018-2 : 2006 CEB STANDARD

AERIAL BUNDLED CONDUCTOR ACCESSORIES

CEYLON ELECTRICITY BOARD SRI L ANKA

Amendment Slip General Amendments to CEB Specification Effect ive from 05-10-2005

REVISED TEXT

1.

Tender form, Schedule of Prices, Letter of Authorization, Power of Attorney documents shall be signed in Blue Ink. Name of the persons signing shall be clearly indicated and their official stamp has to be put in. Bidders shall include with their offer the Type Tests Report/Certificates in accordance with the Standard specified, obtained from an accredited independent test laboratory acceptable to the CEB. Proof of accreditation by a national/international authority shall also be forwarded with the offer. Test Reports shall be complete including all the pages as issued by the Testing Authority. Parts of the Test Report shall not be acceptable.

2.

R\slip.LF

Specification for

AERIAL BUNDLED CONDUCTOR ACCESSORIES

CEB Specification 018-2 : 2006

CEYLON ELECTRICITY BOARD

No. 50, Sir Chittampalam A. Gardiner Mawatha, Colombo 2. Sri Lanka

Telephone: 94-11-2324471-8

Facsimile: 94-11-2449572

CEB SPECIFICATION 018 - 2 : 2006

CONTENTS

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

SCOPE SYSTEM PARAMETERS SERVICE CONDITIONS APPLICABLE STANDARDS BASIC FEATURES AND TECHNICAL REQUIREMENTS ADDITIONAL REQUIRMENTS QUALITY ASSURANCE INSPECTION & TESTING PACKAGING AND DELIVERY

1 1 1 1 2 7 8 8 9 9 10

10.0 INFORMATION TO BE SUPPLIED WITH THE OFFER 11.0 ANNEXURE

CEB SPECIFICATION 018 - 2 : 2006

SPECIFICATION FOR AERIAL BUNDLED CONDUCTOR ACCESSORIES 1.0 SCOPE This specification covers the design, manufacture and testing of Aerial Bundled Conductor Accessories for low voltage distribution systems. 2.0 SYSTEM PARAMETERS (a) (b) (c) (d) (e) 3.0 Nominal Voltage System highest Voltage System frequency Method of earthing System fault level 400/230 V 440 V 50 Hz. Effective earthing 17.5 MVA

SERVICE CONDITIONS (a) (b) (c) (d) (e) Annual average ambient temperature Maximum ambient temperature Maximum relative humidity Environmental condition with polluted atmosphere Operational altitude metres above M.S.L. 30?C 40?C 90% Humid From tropical M.S.L. to climate 1900

4.0

APPLICABLE STANDARDS The equipment and components supplied shall be in accordance with the latest edition of the standards specified below and amendments thereof. (a) French NFC Standard i) ii) iii) NFC 33 040 - 1998 Suspension Equipments for Overhead distribution with Bundle assembled cores, of rated voltage 0,6/1 kV NFC 33 041 1998 Anchoring devices for Overhead Distribution with bundle assembled cores, of rated voltage 0,6/1 kV NFC 33-021 1998 Pre-insulated compression type connecting equipment for Overhead Distributions and Services with bundle assembled cores, of rated voltage 0,6/1 kV NFC 33-020 - 1998 Insulation piercing connectors for overhead

iv)

CEB SPECIFICATION 018 - 2 : 2006

distributions and services with bundle assembled cores, of rated voltage 0,6/1 kV. v) NFC-004 1998 Connecting equipment for overhead distributions and services of rated voltage 0,6/1 kV, with at least one insulated core Electrical ageing test NFC 33042 1998 Anchoring devices for overhead and overheadunderground services with insulated cables, of rated voltage 0,6/1 kV.

vi)

vii) NFC 33209 1998 Bundle assembled cables for overhead systems of rated voltage 0.6/1 kV. (b) IEC 61089 (1991) conductors. Round wire concentric lay overhead electrical stranded

(c) CEB Specification 018-1:1996 Arial Bundled Conductors The supplier may offer Accessories for Aerial Bundled Conductors manufactured to standards not less rigid than the latest editions of the French NFC / EDF Standard Specified. Offers of items manufactured to any other internationally recognized standards or specifications not less rigid shall be accompanied by an English translation of such standards or specifications. The accessories for Aerial Bundled Conductor shall be compatible with the Aerial Bundle Conductors specified in CEB Standard 018-1. 5.0 BASIC FEATURES AND TECHNICAL REQUIREMENTS The accessories for Aerial Bundled Conductor (ABC) are as specified below and they shall satisfy all the loadings and tests as stipulated therein. All the Accessories for ABC shall have the electrical and mechanical characteristics conforming to the relevant Standards specified. 5.1 Suspension Small Angle Assembly Each assembly shall include:a) b) c) 5.1.1 One number suspension bracket. One number movable connecting (articulated) link. One number suspension clamp.

