Specification for: Tapered Tubular Steel Poles 161 kv, 400 kv - Annexure B... · 2019-12-02 · ASTM A36, A572 grade 50, A572 grade 65, or equivalent types according to relevant standards

Israel Electric Corp. Ltd.

Engineering Projects

Transmission Lines Division

Transmission Lines Engineering Headquarter

Specification NCS 14

For Tapered Tubular Steel Poles

161 kv, 400 kV

Edition no.: 5

Issued date: 27.8.2019

Page no. :1 of 48

Specification for:

Tapered Tubular Steel Poles 161 kv, 400 kv

Prepared by: Eng. Bella Shomer

Approved by: Eng. Yeheskel Samoocha (-signed-)

Edition no. 3,4,5 – prepared by Eng. David Chen (-signed-)







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Contents:

No. Of Para. Page No. 1. General 4 2. Threshold Conditions 4 3.Documents For the Proposal 4-6 4. Design and Fabrication Standards 6-7 5. Design

5.1 Material

5.2 Geometry

5.3 Tolerances

5.4 Loading

5.5 Pole joints

5.6 Anchoring

5.7 Climbing devices

5.8 Additional items

7-16

6. Test Inspection and Report 16 7. Marking

7.1 marking of pole segments

7.2 marking of crossarms

7.3 marking of ladders

7.4 marking of templates

7.5 marking of base plate

7.6 marking of cases

7.7 marking of beams for carrying and leveling the

templates and anchor bolts

17-26

8. Shop drawings set

8.1 pole assembly diagram

8.2 shop drawing of all pole components and accesories

26-27

9. Fabrication:

9.1 General

9.2 Welding

9.3 Galvanizing

9.4 Punching and drilling

9.5 Documentation

28-31

10. Shipping:

10.1General

10.2 Anchor bolts

31-32







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10.3 Poles

10.4 Destination

10.5 Packing

11.Quality assurance 32 12 Quality control 33 13. Final documents to be submitted by the Contractor

winner before poles fabrication 33

14. documents to be submitted by the Contractor winner

during and after poles fabrication 34

15. List of drawings 35-38 16. Revisions 39-42

APPENDIX Page No.

1. General drawing of the pole 43

2. Summary table 44

3. Delivery time schedule 44

4. Packing list of goods 45

5. Statement of manufacturing experience 46

6. drawings 47

7. I.E.C quality specification Q – APP - 02 48







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1.GENERAL

This specification describes the requirements of the ISRAEL ELECTRIC

CORPORATION (IEC) pertaining to the design, manufacture and supply of

Tapered Tubular Steel Transmission Pole Structures,(including accessories), which

hereafter shall be called "Poles".

The "Design of Steel Transmission Pole Structures" - ASCE /SEI 48-11 standard ,

shall be the relevant governing standard in conjunction with this order.

In case of discrepancies or nonconformity between documents, priority shall be as

follows:

1. The present specification, or written approval by IEC engineers.

2. ASCE /SEI 48-11 standard.

All documentation to be submitted shall be presented in English, shall be clear and

understood by IEC engineers and shall be submitted in due time to enable IEC's

engineers to check and comment them.

2. THRESHOLD CONDITIONS

According to attached documents of the "IEC Procurement Division".

3. DOCUMENTS FOR THE PROPOSAL

The bidder shall submit together with his offer the following:

3.1 Signed Appendix 5: "Statement of manufacturing experience".

3.2 Valid ISO 9001certificate, issued by a Certification Body , as specified in the

threshold conditions of the tender.

3.3 Declaration indicating that the proposal fully satisfies the requirements of this

specification.







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3.2 A list of the relevant standards to which all respective stages of pole design and

manufacture comply.

3.3 For each type of pole: The design moments at the base and at the slip joints and

at any other critical points along the pole, inlcuding the effects of the secondary

moments due to deflection.

- ground line reactions.

- weight of each structure.

- distance across the angles and thickness at the top and at base of each segment

of the pole.

- Anchor bolts diameter, length and quantity (for anchor base only).

- Stud bolts diameter and quantity per each connection of crossarm to the pole.

- The materials (code name, yield stress) of the all pole components.

3.4 General drawing (Appendix 1) of all pole segments for each structure type

(Shop drawings are not required).

General drawing must represent the following informations:

- Length, thickness, top and bottom outside diameter across angles and flats, for

all pole segments and crossarms.

- Overlap length for all slip joints.

- Total length of pole, distance between crossarms from tip to tip.

- Cross arms raising and overhang.

- Distance between crossarms tips and pole axel.

- number, diameter and distance between bolts in connections of crossarms to

the pole.

- descriptions of pole segments (shafts) and cross arms sections (round or

polygon) and material (code name, yield stress).

- material of bolts (code name, yield stress).

3.5 Summary table (Appendix 2)

3.6 General drawing of templates and anchor bolts assembly (for anchor base only).

The general drawing of templates and anchor bolts assembly must represent the

following informations:

- bolt circle diameter.

- outside and inside diameter of upper and lower templats, and their thicknesses.

- anchor bolts length and diameter, thread length and bond (development)length in

the concrete.

- quantity of anchor bolts, nuts and washers.







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- descriptions of material (type, code name, yield stress and coating) for all parts

of assembly.

3.7 Delivery schedule (Appendix 3).

3.8 The bidder shall submit detailed procedures for the hot dip galvanizing and

metallizing process as described in para.9.3.

3.9 A declaration of capability by the supplier that shall include:

3.9.1 Manufacturer's capability with respect to quantity and types of poles.

The above mentioned documents shall be in English. The units in drawings and

summary table must be SI units.

4. DESIGN AND FABRICATION STANDARDS

Design, materials and fabrication of steel poles shall be in accordance with the latest

edition of international codes and standards listed hereafter:

- ASCE /SEI 48-11 - Design of Steel Transmission Pole Structures.

- EN 10025 - Hot rolled products of structural steels.

- EN 10149-2 - Hot-rolled flat products made of high yield strength for cold forming.

- ASTM A36 - Structural Steel.

- ASTM A572 - High-Strength Low-Alloy Columbium-Vanadium Steels of Structures

Quality.

