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TECHNICAL SPECIFICATION
OF
April -2015
CONTENTS
S. No.
PARTICULARS
Bill of quantity of 66kV transmission line in Faridabad area with tower and
1200mm2 XLPE cable portion under REC-140 scheme
Page No.
1-72
1-8
1-14
1-6
1-15
1-15
1-5
Hardware Fittings for lines with ACSR Zebra and Accessories for lines
with ACSR Zebra
1-16
1-14
10
1-12
11
1-28
12
1-12
13
1-19
14
Annexure-1
1-14
15
Annexure-2
1-145
16
Annexure-3
1-9
SECTION VI (PART-II)
TECHNICAL SPECIFICATION
CONTENTS
SECTION-VI
(PART-II)
CHAPTER-I
TECHNICAL SPECIFICATION
CONTENTS
Clause No.
Description
Page No.
1.1
1.2
1.3
1.4
1.5
RESULTS OF SURVEYS
ACCESS TO THE LINE AND RIGHT OF WAY
DETAILED SURVEY, OPTIMISATION OF TOWER 4
LOCATION
1.6
1.7
1.8
1.9
1.10
2.0
ENVIRONMENTAL CONDITIONS
9
TECHNICAL DATA
STATUTORY REGULATIONS AN STANDARDS 9
QUALITY ASSURANCE, INSPECION AN TESTING
TECHNICAL PARAMETERS OF 220 KV LINE
DETAIL OF LINE MATERIAL FOR 220 KV LIEN
12
2.1
12
2.2
13
4
4
9
10
11
13
2.4
14
EARTHWIRE
3.0
TRANSMISSION TOWERS
14
3.1
14
3.2
TYPE OF TOWER
14
3.3
3.4
MAXIMUM TENSION
18
3.5
MATERIALS
18
3.6
TOWER ACCESSORIES
20
16
3.7
TOWR FABRICALTION
21
3.8
GALVANISING
23
3.9
EARTHING
23
3.10
3.11
TESTINGS OF TOWERS
3.12
STANDARDS
4.0
TOWER FOUNDATION
33
4.3
TYPEOF SOIL
33
4.4
FOUNDATION TYPES
34
4.6
34
4.7
36
4.8
36
4.9
SETTING OF STUBS
37
4.10
37
4.11
38
CONCRETE
24
28
28
4.12
38
4.14
39
5.0
41
GENERAL
41
5.2
41
5.3
ASSEMBLY
42
5.4
42
5.5
INSULATOR HOISTING
42
5.6
5.7
5.8
JOINTING
5.9
SAGGING-IN-OPERATION
5.10
44
44
44
AND EARTHWIRE
5.11
CLIPPING IN
5.12
45
46
ACCESSORIES
5.13
REPLACEMENT
46
5.14
46
MATERIALS
5.15
6.1
6.2
ENGINEERING DATA
47
6.3
DRAWINGS
47
6.4
DESIGN IMPROVEMENTS
6.5
DESIGN COORDINATION
6.6
6.7
PACKING
50
7.1
ERECTION CONDITIONS
50
7.2
49
50
50
50
7.3
51
7.4
PROGRESS REPORT
51
7.5
51
7.6
FIRE PROTECTION
7.7
SECURITY
7.8
52
7.9
CONSTRUCTION MANAGEMENT
53
7.10
53
7.11
51
52
53
BIDDERS LIABILITY
7.12
54
7.13
54
7.14
FOREIGN PERSONNEL
56
7.15
CODE REQUIREMENTS
57
1.1.2
This specification also covers fabrication and supply of Gantry structures as per HVPNL
design for undercrossing the various existing 220/66/132 kV/400kV transmission lines
including supply of bolts, nuts and washers, hanger, D-shackle and all type of accessories
like phase plate, circuit plate, number plate, danger plate, etc. selecting type of foundation,
casting of foundation for gantry footing as per HVPNL design, erection of gantries, tack
welding of bolts and nuts including supply and application of zinc rich paint, gantry earthing,
fixing of insulator string, stringing of conductors and earthwire alongwith all necessary line
accessories. All the clauses in the specification will be relevant for the gantry structures also
unless stated otherwise.
1.1.3
This specification includes the supply of conductor and earthwire, Silicone Rubber Polymer
Insulators / anti fog insulator strings and their hardwares, earthwire suspension and tension
clamps and all other line accessories for conductor & earthwire i.e. mid-span compression
joints for conductor and earthwire, repair sleeve for conductor, vibration damper for
conductor and earthwire, flexible copper bond, Bus post Insulators which shall be supplied
by the Bidder during execution of the project. The Bidder shall clearly indicate in the offer
the sources from where he proposes to procure the raw materials and the components.
1.1.4
The supply & connectivity of OPGW (24F / 48F, as applicable), OFAC & FODP, as required
as per site condition for making connectivity of OPGW of existing /proposed 220kV line shall
be got done as per requirement of SLDC wing of HVPNL. The related clauses of Technical
specification of OPGW is to referred (Annexure-2). It is specifically in the scope of
successful bidder that the supervision of stringing and end to end testing of OPGW shall be
got carried out with the help of OPGW supplier with all means at successful bidders end.
1.1.5
The supply and laying of 66kV 1200mm2 XLPE aluminium cable as per design is in scope
of bidder.
1.1.6
All the raw materials such as steel, zinc for galvanizing, aggregates, reinforcement steel
and cement for tower foundation, coke and salt for tower earthing etc. bolts, nuts, washers,
D-shackles, hangers, links, danger plates, phase plate, number plate, circuit plate, anti
climbing devices etc, required for tower manufacture and erection shall be included in the
Bidders scope of supply, Bidder shall clearly indicate in the offer, the sources from where
he proposes to procure the raw material and the components.
Page-1
1.1.7
The entire stringing work of conductor and earthwire shall be carried out by standard
stringing practice. The Bidder shall indicate in the offer, the detail description of the
procedure to be deployed for stringing operation.
1.1.8
The following 220/66 kV transmission lines are included in the scope of the Bidder for REC140 :-
Sr.
No.
Name of line
Tentative Length of
line in km
2.31
LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV 2.465x8
S/Stn.A4 at 66kv S/Stn.Idgah with 1200mm2 XPLE underground
cable
2.4x8
Creation of LILO of both circuit of the existing 220kV D/C FGPPBBMB Samaypur (PGCIL line) at 220kV S/Stn. Sector-58,
Faridabad on M/C towers, M/C Monopole to be newly designed and
D/C towers
66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV D/C length =13.55km)
S/Stn.Bhagola with 0.4sq ACSR Zebra. (Tower portion and Cable
portion)
66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 4.895 km
0.4sq ACSR Zebra (Tower portion and cable portion).
in all respect for safe, efficient, reliable and trouble free operation shall be deemed to supplied and
erected by the Bidder.
a)
The scope of the supply and installation of plant and equipment project shall include, but not
limited to the following works:
1. Engineering services,
2. Manufacturing, testing, supply of tower and line goods.
3. Transporting of all materials, equipment to the related Site(s), storage and equipment preservation at
related Site including all services to be required at customs (i.e. unloading, loading, storing at customs
stores and other services at customs). Remark that Bidder shall hire a suitable storing area which shall be
approved by the HVPNL.
Page-2
Supervision (i.e. Engineer(s) shall be fully responsible at each Site during the overall job until
commissioning). The Bidder shall identify his supervisors with curriculum vitae, fifteen (15)
days after the signing of the Contract and supervisors shall not be substituted without the
written consent of the HVPNL i.e.
b)
c)
for
the
d)
i) Training
specifications
if
mentioned
in
iii) For the Goods which shall be supplied by HVPNL, if any, (in according to the Appendix7 of Contract Agreement), transportation, civil works, erection and Site testing shall be
done by the Bidder.
Connection between substations and dead-end towers, shall be done by the Bidder if the
substations do exist.
All the works, Goods and services, though not expressly called for in these Specifications, but
necessary for complete and proper operation of the Supplied Goods and of the transmission
line, are considered to be included within the scope of the project.
The provisions under this Section are indented to supplement general requirements for the
equipment, material, works and services covered under other Sections of these bidding
documents and are not exclusive. However, in case of conflict between the requirements
specified in this Section part 1 and requirements specified under other Sections, more
stringent requirements specified under Sections shall prevail.
iv) The technical specification of the work for construction of 66kv lines with 1200mm 2 Aluminum
XLPE underground cable is attached.
1.1.8 It is specifically mentioned that the contractor shall be responsible to provide all necessary
testing and commissioning personnel, tools and plant, testing equipment, etc. All expenses for
carrying out the routine tests as specified in relevant standard shall be to contractors account.
However the expenses w.r.t. purchaser/purchasers representative for witnessing these tests
which contractor shall take into account shall be as follows:-
a) For Inspections/tests to be carried out for equipment offered from within purchasers country, all
tour expenses shall be borne by purchaser.
Page-3
b) For inspections/tests to be carried out for equipment offered from outside purchasers country:It is envisaged that inspection/testing of all such equipment shall be witnessed. Each inspection
shall be carried out by a team of 2 engineers nominated by the purchaser. Their To & Fro travel
expenditure from purchasers country to the place of inspection/testing shall be borne by the
bidder including all boarding and lodging charges.
1.1.9
LOCATION DETAILS:
The above line will be laid in the state of Haryana.
The contractor shall have to erect the
220 kV & 66kV transmission lines completely up to terminal arrangements.
1.2
The transmission lines under this package will be running almost through congested Urban/
Industrial/plain /irrigated farm land/cultivated area.
Tentative route survey of transmission lines covered under these package indicating the
general topography and major crossings like river, power lines, Railways line & Roads are
enclosed with this specification for Bidders reference. There are few small
rivers/distributes/Nalas, small hills etc. to be crossed by the line in the above package.
However these rivers/Nalas etc are envisaged to be crossed by normal towers or
strengthened normal tower to suit specific locations.
1.3
Result of surveys
The details collected through preliminary surveys viz line route, general soil characteristics,
crossings, accessibility and infra-structure details are attached at Annexure-IB for the
Bidders reference.
1.4
1.5
1.5.1
The HVPNL has carried out the tentative survey of transmission lines under this package.
However, detailed survey including profiling, tower optimization and spotting shall be carried
out by the successful Bidder as stipulated herein.
The Bidder shall finalize complete detailed surveys including any changes and will submit
the route plans within 2 months (60 days) of issue of LoI. The soil investigation for the
obligatory points shall be carried out by the successful bidder.
The Bidder is strongly advised to visit and examine the site of works and its surroundings
and obtain for himself at this own responsibility and expense, all information regarding
terrain of the proposed line, line route, general site characteristics, crossing, accessibility,
infrastructure details etc. The cost of visiting the site shall be at Bidders own expense. The
HVPNL will assist the interested Bidder to see & inspect the site of works. For this purpose
Bidders are requested to contact.
Page-4
1.5.2
The Bidder should note that HVPNL will not furnish the topographical maps prepared by
survey of India but will make available any assistance that may be required in obtaining the
topographical maps.
1.5.3
Soil resistivity along the route alignment, shall be measured in dry weather by four-electrode
method keeping spacing of 50 metres. For calculating soil resistivity, formula 2PI ar (where
a =50 metres and r=megger reading in ohms, PI=3.14) shall be adopted. Measurement shall
be made at every 2 to 3 km along the route of transmission lines. In case soil characteristic
changes within 2 to 3 km, the value shall also have to be measured at an intermediate
locations. The megger reading and soil characteristics shall also be indicated in the soil
resistivity results.
1.5.4
ROUTE MARKING
At the starting point of the commencement of route survey, an angle iron spike of 65x65x6
mm section and 1000 mm long shall be driven firmly into the ground to project only 150 mm
above the ground level. A punch mark on the top section of the angle iron shall be made to
indicate location of the survey instrument. Teak wood peg 50x50x650 mm size shall be
driven at prominent position at intervals of not more than 750 meter along the transmission
line to be surveyed upto the next angle point. Nails of 100mm wire should be fixed on the
top of these pegs to show the location of instrument. The pegs shall be driven firmly into the
ground to project 100 mm only above ground level. At angle position stone/concrete pillar
with HVPNL marked on them shall be put firmly on the ground for easy identification.
1.5.5
1.5.6
TOWER LOCATION
checking the tower spotting. The templates shall be on the same scale as that of the
profile.
Page-5
a)
SPAN
The number of consecutive spans between the section points shall not exceed 15 in Plain.
A section point shall comprise of tension point as under as applicable: For D/C line
b)
EXTENSION
An individual span shall be as near to the normal design span as possible. In case an
individual span becomes too short with normal supports on account of undulations in
ground profile, one or both the supports of the span may be extended by inserting
standard body extension designed for the purpose according to technical specification.
c)
ROAD CROSSING
At all important road crossings, the towers shall be fitted with normal suspension or
tension insulator strings depending on type of tower but the ground clearance at the
highest point on the road under maximum temperature and still air be such that even with
conductor bundle broken in the adjacent, the ground clearance of the conductor from the
road surface will not be less than 7.015 meters.
At all National Highways, tension towers with double insulator strings on crossing side
shall be used, the crossing span however will not be more than 250 mtrs., in any case.
d)
RAILWAY CROSSINGS
All the railway crossings coming enroute the transmission line have already been
identified by the HVPNL. At the time of detailed survey, the Railway crossings shall be
finalized as per the regulation laid down by the Railway Authorities. The following are the
important features of the prevailing regulations (revised in 1987):
i)
The crossing shall be supported on DD type tower on either side depending on the
merits of each case and double tension insulator string shall be used on both the
towers on the side of the crossing.
ii)
iii)
The minimum distance of the crossing tower shall be at least equal to the height
of the tower plus 6 metres away measured from the center of the nearest Railway
track.
iv)
Page-6
v)
Minimum ground clearance above Rail level of the lowest portion of any conductor
under condition of maximum sag shall be maintained as per latest Railway
regulations amended from time to time.
The approval for crossing Railway track shall be obtained by the HVPNL from the
Railway Authorities, however six copies of profile and plan, tower and foundation
design and drawings, required for the approval from the Railway Authorities shall
be supplied by the Bidder to the HVPNL.
e)
In case of major river crossing, towers shall be of suspension type and the anchor
towers on either side of the main river crossing shall be DD type tower.
For navigable river, clearance required by navigation authority shall be provided. For
non-navigable river, clearance shall be reckoned with respect to highest flood level
(HFL).
f)
g)
i)
ii)
220 kV to 400 kV
4580 mm
5490 mm
The angle of crossing shall be as near to 90o as possible. However, deviation to the extent
of 30o may be permitted under exceptionally difficult situations.
When the angle of crossing has to be below 60o, the matter will be referred to the authority
inchage of the telecommunication system. On a request from the Bidder, the permission
of the telecommunication authority may be obtained by the HVPNL. Also, in the crossing
span, power line support will be as near the telecommunication line as possible, to obtain
increased vertical clearance between the wires. However, Assistance will be sought from
the Bidder.
h)
DETAILS ENROUTE
All topographical details, permanent features, such as trees, building etc. 17.5 m for 220kV
& 9.0m for 66kV on either side of the alignment shall be detailed on the profile plan.
Page-7
1.5.7
1.5.8
The tree cutting shall be the responsibility of the HVPNL except for that required during
survey. However, the Bidder shall count, mark and put proper numbers with suitable quality
of paint at his own cost on all the trees that are to be cut by the HVPNL at the time of actual
execution of the work. Bidder may please note that HVPNL shall not pay any compensation
for any loss or damage to the properties or for tree cutting due to Bidders work.
1.5.9
Any way leave, which may be required by the Bidder, shall be arranged by the HVPNL as
required by work programme.
1.5.10
To evaluate and tabulate the trees and bushes coming within 17.5 m on either side of the
central line alignment, the trees will be numbered and marked with quality paint serially from
angle point 1 onwards and the corresponding number will be painted on the stem of trees
at a height of 1 meter from ground level. The tree list should contain the following: a) Girth (circumference) measured at a height of 1 meter from ground level.
b) Approximate height of the tree with an accuracy of 2 metres.
c) Name of the type of the species/tree.
d) The bushy and under growth encountered within the 35 m belt should also be evaluated
with its, height, girth and area in square metres, clearly indicating the growth in the
tree/bush statement.
1.5.11
Payment of compensation toward the clearances etc. will be the responsibility of the
HVPNL.
1.5.12
PRELIMINARY SCHEDULE
The profile sheets, duly spotted, alongwith preliminary schedule indicating type of
towers, type of foundations, wind span, weight span, angle of deviation, river or road
crossing and other details shall be submitted for the approval of the HVPNL. After
approval, the Bidder shall submit six more sets of the approved reports along with one
set of reproducible of final profile drawings to the HVPNL for record purpose.
1.5.13
1.5.13.1
The check survey shall be conducted to locate and peg mark the tower positions on
ground conforming to the approved profile and tower schedule. In the process, it is
necessary to have the pit centers marked according to the excavation marking charts.
The levels, up or down of each pit center with respect to the center of the tower location
shall be noted and recorded for determining the amount of earthwork required to meet
the approved design parametres.
Page-8
1.5.13.2
Changes, if required, after check survey in the preliminary tower schedule shall be
carried out by the Bidder and he shall thereafter submit a final tower schedule for the
approval of HVPNL. The tower schedule shall show position of all towers, type of towers,
span length, type of foundation for each towers and the deviation at all angles as set out
with other details.
1.6
ENVIRONMENTAL CONDITIONS
1.6.1
The maximum temperature during summer shall be of the order of 50o C and the minimum
temperature shall be of the order of -2oC. Normal everyday temperature is 320C.
1.7
TECHNICAL DATA
Bidders shall furnish all technical data as per relevant schedules in five copies.
1.8
1.8.1
STATUTROY REGULATIONS
The contractor is required to follow local statutory regulations stipulated in electricity
(supply) Act. 2003, Indian Electricity rules 1956 as amended and other local rules and
regulations referred to in this specifications.
1.8.2
REFERENCE STANDARDS
1.8.2.1
The codes and/or standards referred to in specification shall govern. In all cases
wherever such references are made. In case of a conflict between such codes and/or
standards, and the specifications, latter shall govern. Such codes and/or standards,
referred to shall mean the latest revisions, amendments/changes adopted and
published by the relevant agencies.
1.8.2.2
1.9.
1.9.1
QUALITY ASSURANCE
1.9.1.1
To ensure that the supply and services under the scope of this contract whether
manufactured or performed within the Bidders works or at his sub-contactors premises or
at site or at any other place of work are in accordance with the specifications, the Bidder
shall adopt suitable quality assurance programme to control such activities at all points
necessary. Such programme shall out lined by the Bidder shall be finally accepted by the
HVPNL after discussion before the award of the contract. A quality assurance programme
of the Bidder shall generally cover but not limited to the following:
Page-9
a)
His organization structure for the management and implementation of the proposed quality
assurance programme.
b)
c)
d)
e)
System for shop manufacturing including process controls and fabrication and assembly
controls.
f)
g)
h)
i)
j)
k)
l)
m)
n)
A quality plan detailing out the specific quality control procedure adopted for controlling the
quality characteristics relevant to each item of supply.
The quality plan shall be mutually discussed and approved by the HVPNL after
incorporating necessary corrections by the Bidder as may be required.
1.9.1.2
1.9.1.3
1.9.2
The HVPNL, through his duly authorized representatives, reserves the right to carry out
quality audit and quality surveillance of the system and procedures of the Bidders/his subBidders quality management and control activities.
INSPECTION,TESTING AND INSPECTION CERTIFICATE
The provision of the clause regarding inspection, testing and inspection certificate as described
in conditions of contract shall be applicable to the supply and erection portion of the works. The
HVPNL shall have the right to re-inspect at his expenses any material though previously
inspected and approved by him at the Bidders works, before and after the same are erected at
site. If following the latter, material is found defective, then the Bidder shall bear the cost of this
inspection and reinstatement according to specification
Page-10
1.10
TECHNICAL PARAMETRES
a)
66 KV LINE
a)
Nominal voltage
66 kV
b)
72.5 kV
c)
BlS (Impulse)
325 KV (peak)
d)
140 KV (rms)
b)
220 KV LINE
a)
Nominal voltage
220 kV
b)
245 kV
c)
BIL (Impulse)
1050 KV (peak)
d)
460 KV (rms)
e)
154 KV(rms)
f)
1000 microvolts
Page-11
1.10
TECHNICAL PARAMETRES
A)
DETAILS OF LINE MATERIAL OF 220 KV ON ACSR ZEBRA AND 66kV LINE ON ACSR
ZEBRA :
S. N.
Particulars
Type
Conductor
ACSR
Zebra
conductor
Aluminium
Steel
Earthwire
Glavanised
steel
mm
54/3.18
mm
7/3.18
7/3.15
Sq. mm
484.5
54.55
mm
28.62
9.45
Kg/km
1621
428
Approximate
diameter
Approximate mass
Calculated
DC
resistance at 20 deg.
Centigrade (Max.)
ohm/km
0.06868
2.95
Approximate
calculated breaking
load
kN
130.32
57
Modulus of elasticity
Kg/cm2
7034
19369
Co-efficient of linear
expansion
Per
degree
centigra
de
19.30x10-6
11.5x10-6
10
Gm/sq.
m
260
11
Configuration
conductor
vertical formation
12
Location of earthwire
overall
of
240
One
continuous
earthwire to
run
horizontally
above the
conductors
Page-12
2.1
Sr
No
Type of String
Size
of Minimum
Composite
Creepage
Insulator
Distance
(mm)
(mm)
No.
of
Individual
units
per
string
(Nos.)
EM
strength
of
Insulator
Unit (KN)
Mechanical
strength of
Insulator
string
alongwith
Hardware
fittings
(kN)
Single
Suspension
20X2030
7595
1X1
70
70
Single
pilot
Suspension
20X2030
7595
2X1
70
70
Single Tension
24X2030
7595
1X1
70
120
Double
Tension
24X2175
7595
1X1
120
2x120
Single
Suspension
20X725
2248
1X1
70
70
Single
pilot
Suspension
20X725
2248
1X1
70
70
Single Tension
24X870
2248
1X1
120
120
Double
Tension
24X870
2248
2X1
120
2X120
Page-13
2.2
PARTICULARS OF 220/66kV INSULATOR STRINGS WITH A/F DISC INSULATORS FOR ACSR
ZEBRA LINES( 70KN FOR SUSPENSION STRINGS, 120KN FOR ZEBRA TENSION STRING) :
Sr
No
Particulars
Single
Single
suspension
suspension
string
/pilot pilot string
Strings
Double
string
tension Single
string
tension
No. of standard
insulator discs
1x5
1x5
2x6
1x6
Size of disc mm
255x145
255x145
280x145
280x145
E&M strength of
each insulator
disc
70
70
120
120
(KN)
4
Size
of
designation of
pinball
shank
mm
16, Alt-B
16, Alt-B
20
20
Minimum
creepage
distance of each
disc mm
432
432
432
432
2.3
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Anchor shackle
Ball Hook
Chain link
Yoke plate
Ball clevis
Arcing horn holding plate
Socket clevis
Arcing horns
Clevis eye
Free center type/armour grip suspension clamp for suspension strings and envelope type
clamp for pilot suspension string for jumper support.
Compression type dead end clamp.
k)
2.4
a)
b)
c)
d)
e)
f)
g)
Page-14
3.
TRANSMISSION TOWERS
3.1
3.1.1
The contractor is to fabricate and supply the 220kV/66kV towers of the following types:
a)
b)
220kV Multi-Ckts. (4-Ckts) MA, MB, MC, & MD type Normal towers and Special Extension
MB & MD type towers with +9m to +15 m Extensions of KRR Design.
c)
d)
220kV M/C monopoles to be got newly designed by bidder from reputed manufacture,
technical specification is separately attached.
3.1.2
The towers are of self supporting lattice steel type, designed to carry the line conductors with
necessary insulators, earthwires and all fittings under all loading conditions.
3.1.3
The tower shall be fully galvanized structure. The towers to be fabricated have a combination of two
grades of steel, as detailed in respective structural drawing / bill of material. One is MS steel and
other is HT steel .
3.2
TYPE OF TOWERS
3.2.1
Type of Tower
Deviation limit
Typical use
DA
DB
DC
a)
Angle
towers
with
tension
insulators string.
DD
30 deg.-60 deg.
b) Tension towers for uplift forces
resulting from an uplift span up to
200 m.
DD
0 deg.
Page-15
b)
The Multi-Circuit KRR design towers of HVPNL are of two(2) types i.e. Normal Multi-circuit towers
to be used upto +6m Extension and Special DB & DD type Multi-circuit towers to be used with +9m
, +12m & +15m Extensions as classified below :-
Type of Tower
Deviation limit
Typical use
MA
0 deg.-2 deg.
MB
2 deg.-15 deg.
a) Angle towers
insulators string
with
tension
MB
0 deg.
Special MB
0 to 7 deg.
a) Angle towers
insulators string
with
tension
15 deg.-30 deg.
a) Angle towers
insulators string
with
tension
Type tower
With +9m,
+12m & 15m
Extensions.
MC
30 deg.-60 deg.
a) Angle towers
insulators string
with
tension
0 deg.
Special MD
0 deg.
Type tower
With +9m,
+12m & 15m
Extensions.
Page-16
C)
DA/DE
0 deg. to 2 deg.
Spl. Extn. of DE
0 deg. to be restricted
0 deg. to 15 deg.
a)
(+9m to +18m)
DB/DF
0 deg.
Spl. Extn. of DF
5 deg. to be restricted
(+9m to +12m)
DC/DG
15 deg. to 30 deg.
Spl. Extn. of DG
20 deg. to be restricted
(+9m to +12m)
DD/DH
30 deg.-60 deg.
Spl. Extn. of DH
(+9m to +18m
40 deg. to be restricted
DD/DH
0 deg.
d)
Page-17
3.2.1
EXTENSIONS
3.2.1.1
All the towers are designed for adding body extensions for maintaining adequate ground
clearance without reducing the specified factor of safety in any manner (as per availability of
type of extns. in any design).
3.2.1.2
For 220kv TATA & 66kV KRR design also to be mentioned. The Multi-circuit KRR design towers
are of Two (2) types i.e. one is designed for adding 3 M, 6 M Extensions and other is designed
for Special 9 M, 12 M, 15 M body extensions for maintaining adequate ground clearance without
reducing the specified factor of safety in any manner.
3.2.1.3
All above extension provision to normal towers shall be treated as part of normal tower only.
3.3
3.3.1
NORMAL SPAN
A)
3.3.2
a)
The normal span of 220kV TATA design towers with ACSR Zebra is 350m.
b)
The normal span for normal 220kv Multi-circuit towers (i.e. upto +6m Extension) is 250m.
c)
The special Extension MB+9/+12/+15 tower has been designed with a wind span of 200m
and angle of deviation of 70.. This tower shall be strictly used as per design.
d)
The Special Extension MD+9/+12/+15 tower has been designed for Dead End condition
and third cross-arm with 900 deviation (with slack Tension) for a wind span of 100m.
This tower shall be strictly used as per design.
e)
The normal span of 220kV M/C monopole shall be 200m. However, restriction in span for
special extn., if any, shall be mentioned in the design and drawings.
f)
The normal span of 66kV KRR design towers with ACSR ZEBRA is 275m. However, the
special extn. of DE type tower shall be restricted to 175m.
WIND SPAN
The wind span is the sum of the two half spans adjacent to the support under consideration. For
normal horizontal spans this equal to normal ruling span.
3.3.3
WEIGHT SPAN
The weight span is the horizontal distance between the lowest point of the conductors on the two
spans adjacent to the tower. The weight spans considered for design of towers are as below:
Page-18
A)
Tower type
B)
Normal condition
Max.
Min.
Max.
Min.
(m)
(m)
(m)
(m)
DA
525
200
315
100
DB, DC, DD
525
315
-200
Tower type
DA
Normal condition
Max.
Min.
Max.
Min.
(m)
(m)
(m)
(m)
413
165
248
90
DB, DC, DD
C)
413
165
-150
The weight span is the horizontal distance between the lowest point of the conductors on the two
spans adjacent to the tower. The weight spans considered for design of towers are as below:
Tower type
Normal condition
Max.
Min.
Max.
Min.
(m)
(m)
(m)
(m)
MA
375
225
188
100
MB, MC, MD
375
188
-188
Page-19
D)
The weight span shall be mentioned in new design of 220kv M/C monopoles.
3.3.4
ELECTRICAL CLEARANCES
The min. ground clearances from the bottom conductor shall not be less than 5.5m at the max. sag
conditions i.e. at max. temperature (75oC) and still air for 66kV line and 7.1m for 220kV line on M/C
tower. However, to achieve the above clearance the height of tower has been increased in the
following manner:
a)
b)
For river crossing tower the minimum electrical clearance including ground clearance will be same
as normal towers except an allowance of 4% of maximum sag of conductor instead of 150 mm for
normal towers shall be provided to account for errors in stringing.
In case of Rail crossing the min. height above Rail level of the lowest portion of any conductor under
condition of max. sag, in accordance with the regulation for Electrical crossing of Railway tracks as
prevailing at the time of construction of line shall be applicable.
Page-20
3.3.4.4
i)
66 kV to 66 kV and below:
ii)
iii)
220 kV to 400 kV
2440 mm
4580 mm
5490 mm
S. N
Swing in deg.
Nil
2130
15
1980
30
1830
45
1675
60
Nil
2130
Jumper
Nil
2130
10
2130
20
1675
30
Nil
2130
15
1980
30
1830
45
1675
For 66kV :
S. N
Swing in deg.
Nil
915
15
915
30
760
45
610
60
610
Nil
915
Jumper
Nil
915
10
915
20
610
30
610
Nil
915
15
915
30
610
45
610
Page-21
3.3.5
3.4
MAXIMUM TENSION
3.4.1
b)
3.4.2 The sag-tension calculations for all type of towers is available with HVPNL and will be supplied to
successful bidder after award of contract.
3.4.3
The initial conductor tension at 32oC and without wind shall be 22% of the ultimate tensile strength
of the conductor.
3.4.2
3.4.5
3.5
MATERIALS
3.5.1
3.5.2
3.5.2.1 All bolts and nuts shall conform to IS:6639-1972. All bolts and nuts shall be galvanized and shall
have hexagonal head and nuts, the heads being forged out of the solid steel rods and shall be
truly concentric, and square with the shank, which must be perfectly straight.
Page-22
3.5.2.2 The bolt shall be of 16 mm dia and of property class 5.6 as specified in IS:1367 (part-III) 1979 and
matching nut of property class as specified in IS:1367 (part-VI) 1980. However, some bolts of
MD type 220kV M/C tower are having 24 dia. of 6.8 grade.
3.5.2.3
Bolts up to M 16 and having length upto 10 times the diameter of the bolts should be
manufactured by cold forging and thread rolling process to obtain good and reliable mechanical
Properties and effective dimensional control. The shear strength of bolts for 5.6 grade should
be 310-MPa minimum as per IS: 12427, bolts should be provided with washer in accordance
with IS: 1363 part-I to ensure proper bearing.
3.5.2.4
Nuts should be double chamfered as per the requirement of IS:1363 part-III, 1984. The
manufacturer should ensure that nuts should not be over tapped beyond 0.4 mm oversize on
effective diameter for size upto M16.
3.5.2.5
Fully threaded bolts shall not be used. The length of bolts shall be such that the threaded portion
will not extend into the place of contact of the members.
3.5.2.6
All bolts shall be threaded to take the full depth of the nuts and threaded for enough to permit
firm gripping of the members, but not further. It shall be ensured that the threaded portion of
each bolt protrudes not less than 3 mm and not more than 8 mm when fully tightened. All nuts
shall fit and tight to the point where the shank of the bolt connects to the head.
3.5.2.7
Flat and tapered washers shall be provided wherever necessary. Spring washers shall be
provided for insertion under all nuts. These washers shall be of steel electro-galvanised steel,
positive lock type and 3.5 mm in thickness for 16 mm dia bolt.
3.5.2.8
The bidder shall furnish bolt schedules giving thickness of members connected, the size of bolts
nut and the washer and the length of shank and the threaded portion of bolts and sizes of bolt
holes and any other special details of this nature.
3.5.2.9
To obviate bending stress in bolts or to reduce it to minimum, no bolt shall connect aggregate
thickness of more than three (3) times its diameter.
3.5.2.10
3.5.2.11
Bolts at the joints shall be so staggered that nuts may be tightened with spanners with out
fouling.
3.5.2.12
To ensure effective in-process quality control it is essential that the manufacturer should have
all the testing facilities for test like weight of zinc coating, shear strength, other testing facilities
etc. in-house. The manufacture should also have proper Quality Assurance System, which
should be in line with the requirement of this specification and IS:14000 series quality system
standard.
Page-23
3.5.3
TOWER ACCESSORIES
i)
Each tower shall be provided with step bolts in one of the main leg confirming to IS:10238 of not
less than 16mm diameter and 175 mm long, spaced not more than 450 mm apart and extending
form about 3.5M above the ground level to the top of the tower. The step bolt shall be fixed on
one leg of single circuit tower from 3.5 m above ground level to top of the towers. Each step bolt
shall be provided with two nuts on one end to fasten the bolt securely to the tower and button
head at the other end to prevent the feet from slipping away. The step bolts shall be capable of
withstanding a vertical load not less than 1.5 KN. For special structures, where the height of the
super structure exceeds 50m, ladders along with protection rings as per the HVPNL approved
design shall be provided in continuation of the step bolts on one face of the tower from 30 metres
above ground level to the top of the special structure. From 3.5 m to 30 m height of super
structure step bolts shall be provided. Suitable plat form using 6 mm thick perforated chequred
plates along with suitable railing for access from step bolts to the ladder and from the ladder to
each cross-arm tip and the groundwire support shall to be provided. The platform shall be fixed
on tower by using countersunk bolts.
ii)
a)
I shaped suspension insulator string assemblies shall be used for suspension towers, the
drawing of which is enclosed with specification. For the attachment of suspension insulator
string, a suitable dimensioned swinging hanger on the tower shall be provided so as to obtain
requisite clearance under extreme swinging condition and free from swinging of the string.
The hanger shall be designed to withstand an UTS of 70 KN for single suspension string
and 140 KN for double suspension string.
b)
The Suspension Pilot insulator string assemblies shall be used at Dead end tension tower
at angle of deviation 300 and above.
c)
At tension towers, strain plates of suitable dimensions on the underside of each cross-arm
tip and at the top earthwire peak should be provided for taking the hooks or D-shackle of the
tension insulator strings or earthwire tension clamps, as the case may be. Full details of the
attachments shall be submitted by the bidder for HVPNL approval before starting the mass
fabrication.
iii)
EARTHWIRE CLAMPS
A)
SUSPENSION CLAMP
Earthwire suspension clamps will be supplied by the bidder, the reference drawing for the same
is enclosed with the specification. Earthwire peaks/cross-arms are to be suitably designed to
accommodate the shackle of the suspension clamp.
B)
TENSION CLAMPS
The bidder shall supply earthwire tension clamps for incorporation on the tension towers. The
reference drawing for the same is enclosed with this specification.
Page-24
iv)
ANTICLIMBING DEVICE
Barbed wire type anticlimbing device/ fencing as per enclosed drawing shall be provided and
installed by the Bidder for all towers/gantries. The height of the anticlimbing device shall be
provided approximately 3m above ground level. The barbed wire shall conform to IS:278-1978.
the barbed wires shall be given chromating dip as per procedure laid down in IS:1340-1959.
v)
a) Each tower shall be fitted with a number plate, circuit plate (in case of double circuit) and danger
plate. Each tension tower shall be provided with a set of phase plates also. All the double circuit
towers are to be provided with circuit plate fixed near the legs. The height for fixing these
accessories shall not be more than 4.5m above the ground level.
b) The letters figures and the conventional skull and bones of danger plates shall conform to
IS:2551-1963 and shall be in a signal red on the front of the plate.
c) The corners of the number, danger & circuit plate shall be rounded off to remove sharp edges.
vi)
BIRD GUARDS
To prevent birds perching immediately above the suspension insulator string and fouling the same
with dropping, suitable bird guards shall be provided at cross arm tips of all suspension towers.
The bird guard arrangement shall be such that it shall either prevent bird from perching in position
where they are liable to cause the damages or ensure that if birds do perch, dropping will fall clear
of the insulator string.
3.6
TOWER FABRICATION
3.6.1
Except where hereinafter modified, details of fabrication shall conform to IS:802 (Part-II) 1978 or
the relevant international standards.
3.6.2
The tower structure shall be accurately fabricated to connect together easily at site without any
undue strain on the bolts.
3.6.3
The diameter of the hole shall be equal to the diameter of bolt plus 1.5 mm.
3.6.4
All similar parts shall be made strictly inter-changeable. All steel sections before any work is done
on them, shall be carefully leveled, straightened and made true to detailed drawings by methods
which will not damage the materials so that when assembled, the adjacent matching surfaces are
in close contact throughout. No rough edges shall be permitted in the entire structure.
Page-25
3.6.5
3.6.5.1
Before any cutting work is started, all steel sections shall be carefully straightened and trued by
pressure and not by hammering. They shall again be trued after being punched and drilled.
3.6.5.2
Holes for bolts shall be drilled or punched with a jig but drilled holes shall be preferred. Punching
may be adopted for thickness upto 16mm. tolerances regarding punched holes are as follows:
a) Holes must be perfectly circular and no tolerance in this respect is permissible.
b) The max. allowable difference in diameter of the holes on the two sides of plates or angle is
0.8 mm i.e. the allowable taper in a punched hole should not exceed 0.8 mm in diameter.
c) Holes must be square with the plates or angles and have their walls parallel.
3.6.5.3
All burrs left by drills or punch shall be removed completely. When the tower members are in
position the holes shall be truly opposite to each other. Drilling or reaming to enlarge holes shall
not be permitted.
3.7
ERECTION MARK
3.7.1
3.7.2
Each individual member shall have an erection mark conforming to the component number
given to it in the fabrication drawings. This mark shall be made with marking dies of 16 mm size
before galvanizing and shall be legible after galvanizing.
ERECTION MARK SHALL BE
A-BB-CC-DDD
A =
BB =
Bidders Mark-Numerical
CC =
Tower type-Alphabet
DD =
H =
HT Steel
3.7.3
QUANTITIES VARIATION
3.7.3.1
The provisional quantities required are mentioned in the respective schedule of prices. Final
quantities shall be determined after completion and approval of the detailed route survey and
check survey. The final quantities of towers, gantries, line materials and foundations shall be
confirmed by the HVPNL based on the requirement of quantities of various items furnished by
the Bidder after completion of detailed survey. Hence it will the responsibility of the Bidder to
intimate the exact requirements of all towers, line materials and foundations required for the line
immediately after the survey. The Empowered officer of the HVPNL will order the final quantities
at the unit rates quoted in the bid.
Page-26
3.7.3.2
The Empowered officer of the HVPNL reserves the right to increase or decrease upto 15%
(fifteen percent only) of contract value. The quantity of bid and services specified without any
change in the unit price or other terms and conditions during the execution of the contract. The
quantities of individual items may vary upto any extent after the final route plans and route
profiles of the lines covered in the package are finalised.
3.7.3.3
The estimated unit weight of each type of tower, stubs and extensions shall be furnished by the
HVPNL. The weight of tower shall mean the weight of tower calculated by using the black
sectional (i.e. ungalvanised) weight of steel members of the size indicated in the approved
fabrication drawings and bills of materials, without taking into consideration the reduction in
weights due to holes, notches and bevel-cuts etc. but taking into consideration the weight of
fastners, anticlimbing devices etc.
For payment purpose, the round plane washers, hangers, D-shackles, U-bolts, step bolts, spring
washers, bolts and nuts etc. shall be termed as fasteners.
3.8
GALVANISING
Fully galvanized towers and stub shall be used for the lines. Galvanizing of the member of the
towers shall conform to IS:2629-1985 and IS:4759-1968. All galvanizing members shall withstand
tests as per IS:2633-1986. For fasteners the galvanizing shall conform to IS:1367 (Part-13). The
galvanizing shall be done after all fabrication work is completed, except that the nuts may be
tapped or re-run after galvanizing. Threads of bolts and nuts shall have a neat fit and shall be
such that they can be turned with finger throughout the length of the threads of bolts and they
shall be capable of developing full strength of the bolts. Spring washers shall be electrogalvanised as per grade 4 of IS: 1573-1970.
3.9 EARTHING
3.9.1
The footing resistance of all towers shall be measured by the Bidder in dry weather after tower
erection but before the stringing of earthwire. All the towers are to be earthed, however, in no
case tower footing resistance shall exceed 10 ohms. Pipe type earthing and counterpoise type
earthing wherever required shall be provided in accordance with the stipulations made in IS:30431987 and IS:5613 (part-II/section-2) 1985. The details for pipe and counterpoise type earthing are
given in drawing enclosed with the specification.
3.9.2
The provisional quantities for pipe type earthings and counterpoise earthing, are furnished in price
schedule. The bidders are required to furnish unit rates also for adjustment purpose with actual
quantities. The quoted price shall include fabrication, supply and installation of earthing material
including supply of coke, salt etc. in case of counterpoise type earthing, the quotation shall be
based on 100 metres of wire per tower.
3.10
3.10.1
All standards tests, including quality control tests, in accordance with appropriate
Indian/International standard, shall be carried out unless otherwise specified herein.
Page-27
3.10.2
All Goods being supplied shall conform to type tests, sample tests as per the technical
specifications and shall be subject to routine, acceptance and site tests in accordance with
requirements stipulated under the respective Sections, unless otherwise stated. The HVPNL
reserves the right to witness any or all the type and sample tests. The Bidder shall inform the
HVPNL of the detailed program of tests at least two (2) weeks in advance in case of domestic
supplies and four (4) weeks in advance in case of foreign supplies.
3.10.3
The Bidder shall furnish to HVPNL the reports of all type tests, sample and routine tests as per
technical specification along with the equipment/materials drawings. The type tests conducted
earlier should have been conducted in accredited laboratories (based on ISO/IEC by a reputed
accreditation body) or witnessed by HVPNL or another electric power utility. The type test reports
submitted shall be of the tests conducted within last five (5) years prior to the date of bid opening.
In case the test reports are of a test conducted five (5) years prior to the date of bid opening, and
dont correspond to the offered equipment/material, or dont comply with the Technical
Specifications, the Bidder shall repeat this / these test / tests at no extra cost to the HVPNL before
sample(acceptance) tests. The cost of conducting type tests and additional tests shall be included
in the Bid price .
3.10.4
The HVPNL, his duly authorized representative and/or outside inspection agency acting on behalf
of the HVPNL shall have free access at all reasonable times to the Bidders/sub-vendors premises
or Works and shall have the power at all reasonable times to inspect and examine the
equipment/materials and workmanship of the Works during its manufacture or erection. If part of
the Works is being manufactured or assembled at other premises or works, the Bidder shall obtain
for the HVPNL, his duly authorized representatives and/or outside inspection agency permission
to inspect as if the works were manufactured or assembled on the Bidders own premises or
works. Inspection may be made at any stage of manufacture, dispatch or at the Site at the option
of the HVPNL, and the equipment if found unsatisfactory due to bad workmanship or quality or
material is liable to be rejected.
When the factory tests have been completed at the Bidders or Sup-Bidders works, the
HVPNL/Inspector shall issue a certificate to this effect within fifteen (15) days after the completion
of the tests, but if the tests are not witnessed by the HVPNL/Inspector, the certificate shall be
issued within 15 days of receipt of the Bidders test certificate by the HVPNLs representative.
Failure of the HVPNL/Inspector to issue such a certificate shall not prevent the Bidder from
proceeding with the Works (as defined in SCC). The completion of these tests or the issue of the
certificate shall not bind the HVPNL to accept the equipment/materials should it, on further tests
after erection, be found not comply with the Contract. The equipment/materials shall be
dispatched to Site only after approval of test reports and issuance of the inspection certificate by
the HVPNL.
3.10.5
The inspection by the HVPNL and issue of the inspection certificate thereon shall in no way limit
the liabilities and responsibilities of the Bidder in respect to the agreed quality assurance program
forming part of the Contract.
3.10.6
The HVPNL will have the right of having at his own expenses any other test(s) of reasonable nature
carried out at the Bidders premises or at any other place in addition of aforesaid type and routine
tests to satisfy that the equipment/materials comply with the specifications.
Page-28
3.10.7 The HVPNL deserves the right for getting any field tests not specified in the respective sections of
the technical specifications conducted on the completely assembled equipment at Site. The
HVPNL will provide the testing equipment for these tests.
3.10.8
The Bidder shall ensure that his subBidders manufacturing and supplying the goods (material and
equipment) shall perform the routine tests specified in the related standards and in the Technical
Specifications of this Contract regularly.
3.10.9
The Bidder shall notify the HVPNL in writing at the latest four (4) weeks for inspection outside of
India and two (2) weeks for local inspection and testing or as otherwise directed in advance of the
date and place at which any Material or Work will be ready for inspection and testing.
3.10.10 Should any postponement become necessary, the Bidder shall provide written notification at least
one week prior to the originally scheduled date. The HVPNL shall give 48 hours' notice in writing
to the Bidder, of his intention to attend the tests, or ask for postponement, if required.
3.10.11 Should the HVPNL explicitly waive to attend the relevant test, the Bidder may proceed with the
test, which shall be deemed to have been made in his presence, and the Bidder shall forthwith
forward to the HVPNL duly certified copies of the test reports for approval.
3.10.12 All sample and type tests will be performed at the presence of the authorized personnel of the
Bidder or inspectors authorized by the Bidder, if there is no representative of HVPNL.
3.10.13 HVPNL may or may not be present in any or all sample and type tests but all test reports shall be
approved by HVPNL
3.10.14 This procedure shall not release the Bidder from any of his responsibilities or obligations under
this Contract.
3.10.15 The Bidder shall prepare and agree with HVPNL test programs so that tests to be performed in
foreign countries (i.e., at manufacturer's factory or at internationally recognized test facilities) are
carried out in sequence which would permit HVPNL to organize in an optimal manner the
supervision of the said tests by HVPNL staff.
3.11
Galvanizing Tests:
All fabricated materials shall be tested in accordance with the "Test and Inspection Procedures for
Galvanized Materials "as per Specification and HVPNL shall be notified at least thirty days in
advance of any tests if it is performed in abroad.
3.12 Inspections and Tests: The Bidder shall make adequate tests and inspections to determine whether
the material furnished is strictly in accordance with this Specification. In addition, HVPNL may
inspect and accept or reject the material made under this Specification either at the Fabricator's
plant or at the point of delivery The representatives of HVPNL shall have access to all parts of the
Bidder's plant which concerns the Work while the Work is being done. The Bidder, without
requesting any fee, shall provide all the reasonable facilities to the HVPNL's representatives so as
to satisfy them that, the towers are manufactured strictly in compliance to this Specification.
Page-29
3.13
a)
Steel Mill Test Reports showing chemical, physical and mechanical properties
of the material to be furnished under the Contract.
b)
1-
2-
Date of inspection
3-
3.14
4-
5-
coating
and
other
reasons.
Shop assembly:
One tower of each type and height ordered, including every combination of leg extensions, shall be
assembled in the shop to the extent necessary to assure correct fit of parts, adequate bolt lengths
and proper field erection. Reaming of mismatched holes will not be permitted. A reasonable amount
of drifting will be allowed in assembling approved by HVPNL. The approved assembled parts shall
be dismantled for shipment. Shop assembly shall be controlled and approved by HVPNL.
3.15
Fabrication:
Fabrication shall be in strict accordance with detail Drawings prepared by the Bidder and approved
by the HVPNL. The drilling, punching, cutting and bending of all fabricated steelwork shall be such
as to prevent any possibility of irregularity occurring which might introduce difficulties in the erection
of the structure on the site.
Built pieces shall, when finished, be true and free from all kinks, twists and open joints
and the Material shall not be defective or strained in any way. Fabrication shall begin
after the approval of the shop assembly.
3.16
Identification: All parts designed for bolting together shall be shipped unassembled except as
noted on the drawings. Tower members shall be bundled together in the largest practical bundles
for shipping and each bundle shall be clearly marked. Small parts such as U-bolts and clip angles
shall be boxed and each box clearly marked for identification.
Shipping: Railroad cars, ships or trucks in which steel is shipped shall be reasonably clean and
free from foreign materials which could in any way injure the tower material. At least 8cm
clearance shall be maintained between bundles and floor.
3.17
GENERAL
appropriate
Page-30
3.18 INSPECTION
3.18.1 In addition to the provision of clause regarding inspection in conditions of contract, the following
shall also apply:
a.
The Bidder shall keep the HVPNL informed in advance about the time of starting and of the
progress of manufacture and fabrication of various tower parts at various stages, so that
arrangements can be made for inspection.
b.
The acceptance of any part of items shall in no way relieve the Bidder of any part of his
responsibility for meeting all the requirements of the specification.
3.18.2 The HVPNL or his representative shall have free access at all reasonable times to those parts of
the Bidders works which are concerned with the fabrication of the HVPNL material for satisfying
himself that the fabrication is being done in accordance with the provisions of the specifications.
3.18.3 Unless specified otherwise, inspection shall be made at the place of manufacture prior to dispatch
and shall be conducted so as not to interfere unnecessarily with the operation of the work.
3.18.4 Should any member of the structure be found not to comply with the approved design, it shall be
liable to rejection. No member once rejected shall be re-offered for inspection, except in cases
where the HVPNL or his authorized representative considers that the defects can be rectified.
3.18.5 Defect which may appear during fabrication shall be made good with the consent of and according
to the procedure proposed by the Bidder and approved by the HVPNL.
3.18.6 All gauges and templates necessary to satisfy the HVPNL shall be supplied by the manufacture.
3.18.7 The correct grade and quality of steel shall be used by the Bidder. To ascertain the quality of steel
used, the inspector may at his discretion get the material tested at an approved laboratory.
3.19 Standards
3.19.1The design, manufacturing, fabrication, galvanizing, testing, erection procedure and materials used
for manufacture and erection of towers, design and construction of foundations shall conform to the
following Indian Standards (IS) International standards which shall mean latest revisions, with
amendments/ changes adopted and published, unless specifically stated otherwise in the
specification. In the event of supply of material conforming to standards other than specified, the
bidder shall confirm in his bid that these standards are equivalent to those specified. In case of
award, salient features of comparison between the standards proposed by the contractor and those
specified in this document will be provided by the contractor to establish their equivalence.
3.19.2 The material and services covered under these specifications shall be performed as per
requirements of the relevant standards/codes (latest version) referred hereinafter against each set
of equipment and services. Other internationally acceptable standards which ensure equal or higher
performance than those specified shall also be accepted.
Page-31
SR
No.
INDIAN
STANDARDS
TITLE
INTERNATIONAL&
INTERNATIONALLY
RECOGNISED STANDARDS.
IS:209-REV,
ISO/R/752-1968 ASTM B6
IS:226-1975
Structural steel
ISO/R/630-1967
standard
quality CAN/CSA-G40.21
BS 4360
IS:269-1976
ISO/R/597-1967
IS:383-1970
IS:278
ASTM A 121
IS:432-1966
(part-I&II)
BS-785-1938 CSA-G-30.
IS:456-2000
IS:800-1962
CSA S16.1
of structural steel in
general building construction.
a) IS:802
(part-1)
of structural steel in
overhead transmission
b)IS:802
(part-2) 1978
of structural steel in
ASCE 52
overhead transmission
line. Fabrication,
galvanizing, inspection and packing.
c)IS:802
(part-3) 1978
10
IS:808
11
IS:875
Page-32
12
IS:1139-1966
13
IS:1367-1967
14
IS:1489-1976
15
IS:1786-1989
16
IS:1893-1965
for
ISO/R/863-1968
17
IS:2016-1967
Plain washers
ISO/R/887-1968.
B18.22.1
18
IS:2131-1967
19
IS:2551-1982
20
IS:2629-1966
21
IS:2633-1972
22
IS:3043-1972
23
IS:3063-1972
24
IS:4091-1967
25
IS:5358-1969
26
27
coatings
ANSI
on
Page-33
28
IS:6610-1972
29
IS:6639-1972
30
IS:6745-1972
31
32
33
IS:8500-1977
34
IS:2062-1992
Page-34
Reference/Abbreviation
IS
ISO
CSA
BS
DIN
Rezdale Boulevard,
Indian Electricity Rules 1956 Kitab Mahal ,Baba Kharak Singh Marg, New Delhi-110001 INDIA.
Regulation
for
Electricity
Crossing of Railway Tracks.
ASCE
IEEE
IEC
Page-35
4.0
TOWER FOUNDATION
4.1
GENERAL
These specifications provide general guidelines for the construction of tower foundations as per
design supplied by HVPNL and the gantry tower foundations as per design supplied by HVPNL of
the proposed transmission line(s) covered in the tender.
However, the successful bidder shall develop the design/drawings of 220kV M/C (4 ckt.) A,B,C & D
type monopole. The successful bidder shall also get the design/drawings so developed vetted from
professional govt. institute like CSIR-Structural Engineering Research Centre, Chennai, CPRI etc.
and submit the same for approval of the HVPNL before execution.
4.2
Before start of work, successful bidder shall carry out trial bore-holes (normally up to 6.0 meter
below natural ground level) after every Kilometer en-route or as desired by the Employer to have a
fair idea of soil type/nature and subsoil water position. If the soil characteristics are changing rapidly
or soil up to 6.0 meter is very weak, the depth of bore-hole be increased beyond 6.0 meters so as
to know the soil properties/type below the foundation. The bore log data containing information such
as position of sub-soil water table, soil strata, the crop pattern in the agricultural fields where the
foundation is to be laid and the suitability for founding the required foundation, shall be submitted
to the Employer for according approval for Classification of foundation at each location.
Contractor shall also ensure to check the entry of kids/ animals in to the excavated pits by providing
suitable warning signs and safety measures as per the approval of Engineer-In-Charge.
4.3
TYPE OF SOIL
Soil en-route the following proposed transmission lines under the scheme is generally
normal/Sandy/rocky.
1. LILO of both circuits of existing 220kV Palla to Palli D/C line at proposed 220kV S/Stn. Sector-46
Faridabad on M/C towers by using ROW of existing 66kV D/C NH-3 Palla line presently feeding the
66kV S/Stn. Sector-46.
2. LILO of both circuit of 66kV BBMB Ballabgarh-Jharsetly D/C line at 220kV S/Stn. Sector-58,
Faridabad with 0.4sq ACSR zebra.
3. LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV S/Stn. A4 at 66kV S/Stn. Idgah
with 1200mm2 XPLE underground cable
4. LILO of one ckt. of 66kV Ballabgarh (220kV BBMB) Sector-58 D/C line Section of 66kV Ballabgarh
(220kV BBMB) Sector-58 Faridabad-Jharsetly D/C line at 66kV S/Stn. Sector-59 Faridabad with
1200mm2 XLPE cable and tower portion.
5. LILO of both circuit of the existing 220kV D/C FGPP-BBMB Samaypur (PGCIL line) at 220kV S/Stn.
Sector-58, Faridabad on M/C towers.
6. 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn. Bhagola (proposed) line
with 0.4Sq ACSR zebra.
7. BOQ of 66kV D/C 400kV S/Stn. Nawada to 66kV S/Stn. Badrola with 0.4 Sq ACSR zebra (Tower
portion & cable portion).
8. BOQ of re-alignment of 66kV D/C overhead line from 66kV S/Stn. A-5 Faridabad to 66kV S/Stn.
Fatehpur Biloch from TL No. 15 to 38 by partially 8x1Cx1200 Sq mm XLPE cable and partially by
overhead line on PQRS type tower with 0.4Sq ACSR conductor as a deposit work of HSIIDC (tower
portion & cable portion).
[[
Ground water table enroute all the above said lines generally vary from 20mtr. to 25mtr. below
Natural Ground Level. The sub soil water level at few locations may be different due to local
conditions. The crop pattern enroute all the above said lines is paddy, wheat, sugarcane, cotton
etc. depending on soil and weather conditions.
Page-36
4.4
4.4.1
4.5
4.5.1
CLASSIFICATION OF SOIL
a.
Dry Soil: Soil shall be termed as dry soil where sub-soil water table is below base of the
tower footing and no de-watering is required.
b.
Wet Soil (without de-watering): Soil shall be termed as wet soil (without de-watering)
where sub-soil water is below base of footing and no de-watering is required but crop pattern
is paddy field.
c.
Wet Soil (with de-watering): Soil shall be termed as wet soil (with de-watering) where subsoil water is above base of footing and de-watering has to be done.
d.
Rocky Soil: Hard conglomerate or other soft or fissured rock which can be quarried or split
with crow bars, wedges or pick axes. However, if required, light blasting may be resorted to
for loosening the material.
For excavation purpose, the quoted rates for foundations in wet soil (without de-watering) shall be
considered as applicable for the dry soils. For wet soil (with de-watering), the quoted rates of dewatering have been asked for separately. The de-watering operation shall continue to keep the
foundation pits dry during concreting and thereafter for at least 24 hrs. Any de-watering carried out
for removal of seepage of surface water/rainwater will not be considered as de-watering and the
soil shall be termed as Dry Soil.
FOUNDATION TYPES
GENERAL
Reinforced cement concrete footing shall be used for all types of normal towers/ extension towers
in conformity with the present day practices followed in the country and the specifications laid herein.
All the four footings of the tower and their extensions, if any shall be similar irrespective of down
thrust and uplift.
4.5.2
Foundation includes supply of materials such as cement, fine and coarse aggregates, water,
reinforcement steel and binding wire etc. Rates quoted for foundations shall include all items of
work relating to supply and installation of foundations such as form work, excavation and back filing
with good soil, compaction, stub setting, shoring & timbering etc. where ever required, placing of
reinforcement in position, concreting and all other works related for completion of foundation.
4.6
CLASSIFICATION OF FOUNDATIONS
4.6.1
a.
Dry Foundation: To be used where sub-soil water table is below 6.0 meter from Natural
Ground Level.
b.
Wet Foundation (without de-watering): To be used where sub-soil water table is below
base of footing and up to 6.0 meters from Natural Ground Level or at location where surface
water remains for long periods such as paddy/sugar cane fields irrespective of sub-soil water
depth.
c.
Wet Foundation (with de-watering): To be used where sub-soil water table is above
footing base of foundation and actual de-watering has to be carried out for construction of
foundation for which separate rates have been asked for.
Design of foundation for Wet (without de-watering) and Wet (with de-watering) shall be same.
Page-37
Type of soil
Dry bulk density
Angle of internal friction
Safe Allowable Bearing Capacity
:
:
:
:
Normal/Sandy silt/Rocky
1500kg/m3
28
6.0 T/m2 (F.O.S.=2.5)
4.7.1
4.7.2
Partial safety factor for concrete and steel shall be considered as per latest IS: 456.
4.7.3
Particulars of the foundations designed on the basis of soil particulars given under 4.4 along with
the estimated volumes of concrete and excavation volumes for the various types of towers shall be
given in the drawings to be evolved by the successful bidder. The foundation shall be designed
such as to satisfy the following conditions.
4.7.4
4.7.5
The spread of concrete pyramid or slabs for both PCC and RCC type foundations shall be limited
to 45 degree with respect to the vertical. The centroidal axis of the slab shall coincide with the axis
of the column and pass through the centre of foundation base. The design of the foundations (base
slab and its reinforcement) shall take into account the additional stresses in the foundation resulting
from the eccentricity introduced due to non compliance of this requirement.
4.7.6
At least 100 mm thick pad of size equal to the base of pyramid with its sides vertical will be provided
below the pyramid for PCC type foundations and 150mm for RCC type foundation is to be provided.
Also, at least 100mm thick lean concrete (1:4:8) pad shall be provided below bottom slab/pyramid.
4.7.7
The thickness of base slab at centre i.e. at the point of maximum bending shall not be less than
300mm in case of RCC type foundation.
4.7.8
The total depth of foundations except Hard Rock type below the ground level shall not be less than
1.5m and more than 3.0m. To maintain the interchangeability of stubs for all types of foundations,
for each type of tower, almost the same depths of foundations shall be used for different types of
foundations. However, for pile type foundations, depth limitations are not applicable.
4.7.9
The overload factor for foundations shall be considered as 1.1 i.e. all the reactions (compression,
tension and side thrust) on foundations shall be increased by 10%.
4.8
LOADS ON FOUNDATIONS
4.8.1 The foundations shall be designed to withstand the specific loads of the super structure and for the
full footings reactions obtained from the structural stress analysis in conformity with the relevant
factors of safety.
4.8.2 The reactions on the footings shall be composed of the following type of loads for which these shall
be required to be checked;
4.8.4 The additional weight of concrete in the footing below ground level over the earth weight and the full
weight of concrete above the ground level in the footing and embedded steel parts will also be taken
into account adding to the down thrust.
4.9
STABILITY ANALYSIS
4.9.1
In addition to the strength design, stability analysis of the foundation shall be done to check the
possibility of failure by over-turning, uprooting, sliding and tilting of the foundation.
4.9.2 The following primary type of soil resistance shall be assumed to act in resisting the loads imposed
on the footing in earth:
a.
The uplift loads will be assumed to be resisted by the weight of earth in an inverted frustum of a
conical pyramid of earth on the footing pad whose sides make an angle equal to the angle of repose
of the earth will the vertical, in average soil. The weight of concrete embedded in earth and that
above the ground will also be considered for resisting the uplift. In case where the frustum of earth
pyramids of two adjoining legs super-impose each other, the earth frustum will be assumed
truncated by a vertical plane passing through the centre line of the tower base.
b.
The following load combinations shall be resisted by the bearing strength of soil.
i.
The down thrust loads combined with the additional weight of concrete in footing below
ground over the earth weight and full weight of concrete above ground level in the footing
are assumed to be acting on the total area of the bottom of the footing.
ii.
The moment due to side thrust forces at the bottom of the footing.
iii.
of loading, if any.
The structural design of base slab shall be developed for the above load combination.
In case of toe pressure calculation due to above load combination, allowable bearing pressure can
be increased by 25%.
c.
The chimney shaft shall be designed as per limit state method for the combined action of axial
forces, tension and compression and the associated max. bending moment. In these calculations,
the tensile strength of the concrete shall be ignored. Similarly, since stub angle is embedded in the
centre of chimney, its effectiveness in the reinforcement calculation is to be ignored.
Page-39
4.10
4.10.1. All the properties of concrete regarding its strength under compression, tension, shear, punching
and bond strength etc. as well as workmanship shall confirm to IS: 456 latest.
4.10.2 The concrete used as lean concrete or base concrete shall be as mentioned on respective drawings.
The aggregate size shall be 40 mm nominal. Base concrete shall be well compacted. The top
surface of base concrete shall be leveled before placing the reinforcement.
During excavation, if excavation exceeds the required depth or if any loose pocket of earth is met
below the base of footing, then the loose earth shall be removed or excavation depth be increased
till normal hard soil is met as per satisfaction of the Engineer-in-Charge. This extra depth shall be
filled with lean concrete. No extra shall be paid on account of this extra excavation and lean
concrete.
4.10.3 The cement concrete used for foundation shall be of grade M-20 {irrespective of any grade
mentioned on the drawing(s)}. The Mix Design (conforming to IS standards) shall be done prior to
start of work, as per specifications, got approved from the Employer and shall be used for the
construction, provided there is no change in the source and the quality of materials. The source of
materials shall be intimated to the Employer and shall be ensured that Mix Design is with the
materials from intimated source only and same is not changed during construction. In case source
of material changes or quality of material differs from the earlier approved parameters, the Mix
Design shall be done again. Whenever there is uncertainty of availability of aggregates from a fixed
source, nominal mix is to be followed but the quality of aggregates shall not be compromised. To
avoid the delays, the contractor may go for nominal mix after getting the aggregates tested till such
time the mix design is got approved.
4.10.4 The coarse aggregate used shall be 20 mm graded or two types of single size aggregate mixed in
some fixed ratio to have graded 20-mm aggregate. The Coarse aggregate shall conform to IS 383.
4.10.5 Grading of Fine aggregate shall conform to Zone-II of Table-4 of IS: 383 and shall be free from
deleterious materials.
4.10.6 The environmental exposure condition considered for Mix Design shall be MILD.
4.10.7 For Mix Design the degree of quality control shall be considered as FAIR.
4.10.8 The Water Cement ratio shall be minimum 0.50 and maximum 0.55.
4.10.9 For Transmission Line Tower footings, the minimum Slump shall be 50 mm and maximum 75
mm.
4.10.10 For volumetric use of ingredients for concrete mix, the contractor along with the Mix Design shall
intimate the size of measuring boxes along with the Mix design.
4.10.11The approval of Mix Design shall not absolve the contractor from the responsibility of achieving the
required strength, workability etc. during actual execution. In case of failure of concrete samples,
the work done is liable to be rejected. In such case the contractor shall recast the foundation at the
same location by dismantling the rejected foundation or at a nearby location as directed by the
Employer. In case of honey combing, the contractor shall do the pressure grouting as directed and
to the full satisfaction of Employer. The construction of new foundation in place of rejected one and
pressure grouting if done shall be without any extra payment.
Page-40
4.10.12Ordinary Portland_Cement of Grade 43 of reputed make like JK,, ACC, Ambuja, Shree conforming
to IS: 8112 shall be used. However in case of shortage of OPC Cement, Portland Pozzolona Cement
(fly ash based or calcinated clay based) conforming to IS 1489 Part Part 1 and 2 respectively
may be used in the works other than RCC. In case, Portland Pozzolona Cement is used then curing
period shall be enhanced as directed by Engineer-in-Charge. In RCC works only Ordinary Portland
Cement of Grade 43 shall be used.
4.10.13 The water used for mixing concrete and for curing purpose shall be fresh, clean and free from oils,
acids and alkalis, organic materials or other deleterious substance. Potable water is generally
preferred. Saltish or brackish water shall not be used. Water used shall conform to clause 5.4 of
IS 456.
4.10.14 Reinforcement steel (including TMT) Bars manufactured by TISCO, SAIL, IISCO and RASHTRIYA
ISPAT (primary manufacturers) conforming to IS: 1786 for deformed and cold twisted bars shall
only be used. The bidders shall, however, be allowed to use Amba steel, Rathi steel, Kamdhenu
steel, Barnala steel, P.R.S steel, Shidbali steel (manufactured by secondary manufacturers) only
after obtaining non-availability certificate from the primary manufacturers. Before using secondary
steel, the selected bidder would require to conduct all physical & chemical tests (lot wise & dia.
wise) to establish its conformity to IS Standards. Required grade of steel shall be Fe-415. All
reinforcement shall be clean and free from loose mill scale, dust, loose rust and coats of paint, oil
or other coating, which may destroy or reduce bond with concrete. Reinforcement bars should be
fresh. Contractor shall supply, fabricate and place reinforcement to shapes and dimensions as
indicated on the drawings or as required to carry out the intent of drawings and specifications.
Adequate nos. of chairs, spacers of required size shall be provided to ensure the proper placement
of reinforcement. The reinforcement bars crossing one another should be tied together at every
intersection with two strands of annealed steel wires 0.9 to 1.6 mm thick twisted and tied to make
the skeleton of the steel work rigid so that the reinforcement does not get displaced during concrete
placement.
All the reinforcement steel should be placed/ stacked at site store on raised (at least 0.5 meter from
near surroundings) pucca/brick platform or reinforcement steel should be placed on MS/GI sheets.
The reinforcement steel after stacking should be covered with Tarpaulin to avoid corrosion.
Immediately before concreting (portion of reinforcement to be embedded in concrete) shall be
painted with cement slurry after removing any rust/corrosion/any other foreign material.
4.11
4.11.1 The rates of foundation shall be per tower. These rates shall include excavation, stub setting,
concreting, reinforcement, shuttering, shoring/ timbering, stockpiling, dressing, curing, back filling
(after concreting) with good (excavated/borrowed) earth irrespective of lead. Rates are inclusive of
compaction of earth, carriage of surplus earth to suitable disposal location as required by Employer
or any other activity related to completion of foundation works in all respects.
4.11.2 In case of any change/variation in the foundation drawing(s) attached with bidding document, due
to site conditions or otherwise, the payment shall be made based on formula given in the commercial
clause.
Page-41
4.12
4.12.1 EXCAVATION
Excavation work shall start only after the approval of route plan, the tower foundation schedule,
classification of foundations and the profile by the Employer. The reference natural ground level
shall be so chosen that it is not lower than surroundings and in normal condition water does not
accumulate there, preferably it should be slightly higher than surroundings.
All excavation for footing shall be made to the lines and grades of the foundation. The excavation
wall shall have stable slope and the pit dimensions shall be such as to allow a clearance of 150 mm
on all sides from the foundation RCC pad. The contractor should ensure clearance of 150 mm from
the foundation RCC pad for quality work.
All excavation shall be protected so as to maintain a clean sub-grade until the footing is placed,
using timbering/shuttering, shoring etc., if necessary. Any sand, mud, silt or other undesirable
materials, which may accumulate in the excavated pit, shall be removed by the contractor before
placing concrete.
4.12.2 No extra charges shall be admissible for the removal of the fallen earth in the pit, when once
excavated.
4.12.3
4.13
Wherever ground water table is higher than the base of the foundation, it has to be depressed by
de-watering. During de-watering, water shall be thrown at a place as directed by the Engineer-inCharge. No pit/open de-watering shall be permitted. Instead, over all lowering of the water table
shall be done by providing sufficient number of bores around the tower location and by continuous
pumping of water through these bores. Well point system for de-watering of pits can also be
adopted. It must be ensured that during de-watering/pumping operation, no finer particles of soil
get displaced or any cavity is formed below. The boreholes for de-watering shall be located so as
to avoid any hindrance in normal working for construction of foundation. The construction of
foundation shall be carried out in bone-dry condition, which shall be ensured by effective lowering
of water table so that no caving in happens and also the bottom of the pit is free from slushy
conditions. The bores shall be filled with sand after the work at a particular location is over.
SETTING OF STUBS
The stubs shall be set correctly in accordance with approved method at the exact location and
aligned precisely at correct levels with the help of stub setting templates and leveling instruments.
Stubs shall be set in the presence of Employers representative for which the Contractor shall give
adequate advance intimation to the Employer. All necessary precautions should be taken to ensure
that the stubs finally set in are not disturbed. If these are disturbed due to any reason, the bidder
shall reset the same without any extra cost.
4.14
4.15
4.15.1 The concrete shall be mixed in a mechanical mixer. The mixer shall comply with IS: 1791 & IS:
12119. The mixer shall be fitted with water measuring devices. Mixer without trough should not be
brought at site. In case of difficult terrain, the Employer at his discretion may permit hand mixing but
this should not be made a routine. In case of hand mixing, 10% extra cement shall be used without
any extra cost.
4.15.2Mixing shall be continued until there is uniform distribution of material and the mix become uniform
in colour and consistency. If there is segregation after unloading from mixer, the concrete should
be re-mixed, but in no case the mixing be done for less than two minutes. Normally, mixing shall be
done close to the foundation, but in case it is not possible the concrete may be mixed at a nearest
convenient place. From mixer the concrete shall be put on pucca platform or steel troughs, which
shall be leak proof to avoid any loss of water/slurry.
The concrete shall be transported from the place of mixing to the place of final deposit as rapidly as
practicable by methods, which will prevent the segregation or loss of any ingredient. The concrete
shall be placed and compacted before setting commences.
4.15.3 Form boxes of required size as per approved Mix Design volumes shall be used for casting all type
of foundations. Form boxes shall be rigidly tightened so that there are no distortions in the shape of
foundations. Form boxes shall be made sufficiently strong to withstand all the loads and vibrations.
For bottom pad portion sufficiently wide window of minimum size 450 x 300 mm be left on each side
at top for placing of concrete and for use of vibrators to ensure thorough compaction. After every
use, the form box(es) be checked for any deformation and if necessary be repaired/corrected to
original position for reuse.
4.15.4 On removal of the form-work, if the concrete surface is found damaged, it shall be repaired with rich
cement sand mortar to the satisfaction of the Engineer-in-Charge. The foundation pits be back-filled
only after necessary repairs, if any as required above has been done.
4.16.2 After opening of formwork and removal of shoring and timbering, backfilling shall be started, after
repairs, if any, to the foundation concrete as described under para 4.12.4 above. Backfilling shall
normally be done with excavated soil. In case the excavated soil consists of large boulders/stones,
it should be broken to a maximum size of 80 mm. If the excavated earth has harmful salts, it shall
not, under any circumstance, be used for backfilling. In such case excavated earth shall be disposed
off as directed by the Engineer-in-Charge and suitable earth (clean and free from harmful salts,
organic and other foreign materials) be brought for back filling. This shall be done by the contractor
at his own cost irrespective of lead involved for bringing the suitable earth.
Page-43
4.16.3 The earth shall be deposited in layers (maximum 200 mm layers), leveled and wetted and tampered
properly before another layer is deposited. After the pits have been backfilled to full depth, the stub
template may be removed.
4.16.4 The backfilling and final grading shall be carried upto an elevation of about 75 mm above the
finished ground level to drain out water. After backfilling 50 mm high earthen embankment (bandh)
will be made along the side of excavation pits and sufficient water will be poured in the backfilled.
4.17
CURING
Curing shall start after 24 hours of concreting to keep the concrete wet continuously for a period of
10 days. However, after a minimum period of 72 hours the pit may be backfilled with suitable earth
sprinkled with necessary amount of water and well consolidated in layers not exceeding 200mm.
Both backfilled earth and exposed chimney top shall be kept wet for the remainder of the prescribed
time of 10 days. The uncovered concrete chimney above the backfilled earth shall be kept wet by
providing gunny bags dipped in water fully wrapped around the concrete chimney for curing. It must
be ensured that the bags are kept wet by the frequent pouring of water on them. In case Portland
Pozolona cement has been used, curing period shall be increased as decided by the Engineer-incharge.
4.18
4.18.1 The work shall include all necessary brick/stone masonry (in C.M. 1:4) revetments, earth filling
above ground level and the clearance from stacking on the site of surplus excavated soil. Special
measures for protection of foundation wherever required shall be provided after getting prior
approval of the Employer and as per directions of the Engineer-in-Charge.
4.18.2 The excess quantity of earth required for protection of tower (after utilizing the excavated earth) and to be
brought from outside shall be paid as per the rate provided in the letter of award.
4.18.3 The provisional quantities for foundation protection works are furnished in the Schedule of
Quantities as well as in the Price Schedule. The unit rates shall be applicable for adjusting with the
actual quantities of protection work done.
4.19
The contractor shall strictly follow the Field Quality Control Plan (given here under) for effective
control on quality of civil works. All costs of testing as per the Field Quality Control Plan or as
directed by Employer shall be borne by the Contractor.
4.20
Technical Specification given in the Contract will govern for the different items/activities. The
items/activities for which detailed specifications have not been given in the Contract Agreement will
be governed by latest ISI/ NBC specifications.
4.21 Wherever IS Code has been mentioned, it shall mean IS Code with latest
amendments.
Page-44
1.0
EXCAVTION
1.1
1.2
The specification covers excavation for cable trenches, ducts, structural foundation, jointing bays.
The contractor shall control the grading in the vicinity of all excavations so that the surface of the
ground will be properly sloped or diked to prevent surface water from running in to the excavated
area during construction.
The excavation shall include the removal of all materials required to execute the work properly and
shall be made with sufficient clearance to permit the placing, inspection and setting of forms and
completion of all works for which the excavation was done.
The sides and bottoms of excavation shall be cut sharp and true. Under cutting shall not be
permitted. Earth sides of excavations shall not be used in lieu of form work for replacement of
concrete unless authorized by the Engineer where the limitations of space for large excavation
necessitate such decision.
When machines are used for excavation th last 300 mm before reaching the required level shall be
excavated by hand or by such equipment that will leave the soil at required final level in its natural
condition.
The bottom of the excavation shall be trimmed to the required level and when carried below such
level by error, shall be brought to level, by filling with lean concrete of 1:4:8 Mix at contractors cost.
All excavation for installation of underground facilities shall be open cuts.
The excavations for foundation where specified shall be carried out at least 75 mm or as specified
in relevant drawing below the bottom of the structure concrete and then be brought to the required
level by placing lean concrete of 1:4:8 mix or as specified with aggregate of 40 mm nominal size.
