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SEC III-Technical Specs PDF
SEC III-Technical Specs PDF
SECTION - III
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SECTION-III
(PART-A)
TECHNICAL SPECIFICATIONS
1. GENERAL INFORMATION AND SCOPE
1.1 SCOPE
1.1.1 This Specification covers detailed survey, check survey, tower
spotting/optimization of tower location, soil resistivity measurements and
geotechnical investigation, fabrication and supply of all type of 220kV double
circuit transmission line towers (as per PSTCL design) including bolts, nuts
(normal & Anti-Theft) and washers, U-bolt, D-shackle and all type of tower
accessories like phase plate, circuit plate, number plate, danger plate, anti-
climbing device (with barbed wire) etc. and casting of foundation for tower
footing, erection of towers, tower earthing, fixing of insulator string, stringing
of conductors and earthwire along with all necessary line accessories and
testing and commissioning of the erected transmission lines.
1.1.2 This specification also covers the fabrication and supply of gantry structures
for under-crossing the 220kV and 400kV Transmission Lines including bolts,
nuts and washer, D-shackle and all type of accessories like phase plate,
circuit plate, number plate, danger plate, etc. casting of foundation for gantry
footing, erection of gantries, gantry earthing, fixing of Insulator string, stringing
of conductors and earth wires along with all necessary line accessories. All
the clauses in the specification will be relevant for the gantry structures also
unless stated otherwise.
1.1.3 This Specification includes the supply of insulators and their hard wares,
ACSR Zebra, earthwire of size 7/3.15 mm, earthwire suspension and tension
clamps and all other line accessories for conductor & earthwire like mid-span
compression joints for conductor and earth wire, repair sleeve for conductor,
vibration damper for conductor & Earth wire, flexible copper bond which shall
be supplied by the bidder during execution of the project.
1.1.4 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 plate, number
plate, circuit plate, anti climbing devices etc. required for tower manufacture
and erection shall be included in the bidders scope of supply. Bidder shall
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clearly indicate in the offer, the sources from where he proposes to procure
the raw materials and the components.
1.1.5 The entire stringing work of conductor shall be carried out by standard
stringing practice. The scope of the work includes both single circuit stringing
on DC towers and double circuit stringing on DC Towers and towers are
designed for this. The bidder shall indicate in the offer, the detail description of
the procedure to be deployed for stringing operation.
1.1.6 The Special River crossing towers or any other special type of tower required
as per approved route plan, if any shall be fabricated and supplied by the
Contractor. The construction of river crossing section including casting of
foundation shall also be in the scope of bidder.
1.1.7 The fabrication & inspection of Tower Proto assemblies, wherever required,
shall also be within the scope of the Bidder and no extra payment for the
same shall be made.
1.1.8 The following Package of 220KV transmission lines are included in the scope
of the bidder under this specification:
Package 1:
The proposed completion period for this package is 14 months from Letter of Award.
Package 2:
The proposed completion period for this package is 15 months from Letter of Award.
Package 3:
The proposed completion period for this package is 11 months from Letter of Award.
Package 4:
The proposed completion period for this package is 11 months from Letter of Award.
Package 5:
The proposed completion period for this package is 10 months from Letter of Award.
Package 6:
The proposed completion period for this package is 15 months from Letter of Award.
2. a. Aluminium mm 54/3.18
b. Steel mm 7/3.18 7/3.15
3. TRANSMISSION TOWERS
3.1 Qualifying Requirements &General Description of the Towers.
3.1.1 Incase the Contractor is a Conductor Manufacturer then the manufacturer
from whom he proposes to procure Tower material should have
manufacturing facility for Transmission Lines towers with minimum
manufacturing capacity of 4000 MT per financial year. The average
quantity manufactured per financial year during the last three financial
years should not be less than 2000 MT. Documentary proof in the form of
certificate from Chartered Accountant/ Engineer for the required
manufacturing capacity and performance certificate from any SEB / Utility
for at least 300 MT 132 KV or higher rating Transmission Lines Towers
during last 3 years shall be submitted. On Financial side, the average
Turnover of the manufacturer for the last three financial should be min.20
Crores and he should have liquid assets and / or evidence of access to or
availability of credit facilities of not less than Rs. 2 Crores. Documentary
proof for these shall also be attached with the bid.
3.1.3 The towers are of self supporting lattice steel type, designed to carry the
line conductors with necessary insulators, earthwire and all fittings under
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all loading conditions. Outline diagrams of double circuit towers are
enclosed with the Specification.
3.1.4 The tower shall be fully galvanized structure.
3.2 Type of Towers
3.2.1 The towers are classified as given below for 220 KV Lines
Type Deviation Limit Typical use
3.3.4 In case of certain locations actual spotting spans exceed the design spans
and cross arms and certain members of the tower shall be modified /
reinforced.
3.3.5 ELECTRICAL CLEARANCES
3.3.5.1 GROUND CLEARANCES
The min. ground clearances from the bottom conductor shall not be less
than 7015mm at the max. sag conditions i.e. at max. temperature and still
air. However to achieve the above clearance the height of the tower is
increased in the following manner.
a. A positive allowance of 150 mm shall be provided to account for error in
stringing.
b. Conductor creep shall be compensated by over tensioning the conductor
at temperature of 26oC lower than the stringing temperature for ACSR
ZEBRA.
For river crossing tower, the minimum electrical clearance including
ground clearance will be same as normal tower except an allowance of
4% of maximum sag of conductor instead of 150mm for normal towers
shall be provided to account for errors in stringing.
3.3.5.2 RAILWAY CROSSING
In case of railway crossing, the min. height above rail level to the lowest
portion of any conductor under condition of max. sag in accordance with
the regulations for Electrical Crossing of railway tracks as prevailing at the
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time of construction of line shall be applicable. However, as per existing
Indian Electricity Rules, the minimum clearance is stipulated as 15.40
meters.
Nil 2130
15 1980
Single suspension insulator 30 1830
1.
string
45 1675
60 -
Nil 2130
10 2130
3. Jumper
20 1675
30 -
3.4 Drawings
3.4.1 After award of contract, the contractor shall made proto assembly as per
structural drawing of each type of tower as supplied by employer and get it
inspected and then prepare BOM and shop drawings. The contractor shall
furnish the following in ten (10) copies to the employer for necessary
within fifteen (15) days after approval of drawings.
a Bill of materials, indicating cutting and bending detail against each
member.
b Shop drawings showing all details relevant to fabrication
c. All the drawings for the tower accessories.
d. The contractor should also submit one copy of reproducible drawing/Bill of
materials as mentioned above within 15 days after final approval.
3.4.2 The Contractor is required to submit four copies of the drawings as
mentioned in clause 3.4.1 for employers approval. While submitting the
bill of material and any other drawings pertaining to the subject
transmission line, the Contractor shall clearly indicate on each drawing
PSTCL Specification No., Name of the transmission line and project, letter
reference No. and date on which the submission are made.
3.4.3 The design and drawings as covered in clause above shall be
approved/commented by the Employer as the case may be within 21
(twenty one) days of receipt of designs/drawings in PSTCL Transmission
Design Office. If the design /drawings are commented on by the employer,
the Contractor shall submit 4 sets of revised designs /drawings within 10
(ten) days of date of issue of comments.
3.4.4 The Contractor is required to furnish the progress of submissions and
approvals of drawings on twenty fifth of every month till the completion of
all the design activities.
3.4.5 The details shall include description of drawings, schedule date of
submission, actual date of submission, schedule date of approval, actual
date of approval, schedule date of submission of distribution copies, and
Remarks column. Provision of six additional columns shall also be made
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in the above progress report to indicate date of comments issued by the
Employer and details of submission of revised drawings.
3.5 GANTRIES
3.5.1 The entire clauses relating to towers will be relevant for gantries in general
unless otherwise stated.
3.5.2 The structural drawings for gantries will be provided by employer.
3.6 MATERIALS
3.6.1 TOWER STEEL SECTIONS
Indian Standard steel sections of tested quality in conformity with IS:2062
1980 (Grade A), with latest amendments, or any other equivalent grade of
structural steel angle sections and plates conforming to latest International
standard are to be used in towers, extensions and stub setting templates.
Preferably steel sections used should be as supplied by main producer
like SAIL/TISCO/IISCO etc. However, in case of non availability, if
purchased from secondary re-rollers, the re-rollers must ensure use of
billet of main producer used for manufacture of steel section. Also re-roller
should be a reputed manufacturer having ISI certification mark/license on
its product as per IS:2062 Grade-A. PSTCL reserves the right to witness
the rolling process and to test the billets & sections at the premises of the
Re-roller for which all testing facilities shall be ensured by the bidder free
of cost.
3.6.2 FASTENERS: BOLTS, NUTS AND WASHERS
3.6.2.1 All bolts and nuts (including Anti-Theft) shall conform to IS:12427-1988. All
bolts and nuts shall be galvanized as per IS 2629-1985 with coating as per
IS-1367 Part XIII 1983 and shall have hexagonal head (round in case of
Anti-Theft) and nuts, the heads being forged out of the solid steel rods and
shall be truly concentric, and square with the shank, which must be
perfectly straight. In case of Anti-Theft nuts , the shape & size shall be as
per the attached drawing. The difference between the two minimum
measurement from bolt head size edge on bearing face on the shank of
bolt taken for any to opposite side shall not exceed maximum limit of
0.84mm for M16 type bolts .Similarly the difference between the minimum
wall thickness measured between minor thread diameter and the flats of
any 2 opposite sides of nuts shall not exceed the maximum limit of 0.42
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mm for M 16 size of nuts .Further the bearing face shall be square to
shank with the tolerance of 2 degree.
3.6.2.2 The bolt shall be of 16 mm dia and of property class 5.6 as specified in IS:
1367 (part-III) 1979 and matching nut of property class 5 as specified in
IS:1367 (Part-VI) 1980.
3.6.2.3 Bolts upto M 16mm and having length upto 10 times the diameter of the
bolts should be manufactured by cold forging and thread rolling process to
obtain good and reliable mechanical properties and effective dimensional
control. The shear strength of bolts for 5.6 grade should be 310-MPa
minimum as per IS:12427, bolts should be provided with washer in
accordance with IS:1363 Part-1 to ensure proper bearing.
3.6.2.4 Nuts should be double chamfered as per the requirement of IS:1363 Part-
III, 1984. The manufacturer should ensure that nuts should not be over-
tapped beyond 0.4mm oversize on effective diameter for size upto M 16.
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 that 8 mm when fully tightened. All nuts shall fit and
tight to the point where the shank of the bolt connects to the head.
