Vol-II

REQUEST FOR PROPOSAL

FOR

DESIGN, ENGINEERING, SUPPLY, ERECTION

TESTING & COMMISSIONING

OF

TRANSMISSION LINE(400 KV)

FOR EVACUATION OF POWER FROM 2X600 MW

COAL BASED POWER PLANT AT DERANG, ANGUL, ORISSA

VOLUME II

Jindal India Thermal Power Limited

Plot No. 12, Sector B-1, Local Shopping Complex,

Vasant Kunj, New Delhi – 110 070,

Telephone No. (011) 26139256-65 Fax No. (011) 26121734

INDEX (VOLUME-I)

SECTION 1 - INVITATION TO BID (ITB)

SECTION II - INSTRUCTIONS TO BIDDERS

SECTION III - GENERAL TERMS & CONDITIONS OF CONTRACT

SECTION IV - TENDER SPECIFICATION

1.0 Schedule A : Tower Schedule

2.0 Schedule B : Tender Form

3.0 Schedule C : Void

4.0 Schedule D : Qualifying requirement data schedule (Form 1 to 8)

5.0 Schedule E : Schedule of unit prices and tax break up

6.0 Schedule F : Bid Security form

7.0 Schedule G: Performance security form

8.0 Schedule H: Proforma of Consortium Agreement

9.0 Schedule I : Power of Attorney for Lead Member

10.0 Schedule J : Power of Attorney for each of the other Members of the Consortium

11.0 Schedule K : Performance Security form for Consortium Members

12.0 Schedule L: Proforma of B.G. for Advance payment

13.0 Schedule M: Proforma of Indemnity bond

14.0 Schedule N: Format for Undertaking

15.0 Schedule O: Format for Submission of Financial Bid

INDEX (VOLUME – II)

SECTION I : GENERAL INFORMATION & SCOPE

SECTION II : GENERAL TECHNICAL & ERECTION CONDITIONS

SECTION III : TOWER SPECIFICATION

SECTION IV : PRE-COMMISSIONING PROCEDURES

SECTION V : TECHNICAL SPECIFICATION FOR ACSR ‘MOOSE’

CONDUCTOR

SECTION VI : TECHNICAL SPECIFICATIONS FOR 7/3.66MM

GALVANISED STEEL EARTH-WIRE

SECTION VII : TECHNICAL SPECIFICATIONS FOR PORCELAIN DISC

INSULATORS

SECTION VIII : TECHNICAL SPECIFICATIONS FOR HARDWARE

FITTINGS AND ACCESSORIES FOR CONDUCTOR AND

EARTHWIRE

SECTION IX : ANNEXURES

SECTION IX : ANNEXURES (VOLUME-II)

a) ANNEXURE-1:- PROVISIONAL BILL OF QUANTITY FOR 400KV D/C TRANSMISSION LINE

b) ANNEXURE-II:- BLANK

c) ANNEXURE-III:- BLANK

d) ANNEXURE-IV:- BLANK

e) ANNEXURE-V:- STANDARDS FOR ACSR CONDUCTOR

f) ANNEXURE-VI:- DRAWING CHARTS & DESIGN DATA TO BE SUBMITTED IN PHYSICAL

FORM

g) ANNEXURE-VII:- TESTS ON EARTHWIRE

h) ANNEXURE-VIII:- TEST PROCEDURE FOR INSULATORS

i) ANNEXURE-IX:- GUARANTEED TECHNICAL PARTICULARS FOR DISC INSULATOR UNIT

j) ANNEXURE:- X:- TESTS ON COMPLETE STRINGS WITH HARDWARE FITTINGS

k) ANNEXURE- XI:- ACCEPTANCE TESTS

l) ANNEXURE-XII:- GUARANTEED TECHNICAL PARTICULARS OF SUSPENSION HARDWA RE

FITTINGS FOR MOOSE ACSR CONDUCTOR

m) ANNEXURE- XIII:- PRICE SCHEDULE FOR 400 KV D/C(ACSR TWIN MOOSE CONDUCTOR)

Jindal India Thermal Power Limited Page 1

Volume-II / Section - I EPC Tender for JITPL

SECTION – I

GENERAL INFORMATION & SCOPE



SECTION – I

CONTENTS

Clause Description

Page No

1.0

2.0

3.0

General Information and Scope

Line Data

Service Condition

4

8

10


Volume-II / Section-II EPC Tender for JITPL

TECHNICAL SPECIFICATIONS

SECTION – I

GENERAL INFORMATION & SCOPE

1.

1.1.

General Information and Scope

Scope

1.1.1. This Specification covers the following

(i) Soil resistivity measurement, geotechnical

investigation and check survey and detailed survey if required at the approaching reaches for any deviation during execution (Detailed survey

including route alignment, profiling and tower spotting etc. has already been

completed by the Owner) ;

(ii) fabrication and supply of all type 400 kV double circuit transmission line towers, Body

extensions and unequal leg extensions, as per Owner’s design/ drawings including bolts,

nuts and washers, hangers, D- shackles and all types of tower accessories like phase plate, circuit

plate, number plate, danger plate, anti-climbing device, and supply of Earthwire, Hardware Fittings and Conductor & Earthwire Accessories and design and

supply of any special towers. In case the Contractor is having his own tested

designs he may provide a separate quote (both techno commercial and price bids) for the same apart from the quote based on Owner supplied designs. (iii) Supply of Conductors and Insulators; (iv) Selecting type of foundation for different type of towers and casting of foundation for tower footings as per Owner’s/Contractor’s foundation design; (v) Erection of towers, tack welding of bolts and nuts including supply and application of zinc rich primer & enamel paint, painting of towers and other signaling arrangements for aviation

requirements, tower earthing, fixing of insulator strings, stringing of conductors and earthwires along with all necessary line accessories; (vi) Testing and commissioning of the erected transmission lines,

(vii) Arranging Right of Way;

(viii) Supply of spares and Tools (ix) Any other items for the successful commissioning of the transmission line, unless specifically excluded in the Specification.

1.1.1.1. Contractor shall provide structural/fabrication drawings, shop drawings

and Bill of materials of all 400 KV Double circuit towers and extensions

suitable for Twin ACSR Moose Conductor after the placement of award, in

sequence, suiting the project requirement. The construction drawings for all type of foundations for these towers shall also be provided by Contractor

after the placement of award in sequence suiting the project requirement. The

scope of this specification also provides for fabrication of prototype tower, its assembly and proto-inspection.

1.1.1.2. (a) The provisional quantities of various types of towers, foundations,

conductor, earthwire, insulators etc., are provided in Annexure-1.

However, contractor has to prepare his own estimates for bidding purpose

after site visit.



(b) The various items provided in Annexure-1 shall be read in conjunction

with the corresponding sections in the Technical Specifications including

amendments and, additions, if any. The Bidder’s unit rates shall be based on the description of activities in the Annexure-1 as well as necessary

operations detailed in these Technical Specifications.

(c) The bidder shall include in his bid the supply of mandatory spares, special

tools and tackles, for erection, testing, commissioning of the transmission

line. The list of such spares is provided in Annexure-14 special tools and

tackles is provided in Annexure-15 and prices for supplying such items shall be deemed to be included in the bid price.

(d) The Unit rates quoted in the format given in Annexure 13 shall include

minor details which are obviously and fairly intended, and which may not

have been included in these documents but are essential for the

satisfactory completion of the various works.

(e) The unit rate quoted shall be inclusive of all plant equipment, men,

material, skilled and unskilled labor etc. essential for satisfactory

completion of various works.

(f) All measurements for payment shall be in S.I. units, lengths shall be

measured in meters corrected to two decimal places. Areas shall be computed in square meters & volume in cubic meters, rounded off to two

decimals.

1.1.1.3. The Bidder shall submit his offer taking into consideration that the tower and

foundation designs shall be provided by the Contractor. Further, the Bidder shall

quote the unit rate for these items as per their units mentioned in Annexure-1.

However, payment shall be made on per tower/foundation basis on completion of supply/erection as applicable to be worked out based on the approved Bill of

Materials for towers and approved foundation drawings.

1.1.2. This specification also includes the supply of Conductor, earthwire, Insulators,

hardware fittings and all type of accessories for conductor, earthwire and tower

as detailed in the Specification. Contractor shall clearly indicate in their offer,

the source from where they propose to procure these materials. The technical description of these items is given in relevant sections of this Bidding

Document.

The Contractor shall ensure the safe custody of Conductor, Insulator, tower

parts and other line materials during construction.

1.1.3. All the raw materials such as steel, zinc for galvanizing, reinforcement steel and

cement for tower foundation, coke and salt for tower earthing etc. bolts, nuts,

washers, D-shackles, hangers, links, danger plates, phase plates, number plates,


Volume-II / Section-I EPC Tender for JITPL

Circuit Plates etc., required for tower manufacture and erection shall be

included in the Contractor’s scope of supply. Bidder shall clearly indicate in the

offer, the sources from where they propose to procure the raw materials and components. All the material procurement should be from the reputed

manufacturers/suppliers who are in the PGCIL approved list of

suppliers/manufacturers. However Vendor approval is required to commence

the supply of items.

1.1.4. The entire stringing work of conductor and earthwire shall be carried out by

tension stringing technique. The bidder shall indicate in the offer, the detail description of the procedure to be deployed for stringing operation.

The Contractor shall indicate in their offer, the sets of tension stringing

equipment he is having in his possession and the sets of stringing equipment he

would deploy exclusively for this line. However, the Bidder having requisite

experience has freedom to use helicopter for stringing. The Bidder intending to use helicopter

shall furnish detailed description of the procedure, type and number of helicopter &

accessories etc., to be deployed for stringing operation.

1.1.5. Special River Crossing towers/strengthening of available tower bodies/cross

arms may be required to negotiate river crossing /valleys/hilly terrains . The Contractor has to develop the structural drawings, Bill of Materials and shop

drawings of these river crossing towers at the time of execution. The rates

quoted shall be inclusive of proto-assembly, type testing etc.

1.1.6. N/A

1.1.7. The following 400 kV Transmission line is included in the scope of the

Contractor :

Package – 1

400 KV D/C (Twin ACSR Moose) Derang To Angul - 56 Kms.

Transmission Line ( Line length is approximate)

1.1.8. Location Details and Terminal Points



(i)

400 KV D/C Derang To Angul Transmission Line

This line shall emanate from 1200 MW Jindal Power Project 400

kV Sub-station of JITPL and shall terminate at 400 kV

Sub-station of PGCIL.

1.1.9. The Contractor shall have to Supply & Erect 400 KV DC (Twin ACSR)

Transmission Line completely up to terminal arrangements/terminal points.

1.2.

1.3.

Details of Transmission Line Routes and Terrain

Bidders may visit the line route to acquaint themselves with terrain etc., of the

proposed transmission lines. For this purpose they are requested to contact the

following address :

Jt. President - Projects

Jindal India Thermal Power Limited Plot No. 12, Sector B-1,

Local Shopping Complex,

Vasant Kunj, New Delhi –110 070

Phone No. 011 – 2613 9256 to 9265

Access to the Line and Right of Way

The Contractor shall assist Owner for fixing the tree/crop compensation through

Revenue/Horticulture Department or any other appropriate authorities. The compensation shall be paid subsequently by the Owner. The cost of cutting the

trees, stacking of cut tree, clearing debris & transportation of cut trees (if

required) would be borne by the Contractor.

All statutory clearances including Forest clearance shall be arranged by the

Owner. However, the Contractor shall be responsible for all the activities for

obtaining the statutory clearances viz. collecting input details, preparation of documents etc.

The Contractor shall be responsible for attending to any local issues related to

Right of Way through private property, Government land etc. Right of way and

way leave clearance shall be arranged by the Contractor in accordance with

work schedules.



2.

2.1.

2.2.

Line Data

Electrical System Data

A Nominal Voltage

B Maximum system voltage

C BIL (Impulse)

D Power frequency withstand voltage (wet)

E Switching surge withstand voltage (wet)

F Minimum Corona extinction voltage at 50 Hz

AC system under dry condition

G Radio interference voltage at one MHz for

phase to earth voltage of 305 KV under dry

condition

Details of Line Materials

A. Conductor and earthwire for 400 kV line

kV

kV

kV (Peak)

kV (rms)

kV (peak)

kV (rms) phase to

earth

Micro Volts

400

420

1550

680

1050

320 Min

1000 Max

Sr.No. Description Unit

Earthwire

Conductor

1. Name/Type Galvanised steel ACSR Moose

2.

3.

Size

Conductor per phase

Mm

No.

7/3.66

N.A.

54/3.53 Aluminium

+7/3.53 Steel

4

4. Spacing between

conductor of same phase (sub conductor

spacing)

5. Configuration

6. Overall diameter

Mm N.A.

Mm 10.98

Two

continuously to

run horizontally on top of the

towers and

conductors

457

Vertical (for D/C

with 8000 mm min.

inter phase spacing)

31.77

7. Unit mass Kg/Km. 583 2004

8. Min. UTS KN 68.4 161.2

9. Ruling Design Span metres 400 400



2.3.

Details of Insulator Strings with disc insulator for 400 kV line

Sr.N Particulars Single “I” Double Single “I” Single

Quad

o. suspensio

n string

“I”

suspensio

n String

suspensio

n pilot

string

tension

string

Tension

String

1. Type of Disc

2. E&M Strength of

each Anti Fog

insulator in the

string in KN

Standard Standard Standard Standard Standard

120 120 120 120 160

3. Nos. of Anti Fog 1x23 2x23 1x23 1x24 2x2x24

4.

insulator disc per string

Size of disc in mm 280x145 280x145 280x145 280x145 280x170

5. Size and

designation of pin

ball shank in mm.

20 20 20 20 20

6. Minimum creepage

distance of each

disc in mm.

315 315 315 315 330

2.4.

2.5.

Insulator String Hardware (As may be applicable)

a) Anchor Shackle

b) Chain Link

c) Ball Clevis d) Arcing horn holding plate

e) Yoke plate

f) Socket clevis

g) Arcing horns h) Corona control ring/grading ring

i) Clevis Eye

j) Free centre type/Armour grip suspension clamp for suspension strings. k) Compression type dead end clamp

l) Sag adjuster

m) Balancing weight

Accessories for Conductor & Earthwire (As may be applicable)

a) Performed Armour rods

b) Mid Span compression joint c) Repair Sleeves

d) T-Connector

e) Flexible copper bonds f) Rigid spacers for twin moose



g) Twin Spacer dampers

h) Vibration dampers for earth wires

i) Quad Rigid Spacer j) Suspension clamp for earthwire

k) Tension clamp for earthwire

3.

Service Conditions

Equipment/material to be supplied against this specification shall be suitable for

satisfactory continuous operation under conditions as specified below : Maximum ambient temperature (Degree Celcius) : 50

Minimum ambient temperature (Degree Celcius) : 7.5

Relative humidity (% range) : 10-100 Maximum annual rainfall & short fall (Cm) : As per published

meteriological/

climatological data

Wind zone (as per IS : 875) : 3 Maximum wind velocity (m / sec.) : 44 m/sec. (as per Is-875)

Maximum altitude above mean sea level (Metres) : Upto 1000 m

Isoceraunic level (days / years) : 50

Climate varies from moderately hot and humid tropical climate to cold climate.


Volume-II / Section - II EPC Tender for JITPL

SECTION – II

GENERAL TECHNICAL &

ERECTION CONDITIONS



SECTION –II

CONTENTS

Clause Description

Page No

1.0

2.0 Erection

3.0

General Technical Conditions

Conditions

JITPL’S Environment and Social Policy and its

Implementation

13

20

29




SECTION – II

GENERAL TECHNICAL & ERECTION CONDITIONS

1

General Technical Conditions

1.1 General

The following provisions shall supplement all the detailed technical specifications

and requirements brought out herein. The Contractor’s proposal shall be based on the use of materials complying fully with the requirements specified herein.

1.2 Engineering Data

1.2.1 The furnishing of engineering data by the Contractor shall be in accordance with

the Schedule as specified in the Technical Specifications. The review of these

data by the Owner will cover only general conformance of the data to the specifications and not a through review of all dimensions, quantities and details of

the materials, or items indicated or the accuracy of the information submitted.

This review by the Owner shall not be considered by the Contractor, as limiting any of his responsibilities and liabilities for mistakes and deviations from the

requirements, specified under these specifications.

1.2.2 All engineering data submitted by the Contractor after review by the Owner shall

form part of the contract document.

1.3 Drawings

In addition to those stipulated in clause regarding drawings in GCC, the following

also shall apply in respect of Contractor Drawings.

1.3.1 All drawings submitted by the Contractor 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.

1.3.2 Each Drawing submitted by the Contractor shall be clearly marked with the name

of the Owner, 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.

1.3.3 The drawings submitted by the Contractor shall be reviewed by the Owner as far

as practicable within 30 days and shall be modified by the Contractor if any

modifications and/or corrections are required by the Owner. The Contractor shall



incorporate such modifications and/or corrections and submit the final drawings

for approval. Any delays arising out of failure by the Contractor to rectify the

drawings in good time shall not alter the contract completion date.

1.3.4 The Contractor should submit one plus four drawings for approval to the Owner.

One print of such drawings shall be returned to the Contractor by the Owner

marked “approved/approved with corrections”. The Contractor shall there upon furnish the Owner additional prints as may be required along with one

reproducible in original of the drawings after incorporating all corrections.

1.3.5 The work shall be performed by the Contractor strictly in accordance with these

drawings and no deviation shall be permitted without the written approval of the

Owner, if so required.

1.3.6 All manufacturing, fabrication and erection work under the scope of Contractor,

prior to the approval of the drawings shall be at the Contractor’s risk. The

Contractor 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 Owner.

1.3.7 The approval of the documents and drawings by the Owner shall mean that the

Owner is satisfied that :

(a) The Contractor 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 Owner of any document does imply compliance

with all technical requirements or the absence of errors in such documents.

If errors are discovered any time during the validity of the contract, then the

Contractor shall be responsible of their consequences.

1.3.8 The Owner may use AUTOCAD/PDF system in processing drawings. All

drawings shall be suitable for AUTOCAD/PDF. Drawings which are not suitable

for AUTOCAD/PDF will not be acceptable.

A copy of each drawing reviewed will be returned to the Contractor as stipulated

herein.

1.3.9 Copies of drawings returned to the Contractor will be in the form of a print with

the Owner’s marking, or a print made from a AUTOCAD/PDF of the marked up drawing.



1.3.10 The following is the general list of the documents and drawings that are to be

approved by the Owner.

a) b)

c)

d)

e)

f) g)

h)

i) j)

k)

l)

Work Schedule (Master Network) Plan.

Checking of detail Survey already done by the owner

Tower schedule and foundation classification for individual tower

locations. Tower structural drawing and bill of materials.

Soil Investigation report.

Foundation working drawings/excavation Plan. Tower footing earthing drawing.

Stub and stub-setting template drawings.

Stringing procedure and stringing chart. Tower accessories drawings like design plate, name plate etc.

Quality plan for fabrication and site activities including Quality System.

Sub-vendors approval, etc.

1.3.11 All rights of the design for all types of towers including special towers and

foundation designs Supplied by the Owner shall be strictly reserved with the

Owner only and all the designs/drawings/data sheets submitted by the Contractor

from time to time after successful tower testing shall become the property of the

Owner. Under no circumstances, the Contractor shall be allowed to use/offer

above designs to any other authority without prior permission of the Owner. Any deviation to above is not acceptable and may be a cause of rejection of the Bid.

1.4 Design Improvements

1.4.1 The Owner or the Contractor may propose changes in the specification and if the

parties agree upon any such changes and the cost implication, the specification

shall be modified accordingly.

1.5 Design Co-ordination

The Contractor shall be responsible for the selection and design of appropriate

material/item to provide the best coordinated performance of the entire system.

The basic design requirements are detailed out in this Specification. The design of

various components, sub-assemblies and assemblies shall be so done that it facilitates easy field assembly and maintenance.

1.6 Design Review Meeting

The Contractor will be called upon to attend design review meetings with the

Owner, and the consultants of the Owner during the period of contract. The Contractor shall attend such meetings at his own cost at Delhi or at mutually

agreed venue as and when required.



1.7 Quality Assurance, Inspection & Testing

1.7.1 Quality Assurance

To ensure that the supply and services under the scope of this contract whether

manufactured or performed within the Contractor’s works or at his Sub-

Contractor’s premises or at site or at any other place of work are in accordance

with the specifications, the Contractor shall adopt suitable quality assurance

program to control such activities at all points necessary. Such program shall be

outlined by the Contractor and shall be finally accepted by the Owner after

discussions before the award of contract. A quality assurance program of the

Contractor shall generally cover but not limited to the following:

(a) His organization structure for the management and implementation of the

proposed quality assurance program.

(b) Documentation control system.

(c) Qualification data for Contractor’s key personnel. (d) The procedure for purchases of materials, parts components and, selection

of sub-Contractor’s services including vendor analysis, source inspection,

incoming raw material inspection, verification of material purchases 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 authorizing release of manufactured product to the Owner.

(l) System for maintenance of records.

(m) System for handling 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 and

(o) Field Quality Plan and Manufacturing Quality Plan.

The Quality plan shall be mutually discussed and approved by the Owner after

incorporating necessary corrections by the Contractor as may be required.

1.7.1.1 Quality Assurance Documents

The Contractor shall be required to submit all the Quality Assurance Documents

as stipulated in the Quality Plan at the time of Owner’s inspection of

equipment/material.

1.7.1.2 The Owner or his duly authorized representatives reserves the right to carry out

Quality Audit and quality surveillance of the systems and procedures of the

Contractor’s/his vendor’s Quality Management and Control Activities.



1.7.2. Owner’s Supervision

1.7.2.1.To eliminate delays and avoid disputes and litigation it is agreed between the

parties to the contract that all matters and questions shall be resolved in

accordance with the provisions of this document.

1.7.2.2.The manufacturing of the product shall be carried out in accordance with the

specifications. The scope of the duties of the Owner, 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 Contractor’s drawings, engineering data

etc.

c) Witness or authorise his representative to witness tests at the manufacturer’s

works or at site, or at any place where work is performed under the contract.

d) Inspect, accept or reject any equipment, material and work under the

contract, in accordance with the specifications.

e) Issue certificate of acceptance and/or progressive payment and final

payment certificate.

f) Review and suggest modification and improvement in completion schedules

from time to time, and

g) Supervise the Quality Assurance Program implementation at all stages of

the works.

1.7.3. Inspection & Inspection Certificate

1.7.3.1 The Owner, his duly authorized representative and/or outside inspection agency

acting on behalf of the Owner shall have at all reasonable times access to the

Contractor’s premises and 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 manufacture or assembled at other

premises or works, the Contractor shall obtain from the Owner and/or his duly

authorized representative permission to inspect as if the equipment/materials were manufactured or assembled on the Contractor’s own premises or works.

1.7.3.2 The Contractor shall give the Owner Inspector fifteen (15) days written notice of

any material being ready for testing. Such tests shall be to the Contractor’s

account except for the expenses of the Inspector. The Owner/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 Contractor may

proceed with the test which shall be deemed to have been made in the Inspector’s presence and he shall forthwith forward to the Inspector duly certified copies of

tests in triplicate.

1.7.3.3 The Owner/Inspector shall, within fifteen (15) days from the date of inspection as

defined herein give notice in writing to the Contractor, 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 Contractor shall give due consideration to such objections and shall make the modifications that may be necessary to meet

the said objections.

1.7.3.4 When the factory tests have been completed at the Contractor’s or sub-

Contractor’s works, the Owner/inspector shall issue a certificate to this effect

within fifteen (15) days after completion of tests but if the test are not witnessed

by the Owner/inspector, the certificate shall be issued within fifteen (15) days of receipt of these tests or the issue of the certificate shall not bind the Owner to

accept the equipment should it, on further tests after erection, be found not to

comply with the contract.

1.7.3.5 In all cases where the contract provides for test whether at the premises or works

of, the Contractor or of any sub-Contractor, the Contractor 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 Owner/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 Owner/Inspector or to his authorized representative to

accomplish testing.

1.7.3.6 The inspection by Owner and issue of Inspection Certificate thereon shall in no

way limit the liabilities and responsibilities of the Contractor in respect of the

agreed Quality Assurance Program forming a part of the Contract.

1.7.4. Tests and Standards

1.7.4.1 Tests

The following type, acceptance and routine tests and tests during manufacture

shall be carried-out on the material. For the purpose of this clause.

1.7.4.2 Type Tests shall mean those tests which are to be carried out to prove the process

of manufacture and general conformity of the material to this Specification. These tests shall be carried out on samples prior to commencement of commercial

production against the order. The Bidder shall indicate his schedule for carrying

out these tests.



1.7.4.3 Acceptance Tests shall mean those tests which are to be carried out on samples

taken from each lot offered for pre-dispatch inspection, for the purposes of acceptance of that lot.

1.7.4.4 Routine Tests shall mean those tests which are to be carried out on the material to

check requirements which are likely to vary during production.

1.7.4.5 Tests During Manufacture shall mean those tests, which are to be carried out

during the process of manufacture and end inspection by the Contractor to ensure the desired quality of the end product to be supplied by him.

1.7.4.6 The norms and procedure of sampling for these tests will be as per the Quality

Assurance Program to be mutually agreed to by the Contractor and the Owner.

1.7.4.7 The standards and norms to which these tests will be carried out are listed against

them. Where a particular test is a specific requirement of this specification, the norms and procedure of the test shall be as specified in Annexure-10 or as

mutually agreed to between the Contractor and the Owner in the Quality

Assurance Program.

1.7.4.8 For all type and acceptance tests, the acceptance values shall be the values

specified in this Specification or guaranteed by the Bidder, as applicable.

1.8 Guaranteed Technical Particulars

1.8.1 The Guaranteed Technical Particulars of the various items shall be furnished by

the Bidders in one original plus four (4) copies in the prescribed format as

provided in Annexure-6, Annexure-9 and Annexure12 of the Specifications. The

Bidder shall also furnish any other schedule information as in their opinion is needed to give full description and details to judge the item(s) offered by them.

1.8.2 The data furnished in Guaranteed Technical Particulars should be the minimum or

maximum value (as per the requirement of the specification) required. A Bidder

may guarantee a value more stringent than the specification requirement.

However, for testing purpose or from performance point of view, the material

shall be considered performed successfully if it achieves the minimum/maximum value required as per the technical specification. No preference what so ever shall

be given to the bidder offering better/more stringent values than those required as

per specification.

1.9 Packing

1.9.1 All the materials shall be suitably protected, coated, covered or boxed and created

to prevent damage or deterioration during transit, handling and storage at Site till


Volume-II / Section -II EPC Tender for JITPL

the time of erection. The Contractor shall be responsible for any loss or damage

during transportation, handling and storage due to improper packing.

1.9.2 The Contractor 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.

1.9.3 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.

1.9.4 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.

1.9.5 Each package shall be legibly marked by the Contractor at his expenses showing

the details such as description and quantity of contents, the name of the consignee

and address, the gross and net weights of the package, the name of the Contractor etc.

2.0 Erection Conditions

2.1 General

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.

2.2 Regulation of Local Authorities and Statutes

2.2.1 The Contractor 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 Local State Govt.) and the rules made there under in

respect of any employee or workman employed or engaged by him or his Sub- Contractor.

2.2.2 All registration and statutory inspection fees, if any, in respect of his work

pursuant to this contract shall be to the account of the Contractor. 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 Owner, shall be to the

account of the Owner. Should any such inspection or registration need to be re-



arranged due to the fault of the Contractor or his Sub-Contractor, the additional

fees to such inspection and/or registration shall be borne by the Contractor.

2.3 Contractor’s Field Operation

2.3.1 The Contractor shall keep the Owner 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 Owner shall not relieve the

Contractor of any of his responsibilities towards the field activities. Such reviews

shall also not be considered as an assumption of any risk or liability by the Owner

or any of his representatives and no claim of the Contractor will be entertained

because of the failure or inefficiency of any such plan or schedule or method of

work reviewed. The Contractor shall be solely responsible for the safety,

adequacy and efficiency of tools and plants and his erection methods.

2.4 Progress Report

2.4.1 Appropriate visual charts and photographs shall accompany the monthly progress

report detailing out the progress achieved on all erection activities as compared to

the schedules in both hard and soft copies. 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.

2.5 Man – Power Deployment Report

2.5.1 The Contractor shall submit to the Owner, on the first day of every month, a man

power deployment schedule for each activity.

2.5.2 The Contractor shall also submit to the Owner 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.

2.5.3 Facilities to be Provided by the Contractor

2.5.3.1 Tools, Tackle and Scaffoldings

The Contractor 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 Owner before the commencement of work at site. These tools and tackle shall not be removed from the site without the written permission of the

Owner.



2.5.3.2 First – Aid and General Hygiene

The Contractor shall provide necessary first-aid facilities for all his employees,

representatives and workmen working at the site. Enough number of Contractor’s

personnel shall be trained in administering first aid.

Similarly, the labor colony, the offices and the residential areas of the

Contractor’s employees and workmen shall be kept clean and neat to the entire

satisfaction of the Owner. Proper sanitary arrangements shall be provided by the

Contractor, in the work-areas, office and residential areas of the Contractor.

Waste oil shall be disposed of in a manner acceptable to the Owner. Under no

circumstances shall waste oil be dumped into uncontrolled drains.

2.6 Fire Protection

2.6.1 The work procedures that are to be used during the erection shall be those which

minimize 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 inflammable materials shall be

stored away from the construction site and equipment and material stores in safe containers.

2.6.2 All the Contractor’s supervisory personnel and sufficient number of workers shall

be trained for fire-fighting and shall be assigned specific fire protection duties.

Enough of such trained personnel must be available at the site during the entire

period of the contract.

2.6.3 The Contractor 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.

2.7 Security

The Contractor shall have total responsibility for all equipment and materials in

his custody, stored, loose, semi-assembled and/or erected by him at site. The

Contractor 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.

2.8 Materials Handling and Storage

2.8.1 All the supplies under the contract arriving at site shall be promptly received,

unloaded and transported and stored in the stores by the Contractor.



2.8.2 Contractor shall be responsible for examining all the shipment and notify the

Owner immediately of any damage, shortage, discrepancy etc. for the purpose of

Owner’s information only. The Contractor shall submit a report to the Owner every week, detailing all the receipts during the week. However, the Contractor

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 Contractor.

2.8.3 The Contractor 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 Owner.

2.8.4 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.

2.8.5 All the materials stored in the open or dusty location must be covered with

suitable weather-proof and flameproof covering material wherever applicable.

2.8.6 The Contractor shall be responsible for making suitable indoor storage facilities,

to store all items/materials which require indoor storage.

2.9 Construction Management

2.9.1 Time is the essence of the Contract and the Contractor shall be responsible for

performance of his works in accordance with the specified construction schedule.

If, at any time, the Contractor is failing 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 to otherwise to accelerate the

progress of the work and to comply with schedule and shall communicate such

actions in writing to the Owner, satisfying that his action will compensate for the delay. The Contractor shall not be allowed any extra compensation for such

action.

2.10 Field Office Records

The Contractor shall maintain at his site office up-to-date copies of all drawings,

specifications and other supplementary data complete with all the latest revisions thereto. The Contractor shall also maintain, in addition, the continuous record of

all changes to the above Contractor 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 Owner in required number of

copies.

2.11 Protection of Property And Contractor’s Liability

2.11.1 The Contractor shall 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 Contractor shall be responsible to give

reasonable notice to the Owner 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.

2.12 Insurance

2.12.1 In addition to the conditions covered under the title “insurance” in GCC the

following provisions will also apply to the portion of works to be done beyond the

Contractor’s own or his sub-Contractor’s manufacturing works.

2.12.2 Workmen’s Compensation Insurance

This insurance shall protect the Contractor against all claims applicable under the

workmen’s compensation Act, 1948 (Govt. of India). This policy shall also cover

the Contractor against claims for injury, disability disease or death of his or his

sub-Contractor’s employees, which for any reason are not covered under the

workmen’s Compensation Act, 1948. The liabilities shall not be less that :

Workmen’s Compensation As per Statutory Provisions

Employee’s Liability As per Statutory Provisions

2.12.3 Comprehensive Automobile Insurance

This insurance shall be in such a form to protect the Contractor against all claims

for injuries, disability, disease and death to members of public including the

Owner’s men and damage to the property of other arising from the use of motor

vehicles during on or off the site operations, irrespective of the Ownership of such vehicles. The minimum liability covered shall be as herein indicated :

a)

Fatal Injury

: Rs. 3,00,000 Each person

: Rs. 5,00,000 Each occurrence

b)

Property Damage :

Rs. 5,00,000 Each occurrence



2.12.4 Comprehensive General Liability Insurance

2.12.4.1. The insurance shall protect the Contractor against all claims arising from

injuries, disabilities, disease or death of members of public or damage to

property of others, due to any act or omission on the part of the Contractor, its

agents, its employees, its representative and sub-Contractors or from riots,

strikes and civil commotion.

2.12.4.2. The hazards to be covered will pertain to all the works and areas where the

Contractor, its sub-Contractors, its agents and employees have to perform work pursuant to the contract.

2.12.4.3. The above are only illustrative list of insurance covers normally required and it

will be the responsibility of the Contractor to maintain all necessary insurance

coverage to the extent both in time and amount to take care of all its liabilities

either direct or indirect, in pursuance of the contract.

2.13 Protection of Monuments and Reference Points

The Contractor 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 Owner. Similarly, the Contractor shall ensure that the bench marks, reference points etc., which are marked either with the help of Owner or by the Owner 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 Owner. The Contractor shall provide all necessary materials and assistance for such

relocation of reference points etc.

2.14 Work and Safety Regulations

2.14.1 The Contractor shall ensure safety of all the workmen, materials, plants and

equipment’s belonging to him or to the others, working at the site. The Contractor

shall also provide for all safety notices and safety equipment required by the

relevant legislation’s and deemed necessary by the Owner.

2.14.2 The Contractor will notify, well in advance to the Owner, its intention to bring to

the site any container filled with liquid or gaseous fuel or explosive or petroleum

substance or such chemicals which may involve hazards. The Owner 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 Contractor shall

strictly adhere to and comply with such instructions. The Owner shall also have the right at his sole discretion, in 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 Owner.

Further, any such decision of the Owner shall not, in any way, absolve the

Contractor of his responsibilities and in case use of such a container or entry

thereof into the site area is forbidden by the Owner, the Contractor shall use

alternative methods with the approval of the Owner without any cost implication

to the Owner or extension of work schedule.

2.14.3 Where it is necessary to provide and/or store petroleum products or petroleum

mixtures and explosives, the Contractor shall be responsible for carrying our 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 Owner.

In case, any approval is necessary from the Chief Inspector (Explosives) or any

statutory authorities, the Contractor shall be responsible for obtaining the same.

2.14.4 All equipment used in construction and erection by Contractor shall meet

Indian/International Standards and where such standards do not exist, the

Contractor shall ensure these to be absolutely safe. All equipment shall be strictly operated and maintained by the Contractor in accordance with manufacturer’s

operation manual and safety instructions and as per any existing Guidelines/Rules

in this regard.

2.14.5 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 test shall be properly maintained by

the Contractor and will be promptly produced as and when desired by Owner or

by the persons authorized by him.

2.14.6 The Contractor shall provide suitable safety equipment of prescribed standard to

all employees and workmen according to the need, as may be directed by the

Owner who will also have the right to examine these safety equipment to determine their suitability, reliability, acceptability and adaptability.

2.14.7 Where explosives are to be used, the same shall be used under the direct control

and supervision of an expert, experienced and qualified licensed and competent

person, strictly in accordance with the Code of Practices/Rules framed under

Indian Explosives Act pertaining to handling, storage and use of explosive, with required licenses or permissions.



2.14.8 The Contractor 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 Owner.

The name and address of such safety officer of the Contractor will be promptly

informed in writing to the Owner with a copy to the safety officer-in-charge

before he starts work or immediately after any change of the incumbent is made

during currency of the contract.

2.14.9 In case any accident occurs during the construction / erection or other associated

activities undertaken by the Contractor, thereby causing any minor or major or fatal injury to his employees due to any reason whatsoever, it shall be the

responsibility of the Contractor to promptly inform the same to the Owner and

also to all the authorities envisaged under the applicable laws.

2.14.10The Owner 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 informed in

writing about the nature of hazards and possible injury/accident and he shall remove short-comings promptly. The Contractor after stopping the specific work,

can if felt necessary, appeal against the order of stoppage of work to the Owner

within 3 (three) days of such stoppage of work and the decision of the Owner in this respect shall be conclusive.

2.14.11The Contractor shall not be entitled for any damages/compensation for stoppage

of work due to safety reasons as provided in Clause 2.14.10 above and the plea 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 Supplies liability for

timely completion of the works.

2.14.12The Contractor 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.

2.14.13If the Contractor fails in providing safe working environment as per Safely Rules

or continues the work even after being instructed to stop work by the Owner as

provided in Clause 2.14.10 above, the Contractor shall promptly pay to the Owner on demand, compensation at the rate of Rs.5,000/- (five thousand) per day or part

thereof till the instructions are complied with and so certified by the Owner.

However, in case of accident taking place causing injury, to any individual, the provisions contained in Clause 2.14.14 below shall also apply in addition to

compensation mentioned in this para.



2.14.14If the Contractor does not take all safety precautions and/or fails to comply with

the Safety Rules as prescribed by the Owner or as prescribed under the

applicable-law for the safety of the equipment, plant and personnel and the

Contractor does not prevent hazardous conditions which may cause injury to his

own employees or employees of other Contractors or Owner or any other person

at site or adjacent thereto, the Contractor shall be responsible for payment of

compensation to the Owner as per the following schedule:-

a) Fatal injury or accident

Rs.3,00,000.00

Applicable

for

causing death (Three lakhs only) Per death/ injury to any person person.

b) Major injuries or

accident causing 25 % or more permanent disability

Rs. 50,000/-

(Fifty thousand only) Per person

Whosoever

Permanent disability shall have the same meaning as indicated in Workmen’s

Compensation Act. The compensation mentioned above shall be in addition to the

Compensation payable to the workmen/employees under the relevant provisions

of the Workmen’s Compensation Act and rules framed there under or any other

applicable law as applicable from time to time. In case the Owner is made to pay

such compensation, the Contractor will be liable to reimburse the Owner such

amount(s) in addition to the compensation indicated above.

2.15 Foreign Personnel

2.15.1 In case necessary for the execution of the works, the Contractor shall bring

foreign supervisors for the execution of the contract, at his own cost. The Contractor shall submit to the Owner, 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.

2.15.2 Any person, unsuitable and unacceptable to the Owner, shall not be brought to

India. Any person brought to India, and found unsuitable or unacceptable to the

Owner shall be immediately removed from site and repatriated back, if found necessary, he may be replaced by another personnel acceptable to the Owner.

2.15.3 No person brought to India by the contactor, for the works shall be repatriated

without the consent of the Owner in writing, based on a written request from the

Contractor for such repatriation giving reasons for such an action to the Owner.

The Owner may give permission for such repatriation provided it is satisfied that the progress of work will not suffer due to such repatriation.



2.15.4 The cost of passports, visas and all other travel expenses to and from India, shall

be to the Contractor’s account. The Owner will not provide any residential

accommodation and/or furniture for any of the Contractor’s personnel including foreign personnel Contractor shall make his own arrangements for such facilities.

2.15.5 The Contractor 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 Owner may establish on them. The Contractor’s

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.

2.15.6 The Owner shall assist the Contractor, 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.

2.16 Code Requirements

The erection requirements and procedures to be followed during the execution of the project shall be in accordance with the applicable India/International

standards/Regulations, as indicated in Technical Specifications, good engineering

practice, the Drawings and other applicable Indian codes, laws and regulations.

3.

3.1.

JITPL’s Environment and Social Policy and its Implementation

Development and growth of mankind through Industrialization and unwarranted

use of natural resources has inflicted considerable impact on Environment and

Society. As a result, Environmental and Social issues have emerged as the focal

point of global debate.

In order to address environmental and social issues and to match the rising

expectations of a cleaner, safer and healthier environment, Contractor needs to adhere to the following norms

i) Avoidance of environmentally and socially sensitive areas while planning

project activities.

ii) Minimization of impacts when project activities occur in environmentally

and socially sensitive areas.

iii) Mitigation of any unavoidable adverse impacts arising out of its projects.

3.2. Basic issues to be kept in mind while carrying out construction activities are to



i)

ii)

iii)

iv)

v)

vi)

Avoid socially sensitive areas with regard to human habitations and areas

of cultural significance.

Secure the interest of people affected due to project.

Involve local people affected by transmission line project as per

requirement and suitability.

Consult affected people in decisions having implication to them if

considered necessary.

Apply, efficient and safe technology / practices.

Keep abreast of all potential dangers to people’s health, occupational

safety and safety of environment and the respective mitigatory measures.

vii) Establish preventive mechanisms to guarantee safety.

viii) Mitigation measures in case of accidents.

ix) Avoid unwarranted cutting of trees in forest area.

3.3. While constructing the lines through forest stretches the Contractor will provide

alternate fuel to its employee e.g. working labours /supervisors etc. in order to

avoid cutting of forest woods.

3.4. Contractor will ensure safety to the wild life. During working/camping near to the

National park.

3.5. Contractor during construction of lines in agricultural fields will ensure minimum

damages to the crops, trees, bunds, irrigation etc. If the same is unavoidable, the decision of Engineer-in-charge shall be final.

3.6. The waste/excess material/debris should be removed from the construction site

including agricultural field, forest stretches, river etc. immediately after construction work and obtain a clearance certificate form the Owner of the land.

3.7. The Contractor will ensure least disturbance to the hill slope and natural drainage

so as to avoid soil erosion. Natural drainage in plain area if disturbed is to be

trained to the satisfaction of Engineer-in-charge.

3.8. As far as possible existing path/kachha road/approach shall be used for the

construction.

3.9. The Contractor will ensure supply of stone chips/sand from authorized/approved

quarry areas who are having the required licenses/permits from the local

authorities.

3.10. Proper documentation of above, if any.


Volume-II / Section - III EPC Tender for JITPL

SECTION – III

TOWER SPECIFICATION



SECTION – III

CONTENTS Clause Description

Page No

1.0

Detailed Survey, Optimization of Tower Location

33

2.0 Environmental Conditions

38

3.0 Transmission

4.0 Geotechnical

5.0 Foundations

Tower

Investigations

38

54

75

6.0

7.0

8.0

Tower Erection, Stringing and Installation of Line

Materials

Special River Crossing Tower

Field Quality Plan

Annexure-A

Annexure-B

Annexure-C

Annexure-D

Annexure-E

83

91

92

103

106

107

109

110




SECTION – III

TOWER SPECIFICATION

1.0 Detailed Survey, Optimization of Tower Location

1.1 Detailed survey for both the packages is completed. However near the approaches

to sub-stations and if any deviations in line route, detailed survey including

profiling, tower optimisation , tower spotting and check survey shall have to be carried out by the Contractor on the basis of Tower Spotting Data given by Owner

as stipulated herein.

1.2 The Contractor shall submit the proposal for detailed survey based on the

preliminary route alignment given by the Owner. The Contractor shall finalize

and submit results of detailed survey including any changes suggested within the

time schedule as agreed at the time of award. The soil investigation for the obligatory points are to be carried out by the Contractor as detailed out in this

specification.

1.3 The Contractor should note that Owner 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.

1.4 The detailed survey shall be made along the approved route alignment.

1.5 Soil resistivity along the route alignment, shall be measured in dry weather by

four electrode method keeping inter-electrode spacing of 50 meters. For

calculating soil resistivity formula 2πar (where a = 50 metres and r = megger

reading in ohms) shall be adopted. Measurement shall be made at every 2 to 3 kms along the route of transmission lines. In case soil characteristic, changes

within 2 to 3 kms, the value shall also have to be measured at intermediate

locations. The megger reading and soil characteristics shall also be indicated in

the soil resistivity results.

1.6 Route Making

At the starting point of the commencement of route survey an angle iron spike of

65 x 65 x 6mm section and 1000mm 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 50x50x650mm six shall be driven at prominent position at intervals of

not more than 750 meter along the transmission line to be surveyed up to the next

angle point. Nails of 100mm wire length 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 “JITPLPowerTransco” marked on them shall be put

firmly on the ground for easy identification.

1.7 Profile Plotting & Tower Spotting

From the field book entries, the route plan with en-route details and level profile

shall be plotted and prepared to scale of 1:2000 horizontal & 1:200 vertical in

PLS-CADD software on 10 mm squared paper as per approved procedure.

Reference levels at every 20 meters along the profile are also to be indicated on

the profile besides, R/Ls at undulations. Areas along the profile Sheet, in the view

of the Contractor, 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 accordingly 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 standard. For ‘as built’ profile these shall be in A1

size.

1.8 Tower Location

1.8.1 Sag Template & Tower Spotting Data

Sag template curve drawing and Tower Spotting Data shall be supplied by the

Owner to the successful Bidder on award of Contract. Sag template prepared based on the supplied 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 Contractor to the Owner for the

purpose of checking the tower spotting. The templates shall be on the same scale as that of the profile.

1.8.2 Tower Spotting

With the help of supplied 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

spans or 5 Kms in plain terrain and 10 spans or 3 Kms in hilly terrain. A section

point shall comprise of tension point with DB type or DC type or DD type towers

as applicable.

(b) Extension

An individual span shall be as near to the normal design span as possible. In case an individual span becomes too short with normal supports on account of

undulations in ground profile, one or both the supports of the span may be



extended by inserting standard body extension designed for the purpose according

to technical specification.

(c) Loading

The towers shall be spotted such that wind & weight spans are within permissible

limits (as per tower spotting data), to avoid any loading on towers beyond design

provisions.

(d) Road Crossing

At all important road crossings, the ground clearance at the roads under maximum

temperature and in still air shall be such that even with conductor broken an

adjacent span, ground clearance of the conductor from the road surfaces will not

be less than 8.84 m for 400 KV lines. At all national highways tension towers

shall be used and crossing span will not be more than 250 meters.

(e) Railway Crossings

All the railway crossings coming en-route the transmission line have already been

identified by the Owner. 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)

ii)

iii)

iv)

v)

vi)

The crossings shall be supported on DD type tower on either side

depending on the merits of each case. The crossing shall normally be at right angle to the railway track.

The minimum distance of the crossing tower shall be at least equal to the

height of the tower plus 6 meters away measured from the centre of the

nearest railway track. No crossing shall be located over a booster transformer, traction switching

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

Minimum ground clearance above rail level of the lower portion of any conductor under condition of maximum sag shall be maintained at 17.90

meters.

The crossing span will be limited to 300 meters.

The approval for crossing railway track shall be obtained by the Owner from the

Railway Authority, however, six copies of profile and plan, tower and foundation

design and drawings required for the approval from the Railway Authority shall

be supplied by the Contractor to the Owner.

(f) River Crossings

Suitable type of tension tower shall be used for river crossings. Clearance

required by navigation authority shall be provided. For non navigable river,

clearance shall be reckoned with respect to highest flood level (HFL).



(g) Power line Crossings

Where this line is to cross over another line of the same voltage or lower voltage,

suitable type of tension tower with suitable extensions shall be used for crossings.

Provisions to prevent the possibility of its coming into contact with other

overhead lines shall be made in accordance with the Indian Electricity Rules,

1956 as amended upto date. 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

Contractor except if modifications are required to line below, in which case, the conditions to be agreed upon.

Minimum clearance in meters between lines when crossing each other shall be as

per stipulations of IE Rules.

(h) Telecommunication Line Crossings

The angle of crossing shall be as near to 90 degree possible. However, deviation to the extent of 30 degree may be permitted under exceptionally difficult

situations.

