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i . Cl n u se - 3 ( 1 ) . P a ~ e - 2 : " TR : :1 0 n-1 !Hj R" hn I I he R\I b s l. i t II t (' d wit.hi'I S : 306 - 1 BR3" '

2 Cl n u se - 3 ( i v ) l a s t l i n e . PaRe-2: ..S u b s t i t u t e th e word " c a s t i n g s " wi th " c o a t i n ~ s " .

3. C l [ l l l s e - : ~ (x i ) . PaRe-2:" I S : 2 t l 8 6 ( P t . I ) - 1 9 7 7 " sha LJ ue s u b s t i t u t e d wi t h" I S : 2 4 8 6 ( P t . I ) - 1 9 9 3 . "

." I lS :3 2 H H ( P t . I I - 1 9 7 ! J " nhHl1 lip r . l l h r d , i I . I I L ( ~ d , , , i th " I lS :32RB(PI . .11- IBH3".

5. . C la us e - 7 . 3 . 2nd l i n e . PaRe-7:Subst i . t l l te "lS::W6-19i8" I " i t l l "IS::lOH-19B:1."

6. C l a u s e - 7 . 5 ~ 2nd l i n e . P a ~ e - 7 : S u b s t i t u t e th e word "Clause" with " c l a s s " .

7r C l a u s e - 7 . 7 . PaRe-7:Add a f o o t note a s u n d e r : "Nol.C'; r .10c l . r i c f l l r C ' R ln l . l v l l v t 0 ~ ~ ' ~ ~ i 1 0 ( ' i f i f ' d IInrif ' r p n r f t - 9 0 f

\ LS: IB!J7-1BBJ RIlHll IIC)" 1)(\ a p p l i c a b l e f o r c a t e n a r ydr oppe r c l i p (RI-11921 a n ~ b r i d l e wire d r 6 p p e r c l i p(RT-1194)" .

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CONSTITUENTS PERCENT ( c a B t i n ~ B ) .' S iIi co iI, HflX 0; 02..: :. ..' .,.: n i S III II . t h' . . Mnx 0 .03To ttl.! . .i inj)u t' t. t i ee , ~ l a x . i : ' O.fiO( inc ludes i ron, ' aluminium, r ~ e n i c , .

; ~ . : < ~ ~ , . ~ . ; ' : ant imony, s i l i c o n , bismuth) AI. , , , . " ,. Copper Remainder..:'" ,) ; i, .

. ' .. '" ., ~ ' , l .. ' ( ' > : ; ' ~ i * P ' . s p e c i f i c a l l y r ~ Q u i r e d by th e purchase r , ' t he

. ' , < , : . ' . ~ ' 1.,"I*f)4 .. ~ ~ " ~ I / r mat e r I a l may be supp l Ied wi th r e s t r i c t ed , l e ad c o n t e n t ...... ; ; . ~ . : ' : ~ ? ~ ~ ~ " . ' : ' .. 'l'h(' I I l l \nuf l lcturer. ' s111\J1. ",hen f ' ( ' ( l Idred , ~ u p p l y f r e e o rJ ,L':' ' c h a n ~ e , a copy of h is works a n a l y s i s o f th e m a t e r i a l .Pi The ~ o r k s ana lys i s i s def ined as th e rdu t ine an a ly s i s

.'i ca r r i ed ou t by the manufac ture r in o r d e r to contrC?} th e. \ . ~ ' '. I Qual i ty o f th e mat e r i a l .' I I ' ' ' , ~ 2 , ~ or' ; , .Hechanical p ro p e r t i es :

" l " ' ; ~ / ~ / / i ' , ' ~ " ~ : ~ " j T h e m a t e r i a J . when t e s t ed in accordance :with IS: 2654-I/- 1977++ s ha l l I lave ti le nlechanicaJ propert i"es a s ~ i v e n in

, l' a b 1e - 6 '. ; f, . TABLE - 6: MECHANICAL PROPERTIES

HODE or TENSILE o. 2 PERCENT ELONGATION:CAST TNn STHENr.TII PROOF STRESS PERCENT, ONHPn, Min. Ml'a, Min. GAUGE, LENGTII5.65 lA, Hin

.- .: Sand c a s t i n ~ 260 120 13( S e p n r a t e l ~ cas t )

f '. :' t ,. l Ch i l l c a s t i n ~ 210 120'. t H ~ : 1\1

; i . '. !' . ;" ," Ii i (Reparn te ly caRt)

Forms of t e s t b a r s :' i h c t e s t bars s h a l l be a c c o r d i n ~ to one of theap p ro p r i a t e tYnes descr ibed in I S : 1 4 0 B ~ 1 9 6 B . *

2.0 R_2_0~ . . .l_ t - l_=w .251..... &--- Q - ~ ~ __:. ")'

0"' Hethods o f chemicaL a n a l y s t s o f Q.ronzes..:'F Hethods fo r t e n s i l e t e s t i n ~ o f copper and copper a l l o y s . Hecommended pr 'ocedllre fo r i nspec t ion o f copper hnse a l loy Rllnd c l \ s t i n ~ s .....: .. ,"

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Clause 0 - 2 . 1 . 1 . l a s t l i n e , P a ~ e - 2 7 : Read "27mm of s a n d " in p lace o f "27mm sand".Clause 0-3 .2 , 2nd l i n e and a t the end p a ~ e 2 7 . ' ."" IS : lR l f i - 19 f i l " s h a l l be s u h s t i t u t e d with " J S : 1 R 1 6 ' - 1 9 ~ 9 " .

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GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION\ FOH... F 1TT INGS FOR 25 kV


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GOVERNMENT OF INDIAMINISTRY OF RAILWAYSRESEARCH DESIGNS & STANDARDS ORGANISATIONMANAK NAGAR, LUCKNOW 226.011Spec i f ica t ion No.ETI/OHE/49(9/95)

S ~ e c i f i c a t i o n for Fi t t ings for 25 kV, ~ 50 Hz t rac t ion overnead :equipmento. SCOPE0.1 ~ h e spec i f i ca t ion covers the requirements of thef i t t i ngs used on 25 kV a . c . 50 Hz t rac t ion o v . ~ h e a d equipment.0.2 The f i t t i ngs are made of copper, copper a l loys ,malleable cas t i ron , aluminium al. loy, forged s t ee l , fabr ica ted /welded s tee l and copper s t r i p . The m ~ t e r i a 1 of f i t t i ngs i sspeci f ied in the drawing nf the purchaser but the sampling andthe te s ts sha l l be done in a c c o r d ~ n c e with the re levent c lausesof th i s spec i f ica t ion .0 .3 The f i t t i ngs sha l l be grouped as tension jo in t s / anchor. ~ l a m p s , non tension j o i n t s , suspension clamps and other f i t t i n g s 'Osed'On the cantiLever assembly and'on OHE.

DEVIATION FROM SPECIFICATION.-1.1 Any. d.eviation from th is spec i f i ca t ion ca lcula ted toimprove t h ~ performance. e f f i c i e n ~ y and u t i l i t y of the eqUipmentproposed by the tenderer wil l be given due considera t ion prOVidedfu l l par t icu la rs with J u s t i f i c a t i o ~ thereof are furn ished . Insuch a case t h e t ~ n d e r e ! sha l l quote according to th isspec i f i ca t ion and indica te the devia t ion(s) s e p a r a t e l y in ~ "Sta tement of Dev ta t ions " .

2. SERVICE CONDITIONS2.1 The f i t t i r igs sha l l b e s u i t ~ b l e i o r outdoor use in moistt rop ica l climate and areas s u b j e c t ~ d to heavy ra in fa l l and severelightninl3 in - Ind i a . The l imi t ing weather condit ions which thef i t t i ngs have to w i t h s t ~ n d in s e ~ ~ i c e a r ~ ~ n d i c a t e d below:

Maximum temperature of a i r in shade 4 5 ~ Ci i )Minimum temperature of a i r in shade o . c

tJ ,i i i ) MaKimum temperature a t ta inab le 65.5 Cby an object exposed to Suniv)Maximum re la t ive humidity -1001.v) Average annual ra in fa l l Ran'3in9 frolTl1750 mm to6250 mm

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!.r''':'' . ':--:;:;,;:.J.n:u:11'l number .of , thunder 85"0 ';.,:n-'n, ciay s' p e' r i a ~ l ~ ~ r f l " -'

V:. :i.) 1"'1a ;d TI U.m n l - H n 6 ~ ~ r ' . f;jf dus t sto r tTl 35d , : ~ Y 5 pe r ~ ' f t i ' n a m - .' ' "

viii)Number of ra iny days per annum l20. :; 2

ioK) ' : B ~ c'wj.,n ~ \ - r , ' ~ sure 200 kgf/m. . . . . . . : 1> "IS: 2486 (P t . 1 ) Insu la tor f i t t i n g s fo r overhead power--1977 l ine witi-; .,( nciminal. 'voltag'e )- than 1000 VGenera] requirements and t e s t s .. . , .

'- .- ' : , .k i i ) 15:3091-1965 Aluminium bronze ingots and cast ings fo r -overhead f i t t i ngs in e l e c t r i c t r ac t ion .x i i i )BS:3288(P t . I ) Insu la tor and conductor f i t t i ngs fo r'1979 overhead power l i ne s ( performance andrequirements ) .

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xiv) 18:3658-1981 Code of pra c t i c e fo r l i qu id pene t ran tf law d e t e c t i o n .xv) 18:5561-1970 E lec t r i c power connec to r s .xvi ) ROSD Specn Hot d ip z inc c o ~ t i n 9 on g t e e l mastsNo.ET1/OHE/ ( ro l l e d and f a b r i c a t e d ) , tubes and' 13(4/84) f i t t i n g s , used on 25 kv a . c . OHE.):vii) ROSD Specn St e e l and s t a i n l e s s s t e e l bo l t s , nu t s jNo .,ET l /OHE/ and washers . i18(4 /84) 1

-Ii4. GENERAL REQUIREMENT

4 .1 The f i t t i n g s s h a l l be f r ee from d e f e c t s which a rel i ke ly to be de t r imen ta l to t h e i r per formance in s e rv i c e .4 .2 Aluminium bronze , t i n bronze a n ~ ~ l u m i n i u m a l l oy c a s tf i t t i n g s s h a l l pre fe rab ly be made by pre ssu re d i e c a s t i n g process .The cas t i ngs made o u t of o ther processes l i k e g r a v i t y d i e - c a s t i ngs he l l mould ing / inves tmen t cas t i ng by l o . s tway method sha l l a l sobe accep tab l e so long as the f i t t i n g s / t e s t \ b a r s meet a l l thenecessa ry mechanica l and e l e c t r i c a l proper t i e s s pe c i f i e d inr e l evan t s p e c i f i c a t i o n s . Sand cas t i ng f ~ r t he se cas t f i t t i n g s i snot a c c e p t a b l e . . '

.3 S t e e l / S t a i n l e s s s t e e l b o l t s , nu t s and washer s s h a l lconform to ROSD Sp e c i f i c a t i o n No.ET1/OHE/18(4/84). Non-fer rous Ib o l t s / n u t s s h a l l not be used. 1.'4 .4 A ll p a r t s of the f i t t i n g s s h a l l be manufac tu red by the m a n u f ~ c t u r e ~ in h is works . Components such as f a ~ t e n e r s , washer sand s p l i t pins which form p a r t of th e f i t t i n g s s h a l l be ob ta inedfrom the approved manufac tu re rs wi th the s p e ~ i f i c ap p ro v a l ofCent r a l Dr.;:}an i s a t ion fo r Rai lway EI e c t r if ica:t i on . The supp l i e r ofth e assembly s h a l l ensure t h a t such bought out components conformto th e r e l e v a n t s p e c i f i c a t i o n .4 .5 Pr o t e c t i o n a g a i n s t cor ros ion :4 .5 .1 A ll f i t t i n g s s h a l l be e i t h e r inhe ren t ly r e s i s t a n t tothe a tmospher ic cor ros ion or s u i t a b l y protected a g a i n s tcor ros ion , both during s t o r a g e and in s e rv i c e . A ll f e r r o u s meta lpa r t s , excep t those ~ a d e of s t a i n l e s s steel,.hall be hot d ipga lvan i sed in accordance with ROSO s p e c i f i c a t i o n No.ETI/OHE/

.. 13(4 /84) .4 .5 .2 Mal leab le c a s t i ron f i t t i n g s s ha l l be s h o t or g r i tb las ted befo re and a f t e r hea t t r e a t m e n t .4 . 5 . 3 The t h reads of the t apped holes s h a l l ,be cu t a f t e r

~ a l v a n i s a t i o n and s h a l l be adequa te ly o i l ed o r grea sed . Femalet h reads s h a l l be t apped a f t e r ga lvan i sa t ion and s h a l l be o i1 ed .

