S 141 PDF

DAKSHIN HARYANA BIJLI VITRAN NIGAM
TECHNICAL SPECIFICATIONS
(Specification No. S-141/DD-177)
TECHNICAL SPECIFICATIONS
FOR
FIBRE GLASS CROSS ARMS (FRP) FOR 11 KV LINES
Issued in Sept. 2007
C:\Documents and Settings\Neeraj Verma\Desktop\12-02-08\pdc\sp-141-dd-177 ted-62.doc

TECHNICAL SPECIFICATIONS FOR FIBRE GLASS
CROSS ARMS FOR 11 KV LINES
1. SCOPE:
This specification covers details of Fibre Glass Reinforced Plastic cross
arms to be used on 11 KV overhead lines in distribution system.
2. APPLICABLE STANDARDS:
Unless otherwise mentioned in this specification, the raw materials used
shall comply with IS:10192-1982 and IS: 6746-1972 or their latest version.
3. CLIMATIC CONDITIONS
3.1 Maximum ambient temperature 50ºC
3.2 Maximum ambient temperature -2.5ºC
3.3 Maximum relative humidity 100%
3.4 Maximum relative humidity 26%
3.5 Average number of dust storm days per 35
annum.
3.6 Isoceraunic level 45
3.7 Average no. of rainy days per year Nearly 120 days
3.8 Average annual rainfall 900mm
3.9 Altitude above mean sea level Less than 1000 Mtr.
3.10 Maximum wind pressure 195 Kg./Sq.mtr.
4. SHAPE AND SIZE:

4.1 The cross arms shall be of either channel or rectangular hollow section
with an overall length of 1150mm and a minimum top width of 45mm.
4.2 The cross arms shall have two holes of 22mm dia for fixing of pin insulators.
The centre-to-centre distance between the holes shall be 1070 mm and holes
shall be in the middle of the top width of cross arm.
4.3 If required by the purchaser, holes of specified size and spacing shall also be
provided for fixing of pole back clamp to suit the pole.

4.4 The enclosed fig. 1 gives the general details of a typical rectangular cross
arm showing various dimensions, size of holes, mounting arrangement etc.
These details shall also apply to channel cross arms.
5. GENERAL REQUIREMENTS:
5.1 The cross arms shall be made from good quality fiberglass and plastic
ingredients conforming to standards laid down in this specification in
Clause 2 suitable for outdoor application and shall be manufactured by
automatic pultrusion process.
5.2 The cross arms shall have smooth surface finish and the cut cross section
shall give a homogeneous appearance.
5.3 The cross arms shall be of light colour so as not to attract birds. It shall not
corrode while in contact with steel fittings/fixtures, P.C.C. Poles and aluminium
conductor.
5.4 Supply of cross arms with Ultra Violet resistant Poly Urethene coating shall be
optional for which the Nigam shall specifically mention in their tender.
6. MECHANICAL PROPERTIES:
6.1 The cross arms shall be able to withstand a vertical load of 300kg applied
at each of the two points coinciding with the centre of the pin insulators on
both sides as shown in the enclosed drawing. For the purpose of this test,
the cross arm shall be mounted on a support with 200mm centre-to-centre
distance between clamp bolts (16mm dia). With the application of this load,
no damage should occur to the cross arm and it should remain serviceable.
6.2 In the other direction, the cross arm should be able to withstand a load of
not less than 100 kg applied on both sides as shown in the drawing.
6.3 Accessories for Improving the Mechanical Strength.
For improving the mechanical strength, Rectangular Solid Polymeric
ferrules may be provided as packing material at both ends of the cross arm
(F-2) where the 11 KV Pin insulators are bolted to the cross arm and also
at the center where the cross arm is fixed to the PCC Pole (F-1), to prevent
development of cracks in the cross arm at the place of tightening of bolts.
NOTE:- The polymeric ferrules will be made out of formulation of fire
retardant thermo set resins. The ferrules will be resin cast of the

shape and sizes of solid rectangular bars as per the drawings. The
polymeric ferrules shall be fixed inside the hollow portion of the
cross arms to provide mechanical support while fastening the nuts
and bolts at the pole back clamp and the 11 KV pin.
7. TESTS:
The cross arms shall be subjected to the following tests as per IS: 10192-
1982 and IS: 6746-1972.
7.1 Type tests:
The following tests shall constitute the type tests:
a) Visual inspection
b) Dimensional check
c) Load test
d) Impact strength
e) Tensile strength
f) Comparative tracing (As per IS:10192-1982)
g) Specific Gravity
h) Water absorption
i) Cross Breaking strength
j) Compressive strength
k) Insulation Resistance
l) Flammability (As per IS: 6746-1972)
Tenders without type test certificates are liable to be rejected.
7.2 Acceptance & Routine tests:
The following tests shall constitute the Acceptance & Routine tests:-
a) Visual inspection
b) Dimensional check
c) Load test
d) Specific Gravity
e) Water absorption
f) Cross Breaking strength (As per IS:10192-1982)
g) Compressive strength
h) Insulation Resistance
i) Flammability (As per IS: 6746-1972)

