specification no. csc-72/dh/uh/p&d/2012-20132.0 nfc 33-041 anchoring devices 3.0 nfc 33-003...

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Specification No. CSC-72/DH/UH/P&D/2012-2013

TECHNICAL SPECIFICATION

FOR

ANCHOR (DEAD END) & SUSPENSION ASSEMBLIES

FOR

LT AERIAL BUNCHED CABLES

FOR

WORKING VOLTAGE UPTO AND INCLUDING 1100 VOLTS

Issue Month : May 2012 Common Specification Committee

(CSC Approval Date 1.6.2011)

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TECHNICAL SPECIFICATION FOR ANCHOR (DEAD END) & SUSPENSION ASSEMBLIES FOR LT AERIAL BUNCHED CABLES FOR WORKING VOLTAGE UPTO AND INCLUDING 1100 VOLTS.

11.. SSCCOOPPEE This specification covers the design, manufacture, assembly, testing and supply of Accessories for anchoring & suspending Aerial Bunched Cables rated 1100 volts and insulated with cross-linked polyethylene and aluminium alloy messenger which may be bare or insulated. 22.. CCLLIIMMAATTIICC CCOONNDDIITTIIOONNSS The equipment shall work satisfactorily under the following climatic conditions:- i) Location At various locations in the

state of Haryana ii) Maximum ambient temperature (o 60 C) iii) Minimum ambient air temperature (o -5 C) iv) Maximum average daily ambient temperature (o 40 C) v) Maximum yearly weighed average ambient

temperature (o32

C) vi) Maximum altitude above mean sea level (m) 1000 vii) Minimum Relative Humidity (%) 26 viii) Maximum Relative Humidity (%) 95 ix) Average no of Rainy days/ year 120 x) Average annual rainfall 900 mm xi) Maximum wind pressure 195 kg/m sq. The equipment shall be for use in moderately hot and humid tropical climate, conducive to rust and fungus growth 33.. RREEFFEERREENNCCEE SSTTAANNDDAARRDDSS The design, performance and test requirements shall confirm to this specification and the following standards. However in case of any conflict, the requirements of this specification shall prevail.

1.0 NFC 33-040 Suspension Equipments 2.0 NFC 33-041 Anchoring Devices 3.0 NFC 33-003 Corrosion Resistance 4.0 NFC 20-540 Climatic Ageing 5.0 IS 14255 LV Aerial Bunched Cables 6.0 REC Specification 32/1984 for Aerial Bunched Cable for LT Lines 7.0 IS 8130: Conductors for Insulated cables 8.0 IS 7098 Part 1: XLPE Insulated Cables for working voltages upto 3.3 KV 9.0 IS 398 Part IV : aluminium alloy conductors 10.0 IS 2486 Part 1 : Metal Fittings of Insulators …. Upto 1100 volts 11.0 ASTM A 480 : Stainless Steel

The Devices shall also be compatible with the cables of sizes & dimensions as defined in the Cable Specifications for the cables with which they are intended to be used, and this specification. 44.. CCAABBLLEE DDAATTAA The standard sizes and characteristics of the phase and street lighting conductors, messenger wires shall be as specified in REC specification 32/1984 or IS: 14255-1995.

mm KN (Min)

1 1 C x 25 mm² + 1 C x 25 mm² 7 7 22.4 7

2 3 C x 50 mm² + 1 C x 35 mm² + 1 C x 16 mm² 7 7 28.4 9.8

3 3 C x 95 mm² + 1 C x 70 mm² + 1 C x 16 mm² 7 7 37.5 14

Description of ABC(Insulated Messenger)Sl. No

Phase Messenger

ApproximateOverall

Diameter

Number of wires BreakingLoad

Messenger

Table 1 : ABC Description and Technical Data

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55.. TTHHEE AABBCC AACCCCEESSSSOORRIIEESS AANNCCHHOORR ((DDEEAADD EENNDD)) && SSUUSSPPEENNSSIIOONN AASSSSEEMMBBLLIIEESS The Accessories of LT XLPE suitable for Insulated Aerial Bunched Cables (ABC) described in Table:1 are specified below:

a) Their design should incorporate specific features to prevent damage to the insulation while

meeting the required electrical, mechanical & thermal requirements.

b) The accessories should provide “Double Insulation” so that a single point failure of insulation will not result in the system tripping.

