reasoned document
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Page 1 of 13
Reasoned document
1.0 Draft STR No.TI/STR/006, Rev`04‟for 25 kV Silicone Composite Insulators have been uploaded
on RDSO website for comments/suggestions from manufacturers.
2.0 Comments received from manufacturers on clauses modified/newly added have been
tabulated below.
3.0 On STR clauses where firms have not furnished any comments, it has been
considered as Nil comment.
Clause no Name of
firm
Comment by firm RDSO’s
remark
1.0 SCOPE
This Schedulecovers the technical
requirement for manufacture and
supply of Technical Requirement
(STR) is to assess the manufacturing
capability of the vendors for new
registration/approval of Silicone
Composite Insulators for 25 kV a.c.
50 Hz electric traction. This schedule
pertains to the manufacture of
Composite Insulator by direct
mouldingof polymer sleeveover the
FRP rodand the jointing of metal
fittings with FRP rod by
crimping/threaded engagement duly
sealed by Fevicol or other suitable
sealant.and consequently injection
moulding of Silicone Rubber
Compound over the FRP rod.
This STR shall be read in conjunction
with RDSO‟s Specification No.
TI/SPC/OHE/INSCOM/1071 (with
latest amendment).
DECCAN Nil. Accepted,
Spec no shall
be mentioned
as 1072.
ABI No comments.
AESPL Nil.
Prithvi The above referred scope is agreeable
subject to notification in specification
No.TI/SPC/OHE/INSCOM/1072, as you
have already drafted a new specification.
Raychem Nil.
Adinath Nil.
2.0GENERAL INFRASTRUCTURE
&MANUFATURING FACILITIES:
The manufacturer should have full
fledged in-house testing facilities in
India and indigenous manufacturers
who have developed such in-house
facilities shall be encouraged. Beside
he must have adequate covered
accommodation for storing raw
material, finished items awaiting
dispatch and arranging inspection. The
manufacturer should have system to
ensure that the product conforms to the
requirements of
RDSO'sprototypespecificationNo.TI/S
PC/OHE/INSCOM/1070.No.TI/SPC/O
HE/INSCOM/1071 with latest
amendment.
DECCAN Nil. Accepted,
Specification
no shall be
mentioned as
1072.
ABI No comments.
AESPL Nil.
Prithvi Please refer your new specification No.
TI/SPC/OHE/INSCOM/1072
Raychem Nil.
Adinath Nil.
Page 2 of 13
2.1 MACHINERY AND PLANT.
(i) Equipment for Injection moulding
of polymer sleeve Silicone Rubber
Compound over FRP rod with
Temperature Control.
DECCAN Nil. No change.
ABI No Comments.
AESPL Nil.
Prithvi Acceptable
Raychem Nil.
Adinath Nil.
2.1 MACHINERY AND PLANT.
(ii) Assembly jigs to align the metal
fittings and seal.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable
2.1 MACHINERY AND PLANT.
(iii)Go & No Go Gauges for the overall
length of the insulator.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable
2.1 MACHINERY AND PLANT.
(iv)Measuring equipment like vernier
caliper, inside & outside caliper etc.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable
2.1 MACHINERY AND PLANT.
(v) Crimping Machine of suitable
capacity.
Deccan Nil
No change. ABI No comments.
AESPL Nil.
Prithvi Acceptable
Raychem Nil
Adinath Nil
2.1 MACHINERY AND PLANT.
(vi)Rheometer for determination of
processing parameters of Silicone
Rubber Compound.
Deccan Nil. Not accepted,
it is a
requirement as
per clause no
3.4.4 of Final
Draft
specification
No. TI/
SPC/OHE/IN
SCOM/1072.
ABI No comments.
AESPL This machine may not be required in
case of insulator manufacturer use ready
mixed rubber from approved supplier by
RDSO wherein all process/molding
parameter are pr-define by silicone
rubber supplier.
Prithvi A rheometer either in rotational or
oscillatory mode is used in a laboratory
to measure the reological properties of a
substance. The rheometer graph
highlight over three phase like
processing phase,curing phase and
physical properties phase.
The important results of processing
phase are ML(least torque) and ts1and
ts2i.e. scorch time. The time required for
the increase ofts1to ts2from minimum
torque. This number is an indicator of the
time required for the beginning of the
process of Cross Linking.
The important results of curing phase
are t10 (time corresponding to 10%),
t50(time corresponding to 50% curing),
Page 3 of 13
t90(time corresponding to 90% curing)
which is noted as optimum vulcanization
time.
