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TECHNICAL SPECIFICATIONS

FOR

11 KV, 5KN, 340 Creepage Distance, Pin type Composite (Polymer) Insulator with rod

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Technical Specification for

11 KV, 5KN, 340 Creepage Distance
Pin type Composite (Polymer) Insulator with rod

1. SCOPE:

This specification covers design, manufacture, testing, inspection, packing and supply of composite
insulators for use in the 11 KV overhead transmission lines situated in any part of Gujarat State. The
composite polymer insulators shall be of following type:

1.1 Pin insulators with rod for AAAC/ACSR conductors for straight line point/angle/cut point.

1.2 The Bidder should be original manufacturer of the composite insulators and shall have all
the facilities to manufacturing and in house testing of their product.
This will be pre-qualifying requirement as a “Bidder”.

2. SERVICE CONDITIONS

The composite insulators to be supplied against this specification shall be suitable for satisfactory
continuous operation under following tropical conditions.

2.1 Maximum Ambient Air Temperature °C : 50

2.2 Minimum Ambient Air Temperature °C : 0
2.3 Average daily ambient Air Temperature °C : 40
2.4 Relative humidity (%) : 10 to 100
2.5 Average rainfall per annum (mm) : 1150
2.6 Maximum altitude above mean sea level – Mtr : 1000
2.7 Isoceraunic level (Days/Year) (i.e. Average number of Thunderstorm): 30
2.8 Maximum wind pressure (Kg/Sq. meters) : 200
2.9 Seismic level i.e Earthquake Acceleration
a) Horizontal Seismic Co-efficient (acceleration – g (Zone-5) 0.08
b) Vertical Seismic Co-efficient (acceleration – g (Zone-5): 0.08
2.10 Climate: Moderately hot, saline and humid and polluted by dust & smoke and conductive to
rust and fungus.

As Gujarat state is having largest coastal area having saline & humid atmosphere, the insulatorsif installed in such
area shall be able to function satisfactorily.

3. SYSTEM PARTICULARS

A Nominal system voltage 11 KV (rms)

B Highest System voltage 12 KV (rms)
C Visible discharge test voltage 9 KV (rms)
D Normal Frequency 50 HZ
E Maximum Frequency 51.5 HZ
F Minimum Frequency 47 HZ
G Neutral Earthing Effectively Grounded
H Number of phases 3

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4. 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.

Sr. Indian Standard Title Internationa

No. Standard lStandard
1 Definition, test methods and acceptance criteria for IEC:61109
composite Insulators for a. c. overhead lines above 1000V.
Composite Insulators for a. c. overhead lines above IEC 1109
1000V. Definition, test methods and acceptance criteria
2 IS: 731 Porcelain insulators for overhead power lines with a nominal IEC: 60383
voltage greater than 1000V.
3 IS:2071 Methods of High Voltage Testing. IEC:60060-1
4 IS:2486 Specification for Insulator fittings for overhead power lines IEC:60120
with a nominal voltage greater than 1000V General IEC:60372
Requirements and Tests Dimensional Requirements locking
devices.
5 - Thermal Mechanical performance and mechanical IEC:60575
test performance test on string
Insulators units.
6 Guide for the selection of insulators in respect of polluted
IS: 13134 IEC: 60815
condition.
7 - Characteristics of string insulator units of the long rod type. IEC: 60433
8 - Hydrophobicity Classification Guide. STRI guide 1.92/1
9 - Radio interference characteristics of overhead power lines and CISPR 18.2 Part
high voltage equipment. 2
10 IS:8263 Methods of RI Test of HV Insulators. IEC:60437
11 ANSI C 29.13-
Standard for Insulators- Composite- Distribution Dead-end Type.
2000
12 IS:4759 Hot dip zinc coatings on structural steel & other allied ISO:1459
products.
13 IS:2629 Recommended practice for Hot Dip galvanization for iron and ISO:1461(E)
steel
14 IS:6745 Determination of weight of zinc coating on zinc coated Iron ISO:1460
andsteel articles.
15 IS:3203 Methods of testing of local thickness of electroplated coatings. ISO:2178
16 IS:2633 Testing of Uniformity of coating of zinc coated articles.
17 - Standard specification for glass fiber standards. ASTM D
578-05
18 - Standard Specification / test method for compositional ASTM E 1131-
analysis by Thermo gravimetery. 08
19 IS:4699 Specification for refined secondary zinc
20 Rubber - Identification – Infrared spectrometric methods. ISO 4650:2012
5. GENERAL REQUIREMENTS
5.1 The Composite insulators will be used on lines on which the conductor will be AAAC/ACSR of size
up to 100 Sq.mm. The insulators should withstand the conductor tension, the reversible wind load as
well as the high frequency vibrations due to wind.
5.2 Insulator shall be suitable for 3-ph 50 Hz effectively earthed 11KV Overhead distribution system in a
moderately/heavily polluted atmosphere.