Suspension Bracket

Suspension bracket shall be made of Aluminum Alloy suitable for attachment to a concrete pole by single 16mm galvanized iron bolt. The moveable connecting link shall act as a mechanical fuse in the case of overloading on the bundled conductor, (when breaking, suspension assembly relieves the network of loading and preserves dead - ending) with the following mechanical requirements as given below, as per EDF reference ES 1500. 5.1.2 Suspension clamp and movable Connecting (articulated) link
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CEB SPECIFICATION 018 - 2 : 2006

The suspension clamp and the movable connecting link shall be made of weather resistant and mechanically strong thermoplastic insulating material without any steel component. Clamping of the neutral messenger shall be of controlled slippage. This device shall have the capacity for the suspension and tightening a 54.6 mm neutral messenger conductor. Bolts shall not be used to clamp the neutral messenger conductor to the Suspension Clamp. 5.2 Dead End Assembly

Each assembly shall include :(a) One number Tension Bracket (b) One number wedge type Tension clamp. 5.2.1 Tension Bracket

Tension Bracket shall be made of Aluminum alloy suitable for attachment to a concrete pole by a 16 mm galvanized iron bolt. The mechanical requirements of the assembly and components shall be as per EDF reference EA 1500. 5.2.2 Wedge type Tension (Dead End) Clamp

Housing of the Wedge type Tension Clamp shall be made out of mechanical and weather resisting insulation material, neither bolt for clamping the neutral messenger nor loose parts are allowed. No special tools shall be required for installation of the clamp in the field. To ease the torsional movement involved in the ABC system, the clamp shall be supplied with a flexible attachment to the above bracket by means of a stainless steel flexible braid. The Wedge type Clamp shall be exclusively made of weather resistant Thermo Plastic insulating material and shall be designed to withstand the relevant breaking load of the neutral messenger without slipping (i.e. 1500 daN minimum). The mechanical requirements of the assembly and components shall be as per EDF reference EA 1500. All the components of the material shall be made of corrosion resistant materials . 5.3 Large Angle Assembly

Each assembly shall include: (a) One number Tension Bracket. (b) Two numbers Wedge type Tension Clamps. Description of sub components of the large angle assembly are the same as for the
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CEB SPECIFICATION 018 - 2 : 2006

dead end assembly described in Clause 5.2 above, but two Wedge type Tension Clamps shall be supplied instead of one Wedge type Tension Clamp as in the Dead End Assembly. 5.4 Pre-insulated Sleeves and Bi- metallic Lugs (Palm Copper and Barrel Aluminium)

The joints shall be of Pre-insulated type i.e. the compression is directly made over the insulation but crimping shall not deteriorate the insulation of the sleeve. The Pre-insulated Jointing Sleeves and Bi-metallic Lugs shall be of waterproof type. For this purpose the Pre-insulated Sleeve and Bi-metallic Lugs shall be equipped with a suitable rubber gasket to prevent ingress of water. The Pre-insulated Sleeves and Bi-metallic Lugs shall be pre-filled with any suitable oxide inhibiting compound or silicon grease and their current ratings shall be equivalent to the respective cable/messenger. For easy identification Pre-insulated Sleeves and Bi-metallic Lugs shall have markings indicating size of conductor applicable(or colour coded as per NFC 33-021), sequence and location of hexagonal compression indents and die to be used. Also insulation stripping length shall be indicated on the Sleeves and Bi-metallic Lugs. The current rating of the pre-insulated Sleeves and Bi-metallic Lugs shall not be less than that of the Aerial Bundled Conductor ( 70x3+54.6+16 mm ). The temperature rise in the joint shall not be more than that of the conductor stipulated in the relevant standard specified. Compression of all pre-insulated Sleeves and Bi-metallic Lugs for both phase and messenger neutral shall be achieved by means of using a single die. The grove reference of the Sleeves and barrel of the Lugs and the "Across Flat Dimension" of the die to be used shall be as indicated below; Size of the conductor Across Flat Dimension of the Die to be used 17.3 mm 17.3 mm 14.0 mm Groove reference