The important test on physical
property phase highlights at the last part
on the reograph. MA maximum torque,
the time level of cross linking, the
quality of the rubber used, the filler used,
the compounding process.
This test is done from each batch
but not from each bale or bag is
applicable for immediate product not
final product. But in case of composite
insulator the silicone compound rubber is
a final product of the specified vendor.
They also provide the batch wise
rheometer values of the supplied batch.
So it is not meaning to have a rheometric
value of the supplied batch. So it is also
not meaningful to have a rheometer for
same testing of composite insulator
manufacturer‟s end. Our Mr. A. Sen has
already objected the same during the
meeting held at your office on dated
22.07.2016.
Raychem Nil
Adinath Nil
2.1 MACHINERY AND PLANT.
(vii) Cleaning Plant for FRP Rod and
Electric Oven with Temperature
Control.
Decan Nil. No change
ABI FRP Rod shall be free from dust and
other foreign particles. Electric oven for
preheating the rod.
AESPL Nil.
Prithvi Acceptable
Raychem Nil
Adinath Nil
2.2
The manufacturer shall procure FRP
rod from a reputed firm, according to
the specification made by him suitable
to the requirements of RDSO's
specification. The manufacturer shall
ensure the quality of the FRP rod
supplied by his vendor.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable
2.3
The manufacturer shall procure the
polymer Silicone Rubber compound
from a reputed firm whose product
shall meet the requirement of the
RDSO's specification &should furnish
the product data sheet, if railways ask
for the same. The manufacturer shall
ensure the quality of polymer Silicone
Rubber Compound supplied by his
vendor.
DECCAN Nil. No change.
ABI No Comments.
AESPL Nil.
Prithvi Acceptable.
Raychem Nil.
Adinath Nil
Page 4 of 13
2.4
The manufacturer shall ensure that his
vendors for supply of FRP rod,
polymer sleeve Silicone Rubber
Compound and metal fittings shall
render proper after sales service and
attend to the complaints, if any by
Railways, immediately and-implement
remedial action.
DECCAN The manufacturer shall ensure for supply
of FRP rod, Silicone Rubber Compound
and metal fittings shall render proper
after sales service and attend to the
complaints, if any by Railways
immediately and implement remedial
action.
No change.
ABI No Comments.
AESPL Nil.
Prithvi Acceptable .
Raychem Nil.
Adinath Nil
3.0.TESTING FACILITIES
(i)High voltage transformer set up to
suit the requirements of the
specification.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(ii)Equipment to conduct sudden load
release test at -20°C to -25°.
a) Arrangements shown in Fig
B-1 of IEC: 61109 may be
adopted with suitable device
for test to be conducted at -
20° C to - 25° C.
b) The equipment for Thermal
mechanical test may be suitably
modified and used.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi
Acceptable.
3.0.TESTING FACILITIES
(iii)Equipment for Thermal
mechanical test.
Deccan
AESPL
ABI
Adinath
Nil. Not
acceptable.
Thermo-Mechanical test have been specified as per IEC-61109-2008 and parameters have been defined accordingly.
Raychem
Thermal mechanical test set up with
both tensile loading as per IEC 61109
& cantilever loading as per IEC 61952
& IEC 62231. This change is required
because stay arm & bracket Insulators
are having cantilever loading (bending
load) so design & type test needs to be
conducted with Maximum designed
Cantilever Load (MDCL) as defined in
standard IEC 62231 & IEC 61952.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(iv)UTM machine with facility for
conducting tensile and bending test or
separate machine with facility for
conducting tensile load test and
bending
test can also be provided.This should
be equipped with PLC control
interface.
DECCAN Nil. No change
ABI No Comments.
AESPL Nil
Prithvi Acceptable.
Raychem Nil.
Adinath Nil.
Page 5 of 13
3.0.TESTING FACILITIES
(v)Test set up for test on control of the
slope of the strength - time curve of
the insulator.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(vi)Test set up for inclined plane
tracking and erosion test as per IEC:
60587.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(vii)Test set up for water immersion
test.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(viii)Test set up for dye penetration test
of the core material (FRP rod).
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(ix)Test set up for water diffusion test
of core material (FRP rod) in
line with
Figure 2.3 and 4 of IEC: 61109.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(x)Test set up for water absorption test
of FRP rod.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(xi)Test set up to conduct galvanization
test on the metal fittings.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(xii)Tensile testing machine for
testing of tensile strength and
elongation ofPolymerSilicone
Rubber compound.
DECCAN Nil. No change
ABI No Comments.
AESPL Nil.
Prithvi Acceptable to us.
Raychem Nil.
Adinath Nil.