When the angle of crossing has to be below 60 degree, the matter will be referred

to the authority in-charge of the telecommunication system by the Owner on

intimation from the Contractor. If deviation of telecommunication line is required the same has to be executed by the Contractor at his own cost.

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. Contractor shall also be responsible for various activities viz. collecting

input details, preparation of documents etc. as may be required, for processing of

case for PTCC clearance for the transmission line(s) from the concerned authorities.

(i) Details En-route

All topographical details, permanent features, such as trees, building etc. 23m for

400KV on either side of the alignment shall be detailed on the profile plan.

1.9 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.

1.9.1. The tree cutting shall be the responsibility of the Contractor. The Contractor 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 at the time of actual execution of the work as detailed below. Contractor may please note that Owner shall not pay any

compensation for any loss or damage to the properties or for tree cutting due to

Contractor’s work.



1.9.2. Any way leave which may be required by the Contractor, shall be arranged by the

Contractor as required by work program.

1.9.3. To evaluate and tabulate the trees and bushes coming within 23m for 400KV on

either side of the central line alignment the trees will be numbered and marked

with quality paint serially from angle point 1 (I) onwards and the corresponding

number will be painted on the stem of trees at a height of 1 meter from ground

level. The trees list should contain the following:

a) Girth (circumstances) measured at a height of 1 meter from ground level.

b) Approximate height of the tree with an accuracy of +2 meters.

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

d) The bushy and under growth encountered in the 46 m belt should also be

evaluated with its type, height, girth and area in square meters, clearly

indicating the growth in the tree/bush statement.

1.9.4. Payment of compensation towards the clearance etc. will be the responsibility of

the Owner. Contractor has to obtain the valuation of the trees/crops and pay the

compensation as to the affected parties and get the receipts for reimbursement

from the Owner.

1.10 Preliminary Schedule

The profile sheets, duly spotted, along with preliminary schedules indicating type

of towers, type of foundations, wind span, weight span, angle of deviation, river

of road crossing and other details shall be submitted for the approval of the

Owner. After approval the Contractor shall submit six more sets of the approved reports along with one set of reproducible of final profile drawings to the Owner

for record purpose.

1.11 Check Survey for Tower Location

1.11.1. 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 centre with respect to the centre of the

tower location shall be noted and recorded for determining the amount of earthwork required to meet the approved design parameters.

1.11.2. Changes in the preliminary tower schedule after check survey, if required, shall be

carried out by the Contractor and he shall thereafter submit a final tower schedule

for the approval of Owner. 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.



2.0 Environmental Conditions

2.1 Forest

The line route passing through forest stretches for various transmission lines

covered under this specification shall be furnished to the successful Bidder.

2.2 General Climatic Conditions

Climatic conditions shall be of tropical nature having summer period for 8 months

and winter period for 4 months in a year. Working season shall be approximately

9 months/year and balance 3 months shall be monsoon period.

The maximum temperature during summer shall be of the order of 50oC and the

minimum temperature in the winter shall be of the order of 7.5oC. Normal every

day temperature is 32°C.

2.3 Statutory Regulations and Standards

2.3.1. Statutory Regulations

The Contractor is required to follow local statutory regulations stipulated in

Electricity Act 2003, lndian Electricity Rules, 1956 as amended and other local

rules and regulations referred in these Specifications.

2.3.2. Reference Standards

2.3.2.1.The Codes and/or standards referred to in the 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.

2.3.2.2.Other internationally accepted standards which ensure equal or better

performance than those specified shall also be accepted, subject to prior approval

by the Owner.

3.0 Transmission Tower

3.1 General Description of the Tower

3.1.1. The towers are of the following types:

a) Double Circuit (DA, DB, DC & DD)

b) Special towers


Volume-II / / Section - III EPC Tender for JITPL

3.1.2. The towers are of self supporting hot dip galvanised lattice steel type designed to

carry the line conductors with necessary insulators, earth wires and all fittings

under all loading conditions. Outline diagram of double circuit tower is enclosed

with the Specification.

3.1.3. The tower shall be fully galvanised using mild steel or/and high tensile steel

sections as specified in clause no. 3.6. Bolts and nuts with spring washer are to be

used for connections.

3.2 Type of Towers

3.2.1. The towers for 400 kV Lines are classified as given below

Type of Tower Deviation Limit Typical Use

DA 0 deg To be used as tangent tower.

DB 0 deg – 15 deg a) Angle towers with tension insulator string. b) Also to be used for uplift force resulting from an

uplift span upto 200 m under broken wire condition.

c) Also to be used for Anti Cascading Condition.

DB 0 deg d) To be used as Section Tower

DC 15 deg - 30 deg a) Angle tower with tension insulator string. b Also to be used for uplift forces resulting from an

uplift span upto 200 m under broken wire condition.

c) Also to be used for anti cascading condition.

DC

DD

DDE

0 deg

30 deg-60 deg

0 deg

d) To be used as section tower. Also to be used for

transposition of transmission lines with

modifications

a) Angle tower with tension insulator string.

b) Also to be used for uplift forces resulting from an

uplift span upto 300 m under broken wire condition

c) For river crossing anchoring with longer wind

span & 0 deg. deviation on crossing span side and 0 deg to 30 deg. deviation on other side

a) Complete dead end. b) Dead end with 0 deg to 15 deg deviation both on

line side and sub station side (slack span).

Note:- the above towers can also be used For longer span with smaller angle of

deviations.



3.2.2. Transposition tower

DC type towers with suitable modifications are to be used for transposition of the

line maintaining all the required clearance and shielding. Two numbers of

transposition towers shall be required for double circuit line.

3.2.3. Special Towers

The towers which will be specially designed for very long spans which can not be

crossed by normal tower with extensions, like major river crossings etc. shall be

treated as special towers.

3.2.4. Extensions

3.2.4.1.The Double Circuit towers are designed so as to be suitable for adding 3M, 6M

and 9M body extensions/leg extensions for maintaining adequate ground

clearances without reducing the specified factor of safety in any manner.

3.2.4.2.The provision for addition 18/25M body extension to tower types DA and DD is

also kept by the Owner. For Power Line Crossing, River Crossings or any other

obstacle, tower types DA or DD can be used with 18/25 M extensions depending,

upon the merit of the prevailing site condition. The maximum reduced spans for

DA and DD type towers shall be mentioned in the tower spotting data.

3.2.4.3.Provision for use or unequal leg extensions (upto max. 3m difference) has also

been kept. The details of unequal leg extensions provided in the design shall be

indicated to the Contractor during execution stage, so that proper optimisation of

benching/revetment requirement can be done accordingly by the Contractor.

3.2.4.4.All above extensions provisions to towers shall be treated as part of normal tower

only.

3.3 Span and clearances

3.3.1. Normal Span

The normal ruling span of the line is 400m.

3.3.2. Wind Span

The wind span is the sum of the two half spans adjacent to the support under consideration. For normal horizontal spans this equals 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. For spotting of structures, the

span limits given in Table 3.1 for 400KV lines shall prevail.



TABLE 3.1

(FOR 400 KV D/C LINE PORTION)

TOWER TYPE

NORMAL CONDITION

BROKEN WIRE CONDITION

MAX. (m)

DA 600 200 360 100

DB, DC 600 0 360 (-)200

DD 600 0 360 (-)300

MIN. (m) MAX. (m) MIN. (m)

3.3.4. In case at certain locations where actual spotting spans exceed the design spans

then cross-arms and certain members of towers required to be modified

/reinforced, in that case drawings of the modified/reinforced tower shall be

supplied to the Contractor as per requirement.

3.4 Electrical Clearances

3.4.1. Ground Clearance

The minimum ground clearance from the bottom conductor shall not be less than

8840 mm for 400KV at the maximum sag conditions and still air.

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 a

temperature of 26°C, lower than the stringing temperature for ACSR “MOOSE” for 400KV transmission lines.

3.5 Design and Drawings

3.5.1 The relevant drawings for all the towers and their extension shall be furnished to

the Contractor by the Owner which shall include structural/ erection drawings,

Shop floor drawings single line drawings/diagrams, foundation working drawings. In case the Contractor’s designs/drawings are approved by the Owner, the

Contractor is fully responsible for providing the Owner with structural/ erection

drawings, Shop floor drawings single line drawings/diagrams, foundation working

drawings etc., after incorporating their weights/volumes etc.

3.5.2 The structural/erection drawings for the towers and their extensions shall be given

to the Contractor in two copies. The tower numbers shall be fabricated from the

shop drawings and BOM to be provided by Owner. However, before taking up

the mass fabrication, the Contractor shall arrange for one number proto-

assembly for each type of towers and extensions which shall be inspected by Owner. However no separate charges will be paid by the Owner for proto

assembly of towers along with its extensions. After successful proto assembly

inspection the Contractor shall make reproducible from the given



drawings/documents, add the required note for the subject line; change the

revision number to the drawing documents and incorporate changes, if required to

be made during proto-assembly. The revised drawing/documents (including

structural drawings, BOM etc.) shall be submitted in four copies and will be

finally approved by the Owner.

The mass/fabrication shall be taken up from the approved drawings. The overall

responsibility of fabricating tower members correctly lies with the Contractor

only and the Contractor shall ensure that all the tower members can be fitted

while erecting without any undue strain on them.

3.5.3 Some drawings & documents such as BOM, shop drawings, structural drawings

for some of towers/extensions based on single line design diagrams etc.; if any, required for proper and effective execution of the project may also be required to

be developed by the Contractor. However, no extra cost for the same shall be

payable to the Contractor.

3.5.4 The drawings submitted by the Contractor shall be approved/commented by the

Owner as the case may be within thirty (30) days of receipt of drawings in

Owner’s office. It the designs/drawings are commented by the Owner, the Contractor shall submit revised design/drawings duly incorporating all comments

within fifteen (15) days of date of issue of comments.

3.5.5 The tower accessories drawings like number plate, circuit plate, danger plate,

phase plate, anti-climbing device, step bolt, D-shackle, Hanger etc. including

Earthing drgs. shall also be prepared by the Contractor and shall be submitted to

the Owner, in three copies, along with one reproducible, for record: These drawings shall be prepared in A4 size only.

3.5.6 Not Applicable

3.5.7 While submitting the structural drawings, bill of materials and any other drawings

pertaining to the subject transmission line, the Contractor shall clearly indicate on each drawing “JITPL” Specification No. Name of the transmission line and

project, letter reference no. and date on which the submission are made. The same

practice is also to be followed while submitting distribution copies. The

Contractor shall require to submit 15 copies of all relevant drawings for necessary distribution.

3.6 Materials

3.6.1 Tower Steel Sections

IS Steel Sections of tested quality of conformity with IS:2062 (Designated

Y.S.250 MPa) or/and IS:8500 grade 490B (Designated Y.S.350 MPa) as per the

tower designs are to be used in towers, extensions and stub setting templates. The



Contractor can use other equivalent grade of structural steel angle sections and

plates conforming to latest International Standards. However, use of steel grade

having designated yield strength more than of EN 10025/BS-4360-50B grade (355MPa) is not permissible.

Steel plates below 6mm size exclusively used for packing plates/packing washers

produced as per IS: 1079 -1994 (Grade -0) are also acceptable. However, if below 6mm size plate are used as load bearing plates viz gusset plates, joint splices etc.

the same shall conform to IS: 2062/IS 8500 or equivalent standard meeting

mechanical strength/metallurgical properties corresponding to Fe-410 or above grade (designated yield strength not more than 355MPa), depending upon the type

of grade incorporated into design: Flats of equivalent grade meeting mechanical

strength and metallurgical properties may also be used in place of plates for packing plates packing washers. The chequered plates shall conform to IS:3502-

1994.

For designing of towers rationalised steel sections has been used. During

execution of the project, if any particular section is not available, the same shall

be substituted by higher section at no extra cost to Owner and the same shall be

borne by the Contractor. However, design approval for such substitution shall be obtained from the Owner before any substitution.

3.6.2 Fasteners: Bolts, Nuts and Washers

3.6.2.1.All tower members shall be joined together with Bolts and nuts. The redundants

of first two (2) panels from ground level shall be connected with Anti-theft bolts

and nuts along with spring washers whereas the balance joints shall be connected with the hexagonal bolts & nuts. All hexagonal bolts and nuts shall conform to IS-

12427. They shall have hexagonal head and nuts, the heads being forged out of

the solid, truly concentric, and square with the shank, which must be perfectly straight.

Anti-theft bolts and nuts shall have round tapered heads with hexagonal shear

nuts. They shall conform to IS: 12427 and IS: 1367 for property class 5.6/5 except

for dimensions which shall be as per enclosed drawing no. O-0000-OO-X-X-X-

030.

All bolts and nuts shall be galvanised as per IS: 1367 (Part-13)/IS: 2629.

3.6.2.2.The bolt shall be of 16/24 mm diameter and of property class 5.6 as specified in

IS: 1367 (Part-III) and matching nut of property class 5.0 as specified in IS:1367

(Part-VI).

3.6.2.3.Bolts upto M16 and having length upto 10 times the diameter if 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 face in accordance with IS: 1363 (Part-I) to

ensure proper bearing.

3.6.2.4.Nuts for hexagonal bolts should be double chamfered as per the requirement of

IS: 1363 Part-III. It should be ensured by the manufacturer that nuts should not be

overlapped beyond 0.4MM oversize on effective diameter for size upto M16.

Nuts for Anti-theft bolts should be round tapered with hexagonal shear nuts. The

hexagonal portion of shear nuts shall break away at specified torque

recommended by the Contractor to ensure proper tightening of members and the

fasteners shall not be opened subsequently with tools. The tightening torque and

shearing of anti-theft nuts shall be verified during proto-assembly.

3.6.2.5.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.

3.6.2.6.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 3mm and not more

than 8mm when fully tightened. All nuts shall fit tight to the point where the shank of the bolt connects to the head.

3.6.2.7.Flat and tapered washers shall be provided wherever necessary. Spring washers

shall be provided for insertion under all nuts. These washers shall be steel electro-

galvanized, positive lock type and 3.5mm in thickness for 16mm dia. bolt and

4.5mm for 24mm bolt.

3.6.2.8.To avoid bending stress in bolts or to reduce it to minimum, no bolt shall connect

aggregate thickness of members more than three (3) times its diameter.

3.6.2.9.The bolt positions in assembled towers shall be as per structural drawing.

3.6.2.10. Bolts at the joints shall be so staggered that nuts shall be tightened with

spanners without fouling.

3.6.2.11. To ensure effective in-process Quality control it is essential that the

manufacturer should have in house testing facility for all tests like weight of zinc coating, shear strength and other tests etc. 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

Arrangement shall be provided for fixing of all tower accessories to the tower at a height between 2.5 meters and 3.5 meters above the ground level.



3.7.1 Step Bolts & Ladders

Each tower shall be provided with step bolts conforming to IS: 10238 of not less

than 16mm diameter and 175mm long, spaced not more than 450mm apart and extending from 2.5 meters above the ground level to the top of the tower. For

double circuit tower the step bolt shall be fixed on two diagonally opposite legs

upto 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 with standing a

vertical load not less than 1.5 KN. For special towers, where the height of the

super structure exceeds 50 meters, (ladders along with protection rings as per the Owner 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 3.5m to 30m height of super structure stop bolts shall be provided. Suitable platform using 6mm thick perforated chequered plates alongwith suitable

railing for access from step bolts to the ladder and from the ladder to each cross-

arm tip and the ground wire support shall also to be provided. The platform shall

be fixed on tower by using counter-sunk bolts.

3.7.2 Insulator Strings Attachments

a) For the attachment of suspension Insulator string, a suitable dimensioned swinging hanger on the tower shall be provided so as to obtain specified

clearances under respective swinging condition of the strings. The hanger,

extensions links, D-shackles etc. as required and considered in the design of the tower shall have minimum ultimate tensile strength of 2x120 KN =

240 KN UTS for double suspension string. The design and supply of

hanger, D-shackles, strain plate etc. are also in the scope of Contractor.

b)

At tension towers strain plates of suitable dimensions under each cross-

arm tip, shall be provided for taking the hooks or D-shackles of the tension

insulator strings with ultimate tensile strength of 4 X 160 KN. To achieve requisite clearances, if the design calls for providing extra D-shackles, link

plate etc. before connecting the insulator string the same shall be supplied

by the Contractor.

3.7.3 Earthwire Clamps Attachment

a) Suspension Clamp

Earthwire suspension clamps will be supplied by the Contractor. The drawing shall be submitted by the Contractor for Owner’s approval. The

Contractor shall also supply U bolts/D-shackles, wherever required.

b)

Tension Clamps

The Contractor shall supply earthwire tension clamps, for incorporation on

the tower. Earth wire peaks of tension towers shall be provided with suitable plates to accommodate the shackle of tension clamps. The

Contractor shall also supply the U-bolts wherever required and take



Owners approval for details of the attachments before the mass

fabrication.

3.7.4 Anticlimbing Device

Barbed wire type anti-climbing device, as per enclosed drawing shall be provided

and installed by the Contractor for all towers. The barbed wire shall conform to

IS-278 (size designation Al). The barbed wires shall be given chromating dip as

per procedure laid down in IS:1340.

3.7.5 Danger, Number, Circuit and Phase plate

Danger Plates, Number plates, circuit plates and phase plates shall be provided

and installed by the Contractor.

a) Each tower shall be fitted with a danger plate number plate and two sets of

phase plates for double circuit tower. The transposition towers should

have provision of fixing phase plates on both the transverse phase. Circuit

plates shall be provided on all the Double Circuit towers.

b) The letters, figures and the conventional skull and bones of danger plates

shall conform to IS-2551 and shall be in a signal red on the front of the

plate. .

c) The corners of the danger, number and circuit plates shall be rounded off

to remove sharp edges.

d) The letters at number and circuit plates shall be red enameled with white

enameled background.

3.7.6 Aviation Requirements:

3.7.6.1.Aviation requirements, if required shall be in the scope of the Contractor and the

same shall conform to IS: 5613 (Part-2, Sec-I).

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-Il) or the relevant international standards.

3.8.2 The tower structures 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 1.5mm.



3.8.5 The structure shall be designed so that all parts shall be accessible for inspection

and cleaning. Drain holes shall be provided at all points where pockets of

depression are likely to hold water.

3.8.6 All identical parts shall be made strictly inter-changeable. All steel sections before

any work is done on them, shall be careful leveled, straightened and made true to

detailed drawings by methods which will not injure 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.

3.8.7 Drilling and Punching

3.8.7.1.Before any cutting work is started1 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.

3.8.7.2.Holes for bolts shall be drilled or punched with a jig but drilled holes shall be

preferred. The punching may be adopted for thickness upto 16mm. Tolerances

regarding punch holes are as follows:-

a) Holes must be perfectly circular and no tolerances in this respect are

permissible.

b) The maximum 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 holes should not

exceed 0.8mm on diameter.

c) Holes must be square with the plates or angles and have their walls parallel.

3.8.7.3.All burns 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.

3.8.8 Erection mark

3.8.8.1.Each individual member shall have erection mark conforming to the component

number given to it in the fabrication drawings. The mark shall be marked with marking dies of 16mm size before galvanising and shall be legible after

galvanising.

3.8.8.2.Erection Mark shall be

A-BB-CC-DDD

A = Owner’s code assigned to the Contractors - Alphabet

BB = Contractor’s Mark-Numerical

CC = Tower Type Alphabet.



DDD = Number mark to be assigned by the Contractor- Numerical.

Erection mark for high tensile steel members shall be prefixed by the letter “H”

3.9 Quantities and weights

3.9.1 The quantities of the following items have been envisaged in Annexure-1 for

various types of towers:

i) Basic Body.

ii) Body Extensions. iii) Leg Extension.

iv) Stubs & Cleats

v) Bolts & Nuts including spring washers and step bolts etc.

During detail engineering, proto assembly of each of the above items shall be

inspected and approved by Owner and subsequently shall be released for

fabrication and manufacturing as per the Technical Specification by the

Contractor. The manufacturing of the above items shall be taken up in such a

manner that the Equipment/Material offered for inspection to Owner are on

completed tower basis for each type of tower, completed Stubs & Cleats set basis so as to facilitate availability of erectable tower of each type and erectable stubs &

cleats set for casting to foundation. After inspection of the offered Equipment/

Material by Owner representative(s), a certificate for the inspected quantity shall be issued by Owner for the material meeting the requirements of Technical

Specification. However, MICC shall be issued only on Completed Tower Basis

for each type of tower (comprising the required Basic Body, body extensions

wherever required, four (4) equal or defined unequal Leg Extension, Bolts & Nuts along with Packing and Spring Washers) and on completed Stubs & Cleats set

basis for each type of tower foundation (comprising a set of stubs & Cleats,

required Bolts and Nuts along with Spring Washers).

Accordingly, the payment shall be released for completed Tower Basis for each

type of tower (Comprising the Basic Body, body extensions, wherever applicable, bolts & nuts along with spring washer and step bolts, unequal leg extensions

wherever applicable for a completed Tower) and on completed Stubs and Cleats

set basis for each type of foundation (comprising a set of stubs & cleats, required

Bolts and Nuts along with Spring Washers) based on the weight of the tower parts as calculated as per Clause 3.9.3 and Bolts & Nuts based on the unit rates

incorporated in the contract.

3.9.2 Detail survey for both the packages is completed and tower schedule prepared

based on the detailed survey is attached as Annexure-3. Contractor has to

calculate all the quantities/volumes as per the details provided in Annexure-3 and quote the price accordingly. Unit volumes for the foundations and weights of the

towers and bolts and nuts are provided in Annexure-4 for calculating the total

quantities. However for benching, revetment and other tower protection works,



contractor has to estimate the quantity during the site visit. Contractor is advised

to have thorough site visit and understand the site conditions before submitting

the tender.

3.9.3 Though fully galvanised tower parts are to be supplied, 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 bill of materials, without taking into consideration the

reduction in weights due to holes, notches and level cuts etc. but taking into

consideration the weight of the D-shackles, hangers, strain plates, pack plates, gusset plates and pack washers etc. The weight of stub and cleats also shall be

calculated in similar manner. For bolts and nuts along with spring washers and

step bolts, the weight per tower shall be calculated from the bolt schedule applicable to each type of towers and body extensions as approved by the Owner.

The rate quoted by the bidder for tower/tower part supply is deemed to be

inclusive of galvanising charges including the cost of zinc.

3.10 Galvanising

Fully galvanised towers and stub shall be used for the lines. Galvanising of the

member of the towers shall conform to IS: 2629 and IS: 4759. All galvanised members shall withstand tests as per IS: 2633. For fasteners the galvanising shall

conform to IS: 1367 (Part-13). The galvanising shall be done after all fabrication

work is completed, except that the nuts may be taped or re-run after galvanising. 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 Clause 4 of IS: 1573.

3.11 Earthing

The Contractor shall measure the tower footing resistance (TFR) of each tower after it has been erected and before the stringing of the earthwire during dry

weather. Each tower shall be earthed the tower footing resistance shall not exceed

10 ohms. Pipe type earthing and counter poise type earthing wherein required shall be done in accordance with the latest additions and revisions of:

IS: 3043 Code of practice for Earthing.

IS: 5613 Code of practice for Design, Installation and maintenance (Part

II/Section-2) of overhead power lines.

3.11.1 The details for pipe & counterpoise type earthing are given in the drawings

enclosed with these specifications.

3.11.2 The provisional quantities for pipe type earthings and counterpoise earthing are

furnished in Annexure-1. The bidders are required to quote unit rates for the same

in appropriate schedule. 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 120 meters of wire per

tower.

3.12 Inspection and Tests

3.12.1 General

All standard tests, including quality control tests, in accordance with appropriate

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

3.12.2 Inspection

3.12.2.1.

a) The Contractor shall keep the Owner 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 could be made for inspection.

b) The acceptance of any part of items shall in no way relieve the

Contractor of any part of his responsibility for meeting all the requirements of the

Specification.

3.12.2.2. The Owner or his representative shall have-tree access at all reasonable times to

those parts of the Contractor’s works which are concerned with the fabrication of

the Owner’s material for satisfying himself that the fabrication is being done in accordance with the provisions of the Specification.

3.12.2.3. Unless specified otherwise, inspection shall be made at the place of manufacture

prior to dispatch and shall be concluded so as not to interfere unnecessarily with the operation of the work. –

3.12.2.4. Should any member of the structure be found not to comply with the supplied

design, it shall be liable to rejection. No member once rejected shall be

resubmitted for inspection, except in cases where the Owner or his authorised

representative considers that the defects can be rectified.

3.12.2.5. Defect which may appear during fabrication shall be made good with the

consent of, and according to the procedure proposed by the Contractor and

approved by the Owner.

3.12.2.6. All gauges and templates necessary to satisfy the Owner shall be supplied by the

Contractor. 3.12.2.7. The specified grade and quality of steel shall be used by the Contractor. To

ascertain the quality of steel used, the inspector may at his discretion get the

material tested at an approved laboratory.


Volume-II / Section – III EPC Tender for JITPL

3.13 Packing

3.13.1 Angle section shall be wire bundled.

3.13.2 Cleat angles, gusset plates, brackets, fillet plate, hanger and similar loose pieces

shall be tested and bolted together in multiples or securely wired through holes.

3.13.3 Bolts, nuts washers and other attachments shall be packed in double gunny bags

accurately tagged in accordance with the contents.

3.13.4 The packing shall be properly done to avoid losses & damages during transit.

Each bundle or package shall be appropriately marked.

3.14 Standards

3.14.1 The design, manufacturing, fabrication, galvanising, 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)/lnternational 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.

3.14.2 The material and services covered under these specifications shall be performed

as per requirements of the relevant standard code 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.

Sl. No. Indian Standards (Is)

Title

Internationally

recognized

Standards/Guides

1.

2.

3.

4.

IS: 209-1992

IS 278-1991

IS 800-1991

(a) IS: 802 (Part 1)

Sec 1-1995

Sec 2-1992

(b) IS : 802 – 1990

(Part 2)

Specification for Zinc

Galvanised Steel Barbed Wire

Code of Practice for General Building

Construction in Steel

Code of Practice for General Building

Construction in Steel in Overhead

Transmission Line Towers : Materials,

loads and Permissible Stresses

Section 1 Materials and loads

Section 2 Permissible stresses

Code of practice for use of structural

steel in overhead Transmission Line :

Fabrication, Galvanising, Inspection and

ISO/R/752 ASTM B6

ASTM A131

CSA 6.1

ASCE 52

IEC 826

BS 8100

ASCE 52



Packing

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

(c) IS : 802-1990

(Part 3)

IS : 808-1991

IS : 875-1992

IS : 1363-1990

IS: 1367-1992

IS : 1477 – 1990

IS: 1573-1991

IS: 1852-1993

IS: 1893-1991

IS : 2016-1992

IS: 2062-1992

IS: 2074-1992

IS: 2551-1990

IS : 2629-1990

IS : 2633-1992

IS : 3043-1991

IS : 3063-1994

IS: 3757-1992

IS : 4759-1990

IS : 5369-1991

IS : 5613-1993

IS : 6610-1991

IS : 6623-1992

IS : 6639-1990

Code of practice for use of structural

Steel in overload Transmission Line

Towers Testing

Dimensions for Hot Rolled Steel Beam,

Column, Channel and Angle Sections.

Code of Practice for Design Loads

(other than Earthquakes) for Buildings

and Structures

Hexagon Nuts (size range M5 to M36)

Technical Supply Conditions for

Threaded Steel/Fasteners

Code of practice for Painting of Ferrous

Metals in Buildings : Part-I, Pre-

treatment: Part-II Painting.

Electro-Plated Coatings of zinc on iron

and steel

Rolling and cutting Tolerances of Hot

Rolled Steel Products

Criteria for Earthquake

Resistant Design of Structures

Plain Washers

Steel for general structural purposes

Ready Mixed Paint, Air Drying,

Red Oxide, Zinc Chrome, Prining

Specification

Danger Notice Plates

Recommended Practice for Hot Dip

Galvanising of iron and steel

Method of Testing Uniformity of

coating of Zinc coated Articles

Code of Practice for Earthing

Single coil Rectangular section Spring

Washers for Bolts, Nuts Screws

High strength Structural Bolts

Specification for Hot zinc coatings on

structural steel and other Allied

products

General Requirements for Plain

Washers

Code of practice for design installation

and Maintenance of overhead power

lines section 1 Design Part 2, Section 2 Installation and Maintenance

Specification for Heavy

Washers for steel structures.

High Strength Structural Nuts

Hexagon Bolts for steel structure.

ASCE 52

IEC 652

IEEE 693

ISO/R887 ANSIB18-

22.1

ASTM A123 CSAG164

DIN-127

ASTM A394 CSA B334

28. IS : 6745-1990 Method for Determination of weight of ASTM A90



Zinc coated iron and steel articles

29.

30.

31.

32.

33.

IS : 8500-1992

IS : 10238-1989

IS : 12427-1988

Publication

19(N)/700

Specification for weldable structural

steel (Medium & High Strength

Qualities)

Step Bolts for steel structures

Bolts for Transmission Line Towers

Indian Electricity Rules

No. Regulation for Electrical Crossing of

Railway Tracks

3.14.3 The standards mentioned above are available from

________________________________________________________________________

Reference/Abbreviation Name and address from which the

standards/guides are available ________________________________________________________________________

IS

ISO

CSA

DIN

ASTM

Indian Electricity Rules

Regulation for

Electricity Crossing

Of Railway Tracks

Bureau of Indian Standards

Manak Bhawan, 9, Bahadur Shah Zafar Marg,

New Delhi, India

International Organisation for

Standardisation, Danish Board for

Standardisation, Dansk Standardising

Sraat, Aurehoegvei-12 DK-2900, Hellepruip, DENMARK

Canadian Standard Association

178, Rexadale Boulevard,

Rexdale (Ontario)

Canada, M9W 1R3

Deutsches Institute Fiir Normung

Burggrafenstrassee 4-10

Post Fach 1107 D-1000, Belin-30

GERMANY

American Society for Testing and Material

1916 Race Street

Philadelphia PA

19103-1187 USA

Kitab Mahal

Baba Kharak Singh Marg

New Delhi-110001

INDIA



ASCE

IEEE

IEC

4.0 Geotechnical Investigations

4.1 General

American Society of Civil Engineers

345 East 47th Street

New York, NY 10017-2398 USA

Institute of Electrical and Electronics

Engineers 445 Hoes Lane NJ

0085-1331

USA

International Electrotechnical Commission

Bureau Central de la Commission

1 rue, de varembe Geneva

PIScataway,

Switzerland

4.1.1 Owner requires that a detailed Geotechnical investigation be carried out at various

tower locations to provide the designer with sufficiently accurate information,

both general and specific, about the substrata profile and relevant soil and rock

parameters at site on the basis of which the foundation of transmission line towers

can be classified and designed rationally.

4.1.2 These specifications provide general guidelines for geotechnical investigation of

normal soils. Cases of marshy locations and those affected by salt water or

sulphate shall be treated as special locations and the corresponding description in

these specifications shall apply. Any other information required for such locations shall be obtained by Contractor and furnished to Owner.

4.2 Scope

4.2.1 The scope of work includes detail soil investigations and furnishing bore log data

at various tower locations. Along the line route detailed soil investigation has to be carried out at every 5.0 kM interval apart from the either side towers of River

Crossing, Railway Crossings, Power line Crossings and any other critical points

identified by owner. However, during actual execution of work the quantities shall be decided by the Engineer - in - Charge, depending upon the soil strata and

terrain. Based on the bore log data/soil parameter /soil investigation results, the

Contractor shall recommend the type of foundations suitable for these locations and the same shall be got approved by the Owner. For other tower locations, Trial



pit is to be done in every locations for foundation classification up to

foundation depth. No separate payment for Trial pit shall be done.

4.2.2 These specifications cover the technical requirements for a detailed Geotechnical

investigation and submission of a detailed Geotechnical Report. The work shall

include mobilization of all necessary tools and equipment, provision of necessary

engineering supervision, and technical personnel, skilled and unskilled labour, etc. as required to carry out the entire field investigation as well as laboratory

tests, analysis and interpretation of data collected and preparation of the

Geotechnical Report. Contractor shall also collect data regarding variation of subsoil water table along the proposed line route. The aforementioned work shall

be supervised by a graduate in Civil engineering having at least 5 years of site

experience in geotechnical investigation work.

4.2.3 Contractor shall make its own arrangements to establish the co-ordinate system

required to position boreholes, tests pits and other field test locations as per the

drawings/sketches supplied by Owner. Contractor shall determine the reduced levels (R.L’s) at these locations with respect to benchmarks used in the detailed

survey. Two reference lines shall be established based on survey data/details.

Contractor shall provide at site all required survey instruments to the satisfactions of the Owner so that the work can be carried out accurately according to

specifications and drawings. Contractor shall arrange to collect the data regarding

change of course of rivers, major natural streams and nalas, etc., encountered along the transmission line route from the best available sources and shall furnish

complete hydrological details including maximum velocity discharge, highest

flood level (H.F.L), scour depth etc. of the concerned rivers, major streams and

nalas (canals).

4.2.4 The filed and laboratory data shall be recorded on the proforma recommended in

relevant Indian Standards. Contractor shall submit to Owner two copies of field bore logs (one copy each to Owner site and Corporate Office) and all the field

records (countersigned by the Owner) soon after the completion of each

boreholes/test.

4.2.5 Whenever Contractor is unable to extract undisturbed samples, it shall

immediately inform the Owner. Payment for boring charges shall be subject to

Owner being satisfied that adequate effort has been made to extract undisturbed samples. Special care shall be taken for locations where marshy soils are

encountered and Contractor in such cases shall ensure that specified number of

vane shear tests are performed and the results correlated with other soil parameters.

4.2.6 One copy of all field records and laboratory test results shall be sent to Owner on

a weekly basis. Owner may observe, at the laboratory testing procedures.



4.2.7 The Contractor shall interact with the Owner to get acquainted with the different

types of structures envisaged and in assessing the load intensities on the

foundation for the various types of towers in order to enable him to make specific

recommendation for the depth, founding strata, type of foundation and the

allowable bearing pressure.

4.2.8 After reviewing Contractor’s geotechnical investigation draft report, Owner will

call for discussions, to be held normally within one week at Owners site Office, in

order to comment on the report in the presence of Contractor’s Geotechnical

Engineer. Any expenditure associated with the redrafting and finalising the report,

travelling etc. shall be deemed included in the rates quoted for the geotechnical

investigations.

4.2.9 Contractor shall carry out all work expressed and implied in Clause 4.2. of these

specifications in accordance with requirements of the specification.

4.3 General Requirements

4.3.1 Wherever possible, Contractor shall research and review existing local knowledge

records of test pits, boreholes, etc., types of foundations adopted and the

behaviour of existing structures, particularly those similar to the present project.

4.3.2 Contractor shall make use of information gathered from nearby quarries, unlined

wells excavation etc. Study of the general topography of the surrounding areas will often help in the delineation of different soil types.

4.3.3 Contractor shall gather data regarding the removal of overburden in the project

area either by performing test excavations, or by observing soil erosion or land slides in order to estimate reconsolidation of the soil strata. Similarly, data

regarding recent land fills shall be studied to determine the characteristics of such

land fills as well as the original soil strata.

4.3.4 The water level in neighboring streams and water courses shall be noted.

Contractor shall make enquiries and shall verify whether there are abandoned underground works e.g. worked out ballast pits, quarries, old brick fields, mines,

mineral workings etc.

4.3.5 It is essential that equipment and instruments be properly calibrated at the

commencement of the work. If the Owner so desires, Contractor shall arrange for

having the instruments tested at an approved laboratory at its cost and shall

submit the test reports to the Owner. If the Owner desires to witness such tests, Contractor shall arrange for the same.

4.4 Codes and Standards for Geotechnical Investigations

4.4.1 All standards, specifications and codes of practice referred to herein shall be the

latest editions including all applicable official amendments and revisions. In case



of conflict between the present specifications and those referred to herein, the

former shall prevail. Internationally accepted standards which ensure equal or

higher performance than those specified shall also be accepted.

4.4.2 All work shall be carried out in accordance with the following Indian Standards

and Codes:

International and

Indian

Standards (IS)

IS:1080-1990

Title

Codes of Practice for Design and Construction of Simple Spread Foundations.

Internationally

Recognised

Standard/Code

IS:1498-1992 Classification and Identification of Soils for ASTM D 2487

IS:1892-1992

IS:1904-1986

IS:2131-1992

IS:2132-1992

IS:2720-1992

IS:2809-1991

IS:2911-1980

IS:3025

IS:3043-1991

IS:4078-1990

General Engineering purposes.

Code of Practice for Subsurface Investigation

for Foundation

Code of Practice for Design and Construction

of foundation in Soils: General Requirements

Method of Standard Penetration Test for Soils

Code of Practice for Thin Walled Tube

Sampling of Soils

Method of Test for Soils (Relevant Parts)

Glossary of Terms and symbols Relating to Soil

Engineering

Code of Practice for Design and construction of Pile Foundations (Relevant Parts).

Methods of Sampling and Testing (Physical and Chemical) for water used in Industry.

Code of Practice for Earthing

Code of Practice for Indexing and Storage of

Drill Cores.

ASTM D 2488

ASTM D 1586

ASTM D 1587

ASTM D 420

ASTM D 653

IS:4091 -1987 Code of Practice for Design and Construction

of Foundations for Transmission Line Towers

and Poles.

IS:4434-1992 Code of Practice for In-situ

Vane Shear Test for Soils

IS:4453-1992 Code of Practice for Exploration by Pits, Trenches. Drifts and Shafts.

IS:4464-1990 Code of Practice for Presentation of Drilling information and core description in Foundation

Investigation

IS:4968 (Part-II) Method for Subsurface sounding for soils,

1992 dynamic method using cone and Bentonite

slurry.

IS:5313-1989 Guide for Core Drilling observations.

ASTM D 2573

ASTM D 4648



International and

Indian

Standards (IS)

IS:6403-1990

IS:6926-1990

IS:6935-1989

IS:7422-1990

IS:8009(Part-l)-

1993

IS:8764-1991

IS:9143-1991

IS:9179-1991

lS:9259-1992

IS:9640-1992

IS:10050-1991

IS:11315 (Part-

Il)-1991

Title

Code of Practice for Determination of allowable Bearing Pressure on Shallow

Foundation.

Code of Practice for Diamond Core Drilling for

Site Investigation for River Valley Projects.

Method of Determination of Water level in a Bore Hole.

Symbols and Abbreviations for use in Geological Maps Sections and subsurface

Exploratory Logs (Relevant parts).

Code of Practice for Calculation of Settlements of Foundations (Shallow Foundations subjected

to symmetrical Vertical Loads).

Method of Determination of Point Load

Strength Index of Rocks

Method of Determination of Unconfined Compressive Strength of Rock Materials.

Method of Preparation of Rock Specimen for Laboratory Testing.

Specification for Liquid Limit Apparatus

Specification for Split Spoon Sampler.

Method of Determination of Slake Durability Index of Rocks.

Description of Discontinuities in Rock Mass-

Core Recovery and Rock Quality.

Internationally

Recognised Standard/Code

ASTM D 194

ASTM D 2938

ASTM D 4543

ASTM D 4318

ASTM D 1586

ASTM D 4644

4.5 Field Investigation for Soils

4.5.1 Boring

Boreholes are required for detailed soil investigations.

4.5.1.1.General Requirements

a) Boreholes shall be made to obtain information about the subsoil profile, its

nature and strength and to collect soil samples for strata identification and

for conducting Laboratory tests. The minimum diameter of the borehole

shall be 150mm and boring shall be carried out in accordance with the provisions of IS:1892 and the present specification.



b) All boreholes shall be 7m deep for normal soil conditions. If a strata is

encountered where the Standard Penetration Test Records N values greater

than 100, with characteristics of rock, the borehole shall be advanced by coring at least 3m further in normal locations with prior approval of the

Owner. When the boreholes are to be terminated in soil strata an additional

Standard Penetration Test shall be carried out at the termination depth. No

extra payment shall be made for carrying out Standard Penetration Tests.

c) Casing pipe shall be used when collapse of a borehole wall is probable. The

bottom of the casing pipe shall at all times be above the test of sampling

level but not more than 15cm above the borehole bottom. In case of cohesion less soils, the advancement of the casing pipe shall be such that it

does not disturb the soil to be tested or sampled; The casing shall preferably

be advanced by slowly rotating the casing pipe and not by driving.

d) In-situ tests shall be conducted and undisturbed samples shall be obtained in

the boreholes at intervals specified hereafter. Representative disturbed

samples shall be preserved for conducting various identification tests in the

laboratory. Water table in the borehole shall be carefully recorded and reported following IS:6935. No water or drilling mud shall be used while

boring above ground water table. For cohesionless soil below water table,

the water level in the borehole shall at all times be maintained slightly above the water table.

e) The borehole shall be cleaned using suitable tools to the depth of testing or

sampling, & ensuring least or minimum disturbance of the soil at the bottom of the borehole. The process of jetting through an open tube sampler shall

not be permitted. In cohesive soils, the borehole maybe cleaned by using a

bailer with a flap valve. Gentle circulation of drilling fluid shall be done

when rotary mud circulation boring is adopted.

f) On completion of the drilling, Contractor shall backfill all boreholes as

directed by the Owner.

4.5.1.2.Auger Boring

Auger boring may be employed in soft to stiff cohesive soils above the water

table. Augers shall be of helical or post hole type and the cuttings brought up by

the auger shall be carefully examined in the field and the description of all strata shall be duly recorded in the field borelog as per IS:1498. No water shall be

introduced from the top while conducting auger boring.



4.5.1.3.Shell and Auger Boring

4.5.1.3.1. Shell and auger boring may be used in all types of soil which are free from

boulders. For cohesionless soil below ground water table, the water level in

the borehole shall always be maintained at or above ground water level. The

use of chisel bits shall be permitted in hard strata having SPT-N value greater

than 100 Chisel bits may also be used to extend the bore hole through local obstructions such as old construction. Boulders rocky formations, etc. The

requirements in Clause 4.5.1.2 shall apply for this type of boring also.

Rotary method may be used in all types of soil below water table. In this

method the boring is carried out by rotating the bit fixed at the lower end of

the drill rod. Proper care shall be taken to maintain firm contact between the

bit and the bottom of the borehole. Bentonite or drilling mud shall be used as drilling fluid to stabilise and protect the inside surface of the borehole. Use of

percussion tools shall be permitted in hard clays and in dense sandy deposits.

4.5.2 Standard Penetration Test (SPT)

4.5.2.1.This test shall be conducted in all types of soil deposits encountered within a

borehole, to find the variation in the soil stratification by correlating with the

number of blows required for unit penetration of a standard penetrometer. Structure sensitive engineering properties of cohesive soils and sifts such as

strength and compressibility shall not be inferred based on SPT values.

The test shall be conducted at depths as follows:

________________________________________________________________

Location

Depths (m)

________________________________________________________________ Normal Soils 2.0, 3.0, 5.0, 7.0

________________________________________________________________

4.5.2.2.The spacing between the levels of standard penetration testing and next

undisturbed sampling shall not he less than 1.0m Equipments, accessories and

procedures for conducting the test and for the collection of the disturbed soil

samples shall conform to IS:2131.

4.5.2.3.The test shall be carried out by driving a standard split spoon sampler in the bore

hole by means of a 650 N hammer having a free fall of 0.75 m. The sample shall

be driven using the hammer for 450 mm recording the number of blows for every

150 mm. The number of blow for the last 300 mm drive shall be reported as N

value.



4.5.2.4.This test shall be discontinued when the blow count is equal to 100 or the

penetration is less than 25 mm for 50-blows. At the level where the test is

discontinued, the number of blows and the corresponding penetration shall be

reported. Sufficient quantity of disturbed soil samples shall be collected from the

split spoon sampler for identification and laboratory testing. The sample shall be

visually classified and recorded at the site as well as properly preserved without

loss of moisture content and labelled.

4.5.3 Sampling

4.5.3.1.General

a) Sufficient number of soil samples shall be collected. Disturbed soil

samples shall be collected for soil identification and for conducting tests

such as sieve analysis, index properties, specific gravity, chemical analysis

etc. Undisturbed samples shall be collected to estimate the physical

bearing capacity and settlement properties of the soil.

b) All accessories and sampling methods shall conform to IS:2132: all

disturbed and undisturbed samples collected in the field shall be classified

at site as per IS:1498:

c) All samples shall be identified with date, borehole or test pit number,

depth of sampling, etc. The top surface of these sample in-situ shall also

be marked. Care shall be taken to keep the core and box samples vertical,

with the mark directing upwards. The tube samples shall be properly trimmed at one end and suitably capped and sealed with molten paraffin

wax. The Contractor shall be responsible for packing, storing in a cool

place and transporting all the samples from site to the laboratory within

seven days after sampling with probe, protection against loss and damage.

4.5.3.2.Disturbed Samples

a)

Disturbed soil samples shall be collected in boreholes at regular intervals.

Jar samples weighing approximately 1 kg shall be collected at 0.5m intervals starting from a depth of 0.5m below ground level and at every

identifiable change of strata to supplement the boring records. Samples

shall be stored immediately in air light jars which shall be filled to capacity as much as possible.

b) In designated borrow areas, bulk samples, from a depth of about 0.5m

below ground level shall be collected to establish the required properties

for use as a fill material. Disturbed samples weighing about 25 kg shall be collect at shallow depths and immediately stored in polythene bags as per



IS:1892. The bags shall be sealed properly to preserve the natural moisture

content of the sample and placed in wooden boxes for transportation.

4.5.3.3.Undisturbed Samples

In each borehole undisturbed samples shall be collected at every change of strata

and at depths as follows:

________________________________________________________________

Location

Depths (m)

________________________________________________________________

Normal Soils 1.0, 4.0, 6.0

________________________________________________________________ 4.5.3.3.1. The spacing between the top levels of undisturbed sampling and standard

penetration testing shall not be less than 1.0m. Undisturbed samples shall be at

100mm diameter and 450mm in length. Samples shall be collected in a

manner to preserve the structure and moisture content of the soil Accessories

and sampling procedures shall conform to IS:1892 and IS:2132.

a) Undisturbed sampling in cohesive soil:

Undisturbed samples in soft to stiff cohesive soils shall be obtained using

a thin walled sampler. In order to reduce the wall friction, suitable

precautions, such as oiling the surfaces shall be taken. The sampling tube

shall have a smooth finish on both surfaces and a minimum effective length of 450mm. The area ratio of sampling tubes shall be less than

12.5%. However, in case of very stilt soils area ratio up to 20% shall be

permitted.

b) Undisturbed sampling in very loose, saturated, sandy and silty soils and

very soft clays: -

Samples shall be obtained using a piston sampler consisting of a cylinder

and piston system. In soft clays and silty clays, with water standing in the

casing pipe, piston sampler shall be used to collect undisturbed samples in

the presence of expert supervision.

Accurate measurements of the sampling depth, dimensions of sampler,

stroke and length of sample recovery shall be recorded. After the sampler

is pushed to the required depth, the cylinder and piston system shall be

drawn up together, preventing disturbance and changes in moisture

content of the sample;

c) Undisturbed sampling in cohesionless soils



Undisturbed samples in cohensionless soils shall be obtained in

accordance with IS:8763. Sampler operated by compressed air shall be

used to sample cohesionless soils below ground water table.