When the excavation requires tracing, sheeting, shoring strutting etc. the contractor shall submit to
the Engineer in charge drawings showing arrangement and details of proposed installation and shall
obtain the approval from the Engineer in charge before proceeding with the work.
The contractor shall have to constantly pump out the water collected in the pits, trenches due to
rain, sub soil, springs etc. and maintain dry working conditions at no extra cost to the owner.
During excavation, the required protection is to be done to the foundation/trenches along with
caution signs/protection tapes, around the excavated trenches.
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
However the contractor shall take all precautions at the site of excavation for keeping the free flow
of vehicular and human traffic and to avoid inconvenience in general. The soil transported for
disposal shall be stacked, leveled and dressed neatly.
Page-45
3.0
3.1. The backfilling of excavated trenches around foundation shall consist of one of the following materials
as the Engineer-in-charge may direct in each location.
i) Selected sieved earth from excavated soil.
ii) Selected sieved earth brought from borrows area.
iii) Sand filling (sieved).
3.2 Filling shall be done after the concrete or measonry work has fully set and its curing completed.
3.3 The contractor shall fill in and around any work until it has been properly reinstated and approved by
the Engineer-in charge.
4.0
4.1
Back filling shall be done in horizontal layers of thickness not exceeding 300 mm thickness, free
from pockets with careful watering where necessary for compaction. The backfill shall be riddled
earth free from materials likely to cause damage to the cables.
4.2
The thermal backfill surrounding the cable shall be as per the design approved by the owner.
5.0
5.1
6.0
7.0
7.1
The concrete mix for the various types of pre-cast units shall confirm to IS: 456. The aggregate shall
be mixed by weight and water cement ratio shall be controlled to obtain the dense concrete and the
strength required. The reinforcement shall be as per the design approved. The curing shall be
carried out for the period of minimum seven days from the date of casting and precast element shall
be cured by flooding with water of minimum 25 mm depth over the element for the period mentioned
above.
7.2
8.0
FOUNDATION
Foundations for mounting structures in cement concrete shall be casted by bidder as per approved
drawings.
9.0
10.0
PAINTING
Outdoor Kisok for link boxes etc., shall be painted with anti corrosive paint and red oxide as primer
and two coats of enamel paint. The boxes should be appropriately labeled as per installation at site
regarding the S.No., location, type caution board/danger.
Page-46
11.0
12.0
13.0
13.1
Permanent and durable type, cable route markers/joint indicating blocks should be provided as per
the design approved by the purchaser.
13.2
The Reinforced cement concrete block should be made by the wet process and all the concrete
shall consists of one part cement, one and a half part sand, three parts aggregates of size 20 mm
and down.
13.3
The marking block should be given a smooth cover surface or cement mortar and shall have the
appropriate legends, 5 mm deep engraved on them as HVPNL 66 CABLE Ckt.- I OR HVPNL 66
KV CABLE Ckt.- II, HVPNL 66 KV CABLE or as the case may be.
14.0
PIPES
14.1
HDPE pipes of ISI mark, of approved diameter and thickness, of good quality shall be used for
formation of cable ducts. All sundry materials like coupling, collars, and caps to cover the pipe ends
before cable is pulled in shall be provided.
14.2
The bidder shall furnish the design drawings of foundations, foundation anchor bolts, and design
calculations etc. of these structures.
15.0
SAND
15.1
Sand supplied for backfill shall be river sand, free from flakes, dust, earth, organic matter and large
pebbles and stones and should be free from any chemical contaminats likely to have corrosive
action on the cable coverings. The sand should be sieved through a mesh to remove all large stones
and pebbles. The sand shall be properly graded and shall conform to IS:383 for concreting work.
15.2
The owner will decide on the requirement of the use of sand depending on the availability of the
excavated earth to be used for backfill. The sand should be used with the approval of the owner as
a backfill.
16.0
QUANTITIES
16.1
The quoted price shall also include supply of all material transportation charges, taxes, duties,
Octoroi and tole tax, labour, construction, plant and equipment and fixture, fittings and all temporary
and permanent works necessary for satisfactory completion in all respects.
16.2
If the owner is directed by the Engineer in charge to excavate to a lower level than that indicated in
the drawing, such additional excavation shall not be paid for & will be deemed to be included in the
quoted rates.
16.3
16.4
BY MECHANICAL TRANSPORT
The rate for this item shall include loading, carriage, unloading, stacking and dressing etc. complete.
In no case the excavated soil shall be stacked up to the distance of 1.5 Mtrs. From the edge of
excavation or one third the depth of excavation whichever is more.
16.5
The contractor shall be responsible for estimates, assumptions and conclusions regarding the
nature of the materials to be excavated and difficulty of making and maintaining of required
excavations and performing the work required as shown on the drawing and in accordance with
these specifications. Cofferdams, sheeting, shoring. Draining, dewatering etc. shall be furnished
and installed as required and the cost there of shall be included in the rate quoted. The contractor
shall be held responsible for any damage to any part of the work and property caused by collapse
of sides of excavation. The materials can be salvaged if it can be done with safety for the work and
structure and as approved by the Engineer in charge.
16.6
However, no extra claim shall be entertained for material not salvaged or any other damage to
contractors proper as the results of the collapse. He shall not be entitled to any claim for redoing
the excavations as a result of the same.
17.0
ROAD CUTTING
The road cutting, whether of cement concrete/ asphalt or macadam road surface shall be taken
after obtaining approval for cutting from the civic authorities, traffic police, telephone authorities and
work should be planned to be completed in the shortest possible time. Where necessary work shall
be planned during night or light traffic periods.
18.0
ROAD CROSSING
HDPE pipes shall be used for cable. Pipes diameter should not be less than 1.5 times the cable
diameter.
19.0
FOOTPATH CUTTING
The slabs, kerb- stones, on the roads shall be removed and reinstated without damage.
20.0
REINSTATEMENT
After the cables and pipes have been laid and before the trench is backfill all joints and cable
positions should be carefully plotted and preserved till such time the cable is energized and taken
over by the Engineer. The protective covers shall then be provided, the excavated soil riddled,
sieved and replaced. It is advisable to leave a crown of earth not less than 50 mm and not more
than 100 mm in the centre and tapering towards the sides of the trench.
20.1
The temporary reinstatement of roadways should be inspected at regular intervals, more frequently
in rainy season and immediately after overnight rain for checking settlement and if required the
temporary reinstatement should be done.
20.2
After the subsidence has ceased the trench may be permanently reinstated and the surface resorted
to the best possible condition.
20.3
The road surface being cement concrete, asphalt or tarred macadam, resurfacing will be done by
the civic authorities at owners cost. The fixing of markers etc. shall be co- ordinated by bidder.
20.4
All works shall be carried out under supervision of the Engineer in Charge or his representative.
21.0
Page-49
Page-50
NAME OF LINE :
1)
Grade of
Concrete
a)
Target Mean
Strength
b)
Grade of
Cement
c)
Cement Contents
per cum
d)
Water Cement
Ratio
e)
Slump
2)
Coarse
Aggregate
i)
Nominal size of
aggregate
ii)
Source of
aggregates
iii)
Specific
Gravity
iv)
3)
Fine
Aggregates
i)
Source of
aggregates
ii)
Specific
Gravity
iii)
4)
CEMENT
WATER
SAND
COARSE AGGREGATES
CEMENT
WATER
SAND
COARSE AGGREGATES
i)
By Weight
ii)
By Volume (By
conversion)
iii)
Adjustments, if
any suggested
5)
SIZE OF
MEASUREMENTS
BOXES
SAND
COARSE AGGREGATES
NOTE :
1.
2.
Page-51
3.
The cubes will be tested at site/field lab and cubes of 10% of the total locations of
the line will be tested from approved govt lab.
CERTIFICATE
Sub-Contractor:
Name
:
Name:
Date:
Date:
Name:
Date:
Page-52
NAME OF LINE :
Location Number
Date :
a)
b)
Preceeding Span
As per profile
c)
Succeeding Span
Actual
As per profile
Actual
Tangent Tower:
d)
Bi-section
Actual
e)
f)
Matching of ground
profile:
Calculated
OK detail
CERTIFICATE: Cleared for excavation
Performed and checked by:
Actual
Sub-Contractor:
Name :
Name:
Date:
Date:
Date:
Page-53
NAME OF LINE :
Location No.:
Date :
a)
b)
Total Depth
Leg-3
As
per
Leg-2
Soil Investigation
Leg-4
Leg-1
Depth, Strata-wise be indicated for each leg & also indicate actual depth of pits from
reference
level.
Predominant Soil _____________________________________
c)
Leg-1 (M)
Leg-2
(M)
Leg-3 (M)
d)
e)
Foundation Classification:
Leg-4 (M)
Page-54
As proposed by Contractor
As approved by HVPN
f)
CERTIFICATE:
Name :
Name:
Signature
with Seal:
Date:
Date:
Name:
Date:
Page-55
Date :
A3 :
a)
b)
Alignment of template/prop. :
i)
Yes/No
ii)
Yes/No
c)
Clearance between the lowest part of stub and lean pad (Concrete)
Leg 1 ---------------------- cm
Leg 2 ---------------------- cm
Leg 3 ---------------------- cm
Leg 4 ---------------------- cm
d)
e)
Yes/No
Yes/No
CERTIFICATE:
Name :
Name:
Date:
Date:
Name:
Date:
Page-56
NAME OF LINE :
Location No.:
Date :
PART-A : FOUNDATION
ACTIVITY
A4 :
a)
b)
Sr.No.
Length
Drgs.
c)
Diameter
Actual
Drgs.
Actual
Nos.
Drgs.
Yes/No
REMARKS
Actual
(testing details)
d)
Yes/No.
e)
Yes/No.
Source of
collection :
Sand
Name
Metal/Aggregate
Approved/Not Approved
Name
f)
Quality of Water:
i)
Confirming to specification :
ii)
g)
Required T&P such as mixer, vibrator, slump cone, form boxes, shuttering,
Approved/Not
Approved
Yes/No.
Yes/No.
Page-57
CERTIFICATE:
Sub-Contractor:
Name :
Name:
Date:
Date:
Name:
Date:
Page-58
Date :
A5 :
Lean Concrete
a)
b)
Yes/No
c)
Dewatering done:
Yes/No
d)
Yes/No
e)
Yes/No
f)
Sr.No.
Leg-1
Leg-2
Bags (nos)
Thickness
(mm)
CERTIFICATE:
Performed and checked by:
Sub-Contractor:
Leg-3
Leg-4
Reasons
for
variations
from the
drg.
Name :
Name:
Signature with
Seal:
Date:
Date:
Date:
Page-59
NAME OF LINE :
Location No.:
Date :
A6 :
a)
b)
Yes/No
c)
d)
e)
Yes/No
Yes/No
Yes/No
CERTIFICATE:
Sub-Contractor:
Name :
Name:
Signature
with Seal:
Date:
Date:
Name:
Date:
Page-60
Location No.:
Date :
A7 :
a)
b)
Yes/No
c)
Mixing by mixer:
Yes/No
d)
e)
Yes/No
f)
Yes/No
g)
Yes/No
h)
Yes/No
i)
Slump
mm
j)
Actual
k)
Coping is done:
l)
m)
Yes/No
Sub-Contractor:
Name :
Name:
Signature with
Seal:
Date:
Date:
Date:
Page-61
Date :
A8 :
a)
b)
Checking for curing, form box, template/prop removal & back filling:
Curing is started after 24 hrs. of foundation casting
& foundation is kept continuously wet:
Yes/No
Yes/No
c)
Defects in
concrete:
Sr.No.
Type of Defect(s)
Quality of concrete
Yes/No
Description
Remedial measures
No. of
cement
bags
consumed
Honey combing/rough
surface/smooth surface
Cover
Reinforcement visible/
not visible
Shape
As per drawing/distorted
Nature of defects
Major/Minor
d)
Yes/No
e)
Yes/No
CERTIFICATE: Foundation is cleared for Tower erection subject to the completion of setting
time as per standards
Performed and checked by:
SubContractor:
Name :
Name:
Date:
Date:
Date:
Page-62
LOC.No.
DATED:
A9 :
a)
b)
YES/NO
Details
1-3
2-4
As per drawing
Actual
3-4
4-1
1-2
2-3
Performed and checked by:
Subcontractor
: _________________
Name
: _________________
Name
:
______________
Signature
with Seal
: _________________
:
______________
Date
: _________________
Date
:
______________
Signature with
Seal:
Date:
Page-63
LOC.No.
DATED:
A10 :
1.
2.
Tower can not be located on the level Ground even by providing extension
3.
CASE - I
Sl.No.
PARTICULARS
1.
2.
Revetment
3.
Breast Wall
4.
TOTAL
CASE - II
QTY.
RATE
COST
REMARKS
Sl.No.
1.
PARTICULARS
QTY.
RATE
COST
REMARKS
2.
Revetment
3.
Breast Wall
4.
TOTAL
Page-64
SECTION
LOC.No.
DATED:
CASE - III
Sl.No.
PARTICULARS
QTY.
RATE
COST
REMARKS
1.
2.
Revetment
3.
Breast Wall
4.
5.
TOTAL
Note :
Sub-contractor
: _________________
Name
: _________________
Name
:
______________
: _________________
Signature with
Seal
:
______________
Date
: _________________
Date
:
______________
Page-65
Location No.:
Date :
a)
Grade of Concrete:
b)
c)
Date of casting:
d)
Date of testing:
e)
Size of Cube
Sample No.
Cube No.
Cube Strength
(Kg/Cm2)
7 days
1.
1
2
3
2.
1
2
3
3.
1
2
3
4.
1
2
3
28 days
Name :
Name:
Date:
Date:
Page-66
5.0
5.1
GENERAL
5.1.1
The details of the scope of erection work shall include the cost of labour, all tools and plants and all
other incidental expenses in connection with erection and stringing work.
5.1.2
The Bidder shall be responsible for transportation of all the materials as per the scope of work to
site, proper storage and preservation at their own cost till such time the erected line is taken over
by the HVPNL. Bidder shall set up required number of stores along the line and the exact location
of such stores shall be discussed and agreed to between the Bidder and the HVPNL. It shall be
entirely the responsibility of the Bidder to arrange receipt, unloading and loading and transportation
of the supplied items to the stores, proper storage and safe custody.
5.2
5.3
ASSEMBLY
The method followed for the erection of tower, shall ensure the points mentioned below:
a)
Straining of the members shall not be permitted for bringing them into position, it may,
however be necessary to match hole positions at joints and to facilitate this, tommy bars
not more than 450 mm long may be used.
b)
Before starting erection of an upper section, the lower section shall be completely braced
and all bolts provided and tightened adequately in accordance with approved drawings to
prevent any mishap during tower erection.
c)
All plan diagonals relevant to a section of tower shall be placed in position before assembly
of upper section is taken up.
d)
e)
Tower shall fitted with number plate, danger plate, phase plate, circuit plate and anti-climbing
device barbed wire type as described.
f)
All blank holes, if any left, after complete erection of the tower, are to be filled up by bolts
and nuts of correct size.
Page-67
5.4
5.4.1
All nuts shall be tightened properly using correct size spanner/torque wrench. Before tightening, it
will be seen that filler washers and plates are placed in gaps between members wherever
applicable. Bolts of proper size and length are inserted and one spring washer is inserted under
each nut. In case of step bolts, spring washers shall be placed under the outer nut. The tightening
shall progressively be carried out from the top downwards, care being taken that all bolts at every
level are tightened simultaneously. The threads of bolts projecting outside the nuts shall be punched
at their position on the diameter to ensure that the nuts are not loosened in course of time. If during
tightening a nut is found to be slipping or running over the bolt threads, the bolt together with the
nut shall be replaced.
5.4.2
The threads of all the bolts projected outside the nuts shall be welded at two diametrically opposite
places. The circular length of each welding shall be at least 10mm. The welding shall be provided
from ground level to bottom cross arm level for double circuit towers. After welding, cold galvanized
paint having at least 90% zinc content shall be applied to the welded portion. At least two coats of
the paint shall be applied. The cost of welding and paint including application of paint shall be
deemed to be included in the erection price.
5.4.3
In addition to the tack welding of nuts with bolts, as described above, the Bidder can also propose
some alternative arrangements, like use of epoxy resin adhesive which can serve the purpose of
locking the nut permanently with the bolt and thus preventing pilferage of the tower members.
5.5
INSULATOR HOISTING
5.5.1
I suspension insulator strings shall be used on suspension towers and tension insulator strings on
angle and dead end towers. These shall be fixed on all the towers just prior to the stringing.
Damaged insulators and fittings, if any, shall not be employed in the assemblies. Before hoisting all
insulators shall be cleaned in a manner that will not spoil, injure or scratch the surface of the
insulator, but in no case shall any oil be used for the purpose. Corona control rings/arching horn
shall be fitted in an approved manner. Torque wrench shall be used for fixing different line materials
and their components, like suspension clamp for conductor and earthwire etc. Whenever
recommended by the Bidder of the same for river crossing towers.
5.6
5.6.1
The Bidder shall be entirely responsible for any damage to the towers or conductors during stringing.
While running out the conductors, care shall be taken that the conductors do not touch or rub against
the ground or objects which could cause scratches or damages to the strands. The conductors shall
be run out of the drums from the top in order to avoid damage due to chafing. Immediately after
running out, the conductor shall be raised at the supports to the levels of the clamps and placed
into the running blocks. The groove of the running blocks shall be of such a design that the seat is
semi-circular and larger than the diameter of the conductor/earthwire and it does not slip over or
rub against the sides. The grooves shall be lined with hard rubber or neoprene to avoid damage to
conductor and shall be mounted on properly lubricated bearings.
Page-68
5.6.2
The running blocks shall be suspended in a manner to suit the design of the cross-arm. All running
blocks especially those at the tension end, will be fitted on the cross-arm with jute cloth wrapped
over the steel work and under the slings to avoid damage to the slings as well as to the protective
surface finish of the steel work. In case suspension, or section towers are used even for temporary
terminations, if this be unavoidable, they shall be well guyed and steps shall be taken by the Bidder
to avoid damage. Guying proposal alongwith necessary calculations shall be submitted by the
contactor to HVPNL for the approval. Proper T&P shall also be made available to the HVPNL by
the contactor for checking the tensions in the guy wires. The drums shall be provided with a suitable
braking device to avoid damages, loose running out and kinking of the conductor. The conductor
shall be continuously observed for loose or broken strands or any other damage. When approaching
end of a drum length, at least three coils shall be left when the stringing operations are to be
stopped. These coils are to be removed carefully, and if another length is required to be run out, a
joint shall be made as per the recommendations of the Bidders.
5.6.3
Repairs to conductors. If necessary, shall be carried out during the running out operations, with
repair sleeves. Repairing of conductor surface shall be done only in case of minor damage. Scuff
marks etc. keeping in view both electrical and mechanical safe requirements. The final conductor
surface shall be clean smooth and without any projections, sharp points, cuts, abrasions etc.
5.6.4
Conductor splices shall be so made that they do not crack or get damaged in the stringing operation.
The Bidder shall use only such equipment/methods during conductor stringing which ensures
complete compliance in this regard.
5.6.5
Derricks shall be used where roads, rivers, channels, telecommunication or overhead power line,
Railway line, fences or walls have to be crossed during stringing operations. It shall be seen that
normal services are not interrupted or damage caused to property. Shut down shall be obtained
when working at crossing of overhead power line. The Bidder shall be entirely responsible for the
proper handling of the conductor, earthwire and accessories in the field.
5.6.6
The sequence of running out shall be from top to downwards, i.e. the earthwire shall be run out first,
followed by the conductors in succession. Unbalances of loads on tower shall be avoided as far as
possible.
5.6.7
The proposed transmission line may run parallel for certain distance with the existing transmission
line which may remain energized during the stringing period. As a result there is a possibility of
dangerous voltage build up due to electromagnetic and electrostatic coupling in the pulling wire,
conductors and earthwires, which although comparatively small during normal operations can be
severe during switching. It shall be the Bidders responsibility to take adequate safety precautions
to protect his employees and others from this potential danger.
5.6.8
Towers not designed for one sided stringing shall be well guyed and steps taken by Bidder to avoid
damage. The Bidder has to submit the detailed proposal alongwith the calculation for guying which
shall be approved by the HVPNL. Proper T&P shall be made available to the HVPNL by the Bidder
for checking the tensions in the guy wires. All the expenditure on account of the above work is
deemed to be included in the bid price and no extra payment shall be made for the same.
Page-69
5.7
5.7.1
5.7.2
After being pulled the conductor/earthwire shall not be allowed to hang in the stringing blocks for
more than 96 hours being pulled to the specified sag.
5.7.3
The stringing of conductor shall be done as per initial stringing chart duly approved by the HVPNL.
The Bidder shall prepare the initial stringing chart taking account of conductor creep in respect of
ACSR Zebra/Moose which shall be compensated by over-tensioning the conductor at a
temperature of 26oC lower than the ambient temperature during stringing. Conductor creep in
respect of ACSR Panther shall be compensated by over-tensioning the conductor at a temperature
of 21oC lower than the ambient temperature during stringing
5.7.4
The Bidder shall give complete details of the stringing methods, which he proposes to follow. Before
the commencement of stringing the Bidder shall submit the stringing charts for the conductor and
earthwire for various temperatures and span, alongwith equivalent spans for the approval of the
HVPNL.
5.8
JOINTING
5.8.1
All the joints on the conductor and earthwire shall be of compression type, in accordance with the
recommendations of the Bidder for which all necessary tools, equipment like compressors, dies,
processes etc. shall have to be arranged by the Bidder. Each part of the joint shall be cleaned by
wire brush to make it free of rust or dirt etc. and properly greased with anticorrosive compound if
required, and as recommended by the Bidder before the final compression is done with the
compressors.
5.8.2
All joints or splices shall be made at least 30 metres away from the structures. No joints or splices
shall be made in span crossing over main Roads, Railways, small rivers with tension spans. During
compression or splicing operation the conductor shall be handled in such a manner as to prevent
lateral or vertical bearing against the dies. After pressing the joint the aluminum sleeve shall have
all corners rounded, burrs and sharp edges removed and smoothened.
5.8.3
During stringing of conductor to avoid any damage to the joint, the Bidder shall use a suitable
protector with mid span compression joints in case joints are to be passed over pulley blocks/aerial
rollers. The size of the groove of the pulley shall be such that the joint along with protection can be
passed over it smoothly.
5.9
SAGGING-IN-OPERATION
5.9.1
The conductor shall be pulled up to the desired sag and left in running blocks for at least one hour
after which the sag shall be re-checked and adjusted, if necessary before transferring the
conductors from the running blocks to the suspension clamps. The conductor shall be clamped
within 96 hours of sagging in.
5.9.2
The sag will be checked in the first an the last span of the section in case of sections up to eight
spans and in one intermediate span also for sections with more than eight spans. The sag shall
also be checked when the conductors have been drawn up and transferred from running blocks to
the insulator clamps.
Page-70
5.9.3
The running blocks, when suspended from the transmission structure for sagging shall be so
adjusted that the conductors on running blocks will be at the same height as the suspension clamp
to which it is to be secured.
5.9.4
At sharp vertical angles, the sags and tensions shall be checked on both sides of the angle, the
conductor and earthwire shall be checked on the running blocks for equality of tension on both
sides. The suspension insulator assemblies will normally assume vertical positions when the
conductor is clamped.
5.9.5
Tensioning and sagging operations shall be carried out in calm weather when rapid changes in
temperatures are not likely to occur.
5.10
5.11
CLIPPING IN
5.11.1 Clipping of the conductors in position shall be done in accordance with the recommendations of the
Bidder. Conductor shall be fitted with armour rods where it is made to pass through suspension
clamps.
5.11.2 The jumpers at the section and angle towers shall be formed to parabolic shape to ensure
maximum clearance requirements.
5.11.3 Fasteners in all fittings and accessories shall be secured in position. The security clip shall be
properly opened and sprung into position.
5.12
5.13
REPLACEMENT
If any replacements are to be effected after stringing and tensioning or during maintenance, leg
members and bracing shall not be removed without reducing the tension on the tower with proper
guying or releasing the conductor. If the replacement of cross arms becomes necessary after
stringing, the conductor shall be suitably tied to the tower at tension points or transferred to suitable
roller pulleys at suspension points.
Page-71
5.14
5.14.1 The Bidder shall make every effort to minimize the breakages, losses & wastages of the line material
during erection. However, while calculating the quantities of line materials, HVPNL shall permit the
Bidder extra consumption of conductor and earthwire up to the limit of 1%. The Bidder shall be
permitted to dispose off the scraps, if any, at their end. In case of conductor and earthwire, the
permitted extra consumption limit of 1% is inclusive of sag, stringing damages, losses and wastages
etc. The quantity of conductor and earthwire shall be worked out as per following norms.
a)
Quantity of conductor
b)
Quantity of earthwire
The Bidder shall not be required to return to the HVPNL empty conductor and earthwire drums as
the same shall be deemed to become his property.
For other line materials i.e. Disc insulator, Hardware and accessories for conductor and earthwire
the actual quantity incorporated on transmission lines shall be approved as consumption.
5.14.2 The Bidder shall be permitted to dispose off the empty conductor and earthwire drums at his cost.
5.15
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
Sufficient back filled earth is lying over each foundation pit and it is equately compacted.
Concrete chimneys and their copings are in good finely shaped conditions.
All the tower members are correctly used, strictly according to final approved drawing and
are free of any defect or damage whatsoever.
All bolts are properly tightened and punched/tack welded and painted Zinc rich primer and
enamel paint.
The stringing of the conductors and earthwire has been done as per the approved sag and
tension charts and desired clearances are clearly available.
All conductor and earthwire accessories are properly installed.
All other requirements to complete the work like fixing of danger plate, phase plate, number
plate, anti climbing device, aviation signal (wherever required) etc. are properly installed.
Wherever required it should be ensured that revetment is provided.
The original tracings of profile route alignment and tower, design, structural drawings, bill of
material, shop drawings of all towers other that the towers designed by the HVPNL are
submitted to the HVPNL for reference and record.
The insulation of line as a whole is tested by the contactor by providing his own equipment,
labour etc. to the satisfaction of the HVPNL.
All towers are to be properly grounded.
The line is tested satisfactorily for commissioning purpose.
Page-72
6.1
6.1.1
The following provisions shall supplement all the detailed technical specifications and
requirements brought out herein. The Bidders proposal shall be based on the use of materials
complying fully with the requirements specified herein.
The furnishing of engineering data by the Bidder shall be in accordance with the schedule as
specified in the technical specifications. The review of these data by the HVPNL will cover only
general conformance of the data to the specifications and not a thorough review of all
dimensions, quantities and details of the materials, or items indicated or the accuracy of the
information submitted. This review by the HVPNL shall not be considered by the Bidder, as
limiting any of his responsibilities and liabilities for mistakes and deviations from the
requirements, specified under these specifications.
6.2.2
All engineering data submitted by the Bidder after review by the HVPNL shall form part of the
contract documents.
6.3
DRAWINGS
6.3.1
All drawings submitted by the Bidder including those submitted at the time of bid shall be with
sufficient detail to indicate the type, size, arrangement, dimensions, material description, bill of
materials, weight of each component, break-up for packing and shipment, fixing arrangement
required, the dimensions required for installation and any other information specifically
requested in these specifications.
6.3.2
Each drawing submitted by the Bidder shall be clearly marked with the name of the HVPNL, the
specification title, the specification number and the name of the project. All titles, noting,
markings and writings on the drawing shall be in English. All the dimensions should be to the
scale and in metric units.
6.3.3
The drawings submitted by the Bidder shall be reviewed by the HVPNL as far as practicable
within 30 days and shall be modified by the Bidder if any modifications and/ or corrections are
required by the HVPNL. The Bidder shall incorporate such modifications and/or corrections and
submit the final drawings for approval. Any delays arising out of failure by the Bidder to rectify
the drawings in good time shall not alter the contract completion date.
6.3.4
The drawings submitted for approval to the HVPNL shall be in quadruplicate. One print of such
drawings shall be returned to the Bidder by the HVPNL marked approved / approved with
corrections. The Bidder shall thereupon furnish the HVPNL additional prints as may be required
along with one reproducible in original of the drawings after incorporating all corrections.
6.3.5
The work shall be performed by the Bidder strictly in accordance with these drawings and no
deviation shall be permitted without the written approval of the HVPNL, if so required.
Page-73
6.3.6
All manufacturing, fabrication and erection work under the scope of Bidder, prior to the approval
of the drawings shall be at the Bidders risk. The Bidder may make any changes in the design
which are necessary to conform to the provisions and intent of the Bidder and such changes will
again be subject to approval by the HVPNL.
6.3.7
The approval of the documents and drawings by the HVPNL shall mean that the HVPNL is
satisfied that:
a) The Bidder has completed the part of the works covered by the subject document (i.e.
confirmation of progress of work.)
b) The works appear to comply with requirements of specifications.
In no case the approval by the HVPNL of any document does imply compliance with all technical
requirement nor the absence of errors in such documents.
If errors are discovered any time during the validity of the contract, then the Bidder shall be
responsible of their consequences.
6.3.8
The HVPNL may use a 35mm microfilm system in processing drawings. All drawings shall be
suitable for microfilming. Drawings, which are not suitable for microfilming, will not be accepted.
A copy of each drawing reviewed will be returned to the Bidder as stipulated herein.
6.3.9
Copies of drawings returned to the Bidder will be in the form of a print with the HVPNL marking,
or a print made from a microfilm of the marked up drawing.
6.3.10 The following is the generic list of the documents and drawings that are to be approved by the
HVPNL.
a)
b)
c)
d)
Detailed survey report and profile drawing showing ground clearance and tower locations.
e)
f)
g)
h)
i)
j)
Quality plan for fabrication and site activities including quality system.
k)
Page-74
6.4
DESIGN IMPROVEMENTS
6.4.1
The HVPNL or the Bidder may propose change in the specification and if the parties agree upon
any such changes and the cost implication, the specification shall be modified accordingly.
6.4.2
If any such agreed upon change is such that it affects the price and schedule of completion, the
parties shall agree in writing as to the extent of any change in the price and/ or schedule of
completion before the Bidder proceeds with the change. Following such agreement, the
provision thereof, shall be deemed to have been amended accordingly.
6.5
DESIGN CO-ORDINATION:
6.5.1
The Bidder shall be responsible for the selection and design of appropriate material/item to
provide the best co-ordinated performance of the entire system. The basic design requirements
are detailed out in this specification. The design of various components, sub-assemblies and
assembles shall be so done that it facilitates easy field assembly and maintenance.
6.6
The Bidder will be called upon to attend design review meetings with the HVPNL and the
consultants of the HVPNL during the period of contract. The Bidder shall attend such meetings
at his own cost at Faridabad or at mutually agreed venue as and when required. Such review
meeting will be held generally four times in a year.
6.7
PACKING:
6.7.1
All the materials shall be suitably protected, coated, covered or boxed and crated to prevent
damage or deterioration during transit, handing and storage at site till the time of erection. The
Bidder shall be responsible for any loss or damage during transportation, handing and storage
due to improper packing.
6.7.2
The Bidder shall include and provide for securely protecting and packing the materials so as to
avoid loss or damage during transport by air, sea, Rail and road.
6.7.3
All packing shall allow for easy removal and checking at site. Wherever necessary, proper
arrangement for attaching slings for lifting shall be provided. All packages shall be clearly
marked for with signs showing up and down on the sides of boxes, and handling and unpacking
instructions as considered necessary. Special precaution shall be taken to prevent rusting of
steel and iron parts during transit by sea.
6.7.4
The cases containing easily damageable material shall be very carefully packed and marked
with appropriate caution symbols, i.e. fragile, handle with care, use no hook etc wherever
applicable.
6.7.5
Each package shall be legibly marked by the Bidder at his expenses showing the details such
as description and quantity of contents, the name of the consignee and address, the gross and
net weight of the package, the name of the Bidder etc.
Page-75
7.
ERECTION CONDITIONS:
7.1
The following shall supplement the conditions already contained in the other parts of these
specifications and documents and shall govern that portion of the work on this contract to be
performed at site.
7.2
7.2.1
The contactor shall comply with all the rules and regulations of local authorities during the
performance of his field activities. He shall also comply with the minimum wages act. 1948 and
the payment of wages act (both of the government of India) and the rules made there under in
respect of any employee or workman employed or engaged by him or his sub-Bidder.
7.2.2
All registration and statutory inspection fees, if any, in respect of his work pursuant to this
contract shall be to the account of the Bidder. However, any registration, statutory inspection
fees lawfully payable under the provisions of the statutory laws and its amendments from time
to time during erection in respect of the transmission line, ultimately to be owned by the HVPNL,
shall be to the account of the HVPNL. Should any such inspection or registration need to be rearranged due to the fault of the Bidder or his sub-Bidder, the additional fees to such inspection
and/or registration shall be borne by the Bidder.
7.3
7.3.1
The Bidder shall keep the HVPNL informed in advance regarding his field activity plans and
schedules for carrying out each part of the works. Any review of such plan or schedule or method
of work by the HVPNL shall not relieve the Bidder of any of his responsibilities towards the filed
activities. Such reviews shall also not be considered as an assumption of any risk or liability by
the HVPNL or any of his representatives and no claim of the Bidder will be entertained because
of the failure or inefficiency of any such plan or schedule or method of work reviewed. The
Bidder shall be solely responsible for the safety, adequacy and efficiency of tools and plants
and his erection methods.
7.4
PROGRESS REPORT
7.4.1 Appropriate visual charts shall accompany the monthly progress reports detailing
out the progress achieved on all erection activities as compared to the schedules.
The report shall also indicate the reasons for the variance between the scheduled
and actual progress and the action proposed for corrective measures, wherever
Necessary.
7.5
7.5.1
The Bidder shall submit to the HVPNL, on the first day of every month, a man power deployment
schedule for each activity.
7.5.2
The Bidder shall also submit to the HVPNL on the first day of every month, a man power
deployment report of the previous month detailing the number of persons scheduled to have
been employed and actually employed.
Page-76
7.5.3
7.5.4
7.5.5
Similarly the labour colony, the offices and the residential areas of the contactors employees
and workmen shall be kept clean and neat to the entire satisfaction of the HVPNL. Proper
sanitary arrangements shall be provided by the Bidder, in the work-areas, office and residential
areas of the Bidder. Waste oil shall be disposed off in a manner acceptable to the HVPNL.
Under no circumstances shall waste oil be dumped into uncontrolled drains.
7.6
FIRE PROTECTION
7.6.1
The work procedures that are to be used during the erection shall be those which minimise fire
hazards to the extent practicable. Combustible materials, combustible waste and rubbish shall
be collected and removed from the site at least once each day. Fuels, oils and volatile or
flammable materials shall be stored away from the construction site and equipment and material
stores in safe containers.
7.6.2
All the contactors supervisory personnel and sufficient number of workers shall be trained for
fire-fighting and shall be assigned specific fire protection duties. Enough of such tainted
personnel must be available at the site during the entire period of the contract.
7.6.3
The Bidder shall provide enough fire protection equipment of the types and number for the ware
house, office, temporary structures, labour colony area etc. Access to such fire protection
equipment, shall be easy and kept open at all time.
7.7
SECURITY
The Bidder shall have total responsibility for all equipment and materials in his custody, stored,
loose, semi-assembled and/or erected by him at site. The Bidder shall make suitable security
arrangements including employment of security personnel to ensure the protection of all
materials, equipment and works from theft, fire pilferage and any other damages and loss.
7.8
7.8.1
All the supplies under the contract as well as HVPNL supplied items arriving at site shall be
promptly received, unloaded and transported and stored in the stores by the Bidder.
Page-77
7.8.2
Bidder shall be responsible for examining all the shipment and notify the HVPNL immediately of
any damage, shortage, discrepancy etc. for the purpose of HVPNL information only. The Bidder
shall submit to the HVPNL every week a report detailing all the receipts during the week.
However, the Bidder shall be solely responsible for any shortages or damages in transit,
handling and/or in storage and erection at site. Any demurrage, wharfage and other such
charges claimed by the transporters, Railways etc. shall be to the account of the Bidder.
7.8.3
The Bidder shall maintain an accurate and exhaustive record detailing out the list of all items
received by him for the purpose of erection and keep such record open for the inspection of the
HVPNL.
7.8.4
All items shall be handled very carefully to prevent any damage or loss. The materials stored
shall be properly protected to prevent damage. The materials from the store shall be moved to
the actual location at the appropriate time so as to avoid damage of such materials at site.
7.8.5
All the materials stored in the open or dusty location must be covered with suitable weatherproof and flame proof covering material wherever applicable.
7.8.6
The Bidder shall be responsible for making suitable indoor storage facilities, to store all
items/materials, which require indoor storage.
7.9
CONSTRUCTION MANAGEMENT
7.9.1
Time is the essence of the contract and the Bidder shall be responsible for performance of his
works in accordance with the specified construction schedule. If at any time, the Bidder is falling
behind the schedule for reasons attributable to him, he shall take necessary action to make
good for such delays by increasing his work force or by working overtime or otherwise to
accelerate the progress of the work and to comply with schedule and shall communicate such
actions in writing to the HVPNL, satisfying that his action will compensate for the delay. The
Bidder shall not be allowed any extra compensation for such action.
7.10
The Bidder shall maintain at his site office up-to-date copies of all drawings, specifications and
other supplementary data complete with all the latest revisions there to. The Bidder shall also
maintain, in addition, the continuous record of all changes to the above contract documents,
drawings, specifications, supplementary data, etc. effected at the field and on completion of his
total assignment under the contract shall incorporate data to indicate as installed conditions of
the material supplied and erected under the contract. Such drawings and engineering data shall
be submitted to the HVPNL in required number of copies.
7.11
7.11.1 The Bidder will ensure provision of necessary safety equipment such as barriers, sign-boards,
warning lights and alarms, etc. to provide adequate protection to persons and property. The
Bidder shall be responsible to give reasonable notice to the HVPNL and the HVPNLs of public
or private property and utilities when such property and utilities are likely to get damaged or
injured during the performance of his works and shall make all necessary arrangements with
such HVPNLs, related to removal and/or replacement or protection of such property and utilities.
Page-78
7.12
The Bidder shall ensure that any finds such as relics, antiques, coins, fossils, etc. which he may
come across during the course of performance of his works either during excavation or
elsewhere, are properly protected and handed over to the HVPNL. Similarly, the Bidder shall
ensure that the bench marks, reference points, etc. which are marked either with the help of
HVPNL or by the HVPNL shall not be disturbed in any way during the performance of its works,
if any work, is to be performed which disturbs such reference, the same shall be done only after
these are transferred to other suitable locations under the direction of the HVPNL. The Bidder
shall provide all necessary materials and assistance for such relocation of reference points etc.
7.13
7.13.1 The Bidder shall ensure safety of all the workmen, materials plant and equipment belonging to
him or to the others, working at the site. The Bidder shall also provide for all safety notices and
safety equipment required by the relevant legislations and deemed necessary by the HVPNL.
7.13.2 The Bidder will notify, well in advance to the HVPNL, its intention to bring to the site any
container filled with liquid or gaseous fuel or explosive or petroleum substance of such
chemicals, which may involve hazards. The HVPNL shall have the right to prescribe the
conditions, under which such a container is to be stored, handled and used during the
performance of the works and the Bidder shall strictly adhere to and comply with such
Instructions. The HVPNL shall also have the right, at his sole discretion, to inspect any such
container or such construction plant/equipment for which materials in the container is required
to be used and if in his opinion, its use is not safe, he may forbid its use.
No claim due to such prohibition or towards additional safety provisions called for by him shall
be entertained by the HVPNL.
Further, any such decision of the HVPNL shall not, in any way, absolve the Bidder of his
responsibilities and in case use of such a container or entry there- of into the site area is
forbidden by the HVPNL, the Bidder shall use alternative methods with the approval of the
HVPNL without any cost implication to the HVPNL or extension of work schedule.
7.13.3 where it is necessary to provide and/or store petroleum products or petroleum mixtures and
explosives, the Bidder shall be responsible for carrying out such provision and/or storage in
accordance with the rules and regulations laid down in petroleum act 1934, explosives act 1948
and amendments thereof, and petroleum and carbide of calcium manual published by the Chief
Inspector of explosives of India. All such storage shall have prior approval of the HVPNL. In
case, any approval is necessary from the Chief Inspector (explosives) or any statutory
authorities, the Bidder shall be responsible for obtaining the same.
7.13.4 All equipment used in construction and erection by Bidder shall meet Indian/International
standards and where such standards do not exist, the Bidder shall ensure these to be absolutely
safe. All equipment shall be strictly operated and maintained by the Bidder in accordance with
manufactures operation manual and safety instructions and as per any existing Guideline/Rules
in this regard.
Page-79
7.13.5 Periodical examinations and all tests for all lifting/ hoisting equipment and tackle shall be carried
out in accordance with the relevant provisions of factories act. 1948, Indian Electricity Supply
Act and associated Laws/ Rules in force from time to time. A register of such examinations and
tests shall be properly maintained by the Bidder and will be promptly produced as and when
desired by HVPNL or by the persons authorized by him.
7.13.6 The Bidder shall provide suitable safety equipment of prescribe standard to all employees and
workmen according to the need, as may be directed by the HVPNL who will also have the right
to examine these safety equipment to determine their suitability, reliability, acceptability and
adaptability.
7.13.7 Where explosives are to be used, the same shall be used under the direct control and
supervision of an expert, experienced and qualified competent person, strictly in accordance
with the code of practices /rules framed under Indian Explosives Act pertaining to handling,
storage and use of explosive.
7.13.8 The Bidder employing more than 250 workmen, whether temporary casual, probationer, regular
or permanent or on contract, shall employ at least one full time officer exclusively as safety
officer to supervise safety aspects of the equipment and workmen. Such an officer will coordinate with the project safety officer of the HVPNL.
The name and address of such safety officer of the Bidder will be promptly informed in writing
to the HVPNL with a copy to the safety officer- incharge before he starts work or immediately
after any change of the incumbent is made during currency of the contract.
7.13.9 In case any accident occurs during the construction/erection or other associated activities
undertaken by the Bidder, thereby causing any minor or major or fatal injury to his employees
due to any reason whatsoever, it shall be the responsibility of the Bidder to promptly inform the
same to the HVPNL and also to all the authorities envisaged under the applicable laws.
7.13.10
The HVPNL shall have the right to stop the work, if in its opinion the work is being carried
out in such a way as may cause accidents and endanger the safety of the persons and/or
property. In such cases, the Bidder shall be informed in writing about the nature of hazards and
possible injury/accident and he shall remove short-comings promptly. The Bidder, after stopping
the specific work, can, if felt necessary, appeal against the order of stoppage of work to the
HVPNL within 3 days of such stoppage of work and the decision of the HVPNL in this respect
shall be conclusive.
7.13.11
The Bidder shall not be entitled for any damages/compensation for stoppage of work due to
safety reasons as provided in clause 7.13.10 above and the period of such stoppage of work
will not be taken as an extension of time for completion of work and will not be the ground for
waiver of any part of contactors liability for timely completion of the works.
7.13.12
The Bidder shall follow and comply with all safety rules, relevant provisions of applicable
laws pertaining to the safety of workmen, employees, plant and equipment as may be prescribed
from time to time without any demur, protest or contest or reservation. In case of any conflict
between statutory requirement and safety rules referred above, the most stringent clause shall
be applicable.
Page-80
7.13.13
If the Bidder fails in providing safe working environment as per safety rules or continues the
work even after being instructed to stop work by the HVPNL as provided in clause 7.13.10
above, the Bidder shall promptly pay to the HVPNL on demand, compensation at the rate of Rs.
5,000/- per day or part thereof till the instructions are complied with and so certified by the
HVPNL. However, in case of accident taking place causing injury, to any individual, the
provisions contained in clause 7.13.14 below shall also apply in addition to compensation
mentioned in this para.
7.13.14
If the Bidder does not take all safety precautions and/or fails to comply with the safety rules
as prescribed by the HVPNL or as prescribed under the applicable law for the safety of the
equipment, plant and personnel and the Bidder does not prevent hazardous conditions which
may cause injury to his own employees or employees of other Bidders, or HVPNL or any other
person at site or adjacent thereto, the Bidder shall be responsible for payment of compensation
to the HVPNL as per the statutory provisions.
Permanent disability shall have the same meaning as indicated in workmens compensation act.
The compensation mentioned above shall be in addition to the compensation payable to the
workmen/employees under the provision of workmens compensation act and rules framed
there under or any other applicable law as applicable from time to time. In case the HVPNL is
made to pay such compensation, the Bidder will be liable to reimburse the HVPNL such
amount(s) in addition to the compensation indicated above.
7.14
FOREIGN PERSONNEL
7.14.1 In case necessary for the execution of the works, the Bidder shall bring foreign supervisors for
the execution of the contract, at his own cost. The Bidder shall submit to the HVPNL, data on
all personnel he proposes to bring into India for the performance of the works under the contract,
at least sixty (60)days prior to their arrival in India. Such data shall include the name of each
person, his present address, his assignment and responsibility in connection with the works,
and a short resume of his qualification, experience etc. in relation to the work to be performed
by him.
7.14.2 Any person, unsuitable and unacceptable to the HVPNL, shall not be brought to India. Any
person brought to India, and found unsuitable or unacceptable to the HVPNL shall be
immediately removed from site and repatriated back. If found, necessary, he may be replaced
by another personnel acceptable to the HVPNL.
7.14.3 No person brought to India by the Bidder, for the works shall be repatriated without the consent
of the HVPNL in writing, based on a written request from the Bidder for such repatriation giving
reasons for such an action to the HVPNL. The HVPNL may give permission for such repatriation
provided it is satisfied that the progress of work will not suffer due to such repatriation.
7.14.4 The cost of passports, visas and all other travel expenses to and from India, shall be to the
Bidders account. The HVPNL will not provide any residential accommodation and/ or furniture
for any of the Bidders personnel including foreign personnel Bidder shall make his own
arrangements for such facilities.
Page-81
7.14.5 The Bidder and its expatriate personnel shall respect all Indian Acts, Laws, Rules and
Regulations and shall not, in any way, interfere with Indian political and religious affairs and
shall conform to any other rules and regulations which the government of India, and the HVPNL
may establish on them. The contactors expatriate personnel shall work and live in close cooperation and co-ordination with their co-workers and the community and shall not engage
themselves in any other employment either part-time or full-time nor shall they take part in any
local politics.
7.14.6 HVPNL shall assist the Bidder, to the extent possible, in obtaining necessary permits to travel
to India and back, by issue of necessary certificates and other information needed by the
government agencies.
7.15
CODE REQUIREMENTS
The erection requirements and procedures to be followed during the execution of the project
shall be in accordance with the applicable Indian/International standards/regulations, as
indicated in technical specifications, good engineering practice, the Drawings and another
applicable Indian codes, laws and regulations.
Page-82
ANNEXURE-IA
Sr. No.
Description
Drawing
No.
1.
2.
Circuit Plate
3.
10
10
11
11
12.
12
13
13
earthwire
14
14
ANNEXURE-IB
Sr. No.
Description
Drawing
No.
1.
2.
Circuit Plate
3.
10
10
drawing
11
11
12.
12
drawing
13
13
14
14
drawing
15
15
16
16
drawing
17
17
drawing
18
18
earthwire
19
19
ANNEXURE-IB
Name of line
Tentative Length of
line in km
2.31
LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV 2.465x8
S/Stn.A4 at 66kv S/Stn.Idgah with 1200mm2 XPLE underground
cable
2.4x8
Creation of LILO of both circuit of the existing 220kV D/C FGPPBBMB Samaypur (PGCIL line) at 220kV S/Stn. Sector-58,
Faridabad on M/C towers, M/C Monopole to be newly designed and
D/C towers
66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV D/C length =13.55km)
S/Stn.Bhagola with 0.4sq ACSR Zebra. (Tower portion and Cable
portion)
66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 4.895 km
0.4sq ACSR Zebra (Tower portion and cable portion).
Supply part
BOQ of LILO of both circuits of existing 220kv Palla to Palli D/C line at proposed 220kV S/Stn. sector-46 Faridabad
on M/C towers by using ROW of existing 66kV D/C NH-3- Palla line, presently feeding the 66kV S/Stn. sector-46
(partially on M/C monopole to be newly designed)
Qty.
UNIT
A
220kV line on 220kV D/CTATA Design towers
1.1
1.2
No.
No.
No.
No.
1.3
B
220kV line on 220kV KRR Design M/C towers
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers, D-shakle etc.
of following type of 220kV Multi-circuit ( 4 Ckts.) towers of KRR design.
1.1
No.
1.2
No.
1
No.
Design & type testing, Fabrication and supply of following types of monopole with stubs, bolts & nuts,
step bolts, U-bolts, hangers, D-shakle etc.
2.
No.
No.
No.
No.
i) Pipe type
Sets
18
Sets
-0
3.
No.
18
No.
18
Sets
36
Sets
28
Sets
20
Sets
18
LINE MATERIAL
Km
27.37
Earth wire
KM
0.150
Km
0.662
Hardware set for above 24 Fibre OPGW fibre optic cabling including
all cable fittings & accessories except joint box.
set
2
9
No.
10
Lot
Lot
11
Km
1.648
12
set
3
13
No.
14
Km.
15
set
16
FODP 48F: Indoor type, rack mounted with FCPC coupling and pig tails (
5mtrs. Each) as applicable
No.
17
FODP 96F: Indoor type, rack mounted with FCPC coupling and pig tails (
5mtrs. Each) as applicable
No.
18
No.
84
ii) 120 kN
No.
240
19
sets
NIL
20
Hardware Fittings
Set
60
Set
24
Set
240
Set
No.
19
No.
NIL
No.
No.
18
v)
No.
552
No.
No.
28
No.
NIL
No.
12
i)
ii)
iii)
iv)
As per site
1
1
No.
66kV D/C DD type Tower
No.
66kV Gantry
No.
ii) Dismantlement of existing of 0.4sq ACSR Zebra conductor complete
with H/W fittings for above portion of line and their transportation
proper stacking at any dedicated store of HVPNL.
Note:- Type testing to be got done or waived off as per relevant clause of monopoles.
Km
1.504
BOQ of LILO of both circuit of 66kV BBMB Ballabgarh-Jharsetly D/C line at 220kV S/Stn. Sector-58, Faridabad with 0.4sq ACSR
Zebra.
Qty.
DESCRIPTION
UNIT
A)
66kV KRR Design Towers
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, Ubolts, hangers, D-shakle etc. of following type of 66kV KRR Design D/C towers.
1
i)
No.
ii)
No.
Sets
Sets
i) Danger Plate
No.
No.
Sets
Sets
Sets
Sets
B)
LINE MATERIAL
Km
0.485
Km
0.081
Nil
No.
48
No.
Nil
Hardware Fittings
i.
ii.
iii.
iv.
Set
Set
Set
48
Set
10
i)
No.
Nil
ii)
No.
Nil
iii)
No.
Nil
No.
v)
No.
96
No.
16
No.
No.
No.
12
Note:- The Bidder shall offer only one of the option for the Insulator strings ( A/F disc or Polymer) out of the two mentioned above in
his bid.
Bill of Quantity of LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV S/Stn.A4 at 66kv
S/Stn.Idgah with 1200mm2 XPLE underground cable.
Sr. No.
Description
Unit
Total Quantity
1.
Mtrs.
2465x8
2.
No.
16
3.
No.
4.
No
No
6.
Mtrs
300
7.
No.
8.
No.
16
9.
Supply of HDPE pipes required for various crossings with trench less
Mtr.
227x8
10.
No.
32
4 Pole Rail pole structure for the LILO arrangement and foundation
No.
Nil
Any other items not specified above but are required to complete
the job in all respect.
No.
Lot
11.
12.
Note:-
1. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before finalizing
/ submitting the bids.
2. The said work may involve the route through residential area for which Trench-less digging shall be got done
as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
Bill of Quantity of LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV S/Stn. A4 at 66kv
S/Stn.Idgah with 1200mm2 XPLE underground cable.
Sr.
No.
Description
Unit
Quantity
Running
circuit
2238
Running
circuit
Nos.
Nos.
16
Nos.
Lot
Lot
7. Erection of 4 Pole Rail pole structure for the LILO arrangement and their
Foundations including earthing (if required as per site).
No.
Nil
8. Any other items not specified above but are required to complete the job
in all respect.
Lot
Lot
Note:-
Length
(6+2)
Mtrs.
227
Length
(6+2)
Mtrs.
1. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before finalising
/ submitting the bids.
2. The said work may involve the route through residential area for which Trench-less digging shall be got done
as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative &may vary.
BOQ of LILO of one ckt. of 66kV Ballabgarh (220kV BBMB)-Sector-58 D/C line (Section of 66kV Ballabgarh
(220kV BBMB) sector-58 Faridabad-jharsetly D/C line) at 66kV S/Stn. sector-59 Faridabad with 1200mm2 XLPE
cableand tower portion.
Sr. No.
Description
Unit
Total Quantity
1.
Mtrs.
2400x8
2.
No.
16
3.
No.
4.
No
No
6.
Mtrs
300
7.
No.
8.
No.
16
9.
Supply of HDPE pipes required for various crossings with trench less
Mtr.
92x8
10.
No.
32
4 Pole Rail pole structure for the LILO arrangement and foundation
(if required as per site)
No.
Nil
Any other items not specified above but are required to complete
the job in all respect.
No.
Lot
No.
11.
12.
66kV KRR Design DD+0 type tower complete in all respect including
earthing and fencing
Note:-
1. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before finalising
/ submitting the bids.
2. The said work may involve the route through residential area for which Trench-less digging shall be got done
as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of LILO of one ckt. of 66kV Ballabgarh (220kV BBMB)-Sector-58 D/C line (Section of 66kV Ballabgarh
(220kV BBMB) sector-58 Faridabad-jharsetly D/C line) at 66kV S/Stn. sector-59 Faridabadwith 1200mm2
XLPE cable and tower protion.
Sr.
No.
Description
Unit
Quantity
Running
circuit
2308
Running
circuit
Nos.
Nos.
16
5. Installation of polymericLAs
counter
Nos.
Lot
Lot
7. Erection of 4 Pole Rail pole structure for the LILO arrangement and their
Foundations including earthing (if required as per site).
No.
Nil
No.
9. Any other items not specified above but are required to complete the
job in all respect.
Lot
Lot
Length
(6+2)
Mtrs.
92
Length
(6+2)
Mtrs.
Note:-
1. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before finalizing
/ submitting the bids.
2. The said work may involve the route through residential area for which Trench-less digging shall be got done
as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of creation of LILO of both circuit of the existing 220kV D/C FGPP-BBMB Samaypur
(PGCIL line) at 220kV S/Stn. Sector-58, Faridabad on M/C towers, M/C Monopole and D/C
towers (partially on M/C monopole)
Tentative M/CLength: 1.165kms. approx.
Tentative D/C Length: 0.511 kms. approx.
(Supply portion only)
Sr. No.
A
DESCRIPTION
UNIT
Qty.
1.1
Fabrication and supply of tower part with stubs, bolts & nuts, step
bolts, U-bolts, hangers, D-shakle etc. of following type of Towers
as per TATA design.
1.2
No.
No.
No.
1.1
No.
1.
Design and type testing Fabrication and supply of following types of monopole with stubs,
bolts & nuts, step bolts, U-bolts, hangers, D-shackle etc.
i) 220kV M/C A type Monopole
No.
No.
3.
2
No.
i) Pipe type
Sets
12
Sets
No.
12
No.
12
Sets
40
Sets
48
Sets
Sets
12
LINE MATERIAL
Km
17.22
Km
0.10
Km
0.516
Hardware set for above 24 Fiber OPGW fiber optic cabling including
all cable fittings & accessories except joint box.
set
No.
Lot
Lot
Km
1.177
Hardware set for above 48 Fiber OPGW fiber optic cabling including
all cable fittings & accessories except joint box.(as per
requirement)
set
No.
10
Km.
11
set
12
FODP 48F: Indoor type, rack mounted with FCPC coupling and pig
tails ( 5mtrs. Each) as applicable
No.
13
FODP 96F: Indoor type, rack mounted with FCPC coupling and pig
tails ( 5mtrs. Each) as applicable
No.
14
15
i) 70 kN
No.
42
ii) 120 kN
No.
216
sets
NIL
16
Hardware Fittings
i)
ii)
iii)
iv)
17
Set
24
Set
18
Set
216
Set
No.
12
No.
No.
No.
12
v)
No.
456
conductor
vi)
No.
38
vii)
No.
22
No.
Km
1.5
Note:- Type test to be got done or waived off as per relevant clause of monopoles.
BOQ of 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn.Bhagolawith 0.4sq ACSR Zebra. (Cable
portion)
Sr. No.
Description
Unit
Total Quantity
1.
Mtrs.
1350x8
2.
No.
16
3.
No.
4.
No
No
6.
Mtrs
200
7.
No.
8.
No.
16
9.
Mtr.
Nil
10.
No.
Nil
No.
Nil
No.
Lot
11.
12.
Note:-
1. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
2. The said work may involves the route through residential area for which Trench-less digging shall be got
done as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn.Bhagolawith 0.4sq ACSR Zebra. (Cable
portion)
Sr.
No.
Description
Unit
Quantity
Running
circuit
1350
Length
(6+2) Mtrs.
Running
circuit
nil
Length
(6+2) Mtrs.
Nos.
Nos.
16
Nos.
Lot
Lot
7. Erection of 4 Pole Rail pole structure for the LILO arrangement and
their Foundations including earthing (if required as per site
conditions).
No.
Nil
8. Any other items not specified above but are required to complete
the job in all respect.
Lot
Lot
Note:-
1. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
2. The said work may involves the route through residential area for which Trench-less digging shall be got
done as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
S.No
Qty.
DESCRIPTION
UNIT
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers, Dshakle etc. of following type of KRR Design D/C towers.
1.1
i) DE type 66kV Tower (KRR Design)
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
31
6
1.2
1.3
9
5
1.4
14
2
1.5
1.6
1.7
2.
3.
Sets
63
Sets
i) Danger Plate
No.
63
No.
63
Sets
64
Sets
63
Sets
63
Sets
63
6.
Km
khera
km
Km
42.61
39.50
13.69
i) 70 kN
No.
ii) 120 kN
192
No.
420
8.
Hardware Fittings
i.
No.
36
Set
186
Set
Set
396
Set
12
No.
55
ii)
No.
iii)
No.
17
No.
63
v)
No.
1138
No.
190
No.
66
No.
31
No.
NIL
Note:The Bidder shall offer only one of the option for the Insulator strings (A/F disc or Polymer) out of the two
mentioned above in his bid.
BOQ of 66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 0.4sq ACSR Zebra (Tower portion).
Qty.
DESCRIPTION
UNIT
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers, Dshakle etc. of following type of KRR Design D/C towers.
1.1
66kV DE type tower (KRR Design)
No.
No.
No.
No.
No.
1.2
6
2
1.3
1.4
1.5
2.
3.
No.
Set
No.
No.
i) Pipe type
Sets
23
Sets
i) Danger Plate
No.
23
No.
23
Sets
36
Sets
23
Sets
10
Sets
23
Km
29.66
5.
6.
Km
4.94
No.
42
No.
240
Set
30
Set
12
Set
.228
Set
12
i) 70 kN
ii) 120 kN
8.
Hardware Fittings
(a)
(b)
(c)
(d)
No.
20
ii)
No.
No.
No.
23
v)
No.
492
No.
82
No.
38
No.
Note:- The Bidder shall offer only one of the option for the Insulator strings ( A/F disc or Polymer) out of the two
mentioned above in his bid.
BOQ of 66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrolawith 0.4sq ACSR Zebra
(Cable portion).
Sr. No.
Description
Unit
Total Quantity
13.
Mtrs.
705x8
14.
No.
16
15.
No.
16.
No
No
18.
Mtrs
200
19.
No.
20.
No.
16
21.
Mtr.
100x8
22.
No.
Nil
No.
Nil
No.
Lot
23.
24.
Note:-
4. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
5. The said work may involves the route through residential area for which Trench-less digging shall be got
done as per Technical specification.
6. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of 66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 0.4sq ACSR Zebra
(Cable portion).
Sr.
No.
Description
Unit
Quantity
Running
circuit
605
Length
(6+2) Mtrs.
Running
circuit
100
Length
(6+2) Mtrs.
Nos.
Nos.
16
Nos.
Lot
Lot
15. Erection of 4 Pole Rail pole structure for the LILO arrangement and
their Foundations including earthing (if required as per site
conditions)..
No.
Nil
16. Any other items not specified above but are required to complete
the job in all respect.
Lot
Lot
Note:-
1. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
2. The said work may involves the route through residential area for which Trench-less digging shall be got
done as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of re-alignment of 66kV D/C overhead line from 66kv S/Stn. A-5 Faridabad to 66kV S/Stn.FatehpurBiloch
from TL No. 15 to 38 by partially 8x1C x1200 sq mm XLPE cable and partially by overhead line on KRR type
tower with 0.4sq ACSR conductor as a deposit work of HSIIDC.
(Cable portion)
(Supply Portion only)
Sr. No.
Description
Unit
Total Quantity
66kV 1200 mm2 Single Core Aluminium Conductor Milliken type , XLPE
insulated Cable as per technical specification
Mtrs.
9800
No.
No.
2.
Already procured
48
Already procured
8
Already procured
No
No
12
Mtrs
1200
No.
36
LOT
LOT
Mtr.
800m
10
4 Pole Rail pole structure for the LILO arrangement (if required) along
with its fencing arrangement (if required as per site conditions)..
No.
NIL
11
Any other items not specified above but are required to complete the
job in all respect.
Lot
Lot
Note:-
1. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
2. The said work may involve the route through residential/ industrial area for which Trench-less digging
shall be got done as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of re-alignment of 66kV D/C overhead line from 66kv S/Stn. A-5 Faridabad to 66kV S/Stn. Fatehpur Biloch
from TL No. 15 to 38 by partially 8x1C x1200 sq mm XLPE cable and partially by overhead line on KRR type
tower with 0.4sq ACSR conductor as a deposit work of HSIIDC.
(Cable portion)
(Erection Portion only)
Sr.
No.
Description
Unit
Quantity
1.
Running
circuit
1100
Running
circuit
Nos.
NIL
Nos.
48
Nos.
18
Lot
Lot
No.
NIL
Any other items not specified above but are required to complete the
job in all respect.
Lot
Lot
Note:-
Length
(6+2)
Mtrs.
100
Length
(6+2)
Mtrs.
1. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
2. The said work may involve the route through residential/industrial area for which Trench-less digging
shall be got done as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
S.No
DESCRIPTION
UNIT
Qty.
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers,
D-shackle etc. of following type of KRR 66kV D/C towers.
1.1
D/C E type 66kV Tower (KRR Design)
No.
No.
No.
No.
No.
No.
1.2
1
1
1.3
2.
12
1
3
Sets
21
Sets
i) Danger Plate
No.
21
No.
21
Sets
26
Sets
21
Sets
16
Sets
21
Km
24.05
5.
Km
4.01
6.
3.
i) 70 kN
ii) 120 kN
8.
Hardware Fittings
i.
ii.
iii.
iv.
No.
57
No.
168
No.
Set
48
Set
Set
168
Set
No.
16
ii)
No.
No.
No.
21
v)
No.
408
No.
68
No.
26
No.
10
As per site
No.
66kV D/C DB type Tower
No.
66kV D/C DC type Tower
No.
66kV Gantry
No.
ii) Dismantlement of existing of 0.2sq ACSR Panther conductor complete
with H/W fittings for above portion of line and their transportation
proper stacking at any dedicated store of HVPNL.
Km
16.5
KM
2.75
*The Bidder shall offer only one of the option for the Insulator strings ( A/F disc or Polymer) out of the two
mentioned above in his bid.
SECTION-V
PART-II
SECTION-V
(PART-II A)
TECHNICAL SPECIFICATION
CONTENTS
S. No
Clause
Page No.
1.0
General Information
2.0
Scope
3.0
4.0
5.0
Technical Description
6.0
7.0
8.0
Technical Information
4
4
SECTION-V
(PART- IIA)
1.
General Information
1.1
The material covered in this specification shall be used in 220kv M/c & D/C and 66kV D/C
transmission lines of HVPNL.
2.
Scope:
2.1
The material shall be designed, manufactured and tested as per the requirements specified.
2.2
The material covered under various packages shall be supplied complete in all respect,
including all component, fittings and accessories which are necessary or are usual for their
efficient performance and satisfactory maintenance under the various operating and
atmospheric conditions. Such parts shall deemed to be within the scope of the contract, whether
specially included or not in the specifications or in the contract schedules. The bidder shall not
eligible for any charges for such fittings etc.
3.
All weights and measures shall be in system international (SI) units. All fasteners shall be of
metric size only.
4.1
4.1.1
The following provisions shall supplement all the detailed technical specifications and
requirements brought out in the accompanying technical specifications. The bidders proposal
shall be based on the use of equipment and materials complying fully with the requirements,
specified herein.
4.2
4.2.1
The performance requirements of the items are detailed separately in this specification. These
guarantees shall supplement the general performance guarantee provisions covered under
General Terms and Conditions of Contract in clause entitles Guarantee.
4.2.2
4.3
Liquidated damages for not meeting specified performance shall be assessed and recovered
from the manufacturer. Such liquidated damages shall be without any limitation whatsoever an
shall be in addition to damage, if any payable under any other clause of conditions of contract.
Engineering Data
4.3.1
The furnishing of engineering data by the bidder shall be in accordance with the appropriate
schedule of specification. The review of these data by the HVPNL will cover only general
conformance of the data to the specifications and drawings. This review by the HVPNL may not
indicate a thorough review of all dimensions, quantities and details of the equipment, materials,
any devices or items indicated or the accuracy of the information submitted. This review and/or
approval by the HVPNL shall not be considered by the manufacturer, as limiting any of his
responsibilities and liabilities for mistakes and deviations from the requirements, specified under
these Specifications and documents.
Page-1
4.3.2
All engineering data submitted by the manufacturer after final process including review and approval
by the HVPNL shall form part of the contract document and the entire works performed under these
specifications shall be performed in strict conformity, unless otherwise expressly requested by the
HVPNL in writing.
4.4
Drawings
4.4.1
All drawings submitted by the manufacturer including those submitted at the time of bid shall be in
sufficient detail to dictate the type, size, arrangement, dimensions, material description. Bill
materials, weight of each component, break-up for packing and shipment, fixing arrangement
required, the dimensions required for installation and any other information specifically requested
in the specifications.
4.4.2
Each drawing submitted by the manufacturer shall be clearly marked with the name of the HVPNL,
the unit designation title, the specification number and the name of the project. All titles, notings,
markings and writings on the drawing shall be in English. All the dimensions should be to the scale
and in metric units.
4.4.3
The drawings submitted by the manufacturer shall be reviewed by the HVPNL as far as practicable
within four weeks and shall be modified by the manufacturer if any modifications and/or corrections
are required by the HVPNL. The manufacturer shall incorporate such modifications and/or
corrections and submit the final drawings for approval. Any delays arising out of failure by the
manufacturer to rectify the drawings in good time shall not after the Contract completion date.
4.4.4
The drawings submitted for approval to the HVPNL shall be in quadruplicate. One print of such
drawings shall be returned to the manufacturer by the HVPNLmarked approved/approved with
correction. The manufacturer shall thereupon furnish the HVPNLadditional print as stipulated in
technical specification along with one reproducible in original in original of the drawings after
incorporating all corrections.
4.4.5
Further work by the manufacturer shall be strictly in accordance with these drawings and no
deviation shall be permitted with out the written approval of the HVPNL, it so required.
4.4.6
All manufacturing and fabrication work in connection with the equipment/material prior to the
approval of the drawings shall be at the manufacturers risk. The manufacturer may make any
changes in the design which are necessary to make the equipment conform to the provisions and
intent of the contract and such changes will again be subject to approval by the HVPNL. Approval
of manufacturers drawing or work by the HVPNL shall not relieve the manufacturer of any of his
responsibilities and liabilities under the contract.
4.5
Manufacturing Schedule
The manufacturer shall submit to the HVPNL his manufacturing, testing and delivery schedules of
various items within thirty (30) days from the date of the Letter of Award in accordance with the
delivery requirements stipulated. Schedule shall also include the material and items purchased from
outside manufacturers, if any.
Page-2
4.6
Reference Standards
4.6.1
The codes and/or standards referred to in specifications shall govern, in all cases wherever such
references are made. In case of a conflict between such Codes and/or Standards and the
Specifications, latter shall govern. Such Codes and/or Standards, referred to shall mean the latest
revisions, amendments/changes adopted and published by the relevant agencies. In case of any
further conflict in this matter, the same shall be referred to the HVPNL whose decision shall be final
and binding.
4.6.2
Other internationally acceptable standards which ensure equivalent or better performance than
those specified shall also be accepted.
4.7
Design Improvements
4.7.1
The HVPNL or the manufacturer may propose changes in the specification of the equipment or
quality thereof and if the parties agree upon any such changes, the specification shall be modified
accordingly.
4.7.2
If any such agreed upon change is such that it affects the price and schedule of completion, the
parties shall agree in writing as to the extent of any change in the price and/or schedule of
completion before the manufacturer proceeds with the change. Following such agreement, the
provision thereof, be deemed to have been amended accordingly.
4.8
HVPNLS SUPERVISION
4.8.1
To eliminate delays and avoid disputes and litigation if is agreed between the parties to the contract
that all matters and questions shall be referred to the HVPNLand his decision shall be final.
4.8.2
The manufacturing of the product shall be performed under the direction and supervision of the
HVPNL. The scope of the duties of the HVPNL, pursuant to the contract, will include but not be
limited to the following: -
a)
Interpretation of all the terms and conditions of these documents and specifications.
b)
Review and interpretation of all the manufacturers drawings, engineering data etc.
c)
Witness or authorize his representative to witness tests at the manufacturers works or at site, or at
any place where work is performed data etc.
d)
Inspect accept or reject any equipment, material and work under the contract.
e)
Issue certificate of acceptance and/or progressive payment and final payment certificate.
f)
Review and suggest modification and improvement in completion schedule from time to time; and
g)
Supervision the Quality Assurance programme implementation at all stages of the works.
Page-3
4.9
4.9.1
The HVPNL, his duly authorized representative and/or outside inspection agency acting on behalf
of the HVPNLshall have at all reasonable times access to the manufacturers premises or works
and shall have the power at all reasonable times to inspect and examine the materials and
workmanship of the product during its manufacture and if part of the product is being manufactured
or assembled at other premises or works, the manufacturer shall obtain from the HVPNLand/or his
duly authorized representative permission to inspect as if the equipment/materials were
manufactured or assembled on the manufacturers own premises or works.
The manufacturer shall give the HVPNL/inspector fifteen (15) days written notice of any material
being ready for testing. Such tests shall be to the manufactures account except for the expenses
of the inspector. The HVPNL/inspector, unless witnessing of the tests is virtually waived, will attend
such tests within fifteen (15) days of the date of which the equipment is notified as being ready for
test/inspection or on a mutually agreed date, failing which the manufacturer may proceed and he
shall forthwith forward to the inspector duly certified copies of tests triplicate.
The HVPNL/ inspector shall, within fifteen (15) days from the date of inspector as defined herein
give notice in writing to the manufacturer, of any objection to any drawings and all or any equipment
and workmanship which in his opinion is not in accordance with the contract. The manufacturer
shall give due consideration to such objections and shall make the modifications that may be
necessary to meet the said objections.
When the factory tests have been completed at the manufacturers or sub-manufacturers work, the
HVPNL/inspector shall issue a certificate to this effect within fifteen (15) days after completion of
tests but if the tests are not witnessed by the HVPNL/inspector, the certificate shall be issued within
fifteen (15) days of receipt of the manufacturers test certificate by the HVPNL/inspector. The
completion of these tests of the issue of the certificate shall not bind the HVPNL to accept the
equipment should it, on further tests after erection, be found not to comply with the contract.
In all cases where the contract provides for tests whether at the premises or works of the
manufacturer or of any sub-manufacturer, the manufacturer except where otherwise specified shall
provide free of charge such item as labour, materials, electricity, fuel, water, stores, apparatus and
instruments as may be reasonably demanded by the HVPNL/inspector or his authorized
representative to carry out effectively such tests of the equipment in accordance with the contract
and shall give facilities to the HVPNL/inspector or his authorized representative to accomplish
testing.
4.9.2
4.9.3
4.9.4
4.9.5
4.9.6
The inspection by HVPNL and issue of inspection certificate thereon shall in no way limit the
liabilities and responsibilities of the manufacturer in respect of the agreed Quality Assurance
Programme forming a part of the contract.
5.
Technical Description
5.1
The technical description of conductor, earthwire, insulators, hardware fittings & conductor and
earthwire accessories shall be as specified in part-II of this technical specification.
6.
6.1
The tests and standards for conductor, earthwire, insulators, hardware fittings & conductor and
earthwire accessories are specified in part-II B, IIC & II D of this Technical Specification.
TECHNICAL SPECIFICATION
CONTENTS
S. No
Clause
Page No.
1.
5.
11
6.
Annexure-A
20
SECTION-VI
(CHAPTER-III-A)
TECHNICAL SPECIFICATION
1.0
1.1
1.1.1
The conductor shall generally conform to IS: 398-1998 excepts where otherwise specified herein.
Conductor shall only be accepted from those who have got the ISI certification and documentary
proof for having such certification shall be submitted with the Bid.
1.1.2
The conductor shall be ACSR Zebra and the details of the conductor are tabulated below:
a)
b)
Number of Strands
Core
1st layer
2nd layer
12
3rd layer
18
4th layer
24
428.9 sq. mm
c)
d)
484.5 sq.mm
e)
Overall diameter
28.62 mm
f)
Approximate weight
1621Kg/km
g)
Calculated DC resistance at :
0.06868 ohm/km
h)
Minimum UTS
130.32 kN
Page-1
1.1.3
a)
1.29 KN
1.23 KN
Centigrade
b)
3.626
Ohms/km
10.43 KN
9.95 KN
18 before stranding
16 after stranding
1.2
Workmanship:
1.2.1
All the aluminium and steel strands shall be smooth, uniform and free from all imperfections, such
as spills and splits, diemarks, scratches, abrasions and kinks after drawing and also after stranding.
1.2.2
The finished conductor shall have a smooth surface without any surface cuts, abrasions, scuff marks
and shall be free from dirt, grit, etc.
1.2.3
The steel strands shall be hot dip galvanized and shall have a minimum zinc coating of 260 g/m 2
after stranding. The zinc coating shall be smooth, continuous, of uniform thickness, free from
imperfections and shall withstand a minimum of two and one half dips in the standard preece test.
The steel wire rods shall be of such quality and purity that, when drawn to the size of the strands
specified and coated with zinc, the finished strands and the individual wires shall be of uniform
quality and have the same properties and characteristics as prescribed in IEC:888-1987.
1.2.4
The steel strands shall be preformed and postformed in order to prevent spreading of strands in the
event of cutting of composite core wire. Care shall be taken to avoid damages to galvanization
during preforming and post-forming operations.
1.3
1.3.1
Joints in Wires:
Aluminium Wires
No joints shall be permitted in the individual wires in the outer most layer of the finished conductor.
However, joints in the 12 wire and 18 wire inner layer of the conductor shall be allowed but these
joints shall be made by cold pressure butt-welding and shall be such that no two such joints are
within 15 metres of each other in the complete stranded conductor. The joint shall withstand a stress
of not less than the breaking strength of individual strand guaranteed.
Page-2
1.3.2
Steel Wires
There shall be no joint of any kind in the finished wire entering into the manufacture of the strand
nor strand joint or strand splices in any length of the complete stranded steel core of the conductor.
2.0
Tolerances
The manufacturing tolerances to the extent of following limits only shall be permitted in the
diameter of individual strands and lay-ratio of the conductor:
a)
b)
3.0
Maximum
Minimum
Aluminium
3.18 mm
3.21 mm
3.15 mm
Steel
3.18 mm
3.24 mm
3.12 mm
Max.
Min.
6 Wire layer
28 (Steel)
13
12 wire layer
17 (Al.)
10
18 wire layer
16 (Al.)
10
24 wire layer
14 (Al.)
