Transmission & Distribution in Rural Power Supply Systems Design PDF

Renewable Energy Guidelines
Volume 8
Transmission & Distribution in Rural Power Supply Systems
Design ‐ Specification ‐ Installation
Pakistan Poverty Alleviation Fund, Islamabad

The Renewable Energy Guideline Series has been developed by the German‐Pakistan project “Development of
Hydropower and Renewable Energy (HRE) in Khyber‐Pakhtunkhwa”, funded by German Development Bank
(KfW) on behalf of “Ministry for Economic Cooperation and Development” (BMZ).
Pakistan Poverty Alleviation Fund (PPAF)
Project team:
Mr. Zaﬀar Pervez Sabri
Senior Group Head, Public Goods and Services
Mr. Kamal Afridi
General Manager, Water, Energy & Climate Change
Mr. Shaukat Ali
Renewable Energy Specialist

Contact address:
1‐Hill View Road, Banigalla, Islamabad
PAKISTAN
E‐mail: zaﬀar@ppaf.org.pk
Phone: (+92‐51) 261 3935‐50
Name of Consultants:
INTEGRATION
Team:
Dr. Ulrich Frings ‐ Team Leader
Mr. Sher Khan – Deputy Team Leader

www.integration.org
Author:
Ulrich Frings

Date: September, 2013
Copyright © Pakistan Poverty Alleviation Fund – 2013
Reproduction is authorized provided the source is acknowledged and provided a reference copy is being sent to
PPAF and the reproduction is not sold.
For further information: Pakistan Poverty Alleviation Fund, www.ppaf.org.pk
Note: The information contained within this document has been developed within a specific scope and might be
up‐dated in the future.

Volume 8
Transmission & Distribution

Guidelines & Manuals
Volume 1: Life Cycle Cost Analysis in MHP Planning
Volume 2: Community Contribution Aspects in Rural Power Supply Systems
Volume 3: General Design Criteria on MHPs
Volume 4: Design Aspects of Community PV Systems
Volume 5: Operation & Maintenance Aspects of MHPs
Volume 6: Quality Assurance & Control of Civil Works
Volume 7: Health, Safety & Environmental Aspects in Civil Works
Volume 8: Transmission & Distribution in Rural Power Supply Systems
Volume 9: Electro‐Mechanical Equipment for MHPs
Volume 10: Commissioning Guidelines PV ‐ MHP
Volume 11: Micro/Mini Hydropower Design Aspects
Volume 12: Civil Works in Rural Power Supply Systems

Renewable Energy Guidelines Nov. 2013 i
Volume 8
Table of Contents
1 Background ................................................................................................................................. 1
2 General information ................................................................................................................... 1
2.1 Specification standards and regulations ............................................................................. 1
3 Guidelines ................................................................................................................................... 2
3.1 Demand aspects .................................................................................................................. 2
3.2 Transmission & distribution ................................................................................................ 4
4 Documentation ......................................................................................................................... 13
4.1 Operation and maintenance manuals .............................................................................. 13
4.2 Installation and commissioning procedures ..................................................................... 14
4.3 Operation .......................................................................................................................... 14
5 General requirements and works ............................................................................................. 15
5.1 Electrical equipment/materials ........................................................................................ 15
5.2 Welding and heat treatment ............................................................................................ 17
5.3 Protection of machined surfaces ...................................................................................... 18
6 Erection and installation ........................................................................................................... 21
6.1 General .............................................................................................................................. 21
6.2 Safety practices ................................................................................................................. 21
6.3 Details of installation ........................................................................................................ 21
7 Testing and commissioning ...................................................................................................... 27
7.1 MV lines ............................................................................................................................ 27
7.2 LV lines .............................................................................................................................. 27
7.3 Acceptance ........................................................................................................................ 27
8 Technical specifications ............................................................................................................ 29
8.1 Overhead conductors ....................................................................................................... 29
8.2 Power cables ..................................................................................................................... 32
8.3 Stay wire............................................................................................................................ 35
8.4 Overhead conductor fittings ............................................................................................. 36
8.5 Insulators .......................................................................................................................... 38
8.6 LV outdoor distribution panels for step‐down transformers ........................................... 42
8.7 Distribution substations .................................................................................................... 45
8.8 Concrete poles .................................................................................................................. 49
8.9 Wooden poles ................................................................................................................... 53
8.10 Lattice steel poles ............................................................................................................. 57
8.11 Distribution transformers ................................................................................................. 60
8.12 Customer current meter boxes ......................................................................................... 66
8.13 Mini circuit breaker ........................................................................................................... 70
8.14 LV aerial bundled conductors (ABC) ................................................................................. 72
8.15 Accessories for LV aerial bundled conductor .................................................................... 75
8.16 Single‐phase and three‐phase electronic kWh meters ..................................................... 80
8.17 MV combined disconnector and fuse cut‐outs ................................................................. 83
8.18 Surge arresters .................................................................................................................. 92
8.19 11 kV cable ........................................................................................................................ 94
9 Spare parts, tools and site consumables .................................................................................. 97
9.1 Spare parts ........................................................................................................................ 97
9.2 Tools and appliances ......................................................................................................... 97
9.3 Site Consumables, lubricating oil and grease for first filling ............................................. 97
9.4 Specified spare parts and tools ......................................................................................... 97
10 Annexes .................................................................................................................................. 108

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List of tables
Table 3‐1: Demand figures .................................................................................................................... 3
Table 3‐2: Transmission line – main features ....................................................................................... 5
Table 3‐3: Summary of load flow analysis ........................................................................................... 11
Table 8‐1: Conductors: nominal area and overall diameter ............................................................... 29
Table 8‐2: Characteristics of ACSR conductors ................................................................................... 30
Table 8‐3: Measurements and tests for stay wire .............................................................................. 36
Table 8‐4: Performance characteristics – PIN insulator ...................................................................... 38
Table 8‐6: Performance characteristics – suspension insulator ......................................................... 40
Table 8‐8: Correlation of max. current and size of busbar ................................................................. 43
Table 8‐9: Cable sizing ......................................................................................................................... 46
Table 8‐10: Concrete poles ................................................................................................................. 51
Table 8‐11: Pole dimensions ................................................................................................................ 55
Table 8‐12: System requirements ....................................................................................................... 57
Table 8‐13: System requirements ....................................................................................................... 58
Table 8‐14: Loading test ...................................................................................................................... 59
Table 8‐15: MCB‐Characteristics ......................................................................................................... 71
Table 8‐16: Combined disconnector/fuse cut out .............................................................................. 84
Table 8‐17 Surge arrester performance characteristics ...................................................................... 92

Acronyms and abbreviations
A Ampere
AC Alternating Current
AKRSP Aga Khan Rural Support program
ACSR Aluminium Conductor Steel reinforced
CDM Clean Development Mechanism
CO Community Organizations
DC Direct Current
EC European Commission
ELC Electronic Load Controller
E&M Electro‐mechanic
FDC Flow Duration Curve
GI Galvanized Iron
GIS Geographic Information System
GIZ German Technical Cooperation
GOs Government Organization
GPS Global Positioning System
HDPE High Density Polyethylene
H&S Health & Safety
hrs hours
HV High Voltage
Hz Hertz (frequency unit)
INGOs International Non Governmental Organization
KfW German Development Bank
kW Kilo Watt
kWh Kilo Watt Hour
Renewable Energy Guidelines Nov. 2013 iii

Volume 8
kV Kilo Volt
LED Light‐Emitting Diode
Lit Liter
LSOs Local Support Organizations
LT Low Tension
LV Low Voltage
MCB Moulded Circuit Breaker
MCCB Moulded Case Circuit Breaker
MDPE Medium Density Polyethylene
MHP Mini/micro Hydropower Plant
MSDS Material Safety Data Sheets
NGOs Non‐Governmental Organizations
O&M Operation and Maintenance
PF Power Factor
PCD Pitch Circle Diameter
PPAF Pakistan Poverty Alleviation Fund
POs Partner Organizations (COs)
PPIB Private Power Infrastructure Board
PURE Productive Use of Renewable Energy
PPE Personal Protective Equipment
PV Photovoltaics
PVC Polyvenylchloride
SM Social Mobilizer
SRSP Sarhad Rural Support Program
RCBO Residual Current Breaker with Overload Protection
SSLS Solar Street/home Lighting System
Rs. Pakistani Rupees
T&D Transmission and Distribution
TOP Terms of Partnership
V Volt
WOs Women Organizations
XLPE Cross‐linked polyethylene
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1 Background
The series on technical guidelines and manuals aims to support the POs and COs in the design,
procurement of material and equipment, the supervision of construction, and the later sustainable
operation of the respective power supply system. The manual on Transmission and Distribution (T&D)
provides basic design criteria, necessary field data to be collected and the technical specifications as
basis for procurement.
The transmission and Distribution system is based on the Pakistani standard voltage which is 11 kV for
the transmission, 0.4 kV for the 3‐phase and 230 V for the 1‐phase distribution system. Power frequency
is 50 Hz.
Recommendations towards specific design criteria, material and equipment consider the envisaged
construction methodology and operation approach (both are community based) and the remoteness
and accessibility of construction sites.
2 General information
Within the project “Development of hydropower and renewable Energy in KPK” the construction of a
number of hydropower stations of capacities ranging from between 50 kW to 500 kW is planned.
The following guidelines and technical specifications are dealing with transmission and distribution
systems for rural electrification. They are valid for both hydropower and PV systems.
The POs shall design the respective systems according to the guidelines and shall ensure that the
equipment and material supplied and installed fulfill the below standards.
The compliance of design, material, and equipment with this technical guidelines & standards will be
checked during commissioning and final inspection of the respective subproject. Issuing of completion
and final acceptance certificates and the related final payment is strictly reliant on the complete
application of these technical guidelines & standards.
2.1 Specification standards and regulations
Unless otherwise specified, the Works shall be carried out in accordance with the current requirements
of:
 National Pakistan Standards
 The relevant International Electro‐technical Commission Standards (IEC)
 The relevant standards from the American Society of Mechanical Engineers (ASME)
 The relevant standards from the International Standards Organisation (ISO).

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3 Guidelines
In the following, the principle steps and basic considerations and assumptions to design a transmission
and distribution network in rural power supply systems are presented.
It starts with the assessment of demand and demand growth as basic data for system sizing. It is
followed by detailed discussions of technical parameter of the transmission and distribution system and
the respective calculations to be undertaken.
Standard equipment and configurations are compiled in Annex 2, design examples in Annex 3;.
3.1 Demand aspects
3.1.1 Households
Electricity demand usually varies according to the
 Settlement (urban / rural),
 Household size and households per compound,
 Wealth level,
 Potentials for productive use,
 Work and consumption pattern.
In principle electricity demand shall be calculated based on baseline surveys. If such surveys are not
available the following definitions may be applied:
 household size: 9 persons,
 No. of HH per compound: 1.0.
With respect to the design load, households are divided into 2 groups:
Normal household: Basic power demand for lighting, communication, kitchen appliances, etc.: Peak
load 1 kW.
Better off household: Use electric power for cooking and heating: Peak load 3 kW. These households will
have to pay a additional connection charge due to higher connection costs (cables, etc.( and they are
obliged to pay an upfront deposit to justify their capability to pay the higher bill.
In principle, people should be supported in using electric power for heating and cooking due to the
considerable higher impacts on environmental protection (forest conservation, greenhouse gas
mitigation, etc.). However, consumers should be able to pay for the higher electricity bill, the generation
capacity is sufficient, and the consumers are ready to implement load shifting measures as advised by
the power station1 the people should investments for cables, etc. to those who want (and can afford)
heating and cooking by using electric power

1
This could be limitation to either cooking or heating at the same time, shifting of heating to low load times and storage of heat in night storage
ovens
2 Renewable Energy Guidelines Nov. 2013
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3.1.2 Other consumer groups
Other consumers are divided into the following groups:
 Public
 Mosques
 Shops (normal daily article shops with 230 V AC, 1 phase electricity supply)
 Workshops (with 400 V, AC, 3 phase electricity supply).
Public, mosques
To determine the demand, public buildings such as administration, schools and mosques are treated
similarly to households. Load is calculated at 1 kW with a coincidence factor of 0.5 per connection.
Special loads have been calculated for Basic Health Units (BHU; 3 kW).
Shops – single phase services
Shops connected by a single‐phase service include retail shops, small restaurants, and small workshops
(e.g. electronic repair, photo‐copying shops). They usually have a single light bulb and some minor
electric appliances (e.g. TV, radio, tape, soldering station, small electric tools). Their load was estimated
at being 500 W with a unity coincidence factor (c.f.).
Workshops – three phase services
Workshops receiving a three phase supply comprise heavier machinery and equipment. (e.g. car, metal
workshops and carpenters). The maximum load is estimated at 3 kW with a c.f. of 0.5.
Table 3‐1: Demand figures
Item Load (kW) c.f.* Design load per
connection
Household rural 1: basic 1.0 0.5 0.5
Household rural 2: better off 3.0 0.5 1.5
Public service Institutions 1.0 1.0 1.0
Shops 0.5 0.5 0.25
Mosque 1.0 0.5 0.5
Work shop (3‐phase connection) 3.0 0.5 1.5
Note: c.f. Coincidence factor
Source: Own compilation

3.1.2.1 Estimated growth rates of electricity demand
Annual growth rate of electricity demand for consumptive purposes
Since there is an immediate and positive correlation between population growth, numbers of
households or families, numbers of electricity connections, it was decided to maintain an average 3%
p.a. growth rate for the electricity demand. However, migration is high in the project areas. It amount to
about 2%. The resulting growth rate is 1% per annum.
Annual growth rate of electricity demand for public and social services
The justification for a 1% p.a. growth rate of public electricity demand is less evident and needs further
investigation. Service growth rate in hospitals or schools are correlated with population growth, but
most of these services don’t use electricity yet or only marginal. In other cases it depends on
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government budget allocations or contributions of the Muslim community (mosques), etc. Nevertheless
it was decided to maintain this population‐related growth figure as well for the growth pattern of
electricity demand in public or social services, will be maintained for the time being at best
approximation, but the trend might be more iterative.
Annual growth rate of electricity demand in business development
The figure of 10% p.a. growth rate in the initial three to five years is based on (1) a rapid substitution
process to replace Diesel or Kerosene generators by electric motors for productive use; (2) the large
replacement of water mill flour grinders by more convenient electric flour mills; (3) the improving
general economic environment for business opportunities using electricity productively as soon as
electricity quality is assured; (4) observations of the general trends in other countries where electricity
has been newly installed. The figure 10% growth p.a. nevertheless is a first estimation which needs
further justifications and observations from practical cases. Also in this case the growth rate of
electricity demand for PURE might – after the first three to five years – settle on a lower rate in the
following years.
Other electricity unit standards to estimate demand
The standards applied are based on local conditions and observations, but should be verified by practical
experiences (e.g. kW connection capacity / school; kW connection capacity per BHU, etc.) and likely
growth potential. Presently, hardly any school is connected to an electricity grid or has its own
generator. But, as has been observed in other regions, there will be a trend for electricity demand for
lighting (evening literacy classes, installation of PC training centres in schools, or even teaching material
using electricity) as soon as budgets are allocated by government.
3.2 Transmission & distribution
Transmission and distribution systems networks convey the electric power from the power station to
the consumers. Transmission lines deals with medium or high voltage while distribution is based on low
voltage level, usually 0.4 and 0.23 kV.
3.2.1 Transmission line
Transmission lines are based on 11 kV voltage and comprise of overhead conductor (ACSR) mounted on
9 m or 12 m concrete or steel poles. Pole spacing and selection of required strength shall be based on
the site conditions including the need to locate poles:
 To adequately service the electrical load in the immediate area
 Clear of roads and vehicle and pedestrian access ways
 To ensure all safety and legal clearances above ground and separation from buildings and structures
are obtained all times
 For satisfactory access for construction, future maintenance and operational purposes
 To conveniently service consumer premises.
The average span for MV is anticipated to be approximately 80 m. For longer spans the design adopted
shall provide satisfactory mid‐span separation between conductors and sufficient free board.
The average span for joint MV/LV construction is anticipated to be approximately 50 m
The detailed design of the overhead line routes shall be based on existing routes. Routes shall be
surveyed and pegged prior to the preparation of the drawings. Construction shall follow the approved
drawings.
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The design may be based on standard designs given in Table 3‐2. Otherwise, the following calculations
and verifications need to be conducted:
 Mechanical strength calculations for all pole positions
 Sag and tension calculations for the proposed conductors
 Verification of safety clearances
 Electrical design of route, length and rating of each LV circuit
 Determination of LV neutral earthing points
 Verification of required transformer capacity.
All conductor sagging shall be in accordance with the prevailing ambient temperature.
Table 3‐2: Transmission line – main features
Pole configuration Horizontal type 3
phase conductor
Minimum vertical clearance
‐ ground accessible to pedestrians only 6.5 m
‐ open country 6.0 m
‐ roads, streets 7.0 m
‐ buildings, accessible points, flat roofs upon 5.0 m
which man may stand
‐ power line above trees 2.5 m
‐ power lines above steel structures 3.0 m
‐ power line above telecommunication lines 2.5 m
Normal span 80 m
Maximum span 110 m
Minimum depth of embedment of poles 1.5 m
Minimum horizontal phase to phase separation 1.8 m
Sag tension <22 kN
Wind pressure 380 N/m²
Ice thickness <9.5 mm
Source: Own compilations; the selected parameter follow Din VDE 101 and
Pakistani practice
ACSR conductors will be used, because they comply with the Pakistani standards. In addition, they do
have cost advantages over other conductor material and can at best withstand the climatic conditions in
the project area. Supporting poles are made of concrete of 9 – 12 m height. Special arrangements are
foreseen for road crossings in order to achieve sufficient ground clearance. The overhead line span
lengths vary with alignment conditions from between 50 to 110 m.
Suspension poles are planned at every 10th pole or in case of larger line angles (<30°). For lower line
angles, double supports with twin‐sets of pin insulators will be used.
Sectionalizers and/or reclosers should be provided in extended and large networks to ease starting of
the power station and to isolated fault section without shutting down the entire system.
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Figure 3‐1: Transmission line design ‐ Example

Source: Own compilations

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The final design of the MV network shall include but is not limited to:
 The number and route of MV lines
 The distances between poles
 A GIS location of all MV poles at the design stage
 A GIS based single line “as built” drawing of all MV lines including a GPS location of all poles, kind of
pole and kind of assembly.
The technical data of the 11 kV transmission system are as follows:
 Transmission:
o Voltage: 11 kV
o Conductor: ACSR; 120 mm²
o Poles: Concrete 9 ‐ 12 m
o 3 sectionalizers with 1 auto‐recloser if required
 Sub‐Stations:
o 2‐pole open air type
o Surge arrester/lightning protection
o Manual breaker (MCB) for each feeder line
o 1 main MCB for main line from transformer
o Electric control box with consumption meters, remote sensing devices, etc.
o Short circuit fuses
 Transformer:
o 11 kV/0.4 kV; ONAN; DNy5; uk=4.5%; pole mounted
3.2.2 Distribution network
The distribution network starts from the transformer sub‐station and comprises of the 0.4 kV feeder
network, meter boxes, the customer service lines and the handing over station at the customer’s
premises. The 0.4 kV feeders comprise of ABC cables fixed on 7 m steel tubes or house walls. Meter
boxes are installed at public places are feeder poles. From here double core service lines lead to the
customer’s premises. Design examples are shown in Annex 3.
The final design of the LV network from each distribution substation shall include but is not limited to:
 The number and route of LV distributors
 The cross section of LV wire to be used, based on a 8% maximum allowable voltage drop from the
transformer to the end of each LV distributor
 A location of all MV and LV poles and their distances in between at the design stage
 A GIS based single line “as built” drawing of all LV lines including a GPS location of all poles, kind of
pole and kind of assembly.
Additional sub‐distribution panels may be installed at points where diameter of ABC is reduced.

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The technical data for the 400/230 V distribution network are as follows:
 Distribution Feeder (0.4 kV)
o 0.4kV ABC conductor
o Design radius: 500 m – 700 m
o Public mounted meter boxes with 3 or 6 meters, equipped with one main MCB and MCBs for
every feeder line
 Customer Service Lines and House Connections (0.23 kV):
o Double core, double isolated 8 mm² Al for 1 kW peak load and 10 mm² for 3 kW peak load; 16 to
25 mm² for 3‐phase supplies
o Design load: 0.5 kW; 1.5 kW
o Coincidence factor: 0.5
o RCBO’s in houses selective to MCB’s.
3.2.2.1 Meter boxes
Meter boxes are made of a metal water proof cover and a lockable door and are installed at the feeder
poles. Installation at public locations is preferred because termination of the cable and installation of
the meter within the compound would be more difficult. However, the meters positioned in public
require additional safety devices or larger conductor diameters to safely interrupt power in case of
faults. Considerable attention has been given to minimise and optimise the number of meter boxes
required.
Meter boxes are installed close to a number of compounds each of which is supplied individually via
two‐core cables. The connection from the overhead feeder line to the meter box is done by using 4 x 16
– 25 mm² cables. The meter boxes will be installed in such a way that maximum length of compound
connections is about 50 m with an average length of about 40 m.
Each box is protected via a MCCB fuse breaker of respective size. The number of meters installed in each
meter box varies between 3 and 6 and care must be taken to balance the load distribution between the
three‐phases. Each outgoing line is protected by a MCCB of reasonable size (10 A to 16 A).
3.2.2.2 Compound connection cables
The consumers are to be connected from the meter boxes via a 2 x 8 mm² or 2 x 10 mm² Aluminium
cable. With a design load of 1 kW and a maximum length of 50 m, the voltage drop is well below 1%
(0.8% for 1,000 W). The permissible continuous rating of the connection cable is 45 A is also well above
the maximum expected load current of 5 A. Average length of compound connections is 40 m.
RCBO’s are installed in suitable boxes in each compound. De‐energizing of the compound can then be
achieved via the RCBO which is much faster and more sensitive against faults within the compound as it
can safely isolate all hazardous situations. The RCBO is designed with a current rating of 25 A and a
maximum fault current rating of 30 mA.
3.2.3 Transformer substations
All transformer substations are pole mounted. Transformers do have vector group of Dyn5, and off‐load
tap changer with minimum +/‐5% at 5 positions. The transformer capacity is calculated according to the
total load of all connected feeders. Standard transformer sizes are then used to select the unit required
for each substation.
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The sub‐station comprises of a 11 kV line breaker/disconnector, surge arrestors and high voltage fuses,
the transformer and the low‐voltage switchboard including a main MCB. In addition, a consumption
meter is installed. A typical lay‐out and single line diagram of this arrangement is presented in Annex 2.
Each 0.4 kV feeder can be individually switched via suitable MCBs. The sizes were calculated according
to nominal and fault currents ensuring that maximum fault currents can be withstood while the lowest
fault current (fault at the end of each feeder) is safely tripped. Consumption meters on the low voltage
side of the 20/0.4 kV transformer and on each 0.4 kV feeder will allow close and individual monitoring of
the losses along every feeder line.
The total number of transformers is based on the maximum supply area which is determined by the
maximum permissible power losses or voltage drop which was set at about 8%, which will, together with
the 20 kV voltage drops of about 2% (maximum 3%) lead to a total voltage drop of about 10% which
seems acceptable for the supply system. For concentrated settlement parts, the supply radius of one
transformer is about 500 m while in villages where houses are more scattered and total load is less,
supply radius may reach 600 to 700 m. However, the maximum permissible voltage drop of 8% should
be never exceeded.
3.2.4 Earthing system
Proper earthing is required to ensure consumer personal safety and equipment protection. It is
therefore imperative to achieve a sufficiently low earth resistance to allow the passage of sufficient
current to operate relays or blow fuses. The switchyard and sub‐station earthing system resistances
should therefore be less or equal to 2.0 Ώ. A detailed description of earthing system is compiled in
chapter 6.3.7.
The earthing system includes the following components:
 Switchyard and substations: Separate connections for surge arrestors, neutral point of transformers,
all metal fittings; mixed LV/MV earthing with resulting system lower resulting resistivity or separate
HV and LV earthing system with comparable higher tolerable system resistivity
 Earthing of all poles of the 11 kV transmission line
 0.4 kV distribution line: solidly earthed at substation; earthing of every 10 ‐12th pole, and the
terminal pole of every feeder
 3‐phase workshops: Separate earthing and installation of T‐N system.
3.2.5 Control & protection
The operation of an isolated supply system presents a challenge with respect to a sustainable operation.
Beside the voltage and frequency regulation which may be problematical in case of tripping single high
loads, problems may arise through transient voltage peaks due to lightning or switching, temporary
faults along the transmission overhead line, and through permanent system faults.
Voltage and frequency regulation will be done via the main control system in the power station. With
respect to transient voltage peaks and temporary/permanent faults line sectionalizers and/or recloser
may be installed. The recloser will deal with all transient fault problems while the sectionalizer allows
permanently faulty sections of the transmission overhead line to be isolated while keeping the
remaining sections in operation
The power station should be started under no‐load or part load conditions. Thus, a number of
substations have to be disconnected prior to starting generation. Switching and control of the
substations will be done either manually at each sub‐station or via a remote control system that trips a
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motor driven main switch at the substation. The control system also provides indication of the
operational status of the substation MCB back at the power station’s control room.
3.2.6 Load flow analysis
Comprehensive load flow analyses are required carried out for both the transmission and the
distribution system. The results shall confirm that all standards are met and all safety and protection
devices are fully functioning.
3.2.6.1 Transmission line and sub‐stations
The load flow analysis for the transmission system comprises the transmission line from the power
station to the LV side of the substation transformers. Individual loads per feeder and power losses along
the feeder lines were determined assuming full load conditions. System inputs are as follows:
 Maximum generation capacity: In MVA
 Transmission line (120 mm², ACSR): Length, material, size
 Transformer substations: number, total Capacity in MVA
 Distribution feeders: number, total length, total design load
 Permissible voltage drops: 3.0%
 Load and generation acceleration factor: 1.0
 Solution method: exact (iterative)
 Source impedances: included.


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The analyses shall confirm that the system operates under stable conditions and all standards are
satisfied. All results are summarized in a table (example see Box 1).
Box 1: Results of load flow analysis – Golain Astore project
Table 3‐3: Summary of load flow analysis
Item Voltage drop Σ Losses
VD % kW KVAr KVA
Transformer 0.27 – 1.31 2.4 6.0 24.7
Lines 0.1 ‐ 0.3 0.1 18.5 18.5
Total 0.37 – 1.61 2.5 24.5 24.7
Total installed generation capacity 500.0 125.0 625.0
Total power demand 229.6 97.6 249.5
Load factor of power station* 46%
Power factor 0.92
Source: Own compilations, Annex V‐5.5.1
*Load factor: power demand /capacity installed
Voltage losses at transformer varies between 0.27% and 1.31%; losses along the transmission line
are due to the low load about zero. Thus, total losses are well below the set target of 3%.
The load factor of 46% indicates that sufficient capacity for the supply and further grid extensions
are available. The power factor of 0.92 indicates sufficient reactive power (power factor of
generators = 0.8).
3.2.6.2 Feeder lines
The calculation of conductor/cable size is based on the maximum permissible voltage drop of about 8%
and the minimum current flow required to safely activate the respective tripping devices in the
substation in the event of a fault and feeder loading in excess of the maximum permissible current
rating of the cable. As example the resulting data for Golain Astore projects are compiled in Annex 2.
Voltage drop is well below 1% at a cable size of 35 mm².
The results are compiled in Annex V‐5.5.2. Except one feeder (feeder 1 in TF 1) with a voltage loss of 7%
all other figures are well below 3.3%. The nominal cable diameters vary between 16 mm² and 35 mm²
but should be unified at 35 mm² due to easier handling and stock keeping. The total length of the 400 V
feeders to be erected is estimated at about 36 km.
3.2.7 Fault analysis
Fault studies should be undertaken separately for the distribution system including compound
connections. Short circuit faults along the compound lines are tripped by the MCCB’s in the meter
boxes, while fault current along the 400 V feeders are tripped by the MCB’s in the substations.
Transmission Line
Short circuit studies for the transmission system are based on the 11 kV overhead line. The results of the
short circuit analyses, which should include balanced and unbalanced fault events and which should
indicate that in all cases and for all voltage levels, fault currents are well above the nominal current
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which is required for the safe tripping of short circuit currents. The results are used to further specify
the fuses and current ratings of the circuit breaking devices installed on the 11 kV line.
3.2.7.1 Feeder lines and compound connections
Fault currents at the LV system depend on the entire system impedances and should be calculated for
the following cases:
 Three‐phase balanced short circuit at the substation to determine the maximum system fault current
which has to be withstood by the equipment installed
 Single line‐ground short circuit at the meter box which represents the minimum fault current that
has to be safely tripped
 Single line‐ground short circuit at compound entrance representing the minimum fault currents to be
tripped by the MCCB’s in the meter boxes.
The results for Golain Astore are compiled in Annex 2. According to the results, MCB rating is 40 A at all
feeder lines. The fault current is at minimum 80 A for single and 660 A for three‐phase short circuit. All
feeders will be safely tripped by the 25 A MCBs.


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4 Documentation
4.1 Operation and maintenance manuals
The O & M manuals shall contain the following information in sufficient detail to enable the operator to
maintain, dismantle, reassemble, adjust and operate the works with all its items of works and
installations:
4.1.1 Table of contents
a) List of illustrations
b) Introduction
c) Detailed description
Detailed description shall contain a complete and accurate description of the works, all components
and ancillary equipment, their assembling and dismantling. An accurate list stating clearances,
tolerances, temperatures, fits, etc. shall be included.
d) Operating principles and characteristics
A brief summary of the technical operating principles of the works, including diagrams, circuit
diagrams, sequence diagrams, piping, etc.
e) Operating instructions
The instructions shall contain the sequence of individual manipulations required for operation.
Tables, lists and graphic presentations should be used whenever possible for making the description
readily understandable. An appropriate trouble‐shooting list shall be included in this chapter.
f) Testing and adjustment
The entire testing and adjustment procedure required for the works after overhauls and during
operation shall be described.
g) Maintenance instructions
This section is divided into the following paragraphs:
i) Preventive maintenance, indicating the inspections required at regular intervals, the routine
cleaning and lubricating operations, the regular safety checks and similar steps.
The maintenance instructions shall include a tabular summary of the required activities sorted
according to
 Daily
 Weekly
 Monthly
 Quarterly
 Yearly
 (Or other) cycles as applicable.
ii) Repair and adjustment procedures including fault tracing
iii) Spare part lists, containing all the necessary data for ordering spare parts. Detailed drawing for
each item of spare parts shall be supplied. The above list should include minimum and maximum
quantities of spares to be maintained by the project.
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iv) Tool lists, containing all necessary data of tools required
v) List of Suppliers of bought out items and their contact details.
vi) As‐built drawings.
4.2 Installation and commissioning procedures
The installations procedures shall describe in sequential steps the erection of major equipment and shall
contain sufficient details such as equipment preparation at work shop, handling of large and heavy
pieces, levelling, anchoring, site welding, site painting, erection checks, site pressure tests, site flushing
and cleaning of hydraulic systems, alignment and run out checks to allow the Operator to plan and
supervise the works at site, if required. The documentation shall contain the log sheets for taking
measurements during installation.
Pre‐commissioning tests and procedures shall be described in sequential steps for the pre‐
commissioning of all electrical and mechanical equipment and shall also contain sufficient details viz.
checking of installations, ratings, cable terminal checking and operation test of all auxiliary equipment
etc. necessary log sheets shall be annexed to facilitate proper recording of test results.
The commissioning procedures shall sequentially and in sufficient detail describe activities and tests for
all systems covered by the contract.
4.3 Operation
The operation should contain a detailed description of start and stop sequences, emergency measures,
identification of major fault and resolving thereof, all maintenance works and schedules and additional
useful information to sustainably operate the power station.


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5 General requirements and works
5.1 Electrical equipment/materials
5.1.1 General
All components shall be of an approved and reliable design. The highest extent of uniformity and
interchange ability shall be reached. The design shall facilitate maintenance and repair of the
components.
Unless otherwise stated, ratings of main electrical works (in feeds, bus‐ties), whether originally specified
or not, shall generally include a safety margin of 10% under consideration of the worst case to be met in
service.
Short‐circuit calculations shall be evaluated giving full evidence that every electrical component can
withstand the maximum stresses under fault conditions, for fault levels and durations obtained under
the worst conditions e.g. upon failure of the corresponding main protection device and time delayed
fault clearing by the back‐up protection device.
All works shall be suitable for the prevailing climatic conditions.
5.1.2 Moulded case circuit breakers
All moulded case circuit breakers shall be of 2 or 3‐pole type as required, having thermal time delay and
instantaneous trips with "On‐Trip‐Off", indicating / operating mechanism. Circuit breakers used in
combination type motor starters or contactors shall have the operating mechanisms interlocked with
the starter or contactor cover so that the cover cannot be opened unless the circuit breaker is open. The
breakers shall comply with applicable section of IEC 157/1 or equivalent standards.
5.1.3 Control relays
Relays used as auxiliary control devices in conjunction with motor starters and magnetic contactors shall
be of the type designed for machine tool application featuring contact convertibility. All contacts shall
have a minimum thermal current rating of 10 A over a range of 6 to 600 V AC.
5.1.4 Terminal blocks
All terminal blocks shall be mounted in an accessible position with the spacing between adjacent blocks
not less than 100 mm and space between the bottom blocks and the cable gland plate being a minimum
of 200 mm. Sufficient terminals shall be provided to allow for the connection of all incoming and
outgoing cables, including spare conductors and drain wires. In addition 20 percent spare terminals shall
be provided. In enclosed cubicles, the terminal blocks shall be inclined toward the door for facilitating
terminations.
Terminals shall be of the channel mounting type and shall comprise a system of individual terminals so
that terminal blocks can be formed for easy and convenient cabling consistent with the high reliability
required of the circuits.
Terminal blocks shall be provided with shorting links and paralleling links where applicable and
mounting identification numbers and / or letters.
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Terminal blocks shall conform to the applicable standards. The smallest size to be used shall be
designated for 2.5 mm² wire and not more than two conductors shall be connected under one terminal
clamp.
Terminal identification shall be provided corresponding to wire number of connected leads.
Circuit terminals for 415 V AC shall be segregated from other terminals and shall be equipped with non‐
inflammable, transparent covers to prevent contact with live parts. Warning labels with red lettering
shall be mounted thereon in a conspicuous position.
5.1.5 Equipment wiring
All wiring connections shall be readily accessible and removable for test or other purposes. Wiring
between terminals of the various devices shall be point to point.
Multi‐conductor cables shall be connected to the terminal blocks in such a manner as to minimise
crossovers. Approved claw washers of crimp type connector shall be used to terminate all small wiring.
Each conductor shall be individually identified at both ends through a system providing ready and
permanent identification, utilising slip‐on ferrules
Markers may be typed individually or made up from sets of numbers and letters firmly held in place.
Open markers shall not be accepted.
Markers must withstand the local environment and only fungus proof materials will be accepted.
Ferrules of adhesive type are not acceptable.
All trip circuits shall employ markers having a red background.
5.1.6 Cubicles and control panels
Cubicles and control panel enclosures shall be of sheet steel with minimum thickness of 2.5 mm, of rigid
self‐supporting construction and supplied with channel bases.
Cubicles shall be fitted with close fitting, gasketted, hinged, lift‐off doors capable of being opened
through 180 deg. The doors shall be provided with integral lock and master key.
Cubicles and panels shall be vermin proof. Removable gland plates shall be supplied and located to
provide adequate working clearance for the termination of cables. The cables and wiring shall enter
from bottom or top.
The cubicles and panels shall be adequately ventilated, if required, by vents or louvers. All ventilating
openings shall be provided with corrosion‐resistant metal screens or a suitable filter to prevent entrance
of insects or vermin. Space heating elements with thermostatic control shall be included in each panel.
Where cubicles are split between panels for shipping, terminal blocks shall be provided on each side of
the split with all necessary cable extensions across the splits. These cable extensions shall be confined
within the panels with suitable internal cable ducts.
Unless stated otherwise, all cubicles and panels shall be provided with a ground bus with 40 mm copper
bar extending throughout the length. Each end of this bus shall be drilled and provided with lugs for
connecting ground cables ranging from 70 to 240 mm².
All instruments, control knobs and indicating lamps shall be flush mounted on the panels. Relays and
other devices sensitive to vibration shall not be installed on doors or hinged panels and no equipment
shall be installed on rear access doors.