4.5.4 Ground Water

4.5.4.1.One of the following methods shall be adopted for determining the elevation of

ground water table in boreholes as per 15:6935 and the instructions of the Owner:

a) In permeable soils, the water level in the borehole shall be allowed to

stabilise after depressing if adequately by bailing before recording its

level. Stability of sides-and bottom of the boreholes shall be ensured at all

times;

b) For both permeable and impermeable soils, the following method shall be

suitable. The borehole shall be filled with water and then bailed out to various depths. Observations on the rise or tall of water level shall be

made at each depth. The level at which neither fall nor rise is observed

shall be considered the water table elevation and confirmed by three

successive readings of water level taken at two hours interval.

4.5.4.2.If any variation of the ground water level is observed in any specific boreholes the

water level in these boreholes shall be recorded during the course of the field

investigation. Levels in nearby wells, streams, etc., if any, shall also be noted parallelly.

4.5.4.3.Subsoil water samples

a) Subsoil water samples shall be collected for performing chemical analysis.

Representative ground water samples shall be collected when first

encountered in boreholes and before the addition of water to aid boring or

drilling.

b) Chemical analysis of water samples shall include determination of pH

value, turbidity, sulphate, carbonate, nitrate and chloride contents,

presence of organic matter and suspended solids. Chemical - preservatives

may be added to the sample for cases as specified in the test methods or in

applicable Indian Standards. This shall only be done if analysis cannot be

conducted within an hour of collection and shall have the prior written

permission and approval of the Owner.

4.5.5 Dynamic Cone Penetration Test (For marshy locations)

Dynamic cone penetration test shall be conducted to predict stratification, density,

beating capacity of granular soils, etc. The test shall be conducted to the specified



depth or refusal, whichever comes first. Refusal shall be recorded when the blow

count exceeds 150 for 300mm penetration. Equipment, accessories, test

procedures, field observations and reporting of results shall conform to IS:4968,

Part-II. The driving system shall comprise of a 650kg weight having a free fall of

0.75m. The cone shall be of 65mm diameter provided with vents for continuous

flow of bentonite slurry through the cone and rods in order to avoid friction

between the rods and soil. On completion of the test the results shall be presented

as a continuous record of the number of blows required for every 300mm

penetration of the cone into the soil in a suitable chart supplemented by a

graphical plot of blow count for 300mm penetration vs. depth. On completion of the test, the results shall be presented on the proforma approved by the Owner.

4.5.6 Vane Shear Test (required for boreholes where UDS is not possible in

marshy locations)

Field vane shear test shall be performed inside the borehole to determine the shear

strength and bearing capacity of cohesive soils. Equipment, accessories, test

procedures, field observations shall correspond to IS:4434. Tests may also be

conducted by direct penetration from ground surface. If the cuttings at the test depth in the borehole show any presence of gravel, sand shells, decomposed

wood, etc., which are likely to influence the test results substantially, the test at

that particular depth may be omitted with the permission of the Owner. However, the test shall be conducted at a depth where these obstructions cease to occur. On

completion of the test, the results shall be reported in an approved proforma as

specified in IS:4434, Appendix- A.

4.6 Field Investigation for Rock

4.6.1 Rock Drilling –

4.6.1.1.If, during the investigations, large hard fragments or natural rock beds are

encountered, work shall proceed with core drilling methods. The equipment and

procedures for this operation shall conform to IS:1892. The starting depth of

drilling in rock shall be certified by the Owner. At the end of the investigation, the hole drilled in rock shall be backfilled with grout consisting of 1 part cement and

3 parts sand by weight.

4.6.1.2.Drilling shall be carried out with NX size tungsten carbide (TC) or diamond

tipped drill bits, depending on the type of rock and according to IS:6926. Suitable

type of drill bit (TC/Diamond) and core catchers shall be used to ensure

continuous and good core recovery. Core barrels and core catchers shall be used for breaking off the core and retaining it when the rods are withdrawn. Double

tube core barrels shall be used to ensure better core recovery and to retrieve cores

from layers of bedrock. Water shall be circulated continuously in the hollow rods and the sludge conveying the rock cuttings to the surface shall be collected. A

very high core recovery ratio shall be aimed at in order to obtain a satisfactory



undisturbed sample. Attempt shall be made to recover cores of 1.5m in length.

Normally TC bit shall be used. Change over to a diamond bit shall require the

specific written approval of the Owner, and his decision as to whether a TC or a diamond bit is to be used shall be final and binding on Contractor.

4.6.1.3.No drilling run shall exceed 1.5m in depth, if the core recovery is less than 80% in

any run the length of the subsequent run shall be reduced to 0.75m. During

drilling operations observations on return water, rate of penetration etc. shall be

made recorded and recorded as per IS:5313.

a)

The colour of return water at regular intervals, the depth at which any

change of colour of return water is observed, the depth of occurrence and

amount of flow of hot water, if encountered, shall be recorded.

b) The depth through which a uniform rate of penetration was maintained,

the depth at which marked change in rate of penetration or sudden fail on

drill rod occurs, the depth at which any blockage of drill bit causing core

loss, if any, shall be recorded.

c) Any heavy vibration or torque noticed during the drilling should be

recorded together with the depth of occurrence.

d) Special conditions like the depth at which grouting was done during

drilling, presence of artesian conditions, loss of drilling fluid, observations

of gas discharge with return water, etc., shall also be observed and

recorded.

e) All the observations and other details shall be recorded as per daily drill

and reported in a proforma as given in IS:5313, Appendix A.

4.6.2 Core Sampling

4.6.2.1.Core samples shall be extracted by the application of a continuous pressure at one end of the core with the barrel held horizontally without vibration. Friable cores

shall be extracted from the barrel directly into a suitably sized half round plastic

channel section. Care shall be taken to extrude the samples in the direction of coring to avoid stress reversal.

4.6.2.2.Immediately after withdrawal from the core barrel, the cores shall be placed in a

tray and transferred to boxes specially prepared for this purpose. The boxes shall

be made from seasoned timber or any other durably material and shall be indexed

on top of the lid according to IS:4078. The cores shall be numbered serially and

arranged in the boxes in a sequential order. The description of the core samples shall be recorded as instructed in IS:4464. Where no core is recovered, it shall be

recorded as specified in the standard. Continuous records of core recovery and



rock quality designation (RQD) are to be mentioned in the borelog in accordance

with IS: 1315 (Part-Il).

4.7 Laboratory Testing

4.7.1 Essential Requirements

a) Depending on the types of substrata encountered, appropriate laboratory

tests shall be conducted on soil and rock samples collected in the field.

Laboratory tests shall be scheduled and performed by qualified and

experienced personnel who are thoroughly conversant with the work.

Tests indicated in the schedule of items shall be performed on soil, water

and rock samples as per relevant IS codes. One copy of all laboratory test

data records shall be submitted to Owner progressively every week.

Laboratory tests shall be carried out concurrently with the field

investigations as initial laboratory test results could be useful in planning

the later stages of field work. A schedule of laboratory tests shall be

established by Contractor to the satisfaction of the Owner within one week

of completion of the first borehole.

b) Laboratory tests shall be conducted using approved apparatus complying

with the requirements and specification of Indian Standards or other

approved standards for this type of work. It shall be checked that the

apparatus are in good working condition before starting the laboratory tests. Calibration of all the instruments and their accessories shall be done

carefully and precisely at an approved laboratory.

c) All samples, whether undisturbed or disturbed shall be extracted, prepared

and examined by competent personnel properly trained and experienced in

soil sampling, examination, testing and in using the apparatus in

conformance with the Specified standards.

d) Undisturbed soil samples retained in liners or seamless tube samplers shall

be removed, without causing any disturbance to the samples, using

suitably designed extruders just prior to actual testing. If the extruder is

horizontal, proper support shall be provided to prevent the sample from breaking. For screw tube extruders, the pushing head shall be free from the

screw shaft so that no torque is applied to the soil sample in contact with

the pushing head. For soft clay samples, the sample tube shall be cut by means of a high speed hacksaw to proper test length and placed over the

mould before pushing the sample into it with a suitable piston.

e) While extracting a sample from a liner or tube, care shall be taken to

assure that its direction of movement is the same as that during sampling

to avoid stress reversal.



4.7.2 Tests

4.7.2.1.Tests as indicated in these specifications and as may be requested by the Owner,

shall be conducted. These tests shall include but may not be limited to the

following

a) Tests of undisturbed and disturbed samples

-

-

-

-

-

-

-

Visual and engineering classification;

Sieve analysis and hydrometric analysis

Liquid, plastic and shrinkage limits;

Specific gravity;

Chemical analysis

Swell pressure and free swell index determination

Proctor compaction test

b) Tests of undisturbed samples

-

-

-

-

-

Bulk density and moisture content;

Relative density (for sand),

Unconfined compression test;

Box shear test (for sand);

Triaxial shear tests (depending on the type of soil and field

conditions on undisturbed or remolded samples):

i)Unconsolidated undrained;

ii) consolidated drained test;

-Consolidation.

c) Tests on rock samples

-

-

-

-

-

-

-

Visual classification;

Moisture content, porosity and density;

Specific gravity;

-Hardness;

Stake durability;

Unconfined compression test (both saturated and at in-situ water

content):

Point load strength index;

Deformability test(both saturated and dry samples).

d) Chemical analysis of sub soil water.

4.7.3 Salient Test Requirement

a) Triaxial shear tests shall be conducted on undisturbed soil samples,

saturated by the application of back pressure. Only if the water table is at



sufficient depth so that chances of its rising to the base of the footing are

small or nil, the triaxial tests shall be performed on specimens at natural

moisture content. Each test shall be carried out on a set of three test

specimens from one sample at cell pressures equal to 100, 200 and 300

kPa respectively or as required depending on the soil conditions:

b) Direct shear test shall be conducted on undisturbed soil samples. The three

normal vertical stresses for each test shall be 100, 200 and 300 kPa or as

required for the soil conditions;

c) Consolidation test shall have loading stages of 10,25,50,75, 100, 200, 400

and 800 kPa. Rebound curve shaft be recorded for all samples by

unloading the specimen at its in-situ stress. Additional rebound curves

shall also be recorded wherever desired by the Owner;

d) Chemical analysis of subsoil shaft include determination of PH value,

carbonate, sulphate (both SO3 and SO4). chloride and nitrate contents,

organic matter, salinity and any other chemicals which may be harmful to

the foundation material. Their contents in the soil shall be indicated as

percentage (%);

e) Chemical analysis of subsoil water samples shall include the

determination of properties such as colour, odour, turbidity, PH value and

specific conductivity, the last two chlorides, nitrates, organic matter and any other chemical harmful to the foundation material. The chemical

contents shall be indicated as parts per million (PPM) based on weight.

4.8 Geotechnical Investigation Report

4.8.1 General

a) Contractor shall submit a formal report containing geological information

of the region, procedures adopted for geotechnical investigation, field

observations, summarised test data, conclusions and recommendations. The report shall also include detailed borelogs, subsoil sections, field test

results, laboratory observations and test results both in tabular as well as

graphical form, practical and theoretical considerations for the interpretation of test results, supporting calculation for the conclusions

drawn etc. Initially, Contractor shall submit three copies of the report in

draft form for Owners review;

b) Contractor’s Geotechnical engineer shall visit Owner’s Corporate Office

for a detailed review based on Owner’s comments in order to discuss the

nature of modifications, if any, to be done in the draft report. Contractor

shall incorporate in the report, the agreed modifications and resubmit the revised draft report for approval. One Plus Four copies of the detailed final



approved report shall be submitted to Owner together with one set of

reproducible of the graphs, tables etc.

c) The detailed final report based on field observations, in-situ and laboratory

tests shall encompass theoretical as well as practical considerations for foundations for different types of structures as discussed in Clause 5.3.

4.8.2 Data to be furnished

4.8.2.1.The report shall also include the following

a) A plot plant/location plan showing the locations and reduced levels of all

field test e.g. boreholes, trial pits, static cone penetration tests, dynamic cone penetration tests, etc., property drawn to scale and dimensioned with

reference to the established grid lines;

b) A true cross section of all individual boreholes and test pits with reduced

levels and co-ordinates showing the classification and thickness of

individual stratum, position of ground water table, various in-situ tests

conducted, samples collected at different depths and the rock stratum, if

encountered;

c) Geological information of the area including geomorphology, geological

structure, lithology, stratigraphy and tectonics, core recovery and rock

quality designation (RQD), etc.,

d) Observations and data regarding change of course of rivers, velocity, scour

depths, slit factor, etc., and history of flood details for mid stream and

river bank locations;

e) Past observations and historical data, if available, for the area or for other

areas with similar soil profile, or with similar structures in the surrounding

areas;

f)

Plot of Standard Penetration Test (uncorrected and corrected N values)

with depth for each test site;

g) Results of all laboratory test summarised according to Table 4.0 (i) for

each sample as well as (ii) for each layer, alongwith all the relevant charts, tables, graphs, figures, supporting calculations, conclusions and

photographs of representative rock cores,

h) For all triaxial shear tests, stress vs. strain diagrams as well as Mohr’s

circle envelopes shall be furnished. If back pressure is applied for

saturation, the magnitude of the same shall be indicated. The value of



modulus of elasticity (E) shall be furnished for all tests along with relevant

calculations;

i)

j)

For all consolidation tests, the following curves shall be furnished

i) e vs. log p;

ii) e vs. p;

iii) Compression vs log t or vs √t

depending upon the shape of the plot, for proper determination of

coefficient of consolidation.

The point showing the initial condition (eo, po) of the soil shall be marked

on the curves;

The procedure adopted for calculating the compression index from the

field curve and settlement of soil strata shall be clearly specified. The time

required for 50% and 90% primary consolidation along with secondary

settlements, if significant, shall also be calculated.

Table 4.0

SUMMARY OF RESULTS OF LABORATORY TESTS ON SOIL

AND WATER SAMPLES

1. Bore hole test pit no.

2. Depth (m)

3. Type of sample

4. Density (kg/m3)

a. Bulk

b. Dry

5. Water content (%)

6. Particle Size (%)

a. Gravel

b. Sand

c. Silt

d. Clay

7. Consistency properties

a. LL

b. PL

c. PI



d. LI

8. Soil

a. Classification-IS

b. Description

c. Specific gravity

9. Strength Test

a. Type

b. C (Cohesion)

c. ф (angle of internal friction)

10. Consolidation Test

a. eo

b. Pc

c. Cc

d. DP

e. Mv

f. Cv

11. Shrinkage limit (%)

12. Swell Test

a. S.Pr

b. FS

13. Relative Density (%)

14. Remarks

Notations :

I.

II.

For type of Sample :

DB – Disturbed bulk soil sample.

DP – Disturbed SPT soil sample

DS – Disturbed samples from cutting edge of undisturbed soil sample

RM – Remoulded soil sample

UB – Undisturbed block soil sample

US – Undisturbed soil sample by sampler

W – Water sample

For Strength Test :

SCPT – Static Cone Penetration Test

UCC – Unconfined Compression Test



VST – Vane Shear Test

Tuu – Unconsolidated Undrained Triaxial Test

Note : Replace T by D for Direct Shear Test

Tod – Consolidation Drained Triaxial Test

III.

IV.

For Others :

LL – Liquid Limit (%)

PL – Plastic Limit

Pl – Plasticity Index

Li – Liquidity Index

C – Cohesion (kPa)

ф– Angle of Internal Friction (degrees)

S-Pr. – Swelling Pressure (kPa)

e0 – Initial Void Ratio

Pc – Reconsolidation Pressure (kPa)

Cc – Compression Index

DP – Change in Pressure (kPa)

mv – Coefficient of Volume Compressibility (m2/KN)

Cv – Coefficient of Consolidation (m2/hr)

For Chemical Test

As per Specifications – Clause 4.8.4

4.8.3 Recommendations

4.8.3.1 Recommendations shall be provided for each tower location duly considering soil

type and tower spotting data. The recommendations shall provide all design

parameters and considerations required for proper selection, dimensioning and

future performance of tower foundations as discussed in part but not limited to

Clause 4.2 of these specifications and the following :

a)

b)

The subsurface material must provide safe bearing capacity and uplift

resistance by incorporating safety factors specified in Clause 4.2 all the

while experiencing small deformations throughout, thereby avoiding rupture under ultimate loads;

Movement of the foundation, including short and long term components

under transient and permanent loading, shall be strictly controlled with

regard to settlement, uplift, lateral translation and rotation;



c)

d)

e)

f)

g)

h)

Co-efficient of permeability of various sub soil and rock strata based on

in-situ permeability tests.

Core resistance, frictional resistance total resistance, relation between core

resistance, Standard Penetration Test N value and settlement analysis for

different sizes of foundation based on static cone penetration test.

For shallow foundation the following shall be indicated with

comprehensive supporting calculations :

i) Net safe allowable bearing pressure for isolated square footing of

sizes 2.0 m, 3.0 m and 4.0 m at three different foundation depths

of 1.0 m, 2.0 m and 3.0 m below ground level considering both shear failure and settlement criteria giving reasons for type of shear

failure adopted in the calculation.

ii) Net safe allowable bearing pressure for raft foundations of widths

greater than 5.0 m at 2.0 m, 3.0 m and 4.0 m below ground level

considering both shear failure and settlement criteria.

iii) Rate and magnitude of settlement expected of the structure.

iv) Net safe bearing capacity for foundation sizes mentioned in para (i)

above, modulus of subgrade reaction, modules of elasticity from

plate load test results along with time settlement curves and load

settlement curve in both natural and log graph, variation of Modulus of subgrade reaction with size, shape and depth of

foundation.

The stable slopes for shallow and deep excavations, active and passive

earth pressure at rest and angle of repose for sandy soils shall be furnished.

The loading of the foundations shall not compromise the stability of the

surrounding subsurface materials and the stability of the foundation shall be ensured against sliding or overturning.

Depending on the subsurface material, water table level and tower type,

and either reinforced concrete isolated pad and chimney, cast-in-situ bored

pile of special foundations shall be installed at a given location as discussed in Clause 4.2.

Net safe allowable bearing pressure and uplift resistance shall be provided

for the various sizes of isolated square footings founded at various depths below ground level considering both shear failure and movement criteria;

rate and magnitude of movement expected of the structure (settlement,

uplift, and rotation) shall also be given.

In cases where normal open cast/pile foundations appear to be impractical,

special pile foundations shall be given due consideration along with the

following :

i) Type of pile foundation and reasons for recommending the same

duly considering the soil characteristics.

ii) Suitable founding strata for the pile :



iii)

iv)

Estimated length of pile for 500, 750 and 1000 KN and 4500 KN

capacities; end bearing and frictional resistance shall be indicated

separately:

Magnitude of negative skin friction or uplift forces due to soil

swelling.

i)

j)

k)

l)

m)

n)

Where the subsoil water and soil properties are found to be chemically

aggressive. Contractor shall take suitable precautions during construction including any protective coating to be applied on the foundations;

susceptibility of soil to termite action and remedial measures for the same

shall be dealt with;

Suitability of locally available soils at site for filling, backfilling and

adequate compaction shall be investigated.

If expansive soil such as black cotton soil is encountered recommendation

of removal or retainment of the same shall be given in the latter case,

detailed specifications of special requirements shall also be given;

Susceptibility of subsoil strata to liquefaction in the event of earth quake

and remedial measures, if required, shall be considered.

Any other information of special significance such as dewatering schemes,

etc. which may have a bearing on the design and. construction shall be

provided.

Recommendations for additional soil investigations, beyond the scope of

the present work, shall be given if Contractor considers such

investigations necessary.

4.8.4 Hydrogeological Conditions

4.8.4.1 The maximum elevation of ground water table, amplitudes of its fluctuations and

data on water aggressivity with regard to foundation structure materials shall be

reported. While preparing ground water characteristics the following parameters

should be specified for each acquifier:

a) bicarbonate alkalinity mg-eq/(deg),

b) pH value

c) content of aggressive carbon dioxide, mg/l;

d) content of magnesia salts. mg/l, recalculated in terms of ions Mg+2

e) content of ammonia salts, mg/l, recalculated in terms of ions NH4+

f) content of caustic alkalis, mg/l, recalculated in terms of ions Na+ and K

g)contents of chlorides,mg/l recalculated in terms of ions Cl

h) contents of sulphates, mg/I, recalculated in terms of ions SO4-2

I) aggregate content of chlorides, sulphates, nitrates, carbonates and other salts.

mg/I.



4.9 Rates and Measurements

4.9.1 Rates

The Contractor’s quoted rates shall be inclusive of making observations,

establishing the ground level and co-ordinates at the location of each borehole, test pit etc. No extra payments shall be made for conducting Standard Penetration

Test, collecting, packing, transporting of all samples and cores, recording and

submittal of results on approved formats.

5.0 Foundations

5.1 Foundation includes supply of materials such as cement, sand, coarse aggregates

and reinforcement steel etc.

5.2 Foundations designs for various tower types & their extensions and for foundation

classification as described in Clause 5.3 shall be provided by Owner during

execution stage based on site requirement.

5.3 Classifications of Foundations

The foundation designs shall depend upon the type of soil, sub soil water level

and the presence of surface water which have been classified as follows (except

pile foundation).

5.3.1 Normal Dry

To be used for locations where normal dry cohesive or non-cohesive soils are met.

5.3.2 Sandy Dry Soil

Not Applicable

5.3.3 Wet

To be used for locations:

a)

Where sub-soil water is met at 1.5 meters or more below the ground level.

b) Which are in surface water for long periods with water penetration not

exceeding one meter below the ground level e.g. the paddy fields.

5.3.4 Partially Submerged

To be used at locations where sub-soil water table is met between 0.75 meter to

1.5meter below the ground level.



5.3.5 Fully Submerged.

To be used at locations where sub-soil water table is met at less than 0.75 meter

below the ground level.

5.3.6 Black Cotton Soil

To be need at locations where soil is clayey type, not necessarily black in colour,

which shrinks when dry and swells when wet, resulting in differential movement.

For designing foundations, for such locations the soil is to be considered

submerged in nature.

5.3.7 Fissured - Rock

To be used at locations where decomposed or fissured rock, hard gravel, kankar,

limestone, laterite or any other soil of similar nature is met. Under cut type

foundation is to be used for fissured rock locations.

In case of fissured rock locations, where water table is met at 1.5M or more below

ground level, wet fissured rock foundations shall be adopted. In case of dry

locations dry fissured rock foundations shall be adopted.

5.3.8 Hard Rock

The locations where chiselling, drilling and blasting is required for excavation,

Hard rock type foundations are to be used. For these locations rock anchoring is

to be provided to resist uplift forces. For design purpose, rock level shall be

considered at ground level and no overburden soil weight shall be considered for

resisting the uplift.

5.3.9 In addition to the above, depending on the site conditions other types of

foundations shall also be designed and provided by the Owner suitable for

Intermediate conditions under the above classifications to effect more economy.

5.3.10 The proposal for these types of foundations shall be submitted by the Contractor

based on the detailed soil investigation and approval for the same shall be

obtained from the Owner.

5.4 Type of Foundations

Reinforced Cement Concrete footing shall be used for all type of normal towers.

All the four footings of the tower and their extension shall be similar. The total

depth of foundation except Hard Rock type below the ground level shall not be

more than 3.0 meters. For foundation shape details refer drawing enclosed with

the specification. The working drawing of all type of foundations for all type of

towers shall be provided by the Owner to the Contractor during execution stage

based on site requirements.



5.5 Soil Investigation

The Contractor shall undertake soil investigation as per clause 4.1 at tower

locations as approved by the Owner. The provisional number of testing locations

are furnished in schedule of prices. Unit rates for the same are to be furnished by the bidder in appropriate schedules of price, for adjustment purpose with actual

quantities required for soil testing.

5.6 Properties of Concrete

5.6.1 For open cast type foundation

The cement concrete used for the foundations shall be Nominal Mix Concrete of

grade M-20 having 1:1.5:3 nominal mix ratio with 20mm. coarse aggregate for chimney portion and 40 mm aggregates for pyramid or slab portion. The quantity

of cement to be used per cubic meter shall be as per CPWD specification (DSP).

All the properties of concrete regarding its strength under compression, tension, shear, punching and benching etc. as well as workmanship will conform to IS:

456.

5.6.2 a) The Portland Cement used in concrete shall conform to 33 grade

(IS: 269) or 43 grade (IS: 8112) or 53 grade (IS:12269). .

5.6.3 Concrete aggregates shall confirm to IS:383.

5.6.4 The water used for mixing concrete shall be fresh, clean and free from oil, acids

& alkalies, organic materials or other deletarious substances. Portable water is generally preferred.

5.6.5 Reinforcement shall confirm to IS:432 for MS bars and hard drawn steel wires

and to IS:1139 and IS:1786 for deform and cold twisted bars respectively. Thermo mechanically Treated (TMT) bars (equivalent grade) in place of cold

twisted bars are also accepted. All reinforcement shall be clean and free from

loose mill scales, dust, loose rust and coats of paint, oil or other coatings, which

may destroy or reduce bond. Contractor shall supply, fabricate and place reinforcement to shapes and dimensions as indicated or as required to carry out

the intent of drawings and Specifications.

5.7 Design of Foundations

The working drawing of all type of foundations for all towers shall be provided by

the Owner to the Contractor during execution stage based on site requirements.

5.8 Unit Rates and Measurement for Foundation

5.8.1 The bidder is required to quote the unit rates for different types of foundation after

considering activities like excavation for different types of soil, concreting, supply

and placement of reinforcement and stub setting in the relevant Unit Price



Schedule as provided in Annexure-13. The payment for various types of

foundations will be released on composite rate of total unit cost of foundation as

provided by the bidder in Annexure-13.

5.8.2 Excavation for each type of soil shall include excavation along with all associated

activities like shoring, shuttering, dewatering-till completion of foundation work,

stock piling, dressing, back filling of foundations after concreting with

excavated/borrowed earth (irrespective of lead) and consolidation of earth, carriage of surplus earth to the suitable point of disposal as required by the Owner

or any other activity related to completion foundation work.

5.8.3 Form boxes shall be used for casting of foundations. The unit rate of foundation

shall also include the cost of supply, fabrication and placement of form boxes,

cement, water, coarse and fine aggregates mixing and placing of concrete, curing

of concrete and any other activities related to completion of concreting works of foundation.

5.8.4 The unit rate of foundation shall also include supply and placement of

reinforcement steel, stirrups, wire for binding the reinforcement chairs, bolsters

and spacers etc. as required to complete the foundation work as per the drawing.

5.9 Construction of Tower Foundation, Stub Setting and Earthing

5.9.1 General

Design of tower foundations is treated in Clause 5.2 & 5.3 and the required

geotechnical investigation and geotechnical investigation report in Clause 4.1.

The Contractor shall furnish soil resistivity values to the Owner along with the

line alignment.

5.9.2 Excavation

5.9.2.1 Excavation work in a section must not be started until the tower scheduled and

profile of that section has been approved by the Owner.

5.9.2.2 Except as specifically otherwise provide, all excavation for footings shall be made

to the lines and grades of the foundations. For estimation purposes, the excavation

wall shall be vertical and the pit dimensions shall be based on an assumed

clearance of 150mm on all sides of the foundation pad. For footings without undercut, this clearance will actually be established in practice for facilitating

work. For footings with undercut, no such clearance will be allowed. All

excavation shall be protected so as to maintain a clean subgrade and provide worker safety until the footing is placed, using timbering, shoring, dewatering etc.

as approved by the Owner. Contractor shall especially avoid disturbing the

bearing surface of the pad. Any sand, mud, silt or other undesirable materials which may accumulate in the excavated pit or borehole shall be removed by

Contractor before placing concrete.

5.9.2.3 The soil to be excavated for tower foundations shall be classified as follows :



a) Dry Soil

Soil removable by means of a spade and shovel. This type of excavation will also

include excavation for dry soil in case of wet, partially submerged, fully

submerged and wet black cotton type of foundations.

b)Wet Soil

Where the subsoil water table is encountered within the range of foundation depth

or land where pumping or bailing out of water is required due to presence of surface water shall be treated as wet soil. This type of excavation will also include

excavation for wet soil in case of wet, partially submerged, fully submerged and

wet black cotton type of foundations.

c) Dry Fissured Rock

Limestone, laterite, hard conglomerate or other soft or fissured rock in dry

condition which can be quarried or split with crow bars, wedges or pickaxes. However; if required, light blasting may be resorted to for loosening the material

but this will not in any way entitle the material to be classified as hard rock.

d)Wet Fissured Rock

Above fissured rock, when encountered with subsoil water within the range of

foundation depth or land where pumping or bailing out of water is required, shall

be treated as wet fissured rock.

e) Hard Rock

Any rock excavation, other than specified under fissured rock above, for which

blasting, drilling, chiselling are required. The unit rate quoted for hard rock

excavation shall be inclusive of all costs for such drilling (including drilling

required for anchoring), chiselling and blasting.

5.9.2.4 No extra charge shall be admitted for the removal of fallen earth into a pit or

borehole once excavated shoring and shuttering/timbering as approved by Owner

shall be provided by the Contractor when the soil condition is so bad and that there is likelihood of accident due to the falling of earth.

5.9.2.5 Where rock is encountered, the holes for tower footings shall preferably be

drilled. Blasting where resorted to as an economy measure, shall be done with utmost care to minimise fracturing rock and using extra concrete for filling the

blasted area. All necessary precautions for handling and use of blasting materials

shall be taken. In cases where unnecessarily large quantities are excavated/blasted, resulting in placement of large volumes of concrete, payment

of concrete shall be limited to design volumes of excavation, concreting,



reinforcement etc. In case where drilling is done, the stubs may be shortened

suitably with the approval of the Owner.

5.9.2.6 The Contractor shall supply requisite blasting material and be responsible for its

storage and use.

5.9.2.7 Indian Standard IS:3764 shall be followed regarding safety of excavation work.

5.10 Setting of Stubs

5.10.1 For all towers the Contractor shall submit for approval the proposed method for

setting of stubs.

5.10.2 The stubs shall be set correctly and precisely in accordance with approved method

at the exact location, alignment and levels with the help of stub setting templates

and leveling instruments. Stubs shall be set-in the presence of Owner’s

representative available at site where required and for which adequate advance

intimation shall be given to Owner by Contractor. Tolerances as per provisions of

IS :5613 shall be allowed for stub-setting.

5.10.3 Setting of stub at each location shall be approved by Owner.

5.10.4 However, in hilly region for towers with unequal leg extensions and for river

crossing towers, props may be used with complete accuracy and high skilled

supervision, subject to prior approval from Owner.

5.10.5 Stub Setting Templates

5.10.5.1 Stub setting templates shall be arranged by the Contractor at his own cost for all

heights of towers. Stub templates shall be of adjustable type and painted.

5.10.5.2 The Contractor shall deploy sufficient number of templates for timely

completion of the line without any extra cost to Owner.

5.10.5.3 One set of each type of stub setting template in good working condition shall be

supplied to the Owner, on completion of the project, at no extra cost to Owner.

5.10.5.4 The following number of stub setting templates shall be deployed by the

Contractor for each package :

Templates for tower type

i) for DA type

ii) for DB,

iii) forDC

iv) forDD

For Pkg. 1

5

2

1

4

v) For tower with + 18/25 M Extn. 1 each



However, if Owner feels that more templates are required for timely

completion of the lines, the Contractor shall have to deploy the same without

any extra cost to Owner.

5.11 Mixing, Placing and Compacting of Concrete

5.11.1 The concrete shall be mixed in the mechanical mixer. The water for mixing

concrete shall be fresh, clean and free from oil, acids and alkalis. Saltish or

brackish water shall not be used.

5.11.2 Mixing shall be continued until there is uniform distribution of material and mix

is uniform in color and consistent, but in no case the mixing be carried out for less

than two minutes. Normal mixing shall be done close to the foundation but exceptionally the concrete may be mixed at the nearest convenient place. The

concrete shall be transported from the place of mixing to the place of final deposit

as rapidly as practicable by methods which shall prevent the Segregation or loss of any ingredient. The concrete shall be placed and compacted before setting

commences.

5.11.3 To avoid the possibility of reinforcement rods being exposed due to unevenness

of the bottom of the excavated pit, a, pad of lean concrete 50mm thick and

corresponding to a 1:3:6 nominal mix shall be provided at the bottom of the pad.

5.11.4 Form boxes shall be used for casting all types of foundations except at an

undercut interface for which the adjoining subsurface material shall provide adequate support.

5.11.5 The concrete shall be laid down in 150mm layers and consolidated well, so that

the cement cream works, up to the top and no honey-combing occurs in the concrete. A mechanical vibrator shall be employed for compacting the concrete.

Monolithic casting of foundations must be carried out. However, in case of

unavoidable circumstances, a key construction joint can be provided at the

chimney-pad interface subject to approval of the Owner. After concreting the chimney portion to the required height, the top surface should be finished smooth

with a slight slope towards the outer edge for draining rain water. However

nothing extra shall be paid to the Contractor for providing such construction joints.

5.11.6 Wet locations shall be kept completely dewatered, both during and 24 hours after

placing the concrete, without disturbance of the concrete.

5.11.7 If the concrete surface is found to be defective after the form work has been

removed, the damage shall be repaired with a rich cement sand mortar to the

satisfaction of the Owner before the foundation is back filled.

5.12 Backfilling and Removal of Stub Templates

5.12.1 After opening of form work and removal of shoring, timbering, etc., backfilling

shall be started after repairs, if any, to the foundation concrete. Backfilling shall

normally be done with the excavated soil, unless it is a clay type or it consists of large boulders/stones, in which case the boulders shall be broken to a maximum



size of 80-mm. At locations where borrowed earth is required for backfilling,

Contractor shall bear the cost irrespective of lead & lift.

5.12.2 The backfilling materials shall be clean and free from organic or other foreign

materials. A clay type soil with a grain size distribution of 50% or more passing

the # 200 sieve as well as a black cotton soil are unacceptable for backfilling. The

earth shall be deposited in maximum 200 mm layers, levelled, wetted if necessary

and compacted properly before another layer is deposited. The moisture content for compaction shall be based on the Proctor compaction test results given in the

Geotechnical Report, Clause 4.1. The density of the compacted backfill material

may further be verified to the satisfaction of the Owner based on the sand-cone method described in the ASTM D1556-82 standard.

5.12.3 The backfilling and grading shall be carried to an elevation of about 75mm above

the finished ground level to drain out water. After backfilling 50mm high, earthen embankment (bund) will be made along the sides of excavation pits an sufficient

water will be poured in the backfilling earth for at least 24 hours. After the pits

have been backfilled to full depth the stub template can be removed.

5.13 Curing

The concrete shall be cured by maintaining the concrete wet for a period of atleast

10 day’s after placing. Once the concrete has set for 24 hours the pit may be

backfilled with selected moistened soil and well consolidated in, layers not exceeding 200mm thickness and thereafter both the backfill earth and exposed

chimney shall be kept wet for the remainder of the prescribed 10 days. The

exposed concrete chimney shall also be kept wet by wrapping empty cement bags around it and wetting the bags continuously during the critical 10 days period.

5.14 Benching .

When the line passed through hilly/undulated terrain, leveling the ground may be

required for casting of tower footings. All such activities shall be termed benching and shall include cutting of excess earth and removing the same to a suitable point

of disposal as required by Owner. Benching shall be resorted to only after

approval from Owner. Volume of the earth to be cut shall be measured before cutting and approved by Owner for payment purposes. Further, to minimise

benching, unequal leg extensions shall be considered and provided if found

economical. The proposal shall be submitted by the Contractor with detailed

justification to the Owner.

5.15 Protection of Tower Footing

5.15.1 Tower spotting shall endeavor to minimise the quantity of revetment required.

5.15.2 The work shall include all necessary stone revetments, concreting and earth filling

above ground level, the clearing from site of all surplus excavated soil, special

measures for protection of foundation close to or in nallahs, river bed undulated



terrain, etc., including suitable revetment or galvanised wire netting and meshing

packed with boulders. The top cover of stone revetment shall be sealed with M-15

concrete (1:2:4 mix). Contractor shall recommend protection at such locations

wherever required. Details of protection of tower footing are given in drawing

enclosed with these specifications for reference purpose only.

5.15.3 Tower footings shall generally be backfilled using soil excavated at site unless

deemed unsuitable for backfilling In the latter case, backfilling shall be done with borrowed earth of suitable quality irrespective of lead at the cost of the

contractors. The unit rate for backfilling quoted in Unit Price Schedule shall

include the required lead and consolidation and leveling of earth after backfilling.

5.15.4 The provisional quantities for protection work of foundations are furnished in

Annexure-1. However the contractor has to make a site visit and estimate the

quantities to include the same in his quote for the tower protection works as per the general drawings attached. The unit rates shall also be applicable for adjusting

with the actual quantities of protection works done. These unit rates shall hold

good for protection work carried out on down hills or uphills slopes applicable for

the tower locations.

5.15.5 While quoting the tower protection unit rates contractor shall also consider the

random rubble masonry revetment, excavation & (1:5) random masonry and top

sealing with M-15 concrete.

No extra rates shall be paid for allied work such as excavation, for revetment,

packed stone at head of weep holes etc. However no deduction shall be made for

the volume enclosed by weep holes. The locations where both benching and protection of tower footing are envisaged, an economy got to be established

against providing unequal leg extension.

5.15.6 For some of the locations in nalas, river bed or undulated terrain etc., maximum

size boulders of min. 150 mm dimension bounded and packed in galvanised wire

net/mesh of 8 SWG wire 152 square mesh are to be provided. These stones shall

be provided in crates size of 2.0 m x2.0 m or as deemed suitable for a particular

location. Measurement shall be taken in cubic meters and 15% deduction will be made for void from cage/ stack measurements.

6.0 Tower Erection, Stringing and Installation of Line Materials

6.1 General

6.1.1 The scope of erection work shall include the cost of all labour, tools and plant

such as tension stringing equipment and all other incidental expenses in

connection with erection and stringing work. The bidders shall indicate in the offer the sets of stringing equipment he would deploy exclusively for each

transmission line package, sets which shall be of sufficient capacity to string a

bundle of 2 (Twin) ACSR MOOSE Conductors.



6.1.2 The Contractor shall be responsible for transportation to site of all the materials to

be provided by the Contractor as well as proper storage and preservation of the

same at his own cost, till such time the erected line is taken over by the Owner.

Similarly, the Contractor shall be responsible for transportation, proper storage,

safe custody, and loss or damage of all Owner’s supplied items for incorporation

in the lines and shall maintain and render proper account of all such materials at

all times. The Contractor shall, reimburse the cost of any of the materials lost or damaged during storage and erection.

6.1.3 Contractor shall set up required number of stores along the line and the exact

location of such stores shall be discussed and agreed upon with the Owner. Owner supplied items shall be dispatched to the railway stations situated nearest to the

stores set up by the Contractor. Form these railway stations, receipt, unloading

and transportation to the stores shall be the entire responsibility of the Contractor.

6.1.4 Payment for stringing shall be done on the basis of per kilometer and irrespective

of number of tension/suspension towers. However, stringing for river crossing

spans, if applicable, have been given separately in schedule of Prices.

6.2 Treatment of Minor Galvanisation Damage

Minor defects in hot-dip galvanised members shall be repaired by applying At

least two coats of zinc rich Primer (having approx. 90% zinc content) and two

coats of enamel paint to the satisfaction of the Owner before erection.

6.3 Assembly

The Contractor shall give complete details of the erection procedures he proposes

to follow.

6.3.1 The method for the erection of towers shall ensure the following

a) Straining of the members shall not be permitted for positioning. It may

however, be necessary to match hole positions at joints using tommy bars

not more than 450mm in length;

b) Prior to erection of an upper section, the tower section shall be completely

braced, and all bolts provided tightened adequately in accordance with

approved drawings to prevent any mishap during tower erection.

c) All plan diagonals relevant section of tower shall be in place prior to

assembly of an upper Section;

d) The bolt positions in assembled towers shall be as per lS-5613 (Part

II/Section 2);



e) Tower shall be fitted with number, danger and phase plates as well as anti-

climbing device, as described;

f) After complete erection of the tower, all blank holes, if any, are to be

filled by bolts and nuts of correct size.

6.4 Tightening of Bolts and Nuts

6.4.1 All nuts shall be tightened properly using correct size spanner and torque wrench.

Before tightening, it will be verified that filler washers and Plates are placed in relevant gap between members, 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 nuts. 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.

6.4.2 The threads of all the bolts except for Anti-theft 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 arms for double circuit towers. However, for river crossing

towers, the welding shall be provided from ground level to 30 m height from stub level. After welding zinc-rich primer having approximately 90% zinc content

shall be applied the welded portion. At least two coats of the paint shall be

applied. The surface coated with zinc rich primer shall be further applied with two finish coats of high build enamel of the grade recommended by the manufacturer

of the zinc rich primer. The cost of welding and paint including application of

paint shall be deemed to he included in the erection price.

6.4.3 Not Applicable

6.5 Insulator Hoisting

Double suspension insulator strings shall be used for suspension towers and Quad

tension Insulator strings on tension towers. Damaged insulators and strings, if any, shall not be employed in the assemblies. Prior to 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 that purpose. For checking the soundness of insulators, IR measurement using 5 kV (DC) Megger shall be

carried out on insulators. Corona control rings/arcing horn shall be fitted in an

approved manner. Torque wrench shall be used for fixing various line materials and components, such as suspension clamp for conductor and earthwire, etc.,

whenever recommended by the manufacturer of the same.



6.6 Handling of Conductor and earthwire

6.6.1 Running Out of the Conductors

6.6.1.1 The conductors shall be run out of the drums form the top in order to avoid

damage. The Contractor shall be entirely responsible for any damage to tower or

conductors during stringing.

6.6.1.2 A suitable braking device shall be provided to avoid damaging, loose running out

and kinking of the conductors. Care shall be taken that the conductors do not

touch and rub against the ground or objects which could scratch or damage the

strands.

6.6.1.3 The sequence of running out shall be from the top down i.e. the earthwire shall be

run out first followed in succession by the conductors. Unbalanced loads on

towers shall be avoided as far as possible.

6.6.1.4 The Conductor shall take adequate steps to prevent clashing of sub conductors

until installation of the spacers/spacer dampers. Care shall be taken that sub-

conductors of a bundle are from the same Contractor and preferably from the

same batch so that creep behavior of sub conductors remains identical. During

sagging, care shall be taken to eliminate differential sag in sub-conductors as far as possible. However, in no case shall sag mismatch be more than 25mm.

6.6.1.5 Towers not designed for one sided stringing shall be well guyed and steps taken

by the Contractor to avoid damage. Guying proposal along with necessary calculations shall be submitted by the Contractor to Owner for approval. All

expenditure related to this work is deemed to be included in the bid price and no

extra payment shall be made for the same.

6.6.1.6 When the 400 kV transmission lines runs parallel to existing energised power

lines, the Contractor shall take adequate safety precautions to protect personnel;

from the potentially dangerous voltage built up due to electromagnetic and electrostatic coupling in the pulling wire, conductors and earthwires during

stringing operations.

6.6.1.7 The Contractor shall also take adequate safety precautions to protect personnel

from potentially dangerous voltage build up due to distant electrical storms.

6.6.2 Running Blocks

6.6.2.1 The groove of the running blocks shall be of such a design that the seat is

semicircular and larger than the diameter of the conductor/earthwire and it does not slip over or rub against the slides. The grooves shall be lined with hard rubber

or neoprene to avoid damage to conductor and shall be mounted on properly

lubricated bearings.

6.6.2.2 The running blocks shall be suspended in a manner to suit the design of the cross-

arm. All running blocks, especially at the tensioning end will be fitted on the



cross-arms 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.

6.6.3 Repairs to Conductors

6.6.3.1 The conductor shall be continuously observed for loose or broken strands or any

other damage during the running out operations.

6.6.3.2 Repairs to conductor if necessary, shall be carried out with repair sleeve.

6.6.3.3 Repairing of the conductor surface shall be carried out only in case of minor

damage, scuff marks, etc. The final conductor surface shall be clean, smooth and

free from projections, sharp points, cuts, abrasion, etc.

6.6.3.4 The Contractor shall he entirely responsible for any damage to the towers during

stringing.

6.6.4 Crossings

Derricks or other equivalent methods ensuring that normal services need not be

interrupted nor damage caused to property shall be used during stringing

operations where roads, channels, telecommunication lines, power lines and

railway lines have to be crossed. However, shut down shall be obtained when working at crossings of overhead power lines. The Contractor shall be entirely

responsible for the proper handling of the conductor, earthwire and accessories

in the field.

6.7 Stringing of Conductor and Earthwire

6.7.1 The stringing of the conductor for 400kV shall be done by the control tension

method. The equipment shall be capable of maintaining a continuous tension per bundle such that the sag for each conductor is about twenty percent greater than

the sags specified in the stringing sag table.

6.7.2 The bidder shall give complete details of the stringing methods he proposes to

follow. Prior to stringing the Contractor shall submit the stringing charts for the conductor and earthwire showing the initial and final sags and tension for various

temperatures and spans along with equivalent spans in the lines for the approval

of the Owner.

6.7.3 A controlled stringing method suitable for simultaneous stringing of the sub

conductors shall be used. The Four conductors making up one phase bundle shall

be pulled in and paid out simultaneously. These conductors shall be of matched length. Conductors or earthwires shall not be allowed to hang in the stringing

blocks for more than 96 hours before being pulled to the specified sag. Conductor

creep are to be compensated by over tensioning the conductor at a temperature of



260 C lower than the ambient temperature or by using the initial sag and tensions

indicated in the tables.

6.8 Jointing

6.8.1 When, approaching the end of a drum length at least three coils shall be left in

place when the stringing operations are 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 accessories manufacturer.

6.8.2 Conductor splices shall not crack or otherwise be susceptible to damage in the

stringing operation. The Contractor shall use only such equipment/methods during

conductor stringing which ensures complete compliance in this regard.

6.8.3 All the joints on the conductor and earthwire shall be of the compression type, in

accordance with the recommendations of the manufacturer. for which all

necessary tools and equipment like compressors , dies etc., shall be obtained by the Contractor. Each part of the joint shall be cleaned by wire brush till it is free

of dust or dirt etc., and be properly greased with anti-corrosive compound. If

required and as recommended by the .manufacturer, before the final compression

is carried out with the compressors.

6.8.4 All the joints of splices shall be made at least 30 meters away from the tower

structures. No joints or splices shall be made in spans crossing over main roads,

railways and small river tension spans. Not more than one joint per sub conductor per span shall be allowed. The compression type fittings shall be of the self

centering type or care shall be taken to mark the conductors to indicate when the

fitting is centered properly. 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 compressing the joint the aluminium sleeve shall

have all corners rounded, burrs and sharp edges removed and smoothened.

6.8.5 During stringing of conductor to avoid any damage to the joint, the Contractor

shall use a suitable protector for mid span compression joints in case they are to

be passed over pulley blocks/aerial rollers. The pulley groove size shall be such

that the joint alongwith protection can be passed over it smoothly.

6.9 Tensioning and Sagging Operations

6.9.1 The tensioning the sagging shall be done in accordance with the approved

stringing charts or sag tables. The “initial” stringing chart shall be used for the conductor and final stringing chart for the earthwire. The conductors shall be

pulled up to the desired sag and left in running blocks for at least one hour after

which the sag shall be rechecked 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.



6.9.2 The sag will be checked in the first and the last section span for sections up to

eight spans, and in one additional intermediate span 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.

6.9.3 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.

6.9.4 At sharp vertical angles, conductor and earthwire sags and tensions shall be

checked for equality on both sides of the angle and running block. The suspension

insulator assemblies will normally assume verticality when the conductor is clamped.

6.9.5 Tensioning and sagging operations shall be carried out in calm whether when

rapid changes in temperature are not likely to occur.

6.10 Clipping In

6.10.1 Clipping of the conductors into position shall be done in accordance with the

manufacturers recommendations.

