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HARYANA VIDYUT PRASARAN NIGAM LIMITED

BIDDING DOCUMENT NO. REC-140

TECHNICAL SPECIFICATION

OF

1. 220KV M/C LINES ON M/C MONOPOLE AND M/C


TOWER
2. 220KV D/C LINE WITH 0.4SQ ACSR ZEBRA
3. 66kV LINES WITH 0.4SQ ACSR ZEBRA ON D/C
TOWER
4. 66KV LINE WITH 1200MM2 XLPE CABLE IN
FARIDABAD AREA

Chief Engineer/ MM,


Haryana Vidyut Prasaran Nigam Limited
Shakti Bhawan, Sector-6
Faridabad-134109
Tel/Fax: 0172-2591742

April -2015

CONTENTS
S. No.

PARTICULARS

Technical specification of tower portion

Bill of quantity of 66kV transmission line in Faridabad area with tower and
1200mm2 XLPE cable portion under REC-140 scheme

Drawings for 66kv tower accessories

Page No.
1-72
1-8
1-14
1-6

Technical specification of ACSR Zebra conductor


section-VI (PART-II A)
5

Technical Description of Anti fog Disc insulators

1-15

Technical Description of Silicone Polymer Insulators

1-15

Technical Description of Bus Post Insulators

1-5

Hardware Fittings for lines with ACSR Zebra and Accessories for lines
with ACSR Zebra

1-16

Standard field quality plan for transmission lines

1-14

10

Pre-Commissioning Check List & Testing Of EHV Lines For Charging

1-12

11

Technical Data sheets

1-28

12

Technical specification for manufacture, testing before dispatch and


Supply of 66kV 1200mm2 aluminum XLPE cable.

1-12

13

Technical specification for installation, laying, Erection, testing and


commissioning of 66kV 1200mm2 aluminum XLPE cable.

1-19

14

60kv Polymer Housed surge Arrestors With Surge Counters

Annexure-1
1-14

15

Technical specification of OPGW

Annexure-2
1-145

16

Technical specification of 220kV M/C monopole (new design)

Annexure-3
1-9

SECTION VI (PART-II)

TECHNICAL SPECIFICATION

CONTENTS

CHAPTER-I - TECHNICAL SPECIFICATION FOR TOWERS

CHAPTER-II GENERAL TECHNICAL REQUIREMENTS

CHAPTER-III (A)-TECHNICAL SPECIFICATION OF CONDUCTOR


AND EARTHWIRE.

CHAPTER-III (B)-TECHNICAL SPECIFICATION OF SILICONE


RUBBER POLYMER INSULATORS.

CHAPTER-III (C)-TECHNICAL SPECIFICATION OF BUS POST


INSULATORS.

CHAPTER-III(D)-TECHNICAL SPECIFICATION OF HARDWARE


FITTING AND ACCESSORIES.

CHAPTER-III (E)-TECHNICAL SPECIFICATION OF OPGW AND


ACCESSORIES.

CHAPTER-III (F)-TECHNICAL SPECIFICATION OF 220KV M/C


MONOPOLE.

CHAPTER-III (G)-TECHNICAL SPECIFICATION OF 66KV 1200MM2


XLPE CABLE.

CHAPTER-IV - TECHNICAL DATA/INFORMATION (GTP) TO BE


SUBMTTED WITH THE BID

SECTION-VI

(PART-II)

CHAPTER-I

(SECTION VI, CHAPTER-I)

TECHNICAL SPECIFICATION

CONTENTS

Clause No.

Description

Page No.

1.1

GENERAL INFORMATION AND SCOPE

1.2

DETAIL OF TRANSMISSION LINE ROUTES AND 3


TERRAIN

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

PARTICULAR OF CONDUCTOR AND EARTHWIRE

12

2.2

PARTICULAR OF INSULATOR STRING WITH

13

4
4

9
10
11

STANDARD DISC INSULATIORS


2.3

INSULATOR STRING HARDWARE

13

2.4

ACCESSORIES FOR CONDUCTOR AND

14

EARTHWIRE
3.0

TRANSMISSION TOWERS

14

3.1

GENERAL DESCRIPTION OF THE TOWER

14

3.2

TYPE OF TOWER

14

3.3

SPANS AND CLEARANCES

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

INSPECTION AND TESTS

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

PROPERTIES OF CONCRETE & REINFORCEMENT

34

4.7

UNIT RATES AND MEASUREMENT

36

4.8

CONSTRUCTION OF TOWER FOUNDATIONS

36

4.9

SETTING OF STUBS

37

4.10

STUB SETTING TEMPLATES

37

4.11

MIXING, PLACING AND COMPACTING OF

38

CONCRETE

24
28
28

4.12

BACK-FILLING AND REMOVAL OF STUB


TEMPLATE

38

4.14

PROTECTION OF TOWER FOOTING

39

5.0

TOWER ERECTION, STRINGING AND

41

INSTALLATION OF LINE MATERIAL


5.1

GENERAL

41

5.2

TREATMENT OF MINOR GALVANISING DAMAGE

41

5.3

ASSEMBLY

42

5.4

TIGHTENING ANDPUNCHING OF BOLTS & NUTS

42

5.5

INSULATOR HOISTING

42

5.6

HANDLING OF CONDUCTOR AND EARTHWIRE 42

5.7

STRINGING OF CONDUCTOR & EARTHWIRE

5.8

JOINTING

5.9

SAGGING-IN-OPERATION

5.10

TENSIONING AND SAGGING OF CONDUCTOR 45

44
44
44

AND EARTHWIRE
5.11

CLIPPING IN

5.12

FIXING OF CONDUCTOR ANDEARTHWIRE

45
46

ACCESSORIES
5.13

REPLACEMENT

46

5.14

PERMITTED EXTRA CONSUPTION OF LINE

46

MATERIALS
5.15
6.1

FINAL CHECKING, TESTING AND COMMISSIONING 46


GENERAL TECHCIAL CONDITIONS
47

6.2

ENGINEERING DATA

47

6.3

DRAWINGS

47

6.4

DESIGN IMPROVEMENTS

6.5

DESIGN COORDINATION

6.6

DESIGN REVIEW MEETING

6.7

PACKING

50

7.1

ERECTION CONDITIONS

50

7.2

REGULATION OF LOCAL AUTHORITIES AND


STATUTES

49
50
50

50

7.3

BIDDERSS FIELD OPERATION

51

7.4

PROGRESS REPORT

51

7.5

MAN-POWER DEPLOYMENT REPORT

51

7.6

FIRE PROTECTION

7.7

SECURITY

7.8

MATERIALS HANDLING AND STORAGE

52

7.9

CONSTRUCTION MANAGEMENT

53

7.10

FIELD OFFICE RECORDS

53

7.11

PROTECTION OF PROPERTY AND

51
52

53

BIDDERS LIABILITY
7.12

PROTECTIONS OF MOUNMENTS AND


REFERENCE POINTS

54

7.13

WORK AND SAFETY REGULATIONS

54

7.14

FOREIGN PERSONNEL

56

7.15

CODE REQUIREMENTS

57

(SECTION VI, CHAPTER-I)


TECHNICAL SPECIFICATIONS
1.
1.1.1

General Information and scope


Scope:
This specification covers detailed
survey, profiling & check Survey, tower
spotting/optimization of tower location, soil resistivity measurements and Geotechnical
investigation, fabrication and supply of all type 220 kV D/C towers of TATA Design, 220kv
M/C KRR design towers, 220kV M/C Monopole to be newly designed and 66kV D/C
KRR design towers 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 pole heights and casting of
foundation for tower pole footing as per design, erection of towers, tack welding of bolts and
nuts including supply and application of zinc rich paint, tower earthing, providing of tower
footing protection, fixing of insulator string, stringing of conductors and Earth wire/ OPGW
alongwith all necessary line accessories and testing and commissioning of the erected
transmission line.

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

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 220kV M/C monopole to be
newly designed)

2.31

LILO of both circuit of 66kV BBMB Ballabgarh-Jharsetly D/C line at D/C


length=
220kV S/Stn. Sector-58, Faridabad with 0.4sq ACSR Zebra.
0.040+0.040=0.080km

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

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. (partially on M/C
monopole )

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

Tentative M/C Length:


1.165kms.
Tentative D/C Length:
0.511

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).

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.

D/C length of tower


portion =3.970km

(Cable portion and 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.
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)

i) Construction of civil works,


i) Complete erection and installation,
iii) Commissioning, Site and acceptance testing

c)

i) Supply of the measuring instruments and testing equipment necessary


preliminary acceptance tests,

for

the

ii) Providing of the special tools, instruments and devices to be used in


erection, testing and putting into operation,
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
specifications

of the personnel authorized by HVPNL


ii) Submission of monthly progress reports.

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.

All precaution shall be done for safe erection and operation.

Connection between substations and dead-end towers, shall be done by the Bidder if the
substations do exist.

Demolishing and dismantling works, if any.

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.

v) Technical specification of 220kV M/C Monopole is attached at Annexure-3.

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

Detail of Transmission Line Routes and Terrain.

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

ACCESS TO THE LINE AND RIGHT TO WAY


Right of way and way leave clearance shall be arranged by the HVPNL in accordance with
work schedule. HVPNL will secure way leave and right of way in the forest area, if any.

1.5

DETAILED SURVEY, OPTIMISATION OF TOWER LOCATION

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.

Chief Engineer/TS, HVPNL, Hisar TEL. No. 01662-220794.

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

PROFILE PLOTTING & TOWER SPOTTING


From the field book entries, the route plan with enroute details and level profile shall be
plotted and prepared to scale of 1:2000 horizontal & 1:200 vertical on 1.0, 10 mm squared
paper as per approved procedure. Reference levels at every 20 metres along the profile are
also to be indicated on the profile besides, reduced levels at undulations. Areas along the
profile, which, in the view of the Bidder, are not suitable for tower spotting, shall also be
clearly marked on the profile plots. If the difference in levels be too high, the chart may be
broken up according to requirement. A 10mm overlap shall be shown on each following
sheet. The chart shall progress from left to right. Sheet shall be 594 mm wide in accordance
with the IS. For as built profile these shall be in A1 size.

1.5.6

TOWER LOCATION

1.5.6.1 SAG TEMPLATE

Necessary data in respect of conductor, earthwire shall be provided by HVPNL. On the


basis of these, the Bidder shall prepare the sag template drawing .Sag template prepared
based on the approved sag-template curve drawing shall only be used for tower sporting 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

1.5.6.2 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.

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)

DB type or DC type or DD type & M/C towers

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)

The crossing shall normally be at night angle to the Railway track.

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)

No crossing shall be located over a booster transformer, traction switching station,


traction sub-station or a track cabin location in an electrified area.

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)

POWER LINE CROSSINGS


Where the line is to cross over another line of the same voltage or lower voltage, the tower
with suitable extensions shall be used. Where the line is to cross under the 400 kV power
lines, gantries shall be used. Provisions to prevent the possibility of its coming into contact
with other overhead lines shall be made in accordance with the India electricity rules,
1956. In order to reduce the height of the crossing towers it may be advantageous to
remove the ground wire of the line to be crossed (if this is possible and permitted by the
HVPNL of the line to be crossed). All the works related to the above proposal shall be
deemed to be included in the scope of the Bidder except if modifications are required to
line below, in which case, the conditions to be agreed upon. Suitable Extension for towers
over 11kV line crossing shall be used, where requisite electrical as per I.E. rules is not
available. Minimum clearance between power line to power line shall be as follows:

g)

i)

220 kV to 220 kV and below

ii)

220 kV to 400 kV

TELECOMMUNICATION LINE CROSSING

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

CLEARANCE FROM GROUND, BUILDING, TREES ETC.


Clearance from ground, buildings, trees and telephone lines shall be provided in conformity
with the Indian Electricity rules, 1956 as amended up to date.

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

CHECK SURVEY OF TOWER LOCATION

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

GENERAL CLIMATIC CONDITIONS


The area is in the extreme climate belt, Monsoons are generally active from the months of
July to September. The working season shall be approximately nine months per year.

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

STATUTORY REGULATIONS AND STANDARDS

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

Other in internationally acceptable standards, which ensure equivalent or better


performance than those specified shall also be accepted.

1.9.

QUALITY ASSURANCE, INSPECTION AND TESTING

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)

Documentation control system.

c)

Qualification data for Bidders key personnel.

d)

The procedure for purchases of materials parts/components and selection of sub-Bidders


services including vendor analysis, source inspection, incoming raw material inspection,
verification of material purchase etc.

e)

System for shop manufacturing including process controls and fabrication and assembly
controls.

f)

Control of non-conforming items and system for corrective action.

g)

Control of calibration and testing of measuring and testing equipments.

h)

Inspection and test procedure for manufacture.

i)

System for indication and appraisal of inspection status.

j)

System for quality audits.

k)

System for authorising release of manufactured product to the HVPNL.

l)

System for maintenance of records.

m)

System for handing storage and delivery.

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

QUALITY ASSURANCE DOCUMENTS


The Bidder shall be required to submit all the quality assurance documents as stipulated
in the quality plan at the time of HVPNL inspection of material.

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

Electrical system data

a)

Nominal voltage

66 kV

b)

Maximum system voltage

72.5 kV

c)

BlS (Impulse)

325 KV (peak)

d)

Power frequency withstand voltage (wet)

140 KV (rms)

b)

220 KV LINE

Electrical system data

a)

Nominal voltage

220 kV

b)

Maximum system voltage

245 kV

c)

BIL (Impulse)

1050 KV (peak)

d)

Power frequency withstand voltage (wet)

460 KV (rms)

e)

Minimum corona extinction

154 KV(rms)

voltage at 50Hz AC system


under dry condition

f)

Max. Radio interference voltage

1000 microvolts

at one MHz for phase to earth


voltage of 154 KV under dry condition.

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

Stranding and wire


diameter
a)
b)

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

Total sectional area

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

Mass of zinc coating

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

PARTICULARS OF SILICONE POLYMER INSULATOR STRINGS FOR 220kV WITH ACSR


ZEBRA AND 66KV LINES WITH 0.4 SQ ACSR ZEBRA

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)

220kV LINE ON ACSR ZEBRA (0.4 SQ)

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

66kV LINE ON ACSR ZEBRA (0.4 SQ)

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

INSULATOR STRING HARDWARE

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

ACCESSORIES FOR CONDUCTOR AND EARTHWIRE

a)

Mid-span compression joints

b)
c)
d)
e)
f)
g)

Repair sleeves for conductor


Flexible copper bonds
Vibration dampers for conductor and earthwire
Suspension clamps for earthwire
Tension clamps for earthwire
Preformed Armour rods.

Page-14

3.

TRANSMISSION TOWERS

3.1

General Description of the Towers

3.1.1

The contractor is to fabricate and supply the 220kV/66kV towers of the following types:
a)

220kV D/C towers of TATA Design.

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)

66kV D/C towers of KRR Design.

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

The Towers are classified as given below :a)

220kV TATA DESIGN TOWERS :

Type of Tower

Deviation limit

Typical use

DA

Type towers also to be shown in


specification

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.

a) Complete dead end with 0 deg.


To 15 deg. deviation both on line
and sub-station side (slack span).

Page-15

b)

220kV M/C KRR DESIGN TOWERS :

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.

To be used as tangent tower

MB

2 deg.-15 deg.

a) Angle towers
insulators string

with

tension

b) Tension towers for uplift forces


resulting from an uplift span up to
188 m.
c) Also designed for anti-cascading
condition.

MB

0 deg.

d) To be used as section tower

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

b) Tension towers for uplift forces


resulting from an uplift span up to
188 m.
c) Also designed for anti-cascading
condition.
MD

30 deg.-60 deg.

a) Angle towers
insulators string

with

tension

b) Tension towers for uplift forces


resulting from an uplift span up to
188 m.
MD

0 deg.

a) Complete dead end with 0 deg.


To 15 deg. deviation both on line
and sub-station side (slack span).
b) For river crossing anchoring with
longer wind span with 0 deg.
deviation on crossing span side and
0 deg. to 30 deg. Deviation on other
sides.

Special MD

0 deg.

Type tower

Angle towers with tension insulators


string

With +9m,
+12m & 15m
Extensions.

Page-16

C)

66 kV D/C KRR DESIGN TOWERS :-

DA/DE

0 deg. to 2 deg.

To be used as tangent tower.

Spl. Extn. of DE

0 deg. to be restricted

To be used at wind span of 175m

0 deg. to 15 deg.

a)

(+9m to +18m)

DB/DF

Tension towers with tension


insulators string.
b) Tension towers for uplift forces
resulting from an uplift span
upto 150 m.
c)

Also to be designed for anticascading condition.

d) To be used as Section Tower

0 deg.

Spl. Extn. of DF

5 deg. to be restricted

(+9m to +12m)

DC/DG

15 deg. to 30 deg.

a) Tension towers with tension


insulators string.
b) Tension towers for uplift forces
resulting from an uplift span
upto 150 m.
c)

Spl. Extn. of DG

Also to be designed for anticascading condition.

20 deg. to be restricted

(+9m to +12m)

DD/DH

30 deg.-60 deg.

a) Tension towers with tension


insulators string.
b) Tension towers for uplift forces
resulting from an uplift span
upto 150 m.
c) Dead end with 0 deg. to 15 deg.
deviation both on line and
substation side (slack span).

Spl. Extn. of DH
(+9m to +18m

40 deg. to be restricted

DD/DH

0 deg.

d)

Complete Dead end.

e) For river crossing anchoring with


longer wind span with 0 deg.
deviation on crossing span side
and 0 to 30 deg. deviation on
other side.

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

SPANS AND CLEARNACES

3.3.1

NORMAL SPAN

A)

For 220kV & 66kV D/C line towers :-

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)

For ACSR Zebra of 220kV line :

Tower type

B)

Normal condition

Broken wire condition

Max.

Min.

Max.

Min.

(m)

(m)

(m)

(m)

DA

525

200

315

100

DB, DC, DD

525

315

-200

For KRR Design ACSR Zebra of 66kV line :

Tower type

DA

Normal condition

Broken wire condition

Max.

Min.

Max.

Min.

(m)

(m)

(m)

(m)

413

165

248

90

DB, DC, DD

C)

413

165

-150

For 220kV KRR Design normal M/C Towers:

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

Broken wire condition

Max.

Min.

Max.

Min.

(m)

(m)

(m)

(m)

MA

375

225

188

100

MB, MC, MD

375

188

-188

Page-19

D)

For new Design 220kV M/C monopoles :

The weight span shall be mentioned in new design of 220kv M/C monopoles.

3.3.4

ELECTRICAL CLEARANCES

3.3.4.1 GROUND CLEARANCE

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)

An allowance of 150 mm shall be provided to account for errors in stringing.

b)

Conductor creep shall be compensated by over tensioning the conductor at temperature of


26oC for ACSR Zebra lower than the stringing temperature.

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.

3.3.4.2 RAIL CROSSING

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

3.3.4.3 POWER LINE CROSSING


Minimum clearance between power line to power line shall be as follows:

3.3.4.4

i)

66 kV to 66 kV and below:

ii)

220 kV to 220 kV and below:

iii)

220 kV to 400 kV

2440 mm
4580 mm
5490 mm

LIVE METAL CLEARANCE


The minimum live metal clearance to be provided between the live parts and steel work of super
structure shall be as per IS:5613 (part-ii/sec-1) 1985 as given in table below:
For 220kV

S. N

Type of insulator string

Single suspension insulator string

Swing in deg.

Min. live metal clearance


in mm

Nil

2130

15

1980

30

1830

45

1675

60

Tension insulator string (single/double)

Nil

2130

Jumper

Nil

2130

10

2130

20

1675

30

Nil

2130

15

1980

Double suspension string

30

1830

45

1675

For 66kV :

S. N

Type of insulator string

Single suspension insulator string

Swing in deg.

Min. live metal clearance in mm

Nil

915

15

915

30

760

45

610

60

610

Tension insulator string (single/double)

Nil

915

Jumper

Nil

915

10

915

20

610

30

610

Nil

915

15

915

30

610

45

610

Double suspension string

Page-21

3.3.5

MID SPAN CLEARNACE


The minimum vertical mid span clearance between the earthwire and the nearest power conductor
shall not be less than 8.5 metres for 220 kV and 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 ruling 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.

3.4

MAXIMUM TENSION

3.4.1

Max tension shall be based on either


a)

At 0o C with 36% full wind pressure, or

b)

At 32o C with full wind pressure whichever is more stringent.

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

LIMITING TENSION OF CONDUCTOR & EARTHWIRE


The ultimate tension of conductor and ground wire shall not exceed 70 percent of their ultimate
tensile strengths.

3.4.5

CONDUCTOR AND EARTHWIRE CONFIGURATION


The three phases shall be in near vertical formation on both sides of tower. The phase to phase
spacing for tower shall be not less than 4.9 metres (vertical) and 8.4 metres (horizontal) for 220kV
M/C tower monopoles & D/C and 2.06 metres (vertical) and 4.88 metres (horizontal) for 66kV
towers.

3.5

MATERIALS

3.5.1

TOWER STEEL SECTIONS


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 and other is
HT steel.

3.5.2

FASTENERS: BOLTS NUTS AND WASHERS

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

The bolt position in assembled towers shall be as per IS:5613 (Part-II/secton-2-1976).

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)

STEP BOLTS & LADDERS

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)

INSULATOR STRING AND EARTHWIRE CLAMPS ATTACHMENTS

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)

DANGER, NUMBER, AND PHASE PLATE


Danger, Number, Circuit and phase plates shall be provided and installed by the Bidder.

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

The fabrication of towers shall be in conformity with the following:

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

DRILLING AND PUNCHING

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 =

HVPNL code assigned to the Bidder -Alphabet

BB =

Bidders Mark-Numerical

CC =

Tower type-Alphabet

DD =

Number mark to be assigned by Bidder -Numerical.

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

INSPECTION AND TESTS

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

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)

A Manufacturer's Certificate of Inspection for zinc (hot-galvanized) coatings on structural


steel with the following information:

1-

Purchase order number

2-

Date of inspection

3-

Number of pieces tested for weight of zinc coating with maximum-minimum


and average weights of each.

3.14

4-

Number of pieces tested for adherence of coating.

5-

Number of rejections because of defective


Certified test reports shall be sent to HVPNL.

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 AND SHIPPING

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

All standards tests, including quality control tests, in accordance with


Indian/International standard, shall be carried out unless otherwise specified herein.

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,

Specification for Zinc

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

Ordinary rapid hardening &

ISO/R/597-1967

low heat Portland cement.

IS:383-1970

Coarse and fine aggregates

CSA A23, 1/A 23.2

from natural sources for concrete.

IS:278

Specification for barbed wire.

ASTM A 121

IS:432-1966
(part-I&II)

Mild steel and medium tensile bars

BS-785-1938 CSA-G-30.

IS:456-2000

Code of practice for plain

and hard drawn steel wire for concrete


reinforcement.
ISO/3893-1977

and reinforced concerete.

IS:800-1962

Code of practice for use

CSA S16.1

of structural steel in
general building construction.

a) IS:802

Code of practice for use

(part-1)

of structural steel in
overhead transmission

IEC 826 ASCE 52 BS 8100

line. Materials loads


and permissible stresses.

b)IS:802

Code of practice for use

(part-2) 1978

of structural steel in

ASCE 52

overhead transmission
line. Fabrication,
galvanizing, inspection and packing.
c)IS:802
(part-3) 1978

Code of practice for use of structural


steel in overhead transmission line.
Tower testing.

10

IS:808

Dimensions for Hot Rolled steel beam,


column, channel and angle sections

11

IS:875

Code of practice for design loads


(other than earth-quakes) for buildings
& structures.

Page-32

12

IS:1139-1966

Hot rolled mild steel, medium tensile CAN/CSA G30.18


steel and high yield strength deformed
ASTM A615
bars for concrete reinforcements.

13

IS:1367-1967

Technical supply conditions


threaded fasteners (first revision)

14

IS:1489-1976

Portland pozzolena cement

15

IS:1786-1989

Cold twisted steel bars for concrete


reinforcement.

16

IS:1893-1965

Critecia of earthquake resistant design IEEE 693


of structures

for

ISO/R/863-1968

17

IS:2016-1967

Plain washers

ISO/R/887-1968.
B18.22.1

18

IS:2131-1967

Method of standard penetration test for


soils.

19

IS:2551-1982

Danger notice plates

20

IS:2629-1966

Recommended practice for hot dip


galvanizing of iron & steel.

21

IS:2633-1972

Method of testing uniformity of coating


of zinc coated articles.

22

IS:3043-1972

Code of practice of earthing (with


amendment No. 1and 2)

23

IS:3063-1972

Single coil rectangular section spring


washers for bolts, nuts, screws.

24

IS:4091-1967

Code of practice for design and


construction
of
foundation
for
transmission line towers and poles.

25

IS:5358-1969

Hot dip galvanizing


fasteners.

26

IS:5613 (part- Code of practice for design, installation


2/Sec.-1) 1976
and maintenance of overhead power
lines (Sec-1: (Designs)

27

IS:5613 (part- Code of practice for design, installation


2/Sec.-2) 1976
and maintenance of overhead power
lines
(Sec.-2
installation
and
maintenance)

coatings

ANSI

on

Page-33

28

IS:6610-1972

Specification for heavy washers for


steel structures.

29

IS:6639-1972

Hexagonal bolts for steel structure.

30

IS:6745-1972

Methods for determination of weight of


zinc coating of zinc coated iron and
steel articles.

Indian electricity rules 1956

31

32

Publication No. Regulation for electrical crossing of


19 (N) 700-1963 Railway Tracks.

33

IS:8500-1977

Specification for weldable structural BS: 4360


steel (medium and high strength
qualities)

34

IS:2062-1992

Steel for general structural purposes.

Page-34

The standards mentioned above are available from: -

Reference/Abbreviation

Name and address from which the standards are available.

IS

Bureau of Indian standards, Manak Bhawan, 9 Bahadur Shah


Zafar Marg, New Delhi, INDIA.

ISO

International Organisation for standardization, Danish Board of


Standardisation Danisk Standardisening Sraat, Aureheeugej-12,
DK-2900 Helleprup DENMARK.

CSA

Canadian Standard Association, 178,


Rexdale, Ontario, CANADA, M9W IR

BS

British Standsrds, British Standard Institution, 101, Pentonvile


Road, N-19-ND, UK.

DIN

Deutsches Institue Firr Normung Burggafenstrasse 4-10 Post


Fach 1107 D-1000, Berlin-30

Rezdale Boulevard,

Indian Electricity Rules 1956 Kitab Mahal ,Baba Kharak Singh Marg, New Delhi-110001 INDIA.
Regulation
for
Electricity
Crossing of Railway Tracks.

ASCE

American Society of Civil Engineers, 345, East 47th Street, New


York, NY-10017-2398 USA

IEEE

Institute of Electrical and Electronic Engineers ,445, Hoes Lane


PO. Box, 1331 Piscatawa NJ-08855-1355 USA

IEC

International Electrotechnical Commission Bureau central de La


commission Electrotechnique internatinale 1. Rue de varombe
Geneva Switzerland

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

4.7 DESIGN PARAMETERS


Critical soil data
(i)
(ii)
(iii)
(iv)

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

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.

4.7.3

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

Top of foundation must be at least 225mm above ground level.

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;

a. Max. tension or uplift along the leg slope.


b. Max. compression or down-thrust along the leg slope.
c. Max. horizontal shear or side thrust.
Page-38
4.8.3 The base slab of the foundation shall be designed for additional moments developing due to
eccentricity of the loads.

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.

RESISTANCE AGAINST UPLIFT

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.

RESISTANCE AGAINST DOWN THRUST

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.

Additional moments caused at bottom of footing due to eccentricity

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.

RESISTANCE AGAINST SIDE-THRUST


The lateral load carrying of chimney portion of foundation shall be based on the chimney acting as
cantilever aided by the passive earth resistance developed 500mm below the ground level.

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

PROPERTIES OF CONCRETE & REINFORCEMENT

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.

4.10.15 No admixtures shall be used.

4.11

UNIT RATES AND MEASUREMENT

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

CONSTRUCTION OF TOWER FOUNDATIONS AS PER DESIGN SUPPLIED BY HVPNL

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

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.
Page-42
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.

4.16 BACK-FILLING AND REMOVAL OF STUB TEMPLATE


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.
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

PROTECTION OF TOWER FOOTING

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

FIELD QUALITY CONTROL PLAN

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

SPECIFICATION FOR CIVIL AND STRUCTURAL WORKS FOR LYING CABLES

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

2.0 DISPOSAL OF EXCAVATED EARTH


2.1.1 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-in-charge.
2.2

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

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

BACK FILLING FOR CABLE TRENCH

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

SPECIFIATION FOR CEMENT CONCRETE


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).

6.0

CURING AND PROTECTION OF CONCRETE


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.

7.0

PRECAST RCC ITEMS

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

All the pre-cast element shall be marked, appropriately as specified.

8.0

FOUNDATION
Foundations for mounting structures in cement concrete shall be casted by bidder as per approved
drawings.

9.0

BOLTS, NUTS AND WASHERS


Standard bolts, nuts an washers shall be used in all works. These should be galvanized in
accordance with IS: 5358.

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

MATERILAS USED IN CABLE LAYING


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.

12.0

RCC PRE CAST CABLE PROTECTION COVERS


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.

13.0

CABLE ROUTE MARKERS/JOINT MARKERS

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

LEAD AND LIFT


The rates quoted for all items of works shall include all lifts and leads wherever applicable unless
otherwise specified.
Page-47

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

MAINTENANCE OF SITE CONDITIONS


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-48

Page-49

Page-50

CIVIL FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


(Before start of work)

NAME OF LINE :

PART-A : FOUNDATION ACTIVITY (DETAIL OF CONCRETE MIX)

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)

Aggregate confirming to IS: 383

3)

Fine
Aggregates

i)

Source of
aggregates

ii)

Specific
Gravity

iii)

Aggregate confirming to Zone as per


IS: 383

4)

Mix Proportion FOR 1 BAG OF


CEMENT

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.

Material to be tested before the source is approved and Engineer-in-Charge


can test the
material
periodically.

2.

Mix design is to be re-done on change of


source of aggregates.

Page-51

3.

The source of aggregates to be got approved from


Engineer-in-Charge.

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

Performed and checked by:

Sub-Contractor:

Name
:

Name:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-52

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST

NAME OF LINE :
Location Number

Date :

PART-A : FOUNDATION ACTIVITY


A1 :

Checking for PIT Marking

a)

Foundation Drawing no. followed:

b)

Span on both sides:

Preceeding Span
As per profile
c)

Succeeding Span
Actual

As per profile

Actual

Tangent Tower:

Alignment of the location peg with respect


to other adjacent location or angle, if any

d)

Angle Tower: Cut point

Bi-section in case of angle Tower Location and checking of angles:


Angle of deviation
As per profile

Bi-section
Actual

e)

Reference levels in case of uneven ground:

f)

Matching of ground
profile:

Calculated

OK detail
CERTIFICATE: Cleared for excavation
Performed and checked by:

Actual

Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:
Signature with Seal:

Date:

Page-53

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST

NAME OF LINE :
Location No.:

Date :

PART-A : FOUNDATION ACTIVITY


A2 :

Checking of PIT Excavation & Soil


Classification

a)

Foundation Drawing no. followed:

b)

Details of Soil: Type of Soil and depth

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)

Sub-Soil Water below NGL as on date:

Leg-1 (M)

Leg-2
(M)

Leg-3 (M)

d)

Location position (Paddy fields, Sugarcane, Forest etc.):

e)

Foundation Classification:

Leg-4 (M)

Page-54
As proposed by Contractor

As approved by HVPN

f)

Detail of under cutting, if any:

CERTIFICATE:

Performed and checked by:


Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature
with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-55

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :
Location No.:

Date :

PART-A : FOUNDATION ACTIVITY

A3 :

Checking of Stub Setting

a)

Foundation Drawing no. followed:

b)

Alignment of template/prop. :

i)

In line in case of tangent Tower

Yes/No

ii)

On bisection in case of angle Tower

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)

Levels of template checked by


water level or dumpy
level

Yes/No

Cleat at the bottom of the sub is fitted

Yes/No

CERTIFICATE:

Performed and checked by:


Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-56

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST

NAME OF LINE :
Location No.:

Date :

PART-A : FOUNDATION
ACTIVITY

A4 :

Checking of Foundation material & availability of T&P :

a)

Fabrication & placement of reinforcement steel as per Drawing


no.:

b)

Diameter and lengthwise details of reinforcement steel:

Sr.No.

Length
Drgs.

c)

Diameter

Actual

Drgs.

Actual

Nos.
Drgs.

Yes/No

REMARKS
Actual

(testing details)

Quality of sand as per specification and conforming


to the grade used in Mix Design and sufficient
quantity
is available at location:

d)

Yes/No.

Quality & quantity of coarse Aggregate, metal conforming


to the grade used in Mix Design and sufficient quantity is
available at
location:

e)

Yes/No.

Source of
collection :
Sand
Name

Metal/Aggregate
Approved/Not Approved

Name

f)

Quality of Water:

i)

Confirming to specification :

ii)

pH value of water used :

g)

Required T&P such as mixer, vibrator, slump cone, form boxes, shuttering,

Approved/Not
Approved

Yes/No.

dewatering arrangement & cubes for sampling etc., are


available in good condition and required quantity:
h)

Yes/No.