The ABC Accessories shall consist of the following:

Sl.No Description Application

a) Anchoring Assembly (AA) For fitting onto a pole for anchoring the end of a length of ABC, or for a major change in direction.

b) Suspension Assembly (SA) For supporting a length of ABC at an intermediate pole in a length, with small angle of deviation.

c) Stainless Steel strap & Buckles For fixing clamps to pole through aluminium bracket for dead end, suspension and service clamp pole brackets.

d) Service Clamps To provide the service connections to consumers.

e) Service Pole Brackets To provide an anchoring point for service clamps

Table 2 : ABC Accessory Desription

66.. AANNCCHHOORRIINNGG CCLLAAMMPP FFOORR NNEEUUTTRRAALL MMEESSSSEENNGGEERR ((IINNUULLAATTEEDD OORR BBAARREE)) Anchoring assemblies are used to firmly attach the messenger of ABC to a concrete or steel pole and transmit the mechanical tension.

• at the end of a run • at a major change in direction of over 30 degrees.

The clamp should consists of an Aluminium alloy corrosion resistant casted body or climatically resistant polymer material, flexible rope sling (“bail”) of stainless steel and self adjusting plastic wedges which shall anchor/hold the neutral messenger. The following key criterion to be followed for the design of the same

a) There shall be no loosable part in the process of clamping arrangement

b) Locking mechanism should be wege type self locking. Wedges are to be made of high

strength, climatic resistance Engineering Plastic with glass fibre.

6.1 Anchoring Assembly Each Anchoring Assembly shall include.

• One number pole bracket. • One number wedge type tension clamp as described above

Anchoring assemblies shall be supplied in sets to ensure compatibility of the materials against corrosion or wear of moving parts. 6.2 Pole Bracket for Anchoring Assembly The pole bracket shall be made out of a single piece of Aluminium alloy suitable for attachment to a pole by two stainless Steel straps of 20mm ±0.2 x 0.7mm ±0.05 and buckle as described later in this specification. (or M16 Hot dip galvanized steel bolts also can be used) The pole bracket should be designed with a closed hook; to ensure that Flexible rope (Bail) cannot slip out at any angle. The inner side of the bracket should be min 100 mm from the surface of the pole.

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The pole bracket should be tested for the loads not less than slip strength of Clamp with the load applied at an angle of 45° from the normal to the surface of mounting of the bracket as shown in Fig :1 and comply for load requirement mentioned

Messenger Conductor Size Range

(mm²)

Figure 1

Rating T-Start (1 Minute) (KN)

T-Final <30mm & no-break

(KN)

25 - 70 1500 Kg 12.0 15.0

Table 3 : Load Requirement of tension (Dead-End) Brackets

6.3 Flexible Rope (Bail) of Anchor Assembly

1. The Anchoring assembly shall be supplied with a stainless steel flexible Rope to connect the Tension Clamp to the Pole Bracket.

2. The flexible Rope forming past of clamp should be of length to maintain at least 150mm distance between bracket and body of clamp and shall have sufficient mechanical strength to withstand the mechanical test for the complete assembly tests in this specification, as per Table 3 above.

3. The rope should have sufficient flexibility to ease the torsional movement of the ABC System.

4. The Rope should be pre-fitted with compression type end fittings which needs to be removable and re-fittable at one side of the clamp and locked at the other end of the anchoring clamp.

5. A wear resistant moveable saddle should be un-loosably fitted on the Rope to prevent abrasion at the point of fitting into the tension bracket. Saddle to be made of plastic for insulation.

6. Rope should have sufficient mechanical strength to withstand the mechanical test for the complete assembly tests in this specification.

6.4 Wedge Type Tension Clamp for Anchoring Assembly

1. Wedge type clamps shall be used for clamping the messenger without damaging the insulation in case of insulated messenger or strands in the cable of bare messenger.

2. The clamp shall be capable of clamping an uncut messenger so that it can continue without break to the connecting point or next span.

3. The clamp shall be of aluminium or polymeric body with fully insulating type of mechanical and weather resisting thermoplastic wedges for both bare & insulated messenger.

4. No bolts or loose parts are allowed as part of the Clamping system. 5. No tools shall be needed for fitting the messenger into the clamp. 6. The clamp shall be self tightening and capable of holding without slippage the load

specified in Table – 4


(mm²) Rating (Kg) T start (1Minute) (KN)

T final (KN) Section Area

(mm2 Dia (mm) ) 25 - 35 8 - 11 1000 8.0 10.0

50 - 70 11 - 14 1500 12.0 15.0

Table 4 : Load Requirement of tension (Dead-End) Clamps

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77.. TTEESSTTIINNGG RREEQQUUIIRREEMMEENNTTSS OOFF AANNCCHHOORRIINNGG AASSSSEEMMBBLLYY ((FFOORR IINNSSUULLAATTEEDD OORR BBAARREE MMEESSSSEENNGGEERR))

The following tests are intended to establish design characteristics. Sl No. Test Type Test Acceptance

