APEPDCL

(EASTERN POWER DISTRIBUTION COMPANY OF ANDHRA PRADESH LIMITED)

( CIN:U40109AP2000SGC034117, Corporate Office, Visakhapatnam )

TECHNICAL SPECIFICATIONS

Revamped Reforms-Based and Results -Linked,

Distribution Sector Scheme (RDSS)

Under Ground Cabling & Covered Conductor

Works under Loss Reduction Distribution
Infrastructure

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 INDEX
Table of Contents
S.I Page
Name of Chapter
No No
ABBREVIATIONS 5-8

1 GENERAL TECHNICAL SPECIFICATION 9

2 SPECIFICATION OF PRELIMINARY WORKS 10 - 17

3 ENVIRONMENTAL MANAGEMENT PLAN MEASURES 18 - 34

4 INDIAN STANDARD SPECIFICATIONS 35 - 36

5 CLIMATIC CONDITIONS 37

GENERAL INFORMATION OF SOIL STRATA FOR TRENCH

6 38
EXCAVATION

7 XLPE POWER CABLES (33kV & 11kV) 39 - 45

8 CABLE JOINTING KIT/ TERMINATION ACCESSORIES 46 - 53

9 HIGH DENSITY POLYETHYLENE (HDPE) PIPE 54 - 56

10 GALVANIZED IRON EARTH PIPE 57 - 58

11 GI WIRE 59

12 CABLE LAYING AND INSTALLATION 60 -68

13 HORIZONTAL DIRECTIONAL DRILLING (HDD) 69 - 70

14 RCC CABLE ROUTE MARKERS 71

15 CABLE PROTECTION COVER TILES 72

16 CAUTION TAPE 73

17 EARTHING 74 - 75

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18 CONSTRUCTION STANDARDS FOR CIVIL WORKS 76 - 84

19 SPECIFICATION FOR ROAD WORKS 85-106

SPECIAL SPECIFICATIONS FOR CIVIL WORKS &

SWITCHGEAR 107-
20
119
GUARANTEED TECHNICAL PARTICULARS

PRE COMMISSIONING TESTS 120-

21
126

DISMANTLING OF 33KV & 11 kV OVERHEAD LINES 127-

22
128

SPUN CEMENT CONCRETE POLES 129-

23
195

PRE STRESSED CEMENT CONCRETE POLES (PSCC POLES) 196-

24
199

33KV AB SWITCHES (ISOLATORS) 200-

25
220

26 11KV AB SWITCH 221

11/33 KV COVERED CONDUCTORS 222-

27
260

33V 10 KN COMPOSITE SILICON RUBBER POLYMER 261-

28
PIN INSULATORS WITH GI PINS 274

11KV POLYMER PIN INSULATORS WITH GI PINS 275-

29
280

33KV POLYMER DISC INSULATORS (B&S) 281-

30
295

33KV METAL PARTS (B & S TYPE) 296-

31
298

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 11KV POLYMER DISC INSULATORS (C&T) 299-
32
306

33 11KV METAL PARTS (C & T ) 307

GI STAY WIRES 308-

34
309

35 11KV GUY INSULATOR (HT) 310

36 33KV 2+1 CHANNEL 311

37 312
33KV SIDE ARM
38 313
33KV T RAISER CHANNEL
39 314
33KV TAPPING CHANNEL
40 315
33KV V CROSS ARM & TOP CLEAT
41 316
33KV VF CHANNEL
42 11KV 2+1 CHANNEL IN EXISTING 33-11KV LINE 317

43 11KV SIDE ARM 318

44 ANGLE STRUT FOR V CROSS ARM AT ANGLE POINT 319

45 GUARDING DRAWING 320

46 LT 5W CROSS ARM 321

47 STAY CLAMPS 322

48 STRUT CLAMP FOR STRUT POLES 323

49 11KV SIDE ARM WITH STRUT 324

50 11KV MS STAY SETS WITHOUT BASE PLATE 325

51 11KV TAPING CROSS ARMS 326

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 11KV TOP CLEAT WITH CLAMP 327-
52
328

53 HT G.I BACK CLAMPS SUITABLE FOR SPUN POLES 329

54 G.I BACK CLAMPS FOR 9.1 Mts PSCC POLES 330

55 G.I STAY CLAMPS FOR 8Mts & 9.1Mts PSCC POLES 331

ABBREVIATIONS

AB – Aerial Bunched
AC – Alternating Current
ACB – Air Circuit Breaker
AH – Ampere Hour
APEPDCL – Andhra Pradesh Eastern Power Distribution Company Limited
APSS – Andhra Pradesh Standard Specification
ASCII – American Standard Code for Information Interchange
ASTM – American Society for Testing and Materials
BC – Bituminous Concrete
BIS – Bureau of Indian Standards
BOQ – Bill of Quantities
CB – Circuit Breaker
CBIP – Central Board of Irrigation and Power
CD – Compact Disc
CEA – Central Electricity Authority
CESI – Testing Consulting Engineering Environment
CM – Centi Meter
CMRI – Common Meter Reading Instrument
CPRI – Central Power Research Institute
CPWD – Central Public Works Department
CRGO – Cold Rolled Grain Oriented

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CSA – Cross Sectional Area
CT – Current Transformer
DAS – Distribution Automation System
DB – Distribution Box
DBM – Dense Bituminous Macadam
DC – Direct Current
DMS – Distribution Management System
DTR – Distribution Transformer
DVD – Digital Video Disc
DWG – Drawing
DXF – Drawing eXchange Format
ERDA – Electrical Research and Development Association
ESMF – Environmental and Social Management Framework
FP – Feeder Pillar
FPI – Fault Passage Indicator
FRLS – Fire Retardant Low Smoke
FRP – Fibre Reinforced Plastic
FRPP – Fire Resistant Poly Propylene
FRTU – Feeder Remote Terminal Unit
GI – Galvanized Iron
GIS – Geographic Information System
GoAP – Government of Andhra Pradesh
GOI – Government of India
GPRS – General Packet Radio Service
GS – Galvanized Steel
GSB – Granular Sub Base
GTP – Guaranteed Technical Particulars
GVMC – Greater Visakhapatnam Municipal Corporation
HDD – Horizontal Directional Drilling
HDPE – High Density Poly Ethylene
HRC – High Rupturing Capacity
HT – High Tension
HV – High Voltage
IDMT – Inverse Definite Minimum Time
IEC – International Electrotechnical Commission
IED – Intelligent Electronic Device
IEEE – Institute of Electrical and Electronics Engineers

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IP – Internet Protocol
IRC – Indian Roads Congress
IS – Indian Standard
ISI – Indian Standards Institute
ISO – Indian Organization of Standardization
KA – Kilo Ampere
KG – Kilo Gram
KM – Kilo Meter
KMPH – Kilo Meter Per Hour
KVA – Kilo Volt Ampere
KVAR – Kilo Volt Ampere Reactive
KVAR – Kilo Volt Ampere Reactive Hour
KW – Kilo Watt
KWH – Kilo Watt Hour
LBS – Load Break Switch
LED – Light Emitting Diode
LCD – Liquid Crystal Display
LT – Low Tension
LV – Low Voltage
MAX – Maximum
MCB – Miniature Circuit Breaker
MCCB – Moulded Case Circuit Breaker
MFT – Multi Function Transducer
MIN – Minimum
MM – Milli Meter
MORD – Ministry of Rural Development
MORTH – Ministry of Road Transport and Highways
MS – Mild Steel
MV – Medium Voltage
NABL – National Accreditation Board for Testing and Calibration Laboratories
OFC – Optic Fibre Cable
OH – Over Head
PC – Personal Computer
PCC – Plain Cement Concrete
PF – Power Factor
PIU – Project Implementation Unit
PMU – Project Management Unit

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PT – Potential Transformer
PVC – Poly Vinyl Chloride
QAP – Quality Assurance Plan
RCC – Roller Compacted Concrete
REC – Rural Electrification Corporation
REN – Resilient Electrical Network
RMS – Root Mean Square
RMU – Ring Main Unit
RTI – Right to Information Act
RTU – Remote Terminal Unit
SCADA – Supervisory Control And Data Acquisition
SDBC – Semi Dense Bituminous Concrete
SHG – Self Healing Grid
SMC – Sheet Moulding Compounds
SP – Service Pillar
STW – Short Time Withstand
TOD – Time of Day
TCP – Transmission Control Protocol
TP&N – Triple Pole and Neutral
TTB – Test Terminal Block
TVR – Tri Vector Meter
UG – Under Ground
UV – Ultra Violet
UWT – Underground Warning Tape
USB – Universal Serial Bus
VA – Volt Ampere
VCB – Vacuum Circuit Breaker
VPIS – Voltage Presence Indicator System
VRLA – Valve Regulated Lead Acid
VUDA – Visakhapatnam Urban Development Authority
XLPE – Cross Linked Poly Ethylene
WBM – Water Bound Macadam
WMM – Wet Mix Macadam

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 1. GENERAL TECHNICAL SPECIFICATION

The General Technical Specifications shall be those conforming to the Specifications

prepared by the Central Public Works Department (CPWD), Specifications, Ministry of Road
Transport and Highways, Government of India (GoI) for Road and Bridge works (IVth
Revision) and including up to date amendments there to.

All the electrical works shall be carried by an electrical contractor valid license class and
direct supervision of a person holding a certificate of competency issued by the Director,
Electrical Safety / Chief Electrical Inspector to Government, Department of Energy,
Government of Andhra Pradesh and the Electrical works shall be done conforming to the up
to date Indian Standards, CEA Regulation, Indian Electricity Rules, Code of Practice for
Electrical wiring installations, National Building Code and Electrical Safety Procedures.

In the absence of any definite provisions on any particular issue in the aforesaid
Specifications, reference may be made to the latest codes and specifications of IRC and BIS
in that order. Where even these are silent, the cable laying and completion of the works shall
conform to sound engineering practice as approved by the Engineer and in case of any
dispute arising out of the above, the decision of the Engineer shall be final and binding on the
Contractor.

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 2. SPECIFICATION OF PRELIMINARY WORKS

The Contractor is advised to go through the below specifications and price his bid
accordingly. The Contractor shall include for the requirements of this Clause in his
Programme of Works and his Bill of Quantities.

1. General Responsibilities for utility Works

The Contractor shall be responsible for liaison with Public Utility Departments and other
Government Agencies with regards to the overall co-ordination and programming of UG
Cabling works.

No trench or chamber excavation will be permitted until: -

i) The locations and depth of all existing services have been established by trial-holes to the
satisfaction of the Engineer.

ii) The Contractor has provided the Engineer with accurate setting out information for the line
and level of the proposed work.

iii) The Engineer has confirmed the accurate setting out information for the line and levels of the
proposed work.

The Contractor shall be responsible for arranging, providing and maintaining all road closures
and traffic diversions required by the Works with the Traffic Police Department and the
Engineer.

2. Housing, Water etc.

(a) The Contractor is responsible for transportation of his workmen to and from the Site.

(b) The Contractor is responsible for all arrangements for his workmen and everything
concerning the procurement and employment of labour.

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(c) The Contractor shall be required to provide and maintain at his own cost all camps and
housing to accommodate properly his personnel and labour for the period of the Contract
having due regard for the Statutes, Ordinances, Laws, Regulations and By-Laws in force in
the district and to the approval of the appropriate Government Authorities and as specified in
this bid document. Such camps and housing shall not be permitted to be erected on the Site.

3. Trespass and Nuisance

The Contractor will be held responsible for and shall indemnify the employer against all
claims in connection with noise, vibration, dust, smoke and any other nuisance arising from
the execution of the Works.

4. Temporary Roads

The Contractor shall be required to maintain and provide satisfactory temporary access and
traffic flow to and from and within the areas of the Works. Temporary traffic signs and
lighting for temporary roads and diversions are to be in strict accordance with the
requirements of the Visakhapatnam Police Department, other Government Agencies and any
additional requirements instructed by the Traffic Police or the Engineer. Details of proposals
for any such temporary measures are to be submitted by the Contractor at least 7 days in
advance for approval by the Traffic Police and the Engineer unless otherwise instructed.
Such approval shall not relieve the Contractor of any of his duties or responsibilities under the
Contract.

The Contractor shall maintain at all times access to all properties fronting the roads affected
by the Works.

5. Maintenance of Roads

The Contractor will be held responsible for any damage caused by him, his work people, sub-
Contractors or suppliers to public or private roads, paved areas, paths verges, trees, shrubs,
fences, boundary walls, gates, signs, drains, ducts and services during the execution of the
Contract and shall bear the cost of making good any damage to the entire satisfaction of the
local and other authorities and owners. The Contractor shall keep all private roads and paths
clean and free from dirt and debris and any obstruction associated with the Works which
would prejudice the safe and unimpeded normal use of the said roads and paths.

6. Contractor’s Temporary Buildings

The Employer shall arrange for right of access only within the road reservation. Should the
Contractor require to use adjacent areas of land for camps, plant site, stores etc., he shall
arrange for the right to use the said land himself.

7. Measuring and Recording Equipment

The Contractor shall have the following equipment for the use of the Engineer's
Representative for the duration of the Contract.

a. 1 No.1 second Wild T2 theodolite with calibrated E.D.M. (or equivalent) C/W tripods, prisms
etc.

b. 1 No. Automatic engineer's level including tripod.

c. 1 No. Metric leveling staff.

d. 1 No. Calibrated steel survey band 50 m long.

e. 2 Nos. 30m nylon tape.

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 f. 4 Nos. 5m pocket tapes.

g. 6 Nos. Ranging rods.

h. Level and field books as required.

i. 1No. Mason's Spirit level.

j. 1 No. Thermometer.
k. Total station
l. 0-1000 Amps, 0-600V AC/DC Tong tester for measuring the current in electrical cables
m. Digital Multi-meter
n. 5 KV Megger for measuring insulation resistance of electrical equipment
Other equipment such as pegs, tools, etc., which are necessary for the checking of the Works
shall be provided as requested by the Engineer.

The Contractor shall maintain and replace as necessary the equipment for the duration of the
Contract. Surveying and testing instruments shall be new or in as good as new condition, of
an approved make with a current certificate of calibration. The certificates shall be revalidated
as per standards.

The Contractor shall provide for the use of the Engineer's Representative and his staff, any
technician / qualified assistants to carry out any duties for the works, as required by the
Engineer's Representative.

8. Site Diary

The Contractor shall also supply to the Engineer, weekly returns as to the number of labour
and construction plant employed and the nature of the work on which they were employed.

9. Cleaning the Works

Clearance and Transportation of Building Refuse:

i. The Contractor shall undertake to carry out the following within a maximum period of 15
days after completion of the agreed stretch of road.
a. Removal of all the Contractor's equipment, machinery and other belongings from the
completed stretch of road.
b. Clearance of all earth, debris and refuse whatsoever and transporting them to the location
designated by the concerned Municipality.
ii. In the case of Contractor's delay or refusal to carry out such a job, he shall have to pay a penal
compensation of Rs 10,000/- for delay for each day or part of a day. This compensation shall
be final and the Judiciary shall not be entitled to mitigate it and it does not require
establishing the occurrence of any damage to the owner.
iii. In addition, APEPDCL shall be entitled to clear the refuse themselves and transport it to the
location designated by GVMC. APEPDCL may also stop the final payment due to the
Contractor until such refuse has been cleared and a certificate confirming this has been
obtained from GVMC.

10. Progress and Site Photographs

A. The Contractor shall arrange to obtain a photographic record of the site before the start of the
works by taking photographs from positions agreed with the Engineer. Two number 125 x 90
mm prints of each photograph should be developed and handed to the Engineer within 7 days
of the photographs being taken.

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B. For progress photographs, the Contractor shall take 18 number colour photographs for each
500-meter stretch from positions agreed with the Engineer. Two number 125 x 90 mm prints
should be developed and handed to the Engineer within 7 days of the photographs being
taken. The soft copy of the same shall also be submitted every month.
C. The Contractor will supply to the Engineer, two number photographic albums duly mounting
all site and progress photographs after completing the works.
D. All photographic prints and soft copies shall be the property of the Engineer and shall not be
used for any purpose whatsoever without the Engineers approval. The copyright of all
photographs shall belong to the APEPDCL and the Contractor shall not use the photographs
for any purpose whatsoever without the Engineer’s approval.
F. The Contractor shall take video film of the work-in-progress at the end of every month. The
video film shall not extend beyond 15 minutes, and shall be clear and comprehensive enough
to provide a fair idea on the progress of development. The video film shall show the date of
filming and the description of the works. Two sets of DVDs in good condition shall be
supplied to the Engineer every month. If the video film is not clear or does not provide an
idea of the work progress, the Engineer shall direct the Contractor to remake the video film.
G. Photographs and video film on or about the site shall not be taken without prior approval and
written permission, and any such photography or video film shall not be used for publicity
purposes without the express written approval of the APEPDCL.
H. The contractor shall take care not to photograph / video of sensitive establishments, protected
areas and shall not use the permission given to take photographs / video encroaching on the
privacy of public. If it is found that this activity is done, necessary action as per law will be
initiated by the concerned against the Contractor. APEPDCL will not be responsible for such
acts of Contractor.

11. Method Statements

A. The Contractor shall submit for approval as and when required by the Engineer written
statements with appropriate sketches of the methods of construction he intends to use. The
statements shall be submitted to the Engineer in ample time for proper consideration to be
given to them before the operation described is started and no work is to be done without
approval having been obtained in writing. The acceptance by the Engineer of a method
statement shall not relieve the Contractor of any of his obligations under the Contract. The
required documents shall be submitted for approval 10 days prior to taking up work in a
particular area.

12. As-Built Record Drawings, Survey Drawings and Data

A. The Contractor shall prepare 'as built' record and survey drawings of the works detailing all
works installed under the contract including utilities, services and all finished alignments and
levels. The drawings shall be accompanied by maintenance manuals, service literature and
lists of spare parts where applicable.
B. As built record drawings, operations manuals and maintenance manuals and any other
literature pertaining to and required for the efficient operation of the completed works shall be
supplied by the Contractor to the Engineer free of charge. The drawings pertaining to the
record drawings and operations and maintenance manuals shall be on clear white polyester
film or other durable and easily reproducible medium approved by the Engineer.
C. Where any permanent feature has been added, changed or removed the Contractor shall
conduct a topographical survey. The survey shall be undertaken by approved survey
company. The as built survey shall be delivered to the Engineer for approval.
D. Four copies of the as built drawings and documentation shall be submitted to the Engineer
within 30 days of issue of work completion certificate as stated in the Contract. One copy of
all documents and drawings shall be specifically marked for archival storage in the Prime
Document Storage Centre. The Maintenance Certificate (FCC) will not be signed by the

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 Engineer until all as built drawings and accompanying documents and service literature is
submitted, approved and a certificate has been issued by the Engineer to this effect. The
Contract shall not be considered complete until the Contractor submits to the Engineer all as
built drawings and the documentation and obtains the Engineer's written approval.

13. Digital Data

A. As part of the implementation of computer aided design systems and the development of GIS,
the Contractor shall, upon completion of construction, provide the Engineer with two digital
copies of the as built drawings, maintenance manuals of all equipments supplied under the
contract.
B. It is the Contractors responsibility to ensure that the digital data compiled by the approved
survey company is comprehensive and complete. The Contractor shall at all times during
construction maintain a comprehensive record of all setting out details and data; for chainage,
offsets, levels and of all sub-surface elements, including pipe work, ducts, cables and any
other installation required under the contract. These records shall be verified by the Engineer.
The records shall be incorporated into the as built survey undertaken by the approved survey
company to form a fully comprehensive and complete record of the works.

C. The digital data shall be submitted in the following formats

(i) DXF files for use in AutoCAD shall be created as ASCII text files. File names should
have a maximum of eight characters plus the three character extension .DXF.
(ii) DWG files for use in AutoCAD should have a maximum of eight characters plus the
three character extension DWG.
(iii) A Digital Terrain Model, including break lines and contours shall also be supplied in a
recognized format; namely ASCII data file, SDR MAP File, MOSS GENIO file or as
otherwise agreed with the Engineer.
D. The scale used shall be one-to-one scale.
E. The precision shall be double precision.
F. Feature accuracy shall be at least ± 0.01 meters.
G. Each layer shall contain only one feature type. If necessary, text may be added to a separate
layer to explain the feature type. Colors and line types of features shall be specified by layer
and not individual entities or blocks. Features shall not be duplicated across layers. The
Contractor shall obtain from the Engineer the most current specification detailing colour and
line type conventions.
H. Features should not be represented with user defined symbols. The following representation
shall be applied:
i) Polygons must comprise of lines to form closed areas where possible.
ii) Line entities must be continuous, not a series of consecutive segments.
iii) Arc entities must be continuous radius, not a series of consecutive segments
iv) Block entities are not allowed.
v) User defined symbols, fonts, or line types must not be used on any layer.
I. Layer names should be general descriptions of features (e.g., road centre line, kerb, walls, and
bollards). A list of all layers and associated descriptions shall be provided in the submittal, the
list shall be stored in an ASCII text file called; "layers.txt". Layer names should have up to 16
characters only and shall be restricted to letters and digits with the first character of the name
being a letter. Names shall not contain special characters such as: $, -, #. The Contractor shall
obtain from the Engineer the most current specification detailing naming conventions. Where
the files exceed the capacity of a single disk the files may be compressed using ZIP files and
span disks as approved. The ZIP file should be converted to an executable "exe" file, or the
UNZIP programme included to ensure the files are recoverable.

14. GIS Survey and Network Integration

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A. Background
 The existing overhead infrastructure is to be replaced with underground infrastructure
 APEPDCL has implemented the part-A of RAPDRP in Visakhapatnam city under which
various modules have been provided by the RAPDRP contractor. The GIS mapping of the
electrical infrastructure has been carried out and has been integrated with the consumer
data.

B. Detailed Scope
 The contractor shall survey the area taking the sketches provided as a reference.
 Data Integration: The changes due to replacement of existing over head network
infrastructure with underground cabling network are to be incorporated in the GIS module
of RAPDRP.
 The contractor shall have to prepare afresh/update the same by carrying out the DGPS GIS
survey (Sub-meter accuracy) & mapping of the newly erected infrastructure and consumer
indexing using latest GPS technology & equipments to get accurate results at the time of
execution for conversion to underground infrastructure.
 DGPS GIS survey is to be carried out on the approved format, and which will be checked/
validated by APEPDCL to the 100% accuracy limit and to hand over the same to
APEPDCL to integrate with the existing RAPDRP GIS system.
 The mapping must be done with +/- one-meter location accuracy with differential
corrections.
 The Contractors shall procure/arrange DGPS Base Station and adequate number of DGPS
Rovers and establish a Base Station at a central place for a particular project area.
 Coordinate system (Universal Mercator system-UTM) provided, should allow
superimposition on any standard mapping environment and platform like Google Earth.
 The Contractor shall use Personal Digital Assistants (PDA) or Hand Held Computers
(HHC) for Customer indexing.
 Network and asset survey work shall be carried out Substation wise and feeder wise. All
the features mentioned as per data model shall be surveyed using DGPS Equipments,
attributes to be collected and marked on the maps.
 It is also required to correct the location of the existing Network if the positions are
incorrect on the hardcopy maps.
 All above captured data shall be updated in system using Licensed GIS software.
Contractor has to ensure that exact location of assets, topology, and accurate consumer
indexing.
 Contractor shall ensure the complete data management with data backup management.
 The contractor shall overlay the network map on the base map and make final quality
checks to ensure the perfect match
 It is also required to get the approval from Sub division/Division in-charge about
correctness of captured data.
 All software, hardware infrastructure, to carry out work as mentioned shall be arranged by
Contractor.

C. O&M Work
 Delta changes in infrastructure (other than the project being implemented) during the
course of the execution will be communicated to the contractor to carry out the DGPS
survey and to hand over the same to APEPDCL to integrate with existing RAPDRP

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D. Deliverables
 Contractor shall submit preliminary drawing to engineer in-charge during execution of
work. After the completion of work, as built drawing along with SLD (Single line
Diagram) shall be submitted after incorporating all the suggestions given by engineer in-
charge. In the drawing at one end, title block shall be provided. Legends of symbols used
shall also be provided in the drawing and drawings/maps shall be published by contractor
in mutually agreed format only. The soft and hard copies of as built drawings (in pdf &
AutoCAD both) shall be given by the contractor.
 The drawings/maps to be prepared using specific utility symbols, with colour coding,
legible fonts and easy to understand, eliminating need to refer back to legends. The special
line types developed for utilities should be standardized for all reports enabling data
integration.

15. Other Services Authorities

The Contractor shall make due allowance for carrying out the Works, whilst Service
Authorities are working on the site, during the Contract period.

16. Access

The Contractor shall at all times during the Contract maintain safe and proper access to and
from adjacent buildings and properties.

17. Maintenance of Traffic Flow

A. The Contractor shall allow for the construction of temporary diversions to permit all existing
traffic movements for the duration of the contract period.
B. All diversions shall be constructed in accordance to the Indian Road Congress standards
(IRC:SP:55-2014) and shall be approved prior to their implementation by both the Engineer and
Traffic Police. It is the Contractor's responsibility to ensure that any traffic diversion required is
properly signed, demarcated, illuminated, controlled and maintained at all times.

18. Liaison with the Public Utilities and Other Contractors

A. The Contractor shall liaise with all Public Utilities for water, electricity supply, telephones, etc.
and shall:-
i) Provide Public Utilities with storage areas where applicable.
ii) Assist in unloading of stores and equipment.
iii) Ensure that all services or diversions of services are installed under the carriageway and
footways before they are surfaced.
iv) Work out an overall programme for any works to be carried out by Public Utilities and ensure
that this programme is maintained;
v) Keep Public utilities informed of the Contractor's own progress;
vi) Arrange for supplies of services for temporary accommodation for the duration for the Contract;
vii) Give the appropriate Public Utility adequate notice in writing that he intends to install dry ducts
so that a representative of the Utility concerned may attend the installation and record the
location of the ducts together with the Contractor.
B. The Contractor shall make due allowance for carrying out the Works, whilst Public Utility
Authorities are working on the Site, during, the Contract period. This due allowance shall
include programming of the works to suit the programmes of the Public Utility Authorities.
C. The Main Contractor shall at all times be responsible for the compliance with these
requirements by his sub-Contractors.

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D. Before final surfacing of any carriageways or footways takes place, the Contractor is
responsible for ascertaining from all Public Utility Authorities that their underground works
have been completed. In the event that the Contractor fails to carry out this obligation to the
satisfaction of the Engineer and completed surfacing is subsequently disturbed, the Engineer
may instruct the Contractor to carry out work at his own expense.

19. Government Survey Control Points

A. The Contractor shall protect all Government Survey Control Points within the limits of the site
from any damage whatsoever, during the construction of the Works.

B. All Control Points shall be clearly marked on Site by the Contractor and any necessary
temporary protection works shall be installed as directed by the Engineer.

A. Should any Control Point be damaged during the course of the Works, its replacement and
any other costs incurred (such as resurveying) shall be borne by the Contractor.

20. DEMOLITIONS AND ALTERATIONS

Removal of Existing Services

The following additional Clause shall be part of the scope whether specified elsewhere or not
- Workmanship:

a. When directed by the Engineer and/or after a new service installation has been commissioned,
existing and disused service installations shall be removed.
b. Excavation to locate the disused service and backfill after the removal of the service
installation shall be in accordance with various other specifications.
c. All surplus or unsuitable material shall be removed to an approved tip off s

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 3. ENVIRONMENT MANAGEMENT PLAN
The Contractor is advised to go through the below specifications/environment, health and
safety requirements and price his bid accordingly. The Contractor shall include for the
requirements of this clause in his Programme of Works and his Bill of Quantities. All items
shall be deemed incidental to work unless otherwise provided for in the price schedule.

1. Site clean-up and removal of all waste materials/debris lying within each 2.5 metre
wide and 500 metre long operational area /cable laying segment.
2. Ensure roadside drain chutes are cleared on both upstream and downstream sides of
operational area, prior to commencement of cable laying operations and these drains are
to be periodically cleaned throughout the cable laying phase, followed by final cleanup
just prior to opening the operational area(s) for traffic. Also, ensure no water logging
occurs along barricaded operational area during rainy days/season.
3. Stacking of sand bags in polypropylene (used cement) bags, along inner side of
barricades as required, preventing seepage /water logging of cable trenches in wet
season/rainy days. In case of excess water logging, trenches shall be emptied using
dewatering pump, as may be required.
4. Ensure all tipper trucks are loaded only up to permitted capacities and adequately
covered with wetted cloth, so that en-route dust and spills avoided. Alternatively, water
resistant tarpaulins can also be used to cover trucks. In such case, the top surface of
loaded material(s) viz. excavated soil or bitumen chunks or debris shall be wetted, prior
to covering with tarpaulins.
5. Provision of safe and adequate temporary intermediate access (fabricated MS planks of
adequate size, strength, build and with hand rails) for adjacent building occupants/users
as per requirements.
6. Ensure utmost care is taken that no underground utilities are damaged during trench
18
 excavation. In case of damage to any utilities like water/sewer/sanitary lines as a
consequence of trench excavation works, same is to be restored with least down time
through deployment of dedicated on-site crew group comprising mason, plumber,
carpenter and sheet metal fabricator stationed at operational areas with all required tools
and equipment. The onsite crew shall be provided with mobile van (MUV type) for ease
of movement across operational areas within the package. The number of crew group(s)
deployed shall commensurate with number of active operational areas so as to ensure no
unwarranted/undue delay in restoration of damaged utilities due to inadequate crew
group(s).
7. During all excavation operations, regular sprinkling of water with pressurized fine spray
shall be carried out to contain/limit dust levels within Andhra Pradesh Pollution Control
Board norms as may be required.
8. After the completion of underground cable laying works and prior to opening up of
operational area for traffic, the site has to be cleaned and all waste materials/debris are
to be removed and disposed at pre-approved designated locations/sites.
9. All types of excavated materials from operational areas are to be transported either to
work camp sites for reuse and /or to approved locations for safe disposal.
10. All vehicles/equipment deployed at operational areas shall be in good working
condition and mandatorily have valid Pollution under control certificates, while being
deployed on this project.
11. Establishing work camp sites for macadam mix plants, hot mix plants and stacking of
inventories for cable laying operations and restoring it to previous state, in all respects.
12. No workforce camps shall be set up at any of the operational areas. All work force are
to be provided with suitable type of rented accommodation, if required or can return to
normal places of residence. Pooled transportation facilities as may be required, shall be
provided by contractor.
13. All traffic diversion plans (specific site/stretch wise) wherever required are to be
prepared by contractor, shall be prepared in consultation with Engineer/APEDCL and
requisite approvals from traffic police shall be sought well in advance (at least 7 days).
Approved traffic diversion plans are to be implemented by the contractor during entire
duration of cable laying operations, at a specific site/stretch. This will include provision
of warning and informatory signboards, delineators, cones etc.
14. All road cutting permissions shall be obtained at least 7 days in advance from GVMC
and no excavation shall be commenced without requisite permission and approvals and
intimation to PIU.
15. All operational areas shall be access controlled with fixed entry and exit points and
shall have watch and ward facilities at all times. All workforce shall be provided with
identity cards.
16. After dismantling of overhead infrastructure, the places shall be restored to match with
surrounding places viz, when a pole has been dismantled, the pole location shall be
restored to match with surrounding place, including filling up the foundation pit of the
pole with sand/cement concrete and finishing to match with surrounding surfaces as
may be required.
17. First aid facilities and free emergency care shall be provided to all workforce and third
party and no cost shall be recovered from them on this account – The contractor shall
have CAR policy to cover both Contactor and APEPDCL.

19
18. Transit mixers with delivery hoses shall be used for backing filling of trenches with
sand, to minimize space requirements at operational areas and avoid double handling of
materials.
19. All supervisory staff shall be provided with mobile phones for better communication
across all operational areas, in case of emergency or otherwise.
20. The Contractor as per prevalent rules will carry out negotiations with the landowners
for obtaining their consent for temporary use of land for construction camp etc.
21. Hot Mix plant will be sited sufficiently away from settlements. Such plant will be
located at least 800 m away from the nearest settlement preferably in the downwind
direction. Consent to Establish and Consent to Operate from State Pollution Control
Board will be obtained before establishment and operation of such a plant.
22. All vehicles, equipment and machinery to be procured for construction/protection work
will confirm to the relevant Bureau of Indian Standard (BIS) norms/CPCB standards.
The discharge standards promulgated under the Environment Protection Act, 1986 and
Motor Vehicles Act, 1988 will be strictly adhered to.
23. Information Disclosure Boards showing the name of work, project cost, duration, date
of commencement, date of completion, executing agency and contract telephone
numbers of endorsing grievance etc. will be displayed at project sites.
24. Measures will be taken-up to minimize the construction works during night and
accordingly public to be informed through message, leaflets and other media.
25. There shall be adequate and sufficient lighting arrangements during work at night.
26. Proper moving guards will be provided at all moving machines, like motors & pulleys.
27. All three phase motors, electrical panels and electrical machines, DG set etc. will be
provided double earthing with proper earth pits as per applicable IS code.
28. Electrical cables and wires will be properly arranged with proper electrical safety.
Loose electrical connections will not be allowed at the plant and other work sites.
29. Red danger sign with bone & skull will be displayed as per the Electrical Rules at three
phase motors, electrical panels and electrical machines, DG set, etc.
30. Used oil generated from vehicles/workshop/DG set at plant/camp site will be collected
in close containers and sold to MOEF&CC/SPCB approved used oil recyclers. Oil
interceptor will be provided at the workshop.
31. Housekeeping will be maintained properly. Daily sweeping and cleaning will be done at
site.
32. Solid wastes generated at the plant & camp sites, will be collected in covered waste bins
and segregated as biodegradable (food waste, paper, etc) and non-biodegradable
(plastic, polyethylene bag, etc) wastes. Polyethylene/plastic wastes will be stored in
empty cement bags and to be sent for recycling through scrap dealer. Biodegradable
(food waste, paper, etc) solid waste will be disposed in compost pit or at sites
approved/used by GVMC.
33. Safety awareness signage and posters will be provided at the work sites.
34. All power transmission lines whether claded or sufficiently covered are potential
hazardous at construction sites. The Contractor shall take all required precautions to
prevent danger from electrical cables, wires and equipment and ensure that:

20
 • No construction material will be stacked or placed below/near power transmission
lines, wires and equipment, which can be potential danger to any road user,
workman or public.
• All such electrical installations and wirings shall be barricaded in manner that
ensure safety of the road users, workers, operating vehicles/equipment (such as
cranes, excavators, loaders fabricating units).
• Necessary fencing, illumination and proper insulation of the electrical lines shall be
ensured by the contractor for safety and security of the general public, road users
and workers.
• The Contractor shall ensure proper maintenance of electrical supply lines/ points.
• All such electrical operating units shall be switched off before operation is closed
every day or night as the case may be.
35. The contractor will take every precaution to reduce the level of dust and gaseous
pollution from work sites. The Contractor will take every precaution to reduce the level
of dust (PM 2.5 and PM 10) and make arrangements to minimize dust pollution through
provision of wind screens/barriers, water sprinkling/mist spray unit, and encapsulation
of dust source, as required shall be made.
36. The contractor will procure the construction plant and machinery, which will conform
to the pollution control norms specified by the MoEF&CC/CPCB/SPCB.
37. All construction plant and equipment used in construction will strictly confirm to the
MoEF&CC/CPCB noise standards.
38. The contractor will ensure that all vehicles, equipment and machinery used for
construction works are regularly maintained and confirm that pollution emissions levels
comply with the relevant requirements of CPCB and/Motor Vehicles Rules. The
contractor will submit PUC certificates for all vehicles/ equipment/machinery used for
the project.
39. The unloading of construction materials at construction sites will be limited to day time
only. Screens of hessian cloth, agro-net and such other barricading materials will be
erected along dumped and stock piled sites, so that generation of the dust in the vicinity
of such locations can be minimized to a great extent.
40. Servicing of all construction vehicles and machineries will be done regularly and during
routine servicing operations, the effectiveness of exhaust silencers will be checked and
if found defective, these shall be replaced.
41. Only acoustic enclosures fitted DG set will be allowed at the construction sites and hot
mix plant/camp site.
42. Construction Safety Plan prepared by the Contractor will identify necessary actions in
the event of an emergency.
43. The Contractor shall provide and ensure enforcement with zero tolerance on the
following:
 Safety vests will be used by workers when on road construction site.
 Hard hat or helmets to all workers, supervising staff and inspecting official entering
work site, plant area, and engaged in loading/unloading operations.
 Protective footwear, protective goggles and nose masks (as required) will be
provided to the workers employed. Safety shoes and goggles to all workers
21
 employed for handling of asphalt materials, cement, mortar, concrete and crusher
operations.
 During reinforcement/fabrication, safety appliances like: spectacles, helmets, gum
boots, hand gloves shall be provided to labourers at work site.
 Welder’s protective eye-shields will be provided to workers who are engaged in
welding works.
 Earplugs will be provided to the workers exposed to high noise levels.
 Ear plugs to workers exposed to high noise levels.
 Nettings below and on the sides of overhead construction and excavation work to
prevent mishaps due to accidental fall of workman and debris.
44. The Contractor will arrange for:
 A readily available first aid box including an adequate supply of sterilized dressing
materials and appliances as per rules shall be provided in work zones.
 Emergency numbers will be displayed at camp, plant and construction sites
 Availability of suitable transport at all times to take injured or sick person(s) to the
nearest hospital. Designated vehicles, which can be used as ambulance, which will
be available at construction sites as per requirement.
 Trained First Aid personal with First Aid box will be available at the construction
site.
 Periodic health checks for workers will be ensured.
45. The contractor will make required arrangements so that in case of any mishap on the
road construction site, all necessary steps can be taken for prompt first aid treatment.
46. Labour Camp Management
 The location, layout and basic facility provision of labour camp will be
submitted to Engineer/PIU prior to their construction.
 The Contractor will maintain necessary living accommodation and ancillary
facilities in functional and hygienic manner.
 Fans and proper ventilation (turbine type ventilators) will provided in labour
accommodation.
 Regular cleaning and sweeping will be ensured at the labour camp site.
 Fuel wood will not be allowed for cooking at labour camps. LPG cylinders will be
provided at labour camp by the contractor.
 Necessary HIV/AIDS prevention measures and awareness programme will be put
into place.
47. The contractor will construct and maintain all labour accommodation in such a fashion
that uncontaminated clean water is available for drinking, cooking, bathing and
washing. The Contractor will also provide potable water facilities at road construction
sites and culvert construction sites in an accessible place, as per standards set by the
Building and other Construction Workers (Regulation of Employment and Conditions
of Service) Act, 1996.
48. The Contractor will ensure that :

22
  The sewage system for the camp will be designed, built and operated in such a
manner that no health hazard occurs and no pollution to the air, ground water or
adjacent water courses take place,
 Separate toilets/bathrooms, wherever required, will be provided for men and
women, marked in vernacular language.
 Toilets will be provided with septic tank followed by soak pit.
 Adequate water supply is to be provided in all toilets and urinals,
 Night soil can be disposed of with the help of local municipal extractor.
 The contractor will provide garbage bins in the camp and construction sites and it
will be ensured that these are regularly emptied and disposed off in a hygienic
manner as per the Solid Waste Management Plan as per Solid Wastes (Handling
and Management) Rule 2016.
 Burning of wastes will not be allowed.
 Solid wastes generated at the construction site, plant & camp sites, will be
collected in covered wasted bins and segregated as biodegradable (food waste,
paper, etc) and non-biodegradable (plastic, polyethylene bag, etc) wastes.
Polyethylene/plastic wastes will be stored in empty cement bags and to be sent for
recycling through scrap dealer. Biodegradable (food waste, paper, etc) solid waste
will be disposed in compost pit.
49. The contractor will prepare site restoration and demobilization plan, which will be
approved by the Engineer/Environmental Expert of PIU. The clean-up and restoration
operation are to be implemented by the contractor prior to demobilization. The
Contractor will clear all temporary structures; dispose all garbage, night soils and POL
(Petroleum, Oil and Lubricants) wastes in environmental sound manner.
50. All disposal pits or trenches will be filled in and effectively sealed off.
51. All construction zones including camp, and any other area used/affected due to the
project operations will be left clean and tidy at the contractor’s expense to the entire
satisfaction to the PIU.

