TECHNICAL

SPECIFICATIONS

TECHNICAL SPECIFICATIONS
1.0

SCOPE & BRIEF DESCRIPTION OF THE SYSTEM:

1.1

The scope of this work shall, cover pre survey, design, vetting, manufacturing, supply,
transportation, installation, testing and commissioning of the complete 04 nos. High mast
Towers with all associated parts like Feeder pillar, winch, motor, Light fittings, luminaries
terminal box, laying of cable, lighting transformer, Lighting Distribution boards etc. at various
locations inside GAIL Hazira Plant including 2x400 W HPSV SONT+ luminaries , foundation
work, earthing & lightning protection system, aviation obstruction lights and other associated
works mentioned elsewhere in the bidding documents.

1.2

Design of High Mast foundation depending upon the soil information for foundation design
mentioned at 11.0 below. Design of foundation shall be got vetted by a reputed IIT/National
Institute of Technology and cost of which is deemed to be included in the quoted price of the
design, supply and erection of high mast lighting as detailed elsewhere in the bidding document

1.3

Contractor shall also furnish the following at his own cost:

.
(i)
Wind tunnel test for Structural Stability of the high mast or alternatively certificate for
the structural stability due to wind loading shall be furnished. CERTIFICATE should be
certified from IIT/National Institute of Technology.
(ii)

Test report of high mast design from a reputed laboratory or R&D centre for the
serviceability limit state and ultimate limit state conditions, duly vetted by IIT/National
Institute of Technology.

(iii)

Foundation design and calculations shall be vetted by IIT/National Institute of

Technology. A specific certificate should be obtained from that the design conforms to
the various standards indicated in the bid.
The OEM test certificates of all the cables, High Mass, double drum winches, wire
ropes, luminaries, lighting transformer, control panels for power tool shall be furnished
along with material.

(iv)

1.4

Inspection:
All the supply items shall be inspected by GAIL. Materials shall be accepted only after due
inspection by GAIL. Works of various categories like Civil works, Electrical works, mechanical
fabrication & installation works, testing and pre-commissioning and commissioning shall be
certified for satisfactory quality by Engineers(s) of GAIL before accepting the work for payment.

1.5

The high mast shall be designed as per the latest edition of the following standards among
other standards:
a)

Code No
TR. No. 7

Title
High Mast Lighting specification for design, manufacture,
assembly, erection, testing and maintenance 2000,
published by the Institution of Lighting Engineers, United
Kingdom.

b)

I.S:875 (Part III) 1987

c)
d)

BS EN 10025/10027
BS EN ISO 1461

e)
f)
g)

BS. 5135 / AWS

IS: 3043, 1987
IS: 2309, 1989

Structural stability to sustain maximum reaction arising

from wind.
Yield strength of steel structure.
Environmental protection of the fabrication by hot dip
galvanization
Welding
Earthing
Lightning Protection

1.6

The High mast system supplied by the contractor shall include items like manual handle for
power tool, resting arms for holding lantern carriage in lowered test position, testing chord with
plug and socket for repair in lowered test position etc. and any other item required for
subsequent safe and efficient operation & maintenance of the high mast, whether explicitly
stated in the following pages or not.

2.0

SPECIFICATIONS OF THE HIGHMAST:

2.1

STRUCTURE:
The High mast shall be of continuously tapered, polygonal cross section (more than 16 sided),
presenting a good and smooth appearance and shall be based on proven In-Tension design
conforming to the standards referred above.

2.2

CONSTRUCTION OF HIGH MAST:

The mast shall be fabricated from special steel plates, conforming to BSEN10025/10027 or equivalent, having minimum yield strength of 355 N/sq mm, cut and
folded to form a polygonal section as stated at 2.1 above and shall be telescopically
jointed and welded.

Mast shall be delivered to site in not more than three sections. Each section shall be
fabricated out of individual plates duly folded and welded.

There shall be only one longitudinal seam weld per section.

Sections fabricated out of multiple plates or with more than one longitudinal
weld per section shall not be accepted.

The sections shall be joined together at site by slip-stressed-fit method.

No site welding shall be done on the mast nor shall bolted joint be accepted.

The minimum over-lap distance shall be 1.5 times the diameter at penetration.

The mast shall be provided with fully penetrated flange, which shall be free from any
lamination or inclusions.

2.2.1

2.3

The welded connection of the base flange shall be fully developed to the strength of
the entire section.

The base flange shall be provided with supplementary gussets between the bolt-holes
to ensure elimination of helical stress concentration.

For the environmental protection of the mast, the entire fabricated mast shall be hot
dip galvanized, both internally and externally, as per BS ES ISO 1461.

Mast shall be ventilated. Ventilations provided at bottom of the High Mask shall be
covered with stainless steel net to arrest the entry of the pest inside the pole.

DOOR OPENING

An adequate door opening shall be provided at the base of the mast and the opening
shall be such that it permits clear access to equipment like winch, cables, plug and
socket, etc. and also facilitates easy removal of the winch.

The door opening shall be complete with a close fitting, vandal resistant, weatherproof
door, provided with a heavy-duty double internal lock with special paddle key.