a) b) c) 5.4.1

Phase Conductor Neutral Messenger Street Lamp wire

70 sqmm 54.6 sqmm 16 sqmm

E173 E173 E140

Pre-insulated Sleeves for 70 mm AAC Phase XLPE, 54.6mm AAAC Neutral XLPE Insulated and 16 mm Street Lamp Core

The Pre-insulated Sleeves shall be suitable for making mid-span joints and the mechanical requirements of pre-insulated sleeve after compression shall be as follows. (a) For 70 mm AAC phase cable = and for 16 mm street lamp wire. (b) For 54.6 mm (min) AAAC neutral
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60% of conductor U.T.S. = 95% of messenger U.T.S.

CEB SPECIFICATION 018 - 2 : 2006

5.4.2

Pre Insulated Bi-Metallic Lugs for XLPE insulated 70mm AAC Phase, 54.6 mm AAAC Neutral and 16 mm Street Lamp Core

The Pre Insulated Lugs shall be of friction welded bi-metallic type, suitable for making connections between the aerial bundled conductors and copper terminals of the equipment effectively. The Palm of Bi-metallic Lugs used for phase conductor and neutral messenger shall be provide with a 13mm diameter hole and for street lamp core it shall be 10 mm.

5.5

Insulated Tee-off Piercing Connectors

Tee-off Piercing Connectors are required for connection of service conductors to bundled conductors and for tee-offs of bundled conductors. The Connectors shall be of waterproof design. To achieve the required water tightness a special rubber seal shall be provided around the teeth of the Connector and the Connector shall be greased with neutral grease in order to prevent moisture penetration. The housing shall be made entirely of mechanical and weather resistant plastic insulation material and no metallic part outside the housing is acceptable except for the tightening bolt. It is absolutely necessary that none of the energized parts of the connector can be reached directly by the operator during installation of Piercing Connector on live lines. These Connectors shall be of Insulation Piercing type both on the main and tap conductors. Bolts of the Piercing Connector shall be provided with over torque shear head and the over torque shear head shall allow adequate clamping torque to achieve proper connections to the ABC specified in the CEB Standard 018-1. The number and the length of the teeth shall be adequate enough to penetrate the relevant bundled conductor insulation to establish proper contact without any contact resistance and without stripping the conductor insulation. To ensure good electrical contact 1 bolt Connector shall be provided with minimum of two lower and upper contact teeth and 2 bolt Connectors with minimum of 3 lower and upper contact teeth. The bolt and washers shall be of corrosion resistant type (either stainless steel or aluminium alloy ). The Connector shall have a removable end cap enabling tapping and branching on either side of the Connector. The end cap shall be of slide type enabling easy positioning. The current rating of the Connectors shall be the same as the 70x3+54.6+16 mm aerial bundled conductor. Three types of Connectors required are summarized as follows.

CEB SPECIFICATION 018 - 2 : 2006

Types of Piercing Connector, Conductor Area (mm) and End Cap Size Type A - (1bolt) B - (1 bolt) C - (1 bolt) Main 54.6 - 70 mm 54.6 - 70 mm 6 - 25 mm Tap 54.6 - 70 mm 6 - 25 mm 6 - 25 mm End Cap 54.6-70 mm 6 - 25 mm 6 - 25 mm

i) ii) iii) 5.6

Insulating Binding Strap

The Binding Strap shall be used for binding the cable at different locations with the dead end clamp and suspension clamp. The Strap shall be made of polyamide having a total length of 215m and a clamping capacity of 62mm. The width of the Straps shall not be less than 9mm. There shall be titled grooves on one side of the Strap and the top of the strap shall have a locking and releasing facility. 5.7 Insulation Cap