The routine and acceptance tests should be performed on one sample
chosen at random out of every 20 samples subject to a maximum of 2% of
the supply batch.
8. MARKING:
The following information shall be marked on each cross arm:
a) Manufacturer’s name or trade mark
b) Year of manufacture
9. PACKING:
The FRP cross arms will be packed in quantities of 10 to 20. Each cross
arm will be covered with stretch wrapping film on the winding machine.
The items so wound will be grouped as per numbers per packet. The
information like product quantity should be mentioned on the packets.
10. SCHEDULE OF GUARANTEED TECHNICAL PARTICULARS
The tenderer’s must supply the detailed guaranteed & other technical
particulars as detailed in Annexure-I. Use of ‘Dash’ ‘Do’ ‘Blank’ or ‘As per
ISS IEC’ will not be entertained.
Sd/- Sd/- Sd/- Sd/-

CGM/P&D CGM/MM CGM/Commercial GM/P&D
DHBVN, Hisar DHBVN, Hisar DHBVN, Hisar DHBVN, Hisar

Annexure-I
SCHEDULE OF TECHNICAL & GUARANTEED PARTICULARS FOR FIBRE

GLASS CROSS ARMS FOR 11 KV LINES
S.No. Particulars To be furnished by the

Bidder
1. Name of manufacturer & address
2. Whether channel or rectangular shape with

length size
3. Type of material used
4. Size (Dimensions)
5. Whether raw materials confirming to

relevant IS: 10192 & IS: 6746 or their latest
version.
6. Vertical / Horizontal load capability (Kg)

(‘X’ & ‘Y’)
7. Whether rectangular solid polymeric

ferrules provided as packing material
8 Whether type tests conducted & reports

attached
Sign & Seal of supplier

Rural Electrification Corporation Limited
(A Government of India Enterprise)
STANDARD
TECHNICAL SPECIFICATION
(REC SPECIFICATION 76/2006)
DHBVN SPEC NO.S-140/DD-177
FOR
COMPOSITE INSULATORS
for
11kV & 33kV SYSTEM

New Delhi-110 003 September 2006
Energising Lives-Making A Difference.
FOREWORD
1. Conventionally porcelain insulators have been used in the power distribution/
transmission system. REC specifications 3/1993 & 13/1979 are available for
porcelain insulators for 11KV & 33KV sub-transmission and distribution system
respectively. Recent technological developments have revealed that the use of
composite insulators with weather sheds made of silicon-rubber elastomers with
self cleaning property is promising and possibly better substitute/replacement for
the conventional porcelain insulators. Some of the advantages of polymer
insulators over porcelain insulators are:-
Hydrophobicity Excellent tracking resistance, low leakage
current and less possibility of wet flashover.
Lower maintenance
Light weight Weight is about 33% of porcelain insulators,
hence it is easy to transport & install,
packing erection cost especially in the
inaccessible areas like hilly areas.
Less number of joints So less prone to failure.
Resistance to breakage/vandalism
More reliability No decapping of failure of fittings etc as
observed in case of porcelain insulators
cemented joints.
2. Composite insulators have been in service successful in transmission &
distribution line world wide since more than 35 years; under vide range of
environmental and climatic conditions. Initial certain problems with these
insulators were faced. A lot of worldwide research and developments have been
undergoing for the development of material, design & test procedures for
composite insulators for power sector usage. Now the technology is considered to
be mature enough to be introduced and widely used in the power section in India
at present these insulators are being used by utilities such as JDVVNL,
APTRANSCO, Pashchimanchal (Uttar Pradesh) Vidyut Vitran Nigam Ltd., and
Railways etc. Various utilities have confirmed the advantage of use of Composite
Insulators, with satisfactory performance reports.
3. A Technical Committee was constituted by REC for finalization of specification

on Composite Insulators, with members from CPRI, Powergrid, REC, Jodhpur
Vidyut Vitran Nigam Ltd., APTRANSCO & CEA.
The Committee members have studied and discussed on various technical, O&M
and design aspects and collected performance feedbacks from utilities/
organizations Dr.N.Vasu Dev, Joint Director, CPRI an expert on the subject is a
member of the committee. The technical input provided by Dr.N.Vasu dev, Joint
Director, CPRI has been of great value in finalizing the specification.

