Appendix V

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Specification

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for

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Bare Copper Conductors and
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Earthing Accessories
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 TABLE OF CONTENT

SPECIFICATION FOR COPPER CONDUCTOR AND EARTHING ACCESSORIES ...... 1

1 SCOPE ............................................................................................................................ 1
2 SYSTEM PARAMETERS ............................................................................................. 1
3 SERVICE CONDITIONS .............................................................................................. 1
4 APPLICABLE STANDARDS ....................................................................................... 1
5 MINIMUM REQUIREMENTS FOR MANUFACTURES OF MAIN EQUIPMENT . 2
6 TECHNICAL SPECIFICATIONS ................................................................................. 2
6.1 Stranded Copper Conductors .................................................................................. 2
6.2 Earthing Accessories ............................................................................................... 3

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6.3 Technical Requirements .......................................................................................... 5
7 QUALITY ASSURANCE.............................................................................................. 6
8 INSPECTION & TESTING ........................................................................................... 7

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8.1 Inspection ................................................................................................................ 7
8.2 Acceptance/Sample Tests ........................................................................................ 7

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9 SAMPLE ........................................................................................................................ 7
10 SCOPE OF SUPPLY ...................................................................................................... 8
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11 TECHNICAL PARTICULARS ..................................................................................... 9
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12 DEPARTURES FROM SPECIFICATION ................................................................. 13
13 DOCUMENT CHECKLISTS ...................................................................................... 14
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 SPECIFICATION FOR COPPER CONDUCTOR AND EARTHING
ACCESSORIES

1 SCOPE

This specification covers the Design, Manufacturing, and Testing of Copper Conductor and
Earthing Accessories. The supplier shall take effective measure to manufacture and supply all
equipment as required in this specification and agreed in the contract.

Equipment supplied shall be newly manufactured using latest applicable technology. There
shall be no defect or mistake in design, material and workmanship. Technical documents and
drawings shall be clear, consistent, correct in content and meet the requirements for

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installation, commissioning, operation and maintenance.

2 SYSTEM PARAMETERS

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(a) Nominal Voltage 220 kV

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(b) System highest Voltage 245kV
(c) System frequency 50 Hz.
(d) Number of phases 3
(e) Method of earthing
NEffectively earthed
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(f) System faults level 40 kA rms

3 SERVICE CONDITIONS
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a Annual average ambient 30 ᵒC

temperature
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b Maximum ambient temperature 40 ᵒC

c Maximum relative humidity 90%
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d Environmental conditions Atmospheric Corrosive Category (ISO

12944) – C5-I
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e Operational altitude From M.S.L. to 1500 m above M.S.L.

4 APPLICABLE STANDARDS
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The Stranded Copper Conductors shall be manufactured in accordance with the latest
editions of the Standards specified below and amendments thereof.

1. IEC 60028 International standard of resistance of copper

2. BS 6360/ IEC 60228 Conductors of Insulated Cables
Electric cables. PVC insulated, armoured
3. BS 6346 cables for voltages of 600/1000 V and
1900/3300 V
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5 MINIMUM REQUIREMENTS FOR MANUFACTURES OF MAIN EQUIPMENT

The bidder shall ensure, that each main equipment (listed below) offered under this contract,
is manufactured by a manufacturer with a minimum of five (5) years successful continuous
experience in manufacturing equipment identical in design, in rated voltage and capacity, to
the equipment offered under the contract. In addition, minimum of three (3) years experience
shall be in manufacturing for orders from outside the country of the manufacturer.

Bidder shall provide adequate evidence of compliance to above requirements to the

satisfaction of the PPC(TCP). Bids non-complying with above requirements or with
incomplete evidence of compliance would be rejected.

Main equipment List: -

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Bare Copper Conductors
Earthing Accessories

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6 TECHNICAL SPECIFICATIONS

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6.1 Stranded Copper Conductors
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Copper conductors shall be stranded copper non-compacted conductors (class 2) in
accordance with BS 6360 & BS 6346. Stranded circular non-compacted conductors (class 2)
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shall consist of soft annealed copper. The wires in each conductor shall all have the same
diameter. The number of wires in the conductor shall be not less than the appropriate
minimum number given in table 2 of BS 6360. The resistance of the conductor at 200C when
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determined in accordance with clause 8 of BS 6360 shall not exceed the appropriate maximum
value given in table 2 of the same standard.
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6.1.1 Additional Requirements

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I) Packing
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a) The Copper Conductors shall be supplied in wooden drums.

b) Drums shall be stoutly constructed of good quality timber and clearly marked with the
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length and type of conductor in a manner not easily removable. Drums shall be securely
battened around the perimeter and shall be lined with approved impervious material to
prevent contact between the contents and both the drum itself and any chemicals with
which the drum has been treated. Drums shall be suitable for rolling on the flanges
without causing damage to the conductor and the direction of rolling shall be clearly
shown.