The door opening shall be carefully designed and reinforced with welded steel
section, so that the mast section at the base shall be unaffected and undue buckling
of the cut portion is prevented. The distance from the mast flange plate to the bottom
of the opening shall be a minimum of twice the width of the door opening.

Dynamic Loading for the Mast:

The mast structure shall be suitable to sustain an assumed reaction arising from a
minimum basic wind speed of 44 m/sec as per IS 875 part 3 (three second gust), and
shall be measured at a height of 10 meters above ground level. The design life of the
mast shall be a minimum of 25 years.

Wind excited oscillations shall be dampened by the method of construction and adequate
allowances shall be made for the related stresses.

2.4

Lantern Carriage:

2.4.1

Fabrication

A fabricated Lantern Carriage to mount luminaries suitable for fixing and holding 18
nos. of 2x400 HPSV, SONT+ flood light fittings and control gear boxes shall be
provided.

It shall be fabricated in two halves and jointed together by bolted flanges with stainless
steel bolts and nyloc stainless steel nuts to enable easy installation / removal from the
erected mast.

All the parts of the carriage shall be hot dip galvanized after the fabrication.

2.4.2

The Lantern Carriage shall be of steel tube construction. These tubes shall also act as
conduits for wires and shall have holes fully protected by grommets.

The inner lining of the carriage shall be provided with protective PVC shoe fixed to the
carriage body with the help of countersunk type of screws such that no metal part
bears on the mast surface during the raising and lowering operation of the carriage.

Lantern Carriage shall have a balance after the installation of the luminaries.

Lantern carriage shall have a 2/3 point suspension system.

Junction Box.
Weather proof junction box, made of Cast Aluminum shall be provided on the Carriage
Assembly as required, from which the inter-connections to the designed number of the flood
light Luminaries and associated control gears fixed on the carriage, shall be made. Hard wares
shall be of SS and Hexagonal socket head screw type.

3.0

Raising and lowering mechanism:

For the installation and maintenance of the luminaries and lamps, it will be necessary to lower
and raise the carriage assembly. To enable this, a suitable winch arrangement shall be
provided with the winch fixed at a suitable location in the base compartment of the mast and
the specially designed head frame assembly housing the pulleys and the guides at the top.
Head frame assembly shall have docking arms and guide arms.

3.1

Winch:
The motorized double drum winch shall be of completely self-sustaining type, without the need
for brake shoe, springs or clutches. Each driving spindle of the winch shall be positively locked
automatically by gravity activated PAWLS.
The winch drums shall be grooved to ensure perfect seat for stable and tidy rope lay, with no
chances of rope slippage. The rope termination in the winch shall be such that distortion or
twisting is eliminated and at least 5 to 6 turns of rope remains on the drum even when the
lantern carriage is fully lowered and rested on the rest pads.
The winch shall be suitable to operate by motor mounted in the base compartment of the high
mast. A suitable arrangement shall be provided to couple the motor with winch. A mechanical
torque limiter, pre-set for the safe working load of the winch shall be mounted on the motor
shaft. The torque limiter shall slip on the carriage reaching the docking point and also during
the operation if there is any obstruction/ eccentric load due to winds or other reason etc. The
critical system components like hoisting ropes and winches shall, thus be protected from
damage and safety of operating person. The winch shall have provision for manual operation
by a suitable handle for fine adjustments and for emergency operation in the event of power
failure.
The name plate of the winch shall have capacity, operating speed, safe working load,
recommended lubrication and serial number of the winch clearly marked on it.

The minimum working load shall not be less than 750 kg. The winch shall be self-lubricating
type and shall use oil which is a readily available grade of reputed producers.
It should also be possible to operate the winch manually by a suitable handle independent of
the integral power tool. Winches with manual operation through the power tool shaft shall not
be accepted. A double drum winch shall have 2 drums and two worm gears independent in
operation for increased safety.
It should be possible to remove the double drum after dismantling, through the door opening
provided at the base of the mast. A winch gear box for simultaneous and reversible operation
of the double drum winch shall also be provided so that tension equalization can be carried out.
The type test certificates of the double winches from a reputed institution shall be furnished
along with the supply of masts clearly indicating the safe working load and the test load. No
winch shall be accepted without test certificates.
3.3

3.4

Head Frame Assembly:

The head frame assembly, designed as a capping unit of the mast, shall be of welded
steel construction, galvanized both internally and externally after assembly.

The top pulley shall be of appropriate diameter, large enough to accommodate the
stainless steel wire ropes and the multi-core electric cables. The pulley and the pulley
block shall be made of non-corrodible material such as die cast Aluminum Alloy (LM-6).

Pulleys made of synthetic materials such as Plastic or PVC is not acceptable.

Self-lubricating bearings and stainless steel shaft shall be provided to facilitate smooth
and maintenance free operation for a long period. The pulley assembly shall be fully
protected by a canopy galvanized internally and externally.

Close fitting guides and sheaves shall be provided to ensure that the ropes and cables do
not dislodged from their respective positions in the grooves. The head frame shall be
provided with guides and at least four stops with PVC buffer for docking the lantern
carriage.