- ACI 318 - Building Code Requirements for Reinforced Concrete.

- ASTM A615 - Deformed and plain billet steel bars for concrete reinforcement.

- ASTM A563 - Carbon and Alloy Steel Nuts.







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- ASTM F436 - Hardened Steel Washers.

- ASTM A354 - Quench and Tempered Alloy Steel Bolts, Studs and Other Externally

Threaded Fasteners.

- ANSI B18.21.1. - Lock Washers.

- ASTM A449 – Quench and Tempered Steel Bolts and Studs.

- DIN 127B - Lock Washers.

- ASTM A143 - Safeguarding Against Embrittlement of Hot – Dip Galvanized

Structural Steel Products and Procedure for Detecting Embrittlement.

- AWS D1.1 - Structural Welding Code – steel.

- ASTM A123 - Zinc (Hot-Dip Galvanized) coatings on Iron and Steel Products.

- ASTM A780 - Repair of Damages and Uncoated Areas of Hot-Dip Galvanized

Coatings.

- ASTM 153 - Zinc Coating (Hot Dip) on Iron and Steel Hardware.

- AWS C2.23M - Application of Thermal Spray Coatings (Metallizing) of Aluminum,

Zinc, and Their Alloys and Composites for the Corrosion Protection

of Steel.

or

- ISO 2063 - Thermal spraying – Metallic and other inorganic coatings – Zinc,

aluminum and their alloys.

5. DESIGN

The design of the poles shall include:

- material requirements, relevant standards.

- pole and crossarms design: thickness and radius of each section accesories,

joints, additional items, climbing devices (see para. 5.2-5.8).

- deflection calculations shall be submitted.







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- foundation design recommendations (see para. 5.6).

- shop drawings (see para. 8).

5.1 Material

5.1.1 General

All material shall comply with the applicable requirements of the appropriate

standard.

The supplier is entitled to propose industrial standards acceptable in his own

country, for IEC approval.

The steel shall be of "Hot Deep Galvanizing Quality" and suitable for welding.

The steel shall have Si (Silicon) and P (Phosphorus) contents:

Si <= 0.03% and (Si + 2.5P)<=0.09

or

0.14% <=Si<= 0.25% and P<=0.035%

The Energy - Impact Values should be included in the manufacturer's proposal

and should comply with an accepted authority, e.g., ASTM, DIN.

The certificate of steel composition shall be submitted before galvanizing.

5.1.2 Pole shaft, crossarms, crossarms attachment to pole shaft

Material shall conform to EN 10025 type S235JR, S235J0, S355J2,

ASTM A36, A572 grade 50, A572 grade 65, or equivalent types

according to relevant standards.

5.1.3 cross arms axles

- All studs bolts for crossarm connections shall conform to ASTM A354 grade

B.C. MOD.

- All nuts for crossarm connections shall conform to ASTM A563 grade DH.

- All lock washers for crossarm connections shall conform to ANSI B18.21.1.

5.1.4 Threaded fasteners

- Other bolts shall conform to ASTM A449.

- Other nuts shall conform to ASTM A563 grade C.







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- Other lock washers shall conform to DIN 127B.

5.1.5 Anchor bolts

Anchor bolts shall conform to ASTM A615 Grad 75 MOD (deformed ribbed

bar).

The anchor bolt nuts shall conform to ASTM A563 Grad DH.

The anchor bolt washers shall conform to ASTM F436.

5.2 Geometry

Poles shall have a 12 - 16 sided regular polygonal cross section for suspension and

tension poles.

Cross-arms shall have a tapered polygonal, or round, or square cross section.

According the tender requirements, suspension poles 400 kV may be in two options:

cross-arms with I string or with V string isulators.

Pole height, base diameter ; crossarms shape and length shall be according

to IEC requirements.

compact 161 kV lines crossarms :

For suspension poles - crossarms shall be a composite insulators assemblies with

pivoting base , see drawing NCD 2646, supplied by IEC.

For tension poles - post insulator, see sketch 5370, supplied by IEC .

Compact 400 kV lines insulators:

For suspension poles - composite insulators assemblies is used, see drawing NCD

2658, supplied by IEC.

The vertical insulator is connected to the pole crossarm.

Max. length of segments shall be 16 meters and under certain conditions (after

approval of the Israel Electric Corp. Ltd.) -18 meters.

Please note that if a segment is composed of partial segments, each partial segment

must be not shorter than 3 meters length.

A maximum of one horizontal weld per segment is permissible and under certain

conditions (after approval of the Israel Electric Corp. Ltd.) - two welds.







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All common segments for the same type of pole (pole with all required extensions)

shall be interchangeable.

For each pole, left and right crossarms connection and number of bolts shall be the

same.

Max. weight of segment shall be 28.0 tons. The weight of the first upper part with

the crossarms, platforms, handrailings, ladders, insulators, running block shall be less

than 9.0 tons.

The material thickness shall be not less than 5.0 mm.

A sufficient number of holes should be provided to enable the free flow of the

molten Zinc, and to prevent the build-up of pressures inside closed structural

elements (i.e cross-arms).

5.3 Tolerances

The permitted tolerances shall be as follows:

a. The overall assembled length of each pole: -0.5% / +1.5%.

b. The length of pole segments: -25 mm / +75 mm.

c. Member straightness: less than 3 mm per meter.

d. Bottom part diameter shall be -1.0% / +2.0%.

The supplier shall supply a list of fabrication tolerances to the purchaser for

approval.

5.4 Loadings

5.4.1 General

The poles shall be designed to withstand the specified loadings without

exceeding the specified yield strength of the pole steel (see sketches).

All the loadings are according to IEC standards and include overload factors.

161 kV poles:

The earth wires on poles - OPGW.

The connection of OPGW can be suspension or tension type - for all the

poles







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(tension and suspension). Therefore on earth crossarms there are two type of

connection plates:

- plates no.9 for tension type

- hinge no.1 for suspension type.

Loads for OPGW (see sketches of load trees) shall be applied either on plate

no.9, or on hinge no.1, see sketch 3703.