3.0.TESTING FACILITIES
(xiii)Facility for conducting Tear
Strength.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
Page 6 of 13
3.0.TESTING FACILITIES
(xiv)Test equipment for measurement
of Hardness (Shore A & Barcol).
DECCAN Nil. No change.
ABI For Barcol-Hardness test report will be
accepted from supplier who is having the
facility of Barcol equipment.
AESPL Nil.
Prithvi Acceptable to us.
Raychem Nil.
Adinath Nil.
3.0.TESTING FACILITIES
(xv)Test equipments for conducting
tests for DC Volume resistivity and
Dielectric strength.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(xvi)Facility for conducting test for
specific gravity.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(xvii)Test equipment for testing
resistance to weathering & UV as
per ASTM G 53.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(xviii)Facility for conducting glass
content test on FRP rod.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(xix)Facility and arrangement for
conducting "Brittle fracture resistance
test”.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
3.0.TESTING FACILITIES
(xx)NDT Testing equipment to test
the bonding of rubber.
DECCAN Nil. Not accepted.
However, type
of NDT
testing shall
be specified as
per
specification.
i.e Ultrasonic,
radiography
etc.
ABI No Comments.
AESPL As this equipment may not be full proof
to ensure the perfect bonding throughout
length of insulator, hence this test set-up
should not be mandatory as peel off test
is already incorporated.
Prithvi
Regarding SN.(xx), kindly note our
following representation:
NDT (Non Destructive Testing) methods
are based on Acoustics Emission Testing
(AE), Electromagnetic Testing (ET),
Guided Wave Testing (GW), Ground
penetration Radar (GPR), Laser Testing
Method (LM) etc. if bonding is to be
cheeked here should not be „SQC‟
Page 7 of 13
system or checking of 100 % element is
not possible for total production, as peel
off strength checking system for
checking of silicone polymer to glass rod
bonding on „SQC‟ basis has already been
proposed by yourself, so for same testing
on „SQC‟ basis NDT is not required
rather irrevalent. This type of testing is
required for 220 kV or above
transmission insulators. Introduction of
this kind of odd non required testing will
help to shortlist the present vendors
which will help to create monopolistic
business for few vendors. Our Mr. A.Sen
objected in the joint meeting at RDSO
dated 22.07.2016 for such type of odd
implementation. Peel off test is also
sufficient to check bonding between the
silicone compound and FRP glass rod.
Raychem Nil.
Adinath Under clause no.3.0 of Testing Facilities
point no.XX, your goodself has proposed
for NDT Testing equipment to test the
bonding of rubber.
In respect to above proposed
machine we would like to request you to
please clarify the need to introduce the
same machine and also the exact type of
equipment to be arranged and the
procedure of testing the sample for the
required property. Also please provide us
the testing standard
viz.ASTM/IS/BIS/IEC etc whichever is
applicable for the same. Because from
the above description we are unable to
understand the exact type equipment
required and the testing procedure to be
followed.
3.0.TESTING FACILITIES
(xxi)Test set up for testing of
Eccentric Loading Test (for
Sectioning Insulator manufacturer).
DECCAN Nil. No change.
ABI No Comments.
AESPL Nil.
prithvi Not acceptable for us.
Raychem Nil.
Adinath Nil.
3.0.TESTING FACILITIES
(xxii)Test set up for Torsion Test (for
Post Insulator manufacturer).
DECCAN Nil. No change
ABI No Comments.
AESPL Nil.
prithvi Not acceptable for us.
Raychem Nil.
Adinath Nil.
Page 8 of 13
3.1 OTHER REQUIREMENT
&TESTING FACILITIES:
i. The manufacturer should have
minimum 3 years experience in the
manufacture and supply of line
Insulators at least 66 kV and above.
DECCAN Other Requirement & Testing
Facilities:
i) The manufacturer should have
minimum 5 years experience in the
manufacture and supply of line
Insulators at least 66 kV and above.
ii) The Manufacturer should have a field
service performance of 5000 Nos of
Insulators of at least 66 kV and above for
a period of 3 years.
iii) The Firm should have a minimum
turnover of Rs.50 crores in the last 2
years.
Partially
accepted.
The paragraph
shall be
replaced by
following:
“The
manufacturer
should have
manufactured
and supplied
Insulators of
rating 25 kV
and above to
different
utilities.
ABI No Comments.
AESPL As the product rating of railways
composite insulators are 25 kV, hence
manufacture should have experience of
at least 36kV composite insulators
manufacturing. In case of specified
higher rating, there will possibility of
monopoly of only few insulators
manufacture.