Other environment, health, safety and associated requirements to be followed during the
construction stage are given below:

1 Regulatory  Consent to Establish and Consent to Operate (CTE & CTO) shall be
Compliances obtained for macadam mix plants and hot bitumen mix plants. All
consent conditions stipulated by APPCB are to be compiled.
 No camp sites for macadam or bitumen hot mix plants are to be set up
and/or operated by the contractor prior to obtaining the CTE and CTO
from APPCB.

2 Establishing  Under no circumstances, contractor shall use the cable laying route
work camp sites alignments as an interim stack yard for materials of any kind /type
and material even for limited durations of less than a day.
stacking yards  Essentially, barren lands or uncultivable lands and those away from
human settlements shall be the given selected for establishing work
camp sites.
 The selected land shall not warrant significant change in land forms or

23
 terrain, to make it suitable for establishing work camp sites.
 In case, land had been earlier used for establishing work camp site
and meets the above requirements, same shall be given preference.
 Requisite consent for establishing (CFE) and consent for operate
(CTO) shall be obtained from Andhra Pradesh Pollution Control
Board.
 The ambient air and noise levels within the work camps sites shall be
monitored, once in month and corrective measures if any required
shall be taken in order be complaint with National Ambient Air
Quality and Noise Standards.
 All stipulated consent conditions by APPCB shall be strictly adhered
and complied by contractor.

 The work camp sites shall be access controlled with fixed entry and
exit points.
 The dust levels at the work camps sites is to be controlled through
regular sprinkling of water through similar mobile tankers deployed at
operational areas for cable laying
 Bitumen mix plants, deployed for the project shall conform to
regulatory norms/requirements
 The site shall be cleared from all remnants of construction and debris
and site restored to its previous state, after completion of the works.
 Surplus soil available from excavation of cable trenches (sub-base and
base layers) can be used to grade the site, as well as to restore the site
after works completion, if required.
3 Site Clearance  Cable route, cable trench of 1.0 metre width as well as 2.5 metre wide
and preparation operational area is to be demarcated on ground with yellow paint (7.5
cm wide minimum). The location of inspection chambers (size
2.0x2.5x2.0 metres deep or as per requirement) at every 250 metres
interval along cable route, also to be marked on ground with yellow
paint.
 While demarcating the cable route and cable trench, shall avoid
removal/shifting of any of over ground road side infrastructure like
poles (all types and sizes) and trees (all types and sizes), with
exception of ramps, steps which are extending onto road.
 Ensure centreline of 1.0 metre wide cable trench coincides with
centreline of 2.5 metre wide operational area, with 750mm wide
working space availability on both sides of cable trench.
 Requisite approvals from traffic police shall be obtained at least 7
days in advance prior to start of site clearance operations.
 Details of information about cable laying operations, scheduled work
completion time in such specific stretches shall be shared with all
such institutions/occupants of buildings at least 7 days in advance,
prior to commencement of works. Their requirements with respect to
access or traffic diversions or any other concerns shall be considered
in operations planning and scheduling of work and adhered to without
any lapses on any account.

24
 The occupants of other buildings/establishments along operational
areas to be barricaded shall be informed 7 days in advance about cable
laying operations, scheduled work completion time, restriction in
access for limited time and their specific requirements, if any with
respect to temporary access and arrangements shall be discussed and
finalised prior to barricading and commencement of trench excavation
 Prior to commencement of excavation works, carry out minor repairs
to footpaths (including making good all uneven surfaces along 500
metre cable route segment) adjacent to barricaded area (wherever
applicable) to ensure pedestrian safety as a result of reduced walkway
due to barricading on the road side.
 All noisy operations shall be restricted to only day hours in residential
areas. Only in case of commercial areas, which are most unlikely to
disturb residential pockets, the operations, can be carried out at night
hours with adequate floodlit arrangements and ensure operations are
not a hazard to night traffic.
 At any given point of time, only 500 metre length operational area
shall be opened up for cable laying operations at a particular location
and a maximum one such operational areas per substation zone. Prior
to moving on to next 500 metre segment, all works in the previous
segment shall be completed in all respects including road restoration
(excluding bituminous layers) and worksite shall be completely
cleared, prior to opening to traffic. The laying of the bituminous layer
is to be subsequently taken up immediately after the natural
compaction, expected to take place within 3-4 weeks or as determined
based on site conditions.
 Prior to commencement of excavation operations, permission for road
cutting from GVMC and approvals from traffic police, wherever
required shall be obtained in advance. The telecom department shall
be informed about the cable laying operations.
 Once required permissions from GVMC and traffic police are in
place, barricade(s) shall be placed on either side of the 2.5 metre
demarcated operational area.
 Sand/earth filled polypropylene bags (used cement bags) are to be
placed along inner side of both barricades, to prevent seepage and
water logging of cable trenches during rainy days. Seepage and water
logging will not only prolong cable laying operations but will also
prolong inconvenience to public and vehicular traffic as a result of
barricaded operational area for extended period.
 The barricades shall be provided with energy efficient LED strip
lighting system (on only roadside) as a hazard safety for traffic
moving at nights and late nights. The LED lighting system shall be
switched on between sunset and sunrise hours mandatorily, for the
entire duration of cable laying operations in any segment.
 All work force deployed for cable laying operations shall be
mandatorily provided induction training, which shall include
awareness about the safety practices at work places, safe distances to
be maintained around moving equipment like excavators etc, health
and safety issues with particular emphasis on public safety and on-site
sanitation practices at worksite during cable laying operations.
 Every 500 metre segmental operations area shall be stationed with one
mobile water tanker of 6000 litres capacity to meet all operational

25
 area water requirements. The water tanker shall be fitted with
arrangements for a pressurized fine spray and a hose reel of 600 metre
length. Typically, water shall be used for dust suppression during site
preparation, excavation, consolidation of backfilling layers and
wetting of cloth covered over tipper trucks, prior to their dispatch
from operations site and site clean up after completion of cable laying
 All workforce deployed at site irrespective of level, shall mandatorily
wear personnel protective equipment (PPE) like safety helmets, face
masks, ear plugs, protective gear with reflective jackets and safety
shoes.
 Use of well-maintained and less than 5-year old earth
excavators/moving equipment shall be ensured to limit the noise
levels.
 At some locations like busy roads with commercial complexes and
particularly near or ahead of junctions, location specific traffic
diversion plans are to be planned and implemented to ensure smooth
passage of traffic and avoid congestion. Same may be finalised in
consultation/approval of traffic police, well in advance of at least 7
days.
 Diversion notice boards, or caution notice boards for both pedestrian
as well as vehicular traffic at all appropriate required locations, both
on upstream and downstream both sides of the barricaded area shall
be installed, so that approaching traffic can move with caution. All
boards shall be as per code of practice for road signs IRC: 67-2012
and IRC SP: 52.
 Trained traffic wardens with reflective hand held batons and jackets,
helmets and safety shoes are to be deployed at places, wherever
barricaded operation areas are near to road junctions/intersections in
order to ensure smooth movement of traffic.
 One crew group comprising mason, plumber and carpenter/sheet
metal fabricator (with required labour assistants) shall be assigned
with two 500 metre long segment operation areas within same
substation areas to rectify the damages to underground utilities like
water supply pipelines, sewer lines, drainage and/or sanitary
connections or provide temporary access during excavation. The crew
shall be provided with all resources by contractor to restore damaged
utilities with least down time. The same crew group shall be deployed
to restore the damaged steps, ramps during trench excavation works to
ensure proper drainage alongside barricaded operational area during
and after rains.
 Every 500 metre segment operation area shall be stationed with one
mobile toilet and parked at a suitable place within a maximum
distance of 100 metres from the operational area. The mobile toilet
shall have at least 1000 litres capacity overhead water tank and
replenished regularly. The toilet shall be well maintained and in
usable condition at all times. The bottom tanks shall be emptied on a
regular basis.
 The workforce shall be instructed to use the mobile toilets, specially
provided under the project and not to use any other public/open places
or public toilets.
 Every 500 metre operational area shall be stationed with one drinking
water kiosk with minimum 300 litres capacity, replenished regularly.
The kiosk shall be placed at a suitable place within 100 metres from

26
 operational area.
 The operational area shall display/maintain list of nearby hospitals for
attending to any injury/ fatalities either to workforce and/or to public
as a result of cable laying activities. The site shall also have a first aid
kit and field level supervisory staff shall have undergone first aid
training/orientation.
 Since the work is being carried out along roads in commercial as well
as residential areas, utmost attention shall be exercised to swiftly
complete all operations including cable trench backfilling, prior to
opening up the barricaded area for public use with shortest possible
time.
4 Cable Pullout  Cable trenches are to be properly graded to ensure an even surface all
and Laying through and devoid of any sharp objects/metal pieces/protruding
stores at trench bottom/sides, to rule out damages to cables, while
laying or at a later date.
 Once the trench excavation is completed to required dimensions,
cables (as per required sizes and configuration) need to be pulled out
from cable coils through mini excavators used for trench excavation
fitted with required additional accessories.
 To the extent possible, cable pull out and lowering operations shall be
limited to barricaded operational area and manual operations are
avoided
 During cable pull out and lowering operations, the work site shall
have water proof transparent tarpaulins to cover cable trenches to
prevent seepage or water logging of trenches due to rains (seasonal or
unseasonal), as a contingency measure. Any slippages on this account
will not only delay cable laying operations, but as a consequence will
further prolong the work completion time, thereby inconvenience to
both public and vehicular movement gets extended.
 The transparent tarpaulins can be hung across 2.5 metre wide
barricaded operational area (in small lengths), which will facilitate
work even during rainy/cloudy days.
 The work sites during cable lowering and backfilling shall be
completely access controlled to prevent theft and vandalisation of
cables. The barricaded operational areas are to be mandatorily access
controlled and barred for entry by un-authorized persons from public
safety point of view as well.
 The cable pull out, lowering operations can pose safety concerns and
therefore all work force deployed in operations are to be properly
trained to keep safe distances and provided with all required PPEs like
safety helmets, face masks, ear plugs, protective gear with reflective
jackets and safety shoes mandatorily
 All cables in the lower tier (11 and 33KV cables in Trench Type 1 and
2) shall be drawn through cable conduits (of any suitable type and
material); having a minimum of 40% extra space and conduit ends are
embedded in the walls of the inspection chambers on either side. This
will facilitate attending to cable fault at places other than joints,
without resorting to opening up entire cable stretch and gain easy
access to cables in lower tier.
 In case of any faults in such lower tier cables, which are in conduits,
cables can be pulled out for repairs outside and pushed back into
conduits and joints can be redone at both ends, all of which require

27
 least effort.
5 Trench  In order to avoid on-site space requirements and pace up sand filling
Backfilling operations, sand back filling is to be carried out using transit mixers,
Operations with normally used to transport and pour ready mix concrete.
Sand and other  Use of transit mixers fitted with flexible hoses for delivery of fine
back filling sand directly into cable trenches will enable to swiftly complete a
layers as uniform sand back filling operations and with minimal manual labour
required  The marginal increase in dust levels due to fine sand can be limited
through use of pressurized fine spray of water. All work sites will be
stationed with one water tanker (6000 litres cap.) fitted with
arrangements for pressurized fine spray with 600 metres of hose reel.
 In order to limit off-site impacts, fine sand is to be mandatorily
sourced from sand mining operators, licensed and approved by the
Department of Mines, Government of Andhra Pradesh. A copy of the
license for sand mining has to be submitted to PIU-EHS, prior to
procurement.
 The sand backfilling operation, brought to site in tipper trucks is
normally carried out through manual means; which is time consuming
and will involve double handling of materials at site with additional
space requirement and therefore shall be avoided, the extent possible.
 Backfilling operations, particularly WMM shall be carried out in
layers not exceeding 15 cm along with required level of consolidation
and compaction at optimum moisture content to achieve maximum
density
 Proper compaction at optimum moisture content (OMC) will enable a
firm base and sub base and prevents cracking of upper bitumen
pavement layers and increase life and smooth riding surface,
benefitting road users
 Mechanical compactors with vibratory rollers (width of sub 1 metre)
are available, which can work effectively for trench backfilling
operations shall be deployed for better results.
6 Construction of  Location of inspection chambers are to be pre-determined during on-
Inspection of site marking of cable route itself during site preparation activity itself
Chambers and demarcated on road with yellow paint (7.5 cm wide strips)
 Location of inspection chambers shall not foul with any other
underground utilities, sewer manholes and/or chambers of telecom
department and shall be at least 3 m away from any other similar
appurtenants. Accordingly, location of inspection chambers can be
marginally adjusted to avoid fouling with other pre-existing utilities.
 Construction of inspection chambers is to be commenced,
concurrently with cable in (500 metre segment) laying operations, so
as to complete both inspection chamber and cable laying works in the
estimated 21 days. This will avoid lag in cable laying and construction
of inspection chambers and cable jointing works as well. Moreover,
this will also facilitate complete road restoration in one go and
opening up of fully restored road to public in all respects.
 The top level of inspection chamber is to be finished to be at least
40mm below the existing road level, so that 40mm thick bituminous
concrete as part of road restoration can be laid over inspection
chamber as well (excluding manhole cover), so that only the manhole
cover is visible after road restoration is completed
 Under no circumstances, top level of inspection chamber shall be

28
 finished above the existing road level and thus pose hazard to
pedestrian as well as vehicular traffic, after cable laying operations.
 Inspection chambers shall be provided with one 560mm extra duty
manhole cover to withstand heavy traffic and shall avoid ingress of
water into inspection chamber during rains.
 Ready mix concrete for inspection chambers shall be sourced from
concrete plants having valid consents and authorization of APPCB.
7 Cable Jointing  All cable jointing works are to be carried out as per recommended
at Inspection procedures/specifications by the manufacturer with genuine cable
Chambers jointing materials.
 All cable jointing works are to be carried out in dry conditions and
during clear days, with no possibility of rains. In case of unseasonal
rains, water proof tarpaulins shall be used to cover the work site at
inspection chamber.
 No cable jointing work is to be carried out during rains or under wet
conditions. The inspection chamber shall be in dry condition, before
cable jointing work is resumed.
 The cable joints within the inspection chamber shall be supported on
steel portals on either side of the cable trench, so that the no cable or
joint within the chamber remain in hanging position for more than
0.45m at a stretch.
 The inspection chamber frame and manhole cover shall fit together
well and further joints are sealed with water proof cement mortar (1
cement: 4 cement fine sand) to avoid ingress of water into inspection
chambers during rains and/or storm water blockages on the road at a
later stage
8 Road  Road restoration, particularly bituminous layers shall be taken up only
Restoration and after 3-4 weeks of cable trench backfilling to allow for natural
cleanup compaction or as determined based on site conditions.
operations  In order to limit off-site impacts, sand is to be mandatorily sourced
from sand mining operators, licensed and approved by the Department
of Mines, Government of Andhra Pradesh.
 The increase in dust levels due to fine sand can be contained through
use of pressurized fine spray of water. All work sites will be stationed
with one water tanker (6000 litres cap.) fitted with arrangements for
pressurized fine spray with 600 metres of hose reel.
 The noise levels during this operation shall be controlled through
deployment of well-maintained vehicles and equipment and
conducting operations in a regulated and planned manner
 The traffic is to be regulated during the road restoration operations, in
order to ensure smooth traffic movement and avoid congestion as a
consequence of road restoration works
 In case of restoration of concrete roads, ready mix concrete shall be
used, brought to the site through transit mixer(s) from a ready mix
plant (RMC) located elsewhere. However, concrete will be sourced
only from RMC plants having valid consents and permission or
authorization of APPCB.
 Also, care shall be taken to match the levels of old and newly restored
surfaces, so as to have an even surface after restoration
 All damaged ramps, steps and other structures, within operational area
are to be restored to its previous state per requirements and in

29
 consultation with respective building owners.
 The operational area is to be thoroughly cleaned for all debris, either
un-unusable materials or all unwanted materials are to be collected
and disposed in approved locations by GVMC.
 All drainage outlets into storm drains along barricaded area are to be
checked for blockages, if any and cleared.
 The barricaded area shall be opened up only after ensuring these
measures and site cleanup, prior to moving on to next 500 metre cable
route segment.
9 Construction  All vehicles, equipment, and machinery deployed for cable laying
vehicles, operations shall be in good condition, maintained and preferably not
less than 5 years old.
equipment and
 The Contractor shall ensure that all vehicles, equipment and
machinery
machinery used for construction are regularly maintained and meet
emission limits set by APPCB and Motor Vehicles Acts & Rules.
 The Contractor shall keep a record of the PUC certificates for all
vehicles/equipment/machinery used for the Project and will be made
available to PIU.
10 Water  Water requirements of project are to be met from only existing tube
requirement wells, with the approval of concerned authority and PIU.

11 Workforce for  All work force shall be subjected to an orientation program, which
cable laying familiarize them with work requirements, safety practices at work,
operations safe distances to keep from earth moving equipment, first aid
stockyards facilities, emergency response, on-site sanitation facilities and
practices to be adopted, rights and privileges of workforce among
others. Orientation shall also include concern for safety of public
around operational areas as well.
 All work force deployed in operational areas shall be provided with
PPEs like safety helmets, face masks, gloves, protective gear with
reflective jackets and safety shoes. It shall be mandatory to wear them
at work site. The PPEs shall be provided at no cost to workforce and
shall be replaced once in six months.
 Visitors/officials to worksite are to be provided with PPEs (hard hats
and safety boots & safety jackets) and shall be briefed ongoing
operations on that specific time and related safety requirement at work
site including safe distances to keep, while at site visit.
 Work force shall be subjected only to standard work shifts/hours.
Overtime allowances shall be paid with ceiling limits. Working
beyond such ceiling limits shall be discouraged, even if, so desired
workforce or contractor.
 All workforce deployed shall be governed by Building and Other
Construction Workers (Regulation of Employment and Conditions of
Service) Act, 1996, with regards to safety and welfare measures
(including equal wages for men and women) for workers employed at
building and other construction sites.
 One mobile toilet of 2 seater capacity (1 men and 1 women with
separate entrances) shall be stationed at a suitable place within 100
metres from each operational area of 500 m long segment. The mobile
toilet shall have at least 1000 litres overhead water storage, well
maintained and in usable condition at all times. Bottom tanks shall be
regularly cleaned and overhead tank replenished as per requirement.
Work force shall be oriented to use mobile toilets and avoid using

30
 public toilets and/or nearby open places/parks.
 Every operational area shall be provided with one mobile drinking
water kiosk having a storage of 300 litres and placed at a suitable
place within 100 metres from work site.
 The operational work site shall have first aid kits and details of
major/nearby hospitals displayed prominently in local language, in
case of emergency and/fatalities to work force and/or public, as a
consequence of operations.
 The supervisory staff shall be provided with wireless communication
systemsupplemented with mobile phones for better communication at
operational area and also with other operational area within same
substation area, in case of emergency or otherwise.
 The work sites being within Visakhapatnam city limits, the project
will provide skilled and unskilled employment opportunities largely to
the local people. All work force is expected to return to their places of
residence after work shift hours. For out station workforce if any,
contractor shall provide rented residential accommodation with water,
sanitation and allied facilities for comfortable stay. Pooled
transportation facilities wherever required shall be provided to
workforce as a welfare measure.
12 Transport of  Public safety has to be ensured at all times during transportation and
Materials to protruding of materials outside the body line of the trucks/vehicles
shall be strictly prohibited and suitable size of trailers shall be used in
Operational
such cases.
areas
 Contractor shall only deploy well-maintained and less than 5-year old
vehicles for transportation of construction materials, cable coils etc, to
ensure reduced noise levels and vehicular emissions.
13 Strom Water  EPC Contractor shall ensure that no construction materials like earth,
Drainage stone, or are disposed off in a manner that can block the flow of
drainage in and around the operational areas.
Management at
 All road side drain chutes on either side of the barricaded operational
Operational
area (longitudinally) shall be checked and cleared for any blockages,
areas so as to ensure free flow of storm water and prevent stagnation of
water near or after the barricaded operational area and inconvenience
thereof to vehicular as well as pedestrian traffic.
14 Potential water  The Contractor shall take pre-cautionary measures to ensure that no
pollution from water pollution occurs through surface runoff from construction
vehicle parking areas, fuel/lubricants storage sites, vehicle, and
use of fuel,
machinery/equipment maintenance sites.
lubricants, and  The Contractor shall ensure that all vehicle/machinery and equipment
their operation, maintenance and refuelling shall be carried out in such a
storage/handling manner that spillage of fuel and lubricants do not contaminate soil,
areas at material surface and groundwater.
stock yards  Areas used for handling of fuel and lubricants, wherever applicable
shall be lined with impermeable material to prevent groundwater and
soil contamination in the event of accidental spills.
15 Potential  The Contractor shall take every precaution to reduce the level of dust
increase of dust from operational areas thorough regular sprinkling water through
water tankers fitted with pressurized fine spray system and stationed
level at work
at all operational areas.
sites
 The frequency of water sprinkling shall be determined based on site-
specific requirements to contain dust generated from cable laying
activities.

31
16 Construction  All construction waste materials shall be disposed of at locations
debris and waste approved by GVMC and PIU.
disposal  All vehicles carrying such waste materials for disposal shall be
covered with cloth and wetted prior to dispatch to avoid en-route
spillages on roads, causing inconvenience and visual impacts to local
population. Alternatively, tarpaulins can be used. In such cases, top
surface of loaded materials is to be wetted and then covered with
tarpaulins. All tipper trucks shall be loaded only to their designated
capacities and no over loading shall be allowed
17 Clean-up  The Contractor shall undertake site clean-up of operations as
operations, approved by PIU.
restoration and  The clean-up operations by the Contractor prior to demobilization and
rehabilitation shall include removal of construction debris, unused/waste materials,
etc. and disposal of same at approved locations by GVMC/PIU.
18 Environmental  Monthly monitoring of ambient air quality, noise level, at selected
monitoring at sampling locations across package area representing different
construction categories like residential, commercial, sensitive areas along cable
sites routes, work camp sites and during different stages of cable laying
operations shall be undertaken through an external laboratory
approved by APPCB. This item shall be operated by PIU/PMU. The
Contractor shall only provide required assistance at site and facilitate
monitoring activities and further take any corrective measures
required to main ambient air and noise levels at operational areas, if
any required and as may be determined by PIU/PMU.
19 Communication  Communication channel will be kept open with local people around
with Public and and along operational areas to ensure that cable laying activities are
Grievance not causing undue inconvenience to the local people.
Redressal  All grievance(s) related to disruption of services/utilities/damaged
structures due to the project be attended and resolved with least
downtime as per Grievance Redressal Mechanism laid out for the
project and records shall be maintained.
20 Excavation of  Mechanical excavations are to be essentiality supplemented by
Cable Trenches manual excavation at some stretches in order to manoeuvre minor
obstacles within the barricaded operational area like kerb/road side
(Asphalt/
small trees/saplings, telephone/electric poles, which will otherwise
Bitumen require shifting or removal for movement of excavators, if
Layers) mechanical means of excavation is to be adhered all through the
alignment.
 The excavated material from sub base and base layers is to be tested
and if found to be useful for reusing as wet mixed macadam (WMM),
then it needs to be transported to a central WMM mix plant, to make
it suitable for reuse as WMM as per required gradation requirements
in accordance with IRC guidelines or MoRTH(Ministry of Road
Transport and Highways).
 The excavated material (base and sub base layers) is almost akin to
natural soil, can be beneficially used in embankment construction or
filling low lying areas and/ or can be sourced to other area
development projects, commanding commercial value. Therefore,
options for deploying these excavated material, to the extent of nearly
70,000 cu.m needs to be explored.
 The tipper trucks, which carry the pavement cut materials or the sub
base and base materials, are to be covered with net cloth and wetted
by water sprinkling by pressurized system prior to dispatch at all

32
 times. Alternatively, top surface of the loaded material can also be
wetted through water sprinkling and covered with water proof
tarpaulins to avoid enroute spills and dust. All tipper trucks shall be
mandatorily loaded only up to designated capacities.
 The excavation at some specific locations along operational area may
warrant partial removal of unauthorized ramps/steps along cable
routes. At all such locations, temporary access across barricaded area
are to be provided as an interim measure to avoid/minimize
inconvenience to occupants of the buildings along cable route.
 All work force involved in excavation operations are to be sensitised
to keep safe distances from moving equipment and provided with
PPEs like safety helmets, safety shoes, face masks, ear plugs, and
protective gear with reflective jackets mandatorily. All personnel
exposed to noise levels for prolonged duration will be provided with
one additional break in pre and post lunch session breaks, so as to
limit their exposures.
 In order to suppress dust levels during trench excavation, periodical
sprinkling of water through tankers fitted with pressurized fine spray
has to be carried out, through mobile water tankers fitted with
pressurized spray system with hose reel.
21 Shifting of  Once the project is commissioned, the existing overhead electrical
existing distribution infrastructure shall be dismantled.
overhead  All reusable equipment as determined by PIU shall be stacked in
approved locations in the manner as decided by PIU for redeployment
utilities and
in non-cyclone affected areas as determined by APEPDCL.
handling of  All disposable equipment as determined by PIU shall be stacked in
transformer oil approved locations in the manner as decided by PIU.
 Contractor shall ensure public safety as well as safety of work force
during the dismantling of the existing overhead electrical distribution
infrastructure as well as its transport to approved locations.
 Trained and experienced work force shall be deployed for dismantling
OH infrastructure. The work force shall be provided with all required
safety gears for working at height and other PPEs like safety boots,
reflective jackets, hard hats, among others
 After dismantling of overhead infrastructure, the places shall be
restored to match with surrounding places viz, when a pole has been
dismantled, the pole location shall be restored to match with
surrounding place, including filling up the foundation pit of the pole
with sand/cement concrete and finishing to match with surrounding
surfaces as may be required.
 The serviceable materials like transformers, which have pollution
potential due to leakage of oils/lubes, shall be stored on impermeable
surfaces areas within store yards prior to redeployment or disposal as
scarp, as the case may be. All such impermeable surfaces shall be
covered.
 All other disposables and/or debris (after scavenging for scarp
valuables) shall be disposed off at approved waste disposal sites.
22 Cable Faults  Cables shall be subjected to stringent quality checks at various levels
during viz testing at factory prior to dispatch, testing at storage yards, at work
Operation Stage site prior to pull out and lowering and finally after lowering and
before back filling of trenches, to rule out damages to cables due to
handling at each stage
 Extreme care shall be taken not to over load the cables beyond its

33
 design load capacity, even more importantly for prolonged periods
 Adequate supervisory checks during cable jointing work and adhering
to manufacturer’s specifications/procedures as per relevant Indian
Electricity Regulation, 1956, and latest amendments thereof.
 In the event of cable faults at joints, the area around the man hole of
inspection chamber (about 1.2mX1.2m), shall be barricaded and
caution boards shall be put up for the public/vehicular traffic. Work
shall be planned and swiftly completed. The work site around
chamber shall be restored to its previous state. All waste materials
from work site shall be removed with no trace any debris. The uneven
surfaces, if any surrounding inspection chamber due to opening up of
chamber cover shall also be rectified with rich cement mortar, as may
be required, suitably.
 In case of faults in cables at locations other than joints, which are laid
in upper tiers (11 KV and LT cables in trench type 1 and 2), the area
around cable fault location (about 1.2mX1.5m), shall be barricaded
and caution boards shall be put up for the public/vehicular traffic. The
cable trench shall be opened up at fault location for rectification of
cable, followed by restoration of all intermediate layers including road
restoration as per project design. Work shall be swiftly completed and
work site shall be restored to its previous state. All waste materials
from work site shall be removed with no trace any debris. The uneven
surfaces, if any surrounding the opened up area shall also be restored
to its previous state, suitably
 In case of faults in cables at locations other than joints, particularly.
which are laid in lower tiers (11 KV and LT cables in trench type 1
and 2), the cable faults cannot be rectified by just opening up a small
area at road surface, which is followed for cables laid in upper tiers.
The faults in cables of lower tiers, may even require opening up of
trench between two inspection chambers (250 metres), to replace the
cable or open up a wide and longer stretch of the cable trench at fault
location to gain access to lower tier, all of which requires tremendous
effort, time, increased downtime and inconvenience to public leading
to resentments.
 Therefore, all cables in the lower tier (11 and 33KV cables in Trench
Type 1 & 2 are drawn through cable conduits (of any suitable type
and material); having a minimum of 40% extra space and conduit
ends are embedded in the walls of the inspection chambers on either
side. In case of any faults in such lower tier cables, which are in
conduits, cables can be pulled out for repairs outside and pushed back
into conduits and joints can be redone at both ends, all of which
require least effort, compared to the present configuration of cables in
lower tier. However, this requires additional investment for drawing
all 11 and 33KV cables in lower tier through a conduit.

34
 4. INDIAN STANDARD SPECIFICATIONS
The General Technical Specifications shall be those confirming to the INDIAN STANDARD
SPECIFICATIONS as published by BUREAU OF INDIAN STANDARDS (BIS) from time
to time with all amendments published up to the date of submission of Tenders.

The term Indian Standard Specifications herein after referred to as IS means the relevant
Indian Standard Specifications with all Amendments published up to the date of submission of
tenders.

Equivalent standards of other countries as per World Bank list of countries eligible to
participate in bids are also accepted. However the bidder shall furnish all necessary
documents along with the bid in English language.

A statement of relevant IS applicable to this context, is mentioned below.

LIST OF INDIAN STANDARDS

Sl.No. Short Title Standard

A. 33 kV & 11 kV XLPE Cables

XLPE insulated PVC sheathed cables For working IS 7098 Part 2 : 1985
1
voltages from 3.3 kV up to and including 33 kV
2 PVC Insulation and Sheath of electric Cables IS 5831 : 1984
Conductors for insulated electric cables and flexible IS 8130:1984
3
cords
4 Copper rods and bars for electrical purposes. IS 613:1984
Standard for type test of class IE electric cables, field IEEE-383:1974
5 splices, and connections for nuclear power generating
stations.
6 Standard test method for density of smoke from burning ASTM-D2843,1993

35
Sl.No. Short Title Standard
or decomposition of plastics.
Test on gases evolved during combustion of electric IEC:754
7
cables
8 Test on electric cables under fire conditions IEC: 332
9 Drums for electric cables. IS 10418:1982
B. Cable Accessories
Test methods and requirements for working voltage IS-13573 (Part-
1
from 3.3kV up to and including 33kV II&III):2011
Standard for cable accessories IEC: 60502-04/ 2005
2
VDE 0278
End termination accessories IS 1255-1983
3

C. 33 kV and 11 kV RMUs
AC metal enclosed switchgear and control gear for rated IS 3427
1
voltages above 1 kV and up to and including 52 kV
Classification of degrees of protection provided by IS 12063
2
enclosures of electrical equipment
3 High Voltage Switches IS 9920 (Parts 1 to 4)
Specification for AC disconnectors and earthing IS 9921 (Parts 1 to 5)
4
switches for voltages above 1000 V
5 HV AC Circuit Breakers IS 13118
Dimensions of terminals of HV Switchgear and Control IS 10601
6
gear
General requirements of switchgear and control gear for IS 12729
7
voltages exceeding 1000 V
8 High voltage/Low voltage prefabricated substations IEC 1330
9 Common clauses for MV switchgear standards IEC 60694
10 Monitoring and control IEC 6081
11 Current Transformers IS 2705
12 Voltage transformers IS 3156
13 Specification for Static Protective Relays IS 8686
Standards for high voltage metal clad switchgear up to IEC 61171-200
14
52 KV.
D. Earthing
1 Code of practice for Earthing IS:3043/1987
Steel Tubes, Tubular and Other Wrought Steel Fittings IS1239 Part1/2004
2
Specification Steel Tubes
Mild steel tubes, tubular and other wrought steel IS1239 Part2/1992
fittings,
3
Part2 Mild steel tubular and other wrought steel pipe
fittings
E. PSCC Poles and Spun Poles

36
 Sl.No. Short Title Standard

Specification for Prestressed concrete poles for IS: 1678/1998

1
overhead Power traction and telecommunication lines (R2003):
Method of test for concrete poles for Overhead Power IS: 2905/1989
2
and Telecommunication lines.
Code of practice for Prestressed and plain/reinforced IS:1343/2012 & IS:
3
Concrete 456

5. CLIMATIC CONDITIONS
The Equipment to be supplied against this specification shall suitable for satisfactory continuous
operation under the following climatic conditions.

i. Maximum ambient air temperature (in shade) : 450 C

ii. Maximum ambient air temperature (under sun) : 500 C

iii. Maximum daily average ambient air temperature : 350 C

iv. Maximum yearly average ambient air temperature : 300 C

v. Maximum humidity : 100%

vi. Altitude above M.S.L. : Up to 1000M

vii. Average No. of thunder storm days per annum : 50

viii. Average No. of dust storm days per annum : Occasional

ix. Average No. of rainy days / annum : 90

x. Average Annual Rain fall : 925mm

xi. Normal tropical monsoon period : 4 months

xii. Maximum wind pressure : 150 kg/Sq.M

xiii. Maximum Wind Speed : 220 kmph.

37
 6. GENERAL INFORMATION OF SOIL STRATA FOR
TRENCH EXCAVATION
Normal Soil:

This shall comprise of vegetable or organic soil, turf, sand, sandy soil, silt, loam, clay,
mud, red earth, peat, black cotton soil, soft shale, loose murrum, mud debris, concrete
below ground level, a mixture of all these and similar material which yields to the ordinary
application of pick, shovel, rake or other ordinary digging implement. Removal of gravel
or any other modular material having diameter in any one direction not exceeding 75 mm,
such occurring strata shall be deemed to be covered under this category.

Hard murrum and Ordinary Rock:

This shall include:

1) Stiff heavy clay, hard shale or compact murrum requiring grifting tool or pick or both and
shovel closely applied.
2) Gravel, soft laterite, kankar and cobble stone having maximum diameter in any one
direction between 75 mm and 300 mm.
3) Sliding of road paths, etc., and hard core.
4) Macadam surfaces such as water bound and bitumen/tar bound.
5) Lime concrete, stone masonry in lime/cement mortar below ground level.
6) Soft conglomerate, where the stones may be detached from the matrix with picks.
7) Generally any material which requires the close application of pick axe or scarifies to
loosen and not affording resistance to digging greater than hardest of any soil
mentioned in item (1) to (6) above.

38
 Ordinary rock comprising of lime stone, sand stone, hard laterite, fissured rock, conglomerate
or other soft or disintegrated rock which may be quarried or split with crow bars.
Unreinforced cement concrete which may be broken up with crow bars or picks and stone
masonry in cement mortar below ground level.
Boulders which do not require blasting having maximum diameter in any direction of more
than 300 mm found lying loose on the surface or embedded in river bed, soil, talus slope wash
and terrace material of dissimilar origin.
Hard Rock:
This shall comprise any hard or disintegrated rock or cement concrete or RCC for the
excavation of which the use of mechanical plant or blasting is required.

7. XLPE POWER CABLES (33kV &11kV)

SECTION I
TECHNICAL SPECIFICATIONS
1.0 SCOPE:
This section covers the standard technical requirements of design, manufacturing, testing,
packing and dispatching of 33 kV and 11 kV XLPE HT Power Cable.