Defective T&P required to be repaired/replaced by the


Contractor:

Page-57

CERTIFICATE:

Performed and checked by:

Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-58

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :
Location No.:

Date :

PART-A : FOUNDATION ACTIVITY

A5 :

Lean Concrete

a)

Foundation Drawing no. followed :

b)

Concrete mixing by mixer :

Yes/No

c)

Dewatering done:

Yes/No

d)

Lean concreting done upto specified level of all pits:

Yes/No

e)

Proper levelling of concrete in all


pits:

Yes/No

f)

Number of cement bags used for lean concrete:

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:

Signature with
Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:

Signature with Seal:

Date:

Page-59

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST

NAME OF LINE :

Location No.:

Date :

PART-A : FOUNDATION ACTIVITY

A6 :

Placement of reinforcement steel & form boxes:

a)

Foundation Drawing no. followed :

b)

Reinforcement steel placed as per drawing:

Yes/No

c)

Concrete cover to reinforcement maintained with


adequate no. of cover blocks as per specification:

d)

e)

Yes/No

Form boxes are placed as per drawing & tightened


properly with shuttering oil painted inside:

Yes/No

Earthing strip is fixed as per


drawing:

Yes/No

CERTIFICATE:

Performed and checked by:

Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature
with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-60

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :

Location No.:

Date :

PART-A : FOUNDATION ACTIVITY

A7 :

Checking for foundation casting

a)

Foundation Drawing no. followed


:

b)

Concrete mixing by mixer as per Design Mix ratios:

Yes/No

c)

Mixing by mixer:

Yes/No

d)

Water cement ratio:

e)

Use of vibrator for compaction:

Yes/No

f)

Checking of stub-template level at interval:

Yes/No

g)

Checking diagonal stub-template level at interval:

Yes/No

h)

Casting of leg is done in


continuity:

Yes/No

i)

Slump

mm

j)

Number of cement bags


consumed:
As per Design / Drg

Actual

Reasons for variation

k)

Coping is done:

l)

Top of concrete from average ground level:

m)

No. of concrete samples taken:

CERTIFICATE : Foundation is casted as per drawing

Yes/No

Performed and checked by:

Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature with
Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:

Signature with Seal:

Date:

Page-61

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF
LINE :
Location
No.:

Date :

PART-A : FOUNDATION ACTIVITY

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

Form boxes are removed after 24 hrs. of casting:

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

Any other defect


(s)

d)

Back filling done as per specification:

Yes/No

e)

Template/prop is removed only after complete back


filling:

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:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:

Signature with Seal:

Date:

Page-62

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF
LINE :
SECTION

LOC.No.

DATED:

PART-A : FOUNDATION ACTIVITY

A9 :

Dimension of location after casting

a)

After casting level checked and found OK

b)

Important measurement for the location is measured

YES/NO

after casting and indicated below and dimensions are


within the tolerance limits.

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

: _________________

Signature with Seal

:
______________

Date

: _________________

Date

:
______________

Haryana Vidyut Prasaran Nigam Ltd.


Name:

Signature with
Seal:
Date:

Page-63

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :
SECTION

LOC.No.

DATED:

PART-A : FOUNDATION ACTIVITY

A10 :

Procedure for finalisation of Most Techno-Economical Location

1.

No level Ground is available in the vicinity along the alignment

2.

Tower can not be located on the level Ground even by providing extension

3.

Benching/Revetment or both are unavoidable


Comparative Study of alternatives is indicated below :

CASE - I

: When Complete Benching is Done

Sl.No.

PARTICULARS

1.

Excavation (Type of soil)


a)
b)
c)

2.

Revetment

3.

Breast Wall

4.

Any other work

TOTAL

CASE - II

: When Benching is done partly

QTY.

RATE

COST

REMARKS

Sl.No.
1.

PARTICULARS

QTY.

RATE

COST

REMARKS

Excavation (Type of soil)


a)
b)
c)

2.

Revetment

3.

Breast Wall

4.

Any other work

TOTAL

Page-64

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :

SECTION

LOC.No.

DATED:

PART-A : FOUNDATION ACTIVITY

CASE - III

Sl.No.

: When No Benching is done

PARTICULARS

QTY.

RATE

COST

REMARKS

1.

Excavation (Type of soil)


a)
b)
c)

2.

Revetment

3.

Breast Wall

4.

Tower Structure (with leg


extension, if any)

5.

Any other work

TOTAL

Note :

Relevant Drawings with calculations are to be enclosed.

Performed and checked by:

Sub-contractor

: _________________

Name

: _________________

Name

:
______________

Signature with Seal

: _________________

Signature with
Seal

:
______________

Date

: _________________

Date

:
______________

Haryana Vidyut Prasaran Nigam Ltd.


Name:
Signature with Seal:
Date:

Page-65

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :

Location No.:

Date :

PART-A : FOUNDATION ACTIVITY


A-11:

Testing of concrete cubes

a)

Grade of Concrete:

b)

No. of samples taken:

c)

Date of casting:

d)

Date of testing:

e)

Size of Cube

Sample No.

Cube No.

Wt. Of cube (Kg.)

Load in Kg. at crushing

Cube Strength
(Kg/Cm2)
7 days

1.

1
2
3

2.

1
2
3

3.

1
2
3

4.

1
2
3

28 days

CERTIFICATE: Cube strength meets the requirement of specification & IS code.


Performed and checked by:
Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:
Signature with Seal:
Date:

Page-66

5.0

TOWER ERECTION, STRINGING AND INSTALLATION OF LINE MATERIAL.

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

TREATMENT OF MINOR GALVANISNING DAMAGE


In case any minor damage to galvanizing is noticed, the same shall be treated with zinc rich paint
(commercial grade) (having at least 90% zinc content) before erection.

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)

The bolt position in assembled towers shall be as per IS:5613 (Part-II/section-2)-1976.

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

TIGHTENING AND PUNCHING OF BOLTS AND NUTS.

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

HANDING OF CONDUCTOR AND EARTHWIRE

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.

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5.7

STRINGING OF CONDUCTOR AND EARTHWIRE

5.7.1

The stringing of the conductor shall be done by standard stringing method.

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.
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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

TENSIONING AND SAGGING OF CONDUCTORS AND EARTHWIRE


The tensioning and sagging shall be done in accordance with the approved stringing charts before
the conductors and earthwire are finally attached to the towers through the earthwire clamps for the
earthwire and insulator strings for the conductor. The initial stringing chart for shall be used for the
conductor and final stringing chart for earthwire should be employed for this purpose.
Dynamometers shall be employed for measuring tension in the conductor and earthwire. The
dynamometers employed shall be periodically checked and calibrated with the standard
dynamometer.

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

FIXING OF CONDUCTOR AND EARTHWIRE ACCESSORIES


Vibration dampers for conductor and earthwire and other conductor and earthwire accessories shall
be installed by the Bidder as per the design requirement and respective Bidders instructions within
24 hours of the conductor/earthwire clamping. While installing the conductor and earthwire
accessories, proper care shall be taken to ensure that the surface are clean and smooth and no
damage shall occur to any part of the accessories.

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

PREMITTED EXTRA CONSUMPTION OF LINE MATERIALS

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

line length as per detailed survey


x No. of phases (3) x No. of circuits

b)

Quantity of earthwire

line length as per detailed survey

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

FINAL CHECKING, TESTING AND COMMISSIONING


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:

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

GENERAL TECHNICAL CONDITIONS

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.

6.2 ENGINEERING DATA


6.2.1

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

In addition to those stipulated in clause regarding drawings in conditions of contract, the


following also shall apply in respect of Bidders 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)

Work schedule (master network) plan.

b)

Sag-tension calculation and sag-template curve drawings.

c)

Tower spotting data.

d)

Detailed survey report and profile drawing showing ground clearance and tower locations.

e)

Tower schedule and foundation classification for individual tower locations.

f)

Soil investigation report.

g)

Tower footing earthing drawing.

h)

Stringing procedure and stringing chart.

i)

Tower accessories drawings like design plate, name plate etc.

j)

Quality plan for fabrication and site activities including quality system.

k)

Sub-vendors approval etc.

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

DESIGN REVIEW MEETING:

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

REGULATION OF LOCAL AUTHORITIES AND STATUTES:

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

BIDDERS FIELD OPERATION

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

MAN POWER DEPLOYMENT REPORT

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

FACILITIES TO BE PROVIDED BY THE BIDDER

7.5.4

TOOLS, TACKLE AND SCAFFOLDINGS


The Bidder shall provide all the construction equipment, tools, tackle and scaffoldings required
for construction, erection, testing and commissioning of the transmission line covered under the
contract. He shall submit a list of all such materials to the HVPNL before the commencement of
work at site. These tools and tackle shall not be removed from the site without the written
permission of the HVPNL.

7.5.5

FIRST AID AND GENERAL HYGIENE


The contactor shall provide all necessary first aid facilities for all his employees, representatives
and workmen working at the site. Enough number of Bidders personnel shall be trained in
administering first aid.

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

METERIALS HANDLING AND STORAGE

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

FIELD OFFICE RECORDS

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

PROTECTION OF PROPERTY AND BIDDERS LIABLILITY

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

PROTECTON OF MONUMENTS AND REFERENCE POINTS

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

WORK AND SAFETY REGULATIONS

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

DRAWINGS FOR 220kV & 66kV TOWER ACCESSORIES

Sr. No.

Description

Drawing
No.

1.

Tower Number plate

2.

Circuit Plate

3.

Tower phase plate

Tower danger plate

Pipe type earthing arrangement

Counterpoise type earthing arrangement 6

Detail for flats for earthing

Detail of anticlimbing device

Step bolt drawing

10

Single suspension string drawing

10

11

Single tension string drawing

11

12.

Double tension string drawing

12

13

Compression type tension fitting for

13

earthwire
14

Suspension type assembly for earthwire

14

ANNEXURE-IB

DRAWINGS OF 220kV TOWER ACCESSORIES

Sr. No.

Description

Drawing
No.

1.

Tower Number plate

2.

Circuit Plate

3.

Tower phase plate

Tower danger plate

Pipe type earthing arrangement

Counterpoise type earthing arrangement

Detail for flats for earthing

Detail of Anticlimbing device

Step bolt drawing

10

Single suspension string of ACSR Zebra

10

drawing
11

Single tension string of ACSR Zebra drawing

11

12.

Double Suspension string of ACSR Zebra

12

drawing
13

Double Tension string of ACSR Zebra drawing

13

14

Single suspension string of ACSR Moose

14

drawing
15

Single tension string of ACSR Moose drawing

15

16

Double Suspension string of ACSR Moose

16

drawing
17

Double Tension string of ACSR Moose

17

drawing
18

Compression type tension fitting for

18

earthwire
19

Suspension type assembly for earthwire

19

ANNEXURE-IB

ROUTE ALIGNMENT DETAILS


Sr.
No.

Name of line

Tentative Length of
line in km

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 220kV M/C monopole to be
newly designed)

2.31

LILO of both circuit of 66kV BBMB Ballabgarh-Jharsetly D/C line at D/C


length=
220kV S/Stn. Sector-58, Faridabad with 0.4sq ACSR Zebra.
0.040+0.040=0.080km

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

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. (partially on M/C
monopole )

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

Tentative M/C Length:


1.165kms.
Tentative D/C Length:
0.511

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).

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)

D/C length of tower


portion =3.970km

(DRAWINGS IN SEPARATE FOLIO)

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)

(Tentative length of line =2.31 km)


Sr. No.
DESCRIPTION

Qty.

UNIT

A
220kV line on 220kV D/CTATA Design towers
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

i) 220kV D/C DB type (TATA Design) tower

No.

ii) +6 mtr. extn. only

No.

i) 220kV D/C DD type (TATA Design) Tower

No.

ii) +6mtr. extn. only

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

i) 220kV MA type Normal Multi- Circuit tower

No.

1.2

i) 220kV MB typeNormal Multi- Circuit tower

No.

ii) +3 mtr. Extn. only


1.3

i) 220kV MD typeNormal Multi- Circuit tower

220kV line on 220kV M/C Monopole

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.

i) 220kV M/C A type Monopole

No.

ii) 220kV M/C B type Monopole

No.

iii) 220kV M/C B type Monopolewith +3 mtr. Extn.

No.

iv) 220kV M/C D type monopole with +3 mtr. Extn.

No.

Supply of earthing of towers/ monopole

i) Pipe type

Sets

18

ii) Counterpoise type

Sets

-0

3.

Supply of following Tower accessories


i) Danger Plate
ii) Number Plate
iii) Phase Plate(set of 3)
iv) Circuit Plate (set of 2)
v) Bird Guard (Set of 3)
vi) Anti climbing device

No.

18

No.

18

Sets

36

Sets

28

Sets

20

Sets

18

LINE MATERIAL

Conductor (ACSR Zebra 54/7/3.18mm size)

Km

27.37

Earth wire

KM

0.150

OPGW & Accessories

OPGW (24 fiber) DWSM

Km

0.662

Hardware set for above 24 Fibre OPGW fibre optic cabling including
all cable fittings & accessories except joint box.

set

2
9

Joint Box ( 24 fibre) including jointing box at LILO point

No.

10

End to end testing of OPGW cable (installed) for above under


construction transmission line

Lot

Lot

11

OPGW (48 fiber) DWSM

Km

1.648

12

Hardware set for above 48 Fibre OPGW fibre optic cabling


including all cable fittings & accessories except joint box.

set
3

13

Joint Box ( 48 fibre) as applicable

No.

14

Fibre optic Approach cable, 48 fibre (DWSM)

Km.

15

Hardware set for 48 fibre OFAC (DWSM)

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

Silicone Rubber Polymer Insulators strings


i) 70 kN

No.

84

ii) 120 kN

No.

240

19

220 kV post insulators

sets

NIL

20

Hardware Fittings
Set

60

Set

24

Set

240

Set

i) Mid Span Compression Joint for conductor

No.

19

ii) Mid Span Compression Joint for earth wire

No.

NIL

iii) Repair sleeves for conductor

No.

iv) Flexible copper Bond

No.

18

v)

No.

552

vi) Vibration damper for earthwire

No.

vii) Earrth-wire tension clamp

No.

28

viii) Earth-with suspension clamp

No.

NIL

ix) 0.4sq T-connector

No.

12

i)
ii)
iii)
iv)

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

Conductor & Earth wire Accessories


21

Vibration damper for conductor

DISMANTLEMENT WORK to be included in Erection Part of BOQ


i) Dismantlement of towers and their transportation & proper stacking
at any dedicated store of HVPNL. The dismantlement of tower shall also
include dismantlement of Stub concrete upto a depth of 1M (one meter)
from Natural Ground level, back filling , compaction and clearing the site
of debris

As per site

220kV D/C DA type Tower


No.
220kV D/C DC type Tower
No.

1
1

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

(Supply portion only)

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.

(Approx. D/C length =0.040+0.040=0.080km)


S.No

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)

DH type 66kV tower (KRR Design)

No.

ii)

Extra cross arm (if required)

No.

Supply of earthing of towers


i) Pipe type

Sets

ii) Counterpoise type

Sets

i) Danger Plate

No.

ii) Number Plate

No.

iii) Phase Plate(set of 3)

Sets

iv) Circuit Plate (set of 2)

Sets

v) Bird Guard (Set of 3)

Sets

vi) Anti climbing device

Sets

Supply of following Tower accessories

B)

LINE MATERIAL

Conductor (ACSR Zebra: 54/7/3.18mm)

Km

0.485

Earth wire(7/ 3.15 mm)

Km

0.081

Anti-Fog type Disc Insulator or Silicon Rubber Polymer Insulator strings


i) 70 kN
No.
ii) 120 kN

Nil
No.
48

66kV Post Insulators

No.

Nil

Hardware Fittings
i.
ii.
iii.
iv.

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

Set

Set

Set

48

Set

Conductor & Earth wire Accessories


9

10

i)

Mid Span Compression Joint for conductor

No.

Nil

ii)

Mid Span Compression Joint for earth wire

No.

Nil

iii)

Repair sleeves for conductor

No.

Nil

iv) Flexible copper Bond

No.

v)

No.

96

vi) Vibration damper for earthwire

No.

16

vii) Earth-wire tension clamp

No.

viii) Earth-wire suspension clamp

No.

IX) 0.4sq T-connector for making LILO arrangement

No.

12

Vibration damper for conductor

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.

(Supply Portion only)

Sr. No.

Description

Unit

Total Quantity

1.

66kV 1200 mm2 Single Core Aluminium Conductor Milliken type ,


XLPE insulated Cable as per technical specification

Mtrs.

2465x8

2.

End Terminations as per technical specification suitable for above


cable (at s/stn end) as per bidders standard design

No.

16

3.

Galvanized End Termination Structures complete with Nuts , Bolts,


washers etc.

No.

4.

Indicative quantity of Link Box with SVL

No

No

( to be decided as per requirement)


5.

Indicative quantity of Link Box with-out SVL


( to be decided as per requirement)

6.

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC insulated,


Unarmored, 3.3 KV Sheath Bonding cable

Mtrs

300

7.

66kV polymeric LAs along withearthling material.( Tower side only)


with surge counter

No.

8.

Terminal Connectors including Hardware fitting &ACSR Zebra


conductor etc.

No.

16

9.

Supply of HDPE pipes required for various crossings with trench less

Mtr.

227x8

10.

Straight Through Joints (if required as per site condition)

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.

( Break-up to be specified by the bidder)

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.

(Erection Portion only)

Sr.
No.

Description

Unit

Quantity

1. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each Circuit
(6+2), installation of Straight Through joint, and complete Civil works in all
respect including Manholes for jointing Bays on through rate basis as per
technical specification with trench method (directly Buried).

Running
circuit

2238

2. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each Circuit
(6+2), installation of Straight Through joint, and complete Civil works in all
respect including using of HDPE pipes & Manholes for jointing Bays on
through rate basis as per technical specification with Trench-less method.

Running
circuit

3. Erection of End Termination Structures and their Foundations including


earthing.

Nos.

4. Installation of End Terminations including link boxes, earthing, Terminal


connectors etc. This shall also include erection of Hardware fittings &
conductor

Nos.

16

5. Installation of polymericLAs along with their earthling. With surge counter

Nos.

6. Testing & Commissioning

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

( Break-up to be specified by the bidder)

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.

(Supply Portion only)

Sr. No.

Description

Unit

Total Quantity

1.

66kV 1200 mm2 Single Core Aluminum Conductor Milliken type ,


XLPE insulated Cable as per technical specification

Mtrs.

2400x8

2.

End Terminations as per technical specification suitable for above


cable (at s/stn end) as per bidders standard design

No.

16

3.

Galvanized End Termination Structures complete with Nuts , Bolts,


washers etc.

No.

4.

Indicative quantity of Link Box with SVL

No

No

( to be decided as per requirement)


5.

Indicative quantity of Link Box with-out SVL


( to be decided as per requirement)

6.

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC insulated,


Unarmored, 3.3 KV Sheath Bonding cable

Mtrs

300

7.

66kV polymeric LAs along withearthling material.( Tower side only)


with surge counter

No.

8.

Terminal Connectors including Hardware fitting &ACSR Zebra


conductor etc.

No.

16

9.

Supply of HDPE pipes required for various crossings with trench less

Mtr.

92x8

10.

Straight Through Joints

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.

( Break-up to be specified by the bidder)


13

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.

(Erection Portion only )

Sr.
No.

Description

Unit

Quantity

1. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each Circuit
(6+2), installation of Straight Through joint, and complete Civil works in
all respect including Manholes for jointing Bays on through rate basis as
per technical specification with trench method (directly Buried).

Running
circuit

2308

2. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each Circuit
(6+2), installation of Straight Through joint, and complete Civil works in
all respect including using of HDPE pipes & Manholes for jointing Bays on
through rate basis as per technical specification with Trench-less
method.

Running
circuit

3. Erection of End Termination Structures and their Foundations including


earthing.

Nos.

4. Installation of End Terminations including link boxes, earthing, Terminal


connectors etc. This shall also include erection of Hardware fittings &
conductor

Nos.

16

5. Installation of polymericLAs
counter

Nos.

6. Testing & Commissioning

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. Foundation, erection, termination, earthing, stringing and sagging of


66kV DD+0 KRR design towerincluding casting and fencing complete in
all respect to complete the LILO arrangement

No.

9. Any other items not specified above but are required to complete the
job in all respect.

Lot

Lot

alongwith their earthing. With surge

Length
(6+2)
Mtrs.
92

Length
(6+2)
Mtrs.

( Break-up to be specified by the bidder)

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.

(SUPPLY PART ELECTRICAL)

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.

220kV line on 220kV D/C TATA Design towers

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

i) 220kV D/C DD type (TATA Design) tower

No.

ii) +6 mtr.extn. only

No.

iii) Extra cross arm(set of 3)

No.

220kV line on 220kV KRR Design M/C towers


Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers, Dshackle etc. of following type of 220kV Multi-circuit ( 4 Ckts.) towers of KRR design.

1.1

i) 220kV MD type Normal Multi- Circuit tower

No.

220kV line on 220kV M/C Monopole to be newly designed

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.

ii) 220kV M/C B type Monopole

No.

iii) 220kV M/C D type Monopole


iv) 220kV M/C D type Monopolewith extracrossarm
2.

3.

2
No.

i) Pipe type

Sets

12

ii) Counterpoise type

Sets

No.

12

Supply of earthing of towers/ monopole

Supply of following Tower accessories


i) Danger Plate

ii) Number Plate

No.

12

iii) Phase Plate(set of 3)

Sets

40

iv) Circuit Plate (set of 2)

Sets

48

v) Bird Guard (Set of 3)

Sets

vi) Anti climbing device

Sets

12

LINE MATERIAL

Conductor (ACSR Zebra 54/7/3.18mm size)

Km

17.22

Earth wire size 7/3.15mm

Km

0.10

OPGW & Accessories

OPGW (24 fiber) DWSM

Km

0.516

Hardware set for above 24 Fiber OPGW fiber optic cabling including
all cable fittings & accessories except joint box.

set

Joint Box ( 24 fiber) including jointing box at LILO point

No.

End to end testing of OPGW cable (installed) for above under


construction transmission line

Lot

Lot

OPGW (48 fiber) DWSM

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

Joint Box ( 48 fiber) as applicable

No.

10

Fiber optic Approach cable, 48 fiber (DWSM)

Km.

11

Hardware set for 48 fiber OFAC (DWSM)

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

Silicone Rubber Polymer Insulators strings

15

i) 70 kN

No.

42

ii) 120 kN

No.

216

220 kV post insulators

sets

NIL

16

Hardware Fittings
i)
ii)
iii)
iv)

17

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

Set

24

Set

18

Set

216

Set

No.

12

No.

No.

iv) Flexible copper Bond

No.

12

v)

No.

456

Conductor & Earth wire Accessories


i) Mid Span Compression
ii)

Joint for conductor

Mid Span Compression Joint for earth wire

iii) Repair sleeves for

conductor

Vibration damper for conductor

vi)

Vibration damper for earth wire

No.

38

vii)

Earth-wire tension clamp

No.

22

No.

Km

1.5

viii) Earth-wire suspension clamp


8

DISMANTLEMENT WORK to be included in Erection Part of


BOQ
i) 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 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)

(Supply Portion only)

Sr. No.

Description

Unit

Total Quantity

1.

66kV 1200 mm2 Single Core Aluminium Conductor Milliken


type , XLPE insulated Cable as per technical specification

Mtrs.

1350x8

2.

End Terminations as per technical specification suitable for


above cable (at s/stn end) as per bidders standard design

No.

16

3.

Galvanized End Termination Structures complete with Nuts ,


Bolts, washers etc.

No.

4.

Indicative quantity of Link Box with SVL single phase

No

( to be decided as per requirement)


5.

Indicative quantity of Link Box with-out SVL single phase (to


be decided as per requirement)

No

6.

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC


insulated, Unarmoured, 3.3 KV Sheath Bonding cable

Mtrs

200

7.

66kV polymeric LAs along withearthling material. (Tower


side only)

No.

8.

Terminal Connectors including Hardware fitting &ACSR Zebra


conductor etc.

No.

16

9.

Supply of HDPE pipes required for various crossings with


trench less

Mtr.

Nil

10.

Straight Through Joints

No.

Nil

4 Pole Rail pole structure for the LILO arrangement and


foundation (if required as per site conditions)

No.

Nil

Any other items not specified above but are required to


complete the job in all respect.

No.

Lot

11.

12.

( Break-up to be specified by the bidder)

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)

(Erection Portion only )

Sr.
No.

Description

1. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium


Milliken Conductor 66 KV cable in trefoil formation with one spare
for each Circuit (6+2), installation of Straight Through joint, and
complete Civil works in all respect including Manholes for jointing
Bays on through rate basis as per technical specification with trench
method (directly Buried).
2. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium
Milliken Conductor 66 KV cable in trefoil formation with one spare
for each Circuit (6+2), installation of Straight Through joint, and
complete Civil works in all respect including using of HDPE pipes &
Manholes for jointing Bays on through rate basis as per technical
specification with Trench-less method.

Unit

Quantity

Running
circuit

1350

Length
(6+2) Mtrs.
Running
circuit

nil

Length
(6+2) Mtrs.

3. Erection of End Termination Structures and their Foundations


including earthling.

Nos.

4. Installation of End Terminations including link boxes, earthing,


Terminal connectors etc. This shall also include erection of Hardware
fittings & conductor

Nos.

16

5. Installation of polymericLAs along with their earthling.

Nos.

6. Testing & Commissioning

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

( Break-up to be specified by the bidder)

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.

(Supply portion only)


BOQ of 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn.Bhagola with 0.4sq ACSR Zebra. (Tower
portion)
(Approx. D/C length =13.55km)

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.

ii) +3m extn.

No.

i) DF type 66kV Tower (KRR Design)

No.

i) DG type 66kV Tower (KRR Design)

No.

ii) +3m extn.

No.

i) DH type 66kV Tower (KRR Design)

No.

ii) +3m extn.

No.

Extra cross arm

No.

220kV D/C DD+12 (TATA Design)

No.

Gantry (G1 & B1 type)

No.

31
6

1.2

1.3

9
5

1.4

14
2

1.5

1.6

1.7
2.

3.

Supply of earthing of towers


i) Pipe type

Sets

63

ii) Counterpoise type

Sets

i) Danger Plate

No.

63

ii) Number Plate

No.

63

iii) Phase Plate(set of 3)

Sets

64

iv) Circuit Plate (set of 2)

Sets

63

v) Bird Guard (Set of 3)

Sets

63

vi) Anti climbing device

Sets

63

Supply of following Tower accessories

Conductor (ACSR Zebra: 54/7/3.18mm)

i) Conductor to be procured by the bidder


ii) Conductor to be transported by the bidder from HVPNL DD store
to the site
5.

Earth wire(7/ 3.15 mm)

6.

Anti-Fog type Disc Insulator or Silicon Rubber Polymer Insulator strings

Km
khera

km
Km

42.61
39.50

13.69

i) 70 kN
No.
ii) 120 kN

192
No.
420

66kV Post Insulators

8.

Hardware Fittings
i.

Single I Suspension String


ii. Single suspension pilot string
iii. Single Tension string
iv. Double tension string

No.

36

Set

186

Set

Set

396

Set

12

Conductor & Earth wire Accessories


i)

Mid Span Compression Joint for conductor

No.

55

ii)

Mid Span Compression Joint for earth wire

No.

iii)

Repair sleeves for conductor

No.

17

iv) Flexible copper Bond

No.

63

v)

Vibration damper for conductor

No.

1138

vi) Vibration damper for earth wire

No.

190

vii) Earth-wire tension clamp

No.

66

viii) Earth-wire suspension clamp

No.

31

IX) 0.4sq T-connector for making LILO arrangement

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.

(Supply portion only)

BOQ of 66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 0.4sq ACSR Zebra (Tower portion).

(Approx. length =4.895 km)


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
66kV DE type tower (KRR Design)

No.

i) 66kV DF type tower (KRR Design)

No.

ii) +6 mtr. Extn. for above

No.

66kV DG type tower (KRR Design)

No.

i) 66kV DH type tower (KRR Design)

No.

1.2

6
2

1.3

1.4

1.5

2.

3.

ii) +6 mtr. Extn. for above

No.

iii) Extra cross arm only (set of 3)

Set

i) 220kV DD type D/C TATA Design tower

No.

ii) +9mtr. Extn. for above

No.

i) Pipe type

Sets

23

ii) Counterpoise type

Sets

i) Danger Plate

No.

23

ii) Number Plate

No.

23

iii) Phase Plate(set of 3)

Sets

36

iv) Circuit Plate (set of 2)

Sets

23

v) Bird Guard (Set of 3)

Sets

10

vi) Anti climbing device

Sets

23

Conductor (ACSR Zebra: 54/7/3.18mm)

Km

29.66

Supply of earthing of towers

Supply of following Tower accessories

5.

Earth wire(7/ 3.15 mm)

6.

Anti-Fog type Disc Insulator or Silicon Rubber Polymer Insulator strings

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)

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

Conductor & Earth wire Accessories


i)

Mid Span Compression Joint for conductor

No.

20

ii)

Mid Span Compression Joint for earth wire

No.

iii) Repair sleeves for conductor

No.

iv) Flexible copper Bond

No.

23

v)

No.

492

vi) Vibration damper for earthwire

No.

82

vii) Earth-wire tension clamp

No.

38

viii) Earth-wire suspension clamp

No.

Vibration damper for conductor

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).

(Supply Portion only)

Sr. No.

Description

Unit

Total Quantity

13.

66kV 1200 mm2 Single Core Aluminium Conductor Milliken


type , XLPE insulated Cable as per technical specification

Mtrs.

705x8

14.

End Terminations as per technical specification suitable for


above cable (at s/stn end) as per bidders standard design

No.

16

15.

Galvanized End Termination Structures complete with Nuts ,


Bolts, washers etc.

No.

16.

Indicative quantity of Link Box with SVL single phase

No

( to be decided as per requirement)


17.

Indicative quantity of Link Box with-out SVL single phase (to


be decided as per requirement)

No

18.

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC


insulated, Unarmoured, 3.3 KV Sheath Bonding cable

Mtrs

200

19.

66kV polymeric LAs alongwithearthing material.(Tower side


only)

No.

20.

Terminal Connectors including Hardware fitting &ACSR Zebra


conductor etc.

No.

16

21.

Supply of HDPE pipes required for various crossings with


trench less

Mtr.

100x8

22.

Straight Through Joints

No.

Nil

4 Pole Rail pole structure for the LILO arrangement and


foundation (if required as per site conditions).

No.

Nil

Any other items not specified above but are required to


complete the job in all respect.

No.

Lot

23.

24.

( Break-up to be specified by the bidder)

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).

(Erection Portion only )

Sr.
No.

Description

9. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium


Milliken Conductor 66 KV cable in trefoil formation with one spare
for each Circuit (6+2), installation of Straight Through joint, and
complete Civil works in all respect including Manholes for jointing
Bays on through rate basis as per technical specification with trench
method (directly Buried).
10. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium
Milliken Conductor 66 KV cable in trefoil formation with one spare
for each Circuit (6+2), installation of Straight Through joint, and
complete Civil works in all respect including using of HDPE pipes &
Manholes for jointing Bays on through rate basis as per technical
specification with Trench-less method.

Unit

Quantity

Running
circuit

605

Length
(6+2) Mtrs.
Running
circuit

100

Length
(6+2) Mtrs.

11. Erection of End Termination Structures and their Foundations


including earthing.

Nos.

12. Installation of End Terminations including link boxes, earthing,


Terminal connectors etc. This shall also include erection of Hardware
fittings & conductor

Nos.

16

13. Installation of polymericLAs along with their earthling.

Nos.

14. Testing & Commissioning

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

( Break-up to be specified by the bidder)

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

End Terminations as per technical specification suitable for above


cable on tower / structure as per bidders standard design

No.

Straight Through Joints

No.

A. Description of material already procured and available with HVPNL


1.

2.

Already procured
48
Already procured
8
Already procured

B. Description of material to be arranged/ supplied by successful bidder


4
Indicative quantity of Link Box with SVL single phase

No

No

12

( to be decided as per requirement)


5

Indicative quantity of Link Box with-out SVL


( to be decided as per requirement)

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC insulated,


Unarmored, 3.3 KV Sheath Bonding cable

Mtrs

1200

66kV polymeric LAs along withearthling material.( Tower side only)


with surge counter, fencing & earthling

No.

36

Compatible Terminal Connectors including Hardware fittings & ACSR


Zebra conductor etc.

LOT

LOT

Indicative quantity of supply of HDPE pipes required for various


crossings with trench less or directly buried

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

( Break-up to be specified by the bidder)

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.

Detailed Survey, Laying of Single core 1200 mm2Aluminium Milliken


Conductor 66 KV cable in flat/ trefoil formation with one spare for each
Circuit (6+2), installation of end terminations, Straight Through joint,
and complete Civil works in all respect on through rate basis as per
technical specification with trench method
(directly Buried) with
risers and loops.

Running
circuit

1100

Detailed Survey, Laying of single core 1200 mm2Aluminium Milliken


Conductor 66 KV cable in flat/ trefoil formation with one spare for each
Circuit (6+2), installation of Straight Through joint, and complete Civil
works in all respect including using of HDPE pipes on through rate basis
as per technical specification with Trench-less method.

Running
circuit

Erection of end Termination Structures and their Foundations including


earthing

Nos.

NIL

Installation of end Terminations including link boxes, earthing, Terminal


connectors etc. This shall also include erection of Hardware fittings &
conductor

Nos.

48

Installation of LAs alongwith their earthing with surge counter and


fencing

Nos.

18

Testing & Commissioning

Lot

Lot

Erection of 4 Pole Rail pole structure and their Foundations including


earthing (if required as per site conditions).

No.

NIL

Any other items not specified above but are required to complete the
job in all respect.

Lot

Lot

( Break-up to be specified by the bidder)

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.

Supply portion only


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.
(Tower portion)

S.No

(Approx. D/C length of tower portion =3.970km)

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.

D/C F type 66kV Tower (KRR Design)

No.

i) +3m extn. Only

No.

D/C H type 66kV Tower (KRR Design).

No.

i) +6m extn. Only

No.

ii) Extra cross arm (set of 3)

No.

1.2

1
1

1.3

2.

12
1
3

Supply of earthing of towers


i) Pipe type

Sets

21

ii) Counterpoise type

Sets

i) Danger Plate

No.

21

ii) Number Plate

No.

21

iii) Phase Plate(set of 3)

Sets

26

iv) Circuit Plate (set of 2)

Sets

21

v) Bird Guard (Set of 3)

Sets

16

vi) Anti climbing device

Sets

21

Conductor (ACSR Zebra size 54/7/3.18mm)

Km

24.05

5.