10
Materials
3.1.1 The Aluminium strands shall be hard drawn from electrolytic aluminum rods having a purity
of not less than 99.5% and a copper content not exceeding 0.04%.
3.1.2 The steel wire strands shall be drawn from high carbon steel wire rods produced by either
the acid or basic open hearth process, the electric furnace process, or the basic oxygen
process and shall conform to the following requirements as to the chemical composition:
Element
% composition
Carbon
0.50 to 0.85
Manganese
0.50 to 1.10
Phosphorus
Sulphur
Silicon
0.10 to 0.35
3.1.3 The zinc used for galvanizing shall be electrolytic high grade Zinc of 99.95% purity. It shall
conform to and satisfy all the requirements of IS:209.
Page-3
4.0
4.1
Details of Earthwire
4.1.1
The galvanized steel earthwire shall generally conform to the specification of ACSR core wire as
mentioned in IS:398 (part-II)-1976 except where otherwise specified herein.
4.1.2
7/3.15 mm steel
b)
Number of Strands
Steel core
c)
54.55 sq.mm
d)
Overall diameter
9.45 mm
e)
Approximate weight
428Kg/km
f)
Calculated DC resistance at :
2.95 ohm/km
20 deg. Centigrade
g)
57 kN
strength
h)
Right hand
i)
4.1.3
All steel strands shall be smooth, uniform and free from all imperfection, such as spills and splits,
diemarks, scratches, abrasions and kinks after drawing and also after stranding.
4.1.4
The finished material shall have minimum brittleness as it will be subjected to appreciable vibration
while in use.
4.1.5
The steel strands shall be hot dip galvanized and shall have a minimum zinc coating of 240 g/m2
after stranding. The zinc coating shall be smooth, continuous, of uniform thickness, free from
imperfections and shall withstand three and a half dips after stranding in standard preece test. The
steel wire rods shall be of such quality and purity that, when drawn to the size of the strands
specified and coated with the finished strands shall be of uniform quality and have the same
properties and characteristics as prescribed in ASTM designation B498-74.
4.1.6
The steel strands shall be preformed and postformed in order to prevent spreading of strands while
cutting of composite earthwire. Care shall be taken to avoid damages to galvanization during
performing and postforming operations.
4.1.7
To avoid susceptibility towards wet storage stains (white rust), the finished material shall be
provided with a protective coating of boiled linseed oil.
Page-4
4.2
Joints in Wires
There shall be no joint of any kind in the finished steel wire strand entering into manufacture of the
earthwire. There shall be no strand joints or strand splice any length of the complete stranded
earthwire.
4.3
Tolerances
The manufacturing tolerance to the extent of the following limits only shall permitted in the diameter
of the individual steel strands and lay length of earthwire.
4.4
4.4.1
Standard
Maximum
Minimum
Diameter
3.15 mm
3.20 mm
3.10 mm
Lay length
160 mm
175 mm
145 mm
Materials
Steel
The steel wire strands shall be drawn from high carbon steel rods and shall conform to the following
requirements as to the chemical composition:
Element
Carbon
Manganese
Phosphorus
Sulphur
Silicon
% composition
Not more than 0.55
0.4 to 0.9
Not more than 0.04
Not more than 0.04
0.15 to 0.35
4.4.2 Zinc
The zinc used for galvanizing shall be electrolytic high grade zinc of 99.95% purity. It shall
conform to and satisfy all the requirements of IS:209/1979.
4.5
Standard Length
4.5.1
The Standard Length of the earthwire shall be 2000 meters. The tolerance on length shall be +/5% on the standard length.
4.5.2
Random lengths will be accepted provided no length is less than 70% of the standard length and
total quantity of random lengths is not be more than 10% percent of the total quantity in each
shipment.
5.0
5.1
Tests
5.1.1 The following acceptance and routine tests and tests during manufacture shall be carried out on the conductor and earthwire. For the purpose of this
clause, the following shall apply.
5.1.2 Acceptance tests shall mean those tests which are to be carried out on samples taken from each lot offered for pre-despatch inspection, for the
purpose of acceptance of that lot.
5.1.3 Routine tests shall mean those tests, which are to be carried out on each strand/ spool/length of the conductor and earthwire to check requirements
which are likely to vary during production.
Page-5
5.1.4 Tests during manufacture shall mean those tests, which are to be carried out during the process of manufacture and end inspection by the manufacture
to ensure the desired quality of the end product to be supplied by him.
5.1.5
For all acceptance tests, the acceptance values shall be the values guaranteed by the bidder in the
guaranteed technical particulars of his proposal or the acceptance value specified in this
specification, whichever is more stringent for that particular test.
5.2
Type Tests
5.2.1
The equipment should be offered type tested. Test reports should not be more than seven years
old reckoned from the date of bid opening in respect of all the tests carried out in accredited
laboratories ( based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPNL or another
electric power utility and be submitted by the successful Bidder to HVPNL for approval as per
schedule given in Bar chart.
5.2.2
a)
b)
c)
Stress-strain test
d)
e)
f)
g)
Ductility test
h)
Wrapping test
i)
j)
Galvanizing test
Acceptance Tests
a)
b)
)
)
Annexure-A
)
)
c)
)
)
)
d)
e)
)
)
Annexure-A
)
)
)
f)
Annexure-A
g)
)
)
)
h)
strands
IS:398 (part-II)
Page-6
i)
j)
Annexure-A
Note: All the tests except (j) shall be carried out on Aluminium and steel strands after stranding
only.
5.2.3
a)
)
)
b)
)
)
c)
Dimensional check
) Annexure-A
)
d)
)
)
e) Galvanising test
)
)
f)
g)
Torsion test
Elongation test
)
) IS:398 (part-II)-1976
)
h)
Wrap test
)
)
i)
DC resistance test
)
j)
k)
) IS:398 (part-II)-1976
5.3
Routine Tests
5.3.1
5.3.2
a)
b)
c)
d)
a)
b)
c)
Page-7
5.4
5.4.1
a)
)
) Annexure-A
)
b)
5.4.2
a)
)
) Annexure-A
)
b)
5.5
Testing Expenses
The entire cost of testing for the acceptance and routine tests and tests during manufacture
specified herein shall be treated as included in the quoted unit price except for the expenses of the
inspector/ HVPNL representative.
5.6
Addition Tests
The HVPNL reserves the right of having at his own expenses any other test (s) of reasonable nature
carried out at Manufacturers premises, at site, or in any other place in addition to the aforesaid
type, acceptance and routine tests to satisfy himself that materials comply with the specifications.
5.7
Test Reports
5.7.1
Record of routine test reports shall be maintained by the manufacturer at his works for periodic
inspection by the HVPNL representative.
5.7.2 Test certificates of tests during manufacture shall be maintained by the manufacturer. These shall
be produced for verification as and when desired by the HVPNL.
5.8
Inspection
5.8.1
The HVPNL representative shall at all times be entitled to have access to the works and all places of
manufacture, where conductor shall be manufactured and representative shall have full facilities for
unrestricted inspection of the manufacturer works, raw materials and process of manufacture for
conducting necessary tests as detailed herein.
5.8.2 The manufacturer shall keep the HVPNL informed in advance of the time of starting and of the progress of
manufacture of conductor in its various stages so that arrangements can be made for inspection.
5.8.3 No material shall be despatched from its point of manufacture before it has been satisfactorily inspected
and tested, unless the inspection is waived off by the HVPNL in writing. In the later case also the conductor
shall be despatched only after satisfactory testing for all tests specified herein have been completed.
Page-8
5.8.4
The acceptance of any quantity of material shall in no way relieve the manufacturer of any of his
responsibilities for meeting all requirements of the specification, and shall not prevent subsequent
rejection if such material is later found to be defective.
5.9
Test Facilities
5.9.1
The following additional test facilities shall be available at the manufacturers works:
a) Calibration of various testing and measuring equipment including tensile testing machine,
resistance measurement facilities, burette, thermometer, barometer etc.
b) Standard resistance for calibration of resistance bridges.
c) Finished conductor/Earthwire shall be checked for length verification and surface finish on
separate rewinding machine at reduced speed (variable from 8 to 16 meters per minute). The
rewinding facilities shall have appropriate clutch system and free of vibrations, jerks etc. with
traverse laying facilities.
5.10
5.10.1
The Conductor and earthwire shall be supplied in non-returnable, strong, wooden/ steel drums
provided with lagging of adequate strength, constructed to protect the conductor against all
damage and displacement during transit, storage and subsequent handing and stringing
operations in the field. The manufacturer shall be responsible for any loss or damage during
transportation, handling and storage due to improper packing. The drums shall generally
conform to IS: 1778-1980, except as otherwise specified hereinafter.
5.10.2
The drums shall be suitable for wheel mounting and for letting off the Conductor/earthwire under
a minimum controlled tension of the order of 5 KN.
5.10.3
The general outline of the drum for earthwire shall be as per annexed drawing. The bidder
should submit their proposed drawings alongwith the bid.
5.10.4
For conductor, one standard length and for earthwire two standard lengths shall be
wound on each drum.
5.10.5
For Earthwire, each strand shall be individually welded to prevent parting of two lengths
at a tension less than 15 kN. The two ends where the first length finishes and the second
length starts, shall be clearly marked with adhesive tape and no weld should be present
outside these marks. The length between the two marks shall be treated as scrap and
will not be taken into account for measurement purposes.
5.10.6
All wooden components shall be manufactured out of seasoned soft wood free from
defects that may materially weaken the component parts of the drums. Preservative
treatment shall be applied to the entire drum with preservatives of a quality, which is not
harmful to the conductor and earthwire.
5.10.7
The flanges shall be of two ply construction with each ply at right angles to the adjacent ply
and nailed together. The nails shall be driven from the inside face flange, punched and then
clenched on the outer face. The thickness of each ply shall not very by more than 3 mm from
that indicated in the figure. There shall be at least 3 nails per plank of ply with maximum nail
spacing of 75 mm. Where a slot is cut in the flange to receive the inner end of the conductor,
the entrance shall be in line with the periphery of the barrel.
Page-9
5.10.8
The wooden battens used for making the barrel of the conductor shall be of segmental
type. These shall be nailed to the barrel supports with at least two nails. The battens
shall be closely butted and shall provide a round barrel with smooth external surface.
The edges of the battens shall be rounded or chamfered to avoid damage to the
conductor and earthwire.
5.10.9
Barrel studs shall be used for the construction of drums. The flanges shall be holed
and the barrel supports slotted to receive them. The barrel studs shall be threaded
over a length on either end, sufficient to accommodate washers, spindle plates and
nuts for fixing flanges at the required spacing.
5.10.10
Normally, the nuts on the studs shall stand protruded of the flanges. All the Niles used
on the inner surface of the flanges and the drum barrel shall be counter sunk. The
ends of barrel shall generally be flushed with the top of the nuts.
5.10.11
The inner cheek of the flanges and drum barrel surface shall be painted with bitumen based
paint.
5.10.12
5.10.13
5.10.14
Each batten shall be securely nailed across grains as far as possible to the flange,
edges with at least 2 nails per end. The length of the nails shall not be less than twice
the thickness of the battens. The nails shall not protrude above the general surface
and shall not have exposed sharp, edges or allow the battens to be released due to
corrosion.
5.10.15
The nuts on the barrel studs shall be tack welded on the one side in order to fully secure them.
On the second end, a spring washer shall be used.
5.10.16
Outside the protective lagging, there shall be minimum of two binder consisting of
hoop iron/galvanised steel wire. Each protective lagging shall have two recesses to
accommodate the binders.
5.10.17
The conductor ends shall be properly sealed on the side of one of the flanges to
loosening of the conductor layers during transit and handling.
5.11
avoid
Marking
Each drum shall have the following information stenciled on it in indelible ink alongwith other
essential data:
a)
b)
c)
Page-10
d)
Drum number.
e)
Size of conductor/earthwire.
f)
g)
h)
i)
j)
5.12
k)
l)
m)
n)
Distance between outer most layer of conductor and the inner surface of lagging.
o)
The HVPNL reserves the right to verify the length of conductor and earthwire after unreeling at least
ten (10) percent of the drums in a lot offered for inspection.
5.13
Standards
The conductor/earthwire shall conform to the following Indian / International standards, which shall
mean latest revisions, amendments /changes adopted and pulished, unless otherwise specified
herein before. International and internationally recognized standards to which these standards
generally correspond are also listed below:
----------------------------------------------------------------------------------------------------------Sr.
Indian
No
Standard
Title
International
Standards
----------------------------------------------------------------------------------------------------------1.
IS: 209-1979
BS: 3436-1986
IS: 398-1982
BS: 215-1970
Aluminum
conductor
galvanized steel reinforced
BS: 215-1970
IS:398-1982
Part (II)
IEC:1089
IS:1778-1980
BS:1559-1949
IS:1521-1972
ISO:R8901959
Page-11
IS:2629-1985
IS:2633-1992
IS:4826-1992
ASTM A472-729
Methods of determination of
weight of zinc coating of zinc
coated iron and steel articles
BS:433-1969
10
IEC 888-1987
11
IEC 889-1987
IS:6745-1990
BS: 443-1969
Page-12
Reference Abbreviation
BS
IEC/CISPR
International Electrotechnical
Commission, Bureau Central
De la Commission, Electro
Technique International, 1
Rue de verembe, Geneva
Switzerland
BIS
ISO
NEMA
12, DK-
Page-13
ANNEXURE-A
1.
Tests on Conductor
1.1
1.2
On a conductor sample of minimum 5 m length two contact-clamps shall be fixed with a predetermined bolt torque. The resistance shall be measured by a Kelvin double bridge by
placing the clamps initially zero metre and subsequently one metre apart. The test shall be
repeated at least five times and the average value recorded. The value obtained shall be
corrected to the value at 20o C. The resistance corrected at 20o C shall conform to the
requirement of this specification.
1.3
1.4
Samples taken from the zinc ingots shall be chemically/spectrographically analysed. The
same shall be in conformity requirements stated in the specification.
1.5
The drums shall be visually and dimensionally checked to ensure that they conform to the
requirements of this specification.
1.6
Conductor drums shall be rewound in the presence of the HVPNL. The HVPNL shall visually
check for scratches, joints etc. and that the conductor generally conform to the requirements
of this specification.
1.7
The individual strands shall be dimensionally checked to ensure that they conform to the
requirement of this specification.
Page-14
1.8
1.9
Two Aluminium wire shall be welded as per the approved quality plan and shall be subjected
to tensile load. The welded joint of the wire shall be able to withstand a minimum breaking
load of the individual strand guaranteed by the manufacturer.
1.10
Galvanising test
The Test procedure shall be as specified in IS:4826. The material shall conform to the
requirements of this specification. The adherence of zinc shall be checked by wrapping
around a mandrel four times the diameter of steel wire.
1.11
2.
Tests on earthwire
2.1
UTS test
Circles perpendicular to the axis of the earthwire shall be marked at two places on a sample
of earthwire of minimum 5 m length suitably compressed with dead end clamps at either
end. The load shall be increased at a steady rate upto 50% of UTS and held for one minute.
The circles drawn shall not be distorted due to relative movement of strands. Thereafter the
load shall be increased at steady rate to 100% of UTS and held for one minute. The
earthwire sample shall not fail during this period. The applied load shall then be increased
until the failing load is reached and the value recorded.
2.2
On a earthwire sample of minimum 5 m length two contact- clamps shall be fixed will a predetermined bolt torque. The resistance shall be measured by a Kelvin double bridge by
placing the clamps initially zero metre and subsequently one metre. The test shall be
repeated at least five times and the average value recorded. The value obtained shall be
corrected to the value at 20o C. The resistance corrected at 20o C shall conform to the
requirements of this specification.
Page-15
2.3
Samples taken from the zinc ingots shall be chemically/spectrographically analysis. The
same shall be in conformity to the requirements stated in the specification.
2.4
2.5
The drum shall be visually and dimensionally checked to ensure that they conform to the
requirements of this specification.
2.6
Ten percent drums from each lot shall be rewound in the presence of the HVPNL. The
HVPNL shall visually check for scratches, joints etc. and see that the earthwire generally
conforms to the requirements of this specification. The length of earthwire wound on the
drum shall be measured with the help of counter meter during rewinding.
2.7
Dimensional Check
The individual strands shall be dimensionally checked to ensure that they conform to the
requirements of this specification.
2.8
The lay length shall be checked to ensure that they conform to the requirements this
specification.
2.9
Galvanising Test
The test procedure shall be as specified in IS:4826-1968. The material shall conform to the
requirements of this specification. The adherence of zinc shall be checked by wrapping
around a mandrel four times the diameter of steel wire.
Page-16
TECHNICAL SPECIFICATION
CONTENTS
S. No
Clause
1.
3.
Annexure-A
Page No.
12
SECTION- VI,
CHAPTER-III (B)
1.0
1.1.1
The Insulator strings shall consist of Anti-Fog Type discs for a three phase, 50 Hz, effectively
earthed 66 KV transmission system in a heavily polluted atmosphere. The discs shall be cap and
pin, ball and socket type.
1.1.2
1.1.3
The size of disc insulator, minimum creepage distance, the number to be used in different type of
strings, their electromechanical strength and mechanical strength of insulator string alongwith
hardware fittings shall be as follows:
No. of E
No
insulator
Creepage
discs
(mm)
distance
of
1.2
strength of of
each
each disc(mm)
1
&
string
(kN)
1.
Single Suspension
255x145
432
1x5
70
2.
Single Tension
280x145
432
1x6
120
3.
255x145
432
1x5
70
4.
Double Tension
280x145
432
2x6
2X120
1.2.1
Pin and cap shall be designed to transmit the mechanical stresses to the shell by compression and
develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and
outer surfaces concentric, of such design that will not yield or distort under load conditions.
The pin ball shall move freely in the cap socket but without danger of accidental uncoupling during
erection or in position. The design of the disc should be such that stresses due to expansion or
contraction in any part of the insulator shall not lead to deterioration.
Page-1
1.3
Security clip
1.3.1
Security clip for use with ball and socket coupling shall be of R-shaped hump type which shall
provide positive locking of the coupling as per IS: 2486- (part-III)/ IEC:372. The legs of the security
clips shall be spread after installation to prevent complete withdrawal from the socket. The locking
device should be resilient, corrosion resistant and of suitable mechanical strength. There shall
be no rise of the locking device being displaced accidentally or being rotated when in
position. Under no circumstances shall locking device allow separation of insulator units or fittings.
1.3.2
The hole for the security clip shall be countersunk and the clip shall be of such that the eye of clip
may be engaged by a hot line clip puller to provide for disengagement under energized conditions.
The force required to pull the security clip into its unlocked position shall not be less than 50 N (5
kg) or more than 500 N (50 kg).
1.4
The dimensions of the balls and sockets for 70 KN/90kN and 120 kN Anti-Fog Type discs shall be
of 16mm Alt-B and 20 mm designation respectively in accordance with the standard dimensions
stated in IS:2486- (Part-II)/IEC: 120.
1.5
Permitted dimensional tolerances of the Anti-Fog Type disc insulators shall be as under:-
a)
b)
(0.04d + 1.5) mm
where
(0.03S + 0.3) mm
where
S is spacing in mm.
1.6 Interchangeability
The disc insulators inclusive of the ball and socket fittings shall be of standard design suitable for
use with the hardware fittings of any make confirming to relevant Indian/International standards.
All surfaces must be clean, smooth, without cuts, abrasions or projections. No part
shall be subjected to excessive localised pressure. The metal parts and porcelain
shall be
so designed and manufactured that it shall not generate any Radio Interference beyond specified
limit and not produce any noise generating corona under all
operating conditions.
1.8
Maintenance
1.8.1
The disc insulators offered shall be suitable for employment of hot line maintenance techniques so
that the usual hot line operations can be carried our with ease, speed and safety.
1.8.2
Bidders shall indicate the methods generally used in the routine hot and dead line maintenance of
EHV line for which similar disc insulators have been supplied by them. Bidders shall also indicate
the recommended periodicity of such maintenance.
Page-2
1.9
Materials
1.9.1 Porcelain
The porcelain used in the manufacture of shells shall be sound, free from defects thoroughly vitrified
and smoothly glazed.
1.9.2
Glaze
The finished porcelain shall be glazed in Brown colour. The glaze shall cover all exposed parts of
the insulator and shell have a good luster, smooth surface and good performance under the extreme
weather conditions of a tropical climate. It shall not be cracked or chipped by ageing under the
normal service conditions. The glaze shall have the same co-efficient of expansion as that of the
porcelain body throughout the working temperature range.
1.9.3
Cement
Cement used in the manufacture of the insulator shall not cause fracture by expansion or loosening
by contraction. The cement shall not give rise to chemical reaction with metal fittings and its
thickness shall be as small and uniform as possible. Proper care shall be taken to correctly centre
and locate individual parts during cementing.
1.9.4
1.9.5
Security Clips
Security clips shall be made of good quality stainless steel or phosphor bronge
as per IS:1385-1968. 2.5% extra security clip shall be provided.
1.10
1.10.1.1.1
Workmanship
All the material shall be of the latest design and conform to the best modern practices
adopted in the extra High voltage field. Bidders shall offer only such insulators as are
guaranteed by him to be satisfactory and suitable for 66 kV transmission line and will give
continued good service.
1.10.2
1.10.3
The design, manufacturing process and material control at various stages shall be such
as to give maximum working load, highest mobility, best resistance to corrosion, good finish
and elimination of sharp edges and corners to limit corona and radio interference.
The design of the insulators shall be such that stresses due to expansion and contraction in
any part of the insulator shall not lead to deterioration.
Page-3
1.10.4
Metal caps shall be free from cracks, seams, shrinks, air holes, burrs and rough edges. All
surfaces of the metal parts shall be perfectly smooth with no projecting points or irregularities
which may cause corona. All load bearing surfaces shall
be smooth and uniform so as to
distribute the loading stresses uniformly.
1.10.5
All ferrous parts shall be hot dip galvanized to give a minimum average coating of Zinc
equivalent to 610 gm/sq m and shall be in accordance with the requirement of IS: 2629-1966
and shall satisfy the tests mentioned in IS: 2633-1972. The zinc used for galvanizing shall be
of grade Zn 99.95 as per IS:209-1979. The zinc coating shall be uniform, adherent, smooth,
reasonably bright, continous and free from imperfections such as flux, ash, rust stains, bulky
white deposits, and
blisters. The galvanized metal part shall be guaranteed to withstand
atleast six successive dips each lasting for one (1) minute duration under the standard preece
test.
1.10.6
Before ball fittings are galvanized, all die flashing on the shank and on the bearing surface
of the ball shall be carefully removed without reducing the dimensions below the design
requirements
1.10.7
The design of the insulators shall be such that the shell shall not engage directly with hard
metal. The design shall also be such that when units are coupled together there is no contact
between the shell of one unit and metal of the next adjacent unit. The design of the shell ribs
shall be such that the security clip of the insulator can be engaged and disengaged easily with
hot stick without damaging the shell ribs.
1.10.8
Insulator units after assembly shall be concentric and co-axial within limits as permitted by the
relevant Indian standards.
1.10.9
The manufacturer of the disc insulators shall guarantee an insulator failure rate not exceeding
1 (one) per 10000 (ten thousand) per year. In case the annual failure rate during the first ten
years of service exceeds the above figure, the manufacture shall supply to the HVPNL free of
cost spare insulators equal to 10 time the excess failure.
1.10.10
The manufacture shall guarantee that there shall not be any decapping of insulators on line
under normal operating conditions. In event of any decapping and subsequent line drop, during
the first three years of service the manufacturer shall have to pay Rs. 50,000/- (Rs. Fifty
thousand only) per dropped string towards expenditure to be incurred by HVPNL for this repair.
1.11
Equipment Marking.
1.11.1
Each insulator disc shall be legibly and indelibly marked with the trademark of the manufacture
and year of manufacture. The guaranteed combined mechanical and electrical strength shall
be indicated in kilo Newtons followed by the word kN to facilitate easy identification and to
ensure proper use.
1.11.2
For porcelain insulator, the marking shall be on porcelain. The marking shall be printed, not
impressed and shall be applied before firing.
Page-4
1.11.3
1.12
One 10 mm thick ring of suitable quality of paint shall be marked on the cap of each
insulator of particular strength for easy identification of the type of insulator. The paint
shall not have any deteriorating effect on the insulator performance. Following codes
shall be used as identification mark.
For
70 KN disc
red
For
90 KN disc
Green
For
120KN disc
yellow
Bid Drawings
1.12.1
a)
b)
c)
d)
ii)
e)
f)
g)
h)
Materials
i)
Identification mark
j)
1.12.2
After placement of award, the manufacturer shall submit full dimensioned insulator
drawings containing all the details as given in clause No. 1.12.1 above, in four (4) copies
to HVPNL representative
for approval. After getting approval from HVPNL
representative and successful completion of all the type tests, the manufacturer shall
submit. 12 more copies of the same drawing to the HVPNL representative for further
distribution and field use at HVPNL representative s end.
1.12.3
After placement of award the manufacture shall also submit fully dimensioned insulator
create drawing for different type of insulators.
Page-5
2.
2.1
TESTS
The following acceptance, routine tests and tests during manufacture shall be carried on
the disc insulator individually and alongiwth hardware fittings. For the purpose of this
clause: -
2.1.1
Acceptance tests shall mean those tests which are to be carried out on samples taken
from each lot offered for pre-despatch inspection for the purpose of acceptance of that
lot.
2.1.2
Routine tests shall mean those tests, which are to be carried out on each disc
insulator/hardware fitting to check requirements which are likely to vary during production.
2.1.3
Tests during manufacture shall mean those tests which are to be carried out during the
process of manufacture and end inspection by the manufacture to ensure the desired
quality of the end product to be supplied by him.
2.1.4
For all acceptance tests, the acceptance values shall be the values guaranteed by the
bidder in the Guaranteed Technical Particulars of his proposal or the acceptance value
specified in this specification whichever is more stringent for that particular test.
2.2.
Type tests
The equipment should be offered fully type tested for all the type tests mentioned in
IS:731-1971/IEC-60383-1993/IS:8704-1995 (latest version). Test reports should not be
more than seven years old reckoned from the date of bid opening in respect of all the
tests carried out in accredited laboratories ( based on ISO/IEC) by a reputed accreditatic
body or witnessed by HVPNL or another electric power utility and be submitted by the
successful Bidder to HVPNL for approval as per schedule given in Bar chart.
2.3
2.3.1
Acceptance tests
a)
Visual examination
IS:731-1971
b)
Verification of dimensions
IS:731-1971
c)
IS:731-1971
d)
Galvanizing test
IS:731-1971
e)
IS:731-1971
f)
IEC:60383-1993
g)
IEC:60383-1993
h)
Eccentricity test
IEC:60383-1993
i)
j)
Vibration test
(only once for each type of disc
Annexure-A
2.4
2.5
2.5.1
a) Puncture test
IEC: 60383-1993/IS:7311971
b) Porosity test
IS:731-1971
Routine Tests
a) Visual Inspection
)
b) Mechanical routine test
2.5.2
IS: 731-1971
)
Clause 10.13, 10.14 &
10.15
)
)
)
)
castings.
Annexure-A
Annexure-A
)
d) Hydraulic internal pressure
i) Grain size
2.6
Testing Expenses
The entire cost of testing for acceptance and routine tests and tests
during manufacture specified herein shall be treated included in the
quoted Ex-works price except for the expenses of the inspector/HVPNL
representative.
2.7
2.7.1
The bidder has to indicate the schedule of following activities in their bids:
2.7.2
The HVPNL representative reserves the right of having at his own expense any other test
(s) of reasonable nature carried out at manufacturers premises, at site, or in any other place
in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the
material comply with the specifications.
2.7.3 The HVPNL representative also reserves the right to conduct all the
tests mentioned in this specification at his own expense on the samples
drawn from the site at manufacturers premises or at any other test
center. In case of evidence of non compliance, it shall be binding on the
part of the manufacture to prove the compliance of the items to the
technical specifications by repeat tests or correction of deficiencies, or
replacement of defective items, all without any extra cost to the HVPNL
representative .
2.8
The Bidder/insulator manufacturer shall have to co-ordinate testing of insulators with hardware
fittings to be supplied by other manufacturer and shall have to also guarantee overall
satisfactory performance of the insulators with the hardware fittings.
2.9
Test Reports
2.9.1
Record of routine test reports shall be maintained by the manufacturer at his works for periodic
inspection by the HVPNL representative s representative.
2.9.2
Test certificates of test during manufacture shall be maintained by the manufacturer. These shall
be produced for verification as and when desired by the HVPNL representative .
2.10
INSPECTION
2.10.1
The HVPNL representative s representative shall at all times be entitled to have access to the
works and all places of manufacture, where insulators, and its component parts shall be
manufactured and the representatives shall have full facilities for unrestricted inspection of the
manufacturers and sub-manufacturers works, raw materials, manufacture of the material and for
conducting necessary test as detailed herein.
2.10.2
The material for final inspection shall be offered by the manufacturer only under packed condition
as detailed in clause No. 2.12 of the specification. The HVPNL representative shall select samples
at random from the packed lot for carrying out acceptance tests.
2.10.3
The manufacturer shall keep HVPNL informed in advance of the time of starting and the progress
of manufacture of material in their various stages so that arrangements could be made inspection.
2.10.4
No material shall be despatched from its point of manufacture before it has been satisfactorily
inspected and tested unless the inspection is waived off by the HVPNL representative in writing.
In the latter case also the material shall be despatched only after satisfactory testing for all tests
specified herein have been completed.
2.10.5
The acceptance of any quantity of material shall be in no way relieve the manufacturer of his
responsibility for meeting all the requirements of the specification and shall not prevent
subsequent rejection, if such material are later found to be defective.
Page-8
2.11
2.11.1
All insulators shall be packed in strong seasoned wooden crates. The gross weight of the crates
along with the material shall not normally exceed 200 kg. to avoid handling problem. For marine
transportation crates shall be palleted.
2.11.2
The packing shall be of sufficient strength of withstand rough handling during transit, storage at
site and subsequent handling in the field.
2.11.3
2.11.4
All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their
destination and to avoid the possibility of goods being lost or wrongly despatched on account of
faulty packing and faulty or illegible markings. Each wooden case/crate shall have all the markings
stenciled on it in indeliable ink.
2.12
Standards
2.12.1
The insulators strings and its components shall conform to the following Indian/international
standards which shall mean latest revision, with amendments/changes adopted and published,
unless specifically stated otherwise in the Specification.
2.12.2
In the event of supply of insulators conforming to standards other than specified the Bidder shall
confirm in his bid that these standards are equivalent to those specified. In case of award salient
features of comparison between the standards proposed by the manufacturer and those specified
in his document will be provided by the manufacturer to establish equivalence.
Sr. No.
Indian Standard
Title
International
Standards
1.
IS: 209-1992
IS: 406-1991
IS: 731-1991
BS: 137-1982
IEC:60-1-1989
IS:2071
Part (I)-1993
Part (II)-1991
Part (III)-1991
BS: 3436-1986
(I&II)
IEC:383-1993
IS:2486
Part (I)-1993
BS:3288-1979
Part (II)-1989
Dimensional Requirements
IEC:120-1984
Page-9
Part (III)-1991
Locking devices
IEC:372-1984
IS:2629-1990
ISO:1461 (E)
IS:2633-1992
Testing of Uniformity of
coating of zinc coated
articles
IS:3188-1988
Dimensions
Insulators
IS:6745- 1990
Determination of weight of
zinc coating on zinc coated
iron and steel articles.
ISO:1460 (E)
10
IS:8263-1990
Methods of RI test on HV
insulators
IEC:437-1973
Methods for
impulse test
insulators
switching
on HV
IEC:506-1975
12
Thermal
mechanical
performance
test
and
mechanical
performance
test on string insulator units.
IEC:575-1977
13
IEC:507-1991
11
IS:8269-1990
for
Disc
IEC:305-1978
14
IEC:797-1984
15
IEC:815-1986
16
Tests on insulators of
ceramic material or glass for
overhead line with a
nominal voltage greater
than 1000V
IEC:383-1993
Page-10
Reference Abbreviation
BS
IEC/CISPR
International Electrotechnical
Commission, Bureau Central
De la Commission, Electro
Technique International, 1
Rue de verembe, Geneva
Switzerland
IS
ISO
NEMA
Page-11
ANNEXURE-A
1.
The voltage across each insulator unit shall be measured by sphere gap method. The result
obtained shall be converted into percentage. The voltage across any disc shall not exceed 20%
for suspension insulator string and 22% for tension insulator string.
1.2
1.3
Vibration test
The suspension string shall be tested in suspension mode, and tension string in tension mode
itself in laboratory span of minimum 30 metres. In the case of suspension string a load equal
to 600 Kg shall be applied along the axis of the suspension string by means of turn buckle. The
insulator string along with hardware fittings and conductor tensioned at 2500 Kgf shall be
secured with clamps. The system shall be suitable to maintain constant tension on the
conductor throughout the duration of the test. Vibration dampers shall not be used on the test
span. The conductor shall be vertically vibrated at one of the resonance frequencies of the
insulators string (more than 10 Hz) by means of vibration inducing equipment. The peak to
peak, displacement in mm of vibration at the antinode point nearest to the string shall be
measured and the same shall not be less than 1000 /
f1.8 where is the frequency of vibration in cycles/sec. The insulator string shall be vibrated for
not less than 10 million cycles without any failure. After the test the disc insulators shall be
examined for looseness of pins and cap or any crack in the cement. The hardware shall be
examined for looseness, fatigue failure and mechanical strength test. There shall be no
deterioration of properties of hardware components and insulators after the vibration test.
The insulators shall be subjected to the following tests as per relevant standards:
Page-12
TESTS
60
Performance test
b) Puncture test
2.
2.1
40
The following test shall be performed on 10 nos. of disc insulators selected at random from
the lot offered for selection of sample for type test.
a) Each insulator unit shall be subjected to five successive positive and negative impulse
flashovers with a wave having minimum effective rate of rise of 2500 kV per microseconds.
b) Each unit shall be subjected to three dry power frequency voltage flashovers.
Acceptance Criteria
An insulator shall be deemed to have met the requirement of this test if, having been
successfully subjected to the ten impulse flashovers, the arithmetic mean of the three
subsequent dry power frequency voltage flashover values equals or exceeds 95% of the rated
dry power frequency flashover voltage.
An insulator shall be deemed to have failed to meet the requirement of above testing , if
a) It has not flashed over when the oscillogram or peak voltage indicator shows a marked
reduction in voltage.
or
b) Any one of the subsequent three dry power frequency voltage flashover value is less than
80% of the value specified. Failure of any one unit either in the steep front of wave or
subsequent low frequency voltage test shall be cause for testing on double number of
units.
Page-13
2.2
2.4
(1) The applied mechanical load during this test shall be 70% of the rated
electromechanical strength value.
(2) The acceptance criteria shall be
a) X greater than or equal to R+3S.
Where
X
Standard deviation
i)
Where
X
Standard deviation
ii) The minimum sample size shall be taken as 20. However for larger lot size IEC 591 shall be
applicable.
iii) The individual electro-mechanical strength shall be at least equal to the rated value. Also
electrical puncture shall not occur before the ultimate fracture.
Page-14
3.
3.1
3.2
3.3
Tests on castings
The chemical analysis, mechanical and metallographic tests and magnetic particle
inspection for castings will be as per the internationally recognized procedures for these
tests. The samplings will be based on heat umber and heat treatment batch. The details
regarding test will be as discussed and mutually agreed to by the manufacturer and
HVPNL in quality assurance programme.
Page-15
TECHNICAL SPECIFICATION OF
CONTENTS
S. No
Clause
1.
2.
3.
Annexure-A
Page No.
13
1.1.1
The insulators of the strings shall consist of composite long rod insulators for a three phase, 50 Hz,
effectively earthed 220kV/66kV transmission system application in a very heavy polluted
environment. Couplings shall be ball and socket type.
1.1.2
Bidder shall quote such composite insulators which have proven use under foggy/humid operational
conditions in polluted industrial environment combined with smoke and dust particles. The Bidder
shall furnish evidence in the form of certification from the power utilities that the similar type of
product supplied to them had been performing satisfactory. The Bidder shall also submit certified
test report for an accelerated ageing test of 5000 hours such as that described in Appendix-C of
IEC-61109.
1.1.3
Insulators shall have sheds of the open aerodynamic profile without any under ribs with good selfcleaning properties. Insulator shed profile, spacing projection etc. shall be strictly in accordance
with the recommendation of IEC-60815.
1.1.4
The size of long rod insulator, minimum creepage distance, the number to be used in different type
of strings, their electromechanical strength and mechanical strength of insulator string alongwith
hardware fittings shall be as follows:
1.2
TYPE
String
of Size
of Min.
Composite
Creepage
Insulator
Distance
(mm)
(mm)
No.
of
Individual
units per
string
EM
strength of
Insulator
Unit (KN)
(Nos.)
Mechanical
strength of
Insulator
string
alongwith
Hardware
fittings
(kN)
Single
Suspension
20X2030
7595
1X1
70
70
Double
Suspension
20X2030
7595
2X1
70
2X70
Single
pilot
Suspension
20X2030
7595
1X1
70
70
Single
Tension
24X2550
7595
1X1
120
120
Double
Tension
24X2550
7595
2X1
120
2X120
Page-1
1.3
S.
N.
TYPE
String
of Size
of Min.
Composite
Creepage
Insulator
Distance
(mm)
(mm)
No.
of
Individual
units per
string
EM
strength of
Insulator
Unit (KN)
(Nos.)
Mechanical strength
of Insulator string
alongwith Hardware
fittings
(kN)
Single
Suspension
20X725
2248
1X1
70
70
Single
pilot
Suspension
20X725
2248
1X1
70
70
Single
Tension
24X870
2248
1X1
120
120
Double
Tension
24X870
2248
2X1
2X120
2X120
Note: *The core dia of composite insulators mentioned at column No.3 is minimum
requirement. The bidder shall offer composite long rod insulators of suitable core dia to meet
specified E&M strength requirements. For offered core dia, the bidder shall submit
documentary evidence of past supplies & satisfactory operation of the same for minimum
period of three years. However, the overall string length shall be within the limits specified in
the drawing.
1.4
1.4.1
Pin and cap shall be designed to transmit the mechanical stress and develop uniform mechanical
strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric of
such design that it will not yield or distort under load conditions.
1.4.2
The design shall be such as to permit easy removal of replacement of either insulator units or fittings
under the live line conditions.
1.5
The dimensions of the Ball and Socket shall be of 16mm (Alt-B) for 70kN/90kN and 20 mm for 120
kN Insulators in accordance with the standard dimensions stated in IEC/ IS:2486 (Part-II).
1.6
Where, d being the dimensions in millimeters for diameter, length or creepage distance as the case
may be. However, no negative tolerance shall be applicable to creepage distance.
Page-2
1.7
Interchangeability
The composite long rod insulators inclusive of the ball & socket connection shall be standard design
suitable for use with the hardware fittings of any make conforming to relevant IEC standards.
1.8
All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be
subjected to excessive localized pressure. The insulator and metal parts shall be so designed and
manufactured that it shall avoid local corona formation and shall not generate any radio interference
beyond specified limit under the operating conditions.
1.9
Maintenance
1.9.1
The long rod insulators offered shall be suitable for employment of hot line maintenance technique
so that usual hot line operation can be carried out with ease, speed and safety.
1.9.2
All insulators shall be designed to facilitate cleaning and insulators shall have the minimum practical
number of sheds and grooves. All grooves shall be so proportioned that any dust deposit can be
removed without difficulty either by wiping with a cloth or by remote washing under live line
condition.
1.10
Materials
1.10.1 Core
It shall be a glass-fiber reinforced (FRP rod) epoxy resin rod of high strength. Glass fibers and resin
shall be optimized. The rod shall be electrical grade corrosion resistant (ECR), boron free glass
and shall exhibit both high electrical integrity and high resistance to acid corrosion.
The weathersheds of the insulators shall be of alternate shed profile. The weathersheds shall be
vulcanized to the sheath (extrusion process) or molded as part of the sheath (injection moulding
process) and free from imperfections. The vulcanization for extrusion process shall be at high
temperature and for injection moulding shall be at high temperature & high pressure. Any seams /
burrs protruding axially along the insulator, resulting from the injection moulding process shall be
removed completely without causing any damage to the housing. The track resistance of housing
and shed material shall be class 1A4.5 according to IEC60587. The strength of the weathershed to
sheath interface shall be greater than the tearing strength of the polymer. The composite insulator
shall be capable of high pressure washing.
Page-3
1.10.3 End Fittings
End fittings transmit the mechanical load to the core. They shall be made of malleable cast iron
spheroidal graphite or forged steel. They shall be connected to the rod by means of a controlled
compression technique. The manufacturer shall have in-process Acoustic emission arrangement
or some other arrangement to ensure that there is no damage to the core during crimping. This
verification shall be in-process and done on each insulator. The gap between fitting and sheath shall
be sealed by a flexible silicone rubber compound. The system of attachment of end fitting to the rod
shall provide superior sealing performance between housing and metal connection. The sealing
must be humidity proof and durable with time.
1.10.5
1.10.5.1
1.10.5.2
1.10.5.3
1.10.5.4
Workmanship
All the materials shall be of latest design and conform to the best modern practices adopted in
the extra high voltage field. Bidders shall offer only such insulators as are guaranteed by him
to be satisfactory and suitable for transmission lines specified and will give continued good
service.
The design, manufacturing process and material control at various stages shall be such as to
give maximum working load, highest mobility, best resistance to corrosion, good finish and
elimination of sharp edges and corners to limit corona and radio interference.
The design of the insulators shall be such that stresses due to expansion and contraction in any
part of the insulator shall not lead to deterioration.
The core shall be sound and free of cracks and voids that may adversely affect the insulators.
1.10.5.5
Weathersheds shall be uniform in quality. They shall be clean, sound, smooth and free from
gross defects and excessive flashing at parting lines.
1.10.5.6
End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings
should be effectively, sealed to prevent moisture ingress, effectiveness of sealing system must
be supported by test documents. All surfaces of the metal parts shall be perfectly smooth with
the projecting points or irregularities which may cause corona. All load bearing surfaces shall
be smooth and uniform so as to distribute the loading stresses uniformly.
1.10.5.7
All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent
to 600 gm/sq.m. and shall be in accordance with the requirement of ISO:1461 (E) and shall
satisfy the tests mentioned in ISO:1460 (E). The zinc used for galvanizing shall be of purity of
99.95%. The zinc coating shall be uniform, adherent, smooth, reasonably bright continuous and
free from imperfections such as flux, ash rust stains, bulky white deposits and blisters. The
galvanized metal parts shall be guaranteed to withstand at least six successive dips each lasting
for one (1) minute duration under the standard preece test. The galvanizing shall be carried out
only after any machining.
Page-4
2.0
Equipment Marking
2.1
Each composite long rod unit shall be legibly and indelibly marked with the trade mark of the
manufacturer, name of HVPNL and month & year of manufacture. The guaranteed combined
mechanical and electrical strength shall be indicated in kilo Newton followed by the word kN to
facilitate easy identification and to ensure proper use.
2.2
One 10 mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on the cap/end
fitting of each composite long rod of particular strength for easy identification of the type of insulator.
The paint shall not have any deteriorating effect on the insulator performance. Following codes shall
be used as identification mark :
For
70 KN disc
red
For
120KN disc
yellow
3.0
Bid Drawings
3.1
The Bidder shall furnish full description and illustration of the material offered.
3.2
The Bidder shall furnish along with the bid the outline drawing (6 copies) of each insulator unit
including a cross sectional view of the long rod insulator unit. The drawing shall include but not
limited to the following information :
(a)
Long rod diameter and ball to ball spacing with manufacturing tolerances
(b)
(c)
(d)
(ii)
(e)
(f)
(g)
(h)
Materials
(i)
Identification mark
(ii)
3.3
After placement of award, the Supplier shall submit full dimensioned insulator drawings containing
all the details as given in Clause No. 3.2 above, in four (4) copies to Employer for approval.
3.4
After placement of award the Supplier shall also submit fully dimensioned insulator crate drawing
for different type of insulators.
3.5
After placement of award, the Supplier shall submit full dimensioned manufacturing drawing of
composite long rod insulator unit in six (6) copies to the Employer for reference and record.
Page-5
4.0
4.1
Type Tests
The equipment should be offered fully type tested for all the type tests as detailed below . Test
reports should not be more than seven years old reckoned from the date of bid opening in respect
of all the tests carried out in accredited laboratories ( based on ISO/IEC) by a reputed accreditatic
body or witnessed by HVPNL or another electric power utility and be submitted by the successful
Bidder to HVPNL for approval as per schedule given in Bar chart :-
4.1.1
4.1.2
Fittings
(a)
IEC:383-1993/ Annexure
A
(b)
IEC:383-1993
(c)
IEC:383-1993
(d)
Annexure-A
(e)
Annexure-A
(f)
Vibration test
Annexure-A
(g)
Annexure-A
IEC: 61109
(b)
IEC: 61109
i)
(c)
Annexure-A
(d)
IEC: 61109
(e)
IEC:61109
(f)
i)
Dye penetration test
ii)
Water diffusion test
Flammability test
IEC:61109
(g)
Annexure-A
(h)
IEC:61109
(i)
Annexure-A
(j)
Annexure-A
Page-6
4.1.4
All the type test given in Clause No. 4.1.1 shall be conducted on Single I suspension, Single
Tension, Double tension insulator string along with hardware fittings. All the type tests given in
Clause No. 4.1.1 (a) to (e) shall also be conducted on Single 'I' Pilot suspension insulator string
along with hardware fittings.
4.2
Acceptance Tests:
4.2.1
(a)
Verification of dimensions
IEC : 61109
(b)
Galvanising test
IEC : 60383
(c)
(d)
Verification of tightness
IEC : 60383
IEC : 61109
mechanical load
(e)
Recovery of Hydrophobicity
Annexure-A
IEC: 61109
i)
ii)
iii)
iv)
v)
vi)
(f)
Annexure-A
The test 4.2.1.(e) shall be carried out in case total quantity of insulators of a particular rating
exceeds 5000 nos.
The test 4.2.1.(f) shall be done against each lot or against every 5000 nos. of insulators
whichever is less.
In the event of failure of the sample to satisfy the acceptance test(s) specified in 4.2 above,
the retest procedure shall be as per clause 7.6 of IEC 61109.
4.3
4.3.1
Routine Tests
For Composite Long Rod Insulator Units
a)
Visual Inspection
As per IEC:61109
b)
As per IEC:61109
Page-7
4.4
a)
As per Annexure-A
b)
c)
d)
IEC 60587
4.5
Testing Expenses
4.5.1
The entire cost of testing for acceptance and routine tests and tests
during manufacture specified herein shall be treated included in the
quoted Ex-works price except for the expenses of the inspector/HVPNL
representative.
4.6
4.6.1
The bidder has to indicate the schedule of following activities in their bids:
The HVPNL representative reserves the right of having at his own expense any other test
(s) of reasonable nature carried out at manufacturers premises, at site, or in any other place
in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the
material comply with the specifications.
4.6.3 The HVPNL representative also reserves the right to conduct all the
tests mentioned in this specification at his own expense on the samples
drawn from the site at manufacturers premises or at any other test
center. In case of evidence of non compliance, it shall be binding on the
part of the manufacture to prove the compliance of the items to the
technical specifications by repeat tests or correction of deficiencies, or
replacement of defective items, all without any extra cost to the HVPNL
representative .
4.7
The Bidder/insulator manufacturer shall have to co-ordinate testing of insulators with hardware
fittings to be supplied by other manufacturer and shall have to also guarantee overall
satisfactory performance of the insulators with the hardware fittings.
4.8
Test Reports
4.8.1
Copies of type test reports shall be furnished in at least six (6) copies along
with one original.
One copy shall be returned duly certified by the Employer only after which the commercial
production of the concerned material shall start.
4.8.2
Copies of acceptance test reports shall be furnished in at least six (6) copies. One copy shall be
returned duly certified by the Employer, only after which the material shall be dispatched
Page-8
4.8.3
Record of routine test reports shall be maintained by the manufacturer at his works for periodic
inspection by the HVPNL representative.
4.8.4
Test certificates of test during manufacture shall be maintained by the manufacturer. These shall
be produced for verification as and when desired by the HVPNL representative.
4.9 Inspection
4.9.1
The HVPNL representative shall at all times be entitled to have access to the works and all places
of manufacture, where insulators, and its component parts shall be manufactured and the
representatives shall have full facilities for unrestricted inspection of the manufacturers and submanufacturers works, raw materials, manufacture of the material and for conducting necessary
test as detailed herein.
Page-8
4.9.2
The material for final inspection shall be offered by the manufacturer only under packed condition.
The HVPNL representative shall select samples at random from the packed lot for carrying out
acceptance tests.
4.9.3
The manufacturer shall keep HVPNL informed in advance of the time of starting and the progress
of manufacture of material in their various stages so that arrangements could be made inspection.
4.9.4
No material shall be despatched from its point of manufacture before it has been satisfactorily
inspected and tested unless the inspection is waived off by the HVPNL representative in writing.
In the latter case also the material shall be despatched only after satisfactory testing for all tests
specified herein have been completed.
4.9.5
The acceptance of any quantity of material shall be in no way relieve the manufacturer of his
responsibility for meeting all the requirements of the specification and shall not prevent
subsequent rejection, if such material are later found to be defective.
4.10
4.10.1 All insulators shall be packed in suitable PVC/ plastic tubes along with temporary wrap-on
shields/shrouds for each insulator unit. The packing shall provide protection against rodent. The
shields/shrouds shall be for protection during transport and for preventing bird pecking during
erection. Further, the shields/shrouds shall be made of opaque, weather proof material of adequate
strength and shall be colour coded. The shields/shrouds shall have smaller diameter than the
insulator to stay in place against winds & weather and shall be designed so as to leave only the end
fittings exposed for attachment of insulator to tower and line hardware until line construction is
complete. The shield/shroud shall have suitable pull off loop for easy detachment just prior to
charging of the line without causing any damage to the insulator. The contractor shall furnish
detailed design of the packing and shield/shroud along with attachment and detachment procedure
in this regard. For marine transportation, crates shall be palleted.
4.10.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage at site
and subsequent handling in the field.
4.10.3 Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent
damage or deformation during transit and handling.
4.10.4 The Supplier shall guarantee the adequacy of the packing and shall be responsible for any loss or
damage during transportation, handling, storage and installation due to improper packing.
Page-9
4.10.5 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their
destination and to avoid the possibility of goods being lost or wrongly dispatched on account of
faulty packing and faulty or illegible markings. Each case/crate shall have all the markings stenciled
on it in indelible ink.
4.11
Standards
The insulator strings and its components shall conform to the following Indian/ International
Standards
which
shall
mean
latest
revision,
with
amendments/
changes adopted and published, unless specifically stated otherwise in the Specification.
4.11.1 In the event of supply of insulators conforming to standards other than specified, the Supplier shall
confirm in his bid that these standards are equivalent or better to those specified. In case of award,
salient features of comparison between the standards proposed by the Supplier and those specified
in this document will be provided by the Supplier to establish equivalence.
Sl.
No.
Indian Standard
Title
International
Standard
1.
IS:209-1992
BS:3436
IS:406-1991
BS:3436
Sl.
No.
Indian Standard
Title
International
Standard
2.
3.
IS:731-1991
4.
IS:2071
Part Methods of High Voltage Testing
(I)
1993
(Part(II)-1991
Part(III)-1991
5.
IS:2486
Part-I-1993
Part-II-1989
Part-III-1991
Porcelain insulators for overhead Power lines with BS:137a nominal voltage greater than 1000 V
IEC:60383
(I&II)
IEC:60060-1
and
Tests
BS:3288
Locking Devices
IEC:60120
IEC:60372
6.
IS:2629-1990
Recommended
Practice
for
Galvanisation for iron and steel
Hot,
7.
IS:2633-1992
8.
IS:3188-1988
9.
IS:6745-1990
10.
IS:8263-1990
IEC:60305
IEC:60437
NEMA Publi- cation
No.07/ 1964/ CISPR
11.
IS:8269-1990
12.
13.
IEC:60507
Sl.
No.
Indian Standard
Title
International
Standard
14.
15.
16.
17.
IEC:60815
Page-10
BS
British Standards,
British Standards Institution
101, Pentonvile Road,
N - 19-ND, UK
IEC/CISPR
BIS/IS
ISO
International
Standardization.
Organisation
for
ASTM
Page-11
ANNEXURE-A
1.0
The voltage across each insulator unit shall be measured by sphere gap method. The result obtained
shall be converted into percentage. The voltage across any disc shall not exceed 20% for suspension
insulator string and 22% for tension insulator string.
1.2
The complete insulator string along with its hardware fitting excluding arcing horn, corona
control ring, grading ring and suspension assembly/dead end assembly shall be subjected
to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall
be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held
for five minutes and then removed. After removal of the load, the string components shall
not show any visual deformation and it shall be possible to disassemble them by hand. Hand
tools may be used to, remove cotter pins and loosen the nuts initially. The string shall then
be reassembled and loaded to 50% of UTS and the load shall be further increased at a
steady rate till the specified minimum UTS and held for one minute. No fracture should occur
during this period. The applied load shall then be increased until the failing load is reached
and the value recorded.
1.3
Vibration Test
The suspension string shall be tested in suspension mode, and tension string in tension
mode itself in laboratory span of minimum 30 metres. In the case of suspension string a load
equal to 600 Kg shall be applied along the axis of the suspension string by means of turn
buckle. The insulator string along with hardware fittings and conductor tensioned at 2500
Kgf shall be secured with clamps. The system shall be suitable to maintain constant tension
on the conductor throughout the duration of the test. Vibration dampers shall not be used on
the test span. The conductor shall be vertically vibrated at one of the resonance frequencies
of the insulators string (more than 10 Hz) by means of vibration inducing equipment. The
peak to peak, displacement in mm of vibration at the antinode point nearest to the string
shall be measured and the same shall not be less than 1000 /f1.8 where is the frequency of
vibration in cycles/sec. The insulator string shall be vibrated for not less than 10 million cycles
without any failure. After the test the disc insulators shall be examined for looseness of pins
and cap or any crack in the cement. The hardware shall be examined for looseness, fatigue
failure and mechanical strength test. There shall be no deterioration of properties of
hardware components and insulators after the vibration test. The insulators shall be
subjected to the Mechanical performance test followed by mechanical strength test as per
relevant standards.
1.4
Page-12
2.0
2.1
Assembled core load time test with container that contains1n-HNO3 concentric acid that is
applied at the naked rod. The rod should be held at 80% of SML for the duration of the test.
The rod should not fail within the 96 hour test duration
2.2
2.3
(1)
The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface
to dry and spray with water. Record the HC classification. Dry the sample surface.
(2)
Treat the surface with corona discharges to destroy the hydrophobicity. This can be done
utilizing a high frequency corona tester, Holding the electrode approximately 3mm from the
sample surface, slowly move the electrode over an area approximately 1 x 1. Continue
treating this area for 2 3 minutes, operating the tester at maximum output.
(3)
Immediately after the corona treatment, spray the surface with water and record the HC
classification. The surface should be hydrophilic, with an HC value of 6 or 7. If not, dry the
surface and repeat the corona treatment for a longer time until an HC of 6 or 7 is obtained.
Dry the sample surface.
(4)
Allow the sample to recover and repeat the hydrophobicity measurement at several time
intervals. Silicone rubber should recover to HC 1 HC 2 within 24 to 48 hours, depending
on the material and the intensity of the corona treatment.
2.4
The test is to be carried out at 3800 kPa with nozzles of 6 mm diameter at a distance of 3m
from nozzles to the insulator, followed by a dry power frequency voltage test as per IEC
61109.
Page-13
3.
3.1
3.2
analysed
as
3.3
Tests on Castings
The chemical analysis, mechanical and metallographic tests and magnetic, particle
inspection for castings will be as per the internationally recognised procedures for these
tests. The samplings will be based on heat number and heat treatment batch. The details
regarding test will be as discussed and mutually agreed to by the Supplier and Employer in
Quality Assurance Programme.
Page-14
TECHNICAL SPECIFICATION OF
CONTENTS
S. No
Clause
1.
2.
Page No.
1.
SCOPE
This specification covers design, Engineering, manufacture, stage testing, inspection and testing before
despatch , packing, forwarding and delivery at site FOR destination of 72.5 kV outdoor type bus Post
Insulators and its clamps at the Gantries.
It is not the intent to specify completely all the details of design and construction of the insulator.
However, the insulator shall conform in all respects to the high standard of engineering design and
workmanship and shall be capable of performing in continuous commercial operation up to the Bidders
guarantee in a manner acceptable to the HVPNL. The equipment offered shall be complete in all
components necessary for its effective and trouble free operation. Such components shall be deemed to
be within the scope of supply irrespective of whether those are specially brought out in this specification
or not. All similar parts particularly movable ones shall be interchangeable.
2.
STANDARD
The Post Insulators and their Hardwares shall comply as regards general requirements, test
voltages and test with the latest edition of IS 2544/1973 IS-5350 (P-II) 1973 IS-5350 (P-III)
1971/IEC-168/1979 except in so far as the same may be modified by this Specification.
3.
Sr.
No.
Particulars
Unit
i.
kV
66
ii.
kV
72.5
iii.
Rated frequency
50+/-2.5H
iv.
Minimumcreepage
distance
mm
v.
One
minute
power kV(rms)
frequencywithstand
voltage
140
vi.
Impulsewithstand
voltage
325
kV(peak)
1813
Minimum visual
kV(rms)
Page-1
viii.
Radio
interference Micro Volt
voltage (Micro volt at 1
MHz) at a system
voltage of 156 kV.
>500
ix.
Cantilever
(Upright)
400
x.
Torsion strength
nm
2000
xi.
Bending strength
4000
xii.
Tensile strength
35000
xiii.
Compressive strength
70000
xiv.
Applicable standard
xv.
mm
127
b. Bottom
mm
127
xvi.
Height of insulator
mm
770+/-1
xvii.
No. of
stack
strength Kg.
Insulator
4. CLIMATIC CONDITION
per No.
5. GENERAL REQUIREMENT
72.5 kV Bus Post Insulator shall be either solid core or polycon type insulators complete with all
fittings and accessories required for holding single ACSR 0.4 Sq ACSR Zebra / 0.2sqACSR
Panther. The bus Post Insulator pedestal shall be suitable for fixing on the Gantries.
The bus Post Insulator shall be provided with a completely galvanised steel base designed for
mounting on the Gantries. The base and mounting arrangement shall be such that the insulator
shall be rigid and self supporting and no guying or cross bracings between phases shall be
necessary.
Cap to be provided on top of the insulator shall be of high grade cast iron or malleable steel casting.
It shall be machine faced and hot dip galvanised. The cap shall have four nos. of tapped holes
spaced on a pitch circle diameter to accommodate the terminal clamp . The holes shall be suitable
for bolts with threads having anticorrosive protection. The effective depth of threads shall not be
less than the nominal diameter of the bolt.
The Post Insulator clamps are to be fitted on the top of the bus Post Insulator for holding single
conductor ACSR Zebra /ACSR Panther tightly and rigidly. The clamps shall be made of Aluminium
alloy and shall comply with relevant ISS. The clamps shall be supplied with galvanised steel studs
of the suitable size and maintain the requisite pressure to ensure good and tight joint of low
resistance.
The insulators shall be entirely free from sharp edges, ridges or points and shall not exhibit
appreciable corona formation during service.
Castings shall be free from blow holes, flaws, cracks and other defects and shall be smooth, close
grained and of true forms and dimensions.
Page-2
The porcelain shall be white, finished brown glazed, non-porous of high di-electric, mechanical and
thermal strength, free from defects and thoroughly vitrified. Cement used shall be of high quality,
durable and high strength Portland cement. Cement is not to be treated as an adhesive medium
between the porcelain and metal parts of an insulator. Preference will be given to a fixing medium
of an approved metal alloy. Cement shall be a replenishment material for filling gap between the
porcelain and metal parts to fix them.
6.
GALVANISING
All the ferrous metal parts shall be hot dip galvanised smoothly, as per IS 3638 (as amended up to
date). IS 2633 or any other equivalent authoritative standard. The material shall be galvanised only
after shop operations upon it have been completed. The metal parts before galvanising should be
thoroughly cleaned of any paint, grease, rust, scales or alkalis, or any foreign deposit which are
likely to come in the way of galvanising process. The metal parts coating shall withstand minimum
four for one minute dips in copper sulphate solution as per IEC-168.
The bus Post Insulator unit shall be assembled in a suitable jig to ensure correct positioning of the
top and bottom metal fittings relative to one another. The faces of the metal fittings shall be parallel
and at right angles to the axis of the insulator and the corresponding holes in the top and the bottom
metal fittings shall be in a vertical plane containing the axis of the insulator.
All nuts, bolts and spring washers etc. required for the assembly of the complete insulator stack
shall be in scope of supply. The bolts and nuts shall be hot dip galvanised and shall be of high
strength generally conforming to IS-136 or any other equivalent international standard.
7.
TESTS
7.1
Type Tests
The equipment should be offered type tested. Test reports should not be more than seven years
old reckoned from the date of bid opening in respect of all the tests carried out in accredited
laboratories ( based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPNL or
another electric power utility and be submitted by the successful Bidder to HVPNL for approval as
per schedule given in Bar chart.
1.
Visual examination
2.
Verification of dimensions
3.
4.
5.
6.
7.
8.
9.
Puncture test
10.
Porosity test
11.
Galvanising test
Page-3
7.2
7.2.1
8.
All the acceptance and routine tests as detailed below shall be carried out by the supplier in the
presence of HVPNL. No material shall be dispatched without the approval of test certificates:-
1.
Verification of dimensions
2.
3.
Puncture test
5.
Porosity test
6.
Galvanising test
INSPECTION
The inspection may be carried by the HVPNL at any stage of manufacture. The successful Bidder
shall grant free access to the HVPNL representative at a reasonable time when the work is in
progress. Inspection and acceptance of any equipment under this Specification by the HVPNL shall
not relieve the supplier of his obligation of furnishing equipment in accordance with the Specification
and shall not prevent subsequent rejection if the equipment is found to be defective.
The Bidder shall keep the HVPNL informed in advance about the manufacturing programme so that
arrangement can be made for inspection.
The HVPNL reserves the right to insist for witnessing the acceptance/routine testing of the bought
out items.
9.
GUARANTEED DATA
Guaranteed technical particulars and other technical data in respect of equipment/material offered
should be furnished duly signed in the performa given in GTPs. Any other particulars considered
necessary may also be given in addition to those listed in the schedule.
10.
11. MARKING
Each porcelain insulator unit shall legibly and indelibly be marked to show the following:
a)
Name or Trade Mark of the manufacture.
b)
Month and year of manufacture.
c)
Country of manufacture.
Marking on the porcelain shall be printed and shall be applied before firing.
Page-4
12.
12.1
12.2
Each consignment shall be accompanied by a detailed packing list containing the following
information: -
a)
b)
c)
d)
e)
f)
g)
Page-5
SECTION-VI
(CHAPTER III D)
TECHNICAL SPECIFICATION
CONTENTS
S. No
Clause
1.
2.
3.
Earthwire Accessories
4.
5.
Type Tests
Annexure-A
Annexure-B
SECTION-VI, CHAPTER-III D
TECHNICAL SPECIFICATIONS
1.
1.1
1.1.1
The hardware fittings shall be as per the specification drawings enclosed with this part of the specification.
Each hardware fitting shall be supplied complete in all respects and shall include the following hardware
parts.
1.1.2
Single suspension, Single Tension, Single suspension (Pilot), Double Suspension and Double Tension
hardware fittings, shall be supplied suitable for attaching to hanger/strain plate fixed to tower.
1.1.3
1.1.4
1.1.5
Suspension and dead end assembly to suit conductor size as detailed in clause 1.10 and 1.11 hereinafter.
1.1.6
Other necessary fittings as eye links, ball clevis, socket clevis, clevis eye, U-clevis and chain link etc. to make
the hardware fittings complete.
1.1.7
1.2
1.3
Interchangeability
1.3.1
The hardware for insulator strings with disc insulators together with ball and socket fittings shall be of
standard design, so that these hardware are interchangeable with each other and suitable for use with disc
insulators of any make conforming to relevant Indian/International Standard.
1.4
1.5
Maintenance
1.5.1
The hardware fittings offered shall be suitable for employment of hot line maintenance techniques so
that usual hot line operations cab be carried out with ease, speed and safety. The technique adopted for
hot line maintenance shall be generally bare hand method & hot stick method. The Bidder should clearly
establish in the bid, the suitability of his fittings for hot line maintenance.
Page-1
1.6
Designation
1.6.1
1.7
1.7.1
Security clips for use with ball and socket coupling shall be R-shaped, hump type which provides
positive locking of the coupling as per IS:2486 (Part-III) /IEC : 372. The legs of the security clips shall
be spread after assembly in the works to prevent complete withdrawal from the socket. The locking
device should be resilient, corrosion resistant and of suitable mechanical strength. There shall be no
risk of the locking device being displaced accidentally or being rotated when in position. Under no
circumstances shall the locking devices allow separation of fittings.
1.7.2
The hole for the security clips shall be countersunk and the clip should be of such design that the
eye of clips may be engaged by a hot line clip puller to provide for disengagement under energised
conditions. The force required to pull the security clip into its unlocked position shall not be less
than 50 N (5 kg) or more than 500 N (50 kg).
1.7.3
1.8
1.8.1
The arcing horn shall be either ball ended rod type or tubular type.
1.8.2
For insulators strings with disc insulators, the arcing horn shall be provided as shown on the
drawings of the hardware fittings in this specification.
1.8.3
The spark gap shall be so adjusted to ensure effective operation under actual field conditions.
1.9
Yoke Plates
The strength of yoke plates shall be adequate to withstand the minimum ultimate tensile strength,
as specified in the bid drawings.
The plates shall be either triangular or rectangular in shape as may be necessary. The design of yoke
plate shall take into account the most unfavourable loading conditions likely to be experienced as a
result of dimensional tolerances for disc insulators as well as components of hardware fittings within
the specified range. The plates shall have suitable holes for fixing arcing horn. All the corners and
edges should be rounded off with a radius of at least 3 mm. Design calculations i.e. for bearing &
tensile strength, for deciding the dimensions of yoke plate shall be furnished by the bidder. The
holes provided for bolts in the yoke plate should satisfy shear edge condition as per Clause No. 8.10
of IS: 800-1984.
Page-2
1.10
Suspension Assembly
1.10.1
1.10.2
The suspension assembly shall include either free centre type suspension clamp alongwith standard
preformed armour rods or armour grip suspension clamp except for pilot insulator string for which
only suitable envelope type suspension clamps shall be used.
1.10.3
The suspension clamp alongwith standard preformed armour rods set shall be designed to have
maximum mobility in any direction and minimum moment of inertia so as to have minimum stress
on the conductor in the case of oscillation of the same.
1.10.4
The suspension clamp alongwith standard preformed armour rods/armour grip suspension clamp
set shall have a slip strength between 16 to 24 KN.
1.10.5
The suspension assembly shall be designed, manufactured and finished to give it a suitable shape,
so as to avoid any possibility of hammering between suspension assembly and conductor due to
vibration. The suspension assembly shall be smooth without any cuts, grooves, abrasions,
projections, ridges or excrescence which might damage the conductor.
1.10.6
The suspension assembly/clamp shall be designed so that it shall minimise the static & dynamic
stress developed in the conductor under various loading conditions as well as during wind induced
conductor vibrations. It shall also withstand power arcs & have required level of corona/RIV
performance.
1.10.7
For the free Center Suspension Clamp seat shall be smoothly rounded and curved into a bell
mouth at the ends. The lip edges shall have rounded bead. There shall be at least two U-bolts for
tightening of clamp body and keeper pieces together.
1.10.8
1.10.8.1
The preformed Armour Rod Set suitable for ACSR Zebra (61/3.18) conductor shall be used to
minimise the stress developed in the conductor due to different static and dynamic loads because
of vibration due to wind, slipping of conductor from the suspension clamp as a result of unbalanced
conductor tension in adjacent spans and broken wire condition. It shall also withstand power arcs,
chafing and abrasion from suspension clamp and localised heating effect due to magnetic power
losses from suspension clamps as well as resistance losses of the conductor.
1.10.8.2
The preformed Armour rods set shall have right hand lay and the inside diameter of the helics shall
be less than the outside diameter of the conductor to have gentle but permanent grip on the
conductor. The surface of the Armour rod when fitted on the conductor shall be smooth and free
from projections, cuts and abrasions etc.
Page-3
1.10.8.3
The pitch length of the rods shall be determined by the Bidder but shall be less than that of the
outer layer of conductor and the same shall be accurately controlled to maintain uniformity and
consistently reproducible characteristic wholly independent of the skill of linemen.
1.10.8.4
ACSR Zebra
2540 25
7.87 .10
The tolerance in length of the rods in complete set should be within 13 mm between the longest
and shortest rod. The ends of Armour rod shall be parrot billed.
1.10.8.5
The number of Armour rods in each set shall be twelve. Each rod shall be marked in the middle with
paint for easy application on the line.
1.10.8.6
The amour rod shall not loose their resilience even after five applications.
1.10.8.7
The conductivity of each rod of the set shall not be less than 40% of the conductivity of the
International Annealed Copper Standard (IACS).
1.10.9
1.10.9.1
The Armour grip suspension clamp shall comprise of retaining strap, support housing, elastomer
inserts with aluminum re-enforcements and AGS preformed rod set.
1.10.9.2
1.10.9.3
The AGS preformed rod set shall be as detailed in clause 1.10.10.1 to 1.10.10.7 in general except for
the following.
1.10.9.4
The length of the AGS preformed rods shall be such that it shall ensure sufficient slipping strength as
detailed under clause 1.10.4 and shall not introduce unfavorable stress on the conductor under all
operating conditions.
1.10.10
The seat of the envelope type suspension clamp shall be smoothy rounded and suitably curved at the
ends. The lip edges shall have a rounded bend. There shall be at least two U-Bolts for tightening of
clamp body and keeper pieces together. Hexagonal bolts and nuts with split pins shall be used for
attachment of the clamp.
Page-4
1.11
1.11.1
The dead end assembly shall be suitable for ACSR Zebra (61/3.18) mm conductor.
1.11.2
The dead end assembly shall be compression type with provision for compressing jumper terminal
at one end. The angle of jumper terminal to be mounted should be 30 0 with respect to the vertical
line. The area of bearing surface on all the connections shall be sufficient to ensure positive electrical
and mechanical contract and avoid local heating due to I2 R losses. The resistance of the clamp when
compressed on Conductor shall not be more than 75% of the resistance of equivalent length of
Conductor.
1.11.3
Die compression areas shall be clearly marked on each dead-end assembly designed for continuous
die compressions and shall bear the words COMPRESS FIRST suitably, inscribed near the point on
each assembly where the compression begins. If the dead end assembly is designed for intermittent
die compressions, it shall bear identification marks COMPRESSION ZONE AND NON-COMPRESSION
ZONE distinctly with arrow marks showing the direction of compressions and knurling marks showing
the end of the zones. Tapered aluminum filler plugs shall also be provided at the line of demarcation
between compression & non-compression zone. The letters, number and other marking on the
finished clamp shall be distinct and legible. The dimensional tolerances of the cross section of
aluminum for dead end assembly for ACSR Zebra conductor shall be as per the table given below: -
TABLE-I
Sl.
No.
Item
Dimension before
Compression
Inner
dia
Outer
dia
(mm)
Dimension after
Compression
Face
to face
width
(mm)
(mm)
Corner
to
corner
width
(mm)
1.11.4
1.
Aluminum
310.5
481
460.5
400.5
2.
Steel
100.2
200.5
190.5
160.5
The assembly shall not permit slipping of, damage to, or failure of the complete conductor or any part
there of at a load less than 95% of ultimate tensile strength of the conductor.
Page-5
1.12
1.12.1
All bolts and nuts shall conform to IS: 6639-1972. All bolts and nuts shall be galvanized. All bolts and
nuts shall have hexagonal heads, the heads being forged out of solid truly concentric, and square
with the shank, which must be perfectly straight.
1.12.2
Bolts up to M 16 and having length up to 10 times the diameter of the bolt should be manufactured
by cold forging and thread rolling process to obtain good and reliable mechanical properties and
effective dimensional control. The shear strength of bolt for 5.6 grade should be 310 MPa minimum
as per IS: 12427. Bolts should be provided with washer face in accordance with IS: 1363 Part-I to
ensure proper bearing.
1.12.3
Nuts should be double chamfered as per the requirement of IS: 1363 Part-III, 1984. It should be
ensured by the manufacturer that nuts should not be over-tapped beyond 0.4 mm oversize on
effective diameter for size up to M 16.
1.12.4
Fully threaded bolts shall not be used. The length of the bolt shall be such that the threaded portion
shall not extend into the place of contact of the component parts.
1.12.5
All bolts shall be threaded to take the full depth of the nuts and threaded enough to permit the firm
gripping of the component parts but no further. It shall be ensured that the threaded portion of the
bolt protrudes not less than 3 mm and not more than 8 mm when fully tightened. All nuts shall fit
and tight to the point where shank of the bolt connects to the head.
1.12.6
Flat washers and spring washers shall be provided wherever necessary and shall be of positive lock
type. Spring washers shall be electro-galvanized. The thickness of washers shall conform to IS: 20161967.
1.12.7
The Bidder shall furnish bolt schedules giving thickness of components connected, the nut and the
washer and the length of shank and the threaded portion of bolts and size of holes and any other
special details of this nature.
1.12.8
To obviate bending stress in bolt, it shall not connect aggregate thickness more than three time its
diameter.
1.12.9
Bolts at the joints shall be so staggered that nuts may be tightened with spanners without fouling.
1.12.10
1.13
Materials
The materials of the various components shall be as specified hereunder. However components
made of alternative materials giving equivalent or better performance shall also be considered. The
Bidder shall indicate the material proposed to be used for each and every component of hardware
fittings stating clearly the class grade or alloy designation of the material, manufacturing process &
heat treatment details and the reference standards.
1.13.1
The details of material for different component are listed as in Table No. II.
Page-6
1.14
Workmanship
1.14.1
All the equipment shall be of the latest design and conform to the best modern practices adopted
in the Extra High Voltage field. The Bidder shall offer only such equipment as guaranteed by him to
be satisfactory and suitable for 66 kV transmission line and will give continued good performance.
1.14.2
The design, manufacture process and quality control of all the materials shall be such as to give the
specified mechanical rating, highest mobility, elimination of sharp edges and corners to limit corona
and radio-interference, best resistance corrosion and a good finish.
1.14.3
All ferrous parts including fasteners shall be hot dip galvanised, after all machining has been
completed. Nuts may, however, be tapped (threaded) after galvanising and the threads oiled. Spring
washers shall be electro-galvanised. The bolt threads shall be undercut to take care of the increase
in diameter due to galvanising. Galvanising shall be done in accordance with IS: 2629-1985 and shall
satisfy the tests mentioned in IS: 2633-1986. Fasteners shall withstand four dips while spring
washers shall withstand three dips of one-minute duration in the standard preece test. Other
galvanised materials shall be guaranteed to withstand at least six successive dips each lasting one
(1) minute under the standard preece test for galvanising.
1.14.4
Before ball fittings are galvanised, all die flashing on the shank and on the bearing surface of the ball
shall be carefully removed without reducing the dimensions below the design requirements.
1.14.5
The zinc coating shall be perfectly adherent, of uniform thickness, smooth reasonably bright,
continuous and free from imperfections such as flux, ash, rush stains, bulky white deposits and
blisters. The zinc used for galvanising shall be grade Zn 99.95 as per IS: 209-1979.
1.14.6
Pin balls shall be checked with the applicable GO gauges in at least two directions, one of which
shall be across the line of die flashing, and the other 900 to this line. NO GO gauges shall not pass
in any direction.
1.14.7
Socket ends, before galvanising, shall be of uniform contour. The bearing surface of socket ends
shall be uniform about the entire circumference without depressions of high spots. The internal
contours of socket ends shall be concentric with the axis of the fittings as IS: 2486/IEC: 120.
