UTTAR DAKSHIN HARYANA BLILI VITRAN NIGAM. ao LHW Specification No. CSC-191/DH/UH/P&D/ 2020-24 TECHNICAL SPECIFCATION FOR INSULATED JUMPER ASSEMBLY Issue Month: May, 2020 Common Specifications Committeesoa sfeor sfaron fio firqor » ferent INTAR DAKSHIN HARYANA BLILI VITRAN NIGAM VN Len INSULATED JUMPER ASSEMBLY 4.0 SCOPE This specification covers the design, manufacture, testing & supply of Smart Insulated Jumpers (Ready to Install Kit) which are to be used for line jumpers. The equipment required shall be complete with all components which are necessary for their efficient performance and satisfactory maintenance. 2.0 RATED VOLTAGE The rated voltage of the Smart Insulated jumper shall be 6.35/11KV and the maximum operating voltage shall be 12 KV. 3.0 APPLICABLE STANDARDS Unless otherwise stipulated in this Specification, the following Indian /Intemational Standards with the latest amendments shall be applicable. Any deviation from the standards should be indicated specifically and with recorded reasons. : Sr. Applicable |S Description No. 1 [iss sseta076 ‘Specification for Electric Power Connectors 2 | 1S: 398 (Part 1V)/1994 | Specification for aluminium conductors for overhead transmission 3. | EN 50397-1:2006 ‘Covered Conductor Specification for voltage 1KV to 36KV. 4 | 1S :738:1994 ‘Specification of wrought Aluminium and its alloys-drawn tubes for general engineering purpose _ i} 4.0 CLIMATIC CONDITIONS : The material to be supplied against this specification shall be suitable for satisfactory operation under the following climatic conditions:- [-a_[ Maximum ambient temperature (Degree C) 60°C b_| Minimum temperature of air in shade OSC ¢_| Maximum temperature of air in sun Z 80°C ‘d_| Maximum humidity 95% ‘e_| Average number of thunder storm days per annum a 40 f_| Average number of dust storms per annum 40 [7g _[ Maximum rain fall per annum 98 cm h_| Average rainfall per annum — E 60. cm i_| Limits of ambient temperature averaged over a period of 24hours. | 107 C to 50°C |_| Wind pressure 195 kg/m” k_[Max Altitude above MSL 71000 Meters. © The material shall be for use in moderately hot and humid tropical climate, conducive to rust and fungus growth. The’ climatic conditions are also prone to wide variations in ambient conditions. Smoke is also present in the atmosphere Heavy lightning also ocours during June to October.soa fino efter fort fear from y, G urrax vawsswn BARYANA BLT VITRAN meaM iBVN LEN 5.0 TECHNICAL REQUIREMENTS: 5.1 COVERED CONDUCTOR 5.1.1 PROPERTIES OF CONDUCTORS: TABLE - 1 ALUMINIUM ALLOY (AL-59) STRANDED CONDUCTOR _ Calculated pawl neo | Sera | Aomis, | Anpmr | tance atsode, | Mims cles (max) 1 2 3 _4 5 : 6 Sqmm. | mm mm Kg/km ‘Ohmikm kN ao | 7381 | 1143 | 218.26 0377 18.95 100 714.26 1278 | 272.86 0.301 23.70 5.1.2. PROPERTIES OF WIRES: The properties of aluminum alloy Wires to be used in the construction of the Stranded conductors shall be as in Table 2 - TABLE - 2 5s section: i in Saree | Semecea ant | wae | Mamma esi, [Mex Ream o20 Nom. | Max. 7 | mm_|-mm ‘Sq.mm. Kg/Km KN _t Ohm/Km| 3.81 | 3.85 11.400 30.78 2.70 2.602 426 | 4.30 14.250 38.48 3.38 2.077 5.1.3 In all constructions, the successive layers shall have opposite directions of lay, the outer most layers being right handed. The wires in each layer shall be evenly and closely stranded. 5.1.4 In aluminum alloy stranded conductors having multiple layers of wires, the lay ratio of any layer shalll not be greater than the lay ratio of the layer immediately beneath it. 6.1.5 FILLING (WATER BLOCKING) The Stranded Conductor shall be longitudinally water tight by means of a water blocking material incorporated during the extrusion process. The use of grease /water swellable tape / water- swellable powder etc.... is not permitted. The water blocking material shall be stable at maximum operating conductor temperature of 90 Deg. Cent. The water blocking compound shall be compatible with the conductor material as well as the semi conducting polymer screen layer above it and not adversely affect its electrical or mechanical properties. 