2.0 APPLICABLE STANDARDS

The materials shall conform to the latest editions of the following Indian/International
Standards:
IS 7098 Part 2 1985 XLPE insulated PVC sheathed cables For working voltages from
3.3kV up to and including 33 kV
IS 5831: 1984 PVC Insulation and Sheath of Electric Cables
IS 8130:1984 Conductors for insulated electric cables and flexible cords.
IS 613:1984 Copper rods and bars for electrical purposes.
IS 3975:1988 Mild steel wires, formed and tapes for armoring of cable.
IS 10810:1984 Method of tests for cables.
IEEE-383:1974 Standard for type test of class IE electric cables, field splices, and
connections for nuclear power generating stations.
ASTM-D2843, 1993 Standard test method for density of smoke from burning or
decomposition of plastics.
ASTM-D2863, 1991 Standard test method for measuring minimum oxygen concentration
to support candle - like combustion of plastics (oxygen index).
NEMA-WC5, 1992 Thermoplastic Insulated Wire and cable for the transmission and
distribution of Electrical Energy.
IEC: 754 Test on gases evolved during combustion of electric cables -
(Part-1):1994 Determination of the amount of halogen acid gas evolved during
combustion of polymeric materials taken from cables.
IEC: 332 Test on electric cables under fire conditions
(Part I):1993 Test on a single vertical insulated wire or cable.
IS 3961 Recommended current rating for cables.
(Part II):1967 PVC insulated and PVC sheathed heavy duty cables.
IS 10418:1982 Drums for electric cables.

39
3.0 GENERAL REQUIREMENTS
All cables shall be suitable for high ambient, high humid tropical Indian Climatic conditions.
Cables shall be designed to withstand the mechanical, electrical and thermal stresses under
the unforeseen steady state and transient conditions and shall be suitable for proposed method
of installation.

Conductor shall be of uniform, of good quality, free from defects Aluminum.

Insulation shall be Cross Linked Polyethylene (XLPE).

For 33 kV and 11 kV cables, conductor screen and insulation screen shall both be extruded,
semi-conducting compound and shall be applied along-with XLPE insulation in a single
operation by triple extrusion process. Method of curing for 33 kV cable shall be "Dry curing/
gas curing” only, whereas for 11 kV and 3.3 kV cables it shall be "Dry curing/ gas curing /
Steam curing".

Extruded Semi-conducting screening and metallic screening of copper tape shall be generally
as per IS 7098 (Part-II) with latest amendments. The semi conducting compound shall be
suitable for the operating temperature of the cable and compatible with the insulating
material.

The insulation screen shall be an extruded layer of black semi-conducting compound and
continuously covers the whole area of insulation. The semi-conducting screens should be
effectively cross linked to achieve 90 ᵒ C cable rating. The contact surface between insulation
and insulation screen shall be smooth and free from protrusion and irregularities.

The interface between insulation and insulation screen shall be free of any voids. Insulation
screen shall be strippable type.

The metallic screen shall consist of a layer of copper cable applied in helical form.

Inner sheath - All armored and multi-core un-armored cables shall have distinct extruded
inner PVC sheath of black colour.

Armouring - Material for armour for Single Core Cable shall be Aluminum wire. For Multi-
core cable it shall be GS wire / flat.

Armouring shall be as per relevant IS and it shall have minimum 90% coverage.

Breaking Load of the joints shall be minimum 95% of the normal armour.

Outer Sheath – It shall be of orange colour (for 33 KV XLPE Cables) and yellow colour (for
11 KV XLPE cables) HDPE with Cable size, Voltage grade and Employer name (APEPDCL)
embossed on it. Sequential marking shall be at every 1 (one) Meter distance. Word "FRLS"
shall also be embossed on it at every 5 (Five) meter distance.

FRLS Properties - All cable shall be Flame Retardant, Low Smoke (FRLS) type. Outer sheath
shall have the following properties –
 Acid Gas Generation – Max 20% (as per IEC 754-1)
 Smoke density rating: 60% (As per ASTMD 2843)
 Flammability test - As per Swedish chimney test F3 as per SEN 4241475
 As per IEC 332 part-3 (Category B)
 Minimum bending radius shall be 15D
 Repaired cables shall not be acceptable.

40
4.0 CURRENT RATING OF CABLES

1) Normal current rating shall not be less than that covered by IS 3961. Vendor shall submit data
in respect of all cables in the prescribed format.
2) Tables given de-rating factors for various conditions of cable installation including the
following, for all types of cables shall be furnished.
 Variation in ambient air temperature. - Variation in ground temperature.
 Depth of lying.
 Cables laid in the ground - Cables laid in trench
 Cables laid in ducts - Soil resistivity.
 Grouping of cables.
3) The value of short circuit withstand current ratings of all cables shall be indicated for a short
circuit for 1 second duration and should also specify the maximum temperature during short
circuit.
4) The following factors shall also be accounted for, while specifying the maximum short circuit
withstand of the cables.
5) Deformation of the insulation, due to thermo-mechanical forces produced by the short circuit
conditions, can reduce the effective thickness of insulation.
6) Conductor and core screens can be adversely affected with loss of screening effect. Likewise
the thermal properties of the outer sheath material can be the limitation.
7) It is essential that the accessories which are used in the cable system with mechanical and/or
soldered connections are suitable for the temperature adopted for the cables.
8) Formula for calculating short circuit current for different duration or curve showing short time
current v/s time for different sizes of cables shall be furnished by vendor.

5.0 CABLE DRUMS

5.1 Cables shall be supplied in non-returnable wooden or steel drums of heavy construction and
drum shall be properly seasoned, sound and free from defects. Wood preservative shall be
applied to the entire drum.
5.2 All Power Cables shall be supplied in drum length of 500/1000 m. Each drum shall contain
one continuous length of cable. The measurement shall be on actual quantity laid.
5.3 A layer of water proof paper shall be applied to the surface of the drums and over the outer
most cable layer.
5.4 A clear space of at least 40mm shall be left between the cables and the logging.
5.5 Each drum shall carry manufacturer’s name, APEPDCL’s name, address and contract
number, item number and type, size and length of the cable, net and gross weight stenciled on
both sides of drum. A tag containing the same information shall be attached to the leading end
of the cable. An arrow and suitable accompanying wordings shall be marked on one end of
the reel indicating the direction in which it should be rolled.
5.6 Packing shall be sturdy and adequate to protect the cables, from any injury due to
mishandling or other conditions encountered during transportation, handling and storage.
Both cable ends shall be sealed with PVC/Rubber caps so as to eliminate ingress of water
during transportation and erection.

6.0 TESTS

A. Type Tests
The following shall constitute type tests:
i) Tests on conductor
a. Annealing test (for copper)
b. Tensile tests (for aluminium)
c. Wrapping tests (for aluminium)
d. Resistance test
ii) Tests for armoring wires/strips

41
iii) Test for thickness of insulation and sheath
iv) Physical tests for insulation
a. Tensile strength and elongation at break
b. Ageing in air oven
c. Hot test
d. Shrinkage test
e. Water absorption (gravimetric)
v) Physical tests for outer sheath
a. Tensile strength and elongation at break
b. Ageing in air oven
c. Hot test
d. Shrinkage test
vi) Bleeding and blooming tests (for outer sheath)
vii) Partial discharge test
viii) Bending test
ix) Dielectric power factor test
a. As a function of voltage
b. As a function of temperature
x) Insulation resistance (volume receptivity) tests
xi) Heating cycle test
xii) Impulse withstand test
xiii) High voltage test
xiv) Flammability test

B. Acceptance tests
The following shall constitute acceptance tests:
a) Annealing test (for copper)
b) Tensile test (for aluminum)
c) Wrapping tests (for aluminum)
d) Conductor resistance test,
e) Test for thickness of insulation
f) Hot set test for insulation,
g) Tensile strength and elongation at break test for insulation and sheath
h) Partial discharge test (for screened cables only)
i) High voltage test and
j) Insulation resistance (volume resistively) test

C. Routine Tests
The following shall constitute routine tests:
i) Conductor resistance test
ii) Partial discharge test (for screened cables only) and
iii) High voltage tests.
The Employer reserves the right for witnessing routine tests at the Manufacturer’s plant. The
contractor shall give minimum 15 days notice in writing to the Employer for witnessing the
tests. In case the witness test is waived, the Employer shall communicate the same to the
Contractor within 7 days of receiving such notice.

D. Optional tests
Cold impact tests for outer sheath (IS: 5831-1984) shall constitute the optional tests.
 Type Test Report conducted on similar type of Cable from NABL/ Central Govt. approved
Accredited Testing Laboratory within 3 years from the due date of opening of Tender is to be
submitted.
 Valid Calibration Certificate of instruments used for testing purpose conducted by NABL
accredited Laboratory is to be submitted.

42
7.0 DRAWING & LITERATURE:
The following shall be furnished along with the tender
Cross sectional drawings of the cables, giving dimensional details.
An illustrated literature on the cable, giving technical information, on current ratings, cable
constants, short circuit ratings, de rating factors for different types of installation, packing
date, weights and other relevant information.

The Manufacturer shall furnish a copy of valid BIS license for ISI marking without which the
cable shall not be accepted.

8.0 GUARANTEE:
The cable manufactured shall be guaranteed for the period of 60 months from the date of
installation.

43
 SECTION II
SPECIFIC TECHNICAL REQUIREMENTS.

1. SCOPE
This section of the specification covers System particulars and Specific technical
requirements of 33kV and 11 kV XLPE Cables

2.0 SYSTEM PARTICULARS

a. Line Voltage (kV) 11/33

b. Highest System Voltage (kV) 12/36
c. Number of Circuits 1
d. Frequency 50 HZ
e. Neutral effectively earthed
f. Short circuit level (KA) 25 kA

3.0 SPECIFIC TECHNICAL REQUIREMNTS

Technical Parameters of the cable shall be as follows:

S. No. PARTICULAR Unit DATA DATA

1 Rated Voltage kV 6.35/11 19.0/33
2 Type of Insulation - XLPE XLPE
3 Core - Three Three
4 Armoured - Armoured Armoured
5 Material of Conductor - Aluminium Aluminium
6 System - 11 kV Earthed 33 kV Earthed
7 Highest System Voltage kV 12 36
8 Conductor size sq. mm 300 ,185 400
9 Material Stranded Aluminium Stranded Aluminium
10 Shape of Conductor Circular Circular
11 Short Circuit Current kA 18.35 for 3 secs. 26.24 for 3 secs
Power Frequency
12 KV rms 28 70
Withstand Voltage
Lightning Impulse
13 kVp 75 170
Withstand Voltage
Continuous Withstand
14 Deg C 90 90
Temperature
Short Circuit withstand
15 Deg C 250 250
Temperature
Min 29 (as per ASTMD Min 29 (as per
16 Oxygen Index
2863) ASTMD 2863)
Max 20% (as per IEC Max 20% (as per IEC
17 Acid Gas Generation
754-1) 754-1)
Smoke Density 60% (As per ASTMD 60% (As per ASTMD
18
Generation 2843) 2843)
As per Swedish Chimney As per Swedish
19 Flammability Test
test Chimney test

44
 SECTION-III

GUARANTEED TECHNICAL PARTICULARS for 33 KV & 11 KV XLPE Cables to be submitted

by Bidder for each size and each supplier

Sl. 33 11
11
kV,3Cx kV,3Cx1
Item Particulars Unit kV,3Cx300
400 85
Sq.mm
Sq.mm Sq.mm
1 Manufacturers Name & Address
2 Country of manufacturer
3 Type of cable
4 Applicable standards for manufacturing
5 Applicable standards for testing
6 Rated voltage kV
7 Maximum service voltage kV
8 Maximum continuous current carrying capacity A
per cable when lain in air at an ambient air
temperature of 50 deg. (single core cables solid
bonded)
9 Maximum continuous current carrying capacity A
per cable when laid in ground at a depth of 1.0
m (ground temp. 40 deg. C and soil thermal
resistivity of 150 deg.C/watt/cm max.
Conductor temp. 90 deg. C) (single core cables
solid bonded)
10 Maximum continuous current carrying capacity A
per cable when drawing into duct./pipes (single
core cables solid bonded)
11 Maximum continuous current carrying capacity A
per cable when lain in covered RCC trenches at
an ambient temperature of 50 Deg. C laying
conditions to be specified (Single core cables
solid bonded)
12 Short circuit withstand capacities for 1 second
of (With a conductor temperature of 90 Deg. C
at the commencement
i) Conductor KA
ii) Screen KA
iii) Armour KA
13 Conductor
i) Material & Grade
ii) Nominal cross – sectional area sq.mm
iii) No. of strands
iv) Diameter of each strand (Nominal) Mm
v) Max. DC resistance of conductor at 20 Deg. C ohm/km
vi) Max. AC resistance of conductor at 90 Deg. C ohm/km
14 Reactance of cable at normal frequency ohm/km
(Approx)
15 Electrostatic capacitance at normal frequency Micro
farads
per Km
16 Charging current
17 Loss tangent at normal frequency at Uo
18 Conductor screen
i) Material
ii) Nominal thickness Mm
19 XLPE Insulation
i) Composition
ii) Type of curing
iii) Thickness of insulation (nominal) Mm
ii) Extruded/wrapped
iii) Nominal thickness Mm
iv) Colour
20 Metallic screen
i) Material / composition
ii) Nominal radial thickness / Dia.
21 Nominal diameter over metallic screen Mm
22 Nominal radial clearance allowed under metal Mm
sheath
23 Type and material of filler
24 Armour
i) Material and type
ii) Diameter
 8. CABLE JOINTING KIT/ TERMINATION
ACCESSORIES

1. SCOPE

This specification covers design, manufacturing, testing, supply of ISI mark (IS-13573:2011)
33kVand 11kV XLPE Cable accessories i.e. Joints/Termination (straight through, Indoor and
outdoor End termination Kits) suitable for armoured, XLPE Insulated, Aluminum conductor
cables.

The cable accessories shall conform in all respects to high standards of engineering, design and
workmanship and shall be capable of performing in continuous commercial operation, in a manner
acceptable to APEPDCL, who will interpret the meaning of drawings and specification and shall
have the power to reject any work or material which, in his judgment is not in accordance
therewith. The offered material shall be complete with all components necessary for their effective
and trouble free operation. Such components shall be deemed to be within the scope of Bidder’s
supply irrespective of whether those are specifically brought out in these specifications and or the
commercial order or not.

2. APPLICATION
The cable accessories shall be use on armoured 33kV and 11kV XLPE Aluminum conductors/
cables installed Under Ground Cabling works in Visakhapatnam city.

CABLE JOINTING ACCESSORIES

2.1.1 The cable jointing accessories shall include the Indoor and Outdoor end terminating kits, straight
through joints and also any special tools and tackles required for making these joints.
2.1.2 The contractor shall minimize the use of straight joints.
2.1.3 The straight through joints shall be heat shrinkable type complete with accessories. The joint shall
preferably be built up from the same material as the main cable and shall have electrical and
mechanical withstand capabilities same as or better than the main cable. The joints shall be suitable
for tropical climatic conditions specified in this specification.
2.1.4 The end termination shall be Indoor and outdoor heat shrinkable type complete with accessories.
The outdoor termination should be suitable for heavily polluted atmospheric conditions with total
creep age distance of 25 mm/ kV and protected creep age distance of not less than 50% of the total
creep age distance.
2.1.5 The detailed description on jointing procedure shall be furnished along with the bid.
2.1.6 The details of the end termination/ straight through joints in service with the period in service shall
be furnished.

3 APPLICABLE STANDARDS

IS-13573 (Part-II):2011 – for working voltage from 3.3kV (UE) up to and including 33kV
(E) – Test requirements.
IS-13573(Part-III):2011 – for working voltage from 3.3kV (UE) up to and including 33kV
(E) – Test methods.
IEC: 60502-04/ 2005 VDE 0278 – Standard for cable accessories.
IEEE48 – for terminations of cable.
ESI-09-13 standards – for components used in the Kit
IS 1255-1983 – End termination accessories.

The specification given in this document supersedes the relevant clauses of IS-13573:2011 (Part-
I/II/III) wherever applicable.

4 GENERAL TECHNICAL REQUIREMENT

 Material used for construction of a joint/termination shall perfectly match with the Di-electric,
chemical and physical characteristics of the associated cable. The material and design concepts
shall incorporate a high degree of operating compatibility between the cable and joints.

The Straight through joint kit or termination shall be complete with all accessories, jointing
material, insulating stress control tube and sealing material, lugs, nuts, bolts etc. as well as an
instruction booklet explaining the method of using the kit. In case of heat shrinkable type kit, the
joint shall include a heat shrinkable dual wall tubing which shall be insulating from inside and semi
conductive from outside. Detailed sectional views of the assemblies shall be submitted along with
the offer.

The straight through joints should be absolutely impervious to the entry of water. The manufacturer
shall use the proven technologies and design to ensure a construction which will prevent entry of
water or any other liquid inside the straight through joint and cable. The cable termination kit shall
be suitable for terminating the cable on Indoor and outdoor installation as per requirement.

The Straight - through joints shall be suitable for Buried / Over Head application.

The heat shrinkable component shall be light in weight and shall be made of specially formulated
cross linked polymeric material with excellent tracking & erosion resistance characteristic.
Environmentally sealed system for splicing dielectric shielded power cables. The design of joint
and termination shall be such that on completion of work, the cable can be charged immediately.
The joint/termination shall have range taking feature. The Connector /ferrule used shall be range
taking; Moisture entry into conductor shall be protected by providing special mastic. The
termination kit offered shall provide for total environmental sealing of the cable crutch and at the
lug end. The details of the same shall be submitted along with the offer.

1. Heat Shrinkable Straight through joints.

The heat shrinkable straight through joints shall have following function abilities.
a) For encapsulation, environmental sealing set of heat shrink outer insulating tubes with hot melt
adhesive coating are required to be provided.
b) To reduce stress over conductor, heat shrinkable stress control tube to be provided. The stress
control tube has to be in electrical contact with the outer insulation screen of the cable. Impedance
of the tube shall be constant up to an operating temperature and shall be within the range 1x108
ohm-cm to 8x108 ohm-cm and with Relative permittivity shall be minimum 15.Voidsfilling and
stress relief over crimped connector and cut point of the insulation screen to be provided with void
filling and moisture sealing high permittivity yellow mastic and lubricant. The nested ends of the
heat shrinkable tubing shall be provided with environmental sealing red mastic. Continuity of
copper metallic screen of cable to be provided by Tinned copper mesh with 50% overlap.
Mechanical protection of joint to be provided by roll able Metallic Strip Canister of suitable size
and length for 3 core and by tinned copper mesh for 1 core cable.
c) For joining of main conductor cores suitable size of ferrules/mechanical connectors with range
taking feature should be provided. The cross-sectional area (CSA) of the ferrule/mechanical
connector shall not be less than CSA of the conductor of the cable. Length of the ferrule/connector
shall be sufficient to allow adequate number of crimps/shear head type bolts, to limit temperature
rise at the joint. For providing insulation over the conductor area maximum three layers of heat
shrinkable insulating tube are to be provided. The thickness of the heat shrinkable tube after
installation should not be less than 1.2 times the insulation thickness of the cable. For outer semi
conductor screening of the joint suitable heat shrinkable dual wall tubes which are co-extruded are
to be provided.
d) Earth Continuity between armour to be provided by tinned copper braid of adequate cross section.
This is required for proper ear thing of the joint. Also, to support amour wire support ring is to be
provided. The material of support ring to be steel (G.I.)for 3 core Cable and Aluminum for 1 core
cable- Worm drive clip(jubilee/hose clips) for tightly securing the ear thing braid is required to be
provided in suitable size & quantity.
e) For cleaning of cores, removing burrs on ferrules & rough insulation. Sufficient quantity of
cleaning solvent &aluminum oxide cloth is required to be provided.
f) The cable termination (Indoor-outdoor) shall be of class-I type which consist of following point
(i) stress control layer
(ii) Resistance against UV light environmental protection.
(iii) Moisture seal-for environmental sealing against ingress of moisture & aggressive gases for crutch
portion sealing of cables trifurcating Heat shrinkable breakout is required.
g) To protect the cable breakout mono plast tape/non-adhesive PVC tape is required to be applied
over.ear thing arrangement(worm drive clip installed over copper braid and
h) Armour for suitable length of the termination part.
i) For proper sealing of Lugs at end of the termination suitable size & length of Heat Shrinkable tube
is to be provided. No tape is to be provided for sealing purpose. For earthing tinned copper braid of
adequate cross section is to be provided. Also, to support armour wire GI support ring is to be
provided. Worm drive clip (jubilee clips) for tightly securing the earthing braid is required to be
provided in suitable size & quantity.
j) Suitable size of heat stress control tubes is to be provided to reduce stress at cut back of screed
Void filling yellow mastic is to be provided at semi-conducting screen. Heat shrinkable anti
tracking tubes are to be provided to cover bare XLPE insulation and to provide UV resistance
&environmental sealing.
k) For cleaning of cores, removing burrs on ferrules & rough insulation, sufficient quantity of
cleaning solvent &aluminium oxide cloth is required to be provided. Adhesive tapes to be provided
in sufficient length for marking on cables.
l) Sufficient quantities of heat shrinkable rain sheds are to be provided to increase the creep age
distance and to prevent water collection over termination end portion.
Heat Shrinkable Indoor Type End Termination: Terminations should be designed to withstand
high humidity and surface contamination under electrical stress caused due to condensation and
dust in indoor conditions.
Heat Shrinkable Outdoor Type End Termination: The Terminations should be designed to
withstand exposure to extreme climatic variations &surface contamination, UV rays from sunlight
and electrical stress caused due to heavy pollution & dust in external conditions.

Heat Shrinkable Cable Terminations Kits and required for the following Sizes of XLPE Cables:

Sl.No. No. of Cores Voltage Cable Size in Sq mm

1 3 33 kV 400
2 3 11 kV 300
3 3 11 kV 185

5. MARKING AND LABELING

As per the IS 13573 (Part-II&III):2011 all kits shall be marked and labeled suitably for
identification.
a) Manufacturer’s name or logo and the name of components wherever feasible;
b) Type of jointing materials, the application;
c) Batch number(s), where relevant;
d) Product reference;
e) Defined storage conditions and expiry date, if any;
f) If relevant, the manufacturing date;
g) Health and safety marking and handling instructions, where relevant; and
h) Reference to compliance with this standard.

6. TESTS

TYPE TESTS
The Jointing Kit offered, shall be fully type tested at NABL Lab as per the relevant standards. The
applicable standards are indicated in Clause No.3. The tenderer shall furnish the type test reports
along with the offer. Offer without Type test reports will not be considered. For any change in the
design/type, already type tested and the design/type offered against this specification the
 APEPDCL reserved the right to demand repetition of type tests without any extra cost in presence
of APEPDCL’ representative.

Contractor shall submit type test reports for Terminating/jointing accessories as per IS 17573:1992/
IEC 60840:1999/ IEC62067.

7. TYPE TEST SEQUENCE

The type test shall be carried out as per the test sequence given in IS 13573/2011(Part – II& III)

Acceptance & Routine Tests:

All acceptance and routine tests as stipulated in the relevant standards shall be carried out by the
supplier in presence of APEPDCL’s representative.

The APEPDCL reserves the right to insist for witnessing the acceptance/routine testing of the
bought out items.

8. PRE DESPATCH INSPECTION

All acceptance tests and inspection shall be carried out at the place of manufacturer unless
otherwise specially agreed upon the manufacturer and purchase at the time purchase. Manufacturer
shall offer to the inspector representing the APEPDCL, all the reasonable facilities, free of charge,
for inspection and testing to satisfy him that the material is being supplied in accordance with this
specification.

The Client’s representative/Engineer attending the above test will carried out testing for suitable
number of cable joints/terminations as per sampling procedure laid down in IS:13573(Part-
II,III):2011(amended up to date) and issue test certificate approval to the manufacturer and give
clearance for dispatch. The cable jointing/termination kit shall be sealed after the inspection.

9. INSPECTION AFTER RECEIPT AT STORES

For Random sample testing (RST) the sample Cable Termination/jointing kit will be drawn from
any one of the store.

10. DEMONSTRATION &TRANING:

The APEPDCL reserves the right to ask for demonstration of the equipment offered at the
APEPDCLs place. The Tenderer shall arrange for demonstration of installation of
jointing/termination kits free of cost for giving training to APEPDCLs representative to get
acquainted with the jointing method. The jointing/termination kit along with required length of the
kits to be used for demonstration purpose shall be specified the cable will be provided by the
APEPDCL.

11. GUARANTEE

The Kits shall be suitable for storage without deteriorating at a temperature up to 50degree Celsius
under normal conditions of storage and shall have unlimited shelf storage life. The tenderer shall
guarantee the installed cable accessories for a minimum period of not less than 5 years from the
date of installation. The stores/materials found defective within the above guarantee period, shall
be replaced by the supplier free of cost within one month of receipt of intimation. If the defective
stores/materials are not replaced as per the above guarantee clause, the Company shall recover an
equivalent amount plus 15% supervision charges from any of the supplier’s bills.

12. QUALITY CONTROL

The APEPDCL has a right to send team of experienced Engineers for assessing the capability of
the firm for manufacturing and testing of Cable jointing kit as per this specification. The
APEPDCL representative should be given all assistances and cooperation for inspection and testing
at the bidder’s work.
13. QUALITY ASSURANCE PLAN

The tendered shall invariably furnish QAP along with his offer, The QAP adopted by him in the
process of manufacturing shall be consist of
a. List of Plant and Machinery available at the manufacturer’s premises.
b. List of testing equipments available at the manufacturer’s premises with their calibration schedule.
c. Organizational chart.

14. PACKING
The Cable jointing kits shall be suitably packed to avoid damage or disturbance during transit or
handling. Each Cable jointing kits maybe suitably packed in the first instance to prevent ingress of
moisture and dust and then placed in a cushioned carton of a suitable material to prevent damage
due to shocks during transit. The lid of the cartoon may be suitably sealed. A suitable number of
sealed cartons may be packed in a case of adequate strength with extra cushioning if considered
necessary. The cases may then be properly sealed against accidental opening in transit.

The following information shall be furnished with the consignment:

 Name of consignee
 Details of consignment
 Destination
 Total Weight of consignment.
 Sign showing upper / lower side of the crate
 Sign showing fragility of the material.
 Handling and unpacking instructions.
 Bill of Materials indicating contents of each component and spare materials.
 Installation instructions including drawing or other information specific to the accessories.

15. SCHEDULES
The tenderer shall fill in the following schedules which are part and parcel of the tender
specification and offer. If the schedules are not submitted duly filled in with the offer, the offer
shall be liable for rejection.

The discrepancies if any between the specification and the catalogs and / or literatures submitted as
part of the offer by the bidders, the same shall not be considered and representations in this regard
will not be entertained. The bidder shall furnish these particulars for each size/ rating.

GTP FOR HT CABLE ACCESSORIES i.e., JOINTS &TERMINATIONS(Heat Shrinkable)

Sr. No. Particulars Requirement Bidder Offer

1 Manufacturer’ Name&
Address
2 Brand Name &Country of
Origin
3 Kit Storage Temperature 50 degree C max
4 Voltage Grade(KV) 12, 24 & 36
5 Applicable Standards Indicated in Cl.No.4 of
Technical Spec.
6 Material to be used cross link Polymeric
7 Type Of Kit Offered 1)Straight through
Joint.
2)Indoor End
Termination
3)Outdoor End
Sr. No. Particulars Requirement Bidder Offer
Termination
8 Shelf life of components Unlimited
in the kit
9 Time Required for Immediate.
energisation after
completion of
termination/joint
10 Conductor resistance test Conductor resistance
(As per cable cross shall not vary more
section area) than 10% of initial value
11 A.C. withstand voltage 4.5 Uo for 5 min #
ph/ground) @ 4.5 Uo
12 Heat Cycle in air 8 hours 30 Cycles at 2.5Uo #
total with > 2hours
steady heating and >3
hours cooling
13 Heat Cycle in water 8 30 Cycles at 2.5Uo #
hours total with >2 hours
steady heating and >3
hours cooling
14 Partial discharge test @1.73 Uo 10 pC Max 10 pC#
max at max temp as well as room
temperature
15 Humidity test (Only for Indoor 300hours @ 1.25Uo #
termination)
16 Salt fog test (Only for 1000hours @ 1.25Uo #
Outdoor termination)
17 Dielectric Strength for 1)18(min)
1) Insulating Tube. 2)18(min)
2) Anti tracking Tube 3)18(min)
3) Dual wall tube
18 Dielectric constant for 1)15(min)
1) stress control tube 2)3.5(min)
2) insulating tube 3)3.5(min)
3) anti tracking Tube 4) 3.5(min)
4) dual wall Tube 5)9.0(min)
5) stress control mastic
19 Tensile strength for 8N/mm2(common for
1)stress control tube each)
2)insulating tube
3)anti tracking tube
4)dual wall tube
5) stress control mastic
20 Ultimate Elongation for 1)50%
1)stress control tube 2)100%
2)insulating tube 3)100%
3)anti tracking tube 4)200%
4)dual wall tube 5)500%
Sr. No. Particulars Requirement Bidder Offer
5) stress control mastic
21 Water Absorption for 1)0.3%
1)Stress Control Tube 2) 0.3%
2)Insulating Tube 3) 0.3%
3)Anti Tracking Tube 4) 0.3%
4)Dual wall Tube 5)0.5%
5) Stress control mastic
22 Longitudinal Change for 1)5%
1) stress control tube/ 2) 5%
2) insulating tube 3) 5%
3) anti tracking tube 4) 5%
4) dual wall tube
23 Heat Shock for 1)30min@2000c,
1) stress control Tube 2)30min@2000c,
2) insulating tube 3)30min@2000c,
3) anti tracking tube 4)30min@2000c
4) dual wall tube
24 Flammability for insulating tube/anti Pass
tracking tube/dual wall tube
25 Tracking Resistance for anti tracking Non tracking
tube
26 Dissipation factor for stress control 0.15(max)
mastic
27 Service Temperature for stress control 900C
mastic
28 Heat Shrink Outer insulating tubes
29 Canister
30 Red mastic
31 G.I. Solid Colet
32 Copper Braid
33 Co-extruded Heat shrink
Dual wall tube
34 Heat shrink insulating tube
35 Heat shrink stress control tube
36 Stress Grading mastic
37 Ferrule/Connector
38 PVC NA Tape
39 PVC Adhesive Tape
40 Cleaning Liquid
41 Aluminum Oxide cloth
42 Heat shrink break
Boot(Termination)
43 Heat stress control tube
44 Heat shrink Anti tracking tube
45 Rain sheds (Termination)
46 List Of Contents Of Kit(To Be
Furnished Separately)
# These values are indicated in IS-13575 part –I at clause no.6.1,7.2.
IS-13573 part-II at clause no.4.4.2,4.5.2&5.1,
IS-13573 part-III at clause no.4.1(in accordance with IS -10810), 7.1,9&13
 9.HIGH DENSITY POLYETHYLENE (HDPE) PIPE
1. SCOPE:
This specification covers the manufacturing, testing at works, transport to site, insurance, storage,
erection and commissioning of to high-density polyethylene (PE 63, 4.5Mtr (ductile iron pipe size
O.D) pressure pipe primarily intended for the pressure pipe primarily intended for buried for
underground cable works as per IS: 4984 or any equivalent standard with latest amendment.

This section covers design, manufacture, testing before dispatch, packing, transportation at site,
insurance, supply & delivery F.O.R destination, and laying of ISI Marked HDPE pipes -For
laying of XLPE Power Cable 3 core up to 400Sq.mm

2. Details of requirement of the HDPE Pipe

STANDARD:-

A. TYPE

(i) The HDPE pipe shall be double wall corrugated of standard make suitable for laying 3-core
400,300&185 mm square XLPE cable underground.

(ii) The HDPE pipe shall be ISI marked and complying to technical requirement of IS-14930.

(iii) Size: The HDPE pipe shall have OD/ED (mm) as 160 and have standard length of 6 meters.

(iv) Fitting and Assembly: The scope of work shall include all fittings and accessories namely End
Caps, ends, Tees etc required for the successful execution of laying work of the HDPE pipe.
(v) Non-flame propagating properties: The HDPE pipe shall be of non-flame propagating type as per
IS-14930 (Part-II).
(vi) Anti-rodancy: The HDPE pipe shall have anti-rodancy property to prevent damage caused due to
rodent’s.
Pipes shall be designated according to the grade (PE 63) of material nominal diameter of as follows
Material Grade: PE-63

MRS –Minimum Required strength of materials: 6.3MPa at 20 0 C Maximum allowable Hydrostatic design
stress: 5.0 MPa at 200 C

Outer
Size Material Grade Tolerance Ovality
Diameter
160 mm diameter HDPE pipe (PE-63) 160mm 1.5 3.2
[4.5 Mtrs].

3. General
High Density Polyethylene (HDPE) pipes/fittings all material used in the production shall be
approved by the National Sanitation Foundation (NSF). The pipe shall be designed, constructed
and installed in accordance with the best practices and methods and shall comply with these
Specifications. The pipes are recommended for maximum water temperature of +45 degree C’. The
pipe may also 1~ used up to the ambient temperature of - 40 degree c’. As the creep rupture
strength of the pipe varies with the change in water temperature, the maximum working pressure
and should modify as per IS: 4984.

4. COLOUR:
The colour of the pipe shall be black.

For the purpose of identification of the pipes covered in this standard, each pipe shall contain
minimum three equi-spaced longitudinal stripes of width 3 mm (Min) in blue colour. These stripes
shall be coextruded during pipe manufacturing and shall not be more than 0.2 mm in depth. The
 material of the stripes shall be of the same type of resin, as used in the base compound for the pipe.

5. Materials:

The-material used for the manufacture of pipes should not constitute toxic hazard, should not
support microbial growth and should not give rise to unpleasant taste or odour, cloudiness or
discoloration of, water. Pipe manufacturers shall obtain a certificate to this effect from the
manufacturers of raw material.

High density polyethylene (HDPE) used for the manufacture of pipes shall conform to designation
PEEWA-45-T-006 of IS 7328: 1992. HDPE conforming to designation PEEWA-45-T-012 of IS
7328: 1992 may also be used with the exception that melt flow rating (MFR) shall not exceed 1.10
g/10 minutes. III addition the material shall also conform to 5.6.2 of IS 7328: 1992

The MFR of the material shall be between 0.41 and 1.10 (both inclusive) when tested at 190 UC
with nominal load of 5 kgf as determined by method prescribed in 7 of IS 2530: 1963. The MFR of
the material shall also be within + 20 percent of the value declared by the manufacturer.

The resin shall be compounded with carbon black. The carbon black content in the material shall be
within 2.5 + 0.5% and the dispersion of carbon black shall be satisfactory when tested according to
the procedure described in IS 2530: 1963.

5.1 Anti-oxidant
The percentage of anti-oxidant used shall not be more than 0.3 percent by mass of finished resin.
The anti-oxidant used shall be physiologically harmless and shall be selected from the list given in
IS 10141: 1982

5.2 Reworked Material

The addition of not more than 10 percent of the A-2, Manufacturer’s own rework material resulting
from the manufacture of pipes is permissible. No other reworked or recycled material shall be used.

5.3 Wall Thickness

The minimum and maximum wall thickness of pipes for the grades of materials, namely, PE 63,
shall be as given in Tables 3, respectively as per IS: 4984

5.4 Method of measurement

The outside diameter of the pipe shall be taken as the average of’ two measurements taken at right
angles for pipes up to 160 mm diameter. Alternatively, and for higher sizes, the diameter shall be
measured preferably by using a Flexibly Pi tape or a circometer, having an accuracy of IIO~ less
than 0.1 mm. The wall thickness shall be measured by a dial Vernier or ball ended micrometer. The
resulting dimension shall be expressed to the nearest mm.

NOTES

 The outside diameter shall be measured at a distance of at least 300 mm from the end of
the pipe.
 In the case of dispute, the dimension of pipes shall be measured after conditioning at room
temperature for 4 hours.

Ovality shall be measured as the difference between maximum outside diameter and minimum
outside diameter measured at the same cross section of the pipe, at 300 mm away from the cut end.
For pipes to be coiled, the Ovality shall be measured prior to coiling. For coiled pipes, however, re-
rounding of pipes shall be carried out prior to the measurement of Ovality.

Length of Straight Pipe

The length of straight pipe shall be 4.5 m.
 Inspection & Test

The HDPE pipes shall be offered for inspection at manufactured work before dispatch and test as
per relevant IS shall be conducted by the authority representative of purchaser.

6. VISUAL APPEARANCE

The internal and external surfaces of the pipes shall be smooth, clean and free from grooving and
other defects. The cuds shall be cleanly cut and shall be square with axis of the pipes. Slight
shallow longitudinal grooves or irregularities in the wall thickness shall be permissible, provided
that the wall thickness remains within the permissible limits.

7. MARKING

Each straight length of pipe shall be clearly marked in indelible ink/paints on either end and for coil
at both ends or hot embossed on white base every meter throughout the length of pipe/coil with the
following information:
a) Manufacturer’s name/Trade-mark,
b) Designation of pipe and
c) Lot number/Batch number.
d) BIS Certification Marking

Each pipe may also be marked with Standard Mark.