3.6.2.7 Flat and tapered washers shall be provided wherever necessary. Spring
washers shall be provided for insertion under all nuts. These washers shall
be of spring steel electro-galvanised steel, positive lock type and 3.5mm
in thickness for 16-mm dia bolt as per IS 3063 (latest edition)
3.6.2.8 To obviate bending stress in bolts or to reduce it to minimum, no bolt shall
connect aggregate thickness of more than three (3) times its diameter.
3.6.2.9 The bolt position in assembled towers shall be as per IS:5613 (Part-
II/Section-2-1976).
3.6.2.10 Bolts at the joints shall be so staggered that nuts may be tightened with
spanners without fouling.
3.6.2.11 The bidder shall use Anti-Theft nuts & bolts on the first storey of the tower
(Drg. attached)
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3.6.2.12 To ensure effective in-process Quality control, it is essential that the
manufacturer should have all the testing facilities for tests like weight of
zinc coating, shear strength, other testing facilities etc. in house. The bolts
should have ISI certification mark as per IS 12427-988 & Nuts as per
1363-Part III-1984 with latest amendments.
3.7 Tower Accessories
3.7.1 Step Bolts
Each tower shall be provided with step bolts conforming to IS:10238 of not
less than 16mm diameter and 175 mm long, spaced not more than 450
mm apart and extending from about 3.5metres above the ground level to
the top of the tower. For double circuit tower the step bolt shall be fixed on
one leg from 3.5M above ground level to top of the towers. Each step bolt
shall be provided with two nuts on one end to fasten the bolt securely to
the tower and button head at the other end to prevent the feet from
slipping away. The step bolts shall be capable of withstanding a vertical
load not less than 1.5 KN.
3.7.2 Insulator Strings and Earthwire Clamps Attachments
a. Suspension Insulator string assemblies under the bidders scope of supply
shall be used for suspension towers as per drawings enclosed with
Specification. For the attachment of suspension insulator string, a
swinging D-Shackle on the tower shall be provided as per drawings
enclosed with Specification. The supply of D-shackle is within scope of the
Bidder.
b. At tension towers, strain plates of suitable dimensions on the underside of
each cross arm tip and at the top of earthwire peak should be provided for
taking the hooks or D-Shackle of the tension insulator strings or earthwire
tension clamps, as the case may be.
3.7.3 Earthwire Clamps
a Suspension clamp :Earthwire suspension clamps will be supplied by the
bidder as per the reference drawing enclosed with specification.
b Tension Clamps:The bidder shall supply earthwire tension clamps for use
on the towers. The reference drawings for the same is enclosed with the
specification. However, the contractor shall supply the U-bolts wherever
required.
3.7.4 Anticlimbing Device
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Anticlimbing device/fencing as per enclosed drawings shall be provided
and installed by the Contractor for all towers/gantries. The height of the
anticlimbing device shall be provided approximately 3m above ground
level.
3.7.5 Danger, Number, Circuit and Phase plate
Danger, Number, Circuit and Phase Plates shall be provided and
installed by the Contractor with design & shape as per relevant IS.
a) Each tower shall be fitted with a number plate and danger plate. Each
tension tower shall be provided with a set of phase plates also. All the
double circuit towers are to be provided with circuit plate fixed near the
legs.
b) The letters, figures and the conventional skull and bones of danger plates
shall conform to IS:2551-1963 and shall be in a single red on the front of
the plate.
4 Tower Foundations
4.1 Foundation Types
4.2.1 General
These specifications provide general guide lines for towers for
construction of foundations for transmission and gantry towers for the
transmission lines covered in the tender. The foundation shall be
constructed as per design/drawings to be supplied by the employer.
Drawings for foundations of various tower type upto 6 mtr. extension and
gantry towers are attached.
4.2.2 Before start of work, trial bore holes upto 6 mtr. below ground level shall
be carried out by successful bidder at every kilometer or as desired by
employer. The bore log data comprising of information like position of sub
soil water table, soil strata shall be submitted to the employer for
classification of foundation type to be provided at each location.
4.2.3 Reinforced Cement concrete or special foundations shall be used for all
types of normal towers in conformity with the present day practice followed
in the country and the specifications laid herein. All the four footings of the
tower and their extension shall be similar, irrespective of down thrust and
uplift.
5.1.3 Contractor shall set up required number of stores along the line at his own
cost and the exact location of such stores shall be discussed and agreed
to between the Contractor and the Employer. The employer shall not be
liable for any unpaid rents of the space taken for storing of material or any
damage or liability arising out of such arrangement.
5.2 Treatment of Minor Galvanising Damage
In case any minor damage to galvanising is noticed, the same shall be
treated with zinc rich paint (commercial grade) (having at least 90% zinc
content) before erection.
5.3 Assembly
5.3.1 The method followed for the erection of towers, shall ensure the points
mentioned below:
(a) Straining of the members shall not be permitted for bringing them into
position. It may, however, be necessary to match hole positions at joints
and to facilitate this, tommy bars not more than 450 mm long may be
used.
(b) Before starting erection of an upper section, the lower section shall be
completely braced and all bolts provided and tightened adequately in
accordance with approved drawings to prevent any mishap during tower
erection.
(c) All plan diagonals relevant to a section of tower shall be placed in position
before assembly of upper section is taken up.
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(d) The bolt position in assembled towers shall be as per IS:5613 (Part-
II/Section 2)-1976.
(e) Tower shall be fitted with number plate, danger plate, phase plate, circuit
plate and anti climbing device as described.
(f) All blank holes, if any left, after complete erection of the tower, are to be
filled up by bolts and nuts of correct size.
5.4 Tightening and Punching of Bolts and Nuts
5.4.1 All nuts shall be tightened properly using correct size spanner/torque
wrench. Before tightening, it will be seen that filler washers and plates are
placed in gaps between members wherever applicable bolts of proper size
and length are inserted, and one spring washer is inserted under each nut.
In case of step bolts, spring washers shall be placed under the outer nut.
The tightening shall progressively be carried out from the top downwards,
care being taken that all bolts at every level are tightened simultaneously.
The threads of bolts projecting outside the nuts shall be punched at their
position on the diameter to ensure that the nuts are not loosened in course
of time. If during tightening a nut is found to be slipping or running over the
bolt threads, the bolt together with the nut shall be replaced.
5.4.2 Anti-Theft type nuts & bolts shall be provided upto first storey of tower to
avoid pilferage of tower members.
5.5 Insulator Hoisting
5.5.1 Suspension insulator strings shall be used on suspension towers and
tension insulator strings on angle and dead end towers. These shall be
fixed on all the towers just prior to the stringing. Damaged insulators and
fittings, if any, shall not be employed in the assemblies. Before hoisting, all
insulators shall be cleaned in a manner that will not spoil, injure or scratch
the surface of the insulator, but in no case shall any oil be used for the
purpose. Torque wrench shall be used for fixing different line materials
and their components, like suspension clamp for conductor and earthwire
etc.
5.6 Handling of Conductor and Earthwire
5.6.1 The Contractor shall be entirely responsible for any damage to the towers
or conductors during stringing. While running out the conductors, care
shall be taken that the conductors do not touch or rub against the ground
or objects, which could cause scratches or damages to the strands. The
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conductors shall be run out of the drums from the top in order to avoid
damage due to chafing. Immediately after running out, the conductor shall
be raised at the supports to the levels of the clamps and placed into the
running blocks. The groove of the running blocks shall be of such a design
that the seat is semi-circular and larger than the diameter of the
conductor/earthwire and it does not slip over or rub against the sides. The
grooves shall be lined with hard rubber or neoprene to avoid damage to
conductor and shall be mounted on properly lubricated bearings.
5.6.2 The running blocks shall be suspended in a manner to suit the design of
the cross arm. All running blocks, especially those at the tension end, will
be fitted on the cross-arm with jute cloth wrapped over the steel work and
under the slings to avoid damage to the slings as well as to the protective
surface finish of the steel work. In case suspension, or section towers are
used even for temporary terminations, if this be unavoidable, they shall be
well guyed and steps shall be taken by the Contractor to avoid damage.
Guying proposal alongwith necessary calculations shall be submitted by
the Contractor to Employer for the approval. Proper T&P shall also be
made available to the Employer by the Contractor for checking the
tensions in the guy wires. The drums shall be provided with a suitable
braking device to avoid damages, loose running out and kinking of the
conductor. The conductor shall be continuously observed for loose or
broken strands or any other damage. When approaching end of a drum
length, at least three coils shall be left when the stringing operations are to
be stopped. These coils are to be removed carefully, and if another length
is required to be run out, a joint shall be made as per the
recommendations of the manufacturers.
5.6.3 Repairs to conductors, if necessary, shall be carried out during the running
out operations, with repair sleeves. Repairing of conductor surface shall
be done only in case of minor damage, scuff marks etc. keeping in view
both electrical and mechanical safe requirements. The final conductor
surface shall be clean smooth and without any projections, sharp points,
cuts, abrasions etc.
5.6.4 Conductor splices shall be so made that they do not crack or get damaged
in the stringing operation. The Contractor shall use only such
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equipment/methods during conductor stringing which ensures complete
compliance in this regard.
5.6.5 Derricks shall be used where roads, rivers, channels, telecommunication
or overhead power lines, railway lines, fences or walls have to be crossed
during stringing operations. It shall be seen that normal services are not
interrupted or damage caused to property. Shut down shall be obtained
when working at crossing of overhead power lines. The Contractor shall
be entirely responsible for the proper handling of the conductor, earthwire
and accessories in the field.
5.6.6 The sequence of running out shall be from top to downwards i.e. the
earthwire shall be run out first, followed by the conductors in succession.
Unbalances of loads on towers shall be avoided as far as possible.
5.6.7 The proposed transmission line may run parallel for certain distance with
the existing Transmission lines, which may remain, energised during the
stringing period. As a result there is a possibility of dangerous voltage
build up due to electromagnetic and electrostatic coupling in the pulling
wire, conductors and earthwires which although comparatively small
during normal operations can be severe during switching. It shall be the
Contractors responsibility to take adequate safety precautions to protect
his employees and others from this potential danger.
5.6.8 Towers during stringing shall be well guyed and steps may be taken by
Contractor to avoid damage. Proper T&P shall be made available to the
Employer by the Contractor for checking the tensions in the guy wires. All
the expenditure on account of the above work is deemed to be included in
the bid price and no extra payment shall be made for the same.
5.7 STRINGING OF CONDUCTOR AND EARTHWIRE
5.7.1 The stringing of the conductor shall be done by standard stringing method.
5.7.2 After being pulled, the conductor/earthwire shall not be allowed to hang in
the stringing blocks for more than 96 hours before being pulled to the
specified sag.
5.7.3 The stringing of Conductor shall be done as per initial stringing chart
provided by the Employer.