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~ 6 r male threads , galvanis ing process sha l l be so cont ro l l ed tha tgalvanised f as tener s can be assembled by hand with femalefas teners . Galvani ' ied f as tener s with male threads of . s ize M'12only may be r e t ~ r e a d ro l led t ~ f a c i l i t a t e assembly a f t e rgalvanis ing in accordance with ~ S : 1 3 6 7 (Pt .XIII ) -1983. The threadof a l l bol t s and nuts sha l l be formed conforming' to t he i rre levant spec i f i ca t ion before ga lvani s ing .4 .5 .4 E l e c t r o ~ g a l v a n i s e d bol t s and nuts sha l l not be used.Bolts and nu ts .o f 10 mm diameter and less sha l l be of s t a in lesss t ee l unless o t h ~ r w i s e s ta ted .in the drawing.4 .6 T o l e r a n c e ~ Wherever not spec i f i ed in the drawings,furnished by the Purchaser , the fol lowing to lerances sha l l applyfo r non mating sur faces :

Dimension Tolerance- - - - - - - - - ~ - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - ~ ~ - - - - - -U p t ~ i a n d including 35 mm +/..;.. 0,.5 ITltT,Dve r 35rrit'll + / ~ 1 .5 'Y.

" ; : . . . .- - ~ - - - - - - ~ ~ ~ - ~ - - - - - - - ~ - - - - - - - - - - - - - - - - - - ~ - - - - - -

~ n case of .mating sur faces , to lerances sha l l be +0.5 mm-0 .0on ' t he holes and +0.0 mmon shaf t s . The to le rance for wall. -0 .5th ickness sha l l be +1.0 mm . -0 .5

5.5 .1 The f i t t i n g s sha l l be of fe red fe r i n s p e c t i ~ n i r i lo t s~ ~ i c h m a y : ~ e p r e s e n t e i the r the whole or a par t of the ~ b ~ n t i t y ordered . A lo t sha l l cons i s t of the sarr.e , type, categl;Jry andra t ing of f i t t ihgsmanufac ' f ,ured from the same raIN mater ia l andmadeund.e,r i den t i ca l condi t ions and from one. melt ( in the case of.. cas t n g , s ) ~ , .F i ~ tin/as of di f f e ren t type , c a . t e l ~ o . r y and ra t i ng maybe manufactured ' ou t of the same melt but sha l l cons t i tu tesepara te and di f fe ren t l o t s . The manufacturer sha l l mainta in therecords as to the raw mater ia ls used and temperature for everyc a s t / l o t .5 .2 Castin9S

I f the weight of the f ' i t t i n g i s not more than one kg, alo t sha l l cons i s t of' pie tes makingupto a w ~ i g h t a f n o t fuore than200 kg. I f each f i t t i n g weighs more than one kg, a lo t shall_cons i s t or pieces making upto 500kg fof non-fer rous f i t t i n g s and1500 ~ g for f e ' rou l f i t t i n g s .5 .3 Three t e s t bars sha l l be made f ~ r ~ a c h c a 5 t / ~ e l t for "bea /t ens i l e and eloRgation t e s t s . The t e s t bars sh"'}lli den t i f i c a t i on mark of the lo t and date of melt .

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5 .4 Fofged 1 welded f i t t i n g s : - The lo t of forged. welded orfabr icated fe r rous f i t t i ngs sha l l cons i s t of not more than 500numbers of f i t t i n g s .5 .5 Copper/aluminium a l loy s t r i p formed f i t t i n g :

The lo t of such f i t t i ngs weighin'3 e'ach upto 50 g m s h a l lnot exceed 2500 numbers while for the f i t t in ' :Js weighing more than :,"' I-SO gmT the lo t sha l l be r es t r i c t ed to -1000 numbers. :.'"

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5 .6 Sample s ize5 .6 .1 The number of f i t t i ngs to be se lec ted a ~ : r a n d o m from thelo t sha l l be in accotdance wi th column 1 and 2 0 f t ab le givenbelow. If' ~ e q u i r e d , ar ldi t iona lnumber of f i t t i n g s as g i ~ e n incolumn 3 of t ab le given below sha l l be se lec ted at' r a n d a ~ tosa t i s fy the c r i t e r i a fo r conformity in accordinace with Clause5.6.2 below. SAMPLE SIZE AND CRITERION FOR CONFORMITYLot s ize Fi r s t sample Second sample Acceptance Rejec t ion

N s ize n1 s ize n2 cri teria C'1 Numbe r c2'1-20 1 2 o 12-1-50 2 4 o '15-1-100 4 8 o 2'10'1-500 5 '10 o 250'1-800 7 14 o 3801-'1300 10 20 o 31301-3200 15 .30, 1 43201-8000 25 50 2 5800'1 & above 35 70 2 7

- - - - - - - - - - _ . _ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - -

5 .6 .2 Cr i te r ion iL conformity:5 .6 .2 .1 The lo t sha l l be considered as conforming to therequirements of th e acceptance t e s t s i f the number of fa i lu resfound in the f i r s t sample n1 i s less than or equal to c1. I f thenumber of f a i l u r e s i s grea te r than or equal to c2, the lo t sha l lbe considered as hot conforming to the r e q u i r e m e n t ~ of theacceptance t e s t s and sha l l be r e j e c t ~ d . I f .the number of fa i lu resis between col and,c2 . a s'ec'ond sample of n2 fi t t in' :Js sha l l bese lec ted an.d subjec ted to acceptance t e s t s . I f the number offa i lu res in the two samples conbined is l es s than c2, the ln tsha l l be considered as conforming to the reqUirements ' ofacceptance t e s t s , otherwise i t sha l l be considered to havefa i l ed

.. 6 .0 TESTS6.1 Tests have been spec i f ied according to the mate r i a l andfunc t iona l re1=1uirementof the f i t t ing and are required to beconducted to determine conformity to the mater ia l spec i f i ca t ionand requirements of the f i t t i n g .

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" ,6 .2 ~ L a s s i f ie a t ion 0 f t es t and cri t e r ia 0 f ace e e ta nee:The t e s t are divide,d in to three groups: .i ) Type te s t s i i ) Acceptance t e s t s i i i ) Routine t e s t s

6.2 .1 ~ t e s t s : Type t e s t are intended to es t ab l i sh thegeneral qua l i t i e s and design charac te r i s t i cs of the f i t t i ngs andto prove i t s conformity with the requirements of spec i f ica t ion .The type t e s t s are to be conducted only a f t e r a l l the de5igns anddrawings have been approved and clearance given byRDSO/Purchaserto th i s e f fec t t h ~ m a M u f a c t u r e ~ ' sha l l then take up themanufacture of the prototype fo r ROSO/Purchaser inspec t ion. I tis to be c lear ly understood t ha t any change required to be donein the prototype as required by ROSO/Purchaser sha l l be doneexpedi t iously . Each t e s t sha l l be made on 3 samples . I f thesample fai l ,s in any of the t e s t s the product ion of fur the rf i t t i n g s sha l l be s topped till fur the r inves t iga t ion and 7 improvements in the manufacturing procedure done.6.2 .2 Acceptance t e s t s : Acceptance t e s t s a re car r i ed out tover i fy the qual i ty of mater ia l and workmanship fo r acceptance ofthe l o t .6.2 .3 Routine t e s t s : Routine t e s t s are carr ied out on eachf i t t i ng from the lo t to check the ~ e q u i r e m e n t which are l ike ly tovary during product ion. The defec t ive ones are r e j ec t ed . I f 101-or more f i t t i ngs f a i l to meet the requirement of the rout ine t ~ s t the en t i r e l o t sha l l be re j ec ted .6 .3 Bulk manufacture: Only a f t e r clear wri t ten approval ofthe resu l t s of the t e s t on the prototype i ~ communicated by ROSO/Purchaser to the manufacturer . sha l l he take up bulk manufactureof the f i t t i ngs which sha l l be s t r i c t l y with the same mater ia la n d , process as adopted fo r the proto type. In no c i r ~ u m s t a n c e s sha l l mater ia l o ther than those approved in -the design/drawin'3sand/or t h e ' p ro to ty p e be used fo r bulk ~ ~ h u f a c t u r e on the pleatha t they h ~ d b e e n obtained pr i o r to the a . p ~ r o v a l of theproto type.6 .4 InsRection: Before giving the ca l l to ROSO/Purchaserfo r inspect ion and t es t ing of the prototype of the system. , themanufacturer sha l l submit a d e t a ~ l e d t e s t schedule consis t ir ig ofschematic c i rcu i t d i a g ~ a m s for each of the t e s t s . nature qf thet e s t . venue of the t e s t . durat ion of each t e s t and the to ta lnumber of days required to complete the t e s t a t one s t re tch . Onceschedule is approved. the t e s t s ha l l invar iably be done a ~ c o r d i n g l y . However. during the process of type t es t ing or evenl a t e r . RDSO/Purchaser's representa t iVe r e s e r v ~ s the r igh t toconduct an-y addi t i ona l t e s t s besides, ' those speCified here in . onany equipment /sub-system or system so as to t e s t the system toh is sa t i s fac t ion or fo r gaining addi t iona l inf9rmat ion and

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" ) I " " ' ; ' . ~ . :. , " " , - , , , , , . .' ,.know 1edge ~ ' : t ~ : , ~ ; ~ ' ~ ~ : ~ ~ , ~ ' " ~ , ~ j j e - ~ 1 = l i j t c e :;:p r,'! .rii , ~ ~ ! T f T - : e m f ' ! T \ : t r:i : e be " , : , e en th eman uf ac t ur e r . , . ~ I:f ''!rhe,RlJmIDVPU . C ; h ~ : S : ~ . ! 5 - t ) ~ < , : r : I i ! . p r ~ s f ? l : ' , ~ ~ t . 1 . ~ e du n g the".' ~ r o , 1 . e s ~ _,; of, .. t . tS t l ngas r e ~ a ~ d s the ty'pe ;tes-t':' and/n r th el n t ~ . r , p ' r e } , a t i : ~ ~ " ~ < : a n d 2 a C C 6 ! . p ' t ; ~ ~ l l i l . ~ Y ) ? l ' } r ' ~ { e typ,e t e s t re su l t s 1 i ts ha.11J ~ b e " " b retught1 i t:o , : t : I ' ) e . ~ Q ' t :i:;pe,o.f, i t,h J)'f,r:;e tori 'Gene ra l' (T rae t ion ' .;\,Ins t.3:i la t ' i on h""1 s R D S O p P . ~ r cbi\s e r : ~ a s ' ~ t , ' Q ~ : . ~ a ; s ~ . m ' ~ y b e " w h c i i s ~ . 'd e G i,s,i Ol7t" . ,sh a l l be f i na l and bindin . , ; ) . n. .. 'i ' . " : ~ ; , ; , .; .. 6 .: . ; ~ : in s pe t 6 f ' 9' c' r e 6 eon 5 i b i l i MY 1. ;. . .' .