A lightning finial shall be provided on the canopy.

The head frame shall have docking arms to create a docking plane so that the luminaire
carriage remains docked firmly in tension, motion of the carriage and vibrations are
eliminated as also the damage due to the effect of eccentric loads.

Stainless Steel Wire Ropes:

The suspension system shall essentially be without any intermediate joint and shall consist of
only non-corrodible stainless steel of AISI 316 or better grade.

The stainless steel wire ropes shall be of 7/19 construction, the central core being of the same
material. The overall diameter of the rope shall be such that a factor of safety of 6 or more at
full load is achieved. The end constructions of ropes to the winch drum shall be fitted with
talurit.
The thimbles shall be secured on ropes by means of two compression splices of copper or
other suitable material. Only continuous lengths of stainless steel wire ropes shall be used in
the system and no intermediate joints are acceptable.
3.5

Electrical System, Cable and Cable Connections:

The Luminaires at the lantern carriage shall be fed through two independent circuits.
02 Nos. of Terminal box Flameproof (1 nos. each in one high mast) duly approved by CMRI
and CCE and 02 Nos. weather proof terminal box (One no. each in one high mast) shall also
be provided at the base compartment of the high mast for terminating the incoming cable from
the control panel. The electrical connections from the bottom to the top shall be made by
special trailing cables. The cable shall be EPR insulated and PCP sheathed round copper
conductor power cables to get flexibility and endurance. Size of the cable shall be minimum 5
cores x 4 sq mm copper. At the top there shall be weather proof junction boxes to terminate the
trailing cables. Connections from the top junction boxes to the individual Luminaries shall be
made by using 3 core 2.5 sq. mm flexible PVC copper cables. (Third core shall be connected
for the earth continuity). All trailing cable and flexible PVC Copper cable shall be of ISI and of
approved make
The system shall have in-built facilities for testing the Luminaries while in lowered position.
Suitable provision shall also be made at the base compartment of the mast to facilitate the
operation of internally mounted, electrically operated power tool for raising and lowering of the
lantern carriage assembly. The trailing cables of the lantern carriage rings shall be terminated
by means of suitable metal clad, Multi pin plugs and sockets provided in the base compartment
to enable easy disconnection when required. 04 Nos. Multi pin plug and sockets shall be
flameproof duly approved by CMRI and CCE in the population of 04 High Mast. Remaining 4
nos. Multi pin plug and sockets shall be weather proof type.

4.0 Power Tool for the Winch:

A suitable electrically driven, internally mounted power tool, with manual over ride shall be
supplied for the raising and lowering of the lantern carriage for maintenance purposes.
The speed of the power tool shall be as per the data sheets. The power tool shall be
provided with 02 Nos. winch motor of flameproof duly approved by CCE and CMRI out of
04 winch motors (1 no in each high mast) of suitable rating ensuring that there is no
overheating at the full load.

The power tool shall be supplied complete with a suitable control arrangement which shall
be inside the High mast

The power tool mounting shall be such that it not only supports itself but also aligns the
power tool perfectly with respect to the winch spindle during the operations.

A mechanical torque-limiting device (adjustable) to protect the wire ropes from over
stretching shall also be incorporated. The torque limiter shall trip the load when it exceeds
the adjusted limits. There should be suitable provision for indication to the operator once
the load is tripped off.

Each mast shall have its own power tool complete with motor and an adjustable
mechanical torque limiter.

Each mast shall also be provided with a handle for the manual operation of the winch in
case there is a problem with the electrically operated integral power tool.

5.0

Lightning Finial

6.0

A heavy duty, hot dip galvanized lighting finial of suitable length shall be provided at the
center of the head frame assembly for each mast in accordance with IS : 2309 1989
(latest edition).
It shall be bolted solidly to the head frame to get a direct conducting path to the earth
through the mast body.

The lightning finial shall not be provided on the lantern carriage under any
circumstances in view of safety of the system.

Mast body shall be solidly connected through a suitable GI strip to a pair of solid GI earth
electrodes. A test link shall also be provided in between the mast body and the earth
electrode.

The equipment earthing shall be through a separate earth pit. Earth electrode connected
to the lightning finial shall be kept away from the equipment earthing pit.

The earthing pit shall be as per applicable IS-3043/1966. The drawing for the earth pit is
enclosed elsewhere in the tender.

Aviation Obstruction Lights:

Supply, installation and commissioning of medium intensity without flashing aviation
obstruction lights of LED based design with operating voltage of 230+- 15% volt on each mast.
There shall be independent supply to aviation light from feeder pillar. Specs are as under:
Protection: Weather proof: IP-65: IS 13947/93 (Part-I)
Construction: Cast Metal LM-6 alloy
Dome: Toughened clear glass
Gasket: Endless neoprene
Finish: Powder coated corrosion resistant paint.
Weight: Less than 5 kg
Light service data: Colour: Red output
Total integrated (360) INTEGRATED 600 cd nominal, resulting in relevant radial (directional)
intensity candela not less than 35 cd in any direction in Horizontal plane.
No. of circuits: Minimum 5

No. Of LEDs: Min 400

Aviation obstruction lights: Make: Binay/Altos
7.0

Earthing and Earthing Terminals:

Suitable provisions at a convenient location shall be provided at the base of the Mast for
connecting equipment earthing/ lightning conductor terminals using 2 Nos. of 12 mm diameter
GI/ stainless steel bolts for equipment earthing and lightning earth connections.