TECHNICAL SPECIFICATION
FOR COMPOSITE INSULATORS
FOR USE IN 11kV and 33kV SYSTEM
1.0 SCOPE:
This specification covers design, manufacture, testing and supply of Composite
Insulators for use in 11KV /33KV overhead transmission lines and substations.
The composite insulator shall be of following type;-
i) Long rod insulators for conductors in tension application at angle/cut points. The
insulators shall be of ball and socket type or tongue & clevis type as desired by
the purchaser.
ii) The post insulators or pin insulators for straight line locations.
2.0 APPLICABLE STANDARDS

2.1 Standards:
Following Indian/International Standards which shall mean latest revision with
amendments/changes adopted and published, unless specifically stated otherwise
in the specification, shall be referred while accessing conformity of insulators
with these specifications.
2.1.1 In the event of supply of insulators conforming to standards other than specified,
the Bidder shall confirm in his bid that these standards are equivalent or better to
those specified. In case of award, salient features of comparison between the
standards proposed by the Bidder and those specified in this document will be
provided by the supplier to establish equivalence.
Sr. Indian Title International
No. Standard standard
1. Definition, test mentioned and acceptance criteria for IEC-61109
Composite Insulators for a.c. overhead lines above
1000V
2. IS-731 Porcelain insulators for overhead power lines with a IEC-60383
nominal voltage greater than 1000 V.
3. IS-2071 Methods of High voltage testing IEC-60060
4. IS-2486 Specification for insulators fittings for overhead IEC-60120
power lines with normal voltage greater than 1000V IEC-60372
General requirements and tests Dimensional
Requirement locking Devices.
5. Thermal Mechanical Performance test and IEC-60575
mechanical performance test on string insulator
units.
6. IS-13134 Guide for the selection of insulators in respect of IEC-60815
polluted conditions.
7. Characteristics of string insulator units of the long IEC-60433

rod type.
8. Hydrophobicity classification guide STR Guide
1.92/1
9. Radio interference characteristics of overhead power CISPR:18-2
lines and high-voltage equipment. Part 2
10. IS-8263 Methods of RI Test of HV insulators IEC-60437

11. Standard for insulators— ANS C29:13-
Composite-Distribution Dead-end-Type. 2000
12. IS-4759 Hot dip zinc coating on structural steel & other allied ISO-1459
products. ISO-1461
13. IS-2629 Recommended Practice for Hot Dip Galvanization ISO-1461(E)
for iron and steel.
14. IS-6745 Determination of weight of Zinc coating on Zinc ISO-1460
coated iron and steel articles.
15. IS-3203 Methods of testing of local thickness of electroplated ISO-2178
coating.
16. IS-2633 Testing of Uniformity of coating of zinc coated
articles
17. Standard specification for glass fiber stands ASTMD 578-
05
18. Standard test method for compositional analysis by ASTME
Thermogravimetry. 1131-03
19. IS-4699 specification for refined secondary Zinc
The addressed of organization who offer the above standards are given at Annexure-A
3.0 Technical Description of Composite Insulators

3.1 Service Conditions
The polymer insulators to be supplied shall be suitable for satisfactory continuous
operation under conditions as specified below:-
Maximum ambient temperature **48oC

Minimum ambient temperature -5oC
Relative humidity 0 to 100%
Note:- In some part of India, the ambient temperature may go beyond the limits
specified above. In such cases, the owner may specify maximum ambient
temperature as per requirement.
3.2 Composite Insulators long rod type for tension locations and
pin/post type for suspension locations:
3.2.1 The insulators shall be suitable for 3Ø, 50 Hz, effectively earthed 11KV and 33KV
O/H distribution system in a moderately/heavily polluted atmosphere, long rod
insulators shall be of ball & socket or tongue & clevis type as specified.
3.2.2 Bidder must be a indigenous manufacturer and supplier of Composite Insulators of

rating 33KV or above OR must have developed proven in house technology and
manufacturing process for composite insulators of above rating OR possess
technical collaboration/association with a manufacturer of composite insulators of
rating 33KV or above. The Bidder shall furnish necessary evidence in support of
the above alongwith the bid, which can be in the form of certification from the
utilities concerned, or any other documents to the satisfaction of the owner.
3.2.3 Insulators shall have sheds with good self-cleaning properties. Insulators shed
profile, spacing projection etc. and selection in respect of polluted conditions shall
be generally in accordance with the recommendation of IEC-60815/IS-13134.

3.2.4 The size of Composite Insulator, minimum creepage distance and mechanical
strength alongwith hardware fitting shall be as follows:-

Highest system voltage KV
Impulse withstand voltage
Minimum
creepage
Distance
Nominal system voltage
Pin ball shank diameter

withstand voltage KV
(mm)
Wet power frequency
Visible discharge test
Min. failing load KN

Type of Composite
voltage KV(rms)
polluted (25
(20mm/kv)
moderately
Normal &
Insulators
KV (rms)
KV (rms)
mm/KV)
polluted
Sl. No.
Heavy
(rms)
(rms)
mm
i. Long rod 11 12 9 35 75 240 320 45 16
insulators 33 36 27 75 170 720 900 45/70** 16
ii. Post/Pin 11 12 9 35 75 240 320 5 -
insulators 33 36 27 75 170 720 900 10 -
Note:- 1** To be specified by utility.