Earth wire (7/3.15 mm)

Km

4.01

6.

Anti-Fog type Disc Insulator or Silicon Rubber Polymer Insulator strings**

3.

Supply of following Tower accessories

i) 70 kN

ii) 120 kN

66kV Post Insulators

8.

Hardware Fittings
i.
ii.
iii.
iv.

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

No.

57

No.

168

No.

Set

48

Set

Set

168

Set

Conductor & Earth wire Accessories


i)

Mid Span Compression Joint for conductor

No.

16

ii)

Mid Span Compression Joint for earth wire

No.

iii) Repair sleeves for conductor

No.

iv) Flexible copper Bond

No.

21

v)

Vibration damper for conductor

No.

408

vi) Vibration damper for earthwire

No.

68

vii) Earth-wire Tension clamp

No.

26

viii) Earth-wire Suspension clamp

No.

10

DISMANTLEMENT WORK to be included in Erection Part of BOQ


i) Dismantlement of towers and their transportation & proper stacking
at any dedicated store of HVPNL. The dismantlement of tower shall also
include dismantlement of Stub concrete up to a depth of 1M (one meter)
from Natural Ground level, back filling , compaction and clearing the site
of debris

As per site

66kV D/C DA type Tower

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

iii) Dismantlement of existing of earthwire 7/2.50mm complete with


H/W fittings for above portion of line and their transportation proper
stacking at any dedicated store of HVPNL.

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

Weights and measures

4.0

General Technical conditions

5.0

Technical Description

6.0

Tests and Standards

7.0

Guaranteed Technical Particulars

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.

Weights and measures

All weights and measures shall be in system international (SI) units. All fasteners shall be of
metric size only.

4.1

General Technical Conditions

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

Equipment performance Guarantee

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

Inspection, Testing & Inspection Certificate

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.

Tests and Standards

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.

Guaranteed Technical Particulars


The Guaranteed Technical Particular of the various items covered under this specification shall be
furnished by the bidders in one original and four (4) copies in the prescribed schedules of the
specifications. The bidder shall also furnish any other schedule informations as in their opinion is
needed to give fully description and details to judge the item (s) offered by them.
Page-4

SECTION-VI , CHAPTER III ( A )

TECHNICAL SPECIFICATION

CONTENTS

S. No

Clause

Page No.

1.

Technical Description of Conductor for ACSR Zebra lines

Technical Description of Earth wire

5.

Tests and Standards

11

6.

Annexure-A

20

SECTION-VI

(CHAPTER-III-A)

TECHNICAL SPECIFICATION
1.0

TECHNICAL SPECIFICATION OF ACSR ZEBRA

1.1

DETAIL OF ACSR ZEBRA CONDUCTOR

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)

Stranding and wire diameter :


54/3.18 mm Aluminium
+7/3.18 mm steel

b)

Number of Strands

Core

1st layer

2nd layer

12

3rd layer

18

4th layer

24

Total sectional area Aluminium

428.9 sq. mm

c)

d)

Total sectional area

484.5 sq.mm

e)

Overall diameter

28.62 mm

f)

Approximate weight

1621Kg/km

g)

Calculated DC resistance at :

0.06868 ohm/km

20 deg. Centigrade (Max.)

h)

Minimum UTS

130.32 kN

Page-1

1.1.3

a)

The details of Aluminium strands are as follows:

i) Minimum breaking load of strand before stranding

1.29 KN

ii) Minimum breaking load of strand after stranding

1.23 KN

iii) Maximum D.C. resistance of strand at 20 deg.

Centigrade

b)

3.626
Ohms/km

The details of steel strand are as follows:

i) Minimum breaking load of strand before stranding

10.43 KN

ii) Minimum breading load of strand after stranding

9.95 KN

iii) Minimum number of twists to be withstood

18 before stranding

in torsion test when tested on gauge length


of 100 times of diameter of wire.

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

Diameter of Aluminium & steel Strands


Nominal

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

Lay ratio of Conductor

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

Not more than 0.035

Sulphur

Not more than 0.045

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

Technical Description of Earthwire

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

The details of the earthwire are tabulated below:


a)

Stranding and wire diameter :

7/3.15 mm steel

b)

Number of Strands

Steel core

Outer steel layer

c)

Total sectional area

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)

Minimum ultimate tensile

57 kN

strength

h)

Direction of lay of outer layer :

Right hand

i)

Minimum tensile strength

1100 kgf/mm. sq.

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

Tests and standards

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)

Surface condition test

b)

Test for ultimate breaking load on stranded conductor

c)

Stress-strain test

d)

Measurement of diameter of individual aluminium and steel wires.

e)

Measurement of lay ratio.

f)

Breaking load of individual wires.

g)

Ductility test

h)

Wrapping test

i)

Resistance test and

j)

Galvanizing test

Acceptance Tests
a)
b)

Visual and dimensional check on drum


Visual check for joints scratches etc. )
and lengths of conductor by rewinding

)
)

Annexure-A

)
)

c)

Dimensional check on steel and


Aluminium strands

)
)
)

d)

Galvanising test on steel strands

e)

Torsion and elongation test


On steel strands

)
)

Annexure-A

)
)
)

f)

Check for lay-ratios of various layers )

Annexure-A

g)

Breaking load test on steel and


aluminum strands

)
)
)

h)

Wrap test on steel and aluminum

strands

IS:398 (part-II)

Page-6
i)

DC resistance test on aluminium strands

j)

UTS Test on welded joint of strands

Annexure-A

Note: All the tests except (j) shall be carried out on Aluminium and steel strands after stranding
only.

5.2.3

Acceptance Tests on Earthwire

a)

Visual and dimensional check on drum

)
)

b)

Visual check for joints scratches etc. )


and lengths of Earthwire by rewinding

)
)

c)

Dimensional check

) Annexure-A
)

d)

Lay length check

)
)

e) Galvanising test

)
)

f)
g)

Torsion test
Elongation test

)
) IS:398 (part-II)-1976
)

h)

Wrap test

)
)

i)

DC resistance test

)
j)

Breaking load test

k)

Chemical analysis of steel

) IS:398 (part-II)-1976

5.3

Routine Tests

5.3.1

Routine tests on Conductor

5.3.2

a)

Check to ensure that the joints are as per specification.

b)

Check that there are no cuts, fins etc. on the strands.

c)

Check that drums are as per specification.

d)

All acceptance test as mentioned above to be carried out on each coil.

Routine tests on Earthwire

a)

Check for correctness of stranding.

b)

Check that there are no cuts, fins etc. on the strands.

c)

Check that drums are as per specification.

Page-7

5.4

Tests during manufacture.

5.4.1

Tests during manufacture on conductor

a)

Chemical analysis of zinc


used for galvanizing

)
) Annexure-A
)

b)

5.4.2

Chemical analysis of aluminium


)
used for making aluminium strands ) Annexure-A

Tests during manufacture Earthwire.

a)

Chemical analysis of zinc


used for galvanizing

)
) Annexure-A
)

b)

5.5

Chemical analysis of steel

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

Packing for conductor

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

Before reeling, card board or double corrugated or thick bituminised waterproof


bamboo paper shall be secured to the drum barrel and inside of flanges of the drum
by means of a suitable commercial adhesive material. After reeling the conductor and
earthwire, the exposed surface of the outer layer of conductor/earthwire shall be
wrapped with water proof thick bituminised bamboo paper to preserve the
conductor/earthwire from dirt, grit and damage during transport and handling.

5.10.13

A minimum space of 75 mm for conductor and 50 mm for earthwire shall be provided


between the inner surface of the external protective lagging and outer layer of the
conductor/earthwire.

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)

Contract / Award letter number.

b)

Name and address of consignee.

c)

Manufacturers name and address.

Page-10

d)

Drum number.

e)

Size of conductor/earthwire.

f)

Length of conductor/earthwire in meters.

g)

Gross weight of drum with conductor/earthwire.

h)

Gross weight of drum without lagging.

i)

Weight of empty drum with lagging.

j)

5.12

Bevel diameter at three locations and an arrow marking at the location of


measurement.

k)

Number of turns in the outer most layer.

l)

Arrow marking for unwinding.

m)

Position of the conductor/earthwire ends.

n)

Distance between outer most layer of conductor and the inner surface of lagging.

o)

The conductor drum should bear ISI Monogram or equivalent internationally


recognized Monogram.

Verification of conductor and earthwire length.

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

Specification for Zinc

BS: 3436-1986

IS: 398-1982

Specification for aluminium


conductors for overhead
transmission purposes

BS: 215-1970

Aluminum
conductor
galvanized steel reinforced

BS: 215-1970

IS:398-1982
Part (II)

IEC:1089

IS:1778-1980

Reels and drums for bare


conductors

BS:1559-1949

IS:1521-1972

Method of tensile testing of


steel wire

ISO:R8901959

Page-11

IS:2629-1985

Recommended practice for


hot dip galvanizing of iron
and steel

IS:2633-1992

Method of testing uniformity


of coating on zinc coated
articles

IS:4826-1992

Galvanised coating on round


steel wires

ASTM A472-729

Methods of determination of
weight of zinc coating of zinc
coated iron and steel articles

BS:433-1969

10

Zinc coated aluminium wire


for overhead line conductor

IEC 888-1987

11

Hard drawn aluminium wire


for overhead line conductor

IEC 889-1987

IS:6745-1990

BS: 443-1969

Page-12

The standard mentioned above are available from:

Reference Abbreviation

Name and Address

BS

British Standards, British


Standards Institution 101,
Pentonvile Road, N-19-ND
UK

IEC/CISPR

International Electrotechnical
Commission, Bureau Central
De la Commission, Electro
Technique International, 1
Rue de verembe, Geneva
Switzerland

BIS

Bureau of Indian Standards,


Mank Bhavan,-9, Bahadur
Shah Zafar Marg, New Delhi
110001, INDIA

ISO

International Organisation for


Standardization, Danish Board
Of Standardization Danish
tandardising Sraat, Aurehoegvej2900, Heeleprup, DENMARK.

NEMA

National Electric Manufacture


Association, 155, East 44th Street,
New York, NY 10017
U.S.A.

12, DK-

Page-13

ANNEXURE-A
1.

Tests on Conductor

1.1

Surface condition & UTS test on stranded Conductor


Circles perpendicular to the axis of the conductor shall be marked at two places on a sample
of conductor of minimum 5m length suitably fixed by appropriate fittings on a tensile testing
machine. 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 of 100% of UTS and held for one
minute. The conductor sample shall not fail during this period. The applied load shall then
be increased until the failing load is reached and the value recorded.

1.2

D.C Resistance test on stranded conductor

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

Chemical Analysis of Aluminium and Steel

Samples taken from the aluminium and steel ingots/coils/strands shall be


chemically/spectrographically analysed. The shall be in conformity to the requirements
stated in this specification.

1.4

Chemical Analysis of Zinc

Samples taken from the zinc ingots shall be chemically/spectrographically analysed. The
same shall be in conformity requirements stated in the specification.

1.5

Visual and Dimensional Check on Drums

The drums shall be visually and dimensionally checked to ensure that they conform to the
requirements of this specification.

1.6

Visual Check for Joints, Scratches etc.

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

Dimensional check on strands

The individual strands shall be dimensionally checked to ensure that they conform to the
requirement of this specification.

Page-14

1.8

Check for Lay-ratios of Various Layers


The Lay-ratios of various layers shall be checked to ensure that they conform to the
requirements of this specification.

1.9

Breaking load test on welded Aluminium strands

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

Torsion an Elongation tests on steel strands.


The test procedure shall be as specified in IS: 13.6.1 and 13.6.2 of IS:398 par140. In the
torsion test, the number of complete twists before fracture shall not be less than 18 on a
length equal to 100 times the standard diameter of the strand before stranding, and should
not be less than 16 after stranding. The case test sample length is less or mode than 100
times the stranded diameter of the strand the minimum number of twists shall be
proportioned to the length with fractional numbers rounded off to next higher whole number.
In the elongation test the elongation of the strand shall not be less than 4% for a gauge
length of 200mm.

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

D.C Resistance Test

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

Chemical Analysis of zinc

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

Chemical Analysis of steel

Sample taken from the steel ingots/coils/strands shall be chemically/specigraphically


analysed. The same shall be in conformity to the requirements stated in this specification.

2.5

Visual and Dimensional Check on Drum

The drum shall be visually and dimensionally checked to ensure that they conform to the
requirements of this specification.

2.6

Visual Check for joints, Scratches etc. and length of earthwire

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

Lay length check

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.

2.10 Torsion Test


The minimum number of twists which a single steel strand shall withstand during torsion test
shall be eighteen for a length equal to100 times the standard diameter of the strand. In case
test sample length is less or more than 100 times the stranded diameter of the strand, the
minimum number of twists will be proportioned to the length and if number comes in the
fraction then it will be rounded off to next higher whole number.

Page-16

SECTION-VI, CHAPTER III ( B )

TECHNICAL SPECIFICATION

CONTENTS

S. No

Clause

1.

Technical Description of Disc insulators

Tests and Standards

3.

Annexure-A

Page No.

12

SECTION- VI,

CHAPTER-III (B)

1.0

TECHNICAL DESCRIPTION OF ANTI-FOG TYPE DISC INSULATORS .

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

Bidder shall quote for disc insulators made of electro-porcelain .

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:

For 66kV Lines with ACSR Zebra:-

Sr. Type of string

Size of disc Minimum

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.

Single Suspension Pilot

255x145

432

1x5

70

4.

Double Tension

280x145

432

2x6

2X120

Pin and cap

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

Ball and socket Designation

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

Dimensional Tolerance of Insulator Disc.

Permitted dimensional tolerances of the Anti-Fog Type disc insulators shall be as under:-

a)

b)

On all dimensions for which

(0.04d + 1.5) mm

where

special tolerance do not apply

d being the dimension in mm.

On spacing of string insulator unit

(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.

1.7 Corona and RI performance

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

Pins and Caps


Pins and caps shall be made of drop forged steel and malleable cast iron/ spherodal
graphite iron / drop forged steel respectively, duly hot dip galvanized and shall not be
made by jointing, welding, shrink fitting or any other process from more than one
piece of material.

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

The successful Bidder shall submit 4 sets of following fully dimensional


drawings complete in all respect for approval to HVPNL as per time
schedule given in Bar Chart:-

a)

Shell diameter and ball to ball spacing with manufacturing tolerances.

b)

Minimum creepage distance with positive tolerance.

c)

Protected creepage distance.

d)

Eccentricity of the disc


i)

Axial run out

ii)

Radial run out

e)

Unit mechanical an electrical characteristics.

f)

Size and weight of ball an socket parts

g)

Weight of unit insulator disc.

h)

Materials

i)

Identification mark

j)

Manufacturers catalogue number

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.

Tests and standards

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

For Disc Insulators

a)

Visual examination

IS:731-1971

b)

Verification of dimensions

IS:731-1971

c)

Temperature cycle test

IS:731-1971

d)

Galvanizing test

IS:731-1971

e)

Electromechanical failing load test

IS:731-1971

f)

Mechanical Performance test

IEC:60383-1993

g)

Residual strength test

IEC:60383-1993

h)

Eccentricity test

IEC:60383-1993

i)

Test on locking device for ball

IS: 2486 (Part-IV)

and socket coupling

j)

Vibration test
(only once for each type of disc

Annexure-A

Insulator under the contract)


Page-6

2.4

2.5

2.5.1

For porcelain insulators

a) Puncture test

IEC: 60383-1993/IS:7311971

b) Porosity test

IS:731-1971

Routine Tests

For Disc Insulators

a) Visual Inspection

)
b) Mechanical routine test

c) Electrical routine test

2.5.2

IS: 731-1971

)
Clause 10.13, 10.14 &
10.15
)

Tests During Manufacture

On all components as applicable

a) Chemical analysis of zinc used


for Glavansing

)
)
)

b) Chemical analysis, mechanical

metallographic test and magnetic

particle inspection for malleable

castings.

Annexure-A

c) Chemical analysis, hardness )


tests and magnetic particle

inspection for forgings

Annexure-A

)
d) Hydraulic internal pressure

tests on disc insulator shells )


)
e) Metallurgical tests for metal )
Fittings only (in black condition)

i) Grain size

ii) Inclusion rating

iii) Micro structure

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

Schedule of testing and additional tests

2.7.1

The bidder has to indicate the schedule of following activities in their bids:

a. Submission of drawing for approval.


b. Submission of Quality Assurance programme for approval.
Page-7

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

Co- ordination for testing

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

Packing and Marking

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

Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent


damage or deformation during transit and handling.

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

Specification for Zinc

IS: 406-1991

Method of chemical analysis


of slab zinc

IS: 731-1991

Porcelain insulators for


overhead power line with a
nominal voltage greater
than 1000V

BS: 137-1982

Methods of High Voltage


Testing

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

Specification for Insulator


fittings for overhead power
line with a nominal voltage
greater than 1000V

Part (I)-1993

General Requirements and


tests

BS:3288-1979

Part (II)-1989

Dimensional Requirements

IEC:120-1984

Page-9

Part (III)-1991

Locking devices

IEC:372-1984

IS:2629-1990

Recommended practice for


hot Dip galvanization for
iron and steel

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

Salt fog pollution voltage


withstand test

IEC:507-1991

11

IS:8269-1990

for

Disc

IEC:305-1978

NEMA Publication No.


107/1964/CISPR

14

Residual strength of string


insulator units of glass or
ceramic
material
for
overhead
line
after
mechanical damage of the
dielectric

IEC:797-1984

15

Guide for the selection of


insulators in respect of
polluted conditions

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

The standard mentioned above are available from:

Reference Abbreviation

Name and Address

BS

British Standards, British


Standards Institution 101,
Pentonvile Road, N-19-ND
UK

IEC/CISPR

International Electrotechnical
Commission, Bureau Central
De la Commission, Electro
Technique International, 1
Rue de verembe, Geneva
Switzerland

IS

Bureau of Indian Standards,


Mank Bhavan,-9, Bahadur
Shah Zafar Marg, New Delhi
110001, INDIA

ISO

International Organisation for


Standardization, Danish Board
Of Standardization Danish
Standardising Sraat, Aurehoegvej12
DK-2900, Heeleprup, DENMARK.

NEMA

National Electric Manufacture

Association, 155, East 44th Street,


New York, NY 10017
U.S.A.

Page-11

ANNEXURE-A

1.

Tests on complete strings with Hardware fittings.


1.1

Voltage distribution test

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

Mechanical strength test


The complete insulator string along with its hardware fitting 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. 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 following tests as per relevant standards:

Page-12

TESTS

PERCENTAGE OF DISC INSULATOR UNITS TO BE


TESTED

a) Temperature cycle test


Followed by mechanical

60

Performance test

b) Puncture test

2.

On disc insulator units

2.1

Steep wave front test

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

Hydraulic Internal Pressure Test on Shells


The test shall be carried out on 100% shells before assembly. The details regarding test will be
as discussed and mutually agreed to by the manufacturer and HVPNL in Quality Assurance
Programme.

2.4

Thermal Mechanical Performance Test

Thermal Mechanical Performance Test shall be performed in accordance with IEC-383-1-1993


clause 20 with the following modifications:

(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

Mean value of the individual mechanical failing load.

Rated electromechanical strength test.

Standard deviation

b) The minimum sample size shall be taken as 20.


c) The individual electromechanical failing load shall be at least equal to the rated value.
Also puncture shall not occur before the ultimate fracture.
2.5

Electromechanical Failing Load Test


This test shall be performed in accordance with clause 18 and 19 of IEC-383 with the
following acceptance.

i)

X gareater than or equal to R+3S

Where
X

Mean value of the Electromechanical strength test.

Rated electromechanical strength test.

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

2.6 Residual strength test


The above test shall be performed as per clause 4.4 and 4.5 of IEC 797 preceded by
the temperature cycle test, on orcelain disc insulators. The sample size shall be 25 and
the evaluation of the results and acceptance criteria shall be as per clause No 4.6 of IEC
797.

3.

Tests on all components (As applicable)

3.1

Chemical Analysis of Zinc used for Galvanizing


Samples taken form the zinc ingot shall be chemically analysed as per IS: 209-1979.
The purity of zinc shall not be less than 99.95%.

3.2

Tests for Forgings


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 HVPNL in quality assurance
Programme.

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

SECTION- VI, PART-II, CHAPTER-III (B)

TECHNICAL SPECIFICATION OF

SILICONE RUBBER POLYMER INSULATORS

CONTENTS

S. No

Clause

1.

Technical Description of Silicone Polymer Insulators

2.

Tests and Standards

3.

Annexure-A

Page No.

13

SECTION- VI, PART-II, CHAPTER-III (B)


TECHNICAL SPECIFICATIONS OF COMPOSITE LONG ROD INSULATORS
1.1

Details of Composite Long Rod Insulators

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

PARTICULARS OF SILICONE POLYMER INSULATOR STRINGS FOR ACSR ZEBRA OF 220kV


LINE:Sr
No

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

PARTICULARS OF SILICONE POLYMER INSULATOR STRINGS FOR ACSR ZEBRA OF 66kV


LINES:-

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

Pin and Cap

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

Ball and Socket Designation

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

Dimensional Tolerance of Composite Insulators


The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed as
follows:
(0.04d+1.5) mm when d300 mm.
(0.025d+6) mm when d>300 mm.

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

Corona and R1 Performance

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.

1.10.2 Housing & Weathersheds


The FRP rod shall be covered by a seamless sheath of a silicone rubber compound of a thickness
of minimum 3mm. The housing & weathersheds should have silicon content of minimum 30% by
weight. It should protect the FRP rod against environmental influences, external pollution and
humidity. It shall be extruded or directly molded on the core. The interface between the housing
and the core must be uniform and without voids. The strength of the bond shall be greater than the
tearing strength of the polymer. The manufacturer shall follow non-destructive technique (N.D.T.)
to check the quality of jointing of the housing interface with the core. The technique being followed
with detailed procedure and sampling shall be furnished along with the bid. The details for this shall
be finalized during detailed engineering and finalization of MQP.

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.

1.10.4 Grading Rings


Grading rings shall be used at both ends of each composite insulator unit for reducing the voltage
gradient on and within the insulator and to reduce radio and TV noise to acceptable levels. The
size and placement of the metallic grading rings shall be designed to eliminate dry band
arcing/corona cutting/ exceeding of permissible electrical stress of material. The bidder shall furnish
calculations along with the proposed placement and design of corona ring in support of the above.
Grading rings shall be capable of installation and removal with hot line tools without disassembling
any other part of the insulator assembly.
The supply of grading rings shall be in the scope of the composite insulator supplier.

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)

Minimum Creepage distance with positive tolerance

(c)

Protected creepage distance

(d)

Eccentricity of the long rod unit


(i)

Axial run out

(ii)

Radial run out

(e)

Unit mechanical and electrical characteristics

(f)

Size and weight of ball and socket parts

(g)

Weight of composite long rod units

(h)

Materials
(i)

Identification mark

(ii)

Manufacturer's catalogue number

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

Tests and Standards

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

On the complete composite Long Rod Insulator String with Hardware

Fittings

(a)

Power frequency voltage withstand test with corona


control rings/grading ring and arcing horns under wet
condition

IEC:383-1993/ Annexure
A

(b)

Switching surge voltage withstand test under wet


condition

IEC:383-1993

(c)

Impulse voltage withstand test under dry condition

IEC:383-1993

(d)

Corona and RIV test under dry condition

Annexure-A

(e)

Mechanical Strength test

Annexure-A

(f)

Vibration test

Annexure-A

(g)

Salt-fog pollution withstand test

Annexure-A

On Composite Insulator Units


(a)

Tests on interfaces and connections of metal fittings (Tests to be


performed on the same samples in the sequence given below)
Dry power frequency voltage test
Sudden load release test
Thermal mechanical test
Water immersion test
Steep front impulse voltage test
Dry power frequency voltage test

IEC: 61109

(b)

Assembled core load time test

IEC: 61109

i)

(c)

Determination of the average failing load of the core of


the assembled unit
ii)
Control of the slope of the strength time curve of the
insulator
Brittle fracture resistance test

Annexure-A

(d)

Test of housing, Tracking and erosion test

IEC: 61109

(e)

Tests for the core material

IEC:61109

(f)

i)
Dye penetration test
ii)
Water diffusion test
Flammability test

IEC:61109

(g)

Recovery of Hydrophobicity test

Annexure-A

(h)

Mechanical Load Time test and test of tightness between end


firings and insulator housing

IEC:61109

(i)

Silicone content test

Annexure-A

(j)

High Pressure washing test

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

For Composite Long Rod Insulators

(a)

Verification of dimensions

IEC : 61109

(b)

Galvanising test

IEC : 60383

(c)

Verification of locking system

(d)

Verification of tightness

IEC : 60383

IEC : 61109

of interface between end fittings and

insulator housing and of specified

mechanical load

(e)

Recovery of Hydrophobicity

Annexure-A

Tests on interfaces and connections of

IEC: 61109

metal fittings (Tests to be performed on

the same samples in the sequence given below)

i)
ii)
iii)
iv)
v)
vi)
(f)

Dry power frequency voltage test


Sudden load release test
Thermal mechanical test
Water immersion test
Steep front impulse voltage test
Dry power frequency voltage test

Silicone content test

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)

Mechanical routine test

As per IEC:61109

Page-7

4.4

Tests During Manufacture


On all components as applicable

a)

Chemical analysis of zinc used for galvanising

As per Annexure-A

b)

Chemical analysis, mechanical, metallographic test As per Annexure-A


and magnetic particle inspection for malleable
castings.

c)

Chemical analysis hardness tests and magnetic As per Annexure-A


particle inspection for forgings

d)

Tracking and erosion test on insulating material

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

Schedule of testing and additional tests

4.6.1

The bidder has to indicate the schedule of following activities in their bids:

a. Submission of drawing for approval.


b. Submission of Quality Assurance programme for approval.
4.6.2

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.

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

Co- ordination for testing

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

Packing and Marking

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

Specification for zinc

BS:3436

IS:406-1991

Method of Chemical Analysis of Slab Zinc

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

Specification for Insulator fittings for Overhead


Power Lines with a nominal voltage greater than
1000V
General
Requirements
Dimensional Requirements

and

Tests
BS:3288

Locking Devices

IEC:60120
IEC:60372

6.

IS:2629-1990

Recommended
Practice
for
Galvanisation for iron and steel

Hot,

Dip ISO-1461 (E)

7.

IS:2633-1992

Testing of Uniformity of Coating of zinc coated


articles

8.

IS:3188-1988

Dimensions for Disc Insulators

9.

IS:6745-1990

Determination of Weight of Zinc Coating on Zinc BS:433-1969


coated iron and steel articles
ISO:1460-1973

10.

IS:8263-1990

Methods of RI Test of HV insulators

IEC:60305

IEC:60437
NEMA Publi- cation
No.07/ 1964/ CISPR

11.

IS:8269-1990

Methods for Switching Impulse test on HV IEC:60506


insulators

12.

Thermal Mechanical Performance test and IEC: 60575


mechanical performance test on string insulator
units

13.

Salt Fog Pollution Voltage Withstand Test

IEC:60507

Sl.
No.

Indian Standard

Title

International
Standard

14.

Composite insulators for A.C. Overhead lines with IEC 61109


nominal voltage greater than 1000V Definitions,
test methods and acceptance criteria

15.

Guide for the selection of insulators in respect of


polluted conditions

16.

Tests on insulators of Ceramic material or glass or IEC:60383


glass for overhead lines with a nominal voltage
greater than 1000V

17.

Characteristics of string insulator units of the long IEC : 60433


rod type

IEC:60815

Page-10

The standards mentioned above are available from:


Reference Abbreviation

Name and Address

BS

British Standards,
British Standards Institution
101, Pentonvile Road,
N - 19-ND, UK

IEC/CISPR

International Electro technical Commission,


Bureau Central de la Commission,
electro Technique international,
1 Rue de verembe,
Geneva, SWITZERLAND

BIS/IS

Beureau Of Indian Standards.


Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110001. INDIA

ISO

International
Standardization.

Organisation

for

Danish Board of Standardization


Danish Standardizing Sraat,
Aurehoegvej-12
DK-2900, Heeleprup, DENMARK
NEMA

National Electric Manufacture Association,


155, East 44th Street.
New York, NY 10017 U.S.A.

ASTM

American Society for Testing and Materials,


1916 Race St. Philadelphia, PA19103 USA

Page-11

ANNEXURE-A
1.0

Tests on Complete Strings with Hardware Fittings


1.1

Voltage distribution test

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

Mechanical Strength Test

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

Salt-fog pollution withstand test


This test shall be carried out in accordance with IEC : 60507. The salinity
level for composite long rod insulators shall be 160 Kg/m3 NACL.

Page-12

2.0

Composite Longrod Insulator Units

2.1

Brittle Fracture Resistance Test

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

Recovery of Hydrophobicity Test

(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.

Silicone content test

Minimum content of silicone as guaranteed by supplier shall be verified through FT-IR


spectroscopy & TGA analysis or any other suitable method mutually agreed between
Employer & Supplier in Quality Assurance Programme .

2.4

High Pressure washing test

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.

Tests on All components (As applicable)

3.1

Chemical Analysis of Zinc used for Galvanizing

Samples taken from the zinc ingot shall be chemically


per IS:209-1979. The purity of zinc shall not be less than 99.95%.

3.2

analysed

as

Tests for Forgings


The chemical analysis hardness tests and magnetic particle inspection for forgings, will be
as per the internationally recognised 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 Supplier and Employer in Quality Assurance Programme.

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

SECTION- VI, PART-II, CHAPTER-III (C)

TECHNICAL SPECIFICATION OF

BUS POST INSULATORS

CONTENTS

S. No

Clause

1.

Technical Description of Bus Post Insulators

2.

Tests and Standards

Page No.

TECHNICAL SPECIFICATION FOR 72.5 kV BUS POST INSULATORS

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.

TYPE AND RATING


The 72.5 kV Bus Post Insulators are required for outdoor-system conforming to IS 2544/1973 or
latest version thereof suitable for heavily polluted atmosphere. The Post Insulators shall be
specifically suitable to meet the particular requirements of ultimate torsional strength and cantilever
loads etc. which they will be called upon to resist during service at the rated voltage.

The principal rating of bus Post Insulators shall be as under: -

Sr.
No.

Particulars

Unit

i.

Nominal system voltage

kV

66

ii.

Highest system voltage

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

(+ve & -ve)


vii.

Minimum visual

kV(rms)

discharge voltage level


(extinction)

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.

Pitch Circle Dia:


a. Top

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.

As per 1.6 of Section-V, Part-1.

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.

Visible discharge test

4.

Impulse voltage withstand test

5.

Dry power frequency voltage withstand test.

6.

Wet power frequency voltage withstand test.

7.

Temperature cycle test

8.

Test for mechanial strength

9.

Puncture test

10.

Porosity test

11.

Galvanising test

Page-3

7.2

7.2.1

8.

Acceptance and Routine Tests

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.

Temperature cycle test

3.

Test for mechanial strength

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.

DRAWING AND LITERATURE


The successful Bidder shall submit 4 sets of following fully dimentional drawings complete in all
respect for approval to HVPNL as per time schedule given in Bar Chart:-

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

PACKING AND FORWARDING


The equipments shall be packed in crates suitable to withstand handling during transport and
outdoor storage during transit. The supplier shall be responsible for any damage to the equipment
during transit, due to improper and inadequate packing. The easily damageable material shall be
carefully packed and marked 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.

12.2

Each consignment shall be accompanied by a detailed packing list containing the following
information: -

a)
b)
c)
d)
e)
f)
g)

Name of the consignee.


Details of the consignment.
Destination.
Total weight of consignment.
Sign showing upper/lower side of the crate.
Handling and unpacking instructions.
Bill of material indicating contents of each package.

Page-5

SECTION-VI
(CHAPTER III D)

TECHNICAL SPECIFICATION

CONTENTS

S. No

Clause

1.

Technical Description of Hardware Fittings of ACSR Zebra

2.

Accessories for ACSR Zebra Conductor

3.

Earthwire Accessories

4.

Tests and Standards

5.

Type Tests

Annexure-A

Annexure-B

SECTION-VI, CHAPTER-III D

TECHNICAL SPECIFICATIONS
1.

Technical Description of Hardware Fittings

1.1

Details of Hardware Fittings

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

Suitable arcing horn/intermediate arcing horns as specified in clause 1.8 hereinafter.

1.1.4

Suitable yoke plates complying with the specifications given hereunder.

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

2.5% extra fasteners and Aluminum filler plugs.

1.2

Dimensions of Insulator String Alongwith Hardware Fitting


The various limiting dimensions of the various Suspension, pilot and tension insulator strings alongwith
hardware fittings shall be as per the specification drawings enclosed with this part of the specification.

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

Corona and RI Performance


Sharp edges and scratches on all the hardware fittings shall be avoided. All surfaces must be clean, smooth,
without cuts and abrasions or projections. The Bidder must give suitable assurance about the satisfactory
corona and radio interference performance of the materials offered by him

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

Ball and Socket Designation


The dimensions of the ball and socket shall be of 16mm ALT (B) designation for 70 KN disc Insulators
and 20 mm for 120 KN disc insulators. The designation should be in accordance with the standard
dimensions stated in IS 2486 (Part-II)/ IEC: 120. The dimensions shall be checked by the appropriate
gauge after galvanising only.

1.7

Security Clips and Split Pins

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

Split pins shall be used with bolts & nuts.

1.8

Arcing Horn/Intermediate Arcing Horn

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

The suspension assembly shall be suitable for ACSR Zebra Conductor.

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

FREE CENTER TYPE SUSPENSION CLAMP

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

STANDARD PREFORMED ARMOUR ROD SET

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

The length of each rod and diameter shall be as follows:


Length dia

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

ARMOUR GRIP SUSPENSION CLAMP

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

Elastomer insert shall be resistant to the effects of temperature up to 75 0 C, Ozone ultraviolet


radiations and other atmospheric contaminants likely to be encountered in service. The physical
properties of the elastomer shall be of approved standard. It shall be electrically shielded by a cage
of AGS preformed rod set. The elastomer insert shall be so designed that the curvature of the AGS
rod shall follow the contour of the neoprene insert.