8.0

Control panel
Each mast shall be provided with a feeder pillar which also houses the control for the power
tool. 02 Nos. Feeder pillar shall be of Flame proof duly certified by CMRI and CCE and will
have minimum IP 65 protection
02 Nos. feeder pillar control panel of weather proof type shall be fabricated out of 12 SWG
CRCA sheet steel and finished with two coats of red oxide primer and powder coated with grey
epoxy paint. The feeder pillar shall be designed to incorporate an incomer of 63 A TPN MCB, a
set of copper interconnection wiring, timer with a minimum of two channels, contactors of
suitable ratings to switch on the luminaries at a pre-set time. All feeder panel control should
have suitable canopy.
The control panel shall also house the suitable control arrangement for the up and down
movement of the lantern carriage (reversing of the power tool-motor) and shall have switch
gear arrangement for two separate and independent circuits of luminaires which shall be
capable of operation on two different time settings.
Control panel shall be erected on suitable cement concrete foundation with the help of GI angle
and at least 3.5 ft above the nearest road level. Foundation shall be minimum 600 mm deep
below the ground level and shall also have a muffing of 300mm above the finished floor level.
The muffing shall be cement plastered to provide a smooth finish. The feeder pillar shall have
canopy made out of 12 Gauge Sheet to protect it fully from the rains. The feeder pillar shall
have a provision of working platform made out of PCC.

9.0

Incoming Power Cable

A cable of size 4 x 16 Sq.mm Copper Armoured cable for power supply (Approx. 10 M) and 4 x
2.5 Sq.mm Copper Armored cable for motor supply shall be provided from feeder pillar to the
base compartment of the high mast. Cable shall be taken to the base compartment of the high
mast through the provision made in the foundation. Supply and laying of power cable of
suitable size up to the feeder pillar from supply point of the installation shall be separate but
included in the scope of this contractor.

10

LIGHT FITTINGS / LUMINAIRES/CONTROL GEARS

Luminaries shall be specially designed with suitable non integral lamp housing of pressure die
cast aluminum with glasskote/Al anodised reflector and Min IP-65 protection, Toughened
Glass and separate control gears for 2x400 W HPSV Lamps (SON-T+). The Luminaries
provided along with 2x400 W HPSV Lamps (SON-T+) shall be energy efficient and suitable for
hard duty and installation on high masts with a minimum Flux level of min. 55,000 lm per lamp
(test certificate of the manufacturer to be enclosed) and average rated burning Hrs. of Min.

27000. The luminaries shall have test reports and shall be submitted along with the materials.
Control gears enclosure shall be of LM-6 and shall be having suitable copper ballast, Igniters,
Capacitors, and SP MCB. The hard ware used in the fittings/CG shall be of socket head screw
and of SS. The fittings shall be adjusted in such a way that we should cover an area of 100mt.
radius from the mast with maximum of average lux.
11 0

HIGH MAST FOUNDATION

11.1 Contractor shall design the foundation of the mast of High mast light and get the same vetted
by reputed IIT/National Institute of Technology based on following soil information for foundation
design:a) In general there is a black plastic clay layer possessing expansive nature at the top of
about 3-5 mtrs. This is followed by a loose to medium silly sand strata of about 8-10
meters depth.
b) The net allowable pressure of 5T/M2 shall be taken at 1.5 mtrs depth. However
excavation shall be done to remove black expansive soil up to 750mm depth, below
the foundation bottom.
c) For design purpose ground water table shall be taken at 1.0 mtr below Finished
Ground Level
d) The grade of concrete shall be minimum M20 and Fe-415 conforming to IS-1786,
Sulphate resistant cement shall be used.
11.2 BACKFILLING:
The backfilling in foundation shall be done by excavated earth. This shall be compacted in
layers not exceeding 150 mm thickness.
11.3

SEISMIC LOAD
Design of structures for seismic load and categorization of equipment foundations and
structures for seismic design shall be as per IS: 1893
As per IS: 1893 this project site falls under seismic zone III.

11.4
The PCC (1:2:4) around the high mast shall be min. of 3 mtr radius and shall be min.
of 1 ft above the nearest road level. There shall be approach of PCC to the High mast from the
nearest road. Width of approach road shall be of 1.5 mtrs and depth 0.15 mtrs. Total length of
approach road is approximately 40 mtr, however contractor has to assess actual requirement
before bidding and any upward revision depending upon the site conditions is deemed to be
included in the quoted price. Approximately at 15 locations, contractor may require to put RCC
cover for crossing canal/drainage/pipeline.
12.0

TESTS:
All the tests shall be carried by the contractor as per standards and as per the direction of the
EIC and the cost of the same is deemed to be included in the quoted price and nothing extra
shall be paid.