2. Creepage distances have been considered in line with IS-13134 (which specifies
20mm/kv for moderately polluted & 25mm/kv for heavily polluted environment)
except for a higher valve of 320mm for 11KV insulators in heavily polluted
environment as per existing practice with ceramic insulators. In case utilities are
specifying lower values of creepage distance for ceramic insulators, the same may
be followed for Composite Insulators also.
3.3 Dimensional Tolerance of Composite insulators

The tolerances on all dimensions e.g. diameter, length and creepage distance shall
be allowed as follows in line with-IEC 61109:
+ (0.04d+1.5)mm when d< 300 mm.
+ (0.025d+6)mm when d> 300mm.
Where, d being the dimensions in millimeters for diameter, length or creepage
distance as the case may be.
However, no negative tolerance shall be applicable to creepage distance.
3.4 Interchangeability
The Composite Insulators including the end fitting connection shall be of standard
design suitable for use in the hardware fitting of any make conforming to relevant
IEC/IS standards.
3.5 Corona and RI Performance

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part
shall be subjected to excessive localized pressure. The insulators and metal parts
shall be so designed and manufactured that it shall avoid local corona formation
and not generate any radio interference beyond specified limit under the operating
conditions.
3.6 Maintenance
3.6.1 The Composite Insulators offered shall be suitable for use of hot line maintenance
technique so that usual hot line operation can be carried out with ease, speed and
safety.

4 BASIC FEATURES
4.1 Design and construction
The Composite Insulators shall have a core, housing & weathershed of insulating
material and steel/aluminium hardware components for attaching it to the
support/conductor.
4.1.1 Core
It shall be glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass
fibers and resin shall be optimized in the FRP rod. Glass fibers shall be boron free
electrically corrosion resistance (ECR) glass fiber or boron free E-Glass and shall
exhibit both high electrical integrity and high resistance to acid corrosion. The
matrix of the FRP rod shall be Hydrolysis resistant. The FRP rod shall be
manufactured through Pultrusion process. The FRP rod shall be void free.
4.1.2 Housing (Sheath)

The FRP rod shall be covered by a seamless sheath of a silicon elastometric
compound or silicon alloy compound of a thickness of 3mm minimum.
It should protect the FRP rod against environmental influences, external pollution
and humidity. It shall be extruded or directly molded on the core and shall have
chemical.
No Indian Standard is available on Composite Insulators. The specification has

been formulated and finalized based on various international, Indian Standards
such as IEC, ANSI, ASTM, DIN, STRI Guide, IS standards) for material design,
testing, performance requirements etc. Creepage distance, being a critical
parameter for the size and design of the composite insulators, has been considered
as per IS:13134 and the following values have been adopted.
i) For normal & moderately polluted atmosphere 20 mm/kv

ii) For heavily polluted atmosphere 25 mm/kv
A higher value of creepage distance of 320mm has been considered to 11KV
insulators in heavily polluted atmosphere in line with existing practice for 11KV
porcelain insulators. ________________________________ distance need be
adopted bonding with the FRP rod. The strength of the bond shall be greater than
the tearing strength of the polymer. Sheath material in the bulk as well as in the
sealing/bending area shall be free from voids.
4.1.3 Weathersheds
The composite polymer weathersheds made of silicon elastometic compound or
silicon alloy shall be firmly bonded to the sheath, vulcanized to the sheath or
molded as part of the sheath and shall be free from imperfections. The
weathersheds should have silicon content of minimum 30% by weight. The
strength of the weathersheds to sheath interface shall be greater than the tearing
strength of the polymer. The interface, if any between sheds and sheath (housing)
shall be free from voids.

4.1.4 End Fittings
End fittings transmit the material load mechanical load to the core. They shall be
made of spheroidal graphite cast Iron, malleable cast iron or forged steel or
aluminium alloy. They shall be connected to the rod by means of a controlled
compression technique. The gap between fitting and sheath shall be sealed by a
flexible silicon elastomeric compound or silicon alloy composed sealant system of
attachment of end fitting to the rod shall provide superior sealing performance
between housing, i.e. seamless sheath and metal connection. The sealing must be
moisture proof.
The diamensions of end fitting of insulators shall be in accordance with the