6.10.2 Jumpers at section and angle towers shall be formed to parabolic shape to ensure

maximum clearance requirements. Pilot suspension insulator strings shall be used,

if found necessary, to restrict jumper swing to design values.

6.10.3 Fasteners in all fittings and accessories shall be secured in position. The security

clip shall be properly opened and sprung into position.

6.11 Fixing of Conductors and Earthwire Accessories

Conductor and earthwire accessories including spacers, spacer dampers (for

bundle conductor) and vibration dampers shall be installed by the Contractor as

per the design requirements and manufacturer’s instruction within 24 hours of the

conductor/earthwire clamping. While installing the conductor and earthwire accessories, proper care shall be taken to ensure that the surfaces are clean and

smooth and that no damage occurs to any part of the accessories or of the

conductors. Torque wrench shall be used for fixing the Dampers/Spacer Dampers,

Suspension Clamps etc. and torque recommended by the manufacturer of the same shall be applied.

6.12 Replacement

If any replacement are to be effected after stringing and tensioning or during

maintenance, leg member and bracing shall not be removed without first reducing

the tension on the tower by proper guying techniques or releasing of the

conductor. For replacement of cross arms, the conductor shall be suitably tied to



the tower at tension points or transferred to suitable roller pulleys at suspension

points.

6.13 Not Applicable

6.14 Final checking, Testing and Commissioning

After completion of the works, final checking of the line shall he carried out by

the Contractor to ensure that all foundation works, tower erection and stringing

have been done strictly according to the specifications and as approved by the

Owner. All the works shall be thoroughly inspected in order to ensure that:

a) Sufficient backfilled earth covers each foundation pit and is adequately

compacted;

b) Concrete chimneys and their copings are in good condition and finely

shaped.

c) All tower members are used strictly according to final approved drawing

and are free of any defect or damage whatsoever.

d) All bolts are properly tightened, punched, tack welded and painted with

zinc rich paint;

e) The stringing of the conductors and earthwire has been done as per the

approved sag and tension charts and desired clearances are clearly

available;

f)

All conductor and earthwire accessories are properly installed;

g) All other requirements for completion of works such as fixing of danger

plate, phase plate, number plate, anti-climbing device, aviation signal have

been fulfilled.

h) Wherever required, that proper revetment (erosion protection) is provided;

i) The original tracings of profile and route alignment as well as tower

design, structural drawings, bill of material and shop drawings of all.

towers are submitted to the Owner for reference and record.

j)

The insulation of the line as a whole is tested by the Contractor through

provision of his own equipment, labour etc., to the satisfaction of the

Owner.

k) All towers are properly grounded.



l)

The line is tested satisfactorily for commissioning purpose.

7.0 Special River Crossing Towers

Not Applicable

8.0 Field Quality Plan

All field activity shall be carried out in accordance with Standard Field Quality

plan given in the Specification.


Description of

Activity

Volume-II / Section-III EPC Tender for JITPL

STANDARD FIELD QUALITY PLAN FOR TRANSMISSION LINES

Items to be Checked Tests/Checks to be Ref. documents Check/Testing Counter Check/Test by Owner

done

Acc

authority in

Detailed Survey N/A

.

.

Agency

Extent

JITPL

Check Survey Tower Location &

Final Length

i) Alignment

ii) Final Length

a. Route alignment

b. Tower Schedule

c. Profile

Contractor

-do-

100% at Field

-do-

i) All angle towers in plains and

50% in hilly terrains.

ii) Final length to be checked on

100% basis based on

records/documents

Engineer

Detailed Soil

Investigation

a. Borelog 1. Depth of bore log

2. SPT Test

3. Collection of

samples

As per Owner

Specification

Contractor 100% at Field To witness 20% at Field Engineer

Jindal India Thermal Power Limited Page

92

Description of

Activity

Items to be Checked Tests/Checks to be

done

b. Tests on samples As per tech. Specs.

Volume-II EPC Tender for JITPL

Ref. documents Check/Testing Counter Check/Test by Owner

Agency Extent

As per Owner Lab appd. By Owner 100% by testing lab Review of lab test results

Specification

Accepting

authority in

Line incharge

based on the repor

review by Owner

Foundation

A. Materials

1. Cement

1. Source approval

2. Physical tests

3. Chemical Tests

Chemical

composition of

Cement

Source meeting Owner

Specification/Approved

vendor

As per document at

Annexure-I of this FQP

at Pg. 12, 13 & 14.

-do-

Contractor

Samples to be taken

jointly with Owner and

tested at Owner

approved lab

Contractor to submit

MTC

As proposed by

Contractor

Review of all MTC’s

and one sample for

every 500 MT

100%% review of

MTC by Contractor

To verify the proposal based on

the supply made and factory test

results.

100% review of lab test results

100% review of MTC

Engineer

Engineer

Engineer

2. Reinforcement 1. Source approval

Steel

2. Physical and

Chemical analysis

test

To be procured from

main producers only.

As per annexure-2 of

this FQP at pg. 15

Contractor

Contractor to submit

MTC

As proposed by

Contractor

All MTC’s

To review the proposal based on

the documents.

100% review of MTC

Engineer

Engineer


93

Description of

Activity


done



Agency Extent

Accepting

authority in

3. Coarse

Aggregates

4. Fine aggregate

5. Water

1. Source approval

2. Physical tests

1. Source approval

2. Physical test

1. Cleaniness (Water

shall be fresh and

clean)


Specification

As per document at

Annexure-3 of this FQP

at page 16


Specification

As per Annexure-4 of

this FQP at page 17

Owner Specification

Contractor

Samples to be taken

jointly and tested in

Owner approved lab

Contractor

Samples to be taken

jointly and tested in

Owner approved lab

Contractor

Proposed by the

Contractor, indicating

the location of the

quarry and based on

the test results of Joint

samples tested in

Owner approved lab

One sample per lot of

200 cum or part

thereof

Proposed by the

Contractor, indicating

the location of the

quarry and based on

the results of Joint

samples tested in

Owner approved lab.

One sample per lot of

200 cum or part

thereof

100% visual check at

Field


the documents



the documents.


Verification at random

Engineer

Engineer

Engineer

Engineer

Engineer


94

Description of

Activity


done



Agency Extent

Accepting

authority in

B. Classification

C. Concrete Works

a. Before concreting

1. Bottom of

excavated earth

2. Stub setting

2. Suitability of water

for concreting

1. Visual observation

of soil strata

2. Ground water level

3. History of water

table in adj.

Area/surface water

4. Soil Investigation

wherever required

Depth of foundation

1) Centre Line

2) Diagonals

3) Level of stubs

Owner Specification

Owner Specification

Appd. Drgs.

-do-

Contractor

Contractor

Contractor

-do-

100% Visual Check

at Field

100% at Field

100% at Field

-do-

Verification at random

100% at Field

100% check by Owner

-do-

Engineer

a. Section incharge

b. In case of

WBC/SFR/FS

acceptance by

Engineer

charge

c. For Spl.

Fdns./pile fdns.

Acceptance by

Engineer

charge

Engineer

3. Reinforcement Placement

steel

Bar bending schedule -do- -do- -do-


95

b. During

concreting


Description of

Activity


done

Ref. documents

Agency

Check/Testing

Extent

Counter Check/Test by Owner

Accepting

authority in

1. Workability Slump test Range 25 mm to 55 mm

refer document at

Annexure-5 of this FQP

at Pg. 18

Contractor 100% at field 20% check at random Engineer

charge

2. Concrete

Strength

Cubes Comp Strength CPWD SPEC as

referred in document at

annexure-5 of this page

at 18

Casting of cubes at

site. Cubes to be tested

at Owner appd. Lab

for 28 days strength

One sample of 3 cubes

in each tower locations

100% review of lab test results.

Cubes at 20% location are to be

taken in presence of Owner

officials

Engineer

charge

foundations

1. All materials like

cement, steel

Coarse/fine

aggregate, water

2. Before concreting 1. Check for center

line of each pile

To be tested as per procedure enumerated in the respective columns above

Appd. Drawings Contractor 100%

100%

Engineer

charge

3. During

Concreting

2. Check for

dia/verticality of

each pile

3. Check for depth of

each pile

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-


96

a. Workability

1. Slump test


100-150 mm as per Contractor Every one hour. 100% at field

Engineer

Tower

Erection

b. Concrete

strength

1. Materials

a. Tower

member/bolts &

nuts/washers/acces

sories

2. Erection of

Super-structure

2. Cubes

compressive

strength

Visual checking for

1. Stacking

2. Cleanliness

3. Galvanizing

4. Damages

1. Sequence of

erection

2. Check for

completeness

3. Tightening of

nuts and bolts

4. Check for

verticality

Owner Specn.

As per Owner Specn.

Appd. Drgs./BOM

As per Appd.

Drgs./Owner

specification

-do-

-do-

-do-

Contractor.

One set of cubes

(Min. 6 nos.) to be

taken and tested for

7&28 days strength

at Owner appd. Lab.

Contractor

Contractor

-do-

-do-

-do-

For each pile

One set for each

pile. For Pile caps,

beams, Chimney,

one sample for

every 20 Cu.m. or

part thereof for each

day of concreting.

100% at stores

100% at field

-do-

-do-

-do-

100% cubes for piles, 20%

Pile caps, beams, chimney etc.

to be taken in presence of

Owner officials. 100% review

of test results.

100% verification of records

100% check

-do-

-do-

-do-

charge

Engineer

charge

Engineer

charge

Engineer

charge

dal India Thermal Power Limited Page

97

Description of

Activity


done



Agency Extent

Accepting

authority in

Stringing

3. Tower footing

resistance (TFR)

1. Materials

a. Insulators

5. Tack welding for

bolts & nuts

TFR at locations

before and after

earthing.

1. Visual check for

cleanliness/glazing/

cracks/and white

spots.

2. IR Value

Owner Specification

Owner Specification

Owner Specification

(min. 50M Ohms)

Contractor

Contractor

Contractor

-do-

100% at Field

100% at Field

100% at Field

One test per sample

size of 20 for every

lot of 10,000

100% Check

20% locations to be

verified

100% verification of

records and to carry

random checks 10%

To verify Contractor’s

records 100% and

joint check 20% of

total tests

Engineer

charge

Engineer

charge

Engineer

charge

3. E&M test - Insulator supplier a. 20 per 10,000 for

discs

b. 3 per 1500 for

long rod

Collection of samples,

sealing them and

handing over by

Owner to Insulator

supplier

Tests to be

witnessed/

Appd. by QA&I

at Manufactu

rer’s works

4. Traceability

(Make/batch

Packing list/CIP

Contractor

100% at field

100% Review of

records

Engineer

charge


98

No./Locations

where installed)

Volume-II/ Section-III EPC Tender for JITPL

b. Conductor

On receipt,

1. Visual check of

drum.

Packing list Contractor 100% at stores

20% check

Engineer

charge

c. Earthwire

2. Field activity

a. Before

Stringing

b. During

stringing

2. Check for seals

at both ends, and

Owner sticker on

outer end

3. Check depth

from top of flange

to the top of the

outer most layer

Check for seals at

both ends

Readiness for

stringing

(Conductor/Earth-

wire)

-do-

-do-

Packing list

Stringing procedures

as per Owner

specification

-do-

-do-

Contractor

Contractor

-do-

-do-

100% at stores

Readiness

certificate to be

submitted by the

Contractor

-do-

-do-

20% check

Review of Certificate

Engineer

charge


99

Description of

Activity


done



Agency Extent

Accepting

authority in

1. Scratch/cut

check (Visual)

2. Repair sleeve

3. Mid span Joints

4. Guying (in case

of towers not

designed for one

side stringing)

c. After stringing Check for,

1. Sag/Tension

2. Electrical

clearances

i) Ground

clearance

ii) Live metal

clearance etc.

3. Jumpering

Appd. Drawings/

Owner Specn.

-do-

-do-

Appd. Guying

arrangement/Owner

specn.

Sag tension

chart/tower Spotting

data

As per appd.

Drgs./Owner

specifications

-do-

-do-

-do-

Contractor

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

100% at Field

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

100% record & Field

check 20%

-do-

-do-

100%

100% record & Field

check 20%

-do-

-do-

-do-

-do-

Engineer

charge

Engineer

charge

Engineer

charge


100

Description of

Activity


done



Agency Extent

Accepting

authority in

Testing

4. Copper bond

5. Placement of

spacer/damper

As per Appd.

Drgns./Owner

Specification

As per Specn./drgs/

placement chart

Contractor

-do-

100% at Field

-do-

100% record & Field

Check 20%

-do-

Engineer

charge

-

commissionin

g of lines

Commi-

ssioning of

a. Readiness of

lines for pre-

commissioning

Readiness of lines

for commissioning

1. Completeness of

line.

2. Meggar test of

line

2. Digital

photograph of each

tower to ascertain

the completeness of

tower.

3. Electrical

Inspectors clearance

Owner latest pre-

commissioning

procedures (Doc. No.

D-2-01-70-01-00)

a. Owner latest pre-

commissioni

ng

procedures

(Doc. No. D-

2-01-70-01-

00)

b. Pre-

commissioning

Report

c. CEA clearance

Contractor

-do-

-do-

100%

-do-

-do-

100% joint checking

-do-

-do-

Engineer

charge


101

from CEA.



102


Annexure A

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR CEMENT

INARY PORTLAND CEMENT

Name of the test Ordinary Portland Cement 33

grade as per IS 269

Physical tests

Ordinary Portland Cement

43 grade as per IS 8112

Ordinary Portland Cement

53 grade as per IS 12269

Remarks

To be conducted in apprd. Lab

Fineness

Compressive

strength

Initial & Final

setting time

Soundness

Specific surface area shall not be

less than 225 sq.m. per Kg. or

2250 Cm2/gm.

72+/- 1 hour : Not less than 16

Mpa (16 N/mm2)

168+/-2 hour : Not less than 22

Mpa (22 N/mm2)


Mpa (33 N/mm2)

Initial setting time : Not less

than 30 minutes

Final setting time : Not more

than 600 minutes

Unaerated cement shall not have

an expansion of more than

10mm when tested by Le

chatlier and 0.8% Autoclave test.


less than 225 sq.m. per Kg or

2250 Cm2/gm.


Mpa (23 N/mm2)


Mpa (33 N/mm2)


Mpa (43 N/mm2)

Initial setting time : Not less

than 30 minutes

Final setting time : Not more

than 600 minutes


an expansion of more than

10mm when tested by Le

chatlier and 0.8% Autoclave test


less than 225 sq.m. per Kg or 2250

Cm2/gm.


Mpa (27 n/mm2)


Mpa (37 N/mm2)


Mpa (53 N/mm2)

Initial setting time : Not less than

30 minutes

Final setting time : Not more than

600 minutes


an expansion of more than 10mm

when tested by Le chatlier and

0.8% Autoclave test.

Blaine’s air permeability method

as per IS 4031 (Part-2)

As per IS 4031 (Part-6)

As per IS 4031 (Part-5)

-do-

Le chatlier and Autoclave test as

per IS 4031 (Part-3)


103


Name of the test Ordinary Portland Cement 33 Ordinary Portland Cement Ordinary Portland Cement Remarks

grade as per IS 269 43 grade as per IS 8112 53 grade as per IS 12269

Chemical composition tests Review of MTCC only

a) Ratio of percentage of lime

to percentage of silica,

alumina & iron oxide 0.66

to 1.02

b) Ratio of percentage of

alumina to that of iron

oxide Minimum 0.66%

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

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, c) Insoluble residue, c) Insoluble residue, percentage

Total loss on

Ignition

percentage by mass Max.

4.00%

d) Magnesia percentage by

mass Max. 6%

e) Total sulphur content

calculated as sulphuric

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

percentage by mass Max.

4.00%

d) Magnesia percentage by

mass Max. 6%


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.


by mass Max. 4.00%

d) Magnesia percentage by mass

Max. 6%


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.



104

Name of the test


Remarks

POZZOLANA PORTLAND CEMENT AS PER IS 1489

Physical tests

Chemical

composition tests

i) Fineness

ii) Compressive strength

iii) Initial & Final setting time

iv) Soundness

Specific surface area shall not be less than 300 sq.m. per Kg. or 3000

Cm2/gm

168+/- 2 hour : Not less than 22 Mpa (22 N/mm2)

672+/- 2 hour : Not less than 33 Mpa (33 N/mm2)

Initial setting time : Not less than 30 minutes

Final setting time : Not more than 600 minutes

Unaerated cement shall not have an expansion of more than 10mm

Le chatlier and Autoclave test as

per IS 4031 (Part-3)

a) Magnesia percentage by mass Max. 6%

b) Insoluble material, percentage by mass x + 2 (100-x)/100 where x is the declared % of pozzolana in

the PPC

Review of MTCC only

-do-

c) Total sulphur content calculated as sulpuric anhydride (SO3), percentage by mass Not more than -do-

Total loss on

Ignition

2.75 and 3.0 when tri-calcium aluminate percent by mass is 7 or less and greater than 7

respectively.



105


Annexure B

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR REINFORCEMENT STEEL

Name of the test Mild and medium tensile steel as per IS 432 Cold twisted Deformed bars Fe 415 as Remarks

per IS 1786

Chemical analysis

Physical tests

iii) Bend & Rebend

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

Carbon (For over 20 mm dia) 0.25%

Sulpher 0.055%

Phosphorus 0.055%

a) Ultimate Tensile stress

For all dia bars 410 N/Sq.mm. (min.)

b) Yield stress (N/Sq.mm) min.

For bars upto 20 mm dia 250

For bars above 20 mm dia 240

c) Percentage of elongation 23%

Pass

Carbon 0.30% Max

Sulpher 0.060%

Phosphorus 0.060%

Sulpher & Phosphorus 0.11%

a) 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 415

c) Percentage of elongation 14.5%

(min.)

Pass

Testing in approved lab




106


Annexure C

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR COARSE AGGREGATES AS PER IS

383

Coarse Aggregates

Tests

a) Determination

of particles size

a. IS Sieve

Designation

%age passing for Single-Sized Aggregate

of nominal size

Percentage Passing for grades Aggregate of nominal

size

63 mm

40 mm

100

20 mm

-

16 mm 12.5 mm 10

mm

- - -

40 mm

-

20 mm

-

16 mm

-

40 mm

20 mm

16 mm

85 to 100

0 to 20

-

100

85 to 100

-

-

100

85 to 100

-

-

100

-

-

-

95 to 100

30 to 70

-

100

95 to 100

-

-

100

90-100

12.5 mm

10 mm

-

0 to 5

-

0 to 20

-

0 to 30

85 to 100 100

0 to 45 85 to

100

-

10 to 35

-

25 to 35

-

30 to 70

4.75 mm

2.36 mm

-

-

0 to 5

-

0 to 5

-

0 to 10

-

0 to

20

0 to 5

0 to 5

-

0 to 10

-

0 to 10

-

Flakiness index Not to exceed 25%


107

Crushing Value


Not to exceed 45%

Presence of deletrious material Total presence of deleterious materials not to exceed 5%

Soundness test (for concrete

work subject to frost action)

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


108


Annexure D

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

Fine aggregates

Tests

IS Sieve Designation

Percentage passing for graded aggregate of nominal size

Determination of particle size

b) Silt content

10 mm

4.75 mm

2.36 mm

1.18 mm

600 microns 12.5 mm

300 microns

150 microns

F.A. Zone I

100

90-100

60-95

30-70

15-34

5 to 20

0-10

Not to exceed 8%

F.A. Zone II

100

90-100

75-100

55-90

35-59

8 to 30

0-10

Not to exceed 8%

F.A. Zone III

100

90-100

85-100

75-100

60-79

12 to 40

01-0

Not to exceed 8%

Presence of deleterious material

d) Soundness Applicable to concrete work

subject to frost action

Total presence of deleterious materials shall not exceed 5%

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


109


Annexure E

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR CONCRETE WORK

Concrete

Notes :

a) Workability

b) Compressive strength

Slump shall be recorded by slump cone method and it shall between 25-

55 mm.

Three samples of 15 cm cube for 28 days compressive strength for all

concrete works except pile foundation work shall be taken. For pile

foundation works, six cubes, three for 7 days testing and balance three

for 28 days testing shall be taken.

For nominal (volumetric) concrete mixes, compressive strength for 1:1.5:3 (Sand : Fine aggregates : 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.

ACCEPTANCE CRITERIA BASED ON 28 DAYS COMPRESSIVE STRENGTHS FOR NOMINAL MIX CONCRETE :

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.

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 restricted to 30% only for computation of strength.

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.

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.


110


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 contractor. 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 Contractor.

General Notes :

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.

All materials should have Cat-A CIP before they are erected.

Contractor shall be responsible for implementing/documenting the SFQP. Documents shall be handed over by the contractor to

Owner after the completion of the work.

Project incharge means over all incharge of work. Line Incharge means incharge of the line. Section in-charge means incharge

of the section.

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.

Acceptance criteria and permissible limits for tests are indicated in the Annexures. However for further details/tests Owner

specification and relevant Indian standards shall be referred.

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.

All counter checks/tests by Owner shall be carried out by Owner’s officials atleast at the level of Jr. Engr.

JITPL PowerTransco Limited Page

111

Volume-II / Section-IV EPC Tender for JITPL

SECTION – IV

PRE-COMMISSIONING PROCEDURES



SECTION – IV

CONTENTS

Clause Description

0.0 Introduction

1.0 Definitions

Page No

114

115

2.0 Overall

3.0 Safety

4.0 Inspection

5.0 Statutory

6.0 Handing

7.0 Protective

8.0 Dispatch

9.0 Switching

Procedure

Procedures

Requirement

Over

System

Procedure

Procedure

115

116

116

124

124

125

125

125

10.0

Testing and Measurement Procedures

126

11.0 Energization

12.0 De-Energisation

130

130

13.0

14.0 Passing

Observation and Duration

Criteria

130

130

15.0 Documentation

131




SECTION – IV

PRE-COMMISSIONING PROCEDURES FOR TRANSMISSION LINES

0.0

INTRODUCTION

Over all procedure, safety rules, Statutory Requirements, dispatch procedures,

switching sequences, observations, passing criteria and documentation of test

results have been documented in this report.

The detailed inspection and handing over documents are required to be checked

for the entire length of transmission line before energization.

The detailed inspection/test procedures for each activity has been elaborated in separate section of this documentation. The contents of this report are as

following

1. Definition

2. Overall Procedures.

3. Safety procedures

4. Inspection

5. Statutory Requirements

6. Handing over

7. Protective system

8. Dispatch procedures

9. Switching procedures

10. Testing

11. Energization

12. De-energization

13. Observations and duration

14. Passing criteria

15. Documentation



1.0 DEFINITION

“Main Transmission Lines” means all high pressure cables and overhead lines

(not being an essential part of the distribution system of a licensee) transmitting electricity from a generating station to another generating station or a sub-station,

together with any step-up and step- down transformers, switch-gear and other

works necessary to and used for the control of such cables or overhead lines, and

such buildings or part thereof as may be required to accommodate such transformers, switch-gear and other works and the operating staff thereof;

“Power System” means a system under the control of the Government or any

Board of Generating Company or other agency and having one or more

i) generating station; or

ii) main transmission lines and sub-stations; or

iii) generating stations and main transmission lines and substations;

“Regional Electricity Board” means any of the Boards as constituted immediately

before the commencement of the Electricity Laws (Amendment) Act, 1991, by

resolution of the Central Government for ensuring integrated operation of

constituent system in the region;

“Regional Load Dispatch Centre” means the Centre so designated where the

operation of each of the Regional Electricity Grids constituting the country’s

power system is coordinated

“Sub-Station” means a station for transforming or converting electricity for the

transmission or distribution thereof and includes transformers, convertors, switch-

gear, capacitors, synchronous condensers, structures cables and other appurtenant equipments and any buildings used for that purpose and the site thereof, a site

intended to be used for any such purpose and any buildings used for housing the

staff of the sub section;

“Tie-Line” means a line for the transfer of electricity between two power systems

together with switchgear and other works necessary to, and used for the control of

such line.

2.0 OVERALL PROCEDURE

First it is to be ascertained that the transmission line to be energized is ready for

operation and has been properly handed over (released) in writing. This will

include all safety aspects, Electrical inspector clearance, PTCC clearance, Statutory clearance, and final inspection, if any.



Instructions for the work and supervision is given by the test leader (Line in

charge). However all switching and all operational activities will be executed by

the regular operators.

Line charging instructions received from Owner are clearly understood by the

Line in charge and doubts, if any, are to be got clarified prior to the energisation

of the line.

Once the line is handed over for charging no work shall be permitted without a

valid WORKPERMIT.

When the whole system has been energized, including the AC line, it will be kept

in this state for 8 hours or more for “soaking’ with continuous inspection and

monitoring. However recommendations of the Owner may be checked. Otherwise

it may be put into continuous operation.

3.0 SAFETY PROCEDURES

Energization implies an abrupt and serious change of the working conditions in

the plant.

In order to avoid serious accidents, thorough information must be imparted to all

personnel involved in the construction of transmission line. Incharge of the

Transmission line (Group head OR Divisional head) must ensure that due

publicity has been made to the public in all the villages/areas along the line route

cautioning them against climbing the towers etc. and that the line is proposed to

be charged on so and so date. It is also to be confirmed that the AGENCIES

involved in the construction activities shall not carry out any job on the said line

without a valid WORK PERMIT.

It shall be ensured before charging that all men, material, Tools and plants and

any temporary earthing on any part of the entire length of line are removed.

It must be ensured that any power supply / low voltage charging used as anti-theft

measure must be disconnected and isolated to avoid accidental connection.

All equipment tests and pre-commissioning tests must have been completed,

reterminated (in case cables were isolated for testing purpose) and documented.

The system must be formally declared ready for energization and handed over for

operation in writing.

4.0 INSPECTION

Before the line is scheduled to be handed over for the pre

commissioning/energization the same shall be inspected by representatives of

Owner and Construction Agency as follows:



Such an inspection shall include:

i) Right of way/way leave/electrical clearance

ii) Foundation and Revetments/Protection Work

iii) Tower and Tower accessories

iv) Hardware Fittings

v) Insulators

vi) Conductors and Earthwire

vii) Accessories for conductor and Earthwire

viii) Aviation Warning Signals (Lights/globules/painting)

4.1 RIGHT OF WAY/WAY LEAVE/ELECTRICAL CLEARANCE

4.1.1 Right of way/Way leave clearance

Ensure that no tree/tree branches are falling within the zone of minimum

clearance specified as per Fig. 1.



Guidelines of forest/environmental rules shall be followed to avoid excessive tree

cutting i.e. all the trees should be cut from ROUTE level in the 3 meter corridor

below each line Conductor/Earthwires. In the balance corridor, Trees branches are

only to be lopped to attain the specified clearance as per Table no 1.

TABLE NO. 1

CLEARANCE FOR RIGHT OF WAY

TRANSMISSION VOLTAGE

IN KV

132

220

400

400

4.1.2 Electrical Clearance

MINIMUM RIGHT OF

WAY (IN MTRS)

27

35

52 (S/C)

46 (D/C)

SI.

No.

In case of line crossings, clearance between lowest conductor of line and top

conductor of the other line shall be adequate as follows:

(Minimum clearances in mm between lines when crossing each other)

Nominal System Voltage 132 kV 220 kV 400 kV

1.

2. 220

3.

132 KV

KV

400 KV

3050

4580

5490

4580

4580

5490

5490

5490

5490

Jumpers in the tension tower are properly intact with conductor and form a

parabolic shape in order to achieve adequate clearance from super steel structure.

4.1.2.1 Ground clearance

Normally at the time of construction adequate clearance is provided between lowest conductor and ground, but due to delay in charge/commissioning there are

chances of dumping/heaping soil, either concrete etc. or staking bricks etc. which



may cause reduction in ground clearance. In such cases the stored materials shall

be removed.

Ensure that there is no temporary or permanent construction of houses or shades

below the line. If the same has been constructed they shall be removed before

charging.

s

indicated by Approved Drawings by Owner are to be referred.

ces

The ground profile at the time of commissioning shall be checked with the profile

approved at the time of check survey.

Ground clearance of lowest conductors at critical points/wherever the lowest conductor is touching the ground shall be checked in the field from any of the

prevalent method and the values of ground clearance at these critical points shall

be recorded in the prescribed format.

In case of hilly Terrain and for building clearance, the side clearance from

conductors and jumpers at critical points shall also be checked and recorded for

all phases of conductor/earthwire towards hill/building side.

The permissible minimum ground clearances for different voltages are as given below.

VOLTAGE (KV)

132

220

400

4.1.2.2 Clearance for Telephone line crossings

GROUND CLEARANCE (MM)

6100

7015

8840

The minimum clearances between the conductors of the power line and

telecommunication lines are specified as follows:

VOLTAGE (KV)

132

220

400

CLEARANCE (MM)

2745

3050

4880



The vertical clearances between conductors and between conductor and earth-

wire shall be checked randomly say in any one span of all sections and 10

sections of hilly areas from single line diagram of the towers.

4.2 FOUNDATION AND REVETMENTS/PROTECTION WORK

FOUNDATION:

There shall not be any damage/uneven settlement of founda io

t ns. For this,

tolerances in levels of all four stubs should not exceed the criteria provided in the Annexure-C of IS -5613 (Part -3/Section 2):1989.

It is to be ensured that back filling of foundation is properly done. Soil shall be

filled over all legs upto ground level.

Extra surface earth after foundation back filling shall be removed from legs of

the tower beyond a lead distance of 30 m.

Any crack or break in chimney, if found, shall be repaired.

REVETMENTS / PROTECTION :

Cracks/damages to revetments shall be repaired.

Wherever revetments are provided, weep holes shall have slope such as to flush

out the deposited water away from tower platform.

In case of hill terrain, the benching area should be leveled properly. The area

around tower shall have proper slope for drainage of rain water.

4.3 TOWER AND TOWER ACCESSORIES

4.3.2 Normal Tower

After completion of a transmission line, all the towers shall be thoroughly

checked before charging the line. Special attention shall be given to the points as mentioned below:

Deformed/Buckled/missing/Rusted Members and Nuts and Bolts

It is to be ensured that no members are bend, deformed or rusted have been used

in towers and if so, the same shall be replaced.

If any member is found missing, a new member shall be fixed as per erection

drawing of Towers.

Nuts shall be sufficiently tightened for the required Torque specified by Owner Approved Drawing. Minimum 2/3 complete threads shall be projected outside



the nut. All bolts shall have their nuts facing outside of the tower for Horizontal

connection and Downwards for Vertical connections.

Nuts & bolts shall be properly tack welded/punched as per the specification and proper zinc rich paint shall be applied. It shall be ensured that the circular length

of each welding shall be at least 10mm.

It shall also be ensured that all extra blank holes provided on tower members are

filled with correct size of nuts & bolts.

4.3.2 Special Towers

In addition to the above checks for towers, ladders and platforms provided in

special towers shall be properly tightened and no foreign material shall be left out on such platforms.

Earthing of Towers

Ensure that proper earthing of tower has been done and earthing strip is neither

damaged nor broken and is properly fixed to the stub.

In case of counter poise earthing, it is to be ensured that earth wire is

sufficiently buried in the ground and no where it has drag out during cultivation.

The length of counter-poise is normally 30 m as per TS.

Before charging of the line, ensure that resistance is below 10 ohms. If the value

(before stringing) has been recorded higher than 10 ohm earthing shall be

changed to counterpoise type.

Earthing of special towers shall be verified as per approved drawings applicable

for special towers/special foundation. (In case of anchor foundation bolt/anchor

plate welded with last leg of special tower.)

4.3.3. Tower accessories

All the danger plates, number plates, circuit plates, and phase plates shall be in

position & and as per the specification.

All plates shall be properly tightened.

It shall be ensured that phase plates are fixed in correct phase sequence.

Specially at transposition towers, the phase plates in the correct phase sequence

shall be provided at each towers or end tower as per the specification of the line.

It shall be ensured that the anti-climbing device (ACD) is provided, at the suit-

able height of tower. In case of barbed wire ACD, barbed wire shall be tightly



fixed. In case of spike type ACD, all spikes shall be properly fixed and oriented

towards outer face of tower.

It shall be ensured that the step bolts (for normal towers) are provided upto the

peak of tower. Any missing step bolts shall be replaced. Fixing of birds guards

(upto 220 kV/wherever applicable) shall be ensured.

4.4. HARDWARE FITTINGS

Tightening of all bolts and nuts are to be checked upto specified torque. Check the fixing of all security clips.

Surface condition of corona control rings and distance/alignment between

Tower side arcing horn (wherever applicable) and line side arcing horn/corona

control ring to be checked as per approved drawings.

To restrict the swing of jumpers, the provision of Pilot strings in case of Tension

Towers shall be verified from the approved drawings.

4.5

4.6.

4.7

4.7.1

INSULATORS

All the damaged/broken insulator discs shall be replaced. Unusual deflection in

suspension strings if observed shall be rectified.

The insulators shall be cleaned before charging.

IR value of individual disc of at least 5 insulators at random shall be checked by

5/10 kV Megger.

CONDUCTORS and EARTHWIRES

Surface Condition

Surface of the conductors shall be free from scratches/rubs Ensure that

conductor strands are not cut and opened up. Wherever strands are found cut/damaged/scratched, they must be repaired with repair sleeves/repair

protective rods in case the nos. of damaged strands are within specified limits

(normally upto l/6th nos. of strands in the outer layer).

ACCESSORIES FOR CONDUCTORAND EARTHWIRES

Joints

All joints on conductor/earthwires shall be away from the tower at a distance of

at least 30 meters or as provided in the Technical specification (TS).

Ensure that not more than one joint in a conductor is provided in one span or as

provided in the Technical specification (TS).



Ensure that no mid span joint is provided in major crossings for main roads,

railway crossing and major rivers etc. or as provided in TS.

Ensure that all mid span joints on conductors/earthwire and repair sleeves of compression type are free from sharp edges, rust and dust. Wherever grease are

specified the same shall be applied in the joints.

4.7.2. Clipping

Ensure that conductor is not over tightened in the suspension clamps.

4.7.3

4.7.4

4.7.5

4.7.6.

Spacers, vibration dampers and copper bonds

Placement and no. of spacers/dampers between four sub conductors on each

phase shall be verified as per spacer/damper placement chart.

Damaged/missing spacers shall be replaced and loose/displaced spacers shall be

tightened/relocated.

Spacing of Vibration dampers from the tower and spacing between damper to

damper in case two Vibration Dampers (VD) were provided, shall be verified as

per the damper placement chart. All loose/displaced VD shall be properly

tightened/relocated and missing VDs shall be provided.

To be ensured that no copper bond is loose/missing.

Jumpers

Verify Electrical clearance of jumpers to tower body as per design. All the

jumpers shall be checked properly. In case, jumpers (conductor/earthwire) is found loose, it shall be tightened sufficiently.

Foreign material

Ensure that all foreign materials viz dead bird. fallen tree branches, bird nests etc. on conductors, earthwires, Jumper, insulator string, cross arms are re-

moved.

Others

It shall be ensured that all temporary/local earthing. guys, T & P (Tools and Plants), foreign material and other loose material which were used during

stringing/tower erection have been removed. In case there is any change in the

ground profile before commissioning of line from the approved profile, the extra earth/obstruction/temporary sheds/any other construction shall be

removed.



4.8

5.0

5.1.

5.2

6.0

AVIATION WARNING / OBSTRUCTION SIGNALS

(LIGHTS/GLOBULES/PAINTING).

It shall be ensured that following measures have been taken in the line/Towers

falling within obstruction zone of civil aviation and defense establishments as

per their requirement and our specification.

Day markers

Painting of Full/Top portion of Towers with Red/Orange and White Paints.

Globules on earthwires have been provided.

Night markers

It shall be ensured that proper aviation lights at the peak level/at specified

heights of towers have been provided along with Solar panels/Battery

banks/Control cubicles and other accessories as per specification. The functioning of lights with simulation to be checked/verified.

STATUTORY REQUIREMENT

The concerned authorities shall be informed before commissioning the lines and

their approval obtained in accordance with Indian Electricity Act, 2003 and Indian Electricity Rule, 1956 .

Before charging of the line PTCC approval from P&T Dept. shall be obtained.

HANDING OVER

The transmission line shall be inspected prior to energization and a formal

handing over document to be jointly signed by the representative of the EPC

Contractor and JITPL. However all contractual taking over has to be resolved separately as per the terms and conditions of the contract. The Handing over

shall be limited to the completion of Erection and ready for Energization.

Any outstanding points or remaining activities are to be listed jointly by the

EPC Contractor and JITPL and signed jointly. The remaining activities/outstanding points are classified in the following category.

Details of the SECTIONS:

A. List of outstanding activities remaining in any part of the line

B. A list of temporary arrangements introduced.

C. Check list records properly documented, completed and signed.

D. Original tracing of Profile, Route Alignment, Tower Design, Structural

Drawings, Bill of Materials, Shop Drawings, Stringing charts (initial and

final as applicable) etc. of all towers/line submitted to Owner.



With the outstanding activities mentioned above are solved or with only minor

points without influence on the charging remain (minor issues handing over of

the transmission line shall be accepted by the pre-commissioning team. This handing over for energization with or without remaining activities shall be made

by the group head to the commissioning in charge in writing.

Shortcomings noticed during the inspection, “List of outstanding activities”

shall be recorded and a copy of the format is to be given to the EPC Contractor for corrective action to be taken on a time schedule.

7.0

8.0

9.0

PROTECTIVE SYSTEM

Before energization it must be ascertained that all protective systems for the unit to be energized are operative.

This includes confirmation that the protections have been properly tested and

that the tests have been documented.

It also includes verification by inspection or otherwise, if necessary by

repetition of trip test, that the protections are actually functionally enabled. This

verification serves to prevent that energization takes place of a unit where a

protection has been disabled for test or other reason.

DISPATCH PROCEDURES

All operational activities (switching etc.) must be coordinated and

communicated with the system dispatcher i.e. PGCIL.

In this respect the general procedures already established by PGCIL will be

followed.

SWITCHING PROCEDURES

For each activity the instructions to the operators and the communications to the

dispatchers will be made in writing or by confirmed telephone messages. The

switching procedures first to be properly documented step by step and

understood by everybody involved in the switching operation prior to the enerzisation. Any clarification required in the procedures must be resolved. The

format established by Owner for switching orders and operational data logging

shall be followed.

The implication of this is that each and every activity must be listed and

described, so that complete information is available for detail investigation, if

required in future.



10.0

10.1.

10.2

TESTING AND MEASUREMENT PROCEDURES

Earth Resistance Measurement

Normally Earth tester is used for measuring

a) soil resistivity.

b) earth resistance

a. Prior to the testing of soil resistivity and earth resistance the operation

manual of the testing instrument available at site may be referred and

procedures to be adopted for measurement of soil resistivity and earth

resistance.

A typical Earth tester has 4 terminals. C1, P1, C2, P2 and 4 similar

electrodes are driven in the ground at equal distances and connected to the

instruments in the order of C1’ P1 and P2, C2. Then the handle is rotated

or button is pressed and the reading of the resistance is read on the megger

scale. If R is the resistance measured then the

Specific resistivity = 2πaR

where a is the distance between the electrode and R is the resistance in

ohms measured on the megger.

b) In order to measure earth resistance of electrode of the substation it could

be connected to C1 and the value of R could be read in the scale with the

rotation of the handle of the megger. This will give the earth resistance. The value as far as possible shall be below 10 Ohm. To improve the value,

water shall be sprinkle at the earthing pit.

Before commissioning of the lines following tests maybe carried out.



10.2.1 Insulation Resistance Test

This test may be carried out with the help of a 10 OR 12 KV megger preferably

power driven to ascertain the insulation condition of the line. In case 5 kV megger is used for insulation resistance measurement it shall be ensured that the

induced voltage (CVT reading) is LESS than the instrument withstanding

capacity otherwise it is likely that the instrument maybe damaged.

This Test is to be carried out First prior to the continuity test.

Measurement of Insulation Resistance

One of the most common devices used for testing electrical insulation is the

Megger Insulation Tester.

The DC test voltage is generated by a permanent magnet generator. This

generator is turned either by hand, or by an electric motor. In either case a slip

clutch maintains the generator speed at constant value so long as the slipping speed is exceeded. A constant voltage is important when the insulation under

test has a high capacitance. Common generator output voltage are 500, 1000,

2500 and 5000 volts.

Many Meggers have a “guard” terminal as well as “line” and “earth”. The guard terminal is useful shall one wish to exclude part of the insulation under test from

the measurement. This is possible since current flowing to the generator via the

guard circuit does not pass through the deflecting coil.

Another use of the guard circuit is to shield the “line” lead between the Megger

and the apparatus under test. This prevents leakage to ground from the “line”

lead which would invalidate the Megger reading.

Insulation resistance is the ratio VDC/ IDC . VDC is applied across two conductors

separately by the insulation under test.

IDC is the current flowing through/over the insulation. For a healthy and clean

insulation the megger reading is in mega-Ohms to infinity. For dirty in, insulation and defective, moist insulation the meggers shows a very low

insulation resistance value.

Megger test gives clear indication about the health, cleanliness and dryness of the line/equipment insulation.

2

e used for the

Transmission line keeping all safety requirements, Permit to work, clearance from statutory bodies and other conditions prevailing at the Sub-station where

charging of the line is being co-ordinated.



10.2.2

Conductor Continuity Test

10.2.2.1 The objective of this test is to verify that each conductor of the overhead line

properly connected electrically (the value of electrical resistance of line does not vary abnormally from that of a continuous conductor of the same size and

length). The electrical resistance of the conductor shall be measured with a

Whetstone bridge or other suitable instrument, if available taking the safety

aspects of Equipment as well as testing Engineer.

A simple method of continuity test is illustrated below

Once the insulation is completed and the results confirms no short circuit carry

the following

SENDING END

CLOSER R-Ph GS

RECEIVING END

MEGGER R-Ph

RESULTS (OHMS)

ZERO/LOW

OPEN Y – Ph GS MEGGER Y-Ph

HIGH

OPEN B-Ph GS

OPEN R-Ph GS

MEGGER B-Ph

MEGGER R-Ph

HIGH

HIGH

CLOSE Y-Ph GS MEGGER Y-Ph

ZERO/LOW

OPEN B-Ph GS

OPEN R-Ph GS

MEGGER B-Ph

MEGGER R-Ph

HIGH

HIGH

CLOSE Y-Ph GS MEGGER Y-Ph

HIGH

OPEN B-Ph GS

MEGGER B-Ph

ZERO/LOW

(ALL GS OPEN CONDITIONS)

GS means GROUND SWITCH

If the above test results are OK it confirms the continuity of the line.

10.2.2.2 The continuity Test of the line with proper phase indication or phase marking

can be checked by continuity test as described below:



SENDING END

RECEIVING END

MEGGER BETWEEN

RESULTS (OHMS)

CONNECT R&Y PHASE R PHASE & YPH

B-PHASE & ALL GS Y PHASE & B PH

OPEN B PHASE & R PH

ZERO OR LOW

HIGH

HIGH

CONNECT R & B PHASE

R PHASE & Y PH

HIGH

Y PHASE & ALL GS Y PHASE & B PH

OPEN B PHASE & R PH

HIGH

ZERO OR LOW

CONNECT Y & B PHASE

R PHASE & Y PH

HIGH

R-PHASE & ALL GS Y PHASE & B PH

OPEN B PHASE & R PH

ZERO OR LOW

HIGH

If the test results are OK it confirm that marking of the phases are in order.

10.2.2.2. Phase Sequence

Once the line is charged from one end, without closing the Breaker at the other

end the Phase sequence is to he checked from the CVT output by the help of Phase Sequence Meter. In case there is other feeders available Phase sequence is

to be RECHECKED by the measurement of secondary voltage of both the

Feeders. (New line & available charged line).

Let the secondary Voltage of CVT is 110 volts (ph to ph) for both the Circuit. In

case of correct Phase Sequence the voltage reading shall he as follows :

NEW CIRCUIT

R-Phase

R-Phase

R-Phase

Y-Phase

OLD CIRCUIT

R-Phase

Y-Phase

B-Phase

R-Phase 110

VOLTAGE

0

110

110



Y-Phase

Y-Phase

B-Phase

Y-Phase

B-Phase

R-Phase

0

110

110

B-Phase Y-Phase 110

B-Phase

B-Phase

0

11.0.

12.0

13.0

14.0

In case the resu1ts are not matching the phase sequence in to be rechecked and

reconfirmed before closing the breaker.

ENERGIZATION

Execution of the energization is simply the last event in the switching sequence,

switching of the close control button for the relevant circuit breaker.

DE-ENERGIZATION

Instructions about de-energization will be given only if this is part of the test.

Otherwise de-energization will be considered part of regular operation.

OBSERVATION AND DURATION

Visual and audible inspection (look and listen) of the relevant equipment and

reading of permanent instrumentation will be made.

The system shall be charged at least for 8 hours. During this time continuous

monitoring and inspection will be maintained in control room, auxiliary systems

areas and switch yards.

This will include frequent, scheduled inspection of all equipment and reading of

all permanent instruments and recorders, and surge arrester counters, especially system parameters as per standard procedures adopted by Owner.

PASSING CRITERIA

Neither insulation breakdown nor protective system actions must occur. No irregular equipment behaviour noise, vibration, high temperature is permitted.

Corona discharges may not be “unreasonable”. Local discharges that may be

attributable to sharp points shall be carefully located and recorded. After termination of the energization the equipment shall be closely inspected and the

points rounded or covered.



No unscheduled changes of system nor of equipment is permitted during the 8

hour energized condition.

15.0 DOCUMENTATION

Switching and operational activities will be recorded in regular manner in the

operators log. Likewise all readings of permanent instruments. Copies of this

log, notes on special observations from inspections ad other measurements will

constitute the test records.


Volume-II / Section-V EPC Tender for JITPL

SECTION – V


FOR ACSR ‘MOOSE’ CONDUCTOR



SECTION – V

CONTENTS

Clause Description

1.0 General

Page No

135

2.0 Environmental

Data

135

3.0

4.0

5.0

6.0

7.0

Electrical System Data

Technical Particulars of ACSR “MOOSE”

Conductor

Material

Surface Conditions

Cleaning

135

136

138

139

139

8.0

9.0 Tests

10.0 Testing

11.0 Additional

Temperature Curve

Expenses

Tests

139

139

140

141

12.0

13.0

14.0

Sample Batch for Type Testing

Test Reports

Test Facilities

141

141

141

15.0

17.0 Re-Test

19.0

Description of Tests

and Rejection Insepction

141

144

145

20.0

21.0

22.0

Length of the Conductor

Packing and Marking

Approval of Drawings, Sag Tension Charts and

145

145

147



23.0

N/A

24.0

N/A



TECHNICAL SPECIFICATION

SECTION V

FOR ACSR ‘MOOSE’ CONDUCTOR

1.0

2.0

3.0

GENERAL

This specification covers manufacture, testing, supply and delivery of ACSR

“MOOSE” conductors required for construction/maintenance of 400 KV lines & substation works of JITPLPowerTransco Limited. The conductor shall conform

to the Indian Standards enlisted in Annexure-5.

SCHEDULE -“A” DESCRIPTIVE TECHNICAL INFORMATIONS:

ENVIRONMENTAL DATA

Following are the salient parameters of the environmental data

(a) Maximum ambient temperature degree C : 50

(b) Minimum ambient temperature degree C : 7.5

(c) Maximum daily average temperature degree C : 32

(d) Maximum relative humidity % : 90

(e) Number of rainy days/year : 90

(f) Average number of thunder storm, days/year : 50

(g) Pollution level category : Moderately Polluted.