The axis of the bearing surfaces of socket ends shall be coaxial with the axis of the fittings. There
shall be no noticeable tilting of the bearing surfaces with the axis of the fittings.
1.14.8
In case of casting, the same shall be free from all internal defects like shrinkage, inclusion,
blowholes, cracks etc. Pressure die casting shall not be used for casting of components with
thickness more than 5 mm.
1.14.9
All current carrying parts shall be so designed and manufactured that contact resistance is reduced
to minimum.
Page-7
1.14.10
No equipment shall have sharp ends or edges, abrasions or projections and cause any damage to
the conductor in any way during erection or during continuous operation which would produce high
electrical and mechanical stresses in normal working. The design of adjacent metal parts and mating
surfaces shall be such as to prevent corrosion of the contact surface and to maintain good electrical
contact under service conditions.
1.14.11
All the holes shall be cylinderical, clean cut and perpendicular to the plane of the material. The
periphary of the holes shall be free from burrs.
1.14.12
All fasteners shall have suitable corona free locking arrangement to guard against vibration
loosening.
1.14.13
Welding of aluminum shall be by inert gas shielded tungesten arc or inert gas shielded metal arc
process. Welds shall be clean, sound, smooth, uniform without overlaps, properly fused and
completely sealed. There shall be no cracks, voids incomplete penetration, incomplete fusion,
under-cutting or inclusions. Porosity shall be minimized so that mechanical properties of the
aluminum alloys are not affected. All welds shall be properly finished as per good engineering
practices.
1.15
Bid Drawings
1.15.1
The Bidder shall furnish full description and illustrations of materials offered.
1.15.2
Fully dimensioned drawings of the complete insulator string hardwares and their component parts
showing clearly the following arrangements shall be furnished in five (5) copies along with the bid.
Weight, material and fabrication details of all the components should be included in the drawings.
(i)
(ii)
(iii)
Arcing horn/intermediate Arcing Horn attachment to the string as specified in clause 1.8 of
this technical Specification.
(iv)
Yoke plates.
(v)
Hardware fittings of ball and socket for interconnecting units to the top and bottom Yoke
plates.
(vi)
1.15.3
All drawings shall be identified by a drawing number and contract number. All drawing shall
be neatly arranged. All drafting & lettering shall be legible. The minimum size of lettering shall be 3 mm.
All dimensions & dimensional tolerances shall be mentioned in mm:
(i)
(ii)
Material, fabrication details including any weld details & any specified finishes & coatings. Regarding
material, designation & reference of standards are to be indicated.
Page-8
(iii)
Catalogue No.
(iv)
Marking.
(v)
Weight of assembly.
(vi)
Installation instructions.
(vii)
(viii)
Withstand torque that may be applied to the bolt or cap screw without failure of component parts.
(ix)
(x)
1.15.4
After placement of award, the Manufacturer shall submit fully dimensioned drawing
including all the components in four (4) copies to the HVPNLfor approval. After getting approval from the
HVPNLand successful completion of all the type tests, the Manufacturer shall submit 12 more copies of
the same drawings to the HVPNLfor further distribution and field use at HVPNLs end.
Table-II
Details of Materials
...
Sr. No.
Process of
Reference
Treatment
Standard
...
1.
Security Clips
Stainless
--
AISI 302
Steel/Phos
304-L-As per
Pher Bronze
IS-1385-1968
Remark
2.
3.
Arcing Horn/
Mild Steel
Hot dip
Intermediate
Rod/Tube
galvanized
Arching Horn
Type
Ball Fittings,
Class-IV Drop
Socket, All
As per IS-226
1975 or equivalent
As per IS:2004
Shackles links
equivalent
1978 or equivalent
normalized
Hot dip
galvanized
4.
Yoke Plate
Mild Steel
Hot dip
As per IS:226
galvanized
1975 or equivalent
standard
5.
Free Centre
Clamp
(a) Clamp Body/High StreKeeper Piece
Casted
IS: 617 or
/forged
4600 or LM
Heat
-6 or equiv-
treated
equivalent
alent/6061
Page-9
Mild Steel
Hot dip
IS: 226-1975
Galvanized
IS: 2062-1992
Shackles,
Brackets
(c) U Bolts
Stainless
Forged &
Steel or
heat treated
6. P.A. Rod
High Stren-
Heat
treatment
ASTM-B429
Minimum
tensile
strength
of 35 Kg
/mm2
7.
AGS Clamp
High Stren-
Cast
IS: 617 or
forged
equivalent
-ion resistant
AL. Alloy LM6,
Heat
treated
4600 or
equivalent/6061
ASTM-B429
6061 or
equivalent.
reinforcement
assembly
than 99.5% or
for ACSR
aluminum alloy
Zebra
6201/or equivalent
Conductor
Mild Steel
Galvanised
Page-10
2.
2.1
General
2.1.1
2.1.2
2.2
This portion details the technical particulars of the accessories for ACSR
Conductor.
Zebra 61/3.18
2.2.1
Mid Span Compression Joint shall be used for joining two lengths of conductor. The joint shall have
a resistively less than 75% of the resistivity of equivaler length of conductor. The joint shall not
permit slipping off, damage to, or failure of the complete conductor or any part thereof at a load
less than 95% of the ultimate tensile strength of the conductor.
2.2.2
The joint shall be made of Steel and aluminum sleeves for jointing the conductor. The aluminum
sleeve shall have aluminum of purity not less than 99.5%. If whole of the sleeve is not to be
compressed than tapered aluminum filler plugs shall also be provided on the line of demarcation
between compression and non-compresion zone. The steel sleeve should not crack nor fail during
compression. The Brinnel Hardness of steel sleeve shall not exceed 160. The steel sleeve shall be
hot dip Galvanised. The dimensions and dimensional tolerances of mid span compression joint shall
be as per Table-III.
2.3
Repair Sleeve
Repair Sleeve of compression type shall be used to repair conductor with not more than two strands
broken in the outer layer. The sleeve shall be manufactured from 99.5% pure aluminum and shall
have a smooth surface. The repair sleeve shall comprise of two pieces with a provision of seat for
sliding of the keeper piece. The edges of the seat as well as the keeper piece shall be so rounded
that the conductor strands are not damaged during installation. The dimensions and dimensional
tolerances of repair sleeve shall be as per Table-III.
2.4
Vibration Damper
2.4.1
Vibration dampers of 4R-stockbridge type with four (4) different resonances spread with the
specified aeolian frequency band width corresponding to wind speed of 1m/s to 7 m/s shall be used
at suspension and tension points on each conductor in each span to damp out aeolian vibrations as
mentioned herein after.
2.4.2
Alternate damping systems or offering equivalent or better performance also shall be accepted
provided the manufacturer meets the qualifying requirements stipulated in the Specifications.
Relevant technical documents to establish the technical suitability of alternate systems shall be
furnished by the Bidder along with the bid.
2.4.3
One damper minimum on each side of conductor for suspension points and two dampers minimum
on each side of conductor for tension points shall be used.
Page-11
2.4.4
The Bidder may offer damping system involving more number of dampers per ruling design span
than the specified. However suitable price compensation shall be considered for evaluation. For the
purposed of price compensation 80% of the towers as suspension locations and 20% of the towers
as tension locations and all the spans shall be assumed to be ruling design spans.
2.4.5
The clamp of the vibration damper shall be made of high strength aluminum alloy of type LM-6 or
equivalent. It shall be capable of supporting the damper and prevent damage or chafing of the
conductor during erection or continued operation. The clamp shall have smooth and permanent
grip to keep the damper in position on the conductor without damaging the strands or causing
premature fatigue failure of the conductor under the clamp. The clamp groove shall be in uniform
contact with the conductor over the entire clamping surface except for the rounded edges. The
groove of the clamp body and clamp cap shall be smooth, free form projections, grit or other
materials which could cause damage to the conductor when the clamp is installed. Clamping bolts
shall be provided with self locking nuts and designed to prevent corrosion of threads or loosening
in service.
2.4.6
The messenger cable shall be made of high strength galvanized steel/stainless steel with a minimum
strength of 135 kg/sq mm. It shall be of preformed and postformed quality in order to prevent
subsequent droop of weight and to maintain consistent flexural stiffness of the cable in service. The
number of strands in the messenger cable shall be 19. The messenger cable other than stainless
steel shall be hot dip galvanized in accordance with the recommendations of IS: 4826-1979 for
heavily coated wires.
2.4.7
The damper mass shall be made of hot dip galvanized mild steel/cast iron or a permanent mould
cast zinc alloy. All castings shall be free from defects such as cracks, shrinkage, inclusions and
blowholes etc. The surface of the damper masses shall be smooth.
2.4.8
The damper clamp shall be casted over the messenger cable and offer sufficient and permanent grip
on it. The messenger cable shall not slip out of the grip at a load less than the mass pull-off value of
the damper. The damper masses made of material other than zinc alloy shall be fixed to the
messenger cable in a suitable manner in order to avoid excessive stress concentration on the
messenger cables which shall cause premature fatigue failure of the same. The messenger cable
ends shall be suitably and effectively sealed to prevent corrosion. The damper mass made of zinc
alloy shall be casted over the messenger cable and have sufficient and permanent grip on the
messenger cable under all service conditions.
2.4.9
The damper assembly shall be so designed that it shall not introduce radio interference beyond
acceptable limits.
2.4.10
The vibration damper shall be capable of being installed and removed from energized line by means
of hot line techniques. In addition, the clamp shall be capable of being removed and reinstalled on
the conductor at the designated torque without shearing or damaging of fasteners.
Page-12
2.4.11
The manufacturer must indicate the clamp bolt tightening torque to ensure that the slip strength of
the clamp is maintained between 2.5 kN. and 5 kN. The clamp when installed on the conductor shall
not cause excessive stress concentration on the conductor leading to permanent deformation of the
conductor strands and premature fatigue failure in operation.
2.4.12
The vibration damper shall not have magnetic power loss more than 1 watt at 500 Amps. 50 Hz
alternating current in conductor.
2.4.13
The vibration analysis of the system, with and without damper and dynamic characteristics of the
damper as detailed under Annexure-A, shall have to be submitted by the Bidder along with his bid.
The technical particulars for vibration analysis and damping design of the system are as follows.
...
Sr. No.
Description
Technical Particulars
...
1.
Configuration
conductor per
Phase in vertical
Formation
2.
3.
(ii)
Maximum span :
1100 Meters
(iii)
Minimum span :
100 Meters
Wind Zone
275 Meters
4 (47 m/s)
As per IS:875-1987
4.
3473 Kgf
5.
6.
Standard preformed
armour rods/AGS
Maximum permissible
dynamic strain
150 microstrains
...
Page-13
2.4.14
The damper placement chart for spans ranging from 100m to 1100m shall be submitted by the
Bidder. Placement charts should be duly supported with relevant technical documents and sample
calculations.
2.4.15
2.5
(1)
Location of the dampers for various combinations of spans and line tensions clearly
indicating the number of dampers to be installed per conductor per span.
(2)
Placement distances clearly identifying the extremities between which the distances are to
be measured.
(3)
Placement recommendation depending upon type of suspension clamps (viz Free centre
type/Armour grip type etc.)
(4)
The influence of mid span compression joints, repair sleeves and armour rods (standard and
AGS) in the placement of dampers.
2.5.1
All the equipments shall be of the latest proven design and conform to the best modern practice
adopted in the extra high voltage field. The Bidder shall offer only such equipment as guaranteed
by him to be satisfactory and suitable for 66 kV transmission line application and will give continued
good performance.
2.5.2
The design, manufacturing process and quality control of all the materials shall be such as to achieve
requisite factor of safety for maximum working load, highest mobility, elimination of sharp edges
and corners, best resistance to corrosion and a good finish.
2.5.3
All ferrous parts shall be hot dip galvanized, after all machining has been completed. Nuts may,
however, be tapped (threaded) after galvanising and the threads oiled. Spring washers shall be
electro galvanised. The bolt threads shall be undercut to take care of increase in diameter due to
galvanising. Galvanising shall be done in accordance with IS: 2629-1985 and satisfy the tests
mentioned in IS: 2633-1986. Fasteners shall withstand four dips while spring washers shall
withstand three dips. Other galvanised materials shall be guaranteed to withstand at least six dips
each lasting one minute under the standard Preece test for galvanising unless otherwise specified.
2.5.4
The zinc coating shall be perfectly adherent, of uniform thickness, smooth, reasonably bright,
continuous and free from imperfections such as flux, ash, rust stains, bulky white deposits and
blisters. The zinc used for galvanising shall be of grade Zn 99.95 as per IS: 209-1979.
2.5.5
In case of castings, the same shall be from all internal defects like shrinkage inclusion, blow holes,
cracks etc.
2.5.6
All current carrying parts shall be so designed and manufactured that contact resistance is reduced
to minimum and localized heating phenomenon is averted.
Page-14
2.5.7 No equipment shall have sharp ends or edges, abrasions or projections and shall not cause any
damage to the conductor in any way during erection or during continuous operation which would produce
high electrical and mechanical stresses in normal working. The design of adjacent metal parts and mating
surfaces shall be such as to prevent corrosion of the contact surface and to maintain good electrical
contact under all service conditions.
2.5.8 Particular care shall be taken during manufacture and subsequent handling to ensure smooth
surface free from abrasion or cuts.
2.5.9 The fasteners shall conform to the requirements of IS: 6639-1972. All fasteners and clamps shall
have corona free locking arrangement to guard against vibration loosening.
Die compression areas shall be clearly marked on each equipment designed for continuous die compressions
and shall bear the words COMPRESS FIRST suitably inscribed on each equipment where the compression
begins. If the equipment is designed for intermittent die compressions, it shall bear the identification marks
COMPRESSION ZONE and NON-COMPRESSION ZONE distinctly with arrow marks showing the direction of
compression and knurling marks showing the end of the zones. The letters, number and other markings on
finished equipment shall be distinct and legible.
2.7
Bid Drawings
2.7.1 The Bidder shall furnish detailed dimensioned drawings of the equipments and all component parts.
Each drawing shall be identified by a drawing number and Contract number. All drawings shall be neatly
arranged. All drafting and lettering shall be legible. The minimum size of lettering shall be 3 mm. All
dimensions and dimensional tolerances shall be mentioned in mm.
2.7.2
(i)
Dimensions and dimensional tolerences.
(ii) Material, fabrication details including any weld details and any specified finishes and coatings.
Regarding material, designations and reference of standards are to be indicated.
(iii)
Catalogue No.
(iv)
(v)
(vi)
(vii)
(viii)
Marking
Weight of assembly
Installation Instructions
Design installation torque for the bolt or cap screw.
Withstand torque that may be applied to the bolt or cap screw without failure of component
parts.
The compression die number with recommended compression pressure.
All other relevant technical details.
(ix)
(x)
Page-15
2.7.3
2.7.4
The above drawings shall be submitted in five copies with all the details as stated above along with
the bid document. After the placement of award, the Manufacturer shall again submit the drawings
in four copies to the HVPNL for approval. After HVPNLs approval and successful completion of all
type tests, 12 (twelve) more sets of drawings shall be submitted to HVPNL for further distribution
and field use at HVPNLs end.
Table-III
Dimension before
Dimensions
Compression
after compression
Inner
Outer
dia.
dia.
(mm)
(mm)
Length
(mm)
Corner
Face
To
to
Corner
face
width
width
(mm)
(mm)
470.5
410.5
1.
310.5 481
7105.
Steel Sleeve
100.2 200.5
2405.
Repair Sleeve
310.5 48 1
2755.
Mid Span
Compression
Joint Aluminum
Sleeve
2.
190.5
470.5
160.5
410.5
..
Page-16
3.
Earthwire Accessories
3.1
General
3.1.1
This portion details the technical particulars of the accessories for Galvanized Steel Earthwire.
3.1.2
3.2
...
Sr. No. Item
Dimensions before
Dimensions after
Compression
Compression
...
Inner
Outer
Dia.
Dia.
(mm)
(mm)
Length
(mm)
Corner
Face
To
to
Corner
face
Width
width
(mm)
(mm)
...
1.
Aluminium
Sleeve 220.5
2.
29.40.5 25.00.5
210.5 2305
20.20.5 17.50.5
Steel
Sleeve 100.2
3.
300.5 3155
Filler
Aluminium
Sleeve
..
Page-17
3.3
Vibration Damper
3.3.1
Vibration dampers of 4R-Stockbridge type with four (4) different frequencies spread within the
specified aeolian frequency band-width corresponding to wind speed of 1m/s to 7 m/s shall be used
for suspension and tension points on earthwire in each span to dampout aeolian vibrations as
mentioned hereinafter.
3.3.2
Alternate damping systems offering equivalent or better performance also shall be acceptable
provided the manufacturer meets the qualifying requirements stipulated in the Specifications.
Relevant technical documents to establish the technical suitability of alternate systems shall be
furnished by the Bidder along with the bid.
3.3.3
One damper minimum on each side per earthwire at suspension points and two dampers on each
side at tension points shall be used.
3.3.4
The Bidder may offer damping system involving more number of dampers per ruling design span
than the specified. However suitable price compensation shall be considered for evaluation. For the
purpose of price compensation 80% of towers as suspension towers and 20% of the towers as
tension locations and all the spans shall be assumed to be ruling design spans.
3.3.5
The clamp of the vibration damper shall made of aluminium alloy. It shall be capable of supporting
the damper during installation and prevent damage or chafing of the earthwire during erection or
continued operation. The clamp shall have smooth and permanent grip to keep the damper in
position on the earthwire without damaging the strands or causing premature fatigue failure of the
earthwire under the clamp. The clamp groove shall be in uniform contact with the conductor over
the entire clamping surface except for the rounded edges. The groove of the clamp body and clamp
cap shall be smooth, free from projections, grit or materials which could cause damage to the
earthwire when the clamp is installed. Clamping bolts shall be provided with self locking nuts
designed to prevent corrosion of the threads or loosening during service.
3.3.6
The messenger cable shall be made of high strength galvanized steel/stainless steel with a minimum
strength of 135 Kg/sq. mm. It shall be of preformed and post formed quality in order to prevent
subsequent droop of weights and to maintain consistent flexural stiffness of the cable in service.
The number of strands in the messenger cable shall be 19. The messenger cable ends shall be
suitably and effectively sealed to prevent corrosion.
3.3.7
The damper mass shall be made of hot dip galvanized mild steel/cast iron or a permanent mould
cast zinc alloy. All castings shall be free from defects such as cracks, shrinkages, inclusions and blow
holes etc. The inside and outside surfaces of the damper masses shall be smooth.
Page-18
3.3.8
The vibration analysis of the system, with and without damper, dynamic characteristic of the
damper as detailed under Annexure-A, shall have to be submitted by the Bidder along with his bid.
The technical particulars for vibration analysis and damping design of the system are as follows: ...
Sr. No. Description
Technical Particulars
...
1.
Configuration
2.
66 kV Line
(i)
275 Meters
Ruling design
span
3.
(ii)
Maximum span :
1100 meters
(iii)
Minimum span :
100 meters
Wind Zone
(47m/s)
As per IS: 875-1987
4.
5.
Maximum permissible :
Dynamic strain
1240 Kgf
...
3.3.9
The damper placement chart for spans ranging from 100 m to 1100 m shall be submitted by the
Bidder. All the placement charts should be duly supported by relevant technical documents.
3.3.10
(1)
Location of the dampers for various combinations of spans and line tensions clearly
indicating number of dampers to be installed per earthwire.
(2)
Placement distances clearly identifying the extremities between which the distances are to
be measured.
(3)
(4)
3.4
3.5
Suspension Clamp
3.5.1
Standard twisted shackle for earthwire suspension clamp shall be supplied attaching to the hanger.
3.5.2
3.5.3
There shall be no sharp point in the clamps coming in contact with earthwire. There shall not be any
displacement in the configuration of the earthwire strands nor shall the strands be unduly stressed
in final assembly during working conditions.
3.5.4
The clamping piece and the clamp body shall be clamped by at least two U-bolts of size not less than
10 mm diameter having one nut and one 3 mm thick lock nut with washer on each of its limbs.
Suspension clamps shall be provided with invented type U-bolts. One limb of the U-bolts shall be
long enough to accommodate the lug of the flexible copper bond.
3.5.5
The Manufacturer shall supply al the components of the suspension assembly including shackles,
bolts, nuts, washers, split pin etc. The total drop of suspension assembly from the centre point of
the attachment to the centre point of the earthwire shall not exceed 150 mm. The design of the
assembly shall be such that the direction of run of the earthwire shall be same as that of the
conductor.
3.5.6
The complete assembly shall be guaranteed for slip strength not less than 9 kN and not more than
14 kN. The breaking strength of the assembly shall not less than 25 kN.
3.6
Tension Camp
3.6.1
At all tension towers suitable compression type tension clamps shall be used to hold 7/3.15 mm
galvanized steel earthwire. Anchor shackle shall be supplied which shall be suitable for attaching
the tension clamp to strain plates.
3.6.2
The clamps shall have adequate area of bearing surface to ensure positive electrical and mechanical
contact and shall not permit any slip to the earthwire under working tension and vibration
conditions. The angle of jumper terminal to be mounted should be 30 deg. with respect to the
vertical line.
Page-20
3.6.3
The clamps shall be made of mild steel with aluminum encasing. The steel should not crack or fail
during compression. The Brinnel hardness of steel sleeve shall not exceed 200. The steel sleeve shall
be hot dip galvanized. The aluminum encasing shall have aluminum of purity not less than 99.5%
Filler aluminum sleeve shall also be provided at the end.
3.6.4
The complete assembly shall be so designed as to avoid undue bending in any part of the clamp and
shall not produce any hindrance to the movements of the clamps in horizontal or vertical directions.
3.6.5
The slip strength of the assembly shall not be less than 95% of the ultimate strength of the earthwire.
3.6.6
The clamps shall be complete with all the components including anchor shackle bolts, nuts, washers,
split pin, jumper arrangement etc.
3.7
3.8
Compression Marking
Same as Clause 2.6 of this part of this section.
3.9
Bid Drawings
4.
4.1
Tests
4.1.1
The acceptance and routine tests and tests during manufacture shall be carried out. For the
purpose of this clause, the following shall apply: -
4.1.2
Acceptance Tests shall mean those tests, which are to be carried out on samples taken from each
lot offered for pre-despatch inspection for the purpose of acceptance of that lot.
4.1.3
Routine Tests shall mean those tests, which are to be carried out on each item of the material to
check requirements, which are likely to vary during production.
4.1.4
Tests during Manufacture shall mean those tests, which are to be carried out during the process of
manufacture and end inspection by the HVPNL to ensure the desired quality of the end product to
be supplied by him.
4.1.5
For all acceptance tests, the acceptance values shall be the values guaranteed by the Bidder in the
data requirement sheets of this proposal or the acceptance value specified in this Specification,
whichever is more stringent for that particular test.
Page-21
5.
5.1.1
Type Tests
The material offered should be fully type tested. Test Reports (not more than 7 years old rechecked
from the date of Bid opening) in respect of following type tests carried out in accordance with
relevant IS mentioned against each item, from Govt./Govt. approved/reputed Test House shall be
submitted along with the bid.
5.1.2
a.
b.
Mechanical test
c.
Verifications of dimensions
d.
Galvanizing
e.
f.
g.
h.
i.
5.1.3
)
)
a.
b.
Mechanical test
c.
Verifications of dimensions
d.
Galvanizing
e.
f.
g.
5.1.4
)
IS: 2486 (Part-I)
a.
Visual Examination
b.
Dimensional verification
c.
d.
e.
)
)
)
Earthwire)
f.
Galvanizing test
g.
5.1.5
)
)
a.
Visual Examination
b.
Dimensional verification
c.
d.
5.1.6
a.
5.1.7
5.1.8
b.
c.
d.
Galvanizing test
Visual examination
b.
Verification of dimensions
c.
d.
Fatigue test
e.
f.
g.
h.
i.
j.
Galvanizing/electroplating test
k.
IS: 9708-1993
a.
5.1.9
verification
b.
c.
d.
e.
Galvanizing test
a.
verification
b.
c.
)
)
)
IS: 2121(Part-III)
d.
e.
Galvanizing test
)
)
Page-23
5.2
Acceptance Tests
5.2.1
a.
Visual Examination
)
)
b.
Verification of dimensions
IS: 2486-(Part-I)
)
c.
Galvanizing/Electroplating test
d.
Annexure-A
)
e.
f)
BS: 3288-(Part-I)
Clause 7.3.2
g.
IEC:372 (2)-1984
)
h.
)
)
5.2.2
/castings
Annexure-A
)
Annexure-A
)
)
b.
)
)
Suspension clamp
c.
d.
)
)
)
e.
5.2.3
)
)
5.2.4
)
)
IS:2486 (Part-I)
1971,Clause 5.4
verification
)
b.
Galvanizing test
c.
Hardness test
Annexure-B
Page-24
5.2.5
a.
5.2.6
dimensional verification
dimensional verification
b.
5.2.7
Annexure-B
a.
dimensional verification
)
b.
Galvanizing test
)
)
i.
On damper masses
)
)
ii.
c.
On messenger cable
Verification of resonance
frequencies
)
)
d.
Annexure-B
)
)
e.
)
)
f.
g.
cable
)
)
5.2.8
Annexure-B
a.
dimensional verification
)
b.
Galvanizing test
c.
)
)
d.
on each component
Annexure-A
Page-25
5.2.9
a.
dimensional verification
b.
c.
Galvanizing test
Annexure-A
)
d.
Mechanical strength
(excluding clamp)
)
)
e.
Hardness test
5.3
Routine Tests
5.3.1
5.3.2
a.
Visual examination
b.
Annexure-A
5.4
dimensional verification
a.
Chemical analysis
of zinc used for
galvanizing
)
)
)
)
)
b.
Chemical analysis
mechanical metallographic
castings.
Annexure-A
)
c.
Chemical analysis
magnetic particle
Page-26
5.5
Testing Expenses
The entire cost of acceptance and routine tests and tests during manufacture specified herein shall
be treated as included in the quoted Ex-works/price except for the expenses of the
Inspector/HVPNL.
5.6
5.6.1
The Bidder has to indicate the schedule of following activities in their bids.
a.
b.
5.6.2
The HVPNL the right of having at his own expense another test(s) of reasonable nature carried out
at Manufacturers premises, at site, or in any other place in addition to the aforesaid type,
acceptance and routine tests to satisfy himself that the material comply with the specifications.
5.6.3
The HVPNL also reserves the right to conduct all the tests mentioned in this specification at his own
expense on the samples drawn from the site at Manufacturers premises or at any other test center.
In case of evidence of non compliance, it shall be binding on the part of Manufacturer to prove the
compliance of the items to the technical specifications by repeat tests, or correction of deficiencies,
or replacement of defective items all without any extra cost to the HVPNL.
5.7
The Manufacturer shall have to co-ordinate testing of hardware fittings with insulators and shall
have to also guarantee overall satisfactory performance of the hardware fittings with the insulators.
5.8
Tests Reports
5.8.1
Record of routine test report shall be maintained by the Manufacturer at his works for periodic
inspection by the HVPNLs representative.
5.8.2
Test certificates of tests during manufacture shall be maintained by the Manufacturer. These shall
be produced for verification as and when desired by the HVPNL.
5.9
5.9.1
Inspection
The HVPNLs representative shall at all times be entitled to have access to the works and all places
of manufacture, where the material and/or its component parts shall be manufactured and the
representatives shall have full facilities for unrestricted inspection of the Manufacturers, sub-
Manufacturers works, raw materials, manufacturers of all the material and for conducting
necessary tests as detailed herein.
Page-27
5.9.2
The material from final inspection shall be offered by the Manufacturer only under packed condition
as detailed in clause 5.12 of this part of the Specification. The engineer shall select samples at
random from the packed lot for carrying out acceptance tests.
5.9.3
The Manufacturer shall keep the HVPNL informed in advance of the time of starting and of the
progress of manufacture of material in its various stages so that arrangements could be made for
inspection.
5.9.4
Material shall not be despatched from its point of manufacture before it has been satisfactorily
inspected and tested, unless the inspection is waived off by the HVPNL in writing. In the latter case
also the material shall be despatched only after all tests specified herein have been satisfactorily
completed.
5.9.5
The acceptance of any quantity of accessories shall in no way relieve the Manufacturer of his
responsibility for meeting all the requirements of the Specification, and shall not prevent
subsequent rejection, if such material are later found to be defective.
5.10
5.10.1
All material shall be packed in strong and weather resistant wooden cases/crates. The gross weight
of the packing shall not normally exceed 200 kg to avoid handling problems.
5.10.2
5.10.3
Suitable cushioning, protective padding, dunnage or spacers shall be provided to prevent damage
or deformation during transit and handling.
5.10.4
Bolts, nuts, washers, cotter pins, security clips and split pins etc. shall be packed duly installed and
assembled with the respective parts and suitable measures shall be used to prevent their loss.
5.10.5
Each component part shall be legibly and indelibly marked with trademark of the manufacturer and
year of manufacture.
5.10.6
All the packing cases shall be marked legibly and correctly so as to ensure safe arrival at their
destination and to avoid the possibility of goods being lost or wrongly despatched on account of
faulty packing and faulty or illegible markings. Each wooden case/crate shall have all the markings
stencilled on it in indelible ink.
5.11
Standard
5.11.1
The Hardware fittings; conductor and earthwire accessories shall conform to the following
Indian/International Standard which shall mean latest revisions, with amendments/changes
adopted and published, unless specifically stated otherwise in the Specification.
Page-28
5.11.2
In the event of the supply of hardware fittings, accessories conforming to standards other than
specified, the Bidder shall confirm in his bid that these standards are equivalent to those specified.
In case of award, salient features of comparison between the Standards proposed by the
Manufacturer and those specified in this document will be provided by the Manufacturer to
establish their equivalence.
Sr. No.
Indian Standard
Title
International
Standards
1.
2.
IS: 209-1992
IS: 398-1992
Specification for
BS: 3436-
Zinc
1986
Specification for
IEC: 1089-
Aluminium condu-
1991
Part-V
Aluminum Conductor
Galvanised Steel1991
Reinforced for
Extra High Voltage
(400 kV ) and above
3.
IS: 1573-1976
4.
IS: 2121-1981
Part-I
Specification for
Conductor and
Earthwire Accessories
For Overhead Power
Line.
Part-II
IEC: 1089-
Conductors
5.
IS: 2486
Specification for
Insulator Fittings for
Overhead power line
With Nominal voltage
Greater than 1000 V
Part-I, 1991
General requirements
And tests
6.
IS: 2629-1990
Recommended Practice
for Hot Dip Galvanising
of Iron and Steel
Page-29
7.
IS: 2633-1990
8.
ASTM-D1171
9.
Tests on insulators of
IEC:383-1993
10.
IS: 4826-1992
Galvanized Coating
ASTM A472-
11.
IS: 6745-1990
Methods of Determi-
BS: 433-1969
nation of weight of
ISO: 1460
12.
IS: 6639-1990
13.
IS: 9708-1980
ISO/R272
1968
14.
IS: 8263-1990
IEC: 437-1973
NEMA: 107-1964
insulators.
CIS PR
Page-30
Reference Abbreviation
BS
IEC/CISPR
International Electrotechnical
Commission, Bureau Central
De la Commission, Electro
Technique International, 1
Rue de verembe, Geneva
Switzerland
BIS/IS
ISO
NEMA
Page-31
ANNEXURE-A
TYPE TEST
1.0
The voltage across each insulator unit shall be measured by sphere gap method. The result obtained
shall be converted into percentage. The voltage across any disc shall not exceed 13% for suspension
insulator strings and 14% for tension insulator strings.
1.2
1.3
Vibration Test
The suspension string shall be tested in suspension mode, and tension string in tension mode itself
in laboratory span of minimum 30 metres. In the case of suspension string a load equal to 600 kg
shall be applied along the axis of the suspension string by means of turn buckle. The insulator string
along with hardware fittings and conductors tensioned at 3500 kg. Shall be secured with clamps.
The system shall be suitable to maintain constant tension on conductor throughout the duration of
the test. Vibration dampers shall not be used on the test span. The conductor shall be vertically
vibrated at one of the resonance frequencies of the insulators string (more than 10 Hz) by means of
vibration inducing equipment. The peak to peak, displacement in mm of vibration at the antinode
point nearest to the string shall be measured and the same shall not be less than 1000/f 1.8 where f
is the frequency of vibration in cycles/sec. The insulator string shall be vibrated for not less than 10
million cycles without any failure. After the test the disc insulators shall be examined for looseness
of pins and cap or any crack in the cement. The hardware shall be examined for looseness, fatigue
failure and mechanical strength test. There shall be no deterioration of properties of hardware
components and insulators after the vibration test. The insulators shall be subjected to the following
tests as per relevant standards:
Page-32
Tests
Percentage of insulator
Units to be tested
Disc
a)
60
followed by mechanical
performance test
b)
Puncture test
40
One hollow aluminum tube of 29-mm diameter shall be placed. An alternating current over the range of 300
to 700 amps shall b passed through the tube. The reading of the wattmeter with and without suspension
assemblies shall be recorded. Not less than three suspension assemblies shall be tested. The average power
loss for suspension assembly shall be plotted for each value of current. The value of the loss corresponding
to 500 amperes shall be read off from the graph.
The test shall be carried out as per Clause no. 5.9 of IS: 2486 (Part-I) 1972 except that both uniformity of
zinc coating and standard preece test shall be carried out and the results obtained shall satisfy the
requirements of this specification.
Each component shall be subjected to a load equal to the specified minimum ultimate tensile strength (UTS)
which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for
five minutes and then removed. The component shall then again be loaded to 50% of UTS and the load shall
be further increased at a steady rate till the specified UTS and held for one minute. No fracture should occur.
The applied load shall then be increased until the failing load is reached and the value recorded.
The welded portion of the component shall be subjected to a Load of 2000 kgs for one minute. Thereafter,
it shall be subjected to die penetratration/ultrasonic test. There shall not be any crack at the welded portion.
2.6
The shore hardness at various points on the surface of the elastomer cushion shall be measured by
a shore hardness meter and the shore hardness number shall be between 65 to 80.
2.7
Each component shall be subjected to a load equal to 50% of the specified minimum ultimate tensile
strength which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be
held for one minute and then removed. After removal of the load the component shall not show any visual
deformation.
2.8
The chemical analysis, hardness test, grain size, inclusion rating and magnetic particle inspection for
forging, castings and chemical analysis and proof load test for fabricated hardware shall be as per the
internationally recognized procedures for these tests. The sampling will be based on heat number and
heat treatment batch. The details regarding test will be as in the Quality Assurance programme.
2.9
The complete string without insulators excluding arcing horn, and suspension assembly/dead end
assembly shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength
(UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. This load shall be
held for five minutes and then removed. After removal of the load, the string component shall not show
any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to
remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50%
of UTS and the load shall be further increased at a steady rate till the specified minimum UTS is reached
and held for the one minute. No fracture should occur during this period. The applied load shall then be
increased until the failing load is reached and the value recorded.
This test shall be performed in accordance with ASTM D-1171 by the Ozone chamber exposure method
(method B). The test duration shall be 500 hours and the ozone concentration 50 PPHM. At the test
completion, there shall be no visible crack under a 2 x magnification.
(a)
Page-34
(a)
(a)
i.
Force Vs frequency
ii.
iii.
The Force Vs frequency curve shall not show steep peaks at resonance frequencies and deep troughs
between the resonance frequencies. The consonance frequencies shall be suitably spread within the aeolian
vibration frequency-band between the lower and upper dangerous frequency limits determined by the
vibration analysis of conductor/earthwire without dampers.
a)
(i)
(ii)
The mean reactance and phase angle Vs frequency curves shall be drawn with the criteria of best fit
method.
(iii)
The above mean reactance response curve should lie within 0.135f to 0.540f Kgf/mm limits for ACSR
Zebra conductor damper and 0.050f to 0.3 Kgf/mm limits for earthwire damper where f is frequency
in Hz.
(iv)
The above mean phase angle response curve shall be between 250 to 1300 within the frequency
range of interest.
(v)
If the above curve lies within the envelope, the damper design shall be considered to have
successfully met the requirement.
(vi)
Visual resonance frequencies of each mass of damper is to be recorded and to be compared with
the guaranteed values.
Page-35
(b)
Vibration Analysis
The vibration analysis of the conductor/earthwire shall be done with and without
damper installed on the span. The vibration analysis shall be done on a digital computer using energy
balance approach. The following parameters shall be taken into account for the purpose of analysis:
(i)
The analysis shall be done for single conductor/earthwire without armour rods as per the
parameters given under clause 2.4.13 and 3.3.8 of this part of the Specification. The tension
shall be taken as 3500 kgf for earthwire, for a span ranging from 100m to 1100m.
(ii)
The self damping factor and flexural stiffness (EI) for conductor and earthwire shall be
calculated on the basis of experimental results. The details for experimental analysis with
these data should be furnished.
(iii)
The power dissipation curve obtained from Dynamic Characteristics Test shall be used for
analysis with damper.
(iv)
Examine the Aeolian vibration level of the conductor/earthwire with and without vibration
damper installed at the recommended location or wind velocity ranging from 0 to 30 Km
per hour, predicting amplitude, frequency and vibration energy input.
(v)
(vi)
Page-36
(i)
Test Set Up
The clamp slip and fatigue tests shall be conducted on a laboratory set up with a minimum
effective span length of 30m. The conductor shall be tensioned at 3500 kgf and earthwire
shall be tensioned at 1240 Kgf and shall not be equipped with protective armoured rods at
any point. Constant tension shall be maintained within the span by means of lever arm
arrangement. After the conductor/earthwire has been tensioned, clamps shall be installed
to support the conductor/earthwire at both ends and thus influence of connecting
hardware fittings are eliminated from the free span. The clamps shall not be used for holding
the tension on the conductor/earthwire. There shall be no loose parts, such as suspension
clamps, U bolts, on the test span supported between clamps mentioned above. The span
shall be equipped with vibration inducting equipment suitable for producing steady
standing vibration. The inducting equipment shall have facilities for step less speed control
as well as stepless amplitude arrangement. Equipment shall be available for measuring the
frequency, cumulative number of cycles and amplitude of vibration at any point along the
span.
(ii)
(iii)
Fatigue Test
The vibration damper shall be installed on the test span with the manufacturers specified
tightening torque. It shall be ensured that the damper shall be kept minimum three loops
away from the shaker to eliminate stray signals influencing damper movement.
The damper shall then be vibrated at the highest resonant frequency of each damper mass.
For dampers involving torsional resonant frequencies tests shall be done at torsional modes
also in addition to the highest resonant frequencies at vertical modes. The resonance
frequency shall be identified as the frequency at which each damper mass vibrates with the
maximum amplitude on itself. The amplitude of vibration of the damper clamp shall be
maintained not less than 25/f mm, where f is the frequency in Hz.
The test shall be conducted for minimum ten million cycles at each resonant frequency
mentioned above. During the test if resonance shift is observed the test frequency shall be
tuned to the new resonant frequency.
Page-37
The clamp slip test as mentioned hereinabove shall be repeated after fatigue test without
retorquing or adjusting the damper clamp, and the clamp shall withstand a minimum load
equal to 80% of the slip strength for a minimum duration of one minute.
After the above tests, the damper shall be removed from conductor/earthwire and
subjected to dynamic characteristics test. There shall not be any major deterioration in the
characteristic of the damper. The damper then shall be cut open and inspected. There shall
not be any broken, loose, or damaged part. There shall not be significant deterioration or
wear of the damper. The conductor/earthwire under clamp shall also be free from any
damage.
3.4
(1)
There shall not be any frequency shift by more than 2 Hz for frequencies lower
than 15 Hz and 3 Hz for frequencies higher than 15 Hz.
(2)
The force response curve shall generally lie within guaranteed % variation in
reactance after fatigue test in comparison with that before fatigue test by the
Manufacturer.
(3)
The power dissipation of the damper shall not be less than guaranteed % variation
in power dissipation before fatigue test by the Manufacturer. However, it shall not
be less than minimum power dissipation which shall be governed by lower limits of
reactance and phase angle indicated in the envelope.
The sample involving ferrous parts shall be tested in a manner to simulate service conditions for 50
Hz pure sine-wave. The test should be carried out at various currents ranging from 300 to 700
amperes and the magnetic power loss at various currents should be specified in tabulated graphical
form. The difference between the power losses without and with sample at room temperature shall
be limited to 1 watt for 500 amperes. The losses shall be determined by averaging the observations
obtained from at least four samples.
3.5
(a)
loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified
minimum UTS is reached and held for one minute. No fracture should occur during this
period. The applied load shall then be increase until the failing load is reached and the value
recorded.
Page-38
(b)
(c)
(d)
The tension clamp and the jumper shall be compressed on two suitable lengths of earthwire.
The electrical resistance shall be measured between points on earthwire near the clamp
and near the jumper mouth keeping 25 mm clearance of the fitting and should not exceed
75% of the measured resistance of equivalent length of earthwire. The test shall be
conducted with direct current. The current connections shall be at a distance not less than
50 times the diameter of earthwire of earthwire from the fitting and shall be made so that
effective contact is ensured with all those strands of the earthwire which would be taken
into account in calculating its equivalent resistance. The test shall be repeated with the
polarity reversed and the average of the two results considered as the measured value.
3.6
Chemical analysis of the material used for manufacture of items shall be conducted to check
the conformity of the same with Technical Specification and approved drawing.
4.
4.1
Samples taken from the zinc ingot shall be chemically analysed as per IS: 209-1979. The
purity of zinc shall not be less than 99.95%.
Page-39
4.2
The chemical analysis, hardness tests and magnetic particle inspection for forgings, will be
as per the internationally recognized procedures for these tests. The sampling will be based
on heat number and heat treatment batch. The details regarding test will be as discussed
and mutually agreed to by the Manufacturer and HVPN in Quality Assurance Programme.
4.3
Tests on Castings
The chemical analysis, mechanical and metallographic tests and magnetic particle
inspection for castings will be as per the internationally recognized procedures for these
tests. The samplings will be based on heat number and heat treatment batch. The details
regarding test will be as discussed and mutually agreed to by the Manufacturer and HVPN
in Quality Assurance Programme.
Page-40
ANNEXURE-B
Acceptance Tests
1.
(a)
Hardness Test
The Brinnel hardness at various points on the steel sleeve of conductor core and of the
earthwire compression joint and tension clamp shall be measured.
2.
(b)
3.
(a)
The damper shall be mounted on a shaker table and vibrate at damper clamp displacement
of +/0.5 mm to determine the resonance frequencies. The resonance shall be visually
identified as the frequency at which damper mass vibrates with maximum displacement on
itself. The resonance frequency thus identified shall be compared with the guaranteed
value. A tolerance of 1 Hz at a frequency lower than 15 Hz and 2 Hz at a frequency higher
than 15 Hz only shall be allowed.
(b)
(c)
(d)
Page-41
(e)
Each mass shall be pulled off in turn by fixing the mass in one jaw and the clamp in the other
of a suitable tensile testing machine. The longitudinal pull shall be applied gradually until
the mass begins to pull out of the messenger cable. The pull off loads shall not be less than
the value guaranteed by the Manufacturer.
(f)
The test will be performed as acceptance test with the procedure mentioned for type test
with sampling mentioned below: -
Vibration Damper of
Conductor
1.
The above dynamic characteristics curve for reactance & phase angle will be done for
frequency range of 5 Hz to 45 Hz for vibration damper for conductor and 15 Hz to 70 Hz for
vibration damper for earthwire.
2.
If all the individual curve for dampers are within the envelope as already mentioned for type
test for reactance & phase angle, the lot passes the test.
3.
If individual results do not fall within the envelope, averaging of characteristics shall be
done.
Page-42
Description of
No.
Activity
1.
Detailed Survey
Items to be Checked
Tests/Checks to be
Ref. documents
Check/Testing
done
a. Route alignment
Optimization of route
page 1
a. Preliminary survey.
Agency
Extent
Bidder
100% at Field
Accepting
authority
length
Engineer-incharge of HVPNL
b. Topographical map
c. Tower spotting data
b. Route profiling &
1. Ground clearance.
a. Sag template
Bidder
100% at Field
Engineer-in-
-do-
-do-
-do-
charge of HVPNL
-do-
-do-
-do-
c. Route alignment
-do-
-do-
tower spotting.
2. Cold wt. Span
-do-
-do-
Bidder
100% at Field
5. Angle of Deviation.
2.
Check Survey
i)
Alignment
a. Route alignment
-do-
b. Tower Schedule
-do-
c. Profile
3.
i)
Engineer-incharge of HVPNL
Tower
Foundation
A. Materials
1. Cement
1. Source approval
Bidder
As proposed by Bidder
Engineer-incharge of HVPNL
( 43 grade) as per
Annexure-A
S.
Description of
No.
Activity
Items to be Checked
Tests/Checks to be
Ref. documents
Check/Testing
done
2. Physical tests
Agency
Samples to be taken
tested at HVPNL
authority
Extent
As per document at
Accepting
Engineer-incharge of HVPNL
every 500 MT
approved lab
3. Chemical Tests
-do-
by Bidder
Chemical
Engineer-incharge of HVPNL
composition of
Cement
2. Reinforcement
1. Source approval
Steel
To be procured from
Bidder
As proposed by Bidder
As per annexure-B
All MTCs
Engineer-incharge of HVPNL
Engineer-incharge of HVPNL
Chemical analysis
test
3. Coarse
1. Source approval
Aggregates
Bidder
Specification
Proposed by the
Bidder, indicating the
Engineer-incharge of HVPNL
4. Fine aggregate
1. Source approval
As per document at
Samples to be taken
thereof
Bidder
Proposed by the
Bidder, indicating the
location of the quarry
and based on the
results of Joint
samples tested in
HVPNL approved lab.
Engineer-incharge of HVPNL
Engineer-incharge of HVPNL
Page 2
S.
Description of
No.
Activity
Items to be Checked
Tests/Checks to be
Ref. documents
Check/Testing
done
2. Physical test
5. Water
1. Cleanliness (Water
Agency
Samples to be taken
this FQP
thereof
HVPNL Specification
Bidder
shall be fresh ,
Engineer-incharge of HVPNL
1. Verification at random
2. Lab. test before start of work
Engineer-incharge of HVPNL
authority
Extent
As per Annexure-D of
Accepting
HVPNL Specification
Bidder
for concreting
1. Verification at random
2. Lab. test before start of work
Engineer-incharge of HVPNL
1. Visual observation
2. Ground water
level
3. History of water
table in adj.
Area/surface
water
4. Soil Investigation
wherever
required.
5 Crop pattern
C. Concrete Works
a. Before
concreting
HVPNL Specification
Bidder
100% at Field
100% at Field
of soil strata
Engineer-incharge of HVPNL
1. Bottom of
excavated earth
Depth of foundation
2. Stub setting
1) Centre Line
Appd. Drgs.
Bidder
100% at Field
Engineer-incharge of HVPNL
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
2) Diagonals
3. Reinforcement
steel
3) Level of stubs
b. During
concreting
Placement
Page 3
S.
Description of
No.
Activity
Items to be Checked
Tests/Checks to be
Ref. documents
done
1. Workability
Slump test
As per HVPNL
Check/Testing
Agency
Extent
Bidder
100% at field
Accepting
authority
Engineer-incharge of HVPNL
Specification and
document at AnnexureE of this FQP
2. Concrete
Strength
4.
Tower
Erection
1. Materials
a. Tower
1. Stacking
member/bolts &
2. Cleanliness
nuts/washers/acce
ssories
3. Galvanizing
4. Damages
As per HVPNL
One sample of 6
Specification and
Cubes to be tested at
cubes in each
document at Annexure-
tower locations
E of this FQP
Appd. Drgs./BOM
Bidder
100% at stores
Engineer-incharge of HVPNL
Engineer-incharge of HVPNL
2. Erection of
1. Sequence of
As per approved
Super-structure
erection
Drgs./HVPNL
Bidder
100% at field
100% check
Engineer-incharge of HVPNL
specification
2. Check for
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
completeness
3. Tightening of
nuts and bolts
4. Check for
verticality
3. Tower footing
resistance (TFR)
S.
Description of
No.
Activity
5.
Stringing
Items to be Checked
HVPNL Specification
Bidder
100% at Field
100% Check
---do---
TFR at locations
before and after
earthing.
HVPNL Specification
Bidder
100% at Field
20% locations to be
verified
---do---
Tests/Checks to be
Ref. documents
done
Check/Testing
Agency
Extent
Bidder
100% at Field
Page-4
Accepting
authority
1. Materials
a. Insulators
HVPNL Specification
-do-
3. E&M test
Insulator supplier
100% verification of
records and to carry
random checks 10%
Engineer-incharge of HVPNL
-do-
Collection of samples,
sealing them and handing
Inspecting
officer of HVPNL
Traceability(Make/b
atch No./Locations
where installed)
b. Conductor
over by HVPNL to
Insulator supplier
100% Review of records
Engineer-incharge of HVPNL
20% check
Engineer-incharge of HVPNL
Packing list/CIP
Bidder
100% at field
Packing list
Bidder
100% at stores
-do-
-do-
-do-
-do-
-do-
3. Check depth
from top of flange
to the top of the
outer most layer
-do-
-do-
-do-
-do-
-do-
Packing list
Bidder
100% at stores
20% check
-do-
Stringing procedures
as per HVPNL
specification
Bidder
Readiness
certificate to be
submitted by the
Bidder
On receipt,
1. Visual check of
drum.
c. Earthwire
2. Field activity
a. Before
Stringing
Readiness for
stringing
b. During
stringing
(Conductor/Earthwire)
Review of Certificate
Page 5
Engineer-incharge of HVPNL
S.
Description of
No.
Activity
Items to be Checked
Tests/Checks to be
Ref. documents
done
1. Scratch/cut
Appd. Drawings/
check (Visual)
HVPNL Specn.
Check/Testing
Agency
Extent
Bidder
100% at Field
Accepting
authority
Engineer-incharge of HVPNL
2. Repair sleeve
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
Appd. Guying
-do-
-do-
100%
of towers not
designed for one
Engineer-incharge of HVPNL
arrangement/HVPNL
specn.
side stringing)
c. After stringing
Check for,
1. Sag/Tension
Sag tension
-do-
-do-
chart/tower Spotting
Engineer-incharge of HVPNL
data
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
2. Electrical
As per appd.
clearances
Drgs./HVPNL
specifications
i) Ground
clearance
ii) Live metal
clearance etc.
3. Jumpering
Page 6
S.
Description of
No.
Activity
Items to be Checked
Tests/Checks to be
Ref. documents
done
4. Copper bond
As per Appd.
Check/Testing
Agency
Extent
Bidder
100% at Field
Drgns./HVPNL
Accepting
authority
Engineer-incharge of HVPNL
Specification
6.
5. Placement of
As per Specn./drgs/
spacer/damper
placement chart
-do-
-do-
-do-
-do-
Bidder
100%
Engineer-in-
Final Testing
a. Pre-
a. Readiness of
1. Completeness of
commissionin
line.
g of lines
commissioning
2. Meggar test of
line
Refer pre
charge of HVPNL
commissioning Check
list & testing of EHV
lines for charging
formats attached
with this FQP
b. Commi-
Readiness of lines
ssioning of
for commissioning
line
a. Owner latest
precommissioning
procedures . As
per annexure
enclosed.
-do-
-do-
-do-
-do-
-do-
-do-
-do-
-do-
b. Precommissioning
Report
c. CEA clearance
3. Electrical
Inspectors
clearance from CEA.
Page 7
Annexure A
a)
Physical tests
(i)
Fineness
Specific surface area shall not be less than 225 sq.m. per Kg
or 2250 Cm2/gm.
(ii)
Compressive
strength
(iii)
Soundness
Remarks
Page 8
S. No.
b)
c)
Remarks
a)
a)
c)
d)
e)
Page 9
Annexure B
S.
No.
i)
Chemical analysis
test
Remarks
Carbon
0.30% Max
Sulpher
0.055%
Sulpher
0.060%
Phosphorus
0.055%
Phosphorus
0.060%
Physical tests
a)
b)
250
240
c)
iii)
a)
b)
415
Page 10
Annexure C
ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR COARSE AGGREGATES AS PER IS 383
3.
Coarse Aggregates
i)
Physical Tests
a) Determination
of particles size
a. IS Sieve
Designation
Flakiness index
40 mm
20 mm
16 mm
12.5 mm
10
mm
40 mm
20 mm
16 mm
12.5
mm
63 mm
100
40 mm
85 to 100
100
95 to 100
100
20 mm
0 to 20
85 to 100
100
30 to 70
95 to 100
100
100
16 mm
85 to 100
100
90-100
12.5 mm
85 to 100
100
90 to
100
0 to 5
0 to 20
0 to 30
0 to 45
85 to
100
10 to 35
25 to 35
30 to 70
40 to
85
4.75 mm
0 to 5
0 to 5
0 to 10
0 to
20
0 to 5
0 to 10
0 to 10
0 to 10
2.36 mm
0 to 5
10 mm
b.
c.
Crushing Value
d. Presence of deleterious
material
e.
12% when tested with sodium sulphate and 18% when tested with magnesium sulphate
Page 11
Annexure D
ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR FINE AGGREGATES AS PER IS 383
4.
Fine aggregates
i)
Physical Tests
a)
F.A. Zone I
F.A. Zone II
10 mm
100
100
100
4.75 mm
90-100
90-100
90-100
2.36 mm
60-95
75-100
85-100
1.18 mm
30-70
55-90
75-100
15-34
35-59
60-79
300 microns
5 to 20
8 to 30
12 to 40
150 microns
0-10
0-10
01-0
Not to exceed 8%
Not to exceed 8%
Not to exceed 8%
b)
Silt content
c)
d)
12% when tested with sodium sulphate and 15% when tested with magnesium sulphate
Page 12
Annexure E
1)
Concrete
a)
Workability
Slump shall be recorded by slump cone method and it shall between 50-75 mm. as per
site requirement. However the water cement ratio shall be maintained as per
approved mix design.
b)
Compressive strength
Six samples of 15cm cubes, three for 7 days testing and balance three for 28 days
testing shall be taken.
Notes :
1)
For nominal (volumetric) concrete mixes, compressive strength for 1:1.5:3 (Sand : Fine aggreagates : Coarse aggregates) concrete shall be 265 kg/Sq.cm. for 28
days and for 1:2:4 nominal mix, it shall be 210 kg/Sq.cm.
2)
ACCEPTANCE CRITERIA BASED ON 28 DAYS COMPRESSIVE STRENGTHS FOR NOMINAL MIX CONCRETE :
a) the average of the strength of three specimen be accepted as the compressive strength of the concrete, provided the strength of any
individual cube shall neither be less than 70% nor higher than 130% of the specified strength.
b) If the actual average strength of accepted sample exceeds specified strength by more than 30%, the Engineer-in-charge, if he so desires,
may further investigate the matter. However, if the strength of any individual cube exceeds more than 30% of the specified strength, it
will be restructed to 30% only for computation of strength.
c) If the actual average strength of accepted sample is equal to or higher than specified upto 30%, the strength of the concrete shall be considered in
order and the concrete shall be accepted at full rates.
d) If the actual average strength of accepted sample is less than specified strength but not less than 70% of the specified strength, the concrete may be
accepted at reduced rate at the discretion of Engineer-in-charge.
e) If the actual average strength of accepted sample is less than 70% of specified strength, the Engineer-in-charge shall reject the defective portion of
work represent by sample and nothing shall be paid for the rejected work. Remedial measures necessary to retain the structure shall taken at the risk
and cost of Bidder. If, however, the Engineer-in-charge so desires, he may order additional tests to be carried out to ascertain if the structure can be
retained. All the charges in connection with these additional tests shall be borne by the Bidder.
Page 13
General Notes :
1. This standard Field Quality Plan is not to limit the supervisory checks which are otherwise required to be carried out during execution of
work as per drawings/Technical specifications etc.
2. Bidder shall be responsible for implementing/documenting the SFQP. Documents shall be handed over by the Bidder to HVPNL after the completion
of the work.
3. Project incharge means over all incharge of work. Line Incharge means incharge of the line. Section in-charge means incharge of the section.
4. In case of deviation the approving authority will be one step above the officer designated for acceptance in this quality plan subject to minimum level
of Line incharge.
5. Acceptance criteria and permissible limits for tests are indicated in the Annexures. However for further details/tests HVPNL specification and relevant
Indian standards shall be referred.
6. Tests as mentioned in this FQP shall generally be followed. However E.I.C. reserves the right to order additional tests wherever required necessary at
the cost of the agency.
7. All counter checks/tests by HVPNL shall be carried out by HVPNLs officials atleast at the level of Jr. Engr.
Page 14
ROUTE KM
CKT KM
LINE CHARGING
DATE
Package No.
2.
Maint HQ
3.
Voltage rating
4.
Type of circuit
5.
Type of towers
0-2
215
1530
3060
Dead
Spl.
Others
End
Single Circuit
DA
DB
DC
DD
DD
+3
+6
+9
+12
+18
+25
+/-1.5
+/-3.0
+4.5
+6.0
+7.5
+9.0
Dry
Wet
BC
SR
HR
Number of SC
Double Circuit
Number of DC
Normal Extn. (Metre)
Number of Extns.
Leg Extn. (Metre)
Number of Extns.
6.
Foundation Type
Numbers
PS
FS
Pile
Total
7.
Type of Conductor
8.
9.
Crossing Details
Single
Twin
Triple
Quad
Other
To Loc No.
Name of X-ing
Power Line
PTCC Line
Railway Line
River
Lake
10.
Other Informations
All weather approachable sections
Page 1
11.
Name of towns
(km)
A.
B.
C.
D.
E.
12.
DESCRIPTION
1.
FOUNDATION
a.
b.
c.
d.
e.
f.
g.
2.
TOWER
a.
or
STATUS
REMARKS
YES
Record Deficiencies if
any
NO
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
3.
a.
b.
c.
d.
4.
Insulators
a.
b.
c.
5.
a.
c.
Check that the conductors/ subconductors are free from scratches/ rubs.
d.
e.
S.NO.
DESCRIPTION
f.
g.
h.
i.
j.
k.
l.
m.
n.
o.
STATUS
REMARKS
YES
Record Deficiencies if
any
NO
Erection Agency
Representative
Supplier Agency
Representative
HVPNL
Representative
Signature
Date
Name
Organization
Page 4
Name of line
Circuit
Date of Energisation
Package
Location
Section
Sl.
A/ B/C
No.
Tower
No.
From
To
Observation
Completion
Inspection
Date
Date
Date
Sign
Sign
Sign
Description
Erection Agency
Representative
Signature
Date
Name
Organization
Line In-charge
(HVPNL)
(HVPNL)
a.
b.
c.
d.
Page 5
Name of line
Circuit
Line Section
kV
Type of towers
Voltage rating
Tower locations
Total length
S/C
From
D/C
To
Kms
Details:
S. No.
Description
Status
Yes
1.
2.
3.
No
Remarks
Record deficiencies if any
A
B
C
Points completed
and confirmed
Date
Sign
Points accepted
Date
Sign
S. No.
Description
Status
Yes
4.
5.
6.
No
Remarks
Record deficiencies if any
Page-6
7.
8.
9.
10.
The above line is handed over for energization with/ without remaining activities
Handed over by
Signature
Date
Name
Organization
Commissioning in-charge
Page 7
Name of line
Circuit
COMMISIONING FORMAT
Date of charging
Package
kV
Type of towers
Voltage rating
Tower locations
Total length
S. No.
Description
S/C
From
2.
3.
4.
5.
6.
To
Km
Status
Yes
1.
D/C
No
Remarks
Record deficiencies
if any
Page 8
S. No.
Description
Status
Yes
7.
8.
9.
10.
11.
12.
13.
No
Remarks
Record deficiencies if any
Measurement of tower footing resistance by earth resistance tester or any other suitable
instrument (The value should not be more than 10 ohms)
Location
Value (Ohms)
Remarks
The above inspection and measurements are carried out in the location mentioned above and the
remaining activities, temporary arrangements etc. are documented in format no.02.
Page 9
MEASUREMENT OF INSULATION RESISTANCE FOR BUS BAR (using 5kV motorized megger)
BETWEEN
MEASURED VALUE IN
M OHM
REMARK
CONDITION
All
breakers
and
isolators to be closed for
section of the bus bar to
be energized and all
ground
switches
opened.
BETWEEN
MEASURED VALUE IN
M OHM
REMARK
CONDITION
SENDING END
CONDITIONS
RECEIVING END
Megger between
MEASURE VALUE
IN OHMS
REMARK
CLOSE R PHASE GS
LOW
OPEN Y PHASE GS
HIGH
OPEN B PHASE GS
HIGH
OPEN R PHASE GS
HIGH
CLOSE Y PHASE GS
LOW
OPEN B PHASE GS
HIGH
OPEN R PHASE GS
HIGH
OPEN Y PHASE GS
HIGH
CLOSE B PHASE GS
LOW
LOW
HIGH
HIGH
HIGH
HIGH
LOW
HIGH
LOW
HIGH
Note:
If the test values are as per the remark, phase marking at both ends are correct.
If this test is to be done if the megger value do not show short circuit of the line with ground or between
phases in IR measurement.
Page 10
Measurement of phase sequence
After closing the breaker from one end only the line can be charged.
Check the phase sequence by the phase sequence meter by connecting at the secondary of the CVT.
Ok
Not Ok
Check the phase sequence by the help of multi-meter in case of a charged sub-station at the
secondary of the CVT (old & new) in the control panel as per the measurement indicated below:
Charged old
circuit
1.
R-phase
R-phase
2.
R-phase
Y-phase
Measured voltage
(volts)
Remarks
3.
R-phase
B-phase
4.
Y-phase
R-phase
5.
Y-phase
Y-phase
6.
Y-phase
B-phase
7.
B-phase
R-phase
8.
B-phase
Y-phase
9.
B-phase
B-phase
Once the correct phase sequence is established, the charging instruction received from HVPNL Engg.
to be followed and properly documented regarding status of various parameters with other lines and
generators, if any.
Charging
Instruction No.
a.
b.
c.
Dated
(Copy enclosed)
Date
Time
Charging details
Voltage
b.
Generator Details
kV
Lines connected
S. No.
MW
MVAR
Line reactor
In Service
1
2
Capacity
3
4
5
d.
S.No.
Rating
Status
Page 11
e.
On charging condition
Details
Sending end
Receiving end
Voltage
MVAR
Open end voltage
f.
Details
Sending end
Receiving end
Voltage
MW
MVAR
THE LINE HAS BEEN/ NOT HAS BEEN SUCESSFULLY TEST CHARGED WITH OR WITHOUT
FOLLOWING OPERATIONAL CONSTRAINTS:
1.
2.
3.
4.
Signature
Name
Designation
HVPNL
HVPNL
Line In-charge
S/S in-charge
Date
Page 12
VOLUME-II, PART-II,
CHAPTER-IV
FOR
220kV/66kV Towers
1.
1.1
Bidders
Experience as per
Qualifying
Requirement
1.2
Stringing Procedure
The details of the stringing procedure proposed and all other necessary tools and plants the
Bidder whishes to deploy for timely completion of the work. (Yes/No)
2.0
2.1
Mass in kilogram Std. 3m 6m Spl Tower+ 9m Spl Tower+ 12m Spl Tower+ 15m
for M/C towers
(1) (2) (3) (4)
(5)
(6)
a)
b)
MA type Normal
tower
Fabricated
(Black)
parts
Nuts
&
Bolts
(Galvanised)
c)
Total weight
2.1.2
MB Normal type
tower
a)
Fabricated
(Black)
parts
As per bidder
b)
Nuts
&
Bolts
(Galvanised)
c)
Total weight
2.1.3
MB
type
tower
Spl.
Fabricated
(Black)
parts
a)
b)
Nuts
&
Bolts
(Galvanised)
Total weight
2.1.4
a)
b)
c)
MC type Normal
tower
Fabricated
(Black)
parts
Nuts
&
Bolts
(Galvanised)
Total weight
Page-1
a)
Nuts & Bolts (Galvanised)
b)
c)
Total weight
2.1.6
a)
As per bidder
Total weight
2.1.7
Standard
specifications
according to which the
quality of steel for the
sections
have
been
assumed.
2.1.8
Standard
to
which IS:802
fabrication,
galvanizing
etc. will conform.
2.1.9
3.0
a)
Nuts & Bolts (Galvanised)
b)
c)
Total weight
Standard
specifications
according to which the
quality of steel for the
sections
have
been
assumed.
Standard
to
which IS:802
fabrication,
galvanizing
etc. will conform.
Page-2
Extension
Std.
3m
6m
(1)
(2)
(3)
9m
(4)
12m
15m
18m
25m
(5)
(6)
(7)
(8)
DE type tower
a)
b)
c)
Total weight
4.1.2
DF type tower
a)
b)
c)
Total weight
4.1.3
DG type tower
a)
b)
c)
Total weight
4.1.4
DH type tower
a)
b)
c)
Total weight
4.2
As per bidder
Standard
specifications
according to which the
quality of steel for the
sections
have
been
assumed.
4.2.5
Standard
to
which IS:802
fabrication,
galvanizing
etc. will conform.
4.2.6
Page-3
Unit
1.0
2.0
2.1
Aluminium
(a) Maximium Purity of aluminium
(b) Maximum Copper Content
%
%
2.2
Carbon
Manganese
Phosphorous
Sulphur
Silicon
%
%
%
%
%
2.3
Zinc
(a) Minimum Purity of Zinc
3.0
ALUMINIUM
STRANDING
3.1
Diameter
2
3
4
STRANDS
%
AFTER
Nominal
Maximum
Minimum
Mm
Mm
Mm
3.2
3.3
4.0
4.1
Diameter
(a) Nominal
(b) Maximum
(c) Minimum
KN
Mm
Mm
Mm
As per HVPNL
Requirement
As per Bidder
4.2
4.3
Galvanising
(a) Minimum weight of zinc coating per sqm. of
uncoated wire surface
(b) Minimum number of one minute dips that
the galvanised strand can withstand in the
standard piece test
(c) Min. No. of twists in a guage length equal
to 100 times dia of wire which the strand can
withstand in the torsion test.
KN
Gm
Nos.
Nos.
Page-4
5.0
ACSR CONDUCTOR
5.1
UTS of Conductor
5.2
KN
5.3
DC resistance of conductor at 20 C
Ohm/KM
5.4
kV (rms)
5.5
Micro volts
5.6
5.7
5.8
5.9
6.0
N.A.
Kg/km
Kg/km
Kg/km
Nos.
Page -5
Description
1.0
2.0
2.1
Steel Wires/Rods
(a)
(b)
(c)
(d)
(e)
Carbon
Manganese
Phosphorous
Sulphur
Silicon
Unit
%
%
%
%
%
2.2
Zinc
(a) Minimum purity of Zinc
3.0
3.1
Diameter
(a) Nominal
(b) Maximum
( c)Minimum
mm
mm
mm
3.2
3.3
Galvanising
(a) Minimum weight of zinc coating per sq.m of
uncoated wire surface
(b) Minimum number of one minute dips that
the galvanised strand can withstand in the
standard preece test
(c) Min. No. of twists in guage length equal 100
times the dia. of wire which the strand can
withstand in the torsion test
kN
gm
Nos.
Nos.
4.
4.1
kN
4.2
mm
4.3
ohm
As per HVPNL
Requirement
As per Bidder
4.4
4.6
4.7
m
+m
kg/km
kg/km
kg/km
5.0
Yes/No
Page-6
COMPOSITE LONG ROD INSULATORS FOR 220kV LINE WITH ACSR ZEBRA
Page 1 of 2
Sr.
No.
Description
Unit
Kg
mm
4. Core diameter
mm
mm
Mm
mm
Mm
9. Number of sheds
Nos.
mm
mm
mm
mm
mm
kN
KN
19. Material
a)
b)
c)
d)
e)
FRP rod
Weather sheds with % contents
of silicon
Housing
End fittings
Grading rings
mm
70kN
120kN
As per Bidder
Dry
KV
(rms)
Wet
KV
(rms)
Dry
b)
Wet
KV
(rms)
KV
(rms)
Page-7
COMPOSITE LONG ROD INSULATORS FOR 66KV LINE WITH ACSR ZEBRA
Page 2 of 2
Positive
Negative
KV
(peak)
KV
(peak)
Positive
Negative
KV
(peak)
KV
(peak)
Nos.
Yes/No.
Yes/No.
Page-8
Unit
1.
Name of manufacturer
2.
Address of manufacturer
3.
4.
5.
Material of
drawings
6.
all
components
indicated
in
Watts
7.
8.
KN
No.
Mm
Mm
Mm
(g)
Type of Aluminium alloy used for
manufacture of PA rod set
+ mm
+ mm
mm
Kg/
mm
As per HVPNL
Requirement
As per Bidder
9.
Page-9
10.
Kg.
Kg.
Kg.
11.
KN
KN
KN
12.
13.
14.
%
No.
Page-10
Unit
1.
Name of manufacturer
2.
Address of manufacturer
3.
4.
5.
Material of
drawings
6.
all
components
indicated
in
Ohms
As per HVPNL
Requirement
As per Bidder
7.
8.
KN
Kg.
Kg.
9.
KN
KN
10.
11.
No.
Page-11
No.
1.
2.
Drawing enclosed
3.
4.
5.
mm
(mm)
(mm)
7.
8.
9.
(mm)
b) Steel
(mm)
(mm)
(mm)
Corner to corner
(mm)
(mm)
As per
Bidder
(ii)
Surface to surface
(mm)
(mm)
10.
11.
(mm)
(mm)
Weight of sleeve
(a) Aluminium
(b) Steel
(c) Filler Al-Sleeve
(Kg.)
(Kg.)
(Kg.)
12.
Slipping Strength
13.
(kN)
%
Page-12
Unit
1.
2.
Drawing enclosed
3.
4.
5.
Inside diameter
compression
6.
of
sleeve
(mm)
before
(%)
(mm)
(mm)
(mm)
(mm)
7.
Length of sleeve
(a) Before compression
(b) After compression
8.
Weight of Sleeve
(mm)
(mm)
(Kg)
As per HVPNL
Requirement
As per Bidder
Page-13
Description
1.
2.
Drawing enclosed
3.
Material of Joint
(i)
(ii)
Unit
As per HVPNL
Requirement
As per Bidder
4.
Steel sleeve
Aluminium sleeve
Aluminium filler sleeve
(mm)
(mm)
(mm)
5.
(mm)
Outside
dimensions
compression
of
(mm)
sleeve
after
(mm)
(mm)
Corner to corner
Surface to surface
(mm)
(mm)
7.
Before compression
(b)
After compression
(mm)
(mm)
Page-14
8.
9.
(mm)
(mm)
Weight of sleeve
(a) Steel
(b) Aluminium
(c) Filler Al-sleeve
(Kg)
(Kg)
(Kg)
10.
Slipping Strength
(kN)
11.
(%)
Page-15
1.
2.
Drawing enclosed
Unit
As per make
mm
4.
Kg
5.
mm
6.
7.
8.
9.
10.
11.
12.
(Kg/
mm)
13.
KN
14.
Resonance frequencies
(a) First frequency
(b) Second frequency
As per HVPNL
Requirement
mm
Kg
mm
Hz
Hz
As per
Bidder
15.
16.
Kg-m
KN
KN
17.
18
Material of Clamp
Watts
Page-16
Description
1.
2.
Drawing enclosed
Unit
As per make
(mm)
4.
(Kg)
5.
(mm)
6.
(mm)
7.
(Kg)
8.
9.
10.
11.
12.
13.
14.
Resonance frequencies
(kN)
(Hz)
(Hz)
15.
16.
As per HVPNL
Requirement
Kg-m
As per Bidder
17
Page-17
Description
Unit
1.
2.
Drawing enclosed
3.
Material
4.
(i)
Shackle
(ii)
Clamp Body & Keeper
(iii)
U Bolt
Total drop (maximum)
(mm)
5.
Weight
(Kg)
6.
(kgf)
7.
Slipping Strength
(kN)
8.
Tightening Torque
(kg-m)
As per HVPNL
Requirement
As per Bidder
Page-18
Description
1.
Name of manufacturer
2.
Drawing enclosed
3.
Material
Unit
(i) Shackle
(ii) (a) Compression clamp
5.
(mm)
As per HVPNL
Requirement
As per
Bidder
(mm)
(mm)
(mm)
6.
Length of clamp
(mm)
(a) Before compression
(b) After compression
(mm)
7.
Weight
(Kg)
8.
(kN)
9.
Compression Pressure
(T)
10.
(kgf)
Page-19
Description
Unit
1.
Name of manufacturer
2.
Drawing enclosed
3.
Stranding
4.
(Sq.mm)
5.
(Sq.mm)
6.
7.
Material of lugs
8.
Bolt Size
(i)
(ii)
Diameter
Length
(mm)
(mm)
(mm)
9.
Resistance
10.
(Ohm)
(kg)
As per HVPNL
Requirement
As per Bidder
Page-20
GUARANTEED TECHNICAL PARTICULARS & OTHER TECHNICAL DATA OF 66KV POST INSULATOR
Description
Sl.No.
Unit
1.
Height
mm
2.
KVrms
3.
KVpeak
4.
mm
5.
mm
6.
Kg
7.
Kg
As per Bidder
8.
Tensile strength
9.
Torsional strength
10.
Compression strength
11.
Bending strength
12.
13.
Total weight
14.
N
Nm
Kg
mm
b. Top
mm
15.
16.
mm
Page-21
TECHNICAL SPECIFICAION
FOR
SCOPE
1.1
Scope includes manufacture, testing before dispatch and delivery FOR destination of 66 KV XLPE Power cable of size
1200mm2 as per BOQ conforming to IS-7098.
Sr. No.
Name of line
LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV S/Stn. A4 at 66kv S/Stn. Idgah
with 1200mm2 XPLE underground cable.
LILO of one ckt. of 66kV Ballabgarh (220kV BBMB)-Sector-58 D/C line (Section of 66kV Ballabgarh
(220kV BBMB) sector-58 Faridabad-jharsetly D/C line) at 66kV S/Stn. sector-59 Faridabad with
1200mm2 XLPE cable.
BOQ of 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn.Bhagola with
0.4sq ACSR Zebra. (Tower portion and Cable portion)
66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 0.4sq ACSR Zebra (Tower
portion and cable portion).
BOQ of re-alignment of 66kV D/C overhead line from 66kv S/Stn. A-5 Faridabad to 66kV
S/Stn.FatehpurBiloch from TL No. 15 to 38 by partially 8x1C x1200 sq mm XLPE cable and
partially by overhead line on KRR type tower with 0.4sq ACSR conductor as a deposit work
of HSIIDC.
(Cable portion and Tower portion)
2.0
STANDARDS:
2.1
Unless otherwise stated hereafter, rating, characteristics, test and procedures etc. concerning the 66kV XLPE cable
shall be preferably as per IS, IEC standards given below and shall be in compliance with the latest edition or revisions
thereof and meeting the constructional details and testing requirement as stipulated in foregoing also.
IEC-60228
IEC-60229
IEC-60230
IEC-60270
2.2
IEC-60287-1-1
IEC-60502
IEC- 60840
Power Cables with extruded insulation and their accessories for rated
voltage above 30 kV upto 150 KV.
IEC-62067
Tests for power cables with extruded insulation for rated voltage above
150 kV upto 500 kV.
IEEE:48
The 66 KV XLPE cable may conform to any other authorities standards, which ensures an equal or better quality than
the standard mentioned above. The bidder must specifically indicate the standards to which the cable conforms and
indicate all deviations (if any) from the preferred IS/ IEC codes that affect performance and rating.
Page-1
2.3
Compliance of the 66 kV XLPE cable manufactured with the provisions of this specification does not relieve him of the
responsibility of furnishing 66 kV XLPE cable and accessories of proper design, electrically and mechanically suited to
meet the operating guarantees at the specified service conditions.
2.4
If there are, in the opinion of the bidder, any conflicts between these codes and this specification, these contradictions
shall be brought to the attention of the owner.
3.0
The XLPE Power cable shall be suitable for continuous & satisfactory operation under following conditions:-
3.1
3.2
Climatic Conditions:-
i)
50oC
ii)
40oC.
iii)
(-) 5 oC.
iv)
55 oC
v)
100%
vi)
10%
vii)
40
viii)
100
ix)
10 to 100 cm
x)
4 months
xi)
100 kg/Sq.mm
xii)
1000 M
Conditions of Laying:-
i)
ii)
iii)
iv
3.3
4.0
i)
Ground Temp.
