SPECIFICATION FOR HT PIN (11KV & 22KV) AND 11KV DISC. INSULATORS: - [THIS TENDER IS FOR PURCHASE OF HT (11KV) PIN INSULATORS ONLY] 1. SCOPE: - This specification covers 11KV Disc Type & 11KV / 22KV Pin Type Insulators for 11/22KV H.T. over head power lines. 2. APPLICABLE STANDARDS: - Except when they conflict with specific requirement in this specification, the insulators shall comply with the Indian Standard specification, IS-731/1971and the latest version thereof. The insulators fittings shall comply with the Indian Standard specification IS-2486/Part-I/1993, IS-2486/Part. II/1989 or the latest version thereof. 3. DESCRIPTION: - 3.1 DISC INSULATORS. :- 11KV Brown Glazed 'Disc' insulators conforming to IS-731/71 and subsequent amendment No. 1 to 5 for suspension or tension strings, ball and socket type having ball shank dia.16mm and minimum failing load of 70 KN along with phospher bronze 'W' clips. 3.2 PIN INSULATORS:- 11/22KV Brown Glazed pin insulators confirming to IS-731/1971 and subsequent amendment No.1 to 5 to give rigid support to an over-head line and intended to be mounted vertically on supporting structure by GI Pin passing up inside this insulator with minimum failing loads 10 KN. 4. GENERAL REQUIREMENT: - i) The porcelain shall be sound and free from defects, thoroughly vitrified and smoothly glazed. ii) The glaze shall be brown in colour. The glaze shall cover all the porcelain parts of the insulator except those areas which serve as support during fixing or are left unglazed for the Purpose of assembly. iii) The design of the insulators shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal. iv) Cement used in the construction of the insulators shall not cause fracture by expansion or lessen by contraction and proper care shall be taken to locate the individual parts correctly during cementing. The cement shall not give rise to chemical reaction with metal fitting and its thickness shall be as uniform as possible. 5. ELECTRICAL AND MECHANICAL CHARACTERISTICS : - The electrical and mechanical particulars of 11KV Disc and 11/22KV Pin insulators shall be as per the Guaranteed Technical Particulars shown in Annexure-A & B attached herewith, measured at the following standard atmospheric conditions. 1. Ambient temperature 20 Deg. C 2. Barometric pressure 1013 millibars 11 Grams of water per cubic mtrs. 3. Absolute Humidity Corresponding to 63% relative humidity at 20 Deg. C. [Technical Specification and GTP of 11 KV Pin and Disc Insulators: Ceramic//Page 1 of 7]
6. BASIC INSULATION LEVELS: - 6.1 The test voltage of Disc. And Pin insulators shall be as per the values given in Guaranteed Technical Particulars shown in Annexure-A & attached. 6.2 In this specification power frequency voltages are expressed as peak values divided by 2 and impulse voltages are expressed as peak values. 6.3 The withstand flashover voltages are referred to the reference atmospheric conditions. 7. Ferrous parts of Disc. Insulators as per IS-2108/1977 shall be hot dip galvanized as per IS-2633/1986. 8. As the insulators are to be used anywhere in Gujarat State including the coastal area, the Creepage distances of specified in GTP are minimum. However, the firm may offer insulators of higher creepage distance, but the mechanical and electrical parameters of their product shall be as per the mechanical and electrical requirement given in Appendix-A & B attached. 9. TESTS: - i) All the tenderers must submit copies of type test certificates along with laboratory approved drawings for the products offered by them. The Certificates shall be from CPRI, ERDA, and Indian Institute of Science, Bangalore or any other Govt. recognized laboratory, but not more than 5 years old as on date of opening the tender. ii) Copy of type test certificate of each type offered must be submitted. iii) The type test certificate shall be final and complete for all the tests as per the list of type tests given in specification Cl.No.9.1of the specification. iv) Failure to submit the type test certificates as described above shall be liable for rejection of tender offer. v) Routine test shall be carried out on every insulator as specified in IS-731/71 with amendment No.1 to 5 and certificate issued with each batch. Details of test result on each of the insulator supplied, has to be submitted to inspector for his perusal and verification. vi) The insulators shall comply with the type tests as per IS-731/1971with latest amendment 1 to 5 and as mentioned in Cl.No.9.1 below. 