5.3 Bidder must be an indigenous manufacturer and supplier of composite insulators of rating 11KV 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
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manufacturer of composite insulators of rating 11KV or above. The Bidder shall furnish necessary
evidence in support of the above along with the bid, which can be in the form of certification from the
utilities concerned, or any other documents to the satisfaction of the owner.

5.4 Insulator shall be suitable for the pin type of load. The distance between conductor and metal part at
bottom shall be min 200mm for 11KV pin type composite insulator.

5.5 Insulators shall have sheds with good self-cleaning properties. Insulator 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.

5.6 The type/size of composite insulator, minimum Creepage distance and mechanical strength along
with hardware fittings shall be as follows

A Type of Composite insulators Pin type Insulators with rod, washer & nut
B Nominal system voltage 11 KV (rms)
C Highest System voltage 12 KV (rms)
D Visible discharge test voltage 9 KV (rms)
E Mechanical characteristic Min. bending load :5 KN

F Minimum Creepage distance (mm) 340mm(Min)

G Wet power frequency withstand voltage ≥45 KV(rms)

H Dry lighting Impulse withstand voltage a) Positive ≥110KV
b) Negative: ≥110KV

5.7 Dimensional Tolerance of Composite Insulators :-

The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed asfollows
in line with IEC 61109:
± {0.04d+1.5) mm when d<300 mm,
± (0.025d+6J mm when d>300 mm.

Where, d being the dimensions in millimeters for diameter, length or Creepage distance as the casemay
be. However, no negative tolerance shall be applicable to Creepage distance.

5.8 Interchangeability
The composite insulators including the end fitting connection shall be of standard design suitable for use
with the hardware fittings of any other indigenous make conforming to relevant IEC/IS standards.

5.9 Corona and Rl Performance:-

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to
excessive localized pressure. The insulator 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.