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The instrument and control wiring including all electrical interlocks and all interconnecting wiring
between sections shall be completely installed and connected to terminal blocks by the manufacturer.
The interior of all cubicles and panels shall have a mat white finish unless specified otherwise.
Switched interior light and socket outlets shall be provided for all cubicles and control panels.
All cubicles and control panels shall be provided with nameplates, identifying the purpose of the panel
and all of its components.
All cubicles, switch gear cabinets and control panels shall be protected to IP 54.
5.1.7 Earthing
Provision shall be made for earthing all equipment intended for connection in an A.C. mains supply. All
structural metal work and metal chassis shall be connected to earth. Connection between circuits and
metal work shall only be made for reasons of safety and / or reduction of interference. Where such
connections are made, they shall not be used as normal current carrying earth returns.
Earthing conductors shall be at least equal in cross sectional area to the supply conductors and shall be
capable of carrying the fault current.
5.2 Welding and heat treatment
5.2.1 Welding
All welding (except welding of thin plates or piping of small sizes) shall be performed by electric‐arc
method and where practical, with process‐controlled automatic machines.
Butt welds can be welded from one side only and shall be provided with back strips on the whole length
of the seam to be welded.
After being deposited, welds shall be cleaned of slag and shall show uniform sections, smoothness of
weld metal, feather edges without overlap, and no porosity and clinker. Visual inspection of the ends of
welds shall indicate good fusion with the base metal.
Where weld metal is deposited in successive layers, each layer shall be thoroughly preened before the
next layer is applied.
All welds transverse to the direction of flow shall be ground flush with the plates on the inside. Welds
shall be ground flush on both the inside and the outside wherever dynamic stress occurs.
Particular care shall be taken in aligning and separating the edges of the members to be joined by butt‐
welding so that complete penetration and fusion at the bottom of the joint will be ensured. Where fillet
welds are used, the members shall fit closely and shall be held together during welding.
The cut surfaces of plates requiring weld joints shall be free of all visible defects, such as laminations,
surface defects caused by shearing or flame‐cutting operations. The edges and surfaces to be welded
shall be free of rust, mill scale, grease, oil, paint or any other foreign matter. Welding over painted
surface shall be prohibited ‐ all painting materials next to the joint to be welded shall be removed well
beyond the heat‐affected zone.
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5.2.2 Welding qualifications
For welding of principal stress carrying parts, the standard of welding procedures, welders and welding
operators shall conform to standards equivalent to the requirements of the ASME Boiler and Pressure
Vessel Code, Sections VIII and IX, or DIN 8560, DIN 8563 and EN 287.
All welders and welding operators assigned to the work shall have passed a performance qualification
test. If more than one year has elapsed since the welder or welding operator passed his last test, then
he shall again be tested.
5.2.3 Quality and procedure control
Quality control methods e.g. radiography, ultrasonic crack detection etc. shall be done in accordance
with the appropriate manufacturing code. However, the Supplier shall indicate clearly in the technical
data sheets the extent to which these methods shall be used.
All welded joints, which have to be tight, shall be inspected or tested by dye penetration tests.
All major welds carried out on parts under hydraulic pressure shall be at least 10% radio‐graphically and
100% ultrasonic examined. All welds on the skin‐plates shall be additional dye penetration tested as
directed by the Engineer.
The Supplier shall indicate in the corresponding drawings the type of non‐destructive testing to be
carried out during manufacture and at site.
5.2.4 Defects and repairs
Plates with laminations discovered after cutting shall be rejected unless the laminated portion is only
local and can easily be repaired; such repairs shall require the consent of the Engineer.
Defects in welds, which are to be repaired, shall be chipped out to sound metal and the areas to be DP
(Dye penetration) or ultrasonically tested to ensure that the defective material has been completely
removed before repair of welding is carried out. Repairs shall be carried out in accordance with the
relevant standards and to the approval of the Engineer. The Supplier shall be fully responsible for the in‐
service performance of all welding work.
The Work shall be 100% inspected again by the method used first to determine such faulty work.
5.2.5 Heat treatment
Heat treatment shall be performed on all fabricated parts which are stressed during fabrication as per
the approved heat treatment / weld procedure and are to be finish machined.
Heat treatment of field erection welding seams shall be performed according to the specifications for
the welding procedure for the corresponding parts, which shall be submitted to the Engineer for
approval.
5.3 Protection of machined surfaces
5.3.1 General
Machine‐finished surfaces shall be thoroughly cleaned of foreign matter. Finished surfaces of large parts
and other surfaces shall be protected with wooden pads or other suitable means. Unassembled pins or

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bolts shall be oiled or greased and wrapped with moisture‐resistant paper or protected by other
approved means.
5.3.2 Corrosion protection
All ferrous metal work shall be provided with an effective painted or galvanized finish, applied in
accordance with the best practice to protect from corrosion.
5.3.3 Painting
5.3.3.1 Surface preparation
All surfaces to be painted shall be thoroughly cleaned by suitable means before application of paint.
After cleaning the surfaces shall be rinsed in a manner that no residues will remain.
For removing rust and mill scale on structural steel, piping and other steel surfaces, particularly parts
which will be in contact with water, exposed to heavy condensation and humidity or subjected to high
temperature shall be sandblasted (sandblasting SA 2.5). Parts which cannot be sandblasted, shall be
cleaned of rust by power tool cleaning to the highest degree possible.
The clean surfaces which are in contact with water shall receive a shop coat with a quick‐drying highly
pigmented 2‐pack zinc‐rich primer (e.g. Inertol R, 60 µm each) and three final coats (e.g. Inertol Poxitar
F, 100 µm each), unless otherwise specified.
The clean surfaces which are in contact with air shall receive a shop coat with a quick‐drying highly
pigmented 2‐pack zinc‐rich primer (e.g. Inertol R, 80 µm each) and one final coat (e.g. PVC‐single‐layer
lacquer, 80 µm), unless otherwise specified.
Primed surfaces contaminated with oil or grease shall be de‐greased in a manner not affecting the
quality of the primer. 2‐component coatings older than six (6) months shall be roughened prior to the
application of the next coat.
5.3.3.2 Application procedure
The most commonly used methods of application are painting by brush, roller, pressure and airless
spraying equipment. Selection of the application method depends on the surface to be painted.
For all paints the surface temperature of the metal shall not be higher than +50*C during the painting.
Concerning special paints, the requirements set by the paint manufacturer shall be followed. All painting
shall be free of cracks and blisters and all runs shall be brushed out immediately. After application of the
last coat the paint system shall be free of pores.
Metallic parts, which are embedded in concrete, shall be painted with cement base paints.
5.3.3.3 Galvanizing
Unless otherwise specified, all fasteners and steel structures of exterior and interior steel surfaces of
outdoor Works shall be hot‐dip galvanized or electrolytically galvanized. For galvanizing, only original
blast furnace raw zinc shall be applied, which shall have a purity of 98.5%.
The thickness of the zinc coat shall be:
 For bolts and nuts of sizes above M36 approx. 60 micrometer and for sizes below M36 25
micrometer.
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 For all other parts, except for hydraulic steel structures or parts intermittently or permanently
submerged in water, approx. 50 micrometer
 For hydraulic steel structures or parts intermittently or permanently submerged in water, approx.
100 micrometer.
Cleaning: All material to be galvanized shall be cleaned carefully of rust, loose scale, dirt, oil, grease, and
other foreign matters. Particular care shall be taken to clean slag from welded areas.
Galvanizing of hardware: Bolts, nuts, washers, locknuts and similar hardware shall be galvanized in
accordance with the relevant standards.
Straightening after galvanizing: All plates and shapes, which have been warped by the galvanizing
process, shall be straightened by being re‐rolled or pressed without injury to the protective coating.
Materials that have been harmfully bent or warped in the process of fabrication or galvanizing shall be
rejected.
5.3.4 Bolts, screws, nuts, etc.
All bolts, studs, screws, nuts and washers shall be to the ISO metric system. Mild steel bolts and nuts
shall be of precision cold forged or hot forged type with machined faces parallel to one another.
All parts, other than structural steel work, bolted together shall be spot faced on the back to ensure that
nuts and bolt heads bed down satisfactorily. Mild steel nuts and bolts shall be zinc or cadmium plated.
Stainless steel bolts, nuts, washers and screws shall be used for holding renewable parts in water or
when exposed to high humidity
All bolts or studs which will be subject to high stress and / or temperature shall be of approved high
tensile material with nuts of approved material. All bolts and studs larger than M60 shall be drilled for
heaters or shall have an extension for pre‐tensioning by hydraulic tools.
Fitted bolts shall be a driving fit in the reamed holes they occupy, shall have the screwed portion of a
diameter such that it will not be damaged in driving and shall be marked in a conspicuous position to
ensure correct assembly at site.


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6 Erection and installation
6.1 General
These works include but are not limited to the installation of poles, cross arms, pins, insulators,
hardware, conductors, transformers, relays, fuse cut‐outs, surge arresters; the installation of
transformer boxes, of grounding and stay wires and other support structures and anchors; the
installation of cables.
The PO shall comply with all applicable and approved safety regulations while carrying out the works on
site. He shall be responsible for adequate protection of persons, plant and materials against injuries and
damages resulting from his operations.
6.2 Safety practices
All works shall be undertaken with close attention to high standards of safety to workers, to the public
and to the plant and equipment.
All of the workers shall be effectively trained and competent in safe working practices that must be
adhered to at all times. All personnel shall be issued with and use relevant personal and work team
related safety equipment at all times. The safety equipment shall be maintained in good order and
condition.
Personal safety equipment for linemen and others working on the network shall include but not be
limited to:
 Safety helmet
 Protective gloves
In addition linemen who work on poles or from ladders or elevated platforms shall be supplied with and
use at all times:
 Safety belts and/or harnesses
 Insulating gloves when working on or in proximity to energized LV circuits
 Suitable rated insulated gloves when operating energized MV equipment.
6.3 Details of installation
6.3.1 Erection of poles
In order to prevent obstruction of entrances, windows, driveways and for placement of stays (guys) the
PO shall be responsible for the field verification of pole location to prevent obstructions as mentioned
above prior the commencement of excavation works.
The types of poles included in the specifications shall be used for design taking into account system
requirements, height of installations and loading conditions.
The embedding of poles shall be made in accordance with the respective standard and the dimensions
indicated therein shall be maintained in all cases, with tolerances of 75 mm. The 11 kV poles shall be
made of r/f concrete of round or rectangular shape or lattice steel poles according to the respective
Pakistani Standards.
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ABC cable are fixed on 7 m concrete, steel, or wooden poles. Installation at house walls shall be
considered as an option within villages.
Pole erection shall be made using the equipment and erection techniques that guarantee an erection
free of shocks causing cracks to the poles.
After installation, poles shall be perpendicular and perfectly aligned unless otherwise stated on
drawings.
6.3.2 Erection of stay wires
Anchored guys shall be used on dead‐end poles or any other pole specified in the drawings and/or
required standards.
Stay wires shall avoid interference with line conductors at all times. Stays shall be attached to the pole
or the structure as close as possible to the conductors load centre. Stays shall have an angle not less
than 45° and not greater than 60° in reference to ground level. Stays shall be solidly anchored to the
ground with proper anchors and with depth as specified on standards in order to support the tension
stress. Stays shall be anchored with specified type of galvanized steel anchor rod, and secured to above‐
mentioned anchor.
All stays are to be equipped with insulators of appropriate type. The insulators shall be installed in such
a height that the upper part of the stay wire cannot be touched.
Stays shall be installed before tensioning line conductors and shall have enough tension to slightly
incline the poles in the opposite direction to the line, in such a manner that after tensioning the line
conductor pole acquires its vertical position and shall not yield in any case.
6.3.3 Line construction
MV and LV construction shall be in accordance with Pakistani standards. Poles shall be transported and
handled with care. During transport the poles shall be supported along the full length with minimum
overhang. Lifting shall be done by suitable cranes using straps or slings that cannot damage the pole
surface. The straps and slings shall be applied at the designated lifting points only. Excavation shall be
minimal to permit satisfactory placement and compaction of the backfill. In poor ground bearing pads
for vertical loads shall be provided. Backfill material shall be of dry soil, or cement stabilized soil, or C12
concrete to achieve suitable strength.
All cross arms shall be fitted with two cross arm braces. All bolt heads and nuts that bear on concrete
surfaces shall be fitted with a washer. Pole through bolts, cross arm bolts and mounting bolts for other
equipment shall be long enough to fully engage nut and washer but shall not extend more than 25 mm
beyond the nut after correctly tightened. Anchor deadmen and guys shall be installed before the
conductors are erected. The alignment and tension of the guy wires shall be such as to ensure that the
guys correctly carry the design loads and that poles are plumb at the completion of the works. Pulling
out, tensioning and sagging of conductors shall be carried out in a manner that avoids damage or over
stressing of the conductor. All conductor joints and connectors shall be applied to specifically prepared
and cleaned surfaces using approved corrosion inhibitors. All fittings shall be applied in a workmanlike
manner fully in accordance with the manufacturer’s instructions. Combined disconnectors and dropout
fuses and surge arresters shall be installed in accordance with manufacturer’s instructions. The surge
arresters at distribution transformers shall be installed on the feeder side but as close as possible to the
combined disconnector & dropout fuses.
Necessary tree cleaning and suitably dispose of all debris from the construction site shall be carried out.

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The main specifications regarding installation of conductors used on designs for erection are briefly
described in the following.
Line conductors shall be supported by the structures and shall have cross sections as indicated on
drawings and design specifications.
Before conductor stringing, it shall be assured that no broken, cracked or scratched insulator exists and
that all insulators are of the required type.
The primary circuit conductors shall be supported by specified insulators and shall be fastened to it with
same type of conductor wire.
The primary conductors shall terminate on suspension insulators as specified, with preformed
conductors of proper size with cotter pin attachments at the insulator.
Line conductor splicing shall be made where required provided that splices are at distances greater than
10 m from support of the conductor and no more than one splice in one span.
Conductor splices shall be made using splice sleeves compression.
During stringing operations the conductors shall be carefully manipulated and be continuously inspected
to avoid any kinking or damage.
During stringing it is expressly forbidden to drag conductors over the street, ground, rocky or hard
surfaces, etc., where the conductor can be damaged.
While stringing, the conductor shall be carefully observed in order to eliminate damaged parts and to
avoid formation of knots, twists or premature breakages.
All stringing tools, jacks, wheels, sheaves, etc. shall be of proper type and shall avoid any damage to
conductor such as scratches, kinkings, abrasions etc. during stringing operations.
No line structure shall be brought out of place during stringing and tensioning of conductors.
No stringing and tensioning operations shall be made during periods of high wind or during night.
Stringing blocks (sheaves) shall be fixed on supports which are mounted on the poles to receive the
conductors in order to allow stringing of conductors.
Blocks for stringing and tensioning shall be of adequate diameter. All blocks shall be equipped with ball
or rolling bearings of high quality. The grooves shall be covered with a neoprene lining or in case of
stringing aluminium conductor grooves shall be made of a good aluminium alloy.
No splices or reparation sleeves (armour rods) shall be permitted through stringing blocks.
It shall not be permitted for conductors to hang in blocks for more than a stringing working day before it
is finally clipped in.
Conductors shall be strung by a controlled tension method (braked pull) in order to avoid contact with
the ground or any other object above ground level.
Conductors shall be sagged using a set of appliances (tensioning jacks, come along clamps, etc.)
connected in series to conductors through a dynamometer fixed on the pole where the conductor shall
be deadening. Then tension shall be applied by a tensioning jack until the dynamometer registers the
tension specified in the standard (it shall be necessary to increase tension to allow tension relief when
the apparatus are removed and the conductor is hanging from the insulator string). Gripping clamps
shall be installed immediately and shall be disconnected from all appliances. The air temperature during
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conductor stringing shall be measured by a certified glass thermometer which shall hang totally exposed
to the elements on the parallel conductor to the one being sagged.
Sag conductor values shall be verified on suspension spans according to the local standards and shall be
accepted within a tolerance of 12 mm for spans of 30 m, provided that conductors in same span have
the same sags.
The spans selected for sag checking shall be approximately equal to the ruling span in this line section
and supporting structures on both sides of the span shall preferably be at the same elevation.
6.3.4 Insulated conductors
Low voltage double, triple and quadruple conductors shall be installed following the guidelines
previously mentioned for bare conductor installation which are applicable to LV and according to the
respective standards.
In order not to damage insulation of the conductors during installation, it shall be completely forbidden
to allow conductors to be in contact with the ground. In addition blocks shall have adequate grooves to
accept three or four conductor cables without permitting any damage to them.
6.3.5 Insulators
6.3.5.1 Pin insulators
Pin insulators used on primary transmission and distribution lines shall be installed on the poles before
lifting and mounting of poles. Proper adjustment shall be verified for every element and the position of
the insulator slot in the direction of the line.
Prior to clipping in the conductor the insulators shall be inspected for for cleanliness, damage, groove
alignment, tightness of fixing elements, etc. and shall take the necessary steps to correct all mistakes.
6.3.5.2 Insulator strings
The assembly of insulator strings shall be done carefully, taking special precautions to assure that all
pins remain properly installed. Before proceeding with the assembly it shall be verified that all elements
do not have any defect and are clean.
The insulator string shall be installed on the erected pole in a careful manner in order to avoid shocks
which can cause damage to insulators when lifted.
6.3.5.3 Spool insulators
Spool insulators shall be installed on the corresponding pole attaching support in accordance with the
LV distribution standard, taking precautions to assure that the securing pin is properly installed.
Before installation the insulator shall be inspected to assure that it does not have any defect and is
clean.
6.3.6 Erection of transformers
Transformers shall be installed at support poles. Cut‐out mounting shall be made on pole structures in
an open position. Correct functioning and proper size of fuses shall be verified before mounting. All MV
and LV cable connections shall be made by using compression connectors.

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6.3.7 Earthing
6.3.7.1 General
Earthing layouts for MV and LV systems are compiled in Annex 2. The MV or LV buried earth grid shall
comprise of not less than three standard earth rods spaced 3 m or more in a triangular pattern around
the pole structure, substation, or equipment building. Where Site conditions make this impractical, the
earth grid shall comprise of not less than three standard earth rods spaced 2 m or more apart installed
in a straight line underneath the line of the overhead MV distributor. If additional earthing is required to
achieve the threshold, the earth grid shall be extended in a radial pattern with bare copper conductor
and rods at not less than 2 m spacing.
All earth connections on the distribution network shall be constructed with not less than 35 mm² copper
conductor. All leads from the equipment above ground on the pole or at the substation to the first earth
rod shall be PVC covered. Beyond the first earth rod direct buried 35 mm² copper conductor shall be
used. Copper conductor for earthing may be hard drawn or soft drawn. For mechanical protection, the
earth laid between 2.5 m above to 400 mm below ground shall be installed inside a 20 mm diameter
polyethylene pipe of black colour. The polyethylene pipe and conductor shall be secured to the pole by
stainless steel banding at intervals not less than 750 mm. All buried earth conductors shall be not less
than 450 mm below the ground.
All earth rods shall be made of extensible copper clad steel (or hot dip galvanized), normal length 1,500
x 15 mm diameter. Single or jointed earth rods shall be used as necessary to achieve a satisfactory earth
test. Rods shall be driven into the ground in such a way that the top is not less than 450 mm below the
surface. The earth rod assembly shall be fitted with a purpose designed clamp suitable for up to three
35 mm² copper conductors.
6.3.7.2 MV earthing requirements
Within the MV network all exposed metal work shall be directly earthed to the locally established
earthing system fitted with a test link. Locations include distribution transformer substations, switching
stations, etc. The maximum resistance of the local earth grid shall be not more than 3 Ohm. MV
lightning arresters shall be earthed by an independent connection but may utilize the same earth grid as
other MC equipment. A test link must not be inserted in any lightning arrestor earth connection.
All exposed metal at the substation including transformer tank, transformer bearers, MV fuse supports,
LV cubicle frame, etc. shall be inter connected and connected to the ground with a copper conductor of
not less than 35 mm² cross section preferably in a ring circuit.
6.3.7.3 LV earthing construction requirements
The overall resistivity of the LV distribution system shall be less than 2 Ohm. Where the recommended
practices are followed the overall value will usually be less than 1 Ohm.
At every distribution transformer substation two LV earth grids shall be installed, one each at the first LV
pole away from the transformer at two different LV distributors. This is necessary to ensure sufficient
separation from the MV earth grid at the transformer. Each grid shall be directly connected to the LV
neutral. The earth lead to each of these earth grids shall be fitted with a test link located on the pole just
above the polyethylene pipe and arranged in such a way to isolate the system neutral from the earth
grid for testing. The test link shall be insulated or positioned so that it does not make electrical contact
with the pole when opened. Each of these earth grids must have a measured resistivity of not greater
than 2 Ohm. The provision of two separate earth grids provides security against damage to one of them
and allows for routine testing.
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In case installation of two LV earth grids is not possible on separate poles away from the transformer,
one of the LV grids may be installed adjacent to the transformer pole provided it is separated by less
than 5 m from any part of the MV grid and the buried leads to the LV grid are electrically independent
(e.g. PCV covered conductor installed in polyethylene pipe).
The LV neutral shall be earthed at every third or fourth pole and at least every 200 m, and at all meter
boxes, and at the end of each LV distributor. Earth connections along the LV distributor and at the ends
of the distributor shall comprise a single earth stake solidly connected to the neutral conductor with
35 mm² copper PCV covered conductor. No test link is required. Where LV distributors from adjacent
transformers meet the neutral shall be interconnected and earthed.
6.3.7.4 Earth rods
Earth rods shall be of 19 mm diameter solid copper with integral driving head and shall be provided of 3
m length. Three rods of each size shall be provided for each distribution transformer.
Earth rod clamps shall be of high copper content alloy and provided with stainless steel U‐bolts. The
clamps shall be suitable for either parallel or right angle connection.
PVC water pipe shall be supplied for protection of the 35 mm² earthing conductor used in the
distribution substations. The PVC water pipes shall have 20 mm internal diameter, be UV resistant and
conform to BS 3505 or similar standard and be supplied in 4 m length. For earthings at houses
galvanized steel rods of 1.50 length can be used, always provided that the final maximum resistivity is
achieved.
6.3.7.5 Copper earthing conductor
Insulated Copper earthing conductor is required for outdoor earthing of MV and LV overhead line
equipment. The conductor shall be single core stranded high conductivity annealed copper conductor,
with extruded black PVC and yellow/green XLPE insulation of nominal 1.0 mm thickness; nominal core
size is 35 mm² and 10 mm² for house earthings. The cable shall be rated for 600/1000 V. The conductor
shall be supplied in drums.
Terminal lugs shall be of heavily tinned high purity copper and of compression type pre‐filled with
compound.


Volume 8

7 Testing and commissioning
7.1 MV lines
All primary lines shall be energized, in accordance with local standard procedures.
Voltage measurements shall be made on metallic parts of the structures and guying cables to detect
possible leakage voltage. If such voltages are found, the PO shall proceed to eliminate them with the
necessary corrections.
All loose insulators and insulator ties causing radio interference shall be corrected.
Load measurements shall be made on high voltage lines at the departure structures of the substation,
and load shall be balanced.
Proper phasing of lines at all 90° angles and sectionalizing switches to preserve the same existing phase
sequence to all customers is to be assured.
Primary voltages shall be measured at substation departure structures, at each sectionalizing switch and
other suitable locations.
Special precautions shall be taken to have the same phase sequencing in circuits of different substations
when these circuits are provided with transfer switches.
The load shall be balanced to ±15% of unbalance between phases or 10% difference between the
maximum and minimum values in amperes during peak hour.
7.2 LV lines
All secondary lines shall be disconnected from the feeding transformer(s) prior to energizing of
transformer(s).
The rotation at each three phase customer entrance shall be observed, marked, and disconnected and
rotation of new feed verified prior to reconnection of service from new secondary feed.
The transformer(s) shall be energized and no secondary load voltage shall be measured at the bushing. If
the voltage is correct, then the secondary lines will be connected to the transformer(s) bushings. Prior
to connecting three phase services, the voltage and rotation shall be verified to be correct.
If after connecting the secondary lines to the transformer bushing and prior to connecting any
customer, there is a short circuit in the lines, the reasons shall be identified and measures for short‐cut
clearance to be undertaken.
The load shall be balanced to to ±5% unbalance between phases, or 10% of the difference between
maximum and minimum values in amperes during peak hour on each transformer.
No distribution transformer shall have loads exceeding 150% of nominal capacity during peak hour.
7.3 Acceptance
The taking‐over testing of any part or section of the permanent works which can operate as an
independent unit, shall be performed as per the test procedure agreed upon.
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Immediately upon termination of any such testing of a part or section of the permanent works a
"protocol of acceptance" which shall be deemed to be the test certificate.
This document shall be signed by an authorized representative of the Client (PPAF), the PO and the CO,
and shall form an integral part of the later "taking‐over certificate".
This "protocol of acceptance" shall state:
 The date of testing
 The quantity and type of works concerned
 Statement of all minor defects which have to be corrected by the PO/CO
 Confirmation that the guaranteed data have been proven.
If any test for the verification of the guaranteed data could not be performed for operational reasons,
this part of the acceptance shall be stated in the "protocol of acceptance" and be postponed for a
mutually agreed period.


Volume 8

8 Technical specifications
The technical specifications describe the quality requirements of the various parts. The specifications
shall be included in the request for quotations or tender procedure. All material and equipment supplied
and installed shall be according to these specifications.
The compliance of all material and equipment used shall be guaranteed and confirmed by the site
engineer and shall be subject to revision during commissioning.
All materials, whether fully specified herein or not, shall be of first class quality particularly with regard
to manufacture, strength, ductility and durability and shall conform to the best modern practice and
comply in all respects with these Specifications.
8.1 Overhead conductors
8.1.1 Conductor drums
Overhead conductors shall be delivered wound on strong wooden drums treated to an approved
international standard by vacuum impregnation with copper‐chrome‐arsenate (CCA) preservative to
resist rotting and termite and fungus attacks. Drums with an outside diameter exceeding 2.5 m and an
outside width exceeding 1.4 m shall not be used. The central hole of the drums shall be reinforced with
a steel plate of at minimum 10 mm thickness to fit an axle size of 95 mm diameter. The thread of bolts
used to strengthen the cable drums shall be peened in such a way that the nut can be tightened but
cannot be readily removed. The interior of the conductor drums shall be lined with bituminous paper to
prevent the conductor from being in contact with the timber. Waterproof paper and felt lining shall
overlap at seams by at least 20 mm and the seams shall be sealed.
This specification covers the design, manufacture, testing, supply, delivery and performance
requirements of ACSR for use in the overhead lines.
Table 8‐1: Conductors: nominal area and overall diameter
Conductor Number & Diameter of wires Overall Diameter
(mm)
Al Fe
50/8 6/3.2 1/3.20 9.60
70/12 26/1.85 7/1.44 11.7
95/15 26/2.15 7/1.67 13.6
120/20 26/2.44 7/1.90 15.5
120/70 12/3.60 7/3.60 18.0
150/25 26/2.70 7/2.10 17.1
8.1.2 Standards
The equipment supplied shall conform to the latest edition of the appropriate IEC Specifications and/or
other recognised international standards. In particular:
 IEC 60028 International Standard of resistance of copper
 IEC 6088 Zinc‐coated steel wires for stranded conductors
 IEC 60104 Aluminium – magnesium – silicon alloy wire for overhead line conductors
Volume 8
 EN 50 182.2001 (Table F.19)
 DIN 48204
 DIN 48201/8.
8.1.3 Physical characteristics ACSR CONDUCTOR
The physical, mechanical and electrical characteristics of the required ACSR conductors according to DIN
48 204 are compiled in Table 8‐2.
Table 8‐2: Characteristics of ACSR conductors
Conductor Weight Nominal breaking load Max. DC resistance at 20 °C
(kg/km) (N) (Ohm/km)
50/8 196 16,870 0.595
70/12 284 26,790 0.413
95/15 383 37,200 0.306
120/20 494 45,650 0.243
120/70 904 98,160 0.236
150/25 604 55,250 0.194
8.1.4 Material
The aluminium wires used in the construction of the ACSR stranded conductors shall be made of quality
aluminium material, type GIE in condition H9 as specified in IEC 60889 or equivalent. The galvanised
steel wires used in the construction of the ACSR stranded conductors shall be of the standard tensile
strength grade given in IEC 60888 or equivalent.
Both, aluminium and steel wires shall be smooth and free from inequalities. The aluminium and steel
wires shall have the physical, mechanical and electrical characteristics given in Tables 3‐1 and 3‐2 above.
8.1.5 Constructional features
The constructional features of the round wire, concentric lay, ACSR stranded conductors, starting from
aluminium and steel wires will conform with constructional features of IEC 60889 (aluminium wire), IEC
60888 (steel wire) and IEC 61089 (stranded conductors) and/or DIN 48 204.
In all conductor construction, successive layers shall have opposite directions of lay, the outermost layer
being right handed. Right handed lay and left handed lay shall be as defined in the latest edition of IEC
61089. The wires in each layer shall be evenly and closely stranded. In conductors having multiple layers
of aluminium wires, the lay ratio of each aluminium layer shall not be larger than the lay ratio of the
aluminium layer directly below it. Steel wires shall be formed during stranding so that they remain inert
when the conductor is cut. The finished conductor shall be free from dirt, grit, excessive amounts of
drawing oil and other foreign deposits.
8.1.6 Tolerances
The nominal diameter of wires shall be expressed in millimetres to two decimal digits. In wires used in
ACSR, the measurement of wire diameter shall not depart from the nominal diameter by more than
+0.03 mm for wires up to and including 3.00 mm diameter. For wires above that size, measurements of
wire diameter shall not depart from the nominal diameter by more than +1%.

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For the purpose of checking compliance with the above requirement, the diameter shall be determined
by two measurements at right angles taken at the same cross section. Resistance measurements of
resistance shall be carried out to an accuracy of not less than 0.1%.
8.1.7 Conductor grease
The inner layers of all bare aluminium conductors shall be smeared with an approved anti corrosive
grease having a high melting point. The grease shall completely fill the interstices between the steel core
and the aluminium strands and between all strands. There shall be no excess grease remaining on the
outer surface which might cause adherence of grit and other material during conductor pulling out and
erection. The minimum drop point (IP 31) of the grease shall be 110°C, and it shall not migrate towards
the bottom of the conductor when the conductor is maintained, continuously, at a temperature of 95°C.
The specified characteristics of the grease shall be unimpaired after heating to 15°C above its drop point
for 150 hours. The grease shall not flow within, nor exude from the conductor, at temperatures up to
and including 110°C. All greases shall permit operation of the conductors at a temperature of 80°C. The
grease shall comply with the standard IEC/TS 61394.
8.1.8 Delivery lengths
Bare conductors shall be delivered on drums with conductor lengths of 1,000 m or longer. These lengths
shall be subject to a permitted tolerance of +5%.
It shall be permissible to supply not more than 5% of the drums with random lengths, none of which
shall be shorter than one half of the standard length. All such lengths shall be clearly marked as non‐
standard. Not more than one length of conductor may be contained in any delivery drum. In the case of
conductors delivered in coils, random or non‐standard lengths shall not be permitted.
8.1.9 Tests
Test methods for ACSR conductors or their component wires shall be in accordance with IEC 60888, IEC
60889, IEC 61089, IEC 60468 and IEC 61395 if no type test certificates are provided.

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8.2 Power cables
8.2.1 General
All cables shall be XLPE‐type. 0.4 kV‐XLPE power cables in full length (without intermediate joints) shall
be required to interconnect all LV parts at the substations. Continuous current carrying capacity for
these cables shall be taken as 400 Ampere with a fault level of 18 kA for 1 second. The insulation level of
all these cables shall be maximum 1.0 kV grade.
8.2.2 Design requirements
All cables shall be designed to cope with short circuit conditions and voltage drop. Fusing capacity of
power cables may be taken for fault duration of 200 ms. Maximum short circuit current for 400 V power
circuits shall be 18 kA.
The cables shall be capable of satisfactory operation under a power supply system voltage variation of
±10% and frequency variation of ±5% and a combined frequency voltage variation of 10% (absolute
sum). The cables shall have heat and moisture resistant properties. These shall be of type and design
with proven record of power distribution installation.
The cables shall be maximum 1,000 volts grade, heavy duty multi‐core, stranded aluminium / copper
conductor, colour coded, laid up, armoured inner sheathed, conforming to IEC.
8.2.3 Conductor
The conductor shall be made from stranded annealed aluminium to form compact conductor having a
resistance within the limits specified in relevant IEC.
8.2.4 Conductor shield
The conductor having a semi‐conducting screen shall ensure perfectly smooth profile and avoid stress
concentration. The conductor screen shall be extruded in the same operation as the insulation. The
semi‐conducting polymer shall be cross‐linked.
8.2.5 Insulation
The insulation of the cables shall be extruded type and shall be designed and manufactured for the
specified system voltage. The manufacturing process shall ensure that insulation is free from voids.
The insulation shall withstand mechanical and thermal stresses under steady state and transient
operating conditions. The extrusion method should give very smooth interface between semi‐
conducting screen and insulation. The insulation of the cable shall be of high standard quality.
8.2.6 Insulation shield
In order to confine electrical field to the insulation a non‐magnetic semi‐conducting shield shall be put
over the insulation. The insulation shield shall be extruded in the same operation as the conductor
shield and the insulation by triple extrusion process. The cable insulation shall be strippable. Metallic
screening as given in this specification for the various control and power cables and special cables shall
be provided.

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8.2.7 Sheath
The sheath shall be suitable to withstand the site conditions and specified temperature conditions. It
shall be of adequate thickness and applied by a continuous process to produce a sheath of consistent
quality free from any defects. The sheath shall be extruded.
8.2.8 Armour
Hard drawn aluminium wire armouring / single galvanized steel tape / wire armouring shall be used. The
diameter of the aluminium wire shall be as per the table for the dimensions of the galvanized steel wire
armour given in the relevant standard.
8.2.9 Service and outer sheath
The cable shall have suitable fillers laid up with the conductors, before the sheath is applied and the
fillers shall be of substantially circular cross section. Fillers shall be suitable for operating temperature of
the insulation and compatible with the insulation.
8.2.10 Colour scheme and identification
To facilitate easy identification of phases a colour scheme of red, yellow, and blue for phases and black
for neutral shall be adopted for power cables.
All the cables shall carry manufacturer data in a permanent, legible manner at an interval of at least 3
meter run. The manufacturer’s data shall include the name; cable size, voltage rating together with any
other information.
8.2.11 Cable lugs
Cable lugs shall be supplied as per cable schedule and these shall be made of copper tube electro
tinned. Longneck‐crimping lugs shall be used for cables of size 400 mm² and above. No bimetallic action
shall take place between the aluminium conductor of the cable and the cable‐connecting lug by filling
the lugs with suitable compound. The lugs shall be of standard quality conforming to relevant IEC.
8.2.12 Cable glands
The cable glands shall be of double compression type and shall be made of brass duly electro tinned in
order to avoid corrosion and oxidation of the surface. The nipple threads shall be in accordance with
IEC. Glands shall provide neat, tight, dust and vermin proof termination.
Glands shall be provided with rubber ring to hold the cables firmly when check‐nut is slightly tightened.
Gland shall be complete with suitable washers etc.
8.2.13 Cable junction boxes
Junction boxes shall be constructed of sheet steel of thickness not less than 2 mm. The door shall be
adequately strengthened to ensure rigidity and strength. Sheet steel and sections used in enclosures
shall be cut neatly and finished free from burrs. Ample wiring space shall be provided at the sides, and
back of the enclosure for incoming and outgoing circuits. Removable plates with gaskets shall be fitted
at the top and bottom of the box to provide the entry for conduit or cable. The door shall be suitably
gasketed and fitted with a lock type handle. The door shall be hung on hinges having brass bodies and
stainless steel pins.
Volume 8
Each cable junction box shall be provided with terminals of adequate rating on the terminal strip of
suitable thickness. Disconnecting (sliding) type terminal blocks shall be provided, to facilitate testing &
maintenance without disconnecting the cables.
Multi‐block terminal board of 15 Ampere, 500 V rating shall be provided to form assembly of number of
terminal block. Assembly may be secured with only two screws on the surface. There shall be provision
on the strips to add more terminals in case of further requirement.
8.2.14 Packing
All cables shall be supplied on non‐returnable wooden drums with adequate barrel diameter so as to
avoid any damage to the cables and to withstand rough handling during transportation and storage.
Preferably not more than one length shall be wound on one drum.
A layer of waterproof paper shall be applied to the surface of the drums and over the outer cable layer.
A circular space of at least 40 mm shall be left between the cable and the lagging. Each drum shall carry
the name of the manufacturer, the name of the Project, order number, item number, type, size length
of cable, net and gross weight duly stenciled thereon.
8.2.15 Tests
Certificates for following tests shall be provided.
a) Annealing test (for Cu)
b) Tensile test (for Al)
c) Wrapping test (for Al)
d) Conductor resistance test
e) Test for thickness of insulation and sheath
f) Tensile strength and elongation at break of insulation and sheath
g) Insulation resistance test
h) High voltage test at room temperature.