However, This will be not applicable, in
case of manufacture is already approved
& supplying insulator to Indian
Railways.
Prithvi a)it should not be applicable because
considering all required parameter
registration has been provided to all
existing units.
b) The required load of Railways is 25
kV, hence, the experience if at all
required should be 33 kV only instead of
66 kV and above.
Raychem 1. Indian railways system works on 25
kV AC , hence experience of 66 kV and
above for 3 years is not relevant to this
requirement. This will restrict good
vendors already supplying to global
railways from long time.
2. Experience requirement should be as
follows " The manufacturer should have
minimum 3 years of experience in
manufacturing and supply of 25 kV &
above insulators to global
railways/utilities.
Adinath Under clause no.3.1 of Testing Facilities
point I, your goodself has proposed that
the manufacture should have minimum 3
years experience in the manufacture and
supply of the line insulators at least 66
kV and above.
In respect to above proposed clause,
we are unable to understand why the
same has been proposed with the
Page 9 of 13
condition for minimum 3 years
experience in manufacture and supply of
line insulators of 66 kV and above,
whereas the Railway insulators are of 25
kV rating only and any firm approved by
RDSO for the same is thoroughly
assessed for all type of quality and
infrastructure requirements as per
specified specification of RDSO and all
the required type tests,, design tests and
acceptance tests are performed on the
insulators by RDSO itself or by NABL
approved laboratory before the final
approval is granted to any new
manufacturer. Also above all this the
new manufacturer is approved as a part-
II supplier for the initial period with a
requirement to complete and supply the
minimum required quantity and
completion of minimum period before
upgrading the firm to part-I category and
this practice is followed only because the
new approved manufacturer can gain
some experience before being upgraded
as a regular pat-I supplier.
In view of above we would like to
submit that the same clause should not
be included in the STR requirements as
the same will not support with respect to
quality improvement which is the sole
aim for revision of STR in order to
enhance the quality of the product
whereas introduction of such a clause
will restrict the number of new entrants
to almost nil and will also even reduce
the number of approved manufacturers
from the list of approved vendors from
your list as because most of the present
manufacturers will also not be able to
meet this requirement of 3 years
experience in 66 kV insulators.
Please note that such action will not at
all enhance the quality requirement
whereas it will lead to minimum
manufactures in approval list and the
same will lead to monopolistic approach
and thereby offering of very high prices
in the tenders invited by railways and
will result in high financial loses due to
same.
Also as per speech dated
16.01.2016 of our Honorable Prime
Minister Shri Narender Modi (scanned
copy attached) it is proposed to
encourage the new Start-Up companies
to participate in the growth of our
Page 10 of 13
country.
We would request you to call for a
vendor meet in your office at RDSO to
discuss all the related points in relation
to STR and Specification before
finalizing anything.
3.1 OTHER REQUIREMENT
&TESTING FACILITIES:
ii. The manufacturer should have in-
house facility for designing of the
Insulator with adequate R & D
facility. To meet this requirement
manufacturer should have Design
software e.g. Auto CAD or any other
suitable 2D or 3D modeling etc. and
Electric Field modeling software e.g.
Electron-2D or any other suitable
software to validate design of
insulator.
Deccan Nil. Partially
accepted.
The para 3.1
(ii) shall be
replaced by
the
following:
“The
manufacturer
should have
in-house
facility for
designing of
the Insulator
with adequate
R & D
facility. To
meet this
requirement
manufacturer
should have
Design
software e.g.
Auto CAD or
any other
suitable 2D
or 3D
modeling etc.
and
Manufacturer
should also
have Electric
Field
modeling
software
e.g.Electron-
2D or any other suitable
software to
validate
design of
insulator
(alternatively
firm may out
source Electric Field
modeling to
NABL/NAB
CB
lab/agency).
ABI Electric field modeling software cost is
very high. Hence design validation can
be done at ERDA/CPRI where the
facility is available. Request you to
consider the suggestion.
AESPL Although the manufacturer should have
Auto CAD software for drafting the
design drawing but another software for
Electric Field modeling is not required as
all the design data of insulator i.e.
technical data, overall dimensions of
insulators has already been specified in
the RDSO specification.
prithvi Acceptable for us.
Raychem Nil.
Adinath Nil.
Page 11 of 13
4.1
The firm should have acquired ISO
9001:2000 2008 series certification for
the product for which an approval is
sought and the product should be
broadly covered in the scope of the
certification for manufacture and
supply.
DECCAN Nil. 2008 changed
to 2015. ABI No Comments.
AESPL Nil.
prithvi Acceptable.
Raychem Nil.
Adinath Ni.