12.1

Routine tests / checks shall be conducted on site as per relevant standards as follows:
(A)

Mechanical items:
1.
2.
3.
4.
5.
6.
7.
8.

(B)

Electrical items:
1.
1.
2.
3.
4.

12.2

All dimensions.
Bill of quantities
Galvanization thickness
Raising and lowering speed of the power tool
Measurement of length, diameter and thickness of sheet of various sections.
Measurement of length of overlap shall be done prior to erection of the mast.
Measurement of PCD, hole dia and thickness of bottom flange.
Diameter of foundation bolts.

Continuity test
Insulation (Megger) test
Earth resistance for pits and electrodes
Gauge measurement of the cable conductor strands
Marking of the make, voltage grade, ISI mark shall also be checked.

Test certificates:
Following documents/ certificates are required to be submitted along with the supply items
failing which material / design shall be rejected.
1. Routine test certificates from the manufacturer for power and trailing cables,
luminaries, double drum winch, wire rope, aviation obstruction lights, control panel,
high mast, lighting transformer .
2. Wind tunnel test certificate / vetted calculations for the design of high mast for
Structural stability.
3. Galvanization certificate.
4. Metallurgical analysis report of the high mast to conform to BS EN 10025 or any other
composition considered in the design.
5. Winch test certificate for Safe Working Load.
6. Certificate from a renowned engineering institute like IIT/NIT for the safe and sound
design of the high mast foundation along with design calculations.

12. 3

Miscellaneous:
1. Following tests for stone, sand, cement and concrete shall be carried out by the
contractor, cost of which shall be borne by the contractor.

1.

Stone aggregate

Lab test for soft

deleterious materials

or IS 2386 Pt-II

2.

Stone aggregate

3.

Sand

Field or lab test for particle IS 456

size distribution
Field or lab test for silt IS 383

For all quantites,

that is for every
batch
--Do--Do--

4.
5.
6.

content
Cement concrete or Field test for slump
IS 456
RCC
--Do-Cube test for compressive --Do-strength
Reinforcement
Lab tensile test
IS 1608

Once in a day
For every 5 Cmt.
For every new
batch

2. Contractor at his own cost shall provide all the support and required measuring
instruments for the tests listed at 12.1 (A) and (B)
3. The contractor shall provide a lux distribution diagram at the site indicating illumination
levels at every 10 meter interval.
13.0

Drawings and instruction manuals:

6 copies of the following documents shall be submitted for all High mast installations:
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
(ix)

14.0

General arrangement drawing of the high mast system

Wiring diagram
Bill of Quantities
Foundation details
Design calculations
Data sheets
Installation and maintenance manual
As built drawings incorporating the changes made at site.
CD incorporating all above details-one No

SPECIFICATIONS FOR SUPPLY AND ERECTION OF M.V. CABLES

(i) Codes And Standards: The design, manufacture, testing, supply erection , laying and commissioning of the brand
new cables under this specification shall comply with the latest revisions including
amendments of the following standards: IS: 1554

(PART I) PVC insulated heavy-duty cables for working voltages

Up to 1100 Volts.

IS: 3961-11

Recommended current ratings for cables.

IS: 813

conductors for insulated cables.

IS: 5831

PVC insulation and sheath of electric cable

IS: 10810

Test procedures for cable.

IS: 10418

Specification for drums for electric cables.

(I) GENERAL REQUIREMENTS

1.0

The cable shall be suitable for laying in Cable tray, trenches, GI conduits wherever
canal/drainage crossing.

2.0

Cable armour shall be capable of withstanding the earth fault currents. The current
carrying capacity of the armour shall not be less than the earth fault current values of
the system.

3.0

Progressive automatic in line sequential marking of the length of cables in meters at

every one-meter shall be provided on the outer sheath of all the cables.

4.0

Cables shall be supplied in non-returnable wooden drums as per IS: 10418. Both ends
of the cables shall be properly sealed with PVC/ rubber caps so as eliminate ingress
of water during transportation, storage and erection.

(ii)

Tests and Test Reports

Cable shall be subjected to type tests, routine tests and acceptance tests as per IS:
10810. The GAIL reserves the right to witness any or all the tests (except type test.
Only copy of type test already performed shall require to be submitted) for which at
least 20 days advance notice shall be given by the contractor. The Contractor before
dispatch of the materials from works shall get items inspected by GAIL.

(iv)

Erection Specification for Cabling:

Supply and laying of all the power cables from SS/MCC/ACB etc. is in the scope of
contractor. Cable shall be buried directly underground in excavated trenches
excavated by the contractor at a depth of 90 cms in a 40cm wide trench. Before cables
are placed. The trench bottom shall be filled with a layer of sand 7.5cm thick. This sand
shall be leveled and the cable laid over it. The cable shall be covered with 7.5 cm layer
of sand on top of the cable and lightly pressed. A protective covering with second class
bricks laid over the cable and also on both sides shall than be laid. The remainder of
the trench shall than is back- filled with soil and leveled properly.
Where the cable rises from the trench it shall be taken in G.I. pipe bends for
mechanical support/ protection up to a minimum of 30cm above ground.
Cable ends shall be carefully pulled through the GI conduit to prevent damage to the
cable. Where required approved cable lubricants shall be used for the purpose. Where
cable enters the conduit the cable should be bent in large radius not less than the
bending radius of the cable specified by the manufacturer.
Contractor is to make his own arrangement for breaking the PCC /Road wherever it is
required. The contractor is to make good the PCC/Road as per original after under
grounding the cables. All the materials required for breaking/making good is in the
scope of contractor.