standard dimensions stated in IS:2486/IEC: 60120.
5. Workmanship
5.1 All the materials shall be of latest design and conform to the best engineering
practices adopted in the high voltage field Bidders shall offer only such insulators
as are guaranteed by them to be satisfactory and suitable for continued good service
in power transmission lines.
5.2 The design, manufacturing process and material control at various stages shall be
such as to give maximum working load highest mobility, best resistance to
corrosion, good finish and elamination of sharp edges and corners.
5.3 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.
5.4 The core shall be sound and free of cracks & voids that may affect the insulators.
5.5 Weathersheds shall be uniform in quality. They shall be clean, sound, smooth and
shall be free from defects and excessive fashing at parting line.
5.6 End fittings shall be free from cracks, seams, shrinks, air holes and rough edges.
End fitting should be effectively sealed to prevent moisture ingress, effectiveness
of sealing system must be supported by test documents. All surfaces of the metal
parts shall be perfectly smooth with out projecting points or irregularities, which
may cause corona. All load bearing surfaces shall be smooth and uniform as to
distribute the loading stress uniform;
5.7 All ferrous parts shall be hot dip galvanized to give a minimum average coasting of
zinc equivalent to 610 gm/sq.m or 87 µm thickness and shall be in accordance with
the requirement of IS:4759. The zinc used for galvanizing shall be of purity 99.5%
as per IS:4699. The zinc coating shall be uniform, adherent, smooth, reasonably
bright continuous and free from imperfections such as flue, ash rust stains, bulky
white deposits and blisters. The galvanized metal parts shall be guaranteed to
withstand at least four successive dips each lasting for one (1) minute duration
under the standard preece test. The galvanizing shall be carried out only after any
machining.
6. Equipment Marking
6.1 Each insulator unit shall be legibly and indelibly marked with the following details
as per IEC: 61109.

(a) Month & year of manufacture.
(b) Min. failing load/guaranteed mechanical strength in kilo Newton followed
by the word ‘KN’ to facilitate easy identification.
(c) Manufacturer’s name/Trade mark.
6.2 One 10 mm thick ring or 20mm thick spot of suitable quality of paint shall be
marked on the end fitting of each composite long rod of particular strength in case
of 33KV insulators for easy identification in case both types of insulators are
procured by the utility. The paint shall not have any deteriorating effect on the
insulators performance. Following codes shall be used as identification mark:
For 45 KN long rod unit. Blue

For 70 KN long rod unit. Red
7 Bid Drawings
7.1 The Bidders shall furnish full description and illustration of the material offered.

7.2 The Bidder shall furnish alongwith the bid the outline drawing (3 copies) of each
insulator unit including a cross sectional view of the long rod insulator unit. The
drawing shall include but not be limited to the following information:-
(a) Long rod diameter with manufacturing tolerances.
(b) Minimum creepage distance with positive tolerance.
(c) Protected creepage distance.
(d) Eccentricity of the long rod unit.
(I) Axial run out
(ii) Radial run out
(e) Unit mechanical and electrical characteristics.
(f) Size and weight of ball and socket/tongue & clevis.
(g) Weight of composite long rod unit.
(h) Materials
(i) Identification mark
(ii) Manufacturer’s catalogue number.
7.3 After placement of award, the Supplier shall submit full dimensional
manufacturing insulator drawings containing all the details in four (4) copies to
Owner for approval. After getting approval from owner and successful completion
of all the type tests, the Supplier shall submit 10 more copies of the drawing to the
Owner for further distribution and field use.
7.4 After placement of award the Supplier shall also submit fully dimensional insulator
crate drawing for different type of insulators for approval of the owner.
8 Test and Standards

Insulators offered shall be manufactured with the same configuration & raw
materials as used in the insulators for which design & type test reports are
submitted. The manufacturer shall submit a certificate for the same. The design &
type test reports submitted shall not be more than 03 years old.
8.1 Design Tests

Manufacturer should submit test reports for Design Tests as per IEC-61109
(Clause-5) alongwith the bid. Additionally following tests shall be carried out or
reports for the tests shall be submitted after award of contract.
UV test: The test shall be carried out in line with clause 7.2 of ANSIC29.13.
8.2 Type Tests

The following type tests shall be conducted on a suitable number of individual
insulator units, components, materials or complete strings.
8.2.1 The bidder shall submit type test reports as per IEC 61109 alongwith the bid.
Additional type tests as required above shall be carried out by the manufacturer,
after award of contract for which no additional charges shall be payable. In case the
tests have already been carried out, the manufacturer shall submit report for the
same.
Sr. No. Description of type test. Test procedure/standard

1. Dry lightening impulse withstand voltage As per IEC 61109 (Clause 6.1)
2. Wet power frequency test As per IEC 61109 (Clause 6.2)
3. Mechanical load time test. As per IEC 61109 (Clause 6.4)