Test Routine Test

1 Visual X X

2 Dimensional X X

3 Mechanical & Slip strength X X X

4 Mech strength of Bracket & SS Strap with Buckle X X X

5 Voltage X X

6 Corrosion X

7 Climatic X Table 5 : Classification of Test of Anchoring Assembly

7.1 Visual Design Aspects of the Anchoring Clamp needs to be visually verified as per the descriptions of this specification and criteria defined by the manufacturer in the quality plan and as accepted by customer. Following Mandatory marking should be available. 7.1.1 Marking

Anchoring Clamp, Bracket, Stainless Steel Strap and Buckle should bear - Manufacturers trade mark and logo - Product Code or Reference - Traceability Code /Batch Number 7.1.2 Dimensional

Overall dimension to be verified against the GA Drawings. All Dimensional requirement mentioned in this specification should be verified. 7.2 Mechanical & Slip Strength Test The Anchoring assembly should be fitted at both side of a cable one meter from the end, in the proposed manner as shown in figure 2 below, on a suitable support. After fitting the required messenger in the clamp, load should be increased to “T-Start” as mentioned in Table 4 and held for 1 minute then increased up to “T-Final” and relased. 7.2.1 Requirements

There shall be no breakdown of any part of clamp assembly or slippage not greater than 5mm of messenger in relation to the clamp.

Item Figure 2

1 Neutral Messenger

Anchoring Clamp, mounted on Bracket with SS Strap and Buckle

2 Load Cell

Mechanical Tension Adjustment

3 Tensioning Device

4 minimum 1 meter

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7.3 Voltage Test

• Voltage test is carried out on anchor clamps to ensure no damage is caused to the insulated messenger and no separate earthing of pole is required in case of bare messenger.

• A conductive rod of dia. corresponding to the average dia. that can be accommodated in

the clamp is fitted into the clamp, protruding by approx. 50mm at each end of the tightening piece as shown in figure 3 below.

• The rod and clamp is subjected to tensile load as stated in Table 6 below when fixed to a

support in its normal manner. • A power frequency voltage of 6 kV is applied for 1 minute between the rod and

conductive part of the clamp, or fixation point in absence of conductive part. 7.3.1 Requirements

No breakdown or flashover shall occur. There shall be no tripping due to leakage with a setting of 10 ± 0.5 mA.

Item Figure 3

1 Conductive Part 4 Added Insulation

2 Clamp Body 5 Test Voltage

3 Bare metallic rod

Table 6 : Load Requirement for Voltage test 7.4 Corrosion Test This test is carried out on the wedge type anchor clamp only. The tested clamp is installed horizontally at both ends of the neutral messenger. The free length

between anchoring clamps shall be 0.5 m approximately. The longitudinal opening of the

anchoring clamp is placed downwards. This assembly is submitted to the corrosion test as per

NFC 33 003.

Detailed definitions and charactriasation of the test is as defined in Annexe A of this document.

Neutral Messenger Size Load Applied (KN) Section Area

(mm2 Dia (mm) ) 25 - 35 8 - 11 2.0

50 - 70 11 - 14 4.0

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7.4.1 Requirements A) Mechanical Strength Test At the end of the corrosion cycle and after a recovery period of at least 24 h but not exceeding 72 h at the labortary atmospehere, the assembly is rinsed with deminerized water and then it is submitted to test defined in clause 6.2 of this specification. Load to be increased to values defined in Table 7 below.

No continuopus slippage of slippage of neutral messenger, or clamp break down should occur before the value specified in Table -7 below.

Table 7 : Load Requirement for Tension Clamps after Corrosion & Climatic agieng test B) Corrosion Resistance No traces of rust shall be observed on steel parts of the clamp.

7.5 Climatic Ageing Test This test is carried out on the wedge type anchor clamp only. The tested clamp is installed horizontally at both ends of the neutral messenger. The free length between anchoring clamps shall be 0.5 m approximately. - 6 weekly cycles are required at the enclosure temperature of (70 ± 2) ºC for phases A & C. - The samples longitudinal opening faces the light source. This test is carried out on the anchoring assembly which is submitted to corrosion test as per NFC 20 540. Detaled definitions and charactriasation of the test is as defined in Annexe A of this document. 7.5.1 Requirements

A) Mechanical Strength Test After exposure to climatic cycle as per the above standard, mechanical test as defined in clause 6.2 of this specification. Load to be increased to values defined in Table 7. No continuopus slippage of slippage of neutral messenger nor clamp break down should occur before the value specified in Table -7 below. B) Voltage Test