, ' , I . . ' .; t ~ " \ r l , ' ; , . ! . ' ~ . ~ H , : : ' . ;, ,. i f . ' ' - ; ' : ' ~ ' : ' - ; i : . " ' : - ~ , ; ;,'." of;, , '.:> .." J ; > ~ t t h E ( i n ~ p e c t l r i g , > a . u ; t b f H ' ; ' ~ t Y ' J i S i h a U .. , ~ ~ ' ~ f i ; t . i i . ~ n a proper ) record "

o f ' h ' e n u m b e ' ~ ' o ! ; U ~ ~ : t t ~ n g s : of,erfi!4" f p , r . : , , ~ t : l s . P ~ ~ t ~ 9 n , , } n .. e a t ; ~ ~ g t , ; th enumber of f I t t 'i';'9 sot ' l J -Wh.l,th, a c , c . e . p t l f ; l . ( : , ~ , : ~ , ' t s I w e r ~ .. d C l n ~ " 'antl." t he ,r ~ ' : ' i U ) ( ~ $ : . , t h e r J ~ o f , . i n d i ca t i n g the number' of ' f : r t t i / l ( 9 ' ~ ' , : l r a n y ,

r e , j f ~ } : . < t ~ a , , 'a_t;'d! 'r e a ~ 5 on 51,; I t heY'&l.,f'o;r. ;T,pJi!,se., r'B,Co r ds,o r co pies t here ofs h ) 3 . ' ~ l : ' h ~ , f ~ r h i s J " ~ d ' t ' o ' t l t t e , ' c o n S : i ~ - g : n e ~ ~ s ~ < . w e l l ~ ' a . s : to'it'he" o r d e r i n g ! . ~ p u r c ; J " f t ? ~ i , . n . g a ~ t p ~ d r 1 The' i ' t ls pect i n9 au-tJ,or,i'ty;' ' s ' h ~ 1 l , ' d u r fng 'hLs 'inspect ' i 'on ~ ' a Y ' e f u l l y chec:k: the t jpr.op,er r , ~ . c ; Q . : r : , d . s : c i f r : o ~ t i n e ' , t e s t sand presc r Ibed . ' qua . l i ty assurance checks '" done at : . i ~ " . i ' . ; : ; .. , --)


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8.0 CONDUCTOR END CLAMPS',/MIO'8PAN TENSION JOINTS ANCHORFITTINGS AND TURN:":'BUCKLES(9-TONNE' A D J U S T E ~ S ) : " , . , : ' , .8 .1 Fi t t i ngs fo r cleur;'pi;Ii,9, th e ' conductor 's , which a re in ' - -tension" a t the ends and t he i r"nii d-'s pan'-s'pl i cas ,al"ecal . l ed , ' endclamps and t ens ion j o i n t s re spec t ive ly and 'a:ri:e,c::O'vered' in t f t is group. 8 .2 Requirements : End c i ~ m p . a n d tens ion j g i n t s s h a l l ' bemanufactured a n d f i n ~ s h e d so as to avoid sharp rad ius of

c u r v a t u r ~ , r idges a r i ~ ~ e ~ ~ r e s c e n e s whiah might lead, to loca l i sedpressure"and damage to ' the ' condut tor and f i t t i n g due to v ib ra t i onin serv ice . They s h < 1 l l l ' w f t h s ' ~ a n d ' t h e t e s t s p r ~ s c r : i ~ e d . . . . .. l8 .3 The end clamps and t ~ n ~ i o n j Q i n ~ s may be of aluminium

a l l oy cas t i ng, a l umin i um " b r o n z e t ~ $ t i ng, ' ,me 11 ea.b 1e i rCln cas tinig01" fOl"ged/fabr i cated s t e e l as ' , spec i f i ed in tt'te purchase ' r ' sdl"awings,. The , m a t e ~ i a 1 sha l l conform to t ~ e r e l ~ v a n t spec i f i ca t ions .8 .4 The f i t t i n g may be bo l t ed type , cone type , wedge t y p ~ ~ r compression type , as spec i f i ed in P U l " c h a : $ ' e I ' f . s : d l " a ; w . ~ n : 9 . , 8 . 5 Tes t s . ,

. ,,'.\ , j,8 .5 .1 ~ t e s t s :a), '" Y ~ ~ u a l ' inspet t ior i ' " (Se e C1 .1 1 1 )b) Dimensional ve r i f i ca t i o tC ( S e , , ~ 'C 1 . 11 .2 ) c ) C h e ~ i c a l ' c o m p o s i t ~ o n t e s ~ (8e'e C1 11 .3 ),,d'> , 'flnysj. c,aJ p,I".O pe I"t i as t e s t '( e 11.5)f) G a l v a n i s i n g t e ~ t ( fo rfer'r-ous f i : t t ings only) (See C1 . -1-1. ~ O ) 9 )' Dye penet ra \ ion t e s t ( S e e C l . '11'.12)h) Hardness t e s t ( f ~ r M C l f i t t i n g s ) (See L1"1 .14)

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8 .5 .3 Sam,les taken in accordance with Clause 5 .6 s ha l l besubjec ted to a l l t e s t s l i s t e d under 'Acceptance T es t s ' except fo rchemicalshouldr e s p e ~ t i

composit ion t e s tbe conducted in accordancev e l y ~

and physicalwith proper t i esClause 11.3 t e s tand which11.4

8 .5 .4 Routine t e s t s :a) Visual inspect ion (See Cl.11. ' l)b) Routine ve r i f i ca t ion of dimension (See C1.1"1. '13)c ) Dye penet ra t ion t e s t fo r f i t t i ngsl i s t e d in Appendix 'J' only . (See C1.11.12)

9 .0 NON-TENSION JOINTS (PARALLEL GROOVE AND TERMINAL CLAMPS)9.1 N o n ~ t e n s i o n j o i n t s : The f i t t i ngs used on the overheadconductors fo r e l e c t r i c a l cont inu i ty which are not subjec ted totens ion are c l a s s i f i ed as non- tens ion j o i n t s . Such f i t t i n g sinclude pa ra l l e l groove clamps and t e rminal clamps of jumperassembl ies .9 .2 General requi rements :

Non-tension j o in t s sha l l be designed so t h a t they meetthe requirements of the normal ' se rv i ce condi t i ons . A ra tedcur ren t sha l l be ass igned to every j o i n t which: sha l l be thec r i t e r ion fo r e l e c t r i c a l type t e s t s . Fi t t i ngs intended toconnet t conductors of two d i s - s imi l a r mate r i a l s sha l l be sodesigned t ha t harmful bimeta l l i c cor ros ion when erec ted inexposed a tmospher ic candi t ion is minimised. Non-tension j o i n t sare usual ly cas t ings .9.2.1 Fi t t i ngs 'o r non- tensions s ha l l be manufactured andf in i shed so as to avoid sharp r ~ d i u s of c u r v a t u r ~ 7 r idges whichmay lead to the loca l i sed pressure or damage to the conductor inserv ice .9.3 Non- tension ' j o in t s a re made of t i n -bronze , aluminium

b r o n z e ~ ; a l u m i n i u m a l loy or copper ~ s spec i f i ed by the purchaser .The mate r i a l sha l l conform to t ~ e re levant c lauses of t h i sspec i f i ca t ion .9 .4 Non-tension j o i n t f i t t i n g s a re g e n e f ~ l l y o f bol ted type ,though t he re may be some f i t t i n g s of crimped type or so lderedtype . A ll f i t t i n g s are subjec ted to the t e s t s as s pec i f i ed inre levant paras of t h i s spec i f i ca t ion .9 .5 Tests9 . 5 . '1 ~ t e s t s :

(See Cl. ' l1.1)a ) Visua l inspec t ion (See CI.11 .2)b) Dimensional ve r i f i ca t ion c ) Chemical composi t ion t e s t (See C1.11 .3) . d) Physica l prope r t i e s t e s t (See C1.1"1.4)

9


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Radiographic t e s t (onlyfor cas t ings) (See CI.1 ' l .6)f) Sl ip t e s t (See C1. -1-1. 7)g) E lec t r i c r es i s t ance t e s t ( fo r sp l ices only) (See Cl. '11.8)h) Temperature r i se t e s t( for sp l i ce s only) (See C1. ' l ' l .9)Dye penet ra t ion t e s t (See CI.'1"1.'12)

9 .5 .2 Acceptance t e s t :a ) Visual inspec t ion (See C1. -11 1 )b) Dimensional ve r i f i ca t ion (See CI. '11.2)c ) Chemical composit ion t e s t (See CI. '11.3)d) Physica l proper t ies t e s t (Se e C 1 '1 '1 .4 )e ) Dye penet ra t ion t e s t ( S'e E! C I -11 . '12 )

9 .5 .2 .1 Samples taken in accordance with Clause 5 .6 sha l l besubjec ted to a l l t e s t s l i s t ed under 'Acceptance t e s t ' e x c e p t forchemical comoposit ion t e s t s and phys ica l proper t i es t e s t , which)should be conducted in accordance with Clause 11.3 and 11.4r espec t ive ly .9 .5 .3 Routine t e s t s :

a) Visual inspect ion (See CI.11 .1)b) Routine ver i f i ca t ion of dimensions (See Cl.11.13)10. SUSPENSION CLAMPS AND OTHER CANTILEVER

ASSEMBLY FITTINGS.10.1 Fi t t i ngs which a re used on the can t i l ever assembly andthe s u s p ~ n s i o n of conductors a re covered in t h i s group.10.2 General requirementsi

The clamps and f i t t i ngs sha l l be so designed andmanufactured t ha t the e f fec t of vibra t ions , both on theconduc tors / can t i l eve r assembly and f i t t i n g i t s e l f , are minimised.The suspension clamps, add i t iona l ly , sha l l bemanufactured and f in ished so as to avoid sharp rad ius ofcurva ture , r idges and excrescences which might lead to theloca l i sed p r e s s u ~ e or damage to the conductor ir i serv ice . Thesuspension clamps sha l l permit the conductor to s l i p beforefa i lu re of conductor occurs . The clamp sha l l have su f f i c i en tcontac t surface to minimise damage by f au l t cur ren t s .

10.3 Tests10.3 . 1 .IY..J?e ,t es t s :

a) . Visual inspec t ion (See C l. -H. '1 )b) Dimensional ver i f i ca t ion (Se e C1. -1 '1 .2 )c) Chemical composition t e s t (See C1. '1'1.3)


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d) P h:-:s i ca 1 pro pe ." t:: ~ i ~ ' S : . \.::,s, (See Cl .11 .4 )e ) Fa l l in ' J load tes t . (See Cl .1 '1 .5),; : ; '" f ,t .Ra.di og,r 9 : P ~ J ; < : t f t 9 ; t . o ;n l ;X" i , .'