35o C
ii)
90o C
iii)
Air temperature
50o C
iv)
Depth of trench
1.5 m.
v)
Formation
vi)
vii)
viii)
Page-2
TOWER FOUNDATION
4.1
GENERAL
These specifications provide general guidelines for the construction of tower foundations as per design
supplied by HVPNL and the gantry tower foundations as per design supplied by HVPNL of the proposed
transmission line(s) covered in the tender.
4.2
Before start of work, successful bidder shall carry out trial bore-holes (normally up to 6.0 meter below natural
ground level) after every Kilometer en-route or as desired by the Employer to have a fair idea of soil
type/nature and subsoil water position. If the soil characteristics are changing rapidly or soil up to 6.0 meter
is very weak, the depth of bore-hole be increased beyond 6.0 meters so as to know the soil properties/type
below the foundation. The bore log data containing information such as position of sub-soil water table, soil
strata, the crop pattern in the agricultural fields where the foundation is to be laid and the suitability for founding
the required foundation, shall be submitted to the Employer for according approval for Classification of
foundation at each location.
Contractor shall also ensure to check the entry of kids/ animals in to the excavated pits by providing suitable
warning signs and safety measures as per the approval of Engineer-In-Charge.
4.3
TYPE OF SOIL
Soil en-route the following proposed transmission lines under the scheme is generally normal/Sandy/rocky.
LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV S/Stn. A4 at 66kv
S/Stn. Idgah with 1200mm2 XPLE underground cable.
LILO of one ckt. of 66kV Ballabgarh (220kV BBMB)-Sector-58 D/C line (Section of 66kV
Ballabgarh (220kV BBMB) sector-58 Faridabad-jharsetly D/C line) at 66kV S/Stn. sector59 Faridabad with 1200mm2 XLPE cable.
BOQ of 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn.Bhagola
with 0.4sq ACSR Zebra. (Tower portion and Cable portion)
66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 0.4sq ACSR Zebra
(Tower portion and cable portion).
BOQ of re-alignment of 66kV D/C overhead line from 66kv S/Stn. A-5 Faridabad to 66kV
S/Stn.FatehpurBiloch from TL No. 15 to 38 by partially 8x1C x1200 sq mm XLPE cable
and partially by overhead line on KRR type tower with 0.4sq ACSR conductor as a
deposit work of HSIIDC.
(Cable portion and Tower portion)
Ground water table enroute all the above said lines generally vary from 20mtr. to 25mtr. below Natural
Ground Level. The sub soil water level at few locations may be different due to local conditions. The crop
pattern enroute all the above said lines is paddy, wheat, sugarcane, cotton etc. depending on soil and
weather conditions.
Page-3
5.0
5.1
Conductor:
5.1.1The Milliken segmental type shall be made of Aluminium complying to the requirements of flexibility Class-2 of IEC60228 / IS: 8130. The conductor shall have high compactness & smooth surface finish.
5.1.2 The minimum number of wires in conductor and D.C. resistance shall be as per table-II of IEC-60228 / IS: 8130. The
grade and quality of the Aluminium used for the conductor shall be as per IEC/IS standard.
5.1.3 The material & nominal area of conductor shall be as per BOQ.
5.2
Conductor Screen:
5.2.1
The conductor screen consisting of semi conducting compound layer shall be provided over the conductor by
extrusion which will not only eliminate the risk of electric discharge at the interface between conductor and
insulation but will also present a very smooth protrusion free interface with the insulation to eliminate any localized
stress concentration. The screen shall be firmly bonded to XLPE insulation.
5.2.2
The minimum thickness of extruded conductor screen shall be 1.0 mm. The outer surface of the conductor screen
shall be circular and free from irregularities. A non-hygroscopic semi-conducting tape, if required, shall be applied
to the conductor under extruded layer to prevent penetration of compound in to the conductor interstices.
5.3
Insulation:-
5.3.1
The insulation composed of a special super clean grade layer of cross linked polyethylene (XLPE) shall comply with
the requirement of IS-7098(Part-III)/ IEC. The insulation shall be applied by extrusion over the conductor screen and
vulcanized using dry curing process to form a compact homogeneous body free from micro voids and contaminants.
5.4
Insulation Screening:
5.4.1
The insulation screening shall consist of two parts, namely, non-metallic and metallic.
5.4.2
5.4.2.1 A non-metallic insulation screen of semi-conducting compound similar to conductor screen (clause 5.2) for similar
purpose shall be applied directly over the insulation core by extrusion and shall be continuous and cover whole
surface area of insulation. It shall be firmly bonded to the insulation.
Page-4
5.4.2.2
5.4.3
5.4.3.1
The minimum thickness of extruded insulation screen layer shall be 0.8 mm, the ovality of the core shall be not
more than 5%.
Under-sheath, water barrier shall consist of a synthetic semi-conducting moisture swellable layer (non woven
synthetic tape with suitable water swellable absorbent tape with suitable overlap) covering the whole
surface area of the insulation screen. The barrier shall restrict longitudinal water penetration under the
metallic sheath. The nominal thickness of water swellable tape shall be 0.3 mm.
5.4.3.2
The semi conducting compound and the semi conducting tape shall be compatible with the insulating material
and suitable for the operating temperature of the cable.
5.4.4
The metallic sheath of Aluminium sheath or Lead alloy E shall be provided over the non-metallic part of the
insulation screening. Metallic sheath, together with copper screen (if required) shall be able to withstand short
circuit current of 31.5 kA for duration of 1 second for 66 kV system. The details of metallic sheaths are as under:
5.4.4.1
i)
The lead alloy sheath shall have composition as per IS: 692. The lead alloy E Sheath shall be extruded using a
continuous screw press and shall be free from all extrusion defects. The nominal thickness of lead alloy E
sheath shall be as per IEC-60502-2 / IS: 7098 (Part-3).
Copper wire screen of annealed plain copper wires with gap shall be Helically applied over the Radial Water
Barrier lead alloy metallic sheath.
ii)
An open helix copper tape binder shall be applied over the copper wire screen. The nominal thickness of the
tape shall not be less than 0.1 mm. The minimum thickness shall not fall below the nominal value by more
than 10%. Suitable non-metallic binder tape may also be applied over the copper screen to prevent the
penetration of the outer sheath in to the screen.
5.4.4.2
i)
ii)
When the corrugated aluminium sheath is used, it shall be applied by extrusion/seam-weld and then
passing through a corrugating head. The corrugating head contains rotating dies to form the valleys
between the ribs like sine wave and produce to correct diameter of sheath to fit over the insulation.
The sheath shall be free from pinholes flaws and other imperfections.
Anti-corrosive compound shall be applied over the aluminium sheath.
5.5
Outer Sheath:-
5.5.1
The outer sheath shall consist of an extruded layer of black, PE or PVC type ST-2 as per IEC/IS-7098 (Part-3).
Page-5
5.5.2
The nominal thickness of outer sheath shall not be less than the value calculated as per the recommendation
of IEC 60502-2/IS-7098 (Part-3). The outer sheath shall be of sufficient hardness to discourage termite and
rodent attack.
5.5.3
The outer conductive layer shall be of Graphite coating applied at works. This conductive layer / coating must facilitate testing of the non-metallic outer
sheath. This test is important to ensure the physical integrity of the cable from time to time be it at the factory, after transportation, directly after laying
upon completion of the installation.
6.0
6.1
The cable jointing accessories shall include the end terminating kits, straight through joints. These shall be
CLASS-I as defined in IEEE STANDARD-48 rated for 31.5KA for 66 kV system. The sheath voltage under full load
conditions shall not exceed 65V specified / allowed in relevant standards for safety of personal as well
satisfactory working of cable. The sheath shall be solidly grounded.
6.2
The cable terminations shall be fire resistant. The components of kits shall have flame retardant property.
6.3
All the cable sealing end/end termination kits and straight through joints shall be Pre-moulded/Cold Shrinkable
/Heat shrinkable type complete with accessories from reputed manufacturer of proven design which has
already been extensively used and fully type tested. The make of termination kits and straight through joints
shall be got approved from HVPNL before bringing in use.
6.4
The joint shall preferably be built up from the same material as the main cable and shall have electrical and
mechanical withstand capabilities same as or better than the main cable. The joints shall be suitable for tropical
climatic conditions. The straight through joints shall be suitable for underground buried installation with
incorporated back fill and chances of flooding by water. The straight through joints should be absolutely
impervious to the entry of water. The manufacturer shall use the proven technology and design to prevent
entry of water or any other liquid inside the straight through joints and cables.
6.5
The end termination shall be outdoor Pre-moulded/Cold Shrinkable/Heat shrinkable type with accessories. The
outdoor terminal should be suitable for heavily polluted atmospheric conditions and protected creepage
distance of not more than 50% of the total creepage distance. The cable end terminals for terminating the
cables shall be fully compatible with the cables to be supplied. Field tests of sealing end terminals shall be
made in conjunction with the cables after installation of the cables and terminals.
6.6
The testing of cable termination, sealing ends and straight through joints shall be as per IEC-60840. All the type
tests, sample tests and routine tests shall be as per IEC-60840.
6.7
The cable termination and straight through joints shall bear guarantee for five (5) years from the date of
commissioning. Any defect noticed in the kit shall be attended by the bidder immediately but not later than 24
hours on getting the complaints and if required shall be replaced and installed free of cost, otherwise the same
will be arranged at the bidders risk and cost.
Page-6
7.0
MANUFACTURING PROCESS:
7.1
XLPE cable should be processed in a modern triple head extrusion manufacturing line. XLPE extrusion and
curing through Vertical Catanery Vulcanisation system (VCV) or horizontal MDCV or CCV will be used to ensure
circularity and concentricity of the extruded layers around the conductor.
7.2
The conductor screen, insulation and insulation screen shall be extruded in one simultaneous triple extrusion
process (Clause 14.2.1 of IS: 7098-3) through common triple crosshead. The extruders and triple crosshead
shall be designed to prevent stagnation of materials to eliminate hot spots and ensure smoothness of the
conductor screen and screen surfaces. Insulation thickness should be controlled on-line using X-ray monitoring
system.
7.3
The cross linking, curing and cooling shall be carried out in one operation and shall be a dry curing process
under high pressure to eliminate the formation of voids in the insulation and contaminations in the dielectric.
7.4
Process conditions such as curing and cooling temperature, production speed etc. shall be closely monitored
during manufacture to ensure a good degree of cross-linking through the whole insulation.
7.5
The manufacturing process shall be desired to eliminate irregularities like protrusions, voids and contamination
etc. to ensure the long-term reliability of the cable.
7.6
Loading of the extruder in the manufacturing plant shall be performed entirely closed and dust proof. The
entire line of processing should be controlled from a computerized central control console. Contamination
shall be avoided by use of a fully enclosed material handling system. To avoid contamination XLPE Granules
must be transported using gravitational material feeding system.
8.0
QUALITY ASSURANCE:-
8.1
Raw materials used for manufacture of cable shall be of highest quality and material received
by manufacturer should be checked / tested to ensure that it meets manufacturers material
specification. The materials shall be clean and packed in moisture and dust proof packing.
Page-7
8.2
As the Quality control of EHV XLPE cables while manufacturing is very critical so expert supervision is required
for raw material testing, in process checks and also for final testing. A specially trained quality assurance team
should be in place for maintenance of the quality at an optimum level at the plant. Complete details of
manufacturing process along with details of automatic manufacturing plant, shall be furnished by bidder in the
bid.
8.3
Quality assurance plan indicating test /checks of raw material, process of manufacturer and
final inspection with customer hold point shall be submitted to the purchaser for approval.
9.0
TESTING:-
9.1
GENERAL:-
9.1.1
This schedule gives tests to be carried out on 66 KV, single core XLPE type cables. The schedule of tests to be
followed shall be generally as per IS-7098(Part-3)/ IEC 62067/ IEC-60840 (For 66 KV cable).
9.1.2
The facilities available for site tests shall be clearly and implicitly brought out in the Bid. The
site tests shall be carried out during and after laying/installation by the supplier.
9.1.3
This test schedule can be modified at the discretion of the purchaser to omit or to include additional tests.
Power frequency test shall be carried out at a frequency of 50 Hz.
10.0
10.1
The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable) /IEC62067.
The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable) /IEC62067
The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable) /IEC62067
10.4
TYPE TESTS:-
10.4.1
The cables offered should be fully type tested. Type test reports (not more than seven years old reckoned
from the date of bid opening in respect of all the type tests carried out as per IS-7098(Part-3)/ IEC-60840 (For
66 KV cable) /IEC62067 from Govt./ Govt. approved reputed test house shall be submitted along with the bid.
10.4.2
The bidder must have all testing facilities available at their works for testing the material as
per clause 8 & 10 above. Detailed list of testing equipment along with relevant tests must be
furnished with the tender other wise offers is likely to be ignored.
Page-8
11.0
11.1
MARKING ON OUTER SHEATH:The following particulars shall be marked on cable outer sheath:
Manufacturers name/ or trade name
Voltage grade viz. 38/66 KV.
Cable size ( no. of core x conductor cross section)
Year of manufacture.
Purchasers name i.e. HVPNL
11.2
The spacing between one set of marking and the beginning of the next on the legend shall
not exceed 150 mm.
11.3
Besides above, progressive sequential marking of length shall also be provided at every one meter, which shall
be clear and legible sequential length working by embossing/ engraving/printing.
12.0
12.1
Immediately after the works tests, both ends of every length of cable shall be sealed by means
of heat shrinkable end caps.
12.2
Cables shall be wound on metallic drums. All the drums shall be arranged to take a round
spindle and be legged with strong closely fitting wooden battens so as to prevent damage in
the cable. Each drum shall bear an identification number permanently stenciled or branded
on the outside of the flange.
12.3
Cable reels shall be of rugged construction, with a drum diameter of ample dimensions to
accommodate the single conductor. Manufacturer shall be responsible for any damage to the
cables during transit. Changes in the shape of the cable during transit shall not result in
deformation in metallic drum.
The cable drum/ reel shall carry the following information clearly marked on one flange of
the drum.
Manufacturer's name, Brand or trade mark.
Conductor of cable.
Type of cable and voltage grade.
Size of cable.
Length of cable on the drum.
12.4
As the total length of cable route is different in each line, the cable in one drum shall be so
selected that maximum length should be 500 to 700m for each cable drum. The length shall
be subject to limiting the sheath voltage, safety and ease of cable during wounding on drum,
transportation & its erection. Also the delivery length of cable shall match with the location of
jointing bays as described in Erection part. This length of each cable shall also include the
loop in between the route and both ends to the satisfaction of field office.
Page-9
14.0
14.1
The details of past orders executed by the bidder shall be indicated in the relevant
schedule.
15.0
15.1
The bidder shall furnish guaranteed technical particulars of cable in the relevant schedule enclosed
16.0
ABSOLUTE GUARANTEES:-
16.1
All commissioning tests and performance tests shall be treated as absolute guarantee and in
the event of failure in any of such test(s) the bidder shall take steps to rectify/replace/modify
at his cost the defective components(s), assemblies. The equipment after such
rectification/repair shall be re-tested at bidder cost at site.
16.2
The satisfactory performance of materials supplied shall be Guaranteed as indicated in Commercial bid
document. Technical Parameters of the cable shall be as stipulated in Annexure-I:
Annexure - I
DESIRED TECHNICAL PARTICULARS OF 66 KV XLPE CABLE
S. No.
Particulars
Technical Details
Cable
Applicable standard
1.
2.
3.
4.
5.
i)
ii)
iii)
iv)
v)
YES
Milliken segmental type
1200mm2
Class-2, IEC 228 / IS: 8130
Very well compacted
to be indicated by the Bidder
Page-10
6.
i)
CONDUCTOR SCREENING
Material & type
ii)
iii)
7.
i)
Grade
Thickness
INSULATION
Material
ii)
8.
A
INSULATION SCREENING
Non-metallic part(extruded)
Material
i)
ii)
iii)
i)
ii)
C
i)
ii)
iii)
D
E
Grade
Min. thickness.
Non-metallic part (taped)
longitudinal water barrier over
insulation screen.
Material
Min. thickness
METALLIC SHEATH
Material
Min. Thickness(mm)
Short Circuit Current Withstand
[Metallic sheath, together with
copper screen (if required)]
Bedding over lead sheath
CONCENTRIC COPPER WIRE
SCREEN (IF REQUIRED)
Material and type
i)
Min. area (Sq. mm)
ii)
9.
OUTER SHEATH
Material
i)
ii)
10.
11.
12.
13.
14.
15.
16.
i)
ii)
17.
18.
19.
20.
21.
Recommended minimum
installation radius.
Maximum Resistance of
conductor at 20 deg C in ohm/km.
Continuous current rating for each
circuit when laid in ground in trefoil
formation and other condition
given in specification.
Maximum allowable temperature
for cable and accessories.
At rated full load and at site
conditions.
The conductor temperature after a
short circuit for one second shall
not exceed (with conductor
temperature at start of short
circuits as 900 C).
Basic impulse insulation level
(1.2/50 micro second wave)
Power frequency withstand voltage
As per IEC-228 A
To be indicated
90 Deg C
250 Deg C
As per Standard
As per Standard
Page-12
ERECTION PART
Scope: -
1.1
Complete installation, laying, testing and commissioning of the cable in Faridabad area, as per the detail of lines mentioned
below, shall be the responsibility of the bidder:Sr.
No.
Name of line
LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV S/Stn. A4 at 66kv S/Stn. Idgah
with 1200mm2 XPLE underground cable.
LILO of one ckt. of 66kV Ballabgarh (220kV BBMB)-Sector-58 D/C line (Section of 66kV Ballabgarh
(220kV BBMB) sector-58 Faridabad-Jharsetly D/C line) at 66kV S/Stn. sector-59 Faridabad with
1200mm2 XLPE cable and tower portion.
BOQ of 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn.Bhagola with
0.4sq ACSR Zebra. (Tower portion and Cable portion)
66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 0.4sq ACSR Zebra (Tower
portion and cable portion).
BOQ of re-alignment of 66kV D/C overhead line from 66kv S/Stn. A-5 Faridabad to 66kV
S/Stn.FatehpurBiloch from TL No. 15 to 38 by partially 8x1C x1200 sq mm XLPE cable and partially
by overhead line on KRR type tower with 0.4sq ACSR conductor as a deposit work of HSIIDC.
(Cable portion and Tower portion)
Four nos of the cable per circuit shall be laid as per the tentative route plan enclosed. The scope for installation work shall,
therefore include, but not limiting to: 1.
Route survey for the entire route length under the scope of work.
2.
Clearances from relevant Local Authorities for laying of cables. All the protective measures for laying, protection and for
smooth working of all the cables as per statuary norms/standards to be followed/ensured by the bidder for its safe and
smooth operation in future. The charges on account of statutory clearances (except Chief Electrical Inspector office fee
under Electricity rules) shall be paid by HVPNL as per actual, on production of bills/demand notice.
3.
4.
Measurement of Thermal resistivity of soil. The value of thermal resistivity will be intimated to field office.
5.
6.
All civil works required for laying of the cables, which shall include design, construction materials and labours. Manholes
shall be provided at every proposed joint location for jointing bays. The bidder shall identify the location of the joint bays
after carrying out detailed survey of the cable route and excavation of the trial pits. The delivery lengths of the cables shall
match the location.
7.
Bidder shall carry out the earthing of sheath/screen at cross bonding points as well as at both of termination ends of 66kV
cable using insulation sheath bonding (earhting) cable of required size through link box with / without surge voltage limiter
at cross bonding points and terminal S/Stns.
Page-1
8.
Earthing shall be as per relevant standards and the details of the earthing arrangement offered for the cable
accessories shall be submitted along with the offer.
9.
The sheath/screen shall bound in the earth station through disconnecting type link boxes.
10.
Screen continuity by using tinned copper mesh and earth continuity by tinned copper braids of appropriate size shall
be provided for transfer of screen /earth in straight through joints.
11.
Laying & installation of cables in open cut trench, in ducts, in HDPE pipes and through Trench less method of required
strength for various crossings, in air at terminations at the tower, at varying depths due to obstructions, construction
of cable jointing bays. The death of laying of cables for lines shall be minimum 1.5m approx.
12.
Supply of HDPE pipe of required strength of ISI mark shall be 1.5 times of Cable Diameter. The HDPE pipes are required
for crossing of roads/ Bridge/Railways/culverts/water courses/ Nala/ Sewerage pipe lines/Oil /Gas pipe lines and for
Trench-less system. The pipes to be filled with sand/suitable material after cabling in Road crossing .
13.
Supply & Erection of terminal structures including foundations between the line for supporting cable end terminations,
it shall include the supply of Earthing material, Earthing of each cable, post insulators for cable support, civil foundation
design, construction material and labours etc.
14.
The cables will be terminated on the cable termination structures in the s/stn. premises and the cable will be
terminated on the tower at the point of connection with Over-head line.
Where the cable is to be terminated on Dead End type Terminal tower, the 66kV polymeric LAs with surge
counter will have to be mounted on the tower by making suitable arrangement and the independent earthing of LAs
mounted on the tower and of each cable shall be got done to the satisfaction of Engineer-incharge. The size of
galvanised flat to be used for earthing of LAs shall be 75X12mm2. The specification of polymeric LAs is attached
separately as Annexure-1.
15.
Termination of cables at both ends. Suitable loops shall be provided at both ends to the satisfaction of field office.
16.
It shall be the responsibility of the contractor to terminate the fourth (spare) run of the cable at the terminal structures
in such a way that it shall be possible to connect it to all the three phases of conductor by changing jumpers only.
However this spare cable shall be connected to nearest conductor to avoid theft/moisture in-gress. Necessary bonding
of the cable screen shall be done by the supplier along with its earthing as per IE rules & relevant ISS.
17.
Tentative Quantity of polymeric LAs shall be as per BOQ attached. The drawings of LAs shall be got approved from
HVPNL.
Page-2
18.
Cable markers as per statutory requirements shall be provided all along the route at a maximum distance of 100 meters
and other important locations. Also the location of the underground cable shall be clearly indicated on the marker.
19.
For termination of cable directly at tower, Heat shrinkable cable joint shall be used. If cold shrinkable cable / pre-
moulded type termination kits are to be used, the arrangement shall be made on four poles Railway structure of bidders
design which should be in use in other Utilities and would be got approved from HVPNL before its use.
20.
The bidder shall make his own arrangement for boarding & lodging of his men engaged in the work.
21.
22.
The laying of cables shall be through proposed densely populated residential area. Therefore, utmost precautions shall
be taken for erection of cables by the contractor for safety of the public. All the bidders are strongly advised to visit
the site through field office and acquaint themselves with the topography, infrastructure, crossings involved etc. before
submitting the bids. Suitable protection of XLPE cables and Public property shall be ensured to the satisfaction of
Engineer-incharge. The successful bidder shall be fully responsible for providing all equipment, materials, system and
services specified or not, but are required to complete the erection and successful commissioning of 66 KV cable
complete in all respects. The cost of carrying out such works, shall be deemed to be included by the bidders in the last
column of Supply & Erection portion. Nothing Extra shall be paid later-on on this account except for the variation in
the quantities of the items shown in Supply & Erection portion.
23. After award of contract, its Design/Drawings will be got approved before execution of work.
24.
The design of all type of crossings is in the scope of the bidder and work shall be started only after getting the design /
Drawings approved from HVPNL.
1.2
All the bidders are strongly advised to visit all the sites through respective field offices and acquaint themselves with
the topography. Infrastructure, crossing involved etc. before submitting the bids. The successful bidder shall be fully
responsible for providing all equipment, material, system and services specified or not, but are required to complete
the erection and successful commissioning of 66kV cab le complete in all respects. The cost of carrying out such works
shall be deemed to be included by the bidders in the last column of supply & erection portion. Nothing extra shall be
paid lator-on this account except for the variation in the quantities of the items shown in supply & erection portion.
Page-3
1.3
For all the cable work, Railway line/ road bridge/drain/Nala crossing is involved. Suitable arrangements for these
crossings shall be made as per site visit done before submitting the bids. After award of contract, its design/drawings
will be got approved before execution of work. Suitable protection of XLPE cables and public property shall be ensured
to the satisfaction of Engineer incharge.
1.4
If any, sewerage the water near the site, suitable precaution regarding shuttering work/dewatering shall be taken by
the bidder.
1.5
The design of all type of crossings is in the scope of the bidder and work shall be started only after getting the design /
drawings approved by HVPNL.
2.0
Route Survey
The bidder shall fully familiarize himself with the site and route conditions etc. The complete design and detailed
engineering shall be done by the contractor. The survey shall be conducted for underground routes to finalize the route
and paths for the underground cable. Contractor shall arrange information about existing under ground facilities for
the proposed routes. To do so as built drawings or route index diagram for various services viz water works, electric
supply utilities, telecom services, public health, Gas/oil authorities etc. may be collected from the concerned
authorities. In case details are not available, the contractor shall assess suitably by conducting enquiries and surveys.
The contractor shall prepare and submit the final survey report showing all the details enroute for HVPNL approval.
3.0
Statutory Clearances
The contractor shall coordinate on behalf of owner, for obtaining necessary clearances for laying of cable and carrying
out excavation/ digging work from the authorities on behalf of the Employer and provide requisite copies of
information maps, survey report etc. to the authorities. The employer shall assist the contractor in obtaining such
clearances by providing the authority letter or any other relevant document. The contractor shall ensure quick and
speedy clearances in order to implement the project within stipulated schedule. In case the authorities have some
objections on certain sections of routes proposed and are unwilling to provide clearances, the contractor shall propose
an alternate route, promptly carrying out the survey and submit specific survey report for that and reapply for
clearance after taking into account the comments/objections of the authority. The clearance of the Chief Electrical
inspector under Electricity laws shall solely be in contractors scope. Other charges on account of statutory clearances
shall be paid by HVPNL as per actual, on production of bills/demand notice.
Page-4
4.0
CABLE HANDLING
5.0
DAMAGE TO PROPERTY
The contractor shall take all precautions while excavation of trench, trial pits & drill for trench-less laying etc., to protect
the public and private properties and to avoid accidental damage. Any damage so caused shall be immediately repaired
and brought to the notice of the Employer.
The contractor shall bear all responsibilities and liabilities and shall bear all costs of the damages so caused by him or
by his workman or agents.
6.0
Permanent means of indicating the position of joints and cable route shall be fabricated supplied and erected.
The marker should incorporate the relevant information. The name of the owner, voltage, circuit & Danger sign. The
drawing of marker is enclosed with the bid.
7.0
Depth of laying of cables shall be 1.5m for directly buried cables ( trench method) and Trench-less method as per cl.
No. 1.1 (11) of scope of erection part . Laying at varying depths due to obstructions/site conditions may be accepted
subject to field office approval during detailed Engineering. The typical cross-section drawing of trench is enclosed with
this specification.
8.0
The excavated cable trench shall be drained of all water and the bed surface shall be smooth, uniform and fairly hard
before laying out the cables. The cables shall be rolled in the trench on cable rollers, spaced out at uniform intervals.
The laying out process must be smooth and steady without subjecting the cable to abnormal tension or scratches. The
cable being laid out shall be smoothly and evenly transferred to the ground after proving the sand cushion. The cables
shall never be dropped. Suitable size cable stocking pulling eye shall be used for pulling the cable. While pulling the
cable by winches or machines, the tension loading shall be by tension indicator and shall not exceed the permissible
value for the cable..
The cable end seals shall be checked after laying and if found damaged shall immediately be resealed. Sufficient number
of heat shrinkable cable end sealing caps shall be stocked at site stores for testing and jointing work. The integrity of
the outer sheath shall be checked after the cable is laid in position.
The sealing of power cable ends during the storage, execution & completion of jointing work shall be in the scope of
successful bidder. Under no circumstances, the cable ends shall be kept open. The amount due to damages done
because of water/moisture ingress OR penetration in the cable / conductors during execution shall be recovered form
successful bidder. It shall be responsibility of successful bidder to repair OR replace free of cost without affecting the
completion schedule.
Page-5
9.0
SAND BEDDING:
The cable shall be completely surrounded by well-compacted sand (River bed sand) to such a thickness and of such size
that the cable is protected against damage. The thickness of the cable sand should be a minimum 10cm in all direction
from cable surface.
Precast RCC slabs in M-20 of size 500X300X65mm for 66kV and shall be provided for protection of the cable by covering
the cable as per drawing enclosed. Every pre-cast slab shall carry the engraved words as- HVPNL 66kV.
10.0
BACK FILLING:
11.0
WARNING TAPE:
A pre-warning, Red colour plastic/PVC tape, 250 mm wide 100 microns thick shall be laid at approx. 0.4 m above the
cable specified depth, throughout the cable route. The tape shall carry the legend printed in black continuously as
under CAUTION HVPNL, 66000 V CABLES.
12.0
After the cables have been laid in the trench and until the cables are covered with protective covering, no sharp metal
tool shall be used in the trench or placed in such a position that may fall into the trench.
Straight and curved rollers used shall have no sharp projecting parts liable to damage the cable.
While pulling through pipes and ducts, the cable shall be protected to avoid damage due to sharp edges.
The cables shall never be bent, beyond the specified bending radius.
13.0
The road, Rail & Canal crossing should be done by HDPE pipes of required strength of diameter not less than 1.5 times
the cable diameter.
14.0
If required, trench-less digging shall be used for all roads crossings and through congested Urban streets of HUDA area.
The various methods of trench less digging such as hand/manual auguring (up to 15m), impact moling (from 16m to
about 40-50m). HDD (above 40-50m) shall be adopted based on the soil/site conditions and the requirement and exact
method for trench less digging shall be finalised during detailed engineering as per actual site/soil condition.
Page-6
The contractor shall propose the exact methods and procedures for
implementation of trench less digging at
various crossings taking into
consideration the following guidelines, for approval by the Employer:-
15.0
a)
b)
c)
d)
e)
f)
g)
JOINTING BAY
Manholes shall be provided at every proposed joint location for jointing bays. The bidder shall identify the location of
the joint bays after carrying out detailed survey of the cable route and excavation of the trial pits. The delivery lengths
of the cables shall match the location.
In case of underground portion, the joint bays should have a flat and level surface lined with bricks and properly
plastered. The retaining walls on all sides to the required height shall be of brick/stone masonry. The top of the wall
shall have a cement concrete band 1:2:4 with 20mm size aggregate all-round. The top shall be covered with prefabricated RCC slabs and with an inspection cover. Al the bottom in a corner, a sump-pit shall be made for bailing out
water. The contractor shall submit design and drawing of Jointing bay for HVPNL approval.
All works shall be carried out under supervision of the engineer in charge or his representative.
16.0
The successful bidder shall have all necessary tools, plant and equipment to carry out the survey and cable installation
work.
The bidder are instructed to give all the details of equipment at their disposal, to carry out the work successfully and
speedily.
17.0
BENDING RADIUS:
Cable
Bending radius
Single Core
20 x D
18.0
The cable jointing personnel and his crew shall have good experience in the type of joints and terminations that are
used. The jointing work shall commence as soon as two or three lengths of cables have been laid. All care should be
taken to protect the factory-plumbed caps/ seals on the cable ends and the cable end shall be sealed whenever the
end is exposed for tests.
Jointing of cables in carriage ways, drive ways under costly paving, under concrete or asphalt surfaces and in proximity
to telephone cables and water mains should be avoided whenever possible.
Page-7
Sufficient over lap of cables shall be allowed for making the joints.
The joint bay should be of sufficient dimensions to allow the jointers to work with as much freedom of movement and
comfort as possible. Sufficient space should be kept below the cable to be jointed.
19.0
SUMPHOLES
When jointing cables in water logged ground or under unforeseen rainy conditions, a sumphole should be made at one
end of the joint bay, in such a position so that the accumulated water can be pumped or baled out by buckets, without
causing interference to the jointing operation.
20.0
TENTS/ COVERS
An enclosure or suitable protection cover shall be used in all circumstances wherever jointing work is carried out in the
open irrespective of the weather conditions. The joint shall be made in dust free, moisture free and clean atmosphere.
21.0
The cable end seals should not be opened until all necessary precautions have been taken to prevent circumstances
arising out of rainy/ inclement weather conditions, which might become uncontrollable.
If the cable end seals or cable ends are found to have suffered damage, the cables should not be jointed, without tests
and
rectification.
22.0
23.0
shall be checked.
IDENTIFICATION
The identification of each phase shall be clearly and properly noted. The cable shall be jointed as per the approved
design. Each cable shall have identification for phase at joint bays.
24.0
MAKING A JOINT
Comprehensive jointing instructions should be obtained from the manufacturer of jointing kits and meticulously
followed.
The materials used in the joints like ferrules, screen/sheath continuity bonds, lugs etc., shall be of good quality and
conform to standards. The jointing tools shall be appropriate and as per the requirement of jointing HV XLPE cables.
Page-8
25.0
CABLE TERMINATIONS
The preparation of the cable end for installing the terminations and the precautions to be taken before fixing the
terminations shall be followed as in the case of the cable jointing procedures.
At cable terminating end, the following provisions for supply and erections are to be included:
A sufficient length of spare cable to the satisfaction of field office shall be left in the
The spare cable shall be connected to its nearest cable on load so as to avoid its theft and moisture ingress.
Appropriate labels shall be fixed identifying the phase circuit, voltage and date of commissioning etc., on the cable
supporting structure.
26.0
The terminating structure being provided shall be of bidders standard design as per requirement of cable end sealing,
porcelain bushing etc.
The mounting structure shall be fixed on the cement concrete foundation, the design and drawings of which shall be
submitted to Employer for approval and acceptance during the course of detailed engineering.
After fixing the end termination, the cable shall be fixed to the support, with non-magnetic material clamps to the
required height securely. The mounting structure includes the supports for cable end boxes, post insulators, link boxes
and any other structure required for the intent of the contract. All steel sections used shall be free from all
imperfections, mill scales, slag intrusions, laminations, fillings, rust etc. that may impair their strength, durability and
appearance. All materials shall be of tested quality only.
27.0
Conductor Termination and Fencing Arrangement for 66kV System on Rail poles
The ACSR Zebra conductor from nearest 66kV tower shall be terminated on Rail poles structure (consisting of 3 No. Rail
poles), then to polymeric LAs & cable termination kits. All the Rail poles, LAs support structures and cable termination
structures shall be kept in a Fence / enclosure of 2 m height made of Chain link fence fabric of size 75mm, coated wire
shall be of 3.15mm dia having Zinc coating after weaving. The Chain link fabric shall be fixed to the intermediate parts
and at top & bottom of fence by welding/fixing 50X6mm MS flat all through its length and Barbed wire shall be used at
the top on the MS flat for the safety measure structure (if required as per site condition).
Page-9
The complete arrangement as detailed above shall be made separately for both circuits of conductor at a suitable
distance from the tower to keep the conductor tension on Rail poles structures well within limits in the same direction
of cable. Also proper stay-wire arrangement on back side of Rail pole structure shall be made for its stability.
The design of Rail pole structure and its foundations suitable for ACSR Zebra conductor of proven design of other
utilities shall only be used and the same shall be supplied to HVPNL for reference and record.
Proper phase to phase clearance between conductors (min.2.5 mtr.) shall be maintained. The 1st Rail Poles structures
shall be of height approx. 10 mtr. height above ground level land the 2nd Rail Poles structures shall be of more height
so that minimum clearance of 3 mtr. is maintained between circuit-1 and circuit-2 horizontal configuration conductors.
(For bidders reference, the similar arrangement is already in use in various 66kV cables in Delhi, specially at a site near
Pitampura Metro Railway Station except the difference that for this work, cable termination kit to be used).
28.0
Earthing:-
Bidder shall carry out the earthing of sheath/ screen at the cross bonding points as well as at the ends of cable using
insulation sheath bonding (earthing) cable of required size through link boxes with/ without surge voltage limiter at
cross-bonding points and terminal substations. Earthing shall be as per relevant standards. The sheath /screen shall
bound in the earth station through disconnecting type link boxes. Screen continuity by using tinned copper mesh and
earth continuity by tinned copper braids of appropriate size shall be provided for transfer of screen/earth in straight
through joints.
All the LAs to erected on the towers shall be properly earthed through 75X12mm2 GI strip to the satisfaction of field
office.
29.0
All tests as prescribed in IEC-60840: 1999 shall be performed after installation of cable.
Page-10
1.12 EXCAVTION
1.13
The specification covers excavation for cable trenches, ducts, structural foundation, jointing bays.
1.14
The contractor shall control the grading in the vicinity of all excavations so that the surface of the ground will
be properly sloped or diked to prevent surface water from running in to the excavated area during construction.
1.15
The excavation shall include the removal of all materials required to execute the work properly and shall be
made with sufficient clearance to permit the placing, inspection and setting of forms and completion of all
works for which the excavation was done.
1.16
The sides and bottoms of excavation shall be cut sharp and true. Under cutting shall not be permitted. Earth
sides of excavations shall not be used in lieu of form work for replacement of concrete unless authorized by
the Engineer where the limitations of space for large excavation necessitate such decision.
1.17
When machines are used for excavation th last 300 mm before reaching the required level shall be excavated
by hand or by such equipment that will leave the soil at required final level in its natural condition.
1.18
The bottom of the excavation shall be trimmed to the required level and when carried below such level by
error, shall be brought to level, by filling with lean concrete of 1:4:8 Mix at contractors cost.
1.19
1.20
The excavations for foundation where specified shall be carried out at least 75 mm or as specified in relevant
drawing below the bottom of the structure concrete and then be brought to the required level by placing lean
concrete of 1:4:8 mix or as specified with aggregate of 40 mm nominal size.
1.21
When the excavation requires tracing, sheeting, shoring strutting etc. the contractor shall submit to the
Engineer in charge drawings showing arrangement and details of proposed installation and shall obtain the
approval from the Engineer in charge before proceeding with the work.
1.22
The contractor shall have to constantly pump out the water collected in the pits, trenches due to rain, sub soil,
springs etc. and maintain dry working conditions at no extra cost to the owner.
1.23
During excavation, the required protection is to be done to the foundation/trenches along with caution
signs/protection tapes, around the excavated trenches.
Page-11
The contractor shall arrange to transport the surplus excavated earth by mechanical
transport. It shall however be ensured that no stacked/disposed shall be as directed by the Engineer-incharge.
2.2
3.0
However the contractor shall take all precautions at the site of excavation for keeping the free flow of vehicular and
human traffic and to avoid inconvenience in general. The soil transported for disposal shall be stacked, leveled and
dressed neatly.
3.1. The backfilling of excavated trenches around foundation shall consist of one of the following materials as the Engineer-incharge may direct in each location.
i) Selected sieved earth from excavated soil.
ii) Selected sieved earth brought from borrows area.
iii) Sand filling (sieved).
3.2 Filling shall be done after the concrete or measonry work has fully set and its curing completed.
3.3 The contractor shall fill in and around any work until it has been properly reinstated and approved by the Engineer-in
charge.
Back filling shall be done in horizontal layers of thickness not exceeding 300 mm thickness, free from pockets with
careful watering where necessary for compaction. The backfill shall be riddled earth free from materials likely to cause
damage to the cables.
4.3
The thermal backfill surrounding the cable shall be as per the design approved by the owner.
5.1 For the cement concrete, plain or reinforced for general use, requirement of concrete for nominal mix, strength and
quality pouring at all levels, from works, protection covering, finishing, admixture, inserts, curing etc. the provision of the
latest revision of IS:456 shall be complied with, unless permitted otherwise by any other Indian Standard codes, shall form
the part of the specification to the extent applicable within specification. The cement used shall comply with IS:12269
(OPC).
All fresh concrete shall be covered with the layer of an absorbent material and kept constantly wet for a period
of seven days or more from the date of placing concrete. The immature concrete shall be protected from the
damages and contamination that would impair the strength of the concrete.
The concrete mix for the various types of pre-cast units shall confirm to IS: 456. The aggregate shall be mixed by weight
and water cement ratio shall be controlled to obtain the dense concrete and the strength required. The reinforcement
shall be as per the design approved. The curing shall be carried out for the period of minimum seven days from the
date of casting and precast element shall be cured by flooding with water of minimum 25 mm depth over the element
for the period mentioned above.
7.3
13.0 FOUNDATION
Foundations for mounting structures in cement concrete shall be casted by bidder as per approved drawings.
15.0 PAINTING
Outdoor Kisok for link boxes etc., shall be painted with anticorrovise paint and red oxide as primer and two coats of
enamel paint. The boxes should be appropriately labeled as per installation at site regarding the S.No., location, type
caution board/danger.
Specification in brief on the materials used in installations of the underground cables, like RCC precast cable protection
covers, precluded cement concrete blocks for cable route. Joint indication, cable and mounting structures joints bays,
earthing and other miscellaneous materials are given below. All materials shall conform to relevant standards and shall
be approved by the Engineer in charge.
These should be fabricated as per the design supplied by the contractor and approved by HVPNL. The reinforcement
cement concrete should be in the proportion 1:1.5:3 of 20 mm and down size aggregate and steel reinforcement of 8
mm diameter conform to IS 1786 for deformed and cold twisted steel rods should be used and cured as per Civil
Engineering standards. The covers should carry the legends HVPNL 66 KV Cables as the case may be. The covers should
be free from burrs and projecting edges so that may be easily laid to butt.
13.1
Permanent and durable type, cable route markers/joint indicating blocks should be provided as per the design
approved by the purchaser.
13.2
The Reinforced cement concrete block should be made by the wet process and all the concrete shall consists of one
part cement, one and a half part sand, three parts aggregates of size 20 mm and down.
13.3
The marking block should be given a smooth cover surface or cement mortar and shall have the appropriate legends,
5 mm deep engraved on them as HVPNL 66 CABLE Ckt.- I OR HVPNL 66 KV CABLE Ckt.- II, HVPNL 66 KV CABLE or as
the case may be.
Page-13
14.0 PIPES
14.1
HDPE pipes of ISI mark, of approved diameter and thickness, of good quality shall be used for formation of cable ducts.
All sundry materials like coupling, collars, and caps to cover the pipe ends before cable is pulled in shall be provided.
14.2
The bidder shall furnish the design drawings of foundations, foundation anchor bolts, and design calculations etc. of
these structures.
15.0 SAND
15.1
Sand supplied for backfill shall be river sand, free from flakes, dust, earth, organic matter and large pebbles and stones
and should be free from any chemical contaminats likely to have corrosive action on the cable coverings. The sand
should be sieved through a mesh to remove all large stones and pebbles. The sand shall be properly graded and shall
conform to IS:383 for concreting work.
15.2
The owner will decide on the requirement of the use of sand depending on the availability of the excavated earth to
be used for backfill. The sand should be used with the approval of the owner as a backfill.
16.0 QUANTITIES
16.1
The quoted price shall also include supply of all material transportation charges, taxes, duties, Octoroi and tole tax,
labour, construction, plant and equipment and fixture, fittings and all temporary and permanent works necessary for
satisfactory completion in all respects.
16.2
If the owner is directed by the Engineer in charge to excavate to a lower level than that indicated in the drawing, such
additional excavation shall not be paid for & will be deemed to be included in the quoted rates.
The rate for this item shall include loading, carriage, unloading, stacking and dressing etc. complete. In no case the
excavated soil shall be stacked up to the distance of 1.5 Mtrs. From the edge of excavation or one third the depth of
excavation whichever is more.
Page-14
16.5
The contractor shall be responsible for estimates, assumptions and conclusions regarding the nature of the materials
to be excavated and difficulty of making and maintaining of required excavations and performing the work required as
shown on the drawing and in accordance with these specifications. Cofferdams, sheeting, shoring. Draining, dewatering
etc. shall be furnished and installed as required and the cost there of shall be included in the rate quoted. The
contractor shall be held responsible for any damage to any part of the work and property caused by collapse of sides
of excavation. The materials can be salvaged if it can be done with safety for the work and structure and as approved
by the Engineer in charge.
16.6
However, no extra claim shall be entertained for material not salvaged or any other damage to contractors proper as
the results of the collapse. He shall not be entitled to any claim for redoing the excavations as a result of the same.
The road cutting, whether of cement concrete/ asphalt or macadam road surface shall be taken after obtaining
approval for cutting from the civic authorities, traffic police, telephone authorities and work should be planned to be
completed in the shortest possible time. Where necessary work shall be planned during night or light traffic periods.
25.0 REINSTATEMENT
After the cables and pipes have been laid and before the trench is backfill all joints and cable positions should be
carefully plotted and preserved till such time the cable is energized and taken over by the Engineer. The protective
covers shall then be provided, the excavated soil riddled, sieved and replaced. It is advisable to leave a crown of earth
not less than 50 mm and not more than 100 mm in the centre and tapering towards the sides of the trench.
20.1
The temporary reinstatement of roadways should be inspected at regular intervals, more frequently in rainy season
and immediately after overnight rain for checking settlement and if required the temporary reinstatement should be
done.
Page-15
20.2
After the subsidence has ceased the trench may be permanently reinstated and the surface resorted to the best
possible condition.
20.3
The road surface being cement concrete, asphalt or tarred macadam, resurfacing will be done by the civic authorities
at owners cost. The fixing of markers etc. shall be co- ordinated by bidder.
20.4
All works shall be carried out under supervision of the Engineer in Charge or his representative.
The contractor shall be clean the completed cable route and shall remove all surplus and waste materials, empty cable
reels etc. preferably the same day but not later than the next day after the particular work is completed.
Page-16
Page-17
Page-18
ANNEXURE-1
TECHNICAL SPECIFICATION
FOR
1.0
SCOPE:
1.1
This specification provides for the design, engineering, manufacture, assembly, stage testing, inspection
and testing before dispatch, packing, forwarding and delivery at site of Metal Oxide (gapless) 60 kV
polymer housed Surge Arrestors complete with discharge counter, insulating base and other accessories.
1.2
1.3
It is not the intent to specify completely herein all the details of design and construction of Surge Arrestors.
However, Surge Arrestors shall conform in all respects to the high Standard of design and workmanship
and be capable of performing in continuous commercial operation up to Bidder's guarantee in a manner
acceptable to Purchaser who will interpret the meaning of the drawings and specification and shall have
the power to reject any work or material which in judgment are not in accordance herewith. The Arrestors
and discharge counters offered shall be complete with all parts, necessary for their effective and trouble
free operation. Such components shall be deemed to be within the scope of supply, irrespective of whether
they are specifically brought out in the commercial order or not.
2.0
STANDARDS:
2.1
The Surge Arrestors shall conform to the latest editions and amendments available at the time of supply,
of the standards listed hereunder.
_______________________________________________________________________
Sl.
Standard
No.
Ref. No.
Title
_______________________________________________________________________
1.
2.
IS:3070
(Part-III)
IS: 2629
3.
4.
IS: 2633
5.
IS:2147
6.
------
7.
IEC 61462
8.
IEC-815
(With latest amendments)
Guidefor selection of
Insulators pact polluted condition
9.
IEC-270
10
IEC-60-1
11 IEC-270-2-1976
______________________________________________________________________________
Note:
i)
For the purpose of this specification all technical terms used hereinaftershall have the meaning as per
IEC/ISS specification.
Page-1
ii)
For the parameters of the Arrestor which are not specified in IEC specification for Surge Arrestors, the
provisions of IS: 3070 (Part-I) shall be applicable.
2.2
Surge Arrestors meeting with the requirements of other authoritative standards, which ensure equal or
better quality than the standards mentioned above shall also be acceptable. Where the equipment offered
by the Bidder conforms to other standards, salient points of difference between the standards adopted and
the specified standards shall be clearly brought out in the offer. Four (4) copies of the reference standards
in English language shall be furnished along with the offer.
3.0
CLIMATIC CONDITIONS:
The equipment is required to operate satisfactorily under the following site condition:
i)
Temperature
500C
a) Maximum
b) Minimum
-2.50C
ii)
Relative Humidity
a) Maximum
b) Minimum
100%
26%
iii)
Isocerounic level
45
iv)
v)
900 mm
vi)
vii)
195 Kg./m2
viii)
35
3.1
a)
b)
AC Control and protective 240V, single space, 2 wire 50 Hz, neutral grounded
devices, lighting fixtures, space AC supply
heaters
c)
Each of the foregoing supplies shall be made available by the Purchaser at the terminal point for each
equipment for operation of accessories and auxiliary equipment. Bidders scope shall include supply of
interconnecting cables, terminal boxes, etc., the above supply voltages may vary as below and all devices
shall be suitable for continuous operation over entire range of voltages.
4.0
i)
AC Supply-voltage+10%&-15% frequency + 5%
ii)
DC Supply-15% to +10%
SYSTEM PARAMETERS:
The Surge Arrestors offered under this specification shall conform to the parameters given below:
_____________________________________________________________________
Sl. Particulars
No.
1.
2.
66
72.5
___________
(kV rms)
3.
1.2/50 microsecond
impulse voltage withstand
level:-
Page-2
a. Transformers and
325
Reactors (kVp)
b. Other equipment
325
4.
Minimum prospective
31.5
Anticipated levels of
temporary overvoltage
and its duration
a) Voltage (p.u.)
1.5/1.2
b) Duration (Seconds)
1/10
6.
class -3
7.
500V
8.
-10pc (max.).
9.
System frequency(Hz)
50 2.5 C/S
10
Neutral Grounding
Effectively Earthed
Three
5.0
5.1
The Surge Arrestors shall conform to the technical requirements as per Annexure-I.
5.2
The energy handling capability of each rating of Arrestor offered, supported by calculations, shall be
furnished in the offer.
5.3
The Surge Arrestors shall be fitted with pressure relief devices and arc diverting ports and shall be tested
as per the requirements of IEC specification for minimum prospective symmetrical fault current as specified
in Clause 4.0 (4).
5.4
The grading ring on each complete Arrestor for proper stress distribution shall be provided if required for
attaining all the relevant technical parameters.
5.5
PROTECTIVE LEVELS:
The basic insulation levels and switching impulse withstand levels of the lines and equipment to be
protected, have been specified in clause 4.0, "Principal Parameters". The protective characteristics of the
Arrestors offered shall be clearly specified in the schedule of guaranteed technical particulars.
5.6
GENERAL REQUIREMENTS:
5.6.1
The materials and components not specifically stated in this specification but which are necessary for
satisfactory operation of the equipment are deemed to be included in the scope of supply unless specifically
excluded.
5.6.2
Unless otherwise brought out separately by the Bidder in the schedule of deviations the Surge Arrestors
offered shall conform to the specification scrupulously. All deviations from the specification shall be brought
out in the schedule of deviations. The discrepancies between the specification and the catalogues or
literature submitted as part of the offer shall not be considered as valid deviations unless specifically
brought out in the schedule of deviations.
5.6.3
Any deviation which has not been specifically brought out in the schedule of deviations of the BidProposal
Sheets, shall not be given effect to. The deviations brought out in the schedule shall be supported by
authentic documents, standards and other references.
Page-3
5.6.4
Each individual unit of Surge Arrestor shall be hermetically sealed and fully protected against ingress of
moisture. The hermetic seal shall be effective for the entire life time of the Arrestor and under the service
conditions as specified. The Bidder shall furnish sectional view of the Arrestor, showing details of sealing
employed. The details material, cross sectional thickness etc. shall be indicated in cross sectional drawing.
5.6.5
The Bidder shall furnish in the offer, a sectional view of pressure relief device employed in the Surge
Arrestors offered.
5.6.6
5.7
5.7.1
All the units of Arrestors of same rating shall be inter changeable without adversely affecting the
performance.
5.7.2
5.7.3
All the necessary flanges, bolts, nuts, clamps etc., required for assembly of complete Arrestor with
accessories and mounting on tower to be supplied by the Purchaser, shall be included in Bidder's scope of
supply.
5.7.4
The drilling details for mounting the Arrestor on Purchaser's support shall be supplied by the Supplier.
5.7.5
The minimum permissible separation between the Surge Arrestor and any earthed object shall be indicated
by the Bidder in his offer.
5.7.6
Gapless metal oxide arresters conforming to IEC-60099- (4) & this specification shall be hermetically
sealed, without air voids/gap neither between the housing and the metal-oxide resistors nor the housing
itself. Arresters should not have anyenclosed gas volume between ZnO blocks and casing and no seals
shall be acceptable in order to avoid seal failure and moisture ingress leading to arrester failure. Surge
arresters shall be of heavy duty station class, with nominal discharge current, transmission line discharge
class as per Technical Requirements suitable for outdoor installation on tower. Arresters shall be
adequately designed to withstand specific dynamic over voltage after discharge of two surge of specified
duty class. Arresters shall be capable of discharging lightning, switching, steep & temporary power
frequency over voltages. Internal elements of arresters shall be designed with robust constructions and
shall have good mechanical, electrical and thermal properties to withstand repeated operation.
5.7.7
The arrester shall incorporate adequate creepage distance of 31mm/kV in order to prevent arrester failure
due to uneven voltage gradient across the stack in the event of contamination of arrester housing. Surge
arrester shall be with a housing made of polymeric material without air voids/gap neither between the
housing and the metal-oxide resistors nor the housing itself. Arresters should not have any enclosed gas
volume between ZnO blocks and casing and no seals shall be acceptable in order to avoid seal failure and
moisture ingress leading to arrester failure. Arresters manufactured by slip-on, pre molded housing will not
be accepted in view of the weak interface between the housing and the core. Bidder has to submit sectional
view of the arresters to prove that the arrester is designed as per this requirement.
5.7.8
The adhesion between the polymeric housing and the metal-oxide resistors or any other metallic or nonmetallic parts inside the housing must be strong enough, homogeneous robust and resistant to thermal
cycles and environmental stresses. Tests shall be carried out on each batch during the manufacturing and
records maintained to prove the above.
Page-4
5.7.9
Arrester shall be completely molded unit with absolutely no air volume inside, self-supporting
construction, suitable for mounting on towers. Arresters may be of tubular construction i.e. assembled
in hollow core insulators, or ZnO Block stacked either in cage of Fiber Rods or FRP tube, but enclosed
gas volume are not acceptable. Each surge arrester shall be hermetically sealed single phase multiple
unitsin single column only. The surge arrester shall not have any air volume enclosed within.
The nonlinear blocks shall be sintered metal oxide material. The surge arrester shall be robust
with excellent mechanical and electrical properties. Surge arresters shall be designed to ensure that
the arrester does not explode during the short circuit test condition. All the ZnO blocks shall be either
encapsulated with directly molded Polymer Insulator or having gap between block and insulator duly
filled with suitable insulating material. Seals if provided shall be effectively maintained even when
arrester discharges rated lightning current surge. Housing shall be so coordinated that external
flashover will not occur due to application of any impulse or switching surge voltage up to maximum
design value of surge arrester.
ZnO blocks shall have full metallization to have full face contact and to reduce contact resistance
between adjacent discs. ZnO blocks shall have lead free insulating collar and the insulation thickness
must be consistent and of sufficient thickness to pass the 100kA, 4/10s test. ZnO blocks shall be
tested 100% and as a confirmation should have the following values printed on Aluminum sprayed
surface.
a. Batch No.
b. AC reference voltage measured at reference current
c. Residual voltage measured at nominal discharge current
d. Power loss value measured at continuous operating voltage
The following documents shall be furnished for MOV discs during final inspection.
The batch test reports with necessary quality checks used for individual blocks along with insulation
layer formed across each block.
Details of ageing test carried out on individual batch.
Detailed tests carried out on individual disc during routine tests
5.8.
Polymer Housing:
5.8.1
Polymer housing material shall be silicon rubber. Polymer Rubber housing shall be free from lamination
cavities or other flaws affecting the maximum level of mechanical and electrical strengths. Properties of
the polymeric materials shall be specified in the offer and test reports for the same from aNABL accredited
laboratory shall be submitted for approval of the purchaser. The polymer material which is used for arrester
housing must have resistant to tracking & erosion, and stabilized against UV radiation and have proven
records of at least 7 years in similar application in Country. Surge arrestors (of similar to those offered) with
housing of same material have been supplied and in operation in India for the 5 years at least.
5.8.2
The surge arrester shall not fail due to housing contamination. TERT(Tracking & Erosion resistance test)
test shall be carried out on the material used for housing as per ASTM D 2303and type test reports hall
besubmitted.
5.8.3
The rain sheds / petticoats shall be of polymeric material and shallconfirm to the properties and type
test reports shall be submitted andshall not be pre-molded push on type or slip on type. The
adhesionbetween the polymeric housing and the metal oxide resistors or anyother metallic or nonmetallic parts inside the housing must be strongenough, homogeneous, robust and resistant to thermal
cycles andenvironmental stresses. Tests shall be carried out on each batch duringmanufacturing and
records maintained and provided as & whenrequired during inspection.
5.8.4
Polymer bounding to the core shall be effectively maintained even when surge arrestor discharges
rated surge current.
Page-5
5.8.5
The Polymer weather shed design shall be preferably of self-cleaningtype (Aero foil design.) The
details of the Polymer housing shed profile such as distance, angle of inclination, gap between the
shed, diameter(ID and OD) etc. shall be as per relevant standard and shall be indicated by the Bidder
in his offer in the form, during detailed drawing.
5.8.6
The Arrester housing shall conform to the requirements of latest IEC60099-4 latest specification.
Amended up to date.
5.9
5.9.1
All ferrous parts exposed to atmosphere shall be hot dip galvanized as per IS: 2629as amended from time
to time.Tinned copper/brass lugs shall be used for internal wiring of discharge counter. Screws used for
electrical connections shall be either made of brass or nickel plated. However, all nut & bolts shall be of
MS (HDG) / stainless steel.
5.9.2
Ground terminal pads and name plate brackets shall be hot dip galvanized.
5.9.3
The material shall be galvanized only after completing all shop operations.
5.10
5.10.1
The self-contained discharge counter shall be provided with milla-ammeter for measuring the leakage
current and shall not require any DC or AC Aux. Supply. It shall be suitable for outdoor use. The installation
of discharge counter shall not adversely affect the arrester performance. The Surge monitors shall not have
any metal oxide blocks inside, which could degrade during the usages and add additional residual voltage.
5.10.2
5.10.3
Each surge counter shall have terminals of robust construction for connection to earthling-lead and these
shall be suitably arranged so as to enable the incoming and outgoing connection to be made with minimum
operation
bends. The discharge counter shall be in the Bidder's scope of supply. The connection LA to surge monitors
shall be made from bottom of surge monitor and there shall not be any opening on top of surge monitor.
The connecting cable shall be double PVC sheathed stranded copper flexible twin cables of 50 sq.
mm. duly ferruled by copper lugs on both sides with suitable length of cable.
The length of cable shall be site requirement for LAs to be erected on towers.The discharge counter
shall be so designed that the readings of discharges recorded by the counter and the readings of
mille-ammeter shall be clearly visible through an inspection window to a person standing on ground.
Terminalconnector conforming to IS: 5561 shall be supplied along with the arrester.
5.11
Each Surge Counter shall have terminals of robust construction for connection to Earthling leadand these
shall be suitably arranged so as to enable the incoming andoutgoing connections to be made with minimum
bends.
5.11.1
Suitable grounding terminal shall be provided for earthling of surge arrestors up to water level. Proper
functioning of the Surge counter with Surge Arrestor shall be ensured by the Supplier.
5.11.2The special safety and security of the terminating tower is to be provided by the bidder.
5.12.3
Each surge arrester shall be complete with insulating base for mounting on tower.
Page-6
5.12.4
The grounding terminals shall be suitable for accommodating grounding connection for
of the SurgeArrestor shall be ensured by the Bidder.
proper functioning
The arrestor shall be provided with non-corrosive legible name plate indelibly marked with the following
information:
1.
2.
Order No.
3.
Manufacturer's name or trade mark and identification no. of the Arrestor being supplied.
4.
Rated voltage.
5.
6.
Type.
7.
Rated Frequency.
8.
9.
6.0
TESTS:
6.1.1
Type Test:
All the Lightning Arrester offered shall be fully type tested as per IEC: 60099-4 Edition 2.2 2009-05 at
the Government approved / NABLlaboratory of the eligible county or independent internationally
recognized testing laboratory. The Bidder shall furnish one set of the type test reports for the Lighting
Arrester of the type and Design offered by him along with the offer. The Type Test report shall not be
older than 7(Seven) years and shall be valid up to the expiry of validity of offer, otherwise the offer will
not be considered.
The following type test reports shall be submitted with the technical bid. The offer submitted
without valid type test report shall be evaluated accordingly.
Sr.
No.
10
and TERT (Tracking & Erosion resistance test) as per ASTM D2303
Tests on complete Arrester
11
12
13
Page-7
14
15
16
General
6.1.2
17
18
19
20
All acceptance and routine tests as stipulated in the relevant standards shall be carried out by the
supplier in presence of Purchasers representative.
The following acceptance tests shall be carried out in presence of HVPNL representative:-
6.1.3 Acceptance tests, whenever possible shall be conducted on the complete arrester unit. The number of
samples to be subjected to acceptance tests shall be decided by the purchaser at the time of actual
testing
6.1.4
SURGE MONITOR
The following routine test shall be performed in the presence of purchasers representative:
i)
ii)
iii)
Page-8
7.0
INSPECTION
7.1
The inspection may be carried out by the HVPNL at any stage of manufacture. The successful Bidder shall
grant free access to the HVPNL's representative at all times to the works and all other places of
manufacture, where equipment are being manufactured and the Contractor shall provide all facilities
without extra charges, for unrestricted inspection of the Contractor's works, raw materials, manufacture of
the equipment., all the accessories and for conducting necessary test as detailed herein.
7.2
The Contractor shall keep the HVPNL informed in advance, about the manufacturing program so that
arrangement can be made for inspection.
7.3
No material shall be dispatched from its point of manufacture unless the material has been satisfactorily
inspected and tested.
7.4
The HVPNL reserves the right to insist for witnessing the acceptance/routine testing of the bought out
items.
7.5
The Contractor shall submit their internal inspection report containing manufacturer's test certificates before
offering the material for inspection.
7.6
The acceptance of any quantity of equipment shall in no way relieve the Contractor of his responsibility for
meeting all the requirements of this specification and shall not prevent subsequent rejection if such
equipment are later found to be defective.
8.0
DOCUMENTATION:
8.1
All drawings shall conform to International Standards Organization (ISO) "A" series of drawing
sheets/Indian Standards specifications. All drawings shall be in ink and suitable for microfilming. All
dimensions and data shall be in SI Units.
8.2
The Bidder shall furnish four sets of following drawings along with his offer:
i)
ii)
Drawing showing clearance from grounded and other live objects and between adjacent poles of
Surge Arrestors, required at various heights of Surge Arrestors.
iii)
iv) Detailed drawing of discharge countersalong with the wiring and schematic drawing of discharge
counter and meter.
v)
xi) The detailed dimensional drawing of Polymer housing such as ID, OD, thickness and insulator details
such height, profile of petticoats, angle of inclination and gap between successive petticoats, total
Creepage distance etc.,
8.3
The supplier shall submit four sets of final version of all the above drawings for Purchasers approval. The
Purchaser shall communicate his comments/approval on the drawings to the supplier within four weeks.
The supplier shall, if necessary, modify the drawings & resubmit four copies of the modified drawings for
Purchaser's approval within one weeks from the date of comments.
8.4
The manufacturing of the furnish twenty copies of bound manuals covering erection commissioning
operation and main.
8.5
i)
Four copies of acceptance test reports shall be furnished to the Purchaser. One copy will be returned,
duly certified by the Purchaser and only thereafter shall the materials be dispatched.
ii)
All records of routine test reports shall be maintained by the Supplier at his works for periodic
inspection by the Purchaser.
Page-9
iii)
NOTE:
9.0
All test reports of tests conducted during manufacture shall be maintained by the Supplier. These shall
be produced for verification as and when requested for by the Purchaser.
In case the equipment offered by the Supplier does not meet with the requirement of technical specification
the offer of the Firm shall not be considered.
TEST REPORTS:
I)
Four copies of acceptance test reports shall be furnished to the purchaser and arresters with
accessories shall be dispatched only after approval of these test reports.
II)
All records of routine test reports shall be maintained by the supplier at his works for periodic
inspection by the purchaser.
III)
Record of all test reports of tests conducted during manufacture shall be maintained by the
supplier. These shall be produced for verification as and when requested for by the purchaser.
10.0
10.1 The arrester shall be packed in suitable crates so as to with stand handling during transport and outdoor
storage during transit. The supplier shall be responsible for any damage to the arrester &their
accessories during transit, due to improper and inadequate packing. The easily damageable material
shall be carefully packed and mark design & Seal of Bidder with the appropriate caution symbols.
Wherever necessary, proper arrangement for lifting such as lifting hooks etc. shall be provided. Any
material found short inside the packing cases shall be supplied by supplier without any extra cost.
10.1 Each consignment shall be accompanied by a detailed packing list containing the following information:
a)
b)
Details of consignment.
c)
Destination.
d)
e)
f)
g)
10.2 The supplier shall ensure that the packing list and bill of material areapproved by the Purchaser before
dispatch.
10.3 The material shall be transported within India to the respectivedestination by Road Transport / Rail
Transport as the case may be atthe option of the purchaser.
10.4 Loose material e.g. bolts, nuts etc. shall be packed in gunny bags andsealed in polythene bags with
proper tagging
10.5 Components containing glass shall be carefully covered with chockabsorbing protective material such as
thermocol.All opening in the equipment shall be tightly covered, plugged or capped to prevent dust and
foreign material from entering inall spares parts shall be packed and created for long storageconditions
at site.
10.6 The scope of supply shall include a supply of 2.5 % extra quantity ofbolts, nuts, washers, split pins cotter
pins and such other small looseitems free of cost.
10.7
Erection and Maintenance Manuals: 10 copies of bound manuals containing instructions for
erection,operation and maintenance of the Zinc Oxide surge arrestor along with all relevant information
and drawings shall be supplied, marked erection drawings shall identify the components, parts of the
equipmentHVPNL. tech spec 66kV LAas shipped to enable Engineer / Purchaser to carryout erection
with hisown personnel. All drawings and data shall be annotated in English language. All dimensions
shall be in metric system.
Page-10
ANNEXURE - I
(Surge Arrestors)
SHEET 1 OF 2
_______________________________________________________________________________
Sl.
Particulars
No.
_______________________________________________________________________________
1.
Rated Arrestor
60
Voltage
2.
49
3.
Installation
Outdoor -
4.
Class
station class
5.
Type of cons-
truction for
10 kA rated Arrestor.
6.
Nominal discharge
10KA
7.
Min. discharge
capability.
8.
Type of mounting
9.
Connection
(Between phase
Tower mounted
P/E
to earth P/E)
(Between phase
to phase P/P)
10.
Long duration
discharge class
11.
140
170
Max.residual voltage
186
Minimum pros-
31.5
symmetrical fault
current for pressure
relief test (kA rms)
Page-11
ANNEXURE I
(Surge Arrestors)
SHEET 2 OF 2
_____________________________________________________________________________
Sr.
Particulars
System voltage
15.
a) Terminal Connector
Single Zebra/Panther
16.
b) Take off
Vertical
(corona extinction)
17.
Maximum radio
500
interference
voltage (Microvolt)
when energised
at MCOV
18.
Whether insulating
yes
Minimum creepage
distance of Arrestor
2248
housing (mm)
Page-12
ANNEXURE A
Name of Manufacturer
2.
2a
Material of housing
3.
Applicable Standard.
3.a
3.b
3.c
4.a
4.b
5.
6. i)
ii)
8.
9.
1000 Amps.
ii)
250 Amps.
10.
11.
5 KA
ii)
10 KA
iii)
20 KA
12.
13.
Lighting impulse withstand voltage of Arresterhousing with 1.2/50 micro-second wave KVP)
14.
One minute power frequency withstand voltageof housing (dry /wet) KV (RMS)
Max RIV at cont operating vol.(-micro volts)
15.
High Current short duration impulse withstandlevel with 4/10 micro-second wave (KA) peak.
Page-13
16.
17.
18
19.
20.
21
22.
22.a
23.
24.
25.
26.
27.
b)
Rated current
c)
30.
31
Details of structure
Material
Hot dip galvanizing, zinc coating in gms/m2
Mounting dimensions
32
33.
Page-14
DRS Form 1
Manufacturer:
_______________________________
Configuration:
_______________________________
CABLE CONSTRUCTION
Seq
Parameter:
As per Technical
Specification
1.
No. of Fibres
Dual Window Single-Mode:
2.
Buffer Type:
3.
4.
5.
6.
DRS Form 2
Manufacturer:
_______________________________
Configuration:
_______________________________
CABLE CONSTRUCTION
Seq
Parameter:
As per Technical
Specification
1.
No. of Fibres
Dual Window Single-Mode:
2.
Buffer Type:
3.
4.
5.
DRS Form 3
DATA REQUIREMENTS SHEETS for OPTICAL FIBRE
DUAL-WINDOW SINGLE MODE (DW-SM)
OPTICAL PARAMETERS
Seq
Parameter:
As per Technical
Specification
1.
Fiber manufacturer(s)/Type:
2.
As per Bidder
offering
@ 1550 nm:
3.
4.
5.
Chromatic Dispersion
Coefficient
@ 1310 (1288-1339) nm:
@ 1310 (1271-1360) nm:
@ 1550 nm:
6.
7.
Cutoff wavelength:
Bend Performance:
(37.5 mm radius, 100 turns)
1550nm
@1310 nm
(30 mm radius, 100 turn)
9.
Cladding Diameter
@1550 nm
(nominal deviation):
(16mm radius, 1 turn) @
10.
coefficient
11.
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE: LILO of both circuits of existing 220kV Palla to Palli D/C line at proposed
3
(B)
.
3
(C)
.
Description
2
Detailed Survey
Furnishing bore log data
Construction of 220kV tower foundations as per HVPNL
Drawings & Specifications for 0 to 6M extension including
excavation, concreting, supply and placement of steel
reinforcement and backfilling complete in all respect.
i) Tower type DB (Tata Design) classified as
- Dry
ii) Tower type DD (Tata Design) classified as
- Dry
- Wet (w/out de-watering)
Construction of 220kV Multi Circuit (4 ckt.) KRR design tower
foundations as per HVPNL Drawings & Specifications for 0 to 6M
extension including excavation, concreting, supply and
placement of steel reinforcement and backfilling complete in all
respect.
i) 220kV Tower type MA (KRR Design) classified as
- Dry
- Wet (w/out de-watering)
ii) 220kV Tower type MB (KRR Design) classified as
- Dry
- Wet (w/out de-watering)
iii) 220kV Tower type MD (KRR Design) classified as
- Dry
- Wet (w/out de-watering)
Design, Engineering and construction of 220kV tower
foundations suitable for 220kV M/C (4 ckt.) monopole for 0 to 6M
extension including all labour material approval of design, vetting
of design from CPRI or reputed professional govt. institute
complete in all respect as per HVPNL specifications.
4
3
4
No.
01
No.
No.
01
06
No.
No.
02
01
No.
No.
01
00
No.
No.
01
00
4.
No.
No.
01
01
No.
No.
01
01
No.
No.
No.
01
00
01
Cum
Cum
Cum
Cum
Cum
02
02
01
01
05
design
5.
i)
ii)
iii)
iv)
v)
Protection Measure
Brick masonry in 1:4 cement sand mortar including excavation
Earth filling, compaction, leveling etc inside revetments
M-20 (1:1 :3 mix) concrete for top seal cover, for revetment etc.
Lean concrete (1:4:8)
RCC 1:1.5:3 M-20 excavation, cutting and placing of steel,
centering & shuttering, concreting complete in all respect.
Note:Foundation cost quoted against all types of foundations for different types of towers shall be
per tower basis i.e. for all the four legs of the tower.
SCHEDULE OF PRICES
SCHEDULE 5
LINE
(UNIT RATE SCHEDULE)
NAME OF LINE: LILO of both circuits of existing 220kV Palla to Palli D/C line at proposed
2(b).
3.
4.
DESCRIPTION
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
RATE
(Rs.)
4
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
Note: The above unit rates when multiplied with the respective volumes of work as per foundation
drawing attached with the tender, should match with the unit composite rates quoted for
complete foundation otherwise lowest of the two shall be considered.
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE: LILO of both circuit of 66kV BBMB Ballabgarh-Jharsetly D/C line at 220kV S/Stn.
Sector-58, Faridabad with 0.4sq ACSR zebra.
Length of line: 0.080Km
Sr
No
1
1.
2.
3.
4.
5.
i)
ii)
iii)
iv)
v)
Description
Unit
Qty.
3
Km.
No.
4
1
1
No.
No.
01
01
No.
02
Cum
Cum
Cum
Cum
Cum
02
02
01
01
05
Detailed Survey
Furnishing bore log data
Construction of tower foundations as per HVPNL Drgs. & Specs. for 0 to
6M extension including excavation, concreting, supply and placement of
steel reinforcement and backfilling complete in all respect.
i) 66kV Tower type DH (KRR Design) classified as
- Dry
- Wet (w/out de-watering)
Dewatering of subsoil water for lowering of water table to enable
excavation of earth, concreting for foundations/stub and backfilling, by
boring of tube wells or deploying well point system so that continuous
lowering of water table is made till completion of work, without disturbing
the soil characteristics. The rate shall include all type of expenditure for
required dewatering arrangements and irrespective of type of tower i/c
extensions if any i.e. KRR design or TATA design
Protection Measure
Brick masonry in 1:4 cement sand mortar including excavation
Earth filling, compaction, leveling etc inside revetments
M-20 (1:1 :3 mix) concrete for top seal cover, for revetment etc.
Lean concrete (1:4:8)
RCC 1:1.5:3 M-20 excavation, cutting and placing of steel, centering &
shuttering, concreting complete in all respect.
Note:Foundation cost quoted against all types of foundations for different types of towers shall be
per tower basis i.e. for all the four legs of the tower.
SCHEDULE OF PRICES
SCHEDULE 5
220kV D/C TRANSMISION LINE
(UNIT RATE SCHEDULE)
NAME OF LINE: LILO of both circuit of 66kV BBMB Ballabgarh-Jharsetly D/C line at 220kV S/Stn.
Sector-58, Faridabad with 0.4sq ACSR zebra.
SR.
NO.
1
1.
2(a).
2(b).
3.
4.
DESCRIPTION
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
RATE
(Rs.)
4
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
Note: The above unit rates when multiplied with the respective volumes of work as per foundation
drawing attached with the tender, should match with the unit composite rates quoted for
complete foundation otherwise lowest of the two shall be considered.
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE : LILO of one ckt. of 66kV Ballabgarh (220kV BBMB) Sector-58 D/C line Section
of 66kV Ballabgarh (220kV BBMB) Sector-58 Faridabad-Jharsetly D/C line at
66kV S/Stn. Sector-59 Faridabad with 1200mm2 XLPE cable and tower portion.
Length of line: 2.4 Km
Sr
Description
Unit
Qty.
.
N
o
1
2
3
4
1.
2.
3.
4.
5.
i)
ii)
iii)
iv)
v)
Detailed Survey
Furnishing bore log data
Construction of 66kV D/C tower foundations as per HVPNL Drawings
& Specifications for 0 to 6M extension including excavation,
concreting, supply and placement of steel reinforcement and
backfilling complete in all respect.
i) Tower type DD (KRR Design) classified as
- Dry
- Wet (w/out de-watering)
Dewatering of subsoil water for lowering of water table to enable
excavation of earth, concreting for foundations/stub and backfilling,
by boring of tube wells or deploying well point system so that
continuous lowering of water table is made till completion of work,
without disturbing the soil characteristics. The rate shall include all
type of expenditure for required dewatering arrangements and
irrespective of type of tower i/c extensions if any i.e. KRR design or
TATA design o Jyoti deisgn
Protection Measure
Brick masonry in 1:4 cement sand mortar including excavation
Earth filling, compaction, leveling etc inside revetments
M-20 (1:1 :3 mix) concrete for top seal cover, for revetment etc.
Lean concrete (1:4:8)
RCC 1:1.5:3 M-20 excavation, cutting and placing of steel, centering
& shuttering, concreting complete in all respect.
Km.
No.
1
1
No.
No.
No.