6 TECHNICAL DESCRIPTION OF COMPOSITE INSULATORS

6.1 Composite Insulators shall be designed to meet the light quality, safety and reliability and are
capable of withstanding a wide range of environmental conditions.
(a). Core- the internal insulating part
(b). Housing – the external insulating part.
(c). Metal and fittings – for directly fitting in to fabricated support and to supportConductor
with bindings
6.2 CORE
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It shall be a 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 resistant (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 shall be manufactured through
Pultrusion process. The FRP rod shall be void free. No Joint in Core Material is allowed.
6.3 HOUSING (Sheath)
The FRP rod shall be covered by a seamless sheath of a silicone Elastomer compound of a thickness of 3 mm
minimum. It shall be one-piece housing using injection Molding Principle to cover the core. The elastomer
housing shall be designed to provide the necessary creepage distance and protection against environmental
influences, external pollution and humidity. Housing shall conform to the requirement of IEC 61109:2008
with latest amendments.
It shall be directly molded on core and shall have chemical 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/bonding area shall be free from voids. Manufacturer should furnish a description of its quality
assurance programme including fabrication; testing and inspection for any material (i.e rubber).
Components (i.e rod) or hardware (i.e. end filings). If the manufacturer has had fabricated these
components by other manufacturers, quality plan of that manufacturer should also be included.
Manufacturing methods and material composition documentation will be a part of Technical Bid to be
submitted along with offer.
6.4 WEATHERSHEDS
The composite polymer Weather sheds made of silicone elastomer compound shall be molded as part of
the sheath and shall be free from imperfections. The weather sheds should have silicone rubber content of
minimum 30% by weight. The strength of the weather shed 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.
6.5 METAL END FITTINGS:
There shall be two type of metal end fittings namely, top metal end fitting and bottom metal end
fitting.
Top metal end fitting transfers the mechanical load of conductor two core of the insulator; it shall be a one piece
and tightly fitted with top end the core of the insulator. Top metal end fitting shall be made of S.G. Iron or
Malleable cast iron or forged steel.
Bottom metal end fitting shall be in one piece and tightly fitted with bottom end of the core of
the insulator. Bottom threaded end of the bottom metal end fitting shall be suitable to fix the
insulator on the UGVCL’s fabrication with respective specified mechanical load. Bottom metal
end fitting shall be made up of M.S. Forged steel in single piece.
Top and Bottom metal end fittings shall be hot dip galvanized in accordance with IS 2629. The material
used in the fitting shall be corrosion resistant. Metal end fitting shall be uniform and without sharp edges or
corners and shall be free from crack, flakes, silvers, slag, blow –holes shrinkages defect and localized
porosity.
They shall be connected to the rod by means of a controlled compression technique. As the main duty of the
end fittings is the transfer of mechanical loads to the core the fittings should be property attached to the
core by a coaxial or hexagonal compression process and should not damage the individual fibers or crack
the core.
The gap between fittings and sheath shall be sealed by RTV Silicon sealant. System of attached 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.
Nominal dimensions of the pin insulator shall be strictly in accordance with the dimensions shown in tender
drawing.
Outer portion of the pin should be zinc sleeved with minimum 99.95% purity of electrolytic high grade zinc.
The finished surface shall be smooth and shall have a good performance. The surface shall not crack or get
chipped due to ageing effect under normal and abnormal service conditions or while handling during transit
or erection.
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The design of the fittings and the insulators shall be such that there is no local corona formation or
discharges likely to cause the interference to either should or vision transmission.
Length of thread on shank should be 100 mm and Shank diameter is 20 mm. Minimum Collar diameter
should be 40 mm and its minimum thickness should be of 5 mm. Nuts as per IS 1363 (P-III) and 4 mm thick
Spring Washer shall be as per IS 3063 with latest amendments if any, Nuts and spring washer shall be
hot dip galvanized. Length of unthreaded portion of the rod should be 50 mm. For top fitting conductor
groove radius should be 10 + 1 mm (R10) as shown in tender drawing.
7.0 WORKMANSHIP::
7.1 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.
7.2 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 elimination of
sharp edges and corners.
7.3 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.
7.4 The core shall be sound and free of cracks and voids that may adversely affect the Insulators.
7.5 Weather sheds shall be uniform in quality. They shall be clean, sound, smooth and shall be free
from defects and excessive flashing at parting lines.
7.6 End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings 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 so as to distribute the loading stresses uniformly.
7.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to
610 gm/Sq.m, or 87 m 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 flux, 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 H) minute duration under the standard
preece test. The galvanizing shall be carried out only after any machining.
8.0 TESTS 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 type test reports submitted shall not be more than 07 years old.
8.1 Design tests/Type test (As per Clause 9.1 & 10 of IEC: 61109: 2008)
For polymeric insulators it is essential to carry out design test as per clause 9.1 & 10 of IEC 61109:2008 with
latest amendments.
These tests are intended to verify the suitability of the design, materials and method of manufacture
(technology). A composite suspension insulator design is defined by the following elements:
 materials of the core, housing and their manufacturing method;
 material of the end fittings, their design and method of attachment (excluding the coupling);
 layer thickness of the housing over the core (including a sheath where used);
 Diameter of the core.
When changes in the design occur, re-qualification shall be carried out in accordance with Table 1 of IEC
6119:2008.
When a composite suspension insulator is submitted to the design tests, it becomes a parent insulator for a given
design and the results shall be considered valid for that design only. This tested parent insulator defines a
particular design of insulators which have all the following characteristics:
a) Same materials for the core and housing and same manufacturing method;
b) Same material of the fittings, the same connection zone design, and the same housing-to fitting
Interface geometry;
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c) Same or greater minimum layer thickness of the housing over the core (including a sheath
Where used);
d) Same or smaller stress under mechanical loads;
e) Same or greater diameter of the core;
f) Equivalent housing profile parameters, see Note (a) in Table 1 of IEC 61109:2008
Manufacturer should submit test reports for Design Tests as per IEC-61109: 2008 along with the bid.
8.2 Type Tests:-
The type tests are intended to verify the main characteristics of a composite insulator. The type tests
shall be applied to composite insulators, the class of which has passed the design tests.
Following type test shall be conducted on a suitable number of individual insulator units, components,
materials or complete strings.
SN Description of type test Ten procedure/standard
1. Dry lightning impulse withstand voltage test As per IEC 61109 : 2008 (clause 11.1)
2. Wet power frequency test As per IEC 61109 : 2008 (clause 11.1)
3. Bend test As per IS:731 (Clause- 10.8.2)
4. Radio interference test As per IS: 8263/ IEC:437/CISPR 18-2.
5. Recovery of Hydrophobicity test Annexure-B (As per STRI guide)
This test may be repealed every 3 yrs by
the manufacturer
6. Test for presence of silicone rubber content Annexure-B : Infrared Spectroscopy / As per
and test for percentage content of silicone EDX /thermo-gravimetric method
rubber.
7. Water Diffusion test on FRP rod As per IEC 1109 C.lno.5.4.2
8. Brittle fracture resistance test Annexure – B

