400kV 220kV 132kV

Power frequency withstand : 680 460 275

voltage of the complete string
with Corona Control ring (wet) –
kV rms

Lightning impulse withstand : ±1550 +1050 +650

Voltage of string with corona
control rings (dry) – kVp

Switching surge withstand : ±1050 NA NA

voltage of string with corona
control rings (wet) – kVp

Minimum corona extinction : 320 156 NA

voltage level of string with Corona
Control rings (dry) - kV rms

RIV level in micro volts of string: 1000 (Max.) 1000 with NA

Corona Control (Max.) rings at
320 kV (rms) for 400 kV string and 156 kV for 220 kV string
across 300 Ohms resistor at 1 MHz

Total creepage distance of the : 10500 6125 3625

insulator string (mm)

Total no. of discs per strings : 25

g) 15 10

For tension application, double insulator strings and for suspension purpose single suspension
insulator string shall be used for 400 KV, 220 KV and 132KV system.

2.1.2
2.0
ACSR ‘MOOSE’ CONDUCTOR
2.1
Details of Conductor
2.1.1 The Conductor shall conform to IS:398 (Part V) - 1982 except where otherwise
specified herein.

The details of the conductor are tabulated below:

2.1.3 Stranding and wire diameter :54/3.53 mm Al+7/3.53mm Steel
a)
:
b) Number of Strands Steel
centre 1st Steel Layer 1st 1
Aluminium Layer 2nd Aluminium : 6
Layer 3rd Aluminium Layer : 12
18
24

c) Sectional area of aluminium 528.5 mm2

d) Total sectional area : 597.00 mm2

e) Overall diameter : 31.77 mm

f) Approximate weight : 2004 kg/km

g) Calculated d.c. resistance at 20oC : 0.05552 ohm/km

h) Minimum UTS : 161.2 KN

The details of aluminium strand are as follows:

i) Minimum breaking load : 1.57 kN

of strand before stranding

ii) Minimum breaking load : 1.49 kN

of strand after stranding

iii) Maximum D.C. resitance : 2.921 Ohms/Km

of strand at 20oC.

2.1.4 The details of steel strand are as follows:

i) Minimum breaking load : 12.86 kN

 of strand before stranding

ii) Minimum breaking load : 12.22 kN

of strand after stranding

iii) Minimum number of : 18 - before stranding

twist to be with- 16 - after stranding
stood in torsion test when
tested on a gauge length
of 100 times diameter of
wire

2.2 Workmanship

2.2.1 The finished conductor shall be smooth, compact, uniform and free from all
imperfections including spills and splits, die marks, scratches, abrasions, scuff marks,
kinks (protrusion of wires), dents, press marks, cut marks, wire cross over, over riding,
looseness (wire being dislocated by finger/hand pressure and/or unusual bangle noise on
tapping), material inclusions, white rust, powder formation or black spots (on account of
reaction with trapped rain water etc.), dirt, grit etc.

2.2.2 All the aluminium and steel strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, die marks, scratches, abrasions and kinks after
drawing.

2.2.3 The steel strands shall be hot dip galvanised and shall have a minimum zinc
coating of 260 gm/sq.m. after stranding of the uncoated wire surface. The zinc coating
shall be smooth, continuous and of uniform thickness, free from imperfections and shall
withstand minimum three dips after stranding in standard Preece test. The finished strands
and the individual wires shall be of uniform quality and have the same properties and
characteristics as prescribed in ASTM designation : B 498-74.

2.2.4 The Steel strands shall be preformed and postformed in order to prevent spreading
of strands in the event of cutting of composite core wire. Care shall be taken to avoid
damage to galvanisation during preforming and post-forming operation.

2.3.2
2.3

2.3.1
2.4
Joints in Wires

Aluminium Wires

No joints shall, be permitted in the individual wires in the outermost layer of the
finished conductor. However, joints in the 12 wire and 18 wire inner layers of the
conductor shall be allowed but these joints shall be made by cold pressure butt
welding and shall be such that no such joints are within 15 metres of each other in
the complete stranded conductor. However, Joints in aluminium wires shall be as
per IS:398.