Volume 8

8.3 Stay wire
8.3.1 Design
The stay‐wire covered by this specification is required for use on stays and flying stays from poles.
The stay‐wire must be designed and manufactured in such a way that it will satisfactorily withstand the
thermal, mechanical and environmental stress to which it will be subjected during installation and
throughout its lifetime in service. Its minimum breaking load shall be not less than 36 kN.
8.3.2 Manufacture
The stay‐wire in this specification shall be drawn from steel which shall conform to IEC 60888.
Galvanising shall comply with DIN 50 976 or ASTM A385.
Each wire shall be approximately circular in section and shall contain no weld, joint or splice whatever. It
shall be free from any scale, inequalities, spills, splits or any other defects. The wire shall be galvanised
in accordance with DIN 1548 or ASTM A385 and tested to DIN 50 952 or equivalent.
Each wire shall be completely and smoothly galvanised before stranding. The stranding shall be carried
out in such a way that if an evenly distributed pull is applied at the ends of the completed strand, each
wire shall take an equal share of the pull.
The lay of the wires shall be right handed. The length of lay, which shall be defined as the axial length of
one complete turn of the helix, shall be in accordance with the technical data schedule.
8.3.3 Stay‐wire coils
Normally, the stay‐wire shall be smoothly and uniformly coiled in standard 100 m coils with a tolerance
of ±5%. It shall be permissible to supply not more than 5% of the total length in random lengths, none of
which shall be shorter than one half of the nominal length. These lengths shall be clearly marked as non‐
standard.
The coils shall have a minimum diameter of 520 mm. To prevent damage during transportation,
handling or storage, the coils shall be lagged with paper and hessian or with hessian laminated paper, or
in other alternative manner suggested by the supplier at the time of bidding and demonstrably safe.
8.3.4 Labelling
Each coil shall be clearly labelled with a metallic label marked with the following information:
 Manufacturer's name;
 Size of wire;
 Length of wire in metres; and
 Weight of wire in kilograms.
8.3.5 Tests
Table 8‐3 shows the measurements and tests that shall be carried out on the stay‐wire, in case no type
certificate by a recognized institution is provided by the Supplier:

Volume 8
Table 8‐3: Measurements and tests for stay wire
Description Required Value
Size of Stay‐wire: 7/16 SWG
Diameter of single wire before stranding
‐ Nominal 4.0 mm
‐ Maximum 4.1 mm
‐ Minimum 3.9 mm
Minimum weight of zinc coating before stranding 254 g/m²
Nominal overall diameter of stranded stay‐wire 9.45 mm
Maximum tensile strength of individual wires 850 N/mm²
ultimate tensile strength of individual wires 700 N/mm²
Minimum percent elongation qat rupture
before 5%
after 4.25%
stranding
Break load 36.26 kN
Wrapping test for ductility: Turns on and one being 8
8.4 Overhead conductor fittings
8.4.1 General
requirements of insulator fittings and hardware and of conductor splice and termination connectors as
required by the 11 kV system.
The dimensions and characteristics given in this specification are intended to describe typical
distribution overhead line fittings and hardware which will maintain the general look of the existing
network and will take advantage of the availability of tools and the familiarity of the staff with these
kinds of arrangements.
It will be the supplier’s responsibility to ensure that all fittings, hardware and accessories are capable of
supporting the mechanical and electrical loads imposed on them by climatic conditions and conductor
tensions under worst design conditions.
The preformed fittings shall be compatible with ASCR conductors. The supplier shall ensure that all
preformed fittings are compatible for installation with the insulators and thimbles as required for
correct construction.
Preformed fittings shall be of correct size for the conductor to which it is to be fitted and shall be of
adequate strength for the purpose for which it is intended. The preformed fittings shall not slip whilst
service.

Volume 8

8.4.2 Preformed fittings
8.4.2.1 Connector for MV overhead conductors
Conductor connectors are required for Aluminium to Aluminium non‐tension and tension joints, and for
connecting Aluminium conductor to terminals of outdoor and indoor electrical equipment. Aluminium
connectors shall be suitable for ACSR conductors. These shall be complete with all special tools required,
protective grease, tapes bolts and washers appropriate to the application for which they are used.
All connectors shall be supplied pre‐filled with high quality oxide inhibiting compound and shall be
protectively capped to prevent spillage or spoilage of this compound. All connectors shall be clearly and
permanently marked with the correct size and category.
In addition all connectors shall comply with the following:
 The current must be uniformly distributed among the strands of the conductor
 The connector must have at least the same conductance as the conductor and continuously carry the
full current rating of the conductor size they are designed for
 The original quality of contacts shall be maintained throughout the connector’s service life.
 Glow discharges and radio interferences must be reduced to a minimum.
All compression connectors shall be suitable for installation using either manual or hydraulic
compression tolls. Details of dies and tools required for the compression connectors offered shall be
submitted with the tender documents.
Oxide inhibiting grease shall be suitable for Aluminium to Aluminium and to Copper bolted joints and as
filling compound for Aluminium fittings which accept copper conductors.
The compound shall be free of zinc particles or grit, shall be high “drop point” grease based and shall
remain stable at high temperatures.
8.4.2.2 Full tension mid‐span joints
Full Tension Mid‐Span Joint shall be of compression in‐line sleeve type suitable for connection of
stranded ASCR conductors.
8.4.2.3 General non‐tension connectors
Non‐Tension Connectors shall be of compression type with extrusion section of the H type for
connection of ASCR stranded conductors.
8.4.3 Terminal lugs
Terminal Lugs shall be heavily tinned plated aluminum and of the compression type prefilled with
compound suitable for connection of conductor onto copper terminals using 12 mm diameter bolts.
8.4.4 Stainless steel strap and equipment
Stainless steel strap is required to attach items of overhead line hardware to poles and cross arms. It will
also be used for attaching cables and conduit to poles. The strap shall be made of stainless steel with a
dimension of 10 x 0.7 mm minimum and be supplied in rolls of 50 m length. The stainless steel strap
shall have four smoothed edges to minimize the possibility of cutting.
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8.5 Insulators
requirements of pin insulators, suspension insulators, disc insulators, bobby insulators, and stay
insulators required. It is the supplier’s responsibility to ensure that the mechanical strength of the
proposed insulators is sufficient to support the loads generated, as per line design, by wind acting on the
insulators and by conductor tension for maximum windspan and bad design conditions, for all insulator
duties and for all permitted line deviations. The average span is calculated at being 80 m on MV. The
11 kV conductor cross section shall be 120 mm².
All insulators shall be delivered with all necessary assemblies, mounting and fixing material as clamps,
bolts, nuts, washers, spring rings, brackets, etc. in sufficient quantity, in qualities as required by the
respective standards and of suitable dimensions. All costs are included in the respective unit costs.
All insulators shall be clearly marked with the name or trademark of the manufacturer and the year of
manufacture. In addition, each unit shall be marked with the specified mechanical or electromechanical
failing load. These markings shall be legible and indelible. The markings may be printed or impressed,
provided such impressions do not impair the performance of the insulator. Markings shall be applied
before firing. The insulators shall meet the performance characteristics as compiled in Table 8‐4.
In Pakistan preferably porcelain brown glazed insulators are used, but other type of insulators, with a
proven track record may also be alternatively used.
8.5.1 Pin insulators
8.5.1.1 Performance characteristics
Pin insulators are used along the high and low voltage transmission and distribution lines. They are
mounted at metal crossarms and at the top of the poles.
Table 8‐4: Performance characteristics – PIN insulator
Maximum system voltage 12 kV
Nominal system voltage 11 kV
Minimum creepage distance 350 mm
Power frequency 50 Hwithstand voltage
‐ wet 30 kV
‐ dry 55 kV
Power frequency 50 Hz flashover voltage
‐ wet 30 kV
‐ dry 55 kV
Impulse withstand voltage
positive 90 kVp
negative 110 kVp
8.5.1.2 Design and construction
The relevant vertical dimensions shall be such that when combined with the pin insulator spindle the
design requirements at the relevant voltage level for conductor clearance from the cross‐arm shall be
met.

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The design shall be such that stresses due to expansion and contraction in any part of the insulator shall
not lead to deterioration. Precautions shall be taken to avoid chemical reaction between cement and
metal fittings by the choice of suitable materials or by the manufacturing method. Single piece insulator
construction is preferred.
The insulating material shall not engage directly with hard metal. Pin insulators shall be provided with a
thimble of suitable material. Cement used in the construction of the insulator shall not cause fracture by
expansion or loosening by contraction and proper care shall be taken to locate the individual parts
correctly during cementing. The insulators shall have a centre tap groove.
The insulator spindle shall have the whole length of the stalk threaded to facilitate using the pin
insulators on different line configurations.
Ferrous parts, unless of stainless steel, shall be hot dip galvanised in accordance with EN 1461 or ASTM
A123 and ASTM A385, with the exception of cotter pins which shall be galvanised using the methods of
ASTM A385, but with a coating mass of 500 g/m².
8.5.2 Stay insulators
Stay or guy strain insulators are used at anchoring systems for poles when load conditions exceeds
specified safety load
Power frequency 50Hwithstand voltage
‐ wet 30 kV
‐ dry 55 kV
‐ wet 30 kV
‐ dry 55 kV
positive 90 kVp
negative 110 kVp
8.5.2.1 Dimensions
The Supplier shall guarantee that the dimensions and tolerances of the insulators applied are in
accordance with the drawing and allow easy connection of stay wires. The insulators shall be used with
7/16 SWG steel stay‐wire. The insulators shall be suitable for use with preformed fittings on the stay‐
wire, have a minimum hole diameter of 22 mm and be such that a straight stay‐wire can be passed
through it.
8.5.3 Suspension insulators
Suspension or string insulators are used at poles where line direction changes to a certain degree or in
regular distances to balance weights. The string insulators consist of 2 disk shaped insulators which are
Volume 8
attached to each other by metal clevis pin or ball and socket links. Diameter of disks units is 257 mm and
standard length is 146 mm.
Table 8‐6: Performance characteristics – suspension insulator
Power frequency 50 withstand voltage
‐ wet 30 kV
‐ dry 55 kV
‐ wet 30 kV
‐ dry 55 kV
positive 90 kVp
negative 110 kVp
8.5.4 Post insulators
Post insulators shall be used along the poles and for sub‐stations.
Power frequency 50 withstand voltage
‐ wet 30 kV
‐ dry 55 kV
‐ wet 30 kV
‐ dry 55 kV
positive 90 kVp
negative 110 kVp


Volume 8

8.5.5 Insulator tests
8.5.5.1 General
The Supplier shall provide test certificates by a recognized institution that confirm that:
 the insulators conform with this specification and that the required type tests have been carried out;
 samples have withstood the specified sample tests. Respective reports shall include complete details
of all the tests listed below. Numerical values shall be given for each individual test result in all
appropriate cases; and
 each insulator of any consignment has withstood the routine tests specified.
8.5.5.2 Type tests
Type tests are intended to verify the main electrical characteristics of an insulator which depend chiefly
on its shape and size. These tests are normally made only once. They shall be repeated only when the
design or the material of the insulator is changed. The type tests required are:
 dry, lightning impulse withstand voltage test;
 critical impulse flashover test;
 wet, power frequency voltage test:
Flashover on any of the insulators under the specified withstand test conditions will result in rejection of
the insulator design;
 thermal mechanical performance: the manufacture shall state the result of the thermal mechanical
performance test, carried out in accordance with the requirements of IEC/TR 60575, on a
representative sample of the insulators proposed. The value of Qs shall be not less than the value of
the acceptance constant K, as specified in appendix A6 of IEC/TR 60575;
 radio interference: the manufacturer shall state the result of the radio interference voltage test
carried out in accordance with IEC 60437 at a voltage of 11 kV, 50 Hz. The maximum radio
interference voltage measured at 1 MHz will be 100 mV and 50 mV respectively; and
 power arc test.
Where relevant, these tests shall be carried out in accordance with IEC 60383.
8.5.5.3 Sample tests
These tests are made for the purpose of verifying the characteristics of an insulator and the quality of
the materials used. They are carried out on insulators taken at random from batches offered for
acceptance.
The tests shall be conducted according to the sampling procedure of IEC 60383, clause 23. The minimum
quantity for sample tests shall be 5 units. Failure of one insulator shall warrant re‐testing according to
clause 33 of IEC 60383. Failure of two or more insulators on retest shall result in the rejection of the
batch.
8.5.5.4 Routine tests
These tests are made for the purpose of eliminating insulators with manufacturing defects. They shall be
made on every insulator offered for acceptance. The following tests shall be carried out:
 Visual examination;
 Mechanical test: the tensile load in the mechanical routine test shall be 50% of the specified
electromechanical or mechanical failing load, rather than 40% as required by clause 36 of IEC 60383;
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 Electrical test.
8.6 LV outdoor distribution panels for step‐down transformers
8.6.1 General
The LV cabinets are designed to provide branch circuit feeders for power distribution from the
distribution transformers. The LV cabinets shall be supplied with main MCB on the incoming, and on the
outgoing feeder. The low voltage cable distribution cabinet (switchboard) shall be designed for outdoor
installation at the substations.
The housing shall be made of galvanized steel with two lockable hinged doors for pole mounting. Rated
voltage is 0.6/1,0 kV. They should be pre‐wired with three phase main copper bus bar, one neutral
copper bus bar and one earth bus on ready for service basis. The meter boxes shall basically comply with
the following standards:
 IEC 600068 Environmental testing general and guidance
 IEC 60529 Degree of protection provided by enclosures (IP‐Code)
 IEC 60947‐2 LV switch gear and control gear.
8.6.2 Scope of supply
The equipment to be installed in each LV cabinet shall include the following:
1) One incoming moulded case circuit‐breaker (MCCB) with electronic overcurrent and short‐circuit
protection device (from distribution transformer)
2) Three current transformers
3) Three ampere meters
4) One electronic 3‐phase energy meter
5) One voltmeter 0 ‐ 500 Volt
6) One selector switch
7) Three main copper bus bars
8) One neutral copper bus bar
9) One earth bar
10) Outgoing MCBs with electronic overcurrent and short‐circuit protection device. Number and sizes
are in accordance with the transformer capacity, the number of feder, and the feeder load
11) One receptacle 230 Volt, 16 A, with earthing contact
12) Cabinet illumination with door contact operated on‐off switch
13) Mounting and installation material (bolts, nuts, cable shoes, earthing material for connection to
the station earthing system, etc.)
200% spare fuses shall be supplied with each LV cabinet.
8.6.3 Enclosure
The enclosure shall a metal panel, rigid, self‐supporting structure, with suitable structural steel
reinforcement, stiffening and bracing. When the structures are assembled, the surfaces shall be flat and
smooth and shall have ample strength to withstand all stresses encountered in shipping, installation and
operation without distortion, vibration or other damage. The structures shall be complete with
removable lifting lugs as required.

Volume 8

Doors shall open 100° outwards and shall have a latching device to lock the door in open position during
maintenance or operation on the panel. All doors shall use the same lock and key combination for the
complete supply. Doors shall be rigid and fitted with close fitting flexible seals to prevent ingress of
liquids, moisture, dust and vermin. Each door shall be equipped with a lever type handle and three point
latches sufficiently strong to hold it in alignment when closed. Hinges shall be of the lift‐off pattern with
one pin engaging before the other for ease of fitting.
Provision shall be made for bottom entry of cables. Removable gland plates of an approved type non‐
flammable insulating vermin‐proof material shall be provided. All cables shall enter vertically from
below and at their point of entry the cabinet shall be sealed.
The panel face shall be at least 3 mm cold rolled steel sheet selected for flatness and free from surface
defects. The panel front shall be all welded and ground smooth. After steel fabrication the panel face
shall be flat with a maximum deviation of 1 mm over the total surface.
A lamp shall be fitted inside each cabinet and shall be so arranged that all wiring is illuminated evenly
without dazzle. The lamp shall be controlled by a door switch. One receptacle 230 V, 16 A shall be
provided.
LV Cabinets shall have two compartments: one for the incoming supply with the main MCCB, the
measurement instruments and the energy meter and the second compartment for the outgoings MCCB.
The degree of protection shall be IP51 acc. to IEC 60529.
Main Copper busbar shall be designed for a continuous operation at rated current and for a short circuit
current of 10 kA.
8.6.4 Interior
Earth and neutral bars shall be provided and fitted. The bars will be made of brass. Each neutral
connection shall be identified.
The bus bar shall be constructed from copper conductor insulated as indicated in the table below. The
bus bar shall be fully insulated and colour coded. Crimp lugs shall be supplied for the neutral a dearth
bus bar. The crimp lug shall be supplied in a plastic bag taped to the interior of each LV cabinet.
Table 8‐8: Correlation of max. current and size of busbar
Incoming Current Minimum Size of Busbar
(A) (mm)
200‐400 5 x 30
600 12 x 70
800 15 x 70
1,000 25 x 80
Source: Own compilation
8.6.5 Equipment
8.6.5.1 Molded case circuit breakers (MCCB)
Circuit breakers must be able to make, carry and break currents under normal operating conditions and,
be able to make the current, withstand it and to interrupt it after a defined length of time under
abnormal short circuit conditions.
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The tripping current shall be designed according to the nominal current and the calculated minimum
short circuit current.
MCCB shall be fitted with an electronic tripping unit for overcurrent and short circuit protection. This
unit shall provide an adjustable threshold for overload, short‐circuit and instantaneous short circuit with
different operating times.
The circuit breakers shall be used for routine switching operations and to protect apparatus and sections
of the distribution system from damages of the short‐circuit currents.
Circuit breakers shall be designed for panel board mounting and shall be provided with suitable clamp
type connectors. The interrupting capacity of the breakers shall be minimum 10 kA.
Multi‐pole breakers shall have a single operating handle which shall operate all poles simultaneously to
close or trip the breaker. The operating handles shall clearly indicate whether the breakers are in "ON"
or "OFF" or TRIPPED" position.
The MCCB shall comply with IEC 947‐2 and DIN VDE 0660 part 101.
8.6.5.2 Current transformers
The current transformers shall be commensurate to a rated bus bar current as mentioned above and
shall have a tapped secondary winding to provide two different ratios, e.g. 300:5. Secondary currents
shall be 5 A. It shall comply with IEC 60044‐1 last edition or DIN VDE 0414. Accuracy class shall be IEC 0.5
M5. Rated output shall be at least 15 VA. Current transformers shall be window (slipover) type and shall
be adequate for vertical mounting.
8.6.5.3 Three pole LV fuse switch
Three pole LV fuse switches are required to fuse and switch the low voltage on three phase distribution
transformers. The fuse switches are mounted in the LV cabinets. The equipment supplied shall conform
to the latest edition of the appropriate IEC Specifications and/or other recognised international
standards as IEC 60269, IEC 60529 and IEC 60947. The switch fuses shall be ganged. The fuse switch shall
have bolted tunnel terminals which can accept 95 mm² to 240 mm² copper or aluminum conductor.
8.6.5.4 Electrical and mechanical requirements
The fuse switch shall have the following ratings in compliance with IEC 60947‐3:
 Minimum rated operational voltage: 190 V
 Minimum rated insulation voltage: 1,000 V
 Rated frequency: 50 ‐ 60 Hz
 Minimum operational current:
o with connecting links: 250 A,
o with fuse links: 160 A
 Minimum rated conditional short‐circuit current with: 50 kA
Fuse links
 Infrequent operation with current: 200 minimum
 Infrequent operation without current: 1,400 minimum
 Minimum degree of protection from front: IP 41 to IEC 60529
 Rated making and breaking capacity: AC 20B.

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Marking
The fuse switch shall be clearly marked with the name of the manufacturer or trademark and year of
manufacture.
HRC Fuse links
HRC fuse links in DIN 00 format are required for the three pole LV fuse switches. The fuse links shall be
supplied in two ratings: In=100 A and In=160 A.
8.6.5.5 Testing
The Supplier shall perform type (type tests are required only if no certificates of a recognized institution
are provided), sample and routine tests as prescribed in IEC 60947.
8.7 Distribution substations
Usually 2‐pole distribution transformer structures are used for capacities up to 500 kVA. In exceptional
cases transformer may be placed on masonry supports. In this case the minimum height should be 2 m
with a protection fence. Pole type transformers are mounted directly on steel supports and shall
comprise:
 Required poles
 Supporting structure
 Transformer
 Combined MV disconnector and dropout fuses
 MV surge arresters
 MV earthing
 LV earthing on adjacent poles
 LV control cabinet.
The combined disconnector and dropout fuse unit shall be cross arm mounted above the transformers
and positioned so that the fuses can be safely operated by pulling stick from a ladder or platform placed
on the LV side of the transformer.
The surge arrester shall be mounted adjacent to the drop out fuses and connected on the up steam side
of the fuses. The surge arresters shall be directly earthing to the substation MV grid.
The drop lead from the MV line, the connection to the surge arresters and also the drop lead to the MV
bushings shall be single core 35 mm² Al XLPE covered. An insulated boot shall be provided over the
exposed metal parts of the MV bushing to protect against interruptions from bird, snakes, windblown
debris etc.
An LV cabinet shall be fixed to the structure at a height that does not obstruct pedestrian or other traffic
but is still reasonably accessible for operational purposes. Twin single core copper XLPE LV cables as in
the table below shall be used from the transformer bushings to the LV cabinet. The neutral shall be full
size. Where these cables are less than 2.5 m above ground suitable mechanical protection shall be
provided.

Volume 8
Table 8‐9: Cable sizing
Transformer No and size of
capacity (kVA) cables (mm²)
500 3 x 300
400 3 x 150
315 2 x 150
200‐250 1 x 150
160 1 x 120
100 1 x 70
50 1 x 50
Where underground LV cable is installed for the outgoing LV circuits the cable shall be routed from the
LV cabinet and provided with suitable mechanical protection.
All cable fixed to the poles shall be neatly secured by stainless steel banding at intervals of not more
than 750 mm.
8.7.1 Structure steel for distribution networks and substations
Structure steel cross‐members are required for the two pole distribution transformer substation to
support the lightening arresters (also called surge arresters) the combined disconnector/drop out fuses
(also called fuse cut‐outs) and the distribution transformers. The cross – members shall be designed to
adequately support the static load of the equipment plus the load of maintenance personnel.
Suitable classes of steel for the cross – members are low tensile steel (yield point 220‐260 N/mm²) and a
high tensile steel (yield point 300‐350 N/mm²). Steel shall comply with the requirements of ASTM A 143.
All components / sub – items required to complete the distribution transformer substation assemblies
shall be included.
8.7.2 Cross arms
8.7.2.1 Applicable standards
The cross‐arm assemblies supplied shall be in accordance with the latest editions of the Standards
specified below, or equivalent Standards.
 BSEN 10113‐2 (1999#0) Weldable fine grain structural steel.
 B.S. 4360 (1990 Weldable structural steel
 B.S. 4848 Parts IV & V Hot rolled structural steel sections
 B.S. 464 (1998) Thimbles for wire ropes.
 BSENISO 1461 (1999) Hot dipped galvanized coating on steel.
8.7.2.2 Basic features
The cross‐arm assembly shall consist of three parts: (a) steel angle cross‐arm; (b) flat steel bracing
and (c) steel channel for transformer pole mounting.

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8.7.2.3 Grade and quality of steel
The grade of steel used for the fabrication of cross‐arm assemblies shall be 43DD as per BS 4360 or 355N
as per BSEN10113. The dimensional tolerance of flat steel and angle steel shall be as stipulated in
BS4360 / BSEN 10113 and BS 4848 Part 4 respectively. The minimum thickness of the angle steel shall be
7mm and for channel steel shall be 7mm. The chemical composition of the steel used shall be as
stipulated in BS 4360 / BSEN10113 (Table 14 and Table 1 respectively).
The steel used for the fabrication of cross‐arm assemblies shall be sound and free from any internal and
external defects or surface flaws, which might preclude its fitness for purpose.
8.7.2.4 Mechanical properties
The mechanical properties of steel including the minimum Tensile Strength, Yield Strength and
Elongation shall be as stipulated in BS 4360 /BSEN 10113 (Table 15 and Table 3 respectively).
8.7.2.5 Fabrication
Cross‐arm assemblies shall be fabricated from the following types of steel sections manufactured in
accordance with BS 4360 : 1990 / BSEN 10113 structural steel.
a) Angle steel section 70mm x 70mm x 7mm (for cross‐arm)
b) Channel Steel section of 120mm x 55mm x 7mm (for substations, pole mounted)
c) Flat Steel section of 40 mm x 8mm (for bracing).
The channel steel, flat steel and angle steel sections shall be first cleaned and made rust free by
shot/grit blasting, then necessary holes punched, cut to required sizes, then welding, bending, forging
and identification marking shall be carried out. All components of the cross‐arm assemblies shall be hot
dipped galvanized.
Position and size of holes on the cross‐arms, bracings and channel steel shall be precisely in accordance
with the requirements.
8.7.2.6 Components
a) The components comprising a Pin Cross‐arm are as follows:
o Angle Steel Cross‐arm ‐ 70 mm x 70 mm x 7 mm ‐ 1 No.
o Flat Steel Bracing (40 mm x 8 mm) ‐ 2 Nos.
b) The components comprising a Tension Cross‐arm are as follows:
o Angle Steel Cross‐arm ‐ 70 mm x 70 mm x 7 mm ‐ 2 Nos.
o Flat Steel Bracing (40 mm x 8 mm) ‐ 4 Nos.
c) Bolts, Nuts and Washers necessary for the Pin and Tension Cross‐arm assemblies are not required
to be supplied.
The following routine tests shall be carried out on all the cross‐arm assemblies manufactured.
a) Visual inspection
b) Dimensional check
c) Galvanizing.
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8.7.3 Pole fittings
The following pole fitting for overhead lines shall be provided:
 Single crossarms, complete with two crossarm braces and all necessary nuts, bolts and washers for
attachment to the pole
 Double crossarms, complete with two crossarm braces, spacers, and all necessary nuts, bolts and
washers for attachment to the pole
 Distribution transformers pole mounting steelwork, complete with all necessary nuts, bolts and
washers for attachment to the pole
 Line post insulator attachment fittings.
The fitting shall not compromise the strength of the pole and if required spacers shall be installed to
avoid compression of the pole.
Pole fittings shall be manufactured from the materials specified. They are to be supplied complete with
all necessary nuts, bolts and washers to attach the respective equipment to the pole.
Line post insulator fittings are to enable line post insulators to be mounted at an angle of 15 degree
from horizontal. The fitting shall be designed to support a 4 kN vertical load and 3 kN horizontal load.
8.7.4 Nuts and bolts
Nuts and bolts shall conform to ISO recommendation, for metric threads and spring washers to ISO 630
strength 41 kg/mm² or more. Nuts and heads of all bolts shall be of the hexagonal type and of outline
dimension.
All washers are to be included under this contract, including locking devices and anti‐vibration
arrangements, which are to be subject to the approval of the employer. The washers shall be of
adequate thickness to abridge the projection of the shaft and the commencement of the in readed
portion.
Nuts shall be finger tight on the bolt and will be rejected if they are considered to have an excessively
loose or tight fit. Bolts with re‐cut threads after galvanizing will be rejected.


Volume 8

8.8 Concrete poles
8.8.1 General
This specification includes the design, manufacture, testing, and delivery to site of concrete support
poles. The types of poles that may be used are:
 R/f concrete poles of square, rectangular, or round cross section manufactured in one piece
The supplier should provide poles that are of a standard design and which best meet or exceed the
requirements set out in this specification. All material shall be new and conform to the relevant
standard specifications referred to in this specifications in all respects.
8.8.2 Standards
The equipment supplied shall conform to the latest edition of the appropriate recognized international
standards. In particular:
 ISO 3839 classification by compressive strength.
8.8.3 Inspection and testing
The manufactured items will be inspected at the manufacture’s plant by a representative appointed by
the employer. Tests shall be performed in accordance with this specification and with the relevant
standards. The following definitions apply to this specification:
a) Failure: inability of the pole when under test to support future load or when deformation or
buckling of the pole renders it unserviceable.
b) Longitudinal direction: the horizontal direction parallel to the run of the conductors.
c) Transverse direction: the horizontal direction at right angles to the run of the conductors.
d) Ultimate strength: the strength at which the pole will not accept any further applied force or when
deformation or duckling or the pole renders it unserviceable.
8.8.4 Manufacture of concrete poles
The poles shall be made of r/f watertight concrete with minimum strength of 37 kN /mm² (C 30/37). The
surface of finished poles shall be smooth. A few cracks with a width of less than 0.1 mm may be present.
Pores in the surface may be present depending on the manufacturing method. The total area of the
pores should be less than 5 cm². The mean depth of the pores shall be less than 3 mm. All poles shall be
made in a professional manner in a factory with continuous quality control.
8.8.5 Construction of concrete poles
The deflection of the construction caused by horizontal and vertical loads shall be considered during the
dimensioning. These loads including own weight should be multiplied by the safety factor of three (3).
The deflections shall be verified by practical scale tests. The smallest thickness of covering concrete coat
at reinforcement should be 25 mm.
All poles should be made in a professional manner. The surfaces should be reasonably smooth and free
from burrs or sharps objects.
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8.8.6 Concrete mixing
All concrete shall be mixed in power driven mixers and the concrete making materials shall be
accurately measured to ensure the production of uniform batched of concrete. Volume measurement
shall be carried out using well‐proportioned gauge boxes or automatic weight measuring equipment.
The gauge boxes shall be loose filled with the material being measured then struck off level with a
straight edge then discharged into the mixer.
8.8.7 Consolidation of concrete
All concrete shall be consolidated in the moulds using high frequency internal or external vibrators. The
amount of vibration shall be uniform along the length of the mould and shall be carefully controlled so
that adequate consolidation of the concreter is achieved without causing segregation of the mix
ingredients by over vibration.
8.8.8 Protection and curing of concrete
During the initial stage of hardening the concrete shall be protected from the direct rays of the sun and
from draying winds. The moulds containing the hardened concrete shall not be disturbed or shifted
unless it can be shown that such movements will not impact any damaging stress to the hardening
concrete. All concrete shall be cured in an environment that ensures that it remains saturated or nearly
saturated during the curing period.
8.8.9 Dimensional tolerance of concrete poles
The permitted variation from stated dimension or cross –sectional shape of the finished pole shall be as
follows
 Length: + 50, ‐10 mm (allowances shall be made during design for length reduction due to
prestress)
 Straightness: +15 mm (deviation from a straight line joining the top and the widest dimensions at the
butt)
 Holes: Size – 0+2 mm, Relative position +‐ 5 mm.
8.8.10 Pole length, shape and design loading
Each pole shall be manufactured in one piece. All holes for the mounting of equipment shall be made
during production.
The assembled standard overall length of the poles manufactured shall be 12 m.
The standard design working loads in the transverse direction shall be as follows.


Volume 8

Table 8‐10: Concrete poles
Height of pole Buried length Working Load* Purpose
(m) (m) (kg)
12 1.8 400 MV, single circuit, small angles
12 1.8 800 MV, tension, large angles,
double circuit
sub‐station
*: Applied 300 mm below pole top
Each pole shall be able to resist an independent load in the longitudinal direction of at least 25% of the
transverse loading. The ultimate pole top load to be used for designing each class of pole shall be a
factor of safety (F.O.S.) times the appropriate standard design working load. Ultimate design forces to
be used for the pole design shall result from this load applied to the pole when held in the standard test
frame specified in the pole testing section of this specification. The factor of safety shall be 2.5.
8.8.11 Deflection
The maximum to deflection under the design working load applied in accordance with the pole testing
section of this specification shall be H/25 where H= total pole length.
8.8.12 Testing of poles
The tests given below apply to all concrete pole types.
8.8.12.1 Type tests (destruction tests)
These shall be carried out periodically to check the consistency of the standard of manufacture.
8.8.12.2 Testing arrangement
Poles shall be tested in the horizontal position in a testing bed. The pole shall be tested between two
reaction posts of a width of not more than 300 mm. The lower reaction posts is to be located below the
ground line mark, which is 1/6 of the total length of the pole. The upper reaction post is to be located
bellow the ground line mark, which is 1/6 of the total length of pole. The pole shall be loaded with a
suitable device 300 mm from the top of the pole. The testing arrangement shall be provided with
sufficient supports to ensure that bending moments developed by the self‐weight of the pole are
minimal. These supports shall be detailed to give no horizontal resistance to the applied loads. The
accuracy of all load and deflection measuring equipment shall be +/‐2 percent.
8.8.12.3 Test
These shall be carried out before full‐scale manufacture of a class of pole commences; after any change
are made to the approved design of a class of pole.
A sample consisting of three poles selected at random. similar in all essential features of design and
construction to those purchases, shall be subjected to the type test and must give evidence that the
poles comply with the acceptance criteria of this specification. The test shall be carried out in 2 stages.
Volume 8
1st stage:
The load shall be gradually and uniformly applied in increments of 10% of the ultimate design load up to
120% of the design‐working load. At each increment of load the deflection of the pole type shall be
measured.
The 120% loading shall be maintained for 5 minutes. The load shall then be gradually reduced to zero
and the amount of permanent deflection of the pole tip recorded.
2nd stage:
The test load shall be gradually reapplied up to the design working load and the deflection recorded.
The load shall then be increased in 10% increments until failure accrues. At each load increment the
load and deflection shall be recorded.
The following particulars shall be recorded for each test made:
 Manufactures name and plant location
 Pole classification and type
 Dimensions of the pole
 Date manufactured
 Date tested
 Increments of load
 Deflections at each increment of load
 Permanent deflection after removal of 1st stage loading
 Load at failure
 Nature of failure
 Colour photographs along the axis of the pole at design working and ultimate loads plus photographs
of the failure zone on the pole.
The poles shall be considered acceptable if:
 Permanent deflection of the tip of the pole, after the 1st stage loading is removed, does not exceed
1 mm per meter of pole length.
The average failure load of the three poles tested equals or exceeds the ultimate design load and the
failure load of any single pole is not less than 0.90 times the ultimate design load.
This shall be carried out on poles selected at random by the Employer at the rate of per 100% of the

design‐working load.
The poles will be considered acceptable if the defection at each load increment and the permanent
deflection upon removal of load does not exceed by more than 15% the average of the acceptable tests
of the corresponding values for 1st stage loading of the type tests.
Failure to satisfy acceptance criteria
In the event that a pole does not satisfy any of the above acceptance the Supplier shall modify his pole
design or construction procedure to increase the strength of the pole. Poles manufactured in the same
manner as those that have failed the acceptance tests may be rejected.