9.1 TYPE TESTS: - The following shall constitute the type tests (Cl.No.10.1.1 of IS-731/1971). However, the test voltage value shall be as per GTP enclosed. a) Visual examination. b) Verification of dimensions. c) Visible discharge test. d) Impulse voltage withstand test (+ve wave & -ve wave) e) Impulse voltage flashover test (+ve wave & -ve wave) f) Dry and wet power frequency voltage withstands test. g) Dry and wet power frequency flashover voltage test. h) Temperature Cycle test. i) 24 Hours mechanical failing load test (for Disc insulators only) or mechanical performance test. j) Electro mechanical failing load test (for Disc insulators only) k) Mechanical failing load test (for Pin insulators only) [Technical Specification and GTP of 11 KV Pin and Disc Insulators: Ceramic//Page 2 of 7]
l) Puncture test. m) Porosity test. n) Galvanizing test (for Disc Insulators only) The tests shall be carried out on the two samples in the order mentioned in the Cl.10.1.1 of IS-731/1971. All the tests shall be carried out in the same laboratory. 9.2. ACCEPTANCE TESTS: - From the offered lot, samples shall be drawn randomly as per the criteria given. The firm has to arrange for carrying out all following acceptance tests at firms works only at firm's cost in presence of inspector deputed by MGVCL. a) Verification of dimensions and Visual examination. b) Temperature cycle tests. c) 24 Hours mechanical failing load test or mechanical performance test. (For disc. insulators only) d) Electro mechanical failing load test (for disc. insulators only) e) Mechanical failing load test (for pin insulators only) f) Puncture test. g) Porosity test. h) Galvanizing test (for disc. insulators only) 9.3. ROUTINE TESTS: - The following tests shall be carried out as routine tests by firm on each insulator before offering the lot for inspection. a) Visual examination. b) Mechanical routine test (for type 'B' string insulators units only) c) Electrical routine test (for type 'B' string insulators and rigid insulators). 10. DRAWING AND CATALOGUES: - The tenderer shall furnish catalogues, literature and detailed dimensional drawing of insulators offered showing section of the insulators to show the method of construction connecting arrangement, length and type of threads etc. The drawing shall be got approved by the User Department prior to commencing the bulk supply. 11. MARKING: - 11.1. Each insulator shall be legibly and indelibly marked to show the following. a) Name or trade mark of the manufacturer. b) Month and year of manufacturer. c) Minimum failing load. d) Country of manufacture. e) ISI Certification mark, if any. f) Word 'MGVCL' marked stickers to be provided on each insulator. 11.2. Marking on porcelain shall be printed and shall be applied before firing. [Technical Specification and GTP of 11 KV Pin and Disc Insulators: Ceramic//Page 3 of 7]
12. PACKING:- i) All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling suitable for rail/road transport. Where more than one insulator is packed in a crate, wooden separators shall be fixed between the insulators to keep individual insulator in position, without movement within the crates. Disc. Insulators however, may be assembled in a string and then packed inside a crate, in above fashion. ii) The wooden crates shall be provided with steel hoop and bends for strength and durability to withstand rough handling. The bends shall have descriptive marking of the firm thereon. iii) The firm shall provide at his cost, lead seal and wire on each wooden crate to facilitate sealing by the inspector of MGVCL after acceptance of the lot. 13. INSPECTION: - Party has to offer the materials for inspection duly packed in crates as mentioned in GTP. The inspection approval is valid for a period of 15 days from the date of inspection to enable the firm to dispatch the materials by arranging transportation at destination allotted thereof within the said period. After this period of 15 days, the validity of the inspection will lapse. Thereafter, the inspection approval will be revalidated by competent authority on furnishing written application explaining therein the valid reasons for delay in affecting dispatches. 14. The firm shall not dispatch the offered lot unless the same is inspected by the inspector of MGVCL & accepted by him after passing in all acceptance tests, and/or receipt of waival of inspection in writing from competent authority of MGVCL. Manufacturer's Name and Address. [Technical Specification and GTP of 11 KV Pin and Disc Insulators: Ceramic//Page 4 of 7]