9. Dry power frequency test As per IEC 61109 : 2008 (clause 11.1)
10. UV test: Clause 7.2 of ANSI C29.13.

The bidder shall submit type test reports as per IEC 61109 (with latest amendments, if any) from NABL
approved laboratory along with the bid. Additional type tests required if any 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 reports for the same.
TENDER SAMPLE:-
Five (5) Nos. of final product of 11KV Composite Pin Insulators, eight (8) nos. of FRP rod with
minimum length 30 + 0.5 mm length cut from the FRP Rods that are to be utilized by bidder in Pin
Insulators and one piece of top and bottom metal part are required to be submitted as a tender samples.
These tender samples should reach this office on or before the due date of submission of physical bid.
(Please ref clause 22 of schedule A of tender notice).
Sample submitted with bid will be sent for test at ERDA/Any NABL lab and shall be considered for
lot supply. No further change in dimension or drawing shall be allowed in lot supply. Tender samples
not conform at NABL/ERDA Lab will not be considered for opening of price bid & will be technically
disqualified.
Tender sample shall be tested with reference to tender drawing only and not with supplier’s
drawing

8.3 Acceptance Tests On Tender Sample/Audit sample.

8.3.1 Test shall be carried out for audit test / Tender samples submitted with the bid at ERDA/CPRI or any
other NABL accredited laboratory.
The test samples after having withstood the routine test shall be subjected to the following acceptance
tests. However, company may carry out any type test, if required, on sample his discretion:-

a. Verification of dimensions Clause 12.2 IEC: 61109

b. Galvanizing test IS:2633/IS:6745
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c Bend test As per IS:731 (Clause- 10.8.2)

d Dry Power-Frequency withstand As per IEC:61109: 2008 &
requirement as per GTP
e Water diffusion test on FRP rod As per IEC 1109 C.lno.5.4.2
f Wet Power-Frequency withstand As per IEC:61109: 2008 &
requirement as per GTP
g Test for identification of presence of Silicon Annexure-B Infrared
rubber content and test for percentage content Spectroscopy/ As per EDX/
of thermo-gravimetric Method
silicon rubber.
Sample submitted with bid will be sent for test at ERDA/Any NABL lab and shall considered for lot supply.
No further change in dimension or drawing shall be allowed in lot supply.
As the testing of tender sample is to be done at any govt. approved lab, the witness during testing
will not be allowed in general as per the prevailing practice of UGVCL. The tender sample, which
does not confirm the requirement of specifications in any NABL lab, their respective bid will not be
considered for opening of their price bid and their bid shall be technically disqualified. The tender
samples shall be tested with reference to the tender drawing and not with the bidder’s drawing.
8.3.2 Acceptance Test shall be carried out during lot inspection.
The test samples after having withstood the routine test shall be subjected to the following acceptance
tests:-