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

ENVELOPE TYPE SUSPENSION CLAMP

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

DEAD END ASSEMBLY

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)

Dead end Assembly

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

FASTENERS: BOLTS, NUTS AND WASHERS

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

Fastners of grade higher than 8.8 are not to be used.

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)

Attachment of the hanger or strain plate.

(ii)

Suspension or dead end assembly.

(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)

Links with suitable fittings.

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)

Dimensions and dimensional tolerance.

(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)

Design installation torque for the bolt or cap screw.

(viii)

Withstand torque that may be applied to the bolt or cap screw without failure of component parts.

(ix)

The compression die number with recommended compression pressure.

(x)

All other relevant terminal details.

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.

Name of Item Material

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

Steel or forged &

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

gth Al. Alloy

/forged

4600 or LM

Heat

-6 or equiv-

treated

equivalent

alent/6061
Page-9

(b) Cotter bolts, Galvanized


Hangers,

Mild Steel

Hot dip

IS: 226-1975

Galvanized

IS: 2062-1992

Shackles,
Brackets

(c) U Bolts

Stainless

Forged &

Steel or

heat treated

AISI 302 or 304-L

High Strength Al. Alloy

6. P.A. Rod

High Stren-

Heat

gth Al. Alloy

treatment

ASTM-B429

Minimum
tensile

type 6061 or during


equivalent
manufacturing

strength
of 35 Kg
/mm2

7.

AGS Clamp

High Stren-

(a) Supporting gth Corros


House

Cast

IS: 617 or

forged

equivalent

-ion resistant
AL. Alloy LM6,

Heat

treated

4600 or
equivalent/6061

(b) Al. Insert & High Strength Forged &


of type Heat treated
strap

ASTM-B429

Retaining Al. Alloy

6061 or
equivalent.

(c) Elastomer Moulded on Al.


Cushion

reinforcement

8. Dead End Assembly

(a) Outer Sleeve EC grade Al. of


dead end

purity not less

assembly

than 99.5% or

for ACSR

aluminum alloy

Zebra

6201/or equivalent

Conductor

(b) Steel Sleeve

Mild Steel
Galvanised

Hot dip As per IS: 2062


or equivalent

Page-10

2.

Accessories For ACSR Zebra Conductor

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

2.5% extra fasteners and retaining rods shall be provided.


Mid Span Compression Joint.

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

...

ACSR Zebra 61/3.18

1.

Configuration

Single ACSR Zebra


Double Circuit

conductor per
Phase in vertical
Formation

2.

3.

Span length in meters


(i)

Ruling design span

(ii)

Maximum span :

1100 Meters

(iii)

Minimum span :

100 Meters

Wind Zone

275 Meters

4 (47 m/s)
As per IS:875-1987

4.

Tensile Load in Conductor


At temperature of 0 deg. C
:
And still air

3473 Kgf

5.

6.

Armour rods used

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

The damper placement charts shall include the following: -

(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.

Material and Workmanship

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.

2.6 Compression Markings

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

The drawings shall include:

(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

Placement charts for Vibration damper

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

Dimensions & Dimensional Tolerances for Mid Span Compression


Joint and Repair Sleeve for ACSR Zebra Conductor

Sr. No. Item

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

2.5% extra fasteners shall be supplied.

3.2

Mid Span Compression Joint


Mid Span Compression Joint shall be used for joining two lengths of earthwire. The joint shall be
made of mild steel with aluminium encasing. The steel sleeve should not crack or fail during
compression. The Brinnel Hardness of stainless steel should not exceed 200. The steel sleeve shall
be hot dip galvanized. The aluminium sleeve shall have aluminium of purity not less than 99.5%.
Filler aluminium sleeve shall also be provided at the both ends. The joints shall not permit slipping
off, damage to or failure of the complete earthwire or any part thereof at a load not less than 95%
of the ultimate tensile strength of the earthwire. The joint shall have resistivity less than 75% of
resistivity of equivalent length of earthwire. The dimensions and the dimensional tolerances of the
joint shall be as per the table given below: -

...
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

11.50.2 210.5 252

..

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.

Span length in meters :

66 kV Line

(i)

275 Meters

Ruling design

One galvanized steel Earthwire

span

3.

(ii)

Maximum span :

1100 meters

(iii)

Minimum span :

100 meters

Wind Zone

(47m/s)
As per IS: 875-1987

4.

5.

Tensile load in Earthwire


at temperature of 0 deg. C

and still air

Maximum permissible :

+/- 150 micro strains

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

The damper placement charts shall include the following: -

(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)

Placement recommendation depending upon type of suspension (viz, free centre


type/trunion type etc.)

(4)

The influence of mid span compression joints in the placement of dampers.


Page-19

3.4

Flexible Copper Bond


The flexible copper bond shall be circular in cross-section of minimum 34 sq mm equivalent copper
area and not less than 500 mm in length. It shall consist of 259 wires of 0.417 mm dia. tinned copper
conductor. It shall be laid up as 7 stranded ropes, each of 37 bunched wires. The tinning shall be as
per relevant Standard. Two tinned copper connection lugs shall be press jointed to either of the
flexible copper cable. One lug shall be suitable for 12 mm, dia. Bolt and other for 16 mm dia. bolt.
The complete assembly shall also include one 16 mm dia. 40 mm long HRH MS Bolt hot dip
galvanized with nut and lock washer.

3.5

Suspension Clamp

3.5.1

Standard twisted shackle for earthwire suspension clamp shall be supplied attaching to the hanger.

3.5.2

At all suspension towers, suitable suspension clamps shall be used to support


earthwire of 7/3.15 mm size. The clamps shall be of either free-centre type or trunion and shall
provide adequate area of support to the earthwire. The groove of the camp shall be smooth, finished
in an uniform circular or oval shape and shall slope downwards in a smooth curve to avoid edge
support and hence to reducing the intensity of bending moment on earthwire.

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

Material and Workmanship


Same as Clause 2.5 of this part of this section.

3.8

Compression Marking
Same as Clause 2.6 of this part of this section.

3.9

Bid Drawings

Same as Clause 2.7 of this part of this section.

4.

Tests and Standards

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

On Suspension Hardware Fittings only:

a.

Slip strength test

b.

Mechanical test

c.

Verifications of dimensions

d.

Galvanizing

e.

Visual examination test

f.

Tensile Strength test

g.

Electrical resistance test

h.

Bend test for Armour Rod Set

i.

Resilient test for Armour Rod Set

5.1.3

)
)

IS: 2121 (Part-I)


)

On Tension Hardware Fittings only: -

a.

Slip strength test

IS: 2486 (Part-I)

b.

Mechanical test

c.

Verifications of dimensions

d.

Galvanizing

e.

Visual examination test

f.

Electrical Resistance test

g.

Heating cycle test

5.1.4

)
IS: 2486 (Part-I)

Mid Span Compression Joint for Conductor and Earthwire:

a.

Visual Examination

b.

Dimensional verification

c.

Failling Load test/Slip Strength test

d.

Electrical Resistance test

e.

Heating cycle test (Not Applicable for

)
)
)

Earthwire)
f.

Galvanizing test

g.

Chemical composition test

5.1.5

IS: 2121 (Part-II & III)


)

)
)

Repair Sleeves for Conductor:

a.

Visual Examination

b.

Dimensional verification

c.

Failing Load set

d.

Electrical Resistance test

IS: 2121 (Part-II)


)
Page-22

5.1.6

Flexible Copper Bond:

a.

5.1.7

5.1.8

Visual Examination & Dimensional


Verification

b.

Slip Strength test

c.

Chemical composition test

d.

Galvanizing test

IS: 2121 (Part-III)

Vibration Damper for Conductor & Earthwire:


a.

Visual examination

b.

Verification of dimensions

c.

Resonance frequency test

d.

Fatigue test

e.

Mass pull off test

f.

Dynamic characteristics test

g.

Damping efficiency test

h.

Clamp slip test

i.

Clamp bolt torque test

j.

Galvanizing/electroplating test

k.

Magnetic power loss test

IS: 9708-1993

Earthwire Suspension Clamp Assembly:

a.

5.1.9

Visual examination & Dimensional

verification

b.

Slip strength test

c.

Mechanical strength test

d.

Chemical composition test

e.

Galvanizing test

IS: 2121 (Part-III)

Earth Tension Clamp Assembly:

a.

Visual examination & Dimensional

verification
b.

Electrical resistance test

c.

Mechanical strength test

)
)
)

IS: 2121(Part-III)

d.

Chemical composition test

e.

Galvanizing test

)
)

Page-23

5.2

Acceptance Tests

5.2.1

On Both Suspension and Tension Hardware Fittings

a.

Visual Examination

)
)

b.

Verification of dimensions

IS: 2486-(Part-I)

Clause 5.8& 5.9

)
c.

Galvanizing/Electroplating test

d.

Mechanical strength test of each component

(excluding arcing horn)

Annexure-A
)

e.

Mechanical Strength test of welded joint

f)

Mechanical strength test for corona

BS: 3288-(Part-I)

control rings/grading ring and arcing horn

Clause 7.3.2

g.

Test on locking device for ball and socket


coupling

IEC:372 (2)-1984
)

h.

Chemical analysis, hardness tests,


grain size, inclusion rating & magnetic

)
)

particle inspection forgings

5.2.2

/castings

Annexure-A
)

On Suspension Hardware Fittings Only


a.

Clamp Slip strength Vs Torque


test for suspension clamp

Annexure-A
)
)

b.

Shore hardness test of


Elastomer cushion for AG

)
)

Suspension clamp

c.

Bend test for Armour rod set

IS: 2121 (Part-I)


) Clause 7.5, 7.10,7.11

d.

Resilience test for Armour


Rod set

)
)
)

e.

5.2.3

Conductivity test for Armour


rods set

)
)

On Tension Hardware Fittings Only


a.

5.2.4

Slip strength test for


Dead end assembly

)
)

IS:2486 (Part-I)
1971,Clause 5.4

Mid Span Compression Joint for Conductor and Earthwire


a.

Visual examination and dimensional

verification

IS: 2121 (Part-II)


) Clause 6.2, 6.3 & 6.7

)
b.

Galvanizing test

c.

Hardness test

Annexure-B
Page-24

5.2.5

Repair Sleeve for Conductor

a.

5.2.6

Visual examination and

IS: 2121 (Part-II)

dimensional verification

Clause 6.2, 6.3.

Flexible Copper Bond


a.

Visual examination and

dimensional verification
b.

5.2.7

IS: 2121 (Part-II)


)

Slip strength test

Clause 6.2, 6.3.


)

Annexure-B

IS: 2121 (Part-II)

Clause 6.2, 6.3, & 6.7

Vibration Damper for Conductor and Earthwire

a.

Visual examination and

dimensional verification

)
b.

Galvanizing test

)
)

i.

On damper masses

)
)

ii.

c.

On messenger cable

Verification of resonance

frequencies

)
)

d.

Clamp slip test

Annexure-B

)
)

e.

Clamp bolt torque test

)
)

f.

g.

Strength of the messenger

cable

Mass pull off test

)
)

5.2.8

Annexure-B

Earthwire Suspension Clamp Assembly

a.

Visual examination and

dimensional verification

IS; 2121 (Part-II)

)
b.

Galvanizing test

c.

Clamp slip strength test

)
)

d.

Mechanical strength test

on each component

Annexure-A

Page-25

5.2.9

Earthwire Tension Clamp Assembly

a.

Visual examination and

dimensional verification

IS: 2121 (Part-II)


)

b.

c.

Galvanizing test

Slip strength test

for tension clamp

Annexure-A

)
d.

Mechanical strength

test on each component

(excluding clamp)

)
)

e.

Hardness test

5.3

Routine Tests

5.3.1

For Hardware Fittings

5.3.2

a.

Visual examination

b.

Proof Load Test

IS: 2486 (Part-I) 1971

Annexure-A

For Conductor and Earthwire Accessories


a.

5.4

Visual examination and

IS: 2121 (Part-II)1981

dimensional verification

Clause 6.2 & 6.3

Tests During Manufacture

On all components as applicable

a.

Chemical analysis
of zinc used for
galvanizing

)
)
)
)

)
b.

Chemical analysis

mechanical metallographic

test and magnetic particle

inspection for malleable

castings.

Annexure-A

)
c.

Chemical analysis

hardness tests and

magnetic particle

inspection for forgings

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

Schedule of Testing and Additional Tests

5.6.1

The Bidder has to indicate the schedule of following activities in their bids.

a.

Submission of drawing for approval.

b.

Submission of Quality Assurance programme for approval.

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

Co-ordination for testing

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

Packing and Marking

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

The packing shall be of sufficient


strength to withstand rough handling during transit,
storage at site and subsequent handling in the field.

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

ctors for Overhead


Transmission purpose

Part-V

Aluminum Conductor
Galvanised Steel1991
Reinforced for
Extra High Voltage
(400 kV ) and above

3.

IS: 1573-1976

Electroplated Coating of Zinc on Iron


and Steel.

4.

IS: 2121-1981
Part-I

Specification for
Conductor and
Earthwire Accessories
For Overhead Power
Line.

Part-II

Mid span joints and


Repair Sleeves for

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

Method of Testing Uniformity


of Coating on Zinc Coated
Articles

8.

Ozone test on Elastomer

ASTM-D1171

9.

Tests on insulators of

IEC:383-1993

Ceramic material or glass


For overhead line with a
Nominal voltage greater
Than 1000 V

10.

IS: 4826-1992

Galvanized Coating

ASTM A472-

on rounded steel wires 729 BS: 4431969

11.

IS: 6745-1990

Methods of Determi-

BS: 433-1969

nation of weight of

ISO: 1460

zinc coating of zinc


coated iron and steel
articles

12.

IS: 6639-1990

Hexagonal bolts for


steel structures

13.

IS: 9708-1980

ISO/R272
1968

Specification for stock


bridge vibration dampers
for overhead power line

14.

IS: 8263-1990

Method of radio interfere-

IEC: 437-1973

nce tests on high voltage

NEMA: 107-1964

insulators.

CIS PR

Page-30

The standard mentioned above are available from:

Reference Abbreviation

Name and Address

BS

British Standards, British


Standards Institution 101,
Pentonvile Road, N-19-ND
UK

IEC/CISPR

International Electrotechnical
Commission, Bureau Central
De la Commission, Electro
Technique International, 1
Rue de verembe, Geneva
Switzerland

BIS/IS

Bureau of Indian Standards,


Mank Bhavan,-9, Bahadur
Shah Zafar Marg, New Delhi
110001, INDIA

ISO

International Organisation for


Standardization, Danish Board
Of Standardization Danish
Standardising Sraat, Aurehoegvej12
DK-2900, Heeleprup, DENMARK.

NEMA

National Electric Manufacture


Association, 155, East 44th Street,
New York, NY 10017
U.S.A.

Page-31

ANNEXURE-A
TYPE TEST

1.0

Test on Complete Strings with Hardware Fittings


1.1

Voltage Distribution Test For Insulator String

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

Mechanical Strength Test


The complete insulator string along with its hardware fitting excluding arcing horns 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 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)

Temperature cycle test

60

followed by mechanical
performance test

b)

Puncture test

40

2. Tests on Hardware Fittings

2.1 Magnetic Power Loss Test for Suspension Assembly

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.

2.2 Galvanising/Electroplating Test

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.

2.3 Mechanical Strength Test of Each Component

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.

2.4 Mechanical Strength Test of Welded Joint

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.

2.5 Clamp Slip Strength Vs Torque Test for Suspension Clamp


The suspension assembly shall be vertically suspended by means of a flexible attachment. A suitable length
of Conductor shall be fixed in the clamp. The clamp slip strength at various tightening torques shall be
obtained by gradually applying the load at one end of the conductor. The clamp slip strength vs torque curve
shall be drawn. The above procedure is applicable only for free centre type suspension clamp. For AG
suspension clamp only clamp slip strength after assembly shall be found out. The clamp slip strength at the
recommended tightening torque shall be more than 16 kN but less than 24 kN.
Page-33

2.6

Shore Hardness Test for Elastomer Cushion for AG Suspension Assembly

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

Proof Load Test

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

Tests for Forging Casting and Fabricated Hardware

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

Mechanical Strength Test for Suspension/Tension Hardware Fittings

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.

2.10 Ozone Test for Elastomer

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.

3.1 Mid Span Compression Joint for Conductor and Earthwire

(a)

Slip Strength Test


The fitting compressed on conductor/earthwire shall not be less than one metre in length. The test
shall be carried out as per IS: 2121-(Part-II)-1981 clause 6.4 except that the load shall be steadily
increased to 95% of minimum ultimate tensile strength of conductor/earthwire and retained for
one minute at this load. There shall be no movement of the conductor/earthwire relative to the
fittings and no failure of the fittings during this one minute period.

Page-34

3.2 Flexible Copper Bond

(a)

Slip Strength Test


On applying a load of 3 kN between the two ends, stranded flexible copper cable shall not come out
of the connecting lugs and none of its strands shall be damaged. After the test, the lugs shall be cut
open to ascertain that the gripping of cable has not been affected.

3.3 Vibration Damper for Conductor and Earthwire

(a)

Dynamic Characteristics Test


The damper shall be mounted with its clamp tightened with torque recommended by the
manufacturer on shaker table capable of simulating sinusoidal vibrations for aeolian vibration
frequency band ranging from 5 to 45Hz for damper for conductor and 15 to 70 Hz for damper for
earthwire. The damper assembly shall be vibrated vertically with a 1 mm amplitude from 5 to 15
Hz frequency and beyond 15 Hz at 0.5 mm to determine following characteristics with the help of
suitable recording instruments:

i.

Force Vs frequency

ii.

Phase angle Vs frequency

iii.

Power dissipation Vs frequency

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)

Acceptance criteria for vibration damper.

(i)

The above dynamic characteristics test on five damper shall be conducted.

(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)

From vibration analysis of conductor/earthwire without damper, antinode vibration


amplitude and dynamic strain levels at clamped span extremities as well as antinodes shall
be examined and thus lower and upper dangerous frequency limits between which the
Aeolian vibration levels exceed the specified limits shall be determined.

(vi)

From vibration analysis of conductor/earthwire with damper/dampers installed at the


recommended location, the dynamic strain level at the clamped span extremities, damper
attachment point and the antinodes on the conductor/earthwire shall be determined. In
addition to above damper clamp vibration amplitude and antinode vibration amplitudes
shall also be examined.
The dynamic strain levels at damper attachment points, clamped span extremities and
antinodes shall not exceed the specified limits. The damper clamp vibration amplitude shall
not be more than that of the specified fatigue limits.

Page-36

(c) Clamp Slip and Fatigue Tests

(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)

Clamp Slip Test


The vibration damper shall be installed on the test span. The damper clamp, after tightening
with the manufacturers specified tightening torque, when subjected to a longitudinal pull
of 2.5 kN parallel to the axis of conductor/earthwire for a minimum duration of one minute
shall not slip i.e. the permanent displacement between conductor/earthwire and clamp
measured after removal of the load shall not exceed 1.0 mm. The load shall be further
increased till the clamp starts slipping. The load at which the clamp slips shall not be more
than 5 kN.

(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.

For the purpose of acceptance, the following criteria shall be applied.

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.

Magnetic Power Loss Test for Vibration Damper

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

Mechanical Strength Test for Earthwire Suspension/ Tension Clamp

(a)

The suspension assembly/tension assembly (excluding tension clamp) 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 components shall not
show any visual deformation and it shall be possible to disassemble them by hand. Hand
tools may be used to loosen the nuts initially. The assembly 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 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)

Clamp Slip Strength Vs Torque Test for Suspension Assembly

The suspension assembly shall be vertically suspended by means of a flexible attachment.


A suitable length of 7/3.15 mm G.S. Earthwire shall be fixed in the clamps. The clamp slip
strength at various tightening torques shall be obtained by gradually applying the load at
one end of the earthwire. The clamp slip strength Vs torque curve shall be drawn. The clamp
slip strength at the recommended tightening torque shall be more than 9 kN but should not
be more than 14 kN.

(c)

Slip Strength Test of Tension Clamp

Tension clamps shall be compressed on a 5 m length of earthwire on both ends. The


assembly shall be mounted on a tensile testing machine and anchored in a manner similar
to the arrangement to be used in service. A tensile load of 50% of the specified breaking
load of the earthwire shall be applied & the sample shall be marked in such a way that
movement relative to the fitting can esily be detected. Without any subsequent adjustment
of the fitting the load shall be steadily increased to 95% of the specified breaking load and
maintained for one minute. There shall be no movement of the earthwire relative to the
fitting during this one minute period and no failure of the fitting also.

(d)

Electrical Resistance Test of Tension Clamp

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 Test

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.

Test on All components (As applicable)

4.1

Chemical Analysis of Zinc used for Galvanizing

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

Tests for Forgings

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.

Mid Span Compression Joint for Conductor and Earthwire

(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.

Flexible Copper Bond

(b)

Slip Strength Test

Same as clause 3.2 (a) of Annexure-A.

3.

Vibration Damper for Conductor and Earthwire

(a)

Verification of Reasonance Frequencies

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)

Clamp Slip Test

Same as Clause 3.3 (c) (ii) of Annexure A.

(c)

Clamp Bolt Torque Test

The clamp shall be attached to a section of the conductor/earthwire. A torque of 150 % of


the manufacturers specified torque shall be applied to the bolt. There shall be no failure of
component parts. The test set up is as described in Clause 3.3 (c) (i), Annexure-A.

(d)

Strength of the Messenger Cable


The messenger cable shall be fixed in a suitable tensile testing machine and the tensile load
shall be gradually applied until yield point is reached. The load shall be not less than the
value guaranteed by the Manufacturer.

Page-41

(e)

Mass Pull of Test

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)

Dynamic Characteristics Test

The test will be performed as acceptance test with the procedure mentioned for type test
with sampling mentioned below: -

Vibration Damper of
Conductor

- 1 Sample for 1000 Nos. & below.


- 3 Samples for lot above 1000 & up to
5000 nos.

- Additional 1 sample for every additional 1500


pieces above 5000.

The Acceptance criteria will be as follows :

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.

Force of each damper corresponding to particular frequency shall be taken &


average force of three dampers at the frequency calculated.
Similar averaging shall be done for phase angle.
Average force Vs frequency and average phase Vs frequency curves shall be plotted
on graph paper. Curves of best fit shall be drawn for the entire frequency range.
(d)

The above curves shall be within the envelope specified.

Page-42

STANDARD FIELD QUALITY PLAN FOR TRANSMISSION LINES


S.

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.

Counter Check/Test by HVPNL

Agency

Extent

Bidder

100% at Field

Accepting
authority

100% based on record documents

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

100% based on record documents

Engineer-in-

-do-

-do-

-do-

charge of HVPNL

b. Tower Spotting data

-do-

-do-

-do-

c. Route alignment

-do-

-do-

tower spotting.
2. Cold wt. Span

-do3. Hot wt. Span

-do-

-do-

Bidder

100% at Field

4. Sum of Adj. Span


(wind span)

5. Angle of Deviation.
2.

Check Survey

Tower Location &


Final Length

i)

Alignment

ii) Final Length

a. Route alignment

-do-

b. Tower Schedule

-do-

c. Profile

3.

i)

All angle towers in plains and


50% in hilly terrains.

Engineer-incharge of HVPNL

ii) Final length to be checked on


100% basis based on
records/documents

Tower
Foundation
A. Materials
1. Cement

1. Source approval

Source meeting HVPNL


Specification/Approved
vendor

Bidder

As proposed by Bidder

To verify the proposal based on


the supply made and factory test
results.

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

Counter Check/Test by HVPNL

Samples to be taken

Review of all MTCs

Annexure-A of this FQP

jointly with HVPNL and

and one sample for

tested at HVPNL

authority

Extent

As per document at

Accepting

100% review of lab test results

Engineer-incharge of HVPNL

every 500 MT

approved lab
3. Chemical Tests

-do-

Bidder to submit MTC

100% review of MTC

100% review of MTC

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

main producers only.


2. Physical and

As per annexure-B

Bidder to submit MTC

All MTCs

To review the proposal based on


the documents.
100% review of MTC

Engineer-incharge of HVPNL
Engineer-incharge of HVPNL

Chemical analysis
test
3. Coarse

1. Source approval

Aggregates

Source meeting HVPNL

Bidder

Specification

Proposed by the
Bidder, indicating the

To review the proposal based on


the documents

Engineer-incharge of HVPNL

location of the quarry


and based on the test
results of Joint
samples tested in
approved lab
2. Physical tests

4. Fine aggregate

1. Source approval

As per document at

Samples to be taken

One sample per lot of

Annexure-C of this FQP

jointly and tested in

200 cum or part

HVPNL approved lab

thereof

Source meeting HVPNL


Specification

Bidder

Proposed by the
Bidder, indicating the
location of the quarry
and based on the
results of Joint
samples tested in
HVPNL approved lab.

100% review of lab test results

Engineer-incharge of HVPNL

To review the proposal based on


the documents.

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

Counter Check/Test by HVPNL

Samples to be taken

One sample per lot of

this FQP

jointly and tested in

200 cum or part

HVPNL approved lab

thereof

HVPNL Specification

Bidder

100% visual check at


Field

shall be fresh ,

100% review of lab test results

Engineer-incharge of HVPNL

1. Verification at random
2. Lab. test before start of work

Engineer-incharge of HVPNL

from approved Lab.

clean and potable)


2. Suitability of water

authority

Extent

As per Annexure-D of

Accepting

HVPNL Specification

Bidder

for concreting

100% Visual Check


at Field

1. Verification at random
2. Lab. test before start of work

Engineer-incharge of HVPNL

from approved Lab.


B. Foundation
Classification

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

100% check by HVPNL

Engineer-incharge of HVPNL

-do-

-do-

-do-

-do-

-do-

Bar bending schedule

-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

Counter Check/Test by HVPNL

Agency

Extent

Bidder

100% at field

Accepting
authority

20% check at random

Engineer-incharge of HVPNL

Specification and
document at AnnexureE of this FQP
2. Concrete

Cubes Comp Strength

Strength

4.

Tower
Erection

1. Materials

Visual checking for

a. Tower

1. Stacking

member/bolts &

2. Cleanliness

nuts/washers/acce
ssories

3. Galvanizing
4. Damages

As per HVPNL

Casting of cubes at site.

One sample of 6

Specification and

Cubes to be tested at

cubes in each

document at Annexure-

HVPNL appd. Lab for 7

tower locations

E of this FQP

days & 28 days strength

Appd. Drgs./BOM

Bidder

100% at stores

100% review of lab test results.


Cubes at 20% location are to be
taken in presence of HVPNL
officials

100% verification of records

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

5. Tack welding for


bolts & nuts

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

Counter Check/Test by HVPNL

Agency

Extent

Bidder

100% at Field

Page-4
Accepting
authority

1. Materials
a. Insulators

1. Visual check for


cleanliness/glazing/
cracks/and white
spots.
2. IR Value

HVPNL Specification

(min. 50M Ohms)

-do-

One test per sample


size of 20 for every
lot of 10,000

3. E&M test

Insulator supplier

a. 20 per 10,000 for


discs

100% verification of
records and to carry
random checks 10%

Engineer-incharge of HVPNL

To verify Bidders records


100% and joint check
20% of total tests

-do-

Collection of samples,
sealing them and handing

Inspecting
officer of HVPNL

Traceability(Make/b
atch No./Locations
where installed)
b. Conductor

b. 3 per 1500 for


long rod

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

2. Check for seals


at both ends, and
HVPNL sticker on
outer end

-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-

Check for seals at


both ends

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

Counter Check/Test by HVPNL

Agency

Extent

Bidder

100% at Field

Accepting
authority

100% record & Field


check 20%

Engineer-incharge of HVPNL

2. Repair sleeve

-do-

-do-

-do-

-do-

-do-

3. Mid span Joints

-do-

-do-

-do-

-do-

-do-

4. Guying (in case

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

100% record & Field


check 20%

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

Counter Check/Test by HVPNL

Agency

Extent

Bidder

100% at Field

Drgns./HVPNL

Accepting
authority

100% record & Field


Check 20%

Engineer-incharge of HVPNL

Specification

6.

5. Placement of

As per Specn./drgs/

spacer/damper

placement chart

-do-

-do-

-do-

-do-

Bidder

100%

100% joint checking

Engineer-in-

Final Testing
a. Pre-

a. Readiness of

1. Completeness of

commissionin

lines for pre-

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

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR CEMENT

ORDINARY PORTLAND CEMENT


S.
No.

Name of the test

a)

Physical tests

Ordinary Portland Cement


43 grade as per IS 8112

(i)

Fineness

Specific surface area shall not be less than 225 sq.m. per Kg
or 2250 Cm2/gm.

(ii)

Compressive
strength

72+/- 1 hour : Not less than 23 Mpa (23 N/mm2)


To be conducted in apprd. Lab on every lot of 500 MT.
168+/-2 hour : Not less than 33 Mpa (33 N/mm2)
672+/-4 hour : Not less than 43 Mpa (43 N/mm2)

(iii)

Initial & Final


setting time

Initial setting time : Not less than 30 minutes

Final setting time : Not more than 600 minutes


(iv)

Soundness

Remarks

Unaerated cement shall not have an expansion of more than


10mm when tested by Le chatlier and 0.8% Autoclave test

Page 8

S. No.

b)

c)

Name of the test

Ordinary Portland Cement


43 grade as per IS 8112

Review of MTC only

Chemical composition tests

Total loss on Ignition

Remarks

a)

Ratio of percentage of lime to percentage of silica, alumina % iron oxide


0.66 to 1.02

a)

Ratio of percentage of alumina to that of iron oxide Minimum 0.66

c)

Insoluble residue, percentage by mass Max. 4.00%

d)

Magnesia percentage by mass Max. 6%

e)

Total sulphur content calculated as sulpuric anhydride (SO3), percentage by


mass Not more than 2.5 and 3.0 when tri-calcium aluminate percent by
mass is 5 or less and greater than 5 respectively.

Not more than 5 percent

Page 9

Annexure B

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR REINFORCEMENT STEEL

S.
No.
i)

Name of the test

Chemical analysis
test

Mild and medium tensile steel as per IS 432

Cold twisted Deformed bars Fe 415 as per


IS 1786

Remarks

Carbon (For 20 mm dia and below) 0.23% Max.

Carbon (For over 20 mm dia) 0.25%

Carbon

0.30% Max

Sulpher

0.055%

Sulpher

0.060%

Phosphorus

0.055%

Phosphorus

0.060%

MTCs of Primary Producers to be reviewed.

Sulpher & Phosphorus 0.11%


ii)

Physical tests

a)

Ultimate Tensile stress


For all dia bars

b)

Bend & Rebend


tests

410 N/Sq.mm. (min.)

Yield stress (N/Sq.mm) min.

For bars upto 20 mm dia

250

For bars above 20 mm dia

240

c)
iii)

a)

Percentage of elongation 23%


Pass

Ultimate Tensile stress


10% more than actual 0.2% proof
stress but not less than 485
N/Sq.mm.)

b)

0.2% of proof stress/Yield stress


(N/Sq.mm) min.

For bars upto 20 mm dia


c)

415

Percentage of elongation 14.5%


(min.)
Pass

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

Percentage Passing for grades Aggregate of nominal size

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.

%age passing for Single-Sized Aggregate


of nominal size

Not to exceed 25%

c.

Crushing Value

Not to exceed 45%

d. Presence of deleterious
material

Total presence of deleterious materials not to exceed 5%

e.

12% when tested with sodium sulphate and 18% when tested with magnesium sulphate

Soundness test (for concrete


work subject to frost action)

Page 11
Annexure D

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR FINE AGGREGATES AS PER IS 383

4.

Fine aggregates

i)

Physical Tests

Percentage passing for graded aggregate of nominal size


IS Sieve Designation

a)

F.A. Zone I

F.A. Zone II

F.A. Zone III

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

600 microns 12.5 mm

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

Determination of particle size

Not to exceed 8%

Not to exceed 8%

Not to exceed 8%

b)

Silt content

c)

Presence of deleterious material

Total presence of deleterious materials shall not exceed 5%

d)

Soundness Applicable to concrete work


subject to frost action

12% when tested with sodium sulphate and 15% when tested with magnesium sulphate

Page 12

Annexure E

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR CONCRETE WORK

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

PRE-COMMISSIONING CHECK LIST & TESTING OF EHV LINES FOR CHARGING

NAME OF THE LINE

ROUTE KM

CKT KM

LINE CHARGING
DATE

A. GENERAL DATA AND INFORMATION


1.

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.

No. of conductors in bundle

9.

Crossing Details

Single

Twin

Triple

Quad

Other

From Loc No.

To Loc No.

Name of X-ing

No. of compression joint


R

Power Line
PTCC Line
Railway Line
River
Lake

10.

Other Informations
All weather approachable sections

Submerged sections in monsoon

Forest stretch sections

Hilly terrain sections

Page 1

11.

Name of towns

Distance from line

along the line route

(km)

Approx. time to reach


Hr. Min.

A.
B.
C.
D.
E.

12.

Any other special features of the line

B. CHECK LIST ON CONSTRUCTION


S.NO.

DESCRIPTION

1.

FOUNDATION

a.

Check any damage/ uneven


settlement of foundation.

b.

Check back filling of foundation is


properly filled up to the ground level
of all legs.

c.

Check surface earth/ concrete after


foundation casting is removed from
platform of the tower to beyond a
distance of 30 meters.

d.

Check crack or break in chimney.

e.

Check coping is proper

f.

Check crack or damage to retaining


wall/ revetment and proper weep
holes are provided for flushing water.

g.

Check that all foundation chimneys


are covered with soil and compacted
specially in hilly terrain and river/
nalahs banks upto ground level.

2.

TOWER

a.

Check for deformed/ rusted


damaged tower members.

or

STATUS

REMARKS

YES

Record Deficiencies if
any

NO

b.

Check for missing tower members.

c.

Check for missing bolts & nuts.

d.