(This test is not applicable for clamps with bare messenger) The voltage generator shall trip for a leakage current of (10.0 ± 0.5) mA. The end of neutral messenger, on which the anchoring clamp is fitted, is capped in order to avoid any flashover and the bracket is earthed. An increasing A.C voltage is applied up to 10kV between the bracket and the neutral messemger conductor at the other end of the piece of cable, at a rate of approximately 1kV/S. This voltage is maintained for 30 min. No breakage of neutral sheath shall occur. C) Common test requirement: visual inspection

The marking allowing the identification of the samples shall be legible when examined with normal or corrected vision, without magnification. 88.. SSUUSSPPEENNSSIIOONN AASSSSEEMMBBLLYY ((FFOORR IINNSSUULLAATTEEDD OORR BBAARREE MMEESSSSEENNGGEERR)) Suspension Assembly is used for supporting an ABC by installation on the messenger at an intermediate point of support such as a pole. It can accommodate small angles of deviation upto 30 deg.

Neutral Messenger Size Minimum Load Applied (KN) Section Area

(mm2 Dia (mm) ) 25 - 35 8 - 11 8.0

50 - 70 11 - 14 12.0

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The clamp should be designed to hang L.T – AB cable with bare or insulated neutral messengers. The neutral messengers should be fixed by an adjustable grip device. A movable link should allow longitudinal and transversal movement of the clamp body.

• There should be no loosable part in the process of clamping arrangement. • The clamp and the link should be made of Polymer to provide an additional Insulation

between the cable and the pole to eliminate need for earthing. • The clamps and movable links should be made of weather and UV resistant polymer. • Clamps should be fixed to the pole by aluminium bracket. Bracket should be made of

corrosion resistant aluminium alloy and suitable for fixing to pole by means of two S S Strap of 20mm ±0.2 x 0.7mm ±0.05 mm and SS Buckles.

• Ultimate tensile strength of the clamp should not be less than 90% of messenger strength (see table 1) in direction perpendicular to the direction of the messenger.

Each Suspension Assembly shall consist of:

• One number Suspension Bracket. • One number moveable (articulated) connecting link. • One number Suspension Clamp.

Suspension Assemblies shall be supplied in sets to ensure compatibility of the materials against corrosion or wear of rotating/moving parts. 8.1 Suspension Clamp of Suspension Assembly

• Suspension Clamps are used for locking the messenger of the ABC Bundle without damaging the insulation if any or allowing the messenger to become dismounted from the fitting.

• The suspension clamp shall be made fully of insulating type of mechanically strong and weather resistant plastic.

• The suspension clamp shall be suitable for a minimum messenger wire size range of 25 to 54 sq mm.

• Suspension Clamps for bare messengers shall be different from and easily distinguishable from those for insulated messengers

• Bolts and hand tools shall not be required for fixing and locking the messenger in the clamp.

• There should be no losable parts in the Suspension clamp • The suspension clamp shall be unloosably fitted to the suspension assembly.

8.2 Movable (articulated) link of Suspension assembly Movable links are used betweenthe suspension bracket and the suspension clamp to allow a degree of movement and flexibility between the two.

• Movable links should be made fully of insulating type of mechanically strong and weather resistant plastic.

• The movable link shall be unloosably fitted to the suspension assembly.

8.3 Suspension Bracket of Suspension assembly The Suspension Bracket shall be made from single piece aluminium alloy suitable for attachment to a pole by

a) Two stainless steel straps 20mm ±0.2 x 0.7mm ±0.05 mm and S S buckles

The Suspension Bracket shall be provided with an upper bulge to prevent the clamp from turning over on the Bracket for more than 45° from the horizontal or to within less than 60 mm from the pole.

The Suspension Bracket should be so designed to ensure that the Movable link cannot slip out of it. 99.. TTEESSTTIINNGG RREEQQUUIIRREEMMEENNTTSS OOFF SSUUSSPPEENNSSIIOONN AASSSSEEMMBBLLYY The following tests are intended to establish design characteristics.

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Sl No. Test Type Test Acceptance Test Routine Test

1 Visual X X 2 Dimensional X X 3 Mechanical X X X 4 Slip strength X X 5 Voltage X X 6 Corrosion X 7 Climatic X

Table 8 : Classification of Test of Suspension Assembly

9.1 Visual Design Aspects of the Suspension assembly needs to be visually verified as per the descriptions

of this specification and criteria defined by the manufacturer in the quality plan and as accepted

by customer. Following Mandatory marking should be available.

9.1.1 Marking

Suspension Clamp, Bracket, Stainless Steel Strap and Buckle should bear

- Manufacturers trade mark and logo

- Product Code or Reference

- Traceability Code /Batch Number 9.1.2 Dimensional

Overall dimension to be verified against the GA Drawings. All Dimensional

requirement mentioned in this specification should be verified.