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 c) All timber drums and battens shall be protected from deterioration by termite or fungus
attack by an approved impregnation treatment at the works before dispatch. Such
substance shall not be harmful to the conductor.

d) All drums shall have suitable spindle holes and the holes shall be stoutly reinforced with
steel plates.

e) The exposed end of the cable projecting from the drum shall be sealed and adequately
protected against mechanical damage during handling.

II) Labelling (Marking)

Each Drum shall be labeled with clear stencil on both sides of the drum with the following. The

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letters shall not be less than 75 mm of height and the ink used shall be water-proof.

a) CEYLON ELECTRICITY BOARD, TENDER NO :

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b) Manufacturer's name.
c) Direction of rolling.

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d) Lifting Instructions and limitations
e) Serial No. The serial numbers shall be from 001 onwards.
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f) Conductor type, material and stranding
g) Length of the conductor
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h) Net Weight
i) Gross Weight
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j) Manufacturer's batch number.

k) Winding date
l) Approximate Measurements of the drum
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III) Testing
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Copper Conductors shall be of specified types, and type tested as per the applicable standards
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including tests for Short Circuit Current and Material Composition test certificate. Copies of
type test certificates in English language should be submitted with the bid and failure to
furnish the test reports will result in the offer being rejected.
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6.2 Earthing Accessories

6.2.1 General

C Connectors, grounding clamps and lugs shall be made of Copper Annealed Soft Drawn and
they shall be construction that short circuit current of the system shall pass through. Every
current-carrying part of the connectors, clamps and lug shall be capable of carrying its
specified rated current at rated frequency continuously, and in no part shall its temperature rise
exceed that specified in relevant standards.

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Every part of the connectors, clamps and lug shall also withstand, without mechanical or
thermal damage, the instantaneous peak currents and rated short time current.

The equipment shall withstand all arising voltages. This is applicable for operational and
lightning voltages. The equipment shall be manufacture according to the latest IEEE standard
(IEEE 837).

All the connectors, grounding clamps and lug etc. shall be engraved all the required
technical details such as diameter size, die index, torque, conductor range etc.

C connections, lugs, and splices shall be of copper and grounding clamps shall be of high
copper alloys. Die index and conductor range shall be marked on every connector, lug, and
splice.

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The following information shall be furnished with the offer
 Catalogues describing the equipment and indicating the Model Number and Type

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 Literature describing the operational features of the equipment
 Constructional features, materials used for components and relevant technical

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literature
 Complete dimensional drawings N
 List of names and address of TEN leading purchasers (of similar items only) giving
time of Delivery and quantities supplied within past five years
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 Completed schedule of particulars as per Appendix V and schedule of price as per
Appendix VI
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 ISO 9001 Certificate for the quality of design and manufacturing processes

Failure to furnish the particulars asked above will result in the offer being rejected.
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6.2.2 Testing
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Clamps and Connectors shall be of specified types, and type tested as per the applicable
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standards (IEEE 837) including tests for Tensile Strength, Short Circuit Current and material
constants should be as per the relevant standards. The connectors and lug shall be
mechanically strong and shall withstand all the stresses which may be imposed on them
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during ordinary work due to fixing, vibrations, climatic conditions, short circuit or other
causes. Copies of type test certificates in English language should be submitted with the
bid and failure to furnish the test reports will result in the offer being rejected.

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6.3 Technical Requirements

ITEM 01: 120 mm2 Bare Copper Conductors

- Conductor shall be stranded copper non-compacted conductors (class 2) in

accordance with BS 6360
- Conductor shall be used for earth grid at Polpitiya Grid Substation
- System short circuit level is 40 kA 1s

ITEM 02: 16 mm Diameter, 3m length Copper Rods

- Copper Rods shall be used for connection of test link at Polpitiya Grid Substation
- System short circuit level is 40 kA 1s

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ITEM 03: 150–120mm2 Copper C Connectors (Reference Drawing NO.
CEB/TCP/CLBNPGS/DWG/EC/01)

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- Connectors shall be used for tap and cross connections
- C shaped opening shall permits placing two parallel cables (one side for 120 mm2

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and other side for 150 mm2)
- Tap and run conductor size are 120 mm2 and 150 mm2 copper conductor
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- System short circuit level 40 kA 1s
- Shall be made of copper and manufacture according to the IEEE 837
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ITEM 04: 150–150mm2 Copper C Connectors (Reference Drawing NO.
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CEB/TCP/CLBNPGS/DWG/EC/02)

- Connectors shall be used for tap and cross connections

- C shaped opening shall permits placing two parallel cables
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- Tap and run conductor sizes are150 mm2 copper conductor

- System short circuit level 40 kA 1s
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- Shall be made of copper and manufacture according to the IEEE 837

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ITEM 05: 120mm2 Lugs (two holes) (Reference Drawing NO.

