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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
Jindal India Thermal Power Limited Page 2
Volume-II / Section - I EPC Tender for JITPL
SECTION – I
CONTENTS
Clause Description
Page No
1.0
2.0
3.0
General Information and Scope
Line Data
Service Condition
4
8
10
Jindal India Thermal Power Limited Page 3
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.
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Volume-II / Section - I EPC Tender for JITPL
(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,
Jindal India Thermal Power Limited Page 5
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
Jindal India Thermal Power Limited Page 6
Volume-II / Section - I EPC Tender for JITPL
(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.
Jindal India Thermal Power Limited Page 7
Volume-II / Section - I EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page 8
Volume-II / Section - I EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page 9
Volume-II / Section - I EPC Tender for JITPL
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.
Jindal India Thermal Power Limited Page 10
Volume-II / Section - II EPC Tender for JITPL
SECTION – II
GENERAL TECHNICAL &
ERECTION CONDITIONS
Jindal India Thermal Power Limited Page 11
Volume-II / Section-II EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page 12
Volume-II / Section-II EPC Tender for JITPL
TECHNICAL SPECIFICATIONS
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
Jindal India Thermal Power Limited Page 13
Volume-II / Section - II EPC Tender for JITPL
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.
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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.
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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.
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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)
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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.
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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
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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-
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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.
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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.
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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
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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
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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.
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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.
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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.
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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.
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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
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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.
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SECTION – III
TOWER SPECIFICATION
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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
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TECHNICAL SPECIFICATIONS
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
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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
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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).
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(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.
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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.
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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
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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.
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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.
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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
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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
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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
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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.
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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
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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.
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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.
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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,
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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
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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.
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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
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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
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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
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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
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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.
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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
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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
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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.
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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.
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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.
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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
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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
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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
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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
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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
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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.
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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
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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
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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
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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
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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
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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;
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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 :
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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.
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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.
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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.
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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
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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 :
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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,
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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
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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., back- filling
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
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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
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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.
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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);
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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.
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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
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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
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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.
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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
Jindal India Thermal Power Limited Page 89
Volume-II / Section - III EPC Tender for JITPL
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.
Jindal India Thermal Power Limited Page 90
Volume-II / Section - III EPC Tender for JITPL
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.
Jindal India Thermal Power Limited Page 91
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
Jindal India Thermal Power Limited Page
93
Description of
Activity
Items to be Checked Tests/Checks to be
done
Volume-II / Section-III EPC Tender for JITPL
Ref. documents Check/Testing Counter Check/Test by Owner
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)
Source meeting Owner
Specification
As per document at
Annexure-3 of this FQP
at page 16
Source meeting Owner
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
To review the proposal based on
the documents
100% review of lab test results
To review the proposal based on
the documents.
100% review of lab test results
Verification at random
Engineer
Engineer
Engineer
Engineer
Engineer
Jindal India Thermal Power Limited Page
94
Description of
Activity
Items to be Checked Tests/Checks to be
done
Volume-II / Section-III EPC Tender for JITPL
Ref. documents Check/Testing Counter Check/Test by Owner
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-
Jindal India Thermal Power Limited Page
95
b. During
concreting
Volume-II / Section-III EPC Tender for JITPL
Description of
Activity
Items to be Checked Tests/Checks to be
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-
Jindal India Thermal Power Limited Page
96
a. Workability
1. Slump test
Volume-II EPC Tender for JITPL
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
Items to be Checked Tests/Checks to be
done
Volume-II / Section-III EPC Tender for JITPL
Ref. documents Check/Testing Counter Check/Test by Owner
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
Jindal India Thermal Power Limited Page
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
Jindal India Thermal Power Limited Page
99
Description of
Activity
Items to be Checked Tests/Checks to be
done
Volume-II / Section-III EPC Tender for JITPL
Ref. documents Check/Testing Counter Check/Test by Owner
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
Jindal India Thermal Power Limited Page
100
Description of
Activity
Items to be Checked Tests/Checks to be
done
Volume-II / Section-III EPC Tender for JITPL
Ref. documents Check/Testing Counter Check/Test by Owner
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
Jindal India Thermal Power Limited Page
101
from CEA.
