three design tests specified in Article D-7.c.(4}, (5) and (6) shall be carried out regardless of whether or not the Contractor can furnish previous test certificates as evidence that these design requirements can be met. For insulators of new designs, design tests shall be performed in accordance with all the requirements of aforementioned ANSI standards. (2) Quality Performance Tests. Tests shall be performed in accordance with all the requirements of ANSI C29.2 and ANSI C29.4 for suspension type and strain type insulators respectively except that the criteria of judgement for acceptance for the combined mechanical and electrical strength test shall be as follows: 3:::0 = (R-Rs)/S Where Q = Criteria of judgement for acceptance R = Mean value obtained on the sample of ten insulator units tested Rs = Rated mechanical and electrical strength value of the insulator s = Standard deviation for the ten insulator units tested Each value measured shall not be lower than the specified mechanical and electrical strength. In addition, electrical puncture shall not occur before reaching ultimate failure. For the purposes of sampling and testing, the lot size shall not be more than 3000 units. The Contractor shall furnish certified copies of all tests whether or not inspection is waived. (3) Routine Tests. All insulators shall be subjected to routine tests in accordance with all the requirements of ANSI C29.2 and C29.4 for suspension type and strain type respectively.,{. SP-L-500 kv Rev. I - 09 -
(4) Power Arc Test. Three strings of insulators, each containing six units randomly selected from the first lots brought forth for acceptance, shall be assembled in a vertical configuration without conductors for each 52-8 and 52-11 type of insulator. The strings shall be energized at the bottom and grounded at the top. The insulator strings shall be subject to a 50 hertz power arc of 20,000 amps rms sustained for five cycles. The insulators shall be tensioned to 40 per cent of their rated strength prior to initiation of the arc and this tension shall be maintained for the duration of the arc and for five minutes following its extinction. There shall be no separation of cap and pin during this portion of the test. After arcing, each string of insulators shall be mechanically tested in accordance with paragraph 5.1 of ANSI C29.1, except that the load may be increased rapidly to only 45 per cent of the rated strength of the insulator. The rate of increase of load from 45 per cent to failure shall be as given in Table 1 of ANSI C29.1. If any insulator fails at less than 60 per cent of its rated strength, the insulator design fails to meet these specifications. (5) Thermal - Mechanical Performance Test. Ten insulator units of ANSI class 52-8 and 52-11 shall be selected for testing at random from the first lots brought forth for acceptance. The test shall be performed in accordance with all the requirements of Clause 3 of IEC Publication 575: Thermal - Mechanical Performance Test and Mechanical Performance Test on String Insulator Units except that the concluding stage of the test shall be the combined mechanical and electrical strength test of ANSI C29.1 and the criteria of judgement for acceptance shall be as follows : 3~Q = (R-Rs)/S Where Q = Criteria of judgement for acceptance R = Mean value obtained on the sample of ten insulator units tested Rs = Rated mechanical and electrical strength value of the insulator s = Standard deviation for the ten insulator units tested I") SP-L-500 kv Rev. I - 010 -