ELECTRICAL SYSTEM DATA

(a) Nominal System Voltage : 400 KV

(b) Frequency : 50 Hz

(c) System Highest Voltage : 420 KV

(d) Number of Conductor per phase : 4

(e) Conductor type & size : ACSR “Moose”

520 Sq. mm. nominal.

(f) Spacing between the two conductors of : 457 mm

same phase (sub- conductor spacing)



(g) Phase Configuration

: Vertical

(h) Maximum wind speed considered for line design: 44 m/sec

(i) Ruling design span

: 400 meters

4.0

TECHNICAL PARTICULARS OF ACSR “MOOSE” CONDUCTOR

The line conductor shall meet the following requirements:

(a) Nominal Aluminium area : 520 Sq.mm

(b) Stranding & Wire diameter : Al : 54/3.53 mm

Steel : 7/3.53 mm

(c) No. Of Aluminium strands:

1st layer : 12

2nd layer : 18

3rd layer : 24

(d) Sectional area of aluminium

(e) Total sectional area

(f) Approximate overall diameter

(g) Approximate weight

(h) Calculated d.c. resistance at 20 deg. C.

(i) Approximate calculated breaking load

(1) Co-efficient of linear expansion

(k) Final modulus of elasticity

(1) Resistivity of Aluminium wire at 20 deg. C.

(m) Electrical conductivity at 20 deg. C.

: 528.50 Sq.mm

: 597 Sq.mm

: 31.77 mm

: 2004* Kg/Km

: 0.05552 ohm/Km

: 161.20 KN (Min)

: 19.3 x 10-6 per deg.C.

: 0.703 x 106 Kg/Sq.mm.

: 0.028264 ohms sq

mm/m (maximum)

: 53.3% (standard) of IACS(International

Annealed Copper

Standard).



*This weight is that of ungreased conductor. This figure will change depending on the

density and thickness of coating of the grease.

(n)

(o)

Lay Ratio of Conductor: .

Steel Core (1 Centre core & layer of 6

wires)

Aluminium

1st layer of 12 wires

2nd layer of 18 wires

3rd layer of 24 wires

Strand Details :

Max.

18 16

14

13

12

Min

12

11

10

Materials Steel

Diameter

Aluminium

(p)

(q)

Standard

Maximum

Minimum

Cross Sectional area for nominal

Diameter of wire

Weight

3.53

3.60

3.46

9.787 sq.mm

76.34 kg/km

3.53

3.55

3.51

9.787 sq.mm

26.45 kg/km

(r) Minimum Breaking Load:

(i) Before stranding

(ii) After stranding

(s) D.C. resistance at 20 deg. C.

(t) Joints :

(i) Steel

Aluminium(ii)

Outer Layer

12.86 KN

12.22 KN

2.921 ohms/Km

Not permitted

Not Permitted

1.57 KN

1.49 KN

Inner Layer Joints by cold butt pressure



welding.

No two joints shall be less than 15

meters apart in a complete stranded conductor

(u) Stranding There shall be no tendency to

untwist or spring apart, when the

6 wire & 12 wire layers.

(v)

(w)

(x)

Packing

Temperature rise curve

Standard length/drum

One conductor length per drum

To be submitted along with offer

1800 meters +/- 5%

(y) Corona Extinction Voltage at 50 Hz (AC) Minimum 320 KV phase to

ground

(z)

5

RIV at 1 MHz for phase to ground voltage

MATERIAL

(i) 266 KV (dry condition) – Not

to exceed 500 micro volt

(ii) 100 KV (wet condition) – Not

Exceeding 1000 micro volt

5.1 Aluminium

The Aluminium strands shall be hard drawn from electrolytic aluminium rods

having purity not less than 99.5% and copper content not exceeding 0.04%.

5.2 Steel

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 shall

conform to requirements as to chemical composition given in latest relevant IS.

The chemical composition of high carbon steel wire is given below:

Element

(i) Carbon

(ii) Manganese

(iii) Phosphorous

(iv) Sulphur

(v) Silicon

5.3 Zinc

% Composition

0.50 to 0.85

0.50 to 1.10

Not more than 0.035

Not more than 0.045

0.10 to 0.35

The zinc used for galvanizing shall be electrolytic high grade zinc of 99.95% pure

.it shall conform to and satisfy all the requirements of IS-209. Galvanising may be

done by hot process. Neutral grease may be applied between the layers of wires.



5.3.1 Zinc coating of steel core:

6.0

(i) Number of 1 minute dip:

(ii)Minimum weight of Zinc coating:

(iii)Process of Galvanising:

SURFACE CONDITIONS:

3

260 gm/sq.lnt.

Hot dip

7.0

8.0

9.0

9.1

9.2

The surface of the conductor shall be smooth and free from dents, sharp edges,

abrasion or other departures from smoothness or uniformity of surface contour

that would appreciably increase radio interference and corona loss when used as

phase conductor. When subjected to tension up to 50% of the ultimate tensile

strength of the conductor, the surface shall neither depart from its general

cylindrical form nor any of the component parts or strands shall move relative to

each other in such a way so as to get out of place and disturb the longitudinal

smoothness of the conductor.

CLEANING

The conductor shall be free from excessive amount of die grease, metal particles

and dirt. The Bidder shall describe in complete details, the method which he

proposes to use in production to clean the conductor.

TEMPERATURE RISE CURVE

The Bidder shall furnish curves showing relation between current in amperes at

50 cycles and temperature rise in degree Celsius for ACSR 61/3.53mm.The ambient temperature shall be taken as 40 degree C. The graph shall specifically

indicate current values, for conductor temperature of 60 degree C ( ambient

temperature 40 degree + temperature rise of 20 degree C above ambient), 65

degree C, 70 degree C etc. upto 100 degree C in steps of 5 degree C.

TESTS

The conductor offered in the tender should have been successfully type tested in

line with the standard and technical specification within the last five years from

the date of opening of tender. The bidder shall be required to submit copies of

the type test reports along with the offer in electronic document form.

The type tests, acceptance tests, routine tests and tests during manufacture shall

be carried out on the conductor. For the purpose of this clause:

(a) Type tests shall mean those tests, which are to be carried out to prove the

design, process of manufacture and general conformity of the material to this specification. These tests shall be carried out on sample prior to commencement



of commercial production against the order. The bidder shall indicate his

schedule for carrying out these tests in the offer.

(b) Acceptance tests shall mean those tests, which are to be carried out on

sample taken from each lot, offered for pre-despatch inspection, for the

purposes of acceptance of that lot.

(c) Routine tests shall mean those tests, which are to be carried out on each

strand/spool/length of the conductor to check requirements which are likely to vary during production.

(d) Tests during manufacture shall mean those tests, which are to be carried out

during the process of manufacturing by the Contractor, to ensure the desired quality of the end product to be supplied by him.

9.3

9.4

9.5

10.0

The norms and procedures of sampling for these tests will be as per the Quality

Assurance Plan/Programme to be mutually agreed-to by the Contractor and Owner as per relevant clause of General Conditions of Contract.

The standards and norms to which these tests will be carried out, are listed

against them, where a particular test is a specific requirement of this

specification. The norms and procedures of the test shall be as specified in Annexure-I, or as mutually agreed to, between the Contractor and the Owner, in

the Quality Assurance Programme.

For all type tests and 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.

TESTING EXPENSES:

10.1 The Owner may opt for repetition of Type Test at his own expenses prior to

manufacture.

10.2 In case of failure in any type test, the bidder is either required to modify the

design of the material or repeat the particular type test successfully, at his own

expenses. The decision of the Owner, in this regard shall be final and binding.

10.3 Bidder shall indicate the laboratories, in which he proposes to conduct the type

test. He shall ensure that the tests can be completed in these laboratories, within

the time schedule, guaranteed by him, in the appropriate schedule.

10.4 The entire cost of testing for the acceptance tests, routine tests, and tests during

manufacture, specified herein, shall be treated as included in the quoted unit

price of conductor, except, for the expenses of the inspector/ Owner’s

representative.



11.0 ADDITIONAL TESTS:

The Owner reserves the right of having, at his own expenses, any other test(s) of

reasonable nature carried out at Contractor’s premises, at site, or at any other place in addition to the aforesaid type, acceptance and routine tests to satisfy

himself, that the materials complies with the specification.

12.0 SAMPLE BATCH FOR TYPE TESTING

12.1 The Contractor shall offer at least five (5) drums for selection of samples

required for conducting all the type tests.

13.0 TEST REPORTS (DOCUMENTS IN PHYSICAL FORM)

13.1 One original plus four copies of type test reports shall be furnished to the Owner

within one month of conducting the tests. One copy will be returned duly certified by the Owner to the Contractor within three weeks thereafter and on

receipt of the same, Contractor shall commence commercial production of the

conductor.

13.2 One original plus four copies of the acceptance test reports shall be furnished to

the Owner. One copy will be returned, duly certified by the Owner and only

thereafter, Contractor shall dispatch the conductor.

13.3 All records of routine test reports shall be maintained by the Contractor at his

works for periodic inspection by the Owner.

13.4 All test reports of tests conducted during manufacture, shall be maintained by

the Contractor. These shall be produced for verification as and when requested for by the Owner.

14.0 TEST FACILITIES

14.1 The following additional test facilities shall be available at Contractor’s works:

(i)

(ii)

The testing equipments with Valid Calibration certificate of various testing

equipments including tensile testing machine, resistance measurements

facilities, burette, thermometer, barometer etc.

Standard resistance for calibration of resistance bridges.

15.0 DESCRIPTION OF TESTS

15.1 TYPE TESTS

The following type tests shall be conducted on the samples of conductor in

presence of Owner’s representative. The sample for type tests shall be selected

by Owner’s representative. The type test shall be conducted once on



sample/samples of conductor for every 400 Kms or part thereof of production

from each manufacturing facility.

15.1.1 Ultimate Tensile Strength Test:

Circles perpendicular to the axis of the conductor shall be marked at two places

on a sample conductor of minimum 5 metre length, suitably compressed with

Tension Clamps at either end. Tensile load shall be applied to the sample and

shall be increased at a steady rate up to 50 % of the Ultimate Tensile Strength of the conductor and held for one minute. The circles drawn, shall not be distorted

due to relative movement of strands. The applied load shall then be increased at

steady rate until the failing load is reached. This value shall not be less than the guaranteed breaking load of the conductor.

15.1.2 Corona Extinction Voltage Test

Four samples of conductor of 5 meters length shall be strung with a spacing of

457 mm. between them. This sample assembly when subjected to power

frequency voltage, shall have a corona extinction voltage of not less than 320

KV line to ground under dry conditions. There shall be no evidence corona on any part of the samples when photographed in a darkened room. Corresponding

corona inception and extinction voltage shall also be measured.

15.1.3 Radio Interference Voltage Test

Under the conditions as specified under Clause 15.1.2 above, the conductor

samples shall have a radio interference voltage level below 500 microvolts at

one MHz when subjected to 50 Hz AC voltage of 266 KV line to ground under dry condition.

15.1.4 D.C.Resistance Test

On a conductor sample of minimum 5 metre length, two contact clamps shall be

fixed The resistance shall be measured by a Kelvin Double Bridge by placing the clamps initially zero meter and subsequently one meter 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 20 degree C as per IS:398 (Part V). The resistance corrected at 20 degree C shall conform to the requirements of

this specification.

15.1.5 Stress-Strain Test

(i) Test loads for Complete Conductor

The loading conditions for repeated stress- strain tests for a complete

conductor shall be as follows:

Load initially to 1 KN tension to straighten the conductor. After

straightening, remove the load and set the strain gauge to zero at zero

tension.



For non-continuous stress-strain data recordings, take the strain readings at

1KN intervals at the lower tension and at 5 KN intervals above 30 % UTS.

Load to 30 % UTS and hold for 0.5 hour. Take readings after 5, l0, l5 and

30 minutes during the hold period. Release to initial load.

Reload to 50% UTS and hold for 1 hour. Take readings after 5, 10, 15, 30,

45 and 60 minutes. Release to initial load.


45 and 60 minutes. Release to initial load.


45 and 60 minutes. Release to initial position as per previous loading

After the fourth application of load, again apply tension, increasing

uniformly until the actual breaking strength is reached. Simultaneous

reading of tension and elongation shall be taken-up to 90% UTS at the same intervals as for previous loading.

(ii) Test Loads For Steel Core only

The loading conditions for the repeated stress-strain tests for the Steel

Core of ACSR shall be as follows:

The test shall consists of successive application of load applied in a

manner similar to that for the complete conductor at 30%, 50%, 70% and

85% UTS.

The steel core shall be loaded until the elongation at the beginning of each

hold period corresponds to that obtained on the complete conductor at

30%, 50%, 70% and 85% of UTS respectively.

(iii) Stress-Strain Curves

Obtain the design stress- strain curve by drawing a smooth curve through

the 0.5 and hour points at 30%, 50% and 70% UTS loading.

Remove from the lower end at the design curves, the presence of any

conductor slack, that can be related to any observed extrusion entering the

span from the compression dead-end. Both the laboratory and design

stress-strain curves shall be submitted to the Owner.

15.2 Routine/Acceptance Tests

The following acceptance tests shall be conducted on the samples in presence of

the Owner’s representative and the test values shall conform to IS:398-V.

(i) Visual and Dimensional Check on Drum

The drums shall be visually and dimensionally checked to ensure that they

conform to the requirements of this specification.

(ii) Visual Check for Joints, Scratches etc.



Conductor drums shall be rewound in the presence of Owner’s

representative. The Owner’s representative shall visually check for

scratches, joints etc. and that the conductor generally conforms to the

requirements of this specification.

(iii) Dimensional Check on Aluminium and Steel Strands

The individual strands shall be dimensionally checked to ensure that they

conform to the requirement of this specification.

(iv) Lay- Ratio Test of Various Layers

The Lay-ratios of various layers shall be checked to ensure that they

conform to the requirements of this specification.

(v) Elongation and Torsion Test

The test procedure shall be as specified in IS-398 (Part-V)-1992. The

material shall conform to the requirements of this specification.

(vi) Breaking Load Test on Individual Aluminium and Steel Strand

For the purpose of acceptance test, this test shall be made on both

aluminium and steel. The tensile test shall apply to all wires of ACSR

conductors. The tensile strength of any of the wires shall not be less than the values given in the technical particulars mentioned in this

specification.

When an automatic tensile testing machine is used, the load shall be

applied gradually and rate of separation of the jaws of the testing machine

shall not be less than 25 mm/minute and not greater than 100 mm/minute.

(vii) Resistance Test

As per Clause 13.8 of IS-398-V, the measurement of resistance shall be

made on strands of ACSR conductor, and shall be carried out to an

accuracy of at least one part in a thousand and conform to the specified

values. Certificates as to the accuracy of the apparatus shall be provided.

16.0 Contractor shall conduct all the type tests mentioned above in presence of

Owner’s representative on the samples selected by him for every 1000 KMs of

conductor or part thereof at Contractor’s cost.

17.0 RE-TEST AND REJECTION

Each drum or reel selected for testing, shall be tested for compliance with the

requirements of IS-398-V. Should any selected drum or reel not fulfill any of

the test requirements, that particular drum or reel shall be withdrawn. In respect

of each failure, two test pieces shall be selected from two different drums in the

lot and subjected to the test under which the failure occurred. If either of the two re-test pieces fails to pass that test, the drum or reel concerned shall be rejected.

All rejected drums shall be marked and segregated.



18.0 The Owner reserves the right to have carried out any/all type tests mentioned

under Clause No 15.1 at his own expenses on samples of conductor selected

from the lot supplied at site. The entire conductor shall be rejected if the test results are not satisfactory.

19.0 INSPECTION

The Owner’s representative shall, at all time, be entitled to have access to the

works and all places of the manufacturer, where the conductor shall be made or

prepared and the representative shall have full facilities for unrestricted

inspection of Contractor’s works, the raw materials, the manufacture of the conductor and for conducting necessary tests as detailed herein before. The

Contractor shall keep the Owner informed, well in advance, of the time starting

and of progress of manufacture of conductor at its various stages, so that arrangement could be made for inspection.

No conductor shall be dispatched from its point of manufacture before it has

been satisfactorily inspected and tested and release order is issued by the

Inspecting Officer for dispatch.

20.0 LENGTH OF THE CONDUCTOR

STADARD LENGTH

The standard length of the conductor shall be minimum 1800 meters. Tolerance

of +/- 5 % in standard length offered by the bidder shall be permitted. All length

outside this limit of tolerance shall be treated as random length.

RANDOM LENGTH

Random length will be accepted provided no length is less than 70 % of the

standard length specified and the total quantity of such random lengths shall not

be more than 7 % of the total quantity allotted to each consignee and 5 % of total quantity ordered. If required for special applications, the successful bidder

shall supply 6 (six) nos. of 2500 meters long continuous conductor.

Bidder shall also indicate the maximum single length, above the standard

length, he can manufacture, in the guaranteed technical particulars. This is

required for special stretches like river crossings etc. The Owner reserves the

right to place orders for the above length on to the extent of 10 % of the total ordered quantity on the same terms and conditions applicable for the standard

lengths during the pending period of the contract.

21.0 PACKING AND MARKING

(i) The conductor shall be wound on non-returnable reels or drums of well

seasoned wood, conforming to Indian Standard-1778 specification for



Reels and Drums for bare wire. Only one conductor length shall be packed

on each drum.

The reels shall be of such construction as to assure delivery of conductor

free from displacement and damage and should be able to withstand all

stresses during subsequent Road or rail transport, storage, handling and

stringing operations, so that conductor surface is not dented, scratched or

damage in any way during transport and erection. The conductor shall be preferably lagged on the drums and the proposed method of lagging shall

be clearly stated by the bidder in the tender. The conductor should be

stocked to suit the reel and held in place by steel strapping.

The conductor drum should be suitable for wheel mounting. Before

reeling, the cardboard or other suitable material shall be secured to the

drum and inside flanges of the drum. After reeling the conductor, the exposed surfaces should be wrapped with suitable soft material to protect

the conductor from dirt and grit. Any space between drum lagging and

conductor should be suitably filled with soft, filler material compactly

packed.

All the drums shall be painted inside and outside with aluminium paint.

All reels shall have a layer of water proofs polyethylene film around the

drums under the conductor and another layer over the conductor and under the lagging. The wooden drums shall be capable of being mounted on

tension stringing equipment which shall be power operated. The conductor

drum shall be made as per enclosed drawing.

(ii) Each drum shall have following information stenciled on it, in indelible

ink, along with other essential data:

(a) Contract/Specification No.

(b) Name and address of the Consignee.

(c) Name of the destination.

(d) Maker’s name and address or trade-mark.

(e) Drum number.

(f) Name and size of the conductor.

(g) Length of the conductor in meters.

(h) Gross weight of the drum with protective lagging including conductor.

(i) Weight of the empty drum with protective lagging.

(j) Net weight of the conductor.

(k) Arrow marking for unwinding.

(1) Position of the conductor end.

(m)Lot Number.



(n) Date of Packing.

(o) I.S.I.Marking.

22.0 APPROVAL OF DRAWINGS, SAG TENSION CHARTS & QUALITY

ASSURANCE PLAN

22.1 The successful Bidder (Contractor) shall submit drum drawing for approval of

the Owner before commencement of production.

22.2 The Contractor shall d9iscuss & finalise Quality Assurance Plan in consultation

with Owner before commencement of production.

22.3 The Contractor shall submit sag-tension charts for approval of the Owner before

commencement of supply.

SCHEDULE –“B”

23.0 QUALIFYING REQUIREMENTS : N/A



24.0 REQUIREMENT OF DOCUMENTS : N/A



BLANK


Volume-II / Section-VI EPC Tender for JITPL

SECTION – VI


FOR 7/3.66MM GALVANISED STEEL EARTH-WIRE



SECTION – VI

CONTENTS

Clause Description

1.0 General

Page No

153

2.0

3.0

4.0

5.0

6.0

Climatic and ISO CERAUNIC Conditions

System Particulars

Technical Particulars

Tests

Test Reports

153

153

154

157

160

7.0 Inspection

8.0 Packing

9.0 Marking

161

161

162




SECTION VI

7/3.66MM GALVANISED STEEL EARTH-WIRE

1.0 GENERAL

This specification covers manufacture, testing, supply & delivery of Galvanized

Steel (G.S.) earthwire, required for 400 KV lines, proposed to be erected by the

Owner. The earthwire offered, shall conform to the technical requirements

covered under this specification and latest Indian Standard Specifications.

2.0 CLIMATIC AND ISOCERAUNIC CONDITIONS

The offered earthwire shall be suitable for satisfactory operation under following

environmental conditions.

(i) Temperature

a) Minimum

b) Maximum

c) Everyday average

: 7.5 deg. C

: 50 deg. C

: 32 deg. C

(ii) Relative Humidity maximum

(iii) No. of rainy days per year

(iv) Rainfall per year

(v) Altitude

: 90 %

: 75

: 1500 mm to 3800 mm

: Not more than 1000 Mtrs.

above sea level.

(v) Pollution level : Moderately polluted.

3.0

(v) Isoceraunic level

SYSTEM PARTICULARS

: 20/50

.

The 7/3.66 mm size G.S. earthwire is required for shielding of 400 KV

Transmission Lines with conductor configuration as follows:

Conductor configuration:

Double circuit : Vertical



4.0 TECHNICAL PARTICULARS OF EARTHWIRE SIZE 7/3.66 mm

4.1 Physical properties

i) Material

ii) No. of wires in strand (Nos.)

: Steel

: Steel core Outer layer

Total

iii)

Normal diameter of galvanized

1

: Std.

6 7

Max. Min.

iv)

strand wire (mm.)

Total sectional area (mm.sq.)

3.66

: 73.65

3.74 3.58

v)

Approximate weight (kg/ Km) :583

vi) Minimum breaking load of

strand (KN)

vii) Elongation of strand after

breakage shall not be less than

: 68.4

:4%

-6

viii) Co-efficient of linear : 11.5 x 10

expansion (per deg.C)

3

ix) Modulus

(Kg/sq.mm.)

of elasticity : 19 x 10

x) Permissible variation in

diameter of individual zinc

coated wires for a nominal

diameter of 3.66 mm (percent)

: +/- 2%

xi)

Overall diameter of earthwire

(mm)

: 10.98

xii) Minimum weight of zinc : 275 (should withstand



coating (g/M sq.)

xiii) Calculated D.C. resistance at

20 deg. C (ohm/km)

xiv) Lengths

a) Standard length (M)

b) Random lengths (M)

c) Tolerance in length

d) Strand lay and lay

length

one minute dips = 4 Nos,

1/2minute dips =1 No.

: 2.5

:

2000

Random lengths will be accepted

provided no length is less than 70

% of standard length and total

quantity of random lengths is not more than 10% of the total quantity

in each shipment.

+/- 5% of the standard length.

Minimum : 165

Maximum : 198

xv)

Direction of lay of outer layer : Right hand

xvi)

Density at 20 deg.C (g/cm3)

: 7.8

4.2 Detailed Technical Particulars

4.2.1 Material

The basic metal shall be steel made by the open heart basic oxygen or electric

furnace process and of such quality and purity that when drawn to size of wire

specified and coated with zinc, the finished strand and individual wires shall be of

uniform quality and have the properties and characteristics as prescribed in this specification. The steel shall have following composition as per IS-12776: 1989

Element

Carbon

Manganese

Phosphorous

Composition

0.55 Max

0.40 to 0.9

0.04 Max



Sulphur

Silicon

4.1.2 Galvanizing:

0.04 Max

0.15 to 0.35

The slab zinc, when used for zinc coating, shall be of any grade of zinc

conforming to ASTM specification, B-6, for zinc metal (slab Zinc) process – Hot dip.

4.1.3 Stranding

All steel strands shall be smooth, uniform and free from all imperfections such as

spills and split die marks, scratches, abrasions and kinks after drawing and also after stranding. The finished material shall have minimum brittleness. Unless

otherwise specified, the strand shall right hand lay. All wires shall be stranded

with uniform tension. Stranding shall be sufficiently close to ensure no

appreciable reduction in diameter when stressed to 10% of the specified strength. The 7-wire strand shall consist of central wire with 6-wire layer concentrically

twisted over it with a uniform pitch not more than 16 times the specified nominal

diameter of the strand.

4.1.4 Ductility of steel

The zinc coated wire shall not fracture when wrapped at a rate not exceeding 15

turns per minute in a close helix of at least two turns around a cylindrical mandrel.

The mandrel diameter for extra high strength strand shall be equal to three times

the nominal diameter of the individual wire of the strand.

4.1.5 Joints and splices

There will be no joint/splice in any of the wires of the strand in the standard

length of 2000 meters. The tenders should explicitly mention in their offers that

there will be no joint in any of the wires constituting the ground wire not withstanding the provisions, otherwise, if any, in the IS.

4.1.6 Weight of coating

The weight of zinc coating shall be not less than 275 gm/sq.mtr.

4.1.7 Tests of coating

The weight of the zinc coating shall be determined by stripping test in accordance

with ASTM methods A90, test for weight of coating on zinc coated iron or steel articles.



4.1.8 Adherence of coating

The zinc coated wire shall be capable of being wrapped at a rate not exceeding 15

turns per minute in close helix of at least two turns round a cylindrical mandrel

equal to three times the nominal diameter of the wire under test without cracking

of flaking the zinc coating to such an extent that any zinc can be removed by

rubbing with the bare fingers.

4.1.9 Finish

The zinc-coated wire shall be free from imperfections not consistent with good

commercial practice. The zinc coating shall be continuous and of reasonably

uniform thickness.

4.3 Tests

All type tests and routine tests as per standard methods shall be carried out by the

bidder. The bidder shall however, shall indicate in the tender the tests proposed by

him and also quote the same. Three copies of the Type test certificates shall be

submitted with the tender .

4.4 Standards

The Groundwire shall confirm to the provisions of the latest edition of ASTM

Designation A 475-72(a) pertaining to Standard Specification for Zinc coated

steel wire strand or any other authoritative standard (as amended upto date) except

where specified otherwise, in the specification. The materials conforming to any

international standard, which ensure equal or better performance, shall also be

acceptable.

4.5 Sag Tension Charts

The Contractor shall be required to submit five sets of stringing charts for

earthwire, showing initial and final sags and tensions for various temperatures and

spans. One set of chart shall be in ink on tracing cloth.

4.6 Guaranteed Technical Particulars

The bidder shall fill in the guaranteed technical particulars in the pro-forma as

provided in Annexure-6 and submit the same with this tender.

5 TESTS

This section details out the tests of the earthwire.



5.1 The earthwire offered in the tender should have been successfully type tested in

line with the standard and technical specification within the last five years from

the date of opening of tender.

5.2 The following type, acceptance and routine tests and tests during manufacture shall

be carried out on the earthwire for the purpose of this clause.

5.2.1 Type tests shall mean those tests, which are to be carried out to prove the process

of manufacture and general conformity of the material to these specifications.

These tests shall be carried out on samples prior to commencement of commercial production.

5.2.2 Acceptance tests shall mean those tests, which are to be carried out on samples

taken from each lot offered for pre-dispatch inspection for the purpose of

acceptance of that lot.

5.2.3 Routine tests shall mean those tests, which are to be carried out on each strand

spool/length of the earthwire to check requirements, which are likely to vary

during production.

5.2.4 Tests during manufacture shall mean those tests, which are to be carried out

during the process of manufacture and end inspection by the Contractor to ensure

the desired quality of the end product to be supplied by him.

5.2.5 The norms and procedures of sampling for these tests will be as per the Quality

Assurance Programme to be mutually agreed to, by the Contractor and Owner or

as per relevant IS/International Standard.

5.2.6 The standards and norms to which these tests will be carried out are listed against

them. Where a particular tests is a specific requirement of this specification, the norms and procedures of these tests shall be as specified in Annexure-7 or as

mutually agreed by the Contractor and the Owner in the Quality Assurance

Programme.

5.2.7 For all type and acceptance tests, the acceptance tests, the acceptance values shall

be the values guaranteed by the bidder in the guaranteed technical particulars of

this proposal or the acceptance value specified in these specifications, whichever is more stringent for that particular test.

5.3 Type Tests

The following tests shall be conducted once on sample/samples of earthwire for

every 200 kms of production from each manufacturing facility.

(a)

(b)

UTS Tests

DC Resistance Test

)

)

Owner Specification

Annexure-7



(c)

Surface Condition Test

)

5.4 Acceptance Tests

a) Visual check for joints etc.

: Owner Specification

Annexure-7

b)

c)

d)

e)

f)

g)

h)

Dimensional check on steel strands

Check for Lay – Length of 6 wire

Layer

Wrap test on steel strands

DC resistance test on steel strands

Visual check on drum

Breaking load test on steel strands

Elongation test on steel strand

: - do -

: - do -

: - do -

: - do -

: - do -

: IS-12776:1989

: - do -

i) Torsion

Test

: - do -

j)

*Note:

Galvanizing tests on steel strands

: *IS-4826-1979

Although the tests will be as specified in IS: 4826-1979, no allowance or

relaxation will be given for galvanization tests done on steel wires after stranding

for the purpose of acceptance of any material covered by these specifications.

5.5 Routine Tests

(a)

(b)

(c)

(d)

Check to ensure that there are no joints as per specification.

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

Check for correctness of stranding.

Check that drums are as per specification.

5.6 Test During Manufacture

(a)

Chemical analysis of Zinc )

used for galvanizing )

)

Owner Specification



(b)

Chemical analysis of steel )

for making steel strands )

Annexure-7

5.7 Testing Expenses

5.7.2 The Owner may opt for repetition of Type test at his own expenses, prior to

manufacture.

5.7.3 In case of failure in any type test the bidder is either required to modify the design

of the material or repeat the particular type test successfully at his own expense.

The decision of the Owner in this regard shall be final and binding.

5.7.4 Bidder shall indicate the laboratories in which he proposes to conduct the type

tests. He shall ensure that the tests can be completed in these laboratories within

the time schedule guaranteed by him in the appropriate schedule.

5.7.5 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

of conductor, except for the expenses of the inspector/Owner’s representative.

5.8 Additional Tests

The Owner reserves the right of having at his own expenses any other test(s) of

reasonable nature carried out at Contractor’s premises, at site, or any other place

in addition to the aforesaid type, acceptance and routine tests to satisfy himself

that the materials comply with the specification.

5.9 Sample Batch for Type Testing

5.9.2 The Contractor shall offer at least five (5) drums for selection of samples required

for conducting all the type tests.

5.9.3 The Contractor is required to carry out all the acceptance tests successfully in the

presence of Owner’s representative before dispatch.

6 TEST REPORTS (DOCUMENTS IN PHYSICAL FORM).

6.1 At least 3 (three) copies of type test reports should be furnished. One copy of

type test reports will be returned duly certified by the Owner, only after receipt of

this report, the commercial production of the said material should start.



6.2 At least 3 (three) copies of acceptance test reports shall be furnished. One copy

will be returned duly certified by the Owner, only after receipt of which, the

materials should be dispatched.

6.3 Record of routine test reports should be maintained by the Contractor at his works

for periodic inspection by the Company’s representatives.

7 INSPECTION

7.2 The Company’s representative shall at all times be entitled to have access to the

works and all places of manufacture, where earthwire shall be made or prepared and

the representatives shall have full facilities for unrestricted inspection of the

Contractor’s works, raw materials, manufacture of the earthwire and for conducting

necessary tests detailed herein.

7.3 The Contractor shall keep the Company informed in advance of the time of starting

and of the progress of manufacture of earthwire in its various stages so that

arrangements can be made for inspection.

7.4 No earthwire shall be dispatched from its point of manufacture before it has been

satisfactorily inspected and tested, unless the inspection is waived off by the Owner

in writing. In the later case also, the earthwire shall be dispatched only after

satisfactory testing for all tests specified herein have been completed.

7.5 The acceptance of any quantity of material shall in no way relieve the Contractor of

any of his responsibilities for meeting all requirements of the specification and shall

not prevent subsequent rejection, if such materials are later found to be defective.

8 PACKING

8.1 The earthwire shall be suitably packed before dispatch in strong, non-returnable

wooden drums suitable for ocean/local rail and road transportation, rough handling

and stringing and shall conform in all respects to the latest edition of IS 1778-1961 except as otherwise specified herein.

8.1.1 Standard Length

The standard length of the galvanized steel earth strand shall be 1800 m – 2000 m.

A tolerance of + 5% on the standard length shall be permitted.



8.1.2 Only two lengths of earthwire shall be wound on each drum.

8.1.3 Boiled linseed oil should be applied to earthwire to avoid white rust.

9 MARKING

9.1 Each drum shall have the following information stenciled on it in indelible ink

alongwith other essential data.

(a)

(b)

(c)

(d)

(e)

(f)

(g)

(h)

(i)

(j)

(k)

(l)

Contract / LOI No.

Name and Address of Consignee

Manufacturer’s Name and Address

Drum No. & Lot No.

Size of Earthwire

Length of Earthwire in mtrs.

Gross weight of the drum with earthwire.

Weight of empty drum with laggings.

Arrow marking for unwinding.

Position of the earthwire ends.

Number of lengths on the reel/or drum.

The product may be marked with the standard mark.


Volume-II / Section-VII EPC Tender for JITPL

SECTION – VII


FOR PORCELAIN DISC INSULATORS



SECTION – VII

CONTENTS

Clause Description

1.0 General

Page No

165

2.0

3.0

4.0

Standards Applicable

General Requirement

Details of Insulators

165

166

167

5.0 Drawings

169

6.0

Specific Technical Requirements

169

7.0 Galvanising

171

8.0

Ball and Socket Design

171

9.0 Dimensional Tolerance

10.0 Interchangeability

171

172

11.0

12.0

Corona and RIV Performance

Suitability for Live Line Maintenance

172

172

13.0

14.0

15.0 Test

16.0

Freedom from Defects

String Characteristics

Test Values

172

173

173

178

17.0

Test Procedures and Sampling of Norms

178

18.0

19.0

Additional Tests

Identification marks

179

179

20.0

Guaranteed Technical Particulars for Insulators

179




SECTION VII

PORCELAIN DISC INSULATORS

1.0 GENERAL

This section details the technical particulars of porcelain disc insulators for 400

KV Transmission Lines. The Insulators shall conform in all respects to high standards of Engineering, design, workmanship and latest revisions of relevant

standards

2.0

STANDARDS APPLICABLE:

2.1 Except as modified in this specification, the disc insulators to be supplied shall

conform to the latest version, with amendments thereof, of the following Bureau

of Indian Standards and equivalent International Standards.

Sr. Indian

Title

International

No. Standard

1. IS: 406 Method for Chemical

Analysis of Slab Zinc

2. IS: 209 Specification for Zinc

Standard

BS:3436

3. IS:731

4. IS:2071

Part(I to III)

Porcelain insulators for

overhead power lines

with a nominal voltage

greater than 1000V

Method of High Voltage Testing

BS:137(I&II)

IEC:274

IEC:383

5. IS:2486 Specification for Insulator

fittings for overhead power lines with a nominal

voltage greater than 1000V

Part I General Requirements and Tests

BS:3288

Part II

Part III

Part IV

Dimensional Requirements

Locking Devices

Tests for Locking Devices

IEC:120

IEC:372

IEC:372



6. IS:2629

7. IS:2633

Recommended practice for Hot

Dip Galvanization for iron and steel

Testing for Uniformity of Coating

of Zinc coated articles

8. IS:3188 Dimensions for Disc Insulators

9. IS:6745 Determination of Weight of

Zinc coating on Zinc coated iron and steel articles

IEC:305

10. IS:8263

Methods of RIV Test of

HV Insulators

IEC:437, NEMA

Publication No.

107/1964 CISPR

11. IS:8269

12.

Methods for Switching

impulse test on HV insulators

Thermal Mechanical

performance test and

mechanical performance

test on string insulator units

IEC:506

IEC: 575

2.2 Insulators conforming to any other International standards are also acceptable

provided always that such standards are equivalent to or better than the

corresponding standards specified in 2.1 above. However, in such an event the

salient points of comparison between the standards adopted and the standards

quoted herein shall be detailed in the offer. One copy of authentic English version

of such standards shall be submitted (in physical form) alongwith the offer.

3.0

GENERAL REQUIREMENTS:

a) All raw materials to be used in the manufacture of insulators shall be subject to

strict raw material quality control and to stage testing/quality control during

manufacturing stage to ensure the quality of the final end product. Manufacturing shall conform to the best engineering practices adopted in the field of extra high

voltage transmission. Bidders shall therefore offer insulators as are guaranteed by

them for satisfactory performance on transmission Lines.



b) 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, elimination of sharp edges and corners to limit corona and

radio interference voltages.

c) The design of the insulator shells shall be such that stresses due to expansion and

contraction in any part of the insulator shall not lead to deterioration. Shells with

cracks shall be eliminated by temperature cycle test followed by mallet test.

Shells shall be dried under controlled conditions of humidity and temperature.

d) The cap and pin 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 and of such design that it will not yield or distort under loaded conditions. The head portion of

the pinball shall be suitably designed so that when the insulator is under tension

the stresses are uniformly distributed over the pinhole portion of the shell. The

pinball shall move freely in the cap socket either during assembly of a string or during erection of a string or when a string is placed in position.

e) Insulator units after assembly shall be concentric and coaxial within limits as

permitted by Indian/International standards. f) The insulator design shall be such that when units are coupled together to form a

string, there shall be no contact between the shell of one unit and metal of the

adjacent unit. g) Metal caps shall be free from cracks, seams, shrinks, air holes, blowholes and

rough edges. All metal surfaces shall be perfectly smooth with no projecting parts

or irregularities, which may cause corona. All load bearing surfaces shall be

smooth and uniform so as to distribute the loading stresses uniformly. Pins shall not show any microscopically visible cracks, inclusions and voids.

h) Cap, Pin shall not be manufactured by joining, welding, shrink fitting or by any

other process from more than one piece of metal. i) The insulator design shall be such that the insulating medium shall not directly

engage with hard metal. The surface of porcelain shall be coated with resilient

paint to offset the effect of difference in thermal expansion of these materials.

4.0 DETAILS OF DISC INSULATORS:

a) The insulator strings shall consist of standard discs for a three phase 50 Hz,

effectively earthed 400 KV transmission system in a moderately polluted

atmosphere. The discs shall be cap and pin, ball and socket type.

b) 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 fitting shall be as follows:



Type of Size of Minimum No. of Mechanical

string disc creepage standard strength of insulator distance disc in of insulator

unit of each String (No) string with

(mm)

400 KV

disc (mm) H/W fitting(KN)

Single Susp- (AF) 280x145 430

ension ‘I’

string

Double Susp- (AF) 280x145 430

ension ‘I’ string

23

2x23

120

2x120

Quad

(AF) 305x170 475

4x24

4x160

Tension string

Type of string (400

KV)

Single suspension “I”

string

Double suspension

“I” string

Type

Of insulator

(AF)

(AF)

Length of disc

insulator string

(mm)

3335 9890

3335 9890

Minimum

creepage distance

of disc insulator string (mm)

Quad tension string (AF) 4075 11400

c) The electro-mechanical strength of individual disc unit in strings mentioned above

is as follows:

Sr. Type of String

No

.

A) 400 KV

Electro-Mechanical

strength of individual disc

insulator

1)

2)

Single/Double Suspension ‘I’ string

Quad Tension string

120 KN

160 KN

……………………………………………………………………………………



5.0

DRAWINGS:

5.1 The bidder shall furnish outline drawings of disc insulator unit indicating all

dimensions for scrutiny and approval. All drawings shall be neatly arranged, and

all drafting and lettering shall be standard and legible. Dimensions shall be in SI

units. The drawings shall give following information:

1) The bill of material indicating quantity and nature of material used for various

parts.

2) Details like Ball and Socket designation, Maximum Axial & Radial Runout,

Minimum & Protected Creepage distance, Colour of Glaze, Electro-mechanical

strength, Identification mark and weight of insulator.

3) Electrical characteristics like One minute power frequency withstand and

flashover voltage under dry and wet conditions, Lightening impulse withstand and

flashover voltage, Switching surge impulse withstand voltage, Visible discharge and Radio Interference Voltage.

6.0

SPECIFIC TECHNICAL REQUIREMENTS:

I) NON-METALLIC PARTS

a) PORCELAIN

The porcelain used in the manufacture of the shells shall be ivory white,

nonporous, of high dielectric, mechanical and thermal strength, free from internal

stresses, blisters, laminations, voids, foreign matter, imperfections or other defects

which might render it in any way unsuitable for insulator shells. Porcelain shall

remain unaffected by climatic conditions, ozone, acid, alkalis, zinc or dust. The

manufacturing shall be by the wet process and impervious character obtained by

thorough vitrification.

b) PORCELAIN GLAZE

Surfaces to come in contact with cement shall be made rough by sand glazing. All

other exposed surfaces shall be glazed with ceramic materials having the same temperature coefficient of expansion as that of the insulator shell. The thickness

of glaze shall be uniform throughout and the colour of glaze shall be brown. The

glaze shall have a visible luster, shall be smooth on surface and be capable of

satisfactory performance under extreme tropical climatic weather conditions and prevent ageing of the porcelain. The glaze shall remain under compression on the

porcelain body throughout the working temperature range.



c) FILLER MATERIAL

Cement to be used, as a filler material shall be quick setting, fast curing portland

cement. It shall not cause fracture by expansion or loosening by contraction.

Cement shall not react chemically with metal parts in contact with it and its

thickness shall be as small and as uniform as possible.

II) METALLIC PARTS

a) BALL PINS

These shall be made of forged steel of grade EN-8D (BS:970)/CL-IV(IS:2004) or

equivalent, by drop forging method and normalized. They shall not be manufactured by joining, welding, and shrink fitting or by any other process from

more than one piece of metal. The ball pins shall be free from forging defects.

The bidder shall specify the grade, composition and mechanical properties of steel

used in manufacture of ball pin, in Quality Assurance Plan.

b)

METAL CAP

The caps shall be cast from black heart malleable cast iron of grade BM 320 (IS:

14329) or equivalent and annealed. The caps shall be made in single piece and shall be free from casting defects like misrun, cold shut etc.

The bidder shall specify the grade, composition and mechanical properties of steel

used in manufacture of caps, in Quality Assurance Plan.

c) SECURITY CLIPS

i) These shall be made of Stainless Steel grade AISI 304/316 (ASTM A276) or

Phosphor Bronze.

ii) The security clips to be used as locking device for ball and socket coupling shall

be 'R' shaped hump type to provide for positive locking of the coupling as per

IS:2486 (Part IV). The legs of the security clips shall allow for spreading after

installation to prevent complete withdrawal from the socket. The locking device shall be resilient, corrosion resistant and of sufficient mechanical strength. There

shall be no possibility of the locking device to be displaced or be capable of

rotation when placed in position and under no circumstances shall it allow separation of insulator units.

iii) The hole for the security clip shall be countersunk and the clip shall be of such

design that the eye of the clip may be engaged by a hot line clip puller to provide

for disengagement under energized conditions.



iv) The force required for pulling the R-clip into its unlocked position shall not be

less than 50 N (5 Kgs) or more than 500 N (50 Kgs).

7.0

GALVANISING:

a) All ferrous parts shall be hot dip galvanized in accordance with IS: 2629 and IS:

2633. Before galvanization, the steel section shall be thoroughly cleaned of any

paint, grease, rust, scale, acid/alkali or such other foreign matters as are likely to

interfere with the galvanizing process or with the quality and durability of the zinc coating. Pickling shall be very carefully done and shall be proper.

b) Before ball fittings are galvanized, all die flashing on the shank and on bearing

surface of the ball shall be carefully removed without reducing the designed

dimensional requirements.

c) The zinc used for galvanizing shall be of grade Zn 98 (% of zinc ≥ 99.95%) as per

IS: 209. The mass of zinc coating shall not be less than 610 gm/m2(86 microns).

d) The galvanized surface shall consist of continuous and uniformly thick coating of zinc, firmly adhering to the surface of steel. The finished surface shall be clean

and smooth and shall be free from defects like discolored patches, bare spots,

unevenness of coating, spelter which is loosely attached to the steel, globules, spiky deposits, blistered surface, flaking or peeling off etc. The presence of any of

these defects noticed on visual or microscopic inspection shall render the material

liable to rejection.

e) There shall be no flaking or loosening when struck squarely with a chisel faced hammer. The galvanized components shall withstand minimum four one minute

dips in standard copper sulphate solution as per IS: 2633.

f) Defect in any component indicating presence of impurities in the galvanizing bath

in quantities larger than that permitted by the specifications, or lack of quality

control in any manner in the galvanizing plant, shall render the entire production

in the relevant shift liable to rejection.

8.0

BALL AND SOCKET DESIGNATION:

The dimensions of ball and socket for 120 KN and 160 KN discs shall be 20 mm

in accordance with the standard dimensions stated in IS: 2486 (Part II)/IEC: 120.

9 .0 DIMENSIONAL TOLERANCE:

The dimensions of the disc insulators shall be within the limits specified below:



Diameter of Disc (in mm)

Standard Maximum

Minimum

120 KN (AF)

160 KN (AF)

280

305

293

318

267

292

Standard Maximum

Ball to Ball Spacing between Discs (in mm)

Minimum

120 KN (N, AF)

160 KN (N, AF)

145

170

149

175

141

165

10.0 INTERCHANGEABILITY:

The insulators inclusive of ball and socket fittings shall be of standard design

suitable for use with hardware fittings of any make conforming to relevant Indian

Standards.

11.0 CORONA AND RIV PERFORMANCE:

All surfaces shall be even, smooth, without cuts, abrasions or projections. No part

shall be subjected to excessive localized pressure. The metal parts and porcelain

shall not produce any noise-generating corona under all operating conditions. The

insulators and metal parts shall be so designed and manufactured that it shall

avoid local corona formation and not generate any radio interference beyond

specified limit under operating conditions.

12.0 SUITABILITY FOR LIVE LINE MAINTENANCE:

a) The insulators shall be compatible for use with hot line or live line maintenance

techniques so that usual hot line operations can be carried out with ease, speed

and safety.

b) All insulators shall be designed to facilitate cleaning and insulators shall have

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 cloth or by remote washing under live line condition.

13.0 FREEDOM FROM DEFECTS:

Insulators shall have none of the following defects:

a) Ball pin shake

b) Cementing defects near the pin like small blowholes, hair cracks, lumps, etc.



c) Sandfall defects on the surface of the insulator.

14.0 STRING CHARACTERISTICS:

The characteristic of the complete string shall be as follows:

Sr.

No

STRING TYPE

PARTICULARS

400

KV

Suspension

string

400

KV

Tension

String

1 Switching Surge

Withstand Voltage

(Dry & Wet) (KVp)

2 Dry Lightning Impulse

Withstand Voltage (KVp)

3 50% Lightning Impulse

flashover voltage (KVp)

4 Dry Power frequency

withstand voltage (KV rms)

5 Wet Power frequency

withstand voltage

(KV rms)

6 Corona extinction

Voltage (KV rms)

7 Maximum RIV for complete

string Including corona Rings, arcing horns, clamps etc. at 1.1 times

max. Line to Ground

Voltage (µV)

8 Maximum voltage

across any disc

15.0 TEST

1050 1050

1600 1700

1650 1770

740 740

690 690

320 320

500 500

500 500

9% 10%

The Contractor shall offer the disc Insulator that are already type tested within the

last five years and manufactured by reputed manufacturer approved by

PGCIL/PGCIL. In case the insulators are not type tested within 5 (five) years

as on the date of opening of bids, fresh type test as per relevant IS shall be carried

out in presence of Owner’s representative before supply of materials



15.1

TYPE TESTS:

The list of type tests to be conducted is as follows:

I) On Disc Insulator Unit:

Sr. Particulars of test

No.