5.1.6 INSULATION: The Insulation should be dual layered with the Inner Layer being XLPE with a nominal thickness of 1.2 mm for Voltages up to11KV and the Outer Layer being a suitable XLPE which is UV Resistant, Non Tracking and Erosion Resistant with a nominal wall thickness of 1.1 mm for Voltage of KV The conductor manufacturing and stranding process shall incorporate the longitudinal water blocking also.Pi d ‘UITAR, DAKSHIN HARYANA BLILL VITRAN NIGAM IBYN LN The Semi Conducting Screen, Inner Insulation and Outer Insulation should be extruded in one step ie triple extrusion to ensure a good, permanent bond between the three layers and also with the conductor. It shall be possible to remove the Semi Conducting Screen, Inner and Outer Insulation Layers without damage to the conductor. . af] em [oe | — 2 [acorns fa] Ac + Eat ana + [2 hein Sana 2 eeelien oct | we 5 5 erences foe ; as + eaweeet aie u iqure 41 shows the Cross Section of AAA COVERED Conductor 6.0 TYPE TESTS:- Tests as per IS-5561: 2018 for Connectors / Jumper AsSembly and in accordance with EN 50397-1: 2006 - for MVCC, shall be submitted along with offer. 6.1 ACCEPTANCE TESTS & ROUTINE TESTS All tests shall be as per respective test standards, as amended upto date including Anti tracking testing on selective MVCC samples at manufacturer's work during acceptance test as well as 1S-5561 for connectors / Jumpers. Specification for connector 7.0 CONNECTOR FOR JUMPER * The connector consists of MAIN connector body and slider that is made up of aluminum alloy to maintain constant pressure for a firm electrical contact. The connector shall be used for multiple combinations of solid / stranded AAC, AAAC, ACSR: combination etc. ‘*. It shall be suitable for Raccoon/Dog and any other bare/insulated conductor requirements as specified by customers. ‘© Length of Jumper cable shall be 2.0 meter or any other customized lengths as defined by customers. Connector shall be factory coated with an inhibitor containing abrasive particles to help clean and contact surfaces during installation. © The connector should be easily removable and ‘reusable type. Reusable means that the connector may be removed from service and installed again. Prior to reuse, any instructions to be followed for reconditioning the reusable connector shall be furnished. 7A RATING 7.4.4 Rated Current: the rated current of power connectors shall be selected from one of the following values:saq sfor sharon fort faaqor fara Pa cd ” UTTAR DAKSHIN HARYANA BLILI VITRAN NIGAM iBVN LHEMN 300/400 Amperes. 7.4.2. The rated frequency of the power connector shall be 50 Hz. 7.1.3. Rated Short-Time Current - The rated short-time current shall be one of the standard values laid down in Indian Standards for the associated circuit-breakers, ‘switches, etc. Note- When power connectors are directly associated with a Circuit-Breaker or a switch, the rated short-time current of the power connectors shall not be less than the corresponding rating for the circuit-breaker or switch. 8.0 | MATERIALS 8.1 All materials used shall conform to the relevant Indian Standards. 8.2 Aluminium alloys used in the manufacture of the connector shall be extruded alloy: conforming to IS : 738:1994. 8.3. Steel bolts and nuts shall conform to IS : 1363-1967 + and IS : 1367-1961 * Non-ferrous alloy bolts and nuts shall conform to the relevant Indian Standards. Specification for aluminium and aluminium alloy ingots and castings for general engineering purposes (revised). ‘Specification for black hexagon bolts, nuts and lock nuts (diameter 6 to 39 mm) and black hexagon screws (diameter 6 to 24 mm) (first revision). Technical supply conditions for threaded fasteners (Since revised). 9.0 | REQUIRMENTS } 9.1 Freedom from Defects- The power connectors shall be smooth and free from cavities, blow-holes and such other defects which would be likely to cause them to be unsatisfactory in service. 9.2 Power connectors shall be so designed and proportioned that they are capable of safely withstanding stresses to which they may be subjected (including those due to short-circuit and climatic conditions) and that the effects of vibration both on the conductor and the connector itself are minimized. They shall be designed, manufactured and finished. so as to avoid sharp radii of curvature, ridges and excrescences which might lead to localized pressure on or damage to the conductor in service. 9.3. Bimetallic connectors shall be used to connect conductors of two dissimilar metals. Sufficient contact pressure should be maintained at the joint by the provision of the required number of bolts or other fixing arrangements. But the contact pressure should not be so great as to cause relaxation of the joint by cold flow. The joint should be such that the pressure is maintained within this range under all conditions of service. To avoid excessive local pressure, the contact pressure should be evenly distributed by the use of pressure plates, washers or suitable saddles of adequate area and thickness. 