400 kV poles:

2 types of earth wires are used on poles: 241 ALLOY and OPGW.

The connection of OPGW can be suspension or tension type - for all

the poles (tension and suspension). Therefor on earth crossarms there are

two types of connection plates:

- plates no.17 for tension type

- hinge no.18 for suspension type.

Loads for OPGW (see sketches of load trees) shall be applied either on

plate no.17, or on hinge no.18, see sketch 3192.

5.4.2 Wind load on the pole

The wind loads on the pole shall apply in transverse direction only.

The wind loads on the pole are calculated as follows:

Three (3) values are given in the sketches:

- for normal and cascade (or longitudinal) loading condition.

- for broken wire loading condition

- for service loading condition

These values must be multiplied by the shape factor Ct, by the height factor M1

and by the net pole area (in squaremeters, m²) perpendicular to the wind

direction.

The value of the shape factor Ct is determined from table 1.







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Table 1

SHAPE SQUARE 8 SIDED 12 SIDED 16

SIDED

ROUN

D

Ct 1.5 1.3

0.9 0.85 0.8

The value of the height factor M1 is determined from table 2.

Table 2

Height factor M1 Height above ground level (m)

0.92 0 -25

1.10 25 - 45

1.21 45 - 70

1.31 70 - 100

5.5 Pole joints

Pole sections shall be made with telescopic slip joints.

The sections should be detailed for nominal overlapping length that shall assure a

minimum overlapping length of 1.52 times the maximum inside diameter (across

flats) of the female section.

Nominal overlapping length shall be 1.7 times the maximum inside diameter (across

flats) of the female section.

The maximum overlapping length shall be nominal overlapping length + 100 mm.

The taper of each section at a slip joint should match the taper of the adjacent section

to provide proper splice tolerances.

Joints shall resist compression, tension, bending, shear and torsion under ultimate

loads conditions.

On both sides of slip joints, pole shall be provided with special jacking studs, which

were welded to the pole sections.

For each section of the slip joint, two jacks are required, one jack on each side.

The place of jacking studs shall be according to IEC sketches.







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Minimum distance between segment joint edge and bottom of crossarms connection

attachment shall be equal or more than 1.2 m (see sketch 3183).

Pole assembling shall be by segments - in vertical or horizontal position.

For vertical assembling - the jacking operation shall be made when the assembling

of pole shall be completed.

The jacking studs type shall be selected according to jacking forces from horizontal

position assembling. The possible local buckling, caused by the jacking operation,

shall be checked to jacking forces multiplied by overload factor of 1.3.

Grinding of longitudinal welds, within the maximum slip joint area plus 100 mm,

shall be done. Internal grinding of female and external grinding of male.

5.6 Anchoring

Poles may be furnished for either anchor base construction or for direct embedment

in concrete foundation, or for extended pile reinforcement.

5.6.1 Anchor base

For anchor base construction, anchor bolts are to be used. For anchor bolts

calculation, ultimate loads must be multiplied by safety factor of 1.1 .

Concrete presently in use has the compressive cube strength after 28 days –

300 kg/cm2 (for concrete cube dimensions 10x10 cm).

The number of bolts, their size, thickness, templates, etc., are to be

recommended and supplied by the supplier. Four of the anchor bolts shall be

supplied with extensions of 100 mm, to facilitate positioning of the pole on

the anchor bolt group.

The anchor bolts shall be deformed ribbed bar.

The materials of anchor bolts and nuts are according to para. 5.1.5.

The anchor bolts development length shall conform to ASCE /SEI 48-11

standard.

The development length shall be calculated without taking into account the

template.

The actual development length shall be the calculated development length

plus 300 mm.







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The number of bolts shall be symmetrically relation to the two axes and can

be divided by four.

The templates shall be rounded shape.

Rigid bottom template shall be designed for carrying all anchor bolts with

very small deflections (see drawing NCD 2663).

Each anchor bolt shall be connected to base plate by three nuts and two

washers. The supplier shall provide drawing datail of base plate setting (see

drawing NCD 2663).

The holes diameter on templates shall be threaded diameter of anchor bolt

plus 1 mm.

The holes diameter on base plate shall be threaded diameter of anchor bolt

plus 6 mm. minimum.

The supplier shall provide instructions and drawing datails for anchor bolts

instalation in the concrete foundation.

The supplier shall design two beams for carrying and leveling the anchor

bolts assemblies above the foundation hole (see drawing NCD 2692).

For each pole type, the supplier shall supply two couples of beams for

ordering more then one pole, and one couple for ordering one pole, in the

all period of one contract.

5.6.2 Embeded in concrete foundation

For embedded poles, the length of the embedment shall be as shown in

sketches- Sketch 3562, NCD 1026.

5.6.3 Extended pile reinforcement

For poles for extended pile reinforcement, a bottom part of the pole shall be

placed over the exposed reinforcing structure.

Concrete shall be poured into the pole section to height of 1.5 times of

bottom largest outside diameter.







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Quantity, geometry and position of weld plates shall be according to IEC

requirements (see sketch 3562).

5.7 Climbing devices

A ladder shall start at a height of about 4 m from ground level, and shall be

continuous to a point at about 0.3 m below the top of the pole (see sketch 3183).

For 161 kV poles an additional ladder shall start on opposite side from the platform

bellow upper crossarm and shall be continuous to a point at about 0.3 m below the

top of the pole.

For upper segment of ladder two meters shall be with doubled steps, see sketch 3690.

The length of each ladder segment must be 3 m (except for upper and lower parts).

The ladder, its connecting points and all the welds shall be straight and smooth-

surfaced.

Each segment of ladder shall be straight and its tolerance must be less than 0.001 of

its length. All these requirements are in order to ensure proper work with safety

devices -railblock of PROTECTA AC 101.

The supplier shall check ladders and crossarms rail with railblock before delivery.

For compact 161 kV line poles, no ladder shall be used.

5.8 Additional items

- Plates for warning spheres attachment. For exact position of the attachment on

each pole, see sketch 3183.

- Removable railings and platforms shall be placed on pole according to sketch

3711. No bolts shall protrude above the surface of railing pass, in order to ensure

proper work with safety devices - railblock.