Reference

Standard

a)

Visual examination

}IS:731

b)

Verification of dimensions test

}

IS:731


No.

Reference

Standard

c)

d)

e)

f)

Thermal-Mechanical performance test

Power frequency voltage flashover test

i) Dry

ii) Wet

Lightning Impulse voltage

withstand test (Dry)

50% Lightning Impulse voltage

flashover test (Dry)

}

}

} }

}

}

}

}

}

}

IEC:575 and

Annexure-8 of

this specification

IEC:60383

IEC:60383

IEC:60383

g)

h)

i)

Visible Discharge test (Dry)

Radio Interference Voltage test

(Dry)

Residual strength test

}

}

}

}

}

IS:731

IEC:60437 &

Annex.-8 of this specification

As per Annex.-8

(On 120KN &160KN disc insulator) } of this specification

j)

Steep wave front test

}

As per Annexure – 8

(On 120KN &160KN disc insulator) } of this specification



II) On complete insulator string with hardware fittings:

a)

The type tests on 400 KV strings specified hereunder, shall be conducted

on Double ‘I’ Suspension (2x120 KN) and Quad tension (2x2x160 KN)

insulator strings alongwith hardware fittings.

On 400KV String of 120KN & 160KN insulators

I)

a)

On 1st sample

Power frequency voltage withstand } test with corona control/grading }

rings and arcing horn }

i) Dry } ii) Wet }

IEC:60383 and

Annexure-8 of

this specification

b)

c)

d)

e)

f)

g)

II)

h)

Switching Surge voltage

withstand test (Wet)

Lightning Impulse voltage


50% Lightning Impulse voltage

flashover test (Dry)

Voltage distribution test

(For Disc Insulator only)

Corona and RIV test under dry

condition

Mechanical strength test

i) Double ‘I’ suspension string

ii) Quad Tension string

On 2nd sample

Dynamic test (Vibration test)

}

} }

}

}

}

}

}

}

}

}

}

}

}

}

}

}

}

}

IEC:60383 and

Annexure-8of this specification

IEC:60383 and

Annexure-8 of

this specification

IEC:60383 and

Annexure-8 of

this specification

IEC:383 and

Annexure-8 of

this specification

As per Annexure-8

of this specification

As per Annexure-8


As per Annexure–8


III) On 3rd sample

i) Time Load test

}

As per Annexure–8



15.2 ACCEPTANCE TESTS:

}


This shall mean those tests, which are to be carried out on samples taken from

each lot offered for predespatch inspection for the purpose of acceptance of the

lot.

15.2.1 LIST OF ACCEPTANCE TESTS:

The following acceptance tests shall be conducted on 120KN and 160KN disc

insulators in presence of Owner’s representative for the purpose of acceptance of a lot:


No.

Reference

Standard

a)

b)

c)

d)

e)

f)

Visual examination

Verification of dimensions

Temperature cycle test

Galvanising test

Mechanical performance test

Test on locking device for

}

}

}

}

}

}

IS:731

IS:731

IS:731

IS:731

IEC:60575

IS:2486(IV)

ball and socket coupling

g) Electro-mechanical strength test

}

}

IS:731

h)

i)

j)

Puncture test

Porosity test

Power frequency voltage


}

}

}

}

IS:731

IS:731

IEC:60383

………………………………………………………………………….

15.3 ROUTINE TESTS:



This shall mean those tests, which are to be carried out on each insulator to

check the requirements which are likely to vary during production.

15.3.1 LIST OF ROUTINE TESTS:

The following routine tests shall be conducted on each insulator and results

certified by the manufacturer:


No.

Reference

Standard

a)

b)

c)

Visual Inspection

Mechanical routine test

Electrical routine test

}

}

}

IS:731

IS:731

IEC:60383

15.4 TESTS DURING MANUFACTURING:

Stage tests during manufacturing shall mean those tests, which are to be carried

out during the process of manufacturing to ensure quality control such that the

end product is of the designed quality conforming to the intent of this

specification.

15.4.1 LIST OF TESTS DURING MANUFACTURING:

The following tests, including but not limited to, shall be conducted on raw and in

process material during the process of manufacturing:


No.

Reference

Standard

a) Fineness, Raw appearance, Fired

appearance, Free Magnetic Iron

content, Grain size, Chemical

}

}

}

Relevant Indian

b)

c)

Analysis, Free Moisture Content on } raw materials like Quartz Powder, }

Feldspar Powder, China Clay, Ball }

Clay etc. }

Raw appearance, Fired appearance, }

Chemical Analysis of Glaze material }

}

Visual inspection, Grain size, }

Compressive Strength, Optimum }

water content, Initial and final setting }

/International/ Plant standard

Relevant Indian

/International/

Plant standard

Relevant Indian

/International/



time, Auto Clave Expansion of Cement

}

Plant standard

d)

e)

f)

g)

Hydraulic Pressure Proof load test, }

High Frequency test on Porcelain Shell }

}

Visual inspection, Dimension/Guage }

Checking, Chemical Analysis, Tensile }

Strength, Hardness, Grain size, }

Inclusion rating, Heat treatment, } Magnetic Particle Inspection on ball pins }

Visual inspection, Dimension/ }

Guage Checking, Chemical Analysis, }

Tensile Strength, Hardness, }

Microstructure, Magnetic Particle }

Inspection on MCI caps }

Visual inspection, Dimensional }

verification, Resistance to Bending, } Operation test, Hardness test on }

Security Clip }

Relevant Indian

/International/

Plant standard

As per Annexure-8


As per Annexure-8


As per Annexure-8


h)

Chemical analysis of Zinc used

for galvanizing

}

}

As per Annexure-8


16.0 TEST VALUES:

For all type and acceptance tests, the acceptance values shall be the values

guaranteed by the Bidder in the guaranteed technical particulars or the acceptance value specified in this specification or the relevant standard whichever is more

stringent for that particular test.

17.0 TEST PROCEDURE AND SAMPLING NORMS:

a) The test procedure and sampling norms for carrying out type tests; acceptance

tests and routine tests shall be as per reference standards specified under clause

No. 15.0 of this specification.

b) The test procedure and sampling norms for carrying out tests during

manufacturing shall be as per relevant Indian/ International Standard where

applicable and plant standard for others. The sampling norm for conducting tests

on bought out items shall be as outlined in Annexure-8 of this specification.



c) The bidder shall furnish details regarding sampling norm and reference standard

followed, in Quality Assurance Plan.

18.0 ADDITIONAL TESTS:

The Owner reserves the right for carrying out any other test(s) of a reasonable

nature at the works of the Contractor or at any other recognized

laboratory/research institute in addition to the above mentioned type, acceptance

and routine tests at the cost of the Owner to satisfy himself that the material

complies with the intent of this specification.

19.0 IDENTIFICATION MARK:

a) The porcelain shell of each disc insulator shall be legibly and indelibly marked

with the trade mark/name of the manufacturer, the month and year of

manufacture, country of manufacture, guaranteed electro-mechanical strength in

kilo-newtons abbreviated by 'KN' to facilitate easy identification and proper use. The marking shall be printed and not impressed and the same shall be applied

before firing.

b) The metal cap of each disc insulator shall bear the name of manufacturer by

embossing. The identifying letters shall be at least 5 mm high. The characters

shall be distinct, durable, and conspicuous after galvanizing.

20.0 Guaranteed Technical Particulars for Insulators

The Guaranteed Technical Particulars for Insulators enclosed as Annexure-9 shall

be duly filled in and submitted along with the offer.


Volume-II / Section-VIII EPC Tender for JITPL

SECTION – VIII

TECHNICAL SPECIFICATIONS FOR HARDWARE FITTINGS

AND ACCESSORIES FOR CONDUCTOR AND

EARTHWIRE



SECTION – VIII

CONTENTS

Clause

1.0

2.0

3.0

4.0

Description

Technical Description of Hardware Fittings

Accessories for ACSR ‘MOOSE’ Conductor

G.S. Earthwire Accessories

Tests and Standards

Page No

182

194

202

206




SECTION – VIII

HARDWARE FITTINGS AND ACCESSORIES FOR TWIN ACSR MOOSE

CONDUCTOR & 7/3.66MM EARTHWIRE FOR 400KV LINES

1.0

1.1.

1.1.1.

1.1.2.

1.1.3.

1.1.4.

1.1.5.

1.1.6.

1.1.7.

1.1.8.

1.1.9.

1.2.

Technical Description of Hardware Fittings

Details of Hardware Fittings

The hardware fittings shall be suitable for use with Disc Insulators or

porcelain long rod insu1ators having ball and socket fittings.

The hardware fittings shall be as per the specification drawings enclosed

with the specification. Hardware fittings shall be supplied suitable for

attaching to hanged/strain plate fixed to tower. Each hardware fittings

shall be supplied complete in all respects and shall include the following hardware parts.

Suitable arcing horn as specified in clause 1.8 hereinafter.

Suitable yoke plates for suspension and tension hardware fittings for the

quad bundle arrangement complying with the specifications given hereinafter.

Corona contro1 rings/grading ring with fittings for attachment to line side

yoke p1ate.

Sag adjustment plate for double tension hardware fittings and turn buckle

for single suspension pilot hardware fittings.

Suspension and dead end assembly to suit conductor size as detailed in

clause 1.13, 1.14 and 1.15 hereinafter.

Provisions for attaching balancing weights on the line side yoke plate of

single suspension pilot hardware fittings.

Other necessary fittings viz D-shackles, eye links, extension links, ball

clevis, socket clevis, clevis eye, U clevis and chain link etc. to make the

hardware fittings compete.

2.5% extra fasteners and aluminium filler plugs.

Dimensions of Insulator String along with Hardware Fittings

The various limiting dimensions of the insulator strings alongwith

hardware fittings shall be as per the specification drawings enclosed with the specification.

For every set of quad tension/sing1e tension hardware fitting for quad

bundle conductor, one number of 250 mm rigid spacer suitable for twin ACSR MOOSE conductor shall be provided to ensure that there is no

fouling of conductors or any component of the fittings while bringing



down two top conductors through bottom two conductors of quad bundle

at the jumper connection.

1.3.

1.3.1.

1.4.

1.5.

1.5.1.

1.5.2.

1.6.

1.6.1.

1.7.

1.7.1.

Interchangeability

The hardware for insulator strings with disc insulators or porcelain long

rod 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 porcelain long rod insulators of any make conforming to relevant Indian/International Standard.

Corona and RI Performance

Sharp edges and scratches on all lie hardware fittings shall be avoided. All

surfaces must be clean, smooth, without cuts and abrasions or projections.

The Contractor shall be responsible about the satisfactory corona and radio

interference performance of the materials offered by him.

Maintenance

The hardware fittings offered shall be suitable for employment of hot line

maintenance technique so that usual hot line operations can 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.

The line side yoke plate shall have a notch & a working hole of suitable

size. The design of corona control rings/grading ring shall be such that it can be easily replaced by employing hot line maintenance technique.

Designation

Ball and Socket Designation

The dimensions of the ball and socket shall be of 20 mm wherever 120

KN and 160 KN insulators are used. 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.

Security Clips and Split Pins

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.

1.7.3.

1.8.

1.8.1.

1.8.2.

1.8.3.

1.9.

1.10.

1.10.1.

1.10.2.

The hole for the security clip shall be countersunk and the clip should be

of such design that the eye of clip 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 (50kg).

Split pins shall be used with bolts & nuts -

Arcing Horn

The arcing horn shall be either ball ended rod type or tubular type.

For insulator strings with disc insulators the arcing horn shall be provided

as shown on the drawing of the hardware fittings, in this specification.

The air gap shall be so adjusted to ensure effective operation under actual

field conditions. The arcing distance between arcing horn and corona

control rings/grading ring shall be 3050 mm under nominal dimensions of insulator for insulator strings with disc insulators/long rod insulators.

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 corona control rings/grading ring/arcing horn. All the

corners and edges should be rounded off with a radius of atleast 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 IS-800.

Corona Control Rings/Grading Ring

The Corona control rings/grading ring shall be provided with hardware

fittings and shall be of such design that it should cover atleast one disc

insulator in disc insulator strings so that they will reduce the voltage

across the insulator units. It shall also improve corona and radio interference performance of the complete insulator string alongwith

hardware fittings.

The corona control rings/grading ring shall be made of high strength heat

treated aluminium alloy tube of minimum 2.5 mm wall thickness. If mild

steel brackets are used then the brackets shall not be welded to the pipe but

shall be fixed by means of bolts and nuts on a small aluminium plate

attachment welded to the pipe. The welded centre of the corona control ring/grading ring shall be grinded before buffing. Alternately, Aluminum



tube/flats of suitable dimensions welded to the corona control

rings/grading rings may be used for connection to yoke plate.

1.10.3.

1.10.4.

1.10.5.

1.11.

1.11.1.

1.11.2.

1.11.3.

1.12.

1.12.1.

1.12.2.

1.13.

1.13.1.

1.13.2.

The Corona control rings/grading ring should have a brushed satin finish

and not a blight glossy surface. No blemish should be seen or felt when

rubbing a hand over the metal.

The limiting dimensions of corona control ring shall be as per the

specification drawings.

Bidder may quote for grading ring with armour grip suspension assembly.

The grading ring shall be of open type design with a gap of 125 mm. The

open ends shall be suitably terminated. The outside diameter of the tube shall be 60mm. The ends of grading ring tube shall be sealed with welded

aluminium cap duly buffed.

Sag Adjustment Plate

The sag adjustment plate to be provided with the double tension hardware

fitting shall be of three plate type. The sag adjustment plate shall be

provided with a safety locking arrangement. The device shall be of such,

design that the adjustment is done with ease, speed and safety.

The maximum length of the sag adjustment plate from the connecting part

of the rest of the hardware fittings shall be 435 mm. The details of the

minimum and maximum adjustment possible and the steps of adjustment shall be clearly indicated in the drawing. An adjustment of 150 mm

minimum at the interval of 6 mm shall be possible with the sag adjustment

plate.

Design calculations for deciding the dimensions of sag adjustment plate

shall be furnished by bidder. The hole provided for bolts should satisfy

shear edge condition as per IS-800.

Turn Buckle

The turn buckle is to be provided with single tension hardware fitting. The

threads shall be of sufficient strength to remain unaffected under the

specified tensile load.

The maximum length of the turn buckle from the connecting part of the

rest of the hardware fittings shall be 520 mm. The details of the minimum

and maximum adjustment possible shall be clearly indicated in the drawing. An adjustment of 150 mm minimum shall be possible with turn

buckle.

Suspension Assembly

The suspension assembly shall be suitable for ACSR ‘MOOSE’

Conductor.

The suspension assembly pilot insulator string shall include suitable

Envelope type suspension c1amps.



1.13.3.

1.13.4.

1.13.5.

1.13.6.

1.13.7.

1.13.8.

1.13.9.

1.13.10.

1.13.10.1.

The suspension clamp 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.

The suspension damp shall have a slip strength between 20 to 29 KN.

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.

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.

There shall be a differential price loading for comparison of bids, of

Rs.67.50 per suspension assembly for each watt of magnetic power loss at

a sub-conductor current of 600 amps. The lowest losses quoted by any Bidder shall be used to arrive at the differential price loading to be applied

for that bid. However, bids offering suspension assemblies with magnetic

power loss more than 4 watts except for envelope type clamps for which magnetic power loss more than 8 watts at sub conductor current of 600

amps. shall be liable to be rejected. The Bidder’s are requested to enclose

test certificates for magnetic power loss test alongwith the bid.

In case, the magnetic power loss of the suspension assembly obtained

during type testing of the same exceeds the value guaranteed by the Bidder

in his bid, the material shall be rejected outright or the same shall be

accepted after suitable liquidated damages for non-performance are assessed, which shall be recovered from the contract price. The liquidated

damages thus assessed shall not be less than twice the differential price

loading indicated in Clause 1.13.7, i.e. Rs.135 per watt/suspension assembly.

Free Centre Type Suspension Clamp

For the Free Centre 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.

Standard Preformed Armour Rod Set

The Preformed Armour Rods Set suitable for ACSR ‘MOOSE’ Conductor

shall be used to minimize the stress developed in the sub-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.

1.13.10.2.

1.13.10.3.

1.13.10.4.

1.13.10.5.

1.13.10.6.

1.13.10.7.

1.13.11.

1.13.11.1.

1.13.11.2.

1.13.11.3.

1.13.11.4.

The preformed armour rods set shall have right hand lay and the inside

diameter of the helices 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.

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.

The length each rod shall be 2540± 25mm and diameter shall be 927± 0.10

mm. The tolerance in length of the rods in complete set should be within

13mm between the longest and shortest rod. The ends of armour rod shall

be parrot billed.

The number of armour rods in each set shall be twelve. Each rod shall be

marked in the middle with paint for easy identification.

The armour rod shall not loose their resilience even after five applications.

The conductivity of each rod of the set shall not be less than 40% of the

conductivity of the International Annealed Copper Standard (IACS)

Armour Grip Suspension Clamp.

The armour grip suspension clamp shall comprise of retaining strap,

support housing, elastomer inserts with aluminium reinforcements and

AGS preformed rod set.

Elastomer insert shall be resistant to the effects of temperature up to 85°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.

The AGS preformed rod set shall be as detailed in clause 1.13.10.1 to

1.13.10.7 in general except for the following.

The length of the AGS preformed rods shall be such that it shall ensure

sufficient slipping strength as detailed under clause 1.13.4 and shall not

introduce unfavourable stress on the conductor under all operating

conditions. However the length of AGS preformed rods shall not be less than 2235 ± 25 mm.



1.14.

1.14.1.

1.15.

1.15.1.

1.15.2.

1.15.3.

Envelope type Suspension Clamp

The scat of the envelope type suspension clamp shall be smoothly rounded

& suitably curved at the ends. The edges shall have rounded bead. There shall be atleast 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.

Dead end Assembly

The dead end assembly shall be suitable for ACSR ‘Moose’ Conductor.

The dead end assembly shall be compression type with provision for

comprising jumper terminal at one end. The angle of jumper terminal to be

mounted should be 300 with respect to the vertical line. The area of

bearing surface on all the connections shall be sufficient to ensure positive

electrical and mechanical contact and avoid local heating due to I2R

losses. The resistance of the clamp when compressed on Conductor shall not be more than 75% of the resistance of equivalent length of Conductor.

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 aluminium fillet plugs shall also be provided at the line of demarcation between

compression & non-compression zone. The letters, number and other

markings on the finished clamp shall be distinct and legible. The

dimensional tolerances of the cross section of aluminium and steel dead end; allow for dead end assembly for ACSR ‘MOOSE’ shall be as per the

table given below:

Sl. Item

No.

Dimensions before

Compression

Inner dia (mm) Outer dia

(mm)

Dimensions after

compression

Corner to Face to face

corner (mm) width (mm)

i) Aluminium Sleeve 34±0.5 54±1 53±05 46±0.5

ii) Steel Sleeve 11.1±0.2 21±0.5 20.2±0.5 17.5±0.5

1.15.4.

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 the ultimate tensile strength of the conductor.



1.16.

1.17.

1.17.1.

1.17.2.

1.17.3.

1.17.4.

1.17.5.

1.17.6.

1.17.7.

1.17.8.

Balancing Weights

For holding the single suspension pilot insulator string used for jumper

connections at the transposition towers from excessive deflection, suitable balancing weights, weighting 200 kg are to be suspended through the line

side yoke plate. It shall consist of four weights, each weighting 50 Kg and

shall be connected to yoke plate by means of bolts/eye bolts and shackle

arrangement. The bottom weight shall be provided with recess to shield the ends of eye bolts. The same shall be suitable for use on 400 KV

transmission lines.

Fasteners: Bolts, Nuts and Washers

All bolts and nuts shall conform to IS:6639. All bolts and nuts shall be

galvanised as per IS 1367 (Part 13)/IS:2629. All bolts and nuts shall have hexagonal heads and nuts, the heads being forged out of solid truly

concentric and square with the shank, which must be perfectly straight.

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 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.

Nuts should be double chambered as per the requirement of IS: 1363, Part-

III. It should be ensured by the manufacturer that nuts should not be overtapped beyond 0.4mm oversize on effective diameter for size upto

M16.

Fully threaded bolts shall no 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.

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.

Flat washers and spring washers shall be provided wherever necessary and

shall be of positive lock type. Spring washers shall be electro-galvanised.

The thickness of washers shall conform to IS:2016.

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.

To obviate bending stress in bolt, it shall not connect aggregate thickness

more than three time its diameter.



1.17.9.

1.17.10.

1.17.11.

1.17.12.

1.17.13.

1.18.

1.18.1.

1.18.2.

1.18.3.

Bolts at the joints shall be so staggered that nuts may be tightened with

spanners without fouling.

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 services Quality System Standard.

Fasteners of grade higher than 8.8 are not to be used and minimum grade

to bolts shall be 5.6.

Materials

The material of the various components shall be specified hereunder. 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.

The details of materials for different component are listed as in Table No-

I

Workmanship

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 400 kV transmission lines and will give continued good

performance.

The design, manufacturing 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 to corrosion and a good finish.

All ferrous parts including fasteners shall be hot dip galvanized, after all

machining has been completed. Nuts may, however, be tapped, (threaded)

alter 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/IS:1367 (Part 13) and shall satisfy the tests mentioned in

IS:2633. 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 have a minimum average coating of zinc

equivalent to 600 gm/sq.m., shall be guaranteed to withstand at least six successive dips each lasting one (1) minute under the standard preece test

for galvanising.


Volume-II / Section - VIII EPC Tender for JITPL

1.18.4.

1.18.5.

1.18.6.

1.18.7.

1.18.8.

1.18.9.

1.18.10.

1.18.11.

1.18.12.

1.18.13.

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.

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 any grade in IS-209:1992 ingot (fourth amendment) or IS-13229:1991.

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 90° to this line. “NO GO” gauges shall not pass in any direction.

Socket ends before galvanising, shall be of uniform contour. The bearing

surface of socket ends shall be uniform about the entire circumference without depressions or high spots. The internal contours of socket ends

shall be concentric with the axis of the fittings as per 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.

In case of casting, the same shall be free from all internal defects like

shrinkage, inclusion, blow holes, cracks etc. Pressure die casting shall not

be used for casting of components with thickness more than 5mm.

All current carrying parts shall be so designed and manufactured that

contact resistance is reduced to minimum.

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 condition.

All the holes shall be cylindrical, clean cut and perpendicular to the plane

of the material. The periphery of the holes shall be free from burrs.

All fasteners shall have suitable corona free locking arrangement to guard

against vibration loosening.

Welding of aluminium shall be by inert gas shielded tungsten arc or inert

gas shielded metal arc process. Welds shall be clean, sound, smooth uniform-without overlap, properly fused and completely sealed. There

shall be no cracks, voids incomplete penetration, incomplete fusion,

under-cutting or inclusions. Porosity shall be minimised so that mechanical properties of the aluminium alloys, are not affected. All welds

shall be properly finished as per good engineering practices.



1.19.

1.19.1.

1.19.2.

1.19.3.

Bid Drawings

The Bidder shall furnish full description and illustrations of materials

offered.

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 of 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 attachment to the string as specified in clause 1.8 of

this Technical Specification.

(iv) Yoke plates

(v) Hardware fittings of ball and socket type for inter connecting units

to the top and bottom Yoke plates.

(vi) Corona control rings/grading ring attachment to conductor and

other small accessories.

(vii) Links with suitable fillings.

(viii) Details of balancing weights and arrangements for their attachment

in the single suspension pilot insulator string.

All drawings shall be identified by a drawing number and contract

number. All drawings 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.

The drawings shall include

(ix) Dimensions and dimensional tolerance

(x) Material fabrication details including any weld details & any

specified finishes & coatings. Regarding material designation &

reference of standards are to be indicated.

(xi) Catalogue No.

(xii) Marking

(xiii) Weight of assembly

(xiv) Installation instructions

(xv) Design installation torque for bolt or cap screw.

(xvi) Withstand torque that may be applied to the bolt or cap screw

without failure of component parts.

(xvii) The compression die number with recommended compression

pressure.



(xviii) All other relevant terminal details

1.19.4. After placement or award, the Contractor shall submit fully dimensioned

drawing including all the components in four (4) copies to the Owner for

approval After getting approval from the Owner and successful

completion of all the type tests, the Contractor shall submit thirty (30) more copies of the same drawings to the Owner for further distribution

and field use at Owners end.

TABLE I

Details of Materials

Sr.

No.

1.

2.

3.

4.

5.

Name of item

Security Clip

Arcing Horn

Ball Fittings,

Socket, all

shackles links

cleves Yoke Plate

Sag Adjustment

Plate

Material treatment

Stainless Steel/

Phospher Bronze

Mild Steel Road /

Tube Type

Class-IV Steel

Mild Steel

Mild Steel

Process of

Standard

Hot dip

galvanized

Drop forged & normalized

Hot dip

galvanized Hot dip

galvanized

Hot dip galvanized

Reference

AISI 302 or

304-L/IS 1385

As per IS-226

or IS-2062

As per IS 2004

As per IS-226

or IS-2062

As per IS-226 or IS-2062

Remarks

6(a) Supporting

Brackets &

Mounting Bolts

7(a) Envelope type

Clamp Clamp

Body, Keeper piece

7(b) Envelope type

Clamp : Cotter

bolts/Hangers, Shackles,

Brackets

7(c) Envelope type Clamp : U Bolts

8(a) Dead End

High Strength A1

Alloy

6061/6063/65032/63 400 Type)

High Strength A1,

Alloy 4600/LM-6 or

6061/65032

Mild Steel

Stainless Steel or

High Strength A1

alloy 6061/6063 or

65032/63400 ECgrade A1 of

Heat treated

Hot dip

galvanized

Casted or

forged &

Heat treated

Hot dip

galvanised

Forged &

Heat treated

ASTM-B429

or as per IS-

226 or IS-2062

IS:617 or

ASTM-B429

As per IS-226

or IS-2062

AISI 302 or

304-L

ASTMB429

Mechanical

Strength of

welded joint shall not be

less than 20

KN



Assembly Outer

Sleeve

8(b) Steel Sleeve

purity not less than

99.50%

Mild Steel

Hot dip

Galvanised

IS : 226/IS-

2062

Note :

2.0

2.1.

2.1.1.

2.1.2.

2.2.

2.2.1.

2.2.2.

Alternate materials conforming to other national standards of other countries

also may be offered provided the properties and compositions of these are close to the properties and compositions of material specified. Bidder should

furnish the details of comparison of material offered viz a viz specified in the

bid or else the bids are liable to be rejected.

Accessories for ACSR ‘MOOSE’ Conductor

General

This portion (under clause 2) details the technical particulars of the

accessories for ACSR MOOSE Conductor.

2.5% extra fasteners and retaining rods shall be provided.

Mid Span Compression Joint

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 equivalent 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.

The joint shall be made of steel and aluminium sleeves for jointing the

steel core and aluminium wires respectively. The steel sleeve should not

crack or fail during compression The Brinnel Hardness of steel sleeve

shall not exceed 200. The steel sleeve shall be hot dip galvanised. The

aluminium sleeve shall have aluminium of purity not less than 99.5%.

Tapered aluminium filler plugs shall also be provided on the line of demarcation between compression and non compression zone, dimensions

and dimensional tolerances of mid span compression joint shall be as per

Table – II

Table – II

Dimensions & Dimensional Tolerances for Mid Span Compression Joint, T-

connector and Repair Sleeve

Sr.

No.

Item Dimensions before compression Dimensions

compression

after

Inner Dia

(mm)

Outer Dia

(mm)

Length

(mm)

Corner

to

Corner (mm)

Face to

face

width (mm)

1. Mid Span Compression Joint



i)

Aluminium

Sleeve

34±0.5

54±1

735±5 53±0.5

46±0.5

ii) Steel Sleeve 11.1±0.2 21±0.5 250±5 20.2±0.5 17.5±0.5

2.3.

2.

3.

T-connector Sleeve

Repair

Sleeve

Repair Sleeve

34±0.5

34±0.5

54±1

54±1

400±5 53±0.5

300±5 53±0.5

46±0.5

46±0.5

2.4.

2.5.

2.5.1.

2.5.2.

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 aluminium 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 seal 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-II.

T-Connector

T-Connector of compression type shall be used for jumper connection at

transposition tower. It shall be manufactured out of 99.5 pure aluminium

and shall be strong enough to withstand normal working loads. The T-

connector shall have a resistivity across jumper less than 75% resistivity of equivalent length of conductor. The T-connector shall not permit

slipping off, damage to or failure of complete conductor. The welded

portions shall be designed for 30 KN axial tensile load. Leg sleeve of T-

connector should be kept at an angle of 15 deg. from vertical and horizontal plane of the conductor in order to minimize jumper pull at the

welded portion. The dimensions and dimensional tolerances of T-

connector shall be as per Table-II.

Spacer Damper for quad bundle conductor.

Suitable spacer dampers for four bundle ACSR MOOSE conductor shall

be offered. The spacer damper covered by this specification shall be

designed to maintain the bundle spacing of 457 mm under all normal

operating conditions and to effectively control Aeolian vibrations as well as sub-span oscillation and to restore conductor spacing after release of

any external extraordinary load. The nominal sub conductor spacing shall

be maintained within ±5mm.

The spacer damper shall restore the normal sub-conductor spacing due to

displacement by wind, electromagnetic and electrostatic forces including

the specified short circuit level without permanent deformation or damage

either to bundle conductors or to spacer damper itself.



2.5.3.

S.

No

The design offered shall be presented as a system consisting of spacer

dampers and their staggering scheme for spans ranging from 100 m to

1100 m. A vibration performance test shall be carried out on an experimental test line. The systems tested should be those specified by the

Contractor for the 800kV line conditions. Only systems satisfying the

performance criteria under Annexure-10 shall be submitted by Bidder

alongwith bid.

The test line selected for the performance evaluation shall have been

designed for that purpose, be adequately exposed to wind and properly

instrumented.

Description Technical Particulars

1 Configuration

2 Span length in metres

a. Ruling design span b. Maximum Span

c. Minimum Span

3 Tensile load in each sub-

conductor

Double Circuit

Twin ACSR MOOSE conductors bundle per phase and all three phases per

Circuit in near vertical configuration on

both side of tower

400 meters

1100 meters

100 meters

Sag-tension calculation shall be provided

4 Maximum dynamic strains

permissible ±150 microstrains

2.5.4.

2.5.5.

2.5.6.

2.5.7.

Under the operating conditions specified the spacer damper shall

adequately control Aeolian vibrations throughout the life of the transmission line with wind velocity ranging from 0 to 30 km per hour in

order to prevent damage to conductor at suspension clamps, dead end

clamps and spacer damper clamps

The spacer damper system shall also control the sub-span oscillations in

order to prevent conductor damage due to chaffing and severe bending

stresses at the spacer damper clamps as well as suspension and dead end

clamps and to avoid wear to spacer damper components.

Not Applicable

The spacer damper shall consist of a rigid central body called the frame

linked to the conductor by four articulated arms terminated by suitable clamping system. The articulation shall be designed to provide elastic and

damping forces under angular movement of the arms. The dynamic



characteristics of the articulations shall be maintained for the whole line of

the transmission life.

The damping system shall be designed to provide Firm but gentle and

permanent grip while protecting the conductor against local static or

dynamic stresses expected during normal operating conditions. The

clamping system shall be designed to compensate for any reduction of

conductor diameter due to creep.

2.5.8.

2.5.9.

2.5.10.

2.5.11.

2.5.12.

2.5.13.

Bolted type clamps shall allow installation without removal of the bolts or

the clamps from clamp body. Locking mechanism shall be suitable to

prevent bolt loosening. Clamp locking devices using small, loose

components shall not be accepted. Nut cracker, hinged open or boltless

type clamps are acceptable provided, adequate grip’ can be maintained on the conductor.

Bolts and nuts shall be of mild steel stainless steel, or high strength steel in

accordance with the design of the spacer damper,: Clamp tightening bolt shall be of shear type and clearly marked so that after the correct torque

has been applied the correctly installed bolts may be clearly identifiable

from the ground.

Where elastomer surfaced clamps are used, the elastomer elements shall

be firmly fixed to the clamp. The, insert should be forged from aluminium

alloy of type’6061 or equivalent aluminium alloy having minimum tensile

strength of 25 kg/mm2. The insert shall be moulded on the insert surface.

The insert shall be duly heat treated and aged to retain its consistent characteristics during Service. The grain flow’ of the forged insert shall be in the direction of the maximum tension and Compression loads experienced.

If clamps involving preformed rods are used, the rods shall be designed

for specific conductor size, They shall be made of high strength aluminium alloy of type 6061 or equivalent aluminium alloy having a

minimum tensile strength of 35 kg/mm2.

The rods shall be ball ended. The rods shall be heat treated and aged to

achieve specified mechanical properties and to retain the same during service. The length of the rods shall be such that the ends fall inside the

imaginary square whose sides are vertical and horizontal outer tangents to

the conductor sections

The spacer damper body shall be cast/forged from suitable high strength

corrosion resistant aluminum alloy. The aluminium alloy shall be chosen

in relation with the process used. However a combination of aluminium

alloy and steel shall also be accepted.

The rubber components involved in the design such as damping elements

shall be made with rubber compound selected specifically for that

particular application. The bidder shall submit a complete list of physical



and mechanical properties of the elastomer used. This list shall make

reference to all applicable ASTM standards.

2.5.14.

2.5.15.

2.5.16.

2.5.17.

2.5.18.

2.5.19.

2.5.20.

2.5.21.

2.5.22.

2.5.23.

2.6.

2.6.1.

The rubber components used shall have good resistance to the effects of

temperature upto 850C and to ultraviolet radiation, ozone and other

atmospheric contaminants. The rubber shall have good wear and fatigue resistance and shall be electrically semi-conductive.

The spacer damper involving ferrous material shall not have magnetic

power loss more than one watt at 500 A, 50 Hz alternating current pre sub-

conductor.

The spacer damper assembly shall have electrical continuity. The

electrical resistance between the sub-conductors across the assembly in

case of spacer damper involving elastomer surfaced clamps shall be

suitably selected by the manufacturer to ensure satisfactory electrical performance and avoid deterioration of elastomer under service conditions

The spacer damper assembly shall have complete ease of installation and

shall be capable of removal/reinstallation without any damage.

The spacer damper assembly shall be capable of being installed and

removed from the energized line by means of hot line techniques. The

Bidder shall supply with the bid the complete description of the

installation, removal and reinstallation procedure.

The Bidder shall recommend the staggering scheme for installation of

spacer dampers on the line which shall ensure most satisfactory fatigue

performance of the line as specified: -The scheme shall indicate the number of spacer dampers per phase per span and the sub-span lengths to

be maintained between spacer dampers while installing on the four bundle

conductors.

The staggering scheme shall be provided for spans ranging from 100 m to

1100m. The number of spacer dampers for a nominal ruling span of 400 m

shall not be less than six.

No sub-span shall be greater than 70 m and no end sub-span shall be

longer than 40 m.

The staggering theme shall be such that the spacer dampers be unequally

distributed along the span to achieve sufficient detuning of adjacent sub- spans for oscillation or sub-spans mode and to ensure bundle stability for

wind speeds upto to 60 km/hr.

The Bidder shall furnish all the relevant technical documents in supports

of the staggering scheme recommended for the spacer damper.

Bundle Spacer for jumper

Jumpers tension points shall also be fitted with spacers so as to limit the

length of free conductor to 3.65 m and to maintain the sub conductor



spacing of 457 mm. Bidder shall quote for rigid spacer for jumper. It shall

meet all the requirements of spacer used in line except for its vibration

performance. Spacers requiring retaining rods shall not be quoted for

jumpers.

2.6.2.

2.6.2.1.

2.6.2.2.

2.6.2.3.

2.6.2.4.

2.6.2.5.

2.6.2.6.

2.6.2.7.

2.6.2.8.

2.6.2.9.

2.6.2.10.

2.6.2.11.

The space offered by the Bidder shall satisfy the following requirements.

Spacer shall restore normal spacing of the sub-conductors after

displacement by wind, electromagnetic and the electrostatic forces under all operating conditions including the specified short circuit level without

permanent deformation damage either to conductor or to the assembly

itself. They shall have uniform grip on the conductor.

Where elastomer surfaced clamp grooves are used, the elastomer shall be

firmly fixed to the clamp. The insert should be forged from aluminium

alloy of type 6061/65032. The insert shall be duly heat treated and aged to retain its consistent characteristics during service.

Any nut used shall be locked in an approved manner to prevent vibration

loosening. The ends of bolts and nuts shall be properly rounded for

specified corona performance or suitably shielded.

Clamp with cap shall be designed to prevent its cap from slipping out of

position when being tightened.

The clam grooves shall be in uniform contact with the conductor over the

entire surface, except for rounded edges. The groove of the clamp body

and clamp cap shall be smooth and free of projections, grit or other

material, which cause damage to the conductor when the clamp is installed.

For the spaces involving bolted clamps, 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 leading to permanent deformation of the conductor

strands and premature fatigue failure in operation.

Universal type bolted clamps covering a range of conductor sizes will not

be permitted

No rubbing, other than that of the conductor clamp hinges or clamp swing

bolts, shall take place between any parts of the spacer. Joint incorporating a flexible medium shall be such that there is no relative slip between them.

The spacer shall be suitably designed to avoid distortion or damage to the

conductor or to themselves during service.

Rigid spacers shall be acceptable only for jumpers.

The spacer shall not damage or chafe the conductor in anyway which

might affect its mechanical and fatigue strength or corona performance.



2.6.2.12.

2.6.2.13.

2.6.2.14.

2.6.2.15.

2.6.2.16.

2.6.2.17.

2.6.2.18.

2.7.

2.7.1.

2.7.2.

2.7.3.

The clamping system shall be designed to compensate for any reduction in

diameter of conductor due to creep.

The spacer assembly shall not have any projections, cuts, abrasions etc. or

chattering parts which might cause corona or RIV.

The spacer tube shall be made of aluminium alloy of type 6061:65032. If

fasteners of ferrous material are used, they shall conform to and be

galvanized conforming to relevant Indian Standards. The spacer involving ferrous fasteners shall not have magnetic power loss more than one watt at

600 Amps 50Hz alternating current per sub-conductor.

Elastomer, if used, shall be resistant to the effects of temperature upto 85

deg. C ultraviolet radiation and other atmospheric contaminants likely to

be encountered in service. It shall have good fatigue characteristics. The

physical properties of the elastomer shall be of approved standard.

The spacer assembly shall have electrical continuity. The electrical

resistance between the sub-conductor across assembly in case of spacer

having elastomer clamp grooves shall be suitably selected by the

manufacturers to ensure satisfactory electrical performance and to avoid deterioration of elastomer under all service conditions.

The spacer assembly shall have complete ease of installation and shall be

capable of removal/reinstallation without any damage

The spacer assembly shall be capable of being installed and removed from

the energised line by means of hot line technique.

Material and Workmanship

All the equipment 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 400 kV transmission line application with bundle conductors and will give continued good performance.

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.

All ferrous parts 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 as per grade 4

of IS:1573. 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/IS-1367 (Part-13) 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 have a minimum average coating of Zinc equivalent to 600 gm/sq.m and shall be



guaranteed to withstand at least six dips each lasting one minute under the

standard Peerce test for galvanising unless otherwise specified.

2.7.4.

2.7.5.

2.7.6.

2.7.7.

2.7.8.

2.7.9.

2.8.

2.9.

2.9.1.

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 any grade in IS-209:1992 ingot (fourth

amendment) or IS-13229:1991.

In case of castings, the same shall be free from all internal defects like

shrinkage, inclusion, blow holes, cracks etc

All current carrying parts shall be so designed and manufactured that

contact resistance is reduced to minimum and localised heating

phenomenon is averted.

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.

Particular care shall be taken during manufacture and subsequent handling

to ensure smooth surface free from abrasion or cuts.

The fasteners shall conform to the requirements of IS: 6639. All fasteners

and clamps shall have corona free locking arrangement to guard against vibration loosening.

Compression Markings

Die compression areas shall be clearly mark 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- COMPRESSlON 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.

Bid Drawings

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.



2.9.2.

2.9.3.

2.9.4.

3.0

3.1.

3.1.1.

3.1.2.

3.2.

The drawings shall include:

(i) Dimensions and dimensional tolerances

(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) 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 technical details

Placement charts for spacer/spacer damper and damper.

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 Contractor shall again submit the drawings in four copies to the Owner

for approval. After Owners approval and successful completion of all type tests, 20 (twenty) more sets of drawings shall be submitted to the Owner

for further distribution and field use at Owners end.

G.S. Earthwire Accessories

General

This portion (under clause 3) details the technical particulars of the

accessories for Galvanized Steel Earthwire.

2.5% extra fasteners shall be supplied.

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 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-III.

Table – III

Dimensions & Dimensional Tolerances for Mid Span Compression Joint and

Repair Sleeve

Sr.

No

Item Dimensions before compression Dimensions after

compression

Inner

Dia (mm)

For 7/3.66 mm GS Earthwire

Outer

Dia (mm)

Length

(mm)

Corner to

Corner (mm)

Face to

face with

(mm)

1. Aluminium Sleeve 22 ± 0.5 32±0.5 400±5 29.4±0.5 25.0±0.5

3.3.

2. Steel Sleeve

3. Filler Aluminium

Sleeve

Vibration Damper

11.5±0.2

11.5±0.2

21±0.5 230±5

21±0.5 60±5

20.2±0.5 17.5±0.5

3.3.1.

3.3.2.

3.3.3.

3.3.4.

3.3.5.

Vibration dampers of 4R-Stockbridge type with four (4) different

frequencies spread within the specified Aeolian frequency band-width

corresponding to wind speed of 1 m/sec 7 m/sec shall be used for

suspension and tension points on each earthwire in each span to damp out Aeolian vibrations as mentioned herein after.

Alternate damping systems or “Dogbone” dampers 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.

One damper minimum on each side per earthwire at suspension points and

two dampers on each side per earth wire at tension points shall be used for

ruling design span of 400 meters for 400 kV line. No vibration damper

shall be provided in slack span (in line take off / between dead end tower and gantry structure).

The bidder may offer damping system involving more number of dampers

per ruling design span than the specified. However price compensation shall be considered for evaluation. For the purpose of price compensation

80 % of towers as suspension locations and 20 % of towers as tension

locations and all the spans assumed to be ruling design spans.

The clamp of the vibration damper shall be 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 earthwire 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.

3.3.7.

3.3.8.

The messenger cable shall be made of high strength galvanised

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 standards in the messenger cable shall be 19. The

messenger cable ends shall be suitably and effectively sealed to prevent corrosion.

The damper mass shall be made of hot dip galvanised 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.

The vibration analysis of the system, with and without damper, dynamic

characteristic of the damper as detailed under Annexure-10, shall have to be submitted by the Bidder alongwith his bid. The technical particulars for

vibration analysis and damping design of the system are as follows:

SNo. Description Technical Particulars

For 7/3.66 mm GS Earthwire

1. Span length in meters

2.

3.

4.

i)

ii)

iii)

Ruling design span

Maximum span

Minimum Span

Tensile load in Conductor at temperature

of 0 deg. C and still air

Armor rod s used

Maximum permissible dynamic strain

400 meters

1100 meters

100 meters

As per sag tension

calculations.

Standard preformed

armor s/AGS

+/- 150 micro strains

3.3.9.

3.3.10.

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.

The damper placement charts shall include the following:

(1) Locations of the damper for various combinations for spans and line

tensions clearly indicating number of damper of dampers to be installed per earthwire 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/triunion type etc.)

(4) The influence of mid span compression joints in the placement of

dampers.

3.4.

3.5.

3.5.1.

3.5.2.

3.5.3.

3.5.4.

3.5.5.

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 Indian Standard. Two tinned copper connecting lugs shall be press jointed to either ends of the flexible copper cable. One lug shall

be suitable for 12mm, dia. bolt and the other for 16 mm dia bolt. The

complete assembly shall also include one 16 mm dia., 40mm long HRH

MS Bolt hot dip galvanised with nut and lock washer.

Suspension Clamp

Standard anchor shackle/twisted shackle for earthwire suspension clamp

shall be supplied for attaching to the hanger plate of tower.

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

support the earthwire of 7/3.66 mm size. The clamps shall be of either free centre type or triunion type and shall provide adequate area of support to

the earthwire. The groove of the clamp 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 reduce the intensity of bending

moment on earthwire.

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.

The clamping piece and the clamp body shall be clamped by at least two

U-bolts of size not less than 12 mm diameter having one nut and one 3mm

thick lock nut with washer on each of its limbs. Suspension clamps shall

be provided with inverted type U-bolts. One limb of the U-bolt shall be long enough to accommodate the lug of the flexible copper bond.

The Contractor shall supply all the components of the suspension

assembly including shackles, bolts, nuts, washers, split pin etc. The total drop of the suspension assembly from the centre point of the attachment to

the centre point of the earthwire shall not exceed 150 mm. The design of



he assembly shall be such that the direction of run of the earthwire shall be

same as that of the Conductor.

3.5.6.

3.6.

3.6.1.

3.6.2.

3.6.3.

3.6.4.

3.6.5.

3.6.6.

3.7.

3.8.

3.9.

4.0

4.1.

4.1.1.

4.1.1.1.

The complete assembly shall be guaranteed for slip strength of not less

than 12 kN and not more than 17 kN. The breaking strength of the

assembly shall not be less than 25 kN.

Tension Clamp

At all tension towers suitable compression type tension clamps shall be

used to hold 7 / 3.66 mm Galvanised Steel Earthwire. Anchor shackle

shall be supplied which shall be suitable for attaching to the tension

clamps to strain plates.

The clamps shall have adequate area of bearing surface to ensure positive

electrical and mechanical contact and shall not permit any slip to earthwire

under working tension and vibration conditions. The angle of jumper terminals to be mounted should be 30 deg. with respect to the vertical line.

The clamps shall be made of mild steel with aluminium 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 galvanised. The aluminium encasing shall have aluminium of purity not

less than 99.5%. Filler aluminium sleeve shall also be provided at the end.

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.

The slip strength of the assembly shall not be less than 95% of the ultimate

strength of the earthwire.

The clamps shall be complete with all the component including anchor

shackle, bolts, nuts, washers, split pin, jumper arrangement etc.

Material Workmanship

Same as Clause 2.7 of this section

Compression Marking

Same as clause 2.8 of this section

Bid Drawings

Same as Clause 2.9 of this section

Tests and Standards

Type Tests

On the complete Insulator String with Hardware Fittings

On the complete Disc Insulator String with Hardware Fittings –



a)

b)

c)

d)

e)

f)

g)

h)

i)

Power frequency voltage withstand test with

corona control rings / grading ring and

arcing horns under wet condition

Switching surge voltage withstand test

under wet condition

Impulse voltage withstand test under dry

condition

Impulse voltage flashover under dry

condition

Voltage distribution test

Corona and RIV test under dry condition

Mechanical Strength test

Vibration test

Power Arc Test

As per IEC:383

As per IEC:383

As per IEC:383

As per IEC:383

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

4.1.1.2.

On the complete Porcelain long rod Insulator siring with Hard ware

Fittings

a)

b)

c)

d)

e)

f)

g)

h)

Power frequency voltage withstand test with

corona control rings / grading ring and

arcing horns under wet condition

Switching surge voltage withstand test

under

wet condition

Impulse voltage withstand test under dry

condition

Impulse voltage flashover under dry

condition

Corona and RIV test under dry condition

Mechanical Strength test

Vibration test

Power Arc Test

As per IEC:383

As per IEC:383

As per IEC:383

As per IEC:383

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

4.1.2.