40.0 LIMITS OF TEMPERATURE-RISE 410.1 The limits of temperature-rise specified are based on the following reference ambient temperatures: nt air temperatureaeogq efor eftaron front faaaor front 4 # UTTAR DAKSHIN HARYANA BIJLI VITRAN NIGAM BVN. LEN b) Maximum daily average ambient temperature 35°C cc) Maximum yearly average ambient temperature 30°C 10.2 The temperature-rise of power connectors above a reference ambient temperature of 40°C when carrying rated current shall not exceed 45°C to fulfill the requirement of C1.6 of IS §561(1970) and its latest amendments. 10.3. It the ambient temperature exceeds that specified in 10.2, the permissible temperature- rise shall be reduced by an amount equal to the excess ambient temperature. 41.0 PROTECTION AGAINST CORROSION 41.1. All parts of power connectors shall either be inherently resistant to atmospheric corrosion or be suitably protected against corrosion, both during storage and in service. 41.2 All ferrous metal parts intended for outdoor use, except those made of stainless steel, shall be protected by hot-dip galvanizing in accordance with IS: 2633-1964". 41.3. The threads of nuts and tapped holes shall be cut after galvanizing and shall be well oiled or greased. All other threads shall be cut before galvanizing, 12.0 MARKING 12.4 The connectors shall be indelibly marked with rated current or any identifying mark to enable full particulars of the connector to be obtained. 12.4.1 The electric power connector may also be marked with the ISI Certification Mark. NOTE: the use of the ISI Certification Mark is governed by the provision of the Indian Standards Institution (Certification Marks) Act and the Rules and Regulations made there under. The ISI Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well-defined system of inspection, testing and quality control which is devised and supervised by ISI and operated by the producer. ISI marked products are also continuously checked by ISU for conformity, to that standard as a further safeguard. Details of conditions under which a licence for the use of the IS! Certification Mark may be granted to manufacturers or processors, may be obtained from the Indian Standards Institution. 43.0 TESTS 13.1 Following shall be the tests to be carried out on the connector. 43.1.1 Type Tests- The following type tests shall be carried out on three samples. The purchaser shall accept certified copies of type tests as evidence of compliance of connectors with the requirements of the relevant clauses of this specification, and the manufacturer shall make available originals of such certificates, detailed drawings of the connectors and record of any alteration that may have been made in the connectors subsequent to type tests. The manufacturer shall, if required by the purchaser, certify that the connectors are identical in material and performance with those covered by a certificate of stated date:- a) Tensile tests b) Resistance test c) Temperature-rise testfo saa efor citeron front ftraaor foro Fs UTTAR DAKSHIN HARYANA BLILI VITRAN NIGAM BVN LEN d) Short time current test e) Dimensional check f) Galvanizing test, where applicable 13.1.2 Acceptance tests a) Tensile tests b) Resistance test ©) Dimensional check 4d) Galvanizing test, where applicable 13.4.3 Routine tests a) Visual inspection, and b) Dimensional check 13.2 For acceptance tests the number of samples to be tested shall be the nearest whole number to 0.5 percent of the batch offered for acceptance. If these samples meet the test requirements, the batch is deemed to comply with the standard. In the event of the sample not meeting the requirements, twice the original number of new samples shall be tested. If all these new samples meet the test requirements, the batch is deemed to comply with the ‘standard, but if any fails to do so, the batch is deemed to not comply with the standard. 