- Holes for lifting and attachments for centralizing shall be according to sketch 3183,

5363 for compact 161 kV line.

- Adjusting handles shall be placed on bottom and on each segment of pole, see

sketch 3562, 3183, 5363 for compact 161 kV line .







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- Attachment for anchoring shall be welded on tension pole crossarms, see sketches

3703 for 161 kV, 3186, 3192 for 400 kV.

The main method for devices to climb and work on crossarms is stepping stones -

(see sketch 3685).

Stepping stones shall be placed on all crossarms of suspension

poles, and on only earth wire crossarms of tention poles.

- Attachment for the ladder shall be welded at the end of crossarms, see sketch

3182, 3186.

Sharp edges shall be smooth rounded.

- Attachment for anchoring shall be welded on tension poles crossarms, see sketches

3186, 3192.

- Lifting bars, holes and devices shall be calculated for two segment weights

(except for bottom part that shall be lifted alone).

- Lifting bar and hole shall be calculated for 2/3 of total lifting weight. For

placement see sketch 3183, 3192.

- Lifting devices shall be placed on each segment calculated for doubled

weight of segment, see sketch 3183.

6. TEST INSPECTION AND REPORT

The Purchaser, at his expense, may request that one or more poles, selected from

production at random, be tested to the full design load according testing

procedure of ASCE /SEI 48-11 standard "Design of Steel Transmission Pole

Structures" and IEC 60652 standard "loading tests on overhead line structures".

The Contractor shall furnish a test report for each structure tested. The test report

shall include the method of application of the loads, the deflection under the

various loading conditions and mill test reports for the steel used in the tested

structure.

The pole shall be tested to withstand the full design loads.

The pole shall not sustain any permanent deformation.

After passing the test the pole shall be dismantled.







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7. MARKING

Markings shall be made on all design drawings, calculations, pole elements,

crossarms, pole parts and accessories, so as to define each item individually.

Markings on steel segments shall be clearly engraved or embossed. The size of

the marking shall be in accordance with figure 1. The markings shall be clearly

visible on each part of each pole.

7.1 marking of pole segments

The location of marking on pole segments desceibed in figure 3.

7.1.1 engraved or embossed marking on pole segments

The markings of pole segments shall include the following data:

- trademark of the manufacturer.

- name of pole.

- catalogue number of segment or bottom part (catalogue number

shall be supplied by the purchaser).

- number of section (the section number shall be clearly marked in

accordance with drawing).

see figure 1.

FIGURE 1- engraved or embossed marking of pole segments







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7.1.2 label and painted marking of pole segments

Labels marking shall be attached on the inner part at both ends of

each segment of the pole, see figure 3.

Additional painted markings on steel segments shall be on each

segment of each pole on both sides according figure 3. Markings

shall be according to Figure 3.

The markings of pole segments shall include the following data:

- trademark of the manufacturer

- name of pole

- catalogue number of segment or bottom part (catalogue number

shall be supplied by purchaser)

- number of section (the section number shall be clearly marked in

accordance with drawing).

See figure 2.

FIGURE 2- label and painted marking of pole segments







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FIGURE 3- The locations of marking on pole segments







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7.1.3 center lines marking of pole segments

The center lines on each bottom part shall be marked at 4 sides on

upper & lower edge of the part.

The center lines on each part shall be marked only at two sides, only

on lower edge of the part.

The marking shall be by red paint.

The dimensions of the marking shall be:

- 300 mm -length, 10 mm - width.

See figure 4.

7.1.4 center of gravity marking of pole segments

The center of gravity on each segment shall be marked at 4 sides.

The marking shall be by red paint.



See figure 4.

7.1.5 min. and max. overlapping length marking of pole segments

The min. and max. overlapping length shall be marked at one side, near

to jacking studs line.

The marking shall be by black paint.



See figure 4.







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FIGURE 4 –center lines marking of pole segments







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7.2 marking of crossarms

The marking shall be engraved or embossed.

The markings of pole crossarms shall include the following data:

- trademark of the manufacturer

- name of pole

- catalogue number of crossarm (catalogue number shall be supplied

by the purchaser)

- part number in accordance with drawing

- crossarms position (level on pole and right or left position)

See figure 5.

FIGURE 5- marking of pole crossarms







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7.3 marking of ladders

7.3.1 engraved or embosed marking of ladders

The marking of each ladder shall include the following data:


7.3.2 marking plate

Marking plate should be fastened to a bundle of ladders of one

pole (see appendix 4).

The marking shall be by paint.

The marking plate shall include the following data:


- name of pole.

7.4 marking of templates

7.4.1 engraved or embosed marking of template

The marking of template shall include the following data:


- name of pole.

- catalogue number of anchor bolts & templates (catalogue

number shall be supplied by purchaser).

7.4.2 Axes marking on upper template

The upper template shall be marked by paint on the two axes ( strait line &

“ARM” for arm centerline, and “^” & “LINE” for line (front) centerline).

see figure 6.







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FIGURE 6- axes marking on upper template

7.5 Axes marking on base plate

The base plate shall be marked by paint on the two axes ( strait line &

“ARM” for arm centerline, and “^” & “LINE” for line (front) centerline).

See figure 7.







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FIGURE 7- axes marking on base plate

7.6 marking of cases

Each case for accessories shall be marked, on visible position, by

painted marking.

The marking of case shall include the following data:


- name of pole.

- catalogue number of case (catalogue


See appendix 4.







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7.7 marking of beams for carrying and leveling the templates and anchor

bolts

Each beam shall be marked, on visible position, by

engraved or embossed marking.

The marking of beam shall include the following data:


- name of pole.

- catalogue number beam (catalogue


See drawing NCD 2692.

8. SHOP DRAWINGS SET

shop drawings set must include pole assembly diagram and shop drawing of each

component of the pole.

The supplier shall prepare and submit to the purchaser approval, two prints of each

shop drawing set.

After all corrections are made, a set of revised reproducible prints and

AUTOCAD files shall be sent to the purchaser.

All shop drawings shall be approved by the purchaser before fabrication.