8. INSTALLATION

 HDPE shall be installed either by Open Trench Construction or Directional Bore Method.
 Care shall be taken in loading, transporting and unloading to prevent damage to the pipe. Pipe or
fitting shall not be dropped. All pipe or fitting shall be examined before installation, and no piece
shall be installed which is found to be defective. Any damage to the pipe shall be repaired as
directed by the Engineer. If any defective pipe is discovered after it has been installed, it shall be
removed and replaced with a sound pipe in a satisfactory manner by the contractor, at his own
expense.
 Care shall be taken during transportation of the pipe such that it will not be cut, kinked or otherwise
damaged.
 Good alignment shall be preserved during installation

9. TESTING:

All the type tests, Routine test and Acceptance to be done as per IS: 4984

10. Guaranteed technical parameters of HDPE PIPE

(i) Name of manufacturer

(ii) Size of HDPE pipe (O/D) (I/D) mm.
(iii) Standard length
(iv) Colour
(v) Method of Jointing
(vi) Material
(a) Whether having non-flame propagating property.
(b) Whether having Anti-rodancy feature.
(c) Detail of fitting accessories.
(d) Detail of past supplies & performance.
(e) Type test certification.
 10.GALVANIZED IRON EARTH PIPE
1.0 Scope

This specification covers the manufacturing, testing at works, transport to site, insurance, storage,
erection and commissioning of Cast Iron Earth Pipe used for line & substation as earthing pipe as
per IS: 1729/2002 and Galvanization as per IS: 2629.

STANDARD: The earth’s Pipe shall be comply with Indian Standard Specification as follows and
as amended from time except where they conflict with the specific requirement in this specification
IS: 1729/1964 for cast Iron Earth Pipe
IS: 1239 (part-1) -1991 for Hot dip G.I Pipe
REC construction Standard
IS: 2629-1985; IS: 6745/72; IS: 4736/1986 IS: 2633/1986 for Galvanization.

2.0 General Requirements

Earthing pipe must be made out 50mm nominal bore & 3.2 mm wall thickness medium gauge(no
minus Tolerance allowed) Hot Dip G.I pipe (as per IS ;- 1239, Part- 1, 1990 & REC construction
Standard – J-2) of reputed Make & 2 Mtr. long . The pipe electrode shall be cut tapered at the
bottom side for a length of 75 mm and welded clamp at top end.

The pipe shall be in one piece and no joint shall be allowed in the electrode. 2.3 Staggered drills
hole of 12 mm Dia. of interval of 150mm up to 2 meter from bottom side shall be made before
galvanization.

The GI Earthing Clamp/ Strip (C- Clamp Type) is to be of 50mm width, 6mm thickness & flange
length of 65 mm to be welded with pipe before galvanization. This should be suitable for
termination of 4 nos. of GI Flat earth electrodes. The Clamp/ Strip & Earthing pipe after fabrication
will be hot dip galvanized confirming to IS: 2629/86 with latest amendments. The clamp shall have
two holes in both sides suitable for 5/8 x 2” Bolt & provided with two GI Bolts of 5/8 x 2” long
half threaded with spring washer 2.5 The galvanization tests are to be conducted as per IS: 2633/72
& IS: 6745/72 & its latest amendments.

Earthing pipe must be made out 100 mm nominal bore & 5 mm wall thickness medium gauge(no
minus Tolerance allowed) Hot Dip G.I pipe (as per IS ;- 1239, Part- 1, 1990 & REC construction
Standard – J-2) of reputed Make & 1.8 Mtr. long.

The Dimension of pipe & socket of pipe electrode shall be conforming to the size as shown below.
Nominal length of the pipe with socket 1800 mm & 3000 mm
Nominal diameter of pipe 100mm
External diameter of pipe 110 mm
Thickness of pipe 5 mm
Projection of spigot bead 3 mm
Width of spigot bead 15 mm
Internal Dia. of socket 129 mm
Thickness of socket 6 mm
Internal depth of socket 70 mm
Internal Radius of socket 5 mm
Width of grooves of socket 10 mm
 External dia. of grooves socket 155 mm
Depth of grooves of socket 5 mm
Nominal weight of pipe (approx.) 21.67 KG

3.0 Manufacture:

i) Metal used for the manufacture of pipe shall be good quality cast iron. Cast shall be stripped with
all precautions necessary to avoid wrapping and shrinkage defect. They shall be free from defects
which affect the use of castings. Pipes shall be such that they could be cut, drill or machines.
ii) For galvanization of pipes The weight of zinc deposited shall be in accordance with that stated in
Standard IS 2629 and shall not less than 0.61kg/m² with a minimum thickness of 86 microns for
items of thickness more than 5mm, 0.46kg/m² (64 microns) for items of thickness between 2mm
and 5mm and 0.33kg/m² (47 microns) for items less than 2mm thick.
iii) For Bolts, Nuts & washers shall be made of steel and well galvanized.

4.0 Tolerance: The tolerance limit shall be as per relevant standard.

5.0 Test:
i) Hammer test: Each pipe when tested for soundness by striking with a light hand hammer shall emit
riming sound.
ii) Hydraulic test: If so required, pipe shall be tested hydraulically at a pressure of 0.4KV/ sq.mm
without showing any leakage, sweating or other defect of any kind. The pressure shall be applied
internally and shall be maintained for not less than 15 second. The test shall be conducted before
coating of the pipe.
iii) Galvanization test: Test for galvanization shall be as per IS: 2629/1985 & IS: 2633 -1986.

6.0 Inspection

All testing and Inspection shall; be at the place of manufacturer unless otherwise agreed by the
purchaser or third party nominee at any stage of manufacture. The supplier shall grant free access
to the purchaser's representative or third party nominee at a reasonable time when the work is in
progress. Inspection and acceptance of any equipment under this specification by the purchaser
shall not relieve the supplier of his obligation of furnishing equipment in accordance with the
specification and shall not prevent subsequent rejection if the equipment is found defective.
7.0 Marking

Each coil of wire shall be marked legibly with the finish size of wire, lot number and trade mark of
the name of the manufacturer. The material may also be marked with the ISI certification mark and
name of the project.
 11.G.I. WIRE
1.0 Scope

This specification covers the manufacturing, testing at works, transport to site, insurance, storage,
erection and commissioning of Galvanized Iron Wire of sizes 4 mm and 5 mm diameter.

2.0 General Requirements

It relating to the supply of mild steel wire shall be as per IS: 1387/1967 or equivalent international
specifications and the wire shall be drawn from the wire rods conforming to IS: 7887/1975 or
equivalent international specifications.

The requirements for chemical composition for the wires shall conform to IS: 7887/1975 or
equivalent international specifications.

Mild steel wire for General Engineering purpose shall be of following sizes:
i) 4mm - diameter (8 SWG)
ii) 5mm - diameter (6 SWG)
(iii) 1.626mm diameter (16 SWG)

Tolerance permitted on the diameter of wire shall be as per Table -1 of IS: 280/1978.

3.0 Climatic Conditions

The cross arms should be suitable for the climatic condition mentioned in these bidding documents.

4.0 Mechanical Properties

Tensile Test: Tensile strength of wire when tested in accordance with IS: 1521-1972, shall be
within the limits given in Table-2 of IS: 280/1978.

Wrapping Test: Wires shall be subjected wrapping test in accordance with IS: 1755-1961 or
equivalent international specification. The wire shall withstand without breaking or splitting when
wrapped eight times round its own diameter and subsequently straightened.

5.0 Surface Finish

a. The wire shall have galvanized finishes. The galvanized coating of steel wire shall conform to the
requirements for anyone of the types of coatings given in IS: 4826-1968 as per agreement with the
purchaser.
b. The coating test for finishes other than galvanized, copper coated or tinned shall be subject to
between the purchaser and the manufacturer.
c. Unless otherwise agreed to the method of drawing representative samples of the material and the
criteria for conforming shall be as prescribed in Appendix (A) of IS: 280/1978.
d. All finished wires shall be well and cleanly drawn to the dimensions specified. The wire shall be
sound, free from splits, surface flaws, rough jagged and imperfect edges and other harmful surface
defects.
e. Each coil of wire shall be suitably bound and fastened compactly and shall be protected by suitably
wrapped.
 12. CABLE LAYING AND INSTALLATION
1. INTRODUCTION

1.1 Cable as per scope indicated in this specification, shall be laid underground in flat formation
throughout the route as per relevant IS and approved drawing. However, as per requirement of the
field, the cables shall also have to be laid:

a. In Hume Pipe/HDPE Pipe

b. In air at termination point
c. In trenches of varying depths due to obstructions.
d. In prepared concrete ducts

1.2 The contractor shall prepare the route drawing based on the design and planning criteria as decided
during detail engineering and get the same approved from Employer before starting the cable
laying work.
1.3 The bidder is advised to visit the site and acquaint themselves with the topography, infrastructure
etc. The contractor shall be fully responsible for providing all equipment, materials, system and
services specified or otherwise which are required to complete the erection and successfully
commissioning of cable in all respect.

2. TRENCHING
 The cable trench work involves earth excavation for cable trench, back filling and removal of
excess earth from site. The work site shall be left as clean as possible.
 The trench shall be excavated using manual and mechanical methods including air compressor
driven pneumatic drill as per field conditions. Most main roads are of asphalt surface and some of
the roads with cement concrete surface.
 Where paved footpaths are encountered, the pavement slabs shall be properly stored and reinstated.
In case of damage to existing kerbs or slabs are there photographic evidence shall be taken and the
same shall be informed to the Engineer in writing. The photograph shall show date, time and
location. Identification markers of other services shall be properly stored and restored.
 The sides of the excavated trenches shall, wherever required, be well shored up with timber/Steel
Piles and sheeting.
 Suitable wooden/ sheet steel barriers should be erected on both sides of the trench between the
cable trench and pedestrian/ motorway to prevent accidents. The barrier could be made out of
sheet steel or wood planks. These could be portable types of size 1.5 m long by 1.2 m (height).
These should be painted with red and white colored cross stripes. Warning and caution boards
should be conspicuously displayed. Red lights as warning signal should be placed along the trench
at least at 30 metres distance between each and also at turnings/junctions for visibility during the
nights.
 The excavated material shall be properly stored to avoid obstruction to public and traffic
movement.
 The bottom of the excavated trench should be leveled flat and free from any object, which would
damage the cables. Any gradient encountered shall be gradual.

TRIAL HOLES: The bidder shall excavate trial holes, for alignment purpose at appropriate
distance apart as warranted by the local conditions, keep a record of findings and close the trial
holes properly to avoid hindrance / accidents to pedestrian traffic. The final route alignment of
cable shall be decided based on the finding of the trial hole.

It is the responsibility of the contractor to maintain the required statutory clearances from other
utility services, i.e., GVMC, VUDA, POLICE and other Telecom Service Providers etc.
 Any damage caused, inadvertently to any utility services shall be the sole responsibility of the
contractor and shall be rectified immediately to ensure uninterrupted provision of the services.

3. Trenchless Digging

The trench less digging methods shall generally conform to ITU-T L.38. The various methods of
trenchless digging such as hand / manual auguring (up to 15m), impact moiling (from 16m to about
40-50m) and HDD(Horizontal drilling device) (above 40-50m) shall be adopted based on the
soil/site conditions and the requirement and exact method for trench less digging shall be finalized
during detail engineering as per actual site/soil condition. The equipment used for HDD shall be
capable of drilling at least 100m at one go. The contractor shall propose the exact methods and
procedures for implementation of trench less digging at various crossings taking into consideration
the following guidelines, for approval by the Employer.

a) Excavation and backfilling of trial pits and verification of soil condition.

b) Excavation of entry and Exit pits.
c) Erection of drill machined. Drilling of pilot hole.
d) Placement and driving hand augur.
e) Placement and carrying out impact moiling.
f) Reaming and widening of bore holes in steps (if required).
g) Pulling of product pipe.

4. CABLE HANDLING
The inspection of cable on receipt, handling of cables, paving out, flaking, cushioning with sand ,
back-filling, reinstatement of road surfaces, providing and fixing joint markers, route markers, joint
pits, sump holes and all necessary precautions that are required shall be carefully planned and in
general conform to IS 1255-1983 or its equivalent.

5. DAMAGE TO PROPERTY
The contractor shall take all precautions while excavation of trench, trial pits etc., to protect the
public and private properties and to avoid accidental damage. Any damage so caused shall be
immediately repaired by contractor at his own cost and brought to the notice of the concerned
persons of APEPDCL
- Contractor shall arrange third party liability insurance for the above purpose.
- The contractor shall bear all responsibilities and liabilities and shall bear all costs of the damages
so caused by him or by his workman or agents.
- At places where the cables cross private roads, gates of residential houses or buildings, the cables
shall be laid in RCC Hume pipes/HDPE pipe.

6. CABLE ROUTE MARKERS/CABLE JOINT MARKERS

 Permanent means of indicating the position of joints and cable route shall be fabricated, supplied
and erected.
 Route Marker shall be provided at every 200 meter and at the turning points. In addition markers, if
required shall be provided per the field requirement. If the route passes through open fields,
markers should be conspicuously visible and above ground surface and particularly along the Road
beams except on road & pavements where they may interfere in the movement of traffic or
pedestrians.
 The markers should incorporate the relevant information. The name of the owner, voltage shall be
marked on the route marker.
 The markers shall be of RCC. The design shall be such that it cannot be pulled out. Tile type
marker shall be used along the pavement. RCC markers shall be used at other locations.
 The RCC markers shall be cut into proper size as per drawing, covered with cement plaster with
engraving of the information required.

7. DEPTH OF LAYING & SPACING BETWEEN CABLES:

Minimum depth of lying from ground surface to top of cable shall be as following:
o 11 kV cable: 0.90 meter.
o 11kV, Cables at Road crossing: 1.0 meter.
o 11kV, Cables at Railway crossing (Measured from bottom of sleeper to top of pipe: 1.0 meter.
o 33kV Cable:1.25 meter
o LT Cables : 0.75 meters

The Spacing between Cables as follows:

2. Power cable to control Cables 0.2 M
3. Power cable to Communication cable 0.3 M
4. Power cable to gas/water main 0.3 M
5. Power cable to Power cable 0.3 M

Wherever the proper depth is not achievable due to presence of other services or for other reasons,
the cable shall be laid in Hume pipe or HDPE pipe as required depending upon the site condition.

8. PAVING OUT THE CABLE

The excavated cable trench shall be drained of all water and the bed surface shall be smooth,
uniform and fairly hard before paying out the cable. The cable shall be rolled in the trench on
cable rollers, spaced out at uniform intervals. The paving out process must be smooth and steady
without subjecting the cable to abnormal tension. The cable on being paid out shall be smoothly
and evenly transferred to the ground after providing the sand cushion. The cables shall never be
dropped. All snake bends shall be straightened. Suitable size cable stocking pulling eye shall be
used for pulling the cable. While pulling the cable by winches or machines, the tension loading
shall be by tension indicator and shall not exceed the permissible value for the cable. The cable
laying shall be performed continuously at a speed not exceeding 600 to 1000 meter per hour.

The cable end seals shall be checked after laying and, if found damaged, shall immediately be
resealed. Sufficient number of heat shrinkable cable end sealing caps shall be stocked at site stores
for testing and jointing work. The integrity of the outer sheath shall be checked after the cable is
laid in position.

9. SAND BEDDING AND CONCRETE CABLE COVERS

The cable shall be completely surrounded by well-compacted sand to such a thickness and of such
size that the cable is protected against damage. The thickness of the cable sand should normally be
a minimum of 7.5 cm in all directions from the cable surface. Cable sand with a grain size less than
8 mm shall be preferred to offer good protection to cable.

A Pre-cast concrete cable covers with 1:2:4 concrete mix of size 400 X 450 X 50 mm with an
average breaking load of 300 kg with Steel of 5mm Dia. 3 Nos. and reinforcement of 3mm Dia. 3
Nos. of MS rods duly engraving with 5 mm thick letters on the slab conforming to IS 5820 2001.

SPECIFICATION OF SAND FOR BACK FILLING

10. PURPOSE AND SCOPE
 This specification covers the requirements for imported sand used in bedding and backfill in
trenches for electric cable, electric conduit, and gas pipe where the minimum 95% dry-in-place
density, as determined by ASTM D-1557 or equivalent, is required.

11. APPLICABLE STANDARDS

Sand shall be free of constituents that could cause adverse environmental impact. Used blasting
abrasives containing toxic constituents at or above State or Federal hazardous waste levels shall not
be used as backfill material. Backfill material shall consist of natural sand, manufactured sand,
existing native material, or combinations thereof, and shall conform to the physical properties listed
below:

11.1 Organic Impurities - ASTM C-40

Supernatant shall not be darker than Plate 3 when compared to standard Gardiner Color Series.

11.2 Sand Equivalent - ASTM D-2419

Equal to or greater than 20.

11.3 pH value - ASTM G-51-77

Equal to or greater than 4.5 and less than 9.

11.4 Resistivity R - ASTM G-57

Equal to or greater than 5,000 Ohms-cm.

If Resistivity R is smaller than 5,000 Ohms-cm, the following chemical contents limits shall apply:

1. Total chloride content shall be equal to or less than 500 parts per million as determined by EPA
Method.
2. Total sulfate content shall be equal to or less than 150 parts per million as determined by EPA
Method

11.5 Compaction - ASTM D-1557

Sieve Size Percent Passing (By

Weight)
½ 100
No. 4 75-100
No. 50 0 - 70
No. 100 0 - 30
No. 200 0 - 15

For grains retained on No. 4 sieve, the grain shape shall be rounded or sub-rounded as defined by
ASTM D-2488.

Coefficient of Uniformity, CSubscript Greater than or equal 2.5

C Subscript u = D Subscript 60 /D Subscript 10

D Subscript n = Diameter of grain size in which n% of the total sample is passing.

Test for Sand Equivalent Value of Soil and Fine Aggregate

ASTM G-51-77 pH of Soil for Use in Corrosion Testing
Soil Resistivity Field Measurement Using Wenner Four Electrode Technique

EPA Method 300.0 Determination of Inorganic Anions in Water by Iron Chromatography.

Test Methods for Moisture-Density Relations of Soils and Soil-Aggregate, Mixtures Using 10-lb.
Rammer and 18-in Drop
 Sieve Analysis of Fine and Coarse Aggregate
Test for material Finer than No. 200 Sieve by washing
Supplier shall submit samples of Backfill Sand from each source for testing at an independent lab
in accordance with all listed specifications.
Sand sampling shall follow ASTM D-75. The minimum sample size that will be accepted for
testing is 100 pounds.
Supplier shall obtain new test results when there is a change in the original approved source.

12. FLAKING
The cables shall be flaked and left with slight extra lengths at jointing bays for expansion and
flexibility.

13. BACK FILLING

Normally back filling shall consist of the material earlier excavated. However, bigger stones,
pieces of rock, metal/glass pieces, plastic bottles and any such Non Bio-degradable materials also
should be removed. The disposal should be separately done for bio-degradable and non bio-
degradable materials.

14. PREVENTION OF DAMAGE DUE TO SHARP EDGES

After the cables have been laid in the trench and until the cables are covered with protective
covering, no sharp metal tool shall be used in the trench or placed in such a position that may fall
into the trench. Straight and curved rollers used shall have no sharp projecting parts liable to
damage the cable.
While pulling through pipes and ducts, the cable shall be protected to avoid damage due to sharp
edges.
The cables shall never be bent, beyond the specified bending radius.

15. ROAD, RAILWAY TRACKS, WATER PIPE LINE CROSSINGS

RCC Hume pipe of Class-NP4 Conforming to I.S. No.458/2003shall be used for crossing of Road
and railway track and water pipe line. One spare pipe at each location of 33kV & 11 kV cable
crossing shall be laid. Cable pipe size/ laying details shall be as per IS 1255-1983. The road cutting
for cable trench, whether cement concrete, asphalt or macadam road surface shall be undertaken
after obtaining approval for cutting from the road owning authorities, traffic police, telephone
authorities and work should be planned to be completed in the shortest possible time. Where
necessary the work shall be planned during night or light traffic periods. The railway track crossing
design shall be got approved from the railway authorities and the contractor shall do work in
coordination with them.

In the excavated trench across the road the pipes shall be laid, excavation backfilled compacted and
surface shall be redone in the shortest possible time.

Open Drain Crossing: Where ever the cable has to cross open drains, with long span, the cable shall
be laid in suitable size pipe properly joined with suitable collars. The Pipe shall be firmly supported
on pillars, columns, or suitable support of RCC foundation.

16. FOOT PATH CUTTING

The slabs, kerbstones, on the roads/ footpath shall be removed and reinstated without damage.

17. REINSTATEMENT
After the cables and pipes have been laid and before the trench is backfilled, all joints and cable
positions should be carefully plotted in drawing and preserved and provided to the Engineer of
APEPDCL. The protective covers shall then be provided, the excavated soil riddled, sieved and
 replaced. It is advisable to leave a crown of earth not less than 50 mm and not more than 100 mm
in the centre and tapering towards the sides of the trench.

The temporary reinstatement of roadways should be inspected at regular intervals, more frequently
in rainy season and immediately after overnight rain for checking settlement and if required, the
temporary reinstatement should be redone.

After the subsidence has ceased the trench may be permanently reinstated and the surface restored
to the best possible condition.

In case of the road surface is cement concrete, asphalt or tarred macadam, resurfacing shall be done
by the contractor.

18. JOINTING BAYS

Jointing bays shall be provided at every proposed joint location. The bidder shall identify the
location of the joint bays after carrying out detailed survey of the cable route and excavation of the
trial pits. The delivery lengths of the cables shall match the location.

The joint bay should have a flat and level surface. At the bottom in a corner, a sump pit shall be
made for bailing out water. The jointing bay shall have the sufficient space for carrying out the
jointing activities.

The contractor shall follow standard practice in making joint bay, jointing and back filling after
making joint and testing for the voltage class required.

The contractor shall submit design and drawing of Jointing bay in the buried cable trench portion
for withstanding a live load of 20 tons vehicle plus 30% for impact from moving vehicle.

All works shall be carried out in presence and supervision of the Engineer of Employer/SEB.

19. TOOLS AND PLANTS

The successful bidder shall have all necessary tools, plant and equipment to carry out the survey
and cable installation work.

The bidders are instructed to give all the details of equipment at their disposal, to carry out the
work successfully and speedily.

20. BENDING RADIUS

The minimum bending radius of XLPE insulated cables is as follows:
Cable Bending radius
Three Core 15 x D
“D” means the overall diameter of the completed cable.

21. JOINTING AND TERMINATION OF CABLES

General: The cable jointing personnel and his crew shall have good experience in the type of
joints and terminations that are used. The jointing work shall commence as soon as two or three
lengths of cables have been laid. All care should be taken to protect the factory-plumbed caps/ seals
on the cable ends, and the cable end shall be resealed whenever the end is exposed for tests.
 Jointing of cables in carriage ways, drive ways under costly paving, under concrete or asphalt
surfaces and in proximity to telephone cables and water mains should be avoided wherever
possible.

Sufficient over lap of cables shall be allowed for making the joints which shall be paid to the
contractor under supply. The contractor shall include the cost of erection of overlap cable in their
bid.

The joint bay should be of sufficient dimensions to allow the jointers to work with as much
freedom of movement and comfort as possible. Sufficient space should be kept below the cable to
be jointed.

The joints of different phases shall be staggered.

22. TENTS / COVERS

An enclosure or suitable protection cover shall be used in all circumstances wherever jointing work
is carried out in the open irrespective of the weather conditions. The joint shall be made in dust
free and clean atmosphere.

23. PRECAUTIONS BEFORE MAKING A JOINT/ END TERMINATION

The cable end seals should not be opened until all arrangement have been made for jointing and all
necessary precautions have been taken to prevent circumstances arising out of rainy/ inclement
weather conditions, which might become uncontrollable.

If the cable end seals or cable ends are found to have suffered damage the cables should not be
jointed, without tests and rectification.

24. MEASUREMENT OF INSULATION RESISTANCE

Before and after jointing, the insulation resistance of cables from Phase to earth and Between
Phases shall be checked.

25. IDENTIFICATION
The identification of each phase shall be clearly and properly noted. The cables shall be jointed as
per the design approved by the Employer based on the proposal submitted by the Contractor.

Each cable shall have identification for phase and circuit at joint bays.

26. MAKING A JOINT/ END TERMINATION

Comprehensive jointing instructions should be obtained from the manufacture of jointing/end kits
and meticulously followed.
The materials used in the joints/ end kits like ferrules, screen/armour continuity bonds, lugs etc.,
shall be of good quality and conform to standards.

The jointing tools shall be appropriate and as per the requirement of jointing XLPE/PVC cables.

27. CABLE TERMINATIONS

The cable terminations used are to be of Indoor and outdoor type.

The preparation of the cable end for installing the terminations and the precautions to be taken
before fixing the terminations shall be followed as in the case of the cable jointing procedures.
 The instructions furnished by the termination manufacturer shall be strictly followed.

At cable terminating end, the following provisions for supply and erection are to be included.
 A terminating structure should be provided where necessary for supporting the cable to be
terminated (except at the ring main unit ends)
 A sufficient length of spare cable (5 Meter) shall be left in the ground, for future needs which shall
be paid to the contractor under supply. The contractor shall include the cost of erection of spare
cable in their bid.
 The rise / take off of the cable immediately from the ground shall be enclosed in 150 mm Dia. GI
pipe to protect against direct exposure to the sun.
 The cable shall be properly fastened to the support using non-metallic clamps.
 Appropriate labels shall be fixed identifying the phase circuit, voltage and date of commissioning
etc., on the cable supporting structure.
 The sealing end shall be mounted on insulators to isolate them from their supporting steel work.
 Protection from contact with the exposed metal work at the termination shall be provided by resin
bonded glass fibre shroud.
 Providing earth stations with all required materials, like leads, connectors etc for ear thing of amour
and screen.

28. BONDING OF SCREEN / ARMOUR

The screens and armour at both ends shall be brought out and solidly bonded to the earth station.
All accessories and consumables used in the termination should be of good quality and compatible
with the cable.

29. CONNECTION OF RADIAL WATER BARRIER AND CABLE SCREEN

If the metallic radial water barrier is insulated from the metallic wire screen a connection suitable
to carry the currents occurring during operation must be installed between metallic radial water
barrier of the cable and metallic wire screen in joints and sealing ends.

30. ERECTION OF CABLE TERMINATING STRUCTURES

The terminating structure should be designed as per the requirement of the cable end sealing,
offered by bidder.

The mounting structure shall be of latticed GI suitably grouted to the ground.

After fixing the end termination, the cable shall be fixed to the support, with non-magnetic material
clamps to the required height securely.

The mounting structure includes the supports for cable end boxes, link boxes and any other
structure required for the intent of the contract.

All steel sections used shall be free from all imperfections, mill scales, slag intrusions, laminations,
fillings, rust etc., which may impair their strength, durability and appearance. All materials shall be
of tested quality only unless otherwise permitted by the Employer/SEB. The Contractor shall
fabricate, provide and install the structures.

31. TESTS AFTER INSTALLATION

All tests as prescribed in Clause-6 of IEC-840 shall be performed after installation of cable.

Following minimum tests shall be carried out:

 Insulation Resistance of each cable drum length after laying but before jointing.
 Serving insulation resistance after laying each cable length shall withstand a voltage of 5 kV DC
between each reinforcement and external conducting surface for one minute. In addition, the
serving insulation resistance shall be measured and checked with the values obtained in the routine
factory test.
 On completion of the cable laying and jointing work, the complete installation shall be tested with
a D.C. voltage (high Voltage Test) as per IS 1255.
 Conductor resistance of each cable of each complete circuit shall be measured and compared with
the values obtained during routine factory tests.
 Test for 5 minutes with system voltage applied between the conductor and the armour/ screen
earthed.
 Test for 24 hours with normal operating voltage of the system
 13.HORIZONTAL DIRECTIONAL DRILLING (HDD)
The contractor shall have shall have ISO 9001-2008/18001-2007. The contractor shall bring his own
machinery for this purpose. The contractor who is executing the HDD shall have preferably ownership of
five no’s of HDD and two machines of Rock drilling. The machinery shall be used in such a way that there
is minimum obstruction to traffic and pedestrians. The Horizontal drilling shall be for a distance of not less
than 90 Mtr. at each stretch and subsequently thereafter. The reinstatement of road dug up for drilling at
every 90 Mtr. shall be incorporated in the price for Horizontal Directional Drilling. Hence the reinstatement
of roads to its original condition in the dug up portion where drilling is commenced shall be inclusive and
not charged extra by the Successful Tenderer. Disposal of extra excavated material such as mud, slurry,
stones etc shall be also included in the rate per meter of horizontal drilling and shall not be charged extra.

The trenchless technology shall be used with HDPE casing for the portion of the cable route such as
road, railway, nallah crossing and without HDPE casing for major portion of the cable route. The outer
diameter of the HDPE pipe shall be suitable for insertion in an 8” diameter horizontally drilled bore. The
HDPE pipe shall be of PE 80 grade with pressure rating PN4 conforming to IS 4984/1995 and shall have
wall thickness of 6.20 to 7.10 mm. The HDPE pipes shall be joined by using Butt welding and a 7/20 G.I
wire shall be provided along the entire length of each pipe duct.

The Depth of horizontal drilling shall be between 2 to 3 meters and shall be site specific. The
Successful Tenderer shall carry out radar survey of the route using Ground penetrating Radar and
determine route profile of any other utility cables, pipes etc along the route. The route survey and drilling
profile shall be got approved and finalized by the Engineer-in-Charge prior to commencement of the
drilling, HDPE pipe insertion and cable insertion.

The drilling shall be with a Directional drilling unit equipped with automated pipe handling system
and all necessary accessories. The unit shall utilize Bentonite mud circulation pilot boring, grinding,
reaming and pulling the pipe carefully without damaging other service installations in the vicinity.

The XLPE Cable laying shall include insertion into the HDPE pipe manually with proper safety of the
cable.
i. The rate shall include cost of butt welding, cost of HDPE pipe and other required accessories, cost
of entry and exit pits, restoration of entry and exit pits at original level.
ii. The charges towards all machinery involved including accessories and power requirement thereof
for carrying out the Horizontal Drilling shall be included in the rate for HDD by the contractor.

GUIDELINES FOR HDD

The method described herein is not exhaustive or exclusive. If the Tenderer has any other technique
meeting the requirements of laying of 400 sq.mm XLPE cable, the details may be submitted. However,
the general requirements of HDD technique described herein shall remain as a guideline for submission of
the Tender.

General:
The directional drilling equipment shall consist of a directional drilling rig of sufficient capacity to
perform the bore and pull back the pipe/cable, a drilling fluid mixing, delivery, and recovery system of
sufficient capacity to successfully complete the installation, a drilling fluid recycling system to remove
solids from the drilling fluid so that the fluid can be reused (if required), a magnetic guidance system or
walk over system to accurately guide boring operations, a vacuum truck of sufficient capacity to handle
the drilling fluid volume, and trained and competent personnel to operate the system. All equipment shall
be in good, safe condition with sufficient supplies, materials and spare parts on hand to maintain the
system in good working order for the duration of this project.

Drilling Rig: The directional drilling machine shall consist of a hydraulically powered system to
rotate and push hollow drilling pipe into the ground at a variable angle while delivering a pressurized fluid
mixture to a guidable drill (bore) head. The machine shall be anchored to the ground to withstand the
bulling, pushing and rotating pressure required to complete the installation. The hydraulic power system
shall be self-contained with sufficient pressure and volume to power drilling operations. Hydraulic system
shall be free of leaks. Rig shall have a system to monitor and record maximum pullback pressure during
pullback operations.

There shall be a system to detect electrical current from the drill string and an audible alarm which
automatically sounds when an electrical current is detected.

Head: The drill head shall be steerable by changing its rotation and shall provide necessary cutting
surfaces and drilling fluid jets.

Motors (if required): Mud motors shall be of adequate power to turn the required drilling tools.

Drill Pipe: Shall be constructed of high quality 4130 seamless tubing, grade D or better, with
threaded box and pins. Tool joints should be hardened to 32-36 RC.
 14.RCC CABLE ROUTE MARKERS
1.0 Manufacturing and supplying of RCC cable route markers slab of size 0.70Mtr. height, 0.24Mtr.
width and 0.075Mtr. depth, using reinforced M20 concrete with letters “APEPDCL … KV UG
cable” with an arrow (→) letter showing distance and depth at which cable is buried engraved in
concrete on a smooth and clean finished surface with painting of 2 coats of apex over coat of
primer with yellow shade and the letters with contrast red shade.
2.0 Fixing the RCC cable route markers of size 0.70 Mtr. height, 0.24 Mtr. width and 0.075 Mtr. depth
with PCC (1:3:6) using 20mm down size jelly including earth work excavation of 0.30 Mtr. depth
 15.CABLE PROTECTION COVER TILES

Concrete Cable Protection Cover Tiles, also known as Cable Route Markers, are used frequently by
utility companies to provide a clear indication to site staff who may be working close to
underground electrical cables.

Covers act as a protective barrier against damage to buried electricity cables eliminating the risk of
accidents and costly repairs. They can also be used to locate and identify other underground
services.

Protection covers are reinforced precast concrete units manufactured and tested to BS 2484
specifications. The covers shall be imprinted, as standard, with the words ‘DANGER
ELECTRICITY’ & APEPDCL.

Length Width Depth

450mm 400mm 50mm
 16.CAUTION TAPE

1. Underground Warning Tape (UWT) is a non-adhesive LDPE plastic tape printed with a warning
text to warn future excavators of the danger of the cable or pipe below. Underground warning
tapes should be installed within the trench half way between the cable or pipe and the surface.
2. Underground warning tapes shall be manufactured with yellow color as per the drawing below and
APEPDCL printed and supplied on rolls of 150mm wide x 500m long with thickness of P 100
microns (0.1mm)
3. Material – Linear low density polyethylene
4. Lead free pigments with virgin grade film
5. Soil tolerance from pH 2.5 to pH 11.0 inclusive
6. 100micron grade is manufactured in accordance with ENATS 12-23 specification
 17.EARTHING
1.0 GENERAL SPECIFICATION FOR EARTHING:
All the non-current metal parts of electrical installation shall be earthed properly. All metal
conduits, trucking, cable sheaths, switchgear, distribution fuse boards, lighting fittings & fixtures
and all other parts made of metal shall be bonded together and connected by means of specified
earthing system. All earthing will be conformed to Indian Standard Specifications IS: 3043 – 1987.
The bidder shall measure the resistivity of various places in the proposed areas and design suitable
earthing system and get it approved from APEPDCL.

EARTHING CONDUCTORS:
All earthing conductors shall be of high conductivity G.I. / Aluminum and shall be protected
against mechanical injury or corrosion.

2.0 CONNECTION OF EARTHING CONDUCTORS:

i) Main earthing conductors shall be taken from the earth connections at the RMUs and cable end
terminations to an earth electrode with which the connection is to be made.
ii) Circuit earthing conductor shall run from the exposed metal of equipment and shall be connected to
any point on the main earthing conductor or its distribution boards. Metal conduits, cable sheathing
and armouring shall be earthed at the ends adjacent to the RMUs at which they originate or
otherwise at the commencement of the run by an earthing conductor in effective electrical contact
with cable sheathing. Where equipment is connected by flexible cord, all exposed metal parts of the
equipment shall be earthed by means of an earthing conductor enclosed with the current carrying
conductors within the flexible cord. Switches, accessories, lighting fitting etc. which are rigidly
secured in effective electrical contact with a run of metallic conduit shall not be considered as a
part of earthing conductor for earthing purposes, even though the run of metallic conduit is earthed.
iii) All metal clad switches and other equipment carrying single phase current shall be connected to
earth by a single connection. All metal clad switches, carrying medium voltages and high voltage
shall be connected with earth by two separate and distinct connections. The earthing conductors
inside the building, wherever exposed, shall be properly protected from mechanical injury by
running the same in GI pipe of adequate size.
iv) Earthing conductors, outside the building, shall be laid 3000 mm below the finished ground level.
v) Neutral conductor, sprinkler pipes or pipes conveying gas, water or flammable liquid, structural
steel work, metallic enclosures for cables , metallic conduits and lightning protection stem
conductors shall not be used as a means of earthing an installation or even as a link in an earthing
system. The electrical resistance of metallic enclosures for cables measured between earth
connections at the RMUs, DTRs, Feeder Pillar Boxes and Service Pillar Boxes shall be low enough
to permit the passage of current necessary to operate fuse or circuit breakers and shall not exceed
one ohm.

3.0 PROTECTION FROM CORROSION:

Connections between copper and galvanized equipment shall be made on vertical face and
protected with paint and grease. Galvanized fixing clamps shall be used for fixing earth conductors.
When there is evidence that the soil is aggressive to copper, buried earthing conductors shall be
protected by suitable serving and sheathing.

4.0 CARBON ELECTRODE EARTHING and EARTHING PIT:

 Supply of Eco Friendly maintenance free earthing system comprising of 17.2 mm Dia. 3 Mtr. long
Carbon Earthing Electrode with 250 microns copper coating.

For installation of Earthing Electrode Supply of Pre cast RCC earth pit Chamber (300*300 MM)
and making 100 mm diameter bore, 3 Mtr. Long, making of earth pit and fixing of earth pit
chamber in normal soil.

5.0 EARTH RESISTANCE:

The earth resistivity result of the soil where the earthing areas are located shall be submitted to the
engineer-in-charge before the earthing work starts. If the earth resistance is too high and multiple
electrode earthing does not give adequate low resistance to earth, the soil resistivity immediately
surrounding the earth electrodes shall be reduced by adding Carbon Based conductive concrete
back fill environmental friendly(resistivity of Less than 0.10 Ohm Mtr.) and copper clamp suitable
proportions as required.

6.0 RESISTANCE TO EARTH:

The resistance of each earth system shall not exceed 1 ohm in the case of M.V. system and 0.5 ohm
in the case of H.V. system.
 18.CONSTRUCTION STANDARDS FOR CIVIL WORKS
1.0 Scope
The scope of the specification covers the Construction Standards for Civil Works.

2.0 General
The Contractor should be conversant with Indian Electricity Rules 1956 as amended from time to
time.

2.1 Site work

All works to be carried out in a workman like manner to minimize interference to others In
particular excavations must be guarded. Adequate precautions must be taken to prevent damage or
injury to persons and live stock.