14.0 TECHNICAL PARAMETERS: Please refer Guaranteed Technical Particulars (GTP) in Annex 1 for Complete Jumper Assembly, 45.0 QUALIFICATION REQUIREMENTS: ‘Qualification Requirements: sr. To be filled ne DETAILS DHBVN REQUIREMENT by Bidder 1 | Bidder Name & Address. If consortium | Mention clearly. Only of manufacturers’, please indicate Manufacturers 2 [ISO Certification 180-9001 : 2015 with Design Scope [3] Manufacturing In-House 4 | Acceptance Test Facilities In-House ~ 5 | Jumper Performance | Proven with documents 6 | Type Test Reports ~~ Available or not 16.0. IDENTIFICATION Connectors & MVCC shall be identified with the manufacturer's identification marks and other specified details. 17.0 INSPECTION: The inspection may be carried out by the purchaser at any stage of manufacture. The successful bidder shall grant free access to the purchaser's representative at a reasonable time when the work is in progress. Inspection and acceptance of any equipment under this specification by the purchaser shall not relieve the supplier of his obligation of furnishingaaa sor earor fot firaqor ferent P d WITAR DAKSHIN HARYANA BLILL VITRAN NIGAM BVN. ‘LEN connector in accordance with the specification and shall not prevent subsequent rejection if the equipment is found to be defective, The supplier shall keep the purchaser informed in-advance, about the manufacturing program so that arrangement can be made for inspection. 18.0 PACKING AND FORWARDING: The supplier shall be responsible for damage to the equipment during the transit, due to improper and inadequate packing. The easily damageable materials shall be carefully packed and marked with the appropriate caution symbols. Any material found damaged inside the packing cases shall be supplied by the supplier without any extra cost to the purchaser. 19.0 SUBMISSION OF DRAWINGS: Drawings for each item have to be submitted along with the Tender. The drawing shall be complete in all respects. Dimensions shall be furnished in each of the drawings. Any defects noticed in the manufacture of the equipment during inspection or after receipt at destination have to be promptly set right by the contractor free of all cost to the owner. The following shall be furnished with the offer. a. The catalogues (in English) describing the items and indicating the Model / reference number, Code Name / Across Flat dimension of the relevant die to be used for compression, conductor sizes and other relevant details. b. Constructional features and material used for components and relevant technical literature c. Certification for Quality Assurance conforming to ISO 9001 d. Dimensional Drawings of all items @. Type Test Reports as per GTP 20.0 SUBMISSION OF PERFORMANCE CERTIFICATES Performance Certificates for "Complete Jumper Assemblies” shall be furnished along with the offers from Government or Private Customers. It should be as a complete assembly and shall be in service satisfactorily. 21.0 SAMPLE SUBMISSION: Typical sample of Jumper Assembly offered shall accompany the bid to facilitate analysis and evaluation. Non-Submission of samples shall be considered as bid rejection 22.0 DEVIATION FROM TECHNICAL SPECIFICATION Deviations; as compared to Technical Specifications, if any, shall be brought out in the relevant clause-by-clause in the Techno-Commercial sheet enclosed. [ Superintending Engiicer/P8D Cum-Member Secretary CSC DHBVN & UHBVNsoa efeot efterom fit ftraqor foro : UTTAR DAKSHIN HARYANA BLILI VITRAN NIGAM BVN Annex 4 GTP for Smart Insulated Jumper Assembly Ry | TECHNICAL DETAILS DHBVN REQUIREMENT To be filled by Bidder 1 | Application ~~ | Jumper at poles for Overhead Bare Distribution Lines _ 2 | Type Pre-Insulated, Torque Controlled, Shear _| Bolted 3° | Rated Voltage UPTO 33 KV/ 11 KV | Rated Current ‘400 Amp ~~ ~ 5 | Shear Bolts per 2 Nos 7 connector a _ | Connector outer body | Al Alloy 7 | Shear Head Bolts & Al Alloy ~ Slider 8 | Main Conductor Range _ | Racoon - Dog @ | Tap Conductor Range | Racoon - Dog 10 | Surface finish Suitable Process if applicable 41 ‘| Type Tests 7, Temperature Rise (TR) Test as perIS- | 5561, at rated current shall be less than 35 deg 2. Contact Resistance Test - as per |S-5561 | 3. Tensile Test - as per IS-5561 [42 | Acceptance test with In- | 1. Temperature Rise (TR) Test - as per IS- | house facilities 5561 2. Contact Resistance Test - as per |S-5561 3. Tensile Test - as per IS-5561 4. Torque Assurance Test 5. Conductivity Test 12 | is removable feature to | Yes be provided _ 7 | Is reusable feature to be | Yes (with New Shear Heads, if feasible) provided ; _ 14 | Oxide Inhibitor Yes, factory applied 48 | Installation Instruction | Yes - 46 | Is it feasible for Yes” RETROFIT purpose 7 17 | Drawing Yes