5.8 JOINTING
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5.8.1 All the joints on the conductor and earthwire shall be compression type, in
accordance with the recommendations of the manufacturer for which all
necessary tools and equipment like compressors, dies, processes etc.
shall have to be arranged by the Contractor. Each part of the joint shall be
cleaned by wire brush to make it free from rust or dirt etc. and properly
greased with anti corrosive compound if required, and as recommended
by the Contractor before the final compression is done with the
compressors.
5.8.2 All joints or splices shall be made at least 30 metres away from the
structures. No joints or splices shall be made in spans crossing over main
roads, Railways, small rivers with tension spans. During compression or
splicing operation the conductor shall be handled in such a manner as to
prevent lateral or vertical bearing against the dies. After pressing the joint
the aluminium sleeve shall have all corners rounded, burrs and sharp
edges removed and smoothened.
5.8.3 During stringing of conductor to avoid any damage to the joint, the
Contractor shall use a suitable protector with mid span compression joints
in case joints are to be passed over pulley blocks/aerial rollers. The size of
the groove of the pulley shall be such that the joint alongwith protection
can be passed over it smoothly.
5.9 Sagging-in-Operation
5.9.1 The conductor shall be pulled upto the desired sag and left in running
blocks for atleast one hour after which the sag shall be re-checked and
adjusted, if necessary before transferring the conductors from the running
blocks to the suspension clamps. The conductors shall be clamped within
36 hours of sagging in.
5.9.2 The sag will be checked in the first and the last span of the section in case
of sections upto eight spans and in one intermediate span also for
sections with more than eight spans. The sag shall also be checked when
the conductors have been drawn up and transferred from running blocks
to the insulator clamps.
5.9.3 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.
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5.9.4 At sharp vertical angles, the sags and tensions shall be checked on both
sides of the angle, the conductor and earthwire shall be checked on the
running blocks for equality of tension on both sides. The suspension
insulator assemblies will normally assume vertical positions when the
conductor is clamped.
5.9.5 Tensioning and sagging operations shall be carried out in calm weather
when rapid changes in temperatures are not likely to occur.
5.10 Tensioning and Sagging of Conductors and Earthwire
The tensioning and sagging shall be done in accordance with the
approved stringing charts before the conductors and earthwire are finally
attached to the towers through the earthwire clamps for the earthwire and
insulator strings for the conductor. The Initial stringing chart shall be used
for the conductor and final stringing chart for earthwire should be
employed for this purpose. Dynamometers shall be employed for
measuring tension in the conductor and earthwire. The dynamometers
employed shall be periodically checked and calibrated with the standard
dynamometer.
5.11 Clipping In
5.11.1 Clipping of the conductors in position shall be done in accordance with the
recommendations of the manufacturer. Conductor shall be fitted with
Preformed Armor Rods where it is made to pass through suspension
clamps.
5.11.2 The jumpers at the section and angle towers shall be formed to parabolic
shape to ensure maximum clearance requirements.
5.11.3 Fasteners in all fittings and accessories shall be secured in position. The
security clip shall be properly opened and sprung into position.
5.12 Fixing of Conductor and Earthwire Accessories
Vibration dampers for conductor & earthwire and other conductor &
earthwire accessories which are in bidders scope of supply, shall be
installed by the Contractor as per the design requirement and respective
manufacturers instructions within 24 hours of the conductor/earthwire
clamping. While installing the conductor and earthwire accessories, proper
care shall be taken to ensure that the surfaces are clean and smooth and
no damage shall occur to any part of the accessories.
5.13 Replacement
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If any replacements are to be effected after stringing and tensioning or
during maintenance, leg members and bracings shall not be removed
without reducing the tension on the tower with proper guying or releasing
the conductor. If the replacement of cross arms becomes necessary after
stringing, the conductor shall be suitably tied to the tower at tension points
or transferred to suitable roller pulleys at suspension points.
5.14 Permitted extra consumption of Line Materials
5.14.1 The bidder shall make every effort to minimise the breakages, losses, &
wastages of the line materials during erection. However while working out
the quantities of line materials, Employer shall permit the bidder extra
consumption of Conductor and Earthwire only upto the limit of 1%
For other line materials, i.e. Disc Insulators, Hardware and Accessories for
Conductor and Earthwire, the actual quantity incorporated on transmission
line shall be approved.
5.14.2 The Contractor shall not be required to return to the Employer empty
Conductor and Earthwire drums as the same shall be deemed to become
his property.
5.15 Final Checking, Testing and Commissioning
After completion of the works, final checking of the line shall be done by
the Contractor to ensure that all the foundation works, tower erection, and
stringing have been done strictly according to the specifications and as
approved by the Employer. All the works shall be thoroughly inspected
keeping in view of the following main points:
(a) Sufficient backfilled earth is lying over each foundation pit and it is
adequately compacted.
(b) Concrete chimneys and their copings are in good finely shaped conditions.
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(c) All the tower members are correctly used, strictly according to final
approved drawing and are free of any defect or damage, whatsoever.
(d) All bolts are properly tightened and punched/tack welded.
(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 to complete the work like fixing of danger plate,
phase plate, number plate, anti climbing device, aviation signal (wherever
required) etc. are properly installed.
(h) Wherever required it should be ensured that revetment is provided.
(i) The original tracings of profile route alignment and tower, bill of material,
shop drawings of all towers are submitted to the Employer for reference
and record.
(j) The insulation of line as a whole is tested by the Contractor by providing
his own equipment, labour etc. to the satisfaction of the Employer.
(k) All towers are to be properly grounded as per requirements of the
specification.
(l) The line is tested satisfactorily for commissioning purpose.
6. General Technical Conditions
6.1 The following provisions shall supplement all the detailed technical
specifications and requirements brought out herein. The Contractors
proposal shall be based on the use of materials complying fully with the
requirements, specified herein.
6.2 Engineering Data
6.2.1 The furnishing of engineering data by the Contractor shall be in
accordance with the Schedule as specified in the Technical Specifications.
The review of these data by the Employer will cover only general
conformance of the data to the specifications and not a thorough review of
all dimensions, quantities and details of the materials, or items indicated or
the accuracy of the information submitted. This review by the Employer
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.
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6.2.2 All engineering data submitted by the Contractor after review by the
Employer shall form part of the Contract document.
6.3 Drawings
In addition to those stipulated in clause regarding in general conditions,
the following also shall apply in respect of Contractors drawings.
6.3.1 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.
6.3.2 Each drawing submitted by the Contractor shall be clearly marked with the
name of the Employer, the specification title, the specification number and
the name of the Project. All titles, noting, markings and writings on the
drawings shall be in English. All the dimensions should be to the scale and
in metric units.
6.3.3 The drawings submitted by the Contractor shall be reviewed by the
Employer as far as practicable within 21 days and shall be modified by the
Contractor if any modifications and/or corrections are required by the
Employer. The Contractor shall incorporate such modifications and/or
corrections and submit the final drawings for approval within ten days. Any
delays arising out of failure by the Contractor to rectify the drawings in
good time shall not alter the contract completion date.
6.3.4 The drawings submitted for approval to the Employer shall be in
quadruplicate. One print of such drawings shall be returned to the
Contractor by the Employer marked "approved/approved with corrections".
The Contractor shall thereupon furnish the Employer additional prints as
may be required alongwith one reproducible in original of the drawings
after incorporating all corrections.
6.3.5 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 Employer, if so required.
6.3.6 All manufacturing, fabrication and erection work under the scope of
Contractor, prior to the approval of the drawings shall be at the
Contractors risk. The Contractor may make any changes in the design
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which are necessary to conform to the provisions and intent of the
Contract and such changes will again be subject to approval by the
Employer.
6.3.7 The approval of the documents and drawings by the Employer shall mean
that the Employer 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 Employer of any document does imply
compliance with all technical requirements nor the absence of errors in
such documents.
If errors are discovered any time during the validity of the Contract, then
the Contractor shall be responsible of their consequences.
6.3.8 Copies of drawings returned to the Contractor will be in the form of a print
with the Employers marking.
6.3.9 The following is the generic list of the documents and drawings that are to
be approved by the Employer:
(a) Detailed survey report and profile drawings showing ground clearance and
tower locations.
(b) Tower schedule for individual tower locations.
(c) Bill of material of towers and shop drawings.
(d) Soil investigation report.
6.4 Design Co-ordination
The Contractor shall be responsible for the selection and design of
appropriate material/item to provide the best co-ordinated performance of
the entire system. The basic design requirements are detailed out in this
Specification. The design of various components, sub-assemblies and
assemblies shall be so done that facilitates easy field assembly and
maintenance.
6.5 Design Review Meeting
The Contractor will be called upon to attend review meetings with the
Employer during the period of Contract. The Contractor shall attend such
meetings at his own cost at Patiala or at mutually agreed venue as and
when called for. Such review meeting will be held generally four times in a
year.
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6.6 Packing & Marking
6.6.1 All the materials shall be suitable protected, coated, covered or boxed and
crated to prevent damage or deterioration during transit, handling and
storage at Site till the time of erection. The Contractor shall be responsible
for any loss or damage during transportation, handling and storage due to
improper packing.
6.6.2 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 packages,
the name of the Contractor etc.
7. Erection Conditions
7.1 The following shall supplement the conditions already contained in the
other parts of these specifications and documents and shall govern that
portion of the work on this Contract to be performed at Site.
7.2 Regulation of Local Authorities and Statutes
7.2.1 The 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, the payment of Wages Act
and of EPF act (all of the Government of India) and the rules made there
under in respect of any employee or workman employed or engaged by
him or his Sub-Contractor.
7.2.2 All registration and statutory inspection fees, if any, in respect of his work
pursuant to this Contract shall be to the account of the 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 Employer, shall be to the account of the Employer. Should any
such inspection or registration need to be re-arranged due to the fault of
the Contractor or his Sub-Contractor, the additional fees to such
inspection and/or registration shall be borne by the Contractor.
7.3 Contractors Field Operation
7.3.1 The Contractor shall keep the Employer 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 Employer
shall not relieve the Contractor or any of his responsibilities towards the
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field activities. Such reviews shall also not be considered as an
assumption of any risk or liability by the Employer 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 or tools and plants and his erection methods.
7.4 Progress Report
7.4.1 Appropriate visual charts shall accompany the monthly progress report
detailing-out the progress achieved on all erection activities as compared
to the schedules. The report shall also indicate the reasons for the
variance between the scheduled and actual progress and the action
proposed for corrective measures, wherever necessary.
7.4.2 Facilities to be Provided by the Contractor
7.4.2.1 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.
7.4.2.2 The Contractor shall provide necessary first-aid facilities for all his
employees, representatives and workmen working at the site.