Check for tightening of all bolts & nuts.

e.

Check for punching, tack welding (at


least 10 mm circular length) and zinc
coating of bolts & nuts.

f.

Check filling of blank holes in tower


members with bolts & nuts.

g.

Check verticality of tower.

h.

Check that no tower leg is suspected


to be in sinking land or soil erosion
field of river bank, if so, proper and
adequate protection has been
provided.
Page-2

i.

Check fixing of all tower accessories


namely step bolts, anti climbing device
(ACD),
earthing/
counterpoiseearthing.

j.

Check visibility of danger/ number/


phase & circuit plate along longitudinal
section of line.

k.

Check correct sequence of fixing of


phase/ circuit plate at transposition
towers.

3.

Removal of T&P and foreign materials

a.

Check temporary earthing/ guys used


during stringing and jumpering are
removed.

b.

Check all foreign materials on tower


e.g. dense spider webs, any handling
rod/ wire, kites, bird nests and left
over T&P on tower/ cross arm are
removed.

c.

Check read and white paints on


towers above 45m which fall in
aviation route.

d.

Check aviation warning signals on tall


towers near Airport/ Airstrip as per
rules.

4.

Insulators

a.

Check that all insulator discs are free


from damage and clean.

b.

Check for unusual deflection of


suspension string.

c.

Check whether verticality of string


restored.

5.

Hardware and accessory fittings

a.

Check that proper fixing of hardware


fittings like corona control ring/ arcing

horns etc. are provided as per the


approved drawing/ specification/
b.

Check randomly the condition of cotter


pins and ensure that proper size cotter
pins have provided as per the approved
drawing.

c.

Check that the conductors/ subconductors are free from scratches/ rubs.

d.

Check that all joints on conductor/ earth


wire are away from the tower as per the
specified distance (at least 30 meters)
and joints are as per the approved
drawings/ specification.

e.

Check that not more than one joint in a


sub-conductor is provided in one span.
Page 3

S.NO.

DESCRIPTION

f.

Check that no mid span joints or repair


sleeves are provided in major
crossings for highway, railway and
major rivers.

g.

Check that all mid span joints on


conductors/ earth wire and repair
sleeves of compression type are free
from sharp edges, rust and dust.

h.

Check that conductor is properly


clipped in the suspension clamp.

i.

Check that armour rods are provided


on suspension towers.

j.

Check that spacers are provided


between two sub conductors on each
phase as per the approved chart/
specification.

k.

Check that all spacers are properly


tightened and neoprene cover is
intact.

l.

Check that spacing of vibration


dampers from the tower and spacing
between damper to damper where two
vibration dampers provided are
properly fixed and tightened as per the
damper
placement
chart/
specification.

m.

Check that all jumpers are properly


fixed and torque tightened as per the
approved drawing/ specification.

n.

Check horizontality of sub/ quad


conductors.

o.

Check that on conductors/ earth


wires/ hardware fittings are free from
all foreign material like dead bird/
fallen tree/ bird nests etc.

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

REMAINING ACTIVITIES/ TEMPORARY ARRANGEMENTS LISTED AFTER JOINT INSPECTION


WITH ERECTION AGENCY

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

Erection Area In-charge

(HVPNL)

(HVPNL)

Details of sections to be mentioned in this format:

a.
b.
c.
d.

Outstanding activities remaining in any part of the line.


A list of temporary arrangements introduced.
Checklist records properly completed and signed as per Format-01.
Original tracing of profile, route alignment, tower design, structural drawings, bill of material, shop
drawings, stringing charts indicating initial and final sag etc. of all towers submitted to HVPNL.
e. For space, separate sheets to be enclosed for details of sectional incompleteness jointly signed by
Agency and HVPNL.

Page 5

Name of line

Circuit

Line Section

HANDLING OVER RECORD FOR ENERGIZATION

GENERAL STATUTORY ISSUES CHECK LIST


Package

kV

Type of towers

Voltage rating

Tower locations

Total no. of towers

Total length

S/C
From

D/C

To
Kms

Details:
S. No.

Description

Status
Yes

1.

Check list of entire section of the line


along with towers and accessories
under this division have carried out
and documented in the format no.01.

2.

Inspection has been carried out in all


towers and the outstanding issues
along with temporary arrangements
are documented in the format no. 02.

3.

No. of remaining activities/ points are


listed below and these are minor in
nature and do not stop charging the
line.

No

Remarks
Record deficiencies if any

Handing over check points


Section

Points according to format no.


PTL/TL.Const./10/Format/10
(Nos. of remaining activities)

A
B
C

Points completed
and confirmed
Date

Sign

Points accepted

Date

Sign

S. No.

Description

Status
Yes

4.

All electrical and ground clearances are as


per the approved drawings issued from
Engg. Dept. have been checked and no
deviation has been noted.

5.

All men and material and temporary


antitheft electrical connection, if any, have
been removed from all the locations under
this division.

6.

All electrical clearance has been received


from CEA electrical inspector for charging
of the line vide order no.
dated
(copy enclosed).

No

Remarks
Record deficiencies if any

Page-6

7.

PTCC clearance has been received from


Ministry of Communication Dept for charging
of the line vide order no.
dated
(copy
enclosed).

8.

Railway Crossings clearance has been


received for all the crossings vide order no.
dated . (copy enclosed).

9.

All statutory rules and regulations pertaining


to line charging has been carried out and
nothing is pending.

10.

All working agencies involved in construction/


erection of this line are intimated regarding
charging of this line and further work, if any,
are to be carried out only after availing the
Permit to Work (PTW) from the concerned
sub-station operating staff.

The above line is handed over for energization with/ without remaining activities

Handed over by

Accepted for energization

Signature
Date
Name
Organization

Line in-charge (Constn.)

Commissioning in-charge

Page 7

Name of line

Circuit

COMMISIONING FORMAT

GENERAL DATA AND INFORMATION

Date of charging

Package

kV

Type of towers

Voltage rating

Tower locations

Total no. of towers

Total length

S. No.

Description

S/C
From

The entire section of the line handed over for


energization as per Powerlinks format no. 03 on
dated

2.

No. of remaining activities/ points are listed as


per format no. 02 and these are minor in nature
and do not stop charging the line.

3.

All the equipments involved in charging of the line


are tested and documented as per the precommissioning formats of bay equipment.

4.

Pre-commissioning tests of bay/ feeder as per


approved document has been completed and
test results are documented by substation incharge.

5.

In case reactor provided in this line all tests are


carried out as per prescribed format and all test
results are documented by substation in-charge.

6.

All electrical clearance has been received from


CEA electrical inspector for charging of the line
vide order no. . Dated . (copy to be
enclosed)

To
Km

Status
Yes

1.

D/C

No

Remarks
Record deficiencies
if any

Page 8

S. No.

Description

Status
Yes

7.

All man and material and temporary antitheft


electrical connection, if any, removed from all
the locations.

8.

All electrical clearances have been received


from CEA electrical inspector for charging of
the line vide order no.
dated

9.

PTCC clearance has been received from


Ministry of Communication Dept. for charging
of the line vide order no.
dated

10.

Railway Crossings clearance has been


received for all the crossings vide order no.
dated . (copy enclosed).

11.

All statutory rules and regulations pertaining


to line charging has been carried out and
nothing is pending.

12.

All working agencies involved in construction/


erection of this line are intimated regarding
charging of this line and further work, if any,
are to be carried out only after availing the
Permit to Work (PTW) from the concerned
sub-station operating staff.

13.

All the protections are checked and put into


service as per standard format no. and
documented by substation in-charge.

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

R-PHASE & GROUND


Y-PHASE & GROUND
B-PHASE & GROUND
R-PHASE & Y-PHASE

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.

Y-PHASE & B-PHASE


B-PHASE & R-PHASE

MEASUREMENT OF INSULATION RESISTANCE FOR LINE (using 5 kV/ 10 kV motorized


megger):

BETWEEN

MEASURED VALUE IN
M OHM

R-PHASE & GROUND

REMARK

CONDITION

All ground switches at


other end are opened.
Min. value should be
approx. 150 mega ohm
(value may change with
weather condition)

Y-PHASE & GROUND


B-PHASE & GROUND
R-PHASE & Y-PHASE
Y-PHASE & B-PHASE
B-PHASE & R-PHASE

CONTINUITY TEST OF THE LINE

For phase marking confirmation

SENDING END
CONDITIONS

RECEIVING END
Megger between

MEASURE VALUE
IN OHMS

REMARK

CLOSE R PHASE GS

R-PHASE & GROUND

LOW

OPEN Y PHASE GS

Y-PHASE & GROUND

HIGH

OPEN B PHASE GS

B-PHASE & GROUND

HIGH

OPEN R PHASE GS

R-PHASE & GROUND

HIGH

CLOSE Y PHASE GS

Y-PHASE & GROUND

LOW

OPEN B PHASE GS

B-PHASE & GROUND

HIGH

OPEN R PHASE GS

R-PHASE & GROUND

HIGH

OPEN Y PHASE GS

Y-PHASE & GROUND

HIGH

CLOSE B PHASE GS

B-PHASE & GROUND

LOW

CONNECT R&Y PHASE,


ALL GS OPEN

R-PHASE & GROUND

LOW

Y-PHASE & GROUND

HIGH

B-PHASE & GROUND

HIGH

R-PHASE & GROUND

HIGH

Y-PHASE & GROUND

HIGH

CONNECT R&B PHASE,


ALL GS OPEN

CONNECT Y&B PHASE,


ALL GS OPEN

B-PHASE & GROUND

LOW

R-PHASE & GROUND

HIGH

Y-PHASE & GROUND

LOW

B-PHASE & GROUND

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:

Voltage measurement between


New Circuit

Charged old
circuit

1.

R-phase

R-phase

2.

R-phase

Y-phase

Measured voltage
(volts)

Remarks

In case of correct phase


sequence, the voltage measured
between R&R phase, Y&Y phase,

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

B&B phase of old charged line and


newly charged circuit will be zero
or very small and all other
measurements will show full line
CVT phase to phase secondary
voltage.

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

Pre-charging conditions for sending end


a.

Voltage

b.

Generator Details

kV

Lines connected

S. No.

Name of the line

MW

MVAR

Line reactor
In Service

1
2

Capacity

3
4
5

d.

Status of bus reactor, if any

S.No.

Rating

Status

Page 11

e.

On charging condition

Details

Sending end

Receiving end

Voltage
MVAR
Open end voltage

f.

Post charging condition

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

Organization Line Erection S/S Erection

Line In-charge

S/S in-charge

Date

Page 12

VOLUME-II, PART-II,

CHAPTER-IV

TECHNICAL DATA SHEETS

FOR

66 KV/220kV TRANSMISSION LINE

The following information on the proposed equipment and material shall be


submitted in four (4) copies by the bidder alongwith this proposal as separate
appendices to the proposal.

220kV/ 66KV TRANSMISSION LINE

Bidders Name & Address

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

Particular of 220kV M/C KRR Design towers

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)

As per HVPNL specification to be


provided
2.1.1

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 respective structural drawing of BOM

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

As per HVPNL specification to be


provided
2.1.5

MD type Normal tower


Fabricated parts (Black)

a)
Nuts & Bolts (Galvanised)
b)
c)

Total weight

2.1.6

MD type Spl. tower


Fabricated parts (Black)

a)

As per respective structural drawing of


BOM

As per bidder

Nuts & Bolts (Galvanised)


b)
c)

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

Quality of zinc used for IS:2629, 99.95%


galvanizing (purity) (%)

3.0

220kV TATA Design DD


type tower
Fabricated parts (Black)

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.

Quality of zinc used for IS:2629, 99.95%


galvanizing (purity) (%)

Page-2

66kV KRR Design D/C Towers


4.1

Mass in kilogram for M/C


towers

Extension
Std.

3m

6m

(1)

(2)

(3)

9m
(4)

12m

15m

18m

25m

(5)

(6)

(7)

(8)

As per HVPNL specification to be


provided
4.1.1

DE type tower

a)

Fabricated parts (Black)


Nuts & Bolts (Galvanised)

b)
c)

Total weight

4.1.2

DF type tower

a)

Fabricated parts (Black)


Nuts & Bolts (Galvanised)

b)
c)

Total weight

4.1.3

DG type tower

a)

Fabricated parts (Black)


Nuts & Bolts (Galvanised)

b)
c)

Total weight

4.1.4

DH type tower

a)

Fabricated parts (Black)


Nuts & Bolts (Galvanised)

b)
c)

Total weight

4.2

Gantry Tower G-2

As per respective structural drawing of


BOM

As per bidder

Fabricated parts (Black)


Nuts & Bolts (Galvanised)
Total weight
4.2.4

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

Quality of zinc used for IS:2629, 99.95%


galvanizing (purity) (%)

Page-3

GUARANTEED TECHNICAL PARTICULARS OF ACSR ZEBRA CONDUCTOR


Sl.No Description

Unit

1.0

Name & Address of manufacturer

2.0

PARTICULARS OF RAW MATERIALS

2.1

Aluminium
(a) Maximium Purity of aluminium
(b) Maximum Copper Content

%
%

2.2

Steel Wires / Rods


2
3
4
5
6

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

Minimum Breaking load of strand

3.3

Maximum Resistance of 1m length of strand Ohm


at 20 C

4.0

STEEL STRANDS AFTER STRANDING

4.1

Diameter
(a) Nominal
(b) Maximum
(c) Minimum

KN

Mm
Mm
Mm

As per HVPNL
Requirement

As per Bidder

4.2

Minimum Breaking load of strand

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

Lay ratio of conductor


(a)
(b)
(c)
(d)

KN

Outer steel layer


12 Wire aluminium layer
18 Wire aluminium layer
24 Wire aluminium layer

5.3

DC resistance of conductor at 20 C

Ohm/KM

5.4

Min. corona extinction voltage (line to ground)


under dry condition

kV (rms)

5.5

RIV at MHz at 154 KV (rms) under dry condition

Micro volts

5.6

Standard length of conductor

5.7

Maximum length of conductor

5.8

Tolerance on standard length of conductor

5.9

Direction of lay for outside layer

6.0

Linear mass of the Conductor


(a) Standard
(b) Minimum
(c) Maximum

N.A.

Kg/km
Kg/km
Kg/km

Drum is as per specification


No. of cold pressure butt welding equipments
available at works

Nos.

Page -5

GUARANTEED TECHNICAL PARTICULARS OF 7/3.15 mm EARTH WIRE


Sl.No.

Description

1.0

Name & Address of manufacturer

2.0

PARTICULARS OF RAW MATERIALS

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

STEEL STRANDS AFTER STRANDING

3.1

Diameter
(a) Nominal
(b) Maximum
( c)Minimum

mm
mm
mm

3.2

Minimum Breaking load of strand

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.

STRANDED EARTH WIRE

4.1

UTS of earth wire

kN

4.2

Lay length of outer steel layer

mm

4.3

DC resistance of earthwire at 200C

ohm

As per HVPNL
Requirement

As per Bidder

4.4

Standard length of earth wire


4.5

Tolerance on standard length

4.6

Direction of lay of outer layer

4.7

Linear mass of earth wire


(a) Standard
(b) Minimum
(c) Maximum

m
+m

kg/km
kg/km
kg/km

5.0

Drum is as per specification

Yes/No

Page-6

COMPOSITE LONG ROD INSULATORS FOR 220kV LINE WITH ACSR ZEBRA
Page 1 of 2

Sr.
No.

Description

Unit

1. Name & address of manufacture


2. Weight of single unit

Kg

3. Size and designation of ball & socket


assembly

mm

4. Core diameter

mm

5. Tolerance on core diameter

mm

6. Nominal length (section length)

Mm

7. Tolerance on Nominal length

mm

8. Dry arcing distance

Mm

9. Number of sheds

Nos.

10. Sheds profile (type)


11. Shed spacing

mm

12. Sheds profile (regular alternating )


13. Shed diameter

mm

14. Tolerance on shed diameter

mm

15. Minimum creepage distance

mm

16. Tolerance on Creepage distance

mm

17. Guaranteed mechanical strength

kN

18. Routine mechanical load

KN

19. Material
a)
b)
c)
d)
e)

FRP rod
Weather sheds with % contents
of silicon
Housing
End fittings
Grading rings

20. Minimum thickness of sheath covering


over the core

mm

70kN

120kN

As per Bidder

21. Power frequency withstand voltage of


single unit
f)
b)

Dry

KV
(rms)

Wet
KV
(rms)

22. Power frequency flashover voltage of


single unit
g)

Dry

b)

Wet

KV
(rms)
KV
(rms)
Page-7

COMPOSITE LONG ROD INSULATORS FOR 66KV LINE WITH ACSR ZEBRA
Page 2 of 2

23. Impulse withstand voltage of single unit


(dry)
h)
i)

Positive
Negative

KV
(peak)
KV
(peak)

24. Impulse flashover voltage of single unit


(dry)
j)
b)

Positive
Negative

KV
(peak)
KV
(peak)

25. Purity of zinc used for galvanizing end


fittings

26. Number of dips which the end fittings


can withstand in standard preece test

Nos.

27. Certified test report of accelerated


ageing test of 5000 hours (enclosed)
(appendix-C of IEC-61109)

Yes/No.

28. Drawing enclosed

Yes/No.

Page-8

GUARANTEED TECHNICAL PARTICULARS OF SUSPENSION HARDWARE FITTINGS (SUITABLE


FOR ACSR ZEBRA CONDUCTOR)
Sl.No. Description

Unit

1.

Name of manufacturer

2.

Address of manufacturer

3.

Dimensioned drawings of insulator strings


enclosed

4.

Detailed dimensional drawings of all hardware


components enclosed

5.

Material of
drawings

6.

Maximum magnetic power loss of suspension


assembly at conductor current of 500 Ampere

all

components

indicated

in

Watts
7.

8.

Slipping strength of suspension assembly


(clamp torque Vs slip curve shall be enclosed

KN

Particulars of standard / AGS preformed


armour rod set for suspension assemble
(a) No. of rods per set
(b) Direction of lay
(c) Overall length after fitting on
Conductor
(d) Actual length of each rod along its helix
(e) Diameter of each rod
(f) Tolerance in
(i)
Diameter of each rod
(ii)
Length of each rod
(iii)
Difference of length
Between the longest and shorted rod in a set

No.

Mm

Mm
Mm

(g)
Type of Aluminium alloy used for
manufacture of PA rod set

+ mm

(h) UTS of each rod

+ mm
mm

Kg/
mm

As per HVPNL
Requirement

As per Bidder

9.

Particulars of Elastometer (for AGS Clamp only)


(a) Supplier of elastometer
(b) Type of elastometer
(c) Shore hardness of elastometer
(d) Temperature range for which
elastometer is designed

(e) Moulded on insert

Page-9

10.

Total weight of Assembly


(a) Single Suspension
(b) Single Suspension pilot
(c) Double Suspension

Kg.
Kg.
Kg.

11.

UTS of string hardware


(a) Single Suspension
(b) Single Suspension pilot
(c) Double Suspension

KN
KN
KN

12.

Purity of Zinc used for galvanising

13.

Min. No. of dips in standard piece test, the


ferrous parts can withstand

14.

Design calculations for yoke plates enclosed

%
No.

Page-10

GUARANTEED TECHNICAL PARTICULARS OF TENSION HARDWARE FITTINGS (SUITABLE FOR


ACSR ZEBRA CONDUCTOR)
Sl.No. Description

Unit

1.

Name of manufacturer

2.

Address of manufacturer

3.

Dimensioned drawings of insulator strings


enclosed

4.

Detailed dimensional drawings of all hardware


components enclosed

5.

Material of
drawings

6.

Electrical resistance of dead end assembly

all

components

indicated

in

Ohms

As per HVPNL
Requirement

As per Bidder

7.

Slip strength of dead end assembly

8.

Total Weight of Assembly


(a) Single Tension
(b) Double Tension

KN

Kg.
Kg.

9.

UTS of string hardware


(a) Single Tension
(b) Double Tension

KN
KN

10.

Purity of Zinc used for galvanizing

11.

Min. No. of dips in standard piece test, the


ferrous parts can withstand

No.

Page-11

PARTICULARS OF MID SPAN COMPRESSION JOINT FOR ACSR ZEBRA


As per HVPNL
Sr. Description
Unit
Requirement

No.
1.

Manufacturers Name and Address

2.

Drawing enclosed

3.

Suitable for Conductor size

4.

Purity of Aluminium used for Aluminium sleeve.

5.

Material for steel sleeve

mm

i) Type of material with chemical composition.


ii) Hardness of material (Brinnel Hardness)
iii) Weight of zinc coating
(gm/mm2)
6.

Outside diameter of sleeve before compression


(a) Aluminium
(b) Steel

(mm)
(mm)

7.

8.

9.

Inside diameter of sleeve before compression


(a)Aluminium

(mm)

b) Steel

(mm)

Length of Aluminium Sleeve


i) Before compression

(mm)

ii) after compression

(mm)

Dimensions of sleeve after compression


(a) Aluminium
(i)
Corner to corner
(ii)
Surface to surface
b)Steel
(i)

Corner to corner

(mm)
(mm)

As per
Bidder

(ii)

Surface to surface

(mm)
(mm)
10.

11.

Length of Steel sleeve


i) Before compression

(mm)

ii) after compression

(mm)

Weight of sleeve
(a) Aluminium
(b) Steel
(c) Filler Al-Sleeve

(Kg.)
(Kg.)
(Kg.)

12.

Slipping Strength

13.

Conductivity of the compressed unit expressed as


percentage of the conductivity of equivalent length of
bare conductor

(kN)
%

Page-12

PARTICULARS OF REPAIR SLEEVE FOR ACSR ZEBRA CONDUCTOR


Sl.No. Description

Unit

1.

Manufacturers Name and Address

2.

Drawing enclosed

3.

Suitable for conductor size

4.

Purity of aluminium used for aluminium


sleeve

5.

Inside diameter
compression

6.

Outside dimensions of sleeve

of

sleeve

(a) Dia Before compression

(mm)

before

(%)

(mm)

(mm)

(b) After Compression


(i) Corner to corner
(ii) Surface to surface

(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

PARTICULARS OF MID SPAN COMPRESSION JOINT FOR GALVANISED STEEL EARTHWIRE


(7/3.15 mm)
Sl.No.

Description

1.

Manufacturers Name and Address

2.

Drawing enclosed

3.

Material of Joint
(i)
(ii)

Type of material with chemical


composition
Hardness of the material (Brinnel
Hardness)

Unit

As per HVPNL
Requirement

As per Bidder

4.

Inside diameter of sleeve before compression


(i)
(ii)
(iii)

Steel sleeve
Aluminium sleeve
Aluminium filler sleeve

(mm)
(mm)
(mm)

5.

Outside dimensions of sleeve


(a) Steel sleeve

(mm)

(b) Aluminium filter sleeve


6.

Outside
dimensions
compression

of

(mm)
sleeve

after

(a) Steel sleeve


(i)
Corner to corner
(ii)
Surface to surface
(b) Aluminium cover
(i)
(ii)

(mm)
(mm)

Corner to corner
Surface to surface
(mm)
(mm)

7.

Length of steel sleeve


(a)

Before compression

(b)

After compression

(mm)
(mm)

Page-14

8.

Length of Aluminium sleeve


(a) Before compression
(b) After compression

9.

(mm)
(mm)

Weight of sleeve
(a) Steel
(b) Aluminium
(c) Filler Al-sleeve

(Kg)
(Kg)
(Kg)

10.

Slipping Strength

(kN)

11.

Conductivity of the compressed unit expressed


as a percentage of the conductivity of
equivalent length of bare earthwire.

(%)

Page-15

GUARANTEED TECHNICAL PARTICULARS OF VIBRATION DAMPER FOR ACSR ZEBRA


CONDUCTOR
Sl.No Description

1.

Manufacturers Name & Address

2.

Drawing enclosed

Unit

As per make

(a) Design drawing


(b) Placement chart
3.

Suitable for conductor size

mm

4.

Total weight of one damper

Kg

5.

Diameter of each damper mass

mm

6.

Length of each damper mass

7.

Weight of each damper mass

8.

Material of damper masses

9.

Material of the stranded messenger cable

10.

Number of strands in stranded messenger cable

11.

Lay ratio of stranded messenger cable

12.

Minimum ultimate tensile strength of stranded


messenger cable

(Kg/
mm)

13.

Slipping strength of stranded messenger cable


(mass pull off)

KN

14.

Resonance frequencies
(a) First frequency
(b) Second frequency

As per HVPNL
Requirement

mm

Kg

mm

Hz
Hz

As per
Bidder

15.

Designed clamping torque

16.

Slipping strength of damper clamp


(a) Before fatigue test
(b) After fatigue test

Kg-m

KN
KN

17.

Magmetic power loss per vibration damper for


500 amps. 50 Hz altemating current

18

Material of Clamp

Watts

Page-16

PARTICULARS OF VIBRATION DAMPER FOR GALVANISED STEEL EARTHWIRE (7/3.15 mm)


Sl.No.

Description

1.

Manufacturers Name & Address

2.

Drawing enclosed

Unit

As per make

(a) Design drawing


(b) Placement chart
3.

Suitable for earth wire size

(mm)

4.

Total weight of one damper

(Kg)

5.

Diameter of each damper mass

(mm)

6.

Length of each damper mass

(mm)

7.

Weight of each damper mass

(Kg)

8.

Material of damper masses

9.

Material of the stranded messenger cable

10.

Number of strands in stranded messenger


cable

11.

Lay ratio of stranded messenger cable

12.

Minimum ultimate tensile strength of stranded (Kg/m


messenger cable
m2)

13.

Slipping strength of stranded messenger cable


(mass pull off)

14.

Resonance frequencies

(kN)

(a) First frequency

(Hz)

(b) Second frequency

(Hz)

15.

Designed clamping torque

16.

Slipping strength of damper clamp


(a) Before fatigue test
(b) After fatigue test

As per HVPNL
Requirement

Kg-m

As per Bidder

17

Page-17

PARTICULARS OF SUSPENSION CLAMP FOR GALVANISED STEEL EARTHWIRE (7/3.15 mm)


Sl.No.

Description

Unit

1.

Manufacturers Name & Address

2.

Drawing enclosed

3.

Material

4.

(i)
Shackle
(ii)
Clamp Body & Keeper
(iii)
U Bolt
Total drop (maximum)

(mm)

5.

Weight

(Kg)

6.

Breaking Strength (minimum)

(kgf)

7.

Slipping Strength

(kN)

8.

Tightening Torque

(kg-m)

As per HVPNL
Requirement

As per Bidder

Page-18

PARTICULARS OF TENSION CLAMP FOR GALVANISED STEEL EARTHWIRE (7/3.15 mm)


Sl.No.

Description

1.

Name of manufacturer

2.

Drawing enclosed

3.

Material

Unit

(i) Shackle
(ii) (a) Compression clamp

(b) Hardness of the material


(BHN)
4.

Inside diameter of the clamp before


compression

5.

Outside dimensions of sleeve


(a) Before compression

(mm)

As per HVPNL
Requirement

As per
Bidder

(b) After compression


(i)
Corner to corner
(ii)
Surface to surface

(mm)

(mm)
(mm)
6.

Length of clamp
(mm)
(a) Before compression
(b) After compression

(mm)

7.

Weight

(Kg)

8.

Slip strength (minimum)

(kN)

9.

Compression Pressure

(T)

10.

Minimum breaking strength of assembly


(excluding clamp)

(kgf)

Page-19

PARTICULARS OF FLEXIBLE COPPER BOND


Sl.No.

Description

Unit

1.

Name of manufacturer

2.

Drawing enclosed

3.

Stranding

4.

Cross sectional area

(Sq.mm)

5.

Minimum copper equivalent area

(Sq.mm)

6.

Length of copper cable

7.

Material of lugs

8.

Bolt Size
(i)
(ii)

Diameter
Length

(mm)

(mm)
(mm)

9.

Resistance

10.

Total weight of flexible copper bond

(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.

Power frequency dry one minute withstand


voltage

KVrms

3.

Impulse withstand voltage

KVpeak

4.

Total creepage distance

mm

5.

Protected creepage distance

mm

6.

Cantilever strength inverted

Kg

7.

Cantilever strength upright

Kg

As per Bidder

8.

Tensile strength

9.

Torsional strength

10.

Compression strength

11.

Bending strength

12.

Type and make

13.

Total weight

14.

Pitch circle diameter


a. Bottom

N
Nm

Kg

mm

b. Top
mm
15.

Max. diameter of Insulators

16.

Drawing Reference No.

mm

Page-21

HARYANA VIDYUT PRASARAN NIGAM LIMITED.

TECHNICAL SPECIFICAION

FOR

SUPPLY, ERECTION, CIVIL WORKS, TESTING AND

COMMISSIONING OF 66KV 1200MM2 ALUMINUM XLPE CABLE

IN FARIDABAD AREA UNDER REC 140.

TECHNICAL SPECIFICATION FOR 66 KV XLPE CABLE


1.0

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.

1.2 Description of 66kV line in Faridabad area:-

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

Conductor for insulated cable.

IEC-60229

Tests on cable over sheaths

IEC-60230

Impulse tests on cables and their accessories.

IEC-60270

Partial discharge measurements

2.2

IEC-60287-1-1

Calculation of continuous current carrying capacity.

IEC-60502

Power Cables with extruded insulation and their accessories.

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.

BIS: 7098 (Part-3)

XLPE Cable specification for working voltages from 66 kV upto and


including 220 kV.

IEEE:48

Tests procedures and requirements for high voltage cable terminations.

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

CLIMATIC CONDITIONS AND LAYING CONDITIONS

The XLPE Power cable shall be suitable for continuous & satisfactory operation under following conditions:-

3.1

3.2

Climatic Conditions:-

i)

Peak ambient temperature in shade

50oC

ii)

Maximum average ambient temperature in 24 hours period in shade

40oC.

iii)

Min. ambient air temperature in shade

(-) 5 oC.

iv)

Maximum temperature attainable by an object exposed to sun

55 oC

v)

Maximum relative humidity

100%

vi)

Minimum relative humidity

10%

vii)

Average number of thunder storm days per annum

40

viii)

Average number of rainy days per annum

100

ix)

Average annual rainfall

10 to 100 cm

x)

Number of months of tropical Monsoons conditions.

4 months

xi)

Maximum wind pressure

100 kg/Sq.mm

xii)

Altitude not exceeding

1000 M

Conditions of Laying:-

i)
ii)
iii)
iv
3.3

Laid directly in ground / metaled road.


Installed outdoor in free air in vertical position.
Drawn into underground ducts in RCC trench.
Laid through special arrangement for crossing of Bridge/Nala

Condition of installation of XLPE cable:

4.0

i)

Ground Temp.

35o C

ii)

Maximum conductor temp.

90o C

iii)

Air temperature

50o C

iv)

Depth of trench

1.5 m.

v)

Formation

(1Ckts. in trefoil / flat formation with spare ) X 2


for D/C line as per site suitability
1Ckts. in trefoil / flat formation with spare ) X 1
for S/C line as per site suitability

vi)

Bonding of metallic sheath

Single point/Cross Bonding (as applicable.

vii)

Number of 3 phase circuits

S/C, D/C or M/C as applicable

viii)

Thermal Resistivity of soil

150o C cm/W or as per site conditions

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

MATERIAL AND CABLE CONSTRUCTION:-

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.

5.3.2 The eccentricity of insulation should not be more than 10%.

5.4

Insulation Screening:

5.4.1

The insulation screening shall consist of two parts, namely, non-metallic and metallic.

5.4.2

Non-Metallic Part (extrusion):-

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%.

Non-metallic part (taped)-Longitudinal water barrier:

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

Metallic Part Radial Water Barrier:-

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

Lead alloy E Sheath:

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).

The bedding over the Metallic sheath shall be of semi-conducting tape(s)

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

Corrugated Aluminium Sheath:-

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

Outer conductive coating / layer:

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

CABLE JOINTING ACCESSORIES

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

TESTS AT MANUFACTURES WORKS:-

10.1

The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable) /IEC62067.

10.2 ROUTINE TESTS:-

The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable) /IEC62067

10.3 ACCEPTANCE TESTS:-

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

SEALING AND DRUMMING:-

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

Direction of rotation of drum (by means of an arrow).


Net weight
Gross weight.
Year of manufacture.
Confirming to IEC/IS No
Purchase order details.
Name of owner.
Name of consignee.
13.0

STANDARD LENGTH AND QUANTITY TOLERANCE:-

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

DETAILS OF PAST EXPERIENCE: -

14.1

The details of past orders executed by the bidder shall be indicated in the relevant
schedule.

15.0

GUARANTEED TECHNICAL PARTICULARS:-

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

Single Core, Aluminium


Conductor XLPE cable
Conforming to IEC 60502,60840/
IS 7098(part-3) amended up to
date.
66 KV 10% kV, 50 Hz 3%
72 kV

Applicable standard
1.
2.
3.

System voltage & frequency


Highest System Voltage

4.
5.
i)
ii)
iii)
iv)
v)

Suitable for earthed system


CONDUCTOR
Material
Nominal cross-sectional area
Construction of conductor/flexibility
class
Shape and formation
Approx overall diameter of
conductor

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)

Nominal thickness of insulation

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.

Min. thickness of outer sheath


Conducting layer over outer
sheath
Approx overall diameter of cable
(mm)
Approx. weight per meter of cable
(kg/m)

Extruded, semi conducting


compound layer.
As per IEC/IS
1.0 mm
Cross linked polyethylene(XLPE)
As per 7098 (Part 3)

Extruded semi conducting


Compound layer.
As per IEC/IS: 7098 (Part 3)
0.8 mm

Synthetic Non-woven semi


conducting Water swell-able tape
As per standard.

