TECHNICAL SPECIFICATION FOR COMPRESSION CONNECTORS FOR

SUBSTATION EQUIPMENT AND OVERHEAD LINE

SCOPE :

This specification covers the design, manufacture and testing of compression Connectors for equipment
and HV, EHV substationand overhead lines.
The material offered shall be complete with all components that are necessary for efficient operation.
Such parts shall be deemed to be within scope of the supply whether specifically mentioned or not.
Fittings shall confirm in all respect to the highest standard of engineering, design, and workmanship and
shall be capable of performing trouble free continuous operation.

QUANTITY:

The quantities of various clamps/connectors/fittings are to be considered as set.

SYSTEM PARAMETERS:

Sr.no Descriptions Voltage level

1 Nominal voltage 11 kv 22kv 33kv 66 kv 110kv 132 220 400 765
kv kv kv kv

2 System highest 12 kv 24 kv 36 72.5 123 145 245 420 600

voltage kv kv kv kv kv kv kv

3 System 50 HZ
frequency

4 No of phases 3 phase
5 Fault levels 13.1KA 13. 25 25 KA 31.5 31.5 40 KA 50 KA 50
1K KA KA KA KA
A
6 Method of Effectively Earthing.
earthing

As per CEA regulations.

SERVICE CONDITIONS : As per IS 5613.

 Annual average ambient temperature 30°C

 Maximum ambient temperature 50°C

 Maximum relative humidity 90%

 Environmental conditions Humid tropical climate with polluted atmosphere.

 Operational altitude Upto 1000 meters above M.S.L.

CLIMATIC CONDITIONS:

The overall climate is moderate hot, humid, tropical, highly polluted and conductive to rust and
fungus growth. The clamps/connector shall be given tropical and fungicidal treatment and shall be
capable of satisfactory operation under the hot and humid climatic conditions that would prevail at
sites. The climatic conditions are prone to wide range of variation in ambient conditions. The
materials offered shall be suitable for installation at any of the switchyards in State.

APPLICABLE STANDARDS:

The Compression Connectors and Terminations conform to the latest editions of the standards specified
below and amendments therefore.

IS 5561 (1970) Specification for Electric Power Connectors.

IS 2486 (1989) Metal fitting of insulator for overhead power lines

with nominal voltage greater than 1000 v

IEC 61284 (1997) Overhead lines. Requirements and tests for fittings.

IS 617 Cast aluminum and its alloys ingots and castings for general engineering
purposes - specification

IS191 Copper specification (for bi-metal)

IS 636 Specification for non-percolating flexible firefighting delivery hose

IS 638 Specification for sheet rubber jointing and rubber insertion jointing

IS2633 Methods for testing uniformity of coating of zinc coated articles.

IS 1364 hexagon head bolts, screws and nut.

IS 1367 All Industrial fasteners.

GENERAL TECHNICAL REQUIREMENT OF CLAMP/CONNECTOR:

 All casting shall be free from shrinking, blow holes, surface blisters, cavities, cracks, other
defects and quality of product shall be uniform throughout. All sharp edges and corners shall
be blurred and rounded off.
 Assembly shall be designed and manufactured in such a way so as to have minimum contact
resistance.
 The fittings offered shall be inherently resistive to atmospheric corrosion or
be suitable to protect against corrosion both during storage as well as in service.
 The clamps/connector shall not cause any damage to the conductor in any way.
  All bolts, clamps, etc. shall have suitable locking arrangements to safe guard against vibration and
loosening.
 All ferrous parts shall be hot dip galvanised confirming to IS:2633.
 For bimetallic connectors, copper alloy liner of minimum thickness of 2 mm shall be cast integral
with aluminium body.
 The terminal connector shall be compression type to jumper side / boltless type.
 The required bolts and nuts for terminal connector must be stainless steel with suitable check
nut.

SPECIFIC REQUIREMENTS:

 Clamps and fittings shall be so designed that the post insulators shall not be subject to any
abnormal stress due to thermal changes in conductor. All the clamps and fittings shall enable the
connection to be as short as possible. Wherever possible they shall be in two separate halves. No ‘U’
bolts shall be used.
 The data in respect of bus bars and equipment for which clamps and
connectors are required shall be given.
 The fittings should also have marked upon them the name of the
Manufacture.

DESIGNS:
Responsibility of satisfactory design of the clamps/connectors to safely withstand the specified
mechanical stresses and carry the rated current without exceeding the temperature rise specified, shall
solely rest with the bidder. For this purpose, a minimum factor of safety 2 (two) shall be taken
into account.

TEST:
Individual fittings, clamps, connectors shall be subjected to following Type, Acceptance and Routine
Tests.
CLAMPS & CONNECTORS IS:5561 –(1970):

Type Test:

a) Tensile test :
b) Resistance test :
c) Temperature rise test. :
d) Short time current test :
e) Dimensional check :
f) Galvanizing test :
g) Corona test :}For the fittings suitable for twin
h) Radio interference test. :} Moose and above size

Acceptance Test:

a) Tensile test :
b) Resistance test :
c) Dimensional check :
d) Galvanizing test :
Routine Test:

a) Visual inspection :
b) Dimensional check :

The bidder shall have to submit copies of type test certificates. Type test reports shall not be older than
FIVE years and shall be valid up to the expiry of the validity of the offer. of any Govt. Recognized
Laboratory for consideration along with the technical bid, otherwise, bidder should confirm to arrange
for conducting these tests at their cost before commencement of supply.

MATERIAL REQUIREMENT &WORKMANSHIP:

Material:

The Aluminium /Aluminium Alloy / Compression Connectors and terminations shall be of high strength
and high conductivity aluminum / aluminum alloy / Bimetallic better than or equivalent to IS 617.

In the case of Bi-metallic Connectors, Parts shall be high conductivity copper or high copper content alloy
99.5% or better IS 191.

The Components shall be properly proportioned to minimize stress concentration, corrosion and
deterioration by galvanic action.

Oxide Inhibiting Grease/ Compound:

The internal faces of aluminum fittings shall be coated with oxide Inhibiting Grease/ Compound to
improve electrical contact and ensure maximum electrical performance of fittings.

Workmanship :

High quality Workmanship shall be maintained in the process of manufacture of Compression

Connectors and Terminations.

They shall be free from sharp edges, burs and swarf. The contact surface of the Compression Connectors
shall be uniform to provide effective contact with the conductors.