Volume 8

8.9 Wooden poles
8.9.1 Applicable standards
The treated wooden poles shall be in accordance with the latest editions of the standards specified
below and amendments thereof.
 ANSI 05.1 2002 ‐ Specifications & Dimensions for Wood Poles
 ASTM D 1036‐58 1990 ‐ Standard Test Methods of Static Tests Wood Poles
 BS 1990 ‐ Specification for Wood Poles for overhead lines (Power & Telecommunication Lines). Part 1
‐1984 ‐ Specification for Soft Wood Poles.
 BS 144 ‐ Wood Preservation using coal tar creosotes. Part I: (1990) ‐ Specification for preservative;
Part II: (1990) ‐ Methods for timber treatment.
 AWPA C1 ‐ All timber Products‐ Preservative Treatment by Pressure Process
 AWPA C4 ‐Poles‐ Preservative Treatment by Pressure Process.
8.9.2 Pole species
Poles shall be made of wood and will have a minimum fibre strength of 45 N/mm2. Species of wood
poles shall preferably be as given in the above mentioned American National Standard but local wood
poles of the species Pine (Pinus Sylvestris), Siberian Pine (Pinus Sibirica) and Siberian Larch (Larix Si‐
birica) shall be acceptable if they comply with this specification. Any refractory species offered (such as
Douglas Fir, in general the larches) must be incised at the ground line section. For refractory species,
only strength tests after incision shall be valid.
8.9.3 Defects
8.9.3.1 Prohibited defects
In all poles, the width of sapwood from the butt of the pole to 1m above the proposed ground level
must be a minimum of 25mm and for the rest of the pole not less than 20mm.Poles shall be free from
rot, cracks and defects that may reduce the strength of the pole, render it difficult to climb or make it
visually unacceptable. Elliptical poles shall not be accepted.
Specifically, the following defects shall be prohibited:
 cross breaks (cracks);
 decay except as indicated in 2.2.4 and 2.2.5 for firm red heart, defective butt and decayed knots;
 evidence of fungal fruiting bodies or mycelium in a pole shall be considered as evidence of decay and
the pole shall be permanently rejected as non‐conforming;
 dead streaks;
 holes, open or plugged, other than those provided for in the specification or drilled for test purposes,
which shall be treated and plugged with treated plugs;
 defective butts and hollow butts or tops, except as permitted under pith centres;
 marine borer damage;
 nails, spikes, and other metal not specifically authorised by the Purchaser;
 double sweep;
 mechanical damage;
 insect damage.
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8.9.3.2 Permitted defects
The following defects may be permitted:
 firm red heart provided that it is not present in more than 10 % of the cross section and that it is not
accompanied by softening or other signs of disintegration or decay of the wood;
 hollow pith centres in tops, butts and knots are permitted in poles that are to be given full length
preservative treatment; and
 sap stain that is not accompanied by softening or other disintegration or decay of the wood.
8.9.3.3 Limited defects
The following defects are permitted to the degrees stated:
 bark inclusions: depressions containing bark inclusions provided they are not deeper than 50 mm,
measured from the surface of the pole;
 defective butts: hollowing in the butt caused by splinter pulling in felling the tree is permitted, pro‐
vided that the area of such a hollow is less than 10 % of the butt area;
 knots: individual knots with diameters less than one sixth of the pole girth at that point in the pole
are acceptable. The sum of diameters of sound knots in the worst 150mm length of pole should not
exceed one third of the pole girth at that point;
 scars: a scar is the result of injury to the living tree which has begun to compartmentalise and a sign
that the injury is being contained.
 sound scars on the pole surface are permitted, provided the damage was not done after the tree was
cut, provided the scars are smoothly trimmed and do not interfere with the cutting of any grain and
provided that:
 the circumference at any point on trimmed surfaces located between the butt and 600 mm below
the ground line is not less than the minimum circumference specified at 1.5 m from the butt for the
class and length of the pole; and that
 the depth of the trimmed scar is not more that 50 mm if the diameter is 250 mm or less, or 20% of
the pole diameter at the location of the scar if the diameter is more than 250 mm.
 However, no pole shall have a scar or turpentine cut face located within 600 mm of the ground line.
Turpentine scars need be trimmed only to the extent necessary to examine evidence of fungus in‐
fection and insect damage;
 shakes: shakes in the butt surface which are not closer than 50 mm to the side surface of the pole are
permitted, provided they do not extend to the ground line.
 shakes or a combination of connected shakes which are closer than 50 mm to the side surface of the
poles are permitted provided they do not extend further than 600 mm from the butt surface and do
not have an opening wider than 3 mm.
 However, shakes in the top surface are permitted in poles that are to be given fully length pre‐
servative treatment, provided that the diameter of the shake is not greater than half the diameter of
the top of the pole and that it is not closer than 50 mm from the surface;
 splits and checks: two checks of approximately the same width, each check terminating at the pith
centre and separated by 12.5 mm or less of wood fibre at any point on the pole circumference, shall
be considered a single continuous check.
Splits and checks shall be permitted provided that:
 a split or a combination of two single checks on pole top (each check terminating at the pith centre
and separated by not less than one sixth of the length of the circumference) having one or both
portions located in a vertical plane within 30° of the top bolt hole shall not extend downward along
the pole more than 150 mm. All other splits or combination checks shall not extend downward along
the pole more than 300 mm; and that
 a split or a combination of two single checks on the butt of the pole, shall not extend upward along

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the pole, in its entirety, more than 600 mm.
8.9.4 Inclination
The maximum deviation from the vertical allowed is 25 mm for each 3 m of length between the
respective measuring point for more than 90% of the batch. In the rest of the batch, the poles may have
a maximum deviation of 25 mm for each 1.8 m of length measured as above.
8.9.5 Dimensions
The wooden poles shall be made of the standard size of wood poles shown in Table 8‐11. The poles shall
conform to the following dimensional requirements.
Table 8‐11: Pole dimensions
Pole Class Nominal Pole Min. Pole Top Diameter Min. Dia. 1.5m from
Length (m) (mm) Butt (mm)
Light 6.0 95 125
7.2 120 200
9.2 135 230
Medium 6.0 120 160
7.2 150 235
9.2 150 250
Stout 6.0 120 185
7.2 170 255
9.2 170 270
Note: All wooden poles are to be mounted onto concrete supports above ground.
8.9.6 Tolerances
All measurements are under bark and 5 mm shall be allowed for dressing. Lengths shall be measured to
the short end of the slope and diameters at the minor axis. Poles shall be not more than 75 mm shorter
or 150 mm longer than the nominal length.
8.9.7 Preservative treatment
Long life is a prerequisite for poles and preservative treatment is essential. It is recommended that poles
complying with this standard have an average life of 30 years. All wood poles supplied shall be
preserved by means of either
 Coal Tar Creosote Type 2 according to latest issue of BS:144; or
 Copper/Chromium/Arsenic Compositions (CCA) ‐ according to latest issue of BS:4072.
Before either of the two preservative treatments is applied, the poles shall be seasoned. Poles may be
partially conditioned by natural air seasoning or by forced air circulation, and further conditioned by kiln
drying.
For air seasoning, the poles shall be segregated according to their species and stacked to leave a
minimum ground clearance of 300 mm. On completion, the stacks should appear level and balanced.
The runners between each deck must support each other. In the construction and dismantling of stacks,
poles shall be rolled to and from handling machinery. Under no circumstances are poles to be pulled in a
ramp from an intermediate floor. All poles must be stacked within two weeks of delivery.
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Air seasoned poles dried by natural air circulation shall be checked to the heartwood. The final moisture
content before preservative treatment shall be measured by a resistance meter, both at a depth of
38 mm (1.5 in.) and at the sapwood line, and in neither case shall it exceed 28 %. Extreme care shall be
taken to ensure that air seasoned poles do not have pre‐treatment decay in them. The poles shall not be
heavily stained.
The company's inspector may have all dry poles subjected to a piece by piece inspection, immediately
prior to preservative treatment, during which all poles shall be rolled. Samples shall be taken up to the
pith centre to determine whether the poles have been sterilised before or during treatment.
Before preservative treatment, all poles shall be dressed, drilled and marked.
Coal tar creosote for wood preservation
The preferred preservative treatment is creosoting. Both the specifications of the coal tar creosotes and
the treatment process must be in accordance with the latest issue of BS 144: Wood preservation using
coal tar creosotes and BS 913: Wood preservation by means of pressure creosoting. Alternatively a
treatment according to AWPA C1 and AWPA C4 should be acceptable. In both cases, preservative net
retention shall be, at least, 160 kilograms per cubic meter.
The creosote shall not contain more than 3 % water when in use and it shall be kept at a temperature
between 85 °C and 100 °C during the pressing period.
Sample boring shall be taken from each charge and, if found satisfactory, the batch will be accepted.
After treatment, the poles shall be stacked as outlined above and held for sufficient time to ensure the
supply of dry poles.
Copper/chrome/arsenate composition for wood preservation
The preservation treatment for wood poles is by means of Copper/Chrome/Arsenate composition (CCA).
Both the specifications of Copper/Chrome/Arsenate composition (CCA) and the treatment process,
pressure impregnating must be in accordance with the latest issue of BS 4072. Copper is the fungicide
and Arsenic the insecticide. Chrome acts as s fixing agent, reacting with the Copper and Arsenic once
impregnated into the timber. Then it forms non‐soluble, leach‐resistant compounds affording
permanent protection to the timber.
Preservative net retention shall be, at least, 20 kilogram per cubic metre. After treatment by means of
CCA ‐ Tanalith, the poles shall be re‐dried and they shall be used only after, at least, fourteen days to
ensure use of dry poles.
After treatment, a boring or borings shall be undertaken with a test borer not less than 1.5 m from
either end of each pole of a sample of the poles in the charge. The extent of penetration of the
preservative shall be determined in accordance with latest issue of BS 5666: part 2. If found satisfactory,
the whole batch will be accepted.
Temperature and pressure gauges
The temperature and pressures in the cycle must not be exceeded in both methods of wood
preservation. They shall be recorded on a recording chart and shall be verified by visual observations of
the direct reading gauges, at least hourly throughout the treating cycle, by the treating operator or
Purchaser's inspector.
In addition, all temperature and pressure gauges shall be serviced annually and be certified that they are
in good working order. They shall also be calibrated at regular intervals, as per the Contractor's quality
assurance programme. One copy of the service and calibration certificates must be submitted to
Purchaser by the Contractor together with the Tender or bid documents.


Volume 8

8.10 Lattice steel poles
8.10.1 Scope of supply
Suppliers are called upon to deliver lattice steel poles and cross‐arm for the installation of medium
voltage (11 kV), distribution network.
The Japanese Industrial Standards (JIS) are to be considered in the design, manufacture and testing of
the above mentioned materials. Similar or equivalent international standards such as BS or DIN shall be
treated likewise. Specifications and quantities are stated in the following items.
8.10.2 Technical specification
8.10.2.1 Technical requirements
System data
The system data are compiled in the Table below.
Table 8‐12: System requirements
Item Value
Nominal voltage 11 kV
Maximum voltage 12 kV
Conductor 3‐phase, 3‐wire, delta,
120/20 mm² ACRS
Pole spacing 80 m
Max sagging 2 m
Pole height 12 m above ground
Short circuit breaking current 25 kA
Material
The poles shall be made from hot rolled I‐joists and angle‐steel sections with steel plates specified in JIS‐
G‐3101 (STK‐51) or in accordance with BS 4360 (Steel 52) or in DIN 17100 or in accordance with any
international equivalent standard with considering the design factor of safety equals to (2.0) having the
following properties:

Volume 8
Table 8‐13: System requirements
Item Unit* STK‐51 St 52 (BS 4360) St 52 (DIN 17100)
Tensile strength N 510 520 5230
Yield strength N 360 360 345
Design bending stress N 255 260 260
*: at 2 min
Materials for A‐clamps used at the top of (12 m lattice steel poles) and cross‐arms shall be made of hot
rolled structural carbon steel in accordance with the same specifications above but either STK‐51, Steel‐
52 (to BS or DIN) having the following mechanical properties:
8.10.2.2 Lattice‐steel poles
Each medium voltage lattice steel pole shall be made out of two Nos. I‐steel joists which are to be
welded together and cross‐braced with angle iron size (30×30×3) of steel (ST‐41) or (ST‐37) or any equiv.
forming the shape of latter (A) as shown in drawings No. (2). I‐steel sizes for low voltage is as follows: ‐
 (140×66×5.7x8.6) ST‐52 according to DIN‐17100
 150×75×5.5x9.5) STK‐51 according to JIS‐G‐3101.
 Any equivalent sections ST‐51, ST‐52 according BS‐4360.
And any other size having the same modulus of section shall be acceptable.
Maximum working loads is 7 kN.
The underground portion of the steel pole shall be at minimum 2 m
The whole pole shall be hot‐dip galvanized according to BS 729.
Each of the lattice steel poles shall have an earthing hole (18 mm dia.) located at the center of the lower
plate for earthing purposes.
Every steel lattice ole shall be supplied with (11 Nos.) electrically galvanized, high stress, hexagonal
headed (M‐16) fully threaded bolt (35 mm) length of screw with nut, plain washer & spring washer as
they are used as follows.
 (10 Nos.) for the 2 rows of (5x18 mm) dia. holes of each pole
 (1 No.) for the (18 mm) dia. earthing.
All bolts, nuts etc. shall be firmly tightened in their places on the poles at
The poles shall be supplied with 5% spare bolts, nuts, etc.
8.10.3 Testing
All materials under contract shall be tested at the manufacturing works to verify compliance to our
specifications.
Mill certificates shall submitted for all steel material like joist, angel‐steel, steel plates, channel steel,
bolts, nuts, etc.
Dimensional tests in quantities not less than (5%) of the quantity of each batch, taking into
consideration that eccentricity between top and bottom part of the pole shell not exceed 1/1000.

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Loading tests (type test)
Table 8‐14: Loading test
Load Measuring item Acceptance criteria
Work load (Ps) Specified working load No any defect
Permanent load Ps x 1.5 load No any defect; 13 mm allowable
inclination
Breaking load Ps x 2.0 load destruction
*: at 2 min
The load test shall be carried out on 1% per each batch of 500 nos.
8.10.3.1 Alternative design:
The Supplier may offer an alternative design for the lattice poles, but the new design shall comply with
the above standards and minimum requirements.
8.10.4 Cross‐arms
The cross‐arm shall be used to support insulators carrying bare aluminum conductors on the medium
voltage poles (12 m).
The crossarms shall be made of section (channel steel) (ST‐41), (ST‐42), (ST‐44) or any equiv.
Flat steel, bolts, nuts and washers according to (JIS‐G‐3101 and JIS‐G‐1186) or equivalent. All steel work
shall be hot dip galvanized to BS 729 but bolts nuts; washers shall be electrically galvanized.
As an option the poles could be painted type with two anti‐oxide (red laite) paint layers with cross arms.
All bolts and nuts to be electrically galvanized.

Volume 8
8.11 Distribution transformers
8.11.1 Scope of work
This specification covers the design, manufacture, factory testing, packing, delivery and installation of
oil‐filled three‐phase distribution transformers with a rated capacity of 50 – 500 kVA for outdoor
installation. The transformer shall be designed for outdoor operation and continuous service.
The equipment and materials to be supplied in accordance with this specification shall conform to all
latest applicable standards of sponsor organization as follows:
Unless specified otherwise or modified herein, all IEC standard directly or indirectly applicable including
parts and addenda. Specific Standards include, but are not necessarily limited to the following:
IEC 60076 Power transformers
IEC 60137 Insulating bushings for alternating voltages above 1000 V
IEC 60296 Specification for unused mineral insulating oils for transformers and switchgear
IEC 60722 Guide to the lightning impulse and switching impulse testing of power transformers and
reactors.
8.11.2 Testing and inspection
8.11.2.1 General notes for test
The inspection and test listed hereinafter shall be carried out in accordance with the provisions in the
applicable IEC standard supplement by the specific requirements indicated hereinafter.
In the absence of IEC standards, the inspection and tests shall be carried out in such manner as to be at
least equivalent to conditions, provisions and definitions set out in one of the standards listed in this
specification.
8.11.2.2 Acceptance test
The acceptance test procedure for any delivery of the equipments is as follows:
Visual inspection
 Inspection of the complete equipment
 Checking of the result of the routine and type test
 Carrying out all or part of tests mentioned in the routine test
 Checking of conformity to specification.
8.11.2.3 Routine test
These tests shall be carried out on each individual of the equipment supplied, at the manufacture’s work
to ensure that the product is in accordance with the equipment on which the type has been carried out.
The manufacturer shall supply a certificate giving the result of the entire test carried out on the
equipment.
These tests shall include:
 Power‐frequency test (insulation testing)

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 Resistance test
 No‐load test
 Short‐circuit test
 Measurement of transformation ratios
 Certification of the absence of PCB
A test report containing the test results is to be drawn up for each transformer.
8.11.2.4 Type test
The following tests are to be performed on the specimens produced in accordance with these
specifications or certified through relevant Type Test Certificates issued by a recognized institution:
 Temperature‐rise test
 Noise tests with frequency analysis on all four sides
 Verification of short‐circuit strength, 3 tests for each leg lasting 0.5 sec.
 Impulse voltage test with full wave and with chopped impulse wave
 Leak test on the tank (leak test of the transformer for 24 h)
 Resistance test
 Measurement of transformation ratios
 No‐load test
 Short‐circuit test
 Insulation testing (testing with applied power‐frequency withstand voltage)
 Induced‐voltage test (testing with induced power‐frequency withstand voltage).
8.11.3 Specific requirements
8.11.3.1 Design
The transformers supplied shall be of hermetic design. All active parts – e.g. the core, windings and
internal connections – must be immersed in insulating liquid. The connections are to be executed as
follows:
HV side: Outdoor bushing conforming to standards
LV side: Outdoor bushing conforming to standards with flat connector
The operating pressure of the hermetic transformers shall not exceed 0.3 bars as measured at the
standpipe. In addition, the dimensions of the tank must also take into account the case that under
normal operating conditions the transformers will be run at a load of 140% of the rated power SN. The
difference between the maximum operating pressure and the burst pressure of the tank must be at
least 0.3 bars. The standpipe and other filling plugs are to be welded to the tank cover.
Cooling method
ONAN (oil‐natural, air natural cooling).
Windings
 US Winding made of Cu or Al, strip winding
 OS Layer or coil winding made of Cu or Al wire with varnish insulation.
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Degree of protection
IP54 with IP00 terminal connections.
Interconnecting cables
No riveted, screwed or soft‐solder connections may be used in the wiring and cabling between the
winding and the points of connection of the bushing or an off‐circuit tap changer.
Tank
 Material: Sheet steel
 Hermetically sealed elastic corrugated walls
 The changes in volume of the liquid coolant occurring during operation must be reliably
accommodated.
Cover
Screw design
Sheet thickness:  6.0 mm (opposite surface about 4 mm)
Seals: Asbestos‐free, oil‐resistant, resistant to heat and insulating liquid.
The seals on the bushings may not be larger than the bearing areas of the
bushings
Links: 2 pieces for cable attachment (cable grip).
Tank bottom
 Thickness of tank bottom: less than 4 mm
 Oil drain device
 Pursuant to IEC 60076.
Equipment and accessories
The transformers are to be fitted with the following accessories:
 Earth connections
 Lifting eyes
 Oil level indicator
 Fillers
 Pocket for contact thermometer
 Spark gaps on the HV bushing
 Locking device for the off‐circuit tap changer.
The terminal connections are to be marked as follows:
 Embossed brass plates on the cover assigned to the connections, coated together with the cover.
 Marking for the HV side: A B C
 Marking for the LV side: a b c 0.
Corrosion protection
Hot galvanising (including all metal mounting parts) and an additional priming coat. The intermediate
and top coats are to be in iron mica coating (light grey; total coat thickness: 150 µm) or powder coating
of the same quality. All sealing surfaces are to be furnished with durable corrosion protection. This is to
be certified in a suitable manner.

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External connecting elements, mounting parts and small accessories (e.g. bolts, screws, nuts, as well as
external parts of the off‐circuit tap changer) must all be made of non‐corroding material, preferably
stainless steel. No galvanised screws are to be used.
Insulating liquids
The transformers may only be filled by the manufacturer with one insulating liquid each. Mixing
different products or products from different suppliers is not permissible. Insulating liquid free of PCB
which can be mixed with insulating oil corresponding to a common standard is to be used. The
manufacturer and type of insulating liquid used are to be indicated for each transformer, e.g. in the test
report. The type of insulating liquid, e.g. “Mineral oil‐based insulating oil pursuant to DIN VDE 0370” is
to be indicated on the rating plate of each transformer.
Certification of the absence of PCB is to be submitted for each transformer.
Other requirements
The design of the transformers must also observe the following:
 After delivery, the transformers must be ready for use without any additional preparation (such as
tightening seals etc.)
 The transformers must be guaranteed maintenance‐free for at least three years following delivery
 All components, materials and accessories used must conform with the relevant standards or
demonstrably comply with the recognised state of the art
 The transformers may not include any substances containing PCB or asbestos; nor may they contain
any halogenated hydrocarbons. The absence of such substances must be stated on the rating plate.
8.11.3.2 Labeling and marking
Transformers shall be provided with a rating plate, which can be moved and affixed to any side of the
transformer. It shall be written in English language. All information has to be clearly and indelibly
marked or engraved. The following information shall be given:
 Manufacturer name
 Type
 Year of manufacture
 Serial number
 Operating mode
 Cooling method
 Rated frequency
 Transformation ratios
 Rated current LV and HV
 Rated power
 Connection symbol
 Total weight
 Mass of insulating oil
 Oil type.
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8.11.4 Electrical DATA
8.11.4.1 Short circuit currents
The transformers shall withstand the thermal and mechanical effects of any short‐circuit that can
appear at the terminal of any winding. The short‐time current (1 sec rms) rating shall be 22 kA.
8.11.4.2 Insulation level
The transformers shall be designed for the following insulation levels:
 Highest equipment Voltage: 12 kV
 Basic impulse level as per IEC 76:
 Impulse Test Voltage 1.2/50ys: 95 kV
8.11.4.3 Rated power
The rated output at +45°C maximum ambient temperature is chosen from the respective reports:
8.11.4.4 Rated voltage
Three Phase: 11.000/400 V
The rated secondary voltage shall be 400/230 V.
8.11.4.5 Off‐load tap changer
The high voltage windings shall be provided with an off‐load tap changer providing a neutral position
and 4 positions. Each step shall be 2.5%; total ratio selection is ±5% in 5 steps. The off load tap changer
shall have an external mechanism for manual operation. Tap positions shall be clearly identified. The
operating mechanism shall have an effective blocking device for locking of tap changer at any desired
position.
8.11.4.6 Vector group
The vector group shall be Dyn5.
8.11.4.7 Losses
Subject to compliance with the technical requirements, commercial conditions and delivery
requirements, tenders will be assessed on the basis of the least “Present Worth” of capital cost plus
guaranteed losses
The acceptance of transformers yielding component losses higher than the guaranteed values shall be
governed by the following:
Case A Component losses in excess of guaranteed values, but within the tolerances
permitted under IEC 76‐1.
Transformers under Case A shall be acceptable subject to full compliance with all other technical
particulars including temperature rises at continuous maximum rating and subject to the Supplier
accepting the imposition of penalty charges for each kW or part thereof component losses in excess of
the guaranteed values, at the loss evaluation rates mentioned above.

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Case B Component losses in excess of guaranteed values and exceeding the tolerances
permitted under IEC 76‐1.
The acceptance of transformers under Case B shall be entirely at the discretion of the Client and subject
to the Tenderer accepting the imposition of penalty charges of each kW or part thereof of component
losses in excess of the guaranteed values, at the loss evaluation rates mentioned above.
In the case of transformers yielding component and total losses which are equal to or below the
guaranteed values, the Supplier will not be entitled to any premium in respect of reduction in losses
below the guaranteed values.
No load losses USD 6,500 per kW
Load loss USD 1,500 per kW.
Rejection
The Purchaser shall reject any transformer if during tests any of the following conditions arise:
 No load loss exceeds the guaranteed value by 15% or more.
 Load loss exceeds the guaranteed value by 15% or more. Combined loss exceeds beyond guaranteed
value by 10% increase or more.
 Impedance value exceeds the guaranteed value by + 10% or more.
 Oil or winding temperature rise exceeds the specified value.
 Transformer fails on impulse test.
 Transformer fails on power frequency voltage withstand test.
 Transformer is proved to have been manufactured not in accordance with the agreed specification.
8.11.4.8 Impedance
The percentage impedance at 75°C shall be 4% for transformer rating up to 630 kVA and shall be 6% for
transformer rating more than 1,250 kVA subject to tolerance as per IS IEC‐76‐1, Table‐1 at normal tap.
8.11.4.9 Flux density
Flux density:
Flux density at normal voltage and frequency at any tap shall not exceed for high grade CRGO, (Grade‐
MOH or better), Silicon Steel Laminations: 1.60 Tesla.
Over fluxing:
Over flux in the transformer core shall be limited to 12.5% to ensure that in the event of over‐voltage to
the extent of 12.5%, the core is not saturated. The maximum flux density in any part of the CRGO core
under such condition shall not exceed 1.9 Tesla. Necessary design data shall be supplied in this regard.
8.11.4.10 No load current
No load current at 100% voltage shall not be more than 2.5 % of the full load current and shall be
subject to tolerance as per IEC. No load current at 12.5% over voltage shall not exceed 4%. The supplier
shall furnish necessary design data in support of this stipulation.
Volume 8
8.11.4.11 Protection against transients
In order to ensure that the transformers will withstand lightning/ disturbances, the impulse withstand
strength of transformers windings shall not be less than 95 kV peak for 11 kV.
The high voltage bushings of all transformers shall be provided with single gap arcing horns (adjustable).
8.11.4.12 Overloading
The transformer shall be capable of being overloaded as per IEC‐354 up to 150% of rated load. The safe
overload capacity of the transformer and duration of over load for satisfactory operation at site under
maximum temperature conditions shall be clearly stated in the offer. The temperature limits under the
specified over load capacity should also be stated & there shall be no limitation for over loading
imposed by bushing, tap changer etc. or any other associated equipment.
Bushings
High voltage bushings shall be created to withstand the highest system voltage (12 kV). It shall be
possible to change the bushings without removing the transformer cover. Each bushing will be marked
with manufacturer and type. The out creepage distance of the bushings shall be not less than
23 mm/kV. The insulation levels of the bushings shall be at least equal to those specified for the
windings. The neutral connection shall have permanent special marking which is different from the
phase connections. For pole type transformers HV bushings shall be located at the tank side remote
from the pole. The HV transformer bushings shall be equipped with line clamps suitable for the
connection of ACSR conductors sized from 70 to 150 mm². The LV bushing shall be equipped with line
clamps suitable to aluminum conductor XLPE insulated single core cables as below. The damps shall be
complete with necessary screws, washers and nuts.
8.12 Customer current meter boxes
8.12.1 General requirements
The Meter Boxes (MBs) are for use in the low voltage distribution system to achieve simple and cost
effective means of providing single phase and three phase connections to the customers. Meter boxes
will be installed at poles from the secondary network to provide service connections to small groups of
houses in their vicinity.
They shall be suitable for mounting on a secondary pole or wall or on a cast concrete plinth. All
necessary mounting bolts and wall plugs shall be supplied with the MBs.
The meter boxes shall be suitable for outdoor use in the service condition stipulated in this specification.
Single phase and three phase energy meters, bottom connected, shall be provided separately.
8.12.2 Quality of materials
All materials, whether fully specified herein or not, shall be of first class quality particularly with regard
to manufacture, strength, ductility and durability and shall conform to the best modern practice and
comply in all respects with these Specifications.
All material shall be inspected and tested in full to prove compliance with the requirements of the
Specifications. The testing shall be carried out according to the relevant Standard approved by the
Engineer.

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8.12.3 Surface coating and galvanising
All iron and steel used shall be protected against corrosion effects, after the whole fabrication is
completed, by galvanisation, metallization or paint applications.
The surface coating shall be uniform, clean and smooth. The formulation and application procedure shall
be as recommended by the manufacturer for the appropriate exposure conditions.
The preparation for surface coating and the coating itself shall not distort or adversely affect the
mechanical properties of the materials.
The colour of all top coats shall be approved by the PO if not described in detailed specification below.
If any coated part is found to be imperfect, such part must be replaced. The whole of the expense
involved in the replacement of the imperfect part shall be borne by the Supplier.
8.12.4 Details of meter boxes
8.12.4.1 Applicable Standards
The items and components supplied shall be in accordance with the later editions of the standard
specified below and amendments thereof.
IEC 60947 ‐ Low voltage switchgear and control gear.
 Part 1 ‐1988 ‐ General Rules
 Part 3 ‐1990 ‐ Switches, disconnectors, switch‐disconnectors and fuse‐combination units.
8.12.4.2 Basic features
The Meter Boxes (MBs) are used in the low voltage distribution system.
The box shall be suitable for outdoor mounting on house walls, poles or on cast concrete plinth. All
necessary mounting parts as bolts, nuts, washers, pegs, screws shall be supplied with the MBs.
Two types of meter boxes are foreseen: Meter box with three and six meter places.
Meter boxes shall be equipped with
 Metal housing (meter box) with wiring for single or three phase kWh meters according to Bill of
Quantity
 An installed three pole Mini Circuit Breaker (MCB) of 40 A at the incoming side
 Installed mounting rails for meter
 Installed phase, neutral and ground buses.
 Terminal fittings
 DIN rails for mounting of MCB and power limiter
 Incoming supply and outgoing service cable connections
 Mini circuit breaker for each outgoing service line.
All of the above parts shall be pre‐mounted in the box, wired and ready for operation. In addition
sufficient space for the installation of power limiters shall be foreseen.
8.12.4.3 Design
The meter boxes consist of a detachable metal box with hinged door on either side of the broad side.
Volume 8
The incoming service cable is connected to the distribution terminal blocks through the MCB using
suitable cable lugs terminations. Distribution cable terminations shall be mounted on either side of an
insulated board and both termination shall be connected through a detachable link.
The MBs shall locate three and six meter seats. The meter shall be equally connected to each incoming
phase.
8.12.4.4 Housing
The housing shall be made of sheet steel with a minimum thickness of BWG 16. It shall provide
protection class IP54 according to IEC 60529.
All equipment shall be surface mounted on an interior panel, and shall be accessible from the front and
protected by covers.
A standard mounting rail shall be provided for MCB installation.
The housing shall be equipped with a minimum 2 screened openings for ventilation.
8.12.4.5 Terminals
The terminal blocks shall be of the bolted type, with terminals of bronze or brass, suitable for stranded
copper cable, up to 25 mm².
There shall be three separate terminal blocks: one for the utility cables (Phases A, B, C), one for the
customer cables, one for neutral and one for grounding. Each shall be fitted with a screwed, insulating,
protective cover in the respective standard colour (green/yellow for grounding, blue for neutral).
The temperature in the contacts and terminals shall be within the specified limit as per IEC 947, and
shall not cause any damage of a nature which impairs the performance of the equipment. MBs shall be
pre‐wired.
The equipment shall be supplied complete with terminal fittings suitable for connecting PVC/XLPE 4*16
to 4*25 mm² Al insulated concentric cables for the incoming connection and for PVC/XLPE 2*8 to
4*16 mm² Al isolated cables for customer connection.
When a cable termination uses two fasteners, the order of tightening shall not be detrimental to the
termination. If torque limiting devices are not used, the manufacturer shall mark the required tightening
torque adjacent to the terminal fastener.
The cable termination fasteners shall have hexagon heads of 12 to 18 mm across flats and be accessible
using standard socket spanners.
All metal parts under load shall be covered to prevent touching.
8.12.4.6 Incoming main supply cable connections
It shall have the provision for main supply cable from the secondary distribution network. Termination
of the incoming cable and outgoing cables shall be suitable for use with cable lugs.
8.12.4.7 Outgoing service cable connections
The conductor terminals and the fuse contacts shall be designed and proportioned as to carry
continuously its rated current without exceeding the maximum temperature as indicated in the relevant
standards.

Volume 8

8.12.4.8 Mounting rails
Galvanised mounting rails shall be provided for mounting meters of bottom connected type, the MCB
and eventually the power limiter. Galvanising shall conform to EN ISO 1461 or equivalent.
8.12.4.9 Conduit clamps
Cable entry shall be through bottom entry conduits, conduit clamps, galvanised EN ISO 1461 or
equivalent, shall be provided. Sufficient traction relief shall be ensured for the cables.
8.12.4.10 Locking devices
Doors are to be fitted with padlock holders to prevent unauthorized entry. Triangular headed locking
bolts shall be recessed and protected to exclude opening, except by use of key. Keys to fit these bolts
shall be provided.
8.12.4.11 Grounding
The MBs shall be equipped with a defined grounding point for connection of grounding cable of 10‐
35 mm² size. The grounding connection shall be marked with the grounding symbol. All bolts washers
shall be delivered with the MB.
8.12.4.12 Testing
The routine tests shall follow DIN VDE 0100, part 610. Test certificates shall be provided.

Volume 8
8.13 Mini circuit breaker
8.13.1 Scope
Mini Circuit Breakers are installed to protect the electronic meter and the outgoing service cables until
the in‐house fuses. They also allow to de‐energize the house connections for repair and maintenance.
8.13.2 Basic features
8.13.2.1 Scope of supply
The mini breakers are used in the low voltage distribution system. They shall be pre‐mounted in the
meter box and shall be delivered with all necessary mounting parts.
The applicable standards are DIN VDE 0660/9.92 and IEC/EN 60947‐2.
8.13.2.3 Design
The MCBs shall be of modular type, (moulded compact case‐type) and designed of one piece type, be
removable and interchangeable. The operating mechanism of the MCB shall be mechanically trip free.
Insulated parts of the units shall be of a suitable reinforced plastic material which has, in addition, a high
resistance to solar radiation.
Any current carrying parts shall be of non‐ferrous metal adequate for the rated current capacity.
Padlocking facilities shall be provided to accommodate the circuit breaker in an open position.
MCB for customer shall have nominal currents of 40 A for incoming cables and of 24 A for single phase
service and 40 A for three‐phase service connections and a minimum 10 kA breaking capacity, according
to IEC 60947‐2 Low ‐ voltage switchgear and control gear ‐ circuit breakers.
Rated Impulse Voltage shall be 6 kV and power withstand voltage shall be 2 kV 50 Hz 1 min.
The MCB shall have thermal and magnetic tripping unit. Tripping characteristics are K for all 3‐Phase
MCBs and Z for all single phase MCBs.
The MCBs shall be mounted on DIN rail in the enclosure.
The MCBs shall be pre‐equipped with terminals for cable connection.
The Supplier shall provide all the characteristics, curves, dimensions of the MCBs used.
Testing and inspection will be carried out according to the general specifications. Materials and
equipment will be inspected in the manufacturer's factory.


Volume 8

Table 8‐15: MCB‐Characteristics
Item 230 V/1 phase 400 V/3 phase
Rated voltage 230 V AC 400 V AC
Frequency 50 to 60 Hz
Cable capacity Up to 25 mm²
Life expectancy >5,000 operations
Maximum tightening torque 3 Nm
Ambient temperature ‐25°C to +55°C
Nominal current 25 A 40 A
Tripping characteristic B K
Breaking capacity 6 kA 6 kA
8.13.3 Additional requirements
8.13.3.1 Packing
All items shall be suitable packed to prevent damage due to rough handling.
8.13.3.2 Documentation
The Supplier shall supply along with the equipment relevant drawings and technical literature including
installation, operation and maintenance instructions.