Before energizing the insulation resistance of every circuit shall be measured from
phase to phase and from phase to ground. Measure the resistance of the directly buried
cables before the trenches are back filled. Repeat measurement after back filling and
record. 1000V megger is to be used for insulation testing.
After the cables are installed and tested completely conduit ends above Grade shall be
plugged with suitable weatherproof rubber compound/ putty for sealing purpose. The
cost for the same shall be deemed to have been included in the installation of G.I.
pipe bend.
At road/canal/drainage crossings the cable is to be laid in G.I. pipes of min. 50mm dia
class B. All road crossings and other places where cable enters a pipe, sleeve,
adequate bed of sand shall be given so that the cables do not slack and get damaged
by pipe ends.
Cables from the substations/ other control rooms shall be laid in existing trenches or
cable trays and cleated properly.
G.I. pipes and bends shall be laid as per the requirement. Prior to laying all the burrs etc.
shall be smoothened out. The buried portion shall be given a bitumen coating whereas
exposed portion above grade shall be painted with red oxide and aluminum paint.
Excavation of cable trenches shall be done very carefully to avoid the damage to
already laid cables. If any existing cable gets damaged during excavation then
contractor has to repair the same free of cost.
(iv)

Termination:
All cable shall be terminated at the end by means of flameproof double compression Ni
plated brass cable gland in operational area & whether proof Double compression type
Ni plated brass cable glands in non-operational area. These shall be of brass, have a
screwed nipple with conduit, electrical threads and check nut.
Cable leads shall be terminated at the terminal connectors by means of crimped type
solder less aluminum lugs. Crimping shall be done by means of hydraulic crimping tool/
mechanical crimping tool and conducting jelly shall be applied on the conductor.
Wherever cables are laid in the cable trays, it should be properly tagged and punched
as identification at every 10 mtr. distance and at every bend.

(v)

Route Marker:

(A)

Route marker shall be provided along straight runs of the cables at location approved by
the EIC and generally at interval not exceeding 30m. Markers shall also be provided to
identify change in the direction of the cable route and also for location of every
underground joint. Cost of these shall be deemed to be included in the quoted price of
the cable.

(B)

Route markers shall be made out of 100mm X 100mm X 5mm G.I. plate welded or
bolted on to 35mm X 35mm X 6mm angle iron 60cm. long flushed with ground in cement

foundation. Such plate marker shall be mounted parallel to and 0.5m or so away from
the edge of the trench.
(C)

The working voltage of cable and other details such as voltage grading size etc. as
furnished by the EIC shall be inscribed on the marker.

(D)

At every cable straight through joint, joint marker shall be provided with tag plates both
upstream and downstream of the joint.

(V) JOINTING KIT:

The straight through jointing kits shall be suitable for installation on overhead trays, concrete
lined trenches, and ducts and for underground burial with uncontrolled backfill and possibility of
flooding by water and chemical. These shall be having protection against any mechanical
damage and suitably designed to be protected against rodents and termite attacks.
JOINTING:
All out door jointing of PVC cables shall be done using M-seal jointing materials.
(a)

A licensed/experienced cable jointer shall carry out jointing work.

(b)

At the preliminary stages of laying a cable a proper jointing position should be

selected.

(c)

Sufficient surplus cable shall be left on each side of joints.

(d)

Joints shall be staggered by min. 0. 5 m when two or more cables are laid together in
the same trench.

(e)

Jointing materials and accessories like conductor ferrules, solder, flux, insulating and
protective taps, filling compound, jointing boxes etc. of right quality and correct sizes,
confirming to relevant Indian standards, wherever they exist, shall be used. The design
of the joint box and the composition of the filling compound shall be such as to provide
an effective sealing against entry of moisture in addition to affording proper electrical
characteristic to joints. Where special type of splicing connector kits or epoxy resin
spliced joints are specified materials approved for such application shall be used and
instructions of the manufacturer/ supplier of such materials shall be strictly followed.

(f)

Insulation resistance of cables to be jointed shall be measured with 1000 volts megger
up to 1.1 KV grade and with 2,500/5.000 volts megger for cables of higher voltage.
Unless the insulation resistance values are satisfactory, jointing shall not be done.

(g)

Cores of the cables must be properly identified before jointing.

(h)

Where a cable is to be jointed with the existing cable, the sequence

(i)

Should be so arranged as to avoid crossing of cores while jointing.

(j)

While it would be best to follow strictly the instructions for jointing furnished by the
manufacturers/supplier of cable and joint boxes

(k)

All out door jointing of PVC cables shall be done using best quality of compound and
jointing materials.