01
00
00
Cum
Cum
Cum
Cum
Cum
02
02
01
01
05
Note:Foundation cost quoted against all types of foundations for different types of towers shall be per tower
basis i.e. for all the four legs of the tower.
2(b).
3.
4.
DESCRIPTION
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
3
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
RATE
(Rs.)
4
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE: LILO of both circuit of the existing 220kV D/C FGPP-BBMB Samaypur (PGCIL line)
at 220kV S/Stn. Sector-58, Faridabad on M/C towers.
Length of line : 2.0KM
Sr.
No
1
1.
2.
3
(A).
3
(B).
3
(C)
.
5.
6.
i)
ii)
iii)
iv)
v)
Description
Unit
Qty.
2
Detailed Survey
Furnishing bore log data
Construction of tower foundations as per HVPNL Drawings &
Specifications for 0 to 6M extension including excavation, concreting,
supply and placement of steel reinforcement and backfilling complete in
all respect.
i) 220kV D/C Tower type DD (Tata Design) classified as
- Dry
- Wet (w/out de-watering)
3
Km.
No.
4
2
3
No.
No.
01
02
No.
No.
01
02
No.
No.
01
01
No.
No.
01
00
No.
No.
No.
01
02
02
Cum
Cum
Cum
Cum
Cum
02
02
01
01
05
Note:Foundation cost quoted against all types of foundations for different types of towers shall be per tower basis i.e.
for all the four legs of the tower.
SR.
NO.
1
1.
2(a).
2(b).
3.
4.
DESCRIPTION
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
3
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
RATE
(Rs.)
4
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE: 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn. Bhagola
(proposed) line with 0.4Sq ACSR zebra.
Length of line: 13.55KM
Sr.
No
1
1.
2.
3
(A).
3
(B)
4.
5.
6.
i)
ii)
iii)
iv)
v)
Description
Unit
Qty.
2
Detailed Survey
Furnishing bore log data
Construction of tower foundations as per HVPNL Drawings &
Specifications for 0 to 6M extension including excavation, concreting,
supply and placement of steel reinforcement and backfilling complete in
all respect.
i) 66kV Tower type DE (KRR Design) classified as
- Dry
- Wet (w/out de-watering)
3
Km.
No.
4
14
15
No.
No.
04
27
No.
No.
01
00
No.
No.
02
07
No.
No.
03
11
No.
No.
Set
01
01
06
No.
02
Cum
Cum
Cum
Cum
Cum
02
02
01
01
05
Note:1.
2.
Foundation cost quoted against all types of foundations for different types of towers shall be per tower basis i.e.
for all the four legs of the tower.
Foundation price quoted for gantry tower shall be for one complete location.
SR.
NO.
1
1.
2(a).
2(b).
3.
4.
DESCRIPTION
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
3
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
RATE
(Rs.)
4
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE: BOQ of 66kV D/C 400kV S/Stn. Nawada to 66kV S/Stn. Badrola with 0.4 Sq ACSR
zebra (Tower portion & cable portion).
Length of line: 4.895M
Sr.
No
1
1.
2.
3.
4.
5.
6.
i)
ii)
iii)
iv)
v)
Description
Unit
Qty.
2
Detailed Survey
Furnishing bore log data
Construction of tower foundations as per HVPNL Drawings &
Specifications for 0 to 6M extension including excavation, concreting,
supply and placement of steel reinforcement and backfilling complete in
all respect.
i) 66kV Tower type P (PQRS Design) classified as
- Dry
- Wet (w/out de-watering)
3
Km.
No.
4
5
6
No.
No.
01
04
No.
No.
01
05
No.
No.
01
02
No.
No.
02
05
No.
No.
No.
01
01
02
Cum
Cum
Cum
Cum
Cum
02
02
01
01
05
Note:Foundation cost quoted against all types of foundations for different types of towers shall be per tower basis i.e.
for all the four legs of the tower.
SR.
NO.
1
1.
2(a).
2(b).
3.
4.
DESCRIPTION
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
3
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
RATE
(Rs.)
4
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE: BOQ of re-alignment of 66kV D/C overhead line from 66kV S/Stn. A-5 Faridabad
to 66kV S/Stn. Fatehpur Biloch from TL No. 15 to 38 by partially 8x1Cx1200 Sq
mm XLPE cable and partially by overhead line on PQRS type tower with 0.4Sq
ACSR conductor as a deposit work of HSIIDC (tower portion & cable portion).
Length of line: 3.97KM
Sr.
No
1
1.
2.
3.
4.
5.
i)
ii)
iii)
iv)
v)
Description
Unit
Qty.
3
Km.
No.
4
4
5
No.
No.
02
06
No.
No.
00
01
No.
No.
00
01
No.
No.
No.
02
09
02
Cum
Cum
Cum
Cum
Cum
02
02
01
01
05
Detailed Survey
Furnishing bore log data
Construction of tower foundations as per HVPNL Drawings &
Specifications for 0 to 6M extension including excavation, concreting,
supply and placement of steel reinforcement and backfilling complete in
all respect.
i) 66kV D/C Tower type P (PQRS Design) classified as
- Dry
- Wet (w/out de-watering)
ii) 66kV D/C Tower type Q (PQRS Design) classified as
- Dry
- Wet (w/out de-watering)
iii) 66kV D/C Tower type R (PQRS Design) classified as
- Dry
- Wet (w/out de-watering)
iv) 66kV D/C Tower type S (PQRS Design) classified as
- Dry
- Wet (w/out de-watering)
Dewatering of subsoil water for lowering of water table to enable
excavation of earth, concreting for foundations/stub and backfilling, by
boring of tube wells or deploying well point system so that continuous
lowering of water table is made till completion of work, without disturbing
the soil characteristics. The rate shall include all type of expenditure for
required dewatering arrangements and irrespective of type of tower i/c
extensions if any i.e. KRR design or TATA design or Jyoti design
Protection Measure
Brick masonry in 1:4 cement sand mortar including excavation
Earth filling, compaction, leveling etc inside revetments
M-20 (1:1 :3 mix) concrete for top seal cover, for revetment etc.
Lean concrete (1:4:8)
RCC M-20 (1:1:3 mix) including excavation supply and placement
steel reinforcement centering and shuttering, concreting and backfilling
complete in all respect.
Note:Foundation cost quoted against all types of foundations for different types of towers shall be per tower basis i.e.
for all the four legs of the tower.
SR.
NO.
1
1.
2(a).
2(b).
3.
4.
DESCRIPTION
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
3
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
RATE
(Rs.)
4
REC-140
4.0
4.1
TOWER FOUNDATION
GENERAL
These specifications provide general guidelines for the construction of tower
foundations as per design supplied by HVPNL and the gantry tower foundations as per
design supplied by HVPNL of the proposed transmission line(s) covered in the tender.
However, the successful bidder shall develop the design/drawings of 220kV M/C (4 ckt.)
A,B,C & D type monopole. The successful bidder shall also get the design/drawings so
developed vetted from professional govt. institute like CSIR-Structural Engineering
Research Centre, Chennai, CPRI etc. and submit the same for approval of the HVPNL
before execution.
4.2
Before start of work, successful bidder shall carry out trial bore-holes (normally up to
6.0 meter below natural ground level) after every Kilometer en-route or as desired by
the Employer to have a fair idea of soil type/nature and subsoil water position. If the soil
characteristics are changing rapidly or soil up to 6.0 meter is very weak, the depth of
bore-hole be increased beyond 6.0 meters so as to know the soil properties/type below
the foundation. The bore log data containing information such as position of sub-soil
water table, soil strata, the crop pattern in the agricultural fields where the foundation is
to be laid and the suitability for founding the required foundation, shall be submitted to
the Employer for according approval for Classification of foundation at each
location.
Contractor shall also ensure to check the entry of kids/ animals in to the excavated pits
by providing suitable warning signs and safety measures as per the approval of
Engineer-In-Charge.
4.3
TYPE OF SOIL
Soil en-route the following proposed transmission lines under the scheme is generally
normal/Sandy/rocky.
9. LILO of both circuits of existing 220kV Palla to Palli D/C line at proposed 220kV S/Stn. Sector46 Faridabad on M/C towers by using ROW of existing 66kV D/C NH-3 Palla line presently
feeding the 66kV S/Stn. Sector-46.
10. LILO of both circuit of 66kV BBMB Ballabgarh-Jharsetly D/C line at 220kV S/Stn. Sector-58,
Faridabad with 0.4sq ACSR zebra.
11. LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV S/Stn. A4 at 66kV S/Stn. Idgah
with 1200mm2 XPLE underground cable
12. LILO of one ckt. of 66kV Ballabgarh (220kV BBMB) Sector-58 D/C line Section of 66kV
Ballabgarh (220kV BBMB) Sector-58 Faridabad-Jharsetly D/C line at 66kV S/Stn. Sector-59
Faridabad with 1200mm2 XLPE cable and tower portion.
13. LILO of both circuit of the existing 220kV D/C FGPP-BBMB Samaypur (PGCIL line) at 220kV
S/Stn. Sector-58, Faridabad on M/C towers.
14. 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn. Bhagola (proposed)
line with 0.4Sq ACSR zebra.
15. BOQ of 66kV D/C 400kV S/Stn. Nawada to 66kV S/Stn. Badrola with 0.4 Sq ACSR zebra
(Tower portion & cable portion).
16. BOQ of re-alignment of 66kV D/C overhead line from 66kV S/Stn. A-5 Faridabad to 66kV S/Stn.
Fatehpur Biloch from TL No. 15 to 38 by partially 8x1Cx1200 Sq mm XLPE cable and partially
by overhead line on PQRS type tower with 0.4Sq ACSR conductor as a deposit work of HSIIDC
(tower portion & cable portion).
[[
Ground water table enroute all the above said lines generally vary from 20mtr. to
25mtr. below Natural Ground Level. The sub soil water level at few locations may
be different due to local conditions. The crop pattern enroute all the above said lines
is paddy, wheat, sugarcane, cotton etc. depending on soil and weather conditions.
4.4
CLASSIFICATION OF SOIL
a.
Dry Soil: Soil shall be termed as dry soil where sub-soil water table is below
base of the tower footing and no de-watering is required.
b.
Wet Soil (without de-watering): Soil shall be termed as wet soil (without dewatering) where sub-soil water is below base of footing and no de-watering is
required but crop pattern is paddy field.
c.
Wet Soil (with de-watering): Soil shall be termed as wet soil (with de-watering)
where sub-soil water is above base of footing and de-watering has to be done.
d.
Rocky Soil: Hard conglomerate or other soft or fissured rock which can be
quarried or split with crow bars, wedges or pick axes. However, if required, light
blasting may be resorted to for loosening the material.
4.4.1 For excavation purpose, the quoted rates for foundations in wet soil (without dewatering) shall be considered as applicable for the dry soils. For wet soil (with dewatering), the quoted rates of de-watering have been asked for separately. The dewatering operation shall continue to keep the foundation pits dry during concreting and
thereafter for at least 24 hrs. Any de-watering carried out for removal of seepage of
surface water/rainwater will not be considered as de-watering and the soil shall be
termed as Dry Soil.
4.5 FOUNDATION TYPES
4.5.1 GENERAL
Reinforced cement concrete footing shall be used for all types of normal towers/
extension towers in conformity with the present day practices followed in the country
and the specifications laid herein. All the four footings of the tower and their extensions,
if any shall be similar irrespective of down thrust and uplift.
4.5.2 Foundation includes supply of materials such as cement, fine and coarse aggregates,
water, reinforcement steel and binding wire etc. Rates quoted for foundations shall
include all items of work relating to supply and installation of foundations such as form
work, excavation and back filing with good soil, compaction, stub setting, shoring &
timbering etc. where ever required, placing of reinforcement in position, concreting and
all other works related for completion of foundation.
4.6
CLASSIFICATION OF FOUNDATIONS
a.
Dry Foundation: To be used where sub-soil water table is below 6.0 meter from
Natural Ground Level.
b.
c.
4.6.1 Design of foundation for Wet (without de-watering) and Wet (with de-watering) shall be
same.
4.7
DESIGN PARAMETERS
Critical soil data
(v)
Type of soil
(vi)
Dry bulk density
(vii) Angle of internal friction
(viii) Safe Allowable Bearing Capacity
:
:
:
:
Normal/Sandy silt/Rocky
1500kg/m3
28
4.7.1 Structural design of the foundations shall be done by Limit State Method.
4.7.2 Partial safety factor for concrete and steel shall be considered as per latest IS: 456.
4.7.4
Particulars of the foundations designed on the basis of soil particulars given under 4.4 along
with the estimated volumes of concrete and excavation volumes for the various types of towers
shall be given in the drawings to be evolved by the successful bidder. The foundation shall be
designed such as to satisfy the following conditions.
4.7.4
4.7.5
The spread of concrete pyramid or slabs for both PCC and RCC type foundations shall be
limited to 45 degree with respect to the vertical. The centroidal axis of the slab shall coincide
with the axis of the column and pass through the centre of foundation base. The design of the
foundations (base slab and its reinforcement) shall take into account the additional stresses in
the foundation resulting from the eccentricity introduced due to non compliance of this
requirement.
4.7.6
At least 100 mm thick pad of size equal to the base of pyramid with its sides vertical will be
provided below the pyramid for PCC type foundations and 150mm for RCC type foundation is
to be provided. Also, at least 100mm thick lean concrete (1:4:8) pad shall be provided below
bottom slab/pyramid.
4.7.7
The thickness of base slab at centre i.e. at the point of maximum bending shall not be less than
300mm in case of RCC type foundation.
4.7.8
The total depth of foundations except Hard Rock type below the ground level shall not be less
than 1.5m and more than 3.0m. To maintain the interchangeability of stubs for all types of
foundations, for each type of tower, almost the same depths of foundations shall be used for
different types of foundations. However, for pile type foundations, depth limitations are not
applicable.
4.7.9
The overload factor for foundations shall be considered as 1.1 i.e. all the reactions
(compression, tension and side thrust) on foundations shall be increased by 10%.
4.8
LOADS ON FOUNDATIONS
4.8.1 The foundations shall be designed to withstand the specific loads of the super structure and for
the full footings reactions obtained from the structural stress analysis in conformity with the
relevant factors of safety.
4.8.2 The reactions on the footings shall be composed of the following type of loads for which these
shall be required to be checked;
b.
The down thrust loads combined with the additional weight of concrete in footing below
ground over the earth weight and full weight of concrete above ground level in the footing
are assumed to be acting on the total area of the bottom of the footing.
iv.
The moment due to side thrust forces at the bottom of the footing.
iii.
of loading, if any.
The structural design of base slab shall be developed for the above load combination.
In case of toe pressure calculation due to above load combination, allowable bearing pressure
can be increased by 25%.
ci.
4.10.2 The concrete used as lean concrete or base concrete shall be as mentioned on
respective drawings. The aggregate size shall be 40 mm nominal. Base concrete shall
be well compacted. The top surface of base concrete shall be leveled before placing
the reinforcement.
During excavation, if excavation exceeds the required depth or if any loose pocket of
earth is met below the base of footing, then the loose earth shall be removed or
excavation depth be increased till normal hard soil is met as per satisfaction of the
Engineer-in-Charge. This extra depth shall be filled with lean concrete. No extra shall
be paid on account of this extra excavation and lean concrete.
4.10.3 The cement concrete used for foundation shall be of grade M-20 {irrespective of any
grade mentioned on the drawing(s)}. The Mix Design (conforming to IS standards) shall
be done prior to start of work, as per specifications, got approved from the Employer
and shall be used for the construction, provided there is no change in the source and
the quality of materials. The source of materials shall be intimated to the Employer and
shall be ensured that Mix Design is with the materials from intimated source only and
same is not changed during construction. In case source of material changes or quality
of material differs from the earlier approved parameters, the Mix Design shall be done
again. Whenever there is uncertainty of availability of aggregates from a fixed source,
nominal mix is to be followed but the quality of aggregates shall not be compromised.
To avoid the delays, the contractor may go for nominal mix after getting the aggregates
tested till such time the mix design is got approved.
4.10.4 The coarse aggregate used shall be 20 mm graded or two types of single size
aggregate mixed in some fixed ratio to have graded 20-mm aggregate. The Coarse
aggregate shall conform to IS 383.
4.10.5 Grading of Fine aggregate shall conform to Zone-II of Table-4 of IS: 383 and shall be
free from deleterious materials.
4.10.6 The environmental exposure condition considered for Mix Design shall be MILD.
4.10.7 For Mix Design the degree of quality control shall be considered as FAIR.
4.10.9 The Water Cement ratio shall be minimum 0.50 and maximum 0.55.
4.10.9 For Transmission Line Tower footings, the minimum Slump shall be 50 mm and
maximum 75 mm.
4.10.10 For volumetric use of ingredients for concrete mix, the contractor along with the Mix
Design shall intimate the size of measuring boxes along with the Mix design.
4.10.11The approval of Mix Design shall not absolve the contractor from the responsibility of
achieving the required strength, workability etc. during actual execution. In case of
failure of concrete samples, the work done is liable to be rejected. In such case the
contractor shall recast the foundation at the same location by dismantling the rejected
foundation or at a nearby location as directed by the Employer. In case of honey
combing, the contractor shall do the pressure grouting as directed and to the full
satisfaction of Employer. The construction of new foundation in place of rejected one
and pressure grouting if done shall be without any extra payment.
4.10.12Ordinary Portland_Cement of Grade 43 of reputed make like JK,, ACC, Ambuja, Shree
conforming to IS: 8112 shall be used. However in case of shortage of OPC Cement,
Portland Pozzolona Cement (fly ash based or calcinated clay based) conforming to IS
1489 Part Part 1 and 2 respectively may be used in the works other than RCC. In
case, Portland Pozzolona Cement is used then curing period shall be enhanced as
directed by Engineer-in-Charge. In RCC works only Ordinary Portland Cement of Grade
43 shall be used.
4.10.13 The water used for mixing concrete and for curing purpose shall be fresh, clean and
free from oils, acids and alkalis, organic materials or other deleterious substance.
Potable water is generally preferred. Saltish or brackish water shall not be used. Water
used shall conform to clause 5.4 of IS 456.
4.10.14 Reinforcement steel (including TMT) Bars manufactured by TISCO, SAIL, IISCO and
RASHTRIYA ISPAT (primary manufacturers) conforming to IS: 1786 for deformed and
cold twisted bars shall only be used. The bidders shall, however, be allowed to use
Amba steel, Rathi steel, Kamdhenu steel, Barnala steel, P.R.S steel, Shidbali steel
(manufactured by secondary manufacturers) only after obtaining non-availability
certificate from the primary manufacturers. Before using secondary steel, the selected
bidder would require to conduct all physical & chemical tests (lot wise & dia. wise) to
establish its conformity to IS Standards. Required grade of steel shall be Fe-415. All
reinforcement shall be clean and free from loose mill scale, dust, loose rust and coats
of paint, oil or other coating, which may destroy or reduce bond with concrete.
Reinforcement bars should be fresh. Contractor shall supply, fabricate and place
reinforcement to shapes and dimensions as indicated on the drawings or as required to
carry out the intent of drawings and specifications. Adequate nos. of chairs, spacers of
required size shall be provided to ensure the proper placement of reinforcement. The
reinforcement bars crossing one another should be tied together at every intersection
with two strands of annealed steel wires 0.9 to 1.6 mm thick twisted and tied to make
the skeleton of the steel work rigid so that the reinforcement does not get displaced
during concrete placement.
All the reinforcement steel should be placed/ stacked at site store on raised (at least 0.5
meter from near surroundings) pucca/brick platform or reinforcement steel should be
placed on MS/GI sheets. The reinforcement steel after stacking should be covered with
Tarpaulin to avoid corrosion. Immediately before concreting (portion of reinforcement to
be embedded in concrete) shall be painted with cement slurry after removing any
rust/corrosion/any other foreign material.
4.10.15 No admixtures shall be used.
SETTING OF STUBS
The stubs shall be set correctly in accordance with approved method at the exact
location and aligned precisely at correct levels with the help of stub setting templates
and leveling instruments. Stubs shall be set in the presence of Employers
representative for which the Contractor shall give adequate advance intimation to the
Employer. All necessary precautions should be taken to ensure that the stubs finally set
in are not disturbed. If these are disturbed due to any reason, the bidder shall reset the
same without any extra cost.
4.14
for timely completion of a particular line, the contractor shall have to deploy the same
without any extra cost to the Employer.
After completion of the project, one set of each type of stub setting template as
applicable shall be supplied to the Employer at no extra cost to the Employer.
4.15 MIXING, PLACING AND COMPACTING OF CONCRETE
4.15.1 The concrete shall be mixed in a mechanical mixer. The mixer shall comply with IS:
1791 & IS: 12119. The mixer shall be fitted with water measuring devices. Mixer without
trough should not be brought at site. In case of difficult terrain, the Employer at his
discretion may permit hand mixing but this should not be made a routine. In case of
hand mixing, 10% extra cement shall be used without any extra cost.
4.15.2Mixing shall be continued until there is uniform distribution of material and the mix
become uniform in colour and consistency. If there is segregation after unloading from
mixer, the concrete should be re-mixed, but in no case the mixing be done for less than
two minutes. Normally, mixing shall be done close to the foundation, but in case it is not
possible the concrete may be mixed at a nearest convenient place. From mixer the
concrete shall be put on pucca platform or steel troughs, which shall be leak proof to
avoid any loss of water/slurry.
The concrete shall be transported from the place of mixing to the place of final deposit
as rapidly as practicable by methods, which will prevent the segregation or loss of any
ingredient. The concrete shall be placed and compacted before setting commences.
4.15.3 Form boxes of required size as per approved Mix Design volumes shall be used for
casting all type of foundations. Form boxes shall be rigidly tightened so that there are
no distortions in the shape of foundations. Form boxes shall be made sufficiently strong
to withstand all the loads and vibrations. For bottom pad portion sufficiently wide window
of minimum size 450 x 300 mm be left on each side at top for placing of concrete and
for use of vibrators to ensure thorough compaction. After every use, the form box(es)
be checked for any deformation and if necessary be repaired/corrected to original
position for reuse.
4.15.4 On removal of the form-work, if the concrete surface is found damaged, it shall be
repaired with rich cement sand mortar to the satisfaction of the Engineer-in-Charge. The
foundation pits be back-filled only after necessary repairs, if any as required above has
been done.
4.17
4.16.1 The formwork shall be removed after 24 hours (minimum). Due care shall be taken not
to injure the concrete by excessive striking the formwork. In case the Portland
Pozzolona cement has been used, the removal of formwork shall be delayed suitably
as directed by the Engineer-in-charge.
4.16.2 After opening of formwork and removal of shoring and timbering, backfilling shall be
started, after repairs, if any, to the foundation concrete as described under para 4.12.4
above. Backfilling shall normally be done with excavated soil. In case the excavated soil
consists of large boulders/stones, it should be broken to a maximum size of 80 mm. If
the excavated earth has harmful salts, it shall not, under any circumstance, be used for
backfilling. In such case excavated earth shall be disposed off as directed by the
Engineer-in-Charge and suitable earth (clean and free from harmful salts, organic and
other foreign materials) be brought for back filling. This shall be done by the contractor
at his own cost irrespective of lead involved for bringing the suitable earth.
4.16.3 The earth shall be deposited in layers (maximum 200 mm layers), leveled and wetted
and tampered properly before another layer is deposited. After the pits have been
backfilled to full depth, the stub template may be removed.
4.16.4 The backfilling and final grading shall be carried upto an elevation of about 75 mm above
the finished ground level to drain out water. After backfilling 50 mm high earthen
embankment (bandh) will be made along the side of excavation pits and sufficient water
will be poured in the backfilled.
4.17
CURING
Curing shall start after 24 hours of concreting to keep the concrete wet continuously for
a period of 10 days. However, after a minimum period of 72 hours the pit may be
backfilled with suitable earth sprinkled with necessary amount of water and well
consolidated in layers not exceeding 200mm. Both backfilled earth and exposed
chimney top shall be kept wet for the remainder of the prescribed time of 10 days. The
uncovered concrete chimney above the backfilled earth shall be kept wet by providing
gunny bags dipped in water fully wrapped around the concrete chimney for curing. It
must be ensured that the bags are kept wet by the frequent pouring of water on them.
In case Portland Pozolona cement has been used, curing period shall be increased as
decided by the Engineer-in-charge.
4.18
4.18.1 The work shall include all necessary brick/stone masonry (in C.M. 1:4) revetments,
earth filling above ground level and the clearance from stacking on the site of surplus
excavated soil. Special measures for protection of foundation wherever required shall
be provided after getting prior approval of the Employer and as per directions of the
Engineer-in-Charge.
4.18.2 The excess quantity of earth required for protection of tower (after utilizing the excavated earth)
and to be brought from outside shall be paid as per the rate provided in the letter of award.
4.18.3 The provisional quantities for foundation protection works are furnished in the Schedule
of Quantities as well as in the Price Schedule. The unit rates shall be applicable for
adjusting with the actual quantities of protection work done.
4.19
4.20
Technical Specification given in the Contract will govern for the different items/activities.
The items/activities for which detailed specifications have not been given in the Contract
Agreement will be governed by latest ISI/ NBC specifications.
4.21
Wherever IS Code has been mentioned, it shall mean IS Code with latest amendments.
EXCAVTION
1.25
The specification covers excavation for cable trenches, ducts, structural foundation,
jointing bays.
The contractor shall control the grading in the vicinity of all excavations so that the
surface of the ground will be properly sloped or diked to prevent surface water from
running in to the excavated area during construction.
The excavation shall include the removal of all materials required to execute the work
properly and shall be made with sufficient clearance to permit the placing, inspection
and setting of forms and completion of all works for which the excavation was done.
The sides and bottoms of excavation shall be cut sharp and true. Under cutting shall
not be permitted. Earth sides of excavations shall not be used in lieu of form work for
replacement of concrete unless authorized by the Engineer where the limitations of
space for large excavation necessitate such decision.
When machines are used for excavation th last 300 mm before reaching the required
level shall be excavated by hand or by such equipment that will leave the soil at required
final level in its natural condition.
The bottom of the excavation shall be trimmed to the required level and when carried
below such level by error, shall be brought to level, by filling with lean concrete of 1:4:8
Mix at contractors cost.
All excavation for installation of underground facilities shall be open cuts.
The excavations for foundation where specified shall be carried out at least 75 mm or
as specified in relevant drawing below the bottom of the structure concrete and then be
brought to the required level by placing lean concrete of 1:4:8 mix or as specified with
aggregate of 40 mm nominal size.
When the excavation requires tracing, sheeting, shoring strutting etc. the contractor
shall submit to the Engineer in charge drawings showing arrangement and details of
proposed installation and shall obtain the approval from the Engineer in charge before
proceeding with the work.
The contractor shall have to constantly pump out the water collected in the pits, trenches
due to rain, sub soil, springs etc. and maintain dry working conditions at no extra cost
to the owner.
During excavation, the required protection is to be done to the foundation/trenches
along with caution signs/protection tapes, around the excavated trenches.
1.26
1.27
1.28
1.29
1.30
1.31
1.32
1.33
1.34
1.35
3.0
BACK FILLING MATERIALS
3.1. The backfilling of excavated trenches around foundation shall consist of one of the
following materials as the Engineer-in-charge may direct in each location.
i) Selected sieved earth from excavated soil.
ii) Selected sieved earth brought from borrows area.
iii) Sand filling (sieved).
3.2 Filling shall be done after the concrete or measonry work has fully set and its curing
completed.
3.3 The contractor shall fill in and around any work until it has been properly reinstated and
approved by the Engineer-in charge.
4.0
4.1
4.4
7.0
5.1
6.0
7.0
7.1
7.4
18.0
FOUNDATION
Foundations for mounting structures in cement concrete shall be casted by bidder as
per approved drawings.
19.0
20.0
PAINTING
Outdoor Kisok for link boxes etc., shall be painted with anti corrosive paint and red oxide
as primer and two coats of enamel paint. The boxes should be appropriately labeled as
per installation at site regarding the S.No., location, type caution board/danger.
21.0
22.0
13.0
13.1
13.2
13.3
14.0
14.1
14.2
15.0
15.1
15.2
16.0
16.1
16.2
PIPES
HDPE pipes of ISI mark, of approved diameter and thickness, of good quality shall be
used for formation of cable ducts. All sundry materials like coupling, collars, and caps
to cover the pipe ends before cable is pulled in shall be provided.
The bidder shall furnish the design drawings of foundations, foundation anchor bolts,
and design calculations etc. of these structures.
SAND
Sand supplied for backfill shall be river sand, free from flakes, dust, earth, organic matter
and large pebbles and stones and should be free from any chemical contaminats likely
to have corrosive action on the cable coverings. The sand should be sieved through a
mesh to remove all large stones and pebbles. The sand shall be properly graded and
shall conform to IS:383 for concreting work.
The owner will decide on the requirement of the use of sand depending on the
availability of the excavated earth to be used for backfill. The sand should be used with
the approval of the owner as a backfill.
QUANTITIES
The quoted price shall also include supply of all material transportation charges, taxes,
duties, Octoroi and tole tax, labour, construction, plant and equipment and fixture,
fittings and all temporary and permanent works necessary for satisfactory completion in
all respects.
If the owner is directed by the Engineer in charge to excavate to a lower level than that
indicated in the drawing, such additional excavation shall not be paid for & will be
deemed to be included in the quoted rates.
16.7
16.8
BY MECHANICAL TRANSPORT
The rate for this item shall include loading, carriage, unloading, stacking and dressing
etc. complete. In no case the excavated soil shall be stacked up to the distance of 1.5
Mtrs. From the edge of excavation or one third the depth of excavation whichever is
more.
16.5
16.6
However, no extra claim shall be entertained for material not salvaged or any other
damage to contractors proper as the results of the collapse. He shall not be entitled to
any claim for redoing the excavations as a result of the same.
27.0
ROAD CUTTING
The road cutting, whether of cement concrete/ asphalt or macadam road surface shall
be taken after obtaining approval for cutting from the civic authorities, traffic police,
telephone authorities and work should be planned to be completed in the shortest
possible time. Where necessary work shall be planned during night or light traffic
periods.
28.0
ROAD CROSSING
HDPE pipes shall be used for cable. Pipes diameter should not be less than 1.5 times
the cable diameter.
29.0
FOOTPATH CUTTING
The slabs, kerb- stones, on the roads shall be removed and reinstated without damage.
30.0
REINSTATEMENT
After the cables and pipes have been laid and before the trench is backfill all joints and
cable positions should be carefully plotted and preserved till such time the cable is
energized and taken over by the Engineer. The protective covers shall then be provided,
the excavated soil riddled, sieved and replaced. It is advisable to leave a crown of earth
not less than 50 mm and not more than 100 mm in the centre and tapering towards the
sides of the trench.
20.1
20.2
After the subsidence has ceased the trench may be permanently reinstated and the
surface resorted to the best possible condition.
20.3
The road surface being cement concrete, asphalt or tarred macadam, resurfacing will
be done by the civic authorities at owners cost. The fixing of markers etc. shall be coordinated by bidder.
20.4
All works shall be carried out under supervision of the Engineer in Charge or his
representative.
31.0
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE:
Sr.
No
1
1.
2.
3.
Detailed Survey
Furnishing bore log data
Construction of tower foundations as per HVPNL Drawings &
Specifications for 0 to 6M extension 220 Kv D/C TATA Design
including excavation, concreting, supply and placement of steel
reinforcement and backfilling complete in all respect.
i) type DB ( TATA Design) classified as
- Dry Tower
- Wet (w/out de-watering)
) type DD ( TATA Design) classified as
- Dry Tower
- Wet (w/out de-watering)
Construction of tower foundations as per HVPNL Drawings &
Specifications for 0 to 6M extension 66 Kv D/C KRR Design
including excavation, concreting, supply and placement of steel
reinforcement and backfilling complete in all respect.
i) Tower type DA ( DE KRR Design) classified as
- Dry
- Wet (w/out de-watering)
ii) Tower type DB ( DF KRR Design) classified as
- Dry
- Wet (w/out de-watering)
iii) Tower type DC ( DG KRR Design) classified as
- Dry
- Wet (w/out de-watering)
iv) Tower type DD ( DH KRR Design) classified as
- Dry
- Wet (w/out de-watering)
5.
Dewatering of subsoil water for lowering of water table to enable
excavation of earth, concreting for foundations/stub and
backfilling, by boring of tube wells or deploying well point system
so that continuous lowering of water table is made till completion
of work, without disturbing the soil characteristics. The rate shall
include all type of expenditure for required dewatering
arrangements and irrespective of type of tower i/c extensions if
any i.e. KRR design or TATA design
6.
Protection Measure
i) Brick masonry in 1:4 cement sand mortar including excavation
ii) Earth filling, compaction, leveling etc inside revetments
iii) M-20 (1:1 :3 mix) concrete for top seal cover, for revetment etc.
iv) Lean concrete (1:4:8)
3
Km.
No.
4
5
6
No
No.
01
00
No.
No.
01
00
No.
No.
05
01
No.
No.
04
01
No.
No.
02
01
No.
No.
No.
01
03
02
Cum
Cum
Cum
Cum
02
02
01
01
Note:Foundation cost quoted against all types of foundations for different types of towers shall
be per tower basis i.e. for all the four legs of the tower.
SCHEDULE OF PRICES
SCHEDULE 5
66kV D/C TRANSMISION LINE
(UNIT RATE SCHEDULE)
NAME OF LINE:
SR.
NO.
1
1.
2(a).
2(b).
3.
4.
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
RATE
(Rs.)
4
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
Note: The above unit rates when multiplied with the respective volumes of work as per foundation
drawing attached with the tender, should match with the unit composite rates quoted for
complete foundation otherwise lowest of the two shall be considered.
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE: 66 Kv D/C (composite) line from NH-73 to Sector 22 with 0.4 Sq. conductor
at the cost of HSIIDC (Cable portion and Tower Portion)
Sr.
No
1
1.
2.
3.
4.
5.
i)
ii)
iii)
iv)
Description
2
Detailed Survey
Furnishing bore log data
Construction of tower foundations as per HVPNL Drawings
& Specifications for 0 to 6M extension including excavation,
concreting, supply and placement of steel reinforcement and
backfilling complete in all respect.
i) Tower type DB ( DF KRR Design) classified as
- Dry
- Wet (w/out de-watering)
ii) Tower type DC ( DG KRR Design) classified as
- Dry
- Wet (w/out de-watering)
iii) Tower type DD ( DH KRR Design) classified as
- Dry
- Wet (w/out de-watering)
Dewatering of subsoil water for lowering of water table to
enable excavation of earth, concreting for foundations/stub
and backfilling, by boring of tube wells or deploying well point
system so that continuous lowering of water table is made till
completion of work, without disturbing the soil
characteristics. The rate shall include all type of expenditure
for required dewatering arrangements and irrespective of
type of tower i/c extensions if any i.e. KRR design or TATA
design
Protection Measure
Brick masonry in 1:4 cement sand mortar including
excavation
Earth filling, compaction, leveling etc inside revetments
M-20 (1:1 :3 mix) concrete for top seal cover, for revetment
etc.
Lean concrete (1:4:8)
3
Km.
No.
4
1
2
No.
No.
01
00
No.
No.
01
00
No.
No.
No.
02
01
01
Cum
02
Cum
Cum
02
01
Cum
01
Note:Foundation cost quoted against all types of foundations for different types of towers shall
be per tower basis i.e. for all the four legs of the tower.
SCHEDULE OF PRICES
SCHEDULE 5
66kV D/C TRANSMISION LINE
(UNIT RATE SCHEDULE)
NAME OF LINE:
SR.
NO.
1
1.
2(a).
2(b).
3.
4.
DESCRIPTION
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
RATE
(Rs.)
4
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
Note: The above unit rates when multiplied with the respective volumes of work as per foundation
drawing attached with the tender, should match with the unit composite rates quoted for
complete foundation otherwise lowest of the two shall be considered.
REC-140
4.0
TOWER FOUNDATION
4.1
GENERAL
These specifications provide general guidelines for the construction of tower
foundations as per design supplied by HVPNL and the gantry tower foundations as per
design supplied by HVPNL of the proposed transmission line(s) covered in the tender.
4.2
Before start of work, successful bidder shall carry out trial bore-holes (normally up to
6.0 meter below natural ground level) after every Kilometer en-route or as desired by
the Employer to have a fair idea of soil type/nature and subsoil water position. If the soil
characteristics are changing rapidly or soil up to 6.0 meter is very weak, the depth of
bore-hole be increased beyond 6.0 meters so as to know the soil properties/type below
the foundation. The bore log data containing information such as position of sub-soil
water table, soil strata, the crop pattern in the agricultural fields where the foundation is
to be laid and the suitability for founding the required foundation, shall be submitted to
the Employer for according approval for Classification of foundation at each
location.
Contractor shall also ensure to check the entry of kids/ animals in to the excavated pits
by providing suitable warning signs and safety measures as per the approval of
Engineer-In-Charge.
4.3
TYPE OF SOIL
Soil en-route the following proposed transmission lines under the scheme is generally
normal/Sandy/rocky.
1.
2.
66 Kv D/C (composite) line from NH-73 to Sector 22 with 0.4 Sq. conductor
at the cost of HSIIDC (Cable portion and Tower Portion)
Ground water table enroute all the above said lines generally vary from 20mtr. to
25mtr. below Natural Ground Level. The sub soil water level at few locations may
be different due to local conditions. The crop pattern enroute all the above said lines
is paddy, wheat, sugarcane, cotton etc. depending on soil and weather conditions.
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE:
Sr.
No
1
1.
2.
3.
Description
Detailed Survey
Furnishing bore log data
Construction of tower foundations as per HVPNL Drawings &
Specifications for 0 to 6M extension 220 Kv D/C TATA Design
including excavation, concreting, supply and placement of steel
reinforcement and backfilling complete in all respect.
i) type DB ( TATA Design) classified as
- Dry Tower
- Wet (w/out de-watering)
) type DD ( TATA Design) classified as
- Dry Tower
- Wet (w/out de-watering)
Construction of tower foundations as per HVPNL Drawings &
Specifications for 0 to 6M extension 66 Kv D/C KRR Design
including excavation, concreting, supply and placement of steel
reinforcement and backfilling complete in all respect.
i) Tower type DA ( DE KRR Design) classified as
- Dry
- Wet (w/out de-watering)
ii) Tower type DB ( DF KRR Design) classified as
- Dry
- Wet (w/out de-watering)
iii) Tower type DC ( DG KRR Design) classified as
- Dry
- Wet (w/out de-watering)
iv) Tower type DD ( DH KRR Design) classified as
- Dry
- Wet (w/out de-watering)
5.
Dewatering of subsoil water for lowering of water table to enable
excavation of earth, concreting for foundations/stub and
backfilling, by boring of tube wells or deploying well point system
so that continuous lowering of water table is made till completion
of work, without disturbing the soil characteristics. The rate shall
include all type of expenditure for required dewatering
arrangements and irrespective of type of tower i/c extensions if
any i.e. KRR design or TATA design
6.
Protection Measure
i) Brick masonry in 1:4 cement sand mortar including excavation
ii) Earth filling, compaction, leveling etc inside revetments
iii) M-20 (1:1 :3 mix) concrete for top seal cover, for revetment etc.
iv) Lean concrete (1:4:8)
3
Km.
No.
4
5
6
No
No.
01
00
No.
No.
01
00
No.
No.
05
01
No.
No.
04
01
No.
No.
02
01
No.
No.
No.
01
03
02
Cum
Cum
Cum
Cum
02
02
01
01
Note:Foundation cost quoted against all types of foundations for different types of towers shall
be per tower basis i.e. for all the four legs of the tower.
SCHEDULE OF PRICES
SCHEDULE 5
66kV D/C TRANSMISION LINE
(UNIT RATE SCHEDULE)
NAME OF LINE:
SR.
NO.
1
1.
2(a).
2(b).
3.
4.
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
RATE
(Rs.)
4
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
Note: The above unit rates when multiplied with the respective volumes of work as per foundation
drawing attached with the tender, should match with the unit composite rates quoted for
complete foundation otherwise lowest of the two shall be considered.
REC-140
SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE: 66 Kv D/C (composite) line from NH-73 to Sector 22 with 0.4 Sq. conductor
at the cost of HSIIDC (Cable portion and Tower Portion)
Sr.
No
1
1.
2.
3.
4.
5.
i)
ii)
iii)
iv)
Description
2
Detailed Survey
Furnishing bore log data
Construction of tower foundations as per HVPNL Drawings
& Specifications for 0 to 6M extension including excavation,
concreting, supply and placement of steel reinforcement and
backfilling complete in all respect.
i) Tower type DB ( DF KRR Design) classified as
- Dry
- Wet (w/out de-watering)
ii) Tower type DC ( DG KRR Design) classified as
- Dry
- Wet (w/out de-watering)
iii) Tower type DD ( DH KRR Design) classified as
- Dry
- Wet (w/out de-watering)
Dewatering of subsoil water for lowering of water table to
enable excavation of earth, concreting for foundations/stub
and backfilling, by boring of tube wells or deploying well point
system so that continuous lowering of water table is made till
completion of work, without disturbing the soil
characteristics. The rate shall include all type of expenditure
for required dewatering arrangements and irrespective of
type of tower i/c extensions if any i.e. KRR design or TATA
design
Protection Measure
Brick masonry in 1:4 cement sand mortar including
excavation
Earth filling, compaction, leveling etc inside revetments
M-20 (1:1 :3 mix) concrete for top seal cover, for revetment
etc.
Lean concrete (1:4:8)
3
Km.
No.
4
1
2
No.
No.
01
00
No.
No.
01
00
No.
No.
No.
02
01
01
Cum
02
Cum
Cum
02
01
Cum
01
Note:Foundation cost quoted against all types of foundations for different types of towers shall
be per tower basis i.e. for all the four legs of the tower.
SCHEDULE OF PRICES
SCHEDULE 5
66kV D/C TRANSMISION LINE
(UNIT RATE SCHEDULE)
NAME OF LINE:
SR.
NO.
1
1.
2(a).
2(b).
3.
4.
DESCRIPTION
UNIT
2
Excavation including back filling in
Dry/Wet soil
Concrete (M-20) for RCC foundation
including all material, form work, shoring
and shuttering and other allied works along
with the cost of template required for setting
of stubs for all types of towers except steel
reinforcement.
Concrete (1:4:8) for foundation including
form-work.
Reinforcement steel for foundation (Supply
and placement).
Cost of stub setting per tower.
RATE
(Rs.)
4
Cum
Cum
Cum
MT
No.
Date
Signature
Place
Full Name
Designation
Common seal
Note: The above unit rates when multiplied with the respective volumes of work as per foundation
drawing attached with the tender, should match with the unit composite rates quoted for
complete foundation otherwise lowest of the two shall be considered.
REC-140
4.0
TOWER FOUNDATION
4.1
GENERAL
These specifications provide general guidelines for the construction of tower
foundations as per design supplied by HVPNL and the gantry tower foundations as per
design supplied by HVPNL of the proposed transmission line(s) covered in the tender.
4.2
Before start of work, successful bidder shall carry out trial bore-holes (normally up to
6.0 meter below natural ground level) after every Kilometer en-route or as desired by
the Employer to have a fair idea of soil type/nature and subsoil water position. If the soil
characteristics are changing rapidly or soil up to 6.0 meter is very weak, the depth of
bore-hole be increased beyond 6.0 meters so as to know the soil properties/type below
the foundation. The bore log data containing information such as position of sub-soil
water table, soil strata, the crop pattern in the agricultural fields where the foundation is
to be laid and the suitability for founding the required foundation, shall be submitted to
the Employer for according approval for Classification of foundation at each
location.
Contractor shall also ensure to check the entry of kids/ animals in to the excavated pits
by providing suitable warning signs and safety measures as per the approval of
Engineer-In-Charge.
4.3
TYPE OF SOIL
Soil en-route the following proposed transmission lines under the scheme is generally
normal/Sandy/rocky.
1.
2.
66Kv D/C (composite) line from NH-73 to Sector 22 with 0.4 Sq. conductor
at the cost of HSIIDC (Cable portion and Tower Portion)
Ground water table enroute all the above said lines generally vary from 20mtr. to
25mtr. below Natural Ground Level. The sub soil water level at few locations may
be different due to local conditions. The crop pattern enroute all the above said lines
is paddy, wheat, sugarcane, cotton etc. depending on soil and weather conditions.
4.4
CLASSIFICATION OF SOIL
a.
Dry Soil: Soil shall be termed as dry soil where sub-soil water table is below
base of the tower footing and no de-watering is required.
b.
Wet Soil (without de-watering): Soil shall be termed as wet soil (without dewatering) where sub-soil water is below base of footing and no de-watering is
required but crop pattern is paddy field.
c.
Wet Soil (with de-watering): Soil shall be termed as wet soil (with de-watering)
where sub-soil water is above base of footing and de-watering has to be done.
d.
Rocky Soil: Hard conglomerate or other soft or fissured rock which can be
quarried or split with crow bars, wedges or pick axes. However, if required, light
blasting may be resorted to for loosening the material.
4.4.1 For excavation purpose, the quoted rates for foundations in wet soil (without dewatering) shall be considered as applicable for the dry soils. For wet soil (with dewatering), the quoted rates of de-watering have been asked for separately. The dewatering operation shall continue to keep the foundation pits dry during concreting and
thereafter for at least 24 hrs. Any de-watering carried out for removal of seepage of
surface water/rainwater will not be considered as de-watering and the soil shall be
termed as Dry Soil.
4.5
FOUNDATION TYPES
4.5.1 GENERAL
Reinforced cement concrete footing shall be used for all types of normal towers/
extension towers in conformity with the present day practices followed in the country
and the specifications laid herein. All the four footings of the tower and their extensions,
if any shall be similar irrespective of down thrust and uplift.
4.5.2 Foundation includes supply of materials such as cement, fine and coarse aggregates,
water, reinforcement steel and binding wire etc. Rates quoted for foundations shall
include all items of work relating to supply and installation of foundations such as form
work, excavation and back filing with good soil, compaction, stub setting, shoring &
timbering etc. where ever required, placing of reinforcement in position, concreting and
all other works related for completion of foundation.
4.6
CLASSIFICATION OF FOUNDATIONS
a.
Dry Foundation: To be used where sub-soil water table is below 6.0 meter from
Natural Ground Level.
b.
c.
4.6.1 Design of foundation for Wet (without de-watering) and Wet (with de-watering) shall be
same.
4.7
4.7.1. All the properties of concrete regarding its strength under compression, tension, shear,
punching and bond strength etc. as well as workmanship shall confirm to IS: 456 latest.
4.7.2 The concrete used as lean concrete or base concrete shall be as mentioned on
respective drawings. The aggregate size shall be 40 mm nominal. Base concrete shall
be well compacted. The top surface of base concrete shall be leveled before placing
the reinforcement.
During excavation, if excavation exceeds the required depth or if any loose pocket of
earth is met below the base of footing, then the loose earth shall be removed or
excavation depth be increased till normal hard soil is met as per satisfaction of the
Engineer-in-Charge. This extra depth shall be filled with lean concrete. No extra shall
be paid on account of this extra excavation and lean concrete.
4.7.3 The cement concrete used for foundation shall be of grade M-20 {irrespective of any
grade mentioned on the drawing(s)}. The Mix Design (conforming to IS standards) shall
be done prior to start of work, as per specifications, got approved from the Employer
and shall be used for the construction, provided there is no change in the source and
the quality of materials. The source of materials shall be intimated to the Employer and
shall be ensured that Mix Design is with the materials from intimated source only and
same is not changed during construction. In case source of material changes or quality
of material differs from the earlier approved parameters, the Mix Design shall be done
again. Whenever there is uncertainty of availability of aggregates from a fixed source,
nominal mix is to be followed but the quality of aggregates shall not be compromised.
To avoid the delays, the contractor may go for nominal mix after getting the aggregates
tested till such time the mix design is got approved.
4.7.4 The coarse aggregate used shall be 20 mm graded or two types of single size aggregate
mixed in some fixed ratio to have graded 20-mm aggregate. The Coarse aggregate
shall conform to IS 383.
4.7.5 Grading of Fine aggregate shall conform to Zone-II of Table-4 of IS: 383 and shall be
free from deleterious materials.
4.7.6 The environmental exposure condition considered for Mix Design shall be MILD.
4.7.7 For Mix Design the degree of quality control shall be considered as FAIR.
4.7.8 The Water Cement ratio shall be minimum 0.50 and maximum 0.55.
4.7.9 For Transmission Line Tower footings, the minimum Slump shall be 50 mm and
maximum 75 mm.
4.7.10 For volumetric use of ingredients for concrete mix, the contractor along with the Mix
Design shall intimate the size of measuring boxes along with the Mix design.
4.7.11The approval of Mix Design shall not absolve the contractor from the responsibility of
achieving the required strength, workability etc. during actual execution. In case of
failure of concrete samples, the work done is liable to be rejected. In such case the
contractor shall recast the foundation at the same location by dismantling the rejected
foundation or at a nearby location as directed by the Employer. In case of honey
combing, the contractor shall do the pressure grouting as directed and to the full
satisfaction of Employer. The construction of new foundation in place of rejected one
and pressure grouting if done shall be without any extra payment.
4.7.12Ordinary Portland_Cement of Grade 43 of reputed make like JK,, ACC, Ambuja, Shree
conforming to IS: 8112 shall be used. However in case of shortage of OPC Cement,
Portland Pozzolona Cement (fly ash based or calcinated clay based) conforming to IS
1489 Part Part 1 and 2 respectively may be used in the works other than RCC. In
case, Portland Pozzolona Cement is used then curing period shall be enhanced as
directed by Engineer-in-Charge. In RCC works only Ordinary Portland Cement of Grade
43 shall be used.
4.7.13 The water used for mixing concrete and for curing purpose shall be fresh, clean and
free from oils, acids and alkalis, organic materials or other deleterious substance.
Potable water is generally preferred. Saltish or brackish water shall not be used. Water
used shall conform to clause 5.4 of IS 456.
4.7.14 Reinforcement steel (including TMT) Bars manufactured by TISCO, SAIL, IISCO and
RASHTRIYA ISPAT (primary manufacturers) conforming to IS: 1786 for deformed and
cold twisted bars shall only be used. The bidders shall, however, be allowed to use
Amba steel, Rathi steel, Kamdhenu steel, Barnala steel, P.R.S steel, Shidbali steel
(manufactured by secondary manufacturers) only after obtaining non-availability
certificate from the primary manufacturers. Before using secondary steel, the selected
bidder would require to conduct all physical & chemical tests (lot wise & dia. wise) to
establish its conformity to IS Standards. Required grade of steel shall be Fe-415. All
reinforcement shall be clean and free from loose mill scale, dust, loose rust and coats
of paint, oil or other coating, which may destroy or reduce bond with concrete.
Reinforcement bars should be fresh. Contractor shall supply, fabricate and place
reinforcement to shapes and dimensions as indicated on the drawings or as required to
carry out the intent of drawings and specifications. Adequate nos. of chairs, spacers of
required size shall be provided to ensure the proper placement of reinforcement. The
reinforcement bars crossing one another should be tied together at every intersection
with two strands of annealed steel wires 0.9 to 1.6 mm thick twisted and tied to make
the skeleton of the steel work rigid so that the reinforcement does not get displaced
during concrete placement.
All the reinforcement steel should be placed/ stacked at site store on raised (at least 0.5
meter from near surroundings) pucca/brick platform or reinforcement steel should be
placed on MS/GI sheets. The reinforcement steel after stacking should be covered with
Tarpaulin to avoid corrosion. Immediately before concreting (portion of reinforcement to
be embedded in concrete) shall be painted with cement slurry after removing any
rust/corrosion/any other foreign material.
4.7.15 No admixtures shall be used.
4.8
4.8.1 The rates of foundation shall be per tower. These rates shall include excavation, stub
setting, concreting, reinforcement, shuttering, shoring/ timbering, stockpiling, dressing,
curing, back filling (after concreting) with good (excavated/borrowed) earth irrespective
of lead. Rates are inclusive of compaction of earth, carriage of surplus earth to suitable
disposal location as required by Employer or any other activity related to completion of
foundation works in all respects.
4.8.2 In case of any change/variation in the foundation drawing(s) attached with bidding
document, due to site conditions or otherwise, the payment shall be made based on
formula given in the commercial clause.
4.9
All excavation shall be protected so as to maintain a clean sub-grade until the footing is
placed, using timbering/shuttering, shoring etc., if necessary. Any sand, mud, silt or
other undesirable materials, which may accumulate in the excavated pit, shall be
removed by the contractor before placing concrete.
4.9.2 No extra charges shall be admissible for the removal of the fallen earth in the pit, when
once excavated.
4.9.3 Wherever ground water table is higher than the base of the foundation, it has to be
depressed by de-watering. During de-watering, water shall be thrown at a place as
directed by the Engineer-in-Charge. No pit/open de-watering shall be permitted.
Instead, over all lowering of the water table shall be done by providing sufficient number
of bores around the tower location and by continuous pumping of water through these
bores. Well point system for de-watering of pits can also be adopted. It must be ensured
that during de-watering/pumping operation, no finer particles of soil get displaced or any
cavity is formed below. The boreholes for de-watering shall be located so as to avoid
any hindrance in normal working for construction of foundation. The construction of
foundation shall be carried out in bone-dry condition, which shall be ensured by effective
lowering of water table so that no caving in happens and also the bottom of the pit is
free from slushy conditions. The bores shall be filled with sand after the work at a
particular location is over.
4.10
SETTING OF STUBS
4.11
The stubs shall be set correctly in accordance with approved method at the exact
location and aligned precisely at correct levels with the help of stub setting templates
and leveling instruments. Stubs shall be set in the presence of Employers
representative for which the Contractor shall give adequate advance intimation to the
Employer. All necessary precautions should be taken to ensure that the stubs finally set
in are not disturbed. If these are disturbed due to any reason, the bidder shall reset the
same without any extra cost.
STUB SETTING TEMPLATES
For all types of towers viz. with or without extension and also for leg extensions, the
contractor at his own cost shall arrange the stub-setting templates. Stub templates for
standard towers and towers with extension shall be painted. Normally, for each
transmission line tower package, sufficient numbers of stub templates should be
deployed. However, if the Employer feels that more number of templates are required
for timely completion of a particular line, the contractor shall have to deploy the same
without any extra cost to the Employer.
After completion of the project, one set of each type of stub setting template as
applicable shall be supplied to the Employer at no extra cost to the Employer.
4.12
4.12.1 The concrete shall be mixed in a mechanical mixer. The mixer shall comply with IS:
1791 & IS: 12119. The mixer shall be fitted with water measuring devices. Mixer without
trough should not be brought at site. In case of difficult terrain, the Employer at his
discretion may permit hand mixing but this should not be made a routine. In case of
hand mixing, 10% extra cement shall be used without any extra cost.
4.12.2Mixing shall be continued until there is uniform distribution of material and the mix
become uniform in colour and consistency. If there is segregation after unloading from
mixer, the concrete should be re-mixed, but in no case the mixing be done for less than
two minutes. Normally, mixing shall be done close to the foundation, but in case it is not
possible the concrete may be mixed at a nearest convenient place. From mixer the
concrete shall be put on pucca platform or steel troughs, which shall be leak proof to
avoid any loss of water/slurry.
The concrete shall be transported from the place of mixing to the place of final deposit
as rapidly as practicable by methods, which will prevent the segregation or loss of any
ingredient. The concrete shall be placed and compacted before setting commences.
4.12.3 Form boxes of required size as per approved Mix Design volumes shall be used for
casting all type of foundations. Form boxes shall be rigidly tightened so that there are
no distortions in the shape of foundations. Form boxes shall be made sufficiently strong
to withstand all the loads and vibrations. For bottom pad portion sufficiently wide window
of minimum size 450 x 300 mm be left on each side at top for placing of concrete and
for use of vibrators to ensure thorough compaction. After every use, the form box(es)
be checked for any deformation and if necessary be repaired/corrected to original
position for reuse.
4.12.4 On removal of the form-work, if the concrete surface is found damaged, it shall be
repaired with rich cement sand mortar to the satisfaction of the Engineer-in-Charge. The
foundation pits be back-filled only after necessary repairs, if any as required above has
been done.
4.13
4.13.1 The formwork shall be removed after 24 hours (minimum). Due care shall be taken not
to injure the concrete by excessive striking the formwork. In case the Portland
Pozzolona cement has been used, the removal of formwork shall be delayed suitably
as directed by the Engineer-in-charge.
4.13.2 After opening of formwork and removal of shoring and timbering, backfilling shall be
started, after repairs, if any, to the foundation concrete as described under para 4.12.4
above. Backfilling shall normally be done with excavated soil. In case the excavated soil
consists of large boulders/stones, it should be broken to a maximum size of 80 mm. If
the excavated earth has harmful salts, it shall not, under any circumstance, be used for
backfilling. In such case excavated earth shall be disposed off as directed by the
Engineer-in-Charge and suitable earth (clean and free from harmful salts, organic and
other foreign materials) be brought for back filling. This shall be done by the contractor
at his own cost irrespective of lead involved for bringing the suitable earth.
4.13.3 The earth shall be deposited in layers (maximum 200 mm layers), leveled and wetted
and tampered properly before another layer is deposited. After the pits have been
backfilled to full depth, the stub template may be removed.
4.13.4 The backfilling and final grading shall be carried upto an elevation of about 75 mm above
the finished ground level to drain out water. After backfilling 50 mm high earthen
embankment (bandh) will be made along the side of excavation pits and sufficient water
will be poured in the backfilled.
4.14
CURING
Curing shall start after 24 hours of concreting to keep the concrete wet continuously for
a period of 10 days. However, after a minimum period of 72 hours the pit may be
backfilled with suitable earth sprinkled with necessary amount of water and well
consolidated in layers not exceeding 200mm. Both backfilled earth and exposed
chimney top shall be kept wet for the remainder of the prescribed time of 10 days. The
uncovered concrete chimney above the backfilled earth shall be kept wet by providing
gunny bags dipped in water fully wrapped around the concrete chimney for curing. It
must be ensured that the bags are kept wet by the frequent pouring of water on them.
In case Portland Pozolona cement has been used, curing period shall be increased as
decided by the Engineer-in-charge.
4.15
4.15.1 The work shall include all necessary brick/stone masonry (in C.M. 1:4) revetments,
earth filling above ground level and the clearance from stacking on the site of surplus
excavated soil. Special measures for protection of foundation wherever required shall
be provided after getting prior approval of the Employer and as per directions of the
Engineer-in-Charge.
4.15.2 The excess quantity of earth required for protection of tower (after utilizing the excavated earth)
and to be brought from outside shall be paid as per the rate provided in the letter of award.
4.15.3 The provisional quantities for foundation protection works are furnished in the Schedule
of Quantities as well as in the Price Schedule. The unit rates shall be applicable for
adjusting with the actual quantities of protection work done.
4.16
4.17
Technical Specification given in the Contract will govern for the different items/activities.
The items/activities for which detailed specifications have not been given in the Contract
Agreement will be governed by latest ISI/ NBC specifications.
4.18
Wherever IS Code has been mentioned, it shall mean IS Code with latest amendments.
Supply part
BOQ of LILO of both circuits of existing 220kv Palla to Palli D/C line at proposed 220kV S/Stn. sector-46
Faridabad on M/C towers by using ROW of existing 66kV D/C NH-3- Palla line, presently feeding the 66kV
S/Stn. sector-46 (partially on M/C monopole to be newly designed)
Qty.
UNIT
A
220kV line on 220kV D/CTATA Design towers
1.1
1.2
No.
No.
No.
No.
1.3
B
220kV line on 220kV KRR Design M/C towers
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers, D-shakle etc.
of following type of 220kV Multi-circuit ( 4 Ckts.) towers of KRR design.
1.1
No.
1.2
No.
1
No.
Design & type testing, Fabrication and supply of following types of monopole with stubs, bolts & nuts,
step bolts, U-bolts, hangers, D-shakle etc.
i) 220kV M/C A type Monopole
No.
No.
No.
No.
2.
3.
18
Sets
--
Sets
No.
18
No.
18
Sets
36
Sets
28
Sets
20
Sets
18
LINE MATERIAL
Km
27.37
Earth wire
KM
0.150
Km
0.662
Hardware set for above 24 Fibre OPGW fibre optic cabling including
all cable fittings & accessories except joint box.
set
2
9
No.
10
Lot
Lot
11
Km
1.648
12
set
3
13
No.
14
Km.
15
set
16
FODP 48F: Indoor type, rack mounted with FCPC coupling and pig tails (
5mtrs. Each) as applicable
No.
17
FODP 96F: Indoor type, rack mounted with FCPC coupling and pig tails (
5mtrs. Each) as applicable
18
2
2
1
No.
No.
84
ii) 120 kN
No.
240
19
sets
NIL
20
Hardware Fittings
Set
60
Set
24
Set
240
Set
No.
19
No.
NIL
No.
No.
18
v)
No.
552
No.
No.
28
No.
NIL
No.
12
v)
vi)
vii)
viii)
As per site
No.
220kV D/C DC type Tower
No.
66kV D/C DA type Tower
No.
66kV D/C DD type Tower
No.
66kV Gantry
No.
ii) Dismantlement of existing of 0.4sq ACSR Zebra conductor complete
with H/W fittings for above portion of line and their transportation
proper stacking at any dedicated store of HVPNL.
Note:- Type testing to be got done or waived off as per relevant clause of monopoles.
Km
1.504
BOQ of LILO of both circuit of 66kV BBMB Ballabgarh-Jharsetly D/C line at 220kV S/Stn. Sector-58, Faridabad with 0.4sq
ACSR Zebra.
Qty.
DESCRIPTION
UNIT
B)
66kV KRR Design Towers
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, Ubolts, hangers, D-shakle etc. of following type of 66kV KRR Design D/C towers.
1
ii)
No.
ii)
No.
Sets
Sets
i) Danger Plate
No.
No.
Sets
Sets
Sets
Sets
B)
LINE MATERIAL
Km
0.485
Km
0.081
Nil
No.
48
No.
Nil
Hardware Fittings
v.
vi.
vii.
viii.
Set
Set
Set
48
Set
10
i)
No.
Nil
ii)
No.
Nil
iii)
No.
Nil
No.
v)
No.
96
No.
16
No.
No.
No.
12
Note:- The Bidder shall offer only one of the option for the Insulator strings ( A/F disc or Polymer) out of the two mentioned
above in his bid.
Bill of Quantity of LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV S/Stn.A4 at 66kv
S/Stn.Idgah with 1200mm2 XPLE underground cable.
Sr. No.
Description
Unit
Total Quantity
13.
Mtrs.
2465x8
14.
No.
16
15.
No.
16.
No
No
18.
Mtrs
300
19.
No.
20.
No.
16
21.
Supply of HDPE pipes required for various crossings with trench less
Mtr.
227x8
22.
No.
32
4 Pole Rail pole structure for the LILO arrangement and foundation
No.
Nil
Any other items not specified above but are required to complete
the job in all respect.
No.
Lot
23.
24.
Note:-
4. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
5. The said work may involve the route through residential area for which Trench-less digging shall be got
done as per Technical specification.
6. The route length / Quantities of 66kV line shown above is tentative & may vary.
Bill of Quantity of LILO of one ckt. of 66kV D/C line from 220kV S/Stn. A5 to 66kV S/Stn. A4 at 66kv
S/Stn.Idgah with 1200mm2 XPLE underground cable.
Sr.
No.
Description
Unit
Quantity
Running
circuit
2238
Running
circuit
Nos.
Nos.
16
13. Installation of polymericLAs along with their earthling. With surge counter
Nos.
Lot
Lot
15. Erection of 4 Pole Rail pole structure for the LILO arrangement and their
Foundations including earthing (if required as per site).
No.
Nil
16. Any other items not specified above but are required to complete the job
in all respect.
Lot
Lot
Note:-
Length
(6+2)
Mtrs.
227
Length
(6+2)
Mtrs.
4. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalising / submitting the bids.
5. The said work may involve the route through residential area for which Trench-less digging shall be got
done as per Technical specification.
6. The route length / Quantities of 66kV line shown above is tentative &may vary.
BOQ of LILO of one ckt. of 66kV Ballabgarh (220kV BBMB)-Sector-58 D/C line (Section of 66kV Ballabgarh
(220kV BBMB) sector-58 Faridabad-jharsetly D/C line) at 66kV S/Stn. sector-59 Faridabad with 1200mm2
XLPE cable and tower portion.
Sr. No.
Description
Unit
Total Quantity
13.
Mtrs.
2400x8
14.
No.
16
15.
No.
16.
No
No
18.
Mtrs
300
19.
No.
20.
No.
16
21.
Supply of HDPE pipes required for various crossings with trench less
Mtr.
92x8
22.
No.
32
4 Pole Rail pole structure for the LILO arrangement and foundation
(if required as per site)
No.
Nil
Any other items not specified above but are required to complete
the job in all respect.
No.
Lot
23.
24.
13
66kV KRR Design DD+0 type tower complete in all respect including
earthing and fencing
No.
Note:-
4. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalising / submitting the bids.
5. The said work may involve the route through residential area for which Trench-less digging shall be got
done as per Technical specification.
6. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of LILO of one ckt. of 66kV Ballabgarh (220kV BBMB)-Sector-58 D/C line (Section of 66kV
Ballabgarh (220kV BBMB) sector-58 Faridabad-jharsetly D/C line) at 66kV S/Stn. sector-59
Faridabadwith 1200mm2 XLPE cable and tower protion.
Sr.
No.
Description
Unit
Quantity
Running
circuit
2308
Running
circuit
Nos.
Nos.
16
Nos.
Lot
Lot
16. Erection of 4 Pole Rail pole structure for the LILO arrangement and their
Foundations including earthing (if required as per site).
No.
Nil
No.
Length
(6+2)
Mtrs.
92
Length
(6+2)
Mtrs.
18. Any other items not specified above but are required to complete the
job in all respect.
Lot
Lot
Note:-
4. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
5. The said work may involve the route through residential area for which Trench-less digging shall be got
done as per Technical specification.
6. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of creation of LILO of both circuit of the existing 220kV D/C FGPP-BBMB Samaypur
(PGCIL line) at 220kV S/Stn. Sector-58, Faridabad on M/C towers, M/C Monopole and D/C
towers (partially on M/C monopole)
Tentative M/C Length: 1.165kms. approx.
Tentative D/C Length: 0.511 kms. approx.
(Supply portion only)
Sr. No.
A
DESCRIPTION
UNIT
Qty.
1.1
Fabrication and supply of tower part with stubs, bolts & nuts, step
bolts, U-bolts, hangers, D-shakle etc. of following type of Towers
as per TATA design.
1.2
No.
No.
No.
1.1
No.
1.
Design and type testing Fabrication and supply of following types of monopole with stubs,
bolts & nuts, step bolts, U-bolts, hangers, D-shackle etc.
i) 220kV M/C A type Monopole
No.
No.
3.
2
No.
i) Pipe type
Sets
12
Sets
i) Danger Plate
No.
12
No.
12
Sets
40
Sets
48
Sets
Sets
12
LINE MATERIAL
Km
17.22
Km
0.10
Km
0.516
Hardware set for above 24 Fiber OPGW fiber optic cabling including
all cable fittings & accessories except joint box.
set
No.
Lot
Lot
Km
1.177
Hardware set for above 48 Fiber OPGW fiber optic cabling including
all cable fittings & accessories except joint box.(as per
requirement)
set
No.
10
Km.
11
set
12
FODP 48F: Indoor type, rack mounted with FCPC coupling and pig
tails ( 5mtrs. Each) as applicable
No.
13
FODP 96F: Indoor type, rack mounted with FCPC coupling and pig
tails ( 5mtrs. Each) as applicable
14
No.
i) 70 kN
No.
42
ii) 120 kN
No.
216
15
sets
NIL
16
Hardware Fittings
Set
24
Set
18
Set
216
Set
No.
12
No.
No.
No.
12
v)
No.
456
v)
vi)
vii)
viii)
17
conductor
vi)
No.
38
vii)
No.
22
No.
Km
1.5
Note:- Type test to be got done or waived off as per relevant clause of monopoles.
BOQ of 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn.Bhagolawith 0.4sq ACSR Zebra. (Cable
portion)
Sr. No.
Description
Unit
Total Quantity
25.
Mtrs.
1350x8
26.
No.
16
27.
No.
28.
No
No
30.
Mtrs
200
31.
No.
32.
No.
16
33.
Mtr.
Nil
34.
No.
Nil
No.
Nil
No.
Lot
35.
36.
Note:-
7. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
8. The said work may involves the route through residential area for which Trench-less digging shall be
got done as per Technical specification.
9. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn.Bhagolawith 0.4sq ACSR Zebra. (Cable
portion)
Sr.
No.
Description
Unit
Quantity
Running
circuit
1350
Length
(6+2) Mtrs.
Running
circuit
nil
Length
(6+2) Mtrs.
Nos.
Nos.
16
Nos.
Lot
Lot
23. Erection of 4 Pole Rail pole structure for the LILO arrangement and
their Foundations including earthing (if required as per site
conditions).
No.
Nil
24. Any other items not specified above but are required to complete
the job in all respect.
Lot
Lot
Note:-
4. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
5. The said work may involves the route through residential area for which Trench-less digging shall be
got done as per Technical specification.
6. The route length / Quantities of 66kV line shown above is tentative & may vary.
S.No
Qty.
DESCRIPTION
UNIT
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers, Dshakle etc. of following type of KRR Design D/C towers.
1.1
i) DE type 66kV Tower (KRR Design)
No.
No.
No.
No.
No.
No.
No.
No.
No.
No.
31
6
1.2
1.3
9
5
1.4
14
2
1.5
1.6
1.7
2.
3.
Sets
63
Sets
i) Danger Plate
No.
63
No.
63
Sets
64
Sets
63
Sets
63
Sets
63
5.
6.
Km
khera
km
Km
42.61
39.50
13.69
i) 70 kN
No.
ii) 120 kN
192
No.
420
8.
Hardware Fittings
v.
No.
36
Set
186
Set
Set
396
Set
12
No.
55
ii)
No.
iii)
No.
17
No.
63
v)
No.
1138
No.
190
No.
66
No.
31
No.
NIL
Note:The Bidder shall offer only one of the option for the Insulator strings (A/F disc or Polymer) out of the two
mentioned above in his bid.
BOQ of 66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 0.4sq ACSR Zebra (Tower portion).
Qty.
DESCRIPTION
UNIT
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers, Dshakle etc. of following type of KRR Design D/C towers.
1.1
66kV DE type tower (KRR Design)
No.
No.
No.
No.
No.
1.2
6
2
1.3
1.4
1.5
2.
3.
No.
Set
No.
No.
i) Pipe type
Sets
23
Sets
i) Danger Plate
No.
23
No.
23
Sets
36
Sets
23
Sets
10
Sets
23
Km
29.66
5.
Km
4.94
6.
No.
42
No.
240
Set
30
Set
12
Set
.228
Set
12
i) 70 kN
ii) 120 kN
8.
Hardware Fittings
(e)
(f)
(g)
(h)
No.
20
ii)
No.
No.
No.
23
v)
No.
492
No.
82
No.
38
No.
Note:- The Bidder shall offer only one of the option for the Insulator strings ( A/F disc or Polymer) out of the
two mentioned above in his bid.
BOQ of 66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrolawith 0.4sq ACSR Zebra
(Cable portion).
Sr. No.
Description
Unit
Total Quantity
37.
Mtrs.
705x8
38.
No.
16
39.
No.
40.
No
No
42.
Mtrs
200
43.
No.
44.
No.
16
45.
Mtr.
100x8
46.
No.
Nil
No.
Nil
No.
Lot
47.
48.
Note:-
10. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
11. The said work may involves the route through residential area for which Trench-less digging shall be
got done as per Technical specification.
12. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of 66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 0.4sq ACSR Zebra
(Cable portion).
Sr.
No.
Description
Unit
Quantity
Running
circuit
605
Length
(6+2) Mtrs.
Running
circuit
100
Length
(6+2) Mtrs.
Nos.
Nos.
16
Nos.
Lot
Lot
31. Erection of 4 Pole Rail pole structure for the LILO arrangement and
their Foundations including earthing (if required as per site
conditions)..
No.
Nil
32. Any other items not specified above but are required to complete
the job in all respect.
Lot
Lot
Note:-
4. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
5. The said work may involves the route through residential area for which Trench-less digging shall be
got done as per Technical specification.
6. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of re-alignment of 66kV D/C overhead line from 66kv S/Stn. A-5 Faridabad to 66kV S/Stn.Fatehpur
Biloch from TL No. 15 to 38 by partially 8x1C x1200 sq mm XLPE cable and partially by overhead line on
KRR type tower with 0.4sq ACSR conductor as a deposit work of HSIIDC.
(Cable portion)
(Supply Portion only)
Sr. No.
Description
Unit
Total Quantity
66kV 1200 mm2 Single Core Aluminium Conductor Milliken type , XLPE
insulated Cable as per technical specification
Mtrs.
9800
No.
No.
2.
Already procured
48
Already procured
8
Already procured
No
No
12
Mtrs
1200
No.
36
LOT
LOT
Mtr.
800m
10
4 Pole Rail pole structure for the LILO arrangement (if required) along
with its fencing arrangement (if required as per site conditions)..
No.
NIL
11
Any other items not specified above but are required to complete the
job in all respect.
Lot
Lot
Note:-
4. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
5. The said work may involve the route through residential/ industrial area for which Trench-less
digging shall be got done as per Technical specification.
6. The route length / Quantities of 66kV line shown above is tentative & may vary.
BOQ of re-alignment of 66kV D/C overhead line from 66kv S/Stn. A-5 Faridabad to 66kV S/Stn. Fatehpur
Biloch from TL No. 15 to 38 by partially 8x1C x1200 sq mm XLPE cable and partially by overhead line on
KRR type tower with 0.4sq ACSR conductor as a deposit work of HSIIDC.
(Cable portion)
(Erection Portion only)
Sr.
No.
Description
Unit
Quantity
1.
Running
circuit
1100
Running
circuit
Nos.
NIL
Nos.
48
Nos.
18
Lot
Lot
No.
NIL
Any other items not specified above but are required to complete the
job in all respect.
Lot
Lot
Length
(6+2)
Mtrs.
100
Length
(6+2)
Mtrs.
Note:4. It is specific for all the bidders to visit the office of SE/ TS, Faridabad to see the site constraints before
finalizing / submitting the bids.
5. The said work may involve the route through residential/industrial area for which Trench-less
digging shall be got done as per Technical specification.
6. The route length / Quantities of 66kV line shown above is tentative & may vary.
S.No
DESCRIPTION
UNIT
Qty.
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers,
D-shackle etc. of following type of KRR 66kV D/C towers.
1.1
D/C E type 66kV Tower (KRR Design)
No.
No.
No.
No.
No.
No.
1.2
1
1
1.3
2.
12
1
3
Sets
21
Sets
i) Danger Plate
No.
21
No.
21
Sets
26
Sets
21
Sets
16
Sets
21
Km
24.05
5.
Km
4.01
3.
6.
8.
Hardware Fittings
v.
vi.
vii.
viii.
No.
57
No.
168
No.
Set
48
Set
Set
168
Set
No.
16
ii)
No.
No.
No.
21
v)
No.
408
No.
68
No.
26
No.
10
As per site
No.
66kV D/C DB type Tower
No.
66kV D/C DC type Tower
No.
66kV Gantry
No.
ii) Dismantlement of existing of 0.2sq ACSR Panther conductor complete
with H/W fittings for above portion of line and their transportation
proper stacking at any dedicated store of HVPNL.
Km
16.5
KM
2.75
*The Bidder shall offer only one of the option for the Insulator strings ( A/F disc or Polymer) out of the two
mentioned above in his bid.
SECTION-VI
TECHNICAL SPECIFICAION
FOR
Chief Engineer/MM,
Haryana Vidyut Prasaran Nigam Limited
Shakti Bhawan, Sector-6
Panchkula-134109
Ph:0172-2583724
Fax: 0172- 2583724
January - 2015
CONTENTS
S. No.
PARTICULARS
Page No.
1-4
1-12
1-16
1-71
1-14
1-6
1-17
(PART-III A)
8
1-15
1-15
10
1-5
11
Hardware Fittings for lines with ACSR ZEBRA and Accessories for lines
with ACSR ZEBRA Conductor
1-41
12
1-14
13
1-12
14
1-19
15
1-14
Annexure-1
1.