Corrugated Aluminium / Lead alloy


E sheath IS 692
Conforming to IEC 60502/ IS: 7098
(Part 3)
31.5 kA for one Second

Semi conducting tape(s)

Annealed plain copper wires applied


helically with gap followed by open
helix of copper tape binder
This and lead alloy E sheath shall
meet earth fault current of 31.5kA for
a duration of 1 second.
Extruded Layer of Black PE or PVC
type ST-2 as per IEC-60502 / IS:
7098 (Part 3)
As per standard
Graphite coating
To be indicated by the Bidder
To be indicated by the Bidder
Page-11

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

To be indicated by the Bidder

Symmetrical Short circuit rating for


one second duration for lead
sheath and copper screened
combined/ Aluminium Sheath
Drum Length
Expected cable life.

31.5 kA for 1 Sec.

As per IEC-228 A
To be indicated

90 Deg C
250 Deg C

As per Standard
As per Standard

AS per Clause No.-13.0


35 years.

Page-12

ERECTION PART

Technical specification of laying, erection, testing & commissioning of cables:1.0

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.

Laying of cables under scope as per specification.

4.

Measurement of Thermal resistivity of soil. The value of thermal resistivity will be intimated to field office.

5.

Transportation of cable drums & other material.

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.

Training of HVPNLs Engineers & jointers.

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

The inspection of cable on receipt, handling of cables, paying out,


flaking, cushioning with sand or sieved
compacted soil, back-filling, providing and fixing joint markers, route indicators, and all necessary precautions that are
required shall be carefully planned and in general conform to IS 1255-1983 or its equivalent.

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

CABLE ROUTE MARKERS/CABLE JOINT MARKERS

Permanent means of indicating the position of joints and cable route shall be fabricated supplied and erected.

Markers provided shall be as per the field requirement, if the route


be conspicuously visible above ground surface.

passes through open fields, markers should

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

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

LAYING OUT THE CABLE

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

PREVENTION OF DAMAGE DUE TO SHARP EDGES

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

ROAD, RAIL & CANAL CROSSINGS

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

Trench less Digging:

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)

Excavation and backfilling of trial pits and verification of soil condition.

b)

Excavation of entry and Exit pits.

c)

Erection of drill machined drilling of pilot hole.

d)

Placement and driving hand augur.

e)

Placement and carrying out impact moling.

f)

Reaming and widening of bore holes in steps (if required).

g)

Pulling of product pipe.

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

TOOLS AND PLANTS

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:

The minimum bending radius of XLPE insulated cables are as follows:

Cable

Bending radius

Single Core

20 x D

D means the overall diameter of the completed cable.

18.0

JOINTING AND TERMINATION OF CABLES

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.

The joints of different phases shall be staggered in the jointing bay.

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

PRECAUTIONS BEFORE MAKING A JOINT

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

MEASUREMENT OF INSULATION RESISTANCE

Before jointing, the insulation resistance of both sections of cables

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.

The instructions furnished by the termination manufacturer shall be strictly followed:

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

ground, for future needs.

The cable shall be properly fastened using non-metallic clamps.

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

CABLE TERMINATING STRUCTURES

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

TESTS AFTER INSTALLATION

All tests as prescribed in IEC-60840: 1999 shall be performed after installation of cable.

Page-10

SPECIFICATION FOR CIVIL AND STRUCTURAL WORKS

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

All excavation for installation of underground facilities shall be open cuts.

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

3.0 DISPOSAL OF EXCAVATED EARTH


2.2

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.

BACK FILLING MATERIALS

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.

4.0 BACK FILLING FOR CABLE TRENCH


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.

4.3

The thermal backfill surrounding the cable shall be as per the design approved by the owner.

6.0 SPECIFIATION FOR CEMENT CONCRETE

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).

6.0 CURING AND PROTECTION OF CONCRETE

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.

7.0 PRECAST RCC ITEMS


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.

7.3

All the pre-cast element shall be marked, appropriately as specified.


Page-12

13.0 FOUNDATION

Foundations for mounting structures in cement concrete shall be casted by bidder as per approved drawings.

14.0 BOLTS, NUTS AND WASHERS


Standard bolts, nuts an washers shall be used in all works. These should be galvanized in accordance with IS: 5358.

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.

16.0 MATERILAS USED IN CABLE LAYING

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.

17.0 RCC PRE CAST CABLE PROTECTION COVERS

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.

13.0 CABLE ROUTE MARKERS/JOINT MARKERS

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.

16.5 LEAD AND LIFT


The rates quoted for all items of works shall include all lifts and leads wherever applicable unless otherwise specified.

16.6 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.

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.

22.0 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.

23.0 ROAD CROSSING


HDPE pipes shall be used for cable. Pipes diameter should not be less than 1.5 times the cable diameter.

24.0 FOOTPATH CUTTING


The slabs, kerb- stones, on the roads shall be removed and reinstated without damage.

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.

26.0 MAINTENANCE OF SITE CONDITIONS

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

60KV POLYMER HOUSEDSURGE ARRESTORS

WITH SURGE COUNTERS

TECHNICAL SPECIFICATION FOR


SURGE ARRESTORS (LIGHTNING ARRESTORS)

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

All the LAs shall be suitable for outdoor application on towers.

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.

IEC:99-4With latest amendments

Specification Part-4 for Surge Arrestors without gap for


AC system.

2.

IS:3070

Specification for Lightning Arrestors

(Part-III)

for alternating current system

IS: 2629

Recommended practice for

3.

hot dip galvanizing of iron and steel.

4.

IS: 2633

Method for testing uniformity of


coating on zinc coated articles.

5.

IS:2147

Degree of protection provided by


enclosures for low voltage
switchgear and control.

6.

------

7.

IEC 61462

8.

IEC-815
(With latest amendments)

Indian Electricity Rules, 1956.

Silicon Rubber insulator

Guidefor selection of
Insulators pact polluted condition

9.

IEC-270

partial discharge measurement

10

IEC-60-1

High voltage test techniques part-1 general


definition and test techniques

11 IEC-270-2-1976

Insulation coordination part-2 application guide

______________________________________________________________________________
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)

Approx. no. of rainy days/year

120 days nearly

v)

Average rain fall/year

900 mm

vi)

Altitude above mean sea level

Below 1000 meters

vii)

Max. wind pressure

195 Kg./m2

viii)

Average number of dust storm days per annum

35

The reference ambient temperature may be taken as 500 C.

3.1

AUXILIARY POWER SUPPLY:


The equipment offered under this specification shall be suitable for the following auxiliary power supplies.

a)

Power Devices (like drive motors)

415V, 3 Phase, 4 wire 50 Hz, neutral grounded AC


supply

b)

AC Control and protective 240V, single space, 2 wire 50 Hz, neutral grounded
devices, lighting fixtures, space AC supply
heaters

c)

DC alarm,control and protective 220V, DC 2-Wire


devices

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.

System Voltage (KV rms)


66

Nominal system voltage


(kV rms)

66

Highest system voltage

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

and lines (kVp)

4.

Minimum prospective

31.5

symmetrical fault current


for 1 second at Arrestor
location (kA rms)
5.

Anticipated levels of
temporary overvoltage
and its duration
a) Voltage (p.u.)

1.5/1.2

b) Duration (Seconds)

1/10

6.

Long duration discharge

class -3

7.

Max. RIV when energized at MCOV-

500V

8.

Internal partial discharge at


1.05 time COV

-10pc (max.).

9.

System frequency(Hz)

50 2.5 C/S

10

Neutral Grounding

Effectively Earthed

11. Number of Phases

Three

5.0

GENERAL TECHNICAL REQUIREMENTS:

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

The Surge Arrestors shall be suitable for hot line washing.

5.7

CONSTRUCTION AND FEATURE:

5.7.1

All the units of Arrestors of same rating shall be inter changeable without adversely affecting the
performance.

5.7.2

The Surge Arrestors shall be suitable for tower mounting.

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

GALVANISATION, NICKEL PLATING ETC.:-

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

ACCESSORIES AND FITTINGS:

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

The discharge counter shall register


strikes the Surge Arrestor.

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

whenever lightning or any other type of surge

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.

Haryana Vidyut Prasaran Nigam Ltd.

2.

Order No.

3.

Manufacturer's name or trade mark and identification no. of the Arrestor being supplied.

4.

Rated voltage.

5.

Maximum continuous operating voltage.

6.

Type.

7.

Rated Frequency.

8.

Nominal discharge current.

9.

Long duration discharge class.

10. Pressure relief current in kA rms.


11. Year of manufacture.

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.

List of Type test reports

Tests on metal oxide blocks


1

Steep Current Impulse Residual Voltage test

Lightning impulse Residual voltage test

Switching impulse Residual voltage test


Long duration current impulse withstand test

Operating duty test


- High Current Impulse operating duty test

- Switching Surge Operating Duty test


- Accelerated ageing test
P. F. voltage v/s time characteristic
6

Tests on Arrester with Housing

Lightning Impulse voltage withstand test on insulator (cl. No. 8.2.6)

P.F. (Wet) voltage withstand test on insulator (cl. 8.2.8)

Banding test (cl. No. 10.8.9)


All applicable test on silicon rubber as per standard IEC-61462

10

and TERT (Tracking & Erosion resistance test) as per ASTM D2303
Tests on complete Arrester

11

Weather aging test (5000 h) (cl. 10.8.14)

12

Seismic forces withstand test

13

High current short circuit test

Page-7

14

Low current short circuit test

15

Water immersion test (cl.10.8.9.3.2)

16

leakage check test (cl. 9.1(d )

General

6.1.2

17

STC on Terminal connector (31.5 kA for 1 sec)

18

Degree of Protection test on counter/surge monitor (IP-67)

19

Uniformity of Zinc coating for metal parts

20

Special Thermal stability test as per cl.9.2.2 of IEC 60099-1-2009

ACCEPTANCE AND ROUTINE TESTS:

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:-

SN List of Acceptance test reports


1 Power frequency voltage withstand test
2 Lightning Impulse residual voltage test on complete arrester / unit ofarrester
3 Reference voltage test
4 Leakage check test
5 Partial discharge test
6 Visual / Dimensional check
7 Special Thermal stability test as per cl.9.2.2 of IEC 60099-4-2009
8 Galvanization test on metal parts
9 Functional (operational) tests on surge monitor/counter at nominal is charge currents
(a) 100 Amps with 8/20 microsecond wave shape.
(b) 10/20 KA with 8/20 microsecond wave shape.
10 Water immersion test for a duration of 24 hrs, to check the water penetration, on any one randomly
selected sample from every 50 (Fifty) or below nos. of LA offered for inspection, shall be carried out
and report shall be submitted.

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

The following routine test reports shall be submitted.


S N List of Routine test reports
1 Measurement of reference voltage
2 Lightning Impulse Residual voltage test
3 Partial discharge test
4 Tests on discharge counter
5 Visual / Dimensional check
6Leakage check rate test for a duration of 24 hrs to check the water penetration, on any one randomly
selected sample from every 50 (Fifty) or below nos. of LA offered for inspection, shall be carried out
and report shall be submitted.

6.1.4

SURGE MONITOR

The following routine test shall be performed in the presence of purchasers representative:
i)
ii)
iii)

Tests for satisfactory operation of surge counter while discharging surges.


Test for correctness of leakage current meter before and after the passage of surges.
Visual examination tests.

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)

General outline drawing of thecomplete Arrestors with technical parameters.

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)

Drawings showing details of pressure relief devices.

iv) Detailed drawing of discharge countersalong with the wiring and schematic drawing of discharge
counter and meter.
v)

Outline drawing of insulating base.

vi) Details of grading rings, if used.


vii) Mounting details of Surge Arrestors.
viii) Details of line terminal and ground terminals.
ix) Volt-time characteristics of Surge Arrestors.
x)

Details of galvanizing being provided on different ferrous parts.

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

PACKING & FORWARDING:

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)

Name of the consignee.

b)

Details of consignment.

c)

Destination.

d)

Total weight of consignment.

e)

Sign showing upper/lower side of the crate.

f)

Handling and unpacking instructions.

g)

Bill of materials indicating contents of each package.

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

TECHNICAL REQUIREMENTS FOR SURGE ARRESTORS

_______________________________________________________________________________
Sl.

Particulars

No.

System voltagewise requirement of parameters


66 kV

_______________________________________________________________________________
1.

Rated Arrestor

60

Voltage

2.

M.C.O.V. (kV rms)

49

3.

Installation

Outdoor -

4.

Class

station class

5.

Type of cons-

Single Column, Single Phase---

truction for
10 kA rated Arrestor.

6.

Nominal discharge

10KA

current corresponding to 8/20


microsec wave
shape (kA rms)

7.

Min. discharge

5 KJ/kV (Referred to rated arrester voltage

capability.

corresponding to Min. discharge characteristics)

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.

Max. Switching Surge

140

kV(P) Protective level


voltage at 1000 Amp.
12.

Max. residual voltage

170

kV(P) for nominal


discharge current
10 KA with 8/20
micro second wave
13.

Max.residual voltage

186

kV(P) steep fronted


current impulse of
10 KA.
14.

Minimum pros-

31.5

symmetrical fault
current for pressure
relief test (kA rms)

Page-11

ANNEXURE I

(Surge Arrestors)
SHEET 2 OF 2

TECHNICAL REQUIREMENTS FOR SURGE ARRESTORS

_____________________________________________________________________________
Sr.

Particulars

System voltage

15.

a) Terminal Connector

Single Zebra/Panther

suitable for ACSR


conductor size

16.

b) Take off

Vertical

Voltage (kV rms)

Rated voltage of the Arrestor

(corona extinction)
17.

Maximum radio

500

interference
voltage (Microvolt)
when energised
at MCOV
18.

Whether insulating

yes

base and discharge


counter with
milli-ammeter are
required.
19.

Minimum creepage
distance of Arrestor

2248

housing (mm)

Page-12

ANNEXURE A

GUARANTEED TECHNICAL PARTICULARS FOR 66 KV SURGE ARRESTERS.

(To be filled in by the bidder)

Name of Manufacturer

2.

Arrester Class & Type (with mfr type designation)

2a

Material of housing

3.

Applicable Standard.

3.a

Nos. of unit per phase

3.b

Rating of each unit

3.c

Nos. of ZnO blocks per unit

4.a

Rated Arrester Voltage (kV) of complete unit

4.b

Rated system voltage (kV)

5.

Max continuous operating voltage (MCOV) (kV)

6. i)

Nominal Discharge Current (KA) with 8/20Micro-second wave

ii)

Max resistive component of continuouscurrent at MCOV-mA crest

iii) Max capacitive component of continuouscurrent at MCOV -mA crest


7.

Long Duration Discharge Class

8.

Min. Energy Discharge Capability (KJ/KV rating)


as per IEC for 2 shots

9.

Max. Switching current impulse residual voltage(KVP)


i)

1000 Amps.

ii)

250 Amps.

10.

Max. Residual voltage with 1 micro secondcurrent wave at 10 KA (KVP)

11.

Maxi. Residual voltage with 8/20 micro secondwave (KVP)


i)

5 KA

ii)

10 KA

iii)

20 KA

12.

Pressure Relief Class KA (rms)

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.

Over voltage withstand capability KV


a) 100 Seconds
b) 10 Second
c) 1.0 Second
d) 0.1 Second

17.

A) Reference Voltage (KV)


b) Reference Current (KA)

18

Number of per unit per phase and rating of each unit

19.

Minimum total creepage distance (mm)

20.

Total weight of Arrester (kg.)

21

Total weight of structure (kg.)

22.

Maxi. Cantilever strength of LA (Including Wind Load)

22.a

Cantilever strength of assembled arrester. (Kg/Cm)

23.

Overall Height of LA (mm)

24.

Maxi. Distance recommended from equipment to be protected by LA (mm)

25.

Min. distance between grounded object (mm)

26.

Min. distance between Arrester phase legs (mm)

27.

Clamp and connectors.


a)

Material and composition of clamp and connector

b)

Rated current

c)

Max. Temperature rise when carrying short time current as specified.

28. a) Type test carried out on the similar arrester.


29.

Any other particulars.

30.

Details of metal oxide block


Reference voltages
Material
Diameter
Height

31

Details of structure
Material
Hot dip galvanizing, zinc coating in gms/m2
Mounting dimensions

32

Material and content of polymer housing

33.

Maximum RIV at rated voltage

Page-14

DRS Form 1

DATA REQUIREMENTS SHEETS for


OVERHEAD FIBRE OPTIC CABLE

OPTICAL GROUND WIRE (OPGW) 24 Fibre:

Manufacturer:

_______________________________

Configuration:

_______________________________

CABLE CONSTRUCTION
Seq

Parameter:

As per Technical
Specification

1.

No. of Fibres
Dual Window Single-Mode:

2.

Buffer Type:

3.

Buffer Tube material

4.

No. of Buffer Tubes:

5.

No. of Fibers per bufferTube:

6.

Expected Cable Life:

DRS Form 2

DATA REQUIREMENTS SHEETS for


OVERHEAD FIBRE OPTIC CABLE

OPTICAL GROUND WIRE (OPGW) 48 Fibre:

Manufacturer:

_______________________________

Configuration:

_______________________________

CABLE CONSTRUCTION
Seq

Parameter:

As per Technical
Specification

1.

No. of Fibres
Dual Window Single-Mode:

2.

Buffer Type:

3.

Buffer Tube material

4.

No. of Buffer Tubes:

5.

No. of Fibers per bufferTube:


6.

Expected Cable Life:

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.

Attenuation Coefficient@ 1310 nm:

As per Bidder
offering

@ 1550 nm:
3.

Point discontinuity @ 1310nm:


@ 1550nm:

4.

Nominal Mode Field Diameter


@ 1310 nm:
@ 1550 nm:

5.

Chromatic Dispersion
Coefficient
@ 1310 (1288-1339) nm:
@ 1310 (1271-1360) nm:
@ 1550 nm:

6.

Zero dispersion wavelength:

7.

Cutoff wavelength:

Physical and Mechanical Properties


8.

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.

Polarisation mode dispersion

coefficient
11.

Proof test level

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

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.
Sr.
No
1
1.
2.
3
(A)
.

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.

Length of line: 2.31Km


Unit
Qty.
3
Km.
No.

4
3
4

No.

01

No.
No.

01
06

No.
No.

02
01

No.
No.

01
00

No.
No.

01
00

4.

i) 220kV M/C Tower type A monopole classified as


- Dry
- Wet (w/out de-watering)
ii) 220kV M/C Tower type B monopole classified as
- Dry
- Wet (w/out de-watering)
iii) 220kV M/C Tower type D monopole 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 or monopole

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.

220kV D/C TRANSMISION

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

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.
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 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.

220kV D/C TRANSMISSION


SCHEDULE OF PRICES
SCHEDULE 5
LINE
(UNIT RATE SCHEDULE)
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.
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: 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

Construction of 220kV Multi Circuit (4 ckt.) towers (KRR design)


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 MD (KRR Design) classified as
- Dry
- Wet (w/out de-watering)
Design, Engineering and construction of 220kV towers foundations
suitable for 220kV M/C 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.
i) 220kV M/C Tower type A monopole classified as
- Dry
- Wet (w/out de-watering)
ii) 220kV M/C Tower type B monopole classified as
- Dry
- Wet (w/out de-watering)
iii) 220kV M/C Tower type D monopole 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 or
monopole 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.

220kV D/C TRANSMISSION


SCHEDULE OF PRICES
SCHEDULE 5
LINE
(UNIT RATE SCHEDULE)
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.

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

ii) 66kV Tower type DF (KRR Design) classified as


- Dry
- Wet (w/out de-watering)
iii) 66kV Tower type DG (KRR Design) classified as
- Dry
- Wet (w/out de-watering)
iv) 66kV Tower type DH (KRR Design) classified as
- Dry
- Wet (w/out de-watering)
Construction of tower foundations as per HVPNL Drawings &
Specifications for 220kV D/C including excavation, concreting, supply
and placement of steel reinforcement and backfilling complete in all
respect.
i) 220kV D/C Tower type DD+12 (TATA Design) classified as
- Dry
- Wet (w/out de-watering)
Construction of Gantry foundation as per KRR DESIGN, One set consist
of 3 no. G-1 type foundation including excavation, cutting placing of
steel, concreting, Backfilling complete in all respect
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: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.

220kV D/C TRANSMISSION


SCHEDULE OF PRICES
SCHEDULE 5
LINE
(UNIT RATE SCHEDULE)
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.

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

ii) 66kV Tower type Q (PQRS Design) classified as


- Dry
- Wet (w/out de-watering)
iii) 66kV Tower type R (PQRS Design) classified as
- Dry
- Wet (w/out de-watering)
iv) 66kV Tower type S (PQRS Design) classified as
- Dry
- Wet (w/out de-watering)
Construction of tower foundations as per HVPNL Drawings &
Specifications for 220kV D/C TATA Design tower including excavation,
concreting, supply and placement of steel reinforcement and backfilling
complete in all respect.
i) 220kV Tower type DD+9 (TATA 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.

220kV D/C TRANSMISSION


SCHEDULE OF PRICES
SCHEDULE 5
LINE
(UNIT RATE SCHEDULE)
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).

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.

220kV D/C TRANSMISION


SCHEDULE OF PRICES
SCHEDULE 5
LINE
(UNIT RATE SCHEDULE)
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).

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.

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.

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

6.0 T/m2 (F.O.S.=2.5)

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

Top of foundation must be at least 225mm above ground level.

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;

a. Max. tension or uplift along the leg slope.


b. Max. compression or down-thrust along the leg slope.
c. Max. horizontal shear or side thrust.
4.8.3 The base slab of the foundation shall be designed for additional moments developing due to
eccentricity of the loads.
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.

RESISTANCE AGAINST UPLIFT


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.

RESISTANCE AGAINST DOWN THRUST


The following load combinations shall be resisted by the bearing strength of soil.
iii.

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.

Additional moments caused at bottom of footing due to eccentricity

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.

RESISTANCE AGAINST SIDE-THRUST


The lateral load carrying of chimney portion of foundation shall be based on the chimney acting
as cantilever aided by the passive earth resistance developed 500mm below the ground level.
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.

4.10 PROPERTIES OF CONCRETE & REINFORCEMENT


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.
4.10.9 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.

4.11 UNIT RATES AND MEASUREMENT


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.

4.12 CONSTRUCTION OF TOWER FOUNDATIONS AS PER DESIGN SUPPLIED BY


HVPNL
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.
4.12.4 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.
4.13

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

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.
4.15 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

BACK-FILLING AND REMOVAL OF STUB TEMPLATE

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

PROTECTION OF TOWER FOOTING

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

FIELD QUALITY CONTROL PLAN


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.

SPECIFICATION FOR CIVIL AND STRUCTURAL WORKS FOR LYING CABLES


1.24

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

4.0 DISPOSAL OF EXCAVATED EARTH


2.2.1 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-in-charge.
2.2 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.

3.0
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

BACK FILLING FOR CABLE TRENCH


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.
The thermal backfill surrounding the cable shall be as per the design approved by the
owner.

7.0
5.1

SPECIFIATION FOR CEMENT CONCRETE


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).

6.0

CURING AND PROTECTION OF CONCRETE


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.

7.0
7.1

PRECAST RCC ITEMS


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.
All the pre-cast element shall be marked, appropriately as specified.

7.4
18.0

FOUNDATION
Foundations for mounting structures in cement concrete shall be casted by bidder as
per approved drawings.

19.0

BOLTS, NUTS AND WASHERS


Standard bolts, nuts an washers shall be used in all works. These should be galvanized
in accordance with IS: 5358.

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

MATERILAS USED IN CABLE LAYING


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.

22.0

RCC PRE CAST CABLE PROTECTION COVERS


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.

13.0
13.1

CABLE ROUTE MARKERS/JOINT MARKERS


Permanent and durable type, cable route markers/joint indicating blocks should be
provided as per the design approved by the purchaser.
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.
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.

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

LEAD AND LIFT


The rates quoted for all items of works shall include all lifts and leads wherever
applicable unless otherwise specified.

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

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.

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

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 coordinated by bidder.

20.4

All works shall be carried out under supervision of the Engineer in Charge or his
representative.

31.0

MAINTENANCE OF SITE CONDITIONS


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.

REC-140

SCHEDULE 4
SCHEDULE OF PRICES
NAME OF LINE:

Sr.
No
1
1.
2.
3.

Construction of 66kV S/C (Composite) line with 0.2Sq. ACSR conductor


on D/c towers designed for 0.4Sq. ACSR from 220kV S/Stn. Pinjore
(present 132 Kv S/stn.) to 66 Kv S/Stn. DLF at village Bhagwanpur (
Cable Portion and tower portion)
Tentative length: 5KM approx.
Description
Unit
Qty.
2

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.

Construction of 66kV S/C (Composite) line with 0.2Sq. ACSR conductor


on D/c towers designed for 0.4Sq. ACSR from 220kV S/Stn. Pinjore
(present 132 Kv S/stn. ) to 66 Kv S/Stn. DLF at village Bhagwanpur (
Cable Portion and tower portion)
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: 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

Tentative length: 0.580KM approx.


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) 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.

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)

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.

Construction of 66kV S/C (Composite) line with 0.2Sq. ACSR


conductor on D/c towers designed for 0.4Sq. ACSR from 220kV S/Stn.
Pinjore (present 132 Kv S/stn. ) to 66 Kv S/Stn. DLF at village
Bhagwanpur ( Cable Portion and tower portion)

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:

Construction of 66kV S/C (Composite) line with 0.2Sq. ACSR conductor


on D/c towers designed for 0.4Sq. ACSR from 220kV S/Stn. Pinjore
(present 132 Kv S/stn. ) to 66 Kv S/Stn. DLF at village Bhagwanpur (
Cable Portion and tower portion)

Sr.
No
1
1.
2.
3.

Description

Tentative length: 5KM approx.


Unit
Qty.

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.

Construction of 66kV S/C (Composite) line with 0.2Sq. ACSR conductor


on D/c towers designed for 0.4Sq. ACSR from 220kV S/Stn. Pinjore
(present 132 Kv S/stn. ) to 66 Kv S/Stn. DLF at village Bhagwanpur (
Cable Portion and tower portion)
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: 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

Tentative length: 0.580KM approx.


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) 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.

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)

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.

Construction of 66kV S/C (Composite) line with 0.2Sq. ACSR


conductor on D/c towers designed for 0.4Sq. ACSR from 220kV S/Stn.
Pinjore (present 132Kv S/stn. ) to 66 Kv S/Stn. DLF at village
Bhagwanpur ( Cable Portion and tower portion)

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.

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.

4.6.1 Design of foundation for Wet (without de-watering) and Wet (with de-watering) shall be
same.
4.7

PROPERTIES OF CONCRETE & REINFORCEMENT

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

UNIT RATES AND MEASUREMENT

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

CONSTRUCTION OF TOWER FOUNDATIONS AS PER DESIGN SUPPLIED BY


HVPNL
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.
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 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

MIXING, PLACING AND COMPACTING OF CONCRETE

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

BACK-FILLING AND REMOVAL OF STUB TEMPLATE

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

PROTECTION OF TOWER FOOTING

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

FIELD QUALITY CONTROL PLAN


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.

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)

(Tentative length of line =2.31 km)


Sr. No.
DESCRIPTION

Qty.

UNIT

A
220kV line on 220kV D/CTATA Design towers
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

i) 220kV D/C DB type (TATA Design) tower

No.

ii) +6 mtr. extn. only

No.

i) 220kV D/C DD type (TATA Design) Tower

No.

ii) +6mtr. extn. only

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

i) 220kV MA type Normal Multi- Circuit tower

No.

1.2

i) 220kV MB typeNormal Multi- Circuit tower

No.

ii) +3 mtr. Extn. only


1.3

i) 220kV MD typeNormal Multi- Circuit tower

220kV line on 220kV M/C Monopole

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.

ii) 220kV M/C B type Monopole

No.

iii) 220kV M/C B type Monopolewith +3 mtr. Extn.

No.

iv) 220kV M/C D type monopole with +3 mtr. Extn.

No.

2.

Supply of earthing of towers/ monopole


i) Pipe type
ii) Counterpoise type

3.

Supply of following Tower accessories


i) Danger Plate
ii) Number Plate
iii) Phase Plate(set of 3)
iv) Circuit Plate (set of 2)
v) Bird Guard (Set of 3)
vi) Anti climbing device

18

Sets

--

Sets

No.

18

No.

18

Sets

36

Sets

28

Sets

20

Sets

18

LINE MATERIAL

Conductor (ACSR Zebra 54/7/3.18mm size)

Km

27.37

Earth wire

KM

0.150

OPGW & Accessories

OPGW (24 fiber) DWSM

Km

0.662

Hardware set for above 24 Fibre OPGW fibre optic cabling including
all cable fittings & accessories except joint box.

set

2
9

Joint Box ( 24 fibre) including jointing box at LILO point

No.

10

End to end testing of OPGW cable (installed) for above under


construction transmission line

Lot

Lot

11

OPGW (48 fiber) DWSM

Km

1.648

12

Hardware set for above 48 Fibre OPGW fibre optic cabling


including all cable fittings & accessories except joint box.

set
3

13

Joint Box ( 48 fibre) as applicable

No.

14

Fibre optic Approach cable, 48 fibre (DWSM)

Km.

15

Hardware set for 48 fibre OFAC (DWSM)

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.

Silicone Rubber Polymer Insulators strings


i) 70 kN

No.

84

ii) 120 kN

No.

240

19

220 kV post insulators

sets

NIL

20

Hardware Fittings
Set

60

Set

24

Set

240

Set

i) Mid Span Compression Joint for conductor

No.

19

ii) Mid Span Compression Joint for earth wire

No.

NIL

iii) Repair sleeves for conductor

No.

iv) Flexible copper Bond

No.

18

v)

No.

552

vi) Vibration damper for earthwire

No.

vii) Earrth-wire tension clamp

No.

28

viii) Earth-with suspension clamp

No.

NIL

ix) 0.4sq T-connector

No.

12

v)
vi)
vii)
viii)

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

Conductor & Earth wire Accessories


21

Vibration damper for conductor

DISMANTLEMENT WORK to be included in Erection Part of BOQ


i) Dismantlement of towers and their transportation & proper stacking
at any dedicated store of HVPNL. The dismantlement of tower shall also
include dismantlement of Stub concrete upto a depth of 1M (one meter)
from Natural Ground level, back filling , compaction and clearing the site
of debris

As per site

220kV D/C DA type Tower

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

(Supply portion only)

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.

(Approx. D/C length =0.040+0.040=0.080km)


S.No

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)

DH type 66kV tower (KRR Design)

No.

ii)

Extra cross arm (if required)

No.

Supply of earthing of towers


i) Pipe type

Sets

ii) Counterpoise type

Sets

i) Danger Plate

No.

ii) Number Plate

No.

iii) Phase Plate(set of 3)

Sets

iv) Circuit Plate (set of 2)

Sets

v) Bird Guard (Set of 3)

Sets

vi) Anti climbing device

Sets

Supply of following Tower accessories

B)

LINE MATERIAL

Conductor (ACSR Zebra: 54/7/3.18mm)

Km

0.485

Earth wire(7/ 3.15 mm)

Km

0.081

Anti-Fog type Disc Insulator or Silicon Rubber Polymer Insulator strings


i) 70 kN
No.
ii) 120 kN

Nil
No.
48

66kV Post Insulators

No.

Nil

Hardware Fittings
v.
vi.
vii.
viii.

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

Set

Set

Set

48

Set

Conductor & Earth wire Accessories


9

10

i)

Mid Span Compression Joint for conductor

No.

Nil

ii)

Mid Span Compression Joint for earth wire

No.

Nil

iii)

Repair sleeves for conductor

No.

Nil

iv) Flexible copper Bond

No.

v)

No.

96

vi) Vibration damper for earthwire

No.

16

vii) Earth-wire tension clamp

No.

viii) Earth-wire suspension clamp

No.

IX) 0.4sq T-connector for making LILO arrangement

No.

12

Vibration damper for conductor

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.

(Supply Portion only)

Sr. No.

Description

Unit

Total Quantity

13.

66kV 1200 mm2 Single Core Aluminium Conductor Milliken type ,


XLPE insulated Cable as per technical specification

Mtrs.

2465x8

14.

End Terminations as per technical specification suitable for above


cable (at s/stn end) as per bidders standard design

No.

16

15.

Galvanized End Termination Structures complete with Nuts , Bolts,


washers etc.

No.

16.

Indicative quantity of Link Box with SVL

No

No

( to be decided as per requirement)


17.

Indicative quantity of Link Box with-out SVL


( to be decided as per requirement)

18.

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC insulated,


Unarmored, 3.3 KV Sheath Bonding cable

Mtrs

300

19.

66kV polymeric LAs along withearthling material.( Tower side only)


with surge counter

No.

20.

Terminal Connectors including Hardware fitting &ACSR Zebra


conductor etc.

No.

16

21.

Supply of HDPE pipes required for various crossings with trench less

Mtr.

227x8

22.

Straight Through Joints (if required as per site condition)

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.

( Break-up to be specified by the bidder)

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.

(Erection Portion only)

Sr.
No.

Description

Unit

Quantity

9. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each Circuit
(6+2), installation of Straight Through joint, and complete Civil works in all
respect including Manholes for jointing Bays on through rate basis as per
technical specification with trench method (directly Buried).

Running
circuit

2238

10. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each Circuit
(6+2), installation of Straight Through joint, and complete Civil works in all
respect including using of HDPE pipes & Manholes for jointing Bays on
through rate basis as per technical specification with Trench-less method.

Running
circuit

11. Erection of End Termination Structures and their Foundations including


earthing.

Nos.

12. Installation of End Terminations including link boxes, earthing, Terminal


connectors etc. This shall also include erection of Hardware fittings &
conductor

Nos.

16

13. Installation of polymericLAs along with their earthling. With surge counter

Nos.

14. Testing & Commissioning

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

( Break-up to be specified by the bidder)

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.

(Supply Portion only)

Sr. No.

Description

Unit

Total Quantity

13.

66kV 1200 mm2 Single Core Aluminum Conductor Milliken type ,


XLPE insulated Cable as per technical specification

Mtrs.

2400x8

14.

End Terminations as per technical specification suitable for above


cable (at s/stn end) as per bidders standard design

No.

16

15.

Galvanized End Termination Structures complete with Nuts , Bolts,


washers etc.

No.

16.

Indicative quantity of Link Box with SVL

No

No

( to be decided as per requirement)


17.

