PRODUCT MANUAL ON ACSR CONDUCTORS FOR EXTRA HIGH VOLTAGE ... · PDF fileproduct manual on acsr...

PRODUCT MANUAL

ON

ACSR CONDUCTORS FOR EXTRA HIGH VOLTAGE (400 KV AND ABOVE)

AS Per IS 398 (Part 5): 1992

BUREAU OF INDIAN STANDARDS MANAK BHAWAN

9, B.S. ZAFAR MARG NEW DELHI -110002

PRODUCT CERTIFICATION MANUAL

ACSR Conductors for extra high voltage (400 kV and above)

BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION SCHEME

Doc No: Issue No: Date: Nov 2013 Page No. Prepared by: MDM EEE Head MDM (E & E) Approved by:

Amendment Sheet





FORWORD This manual elaborates principle manufacturing processes, infrastructure and quality controls, Scheme of Testing and inspection ,Marking fee rates, guidelines for writing scope of licence and inclusion of new types, Size of sample to be drawn for testing and manner of sealing it, list of test equipments/facilities, testing charges, testing time and Test facilities at BIS labs/OSLs etc. This also outlines raw materials involved in manufacturing of the product. This manual aims in providing basic inputs and all essential aspects with the expectation of bringing uniformity in BIS certification activity of the product. This document is intended for internal use by BIS inspecting officers who should however do not treat such document as replacement for referred Standards or that of relevant Scheme for Testing and Inspection (STI).





Table of Contents

1. SECTION I PRODUCT

1.1. Description of Product(s) 1.2. Latest Indian Standard 1.3. List of Referred Indian Standards 1.4. Checklist for Submission of an application for GOL

2. SECTION II: RAW MATERIALS 2.1. List of Raw Materials

3. SECTION III: MANUFACTURING PROCESS & IN-PROCESS QUALITY CONTROLS 3.1. Manufacturing Flow Chart and Description 3.2. Infrastructure for production

4. SECTION IV: CERTIFICATION CRITERIA 4.1. Identification of critical requirements of IS 8034:2002 4.2. Scheme of testing and inspection 4.3. Marking fees 4.4. Guidelines for writing scope of licence 4.5. Guidelines for inclusion of new varieties 4.6. Sample Size 4.7. Manner of sealing sample 4.8. Handling of Remnants

5. SECTION IV INSPECTION AND TESTING 5.1. Packing material requirement for samples 5.2. List of required Test Equipment/facilities and frequency of calibration 5.3. Status of Test Facilities in BIS Labs and OSLs with Testing Charges,

and approximate time required for testing by BIS Labs/OSLs 5.4. Basis for Grant of Licence 5.5. Details of Tests to be carried out in factory

6. SECTION V OTHER IMPORTANT ASPECTS





1. SECTION I: PRODUCT

1.1. Description of Product(s): ACSR Conductors for extra high voltage (400 kV and above): Aluminium Conductors-Galvanized Steel Reinforced for extra high voltage (400 kV and above) are generally used in overhead power transmission at high voltage. This standard (Part 5) was first published in 1982. At that time the development of EHV network was envisaged at 400 kV ac only. For this system after detailed techno-economic studies by CEA, 54/3. 53 mm Al+ 7/3.53 mm steel conductor in the form of horizontal twin conductor bundle with a subconductor spacing of 450 mm was identified as the most suitable conductor. However, with the expansion of 400 kV network and with the development of ± 500 kV dc and 800 kV ac systems, use of additional types of ACSR conductors is envisaged in the country. Therefore, the latest version of the standard 1992 covers three types of conductors instead of only one covered in the earlier version of the standard. It is, however, not intended to restrict the standard to the parameters of these conductors only and requirements for other conductors for EHV purpose will be added later as and when the need arises. 1.2. LATEST INDIAN STANDARD:

a) IS 398 (Part 5): 1992, (No of Amendments -2)





1.3. List of referred standard IS No. Title IS No. Title

209 : 1979

Zinc ( third revision )

4826 : 1979

Hot-dipped galvanized coat ings on round steel wires ( first revision )

398 ( Part2 ) : 1996

Aluminium conductors for overhead transmission pur poses : Part 2 Aluminium conductors galvanized steel reinforced ( second revision )

5484 : 1978

Autoclaved cellular concrete blocks

1841 : 1978

EC grade aluminium rod produced by rolling ( second revision )