8.1 pole assembly diagram

pole assembly diagram of each pole type shall include the following information:

- Pole type

- Geomtric outline of the pole with all component and dimensions, as

described in appendix 1.

- The geometric outline shall include also the plats and accessories

connected to the pole, and include numbers of pole elements.

- C.O.G. of pole (including crossarms)

- Pole orientation- Cross section of the pole with the location of ladder

and jacking studs, with axes (writing – “ crossarm axis”) and

numbering the angels points.







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- Details of base plate setting (for anchor base only).

- Shipping weight, thickness, length and cross-sectional geometry (upper

and bottom diameter across angle and flats) for each segment of the

pole.

- Shipping weight, thickness, length and cross-sectional geometry (small

and large diameter across angle and flats) for each crossarm.

- Stud bolts (sizes and quantity) for each crossarm conection to pole.

- parts list of pole segments (shafts), crossarms, anchor bolts &

templats with I.E.C catalogue, climbing devices, accessories, bolts,nuts

washers and lockwashers.

- Table with moments and reactions at the pole base.

- Min. and max. jacking forces (for each type of assembling).

8.2 shop drawings of all pole components and accessories

- Detail drawings of all pole segments and crossarms, and the location

and orientation of all plates and accessories welded to them.

- Detail drawings of all plates and accessories that are welded to the pole

segments or crossarms.

- Typical arm to pole fastener connection detail.

- Detail drawings of climbing devices.

- Detail drawing of all the accessories for climbing. - List of material specification: Material types, minimum yield stress and

relevant specifications

- Details about finishing.

- For each element, to show the location and details of marking

(according to para. 7).

- Detail drawing of anchor bolts and templates and details of base plate

setting

(for anchor base only, see drawind NCD 2663).

- Detail drawing of beams for carrying and leveling the anchor bolts and

templates assembly (see drawing NCD 2692).

- Welding details. - Bill of material for each drawing. - The title of each drawing shall include : the subject of drawing, pole

type, element name and number,cat. No.,400 or 161 kv and “israel

electric corporation ltd”.







161 kv, 400 kV

Edition no.: 5


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9. FABRICATION

9.1 General

After shop drawing approval, prior to mass production for each type of pole

prototype assembly of all removable parts for each segment and cross-arms shall be

done and approved by IEC.

All fabrication checks and procedures are to be performed according to ISO 9001

standard. The manufacturer shall verify correct fitting of every part using suitable

inspection jigs.

Fabrication shall be in according with the latest edition of ASTM A 143.

9.2 Welding

All weldings are to be performed in the shop, prior to galvanization. Welding shall

be in conformance with the AWS D1.1 of the American Welding Society Structural

Welding Code or similar accepted by IEC Material Laboratory.

All welding filler metal used for welding (including tack welds) should be from the

low hydrogen type and shall meet, as a minimum, an impact value of 15 ft/lbs at -20F

as measured by the standard Charpy V - notch test.

They shall equal or exceed the specified physical properties of the base metal being

welded when tested with the applicable AWS specification for welding electrodes.

Welding may be done by the shielded metal-arc, gas shielded flux core, or

submerged- arc process.

Shielded metal-arc welding shall be done with appropriate strength low hydrogen

electrodes.

Welding joint details shall be detailed by the bidder and approved by the IEC.

Longitudinal welds shall be minimum 80% penetration welds, except within the slip

joint area (female and male) plus 200 mm where the penetration shall be full (100%)

penetration welds.

Longitudinal welds within 100 mm of circumferential welds shall be full (100%)

penetration welds.







161 kv, 400 kV

Edition no.: 5


Page no. :29 of 48

All circumferential welds shall be full (100%) penetration welds.

Welding quality shall be according to AWS D1.1.

The bidder may use any combination of inspection methods to satisfy the welding

quality requirements of the above standard.

Ultrasonic or radiographic inspection (in accordance with Israel Electrical Company

laboratory requirements) shall be performed on all full penetration welds -

longitudinal welds in the slip joint area, flange and base plate to pole shaft welds,

crossarm bracket to arm shaft welds, hinges attachment welds and safety related

welds.

Furthermore two ultrasonic or radiographic inspections of the circumferential seams

and one longitudinal seam in each of the other segments must be performed.

Ultrasonic or Radiographic inspection shall be done for every T joint

(horizontal and longitudinal welds junction).

If the quality and number of rejected welds shall be minimum, the number of

radiografic tests can be reduced according to IEC laboratory autorisation.

All welding shall be performed by qualified welders, or welder operators, using only

qualified welding procedures in accordance with the Code AWS D1.1 - prequalifed

WPS shall not be accepted.

All WPS, WPQR and welder's qualifications shall be submitted to I.E.C for review

and for approval.

9.3 Galvanizing

The pole segments (parts) and all accessories shall be hot dip zinc galvanized

according to ASTM A-123 standard, or acceptable equal standard (approved by

IEC). The minimum thickness of the zinc coating shall be 85 microns.

All hollow members shall be galvanized both inside and outside surfaces.

The segments length shall be designed for one dipping. In special cases, double

dipping will be don only after IEC confirmation.

Repair of damaged and uncoated areas of hot dip galvanized coating shall be by

sprayed zinc ((Metallizing), according to ASTM A780 specification.







161 kv, 400 kV

Edition no.: 5


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All attachment bolts and the full length of anchor bolts shall be hot dip galvanized.

Bolts, nuts and washers shall be galvanized in accordance with ASTM 153.

(For attachment bolts, the bidder can propose another coating method for IEC

approval).

The minimum thickness of the zinc coating for bolts and nuts shall be 40 microns

The coating of small bolts for ladders can be:

- hot dip galvanized, minimum thickness of coating shall be 40 microns

- electrogalvanized on cyanide base, minimum thickness of coating shall be 40

microns with pasivation.

- sheradizing, minimum thickness of coating shall be 40 microns + pasivation.

Thread of nuts for bolts coated by hot dip galvanized, electrogalvanized on cyanide

base or sheradizing, shall be tapped, after coating, to oversize 0.38 mm of bolt

diameter.