7.5 Fire Protection
The work procedures that are to be used during the erection shall be
those, which minimise fire hazards to the extent practicable in line with
applicable laws, rules & regulations.
7.6 Security, Materials Handling and Storage
7.6.1 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.
7.6.2.1 For all the supplies 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.
7.7 Construction Management
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 falling behind the
schedule for reasons attributable to him he shall take necessary action to
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make good for such delays by increasing his work force or by working
overtime or otherwise to accelerate the progress of the work and to comply
with schedule and shall communicate such actions in writing to the Employer,
satisfying that his action will compensate for the delay. The Contractor shall
not be allowed any extra compensation for such action.
7.8 Work and Safety Regulations
7.8.1 The Contractor shall ensure safety and well being of all the workmen,
materials plant and equipment belonging to him or to the others, working at
the Site and of Public at large. The Contractor shall comply with all safety
norms, rules & regulations as per Law / relevant legislations and as deemed
necessary by the Employer.
7.8.2 If the Contractor does not take all safety precautions and/or fails to comply
with the Safety Rules 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 Employer or any other person at Site or
adjacent thereto, the Contractor shall be responsible for payment of
compensation to the Employer as per the following schedule:-
The employer will assist the interested bidder to see and inspect the
site of works. For this purpose bidders are requested to contact the
following office:
CHIEF ENGINEER/TL,
Design Directorate Transmission,
B-2, Shakti Vihar, PSTCL,
Patiala.
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SECTION III
PART B
1. General Information
The general scope for supply of all the material / equipment to be used for
complete execution of the 220 KV transmission lines packages is given in
this section.
2. Scope
2.1 The material to be supplied as covered in this volume shall be designed,
manufactured and tested as per the requirement specified.
2.2 The materials covered shall be supplied complete in all respects,
including all components, fittings and accessories which are necessary or
are used for their efficient performance and satisfactory maintenance
under the various operating and atmospheric conditions. Such parts shall
be deemed to be within the scope of the Contract, whether specifically
included or not in the Specification or in the Contract Schedules. The
Contractor shall not be eligible for any extra charges for such fittings etc.
The details of the material required for the above mentioned lines
under this specification are as follows and the tentative quantity of the
same are mentioned in Price Schedules of respective Packages on line-
wise basis.
i) Conductor / Tower material
ii) Earthwire
iii) Insulators
iv) Hardware Fittings
v) Accessories for Conductor and Earthwire
3 Weights and Measures
All weights and measures shall be in System International (S.I.) units. All
fasteners shall be of Metric size only.
4 General Technical Conditions
4.1 The following provisions shall supplement all the detailed technical
specifications and requirements brought out in the accompanying
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Technical Specifications. The Bidders proposal shall be based on the use
of equipment and materials complying fully with the requirements,
specified herein
SECTION III
Part -C
SURVEY & SOIL INVESTIGATION
i. Digitised profiling along the selected route along with plan details.
c. Soil Investigation
1.2 The Provisional quantities for the scope of work are indicated in relevant
Price Schedules. The final quantities for route alignment & detailed survey
(quantities in kms unit) shall be the route length along the approved route
alignment. For contouring at undulated/hilly tower locations and soil
investigations (quantities in Locs. unit), the actual quantities to be
executed shall be decided by Site Engineer-in-charge (Sr.XEN of
Concerned TLSC Division) during execution stage and the final quantities
shall be as approved by Superintending Engineer of concerned TLSC
Circle. The route alignment, detailed survey, including profiling & tower
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spotting, contouring, soil investigation etc shall be carried out by the
Contractor as per the technical specifications stipulated herein.
1.3 The Contractor must note that the Employer shall not be responsible for
loss or damage to properties, trees etc. due to contractors work during
survey. The Contractor shall indemnify the Employer for any loss or
damage to properties, trees etc. during the survey work.
1.4 The Contractor should note that Employer will not furnish the NRSA
satellite imageries or topographical maps prepared by survey of India but
will make available assistance that may be required in obtaining these by
providing letters of recommendation to the concerned authorities.
1.5 The work shall be carried out by the contractor using modern surveying
techniques. The bidder shall indicate in his offer, the detailed description of
the procedure to be deployed. The details of the equipment & facilities
including soft wares for image processing, computer aided tower spotting
etc. available with the bidder or his associates shall also be furnished with
the bid.
1.8 After carrying out the detailed survey and soil investigations, the contractor
shall estimate complete BOQ (Bill of Quantities) of the transmission lines
on Package-wise basis and submit the same (as per the BOQ format
enclosed with the Specifications) to the Employer.
2. Route Alignment
2.1 Wherever the route Alignment has already been carried out for the line
using satellite imageries of NRSA (PAN & LISS-III merged product) and
Survey of India topographical maps (scale 1:50000), any changes
necessitated during execution stage in the route alignment, same shall be
carried out by the contractor using satellite imageries / topographical
maps.
2.2.1. The Re-alignment, if any required, of the transmission line shall be most
economical from the point of view of construction and maintenance. The
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contractor shall identify & examine alternative route alignments and
suggest to the Employer the optimal route alignment.
2.2.3. The route should have minimum crossings of Major river, Railway lines,
National/State highways, overhead EHV power line and communication
lines.
2.2.5. The distance between the terminal points specified shall be kept shortest
possible, consistent with the terrain that is encountered.
2.2.6. Marshy and low lying areas, river beds and earth slip zones shall be
avoided to minimize risk to the foundations.
2.2.8. Crossing of power lines shall be minimum. Alignment will be kept such as
to avoid induction problems on the lower voltage lines.
2.2.11. Restricted areas such as civil and military airfield shall be avoided. Care
shall also be taken to avoid aircraft landing approaches.
2.2.12. All alignment should be easily accessible both in dry and rainy seasons to
enable maintenance throughout the year.
2.2.13. Certain areas such as quarry sites, gardens & nurseries which will present
the Employer problems in acquisition of right of way and way leave
clearance during construction and maintenance should be avoided.
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2.2.14. Angle points should be selected such that shifting of the point within 100 m
radius is possible at the time of construction of the line.
2.2.15. The line routing should avoid large habitations, densely populated areas,
Forest, Animal/Bird sanctuary, reserve coal belt areas, oil pipe
line/underground inflammable pipe lines etc. to the extent possible.
2.2.16. The areas requiring special foundations and those prone to flooding
should be avoided.
2.3 For examination of the alternatives & identification of the most appropriate
route, besides making use of information/data/details available/extracted
through Survey of India Topographical maps and computer-aided
processing of NRSAs satellite imagery, the contractor shall also carryout
reconnaissance/preliminary survey as may be required for verification &
collection of additional information /data /details.
2.4 The contractor shall submit his preliminary observations & suggestions
along with various information/ data / details collected and also processed
satellite imagery data, scanned topographical map data marked with the
alternative routes etc. The final evaluation of the alternative routes shall be
conducted by the contractor in consultation with concerned Sr.XEN/ SE
TLSC and optimal route alignment shall be proposed by the contractor.
During Site visit and field verification to be conducted by the contractor the
Employers representative may join for the proposed route alignment.
2.5 Final digitized route alignment drawing with latest topographical and other
details/features including all rivers, railway lines, canals, roads etc. up to 4
kms on both sides of selected route alignment shall be submitted by the
contractor for Employers approval along with report containing other
information/details as mentioned above.
2.6 Changes in the route alignment, if any, during detail survey, shall be
incorporated in the final digitized route alignment drawings.
3. Detailed Survey
3.1 The detailed survey shall be carried out using GPS, Total stations, digital
theodolites etc. along the approved route alignment.
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3.2 Soil resistivity, along the route alignment shall be measured in dry weather
by four electrode method keeping inter-electrode spacing of 50 mtrs. For
calculating soil resistivity formula 2ar ( Where a=50 m and r= megger
reading in ohms) shall be adopted. Measurement shall be made at every 2
to 3 km along the length of the route. In case soil characteristics changes
within 2 to 3 km, values shall have to be measured at intermediate
locations also. Megger reading and soil characteristics should also be
indicated in the soil resistivity results.
3.3.1. The route of the transmission line shall be recorded using GPS of
positional accuracy less than 3m.
3.3.2. The co-ordinates of all the angle points as well as other important
crossings, landmarks etc. shall be recorded using GPS for easy relocating.
3.3.3. At the starting point of the commencement of route survey the co-
ordinates shall be recorded. The co-ordinates of the location of the survey
instrument shall also be recorded. Further, the co-ordinates at prominent
position at intervals of not more than 750 meter along the transmission line
to be surveyed up to the next angle point shall also be recorded. Wherever
the line alignment crosses the EHT line, Railway line, P&T line or roads,
the contractor shall record co-ordinates on the points of crossing.
Wherever line route alignment passes over permanent land marks such
as rock, boulders, culverts etc. suitable white paint marks with directional
markings shall be made and co-ordinates recorded.
3.4 Profiling
3.4.1. The complete profiling along the route shall be carried out using modern
surveying equipments viz. total stations, GPS, digital theodolite, long
range scanners etc. Reference levels at every 20 metres along the route
are to be recorded. R/Ls at other undulations along the route as well as in
the route plan and other enroute details viz. crossings, building &
structures, trees & other infrastructure etc shall also be recorded. Areas
along the route, which in the view of the contractor, are not suitable for
tower spotting, shall also be marked.
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3.4.2. The complete profiling details shall be digitized and the data shall be
prepared & stored in the format compatible to computer-aided tower
spotting software.
While profiling & spotting the towers, the following shall be borne in mind:
a) Span
The number of consecutive spans between the section points shall not
exceed 10 spans. A section point shall comprise of tension point with B
type (2-D-30) or C Type (2-D-60) as applicable.
b) Extension/Truncation
c) Loading
There shall not be any upward force on suspension towers under normal
working conditions and the suspension towers shall support at least the
minimum weight span as provided in the designs. In case uplift is
unavoidable, it shall be examined if the same can be overcome by adding
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standard body extensions to the towers failing which tension towers
designed for the purpose shall be deployed at such positions.
d) Road Crossing
At all important road crossings, the tower shall be fitted with tension
insulator strings but the ground clearance at the roads under maximum
temperature and in still air shall be such that even with conductor broken
in adjacent span, ground clearance of the conductor from the road
surfaces will not be less than specified. At all national highways crossing
span will not be more than 250 meters.
e) Railway Crossings
f) River Crossings
Where the line is to cross over another line of the same voltage or lower
voltage, A type tower with suitable extensions shall be used. 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 up-to-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 Employer of the line to be
crossed).