7623 : 1985

Lithium base grease for indus trial purposes ( first revision )

1.4. CHECK LIST FOR SUBMISSION OF AN APPLICATION

FOR GOL As per annexure A





2. Section II 2.1. List of Raw Materials: The list of Raw materials along with the refer

standards is as given below Sr. No

Raw Material Reference Standards

1 EC Grade Aluminium Rods IS 1841:1978 2 Zinc IS 209:1979 3 Aluminium Wire before Stranding As per Table 1 of IS 398

(Part 5): 1992 4 Steel Wire Before Stranding As per Table 2of IS 398

(Part 5): 1992





3. Section III: Manufacturing process and in process quality control 3.1. Manufacturing Flow Chart and Description

Note 1: Process Control will be done as per S.T.I. Note 2: This process flow chart is representative purpose only; actual process may defer depending on availability of Machines, Raw materials. e.t.c.

WIRE DRAWING

FINAL STRANDING

PACKING & MARKING

ALUMINIUM WIRE ROD (CCR)

HTGS WIRE

RAW MATERIALS

STEEL STRANDING





Wire drawing: In this process Aluminium Wire drawn in required sizes from Aluminium wire rod in wire drawing Machine. In each die, there is reduction in area about 20% and accordingly, No. of dies are decided. These wires are drawn on required bobbins for further stranding of final products. HTGS wire: HIGH Tensile Galvanized Steel wire (HTGS) is received in coil form from supplier. The coils are then transferred from coil form to bobbins at steel spooling machines. Then seven bobbins are loaded on Seven Strand Tubular Machine for Steel stranding purpose if required for seven cores and steel core is made. This steel wire or Steel core will be used as an input material on stranding machine to make required final product. Welding Machine: For welding of inner core wires if required. Final Stranding: Required no of Aluminium wires drawn in first stage are stranded over HTGS steel wire or required Stranded Steel core on Stranding Machine to make final product.





3.2. Infrastructure for production

The following manufacturing facilities/ machinery are necessary for manufacturing of ACSR Conductors for extra high voltage (400 kV and above)

Sr. No. Machinery 1 Wire Drawing Machine

2 Stranding Machine

3 Rewinding Machine

4 Welding Machine

5 Spooler





4. SECTION IV: Certification Criteria

4.1. Identification of critical requirements of the Indian standard Note: To be provided by CMD

4.2. Scheme of Testing and Inspection: As per Annexure B





4.3. Marking fee rates: As per below table

Description Value

Unit 1 TONNE L S Marking Fee Rs 34000/ S S Marking Fee Rs 29000/ Rate Rs 34.6 per Unit Qty All

4.4. Grouping guidelines: None Presently 4.5. Guidelines for scope of writing : As per below format

GOL is recommended for use of Standards mark as per IS 398 (Part 5): 1992 with Amendment No 2 for Aluminium Conductors for overhead transmission purposes: Part 5 Aluminium Stranded Conductors Galvanized Steel Reinforced for extra High Voltage (400 kV and above) size up to and including (Nominal Aluminium Area Depends on laying capacity of the firm).

4.6. Guidelines for Inclusion of new variety: Firm has to be submit Complete Test Report from any BIS Recognised lab within one month from date of issue of reports with details of Additional Machinery/Equipment installed, if any to BIS.

4.7. Sample size, including guidelines for drawl of separate

samples when samples are required to be sent to different labs for testing: As per below Chart

Sr. No. Descriptions of Samples Sample No 1 Aluminium Conductor Galvanized Steel Reinforced, Al No of

stranding/ Size of Al. Wire + Steel No of stranding wire/ Size of Steel Wire Quantity 5 metre For Acceptance Test as per Cl 13.1.2 of IS 398 (Part 5): 1992

Sample No 2 Aluminium wire before stranding, Dia of wire Quantity 5 metre For Test as per Table 1 of IS 398 (Part 5): 1992

Sample No 3 *Steel wire before stranding, Dia of wire Quantity 5 metre For Test as per Table 2 of IS 398 (Part 5): 1992

Sample No 4 Aluminium Conductor Galvanized Steel Reinforced, Al No of





stranding/ Size of Al. Wire + Steel No of stranding wire/ Size of Steel Wire Quantity 7 metre For Surface Condition and Ultimate Breaking Load Test as per Cl 13.10 & Cl 13.5.1 of IS 398 (Part 5): 1992