2.2 Animals
No dogs or other animals shall be brought on or near to the site.

2.3 Storage
Materials must be tidily stored. All waste material must be removed from site by the end of the
working day.

2.4 Pumping
The Contractor is responsible for piping or channeling all pumped water from excavations to the
nearest ditch, to avoid damage to neighboring land and they will be held responsible for the
cleaning out the ditch should this become silted up due to pumping operations.

2.5 Public Relations

Particular attention should be paid by the Contractor and his workmen to maintain public relations.

3.0 Definitions
 Contractor: The Contractor is a person or corporate body whose bid to carry out the works has
been accepted by the Employer.
 Defect: A defect is any part of the works not completed in accordance with the contract.
 Employer: The Employer (APEPDCL) is the party who will employ the Contractor to carry out the
works.
 Equipment: Equipment is the Contractor’s machinery and Vehicles brought temporarily to the site
for carrying out the works.
 Engineer: The Engineer is a person appointed by the Employer (APEPDCL) who is responsible
for supervising the Contractor, administering the Contract.
 Materials: Materials are all supplies, including consumables, used by the Contractor for
incorporation in the works.
 Specification: Specification means the specification of the works included in the Contract and any
modification or addition made or approved by the Engineer.
 Subcontractor: A sub contractor is a person or corporate body who has a contract with the
Contractor to carry out a part of the work in the Contract which includes work on the site.
 Works: The works are what the Contract requires the Contractor to construct, install and hand over
to the Employer as defined in the Contract Data.

4.0 Cleaning up the Site

Before commencement of works, the site shall be cleaned and dressed with an approved weed
killer. Duringconstruction, the Contractor shall keep the work site and storage area used by him
free from accumulation of waste materials or rubbish and before completing the works, the
Contractor shall at his own cost, remove or dispose off in a manner satisfactory to the Engineer in
charge. All holes in the ground shall be filled in and the land restored to its original state and the
entire premises should be kept in a neat and tidy condition of cleanliness as the Engineer may
 direct. Any damage done to the APEPDCL by the Contractor or his Sub-Contractor shall be made
good at Contractor’s expense.

5.0 Execution of Civil Works

The details mentioned below are applicable to all civil works under these specifications.

5.1 Excavation
This clause covers excavations to be done for all the civil works such as laying foundations for
structures, equipment, retaining wall, buildings (control room) cable trenches etc.
The rate quoted is applicable for all types of soils including hard rock.

Blasting shall not be permitted within the substation site. In rocky soils also excavation has to be
carried out by using any method other than blasting. The method of excavation shall be approved
by the Engineer.

Back filling shall be done with approved back fill material. The Contractor shall provide a method
statement detailing the proposal method of back filling for approval by the Engineer.

Filling Foundations and Basement

Backfilling of foundations is to be done with river sand. Back filling includes watering and
consolidating layers for all soils. Anti-termite and anti-wood treatment for foundations basement
and flooring shall be provided.

Precautions
Back fill shall not be dropped directly upon or against any structure or facility where there is
danger of displacement or damage.

Back fill shall be done in horizontal layers, leveled, wetted and rammed properly before another
layer is deposited.

Trucks, tractors or heavy equipment for depositing or compacting back fill shall not be used within
1.5 meters of the foundation / structures.

While ramming around piping, care should be taken to avoid unequal pressures.

6.0 Concrete
This clause is applicable for all the civil works under this specification. Rate for concrete shall
include cost of shoring, shuttering and de-watering wherever necessary.

7.0 Code of Practice

All concrete and reinforced concrete work shall be carried out in accordance with IS: 456, (code of
practice for plain and reinforced concrete) and APSS No 402 and 403.

7.1 Concrete Proportion

The concrete shall be of nominal mix as specified in the schedule of quantities.

7.2 Consistency
The quantity of water used shall be determined by slump test as per APSS No 402.9.1 and shall be
sufficient to produce a dense concrete of adequate workability for the purpose, and will surround
and properly grip all the reinforcement.

7.3 Water
Potable water free from Chlorides, Sulphur, other salts and organic matter shall be used for mixing
concrete grout and mortar and curing. Water used shall be as per APSS No 129.

7.4 Cement
Cement used shall be ordinary or rapid hardening Portland cement conforming to APSS No 112
 and IS: 269 with the following properties
a) Initial setting time: Not less than 30 minutes.
b) Final setting time : Not more than 600 minutes
c) Minimum compressive strength of standard Mortar Cube with graded sand as per IS:650 – 1966.At
3 days - 160 Kg / Cm2
At 7 days - 220 Kg / Cm2
7.5 Sand
Sand used shall be composed of hard silicon materials and of sharp angular grit. Only river sand
free from Calcium Chloride or other Chlorides and Salts which are likely to promote corrosion of
steel, shall be used. Sand shall be screened before use and shall conform to APSS No 110.

7.6 Coarse Aggregate

The coarse aggregate used in the concrete shall be machine crushed hard granite metal conforming
to IS: 383 – 1970 (specification for coarse and fine aggregates from natural sources for concrete)
and APSS No 108 and size shall be as mentioned in the relevant schedule of quantities.

7.7 Steel
Steel used shall conform to APSS No 126 and APSS No 1101. The cost of reinforcement steel,
binding wire and fabrication charges for all the works shall be included in the corresponding item
of such schedules.

7.8 Mixing Concrete

 Mixing of concrete shall conform to APSS No 402.
 Hand mixing of concrete shall not be permitted.
 Concrete shall be thoroughly mixed to a uniform consistency in the motor operated mixing
machines of approved types.
 The Contractor shall provide a method statement detailing the proposed method of concrete mixing
for approval by the Engineer before commencement of work.
7.9 Samples
 Samples of all materials to be used in the works shall be got approved by the Engineer.
 The materials used in the work shall be at least equal to the approved samples
 No material shall be used in the works unless it has first been approved by the Engineer or his
representative.

7.10 Inspection and Testing

All materials used in the works shall be subject to inspection and tests if required by the Engineer.
The cost of all such tests required by this specification shall be deemed to be included in the rates
and prices quoted by the Contractor in the bill (schedule) of quantities.
Any material which is prepared or manufactured without the notice having been given in writing to
the Engineer may be rejected if the Engineer considers that his inspection was necessary during the
process of manufacture of such material.

7.11 Concreting in Unsuitable Weather

In the event of rain, storms and other severe weather conditions arising, concreting shall be stopped
and appropriate temporary stop ends vee-grooves etc., placed as may be necessary. To meet such
circumstances, the contractor shall always have in readiness on the site, approved framed sheeting,
tarpaulins etc., for the protection of newly placed concrete. Should any concrete be damaged due to
rain, storms or other weather conditions the Engineer may order the cutting out / replacement of
the damaged concrete at the expense of the Contractor.

8.0 Form work

This clause is applicable to form work / centering etc., for all civil works under the specification.

Before commencing the work the Contractor shall provide a method statement detailing the
proposed method of form work he proposes to use for approval by the Engineer before
commencement of work, but such approval shall in no way relieve the Contractor of any of his
responsibilities for the sufficiency and efficiency of the work.
9.0 For the guidance of the Engineer.
 The form work shall conform to Clause 10 of IS: 456 and APSS No 403.5
 The form work shall be designed and arranged so that it will not settle under the load and can be
stripped and removed without causing any blemish or jar to the concrete.
 All forms shall be securely braced and supported to prevent any sagging or bulging during
construction. In no circumstances wire ties shall be used. All forms shall be fixed to the proper line
and tightened up immediately before depositing the concrete. All joints shall be close enough to
prevent leakage of water from the concrete.
 Form work for all exposed faces of mass concrete and for all faces of reinforced concrete shall
consist of approved material so finished as to produce the concrete surface without honey combing,
bulges etc., strutting shall be of such design as to allow accurate adjustment and easy removal.
 Strutting of formwork against the sides of the structures which is subject to movement or vibration
will not be permitted.
 The inside faces of the forms shall be treated with mould oil or other approved preparation. The
treating material shall not have deteriorating effect on concrete as well as formwork. The treating
material shall not come into contact with the reinforcement.

10.0 Removal of Form work

The length of time between concreting and the removal of the form is the sole responsibility of the
Contractor. However the Engineer will be competent to fix a minimum length of time. For structure
foundations minimum time limit specified is 24 hours for removing formwork from the time of
placing concrete.

11.0 Execution of concrete work

Before concreting is commenced all form work shall be scrupulously cleaned and wetted and the
Contractor shall adopt all necessary measures to ensure that all debris, dirt, wash water and other
refuse is removed. The reinforcement and form work will then be inspected by the Engineer and
concreting shall not be commenced until the Engineer gives permission. Such inspection shall not
however relieve the Contractor from any of his responsibilities for the correctness of the work in
every respect.

11.1 Casting Programme

The Contractor’s casting programme shall be such that each section of the work can be
satisfactorily completed in one operation after permission has been given to proceed. No claim for
overtime working for completing a casting programme will be entertained.

11.2 Conveyance of concrete

The concrete shall be conveyed from the mixer to its place in the works as rapidly as possible and
in such a manner that there shall be no separation or loss of the ingredients. In no circumstances
shall more than half an hour lapse between the time when water is added to the mix and the time
when the concrete is finally consolidated in position. The use of concrete distributing chutes at an
angle of more than 45 degrees from the horizontal will not be permitted. In no case shall concrete
be dropped from a height of more than one and half meters.

The arrangements to be adopted by the Contractor for conveying and depositing concrete shall be
subject to the approval of the Engineer.

11.3 Depositing concrete

Before any concrete is put in, the Contractor shall carry out, filling of pockets or trimming the sides
where found necessary to suit the level and line of the concrete to be laid as directed by the
Engineer at site. Concrete shall be placed in one operation.

11.4 Consolidating Concrete

 Concrete shall be consolidated by means of sufficient number of mechanical vibrators.
 The concrete shall be thoroughly vibrated all round the reinforcement and against shutters so that
all enclosed air is duly expelled and the concrete surface when stripped be found to be good and
 free of the formation of air pockets, honey combing or other defects.
 The concrete shall be worked into position where placed and not allowed to flow. For sloping
beams, the work of depositing concrete shall start from the lower end and work upwards.
 The area on which concrete is to be deposited shall be kept free from standing water. Running
water if any shall also be brought under control before concreting is commenced.

11.5 Finish of concrete surface:

Soon after the form work is removed the Contractor shall remove all form marks and other
imperfections in order to give uniform appearance.

The faces of the concrete work shall be sound and solid, free from honey combing. “No Patching”
of any concrete facing will be allowed without the approval of the Engineer.

11.6 Construction Joints

Before depositing any concrete resting or abutting on work, previously carried out, the surfaces and
ends of the existing work shall be thoroughly hacked to such an extent that no portion of the
previous surface remains. Thus roughened surfaces shall be thoroughly cleaned off, brushed and
watered immediately before the succeeding operations are commenced. The roughened surface
shall be coated with 1:2 cement sand mortar 12 mm thick, immediately before the concrete of the
next layer is placed.

11.7 Curing
The curing period shall be for a period of 14 days for switchyard structure foundations below
ground level. For other civil works the curing period shall be 21 days. Top and side surfaces of the
concrete shall be kept moist and be protected from the direct rays of the sun during the period by
covering with Jute bags. Curing shall be done as per APSS No 402.8.

10. Reinforced Concrete

 All the steel used for reinforcement shall conform to APSS No 126.
 All steel reinforcement before the concrete is deposited shall be clean and free from all loose mill
scale, dust and loose rust, and coatings such as paints, cement grout, mould oils etc. Cube samples
shall be taken and tested in Laboratory and the results shall be furnished.

12.1 Mixes
 The mix of concrete shall be 1:1.5:3 using 12 to 20mm machine crushed hard granite metal for
slab, beams, column footings, columns, lintels, sunshades and portico.
 The mix for leveling course shall be 1:4:8 using 40mm machine crushed hard granite metal. The
thickness of concrete shall be 100 mm.
 The mix for flooring bed shall be 1:2:4 for 100 mm thick with 10mm size HBG metal.

12.2 Cover to Reinforcement

 The reinforcement shall be covered in all cases as shown in the drawings. It shall be 15mm for
slabs and 25mm for beams.
 Where two bars cross, the outer should have the minimum cover.
 All reinforcement of columns is to be extended by 930 mm over the top of slab to take up the
future expansion.

1.1 Form Bolts

All form bolts that are in the concrete shall be withdrawn when the forms are stripped. They shall
not be placed within 50mm of any steel reinforcement, so that the holes they leave do not reduce
the effective cover on the steel.

1.2 Bending Reinforcement

All bends shall be made cold round. Heating of bars for any purpose what so ever will not be
allowed. All bends shall have at least four times the diameter of the bars. Where straight rods are
used they shall be truly straight.
1.3 Splicing Reinforcement
Normally splicing in reinforcement is not permissible. In exceptional cases overlapping in
reinforcement is permissible with the approval of Engineer. The spacing and over lapping
measurements shall be as per the directions of the Engineer. No bars shall be joined by welding.

1.4 Fixing Reinforcement

The number, size, form and position of all steel reinforcement bars, stirrups and other parts of
reinforcement shall be exact in accordance with the approved drawings, and such parts shall be
kept in the correct positions in the forms without displacement during the process of working the
concrete into place.

Spacebars, supporting stools and distance pieces to maintain the reinforcement in the correct
position shall be provided by the Contractor as directed by the Engineer, without any extra charge
to the APEPDCL.

All straight bars shall be fixed parallel to each other and to the sides of the forms. Any ties, links or
stirrups connecting the bars shall be tied so that the bars are properly braced.
The inside of the curved parts (stirrups) shall be in actual contact with the bars round which they
are intended to fit.

1.5 Binding wire

Bars shall be bound together with black annealed steel wire No 16, SWG size conforming to IS:
280 – 1972 and the binding shall be done tight with proper pliers or automatic binders. (The free
ends of the binding wire shall be bent towards inner side of the concrete).

1.6 Scaffolding
The Contractor shall provide a method statement detailing the proposed method of providing
scaffolding for approval by the Engineer before commencement of work, but such approval shall in
no way relieve the Contractor of any of his responsibilities for the sufficiency and efficiency of the
work.

1.7 Depositing and Consolidation:

No concrete shall be deposited until the formwork and reinforcement has been inspected and
approved by the Engineer. Care shall be taken that the steel reinforcement is thoroughly surrounded
by the concrete particularly in congested locations and that no voids or cavities are left.
Consolidation of the concrete by mechanical vibration shall be to the satisfaction of the Engineer.
Under any circumstances there shall not be any impact on the formwork during the process of
consolidation.

1.8 Defective work

If, on the removal of the shuttering any honey combing or other defective workmanship is found in
the face of concrete, the Engineer will decide whether, in his opinion, the strength of the member is
affected and whether patching shall be permitted in which case the defective concrete shall be cut
out to the extent ordered by the Engineer, and the remaining concrete thoroughly cleaned and made
good. If before or during this operation any reinforcement bar is exposed, the cutting out shall
continue right round the bar, to form a key. Where reinforcement bars are so exposed, care shall be
taken to ensure that they are not damaged by the tools used for cutting out the concrete.

If in the opinion of the Engineer, the strength of the Member is affected by the defective materials
or workmanship he may direct that the whole member shall be removed and a new member
constructed by the Contractor without any extra charge and without asking for extension of time.

If any “Patching” is discovered which has been carried out without the permission of the Engineer,
the whole member affected will be liable for rejection, in which case the member shall be removed
and a new member constructed by the Contractor, without charge.

11. FINAL INSPECTION

After the completion of the works final patrolling and checking of the line shall be done by the
 contractor to ensure that all the foundation works, pole erection and stringing have been done as
approved by the Engineer, and also to ensure that they are complete in all respects. Contractor
shall prepare pole schedules and hand it over to the Engineer. All works shall be thoroughly
inspected keeping in view of the following main points.

i) Sufficient back filled earth is laid over each foundation pit and it is adequately compacted.
ii) Concreting and coping of poles are in good and finally shaped conditions.
iii) All the accessories and insulators are strictly as per the drawings and are free from any defects or
damages, what so ever.
iv) All the bolts and nuts should be hot dip G.I. material and as per contractual provisions.
v) The stringing of the conductor has been done as per the approved sag and desired clearances are
available.
vi) No damage, minor or major to the conductor, earth wire, accessories and insulator strings will
unattended are noticed.

The contractor shall submit a report to the above effect to the Engineer. In case, it is noticed later
that some or any of the above are not fulfilled the engineer will get such items rectified through
other agencies and recover the cost of such works from the bills payable to the contractor against
that contract or any other contract executed by him for the APEPDCL
After final checking, the lines shall be tested for insulation in accordance with tests prescribed by
the Engineer. All arrangements for such testing or any other test desired by the Engineer shall be
done by the contractor and necessary labour, transport and testing equipment shall be provided by
him. The contractor defects found out as a result of such tests, shall rectify any, forthwith, without
any extra charges to the APEPDCL

12. Supply of materials by the contractor:

The contractor has to make his own arrangements for procurement, supply and use of materials and
compliance of the following should be ensured.

These materials should conform to the relevant Indian Standard specification. These materials
shall be supplied at least one month in advance of their requirement manufactures test certificate
for these materials shall be submitted and got approved by Engineer before utilization. He shall
guarantee the materials so supplied by the contractor for satisfactory performance up to the end of
the maintenance and defects liability period.

All materials to be supplied should fully conform to provisions under clause 3 of Instructions to
Bidders.

In procurement of these items the contractor shall follow all regulations of the
APEPDCL/Government of India in respect of import license etc., if he chooses to procure these
from imports. Further, the contractor shall be responsible for the payment of applicable duties and
taxes, port clearance inland transportation etc.

The materials for which advance is given by APEPDCL is to be insured by the contractor at his
cost from the date of payment of advance to the date stated in the certificate of completion for the
whole of the works.

Material & Quality:

All the material used in the works shall be of the best quality of their respective kinds as specified
herein. They shall be obtained from sources and suppliers approved by the Engineer or his
representatives, and shall comply strictly with the tests, specified herein after or, where tests are not
specified in this specification, they should conform to the requirements of the latest issue of the
relevant Indian standards herein after abbreviated to as (I.S.) or other approved National Standards
authorized by the Engineer. The contractor has got the obligation of showing the proof of source of
any material procured by him, to the APEPDCL on demand.

Inspection and Testing:

Any materials used in the works shall be subject to inspection and tests if required by the Engineer.
 Unless otherwise stated, the costs of all tests required by this specification shall be deemed to be
included in the rates and prices named by the contractor in the bill (schedule) of quantities.

Any material, which is prepared or manufactured without notice having been given in writing to
the Engineer, may be rejected if the Engineer considers that his inspection was necessary during
the process of manufacture of such material.

Approvals: No material shall be used in the works unless the Engineer or his representative has
first approved it.

13. CONSTRUCTION MATERIALS

Cement:
The contractor has to make his own arrangements for the procurement of cement to required
specifications required for the works subjected to the followings:

a. The contractor shall procure cement, required for the works only from reputed cement factories
(Main producer) acceptable to the Engineer–in-Charge. The contractor shall be required to furnish
to the Engineer–in-Charge bills of payment and test certificates issued by the manufactures to
authenticate procurement of quality cement from the approved cement factory. The contractor shall
make his own arrangement for adequate storage of cement.

b. The contractor shall procure cement in standard packing of all 50Kg per bag from the authorized
manufacturers. The contractor shall make necessary arrangement at his own cost to the satisfaction
of Engineer-in-Charge for actual weighment of random sample from the available stock and shall
conform with the specification laid down by the Indian Standard Institution or other standard
foreign institutions as the case may be, Cement shall be got tested for all the tests as directed by
Engineer-in-Charge at-least one month in advance before the use of cement bags brought and kept
in site Go down.

The Contractor free of cost shall supply cement bags required for testing. However, the testing
charges for cement will be borne by the APEPDCL. If the tests prove unsatisfactory, then the
charges will be borne by the Contractor.

c. The Contractor should store the cement of 60 days requirement at least one month in advance to
ensure the quality of cement so brought to site and shall not remove the same without the written
permission of the Engineer-in-Charge.

The Contractor shall forthwith remove from the works area any cement that the Engineer-in-
Charge may disallow for use, on account of failure to meet with required quality and standard.

The contractor shall further, at all times satisfy the Engineer-in-charge on demand, by production
of records and books or by submission of returns and other proofs as directed, that the cement is
being used as tested and approved by Engineer-in-charge for the purpose and the Contractor shall
at all times, keep his records up to date enable the Engineer-in-charge to apply such checks as he
may desire.

Cement which has been unduly long in storage with the Contractor or alternatively has deteriorated
due to in adequate storage and thus become unfit for use in the works will be rejected by the
department and no claim will be entertained. The Contractor shall forthwith remove from the work
area, any cement the Engineer-in-charge may disallow for use on work and replace it by cement
complying with the relevant Indian Standards.

STEEL:
The Contractor shall procure mild steel reinforcement bars, high yield strength deformed (HYSD)
bars, rods and structural steel etc., required for the works, only from the main or secondary
producers manufacturing steel to the prescribed specifications of Bureau of Indian Standard or
equivalent and licensed to affix ISI or other equivalent certifications marks and acceptable to the
Engineer-in-Charge. Necessary ISI list certificates are to be produced to Engineer-in-Charge before
use on works. The unit weight and dimensions shall be as prescribed in the relevant Indian
standard specifications of steel.

WASTAGE:
The contractor will be allowed for claiming additional quantities with the following maximum
additional quantities of materials to cover sag jumpering, wastage & losses etc., during erection of
the line for allowing the contractor for claiming additional quantities for the materials to be
supplied by APEPDCL to cover sag and jumpering as wastage.
(i)AB Cable: Up to 3% of route length for the AB Cable”.

Note: The Contractor has to follow R.E.C. standard for the works wherever it is not specifically
mentioned above.
 19.SPECIFICATION FOR ROAD WORKS
CHAPTER–I: EARTH / MURRUM FILLING WORKS

1.0 SCOPE
This Specification covers classification of soil for earth work in excavation and filling for site
grading work. Reference Standards Classification of soil for earth work in site grading 6-65-0016.

2.0 ORDINARY SOIL

2.1 Soft Soil/loose Soil
Generally any soil which yields to the ordinary application of pick and shovel, or to phawara,
rake or other ordinary digging implements such as:

 Sand, gravel, loam, clay, mud, black cotton soil.

 Vegetation or organic soil, turf, peats, soft shale or loose murrum.
 Mud concrete below ground level.
 Any mixture of soil below ground level.

2.2 Hard / Dense Soil

Generally any soil which requires the close application of picks or Jumpers or Scarifier and
rippers to loosen the same. Such as:
o Stiff heavy clay, hard shale or compact murrum requiring grafting tool and/ or pick and shovel.
o Shingle and river or nallah bed boulders.
o Soling or roads, paths, etc and hard core.
o Macadam surface of any description(water bound, grouted tarmac , etc)
o Lime concrete, stone masonry in lime or cement mortar below ground level.
o Soft conglomerate.

3.0 SOFT ROCK

This is fissured / disintegrated rocky strata, boulders (volume less than 0.4 Cu.m and more than
0.028 Cu.m) and also which cannot be quarried/ excavated by using above manual Tools but can be
quarried/excavated manually by using crow bars is classified as soft rock. Soft rock shall include
all kinds of stiff and stratified rock such as shales, laterite, hard conglomerate, lime stone, sand
stone, and unreinforced cement concrete below ground level. Soft rock may be quarried or split
with crow bar or picks and can also be excavated by rippers, dozers and other mechanical
equipment but without the aid of blasting.

4.0 EXCAVATION
This specification covers in general the scope of excavation for this tender only which is to be
carried out as per drawings and as directed by APEPDCL.

The excavation mainly has to be carried out in soft soil / top soil i.e. to the required line level and
as directed by APEPDCL.

The site will be handed over to contractor with Vegetation/ bushes/ shrubs/ trees etc. Contractor
shall visit the site to ascertain the nature of ground prior to bidding to accept all the responsibilities.
The removal of the above is included in the scope of excavation and no additional payment will be
made on this account.

APEPDCL shall hand over the Bench Marks at site only. The proceeding activities for setting out
of work like plotting grid points with Brick Pedestals on the land, fixing the center point for tanks
as per drawing with physical verification with existing structures/land marks for distances
measurement purpose, setting out the two permanent centre lines for each tank along with RL of
 main B.M. on brick pedestals etc to the satisfaction of APEPDCL after stripping / clearing the
ground complete in all respect. All the survey equipment like theodolite etc, skilled & qualified
surveying manpower, recording & maintaining the measurement book, tools & tackles etc
completely at contractor’s cost to the best satisfaction of APEPDCL.

The contractor shall provide at his own cost all the assistance which EIC may require for checking
the setting out of works. The contractor shall be solely responsible for the horizontal & vertical
alignment, correctness of level, and correctness of every part of work and shall rectify any errors or
imperfection therein on instruction of APEPDCL.

Prior to commencing the excavation, requisite block ground levels of entire plot grid co-ordinate
wise shall be taken by contractor at 5 meter intervals in consultation & presence of APEPDCL. The
proper duly signed record for the same shall be maintained.

Excavation shall be carried out once setting out of work by Contractor is approved by APEPDCL.
Contractor shall excavate the soil as per approved drawings which enumerate the levels to be
achieved. The carting away and leveling of excavated earth shall be carried out as per
specifications and as directed by APEPDCL within the premises. To minimize / avoid side
sloughing and collapse sufficient side slope has to be maintained by Contractor. The excavation for
side slope to avoid sloughing and collapse will not be entertained for payment. Royalty payment, if
any to be made towards excavation shall be made by the Contractor as quoted rates are deemed to
include the same.

Soil strata received as above shall be rolled thoroughly by 10T roller till 95% standard proctor
maximum laboratory dry density is attained as directed by EIC. Thereupon at corresponding co-
ordinates at 5m interval, level shall be taken to ascertain the excavated height as instructed by EIC.

Contractor shall maintain adequate drainage facilities at site at all times during the execution of
work. Additional ditches, drains & such other temporary means to achieve this, over and above
what is shown in drawings, will be provided and maintained by Contractor at his own cost.
Adequate dewatering facilities like dewatering pumps, piping etc will also be provided by the
Contractor for this work and also for dewatering during excavation etc. at his own cost.

5.0 MATERIAL FOR EARTHWORK

Only material considered suitable by the Engineer-in-charge shall be Employed for the
construction and that considered unsuitable shall be Disposed off, as directed by Engineer-in-
charge, at his own cost and no claim for compensation will be entertained.
The Contractor shall give the samples of earth he proposed to use for filling along with the
following characteristics of the samples to Engineer- In-charge, prior to collection and use, for
approval. The tests for these characteristics shall be done in a laboratory/test house as approved by
Engineer-in-charge.
i. Mechanical Analysis or grain size distribution as per IS:2720 part iv
ii. Liquid Limit as per IS:2720 part v
iii. Plastic Limit as per IS:2720 part v
iv. Moisture Density relationship as per IS:2720 part vii

 The material (soil) used for filling shall be free from boulders, lumps, tree roots, rubbish or any
organic deleterious material.
 Material (soil) having plasticity index less than 20 shall be used for filling purposes.
 Soil having laboratory maximum dry density of less than 1.5 gm/cc shall not be used.
 Care shall be taken to see that unsuitable waste material is disposed off in such a manner that there
is no likelihood of its getting mixed with the material proposed to be used for filling. The work
shall be so planned and executed that the best available Material (soil) are reserved for the Top
portion of embankments.

6.0 CLEARING AND STRIPPING

 The areas including depressions, where filling or cutting is to be carried out shall be cleared and
stripped completely of bushes, roots, vegetation, plantation trees, shrubs, trees, organic and other
objectionable materials. All these shall be completely uprooted and virgin soil exposed not merely
scrapped at the surface. The roots of trees shall be removed to a minimum depth of 1 m below
existing ground level and holes, hollows filled up with selected approved available earth within all
leads and lifts and compacted to obtain 90% of laboratory dry density of soil and leveled as
directed by Engineer-in-charge. All soft patches must be worked out to remove soft soil and
selected approved earth must be filled back and the areas (areas coming under filling) compacted to
obtain 90% of maximum laboratory dry density of soil, as per IS: 2720 part vii. The depth of
stripping shall be generally 50 to 150 mm as decided by Engineer-in-charge.
·
· Material obtained from clearing shall be disposed off as directed by Engineer-in-charge and in line
with local bye laws/ statutory requirements.

· Payment
No separate payment shall be made for clearing, stripping and disposal of materials obtained from
clearing .This shall be considered as part of cutting work in areas of cutting and filling work in
areas of filling and the rates quoted under the respective items of:

Earthwork in Excavation/cutting.

Earthwork in filling (Both with available earth & earth obtained from approved borrow areas), shall
be inclusive of clearing and stripping with all operations described above in clause no.5 in
respective areas of cutting and filling.

No separate payment shall be made for cleaning; stripping and disposal of materials obtained from
clearing of borrow areas for earth as directed by Engineer-in-charge. This shall be considered a part
of filling work in area of filling and the rate quoted under the respective items.

7.0 EARTHWORK IN EXCAVATION / CUTTING

After clearing, stripping of areas as specified above, spot levels at intervals and pattern as decided
by Engineer in charge shall be taken jointly with the Contractor and Engineer in charge, and
Excavation / cutting shall commence only after the levels are signed by the contractor as token of
acceptance.

Excavation/ cutting for this work shall be carried out strictly as per the instructions of Engineer in
charge.
If the contractor excavates / cuts beyond the required level, additional quantity of earthwork shall
not be paid for .The excavation taken below the specified level shall be made good by filling with
approved material to the required compaction at contractor’s cost.

The final bed and sides of excavation must be leveled, dressed and compacted. In case of areas
under excavation for Site Grading, the final surface shall be leveled, dressed and consolidated by
means of sheep foot/ power driven rollers to obtain maximum compaction. However, no test
control is required in such areas.

Provision for dewatering shall be governed by relevant clauses.

Payment
Payment for excavation shall be on the basis of volume of excavation Calculated on the basis of
joint level taken for initial and the final finished grade levels, the volume being calculated by the
trapezoidal rule.

8.0 EARTH WORK IN FILLING

· After clearing, stripping and consolidation of areas as specified in clause 6, spot levels at intervals
and pattern as decided by Engineer-in-charge shall be taken jointly with the Contractor and
 Engineer-in-charge and filling shall commence only after the levels are signed by the Contractor as
the token of his acceptance .Approved fill material shall be spread in uniform layers not exceeding
30 cm. in loose depth. The contractor has to make his own approach and access roads from the
borrow area to the demarcated filling areas. While the contractor may make use of such short cuts
as may be available to him for earth movement from borrow areas to the filling areas, the Owner
does not guarantee any pass way or the right of way for the Contractor work other than available at
site. No claim shall also be admissible to the Contractor on the account of his having taken longer
leads or routes for earth movement, than envisaged by him, either due to any road cuttings, non-
availability of routes, or any other grounds whatsoever.

In case of total filling required in any area consists of earth both from borrow areas and available
approved excavated material from within plant area, then joint levels, shall be taken before
commencing filling with earth from borrow area.

However earth from borrow areas required for filling can be used only after the available earth
from within demarcated area has been utilized and clearance to this effect obtained from Engineer-
in-charge.

All clods, lumps etc, shall be broken before compaction.

Successive layers of filling shall not be placed until the layer below has been thoroughly
compacted to satisfy the requirements laid down in the specification.
Prior to rolling, the moisture content of material shall be brought to within plus /minus 2% of the
optimum moisture content as described in IS: 2720 part vii. The moisture content shall preferably
be on the west side for potentially expansive soil.

· After adjusting the moisture content as described, the layers shall be thoroughly compacted by
either sheep foot roller or power driven roller or vibratory roller as approved by Engineer-in-charge
till the specified maximum laboratory dry density is obtained.

· Each layer shall be tested in field for density and accepted by Engineer-in-charge subject to
achieving the required density before laying the next layer. A minimum of one test per 500m2 for
each layer shall be conducted.

· If the layer fails to meet the required density, it shall be reworked or the material shall be replaced
and method of construction altered as directed by Engineer-in-charge to obtain the required
density.

· The filling shall be finished in conformity with the alignment, levels, cross section and dimensions
as shown in the drawing. Earthen embankment shall be filled 300mm on both sides, where height is
more than 1m, and this extra filling shall be dressed, after compaction, in conformity with
alignment, level, cross section and dimensions as shown in drawing to achieve proper compaction
in the slope. No extra payment shall be made in this regards.

· All the royalty payments etc. as deemed admissible to statutory / govt. authorities will be paid by
contractor for all the earth brought for APEPDCL works. It shall be the responsibility for the
contractor to produce all such payments, documents to Engineer-in-Charge during submission of
running bill. At the end of work no objection certificate from relevant authorities will be submitted
to ensure that APEPDCL is kept free from all encumbrances

Extra material shall be removed and disposed off as directed by Engineer-in-charge.

Tolerances
General site grading including cutting and filling in depressions shall be carried out to within up
down tolerance of+/- 5 cm. of final lines grades and slopes.

· Payment
 Payment for filling shall be made on cubic meter of volume calculated on the basis of cross-section
plotted from the levels of ground, where filling is to be carried out and the levels reached after
filling is duly consolidated, volume being calculated by trapezoidal method.

Partial bill will be processed only after submission of duly certified copy of proof of payment
towards royalty.

Final bill will be processed only after submission of “No objection certificate” from relevant
statutory authorities towards payment of royalty.

No extra payment shall be made towards testing charges.

9.0 SPECIFICATION FOR MURRUM FILLING

 This covers the specification for external borrowed earth material i.e. MURRUM for land filling
purposes.
 Only Material considered suitable by APEPDCL shall be employed for the construction and that
consider unsuitable shall be disposed of, as directed by Engineer-in-Charge, at contractors cost and
no claim for compensation will be entertain
 The contractor shall give 4 to 5 samples minimum to cover the best material available in around the
vicinity to Engineer-in-Charge / APEPDCL prior to collection and use for approval The test for
following characteristic for all the samples shall be done in a laboratory / test house as guided by
Engineer-in-Charge:
i) Mechanical analysis is grain size distribution as per IS: 2720 part IV.
ii) Liquid limit as per IS:2720 part V
iii) Plastic limit as per IS: 2720 part V
iv) Moisture density relationship as per IS: 2720 part VII
 The murrum used for filling shall be free from boulders, lumps, tree roots, rubbish or any organic
deleterious materials.
 Murrum approved by APEPDCL shall only be used for filling purpose. Non plastic material will
not be permitted
 Murrum having standard proctor laboratory maximum dry density of less than 1.8 gm/cc shall not
be used. The murrum shall have a Plasticity Index of 7-17(medium Plastic) and not more than
20%Fines, i.e., Clay. Particle size grading shall be 20mm and down size.
 Care shall be taken to see that waste material from murrum is disposed of in such a manner that
there is no likely hood of its getting mixed with the material proposed to be used for filling.
 The contractor has to make own approach and access roads in the borrow areas (Outside Plant
Premises) and to the demarcated filling area (Inside Plant Premises).
 All the royalty payments etc. as deemed admissible to statutory / govt. authorities will be paid by
contractor for all the murrum brought for APEPDCL works. It shall be the responsibility for the
contractor to produce all such payments, documents to Engineer-in-Charge during submission of
running bill. At the end of work no objection certificate from relevant authorities will be submitted
to ensure that APEPDCL is kept free from all encumbrances.
 Approved murrum material shall be spread in uniform layers not exceeding 20 cm in loose
thickness and watered as per OMC.
 After checking the moisture through moisture tester by calcium carbide method in field for OMC,
the layers shall be thoroughly compacted by vibratory roller as approved by Engineer-in-Charge till
95% of Standard proctor maximum laboratory dry density is achieved. Each layer shall be tested in
field for density and accepted by APEPDCL subject to 95% of Standard proctor maximum
laboratory dry density being achieved. A minimum of 1 test per 500 sq.mtr. of compacted area in
field shall be conducted for dry density. Required equipments like Moisture Tester, Oven,
Electronic weighing machine, proctor apparatus shall be supplied by Contractor.
 Successive layers of filling and watering will not be permitted until the layer below has been
compacted thoroughly to satisfy the requirements of the specifications. If the layer fails to meet the
required density, it shall be reworked till the required density is achieved.
 The filling shall be finished in conformity with alignment levels, cross section and dimension as
shown in the drawing. Earthen embankment shall be filled suitably on both sides to achieve the
required compaction and this extra filling shall be dressed after compaction, in conformity with
alignment, levels, cross section and dimensions as shown in the drawing. No extra payment shall
be made in this regard.
 The excavated soil and / or unusable debris from excavation shall be loaded, transported safely and
unloaded at designated spots as specified/ as per local bye laws. In case of disposal within the
premises, the soil/debris after unloading shall be leveled and dozed keeping a distance of at least
5m from the Compound wall to give a uniform appearance. No extra payment shall be made in this
regard.

Payment

Payment for filling shall be made on cubic meter of volume calculated on the basis of cross-section
plotted from the levels of ground, where filling is to be carried out and the levels reached after
filling is duly consolidated, volume being calculated by trapezoidal method.

Partial bill will be processed only after submission of duly certified copy of proof of payment
towards royalty.

Final bill will be processed only after submission of “No objection certificate” from relevant
statutory authorities towards payment of royalty.

No extra payment shall be made towards testing charges.