Volume 8
8.14 LV aerial bundled conductors (ABC)
8.14.1 General
This specification applies to LV aerial bundled conductors. The aluminium standard cross sections are:
 3x35 (phases) + 35 (Neutral messenger) mm²
 3x120 (phases) + 95 (Neutral messenger) mm².
With respect to electric load size of neutral messenger may be reduced from 70 mm² phase size
onwards. However, the Bidder has to justify that mechanical strength is sufficient to carry the cable load
at the given average support distances (poles) of about 50 m.
ABC cable are delivered in three types:
1. ABC cables with all self‐suspension conductors are equally made out of insulated Aluminum with
the same cross section. All four conductors are equally taking the line tension.
2. ABC cables with insulated suspension conductor (mainly the neutral or messenger is used for
this). The 3 phase conductors are made of aluminium while the messenger is made of aluminium
alloy. Only the neutral conductor takes line tension.
3. ABC cables with bare suspension conductor (mainly the neutral or messenger) and three isolated
equal phase conductors. The 3 phase conductors are made of aluminium while the messenger is
made of aluminium alloy. Only the neutral conductor takes line tension.
All three types are applicable. But is has to make sure that at least one conductor can take the tension
load appearing at the chosen pole span and considering wind and other additional loads. Otherwise, a
25 mm² steel wire shall be used for fixing the ABC cable and shall be included in the unit price.
8.14.2 Applicable standards
The equipment supplied shall confirm the latest edition of appropriate IEC specifications and/or
recognized international standards. In particular: DIN VDE 0274, IEC 60889, IEC 509, DIN 57 207, DIN
512210660/9.92 and IEC/EN 60947‐2.
The preferred design of bundled conductors is one of self‐supporting phases and neutral bundles,
designated NFA2X and manufactured to VDE 0274, where the designation stands for:
N VDE standard
F overhead cable
A aluminium conductor
2X XLPE insulation.
However, other designs, such as a bundle with a magnesium and silicon alloy aluminium catenary
doubling up as neutral, stranded and or compacted Al conductor with Al alloy messenger, hard drawn Al
conductor and messenger, Al stranded conductor with steel messenger, not manufactured to VDE
standards shall also be considered, as shall other bundled conductors designed and constructed to
different international standards. However, in very case the Bidder has to justify and show that electric
and mechanic strength are sufficient for the required electric and mechanic loads.

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8.14.3 Electrical characteristics
Nominal voltage of ABC cables is 0.6/1 kV.
 Dielectric strength: Cores shall be designed to withstand without breakdown the application of 10 kV
voltage during 1 minute.
 Impulse withstand: Cores shall be designed to withstand without breakdown a standard impulse
voltage sequence 1.2/50µs of positive and negative polarity with a peak value equal to 20 kV.
 Routine test: 4 kV/15 minutes
8.14.4 Cable structure conductors
The conductor cross sectional area shall be circular.
The strands of phase and neutral conductors shall consist of hard drawn aluminum alloy according to IEC
60 889
The aluminum strands used for the construction of phase and neutral conductors for bundles shall have,
before stranding, an ultimate tensile stress at least equal to 120 MPa.
Insulating Sheath: The insulation sheath shall consist of an extruded sheath of cross‐linked polyethylene
conforming to IEC 502 and shall be black‐coloured. It shall easily be removed. Insulation XLPE thickness
is 1.5 mm.
8.14.5 Markings
Each individual conductor comprising a bundle shall have sufficient markings indicating:
 Manufacturer's identification. As an alternative, a thread beneath the insulation with a stable and
permanent colouring in accordance with the manufacturer's trade mark will be acceptable.
 Year of manufacture: last two digits are sufficient
 Designation of conductor type: for example 3 x 35 + 35
 Rated voltages class: 0.6/1 kV.
8.14.6 Maximum permissible temperatures
The maximum permissible temperatures for the Conductor are as follow:
 90°C during normal operation,
 120°C under a short duration overload (a total 24 hours a year in separate periods of 3 hours at the
most)
 250°C under multi‐phase short circuit conditions.
These temperatures are based on the intrinsic properties of the insulating materials. These values can
only be used for calculating permissible current ratings.
8.14.7 Tests
The inspection and test listed hereinafter shall be carried out in accordance with the provisions in the
applicable IEC standard supplemented by the specific requirements indicated hereinafter. In the
absence of IEC standards, the inspection and tests shall be carried out in such manner as to be at least
equivalent to conditions, provisions and definitions set out in one of the standards listed in this
specification.
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Unless expressly stated otherwise, the ambient temperature for routine tests as well as voltage tests
shall be 15+10°C and 15+5°C for all other tests. The frequency of the alternating test voltage shall be
40 Hz to 62 Hz. The voltage waveform shall be near to sinusoidal.
8.14.7.1 Type tests
The test sample shall be 10 m to 15 m in length. All cores of the bundle shall be tested. The test
sequence shall be as follows. Type tests can be omitted if a certificate issued by a recognized institution
is provided.
 Insulation resistance at ambient temperature;
 Insulation resistance at operating temperature; and
 AC voltage test.
The insulation resistance test at operating temperature shall be conducted in a water bath at 80°C and
in conformity with VDE 0472.
In addition to the tests just described, the routine tests and sample tests listed below shall also be the
object of type tests.
The following measurements or tests shall be carried out on all drums and coils of bundled conductor:
 Conductor resistance; and
 Voltage test.
8.14.7.3 Sample tests
The following sample check, measurements and tests shall be applied:
 Measurement of insulation wall thickness;
 Measurement of outside diameter;
 Thermal expansion test;
 Check of physical characteristics; and
 Tensile strength of the conductor individual wires.
These tests should be carried out on one length from each production batch of the same type.


Volume 8

8.15 Accessories for LV aerial bundled conductor
8.15.1 General
The following accessories for LV Aerial Bundled Conductors shall be supplied: single anchor assembly,
stain clamp, suspension assembly, insulated facade saddle, insulation piercing connector, pre‐insulated
compression sleeve for LV aerial bundled conductors as well as service aerial clamps.
8.15.1.1 Definitions
 Anchor assembly: A bracket and a strain clamp designed to terminate mainline bundled conductor
and to transfer its tensile loading to the supporting structure.
 Suspension assembly: A bracket and a clamp designed to support the bundled conductor at
intermediate positions and light angle positions (45° maximum line deviation).
 Large angle or double dead end: When the deviation of the line is > 45°, called large angle, a bracket
will be used with two strain clamps.
 For a double anchor system, two brackets will be used with two strain clamps.
 Insulated facade saddle: A saddle designed to support an ABC cable at regular intervals on a surface
and which provides a secondary insulation for the bundle.
 Service aerial clamp: A clamp designed to terminate an aerial service conductor bundled to a pole or
a wall anchor.
 Insulation piercing connector: A tap connector which is designed to be applied to the conductor of
bundled ABC without removing the insulation.
 Pre‐insulate compression sleeve: A pre‐insulated junction sleeve designed to joint ABC with other
ABC. Neutral sleeve is full tensioned.
8.15.1.2 Design
All items shall be suitable for the whole range or part of the range of ABC, as well as for the conductor
materials used. The service clamps shall be used for all ABC services lines.
All items shall be designed to meet the performance requirements of the various sections of this
specification. They must be adequately rated for their intended application and retain this rating their
normal lifetime in an outdoor environment.
All items shall be free from defects which could cause them to be incorrectly assembled or to perform
unsatisfactorily in service. Finish shall be such that outer surface are free of sharp edges and burrs which
could result in damage to adjacent material or personnel.
Items comprising different component shall be so designed that they can be applied without
disassembly, the installation of all items shall be possible by one man working alone.
8.15.1.3 Materials
The materials used for manufacturing the lifting, accessories and apparatus covered by this specification
shall be compatible with the materials of the ABC such that the reliability of either will not be impaired
by their association.
Materials shall be resistant to climatic stress. All insulation materials shall be ultraviolet stabilised and
coloured black. Steel parts shall be hot dip galvanized (other treatment is possible if the protection
against corrosion is equivalent or better than hot dip galvanisation) or made in stainless steel. Other
metallic parts shall be non‐corrosive type.
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8.15.1.4 Identification markings
All items shall be legibly and indelibly marked with:
 Manufacturer logo or symbol
 Identification set
 Manufacture code
 Standard.
Special marking for pre‐insulated junction sleeves and pre‐insulated lugs:
 Position and order of compression (cripping)
 Removing insulated Length
 Grove index.
Indelibly test: Each marking shall be rubbed with a rag with water during 15 seconds and rubbed again
with a rag saturated with water during 15 seconds and rubbed again with a rag saturated with petrol
during 15 seconds. After this test, the marking shall be legible.
8.15.1.5 Tests
The inspection and tests shall be carried out in accordance with the provisions in the applicable IEC
standard supplemented by the specific requirements indicated hereinafter. In the absence of IEC
standards, the inspection and tests shall be carried out in such manner as to be at least equivalent to
conditions, provisions and definitions set out in one of the standards listed in this specification.
8.15.2 Anchor assembly
8.15.2.1 Description
Each assembly includes:
 1 tension bracket made of Aluminium Alloy
 1 wedge type dead end clamp.
Brackets shall be made of Aluminium Alloy suitable for attachment to the used type of oole by two M14,
M16 bolts or two stainless steel strap of 20 mm width and 1 mm thickness max. The distance between
the two straps shall be 70 mm. The hook point for clamps shall be 10 cm (+1‐2) from pole.
Clamps shall be designed to anchor ABC with the respective neutral messenger. The clamps shall be
Wedge type. They shall be made of mechanical and weather resisting material. No bolt for clamping the
neutral messenger and no losely parts are allowed.
Also no tools shall be required for installation. The clamp must be supplied with a flexible attachment
into the above bracket by means of stainless steel flexible braid or hook. Parts directly in contact with
the neutral messenger shall be made of insulated material to provide secondary insulation between
conductors and metal parts.
Bracket and wedges clamp shall be specified together to ensure an excellent compatibility between
materials to reduce all mechanical and climatic stresses.
8.15.2.2 Tests
All loading tests shall be carried out with 50 mm² neutral messenger. For the clamp dielectric, tensile,
and slip tests, and for the bracket mechanical tests are to be certified.

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8.15.3 Suspension assemblies
Each assembly includes:
 1 Suspension bracket made of Aluminum Alloy for securing to all types of structures and shall be
feasible indistinctly with one stainless steel strap.
 1 Suspension bracket clamp and movable articulate link made of thermoplastic without any steel
component.
The suspension damp and articulated link is a device where no bolt for tightening the conductor and no
loose parts are allowed. Clamping of the neutral messenger shall be of controlled slippage. This device
must have the capacity for the suspension and tightening of messenger to 50 mm². Both suspension
clamps and articulated link must be made entirely and exclusively of mechanical and weather material.
Parts directly in contact with the neutral messenger shall be made of insulated material to provide
secondary insulation between conductors and metal parts. Not bolt for clamping the neutral messenger
and no loose parts are allowed. Also no tool shall be required for installation of the clamp in the field.
Bracket and suspension clamp shall be specified together to ensure an excellent compatibility between
materials to reduce all mechanical and weathering stresses.
8.15.3.2 Tests
For the clamp dielectric, tensile and slip tests shall be performed and documented; for the brackets
mechanical tests. The suspension assembly shall be subject to fatigue test.
8.15.4 Insulated facade saddle
Saddle shall be used for securing ABC on walls. These saddles can be rapidly fixed onto a wall be means
of a screw or a nail. Saddles are to be supplied complete with the screw (or the nail) and the integral
plug. The distance from the wall is required to be kept 1 cm. They should be able to secure all ABC of the
required cross‐section. Their design must provide a secondary insulation between the conductor and a
facade or any metal part of the saddle attaching to the facade. The design must permit them to be
attached to the facade before ABC is fitted. They must be used on concrete or wooden facades.
Afterwards the ABC must be releasable without removal of the first bundle. The insulating saddle
material must be ultraviolet stabilized, be black in colour, resistant to degradation due to pollution or
weathering. Exposed steel parts must be hot dip galvanizing or equal or better protection surfacing. The
ABC shall be installable without special tool.
8.15.4.2 Tests
The tests shall include dielectric and mechanical tests.
8.15.5 Service aerial clamp/anchoring assembly for service cable
Service aerial clamps shall be designed to fix conductor bundles at poles and at buildings. The clamps

shall be wedge type. They shall be made of mechanical and weather resisting material. No bolt for
clamping the bundles and no losely parts are allowed. Also no tool shall be required for installation of
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the clamp in the field. Parts directly in contact with the bundle shall be made of insulated materials to
provide secondary insulation between conductors and metal parts.
The clamp must be supplied with an attachment of stainless steel braid or hook (aluminum is accepted).
One service aerial clamp shall accept the different bundle thereafter:
 2x 8 mm² Al
 2x10 mm² Al
 2x16 mm² Al
 2x 25 mm² Al
 4x 16 mm² Al.
8.15.5.2 Tests
The tests shall include dielectric and slip tests.
8.15.6 Insulation piercing connectors
 Implementation range: connection of service drop conductors to ABC network and tee‐offs of main
bundled conductors.
 Description: waterproof, high mechanical and climate resistant, insulated structure connector.
The connector shall be insulated and suitable for use on live or deadlines. The insulation piercing
connector shall not have lose components that are liable to be lost during installation. 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 system. The housing shall be an integral part
of the connector. The bolts shall include an overtorque shear head made of suitable material which
allows a clamping torque in conformity with the recommendation of the manufacturer, without the
need of any special tool.
It is absolutely necessary that none of the energized parts of the connector can be reached directly by
the operator during connector installation. Insulation piercing connectors shall be dielectrically
waterproofed in the same manner as the relevant cable. It shall withstand 6 kV while immersed under
water (30 cm depth) for 1 minute. 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 the need to strip the bundled conductor insulation. To achieve the required
water tightness a special rubber seal shall be provided around the teeth of the present connector. The
bolt washers shall be of corrosion resistant type.
The current rating of the connectors shall be according to rating of the specific cables. Two types of
connectors are provided and are summarized as follows.
a) Tee off connector for main network ABC
ABC main and tee‐off connectors shall be of insulation piercing type on the main conductor. The tap
conductor may be disconnected for easy fault location and operation. These connectors shall be
with separate tightening.
o Application: ABC to ABC, separate tightening
o Cross section main conductor: As required and specified
o Cross section tap conductor: As required and specified.
b) Tee off connector for service line to ABC network

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ABC service connectors shall be of simultaneous insulation piercing type on main and tap
conductors. Service lines can be made of Aluminium (ABC), Copper (insulated conventional wire) or
Concentric Copper. These connectors shall be with simultaneous tightening 1 bolt, 1 tap.
o Application: service line to Main ABC
o Cross section main conductor (ABC): As required and specified
o Cross section service tap: 8 to 25 mm²
o Application: house connections, temporarily connections
o Cross section main conductor (ABC): As required and specified
o Cross section service ABC tap: 8 ‐ 25 mm² Al core.
8.15.6.2 Tests
The tests shall include dielectric and water tightness tests and tensile tests on main and tap conductor.

Volume 8
8.16 Single‐phase and three‐phase electronic kWh meters
8.16.1 Standards
For the purpose of design, manufacture, quality of new material, test and manufacturing, the
equipment shall meet this Specification and the following International Electro‐technical Commission
(IEC) standards and recommendations:
EN 62052‐11: Electricity metering equipment (AC) ‐ General requirements, tests and test conditions ‐
Metering equipment
EN 62053‐21: Electricity metering equipment (AC) ‐ Particular requirements ‐ Static meters for active
energy (classes 1 and 2)
EN 62053‐31: Electricity metering equipment (AC) ‐ Particular requirements ‐ Pulse output devices for
electro‐mechanical and electronic meters (two wires only)
EN 62053‐23: Electricity metering equipment (AC) ‐ Particular requirements ‐ Static meters for reactive
energy (classes 2 and 3) or
EN 61000: Electromagnetic compatibility (EMC)
EN 61268: Alternating current static VAr‐hour meters for reactive energy (classes 2 and 3)
EN 62053‐61: Electricity metering equipment (AC) ‐ Particular requirements ‐ Part 61: Power
consumption and voltage requirements
EN 61358: Acceptance inspection for direct connected alternating current static watt‐hour meters for
active energy (classes 1 and 2)
EN 62056‐21: Electricity metering ‐ Data exchange for meter reading, tariff and load control ‐ Direct local
data exchange
EN 60529: Specification for degrees of protection provided by enclosures (IP code).
The above mentioned standards do not exclude other known national or international standards. The
Supplier shall indicate in his offer to which standards his equipment is manufactured and submit to the
Employer with his offer a copy of these standards.
8.16.2 Basic characteristics
8.16.2.1 Characteristics
a) Electronic kWh‐meters shall be of one element for single and three phase installation
b) Nominal voltage and service type shall be 230/400 V for 3 phase meters and 230 V for single phase
meters. Operating range shall be ± 15% of rated voltage. Autoprogrammable on range of 120‐
480 V AC should be also acceptable.
c) Nominal frequency: 50 Hz ± 5 %
d) Nominal current is 10 A (single phase) and 20 A (three‐phase)
e) Maximum current is 30 A (single phase) and 80 A (three phase)
f) The meters are directly connected.
g) Bottom connected

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h) Accuracy class; 2 (Standard IEC 62053‐21) or better.
8.16.2.2 Requirements for measurement
a) Meters shall measure, by mean of digital sampling or any other recognized method the energy
consumption
b) Digital algorithm for measurements processing shall take into account the presence of harmonics.
8.16.2.3 Protection class
Meter shall be able to operate in a closed metal box mounted outdoor. Minimum protection class shall
be IP53 according to IEC 60529.
8.16.2.4 Reading of meters
In case of interruption of electricity supply, electronic meter register shall retain in non‐volatile memory
all metered values. Reading shall be performed through direct reading from display as basic method.
8.16.2.5 Display
All information registered by meter shall be shown on a liquid crystal display with alphanumeric
displaying. Minimum number of digits on display shall be 6. Display format for values shall be selected
by programming (number of integers and decimals).
8.16.2.6 Nameplate
Meter shall have the following minimum information printed in English or Urdu language in indelible ink:
a) Manufacturer's name or trademark
b) Meter serial number. If serial number is marked on a plate fixed to cover, the number shall also be
marked on meter base.
c) Meter type
d) Meter class
e) Nominal voltage operating range
f) Base current and maximum current
g) Frequency
h) Accuracy class
i) Watt‐hour constant
j) Year of manufacturing
k) Identification of system service (number of wires and connection).
8.16.2.7 Meter cover, terminal block and meter case
Meter case
The meter shall have a case made of polycarbonate (PC) or of material with equivalent performance for
this purpose.
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Meter cover
The meter cover shall be made of ultraviolet‐stabilized polycarbonate or material of equivalent
performance for this purpose. It shall be so constructed and arranged that any non‐permanent
deformation shall not prevent the satisfactory operation of the meter.
Terminal block
The terminal block shall be made of polycarbonate (PC) or material of equivalent performance and rated
for the specified purpose. At the terminal block, the meter leads for direct connection are to be
connected at the terminals using a brass current bus bar and screws in accordance with the standards
EN 62053–21 and EN 62052–11, for connection to the CTs respectively. Auxiliary and control terminals
have to be made according to the "PLUG IN" principle or using adequate terminals. All terminals shall be
arranged in one terminal block and be suitable for front connection having adequate insulating
properties and mechanical strength. The manner of fixing the conductors to the terminals shall ensure
firm and durable contact and be secured against loosening to prevent undue heating of the conductors
or the terminals. The material of the terminal block shall be capable of passing the tests given in
standard ISO 75 for a temperature of 135°C and the glow wire test at 960°C. The terminals shall permit
the connection of both solid and stranded aluminium conductor of a cross sectional of 10‐16 mm².
Terminal layout should comply with DIN 43856 / BS7856‐1996 / IEC 61354 and the connection scheme
should be clearly indicated underneath the terminal.
8.16.2.8 Sealing facilities
The meter design shall have provisions for the sealing of meter electronics housing and terminal cover
by using seal wire and lead seal. The active part of the meter shall be factory‐sealed. It shall not be
possible to remove or open the meter without irreparable damage of the seals.
8.16.2.9 Metering, recording and display features
General
The meter shall provide the following measurements:
 Exported active energy for 3‐ph meters
 Exported active energy for 1‐ph meters.
Operating reserve
Meter function must not be disrupted for 3‐ or 1‐phase power outages of less than 500 ms. For a power
cut exceeding 500 ms all non‐stored data shall be stored in a non‐volatile (EEPROM) memory.
Back‐up power supply
In case of power outage, RTC shall be supplied by a super capacitor or battery so that RTC retains date &
time until power comes back. The super‐capacitor must have at least a capacity of 7 days in continuous
operation of supply of RTC and an overall lifetime of min. 15 years. Recharge of the super‐capacitor
should happen as soon as the power comes back and should not take more than 24 hours for a
complete recharge. Where a backup battery is used, it shall have a minimum 3‐year capacity at
continuous operation under normal temperature conditions and expected life time of at least 10 years.
The exchange of the battery shall be possible without removing the seal.

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Other capabilities
The meter shall comply with the above technical specifications but other additional features should be
welcomed for future upgrading or retrofit. Description of the possible characteristics such as time of use
metering or automatic meter reading, modem, etc. shall be included on the bid.
8.16.3 Instruction manuals
For each meter supplied, one (1) complete set of the following instruction manuals shall be provided:
 Mounting, connection and operation manuals,
 Parts manual,
 Installation.
Manuals shall be written in English language. The descriptions shall be clear and precise. If necessary,
they should be accompanied by sketches, diagrams, etc.
8.16.4 Tests
8.16.4.1 Type test
The following type tests shall be conducted in accordance with the latest IEC 62052‐11.
 Heating
 Insulation
 Output elements
 Functional requirements and tests
 Electromagnetic compatibility (EMC)
 Radio interference suppression
 Others according to manufacturer's standard.
The above type tests may be omitted if a record of tests, confirmed by respective certificates issued by a
recognized institution, can be supplied made on the same type and having identical characteristics.
8.16.4.2 Acceptance test
 Each batch of tariff meter shall be acceptance tested in accordance with IEC 61358.
 The Supplier shall submit samples of meters to be checked and accepted by the Purchaser
 Sample inspection using the variable inspection method shall apply.
 If unsatisfactory results occur due to meter errors not being normally recognized and accepted, then
the meters may be inspected by attributes. A different sample selection of tariff meters shall be used
if the batch is inspected by random.
 If unsatisfactory results occur using the inspection by random method, then either 100% of all meters
supplied shall be tested or the entire batch will be rejected.
 The supplier of the equipment shall submit at delivery all protocols and test results (type tests and
routine tests) performed on equipment according to international standards.
8.17 MV combined disconnector and fuse cut‐outs
This specification covers the design, manufacture, testing, supply, delivery and installation requirements
of 11 kV pole mounted, single phase, rod operated, combined disconnector and fuse cut out. The
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technical performance characteristics of the combined disconnector/cut out fuse are compiled in Table
18‐16.
Table 8‐16: Combined disconnector/fuse cut out
Rated frequency 50 Hz
Rated current 100 A
Rated short time current 8 kA
Power frequency 50 Hwithstand voltage 45 kV
Impulse withstand voltage 110 kVp
8.17.1 MV disconnector
8.17.1.1 Scope
This specification covers the general requirements of design, manufacture and testing of high voltage
11 kV disconnectors for high voltage overhead networks.
The equipment and the components supplied shall be in accordance with the latest edition of the
standards specified below and amendments thereof.
 IEC 60129 (1984) ‐ Alternating current disconnectors and earthing switches
 IEC 60265‐1 (1983) ‐ High‐voltage switches for rated voltages above 1 kV and less than 52 kV
 IEC 60694 (1996) ‐ Common clauses for high voltage switchgear and control gear standards
 IEC 60273 (1990) ‐ Characteristics of Indoor & Outdoor Post Insulators for Systems with Nominal
Voltage greater than 1000 V.
 ISO 898 ‐1 & 2 (1988) ‐ Mechanical Properties of Fasteners
 EN ISO 1461(1999) ‐ Hot dip galvanized coatings on iron and steel articles.
8.17.1.3 Design
The disconnecting switches shall be of three phase type, suitable for outdoor use.
They shall be used for isolating spur line/distribution substation from the energised section and they
shall be of the single side break type isolation with manual gang operated mechanism.
The disconnector shall be able to break a small current of 1.5 A at 0.8 PF and necessary replaceable
auxiliary arcing contacts shall also be provided.
The disconnector shall have the feature for install a load interrupter switch for 20 A. The load
interruption shall be achieved by providing a parallel circuit for re‐directing the load current path from
the main isolator contacts. An arc chute shall be provided for each switched pole and circuit interruption
shall take place within the arc‐chute. Insulating barriers between the phases and outer phase with the
enclosure shall be included.

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8.17.1.4 Construction
The construction of the whole unit complete with adjustable support brackets, clamp plates, bolts, nuts
and washers shall be compact, lightweight and robust.
The mechanical design and strength of the unit and components shall be able to bear the mechanical
forces on the terminals when installed and on operation. They should withstand the electrodynamics
forces without reduction of reliability or current carrying capacity of the Disconnectors.
The insulators incorporating the breaking arm shall be securely fixed to the phase coupling bar so as to
achieve a positive closing or opening operation of the three phases simultaneously.
8.17.1.5 Insulators
The insulators shall be of solid core post type. They shall be made of high quality insulating porcelain
utilising clean aero‐dynamic sheds giving extended creepage distances and excellent performance even
under conditions of heavy atmospheric pollution.
8.17.1.6 Stationary and moving contacts
The fixed and moving contacts shall be made out of copper alloy and the contact surface shall be silver
plated. The fixed contacts shall be fitted with stainless steel compression springs to provide the required
contact pressure.
8.17.1.7 Terminals
Clamp type terminals, suitable for vertical/horizontal terminal take off, made of aluminum alloy castings
shall be provided to accommodate 4 mm to 20 mm dia. aluminum conductors (ACSR) and Al XLPE cable.
8.17.1.8 Operating mechanism
It shall be suitable for manual operation with padlocking facilities only in the fully opened or fully closed
position.
The operating mechanism shall be suitable for left hand or right hand mounting of the line post
structure. The direction of operation, ON and OFF position shall be clearly and indelibly marked on the
disconnector operating mechanism.
The phase coupling bar shall be positioned, clamped and secured to the base frame for positive direct
drive. The drive lever shall be suitable for vertical mounting. Stainless steel piercing screws shall be
provided to secure the lever once positioned and clamped.
The vertical drive rod shall be of 8 metres length and facility for extending or reducing the length of the
vertical drive rod by 1 m shall be provided. Necessary threaded couplings and operating rod guides shall
also be supplied with each operating mechanism.
The complete operating mechanism with operating handle shall be arranged for steady hand operation
from ground level. Non ageing and UV treated insulation shall be provided to the holding parts of the
operating handle for safety.
The bearings of the mechanism shall be of permanently sealed corrosion proof, anti‐friction type and
free from maintenance.
All bolts and nuts to conform to the standard specified. The nuts and heads of all bolts to be of
hexagonal type.
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8.17.1.9 Mounting arrangement
The combined system shall be suitable for horizontal mounting on steel crossarms of two poles
transformer substations.
8.17.1.10 Galvanizing
All steel components such as the base section, phase coupling bar, drive lever, vertical drive rod,
mounting attachments, operating rod guide clamp, operating mechanism, bolts nuts and washers shall
be of hot dip galvanized.
Except where specified to the contrary all iron and steel parts shall be galvanized after the processes
such as sawing, shearing, drilling, punching, filling, bending and machining.
Galvanizing shall be applied by hot dip process to comply with EN ISO 1461: 1999 for all parts other than
threaded work and shall have a mean coating (minimum) thickness not less than 85 pm. All threaded
sections shall have a mean coating (minimum) thickness not less than 45 pm.
All items shall be treated with Sodium Dichromate solution after galvanizing to prevent the formation of
white rust.
8.17.1.11 Tools
Any special tools or devices necessary for operation and maintenance of the unit shall be supplied with
the unit and the cost of such tools shall be included in the price quoted for the equipment. Any other
spares recommended by the manufacturer shall also be indicated separately with the prices.
8.17.1.12 Rating plate
The rating and data of the Disconnectors shall be engraved or embossed on a weather and corrosion
proof metal plate. The rating plate containing the following information shall be positioned at the base
supporting frame of the post insulator and shall be prominently visible.
Manufacturer's Identification:
a) Country of Manufacture and Year of Manufacture.
b) Number and the Year of the standard adopted.
c) Designation of Type, Class etc. and Serial Number.
d) Rated voltage and frequency (kV & Hz)
e) Rated 1 minute power frequency withstand voltage (kV) wet.
f) Rated lightning impulse withstand voltage (kV)
g) Rated continuous current (A)
h) Rated short time withstand (1 sec.) current (KA)
i) Rated mechanical terminal load (N)
j) Mass (kg).
8.17.1.13 Testing
Type tests

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The following Certificate of Type Tests carried out in accordance with the lEC 60129 (1984) and lEC
60694(1996).
Dielectric tests
 Lightning impulse withstand voltage tests
 Power frequency wet withstand voltage tests
 Artificial pollution tests
 Temperature‐rise tests
 Measurement of the resistance of the main circuit.
 Short‐time withstand and peak withstand current tests
 Mechanical endurance tests
Routine test
The following routine tests as per lEC 60129 (1984) shall be carried out on all the disconnectors ordered
and the routine test report shall be made available for the observation of the CEB Inspector at the time
of inspection.
 Power frequency voltage withstand tests
 Measurement of the resistance of the main circuit.
 Mechanical operating test
8.17.2 Fuse cut out
8.17.2.1 Design
The fuse cut‐outs shall be capable of being opened on load by means of a built in load‐breaking device
of an arc chute type.
In general, the fuse cut‐outs will be installed for the protection of distribution ground mounted and pole
mounted transformers. The fuse cut‐outs offered shall be class 2 as defined in IEC 60282‐2.
The 10 kV load break fuse cut‐outs offered shall be in accordance with IEC 60282‐2 or ANSI C37.41 and
C37.42. Other equivalent standards may also be considered.
The 20 kV load break fuse cut‐outs described in this specification are intended to correspond to typical,
expulsion type fuse cut‐out devices. However, the Supplier is free to propose alternative equipment
provided there is no reduction in the operating characteristics required. Preferred alternatives are such
with enhanced operating characteristics, such as load break fuse cutouts, which would avoid the
necessity of operators having to use load breaking tools; or fuse cut‐outs in which all three fuse tubes
drop at the same time when one or two fuse elements melt as a result of an earth fault or a two phase
short circuit.
A de‐rating of the continuous current rating of the load break fuse cut‐outs due to altitude, along the
lines of IEC 60282‐2, will be acceptable, but the de‐rating factor shall be given in the technical data
schedule.
8.17.2.2 Technical data
The technical data to be met are compiled in Table XXXX (4‐11)
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8.17.2.3 Temperature rise limits
The assemblies shall be rated 105°C for normal circuit conditions. The complete load break fuse cutouts
shall be able to carry continuously its rated current without exceeding the temperature rise limits set
out in IEC 60282‐2, or equivalent
8.17.2.4 Fuse link range and class
The 11 kV load break fuse cut‐outs shall be suitable in all respects for all standard fuse links within the
range 1 A to 50 A as per IEC and NEMA standards.
8.17.2.5 Interchangeability
The fuse holder of a HV load break fuse cut‐out shall be dimensionally compatible with a universal fuse
tube of a corresponding rating and with the corresponding range of universal fuse links.
8.17.2.6 Insulators
The insulators supporting the load break fuse cut‐outs shall be rated for operation at a maximum
voltage of 12 kV respectively. The insulators shall be of solid core glazed porcelain of high strength and
arc resistivity type and shall be bird proof. They shall meet the electrical and mechanical characteristics
specified in IEC 60383.
The bidder shall also give the following information in the technical data schedule:
 The minimum dry flashover voltage value;
 The minimum wet flashover voltage value; and
 The 50 Hz puncture voltage of insulators.
8.17.2.7 Radio influence voltage
The maximum radio influence voltage shall be 250 µV measured at 1 MHz and in accordance with IEC

60437.
8.17.2.8 Clearances
The bidder shall give the following information in the technical data schedule for 10 kV load break fuse
cut‐outs:
 Minimum phase to phase clearance; and
 Minimum phase to earth clearance
 Minimum creepage distances.
8.17.2.9 Fuse links
The fuse links are required to give protection against short circuits. They shall conform to lEC, NEMA and
ANSI standards or equivalent and they shall be so rated; and shall have such melting characteristics as to
be suitable for selective operations with the fuse links at present in use on the system, namely type K ‐
fast fuse links and type T ‐ slow fuse links, in conformity with NEMA SG‐2 and ANSI C37.42.
In addition, the fuse links shall be suitable for use on 10 kV systems on outdoor, single vented, drop out
fuse tubes with or without arc shortening rods. They shall be compatible with all universal fuse tubes.
The preferred rating of fuse links shall be:

Volume 8

 11 kV: 4 A, 10, 20 and 50 A.
The rated current of the fuse link is the maximum current, which it will carry continuously without
deterioration and undue heating. The bidder shall state on the technical data schedule the maximum
temperature in °C attained by the fuse link after continuous operation at maximum rating.
The time‐current characteristics shall conform to NEMA type K and type T. The bidder shall submit with
the bid the time‐current performance characteristics of all the distribution fuse links on offer. The
performance characteristics of the fuse links shall include:
 Melting time‐current characteristics; and
 Total clearing time‐current characteristics.
The time‐current characteristics shall be presented as curves.
The Supplier shall state the minimum and maximum melting currents required to melt the fuse links at
the three appropriate time points (0.1 s, 10 s and 300 s or 600 s; melting‐currents for type‐K (fast) fuse
links) according to ANSI C37.42.
Fuse links shall be of the removable button head type. The fusible element shall be preferable of silver
but silver‐copper alloy it is acceptable. Fusible elements of tin are not acceptable. The bidder shall
completely describe the composition of the fuse link and of the fusible element.
The diameter of the button head cap on the fuse link shall be 19.1 mm up to 50 A.
Fuse links shall be capable of withstanding a tension pull of 44.5 N when tested cold (20°C to 25°C)
without mechanical or electrical damage to any part of the fuse links.
The bidder shall completely describe the composition of the fuse tube surrounding the fusible element,
its resistance to compression, collapse or twisting when being installed and the degree of fuse tube wall
swelling when wet.
The bidder shall also provide information on the precautions to be taken to avoid damage to the fuse
link and to what extent the time‐current characteristics change over time, making fuse links unreliable
on overload.
Each fuse link shall be legibly and indelibly marked with the following information:
 Manufacturers name or trade mark;
 Type designation (K or T); and
 Continuous current rating.
8.17.2.10 Tests
Routine tests
Routine tests for fuse cut‐outs shall be selected from the type tests listed in IEC 60282 or ANSI C37.41.
The bidder shall include, with the bid, sample test reports of routine tests to be carried out and shall list
them in the test certificates schedule.
Type tests
The following type tests shall be carried out on the fuse cut‐outs:
 Dielectric tests;
 Interrupting tests;
 Radio interference tests;
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 Temperature rise tests in accordance with IEC 60060;
 Load break tests to ANSI C37.41, if applicable;
 Time‐current tests;
 Porosity test; and
 Corrosion performance tests.
Where fault making tests have been performed on the model being offered, the test certificates shall
also be attached.
The following tests shall be carried out on the fuse links:
 Interrupting tests;
 Temperature rise tests; and
 Time‐current tests.
To confirm the interruption capacity of the fuse links, four tests of test series number 5 shall be carried
out with the characteristics set out in Table IVA of IEC 60282‐2 or, alternatively, four tests of test series
number 5 with the characteristics of table 3 of ANSI C37.41. The test load shall have the X/R ratio given
in table 6 of the same ANSI standard.
The temperature rise of the cut‐outs, containing the fuse links being tested in accordance with ANSI
C37.41, shall not go above the limits set out on table 2 of C37.40
For the time‐current tests, comprising melting time‐current tests and total time‐current clearing tests,
the minimum melting‐current characteristics of any fuse link shall agree with the values set out in table
6 of ANSIC37.42.
Corrosion performance tests
Performance shall be tested after the load break cut‐out has been subjected to 1,000 hours of corrosive
salt spray, in conformity with IEC 60507. An equivalent field experience in coastal sites shall be
acceptable.
The bidder shall confirm that the current carrying contacts shall meet the temperature rise
requirements after approximately 20 years of coastal exposure and that other metal parts shall retain
their mechanical strength.
8.17.2.11 Operating tools
The load break fuse cut‐outs will be operated by means of standard operating rod. The load break fuse
cut‐outs offered shall not impede this means of operation.
8.17.3 Assembly
8.17.3.1 Main assembly
The combined system will be installed on 2 poles transformer substation as described above. Top and
bottom contact subassemblies and mounting fittings shall be potted into the porcelain insulators. The
upper fixed contact assembly shall be shielded and positively latch.
All contacts shall be designed to give permanent current carrying capacity at rated current, after
exposure to the Afghan climate for up to 20 years. All current carrying components shall be of copper or
copper alloy. Terminals shall be of copper or heavily tinned bronze, suitable for both copper and
aluminum conductor up to 120 mm² ACSR and compressed palm lugs. Contacts shall be heavily silver
clad on each side of each interface. Embossed surfaces with wiping action are preferred.