Sample No 5 Aluminium Conductor Galvanized Steel Reinforced, Al No of stranding/ Size of Al. Wire + Steel No of stranding wire/ Size of Steel Wire Quantity 7 metre × 2 Nos For Corona and Radio interference voltage Test as per Cl 13.11 & Cl 13.12 of IS 398 (Part 5): 1992

Sample No 6 **Zinc Quantity 50 gram As per Cl 6.2 of IS (Part 5): 1992and IS 209

* If the galvanized steel wire is ISI marked, further testing may not be done ** If the consignment of zinc is accompanied by a test certificate, further testing may not be required

a) Manner of Sealing of Samples: Make in coil form, wrapped with cotton sheet, tied and tagged with sample description and BIS sealed.

b) Remnants of samples: May be scrapped and disposed

c) Procedure to be followed for destroying/deshaping/ recycling the product that does

not meet the quality parameters during regular production: May be destroyed and scraped.





5. SECTION V: INSPECTION AND TESTING

5.1. Packing material requirements (to be available in factory at all times) for packing/ Dispatch of samples: Cotton Roll, Wax and wooden box

5.2. List of test equipment facilities with requirements and

frequency of calibration: This detail is to be provided by CL.

5.3. Status of Test facilities in BIS lab/ OSL:

5.3.1. Status of Test facilities in BIS lab: As per below chart. Partial test faculties at all BIS labs

Lab Quantity Type of Testing Complete/partial Remarks

CL 5 m Elec Partial exc.surface cond,corona,ratio interference test

EROL 3 m + 4.5 m Elec P except surface cond,corona,radio

interference test PBOL 5 m Mech/chem P Excl resistance test

SROL 3 m + 4.5 m Elec P

WROL 5 M Elec P Cl. 13.5.1, 13.7,13.10,13.11,13.12

5.3.2. Status of Test facilities in BIS approved labs: There are three OSL labs which are undertaking testing of ACSR Conductors for extra high voltage (400 kV and above).

Sl

No. Name of the Recognized

Laboratory Lab Code Testing Charges Remarks

1 MSME Testing Centre M/o Micro,Small & Medium Enterprises,Govt.of India 111&112 B.T. Road Kolkata-700108 West Bengal Contact : Sh. P. Ray, Director Tel : 033-25770686/2482 Fax : 033-25771353

5108204 Rs.3500/- for conductors of 3 wires, Rs.4063/- for conductors of 7 wires, Rs.8138/- for conductors of consist with 19 wires, Rs.13825/- for conductors of consist

Except 'Surface Condition test(Cl.13.10), Corona test (Cl.13.11), Radio Interference Voltage test (Cl.13.12)'





with 37 wires, Rs. 17275/- for conductors of 49 wires, Rs.20725/- for conductors of 61 wires.

2 Electrical Research & Development Association P.B. No. 760, ERDA Road, Makarpura Industrial Estate Vadodara-390010 Gujarat Contact : Dr. M.K. Shah, JD&Quality Manager -Mob:09978940911 Tel : 0265-2642942,964,377 Fax : 0265-2648382

7101125 Rs.156950/- for size 520 sq.mm, Rs.175910/- for size 560 to 690 sq.mm [ 25% discount for BIS]

3 Central Power Research Institute Prof.Sir C.V.Raman Road, Sadashivanagar, Sub Post Office, P.B. No.8066, Bangalore-560080 Karnataka Contact : Shri C.P.Jairam, Joint Director & Quality Manager Tel : 080-23605367, Fax : 080-23605367

6101024 Rs.48450/-

Note: Please check http://www.bis.org.in/lab/osladd1.asp for latest status of testing facility in BIS Recognise Laboratory.

5.4. Basis of Grant of Licence: Independent testing basis.

5.5. Test to be carried out for

5.5.1. Applicant Samples/Verification Samples: All test as per IS 398 (Part 5): 1992

5.5.2. Surveillance/ Market Samples: Acceptance Tests as per Cl. 13.1.2 of IS 398 (Part 5): 1992

5.5.3. Raw Material Samples: Aluminium Rod as per IS 1841 : 1978 and Zinc as per Cl. 6.2 of IS (Part 5): 1992 and IS 209 at NABL/BIS approved lab.

PRODUCT MANUAL ON ACSR CONDUCTORS FOR EXTRA HIGH VOLTAGE ... · PDF fileproduct manual on acsr...

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