Nuts coated by hot dip galvanized,shall be oiled after tapping.

Pole segments that are impossible (according to the diameter of pole segments) to be

coated by hot dip galvanizing, shall be zinc sprayed (metallizing)

according to AWS C2.23M or EN ISO 2063.

The minimum thickness of the metallizing zinc coating shall be 120 microns.

The coating shall be continuous and reasonably smooth and uniform in thickness.

Galvanized articles shall be free from uncoated areas, blisters, flux deposits, and

gross dross inclusions. Lumps, projections, globules, or heavy deposits of zinc which

will interfere with the intended use of the material will not be permitted.

The zinc coating color, on all areas of the articles, shall be uniform, without marks.

The bidder shall submit, with his technical bid, detailed procedures for the hot dip

galvanizing and metallizing process as described above, for IEC approval.

9.4 Punching and drilling

Holes in plates of thickness more than 11 mm may be partially punched. Punched

hole shall be enlarged to a final dimension by drilling.

Flame cut holes are not permitted.







161 kv, 400 kV

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9.5 Documentation

The supplier shall submit all relevant certifications concerning material quality,

welding rods, fabrication inspections etc., as all other documents mentioned herein,

according to ISO-EN-10204-3.1B.

10.SHIPPING

10.1 General

The delivery schedule shall be coordinated with and approved by IEC prior to

delivery.

Prior notification of delivery shall be given.

Each shipment and each invoice shall be accompanied by a packing list of all parts

on that particular shipment. Bolts, nuts and other hardware shall be either boxed or

bundled. All bolts, nuts and miscellaneous hardware shall be clearly identified in the

packing list to enable efficient match-up with their respective pole shafts.

The packing shall prevent any damage to the pole elements.

10.2 Anchor Bolts (for anchor base only)

Anchor bolts shall be assembled to the top and bottom template by the supplier.

The supplier shall supply the assembly of anchor bolts and templates (of each

pole) to the purchaser store. The assembly of Anchor bolts and templates shall be

supplied in advance of the poles supply, if so required.

The thread lengths of anchor bolts shall be protected from damage at transportation

stage.

10.3 Poles

Poles shall be normally shipped in open top containers ( unless the pole dimensions

do not permit this) or connventional shipped.







161 kv, 400 kV

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10.4 Destination

Unless otherwise agreed to by the Purchaser, the shipment shall be forwarded

according to the shipping instructions shown in the enquiry.

The Purchaser shall be notified when each shipment is ready for delivery.

10.5 Packing

Poles segments shall be packaged and securely tied with synthetic band or galvanized

steel band with protection band, for transportation. The minimum width of the band

is 2".

Pole segments shall be placed on durable wooden rods, covered by rubber sheets.

All the accessories, bolts, fasteners (packed in plastic bags) for each pole shall be

packed in the wooden case with their packing list.

The wooden case shall resist external environmental conditions for years.

Ladders for each pole shall be packed and securetly tied with slings and placed on

wooden rods.

Safety rails shall be bundled and tied for each pole.

See appendix 4.

11. QUALITY ASSURANCE

11.1 Bidder’s Quality Assurance Program shall meet the requirements that described in

ISO 9001.

11.2 The purchaser shall have the right to audit and comment on Bidder’s Quality

Assurance System regarding of whether it was previously audited by a certifying

agency or any other body.

11.3 The bidder shall submit with his proposal a copy of his Quality Assurance Manual

including Quality Procedures (if applicable).







161 kv, 400 kV

Edition no.: 5


Page no. :33 of 48

12. QUALITY CONTROL

12.1 Quality control requirements shall be according to I.E.C specification

Q – APP – 02 (Appendix 7).

12.2 The bidder shall submit with his proposal a copy of the inspection and test plan

which is applied during the production of the equipment.

Representatives of IEC shall be authorized to visit the manufacturer’s plant and

obtain details of each phase of the equipment’s production.

12.3 Test and inspection certificates as required in the specification and the

applicable standards, shall be submitted immediately following their generation.

The certificates shall be original, signed by the contractor and contain actual

values measured. The generation of certificates, including those generated by sub-

suppliers, shall bear no extra cost to purchaser.

13. FINAL DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR

BEFORE POLES FABRICATION

After reception purchase order ,the contractor winner shall prepare and submit to

the purchaser :

1. Within two weeks after reception of order - the calculations and geometric

outline of each pole type, for IEC approval.

2. Within one month after reception of order - one print of all shop drawings set

for each pole type, for IEC approval.

After making all corrections on the shop drawings, according to IEC remarks, and

final IEC approval, a set of final shop drawings prints and AUTOCAD files shall be

sent to the purchaser.

All shop drawings shall be approved by the purchaser before fabrication.







161 kv, 400 kV

Edition no.: 5


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14. DOCUMENTS TO BE SUBMITTED BY THE CONTRACTOR

DURIND AND AFTER POLES FABRICATION

1. The contractor winner shall send a list of material identification, welder

identity, inspection results and inspector identity.

The contractor winner shall send records of welding procedure and weld

quality tests.

2. For each type of pole, the contractor winner shall prepare and send packing list

according to appendix 4. The packing list shall be approved by IEC, before poles

shipping.







161 kv, 400 kV

Edition no.: 5


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15. LIST OF DRAWINGS

400 kv - Catalogue number for tender only Sketch no.

Catalogue number for poles ZDSC2 B, +5B, +10B NCD 171 e/4

Catalogue number for poles ZDS2 B,G, +5B,+4G JDHK 8603e/3

Catalogue number for poles ZDT2 B,G, +3B, +3G JDHK 8604e/1

Catalogue number for poles ZDT1 +3D, +3H JDHK 8605e/1

Catalogue number for poles ZDSM2 B, +5 B, +10B,

ZDTM2 B, +5 B

JDHK 9420e/1

400 kV

Sketch no.