Schedule for requirement of 11/22KV Pin & Disc Insulators Sr. No 1 2 3 Description of materials 11KV Pin Insulators Brown Glazed porcelain Insulator confirming to IS-731/1971 Ammendment 1 to 5 Type-B with 320mm minimum creepage distance and with lead/zinc thimble suitable for use with G.I.Forged pin having small steel heads as per IS-2486 (P.I)/1993 & IS-2486 (P.II)/1989 and revision with latest ammendment if any. - Confirming to REC Specification. - With minimum failing load of 10 KN. -Confirming to MGVCL specification attached herewith. 11KV Disc Insulators Brown Glazed porcelain Insulator confirming to IS-731/1971 and subsequent amendment 1 to 5 for suspension and tension strings ball and socket type having pin ball. The minimum creepage distance shall be 320 mm. shank dia of 16 mm and minimum failing load of 7140 Kgs (70 KN) confirming to Board's specification attached herewith. The insulators shall have 'W' type phospher Bronze security clips for ball sockets portion of insulators confirming to IS-2486 (P-III/1974). The insulators shall also confirm to MGVCL specifications attached herewith. 22KV Pin Insulators Brown Glazed porcelain Pin Insulators confirming to IS-731/1971 Ammendment 1 to 5 Type-B with 560mm minimum creepage distance and with lead/zinc thimble suitable for use with G.I.Forged pin having large steel head as per IS-2486 (P.I)/1993 & IS-2486 (P.II)/1989- second revision and conforming REC specification. Quantity required. Type Test:- 1. The offers without type test certificate and certified drawing by Government approved laboratory will not be considered. 2. Party should submit his own design drawing with all dimensional details to be supported by type test certificate and attested drawings. [Technical Specification and GTP of 11 KV Pin and Disc Insulators: Ceramic//Page 5 of 7]
Manufacturer's Name and Address: MGVCL/MM/1023/11 KV Pin Insulators: Porcelain/ ANNEXURE-'A' TECHNICAL INFORMATION AND GUARANTEED TECHNICAL PARTICULARS: PART-A BIDDER HAS TO CONFIRM FOLLOWING IMPORTANT REQUIREMENT: Sr. No. Particulars 11KV Pin Insulator 11KV Disc. Insulator 1 Insulator shall be manufactured as per IS-731/1971 and subsequent amendment 1 to 5 or latest amendment of it. 2 Brown colour glazed 3 320mm (Min) creepage distance. 4 Mechanical failing load (Min) i) 10 KN (1020KG for Pin Insulator) ii) 70KN (7140KG for Disc. Insulator) -- -- 5 Lead/Zinc thimble suitable for fixing with 11KV G.I. Pin as per IS-2486 (Part-I)/1993 & IS-2486 (Part-II)/1989 with latest amendment (small steel head) -- 6 Melleable cast iron as per IS-2108/1977 & hot dip galvanized socket as per IS-2633/1986. -- 7 High tensile forged steel hardened and tampered duly hot dip galvanized BALL Pin. -- 8 Phospher bronze 'W' clips -- 9 Ball & Socket size 16mm -- 10 Impulse withstands test voltage. a) 1.2/50 micro sec. +ve wave - 110 KV b) 1.2/50 Micro sec. ve Wave - 110 KV. 11. 12. 13. 14 Impulse flashover test voltage. a) 1.2/50 micro sec. +ve wave - 120 KV b) 1.2/50 Micro sec. -ve Wave - 130 KV. Power frequency withstand test voltage a) Dry - 70 KV b) Wet - 45 KV Power frequency flashover test voltage. a) Dry - 80 KV b) Wet -50 KV Power frequency puncture voltage - 110 KV. [Technical Specification and GTP of 11 KV Pin and Disc Insulators: Ceramic//Page 6 of 7]
15 Visible discharge -9KV voltage. 16 Marking on Insulator as per Clause No. 12.1 and 12.2 of MGVCL Specification. Insulator shall be packed in wooden crates as 17 per Cl.No.13 (i), 13(ii) & 13 (iii) of MGVCL Specification. PART-'B': (Both for 11KV Pin Insulator & 11KV Disc. Insulator) BIDDER HAS TO FURNISH BELOW DETAILS ABOUT MATERIAL. 1. No. Of Insulator to be Packed in one crate. a) For 11KV Pin Insulator: b) For 11KV Disc Insulator: 2. Drawing Number/Product Number. a) For 11KV Pin Insulator: b) For 11KV Disc Insulator. PART-'C': ENCLOSURES: (Both for 11KV Pin Insulator and 11KV Disc. Insulator) Bidder has to enclose following documents and has to confirm for the same. Sr.N o. Particulars Confirmation 1. Drawing with detailed dimension duly signed & stamped 2 Type test certificate covering all the tests as per Cl. No. 9.1 along with attested drawing from Govt. approved laboratory. 3 List of Plant & Machinery at firms works. 4 List of Testing equipments at firms works. 5 List of orders pending/executed at least for past two years for the items offered a) With GUVNL/MGVCL/DISCOM. b) With the purchases other than GUVNL/MGVCL/DISCOM PART-'D':- Bidder has to mention below deviation if any, quoting relevant clause of specification. Signature & Seal of Tenderer Manufacturer's Name and Address [Technical Specification and GTP of 11 KV Pin and Disc Insulators: Ceramic//Page 7 of 7]