Volume 8

The upper contact shall have safety latch to prevent upper contact from dropping due to vibration and
mounted with stainless steel back up spring to ensure the contact pressure between stationary contact
and the movable contact of the fuse.
The lower contact shall house a. stainless steel back up spring to ensure high contact pressure with
positive contribution to release of the toggle connection.
Ferrous components shall be made preferably of stainless steel or galvanized to BS 729. The
manufacturer shall state the mass and thickness of zinc coating on the technical data schedule.
The load break fuse cut‐out shall be designed such that the fuse tube can be closed without using undue
care even when the closing force is applied at an angle. The angle of fuse tube relative to the vertical
shall be stated in on the attached technical data schedule and it shall be less than 20°. The cut out
insulators shall preferably be marked with the rated voltage and with the basic impulse level insulation.
8.17.3.2 Fuse tube assembly
The fuse tubes in the 11 kV load break fuse cut‐outs shall be capable of accepting lEC or NEMA fuse links
up to a maximum continuous current rating of 50 A.
The toggle mechanism shall provide a locking action to protect the fuse link from shock. A stainless steel
spring‐assisted flipper shall assist arc interruption by withdrawal of the fuse tail.
The fuse tube cap may be of the expendable type. The arc shortening rods, if provided, shall be
permanently attached to the fuse tube cap. The Fuse tube shall be made of high strength synthetic fibre
to lessen moisture absorption inside the tube and to extend the life of the fuse holder. Fuse tube shall
be heavily coated with enamel to provide protection against ultra violet rays.
A lifting eye shall be provided on the fuse tube and designed for use with a standard operating rod.
The fuse tubes shall be permanently marked with the following:
 Name of manufacturer and/or trade mark;
 Model;
 Rated voltage;
 Continuous current rating; and
 Rms, symmetrical, rated interrupting capacity.

Volume 8
8.18 Surge arresters
8.18.1 General
requirements of 10 kV nonlinear, metal oxide resistor type surge arresters, without spark gaps, required
by the networks described.
While IEC 60099‐4 is quoted throughout this specification, comparable international standards such as
ANSI/IEEE C62.11 or NEMA LA1 will be acceptable, but in any discrepancy, this specification shall take
precedence.
8.18.2 Performance characteristics
The surge arresters shall meet the performance characteristics shown in Table 8‐17, consistent with an
ungrounded delta system at high voltage (10 kV) and a four wire solidly grounded neutral system and he
low voltage side.
Table 8‐17 Surge arrester performance characteristics
Surge arrester type MOX 11 kV
Rated frequency (Hz) 50
Nominal system voltage (kV) 11
Maximum system voltage (kV;rms) 12
creepage distance (mm) 350
Short circuit rating at 50 Hz, 0.2 s (kA) 20
Long duration impulse current at 200 µs (A) 200
Minimum 10 seconds power frequency wet withstand (kV 60
Normal discharge current 8/20µs current wave (kAp) 10
High discharge current 4/10µs current wave (kAp) 100
The metal oxide resistor type shall be housed in porcelain or polymeric containers and shall be
hermetically sealed.
8.18.3 Terminals
Terminals of surge arresters covered by this specification shall be constructed that conductors of copper
or aluminum may be attached thereto without danger of corrosion. To this end, the arrester terminals
shall be cadmium plated or given alternative treatment which meets with the project manager's
approval.
Full particulars of such alternative treatment shall be submitted at the time of tendering, and must
receive the written approval of the project manager.
The phase and earth terminals shall include a conductor clamp and all necessary bolts, lock‐nuts and
washers. The terminal material shall preferably be either stainless steel or, alternatively, a plated
nonferrous metal, suitable for connection of ACSR in a corrosive salt laden atmosphere.
The arrester terminals shall be suitable for use with a palm lug non tension conductor terminals and
with the following ranges of conductor sizes:

Volume 8

 Aluminum conductor: 25 mm² to 120 mm².
8.18.4 Mounting arrangement
Surge Arresters shall be suitable for vertical or horizontal mounting.
Mounting brackets shall be provided to facilitate mounting of arresters on channel iron type cross‐arms.
Other mounting arrangements will also be considered.
Alternatively, the surge arrestors may be fixed on the HV disconnection switch.
Details of the mounting arrangements shall be supplied.
8.18.5 Tests
The minimum requirement for routine tests shall be:
 Measurement of reference voltage;
 Residual voltage test for lightning impulse current in the range between 0.01 and 2 times the
nominal discharge current;
 Check for absence from partial discharges and contact noise, in conformity with IEC 60270;
 Current leakage tests; and
 Leakage check on the housing seals. The bid shall describe the sensitive checking method adopted by
the manufacturer.
These tests shall be carried out in conformity with IEC 60099‐4.
The reference voltage of each arrester shall be measured at the reference current selected by the
manufacturer.
In addition to tests specified in IEC 60099‐4, the surge arresters shall be subjected to a measurement of
the leakage current at voltages corresponding to 100%, 60% and 40% of the rated voltage.
8.18.5.2 Type tests
The following type tests shall be carried out in conformity with IEC 60099‐4:
 Insulation withstand tests, including lightning impulse voltage test and power frequency voltage test;
 Residual voltage tests, including steep current impulse residual voltage test, lightning impulse
resid¬ual voltage test and switching impulse residual voltage test;
 Long duration current impulse withstand tests;
 Operating duty tests, including accelerated ageing test to determine voltage levels for duty tests,
heat dissipation behaviour test, either high current impulse operating duty test or switching surge
operating duty test and tests to verify thermal stability;
 Pressure relief tests, where applicable, including high current pressure relief test and low current
pressure relief test;
 Tests of arrester disconnectors, if applicable;
 Artificial pollution tests;
 Partial discharge tests; and
 Seal leakage tests.
Before proceeding with the long duration current impulse withstand test, the lightning impulse residual
voltage at nominal discharge current of each test sample shall be measured for evaluation purposes.
Volume 8
After the long duration current impulse withstand test has been carried out, and after the sample has
cooled to near ambient temperature, the residual voltage tests which were made before the long
duration current test shall be repeated and the test specimens shall be judged by their physical
conditions and by comparison of the oscillograms taken during both sets of residual voltage tests.
The values of residual voltage shall not have changed by more than 5% and visual examination of the
samples shall reveal no evidence of puncture, flashover, cracking or other significant damage of the
metal oxide resistors.
Artificial pollution testing shall be carried out on surge arresters, in accordance with IEC 60099‐3 and IEC
60507 to simulate relevant pollution conditions representative of those occurring in service.
Pollution flashover of the surge arrester surface is a serious matter operationally and performance in
this respect shall also be determined.
The manufacturer shall elaborate on the effect of pollution on the performance of the surge arresters
offered.
The bidder shall state the standard to which the seal leakage tests have been carried out.
8.18.5.3 Acceptance tests
Acceptance tests shall be carried out, in conformity with IEC 60099‐4, on the nearest lower whole
number to the cube root of the number of surge arresters to be supplied. The following tests shall be
carried out:
 Measurement of power frequency voltage on the complete arrester at the reference current
measured at the bottom of the arrester.
 Lightning impulse residual voltage on the complete arrester at nominal discharge current or at a
suitable lightning impulse current, depending on the manufacturer's choice of routine test procedure
 Partial discharge test. The discharge intensity shall not exceed 50 pC at 1.05 times the continuous
operating voltage of the surge arresters.
A special thermal stability test as per IEC 60099‐4 may be requested by the purchaser prior to the
commencement of arrester assembly.
The bidder shall include details of any acceptance tests recommended on housings and will include a
sample test report.
8.19 11 kV cable
8.19.1 Technical requirements
The cable design offered shall meet the following requirements:
Triple extruded dielectric single core cable having:
 Stranded circular copper conductor
 Dry‐cured cross‐linked polyethylene insulation
 Non‐magnetic wire armour
 Outer high density polyethylene (HDPE) or polyvinyl chloride (PVC) serving.
The outer serving shall be capable of withstanding a 10 kV DC test voltage for five minutes after
installation and annually thereafter. Current ratings shall be calculated in accordance with IEC 287

Volume 8

"Calculation of the continuous current rating of cables with 100% load factor". The cable design offered
for use shall meet the following requirements.
8.19.2 Conductors
The conductor shall be stranded copper circular compacted, Class 2 as per IEC‐228 .
8.19.2.1 Conductor sizes
The following conductor sizes will be used: 35 mm².
8.19.2.2 Conductor shield
The conductor shield shall consist of an extruded black thermosetting semi‐conducting material.
Conductor shield thickness shall meet the requirements of AEIC 5 Table D1.
8.19.3 Insulation
The insulation shall consist of cross‐linked polyethylene, XLPE. Insulation thickness shall conform to IEC‐
502, Table IV.
8.19.3.1 Insulation shield
The insulation shield shall be an extruded thermosetting semi‐conducting material extruded
simultaneously with the conductor screen and insulation (triple extrusion). The shield colour shall be in
contrast to that of the XLPE insulation so that any particles of insulation shield, adhering to the
insulation, after stripping, will be visible. Shield thickness shall meet the requirements of AEIC 5, Table
D2. The insulation shield shall be plainly identified as a semi‐conducting material at 300 mm intervals.
The following legend, or its equivalent shall be printed on the insulation shield: "SEMI‐CONDUCTING ‐
RE¬MOVE WHEN SPLICING OR TERMINATING".
The shield shall meet the "strippability" test requirements of a National or International standard,
details of which shall be submitted by Bidder.
Where a special tool is required for stripping, details of such tool, shall be provided.
8.19.3.2 Metallic shielding (core screens)
The screen shall consist of copper wires and one or two copper conducting tape spirals. The screen
wires shall lie in a long lay directly over, and in intimate contact with, the insulation screen. The tape
spirals shall be applied in counter helix over, and in electrical contact with, the screen wire(s).
The shield cross sectional area shall be 35 mm².
Screen wire and tape dimensions, electrical characteristics and geometry shall comply with the
requirements of DIN VDE 0273, Clause 5.9.
8.19.3.3 Fillers and binding tape
The three (3) individual cores with copper tape screen shall be laid up together. The cores shall be laid
up with a right‐hand direction of lay. The interstices shall be filled with suitable non‐ hygroscopic fillers
to give the completed cable a substantially circular cross‐section. A suitable binding tape shall be applied
over the laid up cores and the filler material.
Volume 8
8.19.3.4 Core bedding
The core shall be covered with an extruded bedding of PVC compound which shall be formed tightly
around the cable. The thickness of the bedding shall comply with the requirements of IEC 502, Clause
6.6.
8.19.3.5 Armour
The armour shall be applied helically in a layer of non‐magnetic wire over the armour bedding layer.
Armour shall comply with the requirements of IEC 502, Clause 11.
8.19.3.6 Oversheath
An oversheath of red coloured PVC shall be applied over the armour wires. The oversheath shall be
embossed at regular intervals as per clause 12.4 of this specification and shall comply with the
requirements of IEC 502, Clause 12.
8.19.4 Core identification
The cores shall be identified on the non‐metallic part of the insulation screen by legible numbering along
the whole length of each conductor. Cores shall be numbered 1, 2, 3.


Volume 8

9 Spare parts, tools and site consumables
9.1 Spare parts
All spare parts to be supplied shall be interchangeable with the corresponding parts of all the works
supplied under these specifications and shall be of the same material and workmanship. They shall be
replaceable without cutting or destruction of adjacent components.
Each Supplier shall submit completely filled in lists of specified spare parts and tools according to the Bill
of Quantities. Moreover, lists of recommended spare parts shall be included to each bid, comprising
those spare parts which are recommended to store for a period of at least three (3) years, for
maintenance purposes mainly. These lists shall stipulate detailed descriptions and prices.
After mutual discussion, it shall be finally decided which of the specified or recommended spare parts or
tools shall be included in the scope of supply.
All spare parts shall be protected against corrosion / decay and shall be marked with identification
labels. All spare parts, tools and materials shall be delivered in marked boxes of sufficient sturdy
construction to withstand long term storage.
About 5%, but at least two pieces of all types of bolts, screws, nuts, washers, spanner rings and cotters
shall be provided and hand over to the operator. Other spare parts shall be provided for a period of
three (3) years of operation after the date of the completion of the project.
9.2 Tools and appliances
All customary and special tools, as well as auxiliary devices including lifting devices, ropes etc. necessary
for total assembly and disassembly and repair of all parts of the supplied works shall be provided to the
operator. All lifting devices and wire ropes slings to be used at site shall be tested at works.
Suitable toolboxes shall also be included in the delivery. An itemized list and description of all provided
tools, auxiliary devices etc. shall be fixed in each toolbox.
9.3 Site consumables, lubricating oil and grease for first filling
5% of the quantity of painting material, but at least one liter, in new sealed containers, for later repair
works and 330% of lubricating oils, insulating oils and greases etc. required for first filling in the plant
and equipment supplied be supplied (sufficient for the first three fillings and for preparatory works).
9.4 Specified spare parts and tools
The following spare parts and tools to be handed over to the Employer shall be supplied for the various
equipment and installations subject to the scope of the works.
9.4.1 Distribution transformers
 Primary standard porcelain bushings for outdoor pole‐mounted and indoor distribution transformers.
 Primary plug‐in bushings for compact substation type transformers.
 Low voltage bushings.
 Fire percent of total oil quantity of supplied transformers delivered in drums specially sealed for site
conditions.
Volume 8
9.4.2 Tools
9.4.2.1 Scope
The tools and equipment shall comply with this specification. The pictures that are included in this
chapter are for reference of the tools and equipment only.
The materials and equipment supplied shall conform to appropriate norms and international standards.
In the absence of recommendations, the supplier shall give detailed information about the equipment.
Minimum of one year warranty for any manufacturing defects shall be provided for all tools and
equipment.
9.4.2.2 Cable cutter for copper and AAAC conductors
This conductor cutter shall be capable of cutting

aluminum, aluminum alloy and copper conductors of
240 mm² maximum cross section. This mechanical
cutter shall be ratchet type or direct type. For a
ratchet type this cutter shall have an ergonomic
handle for one hand use. For a direct type, this cutter shall have approximately a length of lever handle
of 700 mm. This system is delivered in a carrying case.
9.4.2.3 Cable cutter for ACSR conductors
This conductor cutter shall be capable of cutting ACSR

conductors of 185/30 mm² maximum cross section. This
mechanical cutter shall be ratchet type or direct type. For
a ratchet type this cutter shall have an ergonomic handle
for one hand use. For a direct type, this cutter shall have a
minimum length of lever handle of 700 mm. This system shall be delivered in a carrying case.
9.4.2.4 Cable cutter for EHS guy wire
This conductor cutter shall be capable of cutting 12 mm

Extra Strength (EHS) and standard guy wire and 12 mm
mild steel rods and bolts. This mechanical cutter shall be
ratchet or direct type. For a ratchet type this cutter shall
have an ergonomic handle for one hand use. For a direct
type, this cutter shall have a minimum length of lever handle of 700 mm. This system shall be delivered
in a carrying case.


Volume 8

9.4.2.5 Hand operated hydraulic ACSR cable cutter
This cable cutter shall be capable of cutting ACSR cables of
19 mm diameter (including aluminum and copper cable). The
length of the cutter shall not be less than 500 mm. This
equipment shall be delivered in a carrying case. The supply
include hydraulic cable cutter, cutter blade and fixed cutter
head. This equipment shall be delivered in a carrying case.
9.4.2.6 Hand operated hydraulic cable cutter
This conductor cutter shall be capable of cutting aluminum and copper cables of 85 mm diameter. This
manual hydraulic cutter shall be supplied with a revolving head. The hydraulic pump shall be double
stage type. This equipment shall be delivered in a carrying case.
9.4.2.7 Hand Operated Hydraulic Press 4.5 Ton Minimum Capacity with Dies for Main and
Service ABC
The hydraulic press shall be hand‐operated, having an output capacity of 4.5 tons minimum and suitable
for making all compression type pre‐insulated joints for LV ABC network or other insulated conductor
from 4 mm² up to 150 mm². The press must be supplied with “H” revolving with quick opening and
closing head. The pressure relieve shall be automatically actuated when the compression is completed.
A complete set of hexagonal dies for making all joints shall be supplied. The dies must be made of tool
steel which shall possess high strength to withstand the mechanical stresses to which the dies are
subjected in use without damage. The steel part shall be suitably protected against corrosion.
The die sizes shall be of international standard type(s).
This Hand operated hydraulic press shall be delivered with a ring for attachment and a carrying case able
to accommodate the press and all the necessary dies.
9.4.2.8 Hand operated hydraulic press 12 ton capacity with dies for MV overhead network
The hydraulic press shall be hand‐operated, having an output capacity
of 12 tons or more and suitable for making all compression type joints
for MV overhead network. The press must be supplied with “C”
revolving head. The pressure relieve shall be automatic when the
compression is completed.
A complete set of hexagonal dies for making all joints (AAAC and ASCR
conductors) for cross sections between 25 and 240 mm² shall be
supplied. In addition, a complete set of dies for LV ABC shall be
supplied. The dies must be made of tool steel, which shall possess
high strength to withstand the mechanical stresses to which the dies are subjected in use without
damage. The steel part shall be suitably protected against corrosion. The die sizes shall be of
international standard type(s).
This Hand operated hydraulic press shall be delivered with a carrying case able to receive the press and
all the necessary dies.
9.4.2.9 Electro‐ hydraulic high pressure pumps 700 bar and set of accessories
Volume 8
a) Electro‐hydraulic pump
The hydraulic pump of 700 bars shall be powered by an electric
motor of 500 W at 220 V AC, 50 Hz. A 5 m long connecting cable is
suitable. It shall be able to supply hydraulic energy to a
compression head of 20 kN of output force located on a pole of
12‐meter height.
An excess‐pressure valve shall protect the high‐pressure pump

against overload. The pressure relieve shall be automatically
operated when the compression is completed.
A carrying case shall be supplied.
b) Pluggable hydraulic compression head
This compression tool of "U" type head with tilting arms shall be used
with the single action pump described in a). It shall have a minimum
output force of 120 kN. The return of the internal jack shall be driven by a
spring.
This tool shall allow compression of joints and connectors for MV
overhead networks (copper, AAAC, ACSR) and MV/LV underground networks (copper and aluminum). A
carrying case shall be supplied.
c) Hydraulic hoses
3 hydraulic hoses of 3‐meter length and 2 hydraulic hoses of 6‐meter length shall be supplied. They shall
be equipped with male and female quick couplers locked by balls. These hoses shall be capable of
withstanding a working pressure of 700 bars. A carrying case or bag shall be supplied.
d) Dies
A complete set of dies for junction sleeves, anchor sleeves, lugs, connectors for MV overhead network
of copper, AAAC and ACSR (50 up to 185/30 mm²) and MV / LV underground network of copper and
aluminum cable (16 up to 300 mm²) shall be supplied. Carrying cases for each type of dies shall be
supplied.
9.4.2.10 80 kN hydraulic crimping tool with rechargeable battery
Hydraulic Crimping Tool with rechargeable battery shall be used for indentation or hexagon crimping of
the following connectors:
 “C”, from C10 to C50
 XCT, XCT.C, XCT.EQ copper tubular lugs and XG7T copper joint
sleeves from 6 to 240 mm²
 DIN46235 copper Lugs & Sleeves from 10 to 185 mm²
 DPD7 forged terminal lugs and XL7/XG7 copper terminals from 16
to 240 mm²
 INDUSAL ACX and ACX.C terminal lugs from 35 to 240 mm²
 LV insulated line connectors from 16 to 150 mm²
 LV‐MV bare overhead line connectors from 6 to 240 mm². It is also
able to round the conductors with 7R dies.

Volume 8

 The design shall be compact, self‐contained and rapid electro hydraulic tool for crimping of
connectors from 6 to 240 mm2, ergonomic design and balanced weight allow crimping to be done
one handed and reduce wrist fatigue, shoulder strip for easy handling
 Automatic release with an audible "click" when force of 80 kN is reached. Return of piston by release
trigger.
The operation with rechargeable battery for 100 to 150 crimps operations possible before recharging.
Light indicator gives the state of the charge, shows the end of the crimping.
A complete set of dies for junction sleeves, anchor sleeves, lugs, connectors for MV overhead network
of copper, AAAC and ACSR (50 up to 185/30 mm²) and MV / LV underground network of copper and
aluminum cable (16 up to 300 mm²) shall be supplied according a technical specifications for
conductors, cables and accessories specified in the bidding documents.. Carrying cases for each type of
dies shall be supplied.
Accessories:
 Batteries, plus one spare
 Chargers
 Metallic carrying case.
9.4.2.11 Stripping tool for XLPE cable
The tool shall cover: Stripping outer sheet, Stripping semi conductor and Stripping XLPE insulation. Extra
blades for the tool shall also be delivered. The tool shall cover 24 kV cables with dimensions 1x50 to
1x240 mm2, 0.6/1 kV cable 4x50 to 4x150 mm2.
9.4.2.12 Micro‐ohm meter
This micro‐ohmmeter is required for metering low resistance, such as contact resistance of switching
equipment (breakers, isolators, switches or bus /line joints) according to IEC 60054‐6. It shall be capable
of being carried to any particular site substations, customers' premises for the purpose mentioned
above.
It shall allow changing the direction of the current if there are voltages that interfere with the accuracy
of the measurement are present.
The switch covers any measurement range and a current corresponds to each range which is selected
automatically from 0.1 mA to 100 A. The measuring range of the apparatus shall be 1 up to 200 m.
The indications appear on a liquid crystal display of 4 digits LED 0.5 high, with decimal point and
negative (‐) sign. The time required for the display to stabilize will be of 10 seconds or less.
This apparatus includes an alarm warning if the measurement is impossible: (open circuit, protective
fuse on the instrument blown).
The instrument shall not be used on live systems; however, it shall be protected against a voltage of 30
V peak between any of the Rx terminals.
This instrument uses 120/240 V; 50/60 Hz frequency, with battery.
The minimum dielectric strength will be 1500 V protected by a fuse.
The degree of protection shall be IP 543 according to standard IEC 60529, the safety class II as per IEC
60348 and in keeping with IEC 61010.

Volume 8
The accuracy class shall be ±1% of reading + the 2 least significant digits (range 50 A to 100 A) and ± 2%
of reading + the 1 least significant digit (range 10 A to 20 A).
The maximum ambient temperature °C will be 40°C and a maximum relative humidity (%) 85%.
It will be presented in a plastic work‐site case with a handle and weight shall less than 20 kg.
A complete set of cables for current 2*15 m, a standard grounding cable, a current shunt and an
instruction manual and other specific accessories will be included.
9.4.2.13 Electronic voltage detector for bare conductors
Voltage detector
This electronic voltage detector with acoustic and optical signal shall be suitable for bare MV
conductors. The voltage detecting range shall be from 5 up to 36 kV.
The live conductor shall be signaled by a powerful buzzer and a red LED.
This equipment shall be totally insensitive to the electrical fields and shall detect voltage on contact
only. It shall be equipped with an integral‐testing device. A luminous signal shall indicate the automatic
testing of the apparatus all along operation. It shall be supplied with a complete set of contact probes.
This voltage detector shall be suitable to be fixed with a universal fitting and it shall be delivered in a
carrying case.
One universal fitting, telescopic and insulating, 2 meter minimum stick shall be supplied.
9.4.2.14 Electronic voltage detector for separable connector capacitive dividers
This electronic voltage detector with acoustic and optical signal shall be suitable for detection of
voltages from 5 up to 36 kV capacitive dividers installed on MV separable connectors.
The live separable connector shall be signaled by a powerful buzzer and a red LED.
This equipment shall be totally insensitive to electrical fields and shall detect voltage on contact only. It
shall be equipped with an integral testing device. A luminous signal shall indicate the automatic testing
of the apparatus all along operation. It shall be supplied with specific probe for capacitive divider.
This voltage detector shall be suitable to be fixed with a universal fitting and it shall be delivered in a
carrying case.
One universal fitting, telescopic and insulating, 2 meter minimum stick shall be supplied.
9.4.2.15 Phasing tester for MV overhead distribution circuit
This MV voltmeter shall allow the measure of voltage level and phasing between overhead conductors.
It shall be composed of two fiberglass testers with high impedance, two contact pieces and housing
containing a voltmeter. The connection between the two testers shall be made with an insulated flexible
cable.
The range of the apparatus shall be from 5 up to 24 kV. It shall be supplied with a complete set of
contact probes.
This phasing tester shall be suitable to be fixed with a universal fitting.
It shall be delivered in a carrying case.

Volume 8

Two universal fitting insulating sticks of 3 meter length shall also be supplied.
9.4.2.16 Insulator puncture detector
This portable system is used to detect internal cracking on porcelain insulators prior to total failure; it
shall be capable of testing suspension type insulators onto a standard hot stick for energized lines. This
system shall be readily handled by one line man and shall be safe to use on 24 kV network. The result of
the test shall be easily indicated to the line man with an audible or lighting signal.
This system shall be delivered with all facilities needed to charge the line capacitor from a VDC battery.
It shall be delivered with universal fittings to be fixed on sticks for overhead network; necessary stick(s)
of 3 meter length with universal fittings shall be supplied.
All this equipment shall be delivered in a carrying case.
9.4.2.17 Line fault locator
This portable system shall be used to monitor the status of underground cable, and detect pinpoint fault
on underground cable. This equipment shall be based on an audible signal injected in the cable by an
audio frequency generator. This equipment shall consist of four units:
 a line locator to locate a buried cable,
 a fault locator to locate the fault (with a fault location resistance up to one M),
 a transmitter unit to power the audio frequency signal in three frequency bands (approx. 0.5 kHz, 1
kHz and 10 kHz).
 a receiver with earphones.
This equipment shall be delivered with a carrying case and batteries.


Volume 8
9.4.2.18 Portable multi‐meter
This portable multi‐meter shall be of clamp type and shall be used to measure
current and other electric important values without the need to break the current
circuit.
This clamp multi‐meter shall be capable of measuring:
 Current through the use of Hall effect sensors in the magnetic circuit, the true
RMS values can be measured up to 1500 A AC. The accuracy class shall be <
1.5%.
 Voltage, the true RMS value can be measured up to 600V AC and 1000V DC.
The accuracy class shall be < 1%.
 Active power measurement,
 Apparent power measurement,
 Power factor measurement,
 Frequency measurement,
 Auto‐ranging for each function,
The indications shall appear on a liquid crystal display.
The clamp of the multi‐meter shall be able to measure current on 55 mm diameter cable.
The degree of protection shall be IP40, the safety class II 6 kV as per IEC 60348 and it shall be in
accordance with IEC 61010 1.600V CAT III. This equipment shall be supplied with all accessories, battery
and in a carrying case.
9.4.2.19 Three phase portable earthing kit for 24 kV
Three phase portable earthing kit for 24 kV shall be complete with all leads, clamps, earth spike and
carrying bag for use on Medium Voltage overhead lines and cables.
9.4.2.20 Lead
Lengths to be sufficient for overhead lines with phase distance 2 m. The leads are to be 50 mm2 Cu
earthing strap with transparent plastic‐insulation.
Clamps for lead are to be suitable for connection to both ACSR line and bolts.
Clamps shall be operated with Bayonet socket type of tool.
9.4.2.21 Earth
Lengths shall be sufficient for overhead lines at 12 m above ground. The earth is to be 50 mm2 flexible
Cu earthing strap with transparent plastic‐insulation. Clamps should be of universal type.
Operating rod
Operating rod should be a glass‐fiber reinforced operating pole for outdoor use with rain skirts and it

should at least have insulation level for 24 kV. It shall also have a warning axle for marking of 600mm
insulated length. The rod shall operate Bayonet socket type of clamp.
9.4.2.22 Non‐contact phase sequence indicator
The phase sequence indicator is for use in low voltage system.

Volume 8

 Noncontact detection of phase sequence.
 Self‐adjusting to correct phase if line frequency varies.
 Auto shutoff for maximum battery life.
 Proximity sensor means safe, noncontact sequence.
 Accessories included: (1) 9V battery, case.
9.4.2.23 Cable length meters (600 m)
Feature:
 Direct read length measurements up to 600 m in different sizes
of copper or aluminum insulated cable up to 500 kcmil (240
mm2). 3‐1/2 digit LCD read‐out.
 Calibration coil included for compensation of temperature
coefficients.
The supply shall be included all necessary accessories.
 Capacity 1.5 ‐ 240 mm2
 Cable Size – Cross Section
 1.5, 2.5, 4, 6, 10, 16, 25, 50, 70, 120, 185 & 240 mm2
 Measuring Length 600 m
 Accuracy, 2%.
 Batteries 2 – 9V, included.
9.4.2.24 Cable length meters (2000 m)
 Easy to operate, calibrate and set for cable being
measured. 4‐1/2 digit LCD read‐out.
 Calibration coil included for compensation of temperature
coefficients.
The supply shall be included all necessary accessories.
 Cable Size – Cross Section
 1.5 to 500 mm2
 Measuring Length
 5 meters through 2000 meters in 1/10 meter increments;
 Accuracy, 2%.
 Batteries included with charger
9.4.2.25 Portable infrared thermometer
Portable infrared thermometer for non‐contact temperature measurement is
for use in medium voltage and low voltage system, over head line and
underground system.
The infrared thermometer shall be have the following futures:
Sighting methods: Laser to define the center of the measurement area.

Working distance: 5 cm to 20 m
Temperature range: ‐10º C to 600º C

Volume 8
Temperature resolution: 0.1º C to 600º C
Accuracy: 1% of the reading / +‐ 2% for reading below ‐10º C
Temperature mode: Current temperature, average temperature, maximum/minimum temperature,

differential temperature, temperature unit selection (°C or °F), memory and playback allow scrolling of
memorized temperature.
Temperature display: LCD, 4 digits, automatic backlighting.
Controls: Power ON (auto power OFF with no loss of memory), Up/Down scroll keys, and Laser
disengage key.
Power source: 9V NiMH rechargeable
Battery life: 40 hours without laser (9V replaceable battery)
Ambient temp. range: Operating 0° to 50°C, storage –20° to 60° C
Mounting: 1/4 ‐20 thread for tripod mount
Accessories: Carrying case, replaceable battery, operating manual, charger battery, NiMH Battery,
communicator software.
9.4.2.26 Heavy‐duty rotary hammer with accessories
The electrical rotary hammer shall be for use bit of the 35 mm diameter minimum, with two operating
modes: hammer with rotation and hammer only. This hammer is for use in concrete poles.
The hammer shall be designed with isolation system to reduce operator fatigue and increases comfort
and control. Both handles "float" to absorb hammering action. Dial speed control for rpm and bpm
allows user to match hammer speed and power to application.
The supply shall include 10 sets the followings bits:
Diameter (mm)/max. drilling depth (mm)
14 25
22 25
22 35


Volume 8

9.4.2.27 Heavy‐duty 12 mm drill
The electrical drill shall be heavy‐ duty type, with variable control speed,
two mode operations (hammer with rotation and rotation only), and 360°
Positive Lock Side Handle. 230 V AC, 50 Hz.
The supply shall be included 10 set complete the bits: 5 mm to 12 mm.
All this equipment shall be delivered in a carrying case.
9.4.2.28 Ratchet hoist
Ratchet hoist is to be used for pulling overhead conductors.
They shall be of link chain style with a pulling load of 2000 daN (safety coefficient = 5). At nominal load
the effort exerted on the lever shall not exceed 30 daN.
The single fall chain shall be made of high strength alloy steel with a minimum working length of 1.5
meter and it shall be supplied with hooks in accordance with the nominal load.
9.4.2.29 Insulating ladder
This one section straight insulating ladder shall be made of fiberglass and polyester. The steps could be
made of aluminum. The length shall be 4 meters. They shall have a high mechanical resistance to
bending and twisting and high resistance against climatic conditions and corrosive elements.
The insulation between two steps shall be more than 22 kV.


Volume 8
10 Annexes
Annex 1: Technical Data Sheets .................................................................................................. 109
Annex 2: Drawings ...................................................................................................................... 125
Annex 3: Design Examples .......................................................................................................... 228


Volume 8

Annex 1: Technical data sheets
Technical data sheets should be filled by the supplier. It provides a fast overview on critical technical
parameters. It can also be used to compare offers from different suppliers.
The completeness of and the way how the data sheets are filled is also a good indicator of the
professionalism of the supplier.