Each value measured shall not be lower than the specified mechanical and electrical strength. In addition, electrical puncture shall not occur before reaching ultimate failure. The results of the Thermal-Mechanical Performance Test shall match the results of the ordinary combined mechanical and electrical strength test of paragraph D-7.c.(2), and the fracture pattern shall not change. (6) Steep Wave Front Impulse Test. Ten (10) insulator units of each suspension type insulator of ANSI class 52-8 and 52-11 shall be selected by EGAT at random from the first lot brought forth for acceptance. These units shall be tested as follows : (a) (b) (c) (d) The insulator units shall be subjected to five successive positive impulse flashovers followed by five successive negative impulse flashovers. Each wave impulse shall have an effective rate of rise of 2,500 kv per microsecond. The insulators shall be tested singly. Each unit shall then be subjected to three flashovers of the low frequency dry flashover test of ANSI C29.1 and shall have a flashover value not less than 95% of the rated value. Upon failure of any one unit to pass either the steep wave front of the dry flashover test, an additional quantity of twenty (20) randomly selected units shall be tested in accordance with (a) and (b) above. Failure of any one unit of the second group of samples to pass either test shall constitute failure of the insulator design and evidence that the requirements of this specification are not met. D-8. Marking a. Insulators. Each insulator unit shall bear legible and durable symbols identifying the manufacturer, the year of manufacture and the rated combined mechanical and electrical strength. Marking on porcelain shall be printed, not impressed, and shall be applied before firing. D-9. Packing All insulators or hardware shall be packed in sturdy wooden cases suitable for both ocean and inland transportation and shall be clearly marked with the following informations : SP-L-500 kv Rev. I - 011 - ~~
a. Description of the items b. Number of pieces c. Net weight and gross weight d. Contract number e. Project name f. Destination SP-L-500 kv Rev. I - 012 - '~
AMENDMENT NO. 2 SPECIFICATION NO. L-500 kv (REVISION 1) CONSTRUCTION OF 500 kv TRANSMISSION LINE APRIL 2001 The following amendment shall be made with the entitled specifications. 1. Section 8. Conductor, revise as follows: a) On page 81, Article 8-1. General, delete this article in its entirety and replace with the following: "B-1. General This Specification covers the detail requirements for the design, fabrication, test and shipping of aluminum conductor, concentric-lay-stranded, coated steelreinforced for use as subconductors of a four bundled conductor system. All requirements for the ASTM or TIS Specifications shall be applicable unless superseded or modified by this Specification. It is intended that the conductor covered by this Specification shall be suitable for both tension and slack stringing. Any conductor which, when properly threaded, exhibits "bird caging" or popped strands during stringing may be rejected." b) On page 81, Article 8-2. Standard, delete this article in its entirety and replace with the following: "8-2. Standards The materials covered under this Specification shall conform to the following standards and latest applicable standards referenced therein, except as specified herein. ASTM 8230 Specification for Aluminum Wire, EC-H19 for Electrical Purposes. ASTM 8232 Specification for Aluminum Conductors, Concentric-Lay-Stranded Coated Steel-Reinforced. ASTM 8549 Specification for Concentric-Lay-Stranded Aluminum Conductors, Aluminum-Clad Steel-Reinforced. ASTM 8498 Specification for Zinc-Coated (Galvanized) Steel Core Wire for Aluminum Conductors, Steel Reinforced. ASTM 8502 Specification for Aluminum-Clad Steel Core Wire for Aluminum Conductors, Aluminum-Clad Steel Reinforced. ASTM 8354 Standard Definitions of Terms Relating to Uninsulated Metallic Electrical Conductors. NEMA Pub. 107 Methods of Measurement of Radio Influence Voltage (RIV) to Amendment No.2 Rev.2, April 2016 Specifications No. L-500 kv (Rev.1) - 1 -