9.2 Mechanical Test Mechanical tests on Suspension Assembly to be carried out separately for Suspension sub-

assembly in cluding movable link and aluminium bracket.

9.2.1 Mechanical Test of Suspension Sub-Assembly

The sub assembly should be fitted in the proposed manner on a suitable support using the SS

Straps and buckles.

The Sub Assembly of movable link and suspension body shall be subjected to a vertically

downward load of 90% of the value shown in Table 9, applied as shown in figure 4 below.

9.2.1.1 Requirement There shall be no breakdown of any part of clamp assembly or slippage of messenger in relation to the clamp.

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Item

Figure 4

1 Movable Link 3 Neutral Messenger

2 Suspension Clamp 4 Rigid Fixture

Messenger Conductor

Size Range (mm²) Rating (Kg) T start

(1Minute) (KN) T final

(1Minute) (KN) Section Area (mm2 Dia (mm) ) 25 - 70 6 - 14 1000 9.6 12.0

Table 9 : Load Requirement of Suspension Clamps

9.2.2 Mechanical Test of Suspension Aluminium Bracket Bracket for Suspension Clamp to be installed with SS Straps and Buckles and load to be applied at an angle of 33° as shown in the figure 5 below.

9.2.2.1 Requirement Bracket should withstand a minimum load of 90% of the value shown in Table 10 below.


(mm²)

Figure 5

Rating T-Start (1 Minute) (KN)

T-Final <30mm & no-break

(KN)

25 - 70 1500 Kg 10.0 12.0

Table 10 : Load Requirement of Suspension Brackets

9.3 Slip Strength Test A sample of neutral messenger shall be fitted into a fixed suspension clamp and subjected to a

gradually applied longitudinal load of 300 N. Test setup will be similar to as shown in figure 6

below.

9.3.1.1 Requirement Clamp should hold a miniumum of 300N without any slippage which is greater 5mm .

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Item

Figure 6

1 Clamp to be tested 3 Fixed Point

2 Marking on the cable

9.4 Voltage Test A copper foil is wrapped at the clamping point around the maximum size of Messenger allowed in that clamp. An ac voltage of 6 KV is applied between the copper foil and nearest conductive point of the clamp or, in its absence, to the point of fixation. Generalised test setup is as shown in the figure 7 below

9.4.1.1 Requirement The voltage should be withstood for 1 minute without breakdown or flashover.

Item Figure 7

1 Aluminium Bracket 3 Neutral Sheath

2 Suspension Clmap 4 Copper Foil

9.5 Corrosion Test This test is carried out on the suspension assembly which is submitted to corrosion test as per NFC 33 003. There are 4 cycles of 14 days. A 30 cm piece of neutral messemger is installed in the clamp. A mass of (1.0 ± 0.1) Kg is hung to the clamp, so as to make contact between the metallic parts, and possibly induce galvanic corrosion of dissimilar metals. Detaled definitions and charactriasation of the test is as defined in Annexe A of this document. 9.5.1 Requirements

At the end of the corrosion cycles and after a recovering period of at least 24 h but not exceeding 72 h at the laboratory atmosphere, the assemblies shall be submitted to the mechanical test defined in sub-clause After exposure to corrosion cycle as per the above standard, mechanical test with set up as defined in clause 8.2.1. The load is increased to a value as mentioned in Table 11. There shall be no break down.

Table 11 : Load Requirement of Suspension Clamps after Corrosion Tests

Neutral Messenger Size Minimum Load Applied (KN) Section Area

(mm2 Dia (mm) ) 25 - 70 6 - 14 9.0

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9.6 Climatic Ageing Test This test is carried out on the anchoring assembly which is submitted to climatic ageing test as per NFC 20 540.

- 6 weekly cycles are required at the enclosure temperature (70±2)ºC for phases A and C, - The suspension assemblies are installed vertically, th opening for introducing the cable of

one is facing the light source, and the other one installed in the opposite direction. Detaled definitions and charactriasation of the test is as defined in Annexe A of this document. 9.6.1 Requirements

At the end of the climatic ageing cycles and after a recovering period of at least 24 h but not exceeding 72 h at the laboratory atmosphere, the assemblies shall be submitted to the following tests.

A) Voltage Test The voltage test defined in 8.4 of this specification is carried out and there should not be failure.