CEB/TCP/CLBNPGS/DWG/EC/03)
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- Shall be made of copper

- Copper lug shall be used for 120 mm2 Copper Conductor
- Shall be designed to carry a short circuit current of 40 kA, 1s
- Shall be withstand high mechanical stress
- Shall be designed with two holes as per the referred drawing
- Shall be provided inspection holes to ensure proper cable insertion.
- Shall be manufactured according to the IEEE 837

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ITEM 06: Copper Sleeve Long Barrel for 150mm2 Conductor (Reference Drawing NO.
CEB/TCP/CLBNPGS/DWG/EC/04)

- Shall be made of copper and manufacture according to the IEEE 837

- Copper splices shall be used for 150mm2 Copper Conductor
- Shall be designed to carry a short circuit current of 40 kA, 1s
- Shall be withstand high mechanical stress
- Shall be designed with two inspection probe holes and center stop as per the
referred drawing

ITEM 07: Ground Connector for a 120 mm2 Copper Cable to Flat Bar (Reference Drawing
NO. CEB/TCP/CLBNPGS/DWG/EC/05)

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- Shall be made of high copper alloy and manufacture according to the IEEE 837
- Ground connector shall be used for 120 mm2 Copper Conductor
- Shall be withstand high mechanical stress

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- Shall be designed to carry a short circuit current of 40 kA, 1s
- Shall be separate copper cable from bar as per the referred drawing

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ITEM 08: Ground Connector for Two 120 mm2 Copper Cable to Flat Bar (Reference Drawing
NO. CEB/TCP/CLBNPGS/DWG/EC/06)
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- Shall be made of high copper alloy and type shall be two copper conductors to bar
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- Ground connector shall be used for 120 mm2 Copper Conductor
- Shall be withstand high mechanical stress
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- Shall be designed to carry a short circuit current of 40 kA, 1s

- Shall be separate copper cable from bar as per the referred drawing
- Shall be manufactured according to the IEEE 837
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* Note:
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Bidder shall quote an identical design or equivalent for the clamps and connectors
described in Clause 6 and test reports for all the items should be submitted with the bid.
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7 QUALITY ASSURANCE
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The Manufacturer shall posses ISO 9001 Quality Assurance Certification for the manufacture
of the copper conductor for the plant where the Manufacture of conductor is done. The
Bidder shall furnish a copy of the ISO Certificate certified as true copy of the original by the
Manufacturer, along with the offer.

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8 INSPECTION & TESTING

8.1 Inspection

The selected Bidder shall make necessary arrangements for inspection by an Engineer appointed
by the CEB during manufacture and before dispatch and also to carry out in his presence
necessary Acceptance/sample tests of the materials offered.

8.2 Acceptance/Sample Tests

The necessary Acceptance / Sample Tests conforming to specified standard shall be witnessed
by the representative of the CEB.

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9 SAMPLE

For 120 mm2 Bare Copper Conductor

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The sample length of 300 mm of stranded copper conductor offered in same size of conductor

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shall be furnished with the offer by the Bidder to facilitate analysis and evaluation of Bid. The
Manufacturer shall indicate clearly on the sample, the code name and the physical
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characteristics of the cable sample.
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For Earthing Accessories
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Two (02) different items (Equivalent to Item No. 04 & Item No. 08 of scope of supply) of
sample fittings shall accompany the bid to facilitate analysis and evaluation. Samples shall be of
any size, but Manufacture’s name, Part No., Diameters when applicable, Torque of each nut &
bolt, Tension, etc must be engraved on the surface of the fitting.
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10 SCOPE OF SUPPLY

Following Materials should be supplied as specified in Technical Specification.

Item Description Qty

01 120 mm2 Bare Copper Conductors 2000 m
02 Ø 16 mm, 3m Copper Ground Rods 10 Nos.
03 150 - 120 mm2 Copper C Connectors 500 Nos.
04 150 - 150 mm2 Copper C Connectors 200 Nos.
05 120 mm2 Copper Lugs (Double Hole) 250 Nos.
06 Copper Sleeve Long Barrel for 150 mm2 Conductor 100 Nos.
07 Ground Connector for a 120 mm2 Copper Conductor to Flat 100 Nos.
Bar

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08 Ground Connector for Two Parallel 120 mm2 Copper 300 Nos.
Conductor to Flat Bar

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These Clamps and Connectors should be delivered to the Transmission Construction Projects
Stores at Kotugoda, Sri Lanka.