4. Radio interference test As per IEC 61109 (Clause 6.5)
5. Recovery of Hydrophobicity test Annexure-B This test may be repeated
every year by the
manufacturer.
6. Chemical Composition test for silicon content Annexure-B Or any other method
acceptable to the owner.
7. Brittle fracture resistance test. Annexure-B
8.2.2 It shall be the option of the owner to accept the insulators based on type test reports
submitted by the manufacturer. The owner shall be free to repeat the type test &
may witness the same.
Note:- The owner for the purpose of facilitating the type tests, may ask the bidder
to quote test charges separately.
8.2.3 All the type test given in clause No.8.2 in addition to routine & acceptance test
shall be carried out on insulator along with hardware fittings wherever required.
8.3 Acceptance (sample) Test

8.3.1 For Composite Insulators
(a) Verification of dimensions Clause 7.2 IEC: 61109
(b) Verification of the locking system (if Clause 7.3 IEC: 61109
applicable)
(c) Galvanizing test IS:2633/IS:IS:6745
(d) Verification of the specified mechanical load. Clause 7.4 IEC: 61109
8.4 Routine Tests:

Sr.No. Description Standard
1. Identification of marking As per IEC:61109 Clause 8.1
2. Visual Inspection As per IEC:61109 Clause 8.2
3. Mechanical routine test. As per IEC:61109 Clause 8.3
8.5 Tests During Manufacture.

Following tests shall also be carried out on all components as applicable.
(a) Chemical analysis of zinc used for galvanizing.

(b) Chemical analysis, mechanical, metallographic test and magnetic partical
inspection for malleable castings.
(c) Chemical analysis, hardness tests and magnetic particle inspection for forgings.
8.6 Sample Batch for Type Testing

8.6.1 The bidder shall offer material for sample selection for type testing only after
getting Quality Assurance Programme approved by the owner. The bidder shall
offer at least three times the quantity of materials required for conducting all the
type tests for sample selection. The sample for type testing will be manufactured
strictly in accordance with the Quality Assurance Programme approved by the
Owner.
8.7 Additional Tests

8.7.1 The Owner reserves the right at his own expenses, for carrying out any other test(s)
of reasonable nature carried out at Supplier’s premises, at site or in any other place
in addition to the aforesaid type, acceptance and routine tests to satisfy himself that
the material comply with the specifications.
8.7.2 The Owner also reserves the right to conduct all the tests mentioned in the
specification at his own expenses on the sample drawn from the site at Supplier’s
premises or at any other test centre. In case of evidence of non-compliance, it shall
be binding on the part of the Supplier to prove the compliance of the items to the
technical specifications by repeat tests or correction of deficiencies or replacement
of defective items, all without any extra cost to the Owner.
8.8 Co-Ordination for Testing
8.8.1 The Supplier shall have to co-ordinate testing of insulators with hardware fitting to
be supplied by other Supplier and shall have to guarantee overall satisfactory
performance of the insulators with the hardware fittings.
8.8.2 The bidder shall intimate the owner about carrying out of the type tests and with
detailed testing programme at least 3 weeks in advance of the scheduled date of
testing during which the owner will arrange to depute his representative to be
present at the time of carrying out the tests.
8.9 Quality Assurance Plan

8.9.1 The successful bidders shall submit following information to the owner:-
8.9.1.1 The certificates of the raw materials and bought out accessories.
8.9.1.2 Statement giving list of important raw materials, their grades, alongwith names of
sub-suppliers for raw materials, list of standards according to which the raw
materials are tested. List of tests normally carried out on raw materials in presence
of bidder’s representative.
8.9.1.3 List of manufacturing facilities available.

8.9.1.4 Level of automation achieved and lists of areas where manual proceeding exists.
8.9.1.5 List of areas in manufacturing process, where stage inspections are normally
carried out for quality control and details of such tests and inspections.
8.9.1.6 List of testing equipments available with the bidder for final testing of equipment
alongwith valid calibration reports.
8.9.1.7 The manufacturer shall submit Manufacturing Quality Plan (MAP)approval of the
same shall be followed during manufacture and testing.
8.9.2 The successful bidder shall submit the routine test certificates of bought out raw
material/accessories and central excise passes for raw material at the time of
inspection.
8.10 Guarantee
The supplier of Insulators shall guarantee overall satisfactory performance of the
insulators.