 CHAPTER–II: CONSTRUCTION OF BITUMINOUS ROADS

1.0 TACK COAT

1.1 SCOPE
This work shall consist of application of a single coat of low viscosity liquid bituminous material to
an existing road surface preparatory to another bituminous construction over it.
1.2 Materials:
The binder used for tack coat shall be bitumen conforming to IS: 73-2006 VG30 GRADE
(erstwhile 60/70 as per IS: 73-1992).
2.0 CONSTRUCTION OPERATION :
2.1 Preparation of base: The surface on which the tack coat is to be applied shall be cleaned of dust
and any extraneous material before the application of the binder, by using a mechanical broom or
any other approved equipment/method as specified by the Engineer.
2.2 Application of binder: Binder shall be heated to the temperature appropriate to the grade of
bitumen used and approved by the Engineer and sprayed on the base at the rate specified in Table
below. The rate of spread is in terms of straight bitumen.

Table: Rate of application of tack coat:

Type of Surface Bitumen quantity in
Kg per 10 sq. mtrs. area
i) Normal bituminous surfaces 5 to 5.5
ii) Dry and hungry bituminous surfaces 6.0 to 7.5
iii) Granular surfaces treated with primer 6.0 to 7.5
iv) Non bituminous surfaces
a) Granular base (not primed) 10.0
b) Cement concrete prevalent 7.5

Note: There is no need to apply a tack coat on a freshly laid bituminous course if the subsequent
bituminous course is overlaid immediately without opening it the traffic.
The binder shall be applied alternately with the aid of either self propelled or towed bitumen
pressure sprayer with self heating arrangement and spraying nozzle arrangement capable of
spraying bitumen at specified rates and temperature so as to provide a uniformly unbroken spread
of bitumen. The tack coat shall be applied just ahead of the oncoming bituminous construction.

2.3 Quality Control of Work:

Control on the quality of materials and works shall be exercised by the Engineer in accordance
requirements mentioned in the specifications.

3.0 BITUMINOUS MACADAM ROADS

3.1 Scope: The work shall consist of construction in a single course, of 50 mm/75mm thickness of
compacted crushed aggregates premixed with a bituminous binder, to serve as base/binder course,
laid immediately after mixing, on a base prepared previously in accordance with the requirement
of these specifications and in conformity with the line, grades and cross sections as directly by the
Engineer.
3.2 Materials
3.2.1 Bitumen: The bitumen shall be paving bitumen of suitable penetration grade of VG30 as per IS:
73-2006 ((erstwhile 60/70 as per IS: 73-1992).
3.2.2 Aggregates:
The aggregates shall consist of crushed granite/basalt stone or other stones as approved by EIC.
They shall be clean, strong, durable of fairly cubical shape and free from disintegrated pieces,
organics or other deleterious matters and adherent coating. The aggregates shall preferably be
hydrophobic and of low porosity. If hydrophilic aggregates are to be used the bitumen shall
preferably be treated with anti stripping agents of approved quality in suitable doses. The
aggregates shall satisfy the physical requirements set forth in Table below.

Table: PHYSICAL REQUIREMENTS OR AGREEGATES FOR BITUMINOUS

MACADAM
Sr. Test Test Method Requirements
No.
1 Los Angeles Abrasion value IS: 2386 (Part IV) 40% Maximum
2 Aggregate Impact Value IS: 2386 (Part IV) 30% Maximum
3 Flakiness Index IS: 2386 (Part Ii) 35% Maximum
4 Stripping Value IS: 6241 25% Maximum
5 Soundness :
i)Loss with Sodium Sulphate 12%
5 cycles

ii)Loss with Magnesium Sulphate 5 18%

cycles
6 Water absorption IS:2386(Part III) 2% Maximum

The aggregate for bituminous macadam for different thicknesses shall conform to the Grading
given in tables below.

TABLE: Aggregate Grading for 50mm compacted thickness of bituminous macadam

Sieve Designation (IS) Percent by
weight passing
the aecia
26.5 mm 100
22.4 mm 75-100
11.2 mm 50-85
 5.6 mm 20-40
2.8 mm 5-20
90 mm 0-5

TABLE: Aggregate Grading for 75mm compacted thickness of bituminous macadam

Sieve Designation (IS) Percent by weight
passing the aecia
45 mm 100
26.5 mm 75-100
22.4 mm 60-95
11.2 mm 30-55
5.6 mm 15-35
2.8 mm 5-20
90 um 0-5

3.1 Proportioning of materials :

The bitumen content for premixing shall be 4percent by weight of the total mix except when
otherwise directed by the Engineer.
The quantities of aggregates to be used shall be sufficient to yield the specified thickness after
compaction.
3.2 Variation in proportioning on material :
The contractor shall have the responsibility for ensuring proper proportioning of materials and
producing a uniform mix. A variation in binder content +0.3 percent by weight of total mix shall,
however, be permissible for individual specimens taken for quality control tests.
3.3 Construction Operation
3.5.1 Weather and seasonal limitations: The work of laying shall not be taken up during rainy or foggy
weather or when the base course is damp or wet, or during dust storm or when the atmospheric
temperature in shade is 150c or less.
3.5.2 Preparation of the base : The base on which bituminous macadam is to be laid shall be prepared,
shaped and conditioned to the specified lines, grades and cross sections , and a priming coat where
needed shall be applied as directed by the Engineer.
3.5.3 Tack coat: A tack coat as described above shall be applied over the base.
3.5.4 Preparation and transport of mix: Bituminous macadam mix shall be prepared in a hot mix plant
of adequate capacity and capable to yield a mix of proper and uniform quality with thoroughly
coated aggregates. The plant may be either a weigh batch or volumetric proportioning continuous
or drum mix type. The plant shall have coordinated set of essential units capable of producing
uniform mix within the job mix formula such as :
a) Cold aggregate feed system for providing blended aggregate in the correct proportion (called cold
bin feed arrangement).
b) Rotating cylindrical driver drum fitted with suitable burner capable of heating the aggregate to the
required temperature without any visible un burnt fuel of carbon residue on the aggregate and to
reduce the moisture content of the aggregate to the specified minimum level.
c) The dryer units shall be fitted with approved set of thermometric instruments at appropriate places
so as to indicate or automatically record/register the temperature of heated aggregate before
adding/mixing the binder.
d) Gradation control: Except in case of drum for plant, other two types of plants mentioned aboard
shall have.
e) A screening unit for accurate sizing of hot aggregate ad feeding the same to mixing unit by weight
or volume control as per the specified job mix formula.
f) Paddle Mixer unit shall be capable of producing a homogeneous mix with uniform coating of all
particles of the material aggregate with binder.
g) In case of Drum Mix Plant, the cold feed system shall have variable speed belt conveyors/or other
suitable devices for regulating the accurate proportioning of aggregate into an even feed flow
automatically from a central operating/control cabin.
h) Bitumen control unit: Capable of measuring/metering and spraying required quantity of bitumen at
specified temperature with automatic synchronization of bitumen and aggregate feed.
i) Filler system: A time feeder system suitable to receive bagged or bulk supply of filler material and
its incorporation to the mix in the correct quantity shall be a necessary auxiliary.
j) Dust control: A suitable built in dust control equipments for the dryer to contain the exhaust of fine
dust into atmosphere for environmental control, wherever so specified by the Engineer.
k) Suitable Auxiliary Bitumen Boiler of adequate capacity with self heating arrangement and
temperature control device. The boiling should be fitted with temperature indicating instruments.
The temperature of binder at the time of mixing shall be in the range of 1500 to 1650 C and that of
the aggregate in the range of 1250 to 1500 C, Provided that the difference in temperature between
the binder and aggregate at no time exceeds 250 C.

Mixing shall be thorough to ensure that a homogenous mixture is obtained in which all particles of
the aggregates are coated uniformly and the discharge temperature of mix shall be between 1300 to
1600.
The mixture shall be transported from the mixing plant to the point of use in suitable tipper
vehicles. The vehicle employed for transport shall be clean and be covered over in transit if so
directed by the Engineer.

3.5.5 Spreading: The mix transferred from the tipper to the paver shall bedspread immediately by means
of self propelled mechanical paver with suitable screeds can pebble of spreading, tamping and
finishing the mix true to the specified lines, grades and cross section. The paver finisher shall have
the following essential features :
a) Loading hoppers and suitable distributing mechanism.
b) All drives having hydrostatic drive/control.
c) The machine shall have a hydraulically extendable screed for appropriate width requirement.
d) The screed shall have tamping and vibrating arrangement for initial compaction to the layer as it is
 spread without rutting or otherwise marring the surface. It shall have adjustable amplitude and
infinitely variable frequency.
e) The paver shall be equipped with necessary control mechanism so as to ensure that the finished
surface is free from surface blemishes.
f) The payer shall be fitted with an electronic sensing device for automatic leveling and profile
control within the specified.
g) The screed shall have the internal heating arrangement.

However, in restricted locations and in narrow widths where the available plant cannot be operated
in the opinion of the Engineer, may permit manual laying of the mix.
The temperature of the mix at the time of laying shall be in the range of 120 to 135 deg Centigrade.
In multilayer construction the longitudinal joint in one layer shall offset that in the layer below by
about 150mm. However the joint at the top most joint shall be at the center line of the pavement.
Longitudinal joint and edges shall be constructed true to the delineating line parallel to the central
line of the road, all joints shall be cut vertical to the full thickness of the previously laid mix and
the surface painted with hot bitumen before placing fresh material.

3.5.6 Rolling: After spreading of the mix, rolling shall be done by 8 to 10 hour power rollers or other
approved equipment. Rolling should start as soon as possible after the material has been spread.
Rolling shall be done with care to keep from unduly roughening the pavement surface.
Rolling of the longitudinal joints shall be done immediately behind the paving operation. After this
the rolling shall commence at the edges and progress towards the centre longitudinally except that
on super elevated portions it shall progress from the lower to the upper edge parallel to the central
line of the pavement.

The initial or break down rolling shall be done, with 8 to 12 tonnethree-wheel steel roller, as soon
as it is possible to roll the mix without cracking the surface or having the mix pick up on the roller
wheels. The second or intermediate rolling shall follow the break down rolling as closely as
possible and be down while the paving mix is still at a temperature that will result in maximum
density. The final rolling shall be done while material is still workable enough for removal of roller
marks with 8 to 10 tonne tandem roller. All the compaction operations i.e. Breakdown rolling,
intermediate rolling and final rolling can be accomplished by using a vibratory roller of 8 to 10
forms static weight. During the initial or break down rolling and final rolling, vibratory system
shall be switched off. The joints and edges shall be rolled with 8 to 10 tonne static roller.

When the roller has passed over the whole area one any high spots it depressions which become
apparent shall be corrected by removing or adding mix material. The rolling shall then be
continued till the entire surface has been rolled to compaction, there is no crushing of aggregates
and all rolled makes have been eliminated. Each pass of the roller shall uniformly overlap not less
 than one–third of the track made in the proceeding pass. The roller wheel shall be kept damp if
necessary to avoid bituminous material from sticking to the wheels and being picked up. In a case,
fuel lubricating oil be used for the purpose nor did excessive water pour on the wheels.

Rolling operations shall be completed in every respect before the temperature of the mix falls
below 800.

Roller (s) shall not stand on newly laid material while there is a risk that it will be deformed
thereby. The edges along and transverse of the bituminous macadam laid and compacted earlier
shall be cut to their full depth so as to expose fresh surface which shall be painted with a thin
surface coat of appropriate binder before the new mix is placed against it.

3.5.7 Surface Finish and Quality Control of Work:

The surface finish of construction shall conform to the requirements of specifications of this tender.
Control on the quality of materials and works shall be exercised by the Engineer.
The bituminous macadam shall be covered with either the next pavement course or wearing course,
as the case may be without any delay, if there is to be any delay, the course shall be covered by a
seal coat as per the technical specifications mentioned in the tender before allowing any traffic over
it.

The quoted rate for the work shall be for carrying out all the required operations including:
a) Making arrangement for traffic except for initial treatment to verge shoulders and construction of
diversions.
b) Preparation of base except for laying of profile corrective course but including filling of pot holes.
c) Providing all materials to be incorporated in the work including all royalties, fees, rents where
necessary and all leads and lifts.
d) All labour, tools, equipments, plants and incidental to complete the work to the specification and
all leads and lifts.
e) Carrying out the work in part widths if necessary or wherever directed.
f) Rolling operations shall be completed in every respect.

4.0 SEAL COAT

4.1 Scope

This work shall consist of application of seal coat for sealing the voids in a bituminous surface laid
to the specified levels, grade and cross fall (camber).
Seal Coat shall be as specified below:
Premixed seal coat comprising of a thin application of fine aggregate premixed with bituminous
binder.
4.2 Materials
4.2.1 Binder: As per Clause 3.2.1. Shall apply.
The quantity of binder to be utilized, in terms of straight run bitumen shall be 6.8 Kg. per 10
Square Meter Area for seal coat.
4.2.2 Aggregate for Seal Coat
The aggregate shall be grit and shall consist of clean, hard, durable, uncoated dry particles and shall
be free from dust, soft or flaky materials, organic matter or other deleterious substances. The
aggregate shall pass 2.36 mm sieve and be retained on 180 mm sieve. The quantity used for
premixing shall be 0.06 cubic meter per 10 square meter area.
4.3 Construction Operations
4.3.1 Preparation of Base
The Seal Coat shall be applied immediately after the laying of bituminous course which is required
to be sealed. Before application of seal coat materials, the surface shall be cleaned free of any dust
or other extraneous matters.
4.3.2 Construction of Seal Coat
The Engineers of approved type shall be employed for mixing the aggregates with the bituminous
binder. The binder shall be heated in boilers of suitable design, to the temperature appropriate to
the grade of bitumen approved by the Engineer, Also the aggregates shall be dry and suitably
heated to a temperature directed by the Engineer before the same are placed in the mixer. Mixing
of binder with aggregates to the specified proportions shall be continued till the latter are
thoroughly coated with the former.
The mix shall be immediately transported from the mixing plant to the point of use and spread
uniformly on the bituminous surface to be sealed.
As soon as sufficient length has been covered with the pre-mixed material, the surface shall be
rolled with 6-9 tonne smooth wheeled power rollers. Rolling shall be continued till the pre-mixed
material completely seals the voids in the bituminous course and a smooth uniform surface are
obtained.

4.3.3 Surface Finish and Quality Control of Work

The surface finish of construction shall conform to the requirements of specifications of this tender.
Control on the quality of materials and works shall be exercised by the Engineer
 CHAPTER–III: QUALITY CONTROL IN ROAD WORKS

1.0 GENERAL

1.1. All materials to be used, all methods adopted and all works performed shall be strictly in
accordance with the requirements of these Specifications. The Contractor shall set up a field
laboratory at locations approved by the Engineer and equip the same with adequate equipment
and personnel in order to carry out all required tests and Quality Control work as per
Specifications and/or as directed by the Engineer. The list of equipment and the facilities to be
provided shall be got approved from the Engineer in advance.
1.2. The Contractor’s laboratory should be manned by a qualified Materials Engineer/Civil Engineer
assisted by experienced technicians, and the set-up should be got approved by the Engineer.
1.3. The Contractor shall carry out quality control tests or the materials and work to the frequency
stipulated in subsequent paragraphs. In the absence of clear indications about method and or
frequency of tests for any item, the instructions of the Engineer shall be followed.
1.4. For satisfying himself about the quality of the materials and work, quality control tests will also
be conducted by the Engineer (by himself, by his Quality Control Units or by any other agencies
deemed fit by him), generally to the frequency set forth herein under. Additional tests may also
be conducted where, in the opinion of the Engineer, need for such test exists.
1.5. The Contractor shall provide necessary co-operation and assistance in obtaining the samples for
tests and carrying out the field tests as required by the Engineer from time to time. This may
include provision of labour, attendants, assistance in packing and dispatching and any other
assistance considered necessary in connection with the tests.
1.6. For the work of embankment, sub grade and pavement, construction of subsequent layer of same or
other material over the finished layer shall be done after obtaining permission from the Engineer.
Similar permission from the Engineer shall be obtained in respect of all other items of works prior
to proceeding with the next stage of construction.
1.7. The Contractor shall carry out modifications in the procedure of work, if found necessary, as
directed by the Engineer during inspection. Works falling short of quality shall be rectified /redone
by the Contractor at his own cost, and defective work shall also be removed from the site of works
by the Contractor at his own cost.
1.8. The cost of laboratory including services, essential supplies like water, electricity, sanitary services
and their maintenance and cost of all equipment, tools, materials, labour and incidentals to perform
tests and other operations of quality control according to the Specification requirements shall be
deemed to be incidental to the work and no extra payment shall be made for the same.
Alternatively, the contractor may choose to test all the required tests to be done on the samples,
during construction and as required by EIC in an Engg. College/ University/ Consultancy firm/
reputed laboratory. The above shall be approved by EIC and all the charges shall be borne by the
contractor and shall be deemed to be incidental to the work and no extra payment shall be made for
 the same.
1.9. For testing of samples of soils/soil mixes, granular materials, and mixes, bituminous materials and
mixes, aggregates, cores etc., samples in the required quantity and form shall be supplied to the
Engineer by the Contractor at his own cost.
1.10. For cement, bitumen, mild steel, and similar other materials where essential tests are to be carried
out at the manufacturer’s plants or at laboratories other than the site laboratory, the cost of samples,
sampling, testing and furnishing of test certificates shall be borne by the Contractor. He shall also
furnish the test certificates to the Engineer.
1.11. For testing of cement concrete at site during construction, arrangements for supply of samples,
sampling, testing and supply of test results shall be made by the Contractor as per the frequency
and number of tests specified in the Handbook of Quality Control for Construction of Roads and
Runways (IRO: SP: l1) and relevant IS Codes or relevant clauses of these Specifications, the cost
of which shall be borne by the Contractor.
1.12. The method of sampling and testing of materials shall be as required by the "Handbook of Quality
Control for Construction of Roads and Runways" (IRC: SP: 11), and these MOST Specifications.
Where they are contradicting, the provision in these Specifications shall be followed. Where they
are silent, sound engineering practices shall be adopted. The sampling and testing procedure to be
used shall be as approved by the Engineer and his decision shall be final and binding on the
Contractor.
1.13. The materials for embankment construction shall be got approved from the Engineer. The
responsibility for arranging and obtaining the land for borrowing or exploitation in any other way
shall rest with the Contractor who shall ensure smooth and uninterrupted supply of materials in the
required quantity during the construction period.
1.14. Similarly, the supply of aggregates for construction of road pavement shall be from quarries
approved by the Engineer. Responsibility for arranging uninterrupted supply of materials from the
source shall be that of the Contractor.
1.15. Defective Materials
All materials which the Engineer/his representative have determined as not conforming to the
requirements of the Contract shall be rejected whether in place or not; they shall be removed
immediately from the site as directed. Materials, which have been subsequently corrected, shall not
be used in the work unless approval is accorded in writing by the Engineer. Upon failure of the
Contractor to comply with any order of the Engineer/his----representative, given under this Clause,
he Engineer/his representative shall have authority to cause the removal of rejected material and to
deduct the removal cost thereof from any payments due to the Contractor.
1.16 Imported Materials
At the time of submission of tenders, the Contractor shall furnish a list of materials/finished
products manufactured, produced or fabricated outside India which he proposes to use in the work.
The Contractor shall not be entitled to extension of time for acts or events occurring outside India
 and it shall be the Contractor’s responsibility to make timely delivery to the job site of all such
materials obtained from outside India
The materials imported from outside shall conform to the relevant Specifications of the tender. In
case where materials/ finished products are not covered by the Specifications in the Contract, the
details of Specifications proposed to be followed and the testing procedure as well as laboratories/
establishments where tests are to be carried out shall be specifically brought out and agreed to in
the Contract.
The Contractor shall furnish to the Engineer a certificate of compliance of the tests carried out. In
addition, certified mill test reports clearly identified to the lot of materials shall be furnished at the
Contractor’s cost.
2.0 CONTROL OF ALIGNMENT, LEVEL AND SURFACE REGULARITY

2.1 General

All works performed shall conform to the lines, grades, cross sections and dimensions shown on
the drawings or as directed by the Engineer, subject to the permitted tolerances described herein-
after.
2.2 Horizontal Alignment
Horizontal alignments shall be reckoned with respect to the centre line of the carriageway as the
edges of the carriageway as constructed shall be correct within a tolerance of 10 mm there from.
The corresponding tolerance for edges of the roadway and lower layers of pavement shall be 20
mm.
2.3 Surface Levels
The levels of the sub grade and different pavement courses as constructed, shall not vary from
those calculated with reference to the longitudinal and cross-profile of the road as directed by the
Engineer beyond the tolerances mentioned in Table -1.

TABLE -1 TOLERANCES IN SURFACE LEVELS

1 Sub grade + 10 mm/- 15 mm

2 Sub – base + 10 mm

(a) Flexible Pavement - 15 mm

3. Base – Course for Flexible + 6 mm/- 6 mm
Pavement
a) Bituminous Course
b) Other than bituminous +10 mm
(ii) Machine laid -10 mm
(iii) Manually laid +15 mm & -15 mm
4 Wearing Course for Flexible Pavement
(a) Machine laid +6mm /-6 mm
(b) Manually laid +10 mm/-10 mm
 Provided, however, that the negative tolerance for wearing course shill not be permitted in
conjunction with the positive tolerance for base course, if the thickness of the formers thereby
reduced by more than 6mm for flexible pavements and 5 mm for concrete pavements.

For checking compliance with the above requirement for sub grade, sub-base and base courses,
measurements of the surface levels shall be taken on a grid of points placed at 6.25 in
longitudinally and 3.5 in transversely. For any 10 consecutive measurements taken longitudinally
or transversely, not more than one measurement shall be permitted to exceed the tolerance as
above, this one measurement being - not in excess of 5 mm above the permitted tolerance.
For checking the compliance with the above requirement for bituminous wearing courses and
concrete pavements, measurements of the surface levels shall be taken on a grid of points spaced at
6.25 m along the length and at 0.5 in from the edges and at the centre of the pavement. In any
length of pavement, compliance shall be deemed to be met for the final road surface, only if the
tolerance given above is satisfied for any point on the surface.

2.4 Surface Regularity of Pavement Courses

The longitudinal profile shall be checked with a 3 meter long straight edge/moving straight-edge as
desired by the Engineer at the middle of each traffic lane along a line parallel to the centre line of
the road.
The maximum permitted number of surface irregularities shall be as per Table -2.

TABLE -2 MAXIMUM PERMITTED NUMBER OF SURFACE IRREGULARITIES

Surfaces of Surfaces of lay-byes, service

carriageways areas and all bituminous base
and paved courses
shoulders
Irregularity 4mm 7mm 4mm 7mm
Length(m) 300 75 300 75 300 75 300 75
National Highways/

Expressways 20 9 2 1 40 18 4 2
Roads of lower
Category 40 18 4 2 60 27 6 13

The maximum allowable difference between the road surface and underside of a 3 meter long
straight-edge when placed parallel with, or at right angles to the centre line of the road at points
decided by the Engineer shall be:
for pavement surface (bituminous and cement concrete) 3 mm
for bituminous base courses 6 mm
for granular sub-base/ base courses 8 mm
 for sub-bases under concrete pavements 10 mm

2.5 Rectification
Where the surface regularity of sub-grade and the various pavement courses fall outside the
specified tolerances, the Contractor shall be liable to rectify these in the manner described below
and to the satisfaction of the Engineer.
(i) Sub grade: Where the surface is high, it shall be trimmed and suitably compacted. Where the same
is low, the deficiency shall be corrected by scarifying the lower layer and adding fresh material and
re-compacting to the required density. The degree of compaction and the type of material to he
used shall conform to the requirements.
(ii) Granular Sub-base: Same as at (i) above, except that the degree of compaction and the type of
material to be used shall conform to the requirements.
(iii) Water Bound Macadam/Wet Mix Macadam Sub-base/Base :Where the surface is high or low,
the top 75 mm shall be scarified, reshaped with added material as necessary and re-compacted to
the requirements. This shall also apply to wet mix macadam.
(iv) Bituminous Constructions: For bituminous construction other than wearing course, where the
surface is low, the deficiency shall be corrected by adding fresh material over a suitable tack coat if
needed and re-compacting to specifications. Where the surface is high, the full depth of the layer
shall be removed and replaced with fresh material and compacted to specifications.
For wearing course, where the surface is high or low, the full depth of the layer shall be removed
and replaced with fresh material and compacted to specifications. In all cases where the removal
and replacement of a bituminous layer is involved, the area treated shall not be less than 5 m in
length and not less than 3.5 m in width.

3.0 QUALITY CONTROL TESTS DURING CONSTRUCTION

3.1 General
The materials supplied and the works carried out by the Contractor shall conform to the
specifications prescribed in the preceding Clauses.
For ensuring the requisite quality of construction, the materials and works shall be subjected to
quality control tests, as described hereinafter. The testing frequencies set forth are the desirable
minimum and the Engineer shall have the full authority to carry out additional tests as frequently as
he may deem necessary, to satisfy himself that the materials and works comply with the
appropriate specifications. However, the number of tests recommended in Tables -3 and Table-4
may be reduced at the discretion of the Engineer if it is felt that consistency in the quality of
materials can still be maintained with the reduced number of tests.
Test procedures for the various quality control tests are indicated in the respective Sections of these
Specifications or for certain tests within this Section. Where no specific testing procedure is
mentioned, the tests shall be carried out as per the prevalent accepted engineering practice to the
directions of the Engineer.
3.2. Tests on Earthwork for Embankment, Sub grade Construction and Cut Formation
Borrow material: Grid the borrow area at 25 m c/c (or closer, if the variability is high) to full
depth of proposed working. These pits should be logged and plotted lot proper identification of
suitable sources of material. The following tests on representative samples shall be carried out:
(a) Sand Content [IS: 2720 (Partt4)]: 2 tests per 3000 cubic metres of soil.
(b) Plasticity Test [IS: 2720 (Part-5)]: Each type to be tested, 2 tests per 30(X) cub. metres of soil.
(c) Density Test [IS: 2720 (Par: 8)]: Each soil type to be tested, 2 tests per 3000 cubic metres of soil.
(d) Deleterious Content Test [IS: 2720 (Part-27)]: As and when required by the Engineer.
(e) Moisture Content Test (IS: 2720 (Part-2)1: One test for every 250 cubic metres of soil.
(f) CBR Test on materials to be incorporated in the sub-grade on soaked / un-soaked samples [IS:
2720 (Part-I6)]: One CBR test for every 3000 cu. m. at least or closer as and when required by the
Engineer.
Compaction Control: Control shall be exercised on each layer by taking at least one measurement
of density for each 1000 square metres of compacted area, or closer as required to yield the
minimum number of test results for evaluating a day’s work on statistical basis. The determination
of density shall be in accordance with IS: 2720 (Part 23). Test locations shall be chosen only
through random sampling techniques. Control shall not be based on the result of any one test but on
the mean value of a set of 5-10 density determinations. The number of tests in one set of
measurements shall be 6 (if non-destructive tests are carried out, the number of tests shall be
doubled) as long as it is felt that sufficient control over borrow material and the method of
compaction is being exercised. If considerable variations are observed between individual density
results, the minimum number of tests in one set of measurement shall be increased to 10. The
acceptance criteria shall be. subject to the condition that the mean density is not less than the
specified density plus: 1.65 -1.65times the standard deviation-(No. of samples)*0.5.
However, for earthwork in shoulders (earthen) and in the sub-grade, at least one density
measurement shall be taken for every 500 square metres for the compacted area provided further
that the number of tests in each set of measurements shall be at least 10. In other respects, the
control shall be similar to that described earlier.
Cut formation: Tests for the density requirements of cut formation shall be carried out in
accordance with Clause 3.2.2.
3.3. Tests on Sub-bases and Bases (excluding bitumen bound bases)
The tests and their frequencies for the different types of bases and sub-bases shall be as given in
Table -3. The evaluation of density results and acceptance criteria for compaction control shall be
on lines similar to those set out in Clause 3.2.2.
Acceptance criteria : The acceptance criteria for tests on the strength of cement/lime stabilized
soil and distribution of stabilizer content shall be subject to the condition that the mean value is not
less than the specified value plus :1.65 -1.65times the standard deviation.-----------------------------
--(No. of samples) 0.5
 TABLE -3. CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR SUB-BASES AND
BASES (EXCLUDING BITUMEN (SOUND BASES)

SI. Type of Test Frequency (min.)

No. Construction
1 Granular (i) Gradation One test per 200 m3 One test per
(ii) Atterberg limits 200 m3 One test per 250m2
(iii) Moisture content One test per 500 m3
prior to compaction
As required As required
(iv) Density of
(v) compacted layer
Deleterious
(vi) Constituents
C.B.R.

One test per 200 m3 of aggregate

2 Water Bound (i) Aggregate Impact One test per 100 m3 One test per
Macadam Value, 200 m3 of
(ii) Grading
Aggregate
(iii) Flakiness Index One test per 25 m3 of binding
and Elongation Index material
(iv) Atterberg limits
of binding material One test per 100 cubic meter of
aggregate
(v) Atterberg limits of portion
of aggregate passing 425
micron sieve

3.4 Tests on Bituminous Constructions

3.1.1 The tests and their minimum frequencies for the different types of bituminous works shall be as
given in Table -4.
3.1.2 Acceptance Criteria: The acceptance criteria for tests on density and Marshall stability shall be
subject to the condition that the mean value is not less than the specified value plus:
1.65 -1.65times the standard deviation. Of No. of samples) 0.5
TABLE -4. CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR
BITUMINOUSWORKS

SI. Type of Test Frequency (min.)

No. Construction
Two samples per lot to be
1 Prime Coat / Tack subjected to all or some
tests as directed by the
(i) Quality of Binder Coat
Engineer
(ii) Binder temperature for
Application At regular close intervals.
(iii) Rate of spread of
Application Two tests per day
2 Seal Coat / Surface Two samples per lot
Dressing (i) Quality of Binder Dressing to be subjected
to all or some tests are
directed by the Engineer
(ii) Aggregate Impact Value One test per 50 m3 of
aggregate
(iii) Flakiness Index and - do –
Elongation Index
(iv) Stripping Value of Initially one set of 3
Aggregates representative specimens
for each source of supply.
Subsequently when
warranted by changes in
the quality of aggregates
(v) Water absorption of - do –
Aggregates
(vi) Grading of aggregates One test per 25 m3 of
aggregate
(vii) Stone polishing value As required
(viii) Temperature of binder at At regular close intervals
Application
(ix) Rate of spread of One test per 500 m3 of
3 Open – graded (i) Quality of Binder Two samples per lot to be
premix Carpet / Mix subjected to all or some
– Seal Surfacing tests are directed by the
Engineer
(ii) Aggregate Impact Value
One test per 50 m3 pf
(iii) Flakiness Index and aggregate
Elongation Index of - do –
(iv) Aggregates
Stripping Value of
Aggregates Same as mentioned
(v) Water absorption of under serial no. 2
Aggregates Same as mentioned
(vi) Grading of aggregates under serial no. 2
One test per 25 m3 of
(vii) Stone polishing value aggregate
(viii) Temperature of binder at As required
Application At regular close intervals
(ix) Binder Content Two tests per day
(x) Rate of spread of mixed Regular control through
Material checks on materials and
layer thickness
4 Bituminous (i) Quality of Binder Two samples per lot to be
Macadam subjected to all or some
tests are directed by the
Engineer
(ii) Aggregate Impact Value One test per 50 m3 of
Aggregate
(iii) Flakiness Index and - do –
Elongation Index of
(iv) Aggregates
Stripping Value of Same as mentioned
Aggregates under serial no. 2
(v) Grading of Aggregates Two tests per day per
plant both on the
individual constituents
and mixed aggregates
(vi) Water absorption of from the dryer
Aggregates Same as in Serial No. 2
(vii) Binder content Periodic, Subject to
minimum of two tests per
day per plant

(viii) Control of temperature of At regular close intervals

binder and aggregate for
mixing and of the mix at
the time of laying and
Rolling Regular control through
Rate of spread of mater. checks of layer thickness
20.SPECIAL SPECIFICATIONS FOR CIVIL WORKS FOR
SWITCHGEAR
1.0 GENERAL

1.1 The intent of specification covers the following:

1.1.1 Design, engineering, and construction requirements of all civil works in the substation; All civil
works shall also satisfy the general technical requirements specified in other Section of this
Specification and as detailed below. They shall be designed to the required service conditions/loads
as specified elsewhere in this Specification or implied as per National/International Standards.

1.1.2 All civil works shall be carried out as per applicable Indian Laws, Standards and Codes. All
materials shall be of best quality conforming to relevant Indian Standards and Codes.

1.1.3 The Contractor shall furnish all design, drawings, labour, tools, equipment, materials, temporary
works, constructional plant and machinery, fuel supply, transportation and all other incidental items
not shown or specified but as may be required for complete performance of the Works in
accordance with approved drawings, specifications and direction of Employer.

1.1.4 The work shall be carried out according to the design/drawings to be developed by the Contractor
and approved by the owner based on Tender Drawings Supplied to the Contractor by the Owner.
For all buildings, structures, foundations, etc., necessary layout and details shall be developed by
the Contractor keeping in view the functional requirement of the substation facilities and providing
enough space and access for operation, use and maintenance based on the input provided by the
Owner. Certain minimum requirements are indicated in this specification for guidance purposes
only. However, the Contractor shall quote according to the complete requirements.

2.0 GEO-TECHNICAL INVESTIGATION

The Contractor shall perform a detailed soil investigation to arrive at sufficiently accurate, general
as well as specific information about the soil profile and the necessary soil parameters of the Site in
order that the foundation of the various structures can be designed and constructed safely and
rationally.

A report to the effect will be submitted by the contractor for Owner's specific approval giving
details regarding data proposed to be utilized for civil structures design.

2.1 Scope of Work

This specification covers all the work required for detailed soil investigation and preparation of a
detailed report. The work shall include mobilization of necessary equipment, providing necessary
engineering supervision and technical personnel, skilled and unskilled labour, etc., as required to
carry out field investigation as well as, laboratory investigation, analysis and interpretation of data
and results, preparation of detailed Geo-Technical report including specific recommendations for
the type of foundations and the allowable safe bearing capacity for different sizes of foundations at
different founding strata for the various structures of the substation. The Contractor shall make his
own arrangement for locating the co-ordinates and various test positions in field as per the
information supplied to him and also for determining the reduced level of these locations with
respect to the benchmark indicated by the Owner.

All the work shall be carried out as per latest edition of the corresponding Indian Standard Codes.

2.2 Bore Holes

Drilling of bore holes of 150 mm dia. in accordance with the provisions of IS: 1982 or equivalent
 international specification at the rate of minimum two number of bore holes per bay to 15 m depth
or to refusal which ever occur earlier. (By refusal it shall mean that a standard penetration blow
count (N) of 100 is recorded for 30 cm penetration). However, in case deep pile foundations are
envisaged the depths have to be regulated as per code provisions. In cases where rock is
encountered, coring in one borehole per bay shall be carried out to 3 M in bedrock and continuous
core recovery is achieved.

Perform Standard Penetration Tests at approximately 1.5 m intervals in the bore hole, starting from
1.5 m below ground level onwards and at every change of stratum. The disturbed samples from the
standard penetrometer shall also be collected for necessary tests.

Collect undistributed samples of 100/75 mm diameter 450 mm long from the boreholes at intervals
of 2.5 m and every change of stratum starting from 1.0 m below ground level onwards in clayey
strata.

The depth of Water Table shall be recorded in each borehole.

All samples, both disturbed and undisturbed, shall be identified properly with the borehole number
and depth from which they have been taken.

The sample shall be sealed at both ends of the sampling tubes with wax immediately after the
sampling and shall be packed properly and transported to the Contractor's laboratory without any
damage or loss.

The logging of the boreholes shall be compiled immediately after the boring is completed and a
copy of the bolero shall be handed over to the Engineer-in – Charge.

2.3 Dynamic Cone Penetration Test

Dynamic cone penetration tests of two numbers shall be carried out with the circulation of
Bentonite slurry at specified locations and a continuous record of penetration resistance (NG) up to
15.00 meter from natural ground level or the refusal shall be maintained by the Contractor. IS:
4968 (Part-2) or equivalent international specification shall be followed for carrying out the test
and reporting results.

The location for tests shall be as directed by the Owner. On completion of the test, the results shall
be presented as a continuous record as the numbers of blows required for every 300 mm
penetration of the cone into the soil.

2.4 Trial Pits

Trial pits shall be carried at specified one locations of per bay as directed by the Owner. The trial
pits shall be 2m x 2m in size extending to 4 m depths, or as specified by the Owner. Undisturbed
samples shall be taken from the trial pits as per the direction of the Owner.

2.5 Electrical Resistivity Test

This test shall be conducted to determine the Electrical resistivity of soil required for designing safe
grounding system for the entire station area. The specifications for the equipments and other
accessories required for performing electrical receptivity test, the test procedure, and reporting of
field observations shall confirm to IS: 3043 or equivalent international specifications. The test shall
be conducted using Wagner's four electrode method as specified in IS: 1892, Appendix-B2. Unless
otherwise specified at each test location, the test shall be conducted along two perpendicular lines
parallel to the co-ordinate axis. On each line a minimum of 8 to 10 readings shall be taken by
changing the spacing of the electrodes from an initial small value of 0.5 m up to a distance of 10.0
m.

2.6 Plate Load Test

 Plate load test shall be conducted to determine the bearing capacity, modulus of sub-grade reaction
and load/settlement characteristics of soil at shallow depths by loading a plane and level steel plate
kept at the desired depth and measuring the settlement under different loads, until a desired
settlement takes place or failure occurs. The specification for the equipment and accessories
required for conducting the test, the test procedure, field observations and reporting of results shall
conform to IS: 1888 or equivalent international specifications. Modulus of sub-grade reaction shall
be conducted as per IS: 9214 or equivalent international specifications. The location and depth of
the test shall be as given below:

 One at Control Building location at the proposed foundation depth below finished ground level for
bearing capacity.