B) Mechanical Strength Test The mechanical strength test is applied to the two assemblies having passed the voltage test above. The bracket is fitted on the test set definedAfter exposure to climatic cycle as per the above standard, mechanical test as defined in clause 6.2 of this specification. Load to be increased to values defined in Table 11 Above. No continuopus slippage of slippage of neutral messenger nor clamp break down should occur before the value specified in Table -11 Above. 1100.. SSTTAAIINNLLEESSSS SSTTEEEELL SSTTRRAAPP AANNDD BBUUCCKKLLEESS

The stainless steel strap shall consist of

a) Stainless steel strap of size 20mm ±0.2 x 0.7mm ±0.05 mm and shall have tensile strength of 7.5KN min., elongation 30% Min, finish 2B, and the stainless steel material shall be of high mechanical strength, corrosion and wear resistant as per ASTM SS 202.

b) Tensile strength of strap is to be min 7.5KN to be tested on a loop with buckle. Number of loops for mounting the bracket on pole to be allocated as per load requirement for dead-end and suspension clamp specified in this specification.

c) The SS Strap should be engraved with the name of the Manufacturer and length at a distance of aprox 250 mm.

d) The S S buckle to suit above strap shall be used to tension & fix it. It should have a slot width of not less than 20.5 mm x 1.5 mm

e) The Buckle should be made from ASTM SS 304 of thickness not less than 1.2 mm. f) S S Strap should be supplied in 50 meter roll in plastic dispenser. g) Buckles should be supplied in plastic bags containing 100 pcs per bag.

10.1 TEST REQUIREMENTS FOR STAINLESS STEEL STRAP AND BUCKLES Type tests on SS Straps and Buckles shall consist of Cheical Analysis Test Report of Composition. In addition the SS Strap should have been type tested for Tensile Strength and Ultimate Elongation.


1 Visual X X 2 Dimensional X X 3 Tensile X X X

4 Chemical and Mechanical Prpoerties X

10.2 Visual Design Aspects of the SS Strap and Buckle needs to be visually verified as per the descriptions of this specification and criteria defined by the manufacturer in the quality plan and as accepted by customer. Following Mandatory marking should be available.

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10.2.1 Marking Stainless Steel Strap and Buckle should bear engraved with - Manufacturers trade mark and logo - Traceability Code /Batch Number - Length Indication every 250mm 10.3 Dimensional

Width and Thickness of straps to be verified as mentioned in this specification. Tolerance for the same as below Width = 20mm ±0.2 mm Thickness = 0.7mm ±0.05 mm.

10.4 Tensile Test One loop of SS Strap to be installed on a device similar to pole using Buckle and needs to be tested for a minimum tensile strength . 10.4.1 Requirements

The Strap and Buckle should withstand a load of minimum 7.5KN without breaking or slippage. . 10.5 Chemical Composition Material composition and properties mentioned in this specification for SS Strap and Buckle to be evaluated and cross verified with ASTM standard 10.5.1 Requirements

The values should be in accordance with ASTM standard. 1111.. SSEERRVVIICCEE CCLLAAMMPPSS Service clamps are used for tensionaning the service cable on poles in order to ensure the proper installation of service cables and connectors. The following features requested are to be met for the qualification criteria of service clamps

1. The service clamps should be designed to anchor insulated service cable, XLPE insulated,

armoured/unarmoured PVC sheathed as per IS: 7098 Part-1 or PVC insulated armoured / unarmoured as per IS 1554 Part-1.

2. The clamp should be made of polymer type wedges sliding inside the body to be installed without using any tool.

3. The clamp body receving the wedges should be made of weather proof & UV resistant polymer.

4. Breaking load of the clamp should not be less than 2 kN 5. The clamp should be easy to open type fixing to brackets or pigtails. 6. Hook of the clamp should be made of stainless steel 7. The clamp should be tested to prove mechanical strength as per respective NFC 33 042. 8. Supplier name and identification be marked in the clamp and suitable batch code

traceabilty should be provided. 9. Type test reports for the following test should be submitted as per NFC – 33-042

i. Mechanical Test ii. Voltage Test

11.1 TEST REQUIREMENTS FOR SERVICE CLAMPS Type tests on service clamps shall consist of the following


1 Visual X X 2 Dimensional X X 3 Voltage X X 4 Mechanical test X X X

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11.2 Visual Design Aspects of the service clamps needs to be visually verified as per the descriptions of this specification and criteria defined by the manufacturer in the quality plan and as accepted by customer. Following Mandatory marking should be available. 11.2.1 Marking

Service Clamps should bear engraved with - Manufacturers trade mark and logo - Traceability Code /Batch Number - 11.3 Dimensional

As per approved drawing.. 11.4 Tensile Test As per NFC 33 042. 11.4.1 Requirements

Minimum 2 KN 1122.. SSEERRVVIICCEE BBRRAACCKKEETTSS Pole mounted Service brackets are are used for anchoring the ervice clamps. The following features requested are to be met for the qualification criteria of service brackets

1. The service brackets should be be made of aluminium alloy with 3-Way service provision

each suitable for holding miniumum 2-Service clamps. 2. The design should be as shown in the genral arrangement section of this specification.