IEEE Std. 524 Guide to the Installation of Overhead Transmission Line Conductors. TIS 85 Specification for Round Wire Concentric Lay Overhead Electrical Stranded Conductors TIS 2222 Specification for Hard-Draw Aluminum Wires for Overhead Line Conductors TIS 2221 Specification for Zinc-Coated Steel Wires for Stranded Conductors" c) On pages 81 and 82, Article B-3. Conductor Characteristics, delete this article in its entirety and replace with the following: "8-3. Conductor Characteristics a) Aluminum Conductor, Steel Reinforced (ACSR/GA). The conductor to be furnished shall be aluminum conductor, concentric-lay-stranded, reinforced with Class A zinc coated steel wire and shall conform to the general characteristics shown in Table 18.1. b) Aluminum Conductor, Aluminum-Clad, Steel Reinforced (ACSR/AW). The conductor to be furnished shall be aluminum conductor, concentric-laystranded, reinforced with aluminum-clad steel wire and shall conform to the general characteristics shown in Table 18.1. <L l Amendment No.2 Rev.2, April 2016 Specifications No. L-500 kv (Rev.1) - 2 -
Description Complete Conductor : Code name Nominal aluminum area cmil Outside diameter mm Cross-section area mm 2 Stranding: Aluminum Steel - Number - Diameter mm - Number - Diameter mm Minimum breaking strength Approximate weight Nominal length : returnable metal reel non-returnable wooden reel kg kg/m Length of lay (Aluminum wire layers): First (Outside) Second Third (Inside) Steel wire layer m m TABLE 18.1 CONDUCTOR CHARACTERISTICS 795 kcmil 795 kcmil 1272 MCM 1272 MCM A CSR/GA A CSR/AW A CSR/GA A CSR/GA CONDOR CONDOR - PHEASANT 795,000 795,000 1,272,000 1,272,000 27.73 27.73 33.91 35.10 455.0 455.0 677.8 726.2 54 54 42 54 3.08 3.08 4.42 3.90 7 7 7 19 3.08 3.08 2.46 2.34 12,800 13,290 14,050 19,770 1.523 1.459 2.040 2.433 3,500 3,500 2,400 2,400 1,750 1,750 1,200-10 -13 10-13 10-13 10-13 10-16 10-16 10-16 10-16 10-17 10-17 10-17 10-17 18-30 18-30 18-30 18-30 (6strand) 1272 MCM 1272 MCM A CSR/AW ACSR/AW PHEASANT 1,272,000 1,272,000 33.91 35.10 677.8 726.2 42 54 4.42 3.90 7 19 2.46 2.34 13,820 19,232 2.006 2.336 2,400 2,400 1,200 10-13 10-13 10-16 10-16 10-17 10-17 18-30 18-30 (6strand) 16-24 (12strand) 16-24 (12strand) Component Aluminum Wire : Number Diameter Minimum elongation in 254 mm (average) Minimum tensile strength (average) mm % kg/mm 2 54 54 42 54 3.08 3.08 4.42 3.90 1.8 1.8 2.0 2.0 17.58 17.58 16.87 16.83 42 54 4.42 3.90 2.0 2.0 16.87 16.83 Component Steel Wire : Number Diameter Minimum elongation in 254 mm (average) Minimum stress at 1 per cent extension Minimum tensile strength Minimum weight of zinc coating Minimum weight of aluminum coating mm % kg/mm 2 kg/mm 2 g1m2 g1m2 7 7 7 19 3.08 3.08 2.46 2.34 4.0 1.5 3.5 3.5 127 123 130 130 144 137 144 144 259-229 230-439 - (or Aluminum thickness;, 10% of wire radius) 7 19 2.46 2.34 1.5 1.5 123 123 137 137 349 349 (or Aluminum (or Aluminum thickness ;, 10% thickness;, 10% of wire radius) of wire radius) 11 1t Amendment No.2 Rev.2, April 2016 Specifications No. L-500 kv (Rev.1) - 3 -
d) On page 84, Article 8-5. Tests and Reports, item a. Component Wires, delete this item in its entirety and replace with the following: "a. Component Wires (1) Aluminum wire, before stranding, shall be tested in accordance with the requirements of ASTM 8230 or TIS 2222. (2) Zinc-coated steel wire, before stranding, shall be tested in accordance with the requirements of ASTM 8498 or TIS 2221. (3) Aluminum-clad steel wire, before stranding, shall be tested in accordance with the requirements of ASTM 8502." 2. Section D. Insulators and Hardware, revise as follows: a) On pages D2 and D3, Article D-3. Detail Requirements for Insulators, item b. Suspension Type Insulators, sub-item (1). Dimensions and Characteristics, delete this sub-item in its entirety and replace with the following: "(1) Dimensions and Characteristics. Dimensions and characteristics of each type of insulator shall be in accordance with the following: Particular Standard Tmg Fog Type ANSI Class 52-4 52-8 52-11 Dimensions: Maximum disc diameter mm 273 298 311 298 330 Unit spacing mm 146 146 156 146 178 Minimum leakage mm 292 305 381 432 545 distance Mechanical Values: Combined mechanical kg 6,800 16,300 22,600 16,300 22,600 and electrical strength Mechanical impact m-kg 0.63 1.04 1.04 1.04 1.04 strength Tension proof kg 3,400 8,150 11,300 8,150_ 11,300 Time load kg 4,500 10,880 13,600 10,880 13,600 l1' Electrical Values: Low-frequency dry kv 80 80 80 80 80 flash over Low-frequency wet kv 50 50 50 50 50 flash over Critical impulse flashover, Amendment No.2 Rev.2, April 2016 Specifications No. L-500 kv (Rev.1) Positive kv 125 125 140 125 140 Negative kv 130 130 140 130 140 Low-frequency puncture kv 110 110 125 110 125-4 -