 One test at Transformer foundation location at proposed foundation depth below FGL.

Undisturbed tube samples shall be collected at 1.0 m and 2.5 m depths from natural ground level
for carrying out laboratory tests.

The size of the pit in plate load test shall not be less than five times the plate size and shall be taken
up to the specified depth. All provisions regarding excavation and visual examination of pit shall
apply here.

Unless otherwise specified the reaction method of loading shall be adopted. Settlement shall be
recorded from dial gauges placed at four diametrically opposite ends of the test plate.

The load shall be increased in stages. Under each loading stage, record of time Vs. Settlement shall
be kept as specified in IS: 1888 or equivalent international specification.

Backfilling of the pit shall be carried out as per the directions of the Owner. Unless otherwise
specified the excavated soil shall be used for this purpose. In cases of gravel-boulder or rocky
strata, respective relevant codes shall be followed for tests.

2.7 Sampling and Testing of Concrete

Sampling of materials and concrete shall be done carefully by the Contractor under the direct
supervision of the Departmental staff as per IS 456-1964 at the cost of the Contractor. All
necessary labour, materials, equipment, etc. for sampling, preparing test cubes, curing etc. shall be
provided by the Contractor. Testing of the materials and concrete will be arranged by the
Contractor in approved laboratory at the cost of the Contractor. Compressive strength of ordinary
concrete shall not be less than those specified below:

Sl. No. Mix Work test on 15 cm cubes

Kg/ sq.cm at 7 days kg/ sq.cm at 28 days
1 1:1:2 158 242
2 1:1 ½:3 131 200
3 1:2:4 105 158
4 1:3:6 66 100
5 1:4:8 49 73

One set of six of 15 cm cubes shall be prepared from the concrete to be used in the work for
compression test on each on the first three days operation and thereafter for every 60 Cu.M of
concrete or three day’s work whichever is less, by the Contractor in the presence of a responsible
officer of the Department of a rank not less than that an overseer. If the source of aggregate or
grading is changed, one set of six test cubes shall be taken for each changed batch. Three cubes
shall be used for test of 7 day’s age and three at 28 days.
 After the relation between strengths at 7 days and 28 days is reliably established for the particular
set of material from the same sources, subsequent tests may be carried out only on three cubes at 7
days.
If the average strength of the cubes shows ultimate compressive strength less than the above the
Employer shall have a right to order a change in the mix or water content for the remaining
concrete without extra cost. Defective concrete having strength below 80 percent of the required
strength is liable to be rejected. Concrete of strength up to per cent of the required strength may be
accepted as substandard work at a reduced rate provided such weak concrete is restricted to such
member and in such quantities as will not endanger the safety of the structure.

2.8 Water Sample

Representative samples of ground water shall be taken when ground water is first encountered
before the addition of water to aid drilling of boreholes. The samples shall be of sufficient quantity
for chemical analysis to be carried out and shall be stored in airtight containers.

2.9 Back Filling Bore Holes

On completion of each hole, the Contractor shall backfill all boreholes as directed by the Owner.
The backfill material can be the excavated material.

2.10 Laboratory Test

The laboratory tests shall be carried out progressively during the field work after sufficient number
of samples has reached the laboratory in order that the test results of the initial boreholes can be
made use of in planning the later stages of the field investigation and quantum of laboratory tests.

All samples brought from field, whether disturbed or undisturbed shall be extracted/prepared and
examined by competent technical personnel, and the test shall be carried out as per the procedures
laid out in the relevant I.S. Codes.

The following laboratory tests shall be carried out:

i) Visual and Engineering Classification.

ii) Liquid limit, plastic limit and shrinkage limit for CΦ soils.
iii) Natural moisture content, bulk density and specific gravity.
iv) Grain size distribution.
v) Swell pressure and free swell index determination.
vi) California bearing ratio.
vii) Consolidated un-drained test with pore pressure measurement.
viii) Chemical tests on soil and water to determine the carbonates, sulphates, nitrates, chlorides, Ph
value, and organic matter and any other chemicals which harms the concrete foundation.
ix) Rock quality designation (ROD), RMR in case of rock is encountered.

2.11 Test Results and Reports

1. The Contractor shall submit the detailed report in two (2) copies wherein information regarding the
geological detail of the site, summarized observations and test data, bore logs, and conclusions and
recommendations on the type of foundations with supporting calculations for the
recommendations. Initially the report shall be submitted by the Contractor in draft form and after
the draft report is approved, the final report in four (4) copies shall be submitted. The test data shall
bear the signatures of the Investigation Agency, Vendor and also site representative of APEPDCL.

2. The report showing the locations of the exploration work i.e., bore holes, dynamic cone penetration
tests, trial pits. Plate load test, etc.
 A plan showing the locations of the exploration work i.e., bore holes, dynamic cone penetration
tests, trial pits. Plate load test, etc.
 Bore Logs: Bore logs of each bore holes clearly identifying the stratification and the type of soil
stratum with depth. The values of Standard Penetration Test (SPT) at the depths where the tests
were conducted on the samples collected at various depths shall be clearly shown against that
particular stratum.

Test results of field and laboratory tests shall be summarized strata wise as well in combined
tabular form. All relevant graphs, charts tables, diagrams and photographs, if any, shall be
submitted along with report. Sample illustrative reference calculations for settlement, bearing
capacity, pile capacity shall be enclosed.

3.0 RECOMMENDATIONS

The report should contain specific recommendations for the type of foundation for the various
structures envisaged at site. The Contractor shall acquaint himself about the type of structures and
their functions from the Owner. The observations and recommendations shall include, but not
limited to the following:

Geological formation of the area, past observations or historical data, if available, for the area and
for the structures in the nearby area, fluctuations of water table, etc. slope stability characteristics
and landslide history of the area shall be specifically highlighted. Remedial measures to be adopted
shall also be given.

Recommended type of foundations for various structures. If piles are recommended the type, size
and capacity of pile and groups of piles shall be given after comparing different types and sizes of
piles and pile groups.

Allowable bearing pressure on the soil at various depths for different sizes of the foundations based
on shear strength and settlement characteristics of soil with supporting calculations. Minimum
factor of safety for calculating net safe bearing capacity shall be taken as 3.0 (three).
Recommendation of liquefaction characteristics of soil shall be provided.

Recommendations regarding slope of excavations and dewatering schemes, if required. Required

protection measures for slope stability for cut and fill slopes of switchyard and approach road with
stone pitching/retaining walls shall be clearly spelt out. Calculation shall also be provided for
stability adequacy.

Comments on the Chemical nature of soil and ground water with due regard to deleterious effect of
the same on concrete and steel and recommendations for protective measures.

If expensive soil is met with, recommendation on removal or retainment of the same under the
structure, road, drains, etc., shall be given. In the later case detailed specification of any special
treatment required including specification or materials to be used, construction method, equipments
to be deployed, etc., shall be furnished. Illustrative diagram of a symbolic foundation showing
details shall be furnished.

Recommendations for additional investigations beyond the scope of the present work; if considered
such investigation as necessary

4.0 SITE PREPARARTION

The Contractor shall be responsible for proper leveling of switchyard site as per layout and levels
of switchyard finalized during detailed engineering stage. The Contractor at his own cost shall
make the layout and levels of all structure, etc., from the general grids of the plot and benchmarks
set by the Contractor and approved by the Owner. The Contractor shall give all help in instruments,
materials and personal to the Owner for checking the detailed layout and shall be solely responsible
for the correctness of the layout and levels. Site leveling shall be in the scope of the contractor.
Bidder may decide the level of the sites. However, the level shall be such that it is 300 mm higher
than the highest flood level (HFL) of the site.
3.1 Scope Of Works

This clause covers the design and execution of the work for site preparation, such as clearing of the
site, land development involving land cutting/filling, supply and compaction of fill material, slope
protection by stone pitching/retaining walls depending on the site location/ condition, excavation
and compaction of backfill for foundation, road construction, drainage, trenches and final topping
by stone (broken hard stone).

3.2 General
1) The Contractor shall develop the site area to meet the requirement of the intended purpose. The site
preparation shall conform to the requirements of relevant sections of this specification or as per
stipulations of standard specifications. Necessary protection of slope of switchyard area and
approach road shall also be carried out by contractor.

2) If fill material is required, the fill material shall be suitable for the above requirement. The fill shall
be such a material and the site so designed as to prevent the erosion by wind and water of material
from its final compacted position or the in-site position of undisturbed soil.

3) When embankments are to be constructed on slopes of 15% or greater, benches or steps with
horizontal and vertical faces shall be cut in the original slope prior to placement of embankment
material. Vertical faces shall measure not more than 1 m in height.

4) Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be
constructed by compacting the material in successive uniform horizontal layers not exceeding 15
cm in thickness. (Of loose material before compaction). Each layer shall be compacted as required
by means of mechanical tampers approved by the Owner. Rocks larger than 10 cm in any direction
shall not be placed in embankment adjacent to structures.

5) Earth embankments of roadways and site areas adjacent to buildings shall be placed in successive
uniform horizontal layers not exceeding 20 cm in thickness in loose stage measurement and
compacted to the full width specified. The upper surface of the .embankment shall be shaped so as
to provide complete drainage of surface water at all times.

6) The pitching shall be designed and provided for slope protection as per approved drawings. The
stone used shall be sound, hard, durable and fairly regular in shape. Stones subjected to marked
deterioration by water or weather shall not be used. Suitable measures shall be provided to prevent
erosion by seepage of water. Largest stone procurable shall be used as approved by owner for the
work. Random rubble masonry (1:6) retaining walls shall be provided wherever required as per site
condition.

3.3 Compaction
1. The density to which fill materials shall be compacted shall be as per relevant IS and as per
direction of Owner. All compacted sand filling shall be confined as far as practicable. Backfilled
earth shall be compacted to minimum 95% of the Standard Proctor's density at OMC. The sub-
grade for the roads and embankment filling shall be compacted to 70% relative density (minimum).

2. At all times, unfinished construction shall have adequate drainage. Upon completion of the roads
surface course, adjacent shoulders shall be given a final shaping, true alignment and grade.

3. Each layer of earth embankment when compacted shall be as close to optimum moisture content as
practicable. Embankment material, which does not contain sufficient moisture to obtain proper
compaction, shall be wetted. If the material contains any excess moisture then it shall be allowed to
dry before rolling. The rolling shall begin at the edges overlapping half the width of the roller each
time and progress to the center of the road or towards the building as applicable. Rolling will also
be required on rock fills. No compaction shall be carried out in rainy weather.
4.4 Requirement for fill material under foundation
The thickness of fill material under the foundations shall be such that the maximum pressure from
the footing, transferred through the fill material and distributed onto the original undisturbed soil
will not exceed the allowable soil bearing pressure of the original undisturbed soil. For expansive
soils the fill materials and other protections, etc., to be used under the foundation is to be got
approved by the Owner.

4.0 ANTI-WEED TREATMENT, STONE SPREADING & LANDSCAPE

4.1 Scope of Works

The Contractor shall furnish all labour, equipment and materials required for complete performance
of the work in accordance with the drawings specification and direction of the Owner.

Stone spreading shall be done in the areas of the switchyard wherever equipments and or structures
are to be provided under present scope of work. The stone spreading in future areas shall also be
provided in case potential without stone layer is not well within safer limits.

4.2 General Requirement

The material required for site surfacing/stone filling shall be free from all types of organic
materials and shall be of standard quality, and as approved by the Owner.

The material to be used for stone filling/site surfacing shall be uncrushed/ crushed/broken stone of
20 mm nominal size (upgraded single size) conforming to Table 2 of IS:383-1970 or equivalent
international specifications. Hardness, Flakiness shall be as required for wearing courses are given
below:

a) Sieve Analysis Limits (Gradation)

(IS: 383 - Table 2)
Sieve Size % passing by weight
40mm 100
20 mm 85 - 100
10 mm 0 - 20
4.75 mm 0-5

b) Hardness

Abrasion value (IS: 2386 Part-IV) - not more than 40%

Impact value (IS: 2386 Part-IV) - not more than 30% and frequency shall be one test per 500 cum
with a minimum of one test per source,

c) Flakiness Index

One test shall be conducted per 500 cum of aggregate as per IS: 2386 Part-I and maximum value is
25%,

1. After all the structures/equipments are erected and anti-weed treatment is complete, the surface of
the switchyard area shall be maintained, rolled/ compacted to the lines and grades as decided by
Project Manager. Rolling to be done by spreading Sandy Soil to cover up pot holes/depression
etc(125 mm) De-weeding including removal of roots shall be done before rolling is commenced,
Project Manager shall decide final formation level so as to ensure that the site appears uniform
devoid of undulations, The final formation level shall however be very close to the formation level
indicated in the drawing using half ton roller with suitable water sprinkling arrangement to form a
 smooth and compact surface.

2. A Base Layer of PCC of 75 mm thickness with prop. Of 1:4:8 shall be provided before spreading
of crushed rocks. PCC base shall be done in panels of 4 M x 4 M with expansion gap of 25 mm
between panels. The gap shall be filled with Bitumen. Each panel should be provided four (IV) nos.
of PVC pipes (per panel) of 100 mm dia. of length 600 mm for soaking of water. The pipe will be
provided with gratings at the top and the same will be flushed with the PCC top.

3. Over the PCC base layer a surface course of minimum 100 mm thick (Compact thickness) of 20
mm nominal size (single size ungraded) broken stone aggregate shall be spread and compacted as
directed. In areas that are considered by the Project Manager to be too congested with foundations
and structures for proper rolling of the site surfacing material by normal rolling equipments, the
material shall be compacted by hand, if necessary. Due care shall be exercised so as not to damage
any foundation structures or equipment during rolling compaction.

4. Before taking up stone filling, anti-weed treatment shall be applied in the switchyard area wherever
gravel filling is to be done, and the area shall be thoroughly de-weeded including removal of roots.
The recommendation of local agriculture or horticulture department shall be sought wherever
feasible while choosing the type of chemical to be used. Nevertheless the effectiveness of the
chemical shall be demonstrated by the Contractor in a test area of 10M x 10M (approx.) and
monitored over a period of two to three weeks by the Project Manager. The final approval shall be
given by Project Manager and final approval given based on the results.

5. The anti-weed chemical shall be procured from reputed manufacturers.

The dosage and application of chemical shall be strictly followed as per manufacturer's
recommendation. The contractor shall be required to maintain the area free of weeds for a period of
1 year from the date of application of 1st dose of anti-weed chemicals.

6.0 CABLE AND PIPE TRENCHES

 The cable trenches and precast removable RCC cover (with lifting arrangement)

 The cable trench wall shall be designed for the following loads.

o Dead load of 155 Kg/m length of cable support + 75 Kg on one tier at the end.

o Triangular earth pressure + uniform surcharge pressure of 2 T/m2.

 Cable trench covers shall be designed for self-weight of top slab + UDL of 2000 Kg/ m2 +
concentrated load of 200 Kg at centre of span on each panel.

 Cable trench crossing the road/rails shall be designed for class AA. Loading of IRC/relevant IS
Code and should be checked for transformer loading.

 Trenches shall be drained. Necessary sumps be constructed and sump pumps if necessary shall be
supplied. Cable trenches shall not be used as storm water drains.

 The top of trenches shall be kept at least 100 mm above the finished ground level. The top of cable
trench shall be such that the surface rainwater does not enter the trench.

 All metal parts inside the trench shall be connected to the earthing system.
 Cables from trench to equipments shall run in hard conduit pipes.
 Trench wall shall not foul with the foundation. Suitable clear gap shall be provided.
 The trench bed shall have a slope of 1/500 along the run and 1/250 perpendicular to the run.
 All the construction joints of cable trenches i.e., between base slab to base slab and the junction of
vertical wall to base slab as well as from vertical wall to wall and all the expansion joints shall be
 provided with approved quality PVC water stops of approx. 230 x 5 mm size for those sections
where the ground water table is expected to rise above the junction of base slab and vertical wall of
cable trenches.
 Cable trenches shall be blocked at the ends if required with brick masonry in cement sand mortar
1:6 and plaster with 12 mm thick 1:6 cement sand mortar.
 Cable trenches shall be provided with perforated GI cable trays to support the running cables.

7.0 FOUNDATION I RCC CONSTRUCTION

7.1 General

(i) Work covered under this Clause of the Specification comprises the design and construction of
foundations and other PCC/ RCC constructions for switchyard structures, equipment supports,
trenches, drains, jacking pad, control cubicles, bus supports, transformer, marshalling kiosks,
auxiliary equipments and systems, buildings, tanks, boundary wall or for any other equipment or
service and any other foundation required to complete the work. This clause is as well applicable to
the other ECC constructions.

(ii) Concrete shall conform to the requirements mentioned in IS: 456 or equivalent international
specifications and all the tests shall be conducted as per relevant Indian Standard Codes as
mentioned in Standard field quality plan appended with the specification.

(iii) A minimum grade of M20 concrete (1:5:3 mix) shall be used for all structural/load bearing
members as per latest IS 456 or equivalent international specifications.

(iv) If the site is sloppy, the foundation height will be adjusted to maintain the exact level of the top of
structures to compensate such slopes.

(v) The switchyard foundation's plinths and building plinths shall be minimum 300 mm and 500 mm
above finished ground level respectively.

(vi) Minimum 75 mm thick lean concrete (1:4:8) shall be provided below all underground structures,
foundations, trenches, etc., to provide a base for construction.

(vii) Concrete made with Portland slag cement shall be carefully cured and special importance shall be
given during the placing of concrete and removal of shuttering.

(viii) The design and detailing of foundations shall be done based on the approved soil data and sub-soil
conditions as well as for all possible critical loads and the combinations thereof. The Spread
footings foundation or pile foundation as may be required based on soil/sub-soil conditions and
superimposed loads shall be provided.

(ix) If pile foundations are adopted, the same shall be case-in-situ driven/bored or precast or under-
reamed type as per relevant parts of IS Code 2911. Only RCC piles shall be provided. Suitability of
the adopted pile foundations shall be justified by way of full design calculations. Detailed design
calculations shall be submitted by the bidder showing complete details of piles/pile groups
proposed to be used. Necessary initial load test shall also be carried out by the 'bidder at their cost
to establish the piles design capacity. Only after the design capacity of piles has been established,
the Contractor shall take up the job of piling. Routine tests for the piles shall also be conducted. All
the work (design & testing) shall be planned in such a way that these shall not cause any delay in
project completion.

7.2 Design

All foundation shall be of reinforced cement concrete. The design and construction of RCC
structures shall be carried out as per IS: 456 or equivalent international specifications and
minimum grade of concrete shall be M-20. Higher grade of concrete than specified above may be
 used at the discretion of Contractor without any additional financial implication to the Owner.

Limit state method of design shall be adopted unless specified otherwise in the specification.

For detailing of reinforcement IS: 2502 and SP: 34 or equivalent international specifications shall
be followed. Cold twisted deformed bars (Fe=415 N/mm2) conforming to IS: 1786 shall be used as
reinforcement. However, in specific areas, mild steel (Grade-I) conforming to IS: 432 can also be
used. Two layers of reinforcement (on inner and outer face) shall be provided for wall and slab
sections having thickness of 150 mm and above. Clear cover to reinforcement towards the earth
face shall be minimum 40 mm.

RCC water retaining structures like storage tanks, etc., shall be designed as un-cracked section in
accordance with IS: 3370 (Part I to IV) or equivalent international specifications by working stress
method. However, water channels shall be designed as cracked section with limited steel stresses as
per the above standards by working stress method.

The procedure used for the design of the foundations shall be the most critical loading combination
of the steel structure and or equipment and or superstructure and other conditions, which produces
the maximum stresses in the foundation or the foundation component and as per the relevant IS
Codes of foundation design. Detailed design calculations shall be submitted by the bidder showing
complete details of piles/pile groups proposed to be used.

Design shall consider any sub-soil water pressure that may be encountered following relevant
standard strictly.

Necessary protection to the foundation work, if required shall be provided to take care of any
special requirements for aggressive alkaline soil, black cotton soil or any other type of soil which is
detrimental/harmful to the concrete foundations.

RCC columns shall be provided with rigid connection at the base.

All sub-structures shall be checked for sliding and overturning stability during both construction
and operating conditions for various combinations of loads. Factors of safety for these cases shall
be taken as mentioned in relevant IS Codes or as stipulated elsewhere in the Specifications. For
checking against overturning, weight of soil vertically above footing shall be taken and inverted
frustum of pyramid of earth on the foundation should not be considered.

Earth pressure for all underground structures shall be calculated using coefficient of earth pressure
at rest, co-efficient of active or passive earth pressure (whichever is applicable). However, for the
design of substructures of any underground enclosures, earth pressure at rest shall be considered.

In addition to earth pressure and ground water pressure etc., a surcharge load of 2T/sq. m shall also
be considered for the design of all underground structures including channels, sumps, tanks,
trenches, sub-structure of any underground hollow enclosure, etc., for the vehicular traffic in the
vicinity of the structure.

Following conditions shall be considered for the design of water tank in pumps house, channels,
sumps, trenches and other underground structures:

a) Full water pressure from inside and no earth pressure and ground water pressure and surcharge
pressure from outside (application only to structures, which are liable to be filled up with water or
any other liquid).

b) Full earth pressure, surcharge pressure and ground water pressure from outside and no water
pressure from inside.

c) Design shall also be checked against buoyancy due to the ground water during construction and
maintenance stages. Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring
 the superimposed loadings.

The foundations shall be proportioned so that the estimated total and differential movements of the
foundations are not greater than the movements that the structure or equipment is designed to
accommodate.

The foundations of transformer and circuit breaker shall be of block type foundation. Minimum
reinforcement shall be governed by IS: 2974 and IS: 456 or equivalent international specifications.

The tower and equipment foundations shall be checked for a factor of safety of 2.2 for normal
condition and 1.65 for short circuit condition against sliding, overturning and pullout. The same
factors shall be used as partial safety factor overloads in limit state design also.

7.3 Admixtures & Additives

Only approved admixtures shall be used in the concrete for the Works. When more than one
admixture is to be used, each admixture shall be batched in its own, batch and added to the mixing
water separately before discharging into the mixer. Admixtures shall be delivered in suitably
labeled containers to enable identification.

Admixtures in concrete shall conform to IS: 9103 and the water proofing cement additives shall
conform to IS: 2645 or equivalent international specifications. Owner shall approve concrete
Admixtures/Additives.

The Contractor may propose and the Owner may approve the use of a water-reducing set-retarding
admixture in some of the concrete. The use of such an admixture will not be approved to overcome
problems associated with inadequate concrete plant capacity or improperly planned placing
operations and shall only be approved as an aid to overcoming unusual circumstances and placing
conditions.

The water reducing set-retarding admixture shall be an approved brand of Ligno-sulphonate type
admixture.

The water proofing cement additives shall be used as required/advised by the owner.

8.0 MISCELLANEOUS GENERAL REQUIREMENTS

8.1 Dense concrete with controlled water cement ratio as per IS-code shall be used for all underground
concrete structures such as pump-house, tanks, water retaining structures, cable and pipe trenches
etc. for achieving water tightness.

8.2 All joints including construction and expansion joints for the water retaining structures shall be
made water tight by using PVC ribbed water stops with central bulb. However, kicker type
(externally placed) PVC water stops shall be used for the base slab and in other areas where it is
required to facilitate concreting. The minimum thickness of PVC water stops shall be 5 mm and
minimum width shall be 230 mm.

8.3 All steel sections and fabricated structures which are required to be transported on sea shall be
provided with anti corrosive paint to take care of sea worthiness.

8.4 All mild steel parts used in the water retaining structures shall be hot-double dip galvanized. The
minimum coating of the zinc shall be 750 gm/sq. m for galvanized structures and shall comply with
IS:2629 and IS:2633. Galvanizing shall be checked and tested in accordance with IS: 2633.The
galvanizing shall be followed by the application of an etching primer and dipping in black bitumen
in accordance with B8:3416.

8.5 A screed concrete layer not less than 100 mm thick and of grade not weaker than M10 conforming
to IS: 456-1978 shall be provided below all water retaining structures. A sliding layer of bitumen
 paper or craft paper shall be provided over the screed layer to destroy the bond between the screed
and the base slab concrete of the water retaining structures.

8.6 Bricks having minimum 75 kg/cm2compressive strength can only be used for masonry work.

Contractor shall ascertain himself at site regarding the availability of bricks of minimum 75 kg/cm2
compressive strength before submitting his offer.

8.7 Doors and windows on external walls of the building (other than areas provided, with insulated
metal claddings) shall be provided with RCC sun-shade over the openings with 3000 mm
projection on either side of the openings. Projection of sunshade from the wall shall be minimum
450 mm over window openings and 750 mm over door openings.

8.8 All stairs shall have maximum riser height of 150 mm and a minimum tread width of 300 mm.
Minimum width of stairs shall be 1500 mm. Service ladder shall be provided for access to all roofs.
RCC fire escape staircase shall be provided in control buildings.

8.9 Angles 50 x 50 x 6 mm (minimum) with lugs shall be provided for edge protection all round cut
outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe
trenches supporting covers, edges of manholes supporting covers, supporting edges of manhole
precast cover and any other place where breakage of corners of concrete is expected.

8.10 Anti termite chemical treatment shall be given to column pits, wall trenches, foundations of
buildings, filling below the floors etc. as per IS: 6313 and other relevant Indian Standards. Hand-
railing minimum 900 mm high shall be provided around all floor/roof openings,
projections/balconies, walk ways, platforms, steel stairs etc. All handrails and ladder pipes shall be
32 mm nominal bore MS pipes (medium class) and shall be galvanized (medium-class as per
IS:277). All rungs for ladder shall also be galvanized as per IS: 277 medium classes.

8.11 For RCC stairs, hand railing with 20 mm square MS bars, balustrades with suitable MS flats shall
be provided with black PVC sheathing.

8.12 For all civil works covered under this specification, nominal mix by volume batching as per CPWD
specification is intended. The relationship of grade of concrete and ratio of ingredients shall be as
below:

Coarse Aggregate of 20
SI. No. Mix Cement Sand mm Down Grade as
per IS 383
1. M 10 1 3 6
2. M 15 1 2 4
3. M 20 1 1.5 3

The material specification, workmanship and acceptance criteria shall be as per relevant clauses of
CPWD specification and approved standard Field Quality Plan.

8.13 The details given in tender drawings shall be considered along with details available in this section
of the specification while deciding various components of the building.

8.14 Items/components of buildings not explicitly covered in the specification but required for
completion of the project shall be deemed to be included in the scope.

9.0 INTERFACING

The proper coordination & execution of all interfacing civil works activities like fixing of conduits
in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of
 supports/embedment, provision of cutouts etc. shall be the sale responsibility of the Contractor. He
shall plan all such activities in advance and execute in such a manner that interfacing activities do
not become bottlenecks and dismantling, breakage etc. is reduced to minimum.

10.0 STATUTORY RULES

11.0 Contactor shall comply with all the applicable statutory rules pertaining to factories act (as
applicable for the State). Fire Safety Rules of Tariff Advisory Committee. Water Act for pollution
control etc.

12.0 Provisions for fire proof doors, no. of staircases, fire separation wall, plastering on structural
members (in fire prone areas) etc. shall be made according to the recommendations of Tariff
Advisory Committee.

13.0 Statutory clearance and norms of State Pollution Control Board shall be followed as per Water Act
for effluent quality from plant.

14.0 Requirement of Sulphate resistant cement (SRC) for sub-structural works shall be decided in
accordance with the Indian Standards based on the findings of the detailed soil investigation to be
carried by the bidder.11.5 Foundation system adopted by the Bidder shall ensure that relative
settlement and other criteria shall be as per provision in IS: 1904 and other Indian Standard.

15.0 All water retaining structures designed as an un-cracked section shall also be tested for water
tightness at full water level in accordance with clause No. 10 of IS:3370 (part-I) or equivalent
international specification.

16.0 Construction joints shall be as per IS: 456 or equivalent international specification.

All underground concrete structures like basements, pumps houses, water retaining structures etc.
shall have plasticizer cum water proofing cement additive conforming to IS:9103 or equivalent
international specification. In addition, limit on permeability as given in IS: 2645 shall also be met
with. The concrete surface of these structures in contact with earth shall also be provided with two
coats of bituminous painting for water/damp proofing. In case of water leakage in the above
structures, Injection Method shall be applied for requiring the leakage.
 21. PRE COMMISSIONING TESTS
I GENERAL:

 Testing after erection of each section of cable or a transformer or RMU or Feeder/ Service Pillar or
earth pit or any other equipment shall be done asper the routine test listed in the specifications. The
test procedure after erection shall be detailed by the contractor based on BIS or other standard
specifications referred to in the specifications.

II TESTS PRIOR TO COMMISSIONING:

 Once a particular section of the work is ready for commissioning and directed by the Engineer, the
following tests shall be conducted. The Engineer reserves the right to instruct the contractor to
carry out the routines tests once again along with below tests.
 The tests enumerated below are minimum and if the specifications or standards have listed other
tests the same shall also be carried out without any extra cost.
 If during the tests any of the material fails to pass the relevant requirements, the contractor shall
make good these within a reasonable time. The time shall be mutually agreed between the Engineer
and the Contractor.
 Once the entire works under the Contract is tested and commissioned a thorough check of all the
equipment’s shall be done to ensure proper functioning as specified.

III TESTS FOR CABLES OF ALL VOLTAGES AND TYPES:

1. Compare cable datawith drawings and specifications.

2. Inspect exposed sections of cables for physical damage.
3. Inspect bolted electrical connections for high resistance using one or more of the following
methods:
4. Use of a low-resistance ohmmeter
5. Inspect shield grounding, cable supports, and terminations.
6. Verify that visible cable bends meet or exceed specified in this document and manufacturer’s
minimum published bending radius.
7. Perform resistance measurements through bolted connections with a low-resistance ohmmeter.
8. Perform an insulation-resistance test individually on each conductor with all other conductors
and shields grounded. Apply voltage in accordance with data given in this document or
manufacturer’s data.
9. Perform a shield-continuity test on each power cable.
10. In accordance with standard specifications and other power cable consensus standards, testing
can be performed by means of direct current, power frequency alternating current, or very low
frequency alternating current. These sources may be used to perform insulation-withstand
tests, and baseline diagnostic tests such as partial discharge analysis, and power factor or
dissipation factor. The selection shall be made after an evaluation of the available test methods
and a review of the installed cable system. These tests shall be agreed between the Engineer
and the Contractor before starting the tests.
11. Some of the available test methods are listed below:

Dielectric Withstand:
 Direct current (DC) dielectric withstand voltage
 Very low frequency (VLF) dielectric withstand voltage
 Power frequency (50/60 Hz) dielectric withstand voltage
Baseline Diagnostic Tests:
 Power factor/ dissipation factor (tan delta):
 Power frequency (50/60 Hz)
 Very low frequency (VLF)

DC insulation resistance:
  Off-line partial discharge:
 Power frequency (50/60 Hz)
 Very low frequency (VLF)
IV TESTS ON RMU:

NOTE: Tests must be carried out after the installation, alteration or repair and before putting back to
service. A proper table shall be prepared by the Contractor and accepted by the Engineer to contain
the data given below:

SAFETY: At all times maintain suitable clearance to all other electrical equipment and verify
planned escape routes and fire risks.

In preparation for the tests, wherever possible, de-energise and disconnect the HV cables from the
equipment and make the area safe.

BASIC DATA

1. DATE: Project No. Name of Officer

2. Location of Equipment:
3. RING MAIN DESCRIPTION:
4. Rated Voltage kV:
5. Serial Number

VISUAL INSPECTION AND SAFETY CHECK (SWITCHGEAR)

1. Check that the installation complies with the distribution construction standards and applicable
design drawings.

2. Check that Public Safety has been considered (e.g. cabinets secured and locked, trip hazards
removed where applicable).

3. Check the supply to the switchgear, that it is switched off and isolated if possible.

4. Confirm that the switchgear is de-energized (with approved testing device).

5. Ensure that the earth system is completed as per design drawings (correct size of earths use), and
that the grading ring is installed, undamaged and connected tothe HV earth bar.

6. Check that the nearest conductive material is at least two (2) meters away from the earth
ring/system (take a photo)

7.Measured distance m

8. Switchgear voltage rating matches or is greater than system voltage.

9.Check that the switchgear is numbered and labelled correctly.

10. Check that the gas pressure is sufficient (if applicable record reading). MPa

11 Conduct functional tests of the electrical equipment and parts of the installation; verify settings,
circuitry and programming; verify the operation and configuration by measurement or testing of
protective, monitoring, measuring and control devices.

12. Check the alignment of face plate and operation of the interlocks.

13. Inspect labels, markings, safety signs and safety

 INSULATION RESISTANCE TEST:

1. Ensure no cables are connected to the switchgear, open all earth

2. switches and close all load-carrying switches before testing.
3. Verify the integrity of the bus-bar to earth by using a 5 kV insulation
4. resistance tester for a minimum of 1 minute for a stable reading.
5. Test results are to be greater than 5,000 MΩ.
6. Test Connection Expected Results Test Results
7. Red phase to white phase >5,000 MΩ Ω
8. White phase to blue phase >5,000 MΩ Ω
9. Blue phase to red phase >5,000 MΩ Ω
10. Red phase to earth >5,000 MΩ Ω
11. Instrument Serial no. White phase to earth >5,000 MΩ Ω
12. Date last tested Blue phase to earth >5,000 MΩ Ω
13. Confirm bus-bar has been discharged after each test.

CONTINUITY TEST

1. Using a multi-meter, test between all bushings of the same phase to prove continuity.
2. Test Connection Expected Results Test Results:

Red phase to red phase < 0.1 Ω Pass/Fail

Yellow phase to Yellow phase < 0.1 ΩPass/Fail
Blue phase to blue phase < 0.1 Ω Pass/Fail
Open all load-carrying switches and close all earth switches.
Using a multimeter, test between all bushings of the same phase andearth to prove continuity.

Red phase to earth < 0.1 ΩPass/Fail

Yellow phase to earth < 0.1 Ω Pass/Fail
Blue phase to earth < 0.1 Ω Pass/Fail
HANDOVER OF RESPONSIBILITY FOR THE COMPLETION OF SECTIONS 1 TO
IV:

I hereby certify that sections 1 to IV have been completed with satisfactory results and transfer
responsibility to the commissioning officer.

Testing Officer:

Signature: Date: Time:

V.CABLE TERMINATION AND OTHER CHECKS:

1 Check that all the HV cable terminations are secure and that the correct bailing assemblies are
used.

2 Check that all the HV cable terminations are tightened to the manufactures required standard.

3 Check that the drain wires are fitted to all HV elbow connectors and are connected to the cable
screen.

4 Check that the HV cable screens are all solidly and separately connected and bolted to the HV
earth bar.

5 Ensure that the 25 mm clearance between the cable screens and the cable support brackets is
 maintained.

6 Check that no HV cables are exposed. Backfill if necessary.

7 If the ring main unit is in a kiosk, check that the kiosk body is earthed correctly, including the
kiosk doors.

8 Check the functionality of the switch interlock (i.e. earth cannot be engaged when the switch is
closed)

9 Check the functionality of the earthing interlocks (i.e. switch cannot close when the earth is
engaged)

10 Ensure that all load-carrying and earth switches are as per the switching program, and that
padlocks and danger labels are fitted.

11 Ensure that the site is safe and barricaded where necessary, with no hazards to personnel or
public.

12 Check that the unit has a transportable base: Yes No

13 Check that the face plate is aligned and that the interlocks operate freely.

14 Check that the two black bolts located on the top edge of all switch disconnector panels are
installed and tightened.

15Check the interlocking pin on the top edge of the door panels, and the metal tabs on the inner edge
of the fuse cover panel are ingood condition.

HANDOVER OF RESPONSIBILITY FOR THE COMPLETION OF SECTION V:

I hereby certify that sections 1 to 4 have been completed with satisfactory results and transfer
responsibility to the commissioning officer.

Testing Officer:

Signature: Date: Time:

COMMISSIONING AND ENERGISATION

1. Ensure that the high voltage cable testing schedule is available and that the results are
acceptable.
2. Ensure that the earth system test result is available and that the results are acceptable. Earth
Resistance Value Ω
3. Ensure that the inside of the fuse compartment is clean and install the HV high rupturing
capacity fuses according to the fuse chart size. Ensure that the striker pins face the striker bar.
4. Record switching program:
5. The following checks need to be completed in conjunction with the appropriate steps in the
switching program (where applicable)
6. Check that the neon light is connected to the correct phase by measuring the voltage at the test
points.
7. Take one cubicle as a reference and test the red phase of that cubicle against the red phase and
other phase of another cubicle.
8. Red to red should record minimum volts, and other phases should have a maximum voltage.
 9. Repeat this procedure with all other phases
10. Ensure that all equipment is in its final circuit condition as per the switching program.
11. Ensure that all equipment is locked, numbered and labelled correctly, and secure from
unauthorized entry.
12. The switching operator must ensure that the switchgear labels match the ENMAC or GIS
diagrams.
Note: Any changes to the original design must be marked, documented and stamped “As
Constructed”.

OPERATIONAL HANDOVER:

1. Ensure the work area is left tidy with no hazards to the public.

2. Hand over responsibility to the operating authority

3. Return this sheet to the project/working file as a record of commissioning and as a document required for
the Handover Certificate.

The Testing Officer must ensure that all checks are completed and the test results comply with the
minimum standards.

I hereby certify that all sections have been completed with satisfactory results and transfer responsibility to
the network operating authority. This equipment is ready to be

SAFELYenergised.