1.1
i)
The following 66 kV transmission line is included in the scope of the bidder for this package.
Sr. No.
1.
Name of line
66kV connectivity between 66kv S/Stn. Sec-9, Gurgaon and 66kv S/Stn. Sec10A, Gurgaon by laying of four Nos. 1200mm2 underground XLPE cable
(including tower portion).
ii)
Detailed survey/ check survey of route, manufacture, testing before dispatch, delivery
FOR destination of 66 KV XLPE Power cable of size 1200mm2, laying, complete
installation, testing and commissioning of the cable as per BOQ and technical
specifications (cable portion of length 2.2km S/C four cables).
iii)
Detailed survey, profiling & check survey, tower spotting/optimization of tower location,
soil resistivity measurements and Geotechnical investigation, fabrication and supply of
all type of 66 kV D/C transmission line towers as per KRR design including bolts, nuts
and washers, hanger, D-shackle and all type of tower accessories like phase plate,
circuit plate, number plate, danger plate, anti-climbing device etc., selecting type of
foundation for different tower heights and casting of foundation for tower footing,
providing of tower footing protection, erection of towers, tack welding of bolts and nuts
including supply and application of zinc rich paint, tower earthing, fixing of insulator
string, stringing of conductors and earthwires alongwith all necessary line accessories
and testing and commissioning of the erected transmission lines as per BOQ and
technical specifications (Tower portion of length 0.070km for tower).
Page-1
Bill of Quantity of 66kV connectivity between 66kv S/Stn. Sec-9, Gurgaon and 66kv S/Stn. Sec-10A Gurgaon by
laying of four Nos. 1200mm2 underground XLPE cable (cable portion).
Sr. No.
Description
Unit
Total Quantity
1.
Mtrs.
2200x4
2.
No.
3.
No.
4.
No
5.
No
6.
Mtrs
400
7.
No.
8.
No.
9.
Mtr.
2000x4
10.
No.
Lot
Lot
11.
Note:-
1. It is specific for all the bidders to visit the office of SE/ TS, Gurgaon to see the site constraints before
finalising / submitting the bids.
2. The said work may involve the route through residential area concerned area or along the road for which
Trench-less digging shall be got done as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
Page-2
Bill of Quantity of 66kV connectivity between 66kv S/Stn. Sec-9, Gurgaon and 66kv S/Stn. Sec-10A Gurgaon by
laying of four Nos. 1200mm2 underground XLPE cable.
Sr.
No.
Description
Unit
1.
Running
circuit
Running
circuit
Length
Quantity
200
(3+1)
Mtrs.
Length
2000
(3+1)
Mtrs.
Nos.
Nos.
Nos.
No.
Lot
Lot
Any other items not specified above but are required to complete the job
in all respect. ( Break-up to be specified by the bidder)
Lot
Lot
Note:1. It is specific for all the bidders to visit the office of SE/ TS, Gurgaon to see the site constraints before
finalising / submitting the bids.
2. The said work involves the route through residential area for which Trench-less digging shall be got done
as per Technical specification.
3. The route length / Quantities of 66kV line shown above is tentative & may vary.
Page-3
Bill of Quantity of 66kV connectivity between 66kv S/Stn. Sec-9 and 66kv S/Stn. Sec-10A Gurgaon by laying of four
Nos. 1200mm2 underground XLPE cable (Tower portion).
S.No
Qty.
DESCRIPTION
UNIT
Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers,
D-shakle etc. of following type of 66kV KRR Design D/C towers.
1.
2.
No.
Set
1
1
Sets
Sets
i) Danger Plate
No.
No.
Sets
Sets
Sets
Sets
Km
0.21
5.
Km
0.070
6.
No.
ii) 120 kN
No.
No.
3.
8.
Hardware Fittings
i.
ii.
iii.
iv.
Set
Set
Set
Set
No.
ii)
No.
No.
No.
v)
No.
12
No.
No.
No.
No.
Note:- The Bidder shall offer only one of the option for the Insulator strings ( A/F disc or Polymer) out of the two
mentioned above in his bid.
Page-4
SCOPE
1.3
This specification includes manufacture, testing before dispatch and delivery FOR destination of 66 KV
XLPE Power cable of size 1200mm2 as per BOQ conforming to IS-7098.
Sr.
No.
Name of line
66kV connectivity between 66kv S/Stn. Sec-9, Gurgaon and 66kv S/Stn. Sec-10A Gurgaon by
laying of four Nos. 1200mm2 underground XLPE cable (cable portion)
2.0
STANDARDS:
2.1
Unless otherwise stated hereafter, rating, characteristics, test and procedures etc. concerning the 66kV
XLPE cable shall be preferably as per IS, IEC standards given below and shall be in compliance with the
latest edition or revisions thereof and meeting the constructional details and testing requirement as
stipulated in foregoing also.
IEC-60228
IEC-60229
IEC-60230
IEC-60270
IEC-60287-1-1
IEC-60502
IEC- 60840
Power Cables with extruded insulation and their accessories for rated
voltage above 30 kV upto 150 KV.
IEC-62067
Tests for power cables with extruded insulation for rated voltage
above 150 kV upto 500 kV.
IEEE:48
2.2
The 66 KV XLPE cable may conform to any other authorities standards, which ensures an equal or better
quality than the standard mentioned above. The bidder must specifically indicate the standards to which
the cable conforms and indicate all deviations (if any) from the preferred IS/ IEC codes that affect
performance and rating.
Page-1
2.4
Compliance of the 66 kV XLPE cable manufactured with the provisions of this specification does not
relieve him of the responsibility of furnishing 66 kV XLPE cable and accessories of proper design,
electrically and mechanically suited to meet the operating guarantees at the specified service
conditions.
2.4
If there are, in the opinion of the bidder, any conflicts between these codes and this specification, these
contradictions shall be brought to the attention of the owner.
3.0
The XLPE Power cable shall be suitable for continuous & satisfactory operation under following
conditions:-
3.1
3.2
Climatic Conditions:-
i)
50oC
ii)
40oC.
iii)
(-) 5 oC.
iv)
55 oC
v)
100%
vi)
10%
vii)
40
viii)
100
ix)
10 to 100 cm
x)
4 months
xi)
100 kg/Sq.mm
xii)
1000 M
Conditions of Laying:-
i)
ii)
iii)
iv
3.3
Ground Temp.
35o C
ii)
90o C
iii)
Air temperature
50o C
iv)
Depth of trench
1.5 m.
v)
Formation
vi)
vii)
viii)
Page-2
4.0
4.1
Single Core XLPE cable suitable for 66 KV nominal system shall have construction as under:
The cable shall be made of Segmental type (Milliken as per table2 of IEC:60228) for size of 1200mm2 of
66kV, electrolytic grade Aluminium tapped with semi conducting tape. Conductor screening shall be
with extruded semi conducting thermosetting compound layer. The cable shall be insulated with
completely dry cured XLPE insulation; Insulation screening for non-metallic part shall be with extruded
semi-conducting thermosetting compound layer. Taping with semi conducting water swellable tape
shall be provided for longitudinal water sealing. Screening for metallic part shall be with corrugated
Aluminum or Lead Alloy E sheathed in combination with bedding of semi-conducting tape(s) followed
by annealed copper wires screen and taped with open helix copper tape binder, if required followed by
suitable non-metallic tape binder and overall extruded black, PE or PVC sheath with outer conductive
coating. Power cable shall conform to the IS 7098(Part-III)/ IEC and foregoing paras of this specification.
4.2. The covering shall be watertight, electrically insulated, rodent proof and vermin proof.
4.3
The offered XLPE cable for 66 KV earthed system shall meet the technical particulars indicated in
Annexure-I
4.4
The XLPE Cable shall be suitable for use where combined ambient temperature and temperature rise
due to load result in conductor temperature not exceeding 90 Deg C under normal operation and 250
Deg C under short circuit conditions.
4.5
Offered XLPE cable end termination as well as jointing kits shall be of rated short circuit current of 31.5
kA for duration of 1 second for 66 kV system.
4.6
The XLPE cables shall be designed to withstand the mechanical, electrical and thermal stresses under
the steady state and transient / fault conditions and shall be suitable for proposed method of
installation.
4.7
The cable shall be suitable for underground buried installation with incorporated back fill and some of
areas to be flooded by water in rainy season.
4.8
The sheath voltage under full load conditions shall not exceed the voltage specified / allowed in relevant
standards for safety of personal as well satisfactory working of cable. Sheath shall be solidly grounded
at suitable locations with/without SVL. Bidder must indicate details of configuration proposed alongwith
sufficiency calculation with the bid so as to limit induced voltage of sheath within 65V and the same
shall be got approved from HVPNL in first instance after award of contract.
4.9
The XLPE cable shall be capable of withstanding the normal stress associated with transportation,
erection, reeling and unreeling operations without getting deformed.
4.10 The XLPE cable shall be used on System Voltage of 66 KV for 3-phase AC earthed system. The cables
shall be suitable for continuous operation at a power frequency voltage 10% higher than system voltage.
Page-3
5.0
5.1
Conductor:
5.1.1The Milliken segmental type shall be made of Aluminium complying to the requirements of flexibility
Class-2 of IEC-60228 / IS: 8130. The conductor shall have high compactness & smooth surface finish.
5.1.2 The minimum number of wires in conductor and D.C. resistance shall be as per table-II of IEC-60228 /
IS: 8130. The grade and quality of the Aluminium used for the conductor shall be as per IEC/IS standard.
5.1.3 The material & nominal area of conductor shall be as per BOQ.
5.2
Conductor Screen:
5.2.1
The conductor screen consisting of semi conducting compound layer shall be provided over the
conductor by extrusion which will not only eliminate the risk of electric discharge at the interface
between conductor and insulation but will also present a very smooth protrusion free interface with
the insulation to eliminate any localized stress concentration. The screen shall be firmly bonded to
XLPE insulation.
5.2.2
The minimum thickness of extruded conductor screen shall be 1.0 mm. The outer surface of the
conductor screen shall be circular and free from irregularities. A non-hygroscopic semi-conducting
tape, if required, shall be applied to the conductor under extruded layer to prevent penetration of
compound in to the conductor interstices.
5.3
Insulation:-
5.3.1
The insulation composed of a special super clean grade layer of cross linked polyethylene (XLPE) shall
comply with the requirement of IS-7098(Part-III)/ IEC. The insulation shall be applied by extrusion
over the conductor screen and vulcanized using dry curing process to form a compact homogeneous
body free from micro voids and contaminants.
5.4
Insulation Screening:
5.4.1
The insulation screening shall consist of two parts, namely, non-metallic and metallic.
5.4.2
5.4.2.1 A non-metallic insulation screen of semi-conducting compound similar to conductor screen (clause 5.2)
for similar purpose shall be applied directly over the insulation core by extrusion and shall be
continuous and cover whole surface area of insulation. It shall be firmly bonded to the insulation.
Page-4
5.4.2.2
5.4.3
5.4.3.1
The minimum thickness of extruded insulation screen layer shall be 0.8 mm, the ovality of the
core shall be not more than 5%.
5.4.3.2
The semi conducting compound and the semi conducting tape shall be compatible with the
insulating material and suitable for the operating temperature of the cable.
5.4.4
The metallic sheath of Aluminium sheath or Lead alloy E shall be provided over the non-metallic
part of the insulation screening. Metallic sheath, together with copper screen (if required) shall
be able to withstand short circuit current of 31.5 kA for duration of 1 second for 66 kV system.
The details of metallic sheaths are as under:
5.4.4.1
i)
The lead alloy sheath shall have composition as per IS: 692. The lead alloy E Sheath shall be
extruded using a continuous screw press and shall be free from all extrusion defects. The
nominal thickness of lead alloy E sheath shall be as per IEC-60502-2 / IS: 7098 (Part-3).
Copper wire screen of annealed plain copper wires with gap shall be Helically applied over the
Radial Water Barrier lead alloy metallic sheath.
ii)
An open helix copper tape binder shall be applied over the copper wire screen. The nominal
thickness of the tape shall not be less than 0.1 mm. The minimum thickness shall not fall below
the nominal value by more than 10%. Suitable non-metallic binder tape may also be applied
over the copper screen to prevent the penetration of the outer sheath in to the screen.
5.4.4.2
ii)
ii)
When the corrugated aluminium sheath is used, it shall be applied by extrusion/seamweld and then passing through a corrugating head. The corrugating head contains
rotating dies to form the valleys between the ribs like sine wave and produce to
correct diameter of sheath to fit over the insulation. The sheath shall be free from
pinholes flaws and other imperfections.
Anti-corrosive compound shall be applied over the aluminium sheath.
Page-5
5.5
Outer Sheath:-
5.5.1
The outer sheath shall consist of an extruded layer of black, PE or PVC type ST-2 as per
IEC/IS-7098 (Part-3)
5.5.2
The nominal thickness of outer sheath shall not be less than the value calculated as per the
recommendation of IEC 60502-2/IS-7098 (Part-3). The outer sheath shall be of sufficient
hardness to discourage termite and rodent attack.
5.5.3
The outer conductive layer shall be of Graphite coating applied at works. This conductive layer / coating must facilitate testing of
the non-metallic outer sheath. This test is important to ensure the physical integrity of the cable from time to time be it at the
factory, after transportation, directly after laying upon completion of the installation.
7.0
6.1
The cable jointing accessories shall include the end terminating kits, straight through joints.
These shall be CLASS-I as defined in IEEE STANDARD-48 rated for 31.5KA for 66 kV system. The
sheath voltage under full load conditions shall not exceed 65V specified / allowed in relevant
standards for safety of personal as well satisfactory working of cable. The sheath shall be solidly
grounded.
6.2
The cable terminations shall be fire resistant. The components of kits shall have flame retardant
property.
6.3
All the cable sealing end/end termination kits and straight through joints shall be Premoulded/Cold Shrinkable /Heat shrinkable type complete with accessories from reputed
manufacturer of proven design which has already been extensively used and fully type tested.
The make of termination kits and straight through joints shall be got approved from HVPNL
before bringing in use.
6.4
The joint shall preferably be built up from the same material as the main cable and shall have
electrical and mechanical withstand capabilities same as or better than the main cable. The
joints shall be suitable for tropical climatic conditions. The straight through joints shall be
suitable for underground buried installation with incorporated back fill and chances of flooding
by water. The straight through joints should be absolutely impervious to the entry of water. The
manufacturer shall use the proven technology and design to prevent entry of water or any other
liquid inside the straight through joints and cables.
6.5
The end termination shall be outdoor Pre-moulded/Cold Shrinkable/Heat shrinkable type with
accessories. The outdoor terminal should be suitable for heavily polluted atmospheric
conditions and protected creepage distance of not more than 50% of the total creepage
distance. The cable end terminals for terminating the cables shall be fully compatible with the
cables to be supplied. Field tests of sealing end terminals shall be made in conjunction with the
cables after installation of the cables and terminals.
6.6
The testing of cable termination, sealing ends and straight through joints shall be as per IEC60840. All the type tests, sample tests and routine tests shall be as per IEC-60840.
Page-6
6.7
The cable termination and straight through joints shall bear guarantee for five (5) years from
the date of commissioning. Any defect noticed in the kit shall be attended by the bidder
immediately but not later than 24 hours on getting the complaints and if required shall be
replaced and installed free of cost, otherwise the same will be arranged at the bidders risk and
cost.
7.0
MANUFACTURING PROCESS:
7.1
XLPE cable should be processed in a modern triple head extrusion manufacturing line. XLPE
extrusion and curing through Vertical Catanery Vulcanisation system (VCV) or horizontal
MDCV or CCV will be used to ensure circularity and concentricity of the extruded layers around
the conductor.
7.2
The conductor screen, insulation and insulation screen shall be extruded in one simultaneous
triple extrusion process (Clause 14.2.1 of IS: 7098-3) through common triple crosshead. The
extruders and triple crosshead shall be designed to prevent stagnation of materials to eliminate
hot spots and ensure smoothness of the conductor screen and screen surfaces. Insulation
thickness should be controlled on-line using X-ray monitoring system.
7.3
The cross linking, curing and cooling shall be carried out in one operation and shall be a dry
curing process under high pressure to eliminate the formation of voids in the insulation and
contaminations in the dielectric.
7.4
Process conditions such as curing and cooling temperature, production speed etc. shall be
closely monitored during manufacture to ensure a good degree of cross-linking through the
whole insulation.
7.5
The manufacturing process shall be desired to eliminate irregularities like protrusions, voids and
contamination etc. to ensure the long-term reliability of the cable.
7.6
Loading of the extruder in the manufacturing plant shall be performed entirely closed and dust
proof. The entire line of processing should be controlled from a computerized central control
console. Contamination shall be avoided by use of a fully enclosed material handling system.
To avoid contamination XLPE Granules must be transported using gravitational material feeding
system.
8.0
QUALITY ASSURANCE:-
8.1
Raw materials used for manufacture of cable shall be of highest quality and material received
by manufacturer should be checked / tested to ensure that it meets manufacturers material
specification. The materials shall be clean and packed in moisture and dust proof packing.
Page-7
8.2
As the Quality control of EHV XLPE cables while manufacturing is very critical so expert
supervision is required for raw material testing, in process checks and also for final testing. A
specially trained quality assurance team should be in place for maintenance of the quality at an
optimum level at the plant. Complete details of manufacturing process along with details of
automatic manufacturing plant, shall be furnished by bidder in the bid.
8.3
Quality assurance plan indicating test /checks of raw material, process of manufacturer
and final inspection with customer hold point shall be submitted to the purchaser for
approval.
9.0
TESTING:-
9.1
GENERAL:-
9.1.1
This schedule gives tests to be carried out on 66 KV, single core XLPE type cables. The schedule
of tests to be followed shall be generally as per IS-7098(Part-3)/ IEC 62067/ IEC-60840 (For 66
KV cable).
9.1.2
The facilities available for site tests shall be clearly and implicitly brought out in the Bid.
The site tests shall be carried out during and after laying/installation by the supplier.
9.1.3
This test schedule can be modified at the discretion of the purchaser to omit or to include
additional tests. Power frequency test shall be carried out at a frequency of 50 Hz.
10.0
10.1
The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable)
/IEC62067.
The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable)
/IEC62067
The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable)
/IEC62067
10.4
TYPE TESTS:-
10.4.1
The cables offered should be fully type tested. Type test reports (not more than seven years
old reckoned from the date of bid opening in respect of all the type tests carried out as per IS7098(Part-3)/ IEC-60840 (For 66 KV cable) /IEC62067 from Govt./ Govt. approved reputed test
house shall be submitted along with the bid.
10.4.2
The bidder must have all testing facilities available at their works for testing the material
as per clause 8 & 10 above. Detailed list of testing equipment along with relevant tests
must be furnished with the tender other wise offers is likely to be ignored.
Page-8
11.0
11.1
MARKING ON OUTER SHEATH:The following particulars shall be marked on cable outer sheath:
Manufacturers name/ or trade name
Voltage grade viz. 38/66 KV.
Cable size ( no. of core x conductor cross section)
Year of manufacture.
Purchasers name i.e. HVPNL
11.2
The spacing between one set of marking and the beginning of the next on the
legend shall not exceed 150 mm.
11.3
Besides above, progressive sequential marking of length shall also be provided at every one
meter, which shall be clear and legible sequential length working by embossing/
engraving/printing.
12.0
12.1
Immediately after the works tests, both ends of every length of cable shall be
sealed by means of heat shrinkable end caps.
12.2
Cables shall be wound on metallic drums. All the drums shall be arranged to
take a round spindle and be legged with strong closely fitting wooden battens so
as to prevent damage in the cable. Each drum shall bear an identification
number permanently stenciled or branded on the outside of the flange.
12.3
12.4
13.0
As the total length of cable route is different in each line, the cable in one drum
shall be so selected that maximum length should be 500 to 700m for each cable
drum. The length shall be subject to limiting the sheath voltage, safety and ease
of cable during wounding on drum, transportation & its erection. Also the delivery
length of cable shall match with the location of jointing bays as described in
Erection part. This length of each cable shall also include the loop in between
the route and both ends to the satisfaction of field office.
Page-9
14.0
14.1
The details of past orders executed by the bidder shall be indicated in the
relevant schedule.
15.0
15.1
The bidder shall furnish guaranteed technical particulars of cable in the relevant schedule
enclosed
16.0
ABSOLUTE GUARANTEES:-
16.1
16.2
Annexure - I
DESIRED TECHNICAL PARTICULARS OF 66 KV XLPE CABLE
S. No.
Particulars
Technical Details
Cable
Applicable standard
1.
2.
3.
4.
5.
i)
ii)
iii)
iv)
v)
Construction of conductor/flexibility
class
Shape and formation
Approx overall diameter of
conductor
Page-10
6.
i)
CONDUCTOR SCREENING
Material & type
ii)
iii)
7.
i)
Grade
Thickness
INSULATION
Material
ii)
8.
A
INSULATION SCREENING
Non-metallic part(extruded)
Material
i)
ii)
iii)
i)
ii)
C
i)
ii)
iii)
D
E
Grade
Min. thickness.
Non-metallic part (taped)
longitudinal water barrier over
insulation screen.
Material
Min. thickness
METALLIC SHEATH
Material
Min. Thickness(mm)
Short Circuit Current Withstand
[Metallic sheath, together with
copper screen (if required)]
Bedding over lead sheath
CONCENTRIC COPPER WIRE
SCREEN (IF REQUIRED)
Material and type
i)
Min. area (Sq. mm)
ii)
9.
OUTER SHEATH
Material
i)
ii)
10.
11.
12.
13.
14.
15.
16.
i)
ii)
17.
18.
19.
20.
21.
Recommended minimum
installation radius.
Maximum Resistance of
conductor at 20 deg C in ohm/km.
Continuous current rating for each
circuit when laid in ground in trefoil
formation and other condition
given in specification.
Maximum allowable temperature
for cable and accessories.
At rated full load and at site
conditions.
The conductor temperature after a
short circuit for one second shall
not exceed (with conductor
temperature at start of short
circuits as 900 C).
Basic impulse insulation level
(1.2/50 micro second wave)
Power frequency withstand voltage
As per IEC-228 A
To be indicated
90 Deg C
250 Deg C
As per Standard
As per Standard
Page-12
ERECTION PART
1.0
Scope: -
1.1
Complete installation, laying, testing and commissioning of the cable in Gurgaon area, as per the detail of
lines mentioned below, shall be the responsibility of the bidder:-
S. N.
Name of line
66kV connectivity between 66kv S/Stn. Sec-9, Gurgaon and 66kv S/Stn. Sec-10A Gurgaon by
laying of four Nos. 1200mm2 underground XLPE cable in place of overhead lines
Four runs of the cable per circuit shall be laid as per the tentative route plan enclosed. The scope for
installation work shall, therefore include, but not limiting to: 25.
Route survey for the entire route length under the scope of work.
26.
Clearances from relevant Local Authorities for laying of cables. All the protective measures for laying,
protection and for smooth working of all the cables as per statuary norms/standards to be
followed/ensured by the bidder for its safe and smooth operation in future. The charges on account of
statutory clearances (except Chief Electrical Inspector office fee under Electricity rules) shall be paid by
HVPNL as per actual, on production of bills/demand notice.
27.
28.
Measurement of Thermal resistivity of soil. The value of thermal resistivity will be intimated to field office.
29.
30.
All civil works required for laying of the cables, which shall include design, construction materials and
labours. Manholes shall be provided at every proposed joint location for jointing bays. The bidder shall
identify the location of the joint bays after carrying out detailed survey of the cable route and excavation of
the trial pits. The delivery lengths of the cables shall match the location.
31.
Bidder shall carry out the earthing of sheath/screen at cross bonding points as well as at both of termination
ends of 66kV cable using insulation sheath bonding (earhting) cable of required size through link box with /
without surge voltage limiter at cross bonding points and terminal S/Stns.
Page-1
32.
Earthing shall be as per relevant standards and the details of the earthing arrangement offered for the
cable accessories shall be submitted along with the offer.
33.
34.
The sheath/screen shall bound in the earth station through disconnecting type link boxes.
Screen continuity by using tinned copper mesh and earth continuity by tinned copper braids of
appropriate size shall be provided for transfer of screen /earth in straight through joints.
35.
Laying & installation of cables in open cut trench, in ducts, in HDPE pipes and through Trench less
method of required strength for various crossings, in air at terminations at the tower, at varying depths
due to obstructions, construction of cable jointing bays. The death of laying of cables for lines shall be
minimum 1.5m of Gurgaon area lines
36.
Supply of HDPE pipe of required strength of ISI mark shall be 1.5 times the Cable Diameter. The HDPE
pipes are required for crossing of roads/ Bridge/Railways/culverts/water courses/ Nala/ Sewerage pipe
lines/Oil /Gas pipe lines and for Trench-less system. The pipes to be filled with sand/suitable material
after cabling in Road crossing.
37.
Supply & Erection of terminal structures including foundations between the line for supporting cable
end terminations, it shall include the supply of Earthing material, Earthing of each cable, post insulators
for cable support, civil foundation design, construction material and labours etc.
38.
The cables will be terminated on the cable termination structures in the s/stn. premises and the cable
will be terminated on the tower at the point of connection with Over-head line.
Where the cable is to be terminated on Dead End type Terminal tower, the 66kV polymeric
LAs will have to be mounted on the tower by making suitable arrangement and the independent
earthing of LAs mounted on the tower and of each cable shall be got done to the satisfaction of
Engineer-incharge keeping adequate electrical clearance. The size of galvanised flat to be used for
earthing of LAs shall be 75X12mm2. The specification of polymeric LAs is attached separately as
Annexure-1.
39.
Termination of cables at both ends. Suitable loops shall be provided at both ends to the satisfaction of
field office.
40.
It shall be the responsibility of the contractor to terminate the fourth (spare) run of the cable at the
terminal structures in such a way that it shall be possible to connect it to all the three phases of
conductor by changing jumpers only. However this spare cable shall be connected to nearest conductor
to avoid theft/moisture in-gress. Necessary bonding of the cable screen shall be done by the supplier
along with its earthing as per IE rules & relevant ISS.
41.
Tentative Quantity of polymeric LAs shall be as per BOQ attached. The drawings of LAs shall be got
approved from HVPNL.
Page-2
42.
Cable markers as per statutory requirements shall be provided all along the route at a maximum
distance of 100 meters and other important locations. Also the location of the underground cable shall
be clearly indicated on the marker.
43.
For termination of cable directly at tower, Heat shrinkable cable joint shall be used. If cold shrinkable
cable / pre-moulded type termination kits are to be used, the arrangement shall be made on four poles
Railway structure of bidders design which should be in use in other Utilities and would be got approved
from HVPNL before its use.
44.
1 No. 66 kV KRR design DD type tower required to be erected for making the connectivity with XLPE
cable is in the scope of the bidder as per technical specifications of the tower.
45.
The bidder shall make his own arrangement for boarding & lodging of his men engaged in the work.
46.
47.
The laying of cables shall be through proposed densely populated residential area. Therefore, utmost
precautions shall be taken for erection of cables by the contractor for safety of the public. All the bidders
are strongly advised to visit the site through field office and acquaint themselves with the topography,
infrastructure, crossings involved etc. before submitting the bids. Suitable protection of XLPE cables and
Public property shall be ensured to the satisfaction of Engineer-incharge. The successful bidder shall be
fully responsible for providing all equipment, materials, system and services specified or not, but are
required to complete the erection and successful commissioning of 66 KV cable complete in all respects.
The cost of carrying out such works, shall be deemed to be included by the bidders in the last column
of Supply & Erection portion. Nothing Extra shall be paid later-on on this account except for the variation
in the quantities of the items shown in Supply & Erection portion.
23
After award of contract, its Design/Drawings will be got approved before execution of work.
24
The design of all type of crossings is in the scope of the bidder and work shall be started only after
getting the design / Drawings approved from HVPNL.
1.2
All the bidders are strongly advised to visit all the sites through respective field offices and acquaint
themselves with the topography. Infrastructure, crossing involved etc. before submitting the bids. The
successful bidder shall be fully responsible for providing all equipment, material, system and services
specified or not, but are required to complete the erection and successful commissioning of 66kV cab
le complete in all respects. The cost of carrying out such works shall be deemed to be included by the
bidders in the last column of supply & erection portion. Nothing extra shall be paid lator-on this account
except for the variation in the quantities of the items shown in supply & erection portion.
Page-3
1.3
For all the cable work, Railway line/ road bridge/drain/Nala crossing is involved. Suitable arrangements
for these crossings shall be made as per site visit done before submitting the bids. After award of
contract, its design/drawings will be got approved before execution of work. Suitable protection of XLPE
cables and public property shall be ensured to the satisfaction of Engineer incharge.
1.4
If any, sewerage the water near the site, suitable precaution regarding shuttering work/dewatering shall
be taken by the bidder.
1.5
The design of all type of crossings is in the scope of the bidder and work shall be started only after
getting the design / drawings approved by HVPNL.
2.0
Route Survey
The bidder shall fully familiarize himself with the site and route conditions etc. The complete design and
detailed engineering shall be done by the contractor. The survey shall be conducted for underground
routes to finalize the route and paths for the underground cable. Contractor shall arrange information
about existing under ground facilities for the proposed routes. To do so as built drawings or route index
diagram for various services viz water works, electric supply utilities, telecom services, public health,
Gas/oil authorities etc. may be collected from the concerned authorities. In case details are not
available, the contractor shall assess suitably by conducting enquiries and surveys. The contractor shall
prepare and submit the final survey report showing all the details enroute for HVPNL approval.
3.0
Statutory Clearances
The contractor shall coordinate on behalf of owner, for obtaining necessary clearances for laying of
cable and carrying out excavation/ digging work from the authorities on behalf of the Employer and
provide requisite copies of information maps, survey report etc. to the authorities. The employer shall
assist the contractor in obtaining such clearances by providing the authority letter or any other relevant
document. The contractor shall ensure quick and speedy clearances in order to implement the project
within stipulated schedule. In case the authorities have some objections on certain sections of routes
proposed and are unwilling to provide clearances, the contractor shall propose an alternate route,
promptly carrying out the survey and submit specific survey report for that and reapply for clearance
after taking into account the comments/objections of the authority. The clearance of the Chief Electrical
inspector under Electricity laws shall solely be in contractors scope. Other charges on account of
statutory clearances shall be paid by HVPNL as per actual, on production of bills/demand notice.
Page-4
4.0
CABLE HANDLING
5.0
DAMAGE TO PROPERTY
The contractor shall take all precautions while excavation of trench, trial pits & drill for trench-less laying
etc., to protect the public and private properties and to avoid accidental damage. Any damage so caused
shall be immediately repaired and brought to the notice of the Employer.
The contractor shall bear all responsibilities and liabilities and shall bear all costs of the damages so
caused by him or by his workman or agents.
6.0
Permanent means of indicating the position of joints and cable route shall be fabricated supplied and
erected.
The marker should incorporate the relevant information. The name of the owner, voltage, circuit &
Danger sign. The drawing of marker is enclosed with the bid.
7.0
Depth of laying of cables shall be 1.5m for directly buried cables (trench method) and 2.5m-3.0m in
Trench-less method as per cl. No. 1.1 (11) of scope of erection part . Laying at varying depths due to
obstructions/site conditions may be accepted subject to field office approval during detailed
Engineering. The typical cross-section drawing of trench is enclosed with this specification.
8.0
The excavated cable trench shall be drained of all water and the bed surface shall be smooth, uniform
and fairly hard before laying out the cables. The cables shall be rolled in the trench on cable rollers,
spaced out at uniform intervals. The laying out process must be smooth and steady without subjecting
the cable to abnormal tension or scratches. The cable being laid out shall be smoothly and evenly
transferred to the ground after proving the sand cushion. The cables shall never be dropped. Suitable
size cable stocking pulling eye shall be used for pulling the cable. While pulling the cable by winches or
machines, the tension loading shall be by tension indicator and shall not exceed the permissible value
for the cable..
The cable end seals shall be checked after laying and if found damaged shall immediately be resealed.
Sufficient number of heat shrinkable cable end sealing caps shall be stocked at site stores for testing
and jointing work. The integrity of the outer sheath shall be checked after the cable is laid in position.
The sealing of power cable ends during the storage, execution & completion of jointing work shall be in
the scope of successful bidder. Under no circumstances, the cable ends shall be kept open. The amount
due to damages done because of water/moisture ingress OR penetration in the cable / conductors
during execution shall be recovered form successful bidder. It shall be responsibility of successful bidder
to repair OR replace free of cost without affecting the completion schedule.
Page-5
9.0
SAND BEDDING:
The cable shall be completely surrounded by well-compacted sand (River bed sand) to such a thickness
and of such size that the cable is protected against damage. The thickness of the cable sand should be
a minimum 10cm in all direction from cable surface.
Precast RCC slabs in M-20 of size 500X300X65mm for 66kV and shall be provided for protection of the
cable by covering the cable as per drawing enclosed. Every pre-cast slab shall carry the engraved words
as- HVPNL 66kV.
10.0
BACK FILLING:
Normally back filling shall consist of the material earlier excavated. However, bigger stones or pieces of
rock should be removed & shifted at approved locations of Local Authority. The compaction of Earth
filling shall be ensured by the contractor 95% of the Proctor density.
11.0
WARNING TAPE:
A pre-warning, Red colour plastic/PVC tape, 250 mm wide 100 microns thick shall be laid at approx.
0.4 m above the cable specified depth, throughout the cable route. The tape shall carry the legend
printed in black continuously as under CAUTION HVPNL, 66000 V CABLES.
12.0
After the cables have been laid in the trench and until the cables are covered with protective covering,
no sharp metal tool shall be used in the trench or placed in such a position that may fall into the trench.
Straight and curved rollers used shall have no sharp projecting parts liable to damage the cable.
While pulling through pipes and ducts, the cable shall be protected to avoid damage due to sharp edges.
The cables shall never be bent, beyond the specified bending radius.
13.0
The road, Rail & Canal crossing should be done by HDPE pipes of required strength of diameter not less
than 1.5 times the cable diameter.
14.0
If required, trench-less digging shall be used for all roads crossings and through congested Urban streets
of HUDA area. The various methods of trench less digging such as hand/manual auguring (up to 15m),
impact moling (from 16m to about 40-50m). HDD (above 40-50m) shall be adopted based on the
soil/site conditions and the requirement and exact method for trench less digging shall be finalised
during detailed engineering as per actual site/soil condition.
Page-6
The contractor shall propose the exact methods and procedures for
implementation of trench less
digging at various crossings taking into consideration the following guidelines, for approval by the
Employer:-
15.0
a)
b)
c)
d)
e)
f)
g)
JOINTING BAY
Manholes shall be provided at every proposed joint location for jointing bays. The bidder shall identify
the location of the joint bays after carrying out detailed survey of the cable route and excavation of the
trial pits. The delivery lengths of the cables shall match the location.
In case of underground portion, the joint bays should have a flat and level surface lined with bricks and
properly plastered. The retaining walls on all sides to the required height shall be of brick/stone
masonry. The top of the wall shall have a cement concrete band 1:2:4 with 20mm size aggregate allround. The top shall be covered with pre-fabricated RCC slabs and with an inspection cover. Al the
bottom in a corner, a sump-pit shall be made for bailing out water. The contractor shall submit design
and drawing of Jointing bay for HVPNL approval.
All works shall be carried out under supervision of the engineer in charge or his representative.
16.0
The successful bidder shall have all necessary tools, plant and equipment to carry out the survey and
cable installation work.
The bidder are instructed to give all the details of equipment at their disposal, to carry out the work
successfully and speedily.
17.0
BENDING RADIUS:
Cable
Bending radius
Single Core
20 x D
18.0
The cable jointing personnel and his crew shall have good experience in the type of joints and
terminations that are used. The jointing work shall commence as soon as two or three lengths of cables
have been laid. All care should be taken to protect the factory-plumbed caps/ seals on the cable ends
and the cable end shall be sealed whenever the end is exposed for tests.
Jointing of cables in carriage ways, drive ways under costly paving, under concrete or asphalt surfaces
and in proximity to telephone cables and water mains should be avoided whenever possible.
Page-7
Sufficient over lap of cables shall be allowed for making the joints.
The joint bay should be of sufficient dimensions to allow the jointers to work with as much freedom of
movement and comfort as possible. Sufficient space should be kept below the cable to be jointed.
19.0
SUMPHOLES
When jointing cables in water logged ground or under unforeseen rainy conditions, a sumphole should
be made at one end of the joint bay, in such a position so that the accumulated water can be pumped
or baled out by buckets, without causing interference to the jointing operation.
20.0
TENTS/ COVERS
An enclosure or suitable protection cover shall be used in all circumstances wherever jointing work is
carried out in the open irrespective of the weather conditions. The joint shall be made in dust free,
moisture free and clean atmosphere.
21.0
The cable end seals should not be opened until all necessary precautions have been taken to prevent
circumstances arising out of rainy/ inclement weather conditions, which might become uncontrollable.
If the cable end seals or cable ends are found to have suffered damage, the cables should not be jointed,
without tests and
rectification.
22.0
23.0
IDENTIFICATION
shall be checked.
The identification of each phase shall be clearly and properly noted. The cable shall be jointed as per
the approved design. Each cable shall have identification for phase at joint bays.
24.0
MAKING A JOINT
Comprehensive jointing instructions should be obtained from the manufacturer of jointing kits and
meticulously followed.
The materials used in the joints like ferrules, screen/sheath continuity bonds, lugs etc., shall be of good
quality and conform to standards. The jointing tools shall be appropriate and as per the requirement of
jointing HV XLPE cables.
Page-8
25.0
CABLE TERMINATIONS
The preparation of the cable end for installing the terminations and the precautions to be taken before
fixing the terminations shall be followed as in the case of the cable jointing procedures.
At cable terminating end, the following provisions for supply and erections are to be included:
A sufficient length of spare cable to the satisfaction of field office shall be left in the
future needs.
ground,
for
The spare cable shall be connected to its nearest cable on load so as to avoid its theft and moisture
ingress.
Appropriate labels shall be fixed identifying the phase circuit, voltage and date of commissioning etc.,
on the cable supporting structure.
26.0
The terminating structure being provided shall be of bidders standard design as per requirement of
cable end sealing, porcelain bushing etc.
The mounting structure shall be fixed on the cement concrete foundation, the design and drawings of
which shall be submitted to Employer for approval and acceptance during the course of detailed
engineering.
After fixing the end termination, the cable shall be fixed to the support, with non-magnetic material
clamps to the required height securely. The mounting structure includes the supports for cable end
boxes, post insulators, link boxes and any other structure required for the intent of the contract. All
steel sections used shall be free from all imperfections, mill scales, slag intrusions, laminations, fillings,
rust etc. that may impair their strength, durability and appearance. All materials shall be of tested
quality only.
27.0
The complete arrangement as detailed above shall be made separately for both circuits of conductor at
a suitable distance from the tower to keep the conductor tension on Rail poles structures well within
limits in the same direction of cable. Also proper stay-wire arrangement on back side of Rail pole
structure shall be made for its stability.
The design of Rail pole structure and its foundations suitable for ACSR Zebra conductor of proven design
of other utilities shall only be used and the same shall be supplied to HVPNL for reference and record.
Proper phase to phase clearance between conductors (min.2.5 mtr.) shall be maintained. The 1 st Rail
Poles structures shall be of height approx. 10 mtr. height above ground level land the 2 nd Rail Poles
structures shall be of more height so that minimum clearance of 3 mtr. is maintained between circuit-1
and circuit-2 horizontal configuration conductors.
(For bidders reference, the similar arrangement is already in use in various 66kV cables in Delhi, specially
at a site near Pitampura Metro Railway Station except the difference that for this work, cable
termination kit to be used).
28.0
Earthing:-
Bidder shall carry out the earthing of sheath/ screen at the cross bonding points as well as at the ends
of cable using insulation sheath bonding (earthing) cable of required size through link boxes with/
without surge voltage limiter at cross-bonding points and terminal substations. Earthing shall be as per
relevant standards. The sheath /screen shall bound in the earth station through disconnecting type link
boxes. Screen continuity by using tinned copper mesh and earth continuity by tinned copper braids of
appropriate size shall be provided for transfer of screen/earth in straight through joints.
All the LAs to erected on the towers shall be properly earthed through 75X12mm2 GI strip to the
satisfaction of field office.
29.0
All tests as prescribed in IEC-60840: 1999 shall be performed after installation of cable.
Page-10
1.0
EXCAVTION
1.1
The specification covers excavation for cable trenches, ducts, structural foundation, jointing
bays.
The contractor shall control the grading in the vicinity of all excavations so that the surface of
the ground will be properly sloped or diked to prevent surface water from running in to the
excavated area during construction.
The excavation shall include the removal of all materials required to execute the work properly
and shall be made with sufficient clearance to permit the placing, inspection and setting of forms
and completion of all works for which the excavation was done.
The sides and bottoms of excavation shall be cut sharp and true. Under cutting shall not be
permitted. Earth sides of excavations shall not be used in lieu of form work for replacement of
concrete unless authorized by the Engineer where the limitations of space for large excavation
necessitate such decision.
When machines are used for excavation th last 300 mm before reaching the required level shall
be excavated by hand or by such equipment that will leave the soil at required final level in its
natural condition.
The bottom of the excavation shall be trimmed to the required level and when carried below
such level by error, shall be brought to level, by filling with lean concrete of 1:4:8 Mix at
contractors cost.
All excavation for installation of underground facilities shall be open cuts.
The excavations for foundation where specified shall be carried out at least 75 mm or as
specified in relevant drawing below the bottom of the structure concrete and then be brought to
the required level by placing lean concrete of 1:4:8 mix or as specified with aggregate of 40 mm
nominal size.
When the excavation requires tracing, sheeting, shoring strutting etc. the contractor shall submit
to the Engineer in charge drawings showing arrangement and details of proposed installation
and shall obtain the approval from the Engineer in charge before proceeding with the work.
The contractor shall have to constantly pump out the water collected in the pits, trenches due
to rain, sub soil, springs etc. and maintain dry working conditions at no extra cost to the owner.
During excavation, the required protection is to be done to the foundation/trenches along with
caution signs/protection tapes, around the excavated trenches.
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
PAGE-11
3.0
3.1. The backfilling of excavated trenches around foundation shall consist of one of the following
materials as the Engineer-in-charge may direct in each location.
i) Selected sieved earth from excavated soil.
ii) Selected sieved earth brought from borrows area.
iii) Sand filling (sieved).
3.2 Filling shall be done after the concrete or measonry work has fully set and its curing completed.
3.3 The contractor shall fill in and around any work until it has been properly reinstated and approved
by the Engineer-in charge.
4.0
4.1
Back filling shall be done in horizontal layers of thickness not exceeding 300 mm thickness, free
from pockets with careful watering where necessary for compaction. The backfill shall be riddled
earth free from materials likely to cause damage to the cables.
4.5
The thermal backfill surrounding the cable shall be as per the design approved by the owner.
5.0
5.1
6.0
7.0
7.1
The concrete mix for the various types of pre-cast units shall confirm to IS: 456. The aggregate
shall be mixed by weight and water cement ratio shall be controlled to obtain the dense concrete
and the strength required. The reinforcement shall be as per the design approved. The curing
shall be carried out for the period of minimum seven days from the date of casting and precast
element shall be cured by flooding with water of minimum 25 mm depth over the element for
the period mentioned above.
7.5
23.0
FOUNDATION
Foundations for mounting structures in cement concrete shall be casted by bidder as per
approved drawings.
24.0
25.0
PAINTING
Outdoor Kisok for link boxes etc., shall be painted with anti corrosive paint and red oxide as
primer and two coats of enamel paint. The boxes should be appropriately labeled as per
installation at site regarding the S.No., location, type caution board/danger.
PAGE-12
26.0
27.0
13.0
13.1
Permanent and durable type, cable route markers/joint indicating blocks should be provided as
per the design approved by the purchaser.
13.2
The Reinforced cement concrete block should be made by the wet process and all the concrete
shall consists of one part cement, one and a half part sand, three parts aggregates of size 20
mm and down.
13.3
The marking block should be given a smooth cover surface or cement mortar and shall have
the appropriate legends, 5 mm deep engraved on them as HVPNL 66 CABLE Ckt.- I OR
HVPNL 66 KV CABLE Ckt.- II, HVPNL 66 KV CABLE or as the case may be.
14.0
PIPES
14.1
HDPE pipes of ISI mark, of approved diameter and thickness, of good quality shall be used for
formation of cable ducts. All sundry materials like coupling, collars, and caps to cover the pipe
ends before cable is pulled in shall be provided.
14.2
The bidder shall furnish the design drawings of foundations, foundation anchor bolts, and design
calculations etc. of these structures.
15.0
SAND
15.1
Sand supplied for backfill shall be river sand, free from flakes, dust, earth, organic matter and
large pebbles and stones and should be free from any chemical contaminates likely to have
corrosive action on the cable coverings. The sand should be sieved through a mesh to remove
all large stones and pebbles. The sand shall be properly graded and shall conform to IS:383 for
concreting work.
15.2
The owner will decide on the requirement of the use of sand depending on the availability of the
excavated earth to be used for backfill. The sand should be used with the approval of the owner
as a backfill.
16.0
QUANTITIES
16.1
The quoted price shall also include supply of all material transportation charges, taxes, duties,
Octoroi and tole tax, labour, construction, plant and equipment and fixture, fittings and all
temporary and permanent works necessary for satisfactory completion in all respects.
16.2
If the owner is directed by the Engineer in charge to excavate to a lower level than that indicated
in the drawing, such additional excavation shall not be paid for & will be deemed to be included
in the quoted rates.
PAGE-13
16.9
16.5
The contractor shall be responsible for estimates, assumptions and conclusions regarding the
nature of the materials to be excavated and difficulty of making and maintaining of required
excavations and performing the work required as shown on the drawing and in accordance with
these specifications. Cofferdams, sheeting, shoring. Draining, dewatering etc. shall be furnished
and installed as required and the cost there of shall be included in the rate quoted. The
contractor shall be held responsible for any damage to any part of the work and property caused
by collapse of sides of excavation. The materials can be salvaged if it can be done with safety
for the work and structure and as approved by the Engineer in charge.
16.6
However, no extra claim shall be entertained for material not salvaged or any other damage to
contractors proper as the results of the collapse. He shall not be entitled to any claim for redoing
the excavations as a result of the same.
32.0
ROAD CUTTING
The road cutting, whether of cement concrete/ asphalt or macadam road surface shall be taken
after obtaining approval for cutting from the civic authorities, traffic police, telephone authorities
and work should be planned to be completed in the shortest possible time. Where necessary
work shall be planned during night or light traffic periods.
33.0
ROAD CROSSING
HDPE pipes shall be used for cable. Pipes diameter should not be less than 1.5 times the cable
diameter.
34.0
FOOTPATH CUTTING
The slabs, kerb- stones, on the roads shall be removed and reinstated without damage.
35.0
REINSTATEMENT
After the cables and pipes have been laid and before the trench is backfill all joints and cable
positions should be carefully plotted and preserved till such time the cable is energized and
taken over by the Engineer. The protective covers shall then be provided, the excavated soil
riddled, sieved and replaced. It is advisable to leave a crown of earth not less than 50 mm and
not more than 100 mm in the centre and tapering towards the sides of the trench.
20.1
20.2
After the subsidence has ceased the trench may be permanently reinstated and the surface
resorted to the best possible condition.
PAGE-14
20.3
The road surface being cement concrete, asphalt or tarred macadam, resurfacing will be done
by the civic authorities at owners cost. The fixing of markers etc. shall be co- ordinated by
bidder.
20.4
All works shall be carried out under supervision of the Engineer in Charge or his representative.
36.0
The contractor shall be clean the completed cable route and shall remove all surplus and waste
materials, empty cable reels etc. preferably the same day but not later than the next day after
the particular work is completed.
PAGE-15
PAGE-16
OF
SECTION-VI
TECHNICAL SPECIFICATION
CONTENTS
PART-I
SECTION-VI
(PART-I)
TECHNICAL SPECIFICATION
CONTENTS
1.1
1.11
1.12
1.13
1.14
RESULTS OF SURVEYS
ACCESS TO THE LINE AND RIGHT OF WAY
DETAILED SURVEY, OPTIMISATION OF TOWER 4
LOCATION
1.15
1.16
1.17
1.18
1.19
2.0
ENVIRONMENTAL CONDITIONS
9
TECHNICAL DATA
STATUTORY REGULATIONS AN STANDARDS 9
QUALITY ASSURANCE, INSPECION AN TESTING
TECHNICAL PARAMETERS OF 220 KV LINE
DETAIL OF LINE MATERIAL FOR 220 KV LIEN
12
2.1
12
2.2
13
4
4
9
10
11
13
2.4
14
EARTHWIRE
3.0
TRANSMISSION TOWERS
14
3.1
14
3.2
TYPE OF TOWER
14
3.3
3.4
MAXIMUM TENSION
18
3.5
MATERIALS
18
3.6
TOWER ACCESSORIES
20
16
3.7
TOWR FABRICALTION
21
3.8
GALVANISING
23
3.9
EARTHING
23
3.10
3.11
TESTINGS OF TOWERS
3.12
STANDARDS
4.0
TOWER FOUNDATION
33
4.3
TYPEOF SOIL
33
4.4
FOUNDATION TYPES
34
4.6
34
4.7
36
4.8
36
4.9
SETTING OF STUBS
37
4.10
37
4.11
38
CONCRETE
24
28
28
4.13
38
4.14
39
5.0
41
GENERAL
41
5.2
41
5.3
ASSEMBLY
42
5.4
42
5.5
INSULATOR HOISTING
42
5.6
5.7
5.8
JOINTING
5.9
SAGGING-IN-OPERATION
5.10
44
44
44
AND EARTHWIRE
5.11
CLIPPING IN
5.12
45
46
ACCESSORIES
5.13
REPLACEMENT
46
5.14
46
MATERIALS
5.16
6.1
6.2
ENGINEERING DATA
47
6.3
DRAWINGS
47
6.4
DESIGN IMPROVEMENTS
6.5
DESIGN COORDINATION
6.6
6.7
PACKING
50
7.1
ERECTION CONDITIONS
50
49
50
50
7.2
50
STATUTES
7.3
51
7.4
PROGRESS REPORT
51
7.5
51
7.6
FIRE PROTECTION
7.7
SECURITY
7.8
52
7.9
CONSTRUCTION MANAGEMENT
53
7.10
53
7.11
51
52
53
BIDDERS LIABILITY
7.13
54
7.13
54
7.14
FOREIGN PERSONNEL
56
7.15
CODE REQUIREMENTS
57
SECTION-VI
(PART-I)
TECHNICAL SPECIFICATIONS
2.
1.1
Scope:
1.1.1
1.1.2
This specification also covers the fabrication of 66kV transmission line portion including
bolts, nuts and washers, hanger, D-shackle and all type of accessories like phase plate,
circuit plate, number plate, danger plate, anti-climbing device etc., selecting type of
foundation, casting of foundation for gantry footing , erection of gantries, tack welding of
bolts and nuts including supply and application of zinc rich paint, gantry earthing, fixing of
insulator string, stringing of conductors and earthwires alongwith all necessary line
accessories. All the clauses in the specification will be relevant for the gantry structures also
unless stated otherwise.
1.1.3
This specification includes the supply of Anti-fog type insulator or Polymer Silicone Rubber
insulator and their hardwares, conductor and earthwire, earthwire suspension and tension
clamps and all other line accessories for conductor & earthwire i.e. mid-span compression
joints for conductor and earthwire, repair sleeve for conductor, vibration damper for
conductor and earthwire, flexible copper bond which shall be supplied by the bidder during
execution of the project. The bidder shall clearly indicate in the offer the sources from where
he proposes to procure the raw materials and the components. The type of insulator
(whether Anti -Fog disc type or Silicone Rubber Polymer type) to be used shall be clearly
indicated in the bid by the bidder.
Page-1
a)
1.1.4
All the raw materials such as steel, zinc for galvanizing, aggregates, reinforcement steel and
cement for tower foundation, coke and salt for tower earthing etc. ,bolts, nuts, washers, Dshackles, hangers, links, danger plates, phase plate, number plate, circuit plate, anti
climbing devices etc, required for tower manufacture and erection shall be included in the
bidders scope of supply. Bidder shall clearly indicate in the offer, the sources from where
he proposes to procure the raw material and the components.
1.1.5
The entire stringing work of conductor and earthwire shall be carried out by standard
stringing practice. The bidder shall indicate in the offer, the detail description of the
procedure to be deployed for stringing operation.
1.1.6
The following 66 kV transmission line is included in the scope of the bidder for this package.
Sr. No.
Name of line
1.
66kV connectivity between 66kv S/Stn. Sec-9, Gurgaon and 66kv S/Stn. Sec10A, Gurgaon by laying of four Nos. 1200mm2 underground XLPE cable
(Tower portion).
The tentative bill of quantities for these lines are indicated in the schedule of quantities.
However, any item(s) though not specifically mentioned, but which are required to make the
line(s) complete in all respect for safe, efficient, reliable and trouble free operation shall be
deemed to supplied and erected by the Bidder.
The scope of the supply and installation of plant and equipment project shall include, but not
limited to the following works:
1. Engineering services,
3. Transporting of all materials, equipment to the related Site(s), storage and equipment
preservation at related Site including all services to be required at customs (i.e. unloading,
loading, storing at customs stores and other services at customs). Remark that Bidder shall hire
a
suitable
storing
area
which
shall
be
approved
by
the
HVPNL.
Supervision (i.e. Engineer(s) shall be fully responsible at each Site during the overall job until
commissioning). The Bidder shall identify his supervisors with curriculum vitae, fifteen (15) days
after the signing of the Contract and supervisors shall not be substituted without the written
consent of the HVPNL i.e.
b)
c)
i) Supply of the measuring instruments and testing equipment necessary
for the preliminary acceptance tests,
ii) Providing of the special tools, instruments and devices to be used in erection,
and putting into operation,
testing
iii) Delivery of the materials and equipment which may be supplied or manufactured in India,
or from abroad to Site including all works through customs,
d)
i)
Training of the personnel authorized by HVPNL if mentioned in
specifications ii) Submission of monthly progress reports.
iii) For the Goods which shall be supplied by HVPNL, if any,(in according to the
of
Contract Agreement), transportation, civil works, erection and Site testing shall be done
by the Bidder.
Connection between substations and dead-end towers, shall be done by the Bidder if
the substations do exist.
The provisions under this Section are indented to supplement general requirements for
the equipment, material, works and services covered under other Sections of these
bidding documents and are not exclusive. However, in case of conflict between the
requirements specified in this Section part 1 and requirements specified under other
Sections, more stringent requirements specified under Sections shall prevail.
The route plans shown in bidding document are tentative, as such the quantities of
towers and other material to be manufactured shall be as per requirement of approved
detailed survey only.
1.1.7
S. No.
Description of item
2.
ACSR Conductor
Note: The equipment which are not covered above should be manufactured, tested &
supplied at least 50% of the contract quantity within the last five years prior to bid opening
date and should be in successful operation from two years
Page-3
1.1.8
LOCATION DETAILS:
1.1.8.2 The Bidder shall have to erect the 66 kV transmission lines portion completely up to terminal
arrangements.
1.1.8.3 The entire work shall be executed by the successful bidder in compliance of Environment
Management plan (EMP) and Resettlement & Rehabilitation Action Plan (RRAP) reports.
This shall be taken into account in the bid.
1.2
The transmission lines under this package will be running almost through Gurgaon area.
Preliminary route alignment maps of transmission lines covered under this package
indicating the general topography and major crossings like river, power lines, Railways line
& Roads are enclosed with this specification for bidders reference. There may be few small
rivers/distributes/Nalas etc. to be crossed by the line in the above package.
1.3
Result of surveys
The details collected through tentative surveys viz line route, general soil characteristics,
crossings, accessibility and infra-structure details are attached at Annexure-IB for the
bidders reference.
1.4
1.5
1.5.1
The HVPNL has carried out the tentative route survey of the transmission lines under this
package. However, detailed survey including profiling, tower optimization and spotting shall
be carried out by the successful bidder as stipulated herein.
The Bidder shall finalize complete detailed surveys including any changes and will submit
the route plans within 2 months (60 days) of issue of LoI. The soil investigation for the
obligatory points shall be carried out by the successful bidder.
The bidders are strongly advised to visit and examine the site of works and its surroundings
and obtain for himself at his own responsibility and expense, all information regarding terrain
of the proposed line, line route, general site characteristics, various crossings, accessibility,
infrastructure details etc. The cost of visiting the site shall be at bidders own expense. The
HVPNL will assist the interested bidder to see & inspect the site of works. For this purpose
bidders are requested to contract.
1.5.2
The Bidder should note that HVPNL will not furnish the topographical maps prepared by
Survey of India but will make available any assistance that may be required in obtaining the
topographical maps.
1.5.3
Soil resistivity along the route alignment, shall be measured in dry weather by four-electrode
method keeping inter electrode spacing of 50 metres. For calculating soil resistivity, formula
2PI ar (where a =50 metres and r=megger reading in ohms, PI=3.14) shall be adopted.
Measurement shall be made at every 2 to 3 km along the route of transmission lines. In
case soil characteristic changes within 2 to 3 km, the value shall also have to be measured
at an intermediate locations. The megger reading and soil
characteristics shall also be
indicated in the soil resistivity results.
1.5.7
ROUTE MARKING
At the starting point of the commencement of route survey, an angle iron spike of 65x65x6
mm section and 1000 mm long shall be driven firmly into the ground to project only 150 mm
above the ground level. A punch mark on the top section of the angle iron shall be made to
indicate location of the survey instrument. Teak wood peg 50x50x650 mm size shall be
driven at prominent position at intervals of not more than 750 meter along the transmission
line to be surveyed upto the next
angle point. Nails of 100mm wire should be fixed on the top of these pegs to show the
location of instrument. The pegs shall be driven firmly into the ground to project 100 mm
only above ground level. At angle position stone/concrete pillar with HVPNL marked on them
shall be put firmly on the ground for easy identification.
1.5.8
1.5.9
TOWER LOCATION
Necessary data in respect of conductor, earthwire and insulator have been given in the
specification. On the basis of these, the Bidder shall prepare the sag template drawing and
tower spotting data and submit the same alongwith sag tension calculations for the approval
of the HVPNL. Sag template prepared based on the approved sag-template curve drawing
shall only be used for tower spotting on the profiles. Two numbers of the approved
template, prepared on rigid transparent plastic sheet, shall be provided by the Bidder
to the HVPNL for the purpose of checking the tower spotting. The templates shall be
on the same scale as that of the profile.
PAGE-5
1.5.12.2 TOWER SPOTTING
With the help of approved sag template and tower spotting data, tower locations shall be
marked on the profiles. While locating the towers on the profile sheet, the following shall
be borne in mind.
h)
SPAN
The number of consecutive spans between the section points shall not exceed 15. A
section point shall comprise of tension point as under as applicable: -
i)
EXTENSION
An individual span shall be as near to the normal design span as possible. In case an
individual span becomes too short with normal supports on account of undulations in
ground profile, one or both the supports of the span may be extended by inserting standard
body extension designed for the purpose according to technical specification.
j)
Loading
There shall not be any upward force on Suspension towers under normal working
conditions and the Suspension towers shall support at least the minimum weight
span as provided in the designs. In case uplift is unavoidable, it shall be examined if the
same can be overcome by adding standard body extensions to the towers failing which
tension towers designed for the purpose shall be employed at such positions.
d) ROAD CROSSING
At all important road crossings, the towers shall be fitted with normal suspension or tension
insulator strings depending on type of tower, but the ground clearance at the highest point
of the roads under maximum temperature and still air shall be such that even with the
conductor broken in adjacent span, ground clearance of the conductor from the road
surfaces will not be less specified minimum ground clearance.
At all National Highways, tension towers with double insulator strings on crossing side
shall be used.
e) RAILWAY CROSSINGS
All the Railway crossings coming enroute the transmission line have already been
identified by the HVPNL. At the time of detailed survey, the Railway crossings shall be
finalized as per the regulation laid down by the Railway Authorities. The following are the
important features of the prevailing regulations (revised in 1987):
i)
The crossing shall be supported on DD type towers only on either side and
Double tension insulator string shall be used on both the towers on the side of
the crossing.
ii)
iii)
The minimum distance of the crossing tower shall be at least equal to the height
of the tower plus 6 metres away measured from the center of the nearest Railway
track.
iv)
v)
Minimum ground clearance above Rail level of the lowest portion of any
conductor under condition of maximum sag shall be maintained as per latest
Railway regulations as amended from time to time.
vi)
The approval for crossing Railway track shall be obtained by the HVPNL from the
Railway Authorities, however six copies of profile and plan, tower and foundation
design and drawings, required for the approval from the Railway Authorities shall
be supplied by the Bidder to the HVPNL.
f)
River Crossing:
In case of major river crossing, towers shall be of suspension type and the
towers on either side of the main river crossing shall be DD type tower.
anchor
For navigable river, clearance required by navigation authority shall be provided. For
non-navigable river, clearance shall be reckoned with respect to highest flood level
(HFL).
f)
i)
66 kV to 66 kV and below
2.44 m.
ii)
66 kV to 132 kV
3.05 m.
iii)
66 kV to 220 kV
4.58 m.
iv)
66 kV to 400 kV
5.49 m.
PAGE-7
When the angle of crossing has to be below 60o, the matter will be referred to the
authority inchage of the telecommunication system. On a request from the Bidder, the
permission of the telecommunication authority may be obtained by the HVPNL. Also, in
the crossing span, power line support will be as near the telecommunication line as
possible, to obtain increased vertical clearance between the wires.
h) DETAILS ENROUTE
All topographical details, permanent features, such as trees, building etc. 9.0 m on either
side of the alignment for 66kV line shall be detailed on the profile plan.
1.5.13
1.5.14
The tree cutting shall be the responsibility of the HVPNL except for that required during
survey. However, the Bidder shall count, mark and put proper numbers with suitable quality
of paint at his own cost on all the trees that are to be cut by the HVPNL at the time of actual
execution of the work. Bidder may please note that HVPNL shall not pay any compensation
for any loss or damage to the properties or for tree cutting due to Bidders work.
1.5.15
Any way leave, which may be required by the Bidder, shall be arranged by the HVPNL as
required by work programme.
1.5.16
To evaluate and tabulate the trees and bushes coming within 9.0 m on either side of the
central line alignment, the trees will be numbered and marked with quality paint serially from
angle point 1 onwards and the corresponding number will be painted on the stem of trees
at a height of 1 meter from ground level. The tree list should contain the following: e) Girth (circumference) measured at a height of 1 meter from ground level.
f)
1.5.17
PRELIMINARY SCHEDULE
The profile sheets, duly spotted, alongwith preliminary schedule indicating type of towers,
type of foundations, wind span, weight span, angle of deviation, river or road crossing and
other details shall be submitted for the approval of the HVPNL. After approval, the Bidder
shall submit six more sets of the approved reports along with one set of reproducible of final
profile drawings to the HVPNL for record purpose.
PAGE-8
1.5.12
1.5.13.3
The check survey shall be conducted to locate and peg mark the tower positions on ground
conforming to the approved profile and tower schedule. In the process, it is necessary to
have the pit centers marked according to the excavation marking charts. The levels, up or
down of each pit center with respect to the center of the tower location shall be noted and
recorded for determining the amount of earthwork required to meet the approved design
parameters.
1.5.13.4
Changes, if required, after check survey in the preliminary tower schedule shall be carried
out by the bidder and he shall thereafter submit a final tower schedule for the approval of
HVPNL. The tower schedule shall show position of all towers, type of towers, span length,
type of foundation for each towers and the deviation at all angles as set out with other
details.
1.6
ENVIRONMENTAL CONDITIONS
1.6.2
The maximum temperature during summer shall be of the order of 50o C and the minimum
temperature shall be of the order of -2oC. Normal everyday temperature is 320C.
1.7
TECHNICAL DATA
Bidders shall furnish all technical data as per relevant schedules in five (5) copies.
1.8
1.8.3
STATUTROY REGULATIONS
The bidder is required to follow local statutory regulations stipulated in electricity (supply)
Act. 2003, Indian Electricity rules 1956 as amended and other local rules and regulations
referred to in this specifications.
1.8.4
REFERECNE STANDARDS
1.8.4.1
The codes and/or standards referred to in specification shall govern. In all cases wherever
such references are made. In case of a conflict between such codes and/or standards, and
the specifications, latter shall govern. Such codes and/or standards, referred to shall mean
the latest revisions, amendments/changes adopted and published by the relevant agencies.
1.8.4.2
1.8.5
1.8.3.1
o)
p)
q)
r)
s)
System for shop manufacturing including process controls and fabrication and
assembly controls.
t)
u)
v)
w)
x)
y)
z)
aa)
bb)
A quality plan detailing out the specific quality control procedure adopted for
controlling the quality characteristics relevant to each item of supply.
The quality plan shall be mutually discussed and approved by the HVPNL after
incorporating necessary corrections by the Bidder as may be required.
1.8.3.2
PAGE-10
1.8.3.3
1.9
The HVPNL, through his duly authorized representatives, reserves the right to carry out
quality audit and quality surveillance of the systems and procedures of the Bidders/ his
sub-bidders quality management and control activities.
1.10
Nominal voltage
66 kV
b)
72 kV
c)
BlS (Impulse)
325 KV (peak)
d)
140 KV (rms)
e)
750C
2.0
2.1
Sr. No
Particulars
Conductor
Earthwire
Type
ACSR Zebra
Glavanised steel
stranded
Stranding
diameter
c)
d)
and
wire
Aluminium
Steel
Approximate
diameter
Approximate mass
Calculated DC resistance
at 20 deg. Centigrade
(Max.)
Approximate
breaking load
overall
calculated
mm
54/3.18
mm
7/3.18
7/3.15
Sq. mm
484.5
54.55
mm
28.62
9.45
Kg/km
1621
428
ohm/km
.06868
3.375
kN
130.32
56
Page-11
Modulus of elasticity
Co-efficient
of
linear
Kg/mm2
7034
19361
Per degree
19.30x10-6
11.5x10-6
240
expansion
centigrade
10
Gm/sq. m
260
11
Configuration
D/C line
of
conductor
12
tower
Location of earthwire
One
continuous
earthwire to run
horizontally
above
the
conductors
2.3
Sr
No
Particulars
Single
Double
suspension
suspension
string
/pilot string
Strings
Double
string
tension Single
string
tension
No. of standard
insulator discs
1x5
2x5
2x6
1x6
Size of disc mm
255x145
255x145
280x145(zebra)
280x145(zebra)
E&M strength of
each insulator
disc
70
70
120 (zebra)
120 (zebra)
16
16
20 (zebra)
20 (zebra)
(KN)
4
Size
of
designation of
pinball
shank
mm
Minimum
creepage
distance of each
disc mm
432
432
432
432
Page-12
2.3 PARTICULARS OF SILICONE POLYMER INSULATOR STRINGS FOR ACSR ZEBRA LINES:-
Sr
No
Type of String
Size
of Min.
Composite
Creepage
Insulator
Distance
(mm)
(mm)
No.
of EM strength of
Individual Insulator Unit (KN)
units per
string
(Nos.)
Mechanical
strength
of
Insulator
string
alongwith
Hardware fittings
(kN)
Single
Suspension
20X725
2248
1X1
70
70
Single
pilot
Suspension
20X725
2248
1X1
70
70
Single
Tension
20X870
2248
1X1
120 (zebra)
120 (zebra)
Double
Tension
20X870
2248
2X1
2.4
Anchor shackle
Ball Hook
Chain link
Yoke plate
Ball clevis
Arcing horn holding plate
Socket clevis
Arcing horns
2X120 (zebra)
2X120 (zebra)
i)
j)
k)
2.5
Clevis eye
Free center type/armour grip suspension clamp for suspension strings and envelope
type clamp for pilot suspension string for jumper support.
Compression type dead end clamp.
Page-13
3.
TRANSMISSION TOWERS
3.4
3.4.1
Double circuit DE, DF, DG, & DH type ( KRR Design) for 0.4sq ACSR Zebra lines.
3.4.2 The towers are of self supporting lattice steel type, designed to carry the line conductors with
necessary insulators, earthwire and all fittings under all loading conditions.
3.4.3
The tower shall be fully galvanized structure. The towers to be fabricated have a combination
of two grades of steel, as detailed in structural drawing/Bill of material, one is MS steel and other
is HT steel conforming to IS:2062-2006.
3.5
TYPE OF TOWERS
3.5.1 The towers are classified as given below for 66 kV lines:Type of Tower
Deviation limit
Typical use
DA/DE
0 deg. to 2 deg.
Spl. Extn. of DE
0 deg. to be restricted
0 deg. to 15 deg.
b)
(+9m to +18m)
DB/DF
0 deg.
Spl. Extn. of DF
5 deg. to be restricted
(+9m to +12m)
DC/DG
15 deg. to 30 deg.
Spl. Extn. of DG
20 deg. to be restricted
Page-14
(+9m to +12m)
DD/DH
30 deg.-60 deg.
Spl. Extn. of DH
40 deg. to be restricted
(+9m to +18m
DD/DH
0 deg.
d)
3.5.2
EXTENSIONS
3.2.2.1
3.2.2.2
All above extension provision to normal towers shall be treated as part of normal tower only.
3.5.3
3.5.4
NORMAL SPAN
The normal ruling span of the line shall be 275 meters.
3.2.5
WIND SPAN
The wind span is the sum of the two half spans adjacent to the support under consideration.
For normal horizontal spans this equal to normal ruling span. However, the wind span of
DE type tower of KRR Design shall be reduced to 175m for using +9m and above
Extensions.
3.2.6
WEIGHT SPAN
The weight span is the horizontal distance between the lowest point of the conductors on
the two spans adjacent to the tower. The weight spans shall be intimated to successful
bidder .
Page-15
3.6
ELECTRICAL CLEARANCES
3.3.1
GROUND CLEARANCE
The min. ground clearances from the bottom conductor shall not be less than 5500 mm at
the max. sag conditions i.e. at max. temperature (75oC) and still air. However, to achieve
the above clearance the height of tower shall be increased in the following manner:
c)
d)
For river crossing tower the minimum electrical clearance including ground clearance will be
same as normal towers except an allowance of 4% of maximum sag of conductor instead of
150 mm for normal towers shall be provided to account for errors in stringing.
3.3.2
Sr. No
Single
suspension
insulator string
Swing in deg.
Nil
915
15
915
30
760
45
610
60
610
Nil
915
Jumper
Nil
915
10
915
20
610
30
610
Nil
915
15
915
30
610
45
610
PAGE-16
3.3.3
ANGLE OF SHIELDING
The angle of shielding is defined as the angle formed by the line joining the center
lines
of the earthwire and outer power conductor, in still air, at tower supports, to the vertical line through
the center line of the earthwire. Bidders shall design the tower in such a way that the angle of
shielding does not exceed 30 deg. The drop of the earthwire clamp should be considered while
calculating the minimum angle of
protection. For estimating the minimum angle of protection, the
drop of the earthwire suspension clamp alongwith shackle shall be taken as 150mm.
3.3.4
The minimum vertical mid span clearance between the earthwire and the nearest power
conductor shall not be less than 3.0 meters for 66 kV which shall mean the vertical clearance
between earthwire and the nearest conductor under all temperatures and still air condition in
the normal ruiling span. Further, the tensions of the earthwires and power conductors shall be
so co-ordinated that the sag of earthwire shall be at least 10% less than that of power
conductors under all temperature loading conditions.
3.3.5
HVPNL 66kV towers to be used for construction of 66kV lines are to be designed by calculating
the wind load on tower body as per IS:802 (1995). The following factors for calculating wind
load on tower body were considered while designing the towers:
a)
Wind Zone
4 (47 m/sec.)
b)
Reliability level
c)
d)
701N/m2
e)
0 deg.
3.4.
MAXIMUM TENSION
c)
d)
Sag-tension calculations for Conductor and Earthwire for a span length of 275 mtrs. shall be
supplied by HVPNL & based upon 2 No. the sag templates on rigid Plastic sheet shall be
supplied by the Bidder to HVPNL.
Page-17
3.4.2
The initial conductor tension at 320 C and without wind shall be 22% of the ultimate tensile
strength of the conductor.
3.4.3
3.4.4
The three phases shall be in vertical formation on both sides of tower. The phase to phase
spacing for tower shall not be less than 2.06 meters ( vertical) and 4.88 meters (horizontal).
3.5
Material
3.5.1
The towers shall be fully galvanized structure. The towers to be fabricated have a combination
of two grades of steel, as detailed in structural drawings/bill of material. One is MS steel
confirming to IS: 2062-1992 grade Fe410WA and other is HT steel conforming to IS: 8500-1991
grade Fe490.
3.6
3.6.1 All bolts and nuts shall conform to IS:6639-1972. All bolts and nuts shall be galvanised and shall
have hexagonal head and nuts, the heads being forged out of the solid steel rods and shall be
truly concentric, and square with the shank, which must be perfectly straight.).
3.6.2
The bolt shall be of 16mm dia/24 mm dia and of property class 5.6 as specified in IS:1367 (partIII) 1979 and matching nut of property class as specified in IS : 1367 (part-VI) 1980.
3.6.3
Bolts upto M16 and having length upto 10 times the diameter of the bolt should be manufactured
by cold forging and thread rolling process to obtain good and reliable mechanical properties and
effective dimensional control. The shear strength of bolts for 5.6 grade should be 310 MPa
minimum as per IS: 12427. Bolts should be provided with washer in accordance with IS: 1363
part-I to ensure proper bearing.
3.6.4
Nuts should be double chamfered as per the requirement of IS: 1363 part-III, 1984. It should be
ensured by the manufacturer that nuts should not be overtapped beyond 0.4mm over size on
effective diameter for size upto M16.
3.6.5
Fully threaded bolts shall not be used. The length of bolts shall be such that the threaded portion
will not extend into the place of contact of the members.
Page-18
3.6.6
All bolts shall be threaded to take the full depth of the nuts and threaded for enough to permit
firm gripping of the members, but not further. It shall be ensured that the threaded portion of
each bolt protrudes not less than 3 mm and not more than 8 mm when fully tightened. All nuts
shall fit and tight to the point where the shank of the bolt connects to the head.
3.6.7
Flat and tapered washers shall be provided wherever necessary. Spring washers shall be
provided for insertion under all nuts. These washers shall be of electro-galvanised steel, positive
lock type and 3.5 mm in thickness for 16mm dia bolt, 4.0 mm for 20mm bolt and 4.5 mm for
24mm bolt as per IS: 3063-1972.
3.6.8
The Bidder shall furnish bolt schedules giving thickness of members connected, the nut and the
washer and the length of shank and the threaded portion of bolts and sizes of holes and any
other special details of this nature.
3.6.9
To obviate bending stress in blots or to reduce it to minimum, no bolt shall connect aggregate
thickness of more than three (3) times its diameter.
3.6.10 The bolts positions in assembled towers shall be as per IS: 5613 (part-II/sec. 2)-1976.
3.6.11 Bolts at the joints shall be so staggered that nuts may be tightened with spanners without
fouling.
3.6.12 To ensure effective in-process Quality control it is essential that the manufacturer should have
all the testing facilities for tests like weight of zinc coating, shear strength, other testing facilities
etc. inhouse. The manufacturer should also have proper Quality Assurance System which
should be in line with the requirement of this specification and IS: 14000 series Quality System
Standard.
3.7
TOWER ACCESSORIES
3.7.1
Each tower shall be provided with step bolts in one of the main leg confirming to IS:10238
of not less than 16mm diameter and 175 mm long, spaced not more than 450 mm apart
and extending from about 3.5 metres above the ground level to the top of the tower. The
step bolt shall be fixed on the diagonally opposite legs from 3.5 m above ground level to top
of the towers. Each step bolt shall be provided with two nuts on one end to fasten the bolt
securely to the tower and button head at the other end to prevent the feet from slipping
away. The step bolts shall be capable of withstanding a vertical load not less than 1.5 KN.