Steel Wires

There shall be no joint of any kind in the finished wire entering into the
manufacture of the strand. There shall also be no strand splices in any length of
the completed stranded steel core of the conductor.

Tolerances

The manufacturing tolerances to the extent of the following limits only shall be
permitted in the diameter of individual aluminium and steel strands and lay-ratio
of the conductor.

a) Diameter of Aluminium and steel strands:

Standard Maximum Minimum

Aluminium 3.53 mm 3.55 mm 3.51 mm

Steel 3.53 mm 3.60 mm 3.46 mm

b) Lay ratio of Conductor: Maximum Minimum

Steel 6 wire layer 18 12 16

Aluminium wire layer 14 18 12
wire layer 13 24 11
wire layer 12 10

2.5 Materials

2.5.1 Aluminium

The aluminium strands shall be hard drawn from electrolytic aluminium rods
having purity not less than 99.5% and a copper content not exceeding 0.04%.
2.5.2 Steel

The steel wire strands shall be drawn from high carbon steel wire rods and shall
conform to the following chemical composition:

Element - % Composition

Carbon - 0.50 to 0.85

Manganese - 0.50 to 1.10

Phosphorous - not more than 0.035

Sullphur - not more than 0.045

Silicon - 0.10 to 0.35

2.5.3 Zinc

The Zinc used for galvanising shall be electrolytic High Grade Zinc of 99.95%
purity. It shall conform to and satisfy all the requirements of IS:209-1979.

2.6 Standard Length

2.6.1 The Conductor shall be supplied in standard length of 1500 / 1800 metres
as required. No joint shall be allowed within a single span of stringing.

2.7 Tests :

2.7.1 The following type, acceptance & routine tests and tests during
manufacturing shall be carried out on the conductor.

2.7.2 Type Tests

In accordance with the stipulation of specification, the following type tests reports
of the conductor shall be submitted for approval :

a) UTS test on stranded .

conductor.

b) Corona extinction ) As per Annexure-A

voltage test (dry) )
 (c) Radio Interference
voltage test (dry) )
)
) (d) DC resistance test
) on stranded conductor
)
) Acceptance Tests

2.7.3 a) Visual check for joints, ) ) scratches etc. and lengths of

conductor )
As per Annexure - A
b) Dimensional check on
steel and aluminium strands
)
c) Check for lay ratios of
)
various layers
)
d) Galvanising test on )
steel strands ) -do-

e) Torsion and )
Elongation test on )
steel strands )
)
f) Breaking load test on
steel and aluminium
strands

g) Wrap test on steel and

aluminium strands )
)
h) DC resistance test on IS:398 (Part V) 1982
)
aluminium strands Clauses 12.5.2, 12.7 &
)
12.8
)
i) UTS test on welded joint
of aluminium strands

NOTE: ) As per Annexure - A

)
All the above tests except test )
mentioned at (a) shall be carried out
on aluminium and steel strands after stranding only.
2.7.4 Routine Tests

a) Check to ensure that the joints are as per specification.

b) Check that there are no cuts, fins etc. on the strands.

c) All acceptance test as mentioned in Clause 2.7.3 above to be carried out

on each coil.

2.7.5 Tests During Manufacture

a) Chemical analysis of )
zinc used for galvanising )
)
b) Chemical analysis of )
aluminium used for ) As per Annexure - A
making aluminium strands )
)
c) Chemical analysis of )
steel used for making )
steel strands )

2.7.6 Sample Batch for Type Testing

The Contractor shall offer material for selection of samples for type testing, only
after getting quality assurance plans approved from Owner’s Quality Assurance
Department. The sample shall be manufactured strictly in accordance with the
Quality Assurance Plan approved by Owner.

3.1 GALVANISED STEEL EARTHWIRE

3.2 Details of Earthwire

3.1.1 The galvanised steel earth wire shall generally conform to the specification of
ACSR core wire as mentioned in IS : 398 (Part-II)-1976 except where otherwise
specified herein.

3.1.2 The details of the earth wire are tabulated below:

a) Stranding and wire : 7/3.66 mm steel

diameter

b) Number of strands