On suspension Hardware fitting only

a) Magnetic power loss test for suspension As per Annexure-10

assembly

b) Clamp slip strength Vs torque test for As per Annexure-10

suspension clamp

c) Mechanical strength Test As per Annexure-10



d)

Ozone Test on elastomer

As per Annexure-10

4.1.3.

On Tension Hardware Fitting only

a) Electrical resistance test for dead end

assembly

b) Heating cycle test for dead end Assembly

c) Slip Strength test for dead end assembly

d) Mechanical strength test

As per IS:2486(Part-I)



As per Annexure-10

4.1.4.

4.1.5.

4.1.6.

4.1.7.

Mid Span Compression Joint for Conductor and Earthwire

a) Chemical analysis of materials As per Annexure-10

b) Electrical resistance test As per IS:2121 (part-II)

c) Heating cycle test As per IS:2121 (part-II)

d) Slip strength test As per Annexure-10

e) Corona extinction voltage test (dry) As per Annexure-10

f) Radio interference voltage test (dry) As per Annexure-10

Note: Tests mentioned at (c), (e) & (f) are not applicable to mid span

compression joints for earthwire.

Repair Sleeve for conductor

(a) Chemical analysis of materials As per Annexure-10

(b) Corona extinction voltage test (dry) As per Annexure-10

(c) Radio interference voltage test (dry) As per Annexure-10

T-connector for conductor and Earthwire

(a) Chemical analysis of materials As per Annexure-10

(b) Electrical resistance test As per IS:2121 (Part-II)

Clause 6.5 & 6.6

(c) Heating cycle test As per IS:2121 (Part-II)

(d) Axial tensile load test on welded portion As per Annexure-10

(e) Corona extinction voltage test (dry) As per Annexure-10

(f) Radio interference voltage test (dry) As per Annexure-10


(a) Slip strength test As per Annexure-10



4.1.8.

4.1.9.

4.1.10.

4.1.11.

Vibration Damper for Earthwire

(a) Chemical analysis of materials

(b) Dynamic characteristics test

(c)Vibration analysis

(d) Clamp Slip test

(e) Fatigue tests

(f) Damper efficiency test

Spacer Damper for quad bundle conductor

a) Chemical analysis of materials

b) Clamp slip test

c) Performance test

d) Dynamic characteristics test

e) Fatigue tests

d) Magnetic power loss test (if applicable)

e) Compressive and Tension-Tests

f) Corona extinction voltage test (dry)

g) Radio interference voltage test (dry)

h) Ozone test on elastomer

Rigid spacer for jumper


b) Clamp slip test

c) Magnetic power loss test (if applicable)

d) Tension-compression test

e) Corona extinction voltage test (dry)

f) Radio interference voltage test (dry)

On Earthwire Suspension clamp Assembly


b) Clamp slip strength Vs torque test for

suspension clamp

c) Mechanical strength Test

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per IS:9708

As per Annexure-10

As per Annexure-10

As per Annexure-10

i) Aeolian vibration

As per Annexure-10

ii) Sub-span oscillation

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10

As per Annexure-10



4.1.12.

On Earthwire Tension clamp Assembly


As per Annexure-10

b) Mechanical strength test (excluding clamp) As per Annexure-10

c) Slip strength test for tension assembly As per Annexure-10

4.1.13.

4.1.14.

4.2.

4.2.1.

d) Electrical resistance test for tension clamp As per Annexure-10

All the type tests given under clause no.4.1.1 above shall be conducted on

double suspension and Quadruple tension insulator string along with hardware fittings as applicable. The test specified under clause no. 4.1.1.1

(a) to (f) / 4.1.1.2 (a) to (e) shall be conducted on single suspension pilot

string and single tension string aIongwith hardware fittings.

Heating cycle test on dead end assembly and mid span compression joint

& T-connector for conductor and performance test on spacer dampers

shall not be required to be carried out if a valid test certificate is available for a similar design i.e. tests conducted earlier should have been conducted

in accredited laboratory (accredited based on ISO/IEC guide 25/17025 or

EN 45001 by the National accreditation body of the country where

laboratory is located) or witnessed by the Owners representative(s). The test reports submitted shall be for the tests conduced within last 5 (five)

years prior to the date of bid opening.

In case the tests have been conducted earlier than the above stipulated

period or in the event of any discrepancy in the test report (i.e. any test

report not applicable due to any design / manufacturing change including

substitution of components or due to non-compliance with the requirement stipulated in the technical specifications) the tests shall be conducted by

the Contractor at no extra cost to the Owner.

Acceptance Tests

On Both Suspension and Tension Hardwar Fittings

a) Visual Examination As per IS:2486 (Part-I)

b) Verification of dimension As per IS:2486 (Part-I)

c) Galvanising/Electroplating test As per IS:2486 (Part-I)

d) Mechanical strength test of each component As per Annexure-10

(excluding corona control rings grading ring

and arcing horn)

e) Mechanical Strength test of welded joint As per Annexure-10

f) Mechanical strength test for corona control BS-3288 (Part-I)

ring/grading ring and arcing horn

g) Test on locking device for ball and As per IEC:372(2)

socket coupling



h) Chemical analysis, hardness tests, grain size As per Annexure-10

inclusion rating & magnetic paride

inspection for forgings/castings

4.2.2. On Suspension Hardware Fittings only

a) Clamp Slip strength Vs Torque test for

suspension clamp

As per Annexure-10

b) Shore hardness test of elastomer cushion As per Annexure-10

for AG suspension clamp

4.2.3.

c) Bend test for armour rod set

Resilience test for armour rod set

Conductivity test for armour rods set

On Tension Hardware Fittings only

As per IS:2121 (Part-I)

Clause 7.5,7.10 & 7.11


Clause 7.5,7.10 & 7.11


Clause 7.5,7.10 & 7.11

4.2.4.

4.2.5.

4.2.6.

4.2.7.

a) Slip strength test for dead end assembly As per IS : 2486 (Part-I)

Clause 5.4

On Mid Span Compression Joint for Conductor and Earthwire

a) Visual examination and dimensional As per IS:2121(Part-II),

Verification Clause 6.2, 6.3 7,6.7

b) Galvanising test As per Annexure-11

c) Hardness test As per Annexure-11

T-Connector for conductor

a) Visual examination and dimensional As per IS:2121 (Part-II)

verification

b) Axial tensile load test for welded portion As per Annexure-10

Repair Sleeve for Conductor


verification Clause 6.2, 6.3



verification Clause 6.2, 6.3



4.2.8.

b) Slip strength test


a) Visual examination and dimensional

verification

b) Galvanising test

i) On damper masses

ii) On messenger cable

c) Verification of resonance frequencies

d) Clamp slip test

e) Clamp bolt torque test

f) Strength of the messenger cable

g) Mass pull off test

h) Dynamic characteristics test

As per annexure – 10

As per IS:2121 (Part-II)

Clause 6.2, 6.3 7 6.7










4.2.9.

4.2.10.

4.2.11.

Spacer Damper for conductor/Rigid spacer for Jumper


verification Clause 6.2, 6.3 7 6.7

b) Galvanising test As per annexure – 11

c) Movement test (except for spacer jumpers)As per annexure – 11

d) Clamp slip test As per annexure – 11

e) Clamp bolt torque test As per annexure – 11

f) Compression-tension test As per annexure – 11

g) Assembly torque test As per annexure – 11

h) Hardness test for elastomer (if applicable) As per annexure – 11

i) UTS of retaining rods (if applicable) As per annexure – 11

4.2.10 Earthwire Tension Clamp Assembly


verification As per IS : 2121 (Part-II)

b) Galvanising test As per annexure – 11

c) Slip strength test for tension clamp As per Annexure – 10

d) Mechanical strength test on each As per Annexure –10

component (excluding clamp)

e) Hardness test As per Annexure – 10

Earthwire Suspension Clamp Assembly




verification

b) Galvanising test

c) Clamp slip strength test

As per IS : 2121 (Part-II)

As per Annexure – 11

As per Annexure-10

4.3

4.3.1

4.3.2

4.4

4.5

4.5.1

4.5.2

4.5.3

4.5.4

d) Mechanical strength test on each component As per Annexure-10

(excluding clamp)

Routine Tests

For Hardware Fittings

a) Visual examination As per IS : 2121 (Part-II)

b) Proof Load Test As per Annexure-10

For conductor and earthwire accessories


verification Clause 6.2, 6.3.7 6.7

Tests During Manufacture on all components as applicable

a) Chemical analysis of Zinc used for galvanizing IS:2486 (Part-I)

b) Chemical analysis mechanical metallographic As per Annexure-10

test and magnetic particle inspection for

malleable castings

c) Chemical analysis, hardness tests and As per Annexure-10

magnetic particle inspection for forging

Testing Expenses

Testing charges for all type/routine tests shall be borne by the Contractor

In case of failure in any such type tests, the Contractor whose material has failed

is either required to modify the design of the material & successfully carryout

all the type tests or to repeat that particular type test at least three times

successfully at his own expense. In case of failure of the complete string in any

type test, Contractor shall get the test repeated at his cost. The Contractor whose material has not failed in the test shall be required to supply the requisite

quantity of material.

Contractor shall indicate the laboratories in which they propose to conduct the

type tests. They shall ensure that adequate facilities for conducting the tests are available in the laboratory and the tests can be completed in these laboratories

within the time schedule guaranteed by them in the appropriate schedule.

The entire cost of testing for acceptance and routine tests and tests during

manufacture specified herein shall be treated as included in the quoted Exworks

/ CIF Price.



4.5.5

4.5.6

4.6

4.6.1

4.6.2

4.7

4.7.1

4.7.2

4.7.3

In case of failure in any type test, repeat type test are required to be conducted,

Then, all the expenses for deputation of Inspector/Owner’s representative shall

be deducted from the contract price. Also if on receipt of the Contractors notice of testing, the Owner’s – representative/ lnspector does not find ‘plant’ to be

ready for testing the expense incurred by the Owner for re-deputation shall be

deducted from contract price.

The Contractor shall intimate the Owner about carrying out of the type tests

alongwith detailed testing programme at least 3 weeks in Advance (in case of testing in India) and at least 6 weeks advance (in case of testing abroad) of the

scheduled date of testing during which the Owner will arrange to depute his

representative to be present at the time of carrying out the tests.

Sample Batch for Type Testing

The Contractor shall offer material for sample selection for type testing only

after getting Quality Assurance Programme approved by the Owner. The

Contractor shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. The sample for type testing

will be manufactured strictly in accordance with the Quality Assurance

Programme approved by the Owner.

Before sample selection for type testing the Contractor shall be required to

conduct all the acceptance tests successfully in presence of Owners representative.

Schedule of Testing and Additional Tests

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

(a) Submission of drawing for approval

(b) Submission of Quantity Assurance programme for approval

(c) Offering of material for sample selection for type tests

(d) Schedule of type testing

The Owner reserves the right of having at his own expense any other test(s) of

reasonable nature carried out at Contractors 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.

The Owner also reserves the right to conduct all the tests mentioned in this

specification at his own expense on the sample drawn from the site at Contractor’s premises or at any other test centre. In case of evidence of non

compliance, it shall be binding on the part of Contractor 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 Owner



4.8

4.8.1

4.9

4.9.1

4.9.2

4.9.3

4.9.4

4.10

Co-ordination for testing

The Contractor shall have to co-ordinate testing of hardwire fittings with

insulators and shall have to also guarantee overall satisfactory performance of

the hardware fittings with the insulators.

Test Reports

Copies of type test reports shall be furnished in at least six copies-alongwith one

original - One copy shall be returned duly certified by the Owner, only after

which the commercial production of the concerned material shall start.

Copies of acceptance test report shall be furnished in atleast six copies. One

copy shall be returned, duly certified by the Owner, only after which the materials will be dispatched.

Record of routine test report shall be maintained by the Contractor at his works

for Periodic inspection by the Owner’s representative

Test certificates of tests during manufacture shall be maintained by the

Contractor. These shall be produced for verification as and when desired by the

Owner.

Inspection

4.10.1 The Owner’s 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 or the Contractor’s, sub-Contractor’s works raw

materials, manufacturer’s of all the material and for conducting necessary tests

as detailed herein.

4.10.2 The material for final inspection shall be offered by the Contractor only under

packed condition as detailed in clause 4.11 of this part of the Specification. The engineer shall select samples at random from the packed lot for carrying out

acceptance tests.

4.10.3 The Contractor shall keep the Owner informed in advance of the time of starting

and of the progress of manufacture of material in its various stages so that

arrangement could be made for inspection.

4.10.4 Material shall not be dispatched from its point of manufacture before it has been

satisfactorily inspected and tested unless the inspection is waived of by the

Owner in writing. In the latter case also the material shall be dispatched only

after all tests specified herein have been satisfactorily completed.

4.10.5 The acceptance of any quantity of material shall in no way relieve the

Contractor 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.



4.11

Packing and Marking

4.11.1 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.

4.11.2 The packing shall be of sufficient strength to withstand rough handling during

transit, storage at site and subsequent handling in the field.

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

prevent damage or deformation during transit and handling.

4.11.4 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.

4.11.5 Each component part shall be legibly and indelibly marked with trade mark of

the manufacturer and year of manufacture

4.11.6 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 dispatched 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

4.12 Standards

4.12.1 The Hardware fittings; conductor and earthwire accessories shall conform to the

following Indian/International Standards which shall mean latest revisions, with

amendments/changes adopted and published, unless specifically stated

otherwise in the Specification

4.12.2 In the event of the supply of hardware fittings; conductor and earthwire

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

Contractor and those specified in this document will be provided by the

Contractor to establish their equivalence.

Sr

No

Indian

Standard

Title

International Standard

1 IS: 209-1992 Specification for zinc BS:3436-1986

2 IS: 398-1992 Part-V

3 IS 1573

4 IS: 2121 (Part

–I)

5 IS: 2486 (Part

–I)

Aluminium Conductor Galvanised Steel- Reinforced for Extra High Voltage (400 KV)

and above

Electrolated Coating of Zinc on iron and Steel

Specification for Conductor and Earthwire

Accessories for Overhead Power Lines: Mid- Span Joints and Repair Sleeves for Conductors

Specification for Insulator Fittings for Overhead power Lines with Nominal Voltage greater than

BS:215-1970



1000 V: General Requirements and Tests

6 IS:2629

7 IS:2633

8

9

10 IS:4826

11 IS:6745

12 IS:8263

13 IS:6639

14 IS:9708

15 IS:10162

Recommended Practice for Hot Dip Galvanising of Iron and Steel

Method of Testing Uniformity of Coating on Zinc Coated Articles

Ozone Test on Elastomer

Tests on insulators of Ceramic material or glass

for overhead lines with nominal voltage greater

than 1000V

Galvanised Coating on Round Steel Wires

Methods of Determination of Weight of Zinc

Coating of Zinc Coated Iron and Steel Articles

Method of Radio Interference Tests on High

Voltage Insulators

Hexagonal Bolts for Steel Structures

Specification for Stock Bridge Vibration

Dampers for Overhead Power Lines

Specification for Spacers Dampers for Twin

Horizontal Bundle Conductors

ASTM-D1171

IEC:383-1993

ASTM A472-729

BS:443-1969

BS:433 ISO:1460 (E)

IEC:437 NEMA:107

CISPR

ISO/R-272

The standards mentioned above are available from:

Reference Abbreviation

BS

IEC/CISPR

BIS/IS

ISO

Name and Address

British Standards, British Standards Institution,

101, Pentonvile Road,

N-19-ND, UK

International Electro technical Commission,

Bureau Central de la Commission, Electro Technique international,

1 Rue de verembe,

Geneva SWITZERLAND

Bureau of Indian Standards,

Manak Bhavan, 9, Bahadur Shah Zafar Marg,

New Delhi – 110001

INDIA

International Organisation for

Standardization, 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.


Volume-II / Section-IX EPC Tender for JITPL

SECTION – IX

ANNEXURES



ANNEXURE -1

Provisional Bill of Quantity for 400KV D/C Transmission Line from Derang to Angul

Sl.No Particulars Total

Quantity

Total Length of the Line kMs 56.24

Check Survey 56.24

A SUPPLY OF MATERIALS

HT Unit Wt. (kg)

MS Unit

Wt.(kg) Nos

1 Supply of tower parts

a) (i) 'A' Type towers Normal 5150 6200 111

(ii) 3 M Extension pieces 350 1220 31

(iii) 6 M Extension pieces 630 1900 14

(iv) 9 M Extension pieces 980 2500 1

b) (i) 'B' Type towers Normal 9800 6600 15



(iv) '9 M Extension pieces 2500 3100 1

c) 'C' Type towers 11900 6100 11

d) (i) 'D' Type towers Normal 15000 10000 16



(iv) 9 M Extension pieces 2600 5100 4

(v) 18 M Extension pieces 5400 12400 1

(vi) 25 M Extension pieces 7500 19900 2

2

Supply of Bolts and Nuts (3% of total tower Wt. Of towers) 68761

3 Supply of tower accessories Nos

a) Danger plate (one per tower) 153

b) Number plate (one per tower) 153

c) Phase plate (set of three per tower) x No. of Ckts. 306

d) Anti climbing device (one set per tower) 153

e) Circuit plate (one per circuit in case of two or more ckt) 306

d) Supply of pipe type earthing (60% of total No.) 100

e) Supply of Counter poise earthing (40% of total No.) 53



4 Supply of ACSR Moose Conductor (kM) 685.003

(=Route kM x 3 x No. of Ckts x 2 x 1.015)

5 Supply of 7/3.66mm GSS Ground wire (kM) 114.2

(=Route kM x 2 x 1.015)

6 Supply of Insulators with Hardware Nos

a) 'I' Suspension Insulator Sring (No. Suspn. X 3) x Ckts 630

b) Single 'I' suspn. Pilot string (No. of 'D' type x 1) 48

c) Double Tension string (No. of anchor x 2 x 3 x No. of Ckts) 504

d) Double 'I'' suspn. Insulator string (Special Locations) 36

7 120 kN Insulators 17250

160 kN Insulators 24192

8 Supply of Conductor and GW Accessories Nos

a) Mid span compression Joint for condr. (one No. for 3 kM)

228

b) Mid span compression joint for GW (one No. for 8 kM)

14

c) Repair sleeves for Conductor (2 Nos. for every Route kM)

112

d) Flexible copper Earth bonds (2x 'A' type + 2x2xNo. of Anchor)

390

e) Bundle Spacers for Conductor (6x No. of towers x 3 x Ckts)

5508

f) Rigid spacer for Conductor (2 x No. of anchor x 2 x 3x Ckts)

504

g) Vibration Damper for GW (No. Of towers x 2 x2)

612

h) Earth wire suspension clamp ( No. 'A' towers x 2)

222

I) Earth wire tension clamps (No. of Anchor x 2 x 2)

168

j) Vibration dampers for conductor (No. towersx4xCktsx3x Condr)

7344



B

ERECTION

1 Erection of tower,Stringing of Conductor and Ground wire (Route kM) 56.24

2 Erection of Tower parts(MT)

298

C CIVIL WORKS

1 Geotechnical investigation for towers foundation(Nos) 153

2 Excavations(Cu.M) 37842

3 M20 Concrete (1:1½:3 Concrete) (Cu.M) 5567

4

1:3:6 Concrete (15% of M20 Concrete) in Cu.M 601

5 Reinforcements (4% of weight of M20) in MT 417

6 Benching

a) All kinds of soil except fissured rock 150

b) Fissured rock 1500

7 Revetment works

a) Random Rubble Masonry (1:5 cement mortar) in Cu.M

2500

b) 1:2:4 Cement Concrete revetment 250

c) Back filling and levelling (Included above) 2500



ANNEXURE – 2 :

BLANK



ANNEXURE – 3 :

BLANK



ANNEXURE – 4 :

BLANK



ANNEXURE-5

STANDARDS FOR ACSR CONDUCTOR

The 520 Sq.mm. ACSR “Moose” conductor shall conform to the following Indian

Standard which shall mean latest revision/amendments/changes adopted and published:

(i)

IS :398 Part I to V as relevant

Specification for Aluminium Conductors for

overhead transmission purposes

(ii) IS : 1521 :1972

(iii) IS :1778 :1980

(iv) IS :8263 : 1976

(v) IS :209

(vi) IS : 1841

(vii) IS : 4826

(viii) IS : 7623

Method of Tensile Testing of Steel.

Reel and Drums for bare conductors

Method of Radio Interference tests on High

Voltage Insulators

Specification for Zinc

EC grade Aluminium rod produced by rolling

Hot Dipped Galvanised coatings on round steel

Specification for Lithium soap grease



ANNEXURE – 6

DRAWING CHARTS & DESIGN DATA TO BE SUBMITTED IN PHYSICAL

FORM

(A) Bidder shall furnish full details of earthwire drum offered. The drawing shall

indicate:

i)

iii)

iv)

Size & weight of drum

ii)Materials used. Identification marks.

Any other information, which may be useful to the user.

(B) Successful bidder during the execution of contract shall submit the sag tension

charts of earthwire for approval.

GUARANTEED TECHNICAL PARTICULARS

Unit Specified

Offered

Sr.No D e s c r I p t i o n values Values

1.

2.

3.

1 2

Maker’s name, address and country

Percentage composition of steel wire element

i) Carbon

ii) Sulphur

iii) Phosphorus

iv) Manganese

v) Silicon

Particulars of steel strand:

a) No. of strands

b) Diameter of strand

Standard

3

%

%

%

%

%

Nos.

Mm

4

Not more

than 0.55 Not more

than 0.04

Not more than 0.04

0.4 to 0.9

0.15to 0.35

7

3.66

5



c)

Maximum

Minimum

Sectional area of strand

Mm

Mm

sq.mm.

3.75

3.57

4.

Zinc coating of steel strand:

a) Uniformity of coating (number and duration

of dips withstood)

Minute duration of dips

i) One

ii) Half

No.

No.

4

1

5.

6.

7.

8.

b) Minimum weight of coating

Standard overall diameter of steel wire

Total area of cross section of steel wire.

Guaranteed ultimate tensile strength of steel wire

D.C. resistance in ohms per km. At 20 deg.C

g/m.sq. 275

mm 10.98

sq.mm. 73.65

N/mm2 1100

2.5

9.

10.

11.

12.

Standard length of steel wire (minimum)

Tolerance if any of standard length

Random length of steel wire

Random lengths in No.

Km

%

Km

No.

2.0

+/-5

13.

14.

15.

Modulus of elasticity of steel wire

Co-efficient of linear expansion

1) Strand lay and lay length

Kg/mm 19x10 ³

/deg.C 11.5x10-6

a) b)

c)

Maximum Standard

Minimum

mm mm

mm

198 181

165

2)

Direction of lay of outer layer

Right/L

eft

Right hand

16.

Weight of steel wire

Kg/Km 583



17.

18.

19.

20.

21.

22.

23.

24.

25.

Standard length of steel wire in each drum

Standard weight of steel wire on the drum

Weight of empty drum

Gross weight of the drum

Dimension of the drum in cms.

Initial and final sags and tension and stringing

charts, whether furnished.

Standard according to which the steel wire will be

manufactured

Other particulars, if any

Separate winding & unwinding facilities for

inspection purpose whether available.

Name of the Firm:

Meter 2000

Kg.

Kg.

Kg.

GWB

Yes/No

IS or

equival ent

Yes/No

Signature of the Bidder:

Designation:

Date:



ANNEXURE – 7

TESTS ON EARTHWIRE

1 UTS Test on Earthwire

A sample of earthwire of about 5 m length will be subjected to the ultimate

Tensile strength test. The earthwire shall not fail at a value less than 68.4 KN.

2 Surface Condition Test

A sample of earthwire of 5 m length shall be subjected to a load of 50% of the

UTS of the earthwire. Neither shall the surface depart from its cylindrical form

nor the strands move relative to each other so as to get out of place or disturb the

longitudinal smoothness of the earthwire.

3 D.C. Resistance Test

On strand of minimum 5 m length, two contact clamps shall be fixed. The

Resistance shall be measured by Kelvin bridge by placing the clamps initially

from one end and subsequently one meter apart. The test shall be repeated at each

meter length and the value recorded. The value obtained shall be corrected to the value at 20 deg.C.

4 Visual Check for joints/lengths

Two drums from each lot/50Km. whichever is less, shall be selected at random

and rewound in the presence of the inspector and actual length of earthwire

measured. The weight of the earthwire also will be measured by weighing empty drum and drum with earthwire. The inspector shall visually check for scratches,

joints etc. and see that the earthwire generally conforms to the requirements of

this specification. The expenditure for above measurements, if any, will be to the bidder’s account. The firm should have separate facility for winding and

unwinding for inspection purpose.

5 Visual Check on Drums

The drums shall be visually and dimensionally checked to ensure that they

conform to these specifications.

6 Chemical analysis of Zinc used for galvanizing

Samples taken from the zinc ingots shall be chemically/ spectrographically

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



7 Wrapping Test

One specimen cut from each of the samples of galvanized steel wire shall be

wrapped round a mandrel of diameter equal to 4 times the wire of diameter to

form a close helix of 8 turns. Six turns shall be unwrapped and again closely

wrapped in the same direction as before. The wire shall not break.

8 Lay Length Check

The lay length shall be checked to ensure that they confirm to the requirement of

the specification.



ANNEXURE - 8

TEST PROCEDURE FOR INSULATORS

1.0

PROCEDURE FOR MOUNTING INDIVIDUAL DISC AND

COMPLETE STRING FOR MEASUREMENT OF RIV, VOLTAGE

DISTRIBUTION & VISIBLE DISCHARGE:

a) The insulator unit or insulator string shall be suspended vertically by

means of an earthed wire rope or other suitable means from a supporting

structure. The distance between the upper most point of the insulator metal

work and the supporting structure shall be not less than 1 meter. No other

object shall be nearer to the insulator than 1 meter or 1.5 times the length

of the insulator string, whichever is greater. A length of conductor in the

form of a straight smooth metal rod or tube shall be attached to the lower integral fitting of the insulator unit or insulator string so that it lies in a

horizontal plane and the distance from the lowest shed of porcelain part to

the upper surface of the conductor shall be as short as possible but greater than 0.5 times the diameter of the lowest insulator.

b)

c)

d)

e)

2.0

The diameter of the conductor shall be about 1.5% of the length of the

insulator unit or insulator string with a minimum of 25 mm.

The length of the conductor shall be at least 1.5 times that of the insulator

unit or insulator string and it shall extend at least 1 meter on each side of the vertical axis.

Precaution shall be taken to avoid flashover from the ends of the

conductor.

The test voltage shall be applied between the conductor and earth.

MOUNTING PROCEDURE FOR COMPLETE STRING FOR

WET POWER FREQUENCY, WET SWITCHING SURGE AND DRY IMPULSE WITHSTAND TESTS:

a) The insulator string shall be suspended vertically in an arrangement

simulating a tower body and cross arm. The cross arm is simulated by a

horizontal member, the insulator string being at one end and the vertical

member simulating the tower body at the other. Both members and the

link supporting the insulator string shall be earthed. The width of each

member facing the insulator string shall be from 400 mm minimum to at

least 20% of the length of the insulator string. The distance between the

axis of the insulator string and the vertical member simulating the tower



body shall be between 1.2 and 1.5 times the length of the insulator string.

The distance between the upper most point of the insulator string and the

lower part of the horizontal member simulating the cross arm shall be equal to about 300 mm. The member simulating the tower body shall

extend to at least twice the length of the insulator string below the member

simulating the tower cross arm.

b)

c)

d)

A bundle consisting of two/quad sub conductors in the form of straight

smooth metal rods or tubes shall be attached to the lower integral fittings

of the insulator string at right angles to the cross arm. The two/quad sub conductors of the bundle shall be maintained parallel by means of

horizontal spacers, the sub conductor spacing shall be equal to about one

tenth of the length of the insulator string. The bundle shall extend approximately for the length of the insulator string on each side of the axis

of the insulator string and diameter of each sub conductor shall be between

0.75% and 1.25% of the length of insulator string. To avoid spark over

from the two ends of the bundle, each end shall be protected by means of a suitable device (for instance by means of metal ring). The height of the

conductor above ground shall be equal to about 1.5 times the length of the

insulator string but not less than 6 meters.

The test voltage shall be applied between the conductor bundle and earth,

the H.V. connection being made at one end of the conductor bundle.

During the test, no object other than those described in this clause shall be

nearer to the live end of the insulator string than 1.5 times the length of

string.

e) The insulator string shall be complete with those parts, which are

considered necessarily associated with the string and are specified as such by the manufacturer.

3.0

TESTING PROCEDURE FOR DYNAMIC TEST (VIBRATION

TEST):

Complete string is to be subjected to aeolian vibrations by suitable

arrangement, while keeping the tension at every day stress (e.d.s). The string shall be vibrated at frequencies and double amplitude as already

agreed between Owner and Contractor for 10 million cycles. After 5

million cycles, the string shall be rotated through 90 in horizontal plane. For 'V'/'I' suspension string & quad tension string, the e.d.s. will be 4600

kgs per conductor. All discs shall be thoroughly checked for any damage,

cracks, loosening of pins/caps. Thereafter, all the discs will be subjected to electrical routine test, electro mechanical failing load test and porosity test.

The string shall be deemed to have passed the dynamic test if it withstands

all these tests.



4.0

a)

b)

c)

d)

5.0

a)

b)

TESTING PROCEDURE FOR WET POWER FREQUENCY

WITHSTAND TEST:(As per IEC: 60383/IS: 731)

The insulator string shall be mounted as per mounting arrangement given

above in Clause 2.0.

The characteristics of artificial rain shall be in accordance with Clause 3.3

of IS 2071 (Part-I).

The test voltage to be applied to the insulator string shall be the wet power

frequency withstands voltage adjusted for atmospheric conditions at the

time of test.

A voltage of about 75% of the test voltage so determined shall be applied

and then increased gradually with a rate of rise of about 2% of this voltage

per second. The test voltage at full value shall be maintained for one minute. No flashover or puncture shall occur during this period.

TESTING PROCEDURE FOR WET SWITCHING SURGE

WITHSTAND TEST: (As per IEC: 60381/IS: 731)

The insulator string shall be mounted as per mounting arrangement given

above (Clause 2.0). The impulse generator shall be adjusted to produce a

250/2500 µ second impulse wave. Impulse waves of both positive and negative polarity shall be used. Wet tests shall be made under the

conditions prescribed in specified standards.

The withstand test shall be performed at a specified switching impulse

voltage with application of corrections for atmospheric conditions. Fifteen

impulses shall be applied to the insulator string under test. If the number of flashovers on the external insulation does not exceed two, the insulator

string shall be deemed to have complied with this test requirement.

c. The insulators shall not be damaged by the test but slight marks on

the surface of the insulating parts or chipping of the cement or other

material used for assembly is permitted.

6.0

a)

TESTING PROCEDURE FOR DRY LIGHTNING IMPULSE

VOLTAGE WITHSTAND TEST: (As per IEC: 60383/IS: 731)

The insulator string shall be arranged as per mounting arrangement given

above (Clause 2.0). Impulse waves of both positive and negative polarity



shall be used. However, when it is evident which polarity will give the

lowest flashover voltage it will suffice to test with that polarity.

b)

c)

d)

7.0

The impulse generator shall be adjusted to produce a standard 1.2/50 µ

second impulse wave of a value equal to the specified value of the impulse

withstand voltage corrected for atmospheric conditions.

Five such impulses shall be applied. If there is no flashover or puncture,

the insulator shall be considered to have passed the test. If during the

application of these five impulses, puncture occurs or if there is more than

one flashover, the insulator shall be considered to have failed to comply with the test requirement. If only one flashover occurs, a new series of ten

impulses shall be applied. The insulator will be considered to have passed

the test only if during this new series of impulses there is no flashover or puncture.

The insulators shall not be damaged by the test but slight marks on the

surface of the insulating parts or chipping of the cement or other material used for assembly is permitted.

TESTING PROCEDURE FOR MECHANICAL STRENGTH TEST:

a) The complete disc insulator string consisting of number of units as

stipulated alongwith its hardware fitting excluding arcing horn, corona control ring/grading ring and suspension/dead end assembly shall be

mounted in the Tensile Testing Machine.

b)

c)

The assembly shall then be subjected to a tensile 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 maintained on the string for five minutes and then removed. After removal of the load the string shall be unloaded and dismantled with

hand or small hand tools and the string components shall be inspected for

visual deformation. Should any difficulty be experienced in dismantling and re-assembling the string with hand or small hand tool and/or if there is

any visual deformation caused by the application of the above load, the

string shall be deemed to have failed in this test.

If the string can be re-assembled, it shall again be mounted in the tensile

testing machine and loaded up to 50% of UTS and the load shall be further

increased at a steady rate till the specified minimum UTS is reached and held there 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. The string shall be deemed to have passed the test if the breakage occurs at a load not lower than guaranteed E&M strength.



8.0

a)

b)

9.0

10.0

11.0

11.1

a)

TESTING PROCEDURE FOR TIME LOAD TEST:

The insulator string shall first be subjected to 5 minutes power frequency

routine test. After successful completion of this test, the insulator string

shall be mounted vertically/horizontally and subjected to a load equal to

66% of the specified mechanical strength for duration of 24 hours.

After the completion of above period if the string is found to be intact on

visual examination, it shall again be subjected to 5 minutes power frequency routine test. The string shall be deemed to have passed the time

load test if it successfully withstands 5 minutes power frequency routine

test.

TESTING PROCEDURE FOR VOLTAGE DISTRIBUTION TEST:

The voltage across each insulator unit shall be measured by sphere gap

method. The result obtained shall be converted into percentage and

proportionate correction be applied so as to give a total of 100% distribution. The voltage across any disc shall not exceed the specified

values.

TESTING PROCEDURE FOR CORONA EXTINCTION

VOLTAGE TEST (Dry):

The sample assembly when subjected to power frequency voltage shall

have a corona extinction voltage of not less than the value specified under

dry condition. There shall be no evidence of corona on any part of the

sample when all possible sources of corona are photographed in a darkened room.

TESTS ON INDIVIDUAL DISCS:

VISUAL EXAMINATION:

Visual examination shall be made at random on the lot of insulators. The

color of the insulator shall approximate to the color specified. Some

variation of color shade is permitted and shall not justify rejection of the insulator. The insulator shall be free from physical distortion of shape

within tolerance specified. Defects such as looseness of pins/caps, cracks

etc. in the metal part shall be checked.



b)

c)

The area specified as glazed on the drawing shall be covered by a smooth

hard glaze, free from cracks and other defects prejudicial to satisfactory

performance in service.

Out of the areas specified as glazed on the drawing the total area not

covered by glaze shall not exceed.

1 + DF . cm2

2000

Also the area of any single glaze defect shall not exceed:

0.5 + DF . cm2

20000

Where:

D is the greatest diameter of the insulator in cm.

F is the creepage distance of the insulator in cm.

11.2

11.3

VERIFICATION OF DIMENSIONS:

The dimension of the insulator shall be checked with the approved

drawing. Unless otherwise specified, the tolerance in the diameter shall be:

± (0.04D + 1.5) mm for D less than or equal to 300 mm and

± (0.03D + 6) mm for D more than 300 mm.

Where: D = Specified insulator diameter in mm.

The tolerance in spacing shall be ± (0.03S + 0.3) mm.

Where: S = Specified insulator spacing in mm.

ECCENTRICITY TEST (AXIAL RUNOUT & RADIAL RUNOUT):

The insulator shall be vertically mounted on a fixture using dummy pin

and socket. A vertical scale with horizontal slider shall be used for the

axial run out. The pointer shall be positioned in contact with the bottom of

the outermost petticot of the disc. The disc insulators shall be rotated with reference to the fixture and the slider shall be allowed to move up and

down on the scale but always maintaining contact with the bottom of the

outermost petticot. After one full rotation of the disc the maximum and minimum position the slider has reached on the scale can be found out.


Volume-II / Section - IX EPC Tender for JITPL

Difference between the above two readings shall satisfy the guaranteed

value for axial run out.

Similarly, using a horizontal scale with vertical slider the radial run out

shall be measured. The slider shall be positioned on the scale to establish

contact with the circumference of the disc insulator and disc insulator

rotated on its fixture always maintaining the contact. After one full

rotation the maximum and minimum position of the slider reached on the

scale are found out. The difference between the above readings shall

satisfy the guaranteed value for radial run out.

11.4

11.5

11.6

DRY LIGHTNING IMPULSE VOLTAGE WITHSTAND TEST:

Please refer to Clause No. 6.0 for Testing Procedure.

WET POWER FREQUENCY WITHSTAND TEST:

Please refer to Clause No. 4.0 for Testing procedure.

RADIO INTERFERENCE VOLTAGE TEST:(As per IS 8263)

a) Insulator string or insulators shall be mounted as per mounting

arrangement given above (Clause 1). As radio interference level may be affected by fibres or dust setting on the insulator, the insulators may be

wiped with a clean cloth before taking a measurement. The atmospheric

conditions during tests shall be recorded. It is not known what correction

factors apply to radio interference testing, but it is known that test may be sensitive to high relative humidity exceeding 80%.

b)

c)

The test circuits may be either NEMA-107 or as per Fig.1 of IS: 8263. The

measuring set shall be tuned to 0.5MHz + 10% frequency and the results

shall be expressed as dB above 1 µ volt across a resistance of 300 Ohm.

A voltage of 10% higher than the specified test voltage shall be applied to

the object under test and maintained for at least 5 minutes. The voltage

shall then be decreased by steps down to 30% of the specified test voltage,

raised again by steps to the initial value and finally decreased by steps to

the 30% value. At each step, a radio interference level as recorded during third run v/s the applied voltage shall be plotted.

The curve so obtained is the radio interference characteristics of the

insulator. Each voltage step shall be approximately 10% of the specified

test voltage.



d)

The insulator unit passes the radio interference test if the radio

interference level at the specified test voltage, as read from the radio

interference characteristic, does not exceed the specified radio interference level. Furthermore, no sudden increase shall be found on the radio

interference characteristic between the specified test voltage and 1.1 times

the specified test voltage. Because of high variability, it is preferable to

make radio interference measurements on a number of insulators. The radio interference characteristic is the mean corona obtained after taking

into account all measurements made on insulators of one type.

11.7

TEST

PROCEDURE

FOR

THERMAL-MECHANICAL

a)

b)

c)

d)

e)

f)

PERFORMANCE TEST (As per IEC 575)

The test shall be conducted on string of 5 or 10 or 15 units.

This test has an initial stage of thermal cycles together with mechanical

loading and unloading and a concluding stage of testing the insulator units to failure. Such a failing load test constitutes the basis of the thermal

mechanical performance test in judging the test results.

During the initial stage of test, the insulator units shall be subjected to four

24 hours cycles of cooling and heating and to a tensile load equal to

60% of the specified electro-mechanical failing load. The tensile load shall be applied to the insulator units at room temperature before starting

the first thermal cycle.

Each 24 hours cycle shall comprise a cooling to -30 ± 50C and a heating

to +40 ± 50C. The temperature limits for temporary range of 40

0C may

be suitably changed where the prevailing conditions so require. The temperature sequence shall be first cooling, then heating. The temperature

equipment shall be such as to permit keeping of minimum and maximum

temperatures each for at least four consecutive hours of the temperature cycle.

The tensile load shall be completely removed and reapplied towards the

end of each heating period, the last one excepted.

On completion of the fourth 24 hours cycle and cooling to room

temperature the tensile load shall be removed on the same day. After this load removal, the insulator units shall be subjected individually to an

electromechanical strength test.

The performance of insulator unit will be determined by comparison of the

failing load values and the fracture pattern obtained during the

electromechanical strength test.



11.8

12.0

13.0

A)

1)

RESIDUAL STRENGTH TEST

The test shall be conducted in accordance with clause No. 4.4 and 4.5 of

IEC: 797 proceeded by temperature cycle test. The sample size shall be 25

and the evaluation of results and acceptance criteria shall be as per Clause

No. 4.6 of IEC: 797.

HYDRAULIC INTERNAL PRESSURE TEST ON SHELLS:

The test shall be carried out on 100% disc insulator shells before

assembly. The insulator should withstand required pressure for the preset

time of one second (min.) without breaking.

HIGH FREQUENCY TEST ON SHELLS:

The test shall be carried out on 100% disc insulator shells before

assembly. The insulators should withstand applied High Frequency

voltage for 5 minutes without puncture.

TESTS ON BOUGHT-OUT ITEMS:

Forged Components (Ball Pins):

a) Visual inspection: All material (100% samples) shall be visually checked

for forging defects and general appearance.

b)

c)

d)

e)

f)

Dimensional check: At random check of not less than 1 sample per lot.

The acceptance norm shall be dimensions as per drawing.

Guage Check: The test shall be conducted on 100% samples with ‘GO’

and ‘NO GO’ gauges. The acceptance norm shall be dimensions as per

approved drawing/relevant IS.

Normalising: Time temperature chart/Graph from output of recorder shall

be verified. The same shall conform to required standard.

Hardness test: The test shall be conducted on minimum of 2 samples per

lot of 1000 nos. The acceptance norm shall be hardness as per

IS:1500/175-210 BHN.

Grain Size: The test shall be conducted on minimum of 2 samples per lot

of 1000 nos. The acceptance norm shall be grain size of 6 microns and above (ASTM No. 6 and above).



g)

Inclusion rating : The test shall be conducted as per IS:4163 on minimum

of 1 sample per lot of 1000 nos. The acceptance norm shall be inclusion

rating of ASTM 2 thick series or less.

h) Chemical analysis: The test shall be conducted on minimum of 1 sample

per lot per heat no. The acceptance norm shall be chemical composition

as per BS:970 for EN-8D steel or equivalent.

i)

j)

2)

Failing Load test: At random check of not less than 2 samples per lot of

1000 nos. The sample shall be subjected to proof load limit and held for one minute. The load shall be released and there shall not be any crack or

permanent deformation. Thereafter, the sample shall be subjected to

further loading up to its recommended breaking load and actual breaking load shall be noted.

Magnetic Particle Examination: The test shall be conducted on 100%

samples as per IS:3703 for detection of longitudinal and transverse cracks. There shall not be any surface or sub-surface cracks.

Malleable Cast Iron Cap:

a) Visual inspection: All material (100% samples) shall be visually checked

for freedom from casting defects and identification mark. The surface shall be free from casting defects and shall be cleanly fettled. The cap

shall bear identification mark of the manufacturer.

b)

c)

d)

Dimensional check: At random check of not less than 1 sample per lot of

1000 nos. The acceptance norm shall be dimensions as per drawing.

Guage Check: The test shall be conducted on 100% samples with ‘GO’

and ‘NO GO’ gauges. The acceptance norm shall be dimensions as per

approved drawing/relevant IS.

Hardness test: The test shall be conducted on minimum of 2 samples per

lot of 1000 nos. The acceptance norm shall be hardness as per IS:2108/150

BHN max.

e) Chemical analysis: The test shall be conducted on minimum of 1 sample

per 5000 nos. The acceptance norm shall be chemical composition

confirming to grade BM:320 or equivalent.

f)

Failing Load test: At random check of not less than 2 samples per lot of

1000 nos. The sample shall be subjected to proof load limit and held for one minute. The load shall be released and there shall not be any crack or

permanent deformation. Thereafter, the sample shall be subjected to



further loading upto its recommended breaking load and actual breaking

load shall be noted.

g)

3)

Magnetic Particle Examination: The test shall be conducted on 100%

samples as per IS:3703 for detection of longitudinal and transverse cracks.

There shall not be any surface or sub-surface cracks.

Security clip:

a) Visual inspection: All material (100% samples) samples shall be inspected

for corrosion and surface irregularities. The acceptance norm shall be as

per IS:3063.

b)

c)

d)

e)

f)

B)

I)

1)

II)

1)

Dimensional check: At random check of not less than 1% sample per lot.

The acceptance norm shall be dimensions as per IEC:372/ IS:2486(IV).

Resistance to bending: At random check of not less than 1 sample per lot.

The acceptance norm shall be as per IEC:372/IS:2486(IV).

Operation test: At random check of not less than 1 sample per lot. The

acceptance norm shall be as per IEC:372/IS:2486(IV).

Hardness test: At random check of not less than 2 samples per lot. The

acceptance norm shall be hardness not less than 152 BHN for R-clip and

143 BHN for W-clip.

Chemical analysis: At random check of not less than 1 sample per lot. The

acceptance norm shall be chemical composition confirming to

AISI:304/316 grade as per ASTM A 276.

Hot Dip Galvanized components:

Test on Raw material

Chemical analysis of Zinc: At random check of not less than one sample

per lot. The acceptance norm shall be grade Zn98 (% of zinc > 99.95%) as

per IS:209.

Galvanizing checking:

Visual inspection: All material (100% samples) shall be visually checked

as per IS: 2629. The finished surface shall be clean, smooth and shall be

free from defects like discoloured patches, bare spots, unevenness of coating, spelter which is loosely attached to the steel, globules, spiky

deposits, blistered surface, flaking or peeling off etc.



2)

3)

4)

Uniformity of zinc coating: At random check of not less than 2 samples

per lot. The test shall be conducted as per IS: 2633 and the samples shall

withstand minimum 4 dips of 1 minute each in standard CuSO4 solution without showing signs of red deposits of copper.

Thickness of zinc coating: At random check of not less than 1 sample per

lot. The acceptance norm shall be thickness of coating not less than 610

gms/mm2.

Adherence of zinc coating: At random check of not less than 2 samples

per lot. There shall be no flaking or loosening when struck squarely with a

chisel faced hammer.



ANNEXURE-9

a) GUARANTEED TECHNICAL PARTICULARS FOR DISC INSULATOR

UNIT

Sr.

No.

1)

INSULATOR TYPE ►

PARTICULARS

▼

Manufacturers name, address

and country

160 KN

(N)

160 KN

(AF)

120 KN

(N)

120 KN

(AF)

2) Size and designation of Ball &

Socket and standard to which it will conform (mm)

3)

Outside diameter of

disc (mm)

4) Spacing (mm)

5)

a)

b)

Eccentricity of disc

Axial runout(mm)

Radial runout(mm)

6) Creepage distance of disc

(mm)

7) Electro-mechanical strength of

disc(KN)

8) Withstand voltage of disc

8.1 Power frequency

a) Dry (kV rms)

b) Wet (kV rms)



8.2 Impulse voltage (1.2/50 µsec)

a) +ve (kV peak)

b) −ve (kV peak)

Flashover voltage of

9 Disc

9.1 Power frequency

a) Dry (kV rms)

b) Wet (kV rms)

9.2 50% Lightning impulse

voltage (1.2/50 (sec)

a) (ve (kV peak)

b) (ve (kV peak)

10) Corona inception voltage (kV

rms)

11) Corona extinction

voltage (kV rms)

12) Max. RIV at 1 MHz

and 10 KV AC (rms)

13) Weight of each disc

(kgs)

Signature of the Bidder..........

Name.............................

Designation......................

Date.............................



Common authorized seal of the

bidder...............

b) GUARANTEED TECHNICAL PARTICULARS FOR DISC INSULATOR

STRING (400 KV)

Sr.

No.

1)

STRING TYPE ►

PARTICULARS

▼

No. of insulator discs per

string

SINGLE”I”

SUSPENS-

ION

(120 KN) N/AF

DOUBLE”I”

SUSPENS-

ION

(120KN) N/AF

QUAD

TENSIO

N

(160KN) N/AF

2) Withstand voltage

of complete string

2.1 Power frequency

a) Dry (kV rms)

b) Wet (kV rms)

2.2 Impulse voltage (1.2/50

µsec)

a) +ve (kV peak)

b) −ve (kV peak)

3) Flashover voltage

of complete string

3.1 Power frequency

a) Dry (kV rms)

b) Wet (kV rms)

3.2 50% Lightning impulse

voltage (1.2/50 µsec)

a) +ve (kV peak)

b) −ve (kV peak)



4)

Corona inception voltage

(kV rms)

5) Corona extinction

voltage (kV rms)

6) Max. RIV for complete

string including corona rings,

arcing

horns, clamps

etc. at 1.1 times maximum line to ground voltage

(in (volts)

7) Max. voltage (%)

across any disc

in the string

8) Electromechanical

strength of complete string

(KN)

Signature of the Bidder..........