8.11 Test Reports
8.11.1 At least three copies of type test reports shall be furnished. One copy shall be
returned duly certified by the owner, only after which the commercial production
of the concerned material shall start.
8.11.2 Copies of acceptance test reports shall be furnished in atleast three copies. One
copy shall be returned duly certified by the Owner, only after which the material
shall be despatched.
8.11.3 Record of routine test reports shall be maintained by the supplier at his works for
periodic inspection by the owner’s representative.
8.11.4 Test certificates of test during manufacture shall be maintained by the supplier.
These shall be produced for verification as & when desired by the owner.
9. Inspection
9.1 The Owner’s representative shall at all times be entitled to have access to the works
and all places of manufacture, where insulator and its components shall be
manufactured and the representative shall have full facilities for unrestricted
inspection of the Supplier’s and sub-supplier’s works, raw material and
manufacturing of the material and for conducting necessary test as detailed here.
9.2 The material for final inspection shall be offered by the supplier under packed
condition. The owner shall select samples at random from the packed lot for
carrying out the acceptance tests.
9.3 The supplier shall keep the Owner informed in advance of the time of start and the
progress of manufacture of material in their various stages so that arrangements
could be made for inspection.
9.4 No material shall be despatched from its point of manufacture before it has been
satisfactorily inspected and tested unless the inspection is waived off by the owner
in writing. In the later case also the material shall be despatched only after
satisfactory testing specified herein has been completed.
9.5 The acceptance of any quantity of material shall in no way relieve the supplier of
his responsibility for meeting all the requirements of the specification and shall not
prevent subsequent rejection, if such materials are later found to be defective.
10 Packing
10.1 All insulators shall be packed in strong corrugated box of min. 7 ply plated or
wooden crates. The gross weight of the crates alongwith the material shall not
normally exceed 100Kg to avoid handling problem. The crates shall be suitable for
outdoor storage under wet climate during rainy reason.
10.2 The packing shall be of sufficient strength to withstand rough handling during
transit, storage at site and subsequent handling in the field.
10.3 Suitable cushioning, protective padding or dunnage or spacers shall be provided to

prevent damage or deformation during transit and handling.

10.4 All packing cases shall be marked legibly and correctly so as to ensure to arrival at
their destination and to avoid the possibility of goods being lost wrongly
despatched on account of faulty packing and faulty or illegible marking on each
wooden case/crate/corrugated box shall have all the markings stenciled on it in
indelible ink.
10.5 The bidder shall provide instructions regarding handling and storage precautions to
be taken at site.
Sd/- Sd/- Sd/- Sd/-

GM/P&D, CGM/P&D, CGM/MM, CGM/Comml.,
DHBVN, Hisar. DHBVN, Hisar DHBVN, Hisar. DHBVN, Hisar.

Annexure-A
The standards mentioned in this specification are available from

Reference Abbreviation Name and Address
IEC/CISPR International Electro-technical Commission, Bureau Central
Commission electro-Technique international, 1 Rue de
verembe, Geneva, Switzerland.
BIS/IS Bureau of Indian Standards, Manak Bhawan, 9 Bahadurshah
Zafar Marg, New Delhi-110 001 India.
ISO International Organization for Standardization, Danish Board
of Standardization Danish Standardizing Street,
Aurehoegvej-12 DK-2900-Heelepurup DENMARK.
NEMA/ANSI National Electic Manufacture Association, 155 East 44th
Street, New York, NY 10017 U.S.A.
ASTM American Society for Testing and Materials, 1916, Race St.
Phisledelfhia, U.S.A.
STR, guide STRI, Sweden, Website:www.stri.se.

Annexure B
1) RIV TEST (DRY)

The insulator string along with complete hardware fittings shall have radio
interference voltage level below 100 micro volts at one MHz when subjected to
50 Hz AC voltage of 10 KV & 30 KV for 11 KV & 33 KV class insulators
respectively under dry condition. The rest procedure shall be in accordance
with IS :8763 IEC: 437/CISPR 18-2.
2) BRITTLE FRACTURE RESISTANCE TEST:-
Brittle fracture test shall be carried out on naked rod along with end fitting
by applying in HNO3 acid (63 g Conc. HNO3 added to 937 g water) to the rod.
The rod should be held at 80% of SML for the duration of the test. The rod
should not fail within the 96-hour test duration. Test arrangement should
ensure continuous wetting of the rod with Nitric acid.
3) RECOVERY OF HYDROPHOBICITY & CORONA TEST:-
The test shall be carried out on 4 mm thick samples of 5 cm x 7 cm.
i) The surface of selected samples shall be cleaned with isopropy
alcohol below the surface to dry and spray with water. Record the
Hydrophobicity class location in line with STRI guide for Hydrophobicity
classification (Extract enclosed at Annexure-D) Dry the sample surface.
ii) The sample shall be subjected to mechanical stress by bending the
sample over a ground electrode. Corona is continuously generated by applying
12 KV to a needle like electrode placed 1 mm above the sample surface.
Tentative arrangement shall be as shown in Annexure-E. The test shall be done
for 100 hrs.
iii) Immediately after the corona treatment, spray the surface with water
and accord the HC classification, Dry the surface and repeat the corona
treatment as at Clause-2 above. Note HC classification. Repeat the cycle for
1000 hrs. or until an HC of 6 or 7 is obtained. Dry the sample surface.
iv) Allow the sample to recover and repeat hydrophobicity measurement
at several time intervals silicone rubber should recover to HC-1 –HC-2 within
24 to 48 hours, depending on the material and the intensity of the corona
treatment.
4) CHEMICAL COMPOSITION TEST FOR SILICON CONTENT:-