':' ( ~ n 1Y: r f c : p ~ , . , C i ~ ~ ; t , i ; n . , ; , ) . , '" " ';" . (See Cl .11 .6 ). ,;g): Sl , p ' ; . ~ e ? , t , ; ( , I , l , n l y ,.folr, ...... j"',,;' ~ u ~ p e . t i s i . Q , T , l . : : c ~ ~ m e J . : , .. ,:,:.:i' ....., (See Cl .11.7>'

Cia 1 v , a , } ~ ~ i n 9:t.eS. t., j) 0 f.,.: i ' ; ,.' . i..'f,e.r; r:ous ,.f.H it n g $ , , : ( J . n l.y, .' . ,.,.:; , . ' ~ (See "e L 11. '10)Assembly te s t ( fo r con tac t 'w i . ; . : "droper c l i p and swive l c l i p s orti9> 0 ~ e e C t . 1 1 . ~ 1 j j ) Dye p e n e t r a t i o R . : t ~ ' : ' i t : . r;... "',.,, ,!, (See Cl.: '11.'12)k ) Hardness t e s t ' ( for ' M C l f t tt in g s ) ' ,. ( S e ~ C l . '1 '1.14)

. : ;, ;

.: .' ': ;", g' ;' ' !:,. ; ." 1 0 ~ 3 ~ 2

/a) ' vt s u a l , i ns pec t i on. ('$ee C l . n . 1 ); b ) D,irtlens-ionaJ.viu.ificat.ion ; ' (See C1.11.2) .,,C ) Chem,i tal ' Q A ' l p q ~ ; . t i o j , ' t e s t (See CL'1 'L3)

i \ ,d ) P h y s ' i : c a l p r ; o p ~ r i i e ~ , t e s t : i :" ; . . . (See d l ' 1 ' L 4 ) " 'e ) . , '. Fai1:a. ng : to.aQ. , : t . ~ s , ~ .;. . .... " . (See 'C l +1\5) 'f

:; " ' f ) 81 ip. t e s t , :! f,o:r.: ~ u s p e n ' s ) ~ ; n : .claintd .: : l ( S e e C F. 1 j1-i.,:n:.i : 'g.),'. Ga,lv ~ n i:s,.i ng .t.e,s t '( fo r" f.e r ro!ls' : , : . , . , ! '; ..... . f i t t i ngs " . on l Y) . , . . . ' . , . " ' , ' ' . ' (See 'Cl.'1'1 >10)h) Assembly t e s t ( f o r c : o n t a c t ' 'wire '.'". " Jdropper c 1'i p ' a ndswi ve 1 cl ~ ; s ' " on ly')'( See C : V ~ ~ - 1 1 . ; l 1 ' ) . i> Dye p e n e t r a t i o n t e s . t . . .... . , (See C1.11 .12)j ) Hardness t e s t ({or 'MeT 'f-' it i i n g s r:C-Se:e! C1. '1'1 ~ ' ' l 4 )

. 10. ~ i ~ : : ~ ; ' . ' ~ m ~ l e ~ ' , .. t : ~ k - e , 1 l ','in . ~ c ' ~ d r : , l a n c r J . ; w r t t 1 c 1.3'as'e 5':'6 s ha l l "be!i'ubj e c t e d t o :


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11 n 2 D i ' ~ ; e n s i o n a l ver i f ica . t icm: '' ' ' ' ' ' - . - ~ _ . _ - -A l l . dimensions of r i t t i ' r i . j s s 'ha . ' l lbe ; 'ver i f i ed with the

he lp of g a u ~ c i s , c a l l i p e r s and m ~ 2 r d m ~ t e f ~ t o - check t h a t theyconform l.I'.i ththe appro ed drawings . Th'read' gauges s h a l l be usedto c h e c ~ t h reads where e r pro .... i ~ e d i ' - . ~ Y i G o a n d No-Go gaugesare used . for,. checking 0' dimeris ions . t h e d ... a w i ~ 9 f o r such gaugess h a l l b e ' '.;Jot approved by the"manufa 'c turer beta-re use by thei n spec t ing a U ~ h o r i t y ~ ,, . '", -/ .1, I1'1.3 C h ~ m i ca l composi ti 0'1, t ~ ~ n ...... ;

The chemical composi t ion of the m a t e r i a l s p e c i f i ~ d s ha l l .b e tes t .ed in accordance with th e rele\Oil.nt spElcif icat i .onmentioned i n C l a u s e - 1 In c ~ s e of c a s t i n g s , the t e s t s s ha l l bedone on th e t e s t bars as wal l a s on one sample ' f i t t iT ig o f eachc a s t i n g / m e l t . M ate r i a l sha ; l l co i i f ' o rm to the requ i remen tss pe c j f i e d in th e re l e .... a n t s p e t i f i c a t i o T l . l n c a s e . of fo rged /

w e l d ~ d / fabr i ca t ed f i t t i n g s , the t e s t ' ~ h a l l be c a r r i e d ou t on onesampl,e: .each of raw materi .a l and concerned f i t t i n ' 3s :up to a lo t of200 nos and on. two samples_aeh '0' r ~ w m a t ~ r i a l f a n d ~ i ~ t i n 9 s uptoa lo t o f . ~ O O nos . In case o f Coppe,rhduminium s t . r ip formedf i t t i n g s th e t e s t . sna l l . be c a r r i e d out ' on one f i t t i ng sample one ' V e - r - y ~ . O O no,s ',0 r f ra c:t i on the reo f a l o t ...... . ",.j''11.4 ; " P h y s i c a l prope . r t i e s . t e s t :' 11.4.1 In th e c a s t of cas t ings the ' t e s t s fo r mechanica lproper t i e s s h ~ l l . '.J:>e ccin'dutted on t he t e s t ' ba r s / p i e . ce s made, . j ,naccordance .w.itr\ . ' t . h e r e l e .... a n t s p e c i f i c a t i C i n (Clause . 7) . (See. r e l e .... a n ~ , Appendices .. s o r ~ ' . ," ' ;;;

.1 " . . .l L " . .

If one t e s t piece f a i l s in any t e s t , t w o : . m Q r e ~ , l e s t pieces s h a l l be t e s t e d . The samples s h a l l be deemed. t o . h a v epassed the t e ~ t s i f t he re i s no f a i l u r e i n ' t h ~ ~ ~ t e , t ~ "11.4'.1.'1 In . case of malleable 'ca5t) ' i f 'on (MCI) f i t t ~ n I 3 s , the

m i c r o - s t r u c t u r ~ ; ( j ~ f . ~ l ~ u ~ e 8 .2 ) and h a T d n e s ~ ( r e f . ~ l a u s e 8 .5 )' S ~ h ; a l ; l alsoA . t . . ~ ; , tes"ted . , ," .p., . ;f ' '; " . ' : " : ' -< . ' " : ~ ' . ,', .

.. 11 .4 .2 In case of fo rged / fab r i ca t ed /we lded ' f i t t i ngs p h y s i c ~ l proper t i e s t e s t s s ha l l bi conducted in " ~ ~ t o r d ~ n c e with ther e l e v a n t s pec i f i ca t i ons on one sa m p l e u p t o "a l o t o f 100 nos andon 3. samples fo r a l o t . exceeding '100 'nos; 'Wb;ich sh9u ld be se l ec t eda t random . , I f o n e s ~ p l l ! t . f . a i l s in any t e s t , double th e number oft e s t piece:s s b a l 1 b ~ t e s f e d . ' h e s a m p l ~ s s ha l l :be deemed ,t o havepassed the ! te.sts. . if t he r e i s no ' f a i l u r e in t h e ' r e t e s t . '"

1 ' 1 . 4 ~ 3 In case ~ f ! c o p p e r / ~ l ~ m ~ n f u m ~ t r t p f o r m e d ' ; f i t t i n g sphysica l prope r t i e s .. e ~ t , Qn o n e ~ a m p l e uptb a lo t of 500cnos andon th ree samples on l o t e ~ c e e d i n g 500r i6s s h a l l be condqcted .

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i.

11 .5 E ~ L l i n g ~ t e s t :11.5 .1 For c o n d u c t o r ' ~ clamps4 mid span t ens ion j o i n t s and

,s pIt ces .11 .5 .1 .1 The f i t t i n g s s h a l l be assembled in accordance with th es t anda rd drawings on th e conductors 01 the s i z e and type wi thwhich it i s meant to be used. The assembly s h a l l ,be he ld in at e n s i l e t e s t i ng machine and anchored in a manner a p p r o ~ i m a t i n g asnea r ly as p o ss i b l e , to the ar rangement used in se rv ice ' . Thecompress ion end clamps s ha l l be compressed on th e s pe c i f i e dconducto r . The precau t ion s ha l l be taken to avo id bird caging o fth e conducto r . The length of th e conduc to r between the f i t t i n gunder t e s t and any o t h e r clamp or j o i n t in th e t e s t assemblys h a l l no t be l e s s than 100 t imes th e average o v e r a l l d iam e te r ofthe conduc to r .11 .5 .1 .2 A t e n s i l e load of abou t 50% of th e break ing load of th econductor s h a l l be app l i ed and conductor s h a l l be marked in such

J a manner in t h a t movement r e l a t i v e to the f i t t i n g can be eas i l yde tec ted . Without any subsequent ad jus tmen t of th e f i t t i n g , th eload s h a l l be s t ead i l y i nc r ea sed to 90% of the b reak ing load andmain ta ined fo r one' minu te . There s h a l l be no movement of th econduc to r r e l a t i v e ' to the f i t t i n g due to s l i p during t h i s per iodof one minu te .11 .5 .1 .3 The t e n s i l e load s h a l l then be i nc reased u n t i l th econduc to r e i t h e r s l i p s out of th e f i t t i n g under t e s t or snaps orone or more of the componen t ( s ) , 01 th e f i t t i n g f r a c t u r e ordeform.11 .5 .1 .4 The f i t t i n g s ha l l n o t break , s l i p or deform till th econducto r breaks . Should the wire or conductor s l i p in thef i t t i ng or any component o f th e f i t t i n g f r a c t u r e s o r deformsbefore the f a i l u r e of conductor th e f i t t i n g sha l be deemed tohave f a i l e d in th e load t e s t . I f th e conductor breaks a t a loadl e ss than 95% 01 i t s s pe c i f i e d break ing s t r e ng t h , th e t e s t s ha l lbe r epea t ed .1 1 .5 .1 .5 Af te r the t e s t it shou ld be poss ib l e to d ismant le th ef i t t i ng wi th o u t d i f f i c u l t y and withou t recourse to any t o o l so ther than t hose normal ly employed fo r assembling them.11 .5 .1 .6 The minimum f a i l i ng load of the conduc to rs a rei n d i c a t e d in Tab le -1 .

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-----------------------------------------------------------------

TABLE-1: Ultimate t e n s i l e s t rength of conductors .81 No. and diamter Ult imate t en-No. Type of conductors s i l e s t rength(mm) (kgf)

...., "1 Cadmium copper catenary ( 6 5 m m ~ ) 19/2 .10 39202 Cadmium copper br id le wire 7/2 .10 14433 Hard drawn grooved c 9 ~ p e r con tac t wi re (107 mm 2,. ) 39054 Hard drawn g r o o v e d c ~ p p e r 5475con tac t wire (150 m m ~ ) 5 Hard drawn s t r a n d ~ d copper 37/2 .25 6080conductor ('150 mm 4 ) 16 Hard drawn s t randed cadmium 37/2 .10 7650copper conductor (130 m m ~ ) 7 Annealed copper s t randed 19/1 .80jumper wire (50 mm )8 Annealed copper s t randedjumper wire (105 mm '19/7/-1.0169 Annealed copper s t randedjumper wire (160 mm ) '19/7/ '1.2510 Hard drawn copper wire fo r 5 825droppers .11 Hard drawn copper wire fo r 7 '1530' d ropper s .12 Ear th wire - ACSR (RACCOON) 6 / 1 / 4 . 09 274613 Ear th wire g a l v a n i s e d s t e e l 19/2.,50 5'10014 Return conductors (Spider) '19/3.99 3736(All a lumin ium)15 Aluminium l a rge jumper '133/1.40 338016 Sta in le s s s t ee l wire rope 34x7(6 /1) 380017 Aluminium a l l oy conductor 19/2 .79 33'10

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~ . - - - " -

11 . 5 . 2 t l as t anchor f i t t i n g s , suspension ciampsa n d - o t h e r f i t t i n q s . f1'.5.2,i"1 - Th'e f i t t i n g s h a l l be held in a t e n s i l e t e s t i ng machineina manner approx imat ing , as near ly as p o s s i b l e , to th e

a r r a n g e m e n ~ to be used in s e r v i c e . The conducto r s h a l l ber ep l aced by a , su i t , ab l e r ig id bar ( see f i g . 1 ) . T e n s i l e load eq u a lto 50X o f the sp e c i f i e d f a i l i n g load s h a l l be app l i ed andt h e r e a f t e r i n ~ r e a s e d a t a s t eady r a t e . F i t t i n g s h a l l n o t f a i l ordeform below th e minimum sp e c i f i e d f a i l i ng load main ta ined fo r aperiod o f one minu te .Note: The f a i l i n ~ l o ~ d s of the f i t t i ~ g s . s h a l l be s p e c i f i e da f t e r a c t u a l t e s t s .