Name.............................

Designation......................

Date.............................

Common authorized seal of the

bidder...............



ANNEXURE –10

1.0

1.1.

1.2.

1.3.

1.4.

1.5.

Tests on Complete Strings with hardware Fittings

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 9% for suspension insulator strings and l0% for tension

insulator strings.

Corona Extinction Voltage Test (Dry)

The sample assembly when subjected to power frequency voltage shall have a

corona Extinction voltage of not less than 320 kV (rms) line to ground under

dry condition. There shall be no evidence of corona on any part of the sample.

The atmospheric condition during testing shall be recorded and the test results; shall be accordingly corrected with suitable correction factor as stipulated in

IEC:383.

RIV Test

Under the conditions as specified under (2) above, the insulator string alongwith

complete hardware fittings shall have a radio interference voltage level below 1000 micro volts at one MHz when subjected to 50 Hz AC voltage of 305kV

line to ground under dry condition. The test procedure shall be in accordance

with IS:8263/IEC-437

Mechanical Strength Test

The complete insulator string alongwith 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.

Vibration Test

The suspension string shall-be tested in suspension mode, and tension string in

tension mode itself in laboratory span of minimum 30 meters. 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 alongwith



hardware fittings and two/four sub-conductors each tensioned at 43KN incase of

ACSR Moose/AAAC Moose shall be secured with clamps. The system shall be

suitable to maintain constant tension on each sub- conductors throughout the duration of the test. Vibration dampers shall not be used on the test span. Both

the sub-conductors shall be vertically vibrated simultaneously 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 f is the frequency of vibration in

cycles/sec. The insulator string shall be vibrated for not less than 10 million cycle; 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 disc insulators

after the vibration test. The disc insulators shall be subjected to the following

tests as per relevant standards:

Sr.No. Test Percentage of insulator units to be tested

Disc Insulators Long Rod Insulators

a)

b)

1.6.

Temperature cycle test followed 60

by mechanical performance test

Puncture test/steep wave front test 40

(only for glass insulators)

Power Arc test

100

This test shall be performed on the complete string in accordance with IEC

Technical Report IEC:61467-1997 with the following test series:

Test circuit

B

Short circuit current

In = Isys = 40 KA

Number and duration of test

Two of tn = 0.2s and

One of tn = 0.5 s

2.0

2.1.

The acceptance criteria after the completion of test series shall be following

a) Insulation separation not permitted.

b) Burning/Melting of metal components, breakage of insulator sheds, glaze

removal are permitted.

c) The complete insulator string alongwith its hardware fittings including arcing

horn, corona control ring/grading ring shall withstand 80% of UTS.

Tests on Hardware Fittings -

Magnetic Power Loss Test for Suspension Assembly



Four hollow aluminium tubes of 32 mm diameter shall be placed 457 mm apart

respectively and alternating current over the range of 400 to 800 amps shall be

passed through each tube. The reading of the watt meter with and without two suspension assembly alongwith line side yoke plate, clevis eye 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 600 arnperes shall be read off from the graph.

2.2.

2.3.

2.4.

2.5.

2.6.

2.7.

Galvanising/Electroplating Test

The test shall be carried out as per.Clause no. 5.9 of lS:2486-(Part-l) except that

both uniformity of zinc coating and standard preecee test shall be carried out

and the results obtained shall satisfy the requirements of this specification.

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.

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-penetration / ultrasonic

test. There shall not be any crack at the welded portion.

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 ACSR MOOSE 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 Camp slip

strength vs torque curve shall be drawn. The clamp slip strength at the recommended torque shall be more than 20kN but less than 29kN

Shore HardnessTest for Elastomer Cushion

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

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 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.

2.9.

2.10.

3.0

3.1.

3.2.

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.

Mechanical Strength test for suspension/tension hardware fittings

The complete string without insulators- excluding arcing horn, corona control

rings/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. 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 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.

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 2x magnification.

Tests on Conductor and Earthwire Accessories

Mid Span Compression Joint for Conductor and Earthwire -

Slip Strength Test

The fitting compressed on conductor/earthwire shall not be less than one meter

in length. The test shall be carried out as per IS:2121 (Part-II) Cause 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.

T-Connector

Axial Tensile load test for welded portion

The sleeve portion of the T-Connector shall be compressed on Conductor. The

compressed portion shall be held rigidly on some fixtures and axial load shall be

applied alongwith the jumper terminal. The load shall be increased gradually till

breaking of welded joint occurs. The breaking load should be above 30 KN



3.3.

3.4.


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.


(a) Dynamic Characteristic 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 10 to 60

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

±0.5mm 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 resonance

frequencies shall be suitably spread between the Aeolian vibration frequency

band between the lower and the upper dangerous frequency limits determined by the vibration analysis of earthwire without dampers.

Acceptance criteria for vibration damper

(i) The above dynamic characteristic tests on five dampers 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 0.060f to

0.357f kgf/mm limits for earthwire damper where f is frequency in Hz.

(iv) The above mean phase angle response curve shall be between 25° to 130°

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.

(b) Vibration Analysis

The vibration analysis of the 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 borne for single earthwire without armour rods as per

the parameters given under clause 2.7.13 and 3.3.8 of this part of the

Specification. The tension shall be taken as 14 kN for earthwire for as span

ranging from 100m to 1100m.

(ii) The self damping factor and flexural stiffness (El) for conductor and

earthwire shall be calculated on the basis of experimental results. The details of

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 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.

(vi) From vibration analysis of 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 earthwire with the damper/dampers installed at

the recommended location, the dynamic strain level, at the clamped span

extremities, damper attachment point and the antinodes on the earthwire shall be determined in addition to above damper clamp vibration amplitude and anti

node vibration amplitude shall also be examined

The dynamic strain levels al damper attachment points, clamped span

extremities and the antinodes shall not exceed the specified limits. The damper

clamp vibration amplitude shall not be more than that of the specified fatigue limits.

(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 30 m. The earthwire shall be tensioned at 14 kN and shall not be equipped with protective armour rods at any point Constant

tension shall be maintained within the span by means of lever arm arrangement

After the earthwire has been tensioned, clamps shall be installed to support the

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 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 inducing equipment suitable for

producing steady standing vibration. The inducing equipment shall have



facilities for stepless 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 lightning with the manufacturer’s specified tightening torque, when

subjected to a longitudinal pull of 2.5 kN parallel to the axis of 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 manufacturer’s

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 10 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.

The clamp slip test as mentioned hereinabove shall be repeated after fatigue test

without re-torquing 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 earthwire

under clamp shall also be free from any damage.

For the purpose of acceptance, the following criteria shall he applied

(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 comparision with that before fatigue test by the

Contractor



(3) The power dissipation of the damper shall not be less than guaranteed %

variation in power dissipation before fatigue test by the Contractor. 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.

3.5. Spacer Damper

a) Performance Test

One very important quality of a spacer damper is its ability to control Aeolian

vibrations and sub-span oscillations within acceptable limits. Performance

testing shall be carried out on an experimental test line, as described in

Clause2.5.5 of this Section. After testing there shall not be any slippage greater

than 3mm on conductors loosening of component or damage to conductors or

spacer damper components.

i) Aeolian Vibrations

Under the specified operating conditions the spacer damper shall control

Aeolian vibrations in order to prevent damage to conductors either at

suspensions clamp or at the spacer damper clamps.

For measurements and evaluation purpose, the following criteria shall apply

The peak to peak amplitude of any vibration cycle shall never exceed 1.5 yb,

where yb is the safe “Bending Amplitude’.

The RMS value of any vibration measurement sample shall be lower than 0.6

yb/2, at 89 mm from last point of contact with suspension or spacer clamp.

Sub-span Oscillationsii)

The spacer damper system shall control sub-span oscillations in order to prevent

conductor damage due to clashing or to severe bending stresses at the spacer

damper clamp, and avoid wear of spacer dampers elements.

In order to achieve the performance level sub-span shall be controlled within the

following limits for any wind speed below 60km/hr.

In any individual sub-span the peak to peak amplitude of each sub-conductor

shall never exceed 350mm.

In any individual sub-span, the RMS value (Yrms) of each oscillation

measurement sample shall be such that:

f Yrms<80mm/sec.

Where

Yrms=anti-node amplitude(mm)

f=frequency of the oscillation (cycles/sec)

f=(1/2)

L=Sub-span length (m)

T=Conductor tension (N)



m=Conductor mass (kg/m)

For any set of 10 or more measurement samples associated with a given wind

sector and a given sub-span, the Yrms value shall be such that:

f.Yrms

The wind sector is defined as a combination of 5 km/hr wind speed range and

10 deg.C wind direction range

Each measurement sample shall be at least one (1) minute long.

b) Clamp Slip Test (for spacer for jumper also)

The spacer damper assembly shall be installed on a four conductors bundle

string at a tension of 41 kN. In case of spacer for juniper, the clamps of sample shall be tightened with a specified tightening torque. One of the sample clamps,

when subjected to a longitudinal pull of 2.5 KN parallel to the conductor axis

for a minimum duration of one minute, shall not slip on the conductor i.e. the permanent displacement between the conductor and the clamp of the sample

measured after removal of the load shall not exceed 1.0 mm. Similar testing

shall be performed of the other clamps of the same sample. For spacer dampers

only, such clamp slip tests shall also be conducted after each of the vibration tests mentioned in Clause 5 (a) but under longitudinal load of 2 KN for a

minimum duration of one minute after vibration test without any adjustment of

sample.

Dynamic Characteristic Test for Spacer Damperc)

The purpose of this test is to obtain quantitative information regarding the

dynamic characteristic of the spacer damper. The values obtained during this test will serve as references to evaluate the behaviour of the same spacer damper

under the fatigue test

The test will consist in the application of sinusoidal movement to the spacer

damper articulation and measurement of the force (F), displacement (X) and

phase angle between these two. From these values, the stiffness (K) and

damping factor (n) shall be calculated as:

K = F cos Φ/ Xn = cos Φ

The test frequency shall not be higher than 3 Hz. The test shall be performed at

five different displacement amplitudes. The amplitudes shall be selected to

reproduce 10, 20, 40, 60 and 90 per cent of the maximum displacement

permitted by the spacer damper design.

The test shall be performed on three samples.

In case of spacer dampers with a single articulation for each arm, the central

body shall be fixed and the arm rotated around the axis of the articulation in a

plane perpendicular to the conductor.

For spacer dampers using double articulated arms, the sinusoidal movement

shall be applied between two arms corresponding to a horizontal pair of



conductors. In this case, one spacer clamp may be fixed and the other displaced

in its direction, the central body being free to move.

d) Fatigue Test for Spacer Damper

The purpose of this test is to evaluate the capacity of the spacer damper to

sustain without damage the cyclic movements which can be induced by

vibrations.

The spacer damper articulation shall be subjected to cyclic motions for a total of

10 million cycles. The test frequency shall be between 2 and 3 Hz. The

amplitude of motion shall be established on the following bases.

-

-

the load applied on the spacer damper clamp shall not be less than 300N;

the clamp displacement under the applied load shall not be less than 60%

of the maximum displacement permitted by design;

- if the 300N toad generates movement exceeding the maximum permitted

displacement, the load can be reduced to limit the movement to 95% of the

maximum displacement.

3.6.

- After the test, the sample shall be subjected lo a second dynamic

characteristic test. This test shall be performed at two amplitudes, 10%

and 60% of the maximum displacement

- The spacer damper shall show no signs of cracks or deterioration,

loosening of bolts or abnormal wear

The dynamic characteristics (k and n) shall be less than 60% of the values

measured before the fatigue test. The test shall be performed on three samples.

Ozone Teste)

This test shall be performed on elastomer/rubber components in accordance

with ASTMD-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 2x magnification.

f) Compression and Tensile Tests

Three samples of spacer dampers shall be subjected to a tension compression

test. The load shall be applied between each pair of diagonally opposed

conductors. Under the compressive load, the arms shall be allowed to rotate

until they reach their mechanical stops. A compressive load of l5kN shall first be applied and held for five minutes. Then a tensile load of 5kN shall be applied

on the same pair of arms. The test shall be repeated on the other pair of arms.

After the test, the spacer damper must be dismantled and the components examined. There should not be any failure of components or damage impairing

the reusability of the spacer damper such as permanent deformation. The spacer

geometry shall be maintained within 5 % of the original dimensions.

Magnetic Power Loss Test for Spacer Damper/Spacer for Jumper



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 amperes to 900 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 600 amperes current (rms) for ACSR

MOOSE conductor. The losses shall be determined by averaging the observations obtained from atleast four Samples.

3.7. Earthwire Suspension/Tension Clamp

a) Mechanical Strength Test

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 increased until the

failing load is reached and the value recorded.

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 Earthwire shall be fixed by 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 damp slip strength at the recommended tightening torque shall be more than 12kN but less than l7kN for7/3.66mm earthwire.

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 easily 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 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.

3.8.

3.9.

3.10.

4.0

4.1.

4.2.

4.3.

Corona Extinction Voltage Test (Dry)

The sample when subjected to power frequency voltage shall have a corona

extinction voltage of not less than 320 kV rms line to ground under dry

condition. There shall be no evidence of corona on any part of the sample. The atmospheric condition during testing shall be recorded and the test results shall

he accordingly corrected with suitable correction factor as stipulated in IS: 731.

Radio Interference Voltage Test (Dry)

Under the conditions as specified under (3.8) above, the sample shall have a

radio interference voltage level below l000 microvolts at one MHz when subjected to 50 Hz AC voltage of 305 kV rms line to ground, under dry

condition. The test procedure shall be in accordance with IS: 8263

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.

Tests on All components (As aplicab1e)

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%.

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

Contractor and Owner in Quality Assurance Programme.

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 Contractor and Owner in Quality Assurance Programme.



ANNEXURE-11

ACCEPTANCE TESTS

1.

2.

3.

4.

Mid Span Compression Joint for Conductor and Earthwire

Hardness Test

The Brinnel hardness at various points on the steel sleeve of conduction core

and of the Earthwire compression point and tension clamp shall be measured.

T-Connector for Conductor

(a) Axial Tensile Load Test for Welded Portion

Same as clause 3.2 of Annexure - 10

Flexible Copper Band

(a) Slip Strength Test

Same as clause 3.3 of Annexure-10


(a) Verification of Resonance 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 Cause 3.4 (c) (ii) of Annexure – 10

(c) Clamp Bolt Torque Test

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

percent of the manufacturer’s 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 3.4 (c) (i), Annexure-10.

(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.. Alternatively

each strand of message caste may be fixed in a suitable tensile testing machine and the tensile load shall be gradually applied until yield point is reached. In

such a case, the 95% of yield strength of each wire shall be added to get the

total strength of the caste. The load shall be not less than, the value guaranteed by the Contractor

(e) Mass Pull off Test



Each mass shall be pulled off in turn by fixing the mass at one jaw and the

clamp in the other of a suitable tensile testing machine. The longitudinal pull

shall be applied gradually till the mass begins to pull out of the messenger cable.

The pull off loads shall not be less than the value guaranteed by the Contractor.

(f)

5.

Dynamic Characteristics Test

The test will be performed as acceptance lest with the procedure mentioned for

type test with sampling mentioned below

Vibration Damper of - 1 Sample for 1000 No,. & below

Conductor - 3 Samples for lot above 1000 & upto 5000

nos

- Additional 1 sample for every additional

1500 pieces above 5000.

The acceptance criteria will be as follows:

(i) The above dynamic characteristics curve for reactance & phase angle will be

done for frequency range of 10Hz to 60Hz for vibration damper for 7/3.66-mm

earthwire.

(ii) If all the individual curves for dampers are within the envelope as already

mentioned for type test for reactance & phase angle, the lot passes the test.

(iii) If individual resu1ts do not fall within the envelope, averaging of

characteristics shall be done.

(a) force of each damper corresponding to particular frequency shall be taken &

average force of three dampers at the frequency calculated.

(b) Similar averaging shall be done for phase angle.

(c) Avenge force Vs frequency and avenge 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.

Spacer Damper/ spacer for jumper

(a) Test Set-up.

The test set-up shall be as per Clause 3.4 (c) (i) of Annexure-10.

(b) Movement Test

The spacer assembly shall be capable of the following movements without

damaging the conductor, assuming one conductor is fixed and the other moving

(i) Longitudinal movement ±50mm

parallel to the conductor

(ii) Vertical movement in a vertical direction ±25 mm

at right angle to the conductor



(iii) Torsional movement/angular movement in a

vertical plane parallel to the conductor

(c) Compressive and Tensile Test

±5 deg.

Test procedure shall be same as specified in Clause 3.5 (c) of Annexure-10.

(d) Clamp Slip Test

Same as clause 3.5(b) of Annexure-10

(e) Clamp Bolt Torque Test

The spacer assembly shall be attached to conductor. A torque of 150 per cent of

the manufacturers specified tightening torque shall be applied to the clamp bolts

or cap screws. There shall be no failure of the component parts.

(f) Assembly Torque Test

The spacer assembly shall be installed on conductor. The same shall not rotate

on either clamp on applying a torque of 0.04 kN in clockwise or anti clockwise

direction.

(g) Hardness test for Elastomer

The shore hardness at different points on the elastomer surface of cushion grip

clamp shall be measured by shore hardness meter. They shall lie between 65 to

80.

(h) UTS of Retaining Rods

The ultimate tensile strength of the retaining rods shall be measured. The value

shall not be less than 35 kg/sq. mm.



ANNEXURE-12

GUARANTEED TECHNICAL PARTICULARS OF

SUSPENSION HARDWARE FITTINGS FOR MOOSE ACSR

CONDUCTOR

`Description Unit

Value Specified by the

Owner

Value Guaranteed by the

Bidder

Name of Manufacture

Address of Manufacturer

Maximum magnetic power loss of

suspension assembly at conductor

current of 600 amps.

Slipping Strength of suspension

assembly (clamp torque Vs slip curve

shall be enclosed)

Particulars of standard / AGS preformed

armour rod set for suspension assembly

No. of rods per set

Office

Works

Watt /

ASS

KN

No.

Double “I”

Suspension

AGS

Twin ACSR

Moose

Less than 4

watt

20 to 29 KN

12

Single

Suspension

(Pilot)

Envelope

Twin ACSR

Moose

Less than 8

watt

N.A.

Double “I”

Suspension

AGS

Twin ACSR

Moose

Single

Suspension

(Pilot)

Envelope

Twin ACSR

Moose

Direction of lay

Overall length after fitting on conductor Mm

Right Hand

2235

N.A.

N.A.

Actual length of each rod along its helix Mm 2385 Approx N.A.


263

`Description Unit


Value Specified by the Value Guaranteed by the

Owner Bidder

Diameter of each rod

Tolerance in

Diameter of each rod

Length of each rod

iii) Difference of length between the longest

and shortest rod in a set

Type of Aluminium alloy used for

manufacture of PA rod set

UTS of each rod

Particulars of Elastomer (for AGS

Clamp only)

Mm

+-mm

+-mm

+-mm 13

Kg/sq.mm

Double “I”

Suspension

AGS

Twin ACSR

Moose

9.27

0.10

25

Alu-Alloy 6061

35

Single

Suspension

(Pilot)

Envelope

Twin ACSR

Moose

N.A.

N.A.

N.A.

N.A.

N.A.

Double “I”

Suspension

AGS

Twin ACSR

Moose

Single

Suspension

(Pilot)

Envelope

Twin ACSR

Moose

Contractor of elastomer Owner Approved supplier

Type of elastomer

Neoprene

Rubber

N.A.

Shore hardness of elastomer

Temperature range for which elastomer

is designed

65 To 85

B.H.N.

UPTO 85oC

N.A.

e) Moulded on insert Yes/No Yes N.A.


264

`Description Unit


Value Specified by the Value Guaranteed by the

Owner Bidder

UTS of Hardware Component indicated

in the drawings enclosed with the bid

Purity of Zinc used for galvanizing

Min No of dips in standard precee test

the ferrous parts can withstand

Double “I”

Suspension

AGS

Twin ACSR

Moose

Yes/No Yes Yes

99.95

i) Fasteners 4

dips

ii) Sp. Washers

3 dips

iii) Other

Ferrous parts 6

dips

Single

Suspension

(Pilot)

Envelope

Twin ACSR

Moose

99.95

i) Fasteners 4

dips

ii) Sp. Washers 3

dips

iii) Other Ferrous

parts 6 dips

Double “I”

Suspension

AGS

Twin ACSR

Moose

Single

Suspension

(Pilot)

Envelope

Twin ACSR

Moose


265

Sr.No. Description

1. Name

of manufacturer


GUARANTEED TECHANICAL PARTICULARS OF

TENSION HARDWARE FITTINGS FOR

MOOSE ACSR CONDUCTOR

Unit Value Specified Value

by the Owner Guaranteed b

the Bidder

Address of manufacturer

Dimensional Drawing of Insulator Strings (with Disc/Long Rod

Insulator) enclosed

Detailed dimensioned drawings of all Hardware Components

enclosed

Material of Component enclosed in the drawing

Electrical resistance of dead end assembly as a percentrage of

equivalent length of conductor.

Slip strength of dead end assembly

Total weight of Tension Assembly

UTS of hardware components indicated in the drawing enclosed

with the bid

Purity of Zinc used for galvanizing

Min No. of dips in standard process test the ferrous parts can

withstand

Yes/No Yes

Yes/No

%

KN

Kg

KN

%

Fasteners

Quad Tension /

Single Tension

Yes

Less Than 75

154

260

(Approx)/91

(Approx)

640 for QT/120

for ST

99.95

4

Dips & Spring


266


Design calculation of Yoke Plates and Sag Adjustment Plate

enclosed

Washers

Yes/No Yes

3

Dips, Other

Ferrous parts 6

Dips

Yes, shall be

submitted


267



MID SPAN COMPRESSIOIN JOINT FOR

ACSR MOOSE CONDUCTOR

Sr.No

.

1.

2.

3. 4.

5.

i)

ii)

iii)

6)

a)

b)

7)

a)

b)

8)

i)

ii)

9)

a)

i)

ii)

Description


Drawing enclosed

Suitable for conductor size Purity of Aluminium Aluminium

alloy used for Aluminium sleeve

Material of steel sleeve

Type of material with chemical

composition

Range of Hardness of material

(Brinnel Hardness)

Weight of zinc coating

Outside diameter of sleeve before

compression

Aluminium

Steel

Inside diameter of sleeve before

compression

Aluminium

Steel

Length of sleeve before

compression

Aluminium Steel

Dimensions of sleeve after

compression

Aluminium

Corner to corner

Surface to surface

Unit

mm

gm/m2

mm

mm

mm

mm

mm

mm

mm

mm

Value Specified by

the Owner

Yes

31.77

E.C grade

Aluminium purity not Less than 99.5%

Mild Steel (H.D.G)

Mild Steel Fe-410,

As per IS : 2062

From : 120 To : 200

610

54±1

21±0.5

34±0.5 11.1±0.2

735±5

250±5

53±0.5

46±0.5

Value

Guaranteed by Bidder



Sr.No

.

b)

i) ii)

10)

i)

ii)

11)

a)

b)

c)

12)

13)

14)

15)

Description

Steel

Corner to corner Surface to surface

Length of sleeve after compression

Aluminium

Steel

Weight of sleeve

Aluminium

Steel

Total

Slip Strength

Resistance of the compressed unit

expressed as percentage of the

resistivity of equivalent length of bare conductor

Minimum Corona extinction

voltage under dry condition

Radio interference voltage at

IMHZ for phase to earth voltage of 305 KV under dry condition

Unit

mm mm

mm

mm

kg

kg

kg

KN

%

KV

(rms)

Micro

volts

Value Specified by

the Owner

20.2±0.5

17.5±0.5

785 (Approx)

286 (Approx)

2.56 (Approx)

0.49 (Approx)

3.05 (Approx)

154 (Min)

75

320 phase to earth

Less than 1000

Value

Guaranteed by Bidder


Sr.No

Description

Volume-II / Section - IX EPC Tender for


REPAIR SLEEVE FOR ACSR MOOSE CONDUCTOR

Unit Value Specified by the Owner Value Guaranteed by the Bidder


Drawing enclosed

Suitable for conductor size

Purity of Aluminium Aluminium

alloy used for Aluminium sleeve


compression

Outside diameter of sleeve before

compression

Diameter before compression

Diameter after compression

Length of sleeve

Weight of sleeve


expressed as percentage of the

resistivity of equivalent length of

mm

mm

mm

mm

mm

kg

%

Yes

31.77

E.C grade Aluminium purity not

Less than 99.5%

34±1

54±1

Corner Surface

to Corner to Surface

3±1 46±1

Before After

Compression Compression

300±5 340(approx)

1.060 (approx)

75


270

Sr.No

Description

bare conductor


Unit Value Specified by the Owner Value Guaranteed by the Bidder

Minimum Corona extinction

voltage under dry condition

Radio interference voltage at 1

MHZ for phase to earth voltage of

305 KV under dry condition

KV

(rms)

Micro

volts

320 phase to earth

Less than 1000


271



SPACER DAMPER FOR TWIN ACSR MOOSE CONDUCTOR

Sr.

No.

1.

2.

a) b)

3.

4.

a) b)

c)

d)

5.

a)

b) c)

d)

6.

a)

b)

c)

d)

e) f)

7.

Description Unit

Manufacturer’s Name and Address Office

Works

Drawing enclosed

Design Drawing Yes/No Placement Chart Yes/No

Suitable for Conductor size Mm

Material of Component parts

Insert Damping Ball/Clamp

Main Body

Retaining Rods (if any)

Manufacturing process for

Insert

Damping Ball/Clamp Main Body

Retaining Rods (If any)

Retaining Rods (if any)

Type of Alloy used

Number of retaining rods used for

Each Spacer Damper Diameter

Length

Weight Minimum ultimate tensile strength

For retaining rods

Elastomer (if used)

Value Specified

by the Owner

Yes

Yes

31.77

---

Aluminium Alloy

Aluminium Alloy ---

-----

Die Casting Die Casting -------

N.A.

N.A.

N.A.

N.A. N.A.

N.A.

Value

Guaranteed by

the Bidder



Sr.

No.

a)

b)

c)

d)

e)

f)

8.

a)

b)

9.

10.

11.

a)

b)

12.

13.

i)

ii)

14.

15.

Description Unit

Contractor

Type

Moulded on insert

Shore hardness

Thickness on insert mm

Temp. range for which designed oC

Minimum ultimate tensile strength

Of Spacer

Compressive load KN Tensile load KN

Weight of Spacer Damper Kg.

Designed Clamping torque (if Kg.m

applicable) Slipping strength of

Before Vibration Test KN

After Vibration Test KN

Magnetic Power Loss per Spacer Watts

for 600 Amps. 50 Hz Alternating

Current

Electrical Resistance of Elastomer

cushioned Spacer Maximum KOhm

Minimum KOhm

Minimum Corona Extinction KV(rms

Voltage (phase to earth) under Dry )

condition

Radion Interference Voltage at 1 Micro MHz for phase to earth voltage of Volts

305 KV under Dry condition

Value Specified

by the Owner

PGCIL/PGCIL

approved supplier Synthetic Rubber

No

50 to 60

N.A.

Upto 85

14

7

5.7 (approx)

4

6.5

5.2

Less than 1

1000

10

320

Below 1000

Value

Guaranteed by the Bidder




RIGID SPACER DAMPER FOR TWIN ACSR MOOSE CONDUCTOR

Sr.No. Description

1. Manufacturer’s Name and Address

2. Drawing enclosed

a) Design Drawing b) Placement Chart

3. Suitable for Conductor size

4. Material of Component parts (Indicate i.e. of alloy)

a) Insert / (clamp)

b) Main Body

5. Manufacturing process for

a) Insert / (clamp) b) Main Body

6. Elastomer (if used)

a) Contractor

b) Type

c) Moulded on insert d) Shore hardness

e) Thickness on insert

f) Temp. range for which designed

7. Minimum ultimate tensile strength

Of spacer

a) Compressive load b) Tensil load

8. Weight of

a) Spacer for jumper

9. Slipping strength of spcer clamp

a) Before vibration test

Unit

Office

Works

Yes/No

Yes/No

mm

Mm

Deg.C

KN

KN

Kg

KN

Value Specified

by the Owner

Yes

Yes

31.77

---

Aluminium Alloy LM-6

Aluminium Alloy

LM-6

Die Casting

Die Casting

N.A.

N.A. N.A.

N.A.

N.A. N.A.

14

7

4.0 (approx)

2.5

Value Guaranteed

by the Bidder



b)

10.

11.

12.

13.

After vibration test

Magnetic power loss per spacer for

600 Amps. 50 Hz Alternating

Current

Electrical resistance of elastomer

cushioned spacer

Minimum corona extinction voltage

(phase to earth) under Dry condition

Radio interference voltage at 1 MHz

for phase to earth voltage of 305 Kv

under dry condition

KN

Watts

Kv

(rms)

Micro

volts

2.0

Below 1

N.A.

320

Below 1000




T CONNECTOR FOR TWIN ACSR MOOSE CONDUCTOR

Sr.No. Description


2. Drawing enclosed

Unit Value Specified

by the Owner

Yes

Value Guaranteed

by the Bidder

3. Suitable for conductor size

4. Purity of Aluminium used for T- connector

mm 31.77 99.5%

5.

6.

a)

b)

i)

ii)

7.

a) b)

8.

9.

10.

11.

12.

13.


compression

Outside dimensions of sleeve

Diameter before compression

After compression

Corner to Corner

Surface to Surface

Length of sleeve

Before compression After compression

Angle of leg sleeve of T-Conductor

From vertical axis

Weight of sleeve

Axial Tensile strength of welded

portion of T-conductor

Resistivity of the compressed jumper

as a percentage of equipment length of bare conductor

Minimum corona extinction voltage

under dry conduction. Radio interference voltage at 1MHZ

for phase to earth voltage of 305 KV

(dry condition)

mm

mm

mm

mm

mm

mm

Kg

KV

(rms) Micro

Volts

34±0.5

54±1

53±0.5

46±0.5

400±5

420 (Approx)

15o (Approx)

4.4 (Approx)

30 KN

75%

Not less than 320

Less than 1000

Micro Volts




MID SPAN COMPRESSION JOINT FOR

7/3.66 MM GALVANISED STEEL EARTHWIRE

Sr.No. Description


2. Drawing enclosed

3. Material of joint i) Type of material with chemical

composition

ii) Range of hardness of the steel sleeve

(Brinnel hardness)

4. Inside diameter of sleeve before

compression

Unit Value Specified

by the Owner

Yes

Mild Steel

Mild Steel Fe-

410, As per IS:2062

Not exceeding

200

Value Guaranteed

by the Bidder

i) Steel sleeve ii) Aluminium sleeve

iii) Aluminium filler sleeve

5. Outside dimensions of sleeve

Mm Mm

Mm

11.5 ± 0.2 22 ± 0.5 11.5 ± 0.2

a)

b) c)

6.

a)

i)

ii)

b)

i) ii)

7.

a)

Steel sleeve

Aluminium sleeve Aluminium filler sleeve

Outside dimension of sleeve after

compression Steel sleeve

Corner to corner

Surface to surface

Aluminium cover

Corner to corner Surface to surface

Length of steel sleeve

Before compression

Mm

Mm Mm

Mm

Mm

Mm

Mm

Mm

21 ± 0.5 32 ± 0.5 21 ± 0.5

20.2±0.5

17.5±0.5

29.4 ± 0.5

25.0 ± 0.5

230 ± 5



b)

8.

9.

a)

b)

c)

10.

11.

After compression

Length of Aluminium sleeve

Weight of sleeve

Steel

Aluminium

Aluminium filler sleeve

Slip strength


expressed as a percentage of the resistivity of equivalent length of

bare earthwire

Mm

Mm

Kg.

Kg

Kg

KN

%

265 (Approx)

Before

Compression

400 ± 5

After Compression

435 (Approx)

1 (Approx)

65

Less than 75




FLEXIBLE COPPER BOND

Sr.No. Description


2. Drawing enclosed

3. Stranding

4. Cross sectional area

5. Minimum copper equivalent area 6. Length of copper cable

7. Material of lugs

8. Bolt Size

i) Diameter ii) Length

9. Resistance

10. Total weight of flexible copper bond

Unit

Sq.mm

Sq.mm Mm

Mm

Mm

Ohm

Kg

Value Specified

by the Owner

Yes

37/7/0.417

35 34

500 / +5-0

Tinned Copper

16mm

40mm

0.001429 (Approx)

0.55 kg

(Approx)

Value Guaranteed

by the Bidder




VIBRATION DAMPER FOR 7/3.66 MM EARTHWIRE

Sr.No. Description


2. Drawing enclosed

a) Design drawing

b) Placement chart 3. Suitable for earthwire size

4. Total weight of one damper

5. Diameter of each damper mass

6. Length of each damper mass

7. Weight of each damper mass

8. Material of damper masses 9. Material of clamp

10. Material of stranded messenger cable

11. Number of strands in stranded

messenger cable

12. Lay ratio of stranded messenger cable

13. Minimum ultimate tensile strength of

stranded messenger cable 14. Slip strength of stranded messenger

cable (Mass pull off)

15. Resonance frequencies a) First frequency

b) Second frequency

16. Designed clamping torque

17. Slip strength of damper clamp a) Before fatigue test

b) After fatigue test

18. Percentage variation in Reactance after fatigue test in comparision with

that before fatigue test.

19. Percentage variation in power dissipation after fatigue test in

comparision with that before fatigue

test.

Unit

Yes/No

Yes/No Mm

Kg

Mm

Mm

Kg

Kg/sq.

mm

KN

Hz

Hz

Kg-m

KN

KN

±%

±%

Value Specified by the

Owner

Yes Yes 10.98 2.3 (Approx) Right Left

45±2 40±2

135±5 125±5

0.95±3% 0.7±3% Cast Iron

Aluminium Alloy A-6

High Tensile Steel Wire

19

9 to 11

135

2.5

Right Left

18.5±2 12±1

46±2 30±2 4

2.5

2.0

±20

20

Value

Guaranteed

by the Bidder




SUSPENSION CLAMP FOR 7/3.66mm GALVANISED STEEL EARTHWIRE

Sr.No. Description


2. Drawing enclosed

3. Material

i) Shackle

ii) Clamp Body & Keeper iii) U-Bolt

4. Total drop (maximum)

Unit Value Specified by

the Owner

Yes

Forged Steel

Malleable Iron H.D.G

Mild Steel H.D.G.

Mm 150

Value

Guaranteed

by the Bidder

5. Weight 6. Breaking strength (minimum)

7. Slipping strength

8. Tightening Torque

Kg Kgf

KN

Kgm

3.2 (Approx) 2550 12 to 17 5




TENSION CLAMP FOR 7/3.66 MM EARTHWIRE

Sr.No. Description


2. Drawing enclosed

3. Material

i) Shackle

ii) a) Compression clamp

b) Hardness of the material

(BHN) 4. Inside diameter of the sleeve before

compression

i) Steel Sleeve ii) Aluminium Sleeve


5. Outside dimension of sleeve

a) Before compression i) Steel sleeve

ii) Aluminium Sleeve


Unit

Yes/No

Mm

Mm

Mm

Mm

Mm

mm

Value Specified

by the Owner

Yes

Forged steel

Mild Steel with

Aluminium

encasing

Not exceed 200

11.5±0.2

22.0±0.5

11.5±0.2

21±0.5

32±0.5 21±0.5

Value

Guaranteed by

the Bidder



ANNEXURE-13

PRICE SCHEDULE FOR 400 KV D/C(ACSR TWIN MOOSE

CONDUCTOR)

DERANG- ANGUL TRANSMISSION LINE

S. No Particulars Total

Quantity

Unit Rate

Total Cost in

Rs.

A Total Length of the Line KMs 56.24

I Statutory clearances and charges. LS LS *

II Check Survey (Rs. Per kM) 56.24 * *

III Design and testing of towers LS LS *

TOTAL OF DESIGN AND OTHER EXP. *

B SUPPLY OF MATERIALS

HT Unit Wt. (kg)

MS Unit

Wt.(kg) Nos

Unit Rate

HT/MT

Unit Rate-

MS/MT

Total Cost in

Rs.

1 Supply of tower parts

a) (i) 'A' Type towers Normal 5150 6200 111 * * *

(ii) 3 M Extension pieces 350 1220 31 * * *

(iii) 6 M Extension pieces 630 1900 14 * * *

(iv) 9 M Extension pieces 980 2500 1 * * *

b) (i) 'B' Type towers Normal 9800 6600 15 * * *



(iv) '9 M Extension pieces 2500 3100 1 * * *

c) 'C' Type towers 11900 6100 11 * * *

d) (i) 'D' Type towers Normal 15000 10000 16 * * *



(iv) 9 M Extension pieces 2600 5100 4 * * *

(v) 18 M Extension pieces 5400 12400 1 * * *

(vi) 25 M Extension pieces 7500 19900 2 * * *

2

Supply of Bolts and Nuts (3% of total tower Wt. Of towers) 68761

* *

TOTAL OF TOWERS AND B&N

*

3 Supply of tower accessories

Nos

Unit Rate

Total Cost in

Rs.

a) Danger plate (one per tower) 153 * *

b) Number plate (one per tower) 153 * *

c) Phase plate (set of three per tower) x No. of Ckts. 306

* *




d) Anti climbing device (one set per tower) 153

* *

e) Circuit plate (one per circuit in case of two or more ckt) 306

* *

d) Supply of pipe type earthing (60% of total No.) 100

* *

e) Supply of Counter poise earthing (40% of total No.) 53

* *

TOTAL OF TOWERS ACCESSORIES

*

4 Supply of ACSR Moose Conductor (kM) 685.003

* *

(=Route kM x 3 x No. of Ckts x 2 x 1.015)

5 Supply of 7/3.66mm GSS Ground wire (kM) 114.2

* *

(=Route kM x 2 x 1.015)

TOTAL OF TOWERS CONDUCTER AND GSS GROUND WIRE

*

6 Supply of Insulators with Hardware Nos

a) 'I' Suspension Insulator Sring (No. Suspn. X 3) x Ckts 630

* *

b) Single 'I' suspn. Pilot string (No. of 'D' type x 1) 48

* *

c) Double Tension string (No. of anchor x 2 x 3 x No. of Ckts) 504

* *

d) Double 'I'' suspn. Insulator string (Special Locations) 36

* *

(Three Road crossings) * *

7 120 kN Insulators 17250 * *

160 kN Insulators 24192 * *

TOTAL OF INSULATOR & HARDWARE *

8 Supply of Conductor and GW Accessories

a) Mid span compression Joint for condr. (one No. for 3 kM)

228 * *

b) Mid span compression joint for GW (one No. for 8 kM)

14 * *

c) Repair sleeves for Conductor (2 Nos. for every Route kM)

112 * *

d) Flexible copper Earth bonds (2x 'A' type + 2x2xNo. of Anchor)

390 * *

e) Bundle Spacers for Conductor (6x No. of towers x 3 x Ckts)

5508 * *

f) Rigid spacer for Conductor (2 x No. of anchor x 2 x 3x Ckts)

504 * *

g) Vibration Damper for GW (No. Of towers x 2 x2)

612 * *


TOTAL COST OF SUPPLY

*


h) Earth wire suspension clamp ( No. 'A' towers x 2)

222 * *

I) Earth wire tension clamps (No. of Anchor x 2 x 2)

168 * *

j) Vibration dampers for conductor (No. towersx4xCktsx3x Condr)

7344 * *

TOTAL OF CONDUCTER AND GW ACCESSORIES

*

Excise Duty@ *

*

CST/VAT@ *

*

Total Cost of Design, supply, ED & CST

*

SUPPLY COST PER KM

*

C FREIGHT & INSURANCE

*

D ERECTION

1

Erection Of towers, Stringing of Conductor and Ground wire (LS) 1

* *

2 Erection of Tower parts (LS)

1 *

*

Sub-total cost of Erection *

E CIVIL WORKS

1 Excavations(Cu M) 37842 * *

2 M20 Concrete (1:1½:3 Concrete) (Cu.M) 5567

* *

3

1:3:6 Concrete (15% of M20 Concrete) in Cu.M 601

* *

4 Reinforcements (4% of weight of M20) in MT 417

* *

5 Benching

a) All kinds of soil except fissured rock 150

* *

b) Fissured rock 1500 * *


F&I, ERECTION AND CIVIL WORKS COST PER KM *

* TO BE FILLED BY THE CONTRACTOR


6 Revetment works

a) Random Rubble Masonry (1:5 cement mortar) in Cu M

2500 * *

b) 1:2:4 Cement Concrete revetment

250 * *

c) Back filling and levelling (Included above) 2500

* *

Sub-total cost of Civil Works *

TOTAL COST OF F&I, ERECTION AND CIVIL WORKS

*

TOTAL COST PER KM OF THE LINE

*


ANNEXURE-14

SPARES FOR DERANG TO ANGUL 400 KV DC (TWIN)

TRANSMISSION LINE

I

SL.

NO.

ITEM DESCRIPTION

STUBS AND CLEATS WITH COMPLETE BOLTS, NUTS, PACK

WASHERS and SPRING WASHERS

UNIT QUANTITY

II

III

1 Stubs with cleats for A Type Towers suitable from (+0) to (+9) extensions

2 Stubs with cleats for B Type Tower suitable from (+0) to (+9) Extensions

3 Stubs with cleats for C Type Tower suitable from (+0) to (+9) Extensions

4 Stubs with cleats for D Type Tower suitable from (+0) to (+9) Extensions

5 Stubs with cleats for D Type Tower suitable from (+18) to (+25) Extensions

TEMPLATES WITH COMPLETE BOLTS, NUTS, PACK WASHERS and

SPRING WASHERS

6 Templates for A Type Towers suitable from (+0) to (+9) extensions

7 Templates for B Type Tower suitable from (+0) to (+9) Extensions

8 Templates for C Type Tower suitable from (+0) to (+9) Extensions

9 Templates for D Type Tower suitable from (+0) to (+9) Extensions

10 Templates for D Type Tower suitable from (+18) to (+25) Extensions

TOWER PARTS WITH COMPLETE BOLTS, NUTS, PACK WASHERS

and SPRING WASHERS

11 FOR NORMAL A TYPE TOWER

12 FOR (+) 3M Extension of DA Type Tower





17 FOR NORMAL B TYPE TOWER

18 FOR (+) 3M Extension of DB Type Tower



21 FOR NORMAL C TYPE TOWER

22 FOR (+) 3M Extension of DC Type Tower



25 FOR NORMAL D TYPE TOWER

26 FOR (+) 3M Extension of D Type Tower

27 FOR (+) 6M Extension of D Type Tower

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets 1

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

Sets

10

2

2

2

1

2

1

1

1

10

1

1

1

1

1

2

1

1

1

2

1

1

1

2

1

1



28 FOR (+) 9M Extension of DD Type Tower Sets

1

IV

V

VI

VII

29 FOR (+) 18M Extension of DD Type Tower

30 FOR (+) 25M Extension of DD Type Tower

TOWER ACCESSORIES WITH COMPLETE BOLTS, NUTS, PACK

WASHERS and SPRING WASHERS

31 Name Plate

32 No. Plate

33 Circuit Plate

34 Phase Plate

35 Step Bolts

36 Anti-Climbing Device

37 PipeType Earthing

38 Counter Poise Earthing

39 Hangers for A Type Towers (IF REQUIRED)

ACSR MOOSE CONDUCTOR ACCESSORIES WITH COMPLETE

BOLTS, NUTS, PACK WASHERS and SPRING WASHERS

40 Twin Spacers Dampers

41 Twin Spacers Dampers Rigid

42 Vibration Dampers

43 Dead End Compression Joint

44 Mid-Span Joint

45 Repair Sleeves

46 Jumper Cones

47 T - Connectors

48 Balancing Weight

7/3.66 EARTHWIRE ACCESSORIES WITH COMPLETE BOLTS,

NUTS, PACK WASHERS and SPRING WASHERS

49 Copper Bonds

50 Tension Clamp with dead end joint

51 Mid-Span Joint

52 Vibration Dampers

INSULATORS HARDWARE COMPLETE WITH BOLTS & NUTS

53 Twin Tension Set including Corona Control rings, Arcing Horn etc.

54 Twin Single Suspension including Grading rings, Arcing horn etc.

55 Twin Double Suspension including Grading rings, Arcing horn etc.

Sets

Sets

Nos.

Nos.

Nos.

Sets

Nos.

Sets

Sets

Sets

Nos.

Nos.

Nos.

Nos.

Sets

Sets

Nos.

Nos.

Nos.

Sets

Nos.

Sets

Sets

Nos.

Sets

Sets

Sets

1

1

10

10

10

10

1000

10

5

5

30

500

50

50

250

50

50

50

24

2

24

12

12

48

24

24

6

VIII58 ACSR MOOSE CONDCUTOR (To be supplied in Steel Drums)

IX 59 7/3.66 GS Earth Wire ( To be supplied in Steel Drums)

X 60 120 KN DISC INSULATORS

XI 61 160 KN DISC INSULATORS

kMs.

kMs.

Nos

Nos.

48

4

1000

1000



ANNEXURE-15

TOOLS FOR DERANG TO ANGUL 400 KV DC (TWIN)

TRANSMISSION LINE Sl.

No. DESCRIPTION OF ITEM UNIT QUANTITY

1 Aerial Rollers suitable for Quad Moose

2 Earthwire Rollers

3 Come-Along Clamp suitable for ACSR Moose Auto Type

4 Come-Along Clamp suitable for ACSR Moose Bolt & Nut Type

5 Come-Along Clamp suitable for Earthwire Auto type

6 Come-Along Clamp suitable for Earthwire Bolt & Nut type

7 SLINGS

A) 16MM 30 mtrs Long

B) 12mm 6 mtrs Long

C) 16mm 2 mtrs Long

D) 12mm 2 mtrs Long

8 Four Sheave Pullies Set with 12mm flexible steel rope of 350 mtrs length

9 Double sheave pullies

10 Single Sheave Pullies

11 12mm Flexible steel rope

12 Stay set including steel wire rope and turn buckle set.

13 D-shackles different sizes

14 Spacer cycle suitable for Quad Conductor

15 Tomy Bars

16 CrowBars

17 Safety Belts

18 Helmets

19 First Aid Kit

20 Tool Box

21 Derrick

22 Manila Ropes

A) 16mm

B) 12mm

C) 20mm

23 Drum lifting Jacks for Conductor

24 Turn Table for Earthwire

25 End Socks for ACSR Moose

26 Mid Span Socks for ACSR Moose

Hydraulic Compressor 100T capacity for Jointing including die-sets suitable for

ACSR moose and Earthwire

Nos.

Nos.

Nos.

Nos.

Nos.

Nos.

Nos.

Nos.

Nos.

Nos.

Sets

Nos.

Nos.

Mtrs.

Sets

Nos.

Nos.

Nos.

Nos.

Nos.

Nos.

Nos.

Nos.

Nos.

Bundles

Bundles

Bundles

Sets

Sets

Nos.

Nos.

30

15

6

6

2

2

12

12

12

12

4

4

10

2000

6

24

1

4

8

8

20

2

4

2

4

4

2

1

1

2

2

27 Sets 1


Vol-II

Documents

Transcript of Vol-II