Volume 8
Annex 1.1 11 kV Overhead conductor
Description / Details Unit Specified Offered
Overhead Conductor
Manufacture
Manufacturer's Code
Type ACSR
Nominal area of conductor mm² 120
Stranding ‐ aluminium mm² 26/2.44
Stranding steel mm² 7/1.9
Maximum current rating A
Conductor resistance ohm/km 0.2345
Conductor impedance ohm/km
Conductor inductance mH/km
Conductor capacitance µF/km
Short circuit rating
t= 1.0 seconds A
t= 3.0 seconds A
Conductor weight kg/km 494
Maximum drum wound lengths m
Full drum maximum weight kg


Volume 8

Annex 1.2 ABC cable and accessories
Aerial Bundled Conductor (ABC)
Manufacture
Manufacture's Code
Type
Nominal voltage rating kV 0.6/1.0
Number and nominal size of core mm²
Material phase conductor
Material neutral conductor mm
Neutral conductor insulated Yes/No
Insulation thickness mm
Maximum conductor temp. rating Cº
Maximum current rating A
Conductor resistance ohm/km
Conductor impedance ohm/km
Conductor inductance mH/km
Conductor capacitance µF/km
Short circuit rating
t= 1.0 seconds kA
t= 3.0 seconds kA
Ultimate tensile strength kN
Cable weight kg/km
Maximum drum wound length
Full drum maximum weight kg


Volume 8
Annex 1.3 LV cables and accessories
LV Cables
Manufacturer
Manufacturer's Code Nº
Number of cores
Nominal conductor area mm²
Type of Conductor Al
Stranding Nº/mm
Voltage rating kV 0.6/1.0
Insulation thickness
‐ phase mm
‐ neutral mm
Insulation material XLPE
Sheath material HDPE
Sheath thickness mm
Ultimate tensile strength kN
Weight kg/mm
Conductor resistance at 20 ºC ohm/km
Maximum continuous load current amps
Maximum short‐circuit rating
t= 0.1 seconds kA
t= 0.2 seconds kA
t= 0.3 seconds kA
t=1.0 seconds kA
Maximum drum wound length m >500
Drum diameter maximum mm 2500
Drum width maximum mm 1400
Full drum weight maximum kg/mm 3000
Minimum Bending Radium mm
Maximum Pulling Tension kN
Earthing Conductor
Manufacturer

Volume 8

Number of cores 1
Nominal conductor area mm² 35
Conductor material Cu
Stranding mm
Voltage rating kV 0.6/1.0
Insulation thickness mm
Insulation material PVC / XLPE
Weight kg/mm
Conductor resistance at 20 ºC ohm/km
Maximum continour load current
Maximum short‐circuit rating
t= 0.1 seconds A
t= 0.2 seconds A
t= 0.3 seconds A
t= 1.0 seconds A
Maximum drum wound length m
Full drum weight maximum kg
For each size one data sheet shall be filled


Volume 8
Annex 1.4 Insulators
Line Post Insulators
Manufacturer
Type Post
System Voltage kV 20
Material of Insulator
Designation (ANSI C29.6)
Cantilever strength kN
Nominal diameter mm 150
Nominal height mm 305

Minimum nominal creepage
mm 630
distance
Min. power frequency flashover
voltage
dry kV
wet kV
……….
…………..
……………
‐ length mm
Pin height mm
Weight kg
String Insulators
Manufacturer
Type Disc
Material of Insulator
Designation (IEC 60305) U 70 BL
Mechanical failing load kN
Nominal diameter mm 255
Nominal spacing mm 146

mm 280
distance
Altitude factor used for 2.000 m

Volume 8


Min power frequency flashover
voltage
‐ dry kV 78
‐ wet kV 45
Puncture voltage kV 110
Ball and socket couplings (IEC 60120) mm 16
Weight kg
Guy Wire Insulators
Manufacturer
Manufacturer's Code Nº Guy Wire
Type
Material of Insulator 90
Mechanical failing load kN
Nominal size mm 60

mm
distance
Min. power frequency flashover
voltage
‐ dry kV 35
‐ wet kV 18
Weight kg


Volume 8
Annex 1.5 Distribution transformers
Three Phase 11/0.4 kV Distribution Transformers Pole Mounted
Manufacturer
Rated output kVA 50 100 160 250 315 400 630
Number of phases 3
Rated frequency Hz 50
Rated primary voltage kV 20
Rated no‐load secondary voltage 400/230
Vector group Dny5
Highest primary voltage of primary
kV 12
windings
Insulation levels LI125/AC50/AC3
Temperature insulation class (IEC
A
6000076)
Type of cooling ONAN
Maximum temperature rises
‐ windings ºC 65

‐ top oil with
ºC 60
conservator
‐ top oil without
ºC 55
conservator
Type of primary tapping off‐load % +10. +7.5 .+ 5.0 +2.5
0,‐2.5.‐5.‐7.5.‐10
Impedance %
NO‐LOAD LOSSS Watts
LOAD LOSSES at rated load and 75
Watts
ºC
Magnetising current at nominal
Amp
voltage
Efficiency at 75 ºC and:
100% load PF 1.0 %
PF 0.8 %
75% load PF 1.0 %
PF 0.8 %
50% load PF 1.0 %

Volume 8

PF 0.8 %
25% load PF 1.0 %
PF 0.8 %
Regulation at full load and:
PF 0.8 %
PF 1.0 %
Total weight maximum
Type of oil
Material of windings
Dimensions
Width mm
Length mm
Height mm
Type of breather
Is the transformer hermetically
Yes/No yes
sealed?
Does the transformer already have
Yes/No
type test certificates?
Certification of PCB free oil yes
For each size one data sheet shall

be filled


Volume 8
Annex 1.6 MV surge arrestor
Manufacturer
Type MOX
System voltage kV 11
Rated voltage kV 12
BIL kV >95
Weight kg


Volume 8

Annex 1.7 LV equipment
LV Moulded Case Circuit Breakers
Manufacturer
Type
Number of poles
Rated current A
Maximum rated current A
Short time capacity (1 min) A
Rated voltage V
Breaking capacity (rms) A
Making capacity (peak)
Time/current characteristics Hydraulic+electromagnetic or
thermal + electromagnetic
Non‐ignitable high impact
Dimensions mm
Weight kg
Type of control
Material of casing
Terminal sizes (Aluminium
70 ‐ 300 mm²
conductor)


Volume 8
Annex 1.8 Low voltage electronic meters
Single Phase 5 (20) A Meter
Manufacturer
Model
Rated voltage V
Frequency Hz
Nominal current A
Maximum current A
Measurement method
Accuracy class according to IEC 62053‐
%
21
Error limits:
 Nominal load %
 Inductive load Cos PHI <p = 0.5
 Minimum load, <0.05 In
Service type
Connection form
Starting current mA
Burden
 Voltage circuit VA
 Current circuit VA

Protection class acc. to IEC 60529
Environmental influences:
 Temperature range for operation °C
 Temperature range for storage °C
 Humidity %
Dimensions (length x width x depth) mm
Weight kg

Volume 8

Display:
 Number of digits for quantities
 Size of digit
Three Phase 10 (40) A Meter
Manufacturer
Model
Rated voltage V
Frequency Hz
Nominal current A
Maximum current A
Measurement method
Accuracy class according to IEC 62053‐
%
21
Error limits:
 nominal load %
 inductive load Cos PHI <p = 0.5
 minimum load, <0.05 In
Service type
Connection form
Starting current mA
Burden
 Voltage circuit VA
 Current circuit VA

Protection class acc. to IEC 60529
Environmental influences:
 Temperature range for operation °C
 Temperature range for storage °C
 Humidity %
Dimensions (length x width x depth) mm

Volume 8
Weight kg
Display:
 Number of digits for quantities
 Size of digit


Volume 8

Annex 1.9 11 kV combined disconnector and cut out fuse
Name of manufacturer/Country of

origin
Applicable standard (number & year)
Type
• Outdoor/indoor outdoor
• Double break/single break
• Side break/vertical break
Catalogue no./model no.
Rated voltage kV 12
Rated frequency Hz 50
Rated continuous current A 100
Rated short‐time current/duration kA/sec. 3s
Rated short time current kA 20
Rated peak withstand current kA 50
Rated insulation level:
• Lightning impulse withstand
kV 110
voltage (1.2/50 us)
• Power frequency withstand at 50
Hz
kV
- Wet
- - dry
• Power frequency flashover voltage
kV
at 50 Hz
Total creepage distance (phase to
mm
earth)
Dimensions of operating rod/pipe

(vertical)
• Diameter mm
• Length mm
Distance between phase centres mm
Separation between open contacts mm
Applicable range of sizes of
mm
conductors to the terminals
Is the facility provided for locking of
operating mechanism in fully open Yes/No
or fully closed position?

Volume 8
Is the "ON" and "OFF" position and
direction of operation of the
Yes/No
operating mechanism clearly
marked?
Is the holding part of the operating
Yes/No
handle insulated?
Total weight kg


Volume 8

Annex 2: Drawings


Volume 8
DISTRIBUTION CONSTRUCTION MATERIALS

PPAF – TECHNICAL GUIDELINES AND MANUALS
INDEX

Transmission & Distribution Networks DATE PAGE NO.
1. DISTRIBUTION CONSTRUCTION MATERIALS

1.1 MV CABLES / ACCESSORIES
1.1.1 T1 OUTDOOR TERMINATION KIT 11kV, XLPE insulation
1.1.2 T2 INDOOR TERMINATION KIT 11kV, XLPE insulation
1.1.3 J1 STRAIGHT JOINT KIT 11kV, XLPE insulation
1.1.4 C2 SHRINK CAP, XLPE insulation
1.2 OVERHEAD MV CONDUCTOR / ACCESSORIES
1.2.1 C6 ALUMINIUM CONDUCTOR STEEL REINFORCED (ACSR)
1.2.2 S1 COMPRESSION SPLIES, full tension for ACSR
1.2.3 S2 REPAIR SLEEVE, for ACSR conductors
1.2.4 C7 COMPRESION TAP CONNECTOR, Type H
1.2.5 S3 COMPRESSION STIRRUP CONNECTOR for ACSR
1.2.6 C8 HOT LINE CLAMP, for installation on compression stirrups
1.3 ABC LV CABLES & ACCESSORIES
1.3.1 C9-1 ABC CABLES (QUADRUPLEX) 0.6/1V, aluminium conductor
1.3.4 S4 SPIRAL (PIG TAIL) HOOK
1.3.5 N1-1 NUT HOOK
1.3.6 N1-2 NUT HOOK
1.3.7 N2 NUT HOOK (EXTERNAL ANGLE)
1.3.8 C10 SUSPENSION CLAMP, ABC, small angles
1.3.9 C11 SUSPENSION CLAMP, ABC, tension, dead end, large angles
1.3.10 C12 SUSPENSION CLAMP (UP TO 30º), ABC
1.3.11 C13 TENSION SUPPORT CLAMP, ABC
1.3.12 C14 DEAD-END CLAMP, ABC, for non-insulated neutral AAAC with cutting
1.3.13 C15 DEAD-END CLAMP, ABC, for non-insulated neutral AAAC without cutting
1.3.14 C16 SUSPENSION CLAMP (UP TO 30º)
1.3.15 Y1 YOKE UNIVERSAL
1.3.16 S5 PRE-INSULATED SLEEVES
1.3.17 S6 COMPRESSION SLEEVES (FULL TENSION)
1.3.18 C17 INSULATION PIERCING CONECTOR
1.3.19 C18 SEALING CAP 0.6/1kV
1.3.20 C19 TRANSITION CONNECTOR, ABC to LV

Comment


Volume 8


INDEX

1.4 INSULATORS & ACCESSORIES

1.4.1 I1 SUSPENSION INSULATOR, porcelain, ball& socket
1.4.2 I2 PIN TYPE INSULATOR, porcelain
1.4.3 I3 GUY INSULATOR, porcelain
1.4.4 C20 WEDGE TYPE TENSION CLAMP
1.4.5 C21 WEDGE TYPE TENSION CLAMP, for ACSR conductor with current loop
1.4.6 B4 BALL CLEVIS
1.4.7 N3 EYE NUT
1.4.8 E1 SOCKET EYE STRAIGHT
1.4.9 P1 POLE TOP PIN
1.4.10 P2 SHORT SHANK PIN
1.4.11 P3 OFFSET POLE TOP PIN
1.4.12 P4 DOUBLE ARMING PLATE
1.5 MISCELLANEOUS
1.5.1 A1 SURGE ARRESTER
1.5.2 B1 DOUBLE ARMING BOLT
1.5.3 B2 MACHINE BOLT
1.5.4 B5 BUCKLE FOR STRAPS
1.5.5 C22 COPPER CONDUCTOR
1.5.6 C23 GROUND STUD CONNECTOR (SPILT BOLT)
1.5.7 G1 GROUND WIRE MOULDING GUARD
1.5.8 R1 GROUND ROD
1.5.9 S7 STRAP
1.5.10 S8 STRAPS
1.5.11 S9 FACADE SADLES
1.5.12 W1 ROUND WASHER
1.5.13 W2 SQUARE WASHER
1.5.14 W3 SPRING LOCK WASHER
1.6 GUY
1.6.1 A2 CONE ANCHOR, concrete
1.6.2 G2 GUY HOOD, ductile iron, hot dip galvanized
1.6.3 G3 GUY END, galvanized steel
1.6.4 G4 TAPERED GUY (GUARD)
1.6.5 N4 THIMBLEYENUT, galvanized steel
1.6.6 R3 THIMBLEYE ANCHOR ROD, galvanized steel
1.6.7 R4 TWINEYE ANCHOR ROD, galvanized steel
1.6.8 S12 SPLIT BOLT, copper to galvanized
1.6.9 W4 GUY WIRE

Comment


Volume 8

PPAF – TECHNICAL GUIDELINES AND MANUALS INDEX

DATE PAGE NO.
Transmission & Distribution Networks
2. ASSEMBLIES
2.1.1 AS-01 SINGLE CROSSARM STEEL (2000 mm)
2.1.2 AS-02 SINGLE CROSSARM STEEL (3200 mm)
2.1.3 AS-03 DOUBLE CROSSARM STEEL (2000 mm)
2.1.4 AS-04 DOUBLE CROSSARM STEEL (3200 mm)
2.1.5 AS-05 SINGLE SUPPORT ON CROSSARM (TANGENT)
2.1.6 AS-06 DOUBLE SUPPORT ON CROSSARM (ANGLE)
2.1.7 AS-07 SINGLE SUPPORT ON TOP POLE
2.1.8 AS-08 DOUBLE SUPPORT ON TOP POLE
2.1.9 AS-09 DEAD-END ON CROSSARM
2.1.10 AS-10 DEAD-END ON POLE
2.1.11 AS-11 LV-SINGLE SUPPORT
2.1.12 AS-12 LV-SINGLE DEAD-END
2.1.13 AS-13 LV-SINGLE DEAD-END (existing spiral hook)
2.1.14 AS-14 LV-DOUBLE SUPPORT (angle up to 60º)
2.1.15 AS-15 LV-SINGLE SUPPORT (external angle)
2.1.16 AS-16 LV-DERIVATION SUPPORT
2.1.17 AS-17 LV-SINGLE SERVICE DROP
2.1.18 AS-18 LV-MULTIPLE SERVICE DROP
2.1.19 AS-19 LV-SERIVE CONNECTION CUSTOMER WALL

3. MV STRUCTURES
3.1.1 MV-301C STRUCTURE M1, ALIGNMENT
3.1.2 MV-302C STRUCTURE M2, ALIGNMENT, SMALL ANGLE
3.1.3 MV-303C STRUCTURE M3, TENSION, LARGE ANGLE
3.1.4 MV-304C STRUCTURE M4, TENSION, BRANCH
3.1.5 MV-305C STRUCTURE M5, TENSION, DEAD-END
3.1.6 MV-306C STRUCTURE M6, TENSION, SHACKLE
3.1.7 MV-601C STRUCTURE MM1, ALIGNMENT, DOUBLE CIRCUIT
3.1.8 MV-602C STRUCTURE MM², ALIGNMENT, SMALL ANGLE, DOUBLE CIRCUIT
3.1.9 MV-603C STRUCTURE MM3, TENSION, LARGE ANGLE, DOUBLE CIRCUIT
3.1.10 MV-604C STRUCTURE MM4, TENSION, BRANCH, DOUBLE CIRCUIT
3.1.11 MV-605C STRUCTURE MM5, TENSION, DEAD-END, DOUBLE CIRCUIT
3.1.12 MV-606C STRUCTURE MM6, TENSION, SHACKLE, DOUBLE CIRCUIT
3.1.13 TR-01 POLE MOUNTED TRANSFORMER
4. SUB-STATION STRUCTURES
4.1.1 SS-101 POLE MOUNTED TRANSFORMER
4.1.2 SS102 ELECTRICAL SCHEME OF SUB-STATION
4.1.3 LV-101 CONTROL AND DISTRIBUTION CUBICLE
4.1.4 LV-102 WIRING DIAGRAM CONTROL AND DISTRIBUTION CUBICLE
4.1.5 LV-101 AIR CIRCUIT BREAKER - MOUNTING FRAME)
4.1.6 LV-102 AIR CIRCUIT BREAKER - INSTALLATION
4.1.7 LV-101 SURGE ARRESTER - INSTALLATION
4.1.8 LV-102 FUSE CUT OUT – MOUNTING PLATFORM
4.1.9 SS-110 FUSE CUT OUT – INSTALLATION
4.1.10 SS-111 EARTHING - SUB-STATION
4.1.11 SS-112 EARTHING - DISTRIBUTION

5. LV STRUCTURES
5.1.1 LV-101 STRUCTURE L1, ALIGNMENT (angle 0º to 30º)
5.1.2 LV-102 STRUCTURE L2, TENSION, SHACKLE
5.1.3 LV-103 STRUCTURE L3, TENSION, BRANCH
5.1.4 LV-104 STRUCTURE L4, TENSION, SHACKLE & BRANCH
5.1.5 LV-105 STRUCTURE L5, ALIGNMENT, LARGE ANGLE (angle 30º to 60º)
5.1.6 LV-106 STRUCTURE L6, TENSION, RIGHT ANGLE (angle 60º to 90º)
5.1.7 LV-107 STRUCTURE L7, TENSION, DEAD-END

Volume 8

INDEX

6. SWITCHING EQUIPMENT
6.1.1 PR-01 RECLOSER WITH BYPASS SWITCH
6.1.2 PR-02 RECLOSER WITHOUT BYPASS SWITCH
6.1.3 PR-03 LOAD BREAK SWITCH
6.1.4 PR-04 SINGLE SUPPORT ON CROSSARM DISCONNECTING SWITCH
6.1.5 CT-1 MV CABLE TERMINATION TO OVERHEAD LINE FROM TRANSFORMER
6.1.6 CT-2 MV CABLE TERMINATION TO OVERHEAD LINE FROM GRID/ JUNCTION
7.
8. MISCELLANEOUS
8.1.1 M-001 CONDUIT INSTALLATION
8.1.2 M-002 PAD-MOUNTED FEEDER PILLER & METER BOX
9. GUY
9.1.1 AN-S1 ANCHOR WITH THIMBLEYE ROD
9.1.2 AN-D1 ANCHOR WITH TWINEYE ROD
9.1.3 GU-S1 SINGLE GUY
9.1.4 GU-01 SINGLE OVERHEAD GUY
9.1.5 GU-101C SINGLE DOWN GUY FOR LOW VOLTAGE
9.1.6 GU-102C SINGLE DOWN GUY FOR MEDIUM VOLTAGE
9.1.7 GU-401C SINGLE OVERHEAD GUY
10. CABLES & CONDUCTORS
10.1.1 C-001 TABLE OF CABLE AND CONDUCTORS ASSIGNATION
10.1.2 C-002 OVERHEAD LINE DESIGN CRITERIA
10.1.3 C-003 WEATHER CASE
10.1.4 C-004 SAG TENSION CALCULATIONS – EXAMPLE
11. DESIGN EXAMPLES – GOLAN ASTORE

Comment


Volume 8

DISTRIBUTION CONSTRUCTION
PPAF – TECHNICAL GUIDELINES AND MANUALS MATERIAL
MV CABLES/ACCESSORIES


T1
OUTDOOR TERMINATION KIT 11 KV, XLPE insulation

For cable size
a) all sizes

Used for outdoor MV termination cable

T2
INDOOR TERMINATION KIT 12 KV, XLPE insulation

For cable size
a) all sizes

Used for indoor MV termination cable

'
Comment


Volume 8

MV CABLES/ACCESSORIES

J1
STRAIGHT JOINTS KIT 11 KV, XLPE insulation
For cable size
a) All sizes

Used for joint MV cable
C2
SHRINK CAP, XLPE insulation
For cable size
a) All sizes

Used for protection of cable

Comment


Volume 8

OVERHEAD MV CONDUCTOR/ACCESSORIES

C6
ALUMINUM ALLOY CONDUCTOR STEEL REINFORCED (ACSR)
Overall Breaking
Code Weight
diameter load
a) 70/12 11.5 mm 284 kg/km 26800 N
b) 120/20 15.5 mm 493 kg/km 45650 N
c) 185/30 19.0 mm 741 kg/km 66200 N
Used for transport energy in Medium Voltage
S1
COMPRESSION SPLICE, full tension for ACSR conductor
Conductor size Overall diameter
a) 70/12 mm² 11.5 mm

b) 120/20 mm² 15.5 mm
c) 185/30 mm² 19.0 mm
Used for joint conductor ACSR
S2
REPAIR SLEEVE, for ACSR conductor
a) 70/12 mm² 11.5 mm

b) 120/20 mm² 15.5 mm
c) 185/30 mm² 19.0 mm
Used for repair conductor ACSR

Comment


Volume 8


PPAF – TECHNICAL GUIDELINES AND MANUALS OVERHEAD MV
CONDUCTOR/ACCESSORIES

C7
COMPRESSION TAP CONNECTOR, Type H
Main conductor
Tap conductor (diameter)
(diameter)
a) 70/12 mm² (11.5 mm) 70/12 mm² (11.5 mm)
b) 120/20 mm² (15.5 mm) 120/20 mm² (15.5 mm)
c) 185/30 mm² (19.0 mm) 185/30 mm² (19.0 mm)
d) 120/20 mm² (15.5 mm) 70/12 mm² (11.5 mm)
e) 185/30 mm² (19.0 mm) 70/12 mm² (11.5 mm)
f) 185/30 mm² (19.0 mm) 120/20 mm² (15.5 mm)
Used for joint conductor ACSR
S3
COMPRESSION STIRRUP CONNECTOR, for ACSR conductor, casting aluminum alloy and stirrup copper rod
Stirrups
Casting for conductor
section
Size Diameter
a) 70/12 11.5 mm 284 kg/km
b) 120/20 15.5 mm 493 kg/km
c) 185/30 19.0 mm 741 kg/km
H min = 95 mm and B min = 100 mm
Used for protect conductor of electric arcing
C8
HOT LINE CLAMP, for installation on compression stirrups
Main Tap
a) 4 - 10 mm 4 - 10 mm
Used for installation on energized conductor

Comment


Volume 8
PPAF – TECHNICAL GUIDELINES AND MANUALS DISTRIBUTION CONSTRUCTION MATERIALS

ABC LV CABLES AND ACCESSORIES
C9‐1
ABC CABLES (QUADRUPLEX) 0.6/1 KV, aluminum conductor; bare messenger in Al alloy, messenger diameter adjusted
Phases Neutral
conductor messenger
a) 3 x 50 mm² 1 x 50 mm²
b) 3 x 95 mm² 1 x 70 mm²
c) 3 x 120 mm² 1 x 70 mm²
Used for transport energy in low voltage overhead line
C9‐2
ABC CABLES (QUADRUPLEX) 0.6/1 KV, aluminum conductor; all insulated, all load bearing, equal diameter
Phases Neutral
conductor messenger
a) 3 x 50 mm² 1 x 50 mm²
b) 3 x 95 mm² 1 x 95 mm²
c) 3 x 120 mm² 1 x 120 mm²
Used for support low voltage cables
C9‐3
ABC CABLES (QUADRUPLEX) 0.6/1 KV, aluminum conductor; all insulated, all load bearing; messenger adjusted diameter
Phases Neutral
conductor messenger
a) 3 x 50 mm² 1 x 50 mm²
b) 3 x 95 mm² 1 x 70 mm²
c) 3 x 120 mm² 1 x 70 mm²

Comment


Volume 8



S4
ABC CABLES (QUADRUPLEX) 0.6/1 KV, aluminum conductor
Dimensions
Diameter Length
a) M16 300 mm
b) M16 360 mm
N1‐1
Bolt HOOK (EXTERNAL ANGLE), for non-insulated neutral
For bolt
a) M16

Used Used for support low voltage cables
N1‐2
NUT HOOK (EXTERNAL ANGLE), for non-insulated neutral AAAC
For bolt
a) M16

Used for support neutral messenger in low voltage overhead line

Comment


Volume 8


C10
Clamp, complete set for wall connection, small angles, for ABC

a) 35 mm²
b) 50 mm²
c) 70 mm²
d) 95 mm²
e) 120 mm²
Used for support ABC cable in low voltage overhead line
C11
Suspension clamp for ABC cable, DEAD-END CLAMP, tension poles, dead end and large angles

a) 10-25 mm²
b) 35-50 mm²
c) 70-95 mm²
d) 95-150 mm²

Used for ABC cable in low voltage overhead line
C12
SUSPENSION CLAMP (UP TO 30º), for ABC cable, medium angles
Neutral section
a) 10-50 mm²
b) 50-95 mm²
d) 95-150 mm²

C13
Tension support clamp, for ABC cable,

a) 50-95 mm²
b) 95-120 mm²

Used for support ABC cable in low voltage overhead line

Comment


Volume 8



C14
DEAD-END CLAMP, for non-insulated neutral AAAC with cutting
Neutral section
a) 35 mm²
b) 50 mm²
c) 70 mm²
d) 95 mm²
e) 120 mm²
C15
DEAD-END CLAMP, for non-insulated neutral AAAC without cutting
Neutral section
a) 35 mm²
b) 50 mm²
c) 70 mm²
d) 95 mm²
e) 120 mm²
C16
SUSPENSION CLAMP (UP TO 30º), for non-insulated neutral AAAC
Neutral section
a) 35 mm²
b) 70 mm²
d) 95 mm²
e) 120 mm²
Y1
YOKE UNIVERSAL, with two suspension clamps (line angles up to 60º)
Neutral section
a) 35 - 120 mm²


Comment


Volume 8


S5
PRE-INSULATED SLEEVES, for Aluminum conductor according to Chapter F (Technical Specification)
Conductor section
a) 50 mm²
b) 95 mm²
c) 120 mm²
Used for joint conductor LV
S6
COMPRESSION SLEEVES (FULL TENSION), for ABC cable: non insulated cable
Conductor section
a) 35 mm²
b) 70 mm²

Used for joint ABC cable
C17
INSULATION PIERCING CONNECTOR, for insulated overhead lines
Main range Branch range
a) 25-95 mm² AL 25-95 mm² AL

b) 50-120 mm² AL 50-120 mm² AL
c) 25-95 mm² AL 4-70 mm² CU
d) 50-120 mm² AL 10-95 mm² CU
Used for branch conductor

Comment


Volume 8



C18
SEALING CAP 0.6/1 KV

Used for protection cables LV
C19
TRANSITION CONNECTOR, between LV ABC and bare LV line
Main conductor Tap conductor
a) ------- 11.5 mm
Used for repair conductor ACSR

Comment


Volume 8

INSULATOR AND ACCESSORIES

I1
SUSPENSION INSULATOR, porcelain, ball and socket
Mechanical
Disc diameter Spacing
failing load
a) 175 mm 110 mm 40 kN
Used for support conductor Medium Voltage
I2
PIN TYPE INSULATOR, porcelain
Mechanical
Diameter Height
cantilever load
a) 238 mm 158 mm 20 kN
Used for support conductor Medium Voltage
I3
GUY TYPE INSULATOR, porcelain
Mechanical
Diameter Height
tensile strength
a) 73 mm 140 mm 53 kN
Used for Guy wire (max. wire diameter: 16 mm)
C20
WEDGE TYPE TENSION CLAMP, for ACSR conductor without current loop
a) 70/12 mm² 11.5 mm

b) 120/20 mm² 11.5 mm
c) 185/30 mm² 19.0 mm
Used for support conductor ACSR

Comment


Volume 8



C21
WEDGE TYPE TENSION CLAMP, for ACSR conductor with current loop
a) 70/12 mm² 11.5 mm

b) 120/20 mm² 11.5 mm
c) 185/30 mm² 19.0 mm
B4
BALL CLEVIS, galvanized steel for suspension insulator
Minimum Breaking strength
a) 130 kN

N3
EYE NUT, galvanized steel
For bolt Diameter Minimum Breaking strength
a) M16 130 kN
E1
SOCKET EYE STRAIGHT, galvanized steel for suspension insulator
Minimum Breaking strength
a) 130 kN


Comment


Volume 8


P1
POLE TOP PIN, galvanized pressed steel for pin type insulator
L H S Hole diameter Slotted hole
a) 500 mm 280 mm 200 mm 18 mm 18 x 32 mm
Used for support conductor on pole Medium Voltage
P2
Dimensions
A B C Shank diameter
a) 180 mm 40 mm 75 mm M20
Used for support conductor on crossarm Medium Voltage
P3
Dimensions
L A B S Hole diameter
a) 550 mm 110 mm 300 mm 200 mm 18 mm
Slotted hole
18 x 32 mm
Used for support conductor on pole Medium Voltage
P4
DOUBLE ARMING PLATE, hot dip galvanized short shank pin P2
Dimensions
L A B S Hole diameter
a) 600 mm 370 mm 50 mm 100 mm 22 mm
Used for mounting short shank insulator pin

Comment


Volume 8



A1
SURGE ARRESTER, type gapless, grey, silicon rubber, insulated bracket
Rated
Rated max Rated
continuous
operation discharge Rated frequency
operating
voltage current (peak)
voltage
a) 24 kV 19 kV 10 kA 50 Hz
Used for overvoltage protection
B1
DOUBLE ARMING BOLT, metric thread, 4 hexagonal nut, galvanized steel
Dimensions Minimum
Diameter Length breaking strength
a) M16 250 mm 55 kN
b) M16 300 mm 55 kN
c) M16 350 mm 55 kN
d) M16 400 mm 55 kN
e) M20 300 mm 80 kN
f) M20 350 mm 80 kN
g) M16 500 mm 55 kN
h) M16 550 mm 55 kN
Used for assemblies double crossarm
B2
DOUBLE ARMING BOLT, metric thread, 4 hexagonal nut, galvanized steel
Dimensions Minimum
Diameter Length breaking strength
a) M10 50 mm 19 kN
b) M10 125 mm 19 kN
c) M12 50 mm 35 kN
d) M12 150 mm 35 kN
e) M12 250 mm 35 kN
f) M12 300 mm 35 kN
g) M16 200 mm 55 kN
h) M16 250 mm 55 kN
i) M16 300 mm 55 kN
j) M20 250 mm 80 kN
k) M20 300 mm 80 kN
l) M20 350 mm 80 kN
m) M20 50 mm 80 kN
n) M12 475 mm 35 kN
o) M12 525 mm 35 kN
Used for assemblies single crossarm, pole top pin

Comment


Volume 8


MISCELLANEOUS
B5
BUCKLE FOR STRAPS, stainless steel
Dimensions
L
a) 21 mm

Used for attach cables protection
C22
COPPER CONDUCTOR, stranded; yellow-green insulation for earthing
a) 25 mm² 6.40 mm
b) 35 mm² 7.60 mm
Used for earthing electrical system
C23
GROUND STUD CONNECTOR (SPLIT BOLT), copper bonded
Stud diameter Conductor range
a) 12 mm 25 mm²
b) 12 mm 35 mm²
Used for connect ground lug pole inside to external ground
G1
GROUND WIRE MOLDING GUARD, plastic, grey color
Dimension
a Length
a) 12 mm 2400 mm
Used for protecting of ground wire
R1
GROUND WIRE MOLDING GUARD, plastic, grey color
Dimension
Diameter Length
a) 12 mm 1500 mm
b) 16 mm 1800 mm
Used for connect earth wire to the ground

Comment


Volume 8


MISCELLANEOUS

S7
STRAP, hot dip galvanized, include plastic anchor and slotted hex head with washer head screw
Anchor and
For guard
slotted length
a) 12 mm 25 mm
strap Slotted Anchor

Used for protecting ground wire
S8
STRAPS, stainless steel
Dimensions Breaking
a) 20 mm x 0.4 mm 70 daN/mm²
S9
FACADE SADDLES, include a plastic support, a plastic plug, a standard plastic tie and galvanized steel
For cable size

a) ABC 3 x 120 mm² + 1 x 70 mm²
Used to install LV insulated overhead line on a building
W1
ROUND WASHER, galvanized steel
For Bolt diameter Outside diameter Thickness
a) M12 35 mm 6 mm
b) M16 45 mm 6 mm
c) M20 50 mm 6 mm
Used for miscellaneous assemblies
W2
SQUARE WASHER, galvanized steel
For Bolt diameter Outside diameter
a) M12 35 mm
b) M16 45 mm
c) M20 50 mm
Used for miscellaneous assemblies

Comment


Volume 8


GUY
A2
CONE ANCHOR, concrete
Ultimate For Rod

Area Weight
strength Diameter
a) 161300 mm² 380 N 130 kN 20 mm
Used for guy assembly
G2
GUY HOOD, ductile iron, hot dip galvanized
Guy end Thru Ultimate strength
diameter bolt rating
a) 7.0 mm M16 39 kN
b) 11.0 mm M20 95 kN
G3
GUY END, galvanized steel
For guy
Ultimate strength rating
diameter
a) 7.0 mm 36 kN
b) 11.0 mm 101 kN
Used for guy assembly guy assembly

Comment


Volume 8


GUY
G4
TAPERED GUY (GUARD), half round steel with top clamp
For guy range

Length
diameter
a) 6-0 - 11 mm 2400 mm
Used for protecting guy wire
N4
THIMBLEYENUT, galvanized steel
Minimum
For bolt Guy end
breaking
diameter diameter
strength
a) M16 7.0 mm 110 kN
b) M20 11.0 mm 130 kN
R3
THIMBLEYE ANCHOR ROD, galvanized steel with nut included
ultimate
Diameter Length
strength rating
a) M16 2000 mm 70 kN
b) M20 2400 mm 100 kN
R4
TWINEYE ANCHOR ROD, galvanized steel with nut included
ultimate
Diameter Length strength
rating
a) M20 2400 mm 100 kN

Comment


Volume 8

GUY

S12
SPLIT BOLT, copper to galvanized steel, high strength, high copper, alloy body, electrotined nut, spacer and
pressure bar
Guy strand
Copper strand diameter
diameter
a) 7.0 mm 6.40 mm
b) 11.0 mm 7.60 mm
Use Used for connect guy wire to the ground
W4
GUY WIRE, zinc-coated steel stranded, 1300 grade
ultimate
Strand
Wire size strength
diameter
rating
a) 7 X 2.00 mm 7.0 mm 39 kN
b) 7 X 3.65 11.0 mm 95 kN
W3
SPRING LOCK WASHER, galvanized steel
Inside diameter
For Bolt diameter
Min Max
a) M10 10.5 mm 10.7 mm
b) M12 12.7 mm 13.0 mm
c) M16 16.9 mm 17.3 mm
d) M20 20.1 mm 20.7 mm
Used for keep a bolt-nut in tension

Comment


Volume 8

2. ASSEMBLIES

2.1 AS-01 SINGLE CROSSARM STEEL (2000 mm)
2.2 AS-02 SINGLE CROSSARM STEEL (3200 mm)
2.3 AS-03 DOUBLE CROSSARM STEEL (2000 mm)
2.4 AS-04 DOUBLE CROSSARM STEEL (3200 mm)
2.5 AS-05 SINGLE SUPPORT ON CROSSARM (TANGENT)
2.6 AS-06 DOUBLE SUPPORT ON CROSSARM (ANGLE)
2.7 AS-07 SINGLE SUPPORT ON TOP POLE
2.8 AS-08 DOUBLE SUPPORT ON TOP POLE
2.9 AS-09 DEAD-END ON CROSSARM
2.10 AS-10 DEAD-END ON POLE
2.11 AS-11 LV-SINGLE SUPPORT
2.12 AS-12 LV-SINGLE DEAD-END
2.13 AS-13 LV-SINGLE DEAD-END (existing spiral hook)
2.14 AS-14 LV-DOUBLE SUPPORT (angle up to 60º)
2.15 AS-15 LV-SINGLE SUPPORT (external angle)
2.16 AS-16 LV-DERIVATION SUPPORT
2.17 AS-17 LV-SINGLE SERVICE DROP
2.18 AS-18 LV-MULTIPLE SERVICE DROP
2.19 AS-19 LV-SERIVE CONNECTION CUSTOMER WALL

Drawing:
PPAF – TECHNICAL GUIDELINES
AND MANUALS Medium Voltage Miscellaneous Assemblies

Transmission & Distribution Networks U AS-00

Date: Revision: Scale: -


Volume 8
NO. QT. DESCRIPTION CODE

B2a 2 MACHINE BOLT, METRIC THREAD, HEXAGONAL HEAD AND NUT M10 x 50 mm
B2 1 MACHINE BOLT, METRIC THREAD, HEXAGONAL HEAD AND NUT M12 x REQ`D
LENGTH
LENGTH
B6a 2 FLAT CROSSARM BRACE 40 mm X 8 mm, LENGTH 760 mm
C20a 1 STEEL CROSSARM 70 mm X 70 mm X 7 mm, LENGTH 2000 mm
W2b 1 SQUARE WASHER, 60 mm X 60 mm X 8 mm, FOR BOLT M12
W2c 1 SQUARE WASHER, 75 mm X 75 mm X 8 mm, FOR BOLT M16
W3a 2 SPRING LOCK WASHER, FOR BOLT M10
W3b 1 SPRING LOCK WASHER, FOR BOLT M12
W3c 1 SPRING LOCK WASHER, FOR BOLT M16

PPAF – TECHNICAL Single Crossarm Steel (2000 mm) Drawing:
GUIDELINES AND MANUALS Miscellaneous Assemblies MV
Transmission & Distribution U AS-01
Networks


Volume 8


LENGTH
LENGTH
B6b 2 FLAT CROSSARM BRACE 40 mm X 8 mm, LENGTH 1000 mm
C20c 1 STEEL CROSSARM 70 mm X 70 mm X 7 mm, LENGTH 3200 mm
W2b 1 SQUARE WASHER, 60 mm X 60 mm X 8 mm, FOR BOLT M12

PPAF – TECHNICAL Single Crossarm Steel (3200 mm) Drawing:
U AS-02
Networks


Volume 8

B1 3 DOUBLE ARMING BOLT, METRIC THREAD, 4 HEXAGONAL NUT M16 x REQ`D
LENGTH
LENGTH
B6a 4 FLAT CROSSARM BRACE 40 mm X 8 mm, LENGTH 760 mm
C20a 2 STEEL CROSSARM 70 mm X 70 mm X 7 mm, LENGTH 2000 mm

PPAF – TECHNICAL Double Crossarm Steel (2000 mm) Drawing:
U AS-03
Transmission & Distribution Date: Revision: Scale: -
Networks