a. Verification of dimensions & Sealing Dimension as per cl.no 5.7 &

Sealing as per cl.no 6.5
b. Galvanizing test IS:2633/IS:6745
c. Bend test As per IS:731 (Clause- 10.8.2)
d Dry Power-Frequency withstand test As per IEC:61109: 2008 &
requirement as per GTP
Inspecting officer will randomly pick up / may take six (6) nos. of FRP Rod Samples each of min 30mm
length, at the time of lot inspection and sent to ERDA/any govt. approved NABL lab for water diffusion test
purpose.
8.4 Routine Tests:-
Sr.No Description Standard
1. Dry Power-Frequency withstand test As per IEC:61109: 2008 & requirement as per GTP
2. Visual Examination As per IEC: 61 109:2008 Clause 13.2
3 Bend Test As per IS:731 (Clause- 10.8.2)
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 particle inspection for malleable
castings.
c) Chemical analysis, hardness tests and magnetic particle inspection for forgings.
8.6 Additional Tests:-
The Purchaser reserves the right of getting done any other test(s) of reasonable nature carried out at
Purchaser’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. In such case all the
expenses will be to Suppliers account.
8.7 AUDIT TESTING:
8.7.1 The testing for lot may be carried out at NABL approved laboratory over & above tests carried
out at firm’s works. Minimum 8 nos. samples from each lot offered will be tested for type tests/
acceptance tests (as per clause: 8.3.1) / any test confirming to Specification & GTP as specified in
Specification.
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8.7.2 The necessary charges will be borne by the company. In the event of failure of Sample,
charges will be borne by supplier.
9.0 Quality assurance plan:-
9.1 The successful bidder shall submit following information along with the bid:
9.1.1 Test Certificates of the raw materials and bought out accessories.
9.1.2 Statement giving list of important raw materials, their grades along with 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.
9.1.3 List of Manufacturing facilities available.
9.1.4 Level of automation achieved and lists of areas where manual processing exists.
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.
9.1.6 List of testing equipments available with the bidder for final testing of equipments along with
valid calibration reports.
9.1.7 The manufacturer shall submit Manufacturing Quality Assurance Plan (QAP) for approval and
the same shall be followed during manufacture and testing.
9.2 The successful bidder shall submit the routine test certificates of bought out raw
materials/accessories and central excise passes for raw material at the time of inspection.
9.3 The owner’s representative shall all times be entitled to have access to the works and all places of
manufacture, where insulator, and its component parts shall be manufactured and the
representative shall have full facilities for unrestricted inspection of the Supplier’s and Sub-supplier’s
works, raw materials, manufacture of the material and for conducting necessary test as detailed
herein.
9.4 The material for final inspection shall be offered by the Supplier only under packed condition. The
owner shall select samples at random from the packed lot for carrying out acceptance tests. The lot
offered for inspection shall be homogeneous and shall contain insulators manufactured in 3-4
consecutive weeks.
9.5 The supplier shall keep the owner informed in advance of the time of starting and the progress of
manufacture of material in their various stages so that arrangements could be made for inspection.
9.6 No material shall be dispatched from its point of manufacture before it has been satisfactorily
inspected and tested unless the inspection is waived of by the owner in writing in the later case also
the material shall be dispatched only after satisfactory testing specified herein has been completed.

9.7 The acceptance of any quantity of material shall in no way relieve the supplier at 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. TEST CERTIFICATE :