For power line crossings of voltage level of 132 kV and above, angle
towers shall be provided adjacent to A type tower on either side of the
Power line crossing which can be used in temporary dead end condition
with proper guying to facilitate stringing of the power line crossing
sections separately on obtaining line shutdowns.
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. On a
request from the Contractor, the permission of the telecommunication
authority may be obtained by the Employer.
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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.
i) Details En-route
3.6.1. 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 by the
Employer at the time of actual execution of the work as detailed below.
Contractor may please note that Employer shall not pay any compensation
for any loss or damage to the properties or for tree cutting due to
Contractors work.
3.6.2. To evaluate and tabulate the trees and bushes coming within 17.5 m for
220 KV D/C line 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:
d) The bushs and under growth encountered within the 35 m for 220 kV
line should also be evaluated with its type, height, girth and area in
square meters, clearly indicating the growth in the tree/bush statement.
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3.6.3. The contractor shall also intimate the Employer his assessment about the
likely amount of tree & crop compensation etc. required to be paid by the
Employer during execution stage. This assessment shall be done
considering prevailing practices/guidelines, local regulations and other
enquiries from local authorities.
3.6.4. The Contractor shall also identify the forest/non forest areas involved duly
authenticated by concerned authorities.
e) Village forest maps of affected line and affected forest area and
marking of the same.
3.6.5 The Contractor shall finalize the forest clearance proposal on the
prescribed format duly completed in all respects for submission by the
Employer to the Forest Department.
The profile sheets showing the locations of the towers together with
preliminary schedules of quantities indicating tower types, spans, angle of
deviation, crossing & other details etc. shall be submitted by the contractor
for review & approval by the Employers site-in-charge ( concerned
Sr.XEN /TLSC)
3.8.1. The check survey shall be conducted to locate tower locations on ground
conforming to the approved profile and tower schedule.
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3.8.2. The co-ordinates of all the tower locations shall also be recorded using
GPS of positional accuracy less than 3 m for easy relocating. The position
of all tower locations shall be marked in the final digitized route alignment
drawing with relative distances from any permanent bench mark area.
3.9.1. The levels up or down of each pit centre with respect to centre of tower
location shall be recorded at intervals of 2m using total
stations/GPS/digital theodolite and digitized contour plans shall be made.
Based on the digitized elevation plans, the quantities of benching &
protection work shall be optimized using suitable computer-aided
techniques/software.
3.10 The changes desired by the Employer in the preliminary tower schedule
or as may be required based on detailed survey of tower locations &
contouring by the contractor, shall be carried out by the contractor and the
final tower schedule shall be submitted for approval of Employer. The
tower schedule shall show position of all type of towers, span length, type
of foundation for each tower, benching & revetment requirement, deviation
at all angles, crossings & other details etc.
3.11.1. Complete BOQ of the transmission lines as per format enclosed with this
technical specifications shall be furnished in the survey report.
3.11.2. Each angle point locations shall be shown with detailed sketches showing
existing close by permanent land marks such as specific tree(s), cattle
shed, homes, tube wells, temples, electric pole/tower, telephone pole,
canal, roads, railway lines etc. The relative distance of land marks from the
angle points and their bearings shall be indicated in the sketch. These
details shall be included in the survey report.
3.11.3.1. Information regarding infrastructural facilities available along the final route
alignment like access to roads, railway stations, construction material
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sources (like quarry points for stone, sand and availability of construction
water), labour, existing transport facilities , fuel availability etc. shall be
furnished in the survey report.
3.11.3.2. All observations which the Contractor thinks would be useful to the
construction of the transmission lines mentioned under scope of work are
to be reported.
3.11.3.4. Some portions of the line may require clearance from various authorities.
The Contractor shall indicate the portion of the line so affected, the nature
of clearance required and the name of concerned organizations such as
local bodies, municipalities, P&T (name of circle), Inland navigation,
Irrigation Department, Electricity Boards and Zonal railways, Divisional
Forest Authorities etc.
3.11.4. All the requisite data for processing the case for statutory clearances such
as PTCC, Forest and Railway shall be provided along with the report.
4. Geotechnical Investigations
4.1 General
4.2 Scope
4.2.1. The scope of work includes soil investigations/ furnishing bore log data at
various tower locations. The Soil investigation report/ bore log data will be
submitted to the SE/ Transmission Design, PSTCL, Patiala for foundation
decision in case sub-soil water level is found to be above 6 m. The bore
log data shall indicate the sub-soil water level, nature of soil strata and
bearing capacity of the soil. The bore log data shall be furnished for all
locations on the approved route plan.
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4.2.2. Contractor shall carry out all work expressed and implied in these
specifications in accordance with requirements of the specification.
All work shall be carried out in accordance with the relevant Indian
Standards and Codes.
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SECTION III
PART D
2. STANDARDS:
The conductor shall comply in all respects with the IS-398 (Part-2):1996 with
latest amendments, if any, and also the technical specification detailed
therein. Offers conforming to the standard other than IS-398(Part-2): 1996
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shall be accompanied by the English version of the relevant standard in
support of the guaranteed particulars as given in GTPs.
3. MATERIAL:
3.1 The conductor shall be constructed of hard drawn aluminium and
Galvanized steel wires which have the mechanical and electrical properties
specified in table 1&2 of IS 398 (Part-2) 1996. The conductor to be procured
against this specification is to be installed on 220 KV transmission lines,
hence special care shall be taken during its manufacture to avoid any defects
on conductor. The raw material used for the manufacture of the conductor
shall be EC Grade Aluminium rods conforming to IS-5484, 1978 and
Galvanised steel wire drawn from high carbon steel rods procured by either
acid or base open hearth process, electric furnace or basic oxygen process.
The Mechanical properties of wire shall comply with requirements, given in
table 2 of IS-398(Part-2)1996. The zinc used for galvanizing should be
electrolyte high grade zinc having purity not less than 99.95%. It shall conform
to satisfy all the requirements. IS 209:1992. Zinc coating on steel wire may
be applied by the hot process or electrolytic Process. The stranding of
conductor be completed in single operation . The tenderer shall submit
documentary proof of their capability of making 54 strands conductor in single
operation. The conductor drum should bear ISI Monogram mark or PQM
mark in conformation to ISI/PQM material supplied.
3.2 The responsibility for procurement of good quality raw material shall be
solely of supplier and in any case assistance for the procurement of raw
material not controlled by the Govt. shall not be provided by the Board and
delivery programme shall not be affected due to non supply of raw material.
The supplier will have to ensure adequate quantity of good quality un-
controlled raw material in their stock so that the progress of work is not
hampered. No extension in delivery period will be allowed on the pretext of
non-availability of or short supply of raw material not controlled by Govt. and
this will not constitute a valid reason of Force Majeure. The material used for
finished product shall be of best quality and shall conform to specific details
as laid down in IS:398(Part-2):1996 for tolerances, mechanical properties,
surface conditions, joints in wire and stranding.
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3.3 The aluminium wires(strands) shall be hard drawn from electrolytic aluminium
rod having purity not less than 99.5% and shall conform to relevant ISS. Cut ends
of the conductor shall be properly treated to avoid ingress of moisture. The producer
test certificate in respect of impurity contents of Aluminium conductivity etc. shall
have to be furnished in order to assess whether Aluminium rod of correct quality
has been used for aluminium strands.
The steel wires(strands) shall be drawn from steel produced by either acid or
basis open hearth process by the electric furnace process or basic oxygen
process and shall conform to the requirement as regards to chemical
composition. The steel produced by BESSEMER process shall not be used
for drawing the steel wire strands.
3.4 The steel core wire shall hot dip galvanised conforming to IS:2629/1980
and shall have zinc coating of minimum 250 gms/m2 of the un-coated inner wire
surface as per IS:4826/1968 for hard heavily coated wires. The zinc coated
steel wire after stranding shall successfully withstand 2 dips of one minute duration
and 1 dip of minute duration under Preece test. The zinc coating shall be
reasonably smooth, continuous and of reasonably uniform thickness and free from
imperfections, consistent with good commercial practice and shall meet all the
relevant tests as per the standards. The steel wires shall be for such quality and
purity that when drawn to the size of wire specified and coated with zinc, the
finished strands shall have the same properties and characteristics as prescribed
in the relevant Indian standards. The quality of zinc used for coating of steel wire
shall be as-per IS-209/1992 i.e. electrolytic High grade zinc of 99.95 purity.
3.5 The responsibility to arrange raw material shall be solely of the firm. EC
grade Aluminium ingots or rods of relevant size shall be procured only from
the main producers such as Hindalco , Balco & Nalco. Similarly in case of
HTGS wire of relevant size, the material shall be procured main / reputed
producers like Ratlam Wires, Tata Steel, Usha Martin, Arti Steels, Bajrang
Wires, Bharat Wires & Ropes and Ramsarup industrial Corp.
4. SURFACE CONDITIONS:
The wires used for standard conductor shall be smooth and free from
all imperfections, such as spills and splits. The surface of the conductor shall
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be free from sharp edges, abrasion or other departures from smoothness of
uniformity of surface counter that would increase radio interference and
corona losses. When subjected to tension upto 50% of the ultimate strength of
conductor the surface shall not depart from its cylindrical form nor any part of
the component parts, or strands move relative to each other in such a way so
as to get out of place and disturb the longitudinal smoothness of the
conductor.
The defects like scratches, die marks, surface cuts, abrasion, stuff
mark and deposition of dust, dirt and grit, non-uniformity in diameter, un-even
and loose stranding, discontinuity in steel core wire, overlapping of strands,
joints in individual wires in the outer most layer of the conductor, etc. should
be avoided during manufacturing.
Even though the conductor may pass the relevant tests specified in
this specification or IS but if any of the above defects during visual inspection
are found to exist in the conductor offered, the same shall not be accepted.
5. JOINT IN WIRE:
1. WOODEN COMPONENTS:
Wood used for manufacture of drum shall be seasoned wood preferably soft
wood. It shall be sound and free from visual defects, which may impair its
strength.
2. FLANGES;
All Flanges shall be constructed with two thickness of timber, each ply being
at approximately right angle to the other, nailed, clenched together. Nails shall
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be driven from the inside face of flange, punched and the clenched on the
outer face. Flange boards shall be not less than the nominal thickness by
more than 2mm. There shall be not less than two nails per Board in each
circle. Where a slot is cut in the flange to receive the inner end of the
conductor, the entrance shall be in line with the periphery of the barrel. The
flanges of drum shall be large enough to prevent any possible contact
between the conductor and the ground during handling or transport. The
projection of flanges beyond the outer-most of the conductor shall be at least
100mm.
3. SPINDLE HOLE:
The spindle hole shall be cut through the centre of the middle flange board
and either spindle steel plates or cast iron bushings shall be fitted by bolts and
nuts.