Loading tree ZDSC2 B, +5B, +10B SKETCH 5131b/3

Loading tree ZDS2 B,G, +5B,+4G NCD 175/2

Loading tree ZDT2 B, +3B NCD 179/1

Loading tree ZDT2 G, +3G NCD 180/1

Loading tree ZDT1 +3D, +3H NCD 194/2

Loading tree ZDSM2 B, +5 B, +10B SKETCH 5850/3

Loading tree ZDTM2 B, +5 B SKETCH 5861/3

Diameter, thickness ZDSC2 B, +5B, +10B SKETCH 5132b/3

Diameter, thickness ZDS2 B,G, +5B, +4G NCD 142/3

Diameter, thickness ZDT2 B,G, +3B, +3G NCD 178/0

Diameter, thickness ZDT1 +3D, +3H NCD 193/1

Diameter, thickness ZDSM2 B, +5 B, +10B SKETCH 5851/2

Diameter, thickness ZDTM2 B, +5 B SKETCH 5862/2

Attachments for crossarms (ZDS2C A, B, G) I - string SKETCH 3182/14

Attachments for crossarms (ZDT2 B, G) SKETCH 3186/17

Attachments for crossarms (ZDT1 G, D, H) SKETCH 3192/13

Suspension and tension hinges SKETCH 3191/12

Attachments for composite insulators assemblies NCD 2658/0

Attachments for v string crossarms SKETCH 5847/3

v- string synthetic insulators for poles:zdsc2, zds2b,zds2g NCD 2677/2







161 kv, 400 kV

Edition no.: 5


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400 & 161 kV Sketch no.

Details for tubular steel poles SKETCH 3183/25

Arrangement for warning spheres on tubular poles SKETCH 3698/9

Ladder for tubular poles SKETCH 3690/6

Types of foundations SKETCH 3562/12

Templates and anchor bolts NCD 2663/1

Beams for carrying and leveling the templates and anchor

bolts

NCD 2692/2

Removable stepping stones for suspension poles SKETCH 3685/17

Details of removable platforms and handrailings on pole SKETCH 3711/11

161 kv - Catalogue number for tender only Sketch no.

Catalogue number for poles ZS1 B, G +6, +12 JDHK 7581e/0

Catalogue number for poles ZT1 B, D, +6, +9 JDHK 7582e/0

Catalogue number for poles ZS2 B, +6, +12 JDHK 7584e/0

Catalogue number for poles ZT2 B, D, +6, +9 JDHK 7583e/0

Catalogue number for poles ZMS2 B, G, +6, +12 JDHK 7579e/0

Catalogue number for poles ZTM2 G, H,T +6, +9 JDHK 7580e/0

Catalogue number for poles ZMSC1 B, G, +2,

+4;ZTMC1, +2, +4

JDHK 9011e/0

Catalogue number for poles ZMSC1 D, +4.5D, +9D,

+13.5D; ZTMC1 B, +5B, +10B

NCD 2374/1

Catalogue number for poles ZMSC2 B, G, +2, +4 NCD 496e/1

Catalogue number for poles ZMSM2 B +5, +10 NCD 890 /1

Catalogue number for poles ZTMM2 B, G, +6, +12 NCD 891/1







161 kv, 400 kV

Edition no.: 5


Page no. :37 of 48

161 kV Sketch no.

Loading tree ZS1 B,G SKETCH 3522/5

Loading tree ZT1B,G,D SKETCH 3524/5

Loading tree ZS2 B,G SKETCH 3526/5

Loading tree ZT2 B,G,D SKETCH 3528/5

Loading tree ZMS2 B,G SKETCH 3567/5

Loading tree ZTM2 G,D,H SKETCH 3071/6

Loading tree ZTM2 V,T SKETCH 3070/6

Loading tree ZMSC1 B, G SKETCH 5102/3

Loading tree ZMSC1 D NCD 2382/2

Loading tree ZTMC1 SKETCH 5100/2

Loading tree ZTMC1 B NCD 2391/2

Loading tree ZMSC2 B,G SKETCH 5104/1

Loading tree ZMSM2 B NCD 824/1

Loading tree ZTMM2 B,G NCD 822/2

Diameter, thickness ZS1 B,G SKETCH 3530/4

Diameter, thickness ZS2 B,G SKETCH 3534/3

Diameter, thickness ZT1 B,G,D SKETCH 3532/4

Diameter, thickness ZT2 B,G,D SKETCH 3536/4

Diameter, thickness ZMS2 B,G SKETCH 3566/4

Diameter, thickness ZTM2 G,D,H,V,T SKETCH 3166/5

Diameter, thickness ZMSC1 B, G SKETCH 5101/1

Diameter, thickness ZMSC1 D NCD 2379/1

Diameter, thickness ZTMC1 SKETCH 4099/2

Diameter, thickness ZTMC1 B NCD 2380/2

Diameter, thickness ZMSC2 B,G SKETCH 5103/0

Diameter, thickness ZMSM2 B NCD 825/1

Diameter, thickness ZTMM2 B,G NCD 823/1

Attachments for phase crossarms (V-string insulators) for

ZMSM2 B

NCD 889/1

v- string insulators for ZMSM2 B NCD 2688/0

Attachments for phase crossarms for ZTMM2 B,G pole NCD 888/0







161 kv, 400 kV

Edition no.: 5


Page no. :38 of 48

Attachments for tubular steel poles and crossarms SKETCH 3703/13

Suspension and tension hinges SKETCH 3553/10

Details for tubular steel poles - compact line SKETCH 5363/8

Attachments for suspension steel poles and crossarms - compact

line

SKETCH 5369/3

Attachments for composite insulators assemblies NCD 2646/1

Attachments for tension steel poles- compact line SKETCH 5370/3

Method of handrailing and platforms on crossarms SKETCH 3708/5

Length of embedment (H) NCD 1026/1







161 kv, 400 kV

Edition no.: 5


Page no. :39 of 48

16. REVISIONS

Edition no: 1 - November 2000

1. Added 161 kV 3 type of poles: ZMSM2 B, ZTMM2 B,G

Added new drawings- NCD 822,823,824,825,890E,

2. Added method of galvanization, see para 9.3

3. Added option of conventional shipping, see para 10.3

4. Change drawing 3191/9 to 3191/10, drawing 3553/8 to 3553/9

Edition no: 2 - January 2001

1. Added length of embedment to 161 kV poles - see para. 5.6, drawing NCD 1023.

2. In para. 5.7 added that additional ladder in 161 kV poles shall started from platform

bellow the upper crossarm.