The Insulation Cap shall consist of 4 or 5 nos. of end caps for each conductor of the bundle (depending on the type of ABC ie. as indicated in the schedule of prices) and an overall cover for effectively terminating the Aerial bundled conductors. The inner diameter of the Cap shall be such that it will tightly fit to the individual conductors of the 70x3+54.6+16 mm Aerial Bundled Conductor to prevent entry of moisture. The Overall Cover shall be of heat shrinkable type, made of black colour EPDM suitable for use with the aerial bundled conductor 70x3+54.6 mm with or without 16mm street lamp core as indicated in the schedule of prices. 5.8 Stainless Steel Straps and Buckles

Stainless Steel Strap is used to fix the bracket to poles as and when required. Stainless Steel Strap shall be of grade 18/8, width 20 mm and thickness 0.7mm approximately. The edges shall be smooth and free from burrs. The Buckles used for strapping shall be made of stainless steel suitable for use with the Stainless Steel Strap specified above.

CEB SPECIFICATION 018 - 2 : 2006

6.0

ADDITIONAL REQUIRMENTS 6.1 Type Tests

The equipment/items subjected to the following Type Tests, shall have a proven design. i) For Suspension, Large Angle and Dead End Assembly, a. Mechanical Test 1) Tensile tests on brackets 2) tensile tests on sub assemblies 3) Slippage test on the clamp of the suspension assemblies Voltage tests on sub-assembly suspension clamp & moveable link Ageing Test Corrosion test

b. c. d. ii)

For Pre-insulated Sleeves and Bi-metallic Lugs a. b. c. d. e. f. g. Mechanical tests (Crimping ability test, Tensile tests) Voltage & water tightness test Installation tests at low temperature Current Carrying capacity Climatic ageing test, Electrical ageing test Corrosion test Endurance test under mechanical & thermal stresses

iii)

For Piercing Connectors a. b. c. d. e. f. g. Voltage and water tightness test Temperature rise and over current tests Climatic ageing test Installation tests at Low temperature Mechanical test Corrosion test Electrical ageing test

iv)

For Insulation Cap a. b. Voltage and water tightness tests Ageing test

v)

Stainless Steel Strap and Buckle a. b. Mechanical loading test Chemical composition

6.2

Type Test Certificates

Certificates of Type Tests performed shall conform to the relevant NFC Standards. The Test Certificates should clearly identify the equipment concerned, showing the manufacturer's identity, Type No. and Basic Technical Parameters. The test certificates referred to shall be issued by a accredited Testing Authority acceptable to the purchaser.

CEB SPECIFICATION 018 - 2 : 2006

6.3

Routine Tests

While manufacturing each batch of equipment/item shall be subjected to the Routine Tests conforming to the standard specified. 6.4 Manufacturing Experience

The manufacturer shall have minimum of 5 years experience in manufacturing accessories for Aerial Bundled Conductors. 7.0 QUALITY ASSURANCE The manufacturer shall posses ISO 9001 Quality assurance certification for the manufacture of accessories of Aerial Bundle Conductors for the plant where the manufacturer of the accessories of Aerial bundle Conductors is done. Bidders shall furnish a copy of the ISO certificate certified as true copy of the original by t e h manufacturer, along with the offer. 8.0 INSPECTION & TESTING 8.1 Inspection

The selected Bidder shall make necessary arrangements for inspection by an Engineer appointed by the Purchaser during manufacture and before dispatch and also to carry out in his presence necessary acceptance/sample tests in accordance with the standard specified for the material and equipment offered. 8.2 Acceptance /Sample Test

The following Acceptance /Sample Test shall be witnessed by the engineer appointed by the purchaser. i) For Suspension, Large Angle and Tension Assembly, 1) 2) ii) Mechanical Tests Voltage tests on sub-assembly suspension clamp & moveable link

For Pre-insulated Sleeves and Bi-metallic Lugs 1) 2) 3) 4) Mechanical Tests; Voltage & water tightness test Current Carrying capacity Temperature Rise after crimping

iii)

For Piercing Connectors 1) Voltage and water tightness test 2) Temperature rise and over current tests 3) Mechanical tests

iv)

For Insulation Cap voltage and water tightness test

v)

Stainless Steel Strap and Buckle

CEB SPECIFICATION 018 - 2 : 2006

1) 2) 8.3 SAMPLE STUDY

Mechanical loading Test Chemical composition Test.