Volume-II / Section-III EPC Tender for JITPL
Jindal India Thermal Power Limited Page
102
Volume-II / Section-III EPC Tender for JITPL
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)
672+/-4 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 when tested by Le
chatlier and 0.8% Autoclave test.
Specific surface area shall not be
less than 225 sq.m. per Kg or
2250 Cm2/gm.
72+/- 1 hour : Not less than 23
Mpa (23 N/mm2)
168+/-2 hour : Not less than 33
Mpa (33 N/mm2)
672+/-4 hour : Not less than 43
Mpa (43 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
Specific surface area shall not be
less than 225 sq.m. per Kg or 2250
Cm2/gm.
72+/- 1 hour : Not less than 27
Mpa (27 n/mm2)
168+/-1 hour : Not less than 37
Mpa (37 N/mm2)
672+/-1 hour : Not less than 53
Mpa (53 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.
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)
Jindal India Thermal Power Limited Page
103
Volume-II / Section-III EPC Tender for JITPL
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%
e) Total sulphur content
calculated as sulpuric
anhydride (SO3),
percentage by mass Not
more than 2.5 and 3.0
when tri-calcium
aluminate percent by
mass is 5 or less and
greater than 5
respectively.
Not more than 5 percent
by mass Max. 4.00%
d) Magnesia percentage by mass
Max. 6%
e) Total sulphur content
calculated as sulpuric
anhydride (SO3), percentage
by mass Not more than 2.5
and 3.0 when tri-calcium
aluminate percent by mass
is 5 or less and greater than
5 respectively.
Not more than 5 percent
Jindal India Thermal Power Limited Page
104
Name of the test
Volume-II / Section-III EPC Tender for JITPL
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.
Not more than 5 percent
Jindal India Thermal Power Limited Page
105
Volume-II / Section-III EPC Tender for JITPL
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
Testing in approved lab
Testing in approved lab
Jindal India Thermal Power Limited Page
106
Volume-II / Section-III EPC Tender for JITPL
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%
Jindal India Thermal Power Limited Page
107
Crushing Value
Volume-II / Section-III EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page
108
Volume-II / Section-III EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page
109
Volume-II / Section-III EPC Tender for JITPL
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.
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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.
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SECTION – IV
PRE-COMMISSIONING PROCEDURES
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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
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TECHNICAL SPECIFICATIONS
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
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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.
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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:
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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.
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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
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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
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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
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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
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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).
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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.
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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.
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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.
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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.
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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.
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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:
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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
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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.
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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.
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SECTION – V
TECHNICAL SPECIFICATIONS
FOR ACSR ‘MOOSE’ CONDUCTOR
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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
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23.0
N/A
24.0
N/A
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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)
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(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).
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*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
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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.
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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
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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.
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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
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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.
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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.
Reload to 70% UTS and hold for 1 hour. Take readings after 5, 10, 15, 30,
45 and 60 minutes. Release to initial load.
Reload to 85% UTS and hold for 1 hour. Take readings after 5, 10, 15, 30,
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.
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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.
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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
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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.
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(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
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24.0 REQUIREMENT OF DOCUMENTS : N/A
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SECTION – VI
TECHNICAL SPECIFICATIONS
FOR 7/3.66MM GALVANISED STEEL EARTH-WIRE
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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
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TECHNICAL SPECIFICATION
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
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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
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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
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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.
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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.
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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
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(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
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(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.
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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.
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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.
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SECTION – VII
TECHNICAL SPECIFICATIONS
FOR PORCELAIN DISC INSULATORS
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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
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TECHNICAL SPECIFICATION
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
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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.
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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:
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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
……………………………………………………………………………………
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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.
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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.
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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:
Jindal India Thermal Power Limited Page 171
Volume-II / Section-VII EPC Tender for JITPL
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.