Particular Standard T~ Fog Type ANSI Class 52-4 52-8 52-11 Radio-Influence Voltage Data: Low-frequency test kv 10 10 10 10 10 voltage, rms to ground Maximum RIV at 1000 v 50 50 50 50 50 khz Coupling Type: - K K K K Glaze Color: brown grey or grey or K K (In case porcelain insulators brown brown are supplied) Note : Specific glaze color shall be as specified in the Contract " b) Article D-7. Tests, revise as follows: (1) Article a. Complete Conductor Insulator and Hardware Assemblies, revise as follows: (i) On page 08, item (1) Corona and RIV Tests. Sub-item (c)(5) for Test Arrangement, delete this item in its entirety and replace with the following: 11 (5) The test arrangement shall consist of a four conductor bundle configuration. The length of the conductor to be used shall be approved by EGA T. The conductor to be used for the tests shall be provided by the Contractor at his own expense and shall be in clean and good conditions." (ii) On page 010, item (2) Lightning Impulse. Switching Surge and Power Frequency Flashover Tests, Sub-item (c). Test Arrangement, delete this item in its entirety and replace with the following: 11 (c) Test Arrangement. Simulation arrangement for these tests shall be as follows: (1) Assembly 3 shall be tested on a full-scale mock-up of a DL(3 ) tower. This assembly shall be fixed at a swing angle which results in a conductor to tower clearance of 4 meters for these tests. (2) Assemblies 14 or 14A and 17 shall be tested on a full-scale mock-up of the OT 40 tower." (2) On page 011, Article b. Complete Shield Wrre Insulator and Hardware Assemblies, item (1) Type of Test Assemblies, delete this item in its entirety and replace with the following: 11 (1) Type of Test Assemblies. A complete set of each of the following assemblies shall be subject to test. Type of Assembly Shield wire (insulated) suspension assembly Shield wire (insulated) deadend assembly Reference Assembly 1or1A 11 or 11A " Vt r Amendment No.2 Rev.2, April 2016 Specifications No. L-500 kv (Rev.1) -5-
c) On pages 013 and 014, Article c. Insulators, revise item (4) Power Arc Test, item (5) Thermal - Mechanical Performance Test, and item (6) Steep Wave Front Impulse Test, as well as add item (7) Pollution Test, to read as follows: "(4) Power Arc Test. Three strings of insulators, each containing six units randomly selected from the first lot brought forth for acceptance, shall be assembled in a vertical configuration without conductors for each 52-8, 52-11, and fog type of insulator. The strings shall be energized at the bottom and grounded at the top. The insulator strings shall be subject to a 50 hertz power arc of 20,000 amps rms sustained for five cycles. The insulators shall be tensioned to 40 per cent of their rated strength prior to initiation of the arc and this tension shall be maintained for the duration of the arc and for five minutes following its extinction. There shall be no separation of cap and pin during this portion of the test. After arcing, each string of insulators shall be mechanically tested in accordance with paragraph 5.1 of ANSI C29.1, except that the load may be increased rapidly to only 45 per cent of the rated strength of the insulator. The rate of increase of load from 45 per cent to failure shall be as given in Table 1 of ANSI C29.1. If any insulator fails at less than 60 per cent of its rated strength, the insulator design fails to meet these