The tenderer shall furnish detailed type test reports of the offered composite Insulators as per clause
8.2 of the Technical Specifications from the NABL laboratory to prove that the composite Insulators offered
meet the requirements of the specification. These type Tests should have been carried out within
Seven years prior to the schedule date of opening of this tender.
(i) The offered composite Insulators are already fully type tested at approved Laboratory within five
years prior to the date of opening of this tender.
(ii) There is no change in the design of type-tested composite Insulators and those offers against
this tender.
11. TESTING FACILITIES :
The following additional facilities shall be available at Supplier’s works:-
(a) The tenderer must clearly indicate what testing facilities are available in the works of the manufacturer
and whether facilities are adequate to carryout all Routine & acceptance Tests. These facilities should be
available to Discom’s Engineers if deputed or carry out or witness the tests in the manufacturer
works. If any test cannot be carried out at the manufacturer’s work, the reasons should be clearly stated in the
tender.
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(b) The insulators shall be tested in accordance with the procedure detailed in IEC 61109:2008 with latest
amendments.
(c) Calibration Reports from NABL approved testing laboratory of various testing and measuring equipment
including tensile testing machine, resistance measurement facilities, burelle, thermometer, barometer etc.
(d) Finished insulator shall be checked for dimension verification and surface finish separately.
Manufacturers of foreign origin shall, in addition to the above, also have arrangements in India, either at
works of their authorized representative/ licenses or in the NABL laboratory for conducting sampling test in
accordance with IEC 81109/92-93 with latest amendments.
12. DRAWINGS:
The Drawing of the composite pin insulator is attached herewith and bidder has to supply material
as per tender drawing and specifications. The bidder has to submit UGVCL tender drawing duly
signed and stamped with bid submission.
12.1 The Bidder shall furnish full description and illustration of the material offered.
12.2 The Bidder shall furnish along with the bid the outline drawing (3 copies) of each insulator unit including
a cross sectional view of the pin 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) Unit mechanical and electrical characteristics.
(d) Size and weight of pin rod.
(e) Weight of composite pin rod units.
(f) Materials
(g) Identification mark.
(i) Manufacturer’s catalogue number
(J) Outer diameter of FRP Rod with sheath
12.3 After placement of awards, the Supplier shall submit full dimensioned 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.
12.4 After placement of order, the Supplier shall also submit fully dimensioned insulator crate drawing for
different type of insulators for approval of the owner.

13. RETEST AND REJECTION:-

General Rules (Clause 12.1 of IEC: 61109 : 2008)

For the sample tests, two samples are used, E1 and E2. The sizes of these samples are indicated in Table 4below.
If more than 10000 insulators are concerned, they shall be divided into an optimum number of lots comprising
between 2 000 and 10 000 insulators. The results of the tests shall be evaluated separately for each lot. The
insulators shall be selected from the lot at random. The purchaser has the right to make the selection. The
samples shall be subjected to the applicable sampling tests.
The sampling tests are as follows:
a) Verification of dimensions. (E1 + E2)
b) Galvanizing test. (E2)
c) Bend Test. (E2)
d) Dry Power Frequency Voltage Withstand Test (E1 + E2)
e) Verification of water diffusion test on FRP road shall be carried out as per
IEC: 1109 Cl.no.5.4.2) (E1 –Any one sample)
f) Wet Power Frequency Voltage Withstand Test (E1 + E2)
g) Chemical composition test for identification of presence of Silicon rubber
content and its percentage content by weight (E1 –Any one sample) This test shall be
performed as per Annexure-B (Infrared Spectroscopy / As per EDX/ thermo-gravimetric
Method)
In the event of a failure of the sample to satisfy a test, the re-testing procedure shall be applied as
prescribed in 12.6 of IEC 61109:2008.
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Insulators of sample E2 only can be used in service and only if the galvanizing test is performed with the
magnetic method.
Lot Size (N) Sample Size
E1 E2
N < 300 Subject to
agreement
300 < N ≤ 2000 4 3
2000 < N ≤ 5000 8 4
5000 < N ≤ 10000 12 6

The samples shall be subjected to the applicable sampling tests as per clause 12.2 to12.6 of IEC: 61109:2008
The Audit tests are as per clause 12.2 to 12.5 of IEC:61109:2008 as under:
12.1 Verification of dimensions - (E1+E2)
12.2 Galvanizing test. (E2)
12.3 Bend Test (E2)
12.4 Dry Power Frequency Voltage Withstand Test (E1 + E2)
12.5 Verification of water diffusion test on FRP road shall be carried out As per IEC 61109
C.lno.5.4.2) (E 1-Any one sample)
12.6 Wet Power Frequency Voltage Withstand Test (E1 + E2)
12.7 Chemical composition test for identification of presence of Silicon rubber content and its
percentage content by weight (E1 –Any one sample) This test shall be performed as per
Annexure-B (Infrared Spectroscopy / As per EDX/ thermo-gravimetric Method)
In the event of a failure of the sample to satisfy a test, the retesting procedure shall be as per clause 12.6 of IEC:
61109:2008 as follows:
Verification of dimensions (E1 + E2) (Clause 12.2 of IEC:61109:2008)
The dimensions given in the drawings shall be verified The tolerances given in the drawings are valid. If no
tolerances are given in the drawings the values mentioned in Clause 8 shall be used.
Galvanizing test (E2) (Clause IS:2633/IS:6745)
This test shall be performed on all galvanized parts in accordance with IS:2633/IS:6745.
Verification of the Bend Test (E2) (Clause 12.3 of IEC:61109:2008 )
The Test sample should withstand minimum bending load of 5 KN.
Dry Power Frequency Voltage Withstand Test
This test shall be performed a s per IEC: 61109: 2008 & requirement as per GTP
Verification of water diffusion test on FRP road shall be carried out as per IEC:61109:2008)
This test shall be performed a s per IEC 1109 C.lno.5.4.2
Wet Power Frequency Voltage Withstand Test
This test shall be performed as per IEC:61109: 2008 & requirement as per GTP
Chemical composition test for silicon content-(E1 –Any one sample)
This test shall be performed as per Annexure-B (As per EDX/ thermo-gravimetric Method)
Re-testing procedure:
In general will not allow Retesting & Re-sampling.