For special structures, where the height of the super structure exceeds 50 metres, ladders
along with protection rings as per the HVPNL approved design shall be provided in
continuation of the step bolts on one face of the tower from 30 metres above ground level
to the top of the special structure. From 3.5 m to 30 m height of super structure step bolts
shall be provided. Suitable plat form using 6 mm thick perforated chequred plates along with
suitable railing for access from step bolts to the ladder and from the ladder to each crossarm tip and the groundwire support shall also to be provided. The platform shall be fixed on
tower by using countersunk bolts.
Page-19
3.7.2
3.7.3
d)
I shaped suspension insulator string assemblies shall be used for suspension towers,
the drawing of which is enclosed with specification. For the attachment of suspension
insulator string, a suitable dimensioned swinging hanger on the tower shall be provided
so as to obtain requisite clearance under extreme swinging condition and free from
swinging of the string. The hanger shall be designed to withstand an UTS of 70kN for
single suspension string and 140kN for double suspension string.
e)
At tension towers, strain plates of suitable dimensions on the underside of each crossarm tip and at the top earthwire peak should be provided for taking the hooks or Dshackle of the tension insulator strings or earthwire tension clamps, as the case may be.
Full details of the attachments shall be submitted by the bidder for HVPNL approval
before starting the mass fabrication.
EARTHWIRE CLAMPS
a) suspension clamp
Earthwire suspension clamps will be supplied by the bidder. The reference drawing for the
same is enclosed with the specification. Earthwire peaks/ cross arms are to be suitably
designed to accommodate the shackle of the suspension clamp.
b) TENSION CLAMPS
The earthwire tension clamps will be supplied by the bidder. The reference drawing for the
same is enclosed with this specification. The Bidder shall also supply the U-bolts whereever required.
Barbed wire type anticlimbing device/ fencing as per enclosed drawing shall be provided and
conform to IS:5613(Part-2/Section-1)and installed by the Bidder for all towers/ Ganries. The
height of the anticlimbing device shall be provided approximately 3m above ground level. The
barbed wire shall conform to IS:278-1978. the barbed wires shall be given chromating dip as
per procedure laid down in IS:1340-1959.
3.7.5
Danger, Number, Circuit and phase plates shall be provided and installed by the Bidder.
d) Each tower shall be fitted with a number plate, circuit plate and danger plate. Each tension
tower shall be provided with a set of phase plates also. All the double circuit towers are to
be provided with circuit plate fixed near the legs. The height for fixing these accessories
shall not be more than 4.5m above the ground level.
e) The letters, figures and the conventional skull and bones of danger plates shall conform to
IS:2551-1963 and shall be in a signal red on the front of the plate. Number/ Circuit /Phase
Plate shall conform to IS: 5613(Part-2/Section-1)-1985.The corners of the number, danger
& circuit plate shall be rounded off to remove sharp edges.
Page-20
3.7.6
BIRD GUARDS
To prevent bird perching immediately above the suspension insulator strings and fouling the
same with droppings, suitable bird guards shall be provided at cross arm tips of all suspension
towers. The bird guard arrangement shall be such that it shall either prevent bird from perching
in position where they are liable to cause the damages or ensure that if birds do perch, dropping
will fall clear of the insulator string.
3.8
TOWER FABRICATION
3.8.1
Except where hereinafter modified, details of fabrication shall conform to IS:802 (Part-II) 1992
or the relevant international standards.
3.8.2
The tower structure shall be accurately fabricated to connect together easily at site without any
undue strain on the bolts.
3.8.3
No angle member shall have the two leg flanges brought together by closing the angle.
3.8.4
The diameter of the hole shall be equal to the diameter of bolt plus 1.5 mm.
3.8.5
All similar parts shall be made strictly inter-changeable. All steel sections before any work is
done on them, shall be carefully leveled, straightened and made true to detailed drawings by
methods which will not damage the materials so that when assembled, the adjacent matching
surfaces are in close contact throughout. No rough edges shall be permitted in the entire
structure.
3.9
3.9.1
Before any cutting work is started, all steel sections shall be carefully straightened and trued by
pressure and not by hammering. They shall again be trued after being punched and drilled.
Sharp bends shall be a cause for rejection. Straightening for members up to 110X110X10mm
can be done using a roller straightening machine. Larger angles shall be straightened using a
beam bending machine or Hydraulic press.
3.9.2
Holes for bolts shall be drilled or punched with a jig but drilled holes shall be preferred. Punching
may be adopted for thickness upto 16mm. tolerances regarding punched holes are as follows:
a) Holes must be perfectly circular and no tolerance in this respect is permissible.
b) The max. allowable difference in diameter of the holes on the two sides of plates or angle
is 0.8 mm i.e. the allowable taper in a punched hole should not exceed 0.8 mm in diameter.
c) Holes must be square with the plates or angles and have their walls parallel.
3.9.3
All burrs left by drills or punch shall be removed completely. When the tower members are in
position the holes shall be truly opposite to each other. Drilling or reaming to enlarge holes shall
not be permitted.
Page-21
3.10
ERECTION MARK
3.10.1 Each individual member shall have an erection mark conforming to the component number
given to it in the fabrication drawings. This mark shall be made with marking dies of 16 mm size
before galvanizing and shall be legible after galvanizing.
3.10.2
A =
B =
Bidders Mark-Numerical
CC =
Tower type-Alphabet
DD =
HT Steel.
3.11
QUANTITIES VARIATION
3.11.1
The provisional quantities required are mentioned in the respective schedule of prices. Final
quantities shall be determined after completion and approval of the detailed route survey
and check survey. The final quantities of towers, gantries, line materials and foundations
shall be confirmed by the HVPNL based on the requirement of quantities of various items
furnished by the Bidder after completion of detailed survey. Hence, it will the responsibility
of the Bidder to intimate the exact requirements of all towers, line materials and foundations
required for the line immediately after the survey. The Empowered officer of the HVPNL will
order the final quantities at the unit rates quoted in the bid.
3.11.2
The Empowered officer of the HVPNL reserves the right to increase or decrease upto 15%
(fifteen percent only) of contract value the quantity of bid and services specified without any
change in the unit price or other terms and conditions during the execution of the contract.
The quantities of individual items may very upto any extent after the final route plans and route
profiles of the lines covered in the package are finalised.
3.11.3
The estimated unit weight of each type of tower, stubs and extensions shall be furnished by
the HVPNL. The weight of tower shall mean the weight of tower calculated by using the black
sectional (i.e. ungalvanised) weight of steel members of the size indicated in the approved
fabrication drawings and bills of materials, without taking into consideration the reduction in
weights due to holes, notches and bevel-cuts etc. but taking into consideration the weight of
fastners, anticlimbing devices etc.
For payment purpose, the round plane washers, hangers, D-shackles, U-bolts, step bolts,
spring washers, bolts and nuts etc. shall be termed as fasteners.
Page-22
3.12
GALVANISING
Fully galvanized towers and stub shall be used for the lines. Galvanizing of the member of the
towers shall conform to IS:2629-1985 and IS:4759-1968. All galvanised members shall
withstand tests as per IS:2633-1986. For fasteners the galvanizing shall conform to IS:1367
(Part-13). The galvanizing shall be done after all fabrication work is completed, except that the
nuts may be tapped or re-run after galvanizing. Threads of bolts and nuts shall have a neat fit
and shall be such that they can be turned with finger throughout the length of the threads of
bolts and they shall be capable of developing full strength of the bolts. Spring washers shall be
electro-galvanised as per grade 4 of IS: 1573-1970.
3.13
EARTHING
3.13.1 The footing resistance of all towers shall be measured by the Bidder in dry weather after tower
erection but before the stringing of earthwire. All the towers are to be earthed, however, in no
case tower footing resistance shall exceed 10 ohms. Pipe type earthing and counterpoise type
earthing wherever required shall be provided in accordance with the stipulations made in
IS:3043-1987 and IS:5613 (part-II/section-2) 1985. The details for pipe and counterpoise type
earthing are given in drawing enclosed with the specification.
3.13.2 The provisional quantities for pipe type earhings and counterpoise earthing, are furnished in
schedule of Quantities . The Bidders are required to furnish unit rates also for adjustment
purpose with actual quantities. The quoted price shall include fabrication, supply and installation
of earthing material including supply of coke, salt etc. in case of counterpoise type earthing, the
quotation shall be based on 100 metres of wire per tower.
All standards tests, including quality control tests, in accordance with appropriate
Indian/International standard, shall be carried out unless otherwise specified herein.
All Goods being supplied shall conform to type tests, sample tests as per the technical
specifications and shall be subject to routine, acceptance and site tests in accordance with
requirements stipulated under the respective Sections, unless otherwise stated. The HVPNL
reserves the right to witness any or all the type and sample tests. The Bidder shall inform the
HVPNL of the detailed program of tests at least two (2) weeks in advance in case of domestic
supplies and four (4) weeks in advance in case of foreign supplies.
The Bidder shall furnish to HVPNL the reports of all type tests, sample and routine tests as per
technical specification along with the equipment/materials drawings. The type tests conducted
earlier should have been conducted in accredited laboratories (based on ISO/IEC by a reputed
accreditation body) or witnessed by HVPNL or another electric power utility. The type test
reports submitted shall be of the tests conducted within last five (5) years prior to the date of bid
opening. In case the test reports are of a test conducted five (5) years prior to the date of bid
opening, and dont correspond to the offered equipment/material, or dont comply with the
Technical Specifications, the Bidder shall repeat this / these test / tests at no extra cost to the
HVPNL before sample(acceptance) tests. The cost of conducting type tests and additional tests
shall be included in the bid price.
Page-23
The HVPNL, his duly authorized representative and/or outside inspection agency acting on
behalf of the HVPNL shall have free access at all reasonable times to the Bidders/sub-vendors
premises or Works and shall have the power at all reasonable times to inspect and examine the
equipment/materials and workmanship of the Works during its manufacture or erection. If part
of the Works is being manufactured or assembled at other premises or works, the Bidder shall
obtain for the HVPNL, his duly authorized representatives and/or outside inspection agency
permission to inspect as if the works were manufactured or assembled on the Bidders own
premises or works. Inspection may be made at any stage of manufacture, dispatch or at the
Site at the option of the HVPNL, and the equipment if found unsatisfactory due to bad
workmanship or quality or material is liable to be rejected.
When the factory tests have been completed at the Bidders or Sup-Bidders works, the
HVPNL/Inspector shall issue a certificate to this effect within fifteen (15) days after the
completion of the tests, but if the tests are not witnessed by the HVPNL/Inspector, the certificate
shall be issued within 15 days of receipt of the Bidders test certificate by the HVPNLs
representative. Failure of the HVPNL/Inspector to issue such a certificate shall not prevent the
Bidder from proceeding with the Works (as defined in SCC). The completion of these tests or
the issue of the certificate shall not bind the HVPNL to accept the equipment/materials should
it, on further tests after erection, be found not comply with the Contract. The
equipment/materials shall be dispatched to Site only after approval of test reports and issuance
of
the
inspection
certificate
by
the
HVPNL.
The inspection by the HVPNL and issue of the inspection certificate thereon shall in no way limit
the liabilities and responsibilities of the Bidder in respect to the agreed quality assurance
program forming part of the Contract.
The HVPNL will have the right of having at his own expenses any other test(s) of reasonable
nature carried out at the Bidders premises or at any other place in addition of aforesaid type
and routine tests to satisfy that the equipment/materials comply with the specifications.
The HVPNL deserves the right for getting any field tests not specified in the respective sections
of the technical specifications conducted on the completely assembled equipment at Site. The
HVPNL
will
provide
the
testing
equipment
for
these
tests.
The Bidder shall ensure that his subBidders manufacturing and supplying the goods (material
and equipment) shall perform the routine tests specified in the related standards and in the
Technical
Specifications
of
this
Contract
regularly.
The Bidder shall notify the HVPNL in writing at the latest four (4) weeks for inspection outside
of India and two (2) weeks for local inspection and testing or as otherwise directed in advance
of the date and place at which any Material or Work will be ready for inspection and testing.
Should any postponement become necessary, the Bidder shall provide written notification at
least one week prior to the originally scheduled date. The HVPNL shall give 48 hours' notice in
writing to the Bidder, of his intention to attend the tests, or ask for postponement, if required.
Page-24
Should the HVPNL explicitly waive to attend the relevant test, the Bidder may proceed with the
test, which shall be deemed to have been made in his presence, and the Bidder shall forthwith
forward to the HVPNL duly certified copies of the test reports for approval.
All sample and type tests will be performed at the presence of the authorized personnel of the
Bidder or inspectors authorized by the Bidder, if there is no representative of HVPNL.
HVPNL may or may not be present in any or all sample and type tests but all test reports shall
be approved by HVPNL.
This procedure shall not release the Bidder from any of his responsibilities or obligations under
this Contract.
The Bidder shall prepare and agree with HVPNL test programs so that tests to be performed in
foreign countries (i.e. at manufacturer's factory or at internationally recognized test facilities) are
carried out in sequence which would permit HVPNL to organize in an optimal manner the
supervision of the said tests by HVPNL staff.
All fabricated materials shall be tested in accordance with the "Test and Inspection
Procedures for Galvanized Materials "as per Specification and HVPNL shall be notified at
least thirty days in advance of any tests if it is performed in abroad.
3.14 (b) Inspections and Tests: The Bidder shall make adequate tests and inspections to determine
whether the material furnished is strictly in accordance with this Specification. In addition,
HVPNL may inspect and accept or reject the material made under this Specification either at
the Fabricator's plant or at the point of delivery The representatives of HVPNL shall have access
to all parts of the Bidder's plant which concerns the Work while the Work is being done. The
Bidder, without requesting any fee, shall provide all the reasonable facilities to the HVPNL's
representatives so as to satisfy them that, the towers are manufactured strictly in compliance to
this
Specification.
Certified Tests: Regardless of whether the material is inspected by HVPNL , the Bidder shall
furnish certified test reports as follows:
a)
Steel Mill Test Reports showing chemical, physical and mechanical properties of the
material to be furnished under the Contract.
b)
1-
2-
3-
Date of inspection
Number of pieces tested for weight of zinc coating with maximum-minimum and average
weights of each.
Page-25
4-
5-
3.14( c) Shop Assembly: One tower of each type and height ordered, including every combination
of leg extensions, shall be assembled in the shop to the extent necessary to assure correct
fit of parts, adequate bolt lengths and proper field erection. Reaming of mismatched holes
will not be permitted. A reasonable amount of drifting will be allowed in assembling approved
by HVPNL. The approved assembled parts shall be dismantled for shipment. Shop
assembly shall be controlled and approved by HVPNL.
3.14 (d) abrication: Fabrication shall be in strict accordance with detail Drawings prepared by the
Bidder and approved by the HVPNL. The drilling, punching, cutting and bending of all fabricated
steelwork shall be such as to prevent any possibility of irregularity occurring which might
introduce difficulties in the erection of the structure on the site.
Built pieces shall, when finished, be true and free from all kinks, twists and open joints and
the Material shall not be defective or strained in any way. Fabrication shall begin after the
approval of the shop assembly.
3.15
Identification: All parts designed for bolting together shall be shipped unassembled except as
noted on the drawings. Tower members shall be bundled together in the largest practical
bundles for shipping and each bundle shall be clearly marked. Small parts such as U-bolts and
clip angles shall be boxed and each box clearly marked for identification.
Shipping: Railroad cars, ships or trucks in which steel is shipped shall be reasonably clean
and free from foreign materials which could in any way injure the tower material. At least 8cm
clearance shall be maintained between bundles and floor.
3.16
GENERAL
All standards tests, including quality control tests, in accordance with appropriate
Indian/International standard, shall be carried out unless otherwise specified herein.
3.17
INSPECTION
3.17.1 In addition to the provision of clause regarding inspection in conditions of contract, the following
shall also apply:
a) The Bidder shall keep the HVPNL informed in advance about the time of starting and of the
progress of manufacture and fabrication of various tower parts at various stages, so that
arrangements can be made for inspection.
b) The acceptance of any part of items shall in no way relieve the Bidder of any part of his
responsibility for meeting all the requirements of the specification.
Page-26
3.17.2
The HVPNL or his representative shall have free access at all reasonable times to those parts
of the Bidders works which are concerned with the fabrication of the HVPNL material for
satisfying himself that the fabrication is being done in accordance with the provisions of the
specifications.
3.17.3
Unless specified otherwise, inspection shall be made at the place of manufacture prior to
dispatch and shall be conducted so as not to interfere unnecessarily with the operation of the
work.
3.17.4
Should any member of the structure be found not to comply with the approved design, it shall
be liable to rejection. No member once rejected shall be re-offered for inspection, except in
cases where the HVPNL or his authorized representative considers that the defects can be
rectified.
3.17.5
Defect which may appear during fabrication shall be made good with the consent of and
according to the procedure proposed by the Bidder and approved by the HVPNL.
3.17.6
All gauges and templates necessary to satisfy the HVPNL shall be supplied by the manufacture.
3.17.7
The correct grade and quality of steel shall be used by the Bidder. To ascertain the quality of
steel used, the inspector may at his discretion get the material tested at an approved laboratory.
3.18
TESTING OF TOWER
As the towers to be fabricated have already been tested hence testing of towers is not
required.
3.19
Standards
3.19.1The design, manufacturing, fabrication, galvanizing, testing, erection procedure and materials
used for manufacture and erection of towers, design and construction of foundations shall
conform to the following Indian Standards (IS) International standards which shall mean latest
revisions, with amendments/ changes adopted and published, unless specifically stated
otherwise in the specification. In the event of supply of material conforming to standards other
than specified, the bidder shall confirm in his bid that these standards are equivalent to those
specified. In case of award, salient features of comparison between the standards proposed by
the Bidder and those specified in this document will be provided by the Bidder to establish their
equivalence.
3.19.2 The material and services covered under these specifications shall be performed as per
requirements of the relevant standards/codes (latest version) referred hereinafter against each
set of equipment and services. Other internationally acceptable standards which ensure equal
or higher performance than those specified shall also be accepted.
SR
No.
INDIAN
STANDARDS
TITLE
INTERNATIONAL&
INTERNATIONALLY
RECOGNISED STANDARDS.
IS:209-REV,
ISO/R/752-1968 ASTM B6
Page-27
IS:226-1975
Structural steel
ISO/R/630-1967
standard
quality CAN/CSA-G40.21
BS 4360
IS:269-1976
ISO/R/597-1967
IS:383-1970
IS:278
ASTM A 121
IS:432-1966
(part-I&II)
BS-785-1938 CSA-G-30.
IS:456-2000
IS:800-1962
CSA S16.1
of structural steel in
general building construction.
a) IS:802
(part-1)
of structural steel in
overhead transmission
line. Materials loads
and permissible stresses.
b)IS:802
(part-2) 1978
of structural steel in
overhead transmission
line. Fabrication,
galvanizing, inspection and packing.
c)IS:802
(part-3) 1978
10
IS:808
ASCE 52
11
IS:875
12
IS:1139-1966
13
IS:1367-1967
for
Page-28
14
IS:1489-1976
ISO/R/863-1968
15
IS:1786-1989
16
IS:1893-1965
17
IS:2016-1967
Plain washers
18
IS:2131-1967
19
IS:2551-1982
20
IS:2629-1966
21
IS:2633-1972
22
IS:3043-1972
ISO/R/887-1968.
B18.22.1
ANSI
23
IS:3063-1972
24
IS:4091-1967
25
IS:5358-1969
26
27
28
IS:6610-1972
29
IS:6639-1972
coatings
on
Page-29
30
IS:6745-1972
31
32
33
IS:8500-1977
34
IS:2062-2006
PAGE-30
Reference/Abbreviation
IS
ISO
CSA
BS
DIN
Rezdale Boulevard,
Indian Electricity Rules 1956 Kitab Mahal ,Baba Kharak Singh Marg, New Delhi-110001 INDIA.
Regulation
for
Electricity
Crossing of Railway Tracks.
ASCE
IEEE
IEC
PAGE-31
4.0
TOWER FOUNDATION
4.1
GENERAL
These specifications provide general guidelines for the construction of tower foundations as per
design supplied by HVPNL and the gantry tower foundations as per design supplied by HVPNL
of the proposed transmission line(s) covered in the tender.
4.2
Before start of work, successful bidder shall carry out trial bore-holes (normally up to 6.0 meter
below natural ground level) after every Kilometer en-route or as desired by the Employer to
have a fair idea of soil type/nature and subsoil water position. If the soil characteristics are
changing rapidly or soil up to 6.0 meter is very weak, the depth of bore-hole be increased
beyond 6.0 meters so as to know the soil properties/type below the foundation. The bore log
data containing information such as position of sub-soil water table, soil strata, the crop pattern
in the agricultural fields where the foundation is to be laid and the suitability for founding the
required foundation, shall be submitted to the Employer for according approval for
Classification of foundation at each location.
Contractor shall also ensure to check the entry of kids/ animals in to the excavated pits by
providing suitable warning signs and safety measures as per the approval of Engineer-InCharge.
1. 66kV connectivity between 66kV S/Stn. Sec-9 and 66kV S/Stn. Sec-10A Gurgaon by laying
of four Nos. 1200mm2 underground XLPE cable (tower portion).
[[
Ground water table enroute all the above said lines generally vary from 20mtr. to 25mtr.
below Natural Ground Level.
4.4
4.4.1
CLASSIFICATION OF SOIL
a.
Dry Soil: Soil shall be termed as dry soil where sub-soil water table is below base of the
tower footing and no de-watering is required.
b.
Wet Soil (without de-watering): Soil shall be termed as wet soil (without de-watering)
where sub-soil water is below base of footing and no de-watering is required but crop
pattern is paddy field.
c.
Wet Soil (with de-watering): Soil shall be termed as wet soil (with de-watering) where
sub-soil water is above base of footing and de-watering has to be done.
d.
Rocky Soil: Hard conglomerate or other soft or fissured rock which can be quarried or
split with crow bars, wedges or pick axes. However, if required, light blasting may be
resorted to for loosening the material.
For excavation purpose, the quoted rates for foundations in wet soil (without de-watering) shall
be considered as applicable for the dry soils. For wet soil (with de-watering), the quoted rates
of de-watering have been asked for separately. The de-watering operation shall continue to
keep the foundation pits dry during concreting and thereafter for at least 24 hrs. Any de-watering
carried out for removal of seepage of surface water/rainwater will not be considered as dewatering and the soil shall be termed as Dry Soil.
PAGE-32
4.5
4.5.1
FOUNDATION TYPES
GENERAL
Reinforced cement concrete footing shall be used for all types of normal towers/ extension
towers in conformity with the present day practices followed in the country and the specifications
laid herein. All the four footings of the tower and their extensions, if any shall be similar
irrespective of down thrust and uplift.
4.5.2
Foundation includes supply of materials such as cement, fine and coarse aggregates, water,
reinforcement steel and binding wire etc. Rates quoted for foundations shall include all items of
work relating to supply and installation of foundations such as form work, excavation and back
filing with good soil, compaction, stub setting, shoring & timbering etc. where ever required,
placing of reinforcement in position, concreting and all other works related for completion of
foundation.
4.6
CLASSIFICATION OF FOUNDATIONS
a.
Dry Foundation: To be used where sub-soil water table is below 6.0 meter from Natural
Ground Level.
b.
c.
Wet Foundation (with de-watering): To be used where sub-soil water table is above
footing base of foundation and actual de-watering has to be carried out for construction
of foundation for which separate rates have been asked for.
4.6.1
Design of foundation for Wet (without de-watering) and Wet (with de-watering) shall be same.
4.7
4.7.1. All the properties of concrete regarding its strength under compression, tension, shear, punching
and bond strength etc. as well as workmanship shall confirm to IS: 456 latest.
4.7.2
The concrete used as lean concrete or base concrete shall be as mentioned on respective
drawings. The aggregate size shall be 40 mm nominal. Base concrete shall be well compacted.
The top surface of base concrete shall be leveled before placing the reinforcement.
During excavation, if excavation exceeds the required depth or if any loose pocket of earth is
met below the base of footing, then the loose earth shall be removed or excavation depth be
increased till normal hard soil is met as per satisfaction of the Engineer-in-Charge. This extra
depth shall be filled with lean concrete. No extra shall be paid on account of this extra excavation
and lean concrete.
PAGE-33
4.7.3
The cement concrete used for foundation shall be of grade M-20 {irrespective of any grade
mentioned on the drawing(s)}. The Mix Design (conforming to IS standards) shall be done prior
to start of work, as per specifications, got approved from the Employer and shall be used for the
construction, provided there is no change in the source and the quality of materials. The source
of materials shall be intimated to the Employer and shall be ensured that Mix Design is with the
materials from intimated source only and same is not changed during construction. In case
source of material changes or quality of material differs from the earlier approved parameters,
the Mix Design shall be done again. Whenever there is uncertainty of availability of aggregates
from a fixed source, nominal mix is to be followed but the quality of aggregates shall not be
compromised. To avoid the delays, the contractor may go for nominal mix after getting the
aggregates tested till such time the mix design is got approved.
4.7.4 The coarse aggregate used shall be 20 mm graded or two types of single size aggregate mixed
in some fixed ratio to have graded 20-mm aggregate. The Coarse aggregate shall conform to
IS 383.
4.7.5
Grading of Fine aggregate shall conform to Zone-II of Table-4 of IS: 383 and shall be free from
deleterious materials.
4.7.6
The environmental exposure condition considered for Mix Design shall be MILD.
4.7.7
For Mix Design the degree of quality control shall be considered as FAIR.
4.7.8 The Water Cement ratio shall be minimum 0.50 and maximum 0.55.
4.7.9
For Transmission Line Tower footings, the minimum Slump shall be 50 mm and maximum
75 mm.
4.7.10 For volumetric use of ingredients for concrete mix, the contractor along with the Mix Design shall
intimate the size of measuring boxes along with the Mix design.
4.7.11The approval of Mix Design shall not absolve the contractor from the responsibility of achieving
the required strength, workability etc. during actual execution. In case of failure of concrete
samples, the work done is liable to be rejected. In such case the contractor shall recast the
foundation at the same location by dismantling the rejected foundation or at a nearby location
as directed by the Employer. In case of honey combing, the contractor shall do the pressure
grouting as directed and to the full satisfaction of Employer. The construction of new foundation
in place of rejected one and pressure grouting if done shall be without any extra payment.
4.7.12Ordinary Portland_Cement of Grade 43 of reputed make like JK, ACC, Ambuja, Shree
conforming to IS: 8112 shall be used. However in case of shortage of OPC Cement, Portland
Pozzolona Cement (fly ash based or calcinated clay based) conforming to IS 1489 Part Part 1
and 2 respectively may be used in the works other than RCC. In case, Portland Pozzolona
Cement is used then curing period shall be enhanced as directed by Engineer-in-Charge. In
RCC works only Ordinary Portland Cement of Grade 43 shall be used.
4.7.13 The water used for mixing concrete and for curing purpose shall be fresh, clean and free from
oils, acids and alkalis, organic materials or other deleterious substance. Potable water is
generally preferred. Saltish or brackish water shall not be used. Water used shall conform to
clause 5.4 of IS 456.
PAGE-34
4.7.14 Reinforcement steel (including TMT) Bars manufactured by TISCO, SAIL, IISCO and
RASHTRIYA ISPAT (primary manufacturers) conforming to IS: 1786 for deformed and cold
twisted bars shall only be used. The bidders shall, however, be allowed to use Amba steel,
Rathi steel, Kamdhenu steel, Barnala steel, P.R.S steel, Shidbali steel (manufactured by
secondary manufacturers) only after obtaining non-availability certificate from the primary
manufacturers. Before using secondary steel, the selected bidder would require to conduct all
physical & chemical tests (lot wise & dia. wise) to establish its conformity to IS Standards.
Required grade of steel shall be Fe-415. All reinforcement shall be clean and free from loose
mill scale, dust, loose rust and coats of paint, oil or other coating, which may destroy or reduce
bond with concrete. Reinforcement bars should be fresh. Contractor shall supply, fabricate and
place reinforcement to shapes and dimensions as indicated on the drawings or as required to
carry out the intent of drawings and specifications. Adequate nos. of chairs, spacers of required
size shall be provided to ensure the proper placement of reinforcement. The reinforcement bars
crossing one another should be tied together at every intersection with two strands of annealed
steel wires 0.9 to 1.6 mm thick twisted and tied to make the skeleton of the steel work rigid so
that the reinforcement does not get displaced during concrete placement.
All the reinforcement steel should be placed/ stacked at site store on raised (at least 0.5 meter
from near surroundings) pucca/brick platform or reinforcement steel should be placed on MS/GI
sheets. The reinforcement steel after stacking should be covered with Tarpaulin to avoid
corrosion. Immediately before concreting (portion of reinforcement to be embedded in concrete)
shall be painted with cement slurry after removing any rust/corrosion/any other foreign material.
4.8
4.8.1
The rates of foundation shall be per tower. These rates shall include excavation, stub setting,
concreting, reinforcement, shuttering, shoring/ timbering, stockpiling, dressing, curing, back
filling (after concreting) with good (excavated/borrowed) earth irrespective of lead. Rates are
inclusive of compaction of earth, carriage of surplus earth to suitable disposal location as
required by Employer or any other activity related to completion of foundation works in all
respects.
4.8.2
In case of any change/variation in the foundation drawing(s) attached with bidding document,
due to site conditions or otherwise, the payment shall be made based on formula given in the
commercial clause.
4.9
4.9.1
EXCAVATION
Excavation work shall start only after the approval of route plan, the tower foundation schedule,
classification of foundations and the profile by the Employer. The reference natural ground level
shall be so chosen that it is not lower than surroundings and in normal condition water does not
accumulate there, preferably it should be slightly higher than surroundings.
PAGE-35
All excavation for footing shall be made to the lines and grades of the foundation. The
excavation wall shall have stable slope and the pit dimensions shall be such as to allow a
clearance of 150 mm on all sides from the foundation RCC pad. The contractor should ensure
clearance of 150 mm from the foundation RCC pad for quality work.
All excavation shall be protected so as to maintain a clean sub-grade until the footing is placed,
using timbering/shuttering, shoring etc., if necessary. Any sand, mud, silt or other undesirable
materials, which may accumulate in the excavated pit, shall be removed by the contractor before
placing concrete.
4.9.2 No extra charges shall be admissible for the removal of the fallen earth in the pit, when once
excavated.
4.9.3
4.10
Wherever ground water table is higher than the base of the foundation, it has to be depressed
by de-watering. During de-watering, water shall be thrown at a place as directed by the
Engineer-in-Charge. No pit/open de-watering shall be permitted. Instead, over all lowering of
the water table shall be done by providing sufficient number of bores around the tower location
and by continuous pumping of water through these bores. Well point system for de-watering
of pits can also be adopted. It must be ensured that during de-watering/pumping operation, no
finer particles of soil get displaced or any cavity is formed below. The boreholes for de-watering
shall be located so as to avoid any hindrance in normal working for construction of foundation.
The construction of foundation shall be carried out in bone-dry condition, which shall be
ensured by effective lowering of water table so that no caving in happens and also the bottom
of the pit is free from slushy conditions. The bores shall be filled with sand after the work at a
particular location is over.
SETTING OF STUBS
The stubs shall be set correctly in accordance with approved method at the exact location and
aligned precisely at correct levels with the help of stub setting templates and leveling
instruments. Stubs shall be set in the presence of Employers representative for which the
Contractor shall give adequate advance intimation to the Employer. All necessary precautions
should be taken to ensure that the stubs finally set in are not disturbed. If these are disturbed
due to any reason, the bidder shall reset the same without any extra cost.
4.11
After completion of the project, one set of each type of stub setting template as applicable shall
be supplied to the Employer at no extra cost to the Employer.
4.12
4.12.1 The concrete shall be mixed in a mechanical mixer. The mixer shall comply with IS: 1791 & IS:
12119. The mixer shall be fitted with water measuring devices. Mixer without trough should not
be brought at site. In case of difficult terrain, the Employer at his discretion may permit hand
mixing but this should not be made a routine. In case of hand mixing, 10% extra cement shall
be used without any extra cost.
PAGE-36
4.12.2Mixing shall be continued until there is uniform distribution of material and the mix become
uniform in colour and consistency. If there is segregation after unloading from mixer, the
concrete should be re-mixed, but in no case the mixing be done for less than two minutes.
Normally, mixing shall be done close to the foundation, but in case it is not possible the concrete
may be mixed at a nearest convenient place. From mixer the concrete shall be put on pucca
platform or steel troughs, which shall be leak proof to avoid any loss of water/slurry.
The concrete shall be transported from the place of mixing to the place of final deposit as rapidly
as practicable by methods, which will prevent the segregation or loss of any ingredient. The
concrete shall be placed and compacted before setting commences.
4.12.3 Form boxes of required size as per approved Mix Design volumes shall be used for casting all
type of foundations. Form boxes shall be rigidly tightened so that there are no distortions in the
shape of foundations. Form boxes shall be made sufficiently strong to withstand all the loads
and vibrations. For bottom pad portion sufficiently wide window of minimum size 450 x 300 mm
be left on each side at top for placing of concrete and for use of vibrators to ensure thorough
compaction. After every use, the form box(es) be checked for any deformation and if necessary
be repaired/corrected to original position for reuse.
4.12.4 On removal of the form-work, if the concrete surface is found damaged, it shall be repaired with
rich cement sand mortar to the satisfaction of the Engineer-in-Charge. The foundation pits be
back-filled only after necessary repairs, if any as required above has been done.
4.13.2 After opening of formwork and removal of shoring and timbering, backfilling shall be started,
after repairs, if any, to the foundation concrete as described under para 4.12.4 above. Backfilling
shall normally be done with excavated soil. In case the excavated soil consists of large
boulders/stones, it should be broken to a maximum size of 80 mm. If the excavated earth has
harmful salts, it shall not, under any circumstance, be used for backfilling. In such case
excavated earth shall be disposed off as directed by the Engineer-in-Charge and suitable earth
(clean and free from harmful salts, organic and other foreign materials) be brought for back
filling. This shall be done by the contractor at his own cost irrespective of lead involved for
bringing the suitable earth.
4.13.3 The earth shall be deposited in layers (maximum 200 mm layers), leveled and wetted and
tampered properly before another layer is deposited. After the pits have been backfilled to full
depth, the stub template may be removed.
4.13.4 The backfilling and final grading shall be carried upto an elevation of about 75 mm above the
finished ground level to drain out water. After backfilling 50 mm high earthen embankment
(bandh) will be made along the side of excavation pits and sufficient water will be poured in the
backfilled.
PAGE-37
4.14
CURING
Curing shall start after 24 hours of concreting to keep the concrete wet continuously for a period
of 10 days. However, after a minimum period of 72 hours the pit may be backfilled with suitable
earth sprinkled with necessary amount of water and well consolidated in layers not exceeding
200mm. Both backfilled earth and exposed chimney top shall be kept wet for the remainder of
the prescribed time of 10 days. The uncovered concrete chimney above the backfilled earth
shall be kept wet by providing gunny bags dipped in water fully wrapped around the concrete
chimney for curing. It must be ensured that the bags are kept wet by the frequent pouring of
water on them. In case Portland Pozolona cement has been used, curing period shall be
increased as decided by the Engineer-in-charge.
4.15
4.15.1 The work shall include all necessary brick/stone masonry (in C.M. 1:4) revetments, earth filling
above ground level and the clearance from stacking on the site of surplus excavated soil.
Special measures for protection of foundation wherever required shall be provided after getting
prior approval of the Employer and as per directions of the Engineer-in-Charge.
4.15.2 The excess quantity of earth required for protection of tower (after utilizing the excavated earth) and
to be brought from outside shall be paid as per the rate provided in the letter of award.
4.15.3 The provisional quantities for foundation protection works are furnished in the Schedule of
Quantities as well as in the Price Schedule. The unit rates shall be applicable for adjusting with
the actual quantities of protection work done.
4.16
The contractor shall strictly follow the Field Quality Control Plan (given here under) for effective
control on quality of civil works. All costs of testing as per the Field Quality Control Plan or as
directed by Employer shall be borne by the Contractor.
4.17
Technical Specification given in the Contract will govern for the different items/activities. The
items/activities for which detailed specifications have not been given in the Contract Agreement
will be governed by latest ISI/ NBC specifications.
4.18 Wherever IS Code has been mentioned, it shall mean IS Code with latest
amendments.
PAGE-38
5.0
5.16
GENERAL
5.16.1 The details of the scope of erection work shall include the cost of labour, all tools and plants
and all other incidental expenses in connection with erection and stringing work.
5.16.2 The Bidder shall be responsible for transportation of all the materials as per the scope of work
to site, proper storage and preservation at their own cost till such time the erected line is taken
over by the HVPNL. Bidder shall set up required number of stores along the line and the exact
location of such stores shall be discussed and agreed to between the Bidder and the HVPNL.
It shall be entirely the responsibility of the Bidder to arrange receipt, unloading and loading and
transportation of the supplied items to the stores, proper storage and safe custody.
5.17
5.18
ASSEMBLY
The method followed for the erection of tower, shall ensure the points mentioned below:
g)
Straining of the members shall not be permitted for bringing them into position, it may,
however be necessary to match hole positions at joints and to facilitate this, tommy bars
not more than 450 mm long may be used.
h)
Before starting erection of an upper section, the lower section shall be completely braced
and all bolts provided and tightened adequately in accordance with approved drawings
to prevent any mishap during tower erection.
i)
All plan diagonals relevant to a section of tower shall be placed in position before
assembly of upper section is taken up.
j)
k)
Tower shall be fitted with number plate, danger plate, phase plate, circuit plate and anticlimbing device barbed wire type as described.
l)
All blank holes, if any left, after complete erection of the tower, are to be filled up by bolts
and nuts of correct size.
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5.19
5.19.1 All nuts shall be tightened properly using correct size spanner/torque wrench. Before tightening,
it will be seen that filler washers and plates are placed in gaps between members wherever
applicable. Bolts of proper size and length are inserted and one spring washer is inserted under
each nut. In case of step bolts, spring washers shall be placed under the outer nut. The
tightening shall progressively be carried out from the top downwards, care being taken that all
bolts at every level are tightened simultaneously. The threads of bolts projecting outside the
nuts shall be punched at their position on the diameter to ensure that the nuts are not loosened
in course of time. If during tightening a nut is found to be slipping or running over the bolt
threads, the bolt together with the nut shall be replaced.
5.19.2 The threads of all the bolts projected outside the nuts shall be welded at two diametrically
opposite places. The circular length of each welding shall be at least 10mm. The welding shall
be provided from ground level to bottom cross arm level for double circuit towers. After welding,
cold galvanized paint having at least 90% zinc content shall be applied to the welded portion.
At least two coats of the paint shall be applied. The cost of welding and paint including
application of paint shall be deemed to be included in the erection price.
5.19.3 In addition to the tack welding of nuts with bolts, as described above, the Bidder can also
propose some alternative arrangements, like use of epoxy resin adhesive which can serve the
purpose of locking the nut permanently with the bolt and thus preventing pilferage of the tower
members.
5.19.4 All the inter contact surfaces at the joint shall be painted with zinc rich paint to avoid formulation
rust as per clause 14.3 of IS:5613(Part 3/Section-2)-1989.
5.20
INSULATOR HOISTING
5.20.1 Single I suspension insulator strings shall be used on suspension towers and tension insulator
strings on all tension towers. These shall be fixed on all the towers just prior to the stringing.
Damaged insulators and fittings, if any, shall not be employed in the assemblies. Before hoisting
all insulators shall be cleaned in a manner that will not spoil, injure or scratch the surface of the
insulator, but in no case shall any oil be used for the purpose. Arcing horn shall be fitted in an
approved manner. Torque wrench shall be used for fixing different line materials and their
components, like suspension clamp for conductor and earthwire etc ,whenever recommended
by the manufacturer of the same for river crossing towers.
5.21
5.21.1 The Bidder shall be entirely responsible for any damage to the towers or conductors during
stringing. While running out the conductors, care shall be taken that the conductors do not touch
or rub against the ground or objects which could cause scratches or damages to the strands.
The conductors shall be run out of the drums from the top in order to avoid damage due to
chafing. Immediately after running out, the conductor shall be raised at the supports to the levels
of the clamps and placed into the running blocks. The groove of the running blocks shall be of
such a design
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that the seat is semi-circular and larger than the diameter of the conductor/earthwire and it does
not slip over or rub against the sides. The grooves shall be lined with hard rubber or neoprene
to avoid damage to conductor and shall be mounted on properly lubricated bearings.
5.21.2 The running blocks shall be suspended in a manner to suit the design of the cross-arm. All
running blocks especially those at the tension end, will be fitted on the cross-arm with jute cloth
wrapped over the steel work and under the slings to avoid damage
to the slings as well as to the protective surface finish of the steel work. In case suspension, or
section towers are used even for temporary terminations, if this be unavoidable, they shall be
well guyed and steps shall be taken by the Bidder to avoid damage. Guying proposal alongwith
necessary calculations shall be submitted by the bidder to HVPNL for the approval. Proper T&P
shall also be made available to the HVPNL by the bidder for checking the tensions in the guy
wires. The drums shall be provided with a suitable braking device to avoid damages, loose
running out and kinking of the conductor. The conductor shall be continuously observed for
loose or broken strands or any other damage. When approaching end of a drum length, at least
three coils shall be left when the stringing operations are to be stopped. These coils are to be
removed carefully, and if another length is required to be run out, a joint shall be made as per
the recommendations of the manufacturers.
5.21.3 Repairs to conductors. If necessary, shall be carried out during the running out operations, with
repair sleeves. Repairing of conductor surface shall be done only in case of minor damage.
Scuff marks etc. keeping in view both electrical and mechanical safe requirements. The final
conductor surface shall be clean smooth and without any projections, sharp points, cuts,
abrasions etc.
5.21.4 Conductor splices shall be so made that they do not crack or get damaged in the stringing
operation. The Bidder shall use only such equipment/methods during conductor stringing which
ensures complete compliance in this regard.
5.21.5 Derricks shall be used where roads, rivers, channels, telecommunication or overhead power
line, Railway line, fences or walls have to be crossed during stringing operations. It shall be
seen that normal services are not interrupted or damage caused to property. Shut down shall
be obtained when working at crossing of overhead power line. The Bidder shall be entirely
responsible for the proper handling of the conductor, earthwire and accessories in the field.
5.21.6 The sequence of running out shall be from top to downwards, i.e. the earthwire shall be run out
first, followed by the conductors in succession. Unbalances of loads on tower shall be avoided
as far as possible.
5.21.7 The proposed transmission line may run parallel for certain distance with the existing
transmission lines which may remain energized during the stringing period. As a result there is
a possibility of dangerous voltage build up due to electromagnetic and electrostatic coupling in
the pulling wire, conductors and earthwires, which although comparatively small during normal
operations can be severe during switching. It shall be the Bidders responsibility to take
adequate safety precautions to protect his employees and others from this potential danger.
5.22
5.22.1 The stringing of conductor shall be done by the standard stringing method.
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5.22.2 After being pulled the conductor, earthwire shall not be allowed to hang in the stringing blocks
for more than 96 hours before being pulled to the specified sag.
5.22.3 Conductor creep in respect of ACSR Zebra are to be compensated by over tensioning the
conductor at a temperature of 26 o C lower than the ambient temperature and Conductor creep
in respect of ACSR ZEBRA are to be compensated by over tensioning the conductor at a
temperature of 21oC lower than the ambient temperature.
5.22.4 To Bidder shall give complete details of the stringing methods which he purposes to follow.
Before the commencement of stringing the Bidder shall submit the stringing charts for the
conductor and earthwire for various temperature and span, alongwith equivalent spans for
approval of the HVPNL.
5.23
JOINTING
5.23.1 All the joints on the conductor and earthwire shall be of compression type, in accordance with
the recommendations of the manufacturer for which all necessary tools, equipment like
compressors, dies, processes etc. shall have to be arranged by the Bidder. Each part of the
joint shall be cleaned by wire brush to make it free of rust or dirt etc. and properly greased with
anticorrosive compound if required, and as recommended by the Bidder before the final
compression is done with the compressors.
5.23.2 All joints or splices shall be made at least 30 metres away from the structures. No joints or
splices shall be made in span crossing over main Roads, Railways, small rivers with tension
spans. During compression or splicing operation the conductor shall be handled in such a
manner as to prevent lateral or vertical bearing against the dies. After pressing the joint the
aluminum sleeve shall have all corners rounded, burrs and sharp edges removed and
smoothened.
5.23.3 During stringing of conductor to avoid any damage to the joint, the Bidder shall use a suitable
protector with mid span compression joints in case joints are to be passed over pulley
blocks/aerial rollers. The size of the groove of the pulley shall be such that the joint along with
protection can be passed over it smoothly.
5.24
SAGGING-IN-OPERATION
5.24.1 The conductor shall be pulled up to the desired sag and left in running blocks for at
least one hour after which the sag shall be re-checked and adjusted, if necessary before
transferring the conductors from the running blocks to the suspension clamps. The conductor
shall be clamped within 36 hours of sagging in.
5.24.2 The sag will be checked in the first and the last span of the section in case of sections up to
eight spans and in one intermediate span also for sections with more than eight spans. The sag
shall also be checked when the conductors have been drawn up and transferred from running
blocks to the insulator clamps.
5.24.3 The running blocks, when suspended from the transmission structure for sagging shall be so
adjusted that the conductors on running blocks will be at the same height as the suspension
clamp to which it is to be secured.
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5.24.4 At sharp vertical angles, the sags and tensions shall be checked on both sides of the angle, the
conductor and earthwire shall be checked on the running blocks for equality of tension on both
sides. The suspension insulator assemblies will normally assume vertical positions when the
conductor is clamped.
5.24.5 Tensioning and sagging operations shall be carried out in calm weather when rapid changes in
temperatures are not likely to occur.
5.25
5.26
CLIPPING IN
5.26.1 Clipping of the conductors in position shall be done in accordance with the recommendations
of the manufacturer. Conductor shall be fitted with armour rods where it is made to pass through
suspension clamps.
5.26.2 The jumpers at the section and angle towers shall be formed to parabolic shape to ensure
maximum clearance requirements. Pilot suspension insulator string shall be used, if so desired
by the purchaser to restrict the jumper swings to the designed values.
5.26.3 Fasteners in all fittings and accessories shall be secured in position. The security clip shall be
properly opened and sprung into position.
5.27
5.28
REPLACEMENT
If any replacements are to be effected after stringing and tensioning or during maintenance, leg
members and bracings shall not be removed without reducing the tension on the tower with
proper guying or releasing the conductor. If the replacement of cross arms becomes necessary
after stringing, the conductor shall be suitably tied to the tower at tension points or transferred
to suitable roller pulleys at suspension points.
Page-43
5.29
The bidder shall make every effort to minimize the breakages, losses & wastages of
the
line material during erection. However, while calculating the quantities of line
materials, HVPNL
shall permit the bidder following extra consumption of line material
up to the limit as specified in
table below: The bidder shall be permitted to dispose off the scraps, if any, at their end.
---------------------------------------------------------------------------------------------------------------Items
----------------------------------------------------------------------------------------------------------------
a)
-----------------------------------------------------------------------------------------------------------In case of Conductor & Earthwire , the permitted extra consumption limit of 1% is inclusive of
sag, jumpering, damage, losses& wastages etc. The quantity of Conductor and Earthwire shall
be worked out as per the following norms:
(a)
Quantity of Conductor
(b)
Quantity of Eartwire
The Bidder shall be permitted to dispose off the empty conductor and Earthwire drums at his
cost.
For other line material i.e. Disc Insulators, Hardware fittings & Accessories for
conductor
and Earthwire, the actual quantity incorporated on Transmission line shall
be approved as per
consumption.
5.30
After completion of the works, final checking of the line shall be done by the Bidder to ensure
that all the foundation works, tower erection, and stringing have been done strictly according
to the specifications and as approved by the HVPNL. All the works shall be thoroughly inspected
keeping in view of the following main points:
m)
Sufficient back filled earth is lying over each foundation pit and it is edequately
compacted.
n)
Concrete chimneys and their copings are in good finely shaped conditions.
o)
All the tower members are correctly used, strictly according to final approved drawing
and are free of any defect or damage whatsoever.
p)
q)
The stringing of the conductors and earthwire has been done as per the approved sag
and tension charts and desired clearances are clearly available.
r)
s)
All other requirements to complete the work like fixing of danger plate, phase plate,
number plate, anti climbing device, aviation signal (wherever required) etc. are properly
installed.
Page-44
t)
u)
The original tracings of profile route alignment and tower, design, structural drawings,
bill of material, shop drawings of all towers other than the towers designed by the HVPNL
are submitted to the HVPNL for reference and record.
v)
The insulation of line as a whole is tested by the bidder by providing his own equipment,
labour etc. to the satisfaction of the HVPNL.
w)
x)
8.
8.1.1
The following provisions shall supplement all the detailed technical specifications and
requirements brought out herein. The Bidders proposal shall be based on the use of
materials complying fully with the requirements specified herein.
The furnishing of engineering data by the Bidder shall be in accordance with the schedule
as specified in the technical specifications. The review of these data by the HVPNL will
cover only general conformance of the data to the specifications and not a thorough review
of all dimensions, quantities and details of the materials, or items indicated or the accuracy
of the information submitted. This review by the HVPNL shall not be considered by the
Bidder, as limiting any of his responsibilities and liabilities for mistakes and deviations from
the requirements, specified under these specifications.
8.2.2
All engineering data submitted by the Bidder after review by the HVPNL shall form part of
the contract documents.
6.3
DRAWINGS
6.3.11 All drawings submitted by the Bidder including those submitted at the time of bid shall be
with sufficient detail to indicate the type, size, arrangement, dimensions, material
description, bill of materials, weight of each component, break-up for packing and shipment,
fixing arrangement required, the dimensions required for installation and any other
information specifically requested in these specifications.
6.3.12 Each drawing submitted by the Bidder shall be clearly marked with the name of the HVPNL
, the specification title, the specification number and the name of the project. All titles, noting,
markings and writings on the drawing shall be in English. All the dimensions should be to
the scale and in metric units.
Page-45
6.3.13 The drawings submitted by the Bidder shall be reviewed by the HVPNL as far as practicable
within 30 days and shall be modified by the Bidder if any modifications and/ or corrections
are required by the HVPNL . The Bidder shall incorporate such modifications and/or
corrections and submit the final drawings for approval. Any delays arising out of failure by
the Bidder to rectify the drawings in good time shall not alter the contract completion date.
6.3.14 The drawings submitted for approval to the HVPNL shall be in quadruplicate. One print of
such drawings shall be returned to the Bidder by the HVPNL marked approved / approved
with corrections. The Bidder shall thereupon furnish the HVPNL additional prints as may
be required along with one reproducible in original of the drawings after incorporating all
corrections.
6.3.15 The work shall be performed by the Bidder strictly in accordance with these drawings and
no deviation shall be permitted without the written approval of the HVPNL , if so required.
6.3.16 All manufacturing, fabrication and erection work under the scope of Bidder, prior to the
approval of the drawings shall be at the Bidders risk. The Bidder may make any changes
in the design which are necessary to conform to the provisions and intent of the contract
and such changes will again be subject to approval by the HVPNL .
6.3.17 The approval of the documents and drawings by the HVPNL shall mean that the HVPNL is
satisfied that:
c) The Bidder has completed the part of the works covered by the subject document (i.e.
confirmation of progress of work.)
d) The works appear to comply with requirements of specifications.
In no case the approval by the HVPNL of any document does imply compliance with all
technical requirements nor the absence of errors in such documents.
If errors are discovered any time during the validity of the contract, then the Bidder shall be
responsible of their consequences.
6.3.18 The HVPNL may use a 35mm microfilm system in processing drawings. All drawings shall
be supplied on 35mm microfilm as well as in Autocad.
A copy of each drawing reviewed will be returned to the Bidder as stipulated herein.
6.3.19 Copies of drawings returned to the Bidder will be in the form of a print with the HVPNL s
marking, or a print made from a microfilm of the marked up drawing.
6.3.20 The following is the generic list of the documents and drawings that are to be approved by
the HVPNL .
l)
m)
n)
o)
Detailed survey report and profile drawing showing ground clearance and tower
locations.
p)
q)
Tower design calculation along with single line diagram and electrical clearance
diagram.
r)
s)
t)
u)
v)
w)
x)
y)
z)
Quality plan for fabrication and site activities including quality system.
aa)
6.4
DESIGN IMPROVEMENTS
6.4.3
The HVPNL or the Bidder may propose change in the specification and if the parties agree
upon any such changes and the cost implication, the specification shall be modified
accordingly.
6.4.4
If any such agreed upon change is such that it affects the price and schedule of completion,
the parties shall agree in writing as to the extent of any change in the price and/ or schedule
of completion before the Bidder proceeds with the change. Following such agreement, the
provision thereof, shall be deemed to have been amended accordingly.
6.5
DESIGN CO-ORDINATION:
6.5.2
The Bidder shall be responsible for the selection and design of appropriate material/item to
provide the best co-ordinated performance of the entire system. The basic design
requirements are detailed out in this specification. The design of various components, subassemblies and assembles shall be so done that it facilitates easy field assembly and
maintenance.
Page-47
6.6
The Bidder will be called upon to attend design review meetings with the HVPNL and the
consultants of the HVPNL during the period of contract. The Bidder shall attend such
meetings at his own cost at Panchkula or at mutually agreed venue as and when required.
Such review meeting will be held generally four times in a year.
6.7
PACKING:
6.7.6
All the materials shall be suitably protected, coated, covered or boxed and crated to prevent
damage or deterioration during transit, handing and storage at site till the time of erection.
The Bidder shall be responsible for any loss or damage during transportation, handing and
storage due to improper packing.
6.7.7
The Bidder shall include and provide for securely protecting and packing the materials so
as to avoid loss or damage during transport by air, sea, Rail and road.
6.7.8
All packing shall allow for easy removal and checking at site. Wherever necessary, proper
arrangement for attaching slings for lifting shall be provided. All packages shall be clearly
marked for with signs showing up and down on the sides of boxes, and handling and
unpacking instructions as considered necessary. Special precaution shall be taken to
prevent rusting of steel and iron parts during transit by sea.
6.7.9
The cases containing easily damageable material shall be very carefully packed and marked
with appropriate caution symbols, i.e. fragile, handle with care, use no hook etc wherever
applicable.
6.7.10 Each package shall be legibly marked by the Bidder at his expenses showing the details
such as description and quantity of contents, the name of the consignee and address, the
gross and net weight of the package, the name of the Bidder etc.
9.
ERECTION CONDITIONS:
7.1
The following shall supplement the conditions already contained in the other parts of these
specifications and documents and shall govern that portion of the work on this contract to
be performed at site.
7.3
7.2.1
The bidder shall comply with all the rules and regulations of local authorities during the
performance of his field activities. He shall also comply with the minimum wages act. 1948
and the payment of wages act (both of the government of India) and the rules made there
under in respect of any employee or workman employed or engaged by him or his subbidder.
7.2.3
All registration and statutory inspection fees, if any, in respect of his work pursuant to this
contract shall be to the account of the Bidder. However, any registration, statutory inspection
fees lawfully payable under the provisions of the statutory laws and its amendments from
time to time during erection in respect of the transmission line, ultimately to be owned by
the HVPNL , shall be to the account of the HVPNL. Should any such inspection or
registration need to be re- arranged due to the fault of the Bidder or his sub-bidder, the
additional fees to such inspection and/or registration shall be borne by the Bidder.
Page-48
7.3
7.3.2
The Bidder shall keep the HVPNL informed in advance regarding his field activity plans and
schedules for carrying out each part of the works. Any review of such plan or schedule or
method of work by the HVPNL shall not relieve the Bidder of any of his responsibilities
towards the filed activities. Such reviews shall also not be considered as an assumption of
any risk or liability by the HVPNL or any of his representatives and no claim of the Bidder
will be entertained because of the failure or inefficiency of any such plan or schedule or
method of work reviewed. The Bidder shall be solely responsible for the safety, adequacy
and efficiency of tools and plants and his erection methods.
7.4
PROGRESS REPORT
7.4.1 Appropriate visual charts shall accompany the monthly progress reports detailing
out the progress achieved on all erection activities as compared to the schedules.
The report shall also indicate the reasons for the variance between the scheduled
and actual progress and the action proposed for corrective measures, wherever
Necessary.
7.5
7.5.6
The Bidder shall submit to the HVPNL , on the first day of every month, a man power
deployment schedule for each activity.
7.5.7
The Bidder shall also submit to the HVPNL on the first day of every month, a man power
deployment report of the previous month detailing the number of persons scheduled to have
been employed and actually employed.
7.5.8
7.5.9
Similarly the labour colony, the offices and the residential areas of the bidders employees
and workmen shall be kept clean and neat to the entire satisfaction of the HVPNL . Proper
sanitary arrangements shall be provided by the Bidder, in the work-areas, office and
residential areas of the Bidder. Waste oil shall be disposed off in a manner acceptable to
the HVPNL . Under no circumstances shall waste oil be dumped into uncontrolled drains.
Page-49
7.6
FIRE PROTECTION
7.6.4
The work procedures that are to be used during the erection shall be those which minimise
fire hazards to the extent practicable. Combustible materials, combustible waste and
rubbish shall be collected and removed from the site at least once each day. Fuels, oils and
volatile or flammable materials shall be stored away from the construction site and
equipment and material stores in safe containers.
7.6.5
All the bidders supervisory personnel and sufficient number of workers shall be trained for
fire-fighting and shall be assigned specific fire protection duties. Enough of such tainted
personnel must be available at the site during the entire period of the contract.
7.6.6
The Bidder shall provide enough fire protection equipment of the types and number for the
ware house, office, temporary structures, labour colony area etc. Access to such fire
protection equipment, shall be easy and kept open at all time.
7.7
SECURITY
The Bidder shall have total responsibility for all equipment and materials in his custody,
stored, loose, semi-assembled and/or erected by him at site. The Bidder shall make suitable
security arrangements including employment of security personnel to ensure the protection
of all materials, equipment and works from theft, fire pilferage and any other damages and
loss.
7.8
7.8.7
All the supplies under the contract as well as HVPNL supplied items arriving at site shall be
promptly received, unloaded and transported and stored in the stores by the Bidder.
7.8.8
Bidder shall be responsible for examining all the shipment and notify the HVPNL
immediately of any damage, shortage, discrepancy etc. for the purpose of HVPNL s
information only. The Bidder shall submit to the HVPNL every week a report detailing all
the receipts during the week. However, the Bidder shall be solely responsible for any
shortages or damages in transit, handling and/or in storage and erection at site. Any
demurrage, wharfage and other such charges claimed by the transporters, Railways etc.
shall be to the account of the Bidder.
7.8.9
The Bidder shall maintain an accurate and exhaustive record detailing out the list of all items
received by him for the purpose of erection and keep such record open for the inspection of
the HVPNL .
7.8.10 All items shall be handled very carefully to prevent any damage or loss. The materials stored
shall be properly protected to prevent damage. The materials from the store shall be moved
to the actual location at the appropriate time so as to avoid damage of such materials at
site.
7.8.11 All the materials stored in the open or dusty location must be covered with suitable weatherproof and flame proof covering material wherever applicable.
7.8.12 The Bidder shall be responsible for making suitable indoor storage facilities, to store all
items/materials, which require indoor storage.
Page-50
7.9
CONSTRUCTION MANAGEMENT
7.9.2
Time is the essence of the contract and the Bidder shall be responsible for performance of
his works in accordance with the specified construction schedule. If at any time, the Bidder
is falling behind the schedule for reasons attributable to him, he shall take necessary action
to make good for such delays by increasing his work force or by working overtime or
otherwise to accelerate the progress of the work and to comply with schedule and shall
communicate such actions in writing to the HVPNL , satisfying that his action will
compensate for the delay. The Bidder shall not be allowed any extra compensation for such
action.
7.10
The Bidder shall maintain at his site office up-to-date copies of all drawings, specifications
and other supplementary data complete with all the latest revisions there to. The Bidder
shall also maintain, in addition, the continuous record of all changes to the above contract
documents, drawings, specifications, supplementary data, etc. effected at the field and on
completion of his total assignment under the contract shall incorporate data to indicate as
installed conditions of the material supplied and erected under the contract. Such drawings
and engineering data shall be submitted to the HVPNL in required number of copies.
7.11
7.11.2 The Bidder will ensure provision of necessary safety equipment such as barriers, signboards, warning lights and alarms, etc. to provide adequate protection to persons and
property. The Bidder shall be responsible to give reasonable notice to the HVPNL and the
owners of public or private property and utilities when such property and utilities are likely
to get damaged or injured during the performance of his works and shall make all necessary
arrangements with such owners, related to removal and/or replacement or protection of
such property and utilities.
7.12
The Bidder shall ensure that any finds such as relics, antiques, coins, fossils, etc. which he
may come across during the course of performance of his works either during excavation or
elsewhere, are properly protected and handed over to the HVPNL . Similarly, the Bidder
shall ensure that the bench marks, reference points, etc. which are marked either with the
help of HVPNL or by the HVPNL shall not be disturbed in any way during the performance
of its works, if any work, is to be performed which disturbs such reference, the same shall
be done only after these are transferred to other suitable locations under the direction of the
HVPNL . The Bidder shall provide all necessary materials and assistance for such relocation
of reference points etc.
Page-51
7.13
7.13.15
The Bidder shall ensure safety of all the workmen, materials plant and equipment
belonging to him or to the others, working at the site. The Bidder shall also provide for all
safety notices and safety equipment required by the relevant legislations and deemed
necessary by the HVPNL .
7.13.16
The Bidder will notify, well in advance to the HVPNL , its intention to bring to the site any
container filled with liquid or gaseous fuel or explosive or petroleum substance of such
chemicals, which may involve hazards. The HVPNL shall have the right to prescribe the
conditions, under which such a container is to be stored, handled and used during the
performance of the works and the Bidder shall strictly adhere to and comply with such
Instructions. The HVPNL shall also have the right, at his sole discretion, to inspect any such
container or such construction plant/equipment for which materials in the container is
required to be used and if in his opinion, its use is not safe, he may forbid its use.
No claim due to such prohibition or towards additional safety provisions called for by him
shall be entertained by the HVPNL .
Further, any such decision of the HVPNL shall not, in any way, absolve the Bidder of his
responsibilities and in case use of such a container or entry there- of into the site area is
forbidden by the HVPNL , the Bidder shall use alternative methods with the approval of the
HVPNL without any cost implication to the HVPNL or extension of work schedule.
7.13.17
where it is necessary to provide and/or store petroleum products or petroleum mixtures
and explosives, the Bidder shall be responsible for carrying out such provision and/or
storage in accordance with the rules and regulations laid down in petroleum act 1934,
explosives act 1948 and amendments thereof, and petroleum and carbide of calcium
manual published by the Chief Inspector of explosives of India. All such storage shall have
prior approval of the HVPNL . In case, any approval is necessary from the Chief Inspector
(explosives) or any statutory authorities, the Bidder shall be responsible for obtaining the
same.
7.13.18
All equipment used in construction and erection by Bidder shall meet Indian/International
standards and where such standards do not exist, the Bidder shall ensure these to be
absolutely safe. All equipment shall be strictly operated and maintained by the Bidder in
accordance with manufactures operation manual and safety instructions and as per any
existing Guideline/Rules in this regard.
7.13.19
Periodical examinations and all tests for all lifting/ hoisting equipment and tackle shall
be carried out in accordance with the relevant provisions of factories act.1948, Indian
Electricity Supply Act and associated Laws/ Rules in force from time to time. A register of
such examinations and tests shall be properly maintained by the Bidder and will be promptly
produced as and when desired by HVPNL or by the persons authorized by him.
Page-52
7.13.20
The Bidder shall provide suitable safety equipment of prescribe standard to all
employees and workmen according to the need, as may be directed by the HVPNL who
will also have the right to examine these safety equipment to determine their suitability,
reliability, acceptability and adaptability.
7.13.21
Where explosives are to be used, the same shall be used under the direct control and
supervision of an expert, experienced and qualified competent person, strictly in accordance
with the code of practices /rules framed under Indian Explosives Act pertaining to handling,
storage and use of explosive.
7.13.22
The Bidder employing more than 250 workmen, whether temporary casual, probationer,
regular or permanent or on contract, shall employ at least one full time officer exclusively as
safety officer to supervise safety aspects of the equipment and workmen. Such an officer
will co-ordinate with the project safety officer of the HVPNL .
The name and address of such safety officer of the Bidder will be promptly informed in
writing to the HVPNL with a copy to the safety officer- incharge before he starts work or
immediately after any change of the incumbent is made during currency of the contract.
7.13.23
In case any accident occurs during the construction/erection or other associated
activities undertaken by the Bidder, thereby causing any minor or major or fatal injury to his
employees due to any reason whatsoever, it shall be the responsibility of the Bidder to
promptly inform the same to the HVPNL and also to all the authorities envisaged under the
applicable laws.
7.13.24
The HVPNL shall have the right to stop the work, if in its opinion the work is being
carried out in such a way as may cause accidents and endanger the safety of the persons
and/or property. In such cases, the Bidder shall be informed in writing about the nature of
hazards and possible injury/accident and he shall remove short-comings promptly. The
Bidder, after stopping the specific work, can, if felt necessary, appeal against the order of
stoppage of work to the HVPNL within 3 days of such stoppage of work and the decision of
the HVPNL in this respect shall be conclusive.
7.13.25
The Bidder shall not be entitled for any damages/compensation for stoppage of work
due to safety reasons as provided in clause 7.13.10 above and the period of such stoppage
of work will not be taken as an extension of time for completion of work and will not be the
ground for waiver of any part of bidders liability for timely completion of the works.
7.13.26
The Bidder shall follow and comply with all safety rules, relevant provisions of applicable
laws pertaining to the safety of workmen, employees, plant and equipment as may be
prescribed from time to time without any demur, protest or contest or reservation. In case of
any conflict between statutory requirement and safety rules referred above, the most
stringent clause shall be applicable.
Page-53
7.13.27
If the Bidder fails in providing safe working environment as per safety rules or continues
the work even after being instructed to stop work by the HVPNL as provided in clause
7.13.10 above, the Bidder shall promptly pay to the HVPNL on demand, compensation
at the rate of Rs. 5,000/- per day or part thereof till the instructions are complied with
and so certified by the HVPNL . However, in case of accident taking place causing injury,
to any individual, the provisions contained in clause 7.13.14 below shall also apply in
addition to compensation mentioned in this para.
7.13.28
If the Bidder does not take all safety precautions and/or fails to comply with the safety
rules as prescribed by the HVPNL or as prescribed under the applicable law for the
safety of the equipment, plant and personnel and the Bidder does not prevent hazardous
conditions which may cause injury to his own employees or employees of other Bidders,
or HVPNL or any other person at site or adjacent thereto, the Bidder shall be responsible
for payment of compensation to the HVPNL as per the statutory provisions.
Permanent disability shall have the same meaning as indicated in workmens
compensation act. The compensation mentioned above shall be in addition to the
compensation payable to the workmen/employees under the provision of workmens
compensation act and rules framed there under or any other applicable law as applicable
from time to time. In case the HVPNL is made to pay such compensation, the Bidder
will be liable to reimburse the HVPNL such amount(s) in addition to the compensation
indicated above.
7.14
FOREIGN PERSONNEL
7.14.1
In case necessary for the execution of the works, the Bidder shall bring foreign
supervisors for the execution of the contract, at his own cost. The Bidder shall submit to
the HVPNL , data on all personnel he proposes to bring into India for the performance
of the works under the contract, at least sixty (60)days prior to their arrival in India. Such
data shall include the name of each person, his present address, his assignment and
responsibility in connection with the works, and a short resume of his qualification,
experience etc. in relation to the work to be performed by him.
7.14.2
Any person, unsuitable and unacceptable to the HVPNL , shall not be brought to India.
Any person brought to India, and found unsuitable or unacceptable to the HVPNL shall
be immediately removed from site and repatriated back. If found, necessary, he may be
replaced by another personnel acceptable to the HVPNL .
7.15.3
No person brought to India by the Bidder, for the works shall be repatriated without the
consent of the HVPNL in writing, based on a written request from the Bidder for such
repatriation giving reasons for such an action to the HVPNL . The HVPNL may give
permission for such repatriation provided it is satisfied that the progress of work will not
suffer due to such repatriation.
7.15.4
The cost of passports, visas and all other travel expenses to and from India, shall be to
the Bidders account. The HVPNL will not provide any residential accommodation and/
or furniture for any of the Bidders personnel including foreign personnel Bidder shall
make his own arrangements for such facilities.
Page-54
7.15.5
The Bidder and its expatriate personnel shall respect all Indian Acts, Laws, Rules and
Regulations and shall not, in any way, interfere with Indian political and religious affairs
and shall conform to any other rules and regulations which the government of India, and
the HVPNL may establish on them. The bidders expatriate personnel shall work and
live in close co-operation and co-ordination with their co-workers and the community
and shall not engage themselves in any other employment either part-time or full-time
nor shall they take part in any local politics.
7.15.6
The HVPNL s shall assist the Bidder, to the extent possible, in obtaining necessary
permits to travel to India and back, by issue of necessary certificates and other
information needed by the government agencies.
Page-55
NAME OF LINE :
1)
Grade of
Concrete
a)
Target Mean
Strength
b)
Grade of
Cement
c)
Cement Contents
per cum
d)
Water Cement
Ratio
e)
Slump
2)
Coarse
Aggregate
i)
Nominal size of
aggregate
ii)
Source of
aggregates
iii)
Specific
Gravity
iv)
3)
Fine
Aggregates
i)
Source of
aggregates
ii)
Specific
Gravity
iii)
4)
i)
By Weight
ii)
By Volume (By
conversion)
iii)
Adjustments, if
any suggested
5)
SIZE OF
MEASUREMENTS
BOXES
CEMENT
WATER
SAND
COARSE AGGREGATES
CEMENT
WATER
SAND
COARSE AGGREGATES
SAND
COARSE AGGREGATES
NOTE :
1.
Page-56
3.
The cubes will be tested at site/field lab and cubes of 10% of the total locations of
the line will be tested from approved govt lab.
CERTIFICATE
Sub-Contractor:
Name
:
Name:
Date:
Date:
Name:
Date:
Page-57
NAME OF LINE :
Location Number
Date :
a)
b)
Preceeding Span
As per profile
c)
Succeeding Span
Actual
As per profile
Actual
Tangent Tower:
d)
Bi-section
Actual
e)
f)
Matching of ground
profile:
Calculated
OK detail
CERTIFICATE: Cleared for excavation
Performed and checked by:
Sub-Contractor:
Name :
Name:
Actual
Date:
Date:
Date:
Page-58
NAME OF LINE :
Location No.:
Date :
a)
b)
Total Depth
Leg-3
Leg-2
As
per
Soil Investigation
Leg-4
Leg-1
Depth, Strata-wise be indicated for each leg & also indicate actual depth of pits from
reference
level.
Predominant Soil _____________________________________
c)
Leg-1 (M)
Leg-2
(M)
Leg-3 (M)
d)
e)
Foundation Classification:
Leg-4 (M)
Page-59
As proposed by Contractor
As approved by HVPN
f)
CERTIFICATE:
Name :
Name:
Signature
with Seal:
Date:
Date:
Name:
Date:
Page-60
Date :
A3 :
a)
b)
Alignment of template/prop. :
i)
Yes/No
ii)
Yes/No
c)
Clearance between the lowest part of stub and lean pad (Concrete)
Leg 1 ---------------------- cm
Leg 2 ---------------------- cm
Leg 3 ---------------------- cm
Leg 4 ---------------------- cm
d)
e)
Yes/No
Yes/No
CERTIFICATE:
Performed and checked by:
Sub-Contractor:
Name :
Name:
Date:
Date:
Name:
Date:
Page-61
NAME OF LINE :
Location No.:
Date :
PART-A : FOUNDATION
ACTIVITY
A4 :
a)
b)
Sr.No.
Length
Drgs.
c)
Actual
Diameter
Drgs.
Actual
Nos.
Drgs.
Yes/No
REMARKS
Actual
(testing details)
d)
Yes/No.
e)
Yes/No.
Source of
collection :
Sand
Name
Metal/Aggregate
Approved/Not Approved
Name
f)
Quality of Water:
i)
Confirming to specification :
ii)
g)
Required T&P such as mixer, vibrator, slump cone, form boxes, shuttering,
Approved/Not
Approved
Yes/No.
Yes/No.
Page-62
CERTIFICATE:
Sub-Contractor:
Name :
Name:
Date:
Date:
Name:
Date:
Page-63
Date :
A5 :
Lean Concrete
a)
b)
Yes/No
c)
Dewatering done:
Yes/No
d)
Yes/No
e)
f)
Sr.No.
Leg-1
Yes/No
Leg-2
Leg-3
Leg-4
Reasons
for
variations
from the
drg.
Bags (nos)
Thickness
(mm)
CERTIFICATE:
Performed and checked by:
Sub-Contractor:
Name :
Name:
Signature with
Seal:
Date:
Date:
Date:
Page-64
NAME OF LINE :
Location No.:
Date :
A6 :
a)
b)
c)
Yes/No
d)
e)
Yes/No
Yes/No
Yes/No
CERTIFICATE:
Sub-Contractor:
Name :
Name:
Signature
with Seal:
Date:
Date:
Name:
Date:
Page-65
Location No.:
Date :
A7 :
a)
b)
Yes/No
c)
Mixing by mixer:
Yes/No
d)
e)
Yes/No
f)
Yes/No
g)
Yes/No
h)
Yes/No
i)
Slump
mm
j)
Actual
k)
Coping is done:
Yes/No
l)
m)
Sub-Contractor:
Name :
Name:
Signature with
Seal:
Date:
Date:
Date:
Page-66
Date :
A8 :
a)
Checking for curing, form box, template/prop removal & back filling:
Curing is started after 24 hrs. of foundation casting
& foundation is kept continuously wet:
Yes/No
b)
Yes/No
c)
Defects in
concrete:
Yes/No
Sr.No.
Type of Defect(s)
Quality of concrete
Description
Honey combing/rough
surface/smooth surface
Cover
Reinforcement visible/
not visible
Shape
As per drawing/distorted
Nature of defects
Major/Minor
Remedial measures
No. of
cement
bags
consumed
d)
Yes/No
e)
Yes/No
CERTIFICATE: Foundation is cleared for Tower erection subject to the completion of setting
time as per standards
Performed and checked by:
SubContractor:
Name :
Name:
Date:
Date:
Date:
Page-67
LOC.No.
A9 :
DATED:
a)
b)
YES/NO
Details
As per drawing
Actual
1-3
2-4
3-4
4-1
1-2
2-3
Performed and checked by:
Subcontractor
: _________________
Name
: _________________
Name
:
______________
Signature
with Seal
: _________________
Date
: _________________
Date
:
______________
:
______________
Signature with
Seal:
Date:
Page-68
LOC.No.
DATED:
A10 :
1.
2.
Tower can not be located on the level Ground even by providing extension
3.
CASE - I
Sl.No.
PARTICULARS
1.
QTY.
RATE
COST
REMARKS
a)
b)
c)
2.
Revetment
3.
Breast Wall
4.
TOTAL
CASE - II
Sl.No.
1.
PARTICULARS
QTY.
RATE
COST
REMARKS
2.
Revetment
3.
Breast Wall
4.
TOTAL
Page-69
NAME OF LINE :
SECTION
LOC.No.
DATED:
CASE - III
Sl.No.
1.
PARTICULARS
QTY.
RATE
2.
Revetment
3.
Breast Wall
4.
5.
TOTAL
Note :
COST
REMARKS
Sub-contractor
: _________________
Name
: _________________
Name
:
______________
: _________________
Signature with
Seal
:
______________
Date
: _________________
Date
:
______________
Page-70
Location No.:
Date :
a)
Grade of Concrete:
b)
c)
Date of casting:
d)
Date of testing:
e)
Size of Cube
Sample No.
Cube No.
Cube Strength
(Kg/Cm2)
7 days
1.
28 days
1
2
3
2.
1
2
3
3.
1
2
3
4.
1
2
3
Name :
Name:
Date:
Date:
Page-71
ANNEXURE-IA
Sr. No.
Description
Drawing
No.
1.
2.
Circuit Plate
3.
10
10
11
11
12.
12
13
13
earthwire
14
14