specifications. (5) Thermal - Mechanical Performance Test. Ten insulator units of ANSI Class 52-8, ANSI Class 52-11, and Fog Type shall be selected for testing at random from the first lot brought forth for acceptance. The test shall be performed in accordance with all requirements of Clause 3 of IEC Publication 575: Thermal - Mechanical Performance Test and Mechanical Performance Test on String Insulator Units except that the concluding stage of the test shall be the combined mechanical and electrical strength test of ANSI C29.1 and the criteria of judgement for acceptance shall be as follows: 3~Q = (R - Rs)/S Where Q = Criteria of judgement for acceptance R = Mean value obtained on the sample of ten insulator units tested Rs = Rated mechanical and electrical strength value of the insulator S = Standard deviation for the ten insulator units tested Each value measured shall not be lower than the specified mechanical and electrical strength. In addition, electrical puncture shall not occur before reaching ultimate failure. The results of the Thermal-Mechanical Performance Test shall match the results of the ordinary combined mechanical and electrical strength test of paragraph D-7.c(2), and the fracture pattern shall not change. (6) Steep Wave Front Impulse Test. Ten (10) insulator units of each suspension type insulator of ANSI Class 52-8, ANSI Class 52-11, and Fog Type shall be selected by EGA T at random from the first lot brought forth for acceptance. These units shall be tested as follows: (a) The insulator units shall be subjected to five successive positive impulse flashovers followed by five successive negative impulse flashovers. Each wave impulse shall have an effective rate of rise of 2,500 kv per microsecond. These insulators shall be tested singly. }? Amendment No.2 Rev.2, April 2016 Specifications No. L-500 kv (Rev.1) - 6 -
(b) (c) (d) Each unit shall then be subjected to three flashovers of the low frequency dry flashover test of ANSI C29.1 and shall have a flashover value not less than 95% of the rated value. Upon failure of any one unit to pass either the steep wave front of the dry flashover test, and additional quantity of twenty (20) randomly selected units shall be tested in accordance with (a) and (b) above. Failure of any one unit of the second group of samples to pass either test shall be constitute failure of the insulator design and evidence that the requirements of this specification are not met. (7) Pollution Test. Three (3) strings of insulators, each containing nine (9) units randomly selected from the first lot brought to be tested for acceptance, shall be assembled in a vertical configuration without conductors for each ANSI Class 52-8, 52-11, and fog type of insulator. The test shall be performed on the salt fog method or the solid layer method in accordance with all requirements of IEC Standard 60507 (Artificial Pollution Tests on High-Voltage Insulators to be used on A.G. Systems) and the leakage current shall be measured during this pollution test. The test method for insulator discs on transmission line shall be determined by EGA T. The criteria of judgment for acceptance shall be as follows: For withstand test of all methods : (a) No flashover occurs during three (3) consecutive tests performed on three (3) strings of insulators at specified test voltage where Specified test voltage = 9 * Withstand voltage for each unit (value specified in proposal data) the degree of pollution test (ESDD) shall be determined by EGAT. (b) If only one flashover occurs, the fourth test shall be performed and the insulator then passes the test if no flashover occurs. ( c) The highest leakage current pulse amplitudes occurring on a polluted insulator throughout the duration of all individual withstand tests in withstand conditions shall be not more than those specified in Appendix A of IEC Standard 60507. }l Amendment No.2 Rev.2, April 2016 Specifications No_ L-500 kv (Rev_ 1) - 7 -