CON J j ~ / O A

. . . . . . . '-'-'_.1 .. ++-- ~ : ; ~ G . . . . . 1 t 4 = : : - : E 8 = _ - _ - ~ - , :==@t---+FI/


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F I ~ 2Sl ip .1.gl l for non-tension j o i n t s .i

~ L-oOADtNG

1 L 7 .2, ,11 .7 .2 .1 The j o i n t sha l l be assembled using t h ~ cdnnector undert-est on ionductors of the s i z . with which i t is to be used. The

/ assembly sha l l be mounted in a t ens i l e t e s t ing machine andanchored in such a way t ~ a t t h e t e s t l d a d i s appl ied in thedi rec t ion of t h ~ conductor .11 .7 .2 .2 A t ens i l e load of about 5 p ~ r c e n t o f the breaking loadof the conductor , sub jec t to a maximUm of 55 kgf . sha l l beappl ied and the conductor sha l l be marked in such a way tha tmovement re la t ive to the conductor c a ~ ' ~ a s i l y be detected.Without any subsequent adjustment of the conductor , the loadsha l l be s tead i ly & slowly increased to 101. of the breaking loadof the conductor . sub jec t to maximum of 110 k g f ~ T h i s load ' s ha l lbe maintained for 1 minute. There sha l l be no movement of theconductor re la t ive to connector 'due to t h ~ , s l i p d u H n 9 _ ' t h i ~ oneminute per iod and no fa i lu re of t h ~ c t i n M e ~ t b ~ : " ,11 .8 E l e t t r i c a l Resis tante t ~ $ t s ~ ' 11.8 .1 The f i t t i ngs which a re required to carry curren t sha l lbe subjec ted to the res is tance t e s t s . The t e$ t"sha l i be done ....Jithdi rec t current . The pola r i ty sha l l be reversed ~ n d t e s t ~ e o e a ~ ~ ~ . Average 0' two resul t s sha l l be taken ~ ~ t h e ~ e a ~ u r e d v a l u ~ . 11 .8 .2 The res i s tance measur'ements sh 'a l l be m.ade by mil l ivo l tdrop_ an accurate r e s i s t a n c e b r i d g e o r o t h e r a ~ p r o ~ ~ d m e t h o d s . 11 .8 .3 The actual . s ize of conductor whichwi r l be used withthe connector or f i t t i n g sha l l be used during , the t e s t s .

EQL tension j o i n t s :The f i t t i ng sha l l be assembled in a c c o r d a n ~ e with thes tandard drawing on the conductors of the s ize and type withwhich it i s to be used. The e l ec t r i ca l r ~ s i s t a n c e sha l l bemeasured between two points on the conduc torson e : i the r ,' S ide and. 25mm c lea r of the f i t t i ng . The res i s tance of the conductor withsp l ice sh a l l be of the same order as tha t of the equivalentlength of the conductor . The current connect ions sna t l be crt adis tance of not less than 50 t imes of the diameter of the

conductor from the f i t t i n g and sha l l be made so tha t e f fec t ivecontact i s made with a l l those s t r ands of conductor which wouldbe taken into account in ca lcu la t ing i t s equivalen t res i s tance .""':'_ 16_


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1'1.8.5 f.Q..!:.. non-,tension j o in t s :T ~ ~ r es i s t ance of 1.25 m Ot a conductor , inclUding oneconnector , such a$ pa ra l l e l groove connector sha l l not exceed ther es i s t ance of 1.25 m of the iden t ica l conductor withoutconnec tor , by more than 10 percent . For t e rmina l connectors , theres is tance measured sha l l be the sum of the res i s tancemeasurement t a k e ~ f ~ o m A ~ o B and C to D as shown in f igure 3 . Incases where the coriductor i s a s t randed cable , the s t rands sha l l

be su i t ab ly bonded the . po i . r n : J . tthe measurement.t 0;- ~ ~ . ... ]

l'lee\ -

, ~ S yo .:4 Sfr'l-I CE',..- ~ ~ ; . . . . . . . - ' ~ ~ - 2EJ

076 2 5 )7) )01< 0 .' '"2.. 5 "YI. l-rr ; .RM N /'':-,L.. FtG.i t. CNNcTOF


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11.9 .5 The t e m p e r a t u r e - r i s e s h a l l no t exceed 40 degree Cabove th e r e f e r ence ambient t empera tu re of 45 degree C. I f th eambien t t empera tu re exceeds 45 degree C th e pe rm iss ib let empera tu re r i s e s h a l l be reduced by an amount equal to excessambient t em pe ra tu r e .

Galvan i sa t i on t e s t :The ga lvan i sed component of th e f i t t i n g s s h a l l bet e s t e d fo r mass of z inc coa t ing (Clause 5 .0 of s pe c i f i c a t i onNo.ETI /OHE/13(4/84) . un i fo rm i ty of coa t ing . adherahce and o therdefec t s (Clause 3 .2 of s pe c i f i c a t i on No.ETII OHE/13(4/84) .

11 '11 Assembly ~ fo r con tac t ~ droppertlll and swive l tll l ..:.The dropper c l ip and swive l c l i p s h a l l be assembled on

th e con tac twi r e of th e s t anda rd and maximum p r o f i l e s . Thed i s t ance between th e hooks s h a l l be wi th in the l i m i t s aspresc r ibed in th e r e l evan t s t andard drawings .11.12 Dye pene t ra t i on t e s t :

Dye pene t ra t i on t e s t s h a l l be done e i t h e r by ZygIa .magnaf lux or any o t h e r . approved method in accordance with18:3658-1981 "Code of p r a c t i c e fo r l i qu id pene t ran t f lawde tec t ion" (For list of f i t t i n g s see Appendix - J ) .11.13 Rout ine v e r i f i c a t i o n of dimensions:

Im p o r t an t dimensions of a l l f i t t i n g s s h a l l be checkedp r e f e ~ ~ b l y b y p r o f i l e gauges ~ f grooves and s u i t a b l e G O / N O ~ G a gauges . For purpose o f t h i s . t e s t , dimensions which e f f e c t theassembly , d ~ m e n s i o n which e f f e t t th e s t r e n ~ t h o f f i t t i n g such aswal l t h i ckness and machined dimensions ~ h a l l b e taken asimpor tan t d imens ions .11. '14 Hardness t e s t :

"Hardness. of m a l l ~ a b l e i ron cas t i ngs s h a l l be measured ;on the product by B r i n e l l method as per 18 :1500-1983 . Thehardness of m al leab le i r on cas t ings s h a l l n o t e x ~ e e d 150 HB.12. MARKING:12.1 For th e purpose of i d e n t i f i c a t i o n , th e fo l lowingmarking s ha l l i n v a r i a b l y be made/cas t on each f i t t i n g s / c a s t i n g s .

i ) M anufac tu r e r ' s code numberi i ) Railway I d e n t i f i a t i o n No. (R . I .No . )

18

.] ,


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iii) The month and year of produc t ion s ha l l i nva r i ab ly bei nd ica t ed on th e f i t t i n g s / c a s t i n g s . I f it i s notposs ib le to accommodate any pa r t i cu l a r marking on th ef i t t i n g s / c a s t i n g s , the manu 'ac turer s ha l l obta in pr i o rapprova l of the purchaser to de le t e the m a r k i n 9 ~ o r tomake the marking by any o t h e r s u i t ab l e means.

12.2 I t i s des i rab le t h a t a code giv ing the lo t or mel tnumber i s a l so cas t or engraved on each cas t ing to f a c i l i t a t e thei d e n t i f i c a t i o n 0' lo t number of each f i t t i n g . Al t e rna t i ve l y , themonth and yea r 0' produc t ion may be provided dur ing cas t ing .12.3 In case 0' fabr i ca t ed f i t t i ngs marking s h a l l be punchedon such f i t t i n g s pr i o r to th e ga lvan i sa t ion so t h a t not only themarkings a re c l ea r l y v i s i b l e a f t e r ga l va n i s a t i on , bu t a l so the rei s no damage to the galvanised sur face .12.4 A l ab l e ind ica t ing the in spec to r s code number and da te ,s h a l l be l i xe d i nde l i b l y on every f i t t i n g immedia te ly a f t e rt e5 t s and i nspec t ion .13. DISPOSAL OF REJECTED FITTINGS.

The r ~ j e c t e d f i t t i n g s s h a l l des t royed in thepresence of t he Inspec to r to preven t t h e i r i n - a d v e r t e n t miXingwith the fu tu re supp l i e s and s ha l l adv i se RDSO/CORE with thereasons 'o r r e j e c t i o n .14. PACKING:

For pack ing , wooden cases s ha l l be employed. Thepacking s h a l l be fit to withs tand rough handl ing , dur ing t r a n s i tand s to rage a t des t i na t i on . The heads and th readed por t i ons ofpins and the f i t t i n g s h a l l be proper ly pro tec ted a ga i ns t damage.The gross weight of the packing s h a l l no t normal ly exceed 50 kg.F i t t i n g s of d i f f e r e n t t ypes and ra t ing s ha l l be complete witht h e i r minor accessor i e s f i t t e d in p lace . All nu t s s ha l l be handt igh tened o v e ~ th e bo l t s and screwed upto the f a r t h e s t po in t .

19


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~ __ c-.

!"APPENDIX A '

Proper t i e s of aluminium bronze cas t ings Ext rac t s from 18:3091-1965.

A. '1 C h e m i c ~ l c o m p o ~ i t i ~ n : A.1.4 Th e mate r i a l wh;h a n ~ l y s e d in accordance with 18=40271967* s ha l l have th e ~ h . ~ i c a l c o m p o s ~ t i o n as given in t ab l e -2 .

- - - - - - - - - - - ~ ~ - - - - - - - - - ~ - - _ . - - - - . - - - - - - - - - - - - - - - - - -TABLE - 2 : CHEMICAL COMPOSITICJN'i OF ALVMINIUNBRONZE INGO! AND CASTING8CONSTITUENT \ PERCENT- - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - -Aluminium 9 .0 to '1'1.9I ron 4 .0 to 5 .0Manganese O. '1 to 0 .5Copper balance

A.2The manufac ture r s ha l l supply f ree of charge a copy ofh is works ana lys i s of the mate r i a l . Works a n a l y ~ i s may bedef ined as the rou t ine ana lys i s conducted by the manufacturer inorder to contro l the qua l i t y of mate r i a l .A.3 Cast ing sha l l be clean . sound and f r ee from harmfuli nc lus ions . Any cas t ings may subsequent ly be re j ec t ed due tomanufactur ing de fec t s . notwi ths tanding th e f a c t t h a t it had beenprevious ly passed fo r chemical composi t ion and mechanica lprope r t i e s .A.4 Th e mate r i a l when t e s t ed in accordance wi th 1S:2654-64**sha l l have the t e n s i l e prope r t i e s given in Table-3 .