14. MARKINGS:
Each insulator unit shall be legibly and indelibly Emboss/Engrave with the following details as per IEC- 61109.
(a) Name or trademark of the manufacture.
(b) A/T No, Month and Year of manufacturing.

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(c) Guaranteed mechanical strength in kilo Newton followed by the word ‘KN’ to facilitate easy
identification.
(d) Word “UGVCL”

15. PACKING :
15.1 All insulators shall be packed in strong corrugated box of minimum 7 ply duly plated in good
quality Polythene Plastic bag with max.10 nos of insulators . The gross weight of the crates along with
the material shall not normally exceed 15 Kg. to avoid handling problem. The crates shall be suitable for
outdoor storage under wet climate during rainy season.
15.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and
subsequent handling in the field.
15.3 Suitable cushioning, protective padding of dunnage or spacers shall be provided to prevent damage or
deformation during transit and handling.
15.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination
and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty
or illegible markings.
Each crate shall have all the markings stenciled on it in indelible ink.
15.5 The bidder shall provide instructions regarding handling and storage precautions to be taken at site.
16. 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.
The firms shall not dispatch the offered lot unless the same is inspected by the inspector of UGVCL and
accepted by him after passing in all acceptance tests, and/or receipt of waival of inspection in writing from
competent authority of UGVCL.
17. GUARANTEE:
If the material found defective due to bad design or workmanship the same should be repaired or
replaced by you free of charge if reported within 36 months from the date of supply of material.
The bidder will be responsible for the proper performance of the equipments/material for the respective
guarantee period.

18. Deviation
Bidder shall submit deviations from this specification if any, in Annexure-D

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ANNEXURE : A-1
Guaranteed Technical Particulars of 11KV Composite,5KN, Insulator(Pin Type).
Name of the Manufacturer :
Address of works : BIDDER HAS TO CONFIRM FOLLO WING IMPORTANT REQUIREMENT

Sr.No. Description Uni Min. requirement As per

for11 kV Pin firm
Insulator offer
1. Type of Insulator Polymeric
Composite
2. Standard according to which the IEC 61109
insulators manufactured and
tested.
3. Name of material used in SILICON
manufacture of the insulator with Wacker-Germany
class/grade) Dow Corning-USA
(a) Material of core(FRP rod)
(j) E-glass of ECR-glass. ECR or
(ii) Boom content BORRON FREE
(b) Material of housing & weather sheds SILICONE RUBBER
(silicon rubber content by weight) 30 %
(c) Material of bottom end fittings Forged steel
( single piece only)
(d) Material of top fittings SGI/MCI/Forged steel
(e) Sealing compound for end fittings RTV SILICON
4. Colour GREY
5. Electrical characteristics
(a) Nominal system voltage 11 KV
(b) Highest system voltage 12 KV
(c) Dry Power frequency withstand 70 KV
Voltage
(d) Wet Power frequency withstand ≥ 45 KV
Voltage
(e) Dry lighting impulse withstand voltage
a) Positive
b) Negative ≥ 110 KV
≥ 110 KV
(f) Dry lighting impulse flashover
voltage
a) Positive ≥ 120 KV
b) Negative. ≥ 120 KV
(g) RIV at 1 MHz when energized at <100 micro volts
10 kV/30kV (rms) under dry
condition.
(h) Creepage distance (Min.) ≥ 340 MM(min)