Jindal India Thermal Power Limited Page 172
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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
Jindal India Thermal Power Limited Page 173
Volume-II / Section-VII EPC Tender for JITPL
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
Sr. Particulars of test
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
Jindal India Thermal Power Limited Page 174
Volume-II / Section-VII EPC Tender for JITPL
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
withstand test (Dry)
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
of this specification
As per Annexure–8
of this specification
III) On 3rd sample
i) Time Load test
}
As per Annexure–8
Jindal India Thermal Power Limited Page 175
Volume-II / Section-VII EPC Tender for JITPL
15.2 ACCEPTANCE TESTS:
}
of this specification
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:
Sr. Particulars of test
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
withstand test (Dry)
}
}
}
}
IS:731
IS:731
IEC:60383
………………………………………………………………………….
15.3 ROUTINE TESTS:
Jindal India Thermal Power Limited Page 176
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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:
Sr. Particulars of test
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:
Sr. Particulars of test
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/
Jindal India Thermal Power Limited Page 177
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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
of this specification
As per Annexure-8
of this specification
As per Annexure-8
of this specification
h)
Chemical analysis of Zinc used
for galvanizing
}
}
As per Annexure-8
of this specification
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.
Jindal India Thermal Power Limited Page 178
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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.
Jindal India Thermal Power Limited Page 179
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SECTION – VIII
TECHNICAL SPECIFICATIONS FOR HARDWARE FITTINGS
AND ACCESSORIES FOR CONDUCTOR AND
EARTHWIRE
Jindal India Thermal Power Limited Page 180
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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
Jindal India Thermal Power Limited Page 181
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TECHNICAL SPECIFICATIONS
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
Jindal India Thermal Power Limited Page 182
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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.
Jindal India Thermal Power Limited Page 183
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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
Jindal India Thermal Power Limited Page 184
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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.
Jindal India Thermal Power Limited Page 185
Volume-II / Section-VIII EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page 186
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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.
Jindal India Thermal Power Limited Page 187
Volume-II / Section-VIII EPC Tender for JITPL
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.
Jindal India Thermal Power Limited Page 188
Volume-II / Section-VIII EPC Tender for JITPL
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.
Jindal India Thermal Power Limited Page 189
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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.
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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.
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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.
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(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
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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
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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.
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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
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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
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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
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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.
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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
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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.
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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
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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
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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.
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(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
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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 –
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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
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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 IS:2486(Part-I)
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
Flexible Copper Bond
(a) Slip strength test As per Annexure-10
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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
a) Chemical analysis of materials
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
a) Chemical analysis of materials
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
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4.1.12.
On Earthwire Tension clamp Assembly
a) Chemical analysis of materials
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
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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
As per IS:2121 (Part-I)
Clause 7.5,7.10 & 7.11
As per IS:2121 (Part-I)
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
a) Visual examination and dimensional As per IS:2121 (Part-II)
verification Clause 6.2, 6.3
Flexible Copper Bond
a) Visual examination and dimensional As per IS:2121 (Part-II)
verification Clause 6.2, 6.3
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4.2.8.
b) Slip strength test
Vibration Damper for Earthwire
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
As per annexure – 11
As per annexure – 11
As per annexure – 11
As per annexure – 11
As per annexure – 11
As per annexure – 11
As per annexure – 11
As per annexure – 11
As per annexure – 11
4.2.9.
4.2.10.
4.2.11.
Spacer Damper for conductor/Rigid spacer for Jumper
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) 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
a) Visual examination and dimensional
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
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a) Visual examination and dimensional
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
a) Visual examination and dimensional As per IS:2121 (Part-II)
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.
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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
Jindal India Thermal Power Limited Page 214
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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.
Jindal India Thermal Power Limited Page 215
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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
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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,
Jindal India Thermal Power Limited Page 217
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DK-2900, Heeleprup,
Denmark
NEMA National Electric Manufacture Association,
155, East 44th Street,
New York, NY 10017, U.S.A.