TABLE - 3: TENSILg PROPERTIES OF ALUMIANIUMBRONZE INGOTS BNR CASTINGS.MODE OF CASTINGS TEST BAR PROPERTY VALUEChi l l cas t or any o ther Tens i l e s t r eng th . 60 kgf/sqmmcas t ing process minimum

Elonga t ion on 20 Yo50 mm gaugel ength minimum.0.2'Y. permanent 25 kgf/mlTlsqs e t s t r e s sminimum.

------------------------------------------------------------.* 18 :4027-67 : Method of chemical ana lys i s of bronze .** 1S:2654-64: Method of t e n s i l e t e s t i ng of copper andcoppper a l l oy s .

20


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"' I. ! ~ , E ..!!lber of t e s t s .

~ l . : j . '1 Three cas t to shape t e s t pieces ( f ig . 4) sha l l made fo re'ar:h lo t . The t e s t bar sha l l be i ~ e n t i f i e d ~ i t h lo t and date of

l T l < ; ~ l t .

i ..r ~ t l -I Ld>.::: 5-0 ' I I~ ~ ~ 1 '

I 40 " =t1 Pj1 ! ~ , 4

A.5.2 pieces sha l l be t es t ed a t the expense of themanufacturer in the presence of the Inspec tor .A.5.3 One t e s t piece sha l l ,be t e s t ed . I f the mechanicalproper t ies a re met by th i s one t e s t , the lo t sha l l be accepted .I f the f i r s t t e s t piece f a i l s to c o ~ f o r m t6 the spec i f i ed

~ e q u i r e m e n t s , the two remaining t e s t pieces sha l l be t es ted , andif ' ' e i the r of them f a i l s to meet the spec i f ied requirements , thewhole lo t sha l l be re jec ted .

-- - . ~ . -

The t e s t


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)

;

APPENDIX'SProper t i e s of b lack hear t mal leable cas ti ron cas t ings -E x t r a c t s from 15:2108-1977.

B . 1 ~ h e m i c a l composi t ion .B . 1 ~ 1 The Phosphorus content 0' d i f ' e r e n t grades of mal leablei ron , when t e s t ed in accordance with 15:228-1959* s h a l l be asfo l lows:

- ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -GRADE DESIGNATION PHOSPHORUS,(See IS:4843-1968) PERCENT MAX.- - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - -BM 340 O. 12

BM 310 O. 15SM 290 0.18

B.2 Micro - s t ruc tu re .B.2.1 The mate r i a l s ha l l be ' r e e from pr imary graphi te ands ha l l not conta in ' r e e cement i te or pea r l i t e in a form or amountde t r imen ta l to the phys ica l prope r t i e s 0' mach inab i l i ty of thecas t ing .B.3 .Dlll bars .B.3.1 Prov i s ion of t e s t ba r s - All t e s t bars s ha l l be c a s ts e pa ra t e l y . They s ha l l be s u i t ab ly m a r k ~ d so t h a t the cas t ingsthey r ep resen t could be i d e n t i f i e d .B.3 .2 Test ba rs Shal l be c a s t in green or dry sand moulds ofthe same mate r i a l as the moulds used fo r th e cas t ings theyrepresen t . They s ha l l be c a s t in th e same t ime and 'rom" the samemel t as the cas t ing they represen t .B.3 .3 Test bars s ha l l in a l l cases undergo the mel leab i l i z inghea t t r ea tmen t being toge the r with the cas t ings they represen t .S .3 .4 In the event of any ' u r t h e r hea t t r ea tmen t being givento th e c a s t i ngs , to meet the requirements provided under B-4. thet e s t bars s ha l l be s u i t ab ly hea t t r ea t ed a longwi th the cas t ingsthey represen t .B.3.5 Tens i l e t e s t bars s ha l l be cas t to the dimensionss pec i r f i ed in ' i g u r e - 5 . The dimensions of the shanks may bemodif ied to s u i t the jaws 0' the t e s t ing machine .L ~ ~ 1 s : E 151- .-----'1 t 1

~ I!: ~ ; l ~ 1 i" ~i I ~ o F ,G.522


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- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

B.3.6The c a s t t en s i l e t e s t bars may be dressed or c leaned and:;; h':';\ :'.:i bet ! s t din the . unma chi ned con d i t ion .B.4 Mechanical t e s t s :8.4.1 Tensi le t e s t : A t . n s i l e t e s t bar , c a ~ t as for asprac t i cab le to the dimensions shown in f igure -5 s ha l l when t es tedin accor-dance with IS:1608-1972** without machining the gaugelength , give r e su l t s not l e s s than those s p e c i ~ i e d in t ab l e - 4 .Since the t e s t bars a re in unmachined s t a t e , they may not be qui tec i r c u l a r , in which case the t en s i l e s t rength s ha l l be ca lcula tedon. the mean diamete r a t the midale of the gauge l ength by takingtw o measurements a t r i gh t ang les . one of which s ha l l be maximumdiameter .

TABLE-4: TENSILE PROPERTIES OF BLACK HEARTMALLEABLE IRON CASTINGS.

GRADE DESIG- SECTIONAL .DIAMETER TENSILE 0.5PERCENT ELONGATINATION THICKNESS OF TEST STRENGTH PROOF STRESS (Lo=3D)(See 18:4843 REPRESENTED BAR(mm) N/mm N/mm (m i n. )-'1968 )+ (mm) (D ) (kgf/mm) (h1f /mm) . percent - - - - ~ - - _ .._._-._---

BM 340 A ll s i zes 15 340(35) 2QO( 2-1) -12BM 3-10 A ll s i zes -15 319(32) 190 ( 19) 10BM 290 A ll s i zes 15 290(30) 6- - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - -B-5 Hardness t e s t :8-5 .1 Cast ing of grade BM-340 produced accord ing to t.hiss tandard sha l l not have hardness more than 150 HB.

- ~ . _ - - - - - - - - - ~ - - - - - - - - - - - - - - - - - ~ - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - * IS : 228-1959 : Methods fo r chemical a na l ys i s of the s t e e l .** 18:1608-1972: Methods fo r t en s i l e test i r \9 of s t e e l products .+ IS:4843-1968: Code fo r designat ion of f e r rous cas t ings .

\.

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----------------------------------------------------------------------------------------------

----------------------------------------------------------

APPENDIX - tC 'Pr o p e r t i e s .Q..f. t i ne bronze i nqo t s andg s t i n q s =E:


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( -3 .1 The t e s t bars sha l l be according to one of the. ;lppropriate types descr ibed in 1S:1408-1959.*'? 2 .5 , ' . ' R ~ 1.0 .'en Ft-,j~ ~ - < : __ ~ ' 5 : = : . . : l . ~

T ~ 5 1 8 ~ J < - CAST?O .5/I/-IR4_ - ' ~ I *18=1408-1959 - Recommended procedure fo r inspect ion of copperbase a l loy sand cas t ings .

+18:4027-1967 - Method of chemical analys is of bronze.++18:2654-1964 - Method of t ens i le t es t ing of copper and coppera l l oys .

\

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- - ~ - .:s:-.

APPENDIX - 0,j .

Aluminium and aluminium a l l oy cas t inqs .::'. ."" Ex t ra. ct s.f..!::..!;trr! i 8 : 617-1975 !

D ~ : f C h e ~ , i ctalco,mpos l\i on and me' t :hanical pro pe r t le sO - : , ~ . 1 The c h ~ m i c p . l .compo,si t io ,nand. mechanicjal proper t ie . s of'aluminium and.alt.indnium, a l l oy a re given in Table-7: . The mechanica l

p r o p e ~ t i e s g{ven ' in T ~ b t . - 6 app ly to s e p a r ~ t e l y c a s t t e s t . p iece .The chemical composi t ion ~ f aluminium a l l oy f i t ti n g s I t e s t barss ha l l 'betestedin ac.cord,ance, wi th ' lS=504:" '1963.*, ; - ,- . ,l , :.. . . -. TABLE - 7 : C h e m i c a l c p ' r r ; ~ ( ~ s i t i o n ( g r a v i t y 'or

p ~ e s s u r ~ d ie c i s t i ng a l l o y ) .- - . - - - - - - - - - - - - - ~ - - . - - - - - - ~ - - - - - - - - - - - - - - - - - - - -Alloy d e s i g n a t i o n , '- - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - ~ ~ - - - - - - - - - -Chemical composi t ion; percent (va lues given a ~ e i ~ , m a x . u n l ~ s s shown a s a . rangeCopper 0 .1, 8 i l1con 10 .0 - '13.0Magnesium o. '10I ron . 0 . 60 Man'3anes e 0 .5Nicke l ' 0 .1 Zinc 0.1 Lead 0.1 Tin 0 . 05 Titanium 0 . 2 Aluminium Remainder _ MC o n d i ~ i o n ::' ;'.-----------------------.-----,.-:-------_... .:_------------Me.chan i c a l p r o p e rt-i e s .

Tens i l e s t rengthS a n ; , d - c a s l ~ N/sqmm .( ko3f Isqmm) "165 (-16.5,)C h i l l cas t , N/sqmm(kgf/sqmm) 190(19.0)Elonga t ion (pe rcen t ) (on 5.65 180 or 50 mm gauge lengthSand c a s t 5C h i l l c a s t 7*18:504-1963: Methods of a na l ys i s of aluminium and i t s a l l o y s .

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D-2'-, f . ';-" . ' - ; ". ( ' ; ' t . , - -: _ ...... _ t ' " ' . ' - , , ' ..' , ' . , ' ", ;.

D-2.1 The " 'meta l , fo,.r :"t ,he", ' test , s ~ I T I ' p ; l e t 'shal"ii, be t aken from th ec r u c i b l e or l ad l e fro,,,,,,,\.ihich, the"ca5 ' t ings a re poured and s h a l ln o t b e s u , b j e c t e d ,to any , f u r t h ~ r t r , e ;a tmento ther than ad jus tmen t ofth e t 'em'perat u re; t ,o, ' t hat: ''s u'i t a.b1 e 'fo:r." poU'r'ih g;.i" ..,.,:,' '"

iO''2;.'1 >r' ,,:: S k n ' d C a s t fn''ij= 'Th'e t f / s t ; , $ k m l : ; l e s ; ; ' ~ h a . l l " b ~ cas,t in dry'" sarid mou'ld"s ' " ~ h i c h ' sha l l ' hav ' e i n ' { ~ ' A , " a r r d i ' m ' e h ' s ' i b r i i { ' .:(s" 'shdwn' in':, :'I . r : ( ". . . , '; ,,: - I " ; I _. "" _. -. \ ,' , " , . '. :.. ; ,.. . I . ' , ,_. _ _ ': _. ,figure-10r2 of 18:'617.' The lTloLildsshal l be 'iTl'cl i n ~ d i f r t i m th eve'rt i 'c 'al d t ' ' t ; h e ~ c O I T I ~ I : e n c ' ~ m ~ j , t : ' 1 I ' b f ' pour ifj,ijian'd:!lt'h,:l:! ~ i e t a l ":sha"l1' bepoured in to th'e!' to p elf t H e ' ~ m o u l ' d s : ~ ! i T t l e ' : s a h d o f ' thl,{ ITIQulds iTiay be

rammed i n to any conven ien t c o n t a i n e r l' x=:;::: ----=, .

- - - -+. - I- - - - - . - I ===r= I .. ', ----L - . J ~ . \..D"% )'Ynl'! --..-l ----L ':"':': 'j : " ,CH () 5 S S i .e T ~ A t.. ARE-A S" =- OQ;Y;l1-',''''?