6(a) Mechanical characteristics :

Minimum bending load. 5 KN Bending

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Sr.No. Description Unit Min. requirement As per

for11 kV Pin firm
Insulator offer
7. Dimensions of insulator
(i) Weight Kg. 1.20
KG(Approx.)
(ii) Dia of FRP rod mm 21.7 MM (Min)
(iii) Outer Dia of FRP rod with sheath mm 27.7 MM (Min)
(iv) length of FRP rod Mm Min 200 MM
(v) Dia of weather sheds mm ≥ 90 mm
(vi) Thickness of housing mm 3 MM
(vii) Dry arc distance mm 165 MM (+ ve
Dimensioned drawings of tolerance shall be
insulator (including weight with allowed & no negative
tolerances in weight) enclosed. tolerance shall be
allowed )
8. Method of fixing of sheds to Injection
housing (specify). Single mould or moulding
Modular construction (injection
moulding
9. No of weather sheds 3 (Min.)
10 Type of sheds- Aerodynamic Aerodynamic
11 Packing details
(a) Type of packing Strong corrugated box
of minimum 7 ply duly
paleted in good quality
Polythin Plastic bag
with 10 nos of
insulators

(b) No. of insulators in each pack 10 nos. (Maximum)

© Gross weight of package. 15 KG.(Maximum)
12. Any other particulars which the
bidder may like to give.
13. Length of Crimping dye for both end of mm 25 MM
FRP Rod should be minimum.
14 Each Insulator unit shall have legibly and 1. Name or Trademark
indelibly Emboss/Engrave of the Manufacture.
Following parameters. 2. AT no. (i.e. AT
outward no.)
3. Month and Year of
Manufacturing.
4. Word-“UGVCL”

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ANNEXURE : B
Test on Insulator units
1. RIV Test (Dry)
The insulator string along with complete hardware fittings shall have a radio interference voltage level below
100 micro volts at one MHz when subjected to 50 Hz voltage of 10 kV & 30 kV for 11 kV & 33 kV class
insulators respectively under dry condition. The test procedure shall be in accordance with IS :
8263/IEC:437/CISPR 18-2.

2. Brittle Fracture Resistance Test

Brittle fracture test shall be carried out on naked rod along with end fittings by applying “1n HNO3 acid” ( 63g
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 isopropyl alchohol. Allow the surface to dry
and spray with water. Record the Hydrophobicity classification in line with STRI guide for
Hydrophobicity classification (Extract enclosed at Annexure-D) Dry the sample surface.
(ii) The sample shall subjected to mechanical stress by bending theSample 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 inAnnexure-E. The test shall be done
for 100 hrs.
(iii) Immediately after the corona treatment, spray the surface withWater and record 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 identification of presence of silicone rubber and its content by weight in the composite polymer part of
insulator shall be evaluated by Infrared Spectroscopy / EDX (Energy Dispersion X-ray) Analysis or Thermo-
gravimetric analysis. The test may be carried out at CPRI or any other NABL accredited laboratory .

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ANNEXURE: C
Enclosures:
Bidder has to enclosed following documents and has to confirm for the same.

Sr.
Confirmation
No. Particulars

1 UGVCL tender drawing with detailed dimension duly signed & Yes/No
stamped
2 Type test certificate covering all the tests as per CL. No. Yes/No
8.2 along with attested drawing from Govt.
approved laboratory.
3 List of Plant & Machinery at firms works Yes/No
4 List of Testing Equipments at firms works Yes/No
5 List of orders pending/executed at least for past Yes/No
three years for the items offered.
(a). With GUVNL or its DISCOMs.
(b). With the other DISCOM\s.
(c). With Private Parties.
6 Performance Certificate Yes/No
ANNEXURE: D
Bidder has to mention below deviation if any, quoting relevant
Clause of specification

DEVIATION :

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TENDER NOTICE No. UGVCL/SP/II/1294/11KV Composite Pin Insulator

Date Place Signature of the Tenderer Company’s Round Seal

UGVCL/SP/II/1294/11KV Composite Pin Insulator Page 1 of 17