3. Type test reports for the following test should be submitted

i. Mechanical Test

12.1 TEST REQUIREMENTS FOR SERVICE BRACKETS Type tests on service clamps shall consist of the following


1 Visual X X 2 Dimensional X X 3 Mechanical test X X X

12.2 Visual Design Aspects of the service brackets needs to be visually verified as per the descriptions of this specification and criteria defined by the manufacturer in the quality plan and as accepted by customer. Following Mandatory marking should be available. 12.2.1 Marking

Service Clamps should bear engraved with - Manufacturers trade mark and logo - Traceability Code /Batch Number 12.3 Dimensional

As per approved drawing..

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12.4 Tensile Test The service clamps are installed in the testing M/C to eavalaute the strength in different loading pattarm as shown. The minimum breaking load for different loads F1, F2, F3 and F4 should be a minimum of 15KN

12.4.1 Requirements

Minimum 15 KN in any direction. 1133.. SSAAMMPPLLIINNGG PPLLAANN FFOORR AACCCCEEPPTTAANNCCEE TTEESSTT Sampling Plan for acceptance tests on Anchor, Suspension Clamp Assemblies, SS Straps and Buckles are as per ISO 2859-1 as mentioned below. 13.1 For Visual and Dimensional Sampling Level: General Inspection Level 1 AQL: 4% Rejection in sample size acceptable

SL NO LOT SIZE SAMPLE SIZE 1 2 to 8 2 2 9 to 15 2 3 16 to 25 3 4 26 to 50 5 5 51 to 90 5 6 91 to 150 8 7 151 to 280 13 8 281 to 500 20 9 501 to 1200 32 10 1201 to 3200 50 11 3201 to 10000 80 12 10001 to 35000 125 13 35001 to 150000 200 14 150001 to 500000 315 15 500001& over 500

13.2 For Mechanical & Voltage Sampling Level: Special Inspection Level S-2 AQL: 0.1% Rejection in sample size acceptable

SL NO LOT SIZE SAMPLE SIZE 1 2 to 8 2 2 9 to 15 2 3 16 to 25 2

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4 26 to 50 3 5 51 to 90 3 6 91 to 150 3 7 151 to 280 5 8 281 to 500 5 9 501 to 1200 5 10 1201 to 3200 8 11 3201 to 10000 8 12 10001 to 35000 13 13 35001 to 150000 13 14 150001 to 500000 13 15 500001& over 13

1144.. QQUUAALLIIFFIICCAATTIIOONN TTEESSTT RREEPPOORRTTSS For all accessories, the Qualification Test Report should be from an Independent NABL Accredited Laboratory like CPRI or the International Laboratory Accreditation Corporation, Mutual Recognitions Arrangement ( ILAC,MRA) signatory Laboratory like COFRAC.

1155.. TTYYPPIICCAALL GGEENNEERRAALL AARRRRAANNGGEEMMEENNTT DDIIAAGGRROOMM 15.1 Dead End (Anchor) Clamp for insulated or bare messenger, with Pole Bracket and SS Strap

15.2 Suspension Clamp for insulated or bare , with Pole Bracket and SS Strap

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15.3 Service Clamps

15.4 Service Brackets

15.5 Servicing Arrangement

Service Bracket Stainless Steel straps

Stainless Steel Buckles

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1166.. TTYYPPIICCAALL DDRRAAWWIINNGGSS 16.1 Typical Drawing of Dead-End (Anchoring Assembly)

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16.2 Typical Drawing of Dead-End (Suspension Assembly)

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16.3 Typical Drawing of service Clamps

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16.4 Typical Drawing of Service Bracket

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16.5 Typical Drawing of Stainless Steel Strap & Buckle

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1199.. GGUUAARRAANNTTEEEEDD TTEECCHHNNIICCAALL PPAARRTTIICCUULLAARR FFOORRMMAATT

19.1

1

GTP form for Dead-End (Anchoring Assembly)

Type of Clamp

Dead end clamp Assembly

2 Name & Address of the Manufacturer

3 Standard NFC 33-041.

4 Range of messenger size

5 Type of design Wedge Type 6 Installation (with / without disassembly) Without disassemblying (Ready-to-use)

7 Type & grade Metallic / Nonmetallic Material Al alloy for Body and Thermo plastic for Wedges

8 Marking 9 Colour of Nonmetallic parts Black 10 Dimensions (mm) GA Drawing enclosed 11 Approximate weight (Kg) 12 Breaking Load (KN) as per TNEB requirement

(Acceptance test)