Jindal India Thermal Power Limited Page 218
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SECTION – IX
ANNEXURES
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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
(ii) 3 M Extension pieces 800 1800 1
(iii) 6 M Extension pieces 1700 2250 1
(iv) '9 M Extension pieces 2500 3100 1
c) 'C' Type towers 11900 6100 11
d) (i) 'D' Type towers Normal 15000 10000 16
(ii) 3 M Extension pieces 950 3100 1
(iii) 6 M Extension pieces 1700 3800 2
(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
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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
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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
Jindal India Thermal Power Limited Page 222
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ANNEXURE – 2 :
BLANK
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Volume-II / Section-IX EPC Tender for JITPL
ANNEXURE – 3 :
BLANK
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Volume-II / Section-IX EPC Tender for JITPL
ANNEXURE – 4 :
BLANK
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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
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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
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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
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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:
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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%.
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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.
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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
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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).
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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
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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.
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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.
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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)
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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.............................
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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)
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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...............
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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
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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
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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.
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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
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3.3.
3.4.
Flexible Copper Bond
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.
Vibration Damper for Earthwire
(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
Jindal India Thermal Power Limited Page 252
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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
Jindal India Thermal Power Limited Page 253
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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
Jindal India Thermal Power Limited Page 254
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(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)
Jindal India Thermal Power Limited Page 255
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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
Jindal India Thermal Power Limited Page 256
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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
Jindal India Thermal Power Limited Page 257
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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
Jindal India Thermal Power Limited Page 258
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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.
Jindal India Thermal Power Limited Page 259
Volume-II / Section - IX EPC Tender for JITPL
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
Vibration Damper for Earthwire
(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
Jindal India Thermal Power Limited Page 260
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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
Jindal India Thermal Power Limited Page 261
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(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.
Jindal India Thermal Power Limited Page 262
Volume-II / Section - IX EPC Tender for JITPL
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.
Jindal India Thermal Power Limited Page
263
`Description Unit
Volume-II / Section - IX EPC Tender for JITPL
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.
Jindal India Thermal Power Limited Page
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`Description Unit
Volume-II / Section - IX EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page
265
Sr.No. Description
1. Name
of manufacturer
Volume-II / Section - IX EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page
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Volume-II / Section - IX EPC Tender for JITPL
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
JITPL PowerTransco Limited Page
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Volume-II / Section - IX EPC Tender for JITPL
GUARANTEED TECHANICAL PARTICULARS OF
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
Manufacturer’s Name and Address
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
Jindal India Thermal Power Limited Page 268
Volume-II / Section - IX EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page 269
Sr.No
Description
Volume-II / Section - IX EPC Tender for
GUARANTEED TECHANICAL PARTICULARS OF
REPAIR SLEEVE FOR ACSR MOOSE CONDUCTOR
Unit Value Specified by the Owner Value Guaranteed by the Bidder
Manufacturer’s Name and Address
Drawing enclosed
Suitable for conductor size
Purity of Aluminium Aluminium
alloy used for Aluminium sleeve
Inside diameter of sleeve before
compression
Outside diameter of sleeve before
compression
Diameter before compression
Diameter after compression
Length of sleeve
Weight of sleeve
Resistance of the compressed unit
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
Jindal India Thermal Power Limited Page
270
Sr.No
Description
bare conductor
Volume-II / Section - IX EPC Tender for JITPL
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
JITPL PowerTransco Limited Page
271
Volume-II / Section - IX EPC Tender for JITPL
GUARANTEED TECHANICAL PARTICULARS OF
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
Jindal India Thermal Power Limited Page 272
Volume-II / Section - IX EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page 273
Volume-II / Section - IX EPC Tender for JITPL
GUARANTEED TECHANICAL PARTICULARS OF
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
Jindal India Thermal Power Limited Page 274
Volume-II / Section - IX EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page 275
Volume-II / Section - IX EPC Tender for JITPL
GUARANTEED TECHANICAL PARTICULARS OF
T CONNECTOR FOR TWIN ACSR MOOSE CONDUCTOR
Sr.No. Description
1. Manufacturer’s Name and Address
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.
