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DOC: STI/398(Pt.

5)/2
July 1995
SCHEME OF TESTING AND INSPECTION
FOR CERTIFICATION OF
ALUMINIUM CONDUCTORS GALVANIZED STEEL REINFORCED FOR
EXTRA HIGH VOLTAGE (400 KV and ABOVE)
ACCORDING TO IS 398(Pt. 5):1992
1. LABORATORY -A laboratory shall be maintained which shall be suitably equipped
and staffed where tests shall be carried out in accordance with the methods given in
the specification.
1.1 All the testing apparatus shall be checked periodically and records of such checks
shall be maintained.
1.2 Instruments used in the testing and inspection of conductor shall be calibrated at
periodicity of not more than one year.
2. TEST RECORDS -All records of tests and inspection shall be kept in suitable forms
approved by the Bureau of Indian Standards..
2.1 Copies of any records or charts that may be required by the Bureau shall be made
available at any time on request.
2.2 QUALITY CONTROL It is recommended that, as far as possible, statistical
quality control (SQC) methods may be used for controlling the quality during
production as envisaged in this Scheme [(See IS:397 (Part I)-1972 and (Part II)-1985
and IS :397 (Part III )-1980].
2.3 In addition, effort shall be made to gradually introduce a Quality Management
System in accordance with Quality System Models as per IS/ISO 9001 or IS/ISO 9002
or IS/ISO 9003 as appropriate to the activities of the organization.
3. STANDARD MARK The standard mark (s) as given in column (1) of the First
Schedule of the licence shall be marked on label attached to each coil of conductor and
on each drum on which conductor is coiled, provided always that the conductor to
which this mark is, applied conforms to every requirement of the specification.

4. MARKING - In addition each drum shall have the following information marked on
it along with other essential data:
a)
b)
c)
d)
e)
f)
g)
h)

Contract/specification number;
Name and address of the consignee;
Indication of the source of manufacture;
Drum number;
Size of the conductor;
Length of the conductor;
Gross weight of the drum with protective lagging including conductor;
Weight of empty drum with protective lagging;

j)
k)
m)

Net weight of the conductor;


Arrow marking for unwinding; and
Position of the conductor end.

4.1 The Standard mark shall be applied in such a manner that, as far as possible, the
drums do not retain the Standard Mark intact after opening up, as otherwise these might
be fraudulently used by any person so as to deceive that his product coiled on the drums
carried the Standard Mark and thus conforms to the specification.
5. PACKING The conductor/shall be wound on non-returnable drums conforming to
IS:1778-1980 strong enough and provided with lagging of adequate strength, constructed
to protect the conductor against all damages and displacements during transit, storage and
subsequent handling and straining operations in the field, Only one conductor length shall
be packed on each drum.
5.1 Standard Length- Unless otherwise agreed to between the purchaser and the
manufacturer, galvanized steel reinforced aluminium conductors shall be supplied in the
lengths from 1.2 to 1.5 km.
5.2 Random Length Unless otherwise agreed to between the purchaser and the supplier,
it shall be permissible to supply not more than 5 percent of the length on any one order in
random lengths; none of them shall be shorter than one half of the nominal length.
6. LEVELS OF CONTROL The tests as indicated in Table I and at the levels of
control specified therein, shall be carried out on the whole production of the factory
covered by this scheme and appropriate records maintained in accordance with Para 2
above. All the production which conforms to the Indian Standard and covered by this
licence shall be marked with Standard Mark.
6.1 On the basis of test and inspection results, decision regarding conformity or otherwise
of the lot as a whole with the requirements of the specification shall be made as follows:
6.1.1 Each of the samples taken for tests shall satisfy the requirements of the specification
for acceptance of the lot.
7. In respect of all other clauses of the specification and at all stages of the manufacture,
the factory shall maintain appropriate controls and checks to ensure that their product
conform to the various requirements of the specification
8. REJECTIONS A separate record shall be maintained giving information relating to
the rejections to conductors not conforming to the requirement of the specification and
the method their disposal. Such conductors shall not, in any case, be stored together with
those conforming to the specification.
9. SAMPLES The licensee shall supply, free of charge the sample(s) required in
accordance with regulation of the Bureau of Indian standard, from his factory or godown.
The Bureau shall pay for the samples taken by it from open market.
10. REPLACMENT Whenever a compliant is received soon after the goods with
certification mark of the Bureau have been purchased and used, and if there is adequate
evidence that the goods have not been misused, defective goods or their components shall
be replaced or repaired free of cost by the licensee in case the compliant is proved to be