Indicative quantity of Link Box with-out SVL


( to be decided as per requirement)

18.

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC insulated,


Unarmored, 3.3 KV Sheath Bonding cable

Mtrs

300

19.

66kV polymeric LAs along withearthling material.( Tower side only)


with surge counter

No.

20.

Terminal Connectors including Hardware fitting &ACSR Zebra


conductor etc.

No.

16

21.

Supply of HDPE pipes required for various crossings with trench less

Mtr.

92x8

22.

Straight Through Joints

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.

( Break-up to be specified by the bidder)

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.

(Erection Portion only )

Sr.
No.

Description

Unit

Quantity

10. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each Circuit
(6+2), installation of Straight Through joint, and complete Civil works in
all respect including Manholes for jointing Bays on through rate basis as
per technical specification with trench method (directly Buried).

Running
circuit

2308

11. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each Circuit
(6+2), installation of Straight Through joint, and complete Civil works in
all respect including using of HDPE pipes & Manholes for jointing Bays on
through rate basis as per technical specification with Trench-less
method.

Running
circuit

12. Erection of End Termination Structures and their Foundations including


earthing.

Nos.

13. Installation of End Terminations including link boxes, earthing, Terminal


connectors etc. This shall also include erection of Hardware fittings &
conductor

Nos.

16

14. Installation of polymericLAs


counter

Nos.

15. Testing & Commissioning

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

17. Foundation, erection, termination, earthing, stringing and sagging of


66kV DD+0 KRR design towerincluding casting and fencing complete in
all respect to complete the LILO arrangement

No.

alongwith their earthing. With surge

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

( Break-up to be specified by the bidder)

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.

(SUPPLY PART ELECTRICAL)

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.

220kV line on 220kV D/C TATA Design towers

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

i) 220kV D/C DD type (TATA Design) tower

No.

ii) +6 mtr.extn. only

No.

iii) Extra cross arm(set of 3)

No.

220kV line on 220kV KRR Design M/C towers


Fabrication and supply of tower part with stubs, bolts & nuts, step bolts, U-bolts, hangers, Dshackle etc. of following type of 220kV Multi-circuit ( 4 Ckts.) towers of KRR design.

1.1

i) 220kV MD type Normal Multi- Circuit tower

No.

220kV line on 220kV M/C Monopole to be newly designed

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.

ii) 220kV M/C B type Monopole

No.

iii) 220kV M/C D type Monopole


iv) 220kV M/C D type Monopolewith extracrossarm
2.

3.

2
No.

i) Pipe type

Sets

12

ii) Counterpoise type

Sets

Supply of earthing of towers/ monopole

Supply of following Tower accessories

i) Danger Plate

No.

12

ii) Number Plate

No.

12

iii) Phase Plate(set of 3)

Sets

40

iv) Circuit Plate (set of 2)

Sets

48

v) Bird Guard (Set of 3)

Sets

vi) Anti climbing device

Sets

12

LINE MATERIAL

Conductor (ACSR Zebra 54/7/3.18mm size)

Km

17.22

Earth wire size 7/3.15mm

Km

0.10

OPGW & Accessories

OPGW (24 fiber) DWSM

Km

0.516

Hardware set for above 24 Fiber OPGW fiber optic cabling including
all cable fittings & accessories except joint box.

set

Joint Box ( 24 fiber) including jointing box at LILO point

No.

End to end testing of OPGW cable (installed) for above under


construction transmission line

Lot

Lot

OPGW (48 fiber) DWSM

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

Joint Box ( 48 fiber) as applicable

No.

10

Fiber optic Approach cable, 48 fiber (DWSM)

Km.

11

Hardware set for 48 fiber OFAC (DWSM)

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

Silicone Rubber Polymer Insulators strings

No.

i) 70 kN

No.

42

ii) 120 kN

No.

216

15

220 kV post insulators

sets

NIL

16

Hardware Fittings
Set

24

Set

18

Set

216

Set

No.

12

No.

No.

iv) Flexible copper Bond

No.

12

v)

No.

456

v)
vi)
vii)
viii)

17

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

Conductor & Earth wire Accessories


i) Mid Span Compression
ii)

Joint for conductor

Mid Span Compression Joint for earth wire

iii) Repair sleeves for

conductor

Vibration damper for conductor

vi)

Vibration damper for earth wire

No.

38

vii)

Earth-wire tension clamp

No.

22

No.

Km

1.5

viii) Earth-wire suspension clamp


8

DISMANTLEMENT WORK to be included in Erection Part of


BOQ
i) 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 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)

(Supply Portion only)

Sr. No.

Description

Unit

Total Quantity

25.

66kV 1200 mm2 Single Core Aluminium Conductor Milliken


type , XLPE insulated Cable as per technical specification

Mtrs.

1350x8

26.

End Terminations as per technical specification suitable for


above cable (at s/stn end) as per bidders standard design

No.

16

27.

Galvanized End Termination Structures complete with Nuts ,


Bolts, washers etc.

No.

28.

Indicative quantity of Link Box with SVL single phase

No

( to be decided as per requirement)


29.

Indicative quantity of Link Box with-out SVL single phase (to


be decided as per requirement)

No

30.

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC


insulated, Unarmoured, 3.3 KV Sheath Bonding cable

Mtrs

200

31.

66kV polymeric LAs along withearthling material. (Tower


side only)

No.

32.

Terminal Connectors including Hardware fitting &ACSR Zebra


conductor etc.

No.

16

33.

Supply of HDPE pipes required for various crossings with


trench less

Mtr.

Nil

34.

Straight Through Joints

No.

Nil

4 Pole Rail pole structure for the LILO arrangement and


foundation (if required as per site conditions)

No.

Nil

Any other items not specified above but are required to


complete the job in all respect.

No.

Lot

35.

36.

( Break-up to be specified by the bidder)

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)

(Erection Portion only )

Sr.
No.

Description

17. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium


Milliken Conductor 66 KV cable in trefoil formation with one spare
for each Circuit (6+2), installation of Straight Through joint, and
complete Civil works in all respect including Manholes for jointing
Bays on through rate basis as per technical specification with trench
method (directly Buried).
18. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium
Milliken Conductor 66 KV cable in trefoil formation with one spare
for each Circuit (6+2), installation of Straight Through joint, and
complete Civil works in all respect including using of HDPE pipes &
Manholes for jointing Bays on through rate basis as per technical
specification with Trench-less method.

Unit

Quantity

Running
circuit

1350

Length
(6+2) Mtrs.
Running
circuit

nil

Length
(6+2) Mtrs.

19. Erection of End Termination Structures and their Foundations


including earthling.

Nos.

20. Installation of End Terminations including link boxes, earthing,


Terminal connectors etc. This shall also include erection of Hardware
fittings & conductor

Nos.

16

21. Installation of polymericLAs along with their earthling.

Nos.

22. Testing & Commissioning

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

( Break-up to be specified by the bidder)

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.

(Supply portion only)


BOQ of 66kV D/C line from proposed 220kV Sector-58 Faridabad to 66kV S/Stn.Bhagola with 0.4sq ACSR Zebra.
(Tower portion)
(Approx. D/C length =13.55km)

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.

ii) +3m extn.

No.

i) DF type 66kV Tower (KRR Design)

No.

i) DG type 66kV Tower (KRR Design)

No.

ii) +3m extn.

No.

i) DH type 66kV Tower (KRR Design)

No.

ii) +3m extn.

No.

Extra cross arm

No.

220kV D/C DD+12 (TATA Design)

No.

Gantry (G1 & B1 type)

No.

31
6

1.2

1.3

9
5

1.4

14
2

1.5

1.6

1.7
2.

3.

Supply of earthing of towers


i) Pipe type

Sets

63

ii) Counterpoise type

Sets

i) Danger Plate

No.

63

ii) Number Plate

No.

63

iii) Phase Plate(set of 3)

Sets

64

iv) Circuit Plate (set of 2)

Sets

63

v) Bird Guard (Set of 3)

Sets

63

vi) Anti climbing device

Sets

63

Supply of following Tower accessories

Conductor (ACSR Zebra: 54/7/3.18mm)


i) Conductor to be procured by the bidder
ii) Conductor to be transported by the bidder from HVPNL DD store
to the site

5.

Earth wire(7/ 3.15 mm)

6.

Anti-Fog type Disc Insulator or Silicon Rubber Polymer Insulator strings

Km
khera

km
Km

42.61
39.50

13.69

i) 70 kN
No.
ii) 120 kN

192
No.
420

66kV Post Insulators

8.

Hardware Fittings
v.

Single I Suspension String


vi. Single suspension pilot string
vii. Single Tension string
viii. Double tension string

No.

36

Set

186

Set

Set

396

Set

12

Conductor & Earth wire Accessories


i)

Mid Span Compression Joint for conductor

No.

55

ii)

Mid Span Compression Joint for earth wire

No.

iii)

Repair sleeves for conductor

No.

17

iv) Flexible copper Bond

No.

63

v)

Vibration damper for conductor

No.

1138

vi) Vibration damper for earth wire

No.

190

vii) Earth-wire tension clamp

No.

66

viii) Earth-wire suspension clamp

No.

31

IX) 0.4sq T-connector for making LILO arrangement

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.

(Supply portion only)

BOQ of 66kV D/C line from 400kV S/Stn.Nawada to 66kV S/Stn.Badrola with 0.4sq ACSR Zebra (Tower portion).

(Approx. length =4.895 km)


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
66kV DE type tower (KRR Design)

No.

i) 66kV DF type tower (KRR Design)

No.

ii) +6 mtr. Extn. for above

No.

66kV DG type tower (KRR Design)

No.

i) 66kV DH type tower (KRR Design)

No.

1.2

6
2

1.3

1.4

1.5

2.

3.

ii) +6 mtr. Extn. for above

No.

iii) Extra cross arm only (set of 3)

Set

i) 220kV DD type D/C TATA Design tower

No.

ii) +9mtr. Extn. for above

No.

i) Pipe type

Sets

23

ii) Counterpoise type

Sets

i) Danger Plate

No.

23

ii) Number Plate

No.

23

iii) Phase Plate(set of 3)

Sets

36

Supply of earthing of towers

Supply of following Tower accessories

iv) Circuit Plate (set of 2)

Sets

23

v) Bird Guard (Set of 3)

Sets

10

vi) Anti climbing device

Sets

23

Conductor (ACSR Zebra: 54/7/3.18mm)

Km

29.66

5.

Earth wire(7/ 3.15 mm)

Km

4.94

6.

Anti-Fog type Disc Insulator or Silicon Rubber Polymer Insulator strings

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)

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

Conductor & Earth wire Accessories


i)

Mid Span Compression Joint for conductor

No.

20

ii)

Mid Span Compression Joint for earth wire

No.

iii) Repair sleeves for conductor

No.

iv) Flexible copper Bond

No.

23

v)

No.

492

vi) Vibration damper for earthwire

No.

82

vii) Earth-wire tension clamp

No.

38

viii) Earth-wire suspension clamp

No.

Vibration damper for conductor

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).

(Supply Portion only)

Sr. No.

Description

Unit

Total Quantity

37.

66kV 1200 mm2 Single Core Aluminium Conductor Milliken


type , XLPE insulated Cable as per technical specification

Mtrs.

705x8

38.

End Terminations as per technical specification suitable for


above cable (at s/stn end) as per bidders standard design

No.

16

39.

Galvanized End Termination Structures complete with Nuts ,


Bolts, washers etc.

No.

40.

Indicative quantity of Link Box with SVL single phase

No

( to be decided as per requirement)


41.

Indicative quantity of Link Box with-out SVL single phase (to


be decided as per requirement)

No

42.

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC


insulated, Unarmoured, 3.3 KV Sheath Bonding cable

Mtrs

200

43.

66kV polymeric LAs alongwithearthing material.(Tower side


only)

No.

44.

Terminal Connectors including Hardware fitting &ACSR Zebra


conductor etc.

No.

16

45.

Supply of HDPE pipes required for various crossings with


trench less

Mtr.

100x8

46.

Straight Through Joints

No.

Nil

4 Pole Rail pole structure for the LILO arrangement and


foundation (if required as per site conditions).

No.

Nil

Any other items not specified above but are required to


complete the job in all respect.

No.

Lot

47.

48.

( Break-up to be specified by the bidder)

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).

(Erection Portion only )

Sr.
No.

Description

25. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium


Milliken Conductor 66 KV cable in trefoil formation with one spare
for each Circuit (6+2), installation of Straight Through joint, and
complete Civil works in all respect including Manholes for jointing
Bays on through rate basis as per technical specification with trench
method (directly Buried).
26. Detailed Survey, Laying of Double Circuit 1200 mm2Aluminium
Milliken Conductor 66 KV cable in trefoil formation with one spare
for each Circuit (6+2), installation of Straight Through joint, and
complete Civil works in all respect including using of HDPE pipes &
Manholes for jointing Bays on through rate basis as per technical
specification with Trench-less method.

Unit

Quantity

Running
circuit

605

Length
(6+2) Mtrs.
Running
circuit

100

Length
(6+2) Mtrs.

27. Erection of End Termination Structures and their Foundations


including earthing.

Nos.

28. Installation of End Terminations including link boxes, earthing,


Terminal connectors etc. This shall also include erection of Hardware
fittings & conductor

Nos.

16

29. Installation of polymericLAs along with their earthling.

Nos.

30. Testing & Commissioning

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

( Break-up to be specified by the bidder)

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

End Terminations as per technical specification suitable for above


cable on tower / structure as per bidders standard design

No.

Straight Through Joints

No.

C. Description of material already procured and available with HVPNL


1.

2.

Already procured
48
Already procured
8
Already procured

D. Description of material to be arranged/ supplied by successful bidder


4
Indicative quantity of Link Box with SVL single phase

No

No

12

( to be decided as per requirement)


5

Indicative quantity of Link Box with-out SVL


( to be decided as per requirement)

Indicative Quantity of 1 x 240mm2, Copper Conductor, PVC insulated,


Unarmored, 3.3 KV Sheath Bonding cable

Mtrs

1200

66kV polymeric LAs along withearthling material.( Tower side only)


with surge counter, fencing & earthling

No.

36

Compatible Terminal Connectors including Hardware fittings & ACSR


Zebra conductor etc.

LOT

LOT

Indicative quantity of supply of HDPE pipes required for various


crossings with trench less or directly buried

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

( Break-up to be specified by the bidder)

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.

Detailed Survey, Laying of Single core 1200 mm2Aluminium Milliken


Conductor 66 KV cable in flat/ trefoil formation with one spare for each
Circuit (6+2), installation of end terminations, Straight Through joint,
and complete Civil works in all respect on through rate basis as per
technical specification with trench method
(directly Buried) with
risers and loops.

Running
circuit

1100

Detailed Survey, Laying of single core 1200 mm2Aluminium Milliken


Conductor 66 KV cable in flat/ trefoil formation with one spare for each
Circuit (6+2), installation of Straight Through joint, and complete Civil
works in all respect including using of HDPE pipes on through rate basis
as per technical specification with Trench-less method.

Running
circuit

Erection of end Termination Structures and their Foundations including


earthing

Nos.

NIL

Installation of end Terminations including link boxes, earthing, Terminal


connectors etc. This shall also include erection of Hardware fittings &
conductor

Nos.

48

Installation of LAs alongwith their earthing with surge counter and


fencing

Nos.

18

Testing & Commissioning

Lot

Lot

Erection of 4 Pole Rail pole structure and their Foundations including


earthing (if required as per site conditions).

No.

NIL

Any other items not specified above but are required to complete the
job in all respect.

Lot

Lot

( Break-up to be specified by the bidder)

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.

Supply portion only


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.
(Tower portion)

S.No

(Approx. D/C length of tower portion =3.970km)

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.

D/C F type 66kV Tower (KRR Design)

No.

i) +3m extn. Only

No.

D/C H type 66kV Tower (KRR Design).

No.

i) +6m extn. Only

No.

ii) Extra cross arm (set of 3)

No.

1.2

1
1

1.3

2.

12
1
3

Supply of earthing of towers


i) Pipe type

Sets

21

ii) Counterpoise type

Sets

i) Danger Plate

No.

21

ii) Number Plate

No.

21

iii) Phase Plate(set of 3)

Sets

26

iv) Circuit Plate (set of 2)

Sets

21

v) Bird Guard (Set of 3)

Sets

16

vi) Anti climbing device

Sets

21

Conductor (ACSR Zebra size 54/7/3.18mm)

Km

24.05

5.

Earth wire (7/3.15 mm)

Km

4.01

3.

Supply of following Tower accessories

6.

Anti-Fog type Disc Insulator or Silicon Rubber Polymer Insulator strings**


i) 70 kN
ii) 120 kN

66kV Post Insulators

8.

Hardware Fittings
v.
vi.
vii.
viii.

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

No.

57

No.

168

No.

Set

48

Set

Set

168

Set

Conductor & Earth wire Accessories


i)

Mid Span Compression Joint for conductor

No.

16

ii)

Mid Span Compression Joint for earth wire

No.

iii) Repair sleeves for conductor

No.

iv) Flexible copper Bond

No.

21

v)

Vibration damper for conductor

No.

408

vi) Vibration damper for earthwire

No.

68

vii) Earth-wire Tension clamp

No.

26

viii) Earth-wire Suspension clamp

No.

10

DISMANTLEMENT WORK to be included in Erection Part of BOQ


i) Dismantlement of towers and their transportation & proper stacking
at any dedicated store of HVPNL. The dismantlement of tower shall also
include dismantlement of Stub concrete up to a depth of 1M (one meter)
from Natural Ground level, back filling , compaction and clearing the site
of debris

As per site

66kV D/C DA type Tower

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

iii) Dismantlement of existing of earthwire 7/2.50mm complete with


H/W fittings for above portion of line and their transportation proper
stacking at any dedicated store of HVPNL.

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.

HARYANA VIDYUT PRASARAN NIGAM LIMITED.

SECTION-VI

TECHNICAL SPECIFICAION

FOR

SUPPLY, ERECTION, CIVIL WORKS, TESTING AND COMMISSIONING


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 (INCLUDING TOWER
PORTION).

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.

Scope of the work

1-4

Technical specification for manufacture, testing before dispatch and


Supply of 66kV 1200mm2 aluminum XLPE cable.

1-12

Technical specification for installation, laying, Erection, testing and


commissioning of 66kV 1200mm2 aluminum XLPE cable.

1-16

Technical specification of tower portion

1-71

Drawings for 66kv tower accessories

1-14

1-6

Technical specification of ACSR Zebra conductor


section-VI (PART-II )
7

Technical specification of ACSR Zebra conductor section-VI

1-17

(PART-III A)
8

Technical Description of Anti fog Disc insulators

1-15

Technical Description of Silicone Polymer Insulators

1-15

10

Technical Description of Bus Post Insulators

1-5

11

Hardware Fittings for lines with ACSR ZEBRA and Accessories for lines
with ACSR ZEBRA Conductor

1-41

12

Standard field quality plan for transmission lines

1-14

13

Pre-Commissioning Check List & Testing Of EHV Lines For Charging

1-12

14

Technical Data sheets

1-19

15

60kv Polymer Housed surge Arrestors With Surge Counters

1-14
Annexure-1

1.

Scope of the work

1.1

The scope of work inter-alia, includes:

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).

(Supply Portion only)

Sr. No.

Description

Unit

Total Quantity

1.

66kV 1200 mm2 Single Core Aluminium Conductor


Milliken type , XLPE insulated Cable as per technical
specification

Mtrs.

2200x4

2.

End Terminations as per technical specification suitable


for above cable (at s/stn end) as per bidders standard
design

No.

3.

Galvanized End Termination Structures complete with


Nuts , Bolts, washers etc.

No.

4.

Indicative quantity of single phase Link Box with SVL (to


be decided as per requirement). As per latest relevant IS

No

5.

Indicative quantity of single phase Link Box with-out SVL


( to be decided as per requirement). As per latest relevant
IS

No

6.

Indicative Quantity of 1 x 240mm2, Copper Conductor,


PVC insulated, Unarmoured, 3.3 KV Sheath Bonding
cable

Mtrs

400

7.

66kV polymeric LAs alongwith surge counter, mounting


arrangement earthing material. (Tower side only) with
surge counter and fencing of termination tower

No.

8.

Terminal Connectors including Hardware fitting & ACSR


ZEBRA conductor etc.

No.

9.

Supply of HDPE pipes required for various crossings with


trench less or directly buried

Mtr.

2000x4

10.

Straight Through Joints

No.

Any other items not specified above but are required to


complete the job in all respect.

Lot

Lot

11.

( Break-up to be specified by the bidder)

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.

(Erection Portion only)

Sr.
No.

Description

Unit

1.

Detailed Survey, Laying of Single Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each
Circuit (3+1), installation of Straight Through joint, and complete Civil
works in all respect including Manholes for jointing Bays on through rate
basis as per technical specification with trench method
(directly
Buried/ risers / loops).

Running
circuit

Detailed Survey, Laying of single Circuit 1200 mm2Aluminium Milliken


Conductor 66 KV cable in trefoil formation with one spare for each
Circuit (3+1), installation of Straight Through joint, and complete Civil
works in all respect including using of HDPE pipes & Manholes for
jointing Bays on through rate basis as per technical specification with
Trench-less method.

Running
circuit

Length

Quantity

200

(3+1)
Mtrs.

Length

2000

(3+1)
Mtrs.

Foundation and erection of termination structure at S/Stn. end.

Nos.

Installation of End Terminations including link boxes, earthing, Terminal


connectors etc. This shall also include erection of Hardware fittings &
conductor (with identification mark of each)

Nos.

Installation of LAs alongwith their mounting arrangement, earthing with


surge counter and fencing of termination tower and its allied items.

Nos.

Foundation, erection, termination, earthing, stringing and sagging of


conductor and earthwire 66kV DD+0 KRR design tower with extra cross
arm (set of 3) including casting and fencing complete in all respect to
complete the LILO arrangement

No.

Testing & Commissioning of the line.

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

Supply portion only

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).

(Approx. D/C length of tower portion =0.070 km)

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.

I) DD+0 type 66kV Tower (KRR Design)

No.

ii) Extra cross arms (set of 3)

Set

1
1

Supply of earthing of towers


i) Pipe type

Sets

ii) Counterpoise type

Sets

i) Danger Plate

No.

ii) Number Plate

No.

iii) Phase Plate(set of 3)

Sets

iv) Circuit Plate (set of 2)

Sets

v) Bird Guard (Set of 3)

Sets

vi) Anti climbing device

Sets

Conductor (ACSR Zebra: 54/7/3.18mm)

Km

0.21

5.

Earth wire(7/ 3.15 mm)

Km

0.070

6.

Anti-Fog type Disc Insulator or Silicon Rubber Polymer Insulator strings


i) 70 kN

No.

ii) 120 kN

No.

66kV Post Insulators

No.

3.

Supply of following Tower accessories

8.

Hardware Fittings
i.
ii.
iii.
iv.

Single I Suspension String


Single suspension pilot string
Single Tension string
Double tension string

Set

Set

Set

Set

Conductor & Earth wire Accessories


i)

Mid Span Compression Joint for conductor

No.

ii)

Mid Span Compression Joint for earth wire

No.

iii) Repair sleeves for conductor

No.

iv) Flexible copper Bond

No.

v)

No.

12

vi) Vibration damper for earthwire

No.

vii) Earth-wire tension clamp

No.

viii) Earth-wire suspension clamp

No.

IX) 0.4 sq T-connector for making LILO arrangement

No.

Vibration damper for conductor

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

TECHNICAL SPECIFICATION FOR 66 KV XLPE CABLE


1.0

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.

1.4 Description of 66kV underground cable in Gurgaon area:-

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

Conductor for insulated cable.

IEC-60229

Tests on cable over sheaths

IEC-60230

Impulse tests on cables and their accessories.

IEC-60270

Partial discharge measurements

IEC-60287-1-1

Calculation of continuous current carrying capacity.

IEC-60502

Power Cables with extruded insulation and their accessories.

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.

BIS: 7098 (Part-3)

XLPE Cable specification for working voltages from 66 kV upto and


including 220 kV.

IEEE:48

2.2

Tests procedures and requirements for high voltage cable


terminations.

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

CLIMATIC CONDITIONS AND LAYING CONDITIONS

The XLPE Power cable shall be suitable for continuous & satisfactory operation under following
conditions:-

3.1

3.2

Climatic Conditions:-

i)

Peak ambient temperature in shade

50oC

ii)

Maximum average ambient temperature in 24 hours period in


shade

40oC.

iii)

Min. ambient air temperature in shade

(-) 5 oC.

iv)

Maximum temperature attainable by an object exposed to sun

55 oC

v)

Maximum relative humidity

100%

vi)

Minimum relative humidity

10%

vii)

Average number of thunder storm days per annum

40

viii)

Average number of rainy days per annum

100

ix)

Average annual rainfall

10 to 100 cm

x)

Number of months of tropical Monsoons conditions.

4 months

xi)

Maximum wind pressure

100 kg/Sq.mm

xii)

Altitude not exceeding

1000 M

Conditions of Laying:-

i)
ii)
iii)

Laid directly in ground / metaled road.


Installed outdoor in free air in vertical position.
Drawn into underground ducts in RCC trench.

iv
3.3

Laid through special arrangement for crossing of Bridge/Nala

Condition of installation of XLPE cable:


i)

Ground Temp.

35o C

ii)

Maximum conductor temp.

90o C

iii)

Air temperature

50o C

iv)

Depth of trench

1.5 m.

v)

Formation

(1Ckts. in trefoil / flat formation with spare ) X 2


for D/C line as per site suitability
1Ckts. in trefoil / flat formation with spare ) X 1
for S/C line as per site suitability

vi)

Bonding of metallic sheath

Single point/Cross Bonding (as applicable.

vii)

Number of 3 phase circuits

S/C, D/C or M/C as applicable

viii)

Thermal Resistivity of soil

150o C cm/W or as per site conditions

Page-2

4.0

DESIGN & TECHNICAL DETAILS

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 charging current shall be as low as possible.

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

4.11 Repaired cables shall not be acceptable.

5.0

MATERIAL AND CABLE CONSTRUCTION:-

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.

5.3.2 The eccentricity of insulation should not be more than 10%.

5.4

Insulation Screening:

5.4.1

The insulation screening shall consist of two parts, namely, non-metallic and metallic.

5.4.2

Non-Metallic Part (extrusion):-

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%.

Non-metallic part (taped)-Longitudinal water barrier:

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

Metallic Part Radial Water Barrier:-

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

Lead alloy E Sheath:

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).

The bedding over the Metallic sheath shall be of semi-conducting tape(s)

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

Corrugated Aluminium Sheath:-

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

Outer conductive coating / layer:

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

CABLE JOINTING ACCESSORIES

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

TESTS AT MANUFACTURES WORKS:-

10.1

The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable)
/IEC62067.

10.4 ROUTINE TESTS:-

The tests shall be carried out in accordance with IS-7098(Part-3)/ IEC-60840 (For 66 KV cable)
/IEC62067

10.5 ACCEPTANCE TESTS:-

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

SEALING AND DRUMMING:-

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.
Direction of rotation of drum (by means of an arrow).
Net weight
Gross weight.
Year of manufacture.
Confirming to IEC/IS No
Purchase order details.
Name of owner.
Name of consignee.

12.4

13.0

STANDARD LENGTH AND QUANTITY TOLERANCE:-

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

DETAILS OF PAST EXPERIENCE: -

14.1

The details of past orders executed by the bidder shall be indicated in the
relevant schedule.

15.0

GUARANTEED TECHNICAL PARTICULARS:-

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

Single Core, Aluminium


Conductor XLPE cable
Conforming to IEC 60502,60840/
IS 7098(part-3) amended up to
date.
66 KV 10% kV, 50 Hz 3%
72 kV
YES

Applicable standard
1.
2.
3.
4.
5.
i)
ii)

System voltage & frequency


Highest System Voltage
Suitable for earthed system
CONDUCTOR
Material
Nominal cross-sectional area

Milliken segmental type


1200mm2

iii)
iv)
v)

Construction of conductor/flexibility
class
Shape and formation
Approx overall diameter of
conductor

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)

Nominal thickness of insulation

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.

Min. thickness of outer sheath


Conducting layer over outer
sheath
Approx overall diameter of cable
(mm)
Approx. weight per meter of cable
(kg/m)

Extruded, semi conducting


compound layer.
As per IEC/IS
1.0 mm
Cross linked polyethylene(XLPE)
As per 7098 (Part 3)

Extruded semi conducting


Compound layer.
As per IEC/IS: 7098 (Part 3)
0.8 mm

Synthetic Non-woven semi


conducting Water swell-able tape
As per standard.

Corrugated Aluminium / Lead alloy


E sheath IS 692
Conforming to IEC 60502/ IS: 7098
(Part 3)
31.5 kA for one Second

Semi conducting tape(s)

Annealed plain copper wires applied


helically with gap followed by open
helix of copper tape binder
This and lead alloy E sheath shall
meet earth fault current of 31.5kA for
a duration of 1 second.
Extruded Layer of Black PE or PVC
type ST-2 as per IEC-60502 / IS:
7098 (Part 3)
As per standard
Graphite coating
To be indicated by the Bidder
To be indicated by the Bidder
Page-11

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

To be indicated by the Bidder

Symmetrical Short circuit rating for


one second duration for lead
sheath and copper screened
combined/ Aluminium Sheath
Drum Length
Expected cable life.

31.5 kA for 1 Sec.

As per IEC-228 A
To be indicated

90 Deg C
250 Deg C

As per Standard
As per Standard

AS per Clause No.-13.0


35 years.

Page-12

ERECTION PART

Technical specification of laying, erection, testing & commissioning of cables:-

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.

Laying of cables under scope as per specification.

28.

Measurement of Thermal resistivity of soil. The value of thermal resistivity will be intimated to field office.

29.

Transportation of cable drums & other material.

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.

Training of HVPNLs Engineers & jointers.

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

The inspection of cable on receipt, handling of cables, paying out,


flaking, cushioning with sand
or sieved compacted soil, back-filling, providing and fixing joint markers, route indicators, and all
necessary precautions that are required shall be carefully planned and in general conform to IS 12551983 or its equivalent.

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

CABLE ROUTE MARKERS/CABLE JOINT MARKERS

Permanent means of indicating the position of joints and cable route shall be fabricated supplied and
erected.

Markers provided shall be as per the field requirement, if the route


markers should be conspicuously visible above ground surface.

passes through open fields,

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

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

PAYING OUT THE CABLE

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

PREVENTION OF DAMAGE DUE TO SHARP EDGES

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

ROAD, RAIL & CANAL CROSSINGS

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

Trench less Digging:

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)

Excavation and backfilling of trial pits and verification of soil condition.

b)

Excavation of entry and Exit pits.

c)

Erection of drill machined drilling of pilot hole.

d)

Placement and driving hand augur.

e)

Placement and carrying out impact moling.

f)

Reaming and widening of bore holes in steps (if required).

g)

Pulling of product pipe.

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

TOOLS AND PLANTS

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:

The minimum bending radius of XLPE insulated cables are as follows:

Cable

Bending radius

Single Core

20 x D

D means the overall diameter of the completed cable.

18.0

JOINTING AND TERMINATION OF CABLES

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.

The joints of different phases shall be staggered in the jointing bay.

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

PRECAUTIONS BEFORE MAKING A JOINT

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

MEASUREMENT OF INSULATION RESISTANCE

Before jointing, the insulation resistance of both sections of cables

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.

The instructions furnished by the termination manufacturer shall be strictly followed:

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.

The cable shall be properly fastened using non-metallic clamps.

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

CABLE TERMINATING STRUCTURES

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


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.
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 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

TESTS AFTER INSTALLATION

All tests as prescribed in IEC-60840: 1999 shall be performed after installation of cable.

Page-10

SPECIFICATION FOR CIVIL AND STRUCTURAL WORKS FOR LYING CABLES

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

2.0 DISPOSAL OF EXCAVATED EARTH


2.2.2 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 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-11

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

BACK FILLING FOR CABLE TRENCH

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

SPECIFIATION FOR CEMENT CONCRETE


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).

6.0

CURING AND PROTECTION OF CONCRETE


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.

7.0

PRECAST RCC ITEMS

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

All the pre-cast element shall be marked, appropriately as specified.

23.0

FOUNDATION
Foundations for mounting structures in cement concrete shall be casted by bidder as per
approved drawings.

24.0

BOLTS, NUTS AND WASHERS


Standard bolts, nuts an washers shall be used in all works. These should be galvanized in
accordance with IS: 5358.

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

MATERILAS USED IN CABLE LAYING


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.

27.0

RCC PRE CAST CABLE PROTECTION COVERS


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.

13.0

CABLE ROUTE MARKERS/JOINT MARKERS

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

LEAD AND LIFT


The rates quoted for all items of works shall include all lifts and leads wherever applicable unless
otherwise specified.

16.10 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.

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

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.
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

MAINTENANCE OF SITE CONDITIONS

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

HARYANA VIDYUT PRASARAN NIGAM LIMITED

TECHNICAL SPECIFICATION OF TOWER PORTION

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.