Supply & Installation of Synthetic Rubber Mats infront of electrical Panels (IS code, Total
Quantity to be mentioned)
15.0

Supply and installation of LDB

A. INCOMING LDB:
Incoming Lighting distribution Board as per existing LDB (Spec is enclosed) to maintain the
aesthetic look of substation. Party may visit prior to quote. LDB shall comprise one 250 Amps
TPN MCB as an incomer and Three number of 100 Amp & 02 nos. 63 Amp distribution TPN
MCB for Transformer Incoming . LDB should have indicating lamps for three phases, PVC
Sleeved suitable size copper bus bars, earth bus bar, and connector strip for termination. This
LDB is to be mounted adjacent to the existing LDB. Earthing to be provided with suitable size
of GI earthing wire to earth grid of respective substation/MCC etc.
B. OUT GOING PANEL:
Out going panel shall comprise one incoming of 100 Amp for termination of transformer
outgoing cable & 03 nos. outgoing MCB of 63 Amp rating for out going supply to field DBs of
High mast

16.0

Supply and installation of Lighting Transformer:

The contractor is to supply, install , testing and commissioning of dry type lighting transformer
of 2 nos. 50 KVA with tap changer switch of 1 to 5 position in MCC/Substation .Brief specs
are as under : IS : 2026, Phase :3, 50Hz, Ambient temp: 40 Degree Celsius , 70 Degree
Celsius rise,
HV V: 415 +/- 2.5% +/- 5%

Delta

LV V: 415 Star
Impedance Voltage: 4.36%
Vector Group Ref: DYN 11
Cooling: AN
Insulation: B, Type: DW.
The contractor is to provide equipment earthing and neutral earthing. Lighting transformer shall
be installed at height of 3.5 ft from the floor level of respective substation. Lighting Transformer
shall be put on platform made of Galvanized suitable size angle frame along with working
platform. Equipment earthing shall be connected through the existing earth grid system and
neutral earthing shall be done separately by making separate earth pit.

17.0

Conversion of Blank Compartment in to SFU:

There are blank compartments at 5 locations in existing DGMCC. The contractor shall convert
these compartments into SFU module. Each module shall comprise the trolley for draw out
alongwith 400 Amp SFU in 03 compartments & 250 Amp SFU in 02 compartments complete
with HRC Fuses, Handle, End terminations, Shrouds, Jaws & All other items required to
complete the module operation for drawing power to LDB & future expansion. Complete job is
included in the scope & no extra payment for this is done. This job shall be done with DGMCC
electrically charged & without affecting the plant operation. The aesthetic look of the panel
should be maintained as per original.

18.0

Special conditions for execution of site work:

The contractor is to ensure that the Electrical work at site will be done by a license electrical
contractor.

19.0

Work Permit System:

Following permit system is followed in our plant
a. Cold work permit
b. Hot Work permit
c. Work at height
d. Excavation permit.
Contractor shall invariable follow the work permit system while execution of the job.

LIST OF SUGGESTED MAKES

Sl. No.
1.

Description
High mast 30 Meter

2.

High mast Luminaries

3.
4.
5.

Make
Manufactured by an ISO: 9001
/9002 certificated agency.

Bajaj
-BGENF22
Philips -RVP 301
Weatherproof with Glasskote/Al anodized Crompton-FHD 1424
reflector, Min. Protection IP 65, Toughned
Glass, Housing: Pressure Die cast aluminum
Housing. Separate weatherproof control gear
box of die cast aluminum
PVC Power cables armoured
Finolex/Fort Gloster / CCI/ NICCO/Polycab
Aluminium/Copper
Trailing cable 5Cx4 sqm copper, EPR cable
PCP sheathed
400 W HPSV SON_T+
Min. light output of 55,000 lumens per lamp

Finolex / CCI/ Fort Gloster/NICCO/

Bajaj/Mans field
Bajaj / Crompton / Philips/GE.

6.
7.

and average rated burning hrs. of 27000 Hrs

Double drum Winch
Stainless steel wire rope

8.
(i)

Switch gear
Lighting Transformer

(ii)
(iii)
(iv)

MCB
Electronic Timer
Contactors

(v)
(vi)

Metal clad multi pin plug socket

Flameproof DB, PLUG SOCKET, Cable
Glands
Distribution Boards
Aviation lights

(vii)
9.

ISI marked with type test certificate.

Bharat wire ropes / Usha Martin/ SAFELIFT
ENGG
Indcoil/ Siemens/ CROMPTON/
Voltamp
GE/ MDS/ L&T/Siemens
L&T/MDS/Siemens
L&T/CROMPTON/BCH/SIEMENS/
TELEMECHANIQUE
CROMPTON/MDS/BCH
Baliga/ Sudhir/FCG/Flexpro
MDS/SEIMENS/GE/L&T
Binay/Altos

TECHNICAL DATA SHEET FOR 30 MTR HIGH MASTS WITH INTEGRAL POWER TOOL
AND COMPONENTS (2/3 - WIRE ROPE SYSTEM) For operational area motor, control panel
terminal box and other associated electrical items at bottom should be of flameproof duly
approved by CMRI and CCE.
1.