genuine and the warranty period (where applicable) has not expired. The final authority
to judge the conformity of the product to the Indian Standard shall be with the Bureau.
11. STOP MARKING The marking of the product shall be stopped under intimation
to the BIS if, at any time, there is some difficulty in maintaining the conformity of the
product to the specification, or the testing equipment goes out of order. The marking may
be resumed as soon as the defects are removed under intimation to BIS.
The marking of the product shall be stopped immediately if directed to do so by BIS
for any reason. The marking may then be resumed only after permission by BIS. The
information regarding resumption of marking shall also be sent to BIS.
12. PRODUCTION DATA The licensee shall send to BIS as per the enclosed
proforma a statement of the quantity produced, marked and exported by him and the trade
value thereof during the half-year ending 30 June and 31 December. This statement is
required to be forwarded to BIS on or before the 31st day of July and January for the
preceding
half-year.

DOC:STI/398(Pt. 5)/2
July 1995
IS 398(Pt 5):1992
GALVANISED STEEL REINFORCED ALUMINIUM CONDUCTORS
FOR EXTRA HIGH VOLTAGE (400 KV AND ABOVE)
TABLE 1 OF LEVELS OF CONTROL
(Para 6 of the Scheme of Testing and Inspection)
CLAUSE

TEST DETAILS

TEST METHOD
CLAUSE
REFERANCE

REQUIREMENTS
ALUMINIUM WIRE
7
8.1 and
13.1.2

Freedom from defects


Diameter

7
8.1

IS:398(Pt 5)-1992
-do-

1
1

-do-do-do-

1
1
1

13.1.2
Breaking load
13.1.2
Wrapping test
13.1.2
Resistance
STEEL WIRE

13.5.2
13.7.1
13.8

6.2

6.2

-do-& IS:209-79

7
Freedom from defects
8.1& 13.1.2 Diameter

7
8.1

IS 398(Pt 5)
-do-

13.1.2
13.1.2

13.5.2
13.6.1&13.

Purity of zinc

Breaking load
Ductility test

LEVEL OF CONTROL
NO. OF
FREQUENCY
SAMPLES

-do-do-

1
1
1

Each Wire
Every bobbin of
aluminium wire
drawn

REMARKS

1) If any sample fails in


respect
of any requirement, two
more samples
from the same bobbin/
coil shall be tested for
that requirement and if
there is any further
failure
in retesting the
bobbin/coil
shall be rejected

-do-do-do-

Each
consignment

Each Wire
Each coil of
steel wire
-do-do-

2) If the consignment of zinc


is accompanied by a test
certificate,
further testing may not be
required.
3) If the galvanized steel
wire is ISI
marked,
further testing may not be
done.

6.2

DOC: STI/398(Pt. 5)/2


July 1995
IS 398(Pt 5):1992
GALVANISED STEEL REINFORCED ALUMINIUM CONDUCTORS
FOR EXTRA HIGH VOLTAGE (400 KV AND ABOVE)
TABLE 1 OF LEVELS OF CONTROL
(Para 6 of the Scheme of Testing and Inspection)

CLAUS
E
13.1.2
13.1.2

TEST DETAILS

TEST METHOD
CLAUSE REFERANCE

REQUIREMENTS
Wrapping test
13.7.2
Galvanizing
13.9

-do-do-&
IS 4826:79

STRANDING
10.2&
Lay Ratio
13.1.2

13.4

IS:398(P5)

10..3

13.4

-do-

9.1 & 9.2

-do-

9.

Ratio of nominal
dia. of Al to Steel
Wire
Joint in Wires

LEVEL OF CONTROL
NO. OF
FREQUENCY
SAMPLES
1
-do1
-do-

Each length of
Stranded
conductor
-do-

Each length

REMARKS

DOC:STI/398(Pt. 5)/2
July 1995

IS 398(Pt 5):1992
GALVANISED STEEL REINFORCED ALUMINIUM CONDUCTORS
FOR EXTRA HIGH VOLTAGE (400 KV AND ABOVE)
TABLE 1 OF LEVELS OF CONTROL
(Para 6 of the Scheme of Testing and Inspection)

CLAUS
E

TEST DETAILS
REQUIREMENTS

TEST METHOD
CLAUSE
REFERANC
E

LEVEL OF CONTROL
NO. OF SAMPLES FREQUENC
Y

COMPLETED CONDUCTOR
13.1.1
13.1.1
13.1.1
13.1.1
13.1.1

Visual Examination
Breaking load test
Surface condition
test
Corona test
Radio Interference
voltage test

13.2
13.5.1
13.10

-do-do-do-

1
1
1

13.11
13.12

-do-do-

1
1

Each size

Once in a year

REMARKS