4. BARREL END SUPPORTS
The supports shall be securely fixed to the flanges by nailing and shall be of
segmental type.
5. BARREL
Each batten shall be nailed to the barrel end support with one nail at each
side for 50mm wide Boards and at least two nails for all wider boards. The
battens shall be closely butted & provided with a smooth and round external
surface to the barrel. The edges of the battens shall be chamfered.
6. STRETCHERS;
Stretchers shall be used in the construction of drums and the middle end
supports when provided shall be slotted to receive them.
7. The protective lagging shall be closely fitted. Out-side the protective lagging there shall
be hoop iron or galvanized steel wire. A gap of min.(100mm) shall be kept between last
conductor layer and wooden battens to avoid any damage to conductor. The wooden
battens shall be nailed to the flanges.
8. PROTECTION TO CONDUCTOR;
The barrel surface and inner surfaces of the flanges of the drums shall be
painted with Aluminium Paint. A layer of water proof material shall be provided
over the barrel and inner surfaces of flanges. Another layer of water proof
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material shall be provided over the last layer of conductor and under the
laggings.
The wooden drum shall be constructed as per following details
(All dimensions in mm).
Transverse 900 mm
Flange thickness 3x33 mm
Bore diameter 90 mm
Nail circle -
Nail length 89 mm
Nail size 3.65 mm
Thickness of barrel end lagging 50 mm
No. of stretchers 6 mm
Stretcher size 100x50 mm
No. of bolts 6 mm
Diameter of spindle plate hole 90 mm
No. of spindle bolt plate 4
Spindle plate diameter 12 mm
Thickness of external lagging 50 mm
No. of binders over the external lagging. 3
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GUARANTEED TECHNICAL PARTICULARS OF ACSR ZEBRA
1. CONDUCTOR
a) Nominal Alumn. Area 420mm2
b) Stranding 54/3.18Al.+7/3.18 Steel
2. Sectional area of aluminium 428.9mm2
3. Total sectional area 484.5mm2
4. Appx. Overall diameter 28.62mm
5. Appx. Mass 1621Kg/Km.
6. Calculated resistance at 200 0.06868 /km
7. Appx. Calculated breaking load 130.32KN
8. Lay ratio
a)Steel core Min.-13
Max.-28
b)Aluminium Wires
1. 12 wire layers
Min.-10
Max.-17
2. 18wire layers
Min.-10
Max.-16
3. 24wire layers
Min.-10
Max.-14
9. Modulus of elasticity 69GN/m2
10. Co-efficient of linear expansion 19.3x10-6 /0C
2.DATA FOR INDIVIDUAL WIRE OF ALUMINIUM AND STEEL
USED IN ACSR ZEBRA
1. DIAMETER STEEL ALUMINIUM
Max. 3. 24mm 3.21mm
Min. 3.12mm 3.15mm
2. Cross sectional Area 7.942mm2 7.942mm2
3. Weight 61.95kg/km 21.47kg/km
4. Breaking Load
Before stranding 10.43KN 1.29KN
After stranding 9.91KN 1.23KN
5. Resistance at 200C 3.626/km
6. Zinc Coating.
a) No. & duration of dips 2 dips of One minute each &
1 dip of half minute
b) Min. weight of coating gm/mm2 250gm/m2
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SECTION-III
PART - E
SPECIFICATIONS FOR DISC INSULATORS
2.2.2 The hole for the security clip shall be countersunk and the clip shall be of such
design that the eye of clip may be engaged by a hot line clip puller to provide
for disengagement under energized conditions. The force required to pull the
security clip into its unlocked position shall not be less than 50 N (5 Kg) or
more than 500 N (50 Kg).
2.5 Interchangeability
The disc insulators inclusive of the ball and socket fittings shall be of standard
design suitable for use with the hardware fittings of any make conforming to
relevant Indian/International Standards.
2.6 Corona And RI Performance
All surfaces must be clean, smooth, without cuts, abrasions or projections.
No part shall be subjected to excessive localized pressure. The metal parts shall
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be so designed and manufactured that it shall not generate any Radio
Interference beyond specified limit and not produce any noise generating corona
under the operating conditions.
2.7 Maintenance
2.7.1 The disc insulators offered shall be suitable for employment of hot line
maintenance techniques so that the usual hot line operations can be carried
out with ease, speed and safety.
2.7.2 Bidders shall indicate the methods generally used in the routine hot and dead
line maintenance of EHV Lines for which similar disc insulators have been
supplied by them. Bidders shall also indicate the recommended periodicity of
such maintenance.
2.8 Materials
2.8.1 Porcelain
The porcelain used in the manufacture of shells shall be sound, free
from defects thoroughly vitrified and smoothly glazed.
2.8.2 Glaze
The finished porcelain shall be glazed in brown colour. The glaze shall
cover all exposed parts of the insulator and shall have a good luster, smooth
surface and good performance under the extreme weather conditions of a
tropical climate. It shall not be cracked or chipped by ageing under the
normal service conditions. The glaze shall have the same co-efficient of
expansion as of the porcelain body throughout the working temperature
range.
2.8.3 Cement
Cement used in the manufacture of the insulator shall not cause
fracture by expansion or loosening by contraction. The cement shall not give
rise to chemical reaction with metal fittings and its thickness shall be as small
and uniform as possible. Proper care shall be taken to correctly centre and
locate individual parts during cementing.
2.8.4 Pins and Caps.
Pins and Caps shall be made of drop forged steel and malleable cast
iron/spheriodal graphite iron respectively, duly hot dip galvanized and shall
not be made by jointing, welding, shrink fitting or any other process from more
than one piece of material.
2.8.5 Security Clips
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Security clips shall be made of good quality stainless steel or phosphor
bronze as per IS:1385-1968.
3.0 Workmanship
3.1 All the material shall be of the latest design and conform to the best
modern practices adopted in the extra High voltage field. Bidders shall
offer only such insulators as are guaranteed by him to be satisfactory and
will give continued good service.
3.2 The design, manufacturing process and material control at various stages
shall be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish and elimination of sharp edges and
corners to limit corona and radio interference.
3.3 The design of the insulators shall be such that stresses due to expansion
and contraction in any part of the insulator shall not laed to deterioration.
3.4 Metal caps shall be free from cracks, seams, shrinks, air holes, burrs and
rough edges. All surfaces of the metal parts shall be perfectly smooth with
no projecting points or irregularities which may cause corona. All load
bearing surfaces shall be smooth and uniform so as to distribute the
loading stresses uniformly.
3.5 All ferrous parts shall be hot dip galvanized to give a minimum average
coating of zinc equipment to 600 gm/sq.m. and shall be in accordance with
the requirement of IS:2629-1966 and shall satisfy the tests mentioned in
IS:2633-1972. The zinc used for galvanising shall be as per IS:209-1979.
The zinc coating shall be uniform, adherent, smooth, reasonably bright,
continuous and free from imperfections such as flux, ash, rust stains, bulky
white deposits and blisters. The galvanised metal parts shall be
guaranteed to withstand atleast four successive dips each lasting for one
(1) minute duration under the standard preece test.
3.6 Before ball fittings are galvanized, all die flashing on the shank surface of
the ball shall be carefully removed without reducing the dimensions below
the design requirements.
3.7 The design of the insulators shall be such that the shell shall not engage
directly with hard metal. The design shall also be such that when units are
coupled together there is no contact between the shell of one unit and
metal of the next adjacent unit. The design of the shell ribs shall be such
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that the security clip of the insulator can be engaged and disengaged
easily with hot stick without damaging the shell ribs.
3.8 Insulator units after assembly shall be concentric and co-axial within limits
as permitted by the relevant Indian Standards.
3.9 The manufacturer of the disc insulators shall guarantee an insulator failure
rate not exceeding 1 (one) per 10000 (ten thousand) per year. In case the
annual failure rate during the first ten years of service exceeds the above
figure, under normal operating condition, as will be determined by check to
be conducted as per mutually agreed procedure and conditions upto ten
years (as permitted by the operating situation). The manufacturer shall
supply to the Owner free of cost spare insulators equal to 10 times excess
of the failure.
3.10 The manufacturer shall guarantee that there shall not be any
decapping of insulators on line under normal operating conditions. In event
of any decapping and subsequent line drop, during the first ten years of
service the manufacturer shall have to pay Rs. 50,000/- (Rs. Fifty
thousand) per dropped string towards expenditure to be incurred by
PSTCL for this line repair.
4.0 Equipment marking
4.1 Each insulator disc shall be legibly and indelibly marked with the trade
mark of the manufacturer and year of manufacture. The guaranteed
combined mechanical and electrical strength shall be indicated in kilo
newtons followed by the word kN to facilitate easy identification and to
ensure proper use.
4.2 For porcelain insulator, the marking shall be on porcelain. The marking
shall be printed, not impressed and shall be applied before firing.
5.0 Bid Drawings
5.1 The bidder shall furnish full description and illustration of the material
offered.
5.2 The bidder shall furnish along with the bid the outline drawing (4 copies) of
each insulator unit including a cross sectional view of the insulator shell.
The drawing shall include but not limited to the following information:
(a) Shell diameter and ball to ball spacing with manufacturing tolerances
(b) Minimum Creepage distance with positive tolerance
(c) Protected creepage distance.
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(d) Eccentricity of the disc
(i) Axial run out
(ii) Radial run out
(e) Unit mechanical and electrical characteristics
(f) Size and weight of ball and socket parts.
(g) Weight of unit insulator disc
(h) Materials
(i) Indentification mark
(j) Manufacturers catalogue number
5.3 After placement of award, the Contractor shall submit full dimensioned
insulator drawings containing all the details as given in Clause above, in
four (4) copies to Employer for approval. After getting approval from
Employer , the Contractor shall submit 10 more copies of the same
drawing to the Employer for further distribution and field use at Employers
end.
6.0 Tests and Standards
6.1 Tests
The following type, acceptance, routine tests and tests during
manufacture shall be carried out on the disc insulator individually . For the
purpose of this clause:-
6.1.1 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. Type test certificate indicating conformity
of the material as per relevant standard/PSTCL specification are
required to be submitted along with the bid as per requirements of this
specification.
6.1.2 Acceptance tests shall mean those tests which are to be carried out on
samples taken from each lot offered for pre-despatch inspection for the
purpose of acceptance of that lot.
6.1.3 Routine tests shall mean those tests, which are to be carried out on
each disc insulator/hardware fitting to check requirements which are
likely to vary during production.
6.1.4 Tests during manufacture shall mean those tests which are to be
carried out during the process of manufacture and end inspection by
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the Contractor to ensure the desired quality of the end product to be
supplied by him.
6.1.5 The norms and procedure of sampling for these tests will be as per
applicable ISS / IEC standards.