The content of silicon in the composite polymer shall be evaluated by
EDX (Energy Dispersion X-ray) Analysis or Thermo-Gravimetric analysis.
The test may be carried out at CPRI or any other NABL accredited laboratory.
Annexure-C
Guaranteed Technical Particulars of Composite Insulator
Name of Manufacturer
Address of Works
Sr. Description Units 11 KV 45 KN 33 KV 45 KN

No
1 Type of insulator
2 Standard according to which
the Insulators manufactured
and tested
3 Name of material used for
manufacture of the Insulators
with class/grade.
a) Material of core (FRP rod)
i) E-glass or ECR-
glass
ii) Boron content.
b) Material of housing & weather
sheds ( silicon content by
weight)
c) Material of end fittings
d) Sealing compound for end
fittings
4 Colour
5 Electrical characteristics:
a) Nominal system voltage KV (rms)
b) Highest system voltage KV (rms)
c) Dry Power frequency KV (rms)
withstand voltage
d) Wet Power Frequency KV (rms)
withstand voltage

e) Dry flashover voltage KV (rms)
f) Wet flash over voltage KV (rms)
g) Dry lighting impulse
withstand voltage
i) Positive KV ( Peak)
ii) Negative KV ( Peak)
h) Dry lighting impulse flashover
voltage
i) Positive KV ( Peak)
ii) Negative KV ( Peak)
i) RIV at 1 MHz when energized Microvolt
as 10 KV/30 KV (rms) under
dry condition
j) Creepage distance (Min) mm
6 Mechanical characteristic: KN
i) Minimum failing load
7 Dimensions of insulator
i) Weight Kg.
ii) Dia of FRP rod mm
iii) Length of FRP rod mm
iv) Dia of weathersheds mm
v) Thickness of housing mm
vi) Dry arc distance Mm
Dimensioned drawings of Yes
insulators ( Including weight or
with clearance in weight No
enclosed)
8 Method of fixing of sheds to
housing ( specify) single mould
modular construc-tion
(injection moulding
/compression moulding)
9 No of weathersheds
10 Type of sheds
i) Aerodynamic
ii) With underribs
11 Packing details
a) Type of packing
b) No of insulators in each pack
c) Gross weight of package
12 Any other particulars which
the bidder may like to give,
Signature -----------------------------
Name ----------------------------------

Designation --------------------------
Dated -----------------

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DAKSHIN HARYANA BIJLI VITRAN NIGAM

FIBRE GLASS CROSS ARMS (FRP) FOR 11 KV LINES

Issued in Sept. 2007

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4. SHAPE AND SIZE:

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Sd/- Sd/- Sd/- Sd/-

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SCHEDULE OF TECHNICAL & GUARANTEED PARTICULARS FOR FIBRE

S.No. Particulars To be furnished by the

1. Name of manufacturer & address

2. Whether channel or rectangular shape with

3. Type of material used

5. Whether raw materials confirming to

6. Vertical / Horizontal load capability (Kg)

7. Whether rectangular solid polymeric

8 Whether type tests conducted & reports

Sign & Seal of supplier

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Energising Lives-Making A Difference.

3. A Technical Committee was constituted by REC for finalization of specification

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2.0 APPLICABLE STANDARDS

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3.0 Technical Description of Composite Insulators

Maximum ambient temperature **48oC

3.2.2 Bidder must be a indigenous manufacturer and supplier of Composite Insulators of

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Impulse withstand voltage

Pin ball shank diameter

Min. failing load KN

Note:- 1** To be specified by utility.

3.3 Dimensional Tolerance of Composite insulators

However, no negative tolerance shall be applicable to creepage distance.

3.5 Corona and RI Performance

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4.1.2 Housing (Sheath)

No Indian Standard is available on Composite Insulators. The specification has

i) For normal & moderately polluted atmosphere 20 mm/kv

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The diamensions of end fitting of insulators shall be in accordance with the

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For 45 KN long rod unit. Blue

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8 Test and Standards

8.1 Design Tests

8.2 Type Tests

Sr. No. Description of type test. Test procedure/standard

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8.3 Acceptance (sample) Test

8.4 Routine Tests:

8.5 Tests During Manufacture.

(a) Chemical analysis of zinc used for galvanizing.

8.6 Sample Batch for Type Testing

8.7 Additional Tests

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8.9 Quality Assurance Plan

8.9.1.3 List of manufacturing facilities available.