Volume 8


LENGTH
LENGTH
B6b 4 FLAT CROSSARM BRACE 40 mm X 8 mm, LENGTH 1000 mm
C20c 2 STEEL CROSSARM 70 mm X 70 mm X 7 mm, LENGTH 3200 mm

PPAF – TECHNICAL Double Crossarm Steel (3200 mm) Drawing:
U AS-04
Networks


Volume 8

I2 1 PIN TYPE INSULATOR, 238 mm (DIAMETER) X 158 mm (HEIGHT)
P2 1 SHORT SHANK PIN, FOR POLE TOP INSULATOR I2
W3d 1 SPRING LOCK WASHER, FOR BOLT M20

PPAF – TECHNICAL Single Support on Crossarm (Tangent) Drawing:
U AS-05
Networks


Volume 8


B2m 2 MACHINE BOLT, METRIC THREAD, HEXAGONAL HEAD AND NUT M20 x 50 mm
P2 2 SHORT SHANK PIN, FOR POLE TOP INSULATOR I2
P4 1 DOUBLE ARMING PLATE, FOR SHORT SHANK PIN P2

PPAF – TECHNICAL Double Support on Crossarm (Angle) Drawing:
U AS-06
Networks


Volume 8

LENGTH
P1 1 POLE TOP PIN, 500 mm X 280 mm X 200 mm
W2 2 SQUARE WASHER, 75 mm X 75 mm X 8 mm, FOR BOLT M16

PPAF – TECHNICAL Single Support on Top Pole Drawing:
U AS-07
Networks


Volume 8


LENGTH
P3 2 OFFSET POLE TOP PIN, 550 mm X 110 mm X 200 mm

PPAF – TECHNICAL Double Support on Top Pole Drawing:
Networks


Volume 8

B4 1 BALL CLEVIS, FOR SUSPENSION INSULATOR I1
C16 1 WEDGE TYPE TENSION CLAMP, FOR ACSR CONDUCTOR
E1 1 SOCKET EYE STRAIGHT, FOR SUSPENSION INSULATOR I1
I1 3 SUSPENSION INSULATOR, BALL AND SOCKET 175 mm (DISC. DIAMETER) X 110 mm
(SPACING)
N3 1 EYE NUT, FOR BOLT M16

PPAF – TECHNICAL Dead-end on Crossarm Drawing:
Networks


Volume 8


LENGTH
B4 1 BALL CLEVIS, FOR SUSPENSION INSULATOR I1
C16 1 WEDGE TYPE TENSION CLAMP, FOR ACSR CONDUCTOR
E1 1 SOCKET EYE STRAIGHT, FOR SUSPENSION INSULATOR I1
I1 3 SUSPENSION INSULATOR, BALL AND SOCKET 175 mm (DISC. DIAMETER) X 110 mm
(SPACING)
N3 1 EYE NUT, FOR BOLT M16

PPAF – TECHNICAL Dead-end on Pole Drawing:
U AS-10
Networks


Volume 8

C12 1 SUSPENSION CLAMP, for ABC cable, various kinds
S4 1 SPIRAL (PIG TAIL) HOOK, WITH SQUARE WASHER, SPRING LOCK WASHER AND NUT

PPAF – TECHNICAL Single Support Drawing:
GUIDELINES AND MANUALS Miscellaneous Assemblies LV
U AS-11
Networks


Volume 8


C10 2 DEAD-END CLAMP, FOR ABC, VARIOUS KINDS
S4 1 SPIRAL (PIG TAIL) HOOK, WITH SQUARE WASHER, SPRING LOCK WASHER AND NUT

PPAF – TECHNICAL Single Dead-end Drawing:
Networks


Volume 8

C10 1 DEAD-END CLAMP, FOR ABC, VARIOUS KINDS
N1 1 NUT HOOK FOR BOLT M16

PPAF – TECHNICAL Single Dead-end (Existing Spiral Hook) Drawing:
Networks


Volume 8


C12 2 YOKE UNIVERSAL,WITH COMPLETE SPIRAL HOOK or TENSION CLAMPS FOR ABC
Y1 1

PPAF – TECHNICAL Double Support (Angle Up to 60º) Drawing:
Networks


Volume 8

LENGTH
C12 1 SUSPENSION CLAMP, FOR ABC VARIOUS KINDS
N2 1 NUT HOOK (EXTERNAL ANGLE) FOR BOLT M16

PPAF – TECHNICAL Single Support (External Angle) Drawing:
Networks


Volume 8

PPAF – TECHNICAL Cable Support: Derivation from LV suspension Drawing:
U AS-16
Networks


Volume 8

PPAF – TECHNICAL Single Service Drop Support Drawing:
U AS-17
Networks


Volume 8


LENGTH
C12 1 SUSPENSION CLAMP, FOR ABC VARIOUS KINDS
N2 1 NUT HOOK (EXTERNAL ANGLE) FOR BOLT M16

PPAF – TECHNICAL Multiple Service Support Drawing:
Networks


Volume 8

PPAF – TECHNICAL Sercie Connection at Customer Walls Drawing:
U AS-19
Networks


Volume 8

3. MV STRUCTURES

3.1 MV-301C STRUCTURE M1, ALIGNMENT
3.2 MV-302C STRUCTURE M2, ALIGNMENT, SMALL ANGLE
3.3 MV-303C STRUCTURE M3, TENSION, LARGE ANGLE
3.4 MV-304C STRUCTURE M4, TENSION, BRANCH
3.5 MV-305C STRUCTURE M5, TENSION, DEAD-END
3.6 MV-306C STRUCTURE M6, TENSION, SHACKLE
3.7 MV-601C STRUCTURE MM1, ALIGNMENT, DOUBLE CIRCUIT
3.8 MV-602C STRUCTURE MM², ALIGNMENT, SMALL ANGLE, DOUBLE CIRCUIT
3.9 MV-603C STRUCTURE MM3, TENSION, LARGE ANGLE, DOUBLE CIRCUIT
3.10 MV-604C STRUCTURE MM4, TENSION, BRANCH, DOUBLE CIRCUIT
3.11 MV-605C STRUCTURE MM5, TENSION, DEAD-END, DOUBLE CIRCUIT
3.12 MV-606C STRUCTURE MM6, TENSION, SHACKLE, DOUBLE CIRCUIT

PPAF – TECHNICAL Medium Voltage Drawing:
GUIDELINES AND MANUALS Structures
U MV-00
Networks


Volume 8
NO. QT. DESCRIPTION

AS-01 1 Single crossarm steel (2000 mm) MATERIAL QT. DESCRIPTION
AS-05 2 Single support on crossarm (tangent) 3 Preformed distribution ties for ACSR
AS-07 1 Single support on top pole

Structure M1 - Drawing:
Alignment (Angle 0-5°)
U MV-301C
Transmission & Distribution Networks Date: Revision: Scale: -


Volume 8

NO. QT. DESCRIPTION

AS-03 1 Double crossarm steel (2000 mm) MATERIAL QT. DESCRIPTION
AS-06 2 Double support on crossarm (angle) 6 Preformed distribution ties for ACSR
AS-08 1 Double support on top pole

PPAF – TECHNICAL GUIDELINES AND Structure M2 - Alignment Small Angle Drawing:
MANUALS (Angle 5°-15°)
U MV-302C


Volume 8
NO. QT. DESCRIPTION

AS-03 1 Double crossarm steel (2000 mm) 3 Preformed distribution ties for ACSR
AS-05 3 Single support on crossarm (tangent) C7 3 Compression tap connectors, H type for ACSR,
as requested
AS-09 6 Dead-end on crossarm

PPAF – TECHNICAL GUIDELINES AND MANUALS Drawing:
Structure M3 - Tension,
Large Angle
U MV-303C


Volume 8

NO. QT. DESCRIPTION

AS-05 3 Single support on crossarm (tangent) C7 3 Compression tap connectors, H type for ACSR,
as requested
AS-07 1 Single support on top pole

Structure M4 - Tension,
Branch
U MV-304C


Volume 8
NO. QT. DESCRIPTION


Structure M5 - Tension, Dead-End
U MV-305C


Volume 8

NO. QT. DESCRIPTION

AS-05 3 Single support on crossarm (tangent) 1 Preformed distribution ties for ACSR
AS-09 3 Dead-end on crossarm C7 3 Compression tap connectors, H type for ACSR,
as requested

Structure M6 - Tension, Shackle
U MV-306C


Volume 8
NO. QT. DESCRIPTION

AS-05 6 Single support on crossarm (tangent)

Structure MM1 - Alignment,
Double Circuit
U MV-601C


Volume 8

NO. QT. DESCRIPTION

AS-06 6 Double support on crossarm (angle)

PPAF – TECHNICAL GUIDELINES AND Drawing:
MANUALS
Small Angle, Double Circuit
U MV-602C

Volume 8
NO. QT. DESCRIPTION

AS-05 6 Single support on crossarm (tangent) C7 6 Compression tap connectors, H type for ACSR, as
requested

Double Circuit
U MV-603C


Volume 8

NO. QT. DESCRIPTION

AS-02 1 Single crossarm steel (3200 mm) 6 Preformed distribution ties for ACSR
AS-03 1 Double crossarm steel (2000 mm) C7 3 Compression tap connectors, H type for ACSR, as
requested
AS-05 6 Single support on crossarm (tangent)

PPAF – TECHNICAL GUIDELINES AND MANUALS Structure MM4 - Tension, Branch Drawing:
Double Circuit
U MV-604C


Volume 8
NO. QT. DESCRIPTION

AS-04 1 Double crossarm steel (3200 mm)

PPAF – TECHNICAL GUIDELINES AND MANUALS Structure MM5 - Tension Dead-End Drawing:
Double Circuit
U MV-605C


Volume 8

NO. QT. DESCRIPTION

AS-05 2 Single support on crossarm (tangent) C7 6 Compression tap connectors, H type for ACSR, as
requested

PPAF – TECHNICAL GUIDELINES AND MANUALS Structure MM6 - Tension, Shackle Drawing:
Double Circuit
U MV-606C


Volume 8

4.0 SUB-STATION STRUCTURES
4.1 SS-101 POLE MOUNTED TRANSFORMER

4.2 SS-102 ELECTRICAL SCHEME OF SUB-STATION
4.3 SS-103 CONTROL AND DISTRIBUTION CUBICLE
4.4 SS-104 WIRING DIAGRAM CONTROL AND DISTRIBUTION CUBICLE
4.5 SS-105 AIR CIRCUIT BREAKER - MOUNTING FRAME
4.6 SS-106 AIR CIRCUIT BREAKER - INSTALLATION
4.7 SS-107 SUSPENSION INSULAOR – MOUNTING FRAME
4.8 SS-108 SUREG ARRESTER - INSTALLATION
4.9 SS-109 FUSE CUT OUT – MOUNTING PLATFORM
4.7 SS-110 FUSE CUT OUT – INSTALLATION
4.8 SS-111 EARTHING – SUB-STATION
4.9 SS-112 EARTHING - DISTRIBUTION

PPAF – TECHNICAL GUIDELINES 11/0.4 kV Sub-Station Drawing:
AND MANUALS
U SS-00


Volume 8

Pole Mounted Transformer
U SS-101


Volume 8
Transformer 11/0.4 kV
Class S11 oder better
Un= 11 kV ±5%, Uk=4‐0%

MANUALS Electrical scheme of Sub-Station
U SS-102


Volume 8

Control and Distribution Cubicle
U SS-103


Volume 8

Electrical Circuit Control and
MANUALS
Distribution Cubicle
U SS-104


Volume 8

Air Circuit Breaker – Mounting
MANUALS
Frame
U SS-105


Volume 8

MANUALS Air Circuit Breaker – Installation
U SS-106


Volume 8

Suspension Insulator – Mounting
MANUALS
Frame
U SS-107


Volume 8

MANUALS Surge Arrester - Installation
U SS-108


Volume 8

MANUALS Fuse Cut Out – Mounting Frame
U SS-109


Volume 8

Fuse Cut Out - Installation
U SS-110


Volume 8

Earthing – Sub-Station
U SS-111


Volume 8

Earthing – Distribution
U SS-112


Volume 8

5.0 LV STRUCTURES
5.1 LV-101 STRUCTURE L1, ALIGNMENT (angle 0º to 30º)

5.2 LV-102 STRUCTURE L2, TENSION, SHACKLE
5.3 LV-103 STRUCTURE L3, TENSION, BRANCH
5.4 LV-104 STRUCTURE L4, TENSION, SHACKLE & BRANCH
5.5 LV-105 STRUCTURE L5, ALIGNMENT, LARGE ANGLE (angle 30º to 60º)
5.6 LV-106 STRUCTURE L6, TENSION, RIGHT ANGLE (angle 60º to 90º)
5.7 LV-107 STRUCTURE L7, TENSION, DEAD-END

PPAF – TECHNICAL Low Voltage Construction Drawing:
GUIDELINES AND MANUALS
U LV-00
Networks


Volume 8
NO. QT. DESCRIPTION

AS-11 1 Single support MATERIAL QT. DESCRIPTION
3 Cable ties, self locking (black)

Structure L1 - Alignment
(Angle 0°-30°)
U LV-101


Volume 8

NO. QT. DESCRIPTION

AS-12 1 Single dead-end MATERIAL QT. DESCRIPTION
AS-13 1 Single dead-end (existing spiral hook) 3 Cable ties, self locking (black)

Structure L2 - Tension, Shackle
U LV-102


Volume 8
NO. QT. DESCRIPTION

AS-11 1 Single support MATERIAL QT. DESCRIPTION
C7 1 Compression tap connectors, H type for AAAC, as
requested
C13 3 Insulation piercing connectors, as requested

Structure L3 - Tension, Branch
U LV-103


Volume 8

NO. QT. DESCRIPTION

requested

Structure L4 - Tension, Shackle &
Branch
U LV-104


Volume 8
NO. QT. DESCRIPTION

AS-14 1 Double support (angle up to 60º) MATERIAL QT. DESCRIPTION

Structure L5 - Alignment, Large
Angle(Angle 30°-60°)
U LV-105


Volume 8

NO. QT. DESCRIPTION

requested

PPAF – TECHNICAL GUIDELINES AND MANUALS Structure L6 - Tension, Right Angle Drawing:
(Angle 60°to 90°)

U LV-106


Volume 8
NO. QT. DESCRIPTION


Structure L7 - Tension, Dead-End
U LV-107


Volume 8

7. SWITCHING EQUIPMENT
7.1 PR-01 RECLOSER WITH BYPASS SWITCH
7.2 PR-02 RECLOSER WITHOUT BYPASS SWITCH
7.3 PR-03 LOAD BREAK SWITCH
7.4 PR-04 SINGLE SUPPORT ON CROSSARM DISCONNECTING SWITCH
7.5 CT-1 MV CABLE TERMINATION TO OVERHEAD LINE FROM TRANSFORMER
7.6 CT-2 MV CABLE TERMINATION TO OVERHEAD LINE FROM GRID/JUNCTION

PPAF – TECHNICAL Switching Equipment and Cable Drawing:
GUIDELINES AND MANUALS Terminations to Overhead Line
Transmission & Distribution U PR-00
Networks

Volume 8

MANUALS RECLOSER WITH BY-PASS SWITCH
U PR-01


Volume 8

MANUALS RECLOSER WITH BY-PASS SWITCH
U PR-02


Volume 8

MANUALS LOAD BREAK SWITCH
U PR-03

Volume 8

Single Support On Crossarm
Disconnecting Switch
U PR-04


Volume 8

PPAF – TECHNICAL GUIDELINES AND Assembly No. CT-1 Drawing:
MANUALS MV Cable Termination to Overhead Line from Indoor
or Overhead Plinth Transformer Station
U CT-01

208 Renewable Energy Guidelines
Nov. 2013
Volume 8

PPAF – TECHNICAL GUIDELINES AND Assembly No. CT-02 Drawing:

MANUALS MV Cable Termination to Overhead Line of
MV Feeders from Grid/Switching Stations
U CT-02


Volume 8
8. MISCELLANEOUS

8.1 M-001 CONDUIT INSTALLATION
8.2 M-002 PAD-MOUNTED FEEDER PILLER & METER BOX
8.3 M-003 METER BOX: 3 SEATS
8.4 M-004 METER BOX: 6 SEATS

PPAF – TECHNICAL Drawing:
GUIDELINES AND MANUALS MISCELLANEOUS
U M-00
Networks

Nov. 2013
Volume 8


MANUALS Conduits Installation
U M-001


Volume 8

MANUALS Pad - Mounted Feeder Pillar and Meter Box
U M-002
Nov. 2013
Volume 8

MANUALS Meter Box 3 Seats
U M-003


Volume 8

MANUALS Meter Box – 6 Seats
U M-004

Nov. 2013
Volume 8

9. GUY
9.1 AN-S1 ANCHOR WITH THIMBLEYE ROD

9.2 AN-D1 ANCHOR WITH TWINEYE ROD
9.3 GU-S1 SINGLE GUY
9.4 GU-01 SINGLE OVERHEAD GUY
9.5 GU-101C SINGLE DOWN GUY FOR LOW VOLTAGE
9.6 GU-102C SINGLE DOWN GUY FOR MEDIUM VOLTAGE
9.7 GU-201C TWO DOWN GUYS FOR LOW / MEDIUM VOLTAGE
9.8 GU-202C TWO DOWN GUYS WITH ONE ANCHOR
9.9 GU-301C THREE DOWN GUYS FOR MEDIUM VOLTAGE
9.10 GU-401C SINGLE OVERHEAD GUY

PPAF – TECHNICAL Guys Miscellaneous Assemblies Drawing:
Transmission & Distribution U GA-00
Networks


Volume 8
Assembly AN-S1.1 AN-S1.2

NO. QT. QT. DESCRIPTION CODE
A2 1 1 CONE ANCHOR, CONCRETE AREA (161,300 mm²)
R3a 1 THIMBLEYE ANCHOR ROD, M16 X 2000 mm, 70 kN
R3b 1 THIMBLEYE ANCHOR ROD, M20 X 2400 mm, 100 kN
W2c 1 SQUARD WASHER 75 mm x 75 mm x 8 mm for bolt M16
W2d 1 SQUARD WASHER 100 mm x 100 mm x 10 mm for bolt M20

PPAF – TECHNICAL GUIDELINES Drawing:
Anchor with Thimbleye Rod
AND MANUALS Miscellaneous Assemblies
U AN-
Transmission & Distribution Networks Date: Scale: - S1
Revision:

Nov. 2013
Volume 8


A2 1 CONE ANCHOR, CONCRETE AREA (161,300 mm²)
R4 1 TWINEYE ANCHOR ROD, M20 x 2400 mm
W2d 1 SQUARD WASHER 100 mm x 100 mm x 10 mm for bolt M20

PPAF – TECHNICAL Anchor with Twineye Rod Drawing:
GUIDELINES AND MANUALS Miscellaneous Assemblies
U AN-D1
Networks


Volume 8
Ass GU- GU-

embly S1.1 -S1.2
B2g 1 MACHINE BOLT, METRIC THREAD, HEXAGONAL HEAD AND NUT M16 X 200 mm
B2j 1 MACHINE BOLT, METRIC THREAD, HEXAGONAL HEAD AND NUT M20 X 250 mm
G2a 1 GUY HOOK FOR GUY STRAND DIAMETER 7 mm, THRU BOLT M16, 39 kN ULTIMATE
STRENGTH
G2b 1 GUY HOOK FOR GUY STRAND DIAMETER 11 mm, THRU BOLT M20, 95 kN ULTIMATE
STRENGTH
G3a 2 GUY END FOR GUY STRAND DIAMETER 7 mm, 36 KN ULTIMATE STRENGTH
G3b 2 GUY END FOR GUY STRAND DIAMETER 11 mm, 101 KN ULTIMATE STRENGTH
S12a 1 SPLIT BOLT FOR GUY STRAND DIAMETER 7 mm AND GROUND WIRE DIAMETER 6.4
mm
S12b 1 SPLIT BOLT FOR GUY STRAND DIAMETER 11 mm AND GROUND WIRE DIAMETER 7.6
mm
W2c 1 SQUARE WASHER, 75 mm X 75 mm X 8 m, FOR BOLT M16
W2d 1 SQUARE WASHER, 100 mm X 100 mm X 10 mm FOR BOLT M20
W4a - GUY WIRE, STRAND DIAMETER 7 mm, ULTIMATE STREGHT 39 kN (REQ'D LENGTH)
W4b GUY WIRE, STRAND DIAMETER 11 mm, ULTIMATE STREGHT 95 kN (REQ'D LENGTH)
1 1 GUY INSULATOR
Single Guy
Transmission & Distribution GU-S1
Networks Date: Revision: Scale: -

Nov. 2013
Volume 8

Ass GU- GU-

embly S1.1 -S1.2
B2g 1 MACHINE BOLT, METRIC THREAD, HEXAGONAL HEAD AND NUT M16 X 200 mm
B2j 1 MACHINE BOLT, METRIC THREAD, HEXAGONAL HEAD AND NUT M20 X 250 mm
G3a 2 GUY END FOR GUY STRAND DIAMETER 7 mm, 36 kN ULTIMATE STRENGTH
G3b 2 GUY END FOR GUY STRAND DIAMETER 11 mm, 101 kN ULTIMATE STRENGTH
N4a 2 THIMBLEYENUT for bolt M16 AND GUY STRAND DIAMETER 7 mm, 130 kN
ULTIMATE STRENGTH
N4b 2 THIMBLEYENUT for bolt M20 AND GUY STRAND DIAMETER 11 mm, 130 kN
ULTIMATE STRENGTH
S12a 1 SPLIT BOLT FOR GUY STRAND DIAMETER 7 mm AND GROUND WIRE DIAMETER
6.4 mm
S12b 1 SPLIT BOLT FOR GUY STRAND DIAMETER 11 mm AND GROUND WIRE DIAMETER
7.6 mm
W2c 2 SQUARE WASHER, 75 mm X 75 mm X 8 m, FOR BOLT M16
W2d 2 SQUARE WASHER, 100 mm X 100 mm X 10 mm FOR BOLT M20
W4a - GUY WIRE, STRAND DIAMETER 7 mm, ULTIMATE STREGHT 39 kN (REQ'D
LENGTH)
W4b GUY WIRE, STRAND DIAMETER 11 mm, ULTIMATE STREGHT 95 kN (REQ'D
LENGTH)
Single Overhead Guy
Transmission & Distribution U GU-O1
Networks


Volume 8

MANUALS Single Down Guy for Low Voltage
U GU-101C

Nov. 2013
Volume 8

MANUALS Single Down Guy for Low Voltage
U GU-102C

Volume 8

MANUALS Single Overhead Guy
U GU-401C

Nov. 2013
Volume 8

10. CABLES & CONDUCTORS

10.1 C-001 TABLE OF CABLE AND CONDUCTORS ASSIGNATION
10.2 C-002 OVERHEAD LINE DESIGN CRITERIA
10.3 C-003 WEATHER CASE
10.4 C-004 SAG TENSION CALCULATIONS - EXAMPLE

PPAF – TECHNICAL Cable and Conductors Drawing:
Transmission & Distribution U C-00
Networks


Volume 8
TABLE OF CABLE AND CONDUCTORS ASSIGNATION

Cables and Conductors Assigned to
Conductor ACSR 70/12 mm² MV overhead line
Conductor ACSR 120/20 mm² MV overhead line
Covered Conductor XLPE/AAAC 35 – 240 mm² MV cables (connection to transformer)

Cable ABC various sizes LV overhead line

Cable NYCWY quadruplex core, various sizes, 0.6/1
LV Feeder Pillars to meter boxes
kV
Cables NYY-J 2 x 8 RE, 0.6/1 kV Services Cables / Meter boxes to consumers

Cables NYY-J 4 x 25 RM, 0.6/1 kV Services Cables / Meter boxes to consumers

NYY-J 2 x 8 SM Duplex 0.6/1 kV Meter Box to Consumers (Overhead)
NYY-J 2 x 10 SM Duplex 0.6/1 kV Meter Box to Consumers (Overhead)
NYY-J 4 x 25 SM Q’plex 0.6/1 kV Meter Box to Consumers (Overhead)
Cable NYY 1 x 120 RM, 0.6/1 kV LV bushings transformer to LV Switchboard

Cable NYY 1 x 240 RM, 0.6/1 kV LV bushings transformer to LV Switchboard
Conductor Cu 55 mm² stranded / soft drawn Earth system in LV and consumers

Conductor Cu 35 mm² stranded / soft drawn Earth system in MV (pole to crossarm, earth rod, etc)

Conductor Cu 35 mm² stranded / medium hard drawn OHL to transformers or capacitors banks

MANUALS Table of Cable and Conductors Assignation
U C-001
Nov. 2013
Volume 8
OVERHEAD LINE DESIGN CRITERIA
MV Cond. Alignment Tension/Angl Ruling Max. Sag MoD
S# LINE TYPE Description MV Circuit/s LV Circuit/s Remarks
Arrangement Poles * e Poles Span (m) (m) (deg)**
MV1 MV Single Circuit ACSR 120/20 Delta ‐ P1 P2 80 2 15 Main

1
Branch to sub‐
MV Single Circuit ACSR 70/12 Delta ‐ P1 P2 80 2 20
stations
2 2xMV1 MV Double Circuit 2 x ACSR 120/20 Fig U‐MV‐601 ‐ P1 P2 60 1.2 8 Feeders
3 MV + LV MV/LV Combined ACSR 120/20 Delta ABC 120 P1 P2 50 2 10 Main / Feeders
4 MV + 2xLV MV/LV Combined ACSR 120/20 Delta 2 x ABC 95 P1 P2 50 2 8 Main / Feeders
5 LV1 LV Single Circuit ABC 120 P3 P3 50 1.3 15 LV Feeders
6 2xLV LV Double Circuit 2 x ABC 120 P3 P3 50 1.3 10 LV Feeders
Abbreviations
Poles Conductors or
P1 MV Pole: 12 m, 4 kN ABC 120 ABC 3x120 + 1x70 ABC 120 ABC 4x120
P2 MV Pole : 12 m, 8 kN ABC 95 ABC 3x95 + 1x70 ABC 95 ABC 4x95
P3 LV Pole: 7 m, 3 kN ABC 70 ABC 3x70 + 1x70 ABC 70 ABC 4x70
ABC 50 ABC 3x50 + 1x35 ABC 50 ABC 4x50
ABC50 ABC 3x35 + 1x35 ABC 35 ABC 4x35
* More than 5 deg angles not allowed for Alignment poles.

** MoD : Maximum angle allowed at tension poles without guy

MANUALS Overhead Line Design Criteria
U C-002

Volume 8
TABLE OF CABLE AND CONDUCTORS ASSIGNATION
Temperature Ice thickness Wind

Case
ºC (cm) (km/h)
1. EDS (Every day stress) 25 0.0 0
2. Cold ‐10 0.0 0
3. Cold + ice ‐10 0.5 0
4. Cold + ice + wind ‐10 0.5 40
5. Max wind 15 0.0 120
6. Hot 40 0.0 0
7. Hot (*) 70 0.0 0
(*) Conductor Temperature, Only for MV

MV overhead line
Conductor ACSR 120/20 mm²
Conductor ACSR 70/12 mm²

LV overhead line

Cable ABC various sizes
ABC50 ABC 3x35 + 1x35 ABC 35 ABC 4x35

MANUALS Weather case
U C-003


Volume 8

Sag-Tension Calculations - Example

MANUALS Sag Tension Calculations - Example
U C-004


Volume 8
Annex 3: Design examples (Golain Astore MHP)


Volume 8

Volume 8


Volume 8

wire / Load load* Section Sec. CB Min. RL Ik3max
S Load Length cable sums length load Current Cross-Section (mm²) Vdrop Vdrop CB Sel size RL sums Ik1min
[kVA] kW m kW kWm kWm A calc. selected V % Therm A A mm² Ohm Ohm A
TF1 50 38,0 1.311 120 38 20.498 29.045 100 0,365 0,365 664
1.1 1.1.1 0,0 235 c 12 401 7.956 20 35 50 4 1,0% 40 40 10 0,334 0,334 314
1.1.2 0,0 199 c 11 495 7.555 18 35 35 4 1,1% 0,403 0,737 199
1,0 158 c 10 592 7.060 16 35 35 3 0,8% 0,320 1,056 154
1,5 30 c 9 933 6.468 14 35 35 1 0,1% 0,061 1,117 148
1,5 24 c 7 969 5.535 12 35 35 0 0,1% 0,049 1,166 143
1,0 33 c 6 679 4.566 9 35 35 0 0,1% 0,067 1,233 137
1,0 57 c 5 736 3.887 8 35 35 1 0,1% 0,115 1,348 128
1,0 31 c 4 767 3.151 6 35 35 0 0,1% 0,063 1,411 124
1,5 55 c 3 1.233 2.384 4 35 35 0 0,1% 0,111 1,522 116
1,0 329 c 1 1.151 1.151 2 35 35 1 0,2% 0,666 2,188 86
1.1.1 1,5 32 c 2 48 48 3 35 35 0 0,0% 0,065 0,399 287
1.1.2 1,0 61 c 1 61 61 2 35 35 0 0,0% 0,123 0,860 179
1.2 1,5 62 c 17 93 4.612 28 35 35 2 0,5% 40 40 10 0,125 0,125 447
1,5 63 c 15 188 4.519 25 35 35 2 0,5% 0,127 0,253 355
1.2.1 0,0 66 c 14 797 4.331 23 35 35 2 0,5% 0,134 0,387 292
1,5 37 c 11 342 3.535 18 35 35 1 0,2% 0,075 0,461 265
1,5 41 c 9 404 3.193 15 35 35 1 0,2% 0,083 0,544 241
1,5 37 c 8 459 2.789 13 35 35 1 0,1% 0,075 0,619 223
1.2.3/4 1,5 60 c 6 1.719 2.330 10 35 35 1 0,2% 0,121 0,741 198
0,5 30 c 2 198 611 3 35 35 0 0,0% 0,061 0,801 188
1,0 17 c 1 413 413 2 35 35 0 0,0% 0,034 0,836 183
1.2.1 1,5 59 c 3 89 224 5 35 35 0 0,1% 0,119 0,506 252
1,5 31 c 2 135 135 3 35 35 0 0,0% 0,063 0,569 235
1.2.3 1,5 27 c 2 41 41 3 35 35 0 0,0% 0,055 0,795 189
1.2.4 1,5 21 c 2 32 32 3 35 35 0 0,0% 0,042 0,783 191
1.3 1.3.1 0,0 232 c 10 2.432 7.931 16 35 70 2 0,6% 40 40 10 0,237 0,237 364
1,5 38 c 5 405 5.499 8 35 50 0 0,1% 0,054 0,291 334
1,5 1.408 c 3 2.517 5.094 5 35 50 6 1,6% 2,001 2,292 83
1,5 40 c 2 2.577 2.577 3 35 35 0 0,0% 0,081 2,373 80
1.3.1 0,5 26 c 5 13 1.272 8 35 35 0 0,1% 0,053 0,290 335
1.3.1.1 0,0 99 c 5 399 1.259 8 35 35 1 0,2% 0,200 0,490 257
0,5 50 c 3 88 860 5 35 35 0 0,1% 0,101 0,591 229
1,0 44 c 3 219 773 4 35 35 0 0,1% 0,089 0,680 210
0,5 28 c 2 124 554 3 35 35 0 0,0% 0,057 0,737 199
0,5 63 c 1 155 430 2 35 35 0 0,0% 0,127 0,864 178
0,5 240 c 1 275 275 1 35 35 0 0,1% 0,486 1,350 128
1.3.1.1 1,0 71 c 2 71 212 3 35 35 0 0,1% 0,144 0,634 220
0,5 210 c 1 141 141 1 35 35 0 0,1% 0,425 1,059 154
>


Volume 8

wire / Load load* Section Sec. CB Min. RL Ik3max
S Load Length cable sums length load Current Cross-Section (mm²) Vdrop Vdrop CB Sel size RL sums Ik1min
[kVA] kW m kW kWm kWm A calc. selected V % Therm A A mm² Ohm Ohm A
TF2 50 21,5 5.146 w 22 204.040 4.396 4.761 50 163 40,7% 100 7,315 7,315 33
2.1 2.1.1/2 1,5 45 c 16 395 2.258 26 35 35 1 0,4% 40 40 10 0,091 0,091 481
1,5 33 c 11 117 1.863 18 35 35 1 0,2% 0,067 0,158 419
2.1.3 1,5 34 c 9 423 1.746 15 35 35 1 0,2% 0,069 0,227 371
1,5 47 c 6 239 1.323 10 35 35 1 0,1% 0,095 0,322 319
1,5 38 c 5 296 1.085 8 35 35 0 0,1% 0,077 0,399 287
0,5 24 c 3 111 789 5 35 35 0 0,0% 0,049 0,447 270
1,0 30 c 3 251 679 4 35 35 0 0,0% 0,061 0,508 251
1,5 34 c 2 428 428 3 35 35 0 0,0% 0,069 0,577 233
2.1.1 1,5 49 c 2 74 117 3 35 35 0 0,1% 0,099 0,190 395
0,5 38 c 1 44 44 1 35 35 0 0,0% 0,077 0,267 347
2.1.2 1,5 35 c 2 53 53 3 35 35 0 0,0% 0,071 0,162 416
2.1.3 1,5 58 c 2 87 87 3 35 35 0 0,0% 0,117 0,344 309
2.2 2.1.1 1,0 225 c 6 510 2.138 10 35 35 3 0,7% 40 40 10 0,455 0,455 267
2.2.2 1,0 60 c 4 619 1.628 7 35 35 1 0,1% 0,121 0,577 233
0,5 129 c 2 207 1.010 3 35 35 1 0,1% 0,261 0,838 182
0,5 85 c 2 250 803 3 35 35 0 0,1% 0,172 1,010 160
0,5 33 c 1 266 553 2 35 35 0 0,0% 0,067 1,077 152
0,5 42 c 1 287 287 1 35 35 0 0,0% 0,085 1,162 144
2.1.1 0,5 43 c 1 22 60 2 35 35 0 0,0% 0,087 0,542 242
0,5 34 c 1 39 39 1 35 35 0 0,0% 0,069 0,611 225
2.2.2 0,5 33 c 1 17 49 2 35 35 0 0,0% 0,067 0,644 217
0,5 31 c 1 32 32 1 35 35 0 0,0% 0,063 0,706 205

Volume 8

Golain T&D
LS [kW] S [kVA] Dist. [m] LMS [kWm Ik3[A]
TF1 38 100 1311 20498 664
Line TL [m] LMS [kWm I [A] VDm [%] A [mm2] Ik1min [A] CB [A]
1.1 12 1244 7956 20 3,70% 50 86 40 >>l=1151m
1.2 16 551 4612 28 2,30% 35 183 40
1.3 10 2549 7931 16 2,20% 70 80 40 >>l=1718m
LS [kW] S [kVA] Dist. [m] LMS [kWm Ik3[A]

TF2 22 100 5146 4396 660
Line TL [m] LMS [kWm I [A] VDm [%] A [mm2] Ik1min [A] CB [A]
2.1 16 465 2258 26 1,10% 35 232 40
2.2 6 715 2138 10 1,10% 35 144 40
Circuit Breaker calculated based on branch current.

40 A 5
Circuit Breaker selected in Excel sheet.

40 A 5
Cable length per size

35 mm2 3,6 km
50 mm2 1,7 km
70 mm2 0,2 km
5,5 km Total


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Renewable Energy Guidelines

ii Renewable Energy Guidelines Nov. 2013

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This shall be carried out on poles selected at random by the Employer at the rate of per 100% of the

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Service aerial clamps shall be designed to fix conductor bundles at poles and at buildings. The clamps

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The maximum radio influence voltage shall be 250 µV measured at 1 MHz and in accordance with IEC

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This conductor cutter shall be capable of cutting

This conductor cutter shall be capable of cutting ACSR

This conductor cutter shall be capable of cutting 12 mm

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An excess‐pressure valve shall protect the high‐pressure pump

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Operating rod should be a glass‐fiber reinforced operating pole for outdoor use with rain skirts and it

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