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11 TECHNICAL PARTICULARS

11.1 120 mm2 Bare Copper Conductor

Item Units Required Tendered

1. Manufacturer's Name
2. Manufacturer's Address
3. Applicable Standard
4. Material Cu

5. Type of the Conductor

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6. Number of Wires in a Conductor
7. Diameter of individual Wire mm
8. Cross Sectional Area of a Wire mm2

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9. Overall Diameter of the Conductor mm
10. Nominal Section of the Conductor

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11. Maximum Rated Current of Conductor (1 sec) A
12. Resistance of Conductor per 100m at 30 °C
N Ω
13. Drawing Submitted Yes/No Yes
14. Test Reports Yes/No Yes
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11.2 Ø 16 mm, 3m Copper Ground Rods
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Item Units Required Tendered

1. Manufacturer's Name
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2. Manufacturer's Address
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3. Applicable Standard
4. Material Cu
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5. Diameter of the Rod mm 16

6. Length of the Rod m 3
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7. Diameter of individual Wire mm

8. Nominal Section of the Rod mm2
9. Maximum Rated Current of the Rod A
10. Resistance of Rod Ω
11. Drawing Submitted Yes/No Yes
12. Test Reports Yes/No Yes

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11.3 150-120mm2 Copper C Connectors (Item 03) (Drawing No.
CEB/TCP/CLBNPGS/DWG/EC/01)

Item Units Required Tendered

1. Manufacturer's Name
2. Manufacturer's Address
3. Material Cu
4. Copper conductor size (Tap and Run) mm2 150 - 120
5. Maximum short-circuit withstand current (1s) kA 40
Whether opening shall permits placing two
6. Yes/No Yes
parallel cables

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7. Tensile breaking stress of material kN/m2
8. Required die size
9. Drawing submitted Yes/No Yes

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10. Manufacture standard IEEE 837
11. Test Reports Yes/No Yes

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11.4 150-150mm2 Copper C
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Connectors (Item 04) (Drawing No.
CEB/TCP/CLBNPGS/DWG/EC/02)
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Item Units Required Tendered

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1. Manufacturer's Name
2. Manufacturer's Address
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3. Material Cu
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4. Copper conductor size (Tap and Run) mm2 150 - 150

5. Maximum short-circuit withstand current (1s) kA 40
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Whether opening shall permits placing two

6. Yes/No Yes
parallel cables
7. Tensile breaking stress of material kN/m2
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8. Required die size

9. Drawing submitted Yes/No Yes
10. Manufacture standard IEEE 837
11. Test Reports Yes/No Yes

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11.5 120mm2 Copper Lugs (Two Holes) (Item 05) (Drawing No.
CEB/TCP/CLBNPGS/DWG/EC/03)

Item Units Required Tendered

1. Manufacturer's Name
2. Manufacturer's Address
3. Material Cu
4. Copper conductor size mm2 120
Maximum short-circuit withstand current
5. kA 40
(1s)
6. Tensile breaking stress of material kN/m2

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7. Required die size
8. Drawing submitted Yes/No Yes
9. Manufacture standard IEEE 837

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10. Test Reports Yes/No Yes

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11.6 Copper Sleeve Long Barrel for 150mm2 Conductor (Item 06) (Drawing No.
CEB/TCP/CLBNPGS/DWG/EC/04)
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Item Units Required Tendered
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1. Manufacturer's Name
2. Manufacturer's Address
3. Material Cu
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4. Copper conductor size mm2 150

Maximum short-circuit withstand current
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5. kA 40
(1s)
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6. Tensile breaking stress of material kN/m2

7. Required die size
8. Drawing submitted Yes/No Yes
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9. Manufacture standard IEEE 837

10. Test Reports Yes/No Yes

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11.7 Ground Connector for a 120mm2 Copper Conductor to Flat Bar (Item 07)
(Drawing No. CEB/TCP/ CLBNPGS /DWG/EC/05)

Item Units Required Tendered

1. Manufacturer's Name
2. Manufacturer's Address
3. Material Cu Alloy
4. Copper conductor size mm2 120
5. Tensile breaking stress of material kN/m2
6. Drawing submitted Yes/No Yes
7. Manufacture standard IEEE 837

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8. Test Reports Yes/No Yes

11.8 Ground Connector for Two 120mm2 Copper Conductor to Flat Bar (Item 08)

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(Drawing No. CEB/TCP/CLBNPGS/DWG/EC/06)

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Item Units Required Tendered

1. Manufacturer's Name
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2. Manufacturer's Address
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3. Material Cu Alloy
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4. Copper conductor size mm2 120

5. Tensile breaking stress of material kN/m2
6. Drawing submitted Yes/No Yes
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7. Manufacture standard IEEE 837

8. Test Reports Yes/No Yes
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Seal and Signature of the Manufacturer and date
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