3. Added thickness and methods of galvanization for bolts and nuts - see para.9.3.

4. Para. 2 - threshold conditions -was changed.

5. Change of drawings:

5861 to 5861/2

5862 to 5862/2

NCD 171 e/1 to NCD 171 e/2

8603 e/1 to 8603 e/2

3070/4 to 3070/5

3071/4 to 3071/5

NCD 822 to NCD 822/1


NCD 890 e to NCD 890/1

3562/10 to 3562/11

Edition no: 3 - March 2003 (prepared by Eng. David Chen)

1. Added two 161 kv compact poles : ZMSC1 D, ZTMC1 B.

2. updated para. 3.3, 3.4, 3.6.

3. Added standard ACI 318 for anchor bolts length - see para.4.

4. Added material of anchor bolts and their nuts - see para.5.1.5.

5. Changed drawings of 161 & 400kv composite insulator assemblies - see para.5.2.

6. updated para 5.2.

7. updated para 5.4.2

8. updated para 5.5.

9. Added details of anchor bolts and templates - see para.5.6.







161 kv, 400 kV

Edition no.: 5


Page no. :40 of 48

10. Added details for marking - see Para. 7.

11. updated para 8.

12. Para. 9.3. – galvanizing- apdated.

13. Changed anchor bolts shiping – see para. 10.2.

14. Added new drawings –NCD 2382/1, 2391/1, 2379/1, 2380/1, 2374/1, 2658/0,

2677/0, 2646/0, 2688/0, 2663/0, 2692/0.

15. Changed of drawings:

sketch 5850 to sketch 5850/1


sketch 5132b/1 to sketch 5132b/2


NCD 142/1 to NCD 142/2





NCD 496e to NCD 496e/1

NCD 1026 to NCD 1026/1

sketch 5363/4 to sketch 5363/5











16. Deleted drawing sketch 5860/1 (instead, added drawing NCD 2658/0).

Edition no: 4 –January 2010 (prepared by Eng. David Chen)

1. updated para. 1, 2, 3, 4, 5.1, 5.2, 5.5, 5.8, 6.

2. Changed figures 3, 4.

3. Added para.7.1.4, 7.1.5, 7.7.

4. updated para 9.2, 9.3, 10.2, 10.5, 13.

5. Added para 14.

6. updated appendix 4.







161 kv, 400 kV

Edition no.: 5


Page no. :41 of 48


JDHK 9420e to JDHK 9420e/1.

SKETCH 5131b/1 to SKETCH 5131b/2.

NCD 175/1 to NCD 175/2.

NCD 180 to NCD 180/1.

NCD 194/1 to NCD 194/2.

SKETCH 5850/2 to SKETCH 5850/3.





NCD 2677 to NCD 2677/1.





NCD 2663 to NCD 2663/1.

NCD 2692 to NCD 2692/1.










NCD 2382/1 to NCD 2382/2.


NCD 2391/1 to NCD 2391/2.

SKETCH 5104 to SKETCH 5104/1.

NCD 824 to NCD 824/1.

NCD 822/1 to NCD 822/2.


NCD 2380/1 to NCD 2380/2.










161 kv, 400 kV

Edition no.: 5


Page no. :42 of 48


NCD 2646 to NCD 2646/1.


Edition no: 5 –August 2019 (prepared by Eng. David Chen)

1. Updated para. 1, 3, 4, 5.1.1, 5.1.2, 5.2, 5.3, 5.5, 5.6.1, 5.8, 6, 8.1, 9.1, 9.2, 9.3, 11,

12.

2. Appendix 5 was added.









NCD 2692/1 to NCD 2692/2.









161 kv, 400 kV

Edition no.: 5


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APPENDIX 1 – GENERAL DRAWING OF THE POLE







161 kv, 400 kV

Edition no.: 5


Page no. :44 of 48

APPENDIX 2 - SUMMARY TABLE

Name

of

pole

Total

length

(m)

Total

weight

(ton)

External diameter

across angles (mm)

Maximum force and

moment at the base of pole

(ton x m)

Top

displacement

under service

load (m)

Note

Thickness (mm) B

endin

g

mom

ent

Tors

ion

mom

ent

Tra

n. or

Long. fo

rce

Ver

t. f

orc

e

Top

Bott

om

Gro

und

level

APPENDIX 3 - DELIVERY SCHEDULE

ITEM WEEKS Date of

delivery

to port

in

abroad

Date of

delivery

in

ISRAEL

1 2 3 4 5 ------

Bottom

part

Pole







161 kv, 400 kV

Edition no.: 5


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APPENDIX 4 – PACKING LIST OF GOODS







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Edition no.: 5


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APPENDIX 5- STATEMENT OF MANUFACTURING EXPERIENCE

I, ______________ (enter name), hereby state the following:

1. I________________ (enter name), am authorized to sign this statement on the

behalf of_________________("the manufacture").

2. I hold the position of _________________________________________ (enter

job title and description i.e. partner, production manager, sale manager, etc.) at

the Manufacturer.

3. I have been in this position since _______________ (enter date).

4. I am providing this statement with regards to I.E.C's tender number _______

("The Tender").

5.___________________ (the Manufacturer) have experience in manufacturing at least 10 (ten)

tapered tubular steel poles for at least 161 kv transmission line, in the last 10 (ten) years

(preceding the last date of submission the first stage documents).

6. The facts/details given in this statement have been checked and verified by me.

7. I hereby under take to provide, upon IEC's request and at its sole discretion, any

other documents (reference list, quantity, dates of supply, letter of recommendation etc.)

or other information requested for this Tender for purposes of proving said experience.

Signature: ______________

Date: __________________







161 kv, 400 kV

Edition no.: 5


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APPENDIX 6 – DRAWINGS







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Edition no.: 5


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APPENDIX 7

I.E.C QUALITY SPECIFICATION

Q – APP – 02

PROCUREMENT QUALITY REQUIREMENTS