F \ ~ . 7D-3.2 The t e s t i ng . procedure fo r c a r ry in9 out;'tt-fe' t e n s i Ie t e s ts ha l l be as l a i d down in IS='-1'816":"'19'61*:'"D-3.3 Should a t e s t p iece break ' ou ts : ide , themi 'dd ' t e , : , ha l f o fth e gauge l eng th , t e s t may a t the op t ion of the su p p l i e r bedi s carded and an o t he r t e s t made. '" ' , " , ;, c: :*IS: 1816- '1961':" Me t hdd fo r t ens i l e te:stf o . r : ~ /1 i:glTt.t.nle t aLs: 'an'I!l,-,l he i rCl,lloys.

" " . l . :' ..; j.: .

; ' ,- ",\ ". .'

- - ~ ~ . - - - .. - -_ .._-....-::".1'::

27


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- - - - - - - - - - - - -

APPENDIX 'E9. ':j .: ' - : ,

E-1 Chemical composit ion... . . . . . , . " . . " , , . I .E"';-1 -1 L a ~ ~ ! e ' a . J ; l a l y s L ~ .. -The ana lys is of the ' s t ee l sha l l conformto the requl rements given . in Table-8. . The methods of, chemicala n a l y s ~ s ~ h a l l be a ~ prescr ibed ,in the re levant p ~ r t o f IS:228.0I

: . :",T A B L ~ - 8 : CHEMICAL COMPOSITION- - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - ~ - - ~ - - - - - - - - - - - -. DESIGNATION . CONSTITUENT, p e ~ c ~ h t . CLASS I S : 1 7 6 2 ( P t . I ) - - - ~ ~ - - - - - - - - - - - ~ - - - - - - ~ - - - - - - - ~ ~ - - - - - - - - - - - - - --1974* Carbon Si l icon Manganese Sulphur Phosphorus

t 1 , ~ x . . Max.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - _. ~ - - - _ . _ - - - -1 14 C6 0.10 to O. '15 to 0.40 to 0.040 0.0400.18 . 0.35 0.701A -15 C8 0.10 to 0.15 to 0.60 to 0.040 0.0400.20 0.35 0.90

20 C8 0.15 to 0.15 to 0.60 to 0.040 0.0400 .25 0.35 0.902A 25 C8 0 . 20 .to 0.15 to 0.60 to 0.040 0.040.0 .30 0.35 0.90 .3 30 C8 0.25 to .0.15 to 0.60 tQ 0.040. 0.0400.35 0.35 0.903A. 35 C8 (': :', 0.30 to 0 .15 1.,0, ' o . ~ o . to 0.040 . 00400.40 0 ~ 3 5 0.90" ;" ".4 45 C8 0.40 to O. -15 to 0 ..60 to . ,Q .040 . 0.0400.50 0.35 0.90..5 55 CB 0.50. ~ o 0.15 to 0.60 t aQ , 0 40 0.0400.60. 0.35 0.906 65 C6 O. 60 O. '15 to 0.5Q ,.to O ~ ; ~ 4 0 0.0400.70,( , 0.35 0.80

- - - - - - - - - - - - - - - - - - - - - - - - ~ ~ - - - - - - - - - - - - - - - - - - - - - - - - ~ . - ;,Note(1) : When the s t ee l is aluminium ki l l ed or .k i l l ed with bothaluminium and s i l i con , the requirement of minimums i l i con content sha l l not apply. For aluminium ki l leds tee l the t o t a l aluminium content sha l l b ~ w i t h i n 0 ~ 0 2 to 0.05 percent . . j, '. .: \ , ' . ,1*IS:1762CPt.!)-1974=Code for designat ion of Stee l s - based. on thel e t t e r symbols.

iil1S:22B= "Method for chemical ana lys is of ;s t ,eel .28


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:, ;:::,.. { V ~ ! L : , ;;, Check ana lys i s : The purchaser may speci fy checkanalys i s on f in i shed f o r g i ~ g s . The number of samples on which the,3.na 1ys :i s h a s : : : " ~ t o b e ; ' ~ : a r ' r i ed:out sha l l be; at: ether-ate of one samplep er cas t per sec t ion .E-1.2 :1 The permissible devia t ion in c h ~ c ~ a n a l y s i s from the

~ ' { : e : t H ' i ' e d corrfposition li"i'nits, $'hal1', be 'a s gi'yen' berow:" ','; , . ; __ :.......:. L_ .... _.;;. ...:.. .:.. !.::. .;;...:.: ,__ ::..:.. ._., ~ C o n s t i t ' u e n t $ " "Va;"'fation' froiTt;'the ~ ' p e ~ i f ' i ~ d percent ", , , .Pmits, percent . :;l'....._.1......'.. . : ' . . ; , . _ , _ ~ ~ __ _ o . . . : . _ ~ __ ~ _ ~ ~ _ . ~ . . . ; . ; . ~ , . ~ ~ _

Carbon ;-,. I'. upto, 0.?5 , +/-6.02

ave r 0\.25 and upto +/-0.03and i ~ c l u d i n g 0.50over 0.50 + / - o ~ 04;8i l ican ' +/-:'0.03! .. 'Manganese +/ -0 .04

", , . , ' , , "" ,,' , '.Sulphur +/-0.005+/":'0.005

- - - - - - - - - - - - - - ~ - - ~ - - - - - - ~ ~ - ~ - - - - - - - ~ - ~ - - - - - - - - -Note: Varia t ions sha l l n o t b ~ a p p l i c a b l ~ ~ o t h over .. ~ n d under thes p ~ c ' i f i e d ' l i nh t s i n ' s evedd de te r lTl in 'a t ions ' in a. he-a.-t._E-1.3 Elements not spec i f i ed in table 8 sha l l not be added to the s t ee l , "except "c.ilhen ag;eed to;. ' o ther than f ,o r the purpose off in ishing the heat and"shal l not ' exceed 'the' fo l lowing:

"! I.

Canst i tuer{t ' ,; Percent,', :"'Nickel '" 0 ..30 ' Chromium 0.30"--:' .,Copper , 0.25 " Mo l'ybydenurn '< 0 ~ : 0 5 Vanadium " 0.05" ,Tin 0.05 Boron 0.0003

" ,'. r ( "; r T .....

' M ~ c h a n i ta l t e ~ t : . \ . '; ,j::-',': . ';: J; ' ...E-2.1 Tensi le t e s t s : The t e n s i l e t ~ 9 ' ~ s h a l r b e c c a r r i e d out inaccordance with 18:1608-1972*. The t e s t pieces sha l l be machined"

l e n g t h ~ w t s e ffbm!each t e ~ t ' s a m p t ~ . - T h e ~ t i n ~ i l ~ prope r t i . s sha l lconform to the requirements ~ i ~ e n , ' i n t ab le 9.*Note: See e:


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- ~ - - - - -

TABLE 9 -TENSILE PROPERTIES AND HARDNESS- " - _ . _ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - -

TENSILE YIELD ELONGATION HARDNESS NORMALIZINGCLASS STRENGTH STRENGTH PERCENT TEMPERATUREMin(MPa) Min(MPa) Min. Min. DEGREE c( a u l ~ e length (HB)5.65-ISo-1 370 200 26 '100 880-910'1A 4'10 220 25 110 880-9102 430 230 24 '120 880-9102A 460 250 22 -130 880-9103 490 270 21 140 860-8903A 540 280 20 155 850-8804 620 320 15 175 830-8605 7-10 350 13 200 8-10-8406 740 370 10 210 800-830

., -----------------------------------------------_._------------*IS:1608-1972: Methods foY t ens i le t es t ing of s t ee l pYoducts

.. /

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APPENDIX 'F '~ t r u c t u r a l St e e l =Ext rac t s from 15:2062-1992.

Chemical Composi t ion:F.1 .1 The chemical composit ion ~ h a l l be determined on th esamples of f in i shed product from the s tandard pos i t i on . Thespec i f i ed contents a re as under :

Grade Desiqna t ion LaddIe ana lys i s . Percen t , ~ . !; Mn E SiA Fe410W A 0.23 '1.5 0.050 0.050B Fe410W B 0.22 '1.5 0.045 0.045 0 .4C Fe4'10W C 0.20 1 .5 0.040 0.040 0 .4

F .2 Mechanical 1es t s :F. 2.1 Tens i l e t e s t s :F.2.-1.1 The t e n s i l e s t r eng th . y i e ld s t rength and percentageelongat ion of s t e e l s ha l l be oete rmined from s tandard t e s t piecescut l ength-wise or crosswise from p l a t e s and l engthwise froms ec t i ons , f l a t s and b a r s . The t e s t s h a l l be ca r r i ed o u t ~ _ o n s tandard t e s t pieces prepared in accordance with 18:1608-197a.F . 2 . i . 2 .As a ru le only propor t ional t e s t p i e c e ~ complying withthe requi rements Lo=5.65 ISo should be used fo r t e n s i l e t e s t .where La i s th e gauge length and 50' i s the l;:ross s e c t i ona l a reaof th e t e s t p iece .,F .2 .1 .3 The gau '3e l eng ths o the r than 5.65,;.../So may a lso be usedin which case the e longa t ions s ha l l be read from 18:3803 ( P t . 1 ) 1989 .... '#;F . 2 .1 .4 The t e n s i l e s t ren '1 th ; y ie ld s t rength a n d ; percentagee longa t ion determined in accordance with IS:1608-1972 s ha l l be asgiven in Table - i0 .F .2 .1 .5 In case of sec t ions the th i ckness of which i s no tuniform th roughout the p r o f i l e . th e l imi t s of s i zes given inTable-10 s h a l l be appl ied according to the a c t ua l maximumt h i ckness of the piece adopted fo r t e s t i ng .*15: 1608-1972 - Method fo r t e n s i l e t e ~ t i n g of s t e e l produc t s .** I5 :3803(P t .1 ) -1989 - St e e l conversion of elongat ion va lues :Carbon and lo w a l l oy s t e e l s .

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TABLE-10: MECHANICAL PROPERTIESTens i le Yie ld Elonga t ion Bend t e s t

CJrad.e> Desi9na. s t rength s t rength percent Min ( In t e rna l t ion Min. Min.MPa ( In gauge DIA) Min.(Kgf Immz' ) l ength)MPa 2 40 5.65_/50(kgf/mm ) mm mm mm

410 250 240 230A Fe4-10W A (42) (25 .5) (24 .5) (23 .5) 23 3 t 4'10 250 240 230

B Fe4-1()W B (42) (25 .5) (24 .5) (23 .5) 23 2 t fo r l e s s than or equal to 25mm t h i c kness . 3 t fo r morethan 25mlTlth i ck produc ts . ~ - " " - . '-.,.

410 250 240 230 2 t .i C Fe410W C (42) (25 .5) (24 .5) (23 .5) 23

't ' i s the th ickness of the m a t e r i a l .- - ~ - - - - - - -

F.2 .2 Bend T e s t :

F.2 .2 .1 Bend t e s t p iece :Test p ieces s ha l l be cut lengthwise or crosswise frompla tes and s t r i p s and lengthwise from s e c t i o n s ~ f l a t s and bar s . When sec t ions permi t , these s h a l l not be l ess than 40 mm wide. ,In a l l bend t e s t pieces 7 the rough edge or a r r i s re su l t i ng from shear ing may be removed by f i l l i n g or gr inding ormachining but the t e s t pieces s h a l l receive no other prepara t ion . The t e s t p ieces s ha l l no t be annea led or otherwise sub jec ted to heat t r ea tmen ts unless the mate r i a l from which these a re taken i s s imi l a r l y t r e a t e d . In such cases 7 th e t e s t pieces s ha l l bes imi l a r l y t r ea t ed in the same furnace with the mate r i a l before

. t e s t i n g .F .2 .2 .2 Bend t e s t s ha l l be conducted in accordance wi th 15:1599'1985.F.2 .2 .3 For bend t e s t , the t e s t piece a t room tempera ture sha l l withs tand bending through 180 Deg. to an i n t e r na l diameter not gre a t e r than t h a t given in Table -10 .