Two samples of all Accessories offered shall accompany the bid to facilitate analysis and evaluation 9.0 PACKAGING AND DELIVERY The Accessories for Aerial Bundled Conductors Shall be Packed as indicated below. Name of Item and the quantity shall be clearly marked on each packing. a) i. The complete Suspension Small Angle Assembly shall be delivered in a single pack in a suitable bag. ii. The complete Dead End Assembly shall be delivered in a single pack in a suitable bag. iii. The complete Large Angle Assembly shall be delivered in a single pack in a suitable bag. b) i. Each Pre-Insulated Sleeve shall be packed in a suitable sealed bag to avoid moisture penetration during transport and storage and 25 numbers of such bags shall be packed in a card board box . ii. Each Pre-Insulated Bi-metallic Lug shall be packed in a suitable sealed bag to avoid moisture penetration during transport and storage and 25 such bags shall be packed in a card board box. c) Each Piercing Connector shall be packed in a suitable sealed bag to avoid moisture penetration during transport and storage and 10 numbers of such bags shall be packed in a card board box. d) Insulating Binding Strap shall be packed in suitable bags and each bag shall contain 100 Nos. of Insulating Binding Straps. e) A set of Insulation End Caps with overall cover shall be packed in a suitable sealed bag to avoid moisture penetration during transport and storage and 10 such bags shall be packed in a card board box. f) i. The Stainless steel Buckles shall be supplied in packs of 100 ii. The Stainless Steel Straps shall be supplied in carton rolls of 50 metres each.

10.0

INFORMATION TO BE SUPPLIED WITH THE OFFER

CEB SPECIFICATION 018 - 2 : 2006

The selected Bidder shall supply all relevant drawings, technical literature, hand books etc. in English, in order to facilitate proper installation. Routine Test Certificates conforming to the Clause 6.3 shall be furnished with the equipment. The Bid shall be accompanied with the following also; a. English version of catalogues describing the equipment and indicating the type/model number. b. Technical literature in English describing the constructional and operational features of the equipment. c. The standard to which the goods have been manufactured d. Recommended current carrying capacity of the connectors, sleeves and lugs. e. Dimensioned drawings of the conductor accessories. f. Packing details.

g. Completed schedule of particulars as per annexure A - 1. h. Type test certificates for the following items conforming to Clause 6.0: i. ii. iii. iv. v. Suspension, Large Angle and Dead End Assembly, Pre-insulated Sleeves and Bi-metallic Lugs Piercing Clamps Insulation Cap Stainless Steel Strap and Buckle

The Bidder shall furnish information to ascertain that manufacturer has over 5 years of manufacturing accessories for ABC. Failure to furnish the above details, data as per Clause 6.0 and samples as per Clause 8.3 will result in the offer being rejected. 11.0 ANNEXURE A- 1 Schedule of Particulars

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CEB SPECIFICATION 018 - 2 : 2006

ANNEXURE A - 1 SCHEDULE OF GURANTEED TECHNICAL PARTICULARS 1. 2. 3. 4. Name of manufacturer Country of manufacture Applicable Standards Material a. Suspension small angle assembly i) ii) iii) iv) v) b. Suspension bracket Movable articulated link Suspension clamp Clamping bolt Clamping straps -

Large angle assembly i) ii) iii) Clamping straps Tension bracket Dead end clamp -

c.

Dead end assembly i) ii) iii) Clamping straps Tension bracket Dead end clamp -

5.

Strength of a. b. c. d. e. Suspension clamp Suspension bracket Dead end assembly Dead end bracket Large angle assembly -

f.

Pre-insulated Sleeves after

CEB SPECIFICATION 018 - 2 : 2006

compression of; i) ii) iii) 6. Phase cable Street lamp wire Neutral messenger -

Current rating of the pre-insulated sleeves / bi metallic lugs i) ii) iii) Phase cable. Street lamp wire Neutral messenger -

7.

Description of Dies Across flat dimension of dies to be used for i) ii) iii) Phase cable. Street lamp wire Neutral messenger -

8.

Current rating of the piercing connectors i) ii) iii) Type A - (1 bolts) Type B - (1 bolt) Type C - (1 bolt) -

--------------------------------------------------------------------------------SEAL AND SIGNATURE OF THE MANUFACTURER / BIDDER

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