Inside diameter of sleeve before
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
Jindal India Thermal Power Limited Page 276
Volume-II / Section - IX EPC Tender for JITPL
GUARANTEED TECHANICAL PARTICULARS OF
MID SPAN COMPRESSION JOINT FOR
7/3.66 MM GALVANISED STEEL EARTHWIRE
Sr.No. Description
1. Manufacturer’s Name and Address
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
Jindal India Thermal Power Limited Page 277
Volume-II / Section - IX EPC Tender for JITPL
b)
8.
9.
a)
b)
c)
10.
11.
After compression
Length of Aluminium sleeve
Weight of sleeve
Steel
Aluminium
Aluminium filler sleeve
Slip strength
Resistance of the compressed unit
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
Jindal India Thermal Power Limited Page 278
Volume-II / Section - IX EPC Tender for JITPL
GUARANTEED TECHANICAL PARTICULARS OF
FLEXIBLE COPPER BOND
Sr.No. Description
1. Manufacturer’s Name and Address
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
Jindal India Thermal Power Limited Page 279
Volume-II / Section - IX EPC Tender for JITPL
GUARANTEED TECHANICAL PARTICULARS OF
VIBRATION DAMPER FOR 7/3.66 MM EARTHWIRE
Sr.No. Description
1. Manufacturer’s Name and Address
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
Jindal India Thermal Power Limited Page 280
Volume-II / Section - IX EPC Tender for JITPL
GUARANTEED TECHANICAL PARTICULARS OF
SUSPENSION CLAMP FOR 7/3.66mm GALVANISED STEEL EARTHWIRE
Sr.No. Description
1. Manufacturer’s Name and Address
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
Jindal India Thermal Power Limited Page 281
Volume-II / Section - IX EPC Tender for JITPL
GUARANTEED TECHANICAL PARTICULARS OF
TENSION CLAMP FOR 7/3.66 MM EARTHWIRE
Sr.No. Description
1. Manufacturer’s Name and Address
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
iii) Aluminium filler sleeve
5. Outside dimension of sleeve
a) Before compression i) Steel sleeve
ii) Aluminium Sleeve
iii) Aluminium filler 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
Jindal India Thermal Power Limited Page 282
Volume-II / Section - IX EPC Tender for JITPL
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 * * *
(ii) 3 M Extension pieces 800 1800 1 * * *
(iii) 6 M Extension pieces 1700 2250 1 * * *
(iv) '9 M Extension pieces 2500 3100 1 * * *
c) 'C' Type towers 11900 6100 11 * * *
d) (i) 'D' Type towers Normal 15000 10000 16 * * *
(ii) 3 M Extension pieces 950 3100 1 * * *
(iii) 6 M Extension pieces 1700 3800 2 * * *
(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
* *
Jindal India Thermal Power Limited Page 283
Volume-II / Section - IX EPC Tender for JITPL
Jindal India Thermal Power Limited Page 284
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 * *
Volume-II / Section - IX EPC Tender for JITPL
TOTAL COST OF SUPPLY
*
Jindal India Thermal Power Limited Page 285
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 * *
Volume-II / Section - IX EPC Tender for JITPL
F&I, ERECTION AND CIVIL WORKS COST PER KM *
* TO BE FILLED BY THE CONTRACTOR
Jindal India Thermal Power Limited Page 286
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
*
Volume-II / Section - IX EPC Tender for JITPL
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
13 FOR (+) 6M Extension of DA Type Tower
14 FOR (+) 9M Extension of DA Type Tower
15 FOR (+) 18M Extension of DA Type Tower
16 FOR (+) 25M Extension of DA Type Tower
17 FOR NORMAL B TYPE TOWER
18 FOR (+) 3M Extension of DB Type Tower
19 FOR (+) 6M Extension of DB Type Tower
20 FOR (+) 9M Extension of DB Type Tower
21 FOR NORMAL C TYPE TOWER
22 FOR (+) 3M Extension of DC Type Tower
23 FOR (+) 6M Extension of DC Type Tower
24 FOR (+) 9M 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
Jindal India Thermal Power Limited Page 287
Volume-II / Section - IX EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page 288
Volume-II / Section - IX EPC Tender for JITPL
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
Jindal India Thermal Power Limited Page 289