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--, .._-. - - - - ~ " . _ .. _ . , : ~ ; : . : . : : " - - " " - : : " : : : : - - : : : : : : : : - " - : : ...:::::::::

.::-' .... : ;, .'.. . ~ . - < . ) ";". . . ,'i . '. '. .' :. ...' . '. - ." . : :! : .,F.3 Re 1e t' e:< t'r'a'c C f r om"!S.:'160;8:"'1972:, l' , ~ , , : :,: ,:.,'

- GRi P'P.E. D,'


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TABLE-11: DIMENSIONS OF CIRCULAR SECTION TEST PIECES.


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II !

TABLE-13: TOLERANCE ON DIMENSIONS OF CIRCULAR CROSS-SECTIONTEST PIECES (Clause 5 .1 .2)(All dimensions in mm.)

.........- -. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - ~ ~ r : : : ; ' i l l ; " t rn ",t 1 Machining to lerance* Tolerancec'.irnensions on nominal dimensions on form. . . . . . . . . -.11__._--:.....--- _f.! to 6 +/- 0.06 0 ..03over" 6 to '10 +/- 0.075 0.04C"" e r '10 to 18 +/- 0.09 0.04over -18 to 30 +/- 0.105 0.05*The machining to l e rance appl i e s when i t i s des i r ed to usethe nominal c ross - sec t ion without measurement or ca l cu l a t i on ._._ ...._----------------------"':'""--------------------------------

T A B L E ~ 1 4 : TOLERANCE ON DIMENSIONS OF RECTANGULARSECTION TEST PIECES MACHINED ON TWOOPPOSITE FACES. (Clauses 5 .1 .2)(All dimensions a re in mm)

NOMINAL DIMENSION TOLERANCE ON EQBl:1 VALUES3 to 6 0.186 to 10 0.'2210 to -18 0.2718 to 30 0.3330 to 50 0.39

Note-1: Dimensions of the ends of the ~ e d u c e d sec t ion of t e s tpieces should not d i f f e r in width by more than O.imm.Note-2: For r ec tangu la r sec t ion t e 5 t pieces machined pn the fourf aces . same t o l e rances as fo r diamete r Qf c i r cu la r s ~ c ~ ~ o n t e s tpieces sha l l apply .

- - - - - - - ._. -

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' . ' "

., ' .. '


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="" --"O..,. __ -... __ ~ : , : ; ; - . , . - ; - " ~ ...__

APPENDIX - ' G 'Copper s t r i p Tor e l e c t r i c a l purposes(Ex t rac t s from 15=1897-1983)

ChemicaL Composi t ion .G.1 .1 The chemical composi t ion s h a l l be determined e i t h e r byth e method s pe c i f i e d in IS :440-64* or any o t h e r es t ab l i shedi n s t rum en ta l / chem ica l method. In case of d ispu te the procedurespec i f i ed in l a t e s t e d i t i o n of IS :440-1964*for chemical a n a l y s i ss h a l l be the r e fe rence method . The mate r i a l s h a l ; conform tograde ETP or FRHC of IS:191 ( P t . I to X)-1980.**G.2 Phys ica l Prope r t i e s .G. 2 . -1 The m a t e r i a l when t e s t ed in accordance with 18:3260-1965#given and IS :2654-1977+sha l l have thein Clause 7 .2 & 7 .3 r e sp e c t i v e l y . phys ica l proper t i e s asG.3 Bend t e s t .G.3.1 Where poss ib le . th e s t r i p s ha l l be sub jec t ed t o at r ansve r se bend t e s t made on t e s t pieces cut wi th t h e i r majoraxes a t r i gh t ang le s to the d i r e c t i on of ro l l i ng ( see F i g . 9 ) ;where t h i s i s no t poss ib le it s h a l l be sub jec t ed to along i tud ina l bend t e s t made on t e s t p ieces cut wi th t h e i r majoraxes pa r a l l e l to the d i r e c t i on of r o l l i n g . (see f i g u r e - 9 ) . Bothsu r faces of t he p iece s s ha l l be t e s t e d .

~ T r a n s . v e r s e B e r . ~ . Test spec imenLoneitud m al bend t es t .- ~ Spec :trnen J - - - : = l ) t ~ - - - ' I " " " ----.....-:1'H- ~ A x i s of bend - . / ~ - - - - - - - - - ~ ~ l r e c t l o n of ro l l ing on drawing .F l ~ . 9 - T r a n s ~ ~ r s e a n d _ ~ ~ i ~ u d 1 n ~ _ 1 __ b ~ d .. e ~ ~ " p e c 1 m e n .

G.3.2 The t e s t pieces s h a l l not crack when ben t once throughthe appropr ia te angle as s pe c i f i e d below:BEND TEST

Bend t e s tThickness Condi t ion T ran s v e r .. . !_ .Lon.9...tt ud i lJ.a 1:.Angle in rad iusdegreeUpto and Annealed (0 ) 180 Closei nc lud ing Half hard (HB) -180 t10 mm Hard (HD) 90 tt= th ickness of m a t e r i a l

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G.3 .3 The t e s t pieces s ha l l be of conventent length and thewidth s ha l l be ~ s fo l lows:

Upto and inc luding 6.0mm 15mm w h e ~ e ~ o s s i b l e , o t he r wise f u l l wid th .Over 6 .0 mm 2 ' t i m e s the t h i ckness ofmate r i a l .G.3 .4 The longer edges s ha l l be c a re fu l l y rounded andsmoothened l ong i tUd ina l ly so t ha t ~ h e c r o s 5 sec t ion hasapprox imate ly se m i - c i r c u l a r edges .G.4 Tens i l e Tes t .G.4.1 M ate r i a l of t h i ckness O.50mm and upto and inc lUding10mm s ha l l comply with the requ i remen ts of t e n s i l e t e s t given inTable-15 . M ate r i a l below O.50mm th i ck s ha l l not be sub jec t ed t e n s i l e t e s t .G.4 .2 Tes t pieces of f u l l t h i ckness of the m a t e r i ~ l with agauge length 4 IArea or 50mm s ha l l be used . The long i tud ina lax i s of the t e s t p iece s ha l l be in the d i r e c t i on of r o l l i ng .

TABLE-1S: TENSILE PROPERTIES OF STRIPUPt 0 and i n L: II I d ] Tl '] Over- :300wm upto300 mm v,'i dth ,and inc 1u d i I'll;:)

Thickness Tempe r '1000 mm ' /Jidth. ~ - ' - - - " " ' _ . _ " - ' ' ' _ . - - . - - - - ' - ~ ' - ' ' ' ' ' - ' ' - ' ' - ' - - ' ' ' ' ' - ' ' - ' ' - - - ' . - _ . _ . _ ....._..- ..... _--_ .._-Over, Upto & Tens i l e E l o n g ~ \ t i o n Tens i le Elon ')a t ionmm inc ludinlJ ~ t f " e n q t h percent on stroength p e r c . e n ~ : , on

..mm kgf/sqmm 4_iArea kqf /sqrrlfTI 1.10_1 (1 .. ' : , ~ d (Min. ) o r 50mm (Mi ~ ) 'Ja.Ul;J E'']'3.U'J e lenqthlen,]th


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G.5 E l e c t r i c a l r e s i s t i v i t y t e s t .('G.5.1 The s tandard values a t 20 C for the e l e c t r i c a l

r e s i s t i v i t y a t aDnealed high conduc t iv i ty copper sh a l l be takenas 0.01724 ohm mm/m. The e l e c t r i c a l r e s i s t i v i t y Ot s t r i p s ha l l bemeasured in accordance with IS:3635-1966*. Th e e l e c t r i c a lr e s i s t i v i t y values are given in Table-16., TABLE-16: ELECTRICAL RESISTIVITY

Re s i s t i y i t y Conduc t iv i tyCondi t ion (Ohm mm" /rrd ( pe r c en t 1'1 in . )oa t 20 C (Ma x. )- - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Annealed (0 ) 0.01737 99.25Half hard(HB) 0.01777 97.00Hard (HD) 0.01777 97.00

Note: Conduc t iv i ty percent i s expressed as percentage of thes tandard value fo r s t anda rd annealed copper of 100%conduc t iv i ty as l a id down by the In t e rn a t i o n a lE lec t r o t ech n i ca l Commission.*IS=3635 Methods of t e s t fo r re s i s t ance of meta l l i ce l e c t r i c a l re s i s t ance mater ia l

..

. 1

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'. :"

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APPENDIX 'K '., Maximum permiss ib le l eve l o f d i s c on t i nu i t yin rad iographic examinat ion . .. - - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ~ - - - - - - - - - - - - - ~ - - - ~ - - ~ - . _ ~ - - ~ ~ - - - - - - - - - - - - - - - - ~ Sl . Alloy Spec i f i ca t ion for s tndard Discon t inu i ty l eve lNo. r e fe rence rediographs . permiss ib le- - - - - - - - - - ~ - - ~ - - - - - ~ ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - _ . _ - - - - - - - - - - - - -(2 ) (3 ) (4 )

- - - - - - - - - ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - -1 A l u ~ i n i u m M a t e r i a l s pec i f i ca t i onbronze 18:3091 Genera l condi t ionscas t ings fo r rad iograph as per ASTM-272 (S t andard ) .a) S e n s i t i v i t y ofrad iographs - 21.b) IGI must be used

" in a l l cases

' ;: 'c . . Tin Mater i a l s pec i f i ca t i onbr.onze 18=306. Genera l condi t ionscas t ing fo r rad iographs s t andardas per ASTM E-310

a ) S e n s i t i v i t y ofrad iographs - 2%b) IGI must be usedin a l l cases .

a) Hot t e a r s no t pet-mi t t e d .b) Shrinkage - not permi t ted .c ) Poros i ty - pin hole poros i ty a t i so la ted l oca t ionspermi t t ed . Clus t e r s ofpinhole poros i t i e s not

permi t ted . The minimumd is tance between pinholesto be 15mm. Defec t s nearedges not accep tab le .

d) Inc lus ions Inc lus ions dueto dross and fore ignmate r i a l rounded in shapeof the s i ze not exceeding2mm a t one or two placespermi t ted .

a ) Hot t e a r s not permi t t ed .b) Shrinkage - not permi t t ed .c ) Gas holes Rounded orelongated smooth edgedd i s c o n t i n u i t i e s permi t teda t i s o l a t ed l oc a t i ons .Clus te r ing of holes not

permi t t ed . Maximum s i ze ofthe holes not to exceed1.5mm and minimum d is tancebetween 2 gas ho les . ifpresen t not to be c lose rthan 15mm. D e f ~ c t s nearedges not accep tab le .

d) Inc l us i ons - Inc l us i ons dueto dross and fore ignmate r i a l rounded in shapeof the diameter no texceeding 1.5 mm a ti s o l a t ed places permi t ted .C lus te r ing of inc lus ionsand presence of i nc lus ionsnear edges not accep tab le .

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- - - - - - - - - - - - - - - - - - - - - - - - - -

- - ... - - ....- . _ - ~ . ~ - - - - - - - _ . _ - - - ~ ~ - - - - ~ ~ - - ~ ~ - - - - - - - - - - - - - - - - - - - - - - - - - - - ..__ . _ . _ - - - ~ - - - - - - - - - _ . _ - - - - , - - ~ _ . (1) (3 ) (4)

- ~ - ~ ~ ~ - - - ~ - - - - - - - - ~ - - - - - - - ~ - - - - _ . _ - - . - - - - - - - - - - - - . _ ~ - 3 . Aluminiuma l loy M ~ t e r i a l 18:6'17 spec i f i c a t i on. a) Cracks- not ac CC! pt

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