4.2
Quality manual of the firm for ISO
9001:2000 2008 should clearly indicate
at any stage the control over
manufacturing and testing of the said
product.
DECCAN Nil. 2008 changed
to 2015. ABI No Comments.
AESPL Nil.
prithvi Acceptable.
Raychem Nil.
Adinath Ni.
4.3
There exists a system of easy
traceability of the product item at
supply by
vendor stage and finished product
stage.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
4.4.
a. The Quality Assurance Plan (QAP)
should be prepared as per RDSO‟s
guideline and approved by RDSO.
DECCAN Nil. No change.
ABI No Comments.
AESPL Nil.
prithvi Acceptable.
Raychem Nil.
Adinath Ni.
4.4.
b. The Firm should have an approved
copy of the product for
implementation.
DECCAN Nil. Word product
shall be
replaced
by”QAP”.
ABI No Comments.
AESPL Nil.
prithvi Acceptable.
Raychem Nil.
Adinath Ni.
4.5
The assembly of the insulator shall be
done by well trained staff under the
supervision of qualified staff with
experience in the field.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi Acceptable.
4.6
Quality manual of the firm indicating
the extent of control over production
and testing should be available.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi
Acceptable.
Page 12 of 13
4.7
System should exist for documentation
of the following:
a. Incoming raw material with TC
reference of supplier as well as
internal
test and audit checking from
outside agency & product data
sheet,
wherever required.
b. Ensure that the details regarding
stage inspection and
test result are available.
c. Ensure that a system exists for
calibration of testing
&measuring equipment and record is
maintained.
Deccan
AESPL
ABI
Raychem
Adinath
Nil. No change.
Prithvi
Acceptable.
4.8 System should exist for
documentation of the
following:
Deccan
AESPL
Prithvi
ABI
Raychem
Adinath
Nil. No change.
Other Points
Addition. Deccan In Testing facilities the following test
equipments to be included:
i)Water boiling equipment.
ii)Impulse Generator
Since all the equipment for conducting
Test on Interfaces and connections of
end fittings as per CL.10 of IEC 61109
are made available with the
manufacturer this test set up is also to be
included with the manufacturer.
The minimum
M & P and
testing
facilities
required for
manufacturing
Composite
Insulators have
been specified
in this STR.
To not incorporate. Prithvi Considering our above cited comments,
we request you to take a note of our
representation and not incorporate the
following items in the rectified STR:
1.Rheometer.
2.NDT testing equipment
3.Experience in manufacture and supply
of insulator at least 66 kV and above.
Covered in
clause no. 2.1
(vi), 3.0 (xx) &
3.1 (i)
respectively.
Addition Raychem
Test setup for the verification of the
maximum design cantilever load
(MDCL) as per IEC 61952, This test
setup is required because stay arm &
bracket insulators are loaded with
cantilever load in actual application &
defining MDCL load is must for these
insulators
Not accepted.
Tests have been specified as per IEC-61109-2008 and parameters /test methods have been defined accordingly.
Page 13 of 13
Raychem
Raychem
Raychem
Raychem
Addition Surface roughness (Ra, Ry & Rz)
measuring equipment. (This is requried to check the inner bore
surface rougness of end fittings used in
insulators. Surface roughess
measurement is important as without
this there will not be consistency in
crimping with other parameters like
crimping pressure kept same. There is
also chance of FRP rod crack due to
sharp surface inside bore of Insulator, It
is practically impossible to get
consistent quality &mechanical
parameters without control on surface
roughness)
The minimum
M & P and
testing
facilities
required for
manufacturing
Composite
Insulators have
been specified
in this STR.
however
manufacturers
may have
additional
facilities.
These parameters shall be specified by manufacturers in their QAP along with acceptance criteria.
Addition Brinnel Hardness testing equpment
for End fittings. (This is required to
check the hardness of end fitting for
each lot. The hardness varies for each lot
& crimping pressure parameter depends
on hardness factor so it is very important
to know the batch hardness
These parameters shall be specified by manufacturers in their QAP along with acceptance criteria.
Addition Reference standard should also
include IEC 62217, 61952 and 62231 as it gives direct reference to test clause
with MDCL values
IEC-61109
have been
specified for
composite
Insulators.
Other relevant
IECs are
referred in the
same.
Addition HV test setup for 100% routine testing
of FRP rod leakage current
measurement at pre stressed Voltage of
@ 175 V/mm length of FRP rod. The
setup should have least count of 0.01
mA & and with stray capacitive leakage
suppression.
These parameters shall be specified by manufacturers in their QAP along with acceptance criteria.
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