SECTION-VI

TECHNICAL SPECIFICATION

CONTENTS

PART-I

TECHNICAL SPECIFICATION FOR TOWERS

PART-II TECHNICAL SPECIFICATION FOR LINE MATERIAL

PART-III TECHNICAL DATA/INFORMATION TO BE SUBMTTED


WITH THE BID

SECTION-VI
(PART-I)

TECHNICAL SPECIFICATION
CONTENTS

1.1

GENERAL INFORMATION AND SCOPE

1.11

DETAIL OF TRANSMISSION LINE ROUTES AND 3


TERRAIN

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

PARTICULAR OF CONDUCTOR AND EARTHWIRE

12

2.2

PARTICULAR OF INSULATOR STRING WITH

13

4
4

9
10
11

STANDARD DISC INSULATIORS


2.3

INSULATOR STRING HARDWARE

13

2.4

ACCESSORIES FOR CONDUCTOR AND

14

EARTHWIRE
3.0

TRANSMISSION TOWERS

14

3.1

GENERAL DESCRIPTION OF THE TOWER

14

3.2

TYPE OF TOWER

14

3.3

SPANS AND CLEARANCES

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

INSPECTION AND TESTS

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

PROPERTIES OF CONCRETE & REINFORCEMENT

34

4.7

UNIT RATES AND MEASUREMENT

36

4.8

CONSTRUCTION OF TOWER FOUNDATIONS

36

4.9

SETTING OF STUBS

37

4.10

STUB SETTING TEMPLATES

37

4.11

MIXING, PLACING AND COMPACTING OF

38

CONCRETE

24
28
28

4.13

BACK-FILLING AND REMOVAL OF STUB


TEMPLATE

38

4.14

PROTECTION OF TOWER FOOTING

39

5.0

TOWER ERECTION, STRINGING AND

41

INSTALLATION OF LINE MATERIAL


5.1

GENERAL

41

5.2

TREATMENT OF MINOR GALVANISING DAMAGE

41

5.3

ASSEMBLY

42

5.4

TIGHTENING ANDPUNCHING OF BOLTS & NUTS

42

5.5

INSULATOR HOISTING

42

5.6

HANDLING OF CONDUCTOR AND EARTHWIRE 42

5.7

STRINGING OF CONDUCTOR & EARTHWIRE

5.8

JOINTING

5.9

SAGGING-IN-OPERATION

5.10

TENSIONING AND SAGGING OF CONDUCTOR 45

44
44
44

AND EARTHWIRE
5.11

CLIPPING IN

5.12

FIXING OF CONDUCTOR ANDEARTHWIRE

45
46

ACCESSORIES
5.13

REPLACEMENT

46

5.14

PERMITTED EXTRA CONSUPTION OF LINE

46

MATERIALS
5.16
6.1

FINAL CHECKING, TESTING AND COMMISSIONING 46


GENERAL TECHCIAL CONDITIONS
47

6.2

ENGINEERING DATA

47

6.3

DRAWINGS

47

6.4

DESIGN IMPROVEMENTS

6.5

DESIGN COORDINATION

6.6

DESIGN REVIEW MEETING

6.7

PACKING

50

7.1

ERECTION CONDITIONS

50

49
50
50

7.2

REGULATION OF LOCAL AUTHORITIES AND

50

STATUTES
7.3

BIDDERSS FIELD OPERATION

51

7.4

PROGRESS REPORT

51

7.5

MAN-POWER DEPLOYMENT REPORT

51

7.6

FIRE PROTECTION

7.7

SECURITY

7.8

MATERIALS HANDLING AND STORAGE

52

7.9

CONSTRUCTION MANAGEMENT

53

7.10

FIELD OFFICE RECORDS

53

7.11

PROTECTION OF PROPERTY AND

51
52

53

BIDDERS LIABILITY
7.13

PROTECTIONS OF MOUNMENTS AND


REFERENCE POINTS

54

7.13

WORK AND SAFETY REGULATIONS

54

7.14

FOREIGN PERSONNEL

56

7.15

CODE REQUIREMENTS

57

SECTION-VI

(PART-I)

TECHNICAL SPECIFICATIONS

2.

General Information and scope

1.1

Scope:

1.1.1

This specification covers 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.

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,

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.

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)

i) Construction of civil works,


i) Complete erection and installation,
iii) Commissioning, Site and acceptance testing
Page-2

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.

All precaution shall be done for safe erection and operation.

Connection between substations and dead-end towers, shall be done by the Bidder if
the substations do exist.

Demolishing and dismantling works, if any.


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.

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

Technical requirement of equipments

S. No.

Description of item

Towers for transmission lines

2.

ACSR Conductor

Minimum criteria to be met

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:

1.1.8.1 The above line will be laid in the state of Haryana.

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

Detail of Transmission Line Routes and Terrain.

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

ACCESS TO THE LINE AND RIGHT TO WAY


Right of way and way leave clearance shall be arranged by the HVPNL in accordance with
work schedule. HVPNL will secure way leave and right of way in the forest area, if any.

1.5

DETAILED SURVEY, OPTIMISATION OF TOWER LOCATION

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.

Chief Engineer/Transmission System, HVPN, Hisar. TEL. No. 01662-220038.


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 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

PROFILE PLOTTING & TOWER SPOTTING


From the field book entries, the route plan with enroute details and level profile shall be
plotted and prepared to scale of 1:2000 horizontal & 1:200 vertical on 1.0, 10 mm squared
paper as per approved procedure. Reference levels at every 20 metres along the profile are
also to be indicated on the profile besides, reduced levels at undulations. Areas along the
profile, which, in the view of the Bidder, are not suitable for tower spotting, shall also be
clearly marked on the profile plots. If the difference in levels be too high, the chart may be
broken up according to requirement. A 10mm overlap shall be shown on each following
sheet. The chart shall progress from left to right. Sheet shall be 594 mm wide in accordance
with the IS. For as built profile these shall be in A1 size.

1.5.9

TOWER LOCATION

1.5.6.1 SAG TEMPLATE

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: -

For D/C line forDB type or DC type or DD type tower 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)

The crossing shall normally be at right angle to the Railway track.


PAGE-6

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)

No crossing shall be located over a booster transformer, traction switching


station, traction sub-station or a track cabin location in an electrified area.

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)

POWER LINE CROSSINGS


Where the line is to cross over another line of the same voltage or lower voltage, towers
with suitable extensions shall be used. Where the line is to cross under the power lines,
gantries shall be used. Provisions to prevent the possibility of its coming into the contact
with other overhead lines shall be made in accordance with Indian Electricity
Rules,1956. In order to reduce the height of the crossing towers, it may be advantageous
to remove the ground wire of the line to be crossed (if this is possible and permitted by
the owner of the line to be crossed). All the works related to the above proposal shall
be deemed to be included in the scope of the Bidder except if modifications are required
to line below, in which case, the conditions to be agreed upon. Suitable Extension for
towers over 11kV line crossing shall be used, where requisite electrical as per I.E. rules
is not available. The minimum clearance between power line to power line shall be as
follows:

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.

g) TELECOMMUNICATION LINE CROSSING


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.

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

CLEARANCE FROM GROUND, BUILDING, TREES ETC.


Clearance from ground, buildings, trees and telephone lines shall be provided in conformity
with the Indian Electricity Rules, 1956 as amended from time to time.

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)

Approximate height of the tree with an accuracy of 2 metres.

g) Name of the type of the species/tree.


h) The bushy and under growth encountered within the 18 m belt should also be evaluated
with its type, height, girth and area in square metres, clearly indicating the growth in the
tree/bush statement.
Payment of compensation toward the clearances etc. will be the responsibility of the
HVPNL.

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

CHECK SURVEY OF TOWER LOCATION

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

GENERAL CLIMATIC CONDITIONS


The area is in the extreme climate belt. Monsoons are generally active from the months of
July to September. The working season shall be approximately nine months per year.

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

STATUTORY REGAULATION AND STANDARDS

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

Other internationally acceptable standards, which ensure equivalent or better performance


than those specified shall also, be accepted.
PAGE-9

1.8.5
1.8.3.1

QUALITY ASSURANCE, INSPECTION AND TESTING


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-bidders 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 be outlined by the Bidder and shall be finally accepted
by the HVPNL after discussions before the award of the contract. A quality assurance
programme of the Bidder shall generally cover but not limited to the following:

o)

His organization structure for the management and implementation of the


proposed quality assurance programme.

p)

Documentation control system.

q)

Qualification data for bidders key personnel.

r)

The procedure for purchases of materials parts/components and selection of


sub-bidders services including vendor analysis, source inspection, incoming
raw material inspection, verification of material purchase etc.

s)

System for shop manufacturing including process controls and fabrication and
assembly controls.

t)

Control of non-conforming items and system for corrective action.

u)

Control of calibration and testing of measuring and testing equipments.

v)

Inspection and test procedure for manufacture.

w)

System for indication and appraisal of inspection status.

x)

System for quality audits.

y)

System for authorising release of manufactured product to the HVPNL.

z)

System for maintenance of records.

aa)

System for handing storage and delivery.

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

QUALITY ASSURANCE DOCUMENTS


The Bidder shall be required to submit all the quality assurance documents as stipulated
in the quality plan at the time of HVPNLs inspection of material.

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.

INSPECTION,TESTING AND INSPECTION CERTIFICATE


The provision of the clause regarding inspection, testing and inspection certificate as
described in GCC & SCC 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.

1.10

TECHNICAL PARAMETRES OF 66kV LINE

Electrical system data


a)

Nominal voltage

66 kV

b)

Maximum system voltage

72 kV

c)

BlS (Impulse)

325 KV (peak)

d)

Power frequency withstand voltage (wet)

140 KV (rms)

e)

Max. Temp. for which

750C

ACSR conductor is designed.

2.0

DETAILS OF LINE MATERIAL FOR 66 kV LINE

2.1

Particulars of Conductor and Earthwire:-

Sr. No

Particulars

Conductor

Earthwire

Type

ACSR Zebra

Glavanised steel
stranded

Stranding
diameter
c)
d)

and

wire

Aluminium
Steel

Total sectional area

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

Mass of zinc coating

Gm/sq. m

260

11

Configuration

D/C line

Near vertical on each side of

of

conductor

12

tower

Location of earthwire

One

continuous

earthwire to run

horizontally
above

the

conductors

2.3

PARTICULARS OF INSULATOR STRINGS WITH A/F DISC INSULATORS FOR ACSR


ZEBRA LINES(70KN FOR SUSPENSION STRINGS & 120KN FOR TENSION STRING) :

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

INSULATOR STRING HARDWARE


a)
b)
c)
d)
e)
f)
g)
h)

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.

ACCESSORIES FOR CONDUCTOR AND EARTHWIRE


a)
b)
c)
d)
e)
f)
g)

Mid-span compression joints


Repair sleeves for conductor
Flexible copper bonds
Vibration dampers for conductor and earthwire
Suspension clamps for earthwire
Tension clamps for earthwire
Preformed Armour rods.

Page-13

3.

TRANSMISSION TOWERS

3.4

General Description of the Tower

3.4.1

The towers are of following types:-

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.

To be used as tangent tower.

Spl. Extn. of DE

0 deg. to be restricted

To be used at wind span of 175m

0 deg. to 15 deg.

b)

(+9m to +18m)
DB/DF

Tension towers with tension


insulators string.
b) Tension towers for uplift forces
resulting from an uplift span
upto 150 m.
c)

Also to be designed for anticascading condition.

d) To be used as Section Tower

0 deg.

Spl. Extn. of DF

5 deg. to be restricted

(+9m to +12m)
DC/DG

15 deg. to 30 deg.

a) Tension towers with tension


insulators string.
b) Tension towers for uplift forces
resulting from an uplift span
upto 150 m.
c)

Spl. Extn. of DG

20 deg. to be restricted

Also to be designed for anticascading condition.

Page-14

(+9m to +12m)

DD/DH

30 deg.-60 deg.

a) Tension towers with tension


insulators string.
b) Tension towers for uplift forces
resulting from an uplift span
upto 150 m.
c) Dead end with 0 deg. to 15 deg.
deviation both on line and
substation side (slack span).

Spl. Extn. of DH

40 deg. to be restricted

(+9m to +18m

DD/DH

0 deg.

d)

Complete Dead end.

e) For river crossing anchoring with


longer wind span with 0 deg.
deviation on crossing span side
and 0 to 30 deg. deviation on
other side.

3.5.2

EXTENSIONS

3.2.2.1

The towers are designed for adding 3 M, 6 M, 9 M, 12 M, 15 M, 18 M, body extensions for


D/C KRR design for maintaining adequate ground clearance without reducing the specified
factor of safety in any manner.

3.2.2.2

All above extension provision to normal towers shall be treated as part of normal tower only.

3.5.3

SPANS AND CLEARNACES

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)

An allowance of 150 mm shall be provided to account for errors in stringing.

d)

Conductor creep shall be compensated by over tensioning the conductor at temperature


of 26oC lower than the stringing temperature for ACSR Zebra.

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

Live Metal Clearance :


The minimum live metal clearance to be provided between the live parts and steel work of super
structure shall be as per IS:5613 (part-II/sec-1) 1985 as given in table below:

Sr. No

Type of insulator string

Single
suspension
insulator string

Swing in deg.

Min. live metal clearance in mm

Nil

915

15

915

30

760

45

610

60

610

Tension insulator string


(single/double)

Nil

915

Jumper

Nil

915

Double suspension string

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

MID SPAN CLEARNACE

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

Wind Load on Tower Body

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)

Terrain category/ground roughness =

d)

Design wind pressure (pd)

701N/m2

e)

The angle of incidence of wind (Theta)

0 deg.

3.4.

MAXIMUM TENSION

3.4.1 Max tension shall be based on either

c)

At 0o C with 36% full wind pressure, or

d)

At 32o C with full wind pressure whichever is more stringent.

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

LIMITING TENSION OF CONDUCTOR & EARTHWIRE


The ultimate tension of conductor and ground wire shall not exceed 70 percent of their ultimate
tensile strengths.

3.4.4

CONDUCTOR AND EARTHWIRE CONFIGURATION

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

Tower steel sections

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

Fasteners: Bolts, Nuts an Washers

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

STEP BOLTS & LADDERS

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

INSULATOR STRING AND EARTHWIRE CLAMPS ATTACHMENTS

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.

3.7.4 ANTICLIMBING DEVICE

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 PLATE

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

The fabrication of towers shall be in conformity with the following:

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

DRILLING AND PUNCHING

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

ERECTION MARK SHALL BE


A-BB-CC-DDD

A =

HVPNLs code assigned to the Bidder-Alphabet

B =

Bidders Mark-Numerical

CC =

Tower type-Alphabet

DD =

Number mark to be assigned by Bidder-Numerical.

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.

3.14 INSPECTION AND TESTS

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.

3.14 (a) 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.

3.14 (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)

A Manufacturer's Certificate of Inspection for zinc (hot-galvanized) coatings on structural


steel with the following information:

1-

Purchase order number

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-

Number of pieces tested for adherence of coating.

5-

Number of rejections because of defective coating and other reasons.

Certified test reports shall be sent to HVPNL.

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 AND SHIPPING

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,

Specification for Zinc

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

Ordinary rapid hardening &

ISO/R/597-1967

low heat Portland cement.

IS:383-1970

Coarse and fine aggregates

CSA A23, 1/A 23.2

from natural sources for concrete.

IS:278

Specification for barbed wire.

ASTM A 121

IS:432-1966
(part-I&II)

Mild steel and medium tensile bars

BS-785-1938 CSA-G-30.

IS:456-2000

Code of practice for plain

and hard drawn steel wire for concrete


reinforcement.
ISO/3893-1977

and reinforced concerete.

IS:800-1962

Code of practice for use

CSA S16.1

of structural steel in
general building construction.

a) IS:802

Code of practice for use

(part-1)

of structural steel in

IEC 826 ASCE 52 BS 8100

overhead transmission
line. Materials loads
and permissible stresses.

b)IS:802

Code of practice for use

(part-2) 1978

of structural steel in
overhead transmission
line. Fabrication,
galvanizing, inspection and packing.

c)IS:802
(part-3) 1978

10

IS:808

Code of practice for use of structural


steel in overhead transmission line.
Tower testing.

Dimensions for Hot Rolled steel beam,


column, channel and angle sections

ASCE 52

11

IS:875

Code of practice for design loads


(other than earth-quakes) for buildings
& structures.

12

IS:1139-1966

Hot rolled mild steel, medium tensile CAN/CSA G30.18


steel and high yield strength deformed
ASTM A615
bars for concrete reinforcements.

13

IS:1367-1967

Technical supply conditions


threaded fasteners (first revision)

for
Page-28

14

IS:1489-1976

Portland pozzolena cement

ISO/R/863-1968

15

IS:1786-1989

Cold twisted steel bars for concrete


reinforcement.

16

IS:1893-1965

Critecia of earthquake resistant design IEEE 693


of structures

17

IS:2016-1967

Plain washers

18

IS:2131-1967

Method of standard penetration test for


soils.

19

IS:2551-1982

Danger notice plates

20

IS:2629-1966

Recommended practice for hot dip


galvanizing of iron & steel.

21

IS:2633-1972

Method of testing uniformity of coating


of zinc coated articles.

22

IS:3043-1972

Code of practice of earthing (with


amendment No. 1and 2)

ISO/R/887-1968.
B18.22.1

ANSI

23

IS:3063-1972

Single coil rectangular section spring


washers for bolts, nuts, screws.

24

IS:4091-1967

Code of practice for design and


construction
of
foundation
for
transmission line towers and poles.

25

IS:5358-1969

Hot dip galvanizing


fasteners.

26

IS:5613 (part- Code of practice for design, installation


2/Sec.-1) 1976
and maintenance of overhead power
lines (Sec-1: (Designs)

27

IS:5613 (part- Code of practice for design, installation


2/Sec.-2) 1976
and maintenance of overhead power
lines
(Sec.-2
installation
and
maintenance)

28

IS:6610-1972

Specification for heavy washers for


steel structures.

29

IS:6639-1972

Hexagonal bolts for steel structure.

coatings

on

Page-29

30

IS:6745-1972

Methods for determination of weight of


zinc coating of zinc coated iron and
steel articles.

Indian electricity rules 1956

31

32

Publication No. Regulation for electrical crossing of


19 (N) 700-1963 Railway Tracks.

33

IS:8500-1977

Specification for weldable structural BS: 4360


steel (medium and high strength
qualities)

34

IS:2062-2006

Steel for general structural purposes.

PAGE-30

The standards mentioned above are available from: -

Reference/Abbreviation

Name and address from which the standards are available.

IS

Bureau of Indian standards, Manak Bhawan, 9 Bahadur Shah


Zafar Marg, New Delhi, INDIA.

ISO

International Organisation for standardization, Danish Board of


Standardisation Danisk Standardisening Sraat, Aureheeugej-12,
DK-2900 Helleprup DENMARK.

CSA

Canadian Standard Association, 178,


Rexdale, Ontario, CANADA, M9W IR

BS

British Standsrds, British Standard Institution, 101, Pentonvile


Road, N-19-ND, UK.

DIN

Deutsches Institue Firr Normung Burggafenstrasse 4-10 Post


Fach 1107 D-1000, Berlin-30

Rezdale Boulevard,

Indian Electricity Rules 1956 Kitab Mahal ,Baba Kharak Singh Marg, New Delhi-110001 INDIA.
Regulation
for
Electricity
Crossing of Railway Tracks.

ASCE

American Society of Civil Engineers, 345, East 47th Street, New


York, NY-10017-2398 USA

IEEE

Institute of Electrical and Electronic Engineers ,445, Hoes Lane


PO. Box, 1331 Piscatawa NJ-08855-1355 USA

IEC

International Electrotechnical Commission Bureau central de La


commission Electrotechnique internatinale 1. Rue de varombe
Geneva Switzerland

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.

4.3.1 TYPE OF SOIL


Soil en-route the following proposed transmission lines under the scheme is generally
normal/Sandy/rocky.

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.

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.

4.6.1

Design of foundation for Wet (without de-watering) and Wet (with de-watering) shall be same.

4.7

PROPERTIES OF CONCRETE & REINFORCEMENT

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.

4.7.15 No admixtures shall be used.

4.8

UNIT RATES AND MEASUREMENT

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

CONSTRUCTION OF TOWER FOUNDATIONS AS PER DESIGN SUPPLIED BY HVPNL

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

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

MIXING, PLACING AND COMPACTING OF CONCRETE

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 BACK-FILLING AND REMOVAL OF STUB TEMPLATE


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-incharge.

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

PROTECTION OF TOWER FOOTING

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

FIELD QUALITY CONTROL PLAN

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

TOWER ERECTION, STRINGING AND INSTALLATION OF LINE MATERIAL.

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

TREATMENT OF MINOR GALVANISNING DAMAGE


In case any minor damage to galvanizing is noticed, the same shall be treated with zinc rich
paint (commercial grade) (having at least 90% zinc content) before erection.

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)

The bolt position in assembled towers shall be as per IS:5613 (Part-II/section-2)-1976.

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.

Page-39

5.19

TIGHTENING AND PUNCHING OF BOLTS AND NUTS.

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

HANDLING OF CONDUCTOR AND EARTHWIRE

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

Page-40
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

STRINGING OF CONDUCTOR AND EARTHWIRE

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

TENSIONING AND SAGGING OF CONDUCTORS AND EARTHWIRE


The tensioning and sagging shall be done in accordance with the approved stringing charts
before the conductors and earthwire are finally attached to the towers through the earthwire
clamps for the earthwire and insulator strings for the conductor. The initial stringing chart shall
be used for the conductor and final stringing chart for earthwire should be employed for this
purpose. Dynamometers shall be employed for measuring tension in the conductor and
earthwire. The dynamometers employed shall be periodically checked and calibrated with the
standard dynamometer.

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

FIXING OF CONDUCTOR AND EARTHWIRE ACCESSORIES


Vibration dampers for conductor and earthwire and other conductor and earthwire accessories
shall be installed by the Bidder as per the design requirement and respective manufacturers
instructions within 24 hours of the conductor/earthwire clamping. While installing the conductor
and earthwire accessories, proper care shall be taken to ensure that the surface are clean and
smooth and no damage shall occur to any part of the accessories.

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

PREMITTED EXTRA CONSUMPTION OF LINE MATERIALS

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

% of permitted extra consumption

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

a)

Conductor & Earthwire

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

= Line Length as per detailed Survey


x No. of phases(3) x No. of Circuits

= Line Length as per detailed Survey

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

FINAL CHECKING, TESTING AND COMMISSIONING

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)

All bolts are properly tightened and punched/tack welded.

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)

All conductor and earthwire accessories are properly installed.

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)

Wherever required it should be ensured that revetment is provided.

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)

All towers are to be properly grounded.

x)

The line is tested satisfactorily for commissioning purpose.

8.

GENERAL TECHNICAL CONDITIONS

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.

8.2 ENGINEERING DATA


8.2.1

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

In addition to those stipulated in clause regarding drawings in conditions of contract, the


following also shall apply in respect of Bidders 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)

Work schedule (master network) plan.

m)

Sag-tension calculation and sag-template curve drawings.


Page-46

n)

Tower spotting data.

o)

Detailed survey report and profile drawing showing ground clearance and tower
locations.

p)

Tower schedule and foundation classification for individual tower locations.

q)

Tower design calculation along with single line diagram and electrical clearance
diagram.

r)

Tower structural drawings and bill of materials.

s)

Tower test data/ rigging chart.

t)

Soil investigation report.

u)

Foundation design along with foundation working drawings/excavation plan.

v)

Tower footing earthing drawing.

w)

Stub and stub-setting template drawings.

x)

Stringing procedure and stringing chart.

y)

Tower accessories drawings like design plate, name plate etc.

z)

Quality plan for fabrication and site activities including quality system.

aa)

Sub-vendors approval etc.

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

DESIGN REVIEW MEETING:

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

REGULATION OF LOCAL AUTHORITIES AND STATUTES:

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

BIDDERS FIELD OPERATION

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

MAN POWER DEPLOYMENT REPORT

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

FACILITIES TO BE PROVIDED BY THE BIDDER

7.5.9

TOOLS, TACKLE AND SCAFFOLDINGS


The Bidder shall provide all the construction equipment, tools, tackle and scaffoldings
required for construction, erection, testing and commissioning of the transmission line
covered under the contract. He shall submit a list of all such materials to the HVPNL before
the commencement of work at site. These tools and tackle shall not be removed from the
site without the written permission of the HVPNL .

7.5.10 FIRST AID AND GENERAL HYGIENE


The bidder shall provide all necessary first aid facilities for all his employees, representatives
and workmen working at the site. Enough number of Bidders personnel shall be trained in
administering first aid.

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

METERIALS HANDLING AND STORAGE

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

FIELD OFFICE RECORDS

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

PROTECTION OF PROPERTY AND BIDDERS LIABLILITY

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

PROTECTON OF MONUMENTS AND REFERENCE POINTS

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

WORK AND SAFETY REGULATIONS

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.

7.16 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-55

CIVIL FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


(Before start of work)

NAME OF LINE :

PART-A : FOUNDATION ACTIVITY (DETAIL OF CONCRETE MIX)

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)

Aggregate confirming to IS: 383

3)

Fine
Aggregates

i)

Source of
aggregates

ii)

Specific
Gravity

iii)

Aggregate confirming to Zone as per


IS: 383

4)

Mix Proportion FOR 1 BAG OF


CEMENT

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.

Material to be tested before the source is approved and Engineer-in-Charge

can test the


material
periodically.
2.

Mix design is to be re-done on change of


source of aggregates.

Page-56
3.

The source of aggregates to be got approved from


Engineer-in-Charge.

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

Performed and checked by:

Sub-Contractor:

Name
:

Name:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-57

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST

NAME OF LINE :
Location Number

Date :

PART-A : FOUNDATION ACTIVITY


A1 :

Checking for PIT Marking

a)

Foundation Drawing no. followed:

b)

Span on both sides:

Preceeding Span
As per profile
c)

Succeeding Span
Actual

As per profile

Actual

Tangent Tower:

Alignment of the location peg with respect


to other adjacent location or angle, if any

d)

Angle Tower: Cut point

Bi-section in case of angle Tower Location and checking of angles:


Angle of deviation
As per profile

Bi-section
Actual

e)

Reference levels in case of uneven ground:

f)

Matching of ground
profile:

Calculated

OK detail
CERTIFICATE: Cleared for excavation
Performed and checked by:
Sub-Contractor:

Name :

Name:

Actual

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:
Signature with Seal:

Date:

Page-58

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST

NAME OF LINE :
Location No.:

Date :

PART-A : FOUNDATION ACTIVITY


A2 :

Checking of PIT Excavation & Soil


Classification

a)

Foundation Drawing no. followed:

b)

Details of Soil: Type of Soil and depth

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)

Sub-Soil Water below NGL as on date:

Leg-1 (M)

Leg-2
(M)

Leg-3 (M)

d)

Location position (Paddy fields, Sugarcane, Forest etc.):

e)

Foundation Classification:

Leg-4 (M)

Page-59
As proposed by Contractor

As approved by HVPN

f)

Detail of under cutting, if any:

CERTIFICATE:

Performed and checked by:


Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature
with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-60

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :
Location No.:

Date :

PART-A : FOUNDATION ACTIVITY

A3 :

Checking of Stub Setting

a)

Foundation Drawing no. followed:

b)

Alignment of template/prop. :

i)

In line in case of tangent Tower

Yes/No

ii)

On bisection in case of angle Tower

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)

Levels of template checked by


water level or dumpy
level

Yes/No

Cleat at the bottom of the sub is fitted

Yes/No

CERTIFICATE:
Performed and checked by:
Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-61

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST

NAME OF LINE :
Location No.:

Date :

PART-A : FOUNDATION
ACTIVITY

A4 :

Checking of Foundation material & availability of T&P :

a)

Fabrication & placement of reinforcement steel as per Drawing


no.:

b)

Diameter and lengthwise details of reinforcement steel:

Sr.No.

Length
Drgs.

c)

Actual

Diameter
Drgs.

Actual

Nos.
Drgs.

Yes/No

REMARKS
Actual

(testing details)

Quality of sand as per specification and conforming


to the grade used in Mix Design and sufficient
quantity
is available at location:

d)

Quality & quantity of coarse Aggregate, metal conforming

Yes/No.

to the grade used in Mix Design and sufficient quantity is


available at
location:

e)

Yes/No.

Source of
collection :
Sand
Name

Metal/Aggregate
Approved/Not Approved

Name

f)

Quality of Water:

i)

Confirming to specification :

ii)

pH value of water used :

g)

Required T&P such as mixer, vibrator, slump cone, form boxes, shuttering,

Approved/Not
Approved

Yes/No.

dewatering arrangement & cubes for sampling etc., are


available in good condition and required quantity:
h)

Yes/No.

Defective T&P required to be repaired/replaced by the


Contractor:

Page-62

CERTIFICATE:

Performed and checked by:

Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-63

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :
Location No.:

Date :

PART-A : FOUNDATION ACTIVITY

A5 :

Lean Concrete

a)

Foundation Drawing no. followed :

b)

Concrete mixing by mixer :

Yes/No

c)

Dewatering done:

Yes/No

d)

Lean concreting done upto specified level of all pits:

Yes/No

e)

Proper levelling of concrete in all


pits:

f)

Number of cement bags used for lean concrete:

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:

Signature with
Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:

Signature with Seal:

Date:

Page-64

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST

NAME OF LINE :

Location No.:

Date :

PART-A : FOUNDATION ACTIVITY

A6 :

Placement of reinforcement steel & form boxes:

a)

Foundation Drawing no. followed :

b)

Reinforcement steel placed as per drawing:

c)

Concrete cover to reinforcement maintained with

Yes/No

adequate no. of cover blocks as per specification:

d)

e)

Yes/No

Form boxes are placed as per drawing & tightened


properly with shuttering oil painted inside:

Yes/No

Earthing strip is fixed as per


drawing:

Yes/No

CERTIFICATE:

Performed and checked by:

Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature
with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.

Name:

Signature with Seal:

Date:

Page-65

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :

Location No.:

Date :

PART-A : FOUNDATION ACTIVITY

A7 :

Checking for foundation casting

a)

Foundation Drawing no. followed


:

b)

Concrete mixing by mixer as per Design Mix ratios:

Yes/No

c)

Mixing by mixer:

Yes/No

d)

Water cement ratio:

e)

Use of vibrator for compaction:

Yes/No

f)

Checking of stub-template level at interval:

Yes/No

g)

Checking diagonal stub-template level at interval:

Yes/No

h)

Casting of leg is done in


continuity:

Yes/No

i)

Slump

mm

j)

Number of cement bags


consumed:
As per Design / Drg

Actual

Reasons for variation

k)

Coping is done:

Yes/No

l)

Top of concrete from average ground level:

m)

No. of concrete samples taken:

CERTIFICATE : Foundation is casted as per drawing

Performed and checked by:

Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature with
Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:

Signature with Seal:

Date:

Page-66

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF
LINE :
Location
No.:

Date :

PART-A : FOUNDATION ACTIVITY

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)

Form boxes are removed after 24 hrs. of casting:

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

Any other defect


(s)

d)

Back filling done as per specification:

Yes/No

e)

Template/prop is removed only after complete back


filling:

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:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:
Signature with Seal:

Date:

Page-67

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF
LINE :
SECTION

LOC.No.

PART-A : FOUNDATION ACTIVITY

A9 :

Dimension of location after casting

DATED:

a)

After casting level checked and found OK

b)

Important measurement for the location is measured

YES/NO

after casting and indicated below and dimensions are


within the tolerance limits.

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

: _________________

Signature with Seal

Date

: _________________

Date

:
______________
:
______________

Haryana Vidyut Prasaran Nigam Ltd.


Name:

Signature with
Seal:
Date:

Page-68

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :
SECTION

LOC.No.

DATED:

PART-A : FOUNDATION ACTIVITY

A10 :

Procedure for finalisation of Most Techno-Economical Location

1.

No level Ground is available in the vicinity along the alignment

2.

Tower can not be located on the level Ground even by providing extension

3.

Benching/Revetment or both are unavoidable


Comparative Study of alternatives is indicated below :

CASE - I

: When Complete Benching is Done

Sl.No.

PARTICULARS

1.

Excavation (Type of soil)

QTY.

RATE

COST

REMARKS

a)
b)
c)
2.

Revetment

3.

Breast Wall

4.

Any other work

TOTAL

CASE - II

: When Benching is done partly

Sl.No.
1.

PARTICULARS

QTY.

RATE

COST

REMARKS

Excavation (Type of soil)


a)
b)
c)

2.

Revetment

3.

Breast Wall

4.

Any other work

TOTAL

Page-69

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST

NAME OF LINE :

SECTION

LOC.No.

DATED:

PART-A : FOUNDATION ACTIVITY

CASE - III

: When No Benching is done

Sl.No.

1.

PARTICULARS

QTY.

RATE

Excavation (Type of soil)


a)
b)
c)

2.

Revetment

3.

Breast Wall

4.

Tower Structure (with leg


extension, if any)

5.

Any other work

TOTAL

Note :

Relevant Drawings with calculations are to be enclosed.

Performed and checked by:

COST

REMARKS

Sub-contractor

: _________________

Name

: _________________

Name

:
______________

Signature with Seal

: _________________

Signature with
Seal

:
______________

Date

: _________________

Date

:
______________

Haryana Vidyut Prasaran Nigam Ltd.


Name:
Signature with Seal:
Date:

Page-70

FIELD QUALITY CONTROL PLAN/LINE CONSTRUCTION CHECK LIST


NAME OF LINE :

Location No.:

Date :

PART-A : FOUNDATION ACTIVITY


A-11:

Testing of concrete cubes

a)

Grade of Concrete:

b)

No. of samples taken:

c)

Date of casting:

d)

Date of testing:

e)

Size of Cube

Sample No.

Cube No.

Wt. Of cube (Kg.)

Load in Kg. at crushing

Cube Strength
(Kg/Cm2)
7 days

1.

28 days

1
2
3

2.

1
2
3

3.

1
2
3

4.

1
2
3

CERTIFICATE: Cube strength meets the requirement of specification & IS code.


Performed and checked by:
Sub-Contractor:

Name :

Name:

Signature with Seal:

Signature with Seal:

Date:

Date:

Haryana Vidyut Prasaran Nigam Ltd.


Name:
Signature with Seal:
Date:

Page-71

ANNEXURE-IA

DRAWINGS FOR 66kV TOWER ACCESSORIES

Sr. No.

Description

Drawing
No.

1.

Tower Number plate

2.

Circuit Plate

3.

Tower phase plate

Tower danger plate

Pipe type earthing arrangement

Counterpoise type earthing arrangement 6

Detail for flats for earthing

Detail of anticlimbing device

Step bolt drawing

10

Single suspension string drawing

10

11

Single tension string drawing

11

12.

Double tension string drawing

12

13

Compression type tension fitting for

13

earthwire
14

Suspension type assembly for earthwire

14

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