HIGHMAST SYSTEM

a)

Height of mast

30 Meter

b)

No. of Sections

c)

OEM/OES

d)

Material of construction

BS:EN 10025/10027

e)

Minimum Thickness of the sections

Basic Section-6mm
Middle Section-5mm
Top Section-4mm

f)

No. of longitudinal welds /section

One

g)

No. of circumferential welds/ section

Nil

h)

Length of individual sections

as per manufacturers design

i)

Min. Base dia. and top diameter

as per manufacturers design

j)

Type of joints

Stress fit at site

k)

Length of overlap

as per manufacturers design

l)

Metal protection treatment for Mast Section

As per BSEN ISO1461.

m)

Min Thickness of galvanization (in micron)

85 micron

n)

Size of opening /door at base

o)

Min. Thickness of base plate

suitable for repair / removal of

winch
as per manufacturers design

p)

Size of anchor plate and thickness

as per manufacturers design

q)

Lightning protection

2.

G. I finial (single spike) erected on the

head frame of the mast. Main body of
the mast may act as a down
conductor. The base plate of the
mast shall be connected to two GI
electrodes, driven in undisturbed soil,
providing an earth resistance of not
more than 10 ohms
DESIGN CRITERION FOR DYNAMIC LOADING AT SITE

a)

Max. wind speed

as per IS 875 part 3

b)

Max. gust speed time

3 seconds

c)
Height above ground level at which the
above two factors are measured
d)
Min. Factor of safety for wind load

10 mtr

e)

Min. Factor of safety for other load

1.15

3.

FOUNDATION DETAILS

1.25

a)

Size of foundation

Open raft shallow footing or

as per design
As per design

b)

Depth of foundation

As per design

c)

Number of foundation bolts

As per design

d)

PCD of foundation bolts

e)

Type of foundation bolts

f)

Min. Bolt diameter

Type of foundation

4.

LANTERN CARRIAGE

a)

Material of construction

b)

Diameter of carriage ring (mm)

High yield tensile Cold

Rolled Pitched threads
(680 N/sq. mm.)
As per design

As per manufactured design. MS

Pipe with hot dip galvanized
As per design

c)
Buffer arrangement between Carriage and
Masts
f)
Safe working Load

PVC sleeve on carriage

g)

Total weight of assembly with fittings

750 Kgs. (maximum)

h)

Number of fittings.

18 nos.

i)

Type of fittings/fixture

2x 400 W SON-T+
suitable for erection at high mast

5.

WINCH

750Kgs

a)

Make of winch

b)

Number of drums/winch

ISI or As per standard package of

the OEM/OES
Double drum type

c)

Gear Ratio

as per manufacturers Design

d)

Capacity

for min. working load of 750kgs.

e)

Raising speed of winch

Approx. 1.5 Meter/min.

f)

Method of operation

Manual & Electrical

g)

Lubrication arrangement

as per manufacturers design

h)

Type of lubricant

as per manufacturers design

i)

Tested load on winch (kg)

1500kgs. Max.

6.

STAINLESS STEEL WIRE ROPE

a)

Make

b)

Grade

B.W.LTD/SAFELIFT ENGG/USHA
MARTIN
AISI 316

c)

Number of ropes

2/3 continuous ropes.

d)

Construction

7/19

e)

Centre core material

Stainless steel core

f)

Min. Diameter (mm)

as per design

g)

Thimbles & Talurit

SS Thimble, Copper Talurit

h)

Braking load capacity

2350kgs. X 2

i)

Factor of safety

>5 for system at full load

7.

TRAILING CABLE

a)

Type

EPR insulated PCP sheathed

b)

Material

Copper conductor,

c)

Make

Finolex
Finolex
/ CCI/
/ CCI/
FortFort
Gloster/NICCO
Gloster/NICCO

d)

Min. Current carrying capacity

24 Amp

e)

Aprox. Conductor size

4.0 sq. mm.

f)

No. of cores

5 nos.

g)

No. of circuits

two

8.

POWER TOOL

a)

Model

Integral

b)

Input supply

3 PH 415 Volts

c)

Min. Wattage

as per design

d)

Number of speeds

Single speed

e)

Operating speed.

1.5 M/minute approx

9.

TORQUE LIMITER

a)

Lifting capacity

Up to 750 Kgs

b)

Adjustable/ Non-adjustable

Adjustable

c)

Tripping device

Mechanical

TENTATIVE CABLE LENGTH

Length (Mt.) of power cable required to be laid for High mast
3 core X 50 sq mm

4 core X 35 sq mm

4 core X 16 sq mm

3core X 2.5 sq mm

300 mtrs

2500 mtrs

200 mtrs

200 mtrs

TENTATIVE CABLE LAYING THROUGH VARIOUS ROUTE

PCC
20 mtrs.

ROAD
CUTTING
50 mtrs

UNDER
GROUND
1500 mtrs

DRAIN CROSSING

OVER THE CABLE TRAY

10 mtrs.

200 mtrs