6.1.6 The standard and norms to which these tests will be carried out are
listed against them.
6.1.7 For all types and 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 this
specification whichever is more stringent for that particular test.
6.1.8 For all type and acceptance tests, the Bidder shall guarantee only
minimum values in the Guaranteed Technical Particulars. Bidder shall
be required to achieve the same or higher values, as guaranteed,
during testing for all type and acceptance tests except for voltage
distribution test. Bidder shall be required to achieve the same or lower
values during testing.
6.2 Type Tests
The type test are meant to demonstrate conformity to the specification of design &
material used in the manufacture of goods. The disc insulators to be offered by
the bidders should have successfully passed the type test (As per IS 731 / relevant
IEC) given below :
a) Visual examination
b) Verification of dimension
c) Visible discharge test
d) Impulse voltage withstands test
e) Wet power frequency voltage withstand test
f) Temperature cycle test
g) Electro-mechanical failing load test
h) 24 hrs. Mechanical strength test/Electro mechanical strength test
i) Puncture test
j) Porosity test
k) Galvanising test
6.3 Acceptance Tests
a) Visual examination.
b) Verification of dimensions. IS :731-1971
c) Temperature cycle test.
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d) Galvanising test.
e) Electro Mechanical Strength }IEC:575-1975,
test/24 hrs. Mechanical Strength Clause
f) test. 4.0
Test on locking device for ball }IEC:373(2)-
g) and socket coupling. 1976
h) Puncture test
i) Porosity test
Electro-mechanical failing load
test
a) Visual Inspection.
b) Mechanical routine test. IS-731-1971 Clause-
10.13, 10.14 & 10.15
c) Electrical routine test (for
porcelain insulator only)
SECTION-III
PART - F
SPECIFICATIONS FOR EARTH WIRE
1. Technical Description of Earthwire
1.1 Scope & Qualifying Criteria:
i) The bidder is to arrange for supply of HTGSS wire (Earth Wire) of size
7/3.15 mm to be used on 220 KV Transmission Lines.
ii) The bidder shall ensure that the manufacturer fulfills the following
Qualifying Criteria:
a) The manufacturer must have capacity to make at least 2000 MT Earthwire
of size 7/3.15 mm & above per annum. Documentary proof in form of a
certificate from a chartered Accountant / Engineer must be attached with
the Bid.
b) The manufacturer must have supplied at least 1000 MT Earthwire of size
7/3.15mm & above during the last three years. Documentary proof in form
of a certificate from a chartered Accountant / Engineer must be attached
with the Bid.
c) Performance Cetificate(s) from any SEB/ Utility for supply of at least 250
MT Earthwire of size 7/3.15 mm or above shall be funished with the Bid.
d) The average annual turnover of the manufacturer shall not be less than
Rs. 10 crores per annum and he should have liquid assets and / or
evidence of access to or availability of credit facilities of not less than Rs. 2
Crores. Documentary proof for these shall also be attached with the bid.
1.2 Details of Earthwire
1.2.1 The galvanised steel earthwire shall generally conform to the
specification of ACSR core wire as mentioned in IS:12776-1989 & IS:
4826-1979 (latest) except where otherwise specified herein.
1.3 Workmanship
1.3.1 All steel strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, die marks, scratches, abrasions
and kinks after drawing and also after stranding.
1.3.2 The finished material shall have minimum brittleness as it will be
subjected to appreciable vibration while in use.
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1.3.3 The steel strands shall be Hot dip galvanised and shall have a
minimum zinc coating of 240 gms/sqm. After stranding of the uncoated
wire surface. The zinc coating shall be smooth, continuous, of uniform
thickness, free from imperfections and shall withstand three and a half
dips after stranding in standard Preece test.
1.3.4 The steel strands shall be preformed and post formed in order to
prevent spreading of strands while cutting of composite earthwire.
Care shall be taken to avoid damage to galvanization during
preforming and post forming operation.
1.3.5 To avoid susceptibility towards wet storage strains (while rust), the
finished material shall be provided with a protective coating of boiled
linseed oil.
1.4 Joints in Wires
There shall be no joint of any kind in the finished steel wire strand
entering into the manufacture of the earth wire. There shall be no
strand joints or strand splices in any length of the completed stranded
earthwire.
1.5 Tolerances
The tolerances shall be as per the relevant ISS.
1.6 Materials
1.6.1 Steel
The steel wire strands shall be drawn from high carbon steel rods and
shall conform to the following requirements as to the chemical composition
:-
Element % Composition
Carbon Not more than 0.55
Manganese 0.4 to 1.10
Phosphorous Not more than 0.05
Sulphur Not more than 0.05
Silicon 0.15 to 0.35
1.6.2 Zinc
The zinc used for galvanising shall be electrolytic High Grade Zinc of
99.95% purity. It shall conform to and satisfy all the requirements of
IS:209-1979
1.7 Standard length
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1.7.1 The standard length of the earthwire shall be 2000 meters. The
tolerance on length shall be 5% on the standard length.
1.7.2 Random length will be accepted provided no length is less than 50% of
standard length and the total quantity of random lengths is not more
than ten(10)percent of the total quantity in each shipment.
2.0 Tests and Standards
2.1 Tests
The following type, acceptance and routine tests and tests during
manufacture shall be carried out on the earthwire. For the purpose of this
clause:
2.1.1 Type Tests shall mean those test which are to be carried out to prove
the process of manufacture and general conformity of the material to
this Specification. Type test certificates indicating conformity of the
material as per relevant Standard/PSEB specification are required to
be submitted alongwith the bid as per requirements of section II of this
specification.
2.1.2 Acceptance Tests shall mean those tests which are to be carried out
on samples taken from each lot offered for pre-despatch inspection, for
the purposes of acceptance of that lot.
2.1.3 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.
2.1.4 Tests during Manufacture shall mean those tests, which are to be
carried out during the process of manufacture and end inspection by
the Contractor to ensure the desired quality of the end product to be
supplied by him.
2.1.5 The norms and procedure of sampling for these tests will be as per the
Quality Assurance Programme to be mutually agreed to by the
Contractor and the Employer.
2.1.6 The standards and norms to which these tests will be carried out are
listed against them.
2.1.7 For all type 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.
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2.2 Type Tests, Acceptance Tests, Routine Tests and Test During
Manufacture.
2.2.1 Type Tests on Earthwire
All the tests under clause 2.2.2 (Acceptance Tests)
2.2.2 Acceptance Test on Earthwire
e) Galvanising test
f) Torsion test
g) Elongation Test
h) Wrap test.
i) DC resistance test. IS:398(Part-III)
j) Breaking load test
k) Chemical Analysis of steel
1.1 Chemical Analysis of Steel :Samples taken from the Steel ingots
coils/strands shall be chemically/ spectrographically analysed. The same shall
be in conformity with the requirements stated in this specification.
1.2 Visual and Dimensional Check on Drums:The drums shall be visually and
dimensionally checked to ensure that they conform to the requirements of this
specification.
1.3 Visual Check for Joints, Scratches, etc.:Earth wire drums shall be rewound
in the presence of the Purchaser. The purchaser shall visually check for
scratches, joints, etc. and that the conductor generally conforms to the
requirements of this specification.
1.4 Dimensional Check on Steel :The individual strands shall be dimensionally
checked to ensure that they conform to the requirements of this specification.
1.5 Check for Lay Ratios of various Layers :The lay ratios of various layers
shall be checked to ensure that they conform to the requirements of this
specification.
1.6 Galvanising Test :The test procedure shall be as specified in IS:4826. The
material shall conform to the requirements of this specification. The
adherence of zinc shall be checked by wrapping around a mandrel four times
the diameter of the steel wire.
1.7 Torsion and Elongation Tests on Steel Strands :The test procedures shall
be as per of IS:398 (Part-II ).
Page 113 of 143
SECTION III
PART - G
SPECIFICATIONS FOR HARDWARE FITTINGS
iv) The assembly shall not permit slipping or damage to, or failure of the
complete conductor or any part thereof at a load less than 95% of the ultimate
tensile strength of the conductor.
2.11 Yoke Plates
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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 into account the most unfavorable loading conditions likely to
be experienced as a result of dimensional tolerances for disc insulators as
well as components of hardware fittings within the specified range. The plates
shall have suitable holes for fixing arcing horn. All the corners and edges
should be rounded off with a radius of atleast 3mm. The holes provided for
bolts in the yoke plate should satisfy shear edge condition as per Clause
No.8.10 of IS:800-1984.
4.0 Materials:
i) The materials of the various components shall be as specified hereunder.
However components made of alternative materials giving equivalent or
better performance shall also be considered. The Bidder shall indicate the
material proposed to be used for each and every component of hardware
fittings stating clearly the class, grade or alloy designation of the material,
manufacturing process & heat treatment details and the reference
standards.
ii) Raw material to be used for the manufacture of various hardware fittings
made of mild steel, forged steel and aluminium alloy, nuts and bolts, cotter
pins, security clips, galvanizing or electro-plating shall conform to relevant
Indian standard and may be tested by purchaser according to the tests laid
therein.
4.1 Mild Steel:
Raw material to be used for the manufacture of various hardware
fittings made of mild steel shall be tested according to the tests laid in the
relevant Indian standard, if so desired by the purchaser.
4.2 Aluminium or Aluminium Alloy fittings:
The Aluminium or Aluminium Alloy fittings shall be of extruded sections
as mentioned against each. The type of Aluminium/ Aluminium Alloy, its
mechanical properties and chemical composition shall be indicated in the
tender.
4.3 Forgings:
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All the forged fitting shall be made from forged steel and all the tests
specified in the corresponding IS shall be performed on the test bars, if
desired by the purchaser. The Bidder shall specify whether cold or hot
process shall be used and the forging done with drop hammer or press,
alongwith the size and capacity of the forging equipment. All the forged
fittings shall be made out of one piece and these shall not be made by
joining welding or shrunk fitted or with any other process.
The Bidder shall indicate type of forging steel and its mechanical
properties, which will be used for producing forged hardware fittings.
The details of materials for different component are listed as in Table No.1
5.0 Workmanship:
i) All the equipment shall be of the latest design and conform to the best modern practices
adopted in the Extra High Voltage field.
ii) All ferrous parts including fasteners shall be hot dip galvanized, after all
machining has been completed. Nuts may, however, be tapped (threaded)
after galvanizing and the threads oiled. Spring washers shall be electro-
galvanized. The bolt threads shall be undercut to take care of the increase in
diameter due to galvanizing. Galvanizing shall be done in accordance with
IS:2629-1985 and shall satisfy the tests mentioned in IS:2633-1986.