13 Di-Electric test (Min 6 KV AC for 1 minute)

Yes.Withstand Min 6 KV AC for1minute

14 Maximum load holding capacity (KN) 15 Max. vertical load sustained by clamp (KN.)

16 Is type test report enclosed as per NFC 33-041 Yes

19.2

11

GTP form for Suspension Assembly

Type of Clamp Suspension Clamp Assembly 2 Name of the Manufacturer 3 Address of the Manufacturer 4 Standard NFC 33-040. 5 Type 6 Range of conductor size 7 Installation (with / without disassembly) Without disassemblying (Ready-to-use) 8 Is bracket & movable link included Yes 9 Type & grade Metallic / Nonmetallic

Material Al alloy for Bracket &Thermo plastic for Suspension Clamp body,Movable link & Lever

10 Marking 11 Colour of Nonmetallic parts Black 12 Breaking Load (KN) 12 KN 13 High voltage test (Acceptance test) Yes.Withstand Min 6 KV AC for 1minute 14 Maximum load holding capacity (KN)

(Acceptance test)

15 Max. longitudinal load sustained by clamp (Acceptance test)

16 Are all type test reports as per NFC 33 040 enclosed

Yes

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19.3

Sl No

GTP form for Service Clamp

Particulars

1 Name of the Manufacturer

2 Application standard NFC 33 042

3 Is any metallic part carrying potential in operation exposed during installation

No

4 Type clamping mechanism Wedge Type

5 Material of clamps Climatic resistant thermo plastic.

6 Ultimate tensile strength 2 kN 7 Minimum and maximum overall cable dia accomodated

8 Marking and identification on the clamps 9 Are all type test reports submitted as per REC / NFC 33

042? Yes.

19.4

1

GTP form for Service Bracket

Type of Bracket

Service Bracket

2 Name of the Manufacturer

3 Place of Manufacturer

4 Type of design 6-Line Servicing 5 Type & grade Metallic / Nonmetallic Material Al Alloy

6 Dimensions (MM) 7 Approximate weight (Kg) 8 Ultimate Tensile Strength (KN) 15 KN (Minimum)

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19.5

Sl. No.

GTP form for SS Strap

Parameters Unit Value

1 Material composition -

2 Weight of the material Kg/m 3

Tensile strength KN/Sq.mm

4 Type test report for Tensile strength

-

19.6

Sl. No.

GTP form for Buckle

Parameters Unit Value

1 Material composition -

2 Weight of the material Grams

3

Tensile strength KN/Sq.mm

4

Type test report for A.Tensile strength

-

Enclosed

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ANNEXURE – A

1. Climatic Ageing Test

The samples are submitted to the climatic ageing test as per NFC 20-540 or HD 626-2 sub-clause 2.5.1 with following details. During the test the wavelength and intensity of the UV at the location of the Connector under test shall be measured and must meet with the requirements of the Test Procedure of NFC 20 -540.

6 weekly cycles are required at the enclosure temperature (70±2)°C for phases A & C. After completion of the Climatic Test, and after more than 24 hours but within 72 hours under ambient conditions, the connector shall be tested with requirement as below:

2. Corrosion Test

Equipments for aerial networks with bare or insulated cables are submitted to more or less humid and corrosive natural atmospheres.

The two main factors involved in atmosphere corrosiveness after the duration during which a surface stays we are :

- Chloride ion, mainly in marine atmosphere : - Suphur dioxide, mainly in industrial atmosphere ; - Occasionally, both at the same time, in, iced, marine and industrial atmospheres.

The connector is installed with a main core and with 1 or 2 minimum cross-section tap core(s). The connector is placed in the middle of the main core of 0.5 m to 1.5 m. Then it is tightened up to the minimum torque indicated by the manufacturer.

Then the corrosion test defined in the standard NFC 33 003 is applied to the connector and conductor.

There are 4 cycles of 14 days. Each 14 day period, or basic module, comprises two weekly sequences:

- 7 Days (168 h) with salt spray exposure; Concentration shall be (5±1)% in weight and

the enclosure temperature shall be maintained at (35±2)°C. - & cycles of 24 h (168h), each cycle including 8 h exposure with saturated humidity and

high sulphur doixide conenet atmosphere (that is 56h), and a 16h exposure at the laboratory atmosphere by opening the enclosure door (that is 112h). volume concentration of sulphur dioxide shall be 0.067%. Each cycle of 24 h includes first a 8 h heating period, and secondly a 16 h rest period. During the first period the temperature is raised to (40±3)°C in a humidity saturated atmosphere. During the second period the enclosure remains at ambient temperature.

No cleaning shall be performed between both sequences. At the end of each 14day period, the samples shall be cleaned first by normal water for 5 minutes to 10 min and then by dematerialized water for the same duration. Water temperature shall not exceed 35°C during both operations.