Fasteners shall withstand four dips while spring washers shall withstand three
dips of one-minute duration in the standard preece test. Before ball fittings are
galvanized, all die flashing on the shank and on the bearing surface of the ball
shall be carefully removed without reducing the dimensions below the design
requirements.
iii) 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
galvanizing shall be grade Zn 99.95 as per IS: 209-1979.
iv) Pin balls shall be checked with the applicable GO gauges in at least two
directions, one of which shall be across the line of die flashing and the
other 900 to this line. NO GO gauges shall not pass in any direction.
v) Socket ends, before galvanizing, shall be of uniform contour. The bearing
surface of socket ends shall be uniform about the entire circumference
without depressions of high spots. The internal contours of socket ends
shall be concentric with the axis of the fittings as per IS: 2486.
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vi) 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.
vii) In case of casting, the same shall be free from all internal defects like
shrinkage inclusion, blowholes, cracks etc. Pressure die-casting shall not
be used for casting of components with thickness more than 5 mm.
viii) All current carrying parts shall be so designed and manufactured that
contact resistance is reduced to minimum & localized heating
phenomenon is averted.
ix) No equipment shall have sharp ends or edges, abrasions or projections
and cause any damage to the conductor in any way during erection or
during continuous operation, which would produce high electrical and
mechanical stresses in normal working. The design of adjacent metal parts
and mating surfaces shall be such as to prevent corrosion of the contact
surface and to maintain good electrical contact under service conditions.
x) 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.
xi) All fasteners shall have suitable corona free locking arrangement to guard
against vibration loosening.
xii) Welding of aluminium shall be by inert gas shielded tungsten arc or inert
gas shielded metal arc process. Welds shall be clean, sound, smooth, and
uniform without overlaps, properly fused and completely sealed. There
shall be no cracks, voids incomplete penetration, incomplete fusion, under-
cutting or inclusions. Porosity shall be minimized so that mechanical
properties of the aluminium alloys are not affected. All welds shall be
properly finished as per good engineering practices.
xiii) The particular care shall be taken during manufacture & subsequent
handing to ensure smooth surface free from abrasion or cuts.
6.0 Bid Drawings:
i) The Bidder shall furnish full description and illustrations of materials offered.
ii) Fully dimensioned drawings of the complete insulator string hardwares and
the component parts showing clearly the following arrangements shall be
furnished in four (4) copies alongwith the bid. Weight, material and fabrication
details of all the components should be included in the drawings.
(a) Attachment of the hanger or strain plate.
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(b) Suspension or dead end assembly.
(c) Links with suitable fittings.
iii) All drawing 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 3 mm. All dimensions & dimensions tolerances
shall be mentioned in mm:
The drawing shall include:
(a) Dimensions and dimensional tolerance.
(b) Materials, fabrication details including any weld details & any
specified finishes & coatings. Regarding material, designation &
reference of standards are to be indicated.
(c) Catalogue No.
(d) Marking
(e) Weight of assembly
(f) Installation instructions
(g) Design installation torque for the bolt or cap screw.
(h) Withstand torque that may be applied to the bolt or cap screw
without failure of component parts.
(i) The compression die number with recommended compression
pressure.
(j) All other relevant terminal details.
iv) After placement of award, the Contractor shall submit fully dimensioned
drawing including all the components in four (4) copies to the Purchaser for
approval. After getting approval from the Purchaser and successful
completion of all the type tests, the Contractor shall submit 10 more copies
of the same drawings to the Purchaser for further distribution and field use
at Purchasers end.
Table-1
Details of Materials for ACSR Zebra
Sr. Name of item. Material Reference
No. Standard
1. Security Clips SS/Phosphor Bronze IS: 7814:1975/
IS:6603-1972
2. U-clevis/ Anchor Forged Steel Grade-4 As per IS:2004
shackle 1978 or
equivalent.
3. Ball Eye/ Ball clevis Forged Steel Grade-4 As per IS:2004
1978 or
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equivalent.
4. Socket clevis / Forged Steel Grade-4 As per IS:2004
Clevis-clevis 1978 or
equivalent.
5. Tension Clamp Extruded Aliminium As per IS:2004
(99.5% pure) 1978 or
equivalent.
6. Suspension Clamp High Strength Al. Alloy IS: 6051:1910
7. Dead End
Assembly
(a)Outer Sleeve (of EC grade of Extruded
dead end Aluminium (99.5%
assembly) pure)
(b) Steel Sleeve Mild Steel/FS As per IS:226-
1975
8. Jumper Bolts / U- Stainless Steel IS: 6603:1972
bolts with flat
washer & nut
1. Type Compression
2. Material
i) Outer Sleeve Aluminium (Extruded tube) 99.5%
pure
II) Inner Sleeve Steel (Hot Dip galvanized)
3. Shape of cross section
i) Before compression Round
ii) After compression Hexagonal
4. Min. failing load Not less than 95% of the breaking
load of the conductor
5. Electrical resistance of the Not more than 75% of measured
joint after installation resistance of the equivalent length
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of conductor
6. Marking Compression & non compression
zone to be marked clearly of the
Aluminium sleeve
7. Weight 0.4 kg (indicative only)
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Table II
Dimensions & Dimensional Tolerances for Mid Span Compression Joint
and Repair Sleeve for ACSR Zebra
Sr Item Dimensions before Dimensions after
No. Compression Compression
Inner Outer Length Corner Face to
Dia Dia to Face
Corner
(mm) (mm) (mm) (mm) (mm)
1 Mid Span Compression joint for ACSR Zebra
A Aluminium 31+0.5 48+1 710+5 46+0.5 40+0.5
Sleeve
B Steel Sleeve 10.7 28.8 20.2 17.5
Table III
1. Type Compression type, in two parts
with provision of seat for sliding of
keeper piece
2. Shape of cross section
i) Before compression Generally round
ii) After compression Hexagonal
3. Dimensions As per given in Table II
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4. Suitable for ACSR ZEBRA conductor
5. Material Extruded Aluminium 99.5% pure
6. UTS Not less than 95% of UTS of
conductor
7. Standard IS: 2121-1981 (Part-II)
8. Max. Electrical resistance Not more than 75% of measured
of repaired portion resistance of the equivalent length
of conductor
9. Min. failing load 95% of breaking load of conductor
10. Length As per given in Table II
viii) The damper placement chart for spans ranging from 100m to 500m 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) Location of the dampers for various combinations as spans and lien
tension clearly indicating numbers of dampers to be installed per
earthwire per span.
2) Placement distances clearly identifying the extremities between which
the distances are to be measured.
3) Placement recommendation depending upon type of suspension
clamps (viz, free center type/trunion type etc.)
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4) The influence of mid span compression joints in the placement of
dampers.
10.4 Flexible Copper Bond
The flexible copper bond shall be circular in cross section of minimum
34 sq. mm equivalent copper area and not less than 500mm in length, it shall
consist of 259 wires of 0.417mm 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
122mm dia bolt and the other for 16mm dia bolt. The complete assembly shall
also include one 16mm dia 40mm long HRH MS Bolts hot dip galvanized with
nut and lock washer.
10.5 Suspension Clamp
1. Standard suspension clamp for Earthwire size 7/3.15 mm as per PSTCL
deign shall be supplied.
2. The clamps shall be of free-centre type and shall provide adequate area of
support to the earthwire. The groove of the clamp shall be smooth,
finished in a uniform circular or oval shape and shall slope downwards in
the smooth curve to avoid edge support and hence to reduce the intensity
of bending moment on earthwire.
3. There shall be no sharp point in the clamps coming in contact with
earthwire. There shall not be any displacement in the configuration of the
earthwire strands nor shall the strands be unduly stressed in final
assembly during working conditions.
4. The clamping piece and the clamp body shall be clamped by at least two
U-Bolts of size not less than 10mm diameter having one nut and one 3
mm thick lock nut with washer on each of its limbs. Suspension clamps
shall be provided with inverted type U-bolts.
5. 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 earthwire
shall not exceed 150mm. The design of the assembly shall be such that
the direction of run of the earthwire shall be same as that of the conductor.
10.6 Tension Clamp
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1. At all tension towers suitable compression type tension clamps shall be
used to hold 7/3.15mm galvanized steel earthwire. Anchor shackle shall
be supplied which shall be suitable for attaching the tension clamp to
strain plates.
2. The clamps shall have adequate area of bearing surface to ensure
positive electrical and mechanical contact and shall not permit any slip to
the earthwire under working tension and vibration conditions. The angle of
jumper terminal to be mounted should be 30 deg. with respect to the
vertical line.
3. The clamp shall be made of mild steel . The steel should not crack or fail
during compression. The Brinnel hardness of steel sleeve shall not exceed
200. The steel sleeve shall be hot dip galvanized.
4. The complete assembly shall be so designed as to avoid undue bending in
any part of the clamp and shall not produce any hindrance to the
movements of the clamps in horizontal or vertical directions.
5. The slip strength of the assembly shall not be less than 95% of the
ultimate strength of the earthwire.
6. The clamps shall be complete with all the components including anchor
shackle, bolts nuts washers, split pin, jumper arrangement etc.
11.1 Type tests
On suspension Hardware Fittings only
a) Visual Inspection IS: 2486(Part-I)
b) Verification of Dimensions
c) Slip strength test
d) Ultimate Tensile Strength test
e) Mechanical strength test
f) Magnetic power loss test for suspension
assembly
g) Clamp slip strength Vs torque test for
suspension clamp
h) Galvanizing/Electroplating tests IS: 2633
i) Chemical composition test
On Tension Hardware fittings only
a) Visual Inspection IS: 2486(Part-I)
b) Verification of Dimensions
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c) Slip strength test for dead-end assembly
d) Heating cycle test for dead end Assembly
e) Electrical resistance test for dead end
Assembly
f) Ultimate Tensile Strength test
g) Mechanical strength test
h) Chemical composition test
i) Galvanizing/Electroplating tests IS: 2633
Mid Span Compression joint for Conductor and Earthwire
a) Visual Inspection IS: 2121(Part-II)
b) Verification of Dimensions
c) Heating cycle test
d) Failing Load Test
e) Electrical resistance test
f) Slip strength test
g) Chemical analysis of materials
i) Galvanizing tests IS: 2633
Repair Sleeve for Conductor
a) Chemical analysis of materials
Vibration Dampers
a) Visual Inspection IS: 9708-1993
b) Verification of Dimensions
c) Resonance frequency Test
d) Fatigue tests
e) Mass Pull off Test
f) Dynamic characteristics test
g) Damper efficiency test
h) Clamp Slip Test
i) Clamp Bolt Tightening Test
j) Chemical analysis of materials
k) Magnetic power loss test
l) Galvanizing/Electroplating tests IS: 2633