Testing Officer:

Signature: Date: Time:

VI .EARTHING PITS:

The method below will be used for testing earth pits. The Engineer can decide the number of earth pits to
be tested in each section

Fall of Potential Method: -

The basic procedure for the Fall-of-Potential method is to first connect the test set terminals C1 and P1 to
the earth electrode under test, connect the test set C2 terminal to a current probe located some distance from
the earth electrode and finally connect the test set P2 terminal to a potential probe located a variable
distance between. The two probes normally are located in a straight line. At each potential probe location,
the resistance is recorded (a form is provided in

1. Connect C1 and P1 terminals on the test set to the earth electrode as shown in fig below
2. Drive a probe into the earth 20 to 30 feet from the centre of the electrode and connect to terminal C2.

This probe should be driven to a depth of 6 – 12 inches.

3. Drive another probe into the earth midway between the electrodes and probe C2 and connect to terminal
P2. This probe should be driven to a depth 6 – 12 inches.

4. Record the resistance measurement.

5. Move the potential probe 10 feet farther away from the electrode and make a second measurement.

6. Move the potential probe 10 feet closer to the electrode and make a third measurement.

7. If the three measurements agree with each other within a few percent of their average, then the average
of the three measurements may be used as the electrode resistance.

Note: If the three measurements disagree by more than a few percent from their average, then
additional measurement procedures are required.The Engineer and Contractor will arrive at a format
for recording the details.
Acceptance:

The testing officer and the Contractor shall confirm that all the above are in Conformity with BIS and other
specifications in this document and Energise the Transformer.

Testing Officer:

Signature: Date: Time:

VII: OTHER EQUIPMENT / MATERIALS NOT LISTED ABOVE:

Those equipment or materials which are not specifically mentioned above shall be tested as per BIS or
other procedures mentioned in these specifications. The items to be tested shall be decided by the Engineer
and communicated to the Contractor with minimum of 30 days’ notice.
 22.DISMANTLING OF 33KV&11 kV OVER HEAD LINES
1.0 GENERAL:

In other parts of this specification laying of 33kV & 11 kV UG cable and RMUs, etc. are proposed
consequent to which dismantling of existing 33KV & 11 kV overhead lines include conductors,
poles, all accessories & hardware fitting etc may become necessary. This part of the specification
covers dismantling of the overhead lines including transportation of the materials to APEPDCL’s
stores.

2.0 SCOPE:

The work comprises of dismantling the existing 33KV & 11 kV overhead Distribution lines, and
over head service mains of the consumers completely after commissioning of the UG cable
distribution system.

The successful bidder has to dismantle the HT over head lines, , AAAC/ACSR conductors, of
varying sizes like squirrel, weasel, rabbit , Raccoon, Wolf, the hardware associated with it and the
insulators, etc.

The supports are generally of PSCC poles, steel tubular poles, rail poles, etc., of varying lengths
from 8.0M, 9.1M, 11M, 12M long and of Single pole, double pole, triple or four pole structures are
to be released from the ground and the earth work back filled.

The conductor spans vary from 10 mtrs. to 100 mtrs.

The work also includes transporting of all the released materials inclusive of scrap to the
APEPDCL stores

3.0 JOINT INVENTORY:

The contractor and APEPDCL field staff should after a joint inspection, draw up a detailed
inventory of the over head distribution system to be dismantled giving numbers of make and
numbers of type of poles to be dismantled, insulators, conductors, cross arms, etc., including their
condition and over head service mains of the consumers (HT).

The Joint inventory of the proposed to be dismantled materials/equipments will be prepared and
handed over to the contractor.

The contractor to carefully and safely dismantle the materials as per the approved list and transport
them to the designated APEPDCL stores.

The contractor should only take up the work after joint inventory.

4.0 METHOD OF WORK:

o
Contractor should avail work permit from the engineer to work on these lines every day, release the
materials carefully and transport them to the APEPDCL stores preferably the same day.
o
An acknowledgement shall be obtained from the stores which will form the basis for payment of
labour charges & final bills of the contract. A copy of this shall be given to the field engineer.
o
The field engineer will prepare the bill after completion of dismantling and return of materials to
APEPDCL stores. He shall also verify the materials returned to stores.
o
The cost of the materials damaged during releasing/transportation will be deducted in the bills
before making payment. The poles should be released carefully without damaging either at the
ground level or at the top.
o
They should be lowered carefully without causing any harm to the public and its position on the
footpath/road should not obstruct movement of people/vehicle.

UNIT RATES: Unit rates for materials to be dismantled are to be given as per price schedule which
shall include transportation cost, loading/unloading at site and stores and any other incidental cost
in Dismantling BOQ.
 23. SPUN CEMENT CONCRETE POLES
(PRETENSIONED TYPE)
Scope
This specification covers the manufacture of pre-tensioned pre-stressed circular Spun cement
concrete poles and The poles shall comply with the relevant provisions made in the following

Indian standard specifications with latest amendment.

i) IS: 13158:1991: Specification for Prestressed concrete circular Spun poles for overhead
power, Traction and Telecommunication lines

ii) IS: 2905/1989: Method of test for concrete poles for Overhead Power
and Telecommunication lines.

iii) IS:1343/2012 & IS: 456:Code of practice for Prestressed and plain/reinforced
Concrete.
Designs and drawings:-
a) The poles shall be manufactured in accordance with the APEPDCL design & drawing,
enclosed. The poles are designed to withstand the working loads of 350Kg of 11.0 M and 350Kg
of 12.5M lengths respectively as the case may be, acting at 0.6 M from top of the poles and the
planting depth for different types of poles as per IS 13158-1991 is as follows.

S.No Length of pole Minimum depth of planting in the

(Meters ) Ground
( Meters )
1 9.5 to 11.0 1.8
2 11.5 to 13.0 2.0

Materials:- All the materials procured by the contractor for manufacture of poles shall comply
with standard specifications of BIS codes.

a) HT Steel :- Shall be 4mm HT steel with guaranteed ultimate tensile strength of 175Kg/sqmm
as per IS 6003/1983. Test certificates for each lot of supply shall be verified by the Engineer and
approved before commencement of the work. In the absence of test reports three samples shall be
selected in the presence of the Engineer and tests conducted in stock tested periodically at the cost
of the tenderer.

b) 53 grade Cement:- The cement used shall conform to IS 269-1976 (Specification for
ordinary and low heat Portland cement for the following minimum requirements). And IS
12269:1987.
(i) Initial setting time Not less than 30 minutes.
(ii) Final setting time Not less than 600 minutes.
(iii) The minimum compressive strength of standard mortar cube with graded sand as per
IS : 650-1966 (1st revision ) at 7 days shall be 220 kg./sq.cm
(iv) 53 grade cement manufactured by the standard company shall be used in the work.
(v) As far as possible, the cement shall be obtained from one source to minimize variations in
the quality. A test certificate shall cover each consignment. Each consignment of cement shall be
stacked separately and shall be clearly identified.
(vi) Before using a particular batch of cement, a minimum of 3 trial cubes shall be made with
aggregate grading as followed for the approved design mix and the average compressive strength
results at 7 days shall be determined to assess the suitability of the cement.
 c) GI wire:- The contractor has to procure No 8 GI wire for Earthing of PSCC pole.

d) Aggregate :

i) Aggregate used for the manufacturing of pre stressed concrete poles shall conform to IS:
383-1970.Aggregate shall consist of naturally occurring crushed black metal. They shall be hard,
strong, dense, durable, clear and free from veins and adherent coating, and free from injurious
amount of disintegrated pieces, alkali, vegetable material, and other deterious substances. So far as
possible flaky and allocated pieces should be avoided. It should not contain organic or other
admixture that may cause corrosion of the reinforcement or impair the strength or durability of the
concrete.
ii) The coarse aggregate shall consist of trap (preferably black) metal and in no case exceed 20
mm and minimum size of aggregate or one-fourth of minimum thickness of pole, which ever is
less and the nominal maximum size of coarse aggregate shall be least 5mm less than the spacing
between respective wires. For adequate control of concrete, the coarse aggregates shall be
classified into two sizes and the requisite proportions of each size shall be used in making the
concrete. Each size of graded aggregates shall be stacked in different storage bins or stock piles
and shall be mixed only after the quantity required for each size has been separately weighed. The
storage bins or stock piles shall be under cover protected from weather.

e.Sand:-

i.The fine aggregate shall be sharp, free from impurities and required fine modules as
specified. The sand shall not contain silt and deterious materials. The grading of fine
aggregate shall be in accordance with IS: 2386 – 1963 ( Part 1 to VIII) with latest amendment.

e) Water:-

i) Potable water only shall be used for manufacture of poles. Water to be used for process of
manufacturing PSC poles like concrete mix and curing should be free from chlorides, other salts
and organic materials and it should be got tested in Govt. Laboratory at least once in a year by the
party

f) STORAGE OF MATERIALS

The cement shall be stored at the work side in such a manner as to prevent deterioration due to
moisture or intrusion of foreign matter. Steel reinforcement shall ordinary be stacked in such a
way so as to avoid distortion and to prevent deterioration and corrosion. It is good practice to coat
reinforcement with cement wash before stacking to prevent scale and rust. The aggregates shall be
stored in such a way as to prevent mixing of foreign materials. The heaps of fine and coarse
aggregates shall be kept separately. When different sizes of fine or coarse aggregate are procured
separately, they shall be stored in separate stockpiles, to prevent the material at the edges of the
piles from getting intermixed. Any material, which has deteriorated or has been damaged or is
otherwise considered defective, shall not be used for the concrete.

g) TESTING OF MATERIALS:

The contractor shall arrange for the necessary testing of the material like Metal, Sand, Water etc.
and see that the materials to be used in the manufacturing conform to relevant IS

Concrete :
 a) The concrete shall be of ‘Controlled’ quality with the nominal maximum size of aggregates
limited to 20mm or one-fourth of minimum thickness of pole . The cement concrete shall be
mixed only in electrically /mechanically operated concrete mixer machine. The hand broken metal
shall not be permitted. The cement content in Mix should preferably not to exceed 470 Kg / m3

b) The moisture content in fine aggregates shall be determined daily and the required
quantities of water to be added in the concrete mix shall be determined. Water in concrete shall be
added with proper measurement to maintain required water cement ratio

Design Mix:-

The design mix of M50 Grade of 53 grade Cement : Sand : Metal for manufacture of SPUN poles
shall be laid down in IS1343:1980 and as per IS 456-. The strength of the concrete shall be as
below :
i) Compressive strength at 28 days: The work test cube crushing strength of the concrete
shall not be less than 400 Kg/Sq Cm. The specified strength of the mix to be used in the works is
400 Kg/Sq.Cm. The designed target strength of the mix is 466 Kg/Sq.cm
ii) Compressive strength at transfer : The works cube compressive strength at transfer of
prestress shall not be less than 200 Kg/Sq.Cm under conventional water curing process.
b) A minimum of 6 test specimens of 15 Cms cubes shall determine the compressive strength
of concrete at each stage. The compressive strength stipulated above shall be based on the lowest
cube test result of the 6 test specimens. This shall, however, be relaxed to the second lowest cube
test result in case the number of test specimens is increased to a minimum of 12 at each stage.

Method of Manufacture of Poles:-

a) Moulds

i) Moulds shall be of steel and shall be of rigid construction to prevent distortion. The
moulds shall not allow any leakage of cement grout in casting. The holes in the end plates, for the
H.T. wires shall be accurately drilled by jig to ensure interchangeability.
ii) Before the wires are stretched and tensioned it should be ascertained that all the moulds
are thoroughly cleaned from grit and it should be fitted rigidly and waste oil applied in side the
moulds for easy separation of poles from the moulds.
iii) In the case of the long line method of manufacture the casting bed shall have provision
to ensure correct alignment of the moulds. The moulds shall be free to move/slide along the line to
permit transfer of pre stressing force along the line without restraint.

b) Stretching of wires

i) In the stretching of the H.T.Steel wires, the tensile force in each 4mm dia HT wire should
be 1750 Kgs. The anchoring of the stretched wires shall be such that during manufacture and until
the wires are released, no slipping occurs.

ii) The tensioning of pre stressing steel shall be carried out in a manner that will induce a
smooth and even rate of increase of stress in the wires.

iii) Tensioning shall be done by means of a device either with chain pully block or power
operated hoist with the help of dynamometer.

iv) The HT steel wires do not come in contact with waste oil of mould.
 v) Alignment and levels of the pedestal foundations are in order after stretching. Deformity in
moulds is not permitted.

vi) All components of moulds like side channels and bottom plates should be assembled and
tightened and brought to the true alignment.

c) Earthing

i) Earthing shall be provided by 8 No SWG G1 wire embedded in concrete during

manufacture and the ends of wire left projecting from the pole to a length of 100 mm at 1150 mm
from top and 150 mm below ground level.

ii) The earth wire shall not be allowed to come in contact with pre-stressing wires.

d) Mixing and consolidation of concrete

i) Provision shall be made to measure the quantities of cement, fine and coarse aggregates by
weight only. The accuracy of the measuring equipment shall be +/-3%. All the measuring
equipment shall be maintained in a clean, serviceable condition and its accuracy checked
regularly. Volume batching is not permissible. Mixing of concrete shall be done in a mixer only
and hand mixing is not allowed. Modern high speed mixers, preferably pan or turbine type should
be used for mixing of concrete.

ii) Mixing and placing of concrete shall as far as possible be avoided during the extreme
temperature in summer and winter. The concreting shall commence within one hour of stretching
of the wires, failing which the High Tensile Steel wires shall be checked and re-tensioned if
necessary.

iii) The manufacture of poles shall be done under suitable cover and the poles shall not be cast
in the open.

iv) The concrete shall be thoroughly mixed and consolidated by means of high frequency
vibrators. The extent of vibration required for obtaining full consolidation should be determined
on actual field trials.

v) The freshly cast poles shall be protected during the first stage of hardening from the
harmful effects of sunshine, dry winds, cold and rains.

vi) Over-vibration or under-vibration or vibration of very wet mix is harmful and should be
avoided. The Hand compaction shall not be permitted.. The mixture of cement & sand for filling
up the gap as well as finishing work will not be permitted. And density of compaction is not less
than 2.4 T / m3

vii) Proper cover for concrete should be maintained throughout process of pouring, compacting
etc. of concrete mix

e) De-tensioning of Wires :

i) After ascertaining that concrete has attained required strength the stretched wires are
released from the anchor blocks and cut with the help of welding machine. The cutting shall be
started only from the centre of the bed length. The pole is then removed from the bed by lifting at
2 points using gantry and moved to the Curing Pond
ii) The anchoring system shall provide a device for gradual de-tensioning of the wires. No
back pulling of the wires shall be permitted in the gradual de-tensioning device for the purpose of
release of any wedge or other parts of the de-tensioning device. Flame cuttings of the wires before
release of the full tension shall be strictly prohibited. Either arc cutting or mechanical cutters shall
be employed to cut the wires.

iii) De-tensioning of HT wire shall be done after 72 hours only and after attaining 50 % of its
28 days strength..

iv) It may be ensured that the concreting is completed within 1 to 2 hours of tensioning of HT
wire.

f) Curing

i) The curing of poles shall be carried out by covering the poles with empty gunny bags after
2 to 3 hours of concreting and constantly wetted for 72 hours prior to de-tensioning.
ii) After de-tensioning the poles shall be cured in the ponds not less than 14 days The poles
during this period of curing shall not be allowed to dry out at any cost.

iii) The curing pond shall be full of water and each pole must be immersed in the water for a
period of at least 14 days. If required, water sprinkling shall be done at intervals to keep the poles
constantly wet as per I.S.No.1678-1998.

iv) Before transferring the poles into curing ponds the following particulars are marked on the
poles. 1) A mark showing planting depth. 2) Date of Manufacture, centre name and length of pole.
3) makers serial number or mark.

v) Any vegetation or mass that grow in the curing ponds may be periodically removed.

vi) The concrete shall be covered with a layer of sacking,canvas, hessian or similar absorbent
material and kept constantly wet up to the time of transfer of prestress. If desired by the
manufacturer, steam curing at atmospheric pressure may be done till transfer of prestress. Prior
approval of purchaser shall be obtained for the process and details such as temperature, duration,
etc, for the steam curing cycle. After detensioning, the poles shall be cured for a further period of
not less than 14 days by submerging in water tanks. Alternatively, the poles may be cured by
submerging them in water tanks for a period of 7 days followed by curing for a further period of 7
days with mechanical water spraying arrangements which shall be invariably carried out under

Supervision :

a) A competent and qualified person shall be employed by the manufacturer whose duty will
be to supervise at all stages of the placement of the concrete.
b) All tests on materials, making and testing of cubes, the maintenance and calibration of all
mixing and measuring plants and gauges shall be carried out under his direct supervision.
c) He shall also maintain a direct record of the quantities, proportions and source of supply of
aggregates used, nature and duration of curing actually done, the results of internal as well as
external tests etc. these records shall be kept available for scrutiny by the Engineer at all times.
d) The name of the competent person shall be intimated to the Engineer before commencing
manufacture.

Tolerances :
 a) The tolerance on overall length of the poles shall be - ± 15 mm.
b) The tolerance on out side diameter shall be +4 /-2 mm.
c) The tolerance on uprightness of the pole shall be - 0.5 % .

Finish:
a) All poles shall be free from surface defects including hair cracks. The surface of the poles
in contact with the steel moulds shall be smooth and regular in shape, and as far as possible, be
free from pores. Water retaining pockets or honey combing formations shall not be admissible.
25mm thick 1:2 cement mortar cover shall be provided on the full area of the top of pole.
b) The ends of the pre-stressing wires shall be cut as close to the surface of the poles as
possible and in any case, shall not project more than 3 mm.
c) The ends of high tensile steel wires shall be given two coats of suitable epoxy or
anticorrosive paints approved by the Engineer.
d) No touching up or finishing by cemnt grout etc, shall be done on the poles after it is
removed from the moulds.
Stacking in Lots :

a) After the poles have been checked both dimensionally and from the point of view of finish
they shall be stored at a convenient place in lots, each lot comprising of all pole
b) cast together and de-tensioned simultaneously in one long line (of single or multiple moulds).
c) The poles shall be stacked on leveled and consolidated grounds, on one another up to a height
corresponding to not more than 15 poles. Each pole shall be separated from the other vertically by
wooden battens of size 50mmX50mm to ensure that the poles are stacked evenly without
damages.
Inspection and Testing
a) Inspection

i) The Supplier shall supply at his expense all the poles required for tests and for retest,
samples of materials and all labour, machines, tools, gauges, apparatus, forms of tests reports etc.,
and all things which may be necessary or required by the Engineer for carrying out any or all of
the checks and tests mentioned in the specifications and shall tender all reasonable assistance in
making such checks and tests.

ii) Sample of 15Nos out of 200Nos lot shall be tested for overall length, cross section and
uprightness. A pole falling to satisfy one or more of these requirements shall be considered as
defective.

iii) One pole for every 200 poles shall invariably be tested transfer strength ultimate.. If one pr
more poles fail, twice the number of poles originally tested shall be selected from these already
selected and subjected to this test. If there is no failure among this poles, the lot shall be
considered to have satisfied the requirement of this test.

iv) All pressure gauges and measuring dials on the compression test machines, pre-tensioning
equipment, static bending Test Machine, Weigh Batching Machine shall be got checked and
calibrated regularly as directed by the Engineer by an independent agency and the adjustment
certificates shall be furnished to the Engineer. The frequency of calibration of different gauges is
given below.

Frequency for calibration of different gauges and testing equipment

1. Cube testing Once in six months
machine
2. Weigh batching Every week or after casting 500 poles which ever
 machine is earlier
3. Pole testing After testing 250 poles on machine jack or three
machine months whichever is earlier.
4. Tensioning jack Every three months or after tensioning 5000 poles
whichever is earlier.
5. Dimensional Three months or after checking 5000 poles
gauges whichever is earlier

v) The Engineer shall have free access at all times to the works in which the poles are
manufactured. They shall be at liberty to inspect the manufacture at any stage and to reject any
material or work, not conforming to the terms of this specifications.
b) Check and Tests :
i) In addition to the control checks exercised on the materials and manufacturing process
specified in Clauses above, the concrete and finished pole shall be subject to the following
periodical checks and tests.
1. Compressive strength test of concrete at 28 days.
2. Compressive strength test of concrete at the time of de-tensioning.
3. Check for dimensional tolerances and surface finish of poles
4. Static Bending Strength test of poles.

ii) Pole to be tested shall be selected at random by the Engineer. One hour before the tests, the
poles shall be given a coat of lime wash in order to make the cracks easily visible. The poles shall
be tested as per the Annexure enclosed to this tender.

c) Compressive Strength tests of concrete

i) Test cubes of size 15 cm X 15 cm X 15 cm shall be made and consolidated from the same
concrete simultaneously with the poles. The cubes shall be cured along with the poles in the same
manner and tested prior to transfer of pre stress (72 hours), to check that the concrete has
developed the requisite minimum compressive strength specified at transfer. The remainder of
cubes shall be cured as specified in IS-456-2000 and tested at the end of 28 days to determine the
concrete strength at that age. The pre stress will be released only if the concrete has attained the
minimum strength at transfer.
ii) Cube testing machine shall always be kept in the working condition and regular cube tests
shall be taken and results be recorded in the registers duly signed by engineer-in -charge and
representative of the contractor.

d) Check for Dimensional Tolerance and finish

i) The poles shall be examined visually for finish and free from surface defects. The
dimensional tolerances specified, directed by the Engineer.
e) Static Bending Strength test of poles

i) The pole shall be tested only in the horizontal position or as specified in I.S.1678 / latest
amendment & I.S. 2905 /1989 latest amendment .While testing in the horizontal position,
provision shall be made by suitable supports to compensate for the overhanging weight of the
pole; for this purpose the overhanging portion of the pole may be supported on a movable trolley
or similar device. The frictional resistance of the supporting devices should be separately
determined and deducted from the total final load applied on the pole. Theoretically the permanent
deflection should be as per IS 2905 / 1989 and latest amendment thereof. The recovery of
deformations should not be less than 90%.

ii) Testing Arrangement -The pole shall be fixed in the crib longitudinally from butt to its
ground line and then it shall be secured firmly in place. Wooden saddles with concave
surfaces and other packing shall be placed around the pole to prevent injury to the butt section as
specified in IS: 2905/1989 – latest amendment. To minimise vertical movement at the point of
load application and to reduce the stresses due to dead weight of the pole, a rail support shall be
provided near the point of load application, or alternately a number of friction less supports in the
form of trolleys may be provided near the end or throughout the length of the pole. The rail
support or other forms of support shall be such that any friction associated with the deflection of
the pole under load shall not be a significant portion of the measured load on the pole.
iii) Loading - The load shall be applied at a point 600 mm from the top of the pole by means
of a suitable device, such as a wire rope and winch placed in a direction normal to the direction of
the length of the pole, so that the minimum length of the straight rope under pull (excluding the
curved portion near the transmitting devices) is not less than two times the length of the pole. If
the loading device is set sufficiently far away from the pole to make the angle between the initial
and final positions of pulling line small, the error in assuming that the pull is always perpendicular
to the original direction of the pole axis will be negligible. The pulling line shall be kept level
between the winch position and the point where load is applied to the pole. The load shall be
applied at a constant rate of 4 percent of the specified test load per minute
and in accordance with procedure.
iv) Pulling Line: The pulling line shall be secured around the pole at the load point. Load
measuring device shall be placed in a way so as to accurately measure in the tension in the pulling
line. The other end of which is attached to the loading equipment (winch).

v) Load Measurement: Load Cell with accuracy of 5 Kg. for measurement may be adopted.
Load cell shall be calibrated before every test. The load measuring device shall be supported in
such a way that the force required to pull it shall not add to the measured load on the pole and that
no damage is cause to the instrument if the pole suddenly breaks under test. No pullies or any
other device in between load application point and load cell will be allowed.

vi) Deflections - The deflection of the pole and the load applied shall be measured
simultaneously at different stages of loading to provide at least five sets of readings or as specified
in I.S.2905 & latest amendment thereof. The measurement of the deflection of the load point shall
be made in a direction perpendicular to the unloaded position of the pole axis. The measurement
shall be made correct to the nearest 1 mm by use of datum board. A second datum line shall also
be established from which the movement of the ground line if any, shall be measured.

PROCEDURE:
c ) For 11.0 M / 350 Kg Spun pole : Load shall be applied at a point 600 mm from the top of the
pole and shall be steadily and gradually increased in increments of 70 Kg. till formation of 1st
crack recording deflection at each increment. After applying 50% of the load, the load shall be
then reduced to zero and then increased gradually in 70 Kg. increments to 560 Kg load. Each load
increment be successively increased by 35 Kg. up to design ultimate transverse load (i.e. 700 Kg.).
After wards the load shall be increased in steps of 35 Kg. to measure ultimate transverse load,
until failure occurs. Each time the load is applied same shall be held for 2 minutes. The load
applied to prestressed concrete poles at the point of failure shall be measured to the nearest five
kilograms
vii) RECORDING OF DATA AND MEASUREMENTS: (i) Any hair cracks appearing at a
stage prior to the application of the design transverse load at first crack shall be measured using
feeler gauges & shall be recorded. It should also be recorded, whether the hair cracks, if any,
produced on application of the 70 percent of the minimum ultimate transverse load close up on the
removal or reduction of the test load.

(ii) The load applied to the pole at the time of failure shall be measured to the nearest 5Kg.
(iii) A Prestressed concrete pole shall be deemed not to have passed the test if crack wider than
0.1mm appears at a stage prior to the application of the design transverse load at first crack (200
Kg.)
viii) ULTIMATE FAILURE: The conditions existing when the pole ceases to sustain a load
increment owing to either crushing of concrete or snapping of the prestressing tension or
permanent stretching of the steel in any part of the pole.
ix) The loading arrangements for conducting the static bending strength tests shall be with the
load applied at 0.6 m from top of the pole. Bottom supports shall be carefully fixed to avoid un-
even leveling and the bearing surfaces shall be proper to ensure uniform line contact with concrete
surface. Any roughness and unevenness of concrete in the tearing area shall be made up with
plaster of Paris gypsum or suitable rubber packing. The testing shall be done at point of
application of load, fixing the pole from the bottom as follows

S.No Length of pole Minimum depth of planting in the

(Meters ) Ground ( Meters )
1 9.5 to 11.0 1.8
2 11.5 to 13.0 2.0

x) When testing the concrete poles the formation of the hair cracks shall be carefully observed and
the load shall be increased up to the point at which hair cracks just perceptible to the naked eye
appear and load noted. The loads shall be increased at the rate of 60 Kg for 9.5 M /300 Kg , 70Kg
for 9.5 M /350 Kg , 11.0 M /350 Kg and 12.5 M /350 Kg interval between two installments being
2 minutes for observing cracking moment and failure moment.
Frequency of check and testing :
xi) For each lot of poles, compressive strength tests on concrete both at 28 days and
transfer of load shall be carried out on a minimum of 3 cubes each time.
xii) For the check and tests on the poles, the number of poles to be tested and the
frequency of testing shall be as follows :

(a) Dimensional checks and surface finish :

The frequency of dimensional check shall be at the rate of 10% from each lot of pole for
dimensions like length, breadth, width where such dimensions depend up on the accuracy of the
mould.

(b) Static bending strength :

In case of lots whose works concrete cube strength is equal to or more than 400 Kg/Sq.cm, the
Static Bending tests shall be carried out at 0.6m from top of pole at the rate of one pole for every
200 poles manufactured.

Xiii) Inspection
The APEPDCL may carry out inspection at any stage of manufacture. The successful tenderer
shall grant free access to the representative of APEPDCL at a reasonable time when the work is in
progress. Inspection and acceptance of any material under this specification by the purchaser shall
not relieve the supplier of his obligation of furnishing materials in accordance with the
specification and shall not prevent subsequent rejection if the material is found to be defective.
 The supplier shall keep the representative of APEPDCL informed in advance about the
manufacturing programme so that arrangements can be made for inspection. The APEPDCL
reserves the right to insist for witnessing the acceptance/routine testing of the bought out items.
The supplier shall give 15 days (for local supply) 30 days (in case of foreign supply) advance
intimation to enable the APEPDCL to depute its representative for witnessing the acceptance and
routine tests.

 Acceptance of poles

a) The standard of acceptance for the cube test on concrete:- The compressive strength shall
be as specified in above clauses where the compressive strength of concrete at 28 days as
determined above, falls below 400 Kg/Sq.cm, the corresponding lots of poles shall be rejected.

b) Dimensional tolerances and surface finish : -The poles are also checked for the
requirements of overall length, up rightness and cross section etc., and if they exceed the
corresponding limits’ specified in IS: 1678-1998/ IS 13158-1991 these poles are summarily
rejected from lots or sub-lots.

c) A lot of poles shall be considered acceptable, if compressive strength of the concrete is

acceptable and the corresponding test pole from the lot passes all the tests mentioned in Clause 11
(e.)

d) A lot or sub-lot shall be considered as conforming to the specification if the tested poles
satisfies the requirements as per the conditions given in IS: 1678-1998/ IS 13158-1991 which are
as follows.
1. A Pressed Concrete Spun pole shall be deemed not to have passed the test-if cracks
wider than 0.1mm appears are developed at a stage prior to application, of working Load.
2. A Pressed Concrete Spun pole Poles Shall be deemed not to have passed the test if the
cracks developed up to 70% of transverse load are not closed when the load is brought back
to zero.
3. A Pressed Concrete Spun pole Pole shall be deemed not to have passed the test if the
observed ultimate transverse load is less than the designed ultimate transverse load.

e) During the transverse strength test, if one or more poles fail, twice the number of poles
originally tested may be selected from lot and subjected to test. If there is no failure among these
poles the lot or sub-lot shall be considered to have satisfied the requirements of this test.

Re-tests
a) If any of the poles tested for Static Bending Strength as per Clause 12 fails to fulfill the
values, then two additional poles from the same lot shall be selected for re-testing and if both
those poles pass the test, the lot presented by these pole shall be accepted if the lot is otherwise
acceptable except for the poles which originally failed in the test. If either of those two additional
poles fail, the whole lot shall be rejected.

Loading and dispatching

a) Only those poles which have been passed by the Engineer shall be loaded for dispatch.
b) The loading of the poles in the vehicles and unloading at destination shall be the
responsibility of the Supplier who will take all necessary precautions so as to avoid any damage to
the poles in loading and transit. The loading shall be done according to the arrangement approved
by the Engineer. The poles shall be properly secured in the vehicles to avoid movement and
displacement in transit.
 c) The poles if any damaged during the transit or due to mishandling, the cost of such poles
(damaged ) are to be suppliers account and the balance poles supplied in good condition only will
be taken into account.
d) The supplier should intimate the officer concerned in the field about the date of delivery in the
field well in advance of the intended date of dispatch.
e) The serial number on each pole should legibly marked with paint on sided also
f) MARKING: The poles shall be clearly and indelibly marked with the following particulars
during manufacture. The mark shall be done by pressing embossed figures / letters of 50 mm
height and 20 mm width with gap of 5 mm between two figures.
(i) Date, month & year of manufacture, (On front face)
(ii) Serial number of pole, and (On front face)
(iii) Maker’s serial number or mark (On both side faces) in oil painting to be marked
before placing in curing pond.
(i) “APEPDCL” symbol (above planting depth) in oil painting to be marked with Yellow back
ground with Black coloured letters
v) The pole shall also be suitably marked for the planting depth from bottom.

g) The poles have passed test from the lot at 1 in 200 should only dispatched to the field and
the serial number of poles supplied shall be noted in the invoice / gate pass

Guarantee

b) The Supplier shall guarantee the poles for a period of 18 months from the date of
delivery of pole. or one year after they have been put in service in line, whichever is earlier.
If during the guarantee period, any poles are found to develop defects attributable to bad materials
and workmanship requiring withdrawal from service, the cost of replacement shall be born by the
Supplier. The defective poles withdrawn from service shall be handed over at site to the Supplier
for his disposal. The manufacturer shall make good the cost of replacement within 60 days of
advice of defects, during which period, the manufacturer or his representative shall be given
permission to inspect the poles, make his observations and carry out check or examine jointly with
the Engineer.

TESTING OF 11.0 M LONG PRESTRESSED CONCRETE SPUN POLE

WORKING LOAD 350 Kg.

POLE NO. :- Agreement No :

Crack width : 0.1 mm Date of Casting :
Date of testing :
Cover : 20 mm F.O.S.:- 2.0

Percentage of Land applied Deflection Permanent Remarks on

Ultimate Load in Kg. deflection cracks obseved
(mm)
At tip At At At
(mm) load tip load
(mm) (mm (mm)
)
10% 70 Kg
20% 140 Kg
30% 210 Kg
40% 280 Kg
50% 350 Kg
 0
60% 420 Kg
0
70% 490 Kg
0
80% 560 Kg
85% 595 Kg
90% 630 Kg
95% 665 Kg
100% 700 Kg
With F.O.S. of 2.0 the ultimate load to be applied works out to 700 Kg. for a W.L. of 350 Kg.

TESTING OF 12.5 M LONG PRESTRESSED CONCRETE SPUN POLE

WORKING LOAD 350 Kg.

POLE NO. :- Agreement No :

Crack width : 0.1 mm Date of Casting :
Date of testing :
Cover : 20 mm F.O.S.:- 2.0

Percentage of Land applied Deflection Permanent Remarks on

Ultimate Load in Kg. deflection cracks obseved
(mm)
At tip At At At
(mm) load tip load
(mm) (mm (mm)
)
10% 70 Kg
20% 140 Kg
30% 210 Kg
40% 280 Kg
50% 350 Kg
0
60% 420 Kg
0
70% 490 Kg
0
80% 560 Kg
85% 595 Kg
90% 630 Kg
95% 665 Kg
100% 700 Kg

With F.O.S. of 2.0 the ultimate load to be applied works out to 700 Kg. for a W.L. of 350 Kg.

S.No Parameter 11-190-350 12.5-190-350

12.5-190-
11-190-50(190TipØ,
1 Product Designation 350(190TipØ,
working Load 350Kg)
working Load 350Kg)
2 Height of Pole 11 mtr 12.5 mtr
3 Tip Diameter of the pole 190mm 190mm
Bottom Diameter of the
4 337mm 357mm
Pole
5 Shell Thickness 50mm 50mm
13.33 per running
6 Tapper 13.33 per running meter
meter
7 Working Load 350Kg 350Kg
8 Factor Of safety 2 2
M50 – conforming as per M50 – conforming as
9 Concrete Mix
IS 456-2000 per IS 456-2000
10 Weight of the pole 905kg 1080kg
11 Planting Depth 1.8 M 2.0 M
 8M/200 Kg PSCC Pole Design details
145 90
ALL DIMENSIONS ARE IN mm
250
600
GI Earth wire No 8
SWG -1 No
TENSIONED WIREs 12
Nos-4mm

UNTENSIONED WIREs 2
Nos-4mm

59
5900 20
8000 20

TOP SECTION
3900

290
GL 24
59
20
150

1100
0
BOTTOM SECTION
290 90 DENOTES TENSIONED WIRES
ELEVATION SIDE VIEW
DENOTES UN-TENSIONED WIRES
 8M/300 Kg PSCC Pole Design details
145 100
ALL DIMENSIONS ARE IN mm
250
600
GI Earth wire No 8 -
SWG 1 No
TENSIONED WIREs 12
Nos-4mm

59
20
8000 5900 20

TOP SECTION

380
GL 24
59
20
150

1500

BOTTOM SECTION
380 100 DENOTES TENSIONED WIRES
ELEVATION SIDE VIEW
 9.1m/280 Kg PSCC Pole Design
13 15
250

ALL
300
DIMENSIONS
ARE IN mm
GI Earth wire
No 8 - SWG 1
No

910 200

150

225

GL
300
15

125
110

150
360 150
ELEVATION SIDE VIEW
 9.1m/280 Kg PSCC Pole Design details
ALL DIMENSIONS ARE IN mm
130
360
65 230 65
26

26 35

35
150 28
50
28 35
150
35
26

26 30 30 30
20 20
30
BOTTOM SECTION TOP SECTION
20
PSCC SPUN POLE 9.50 M – 190 – 300
PSCC SPUN POLE 9.50 M – 190 – 350
PSCC SPUN POLE 11.00 M – 190 – 350
PSCC SPUN POLE 12.50 M – 190 – 350
2.0 GENERAL:

The contractor should be well acquainted with the I.E. Rules 1956 as amended
from time to time and with the Indian Telegraph Act 1889 so that the necessary
provisions therein may be followed.

3.0 SURVEY OF THE ROUTE:

The tentative route map of the line to be erected will be furnished by the
APEPDCL to the contractor along with the copy of the concluded agreement.

The contractor is required to carry out the detailed survey of the route of the
line and fix up the locations at the average span indicated in the schedule and
mark the locations and submit a detailed route map to the Engineer in charge of
the work within 30 days for approval. In the course of surveying by the
contractor, any conspicuous variations in the change and physical feature to
those indicated in route map and as actually existing as noticed, the deviations
must be brought to the notice of the APEPDCL’s Engineer. The APEPDCL’s
Engineer if considered necessary shall make alterations to the route map and
communicate the same to the contractor in writing. As such alterations shall be
carried out accordingly and the APEPDCL’s Engineer, after inspecting the
surveyed route and the revised route map shall be given for final approval by
the Engineer in charge in writing to the contractor.

4.0 WAY LEAVES AND TREE CUTTINGS:

The contractor shall submit proposals for way leaves and right of way.
Permission will be obtained by the APEPDCL within reasonable time for the
contractor shall give which due notices. The contractor shall arrange for tree
cuttings or tree branches cutting also without any extra cost.

The width of tree clearance to be adopted for the lines of various voltages is as
detailed below:
11 KV line (Normal Line):

All growth within 4.572 M (15ft) on either side from center line of support all
trees that may fall and foul the line.

In the case of beetle leaf garden all growth within 3.048 Meters (10ft.) on either
side of the line.
11/33 KV (trunk lines):

All growth within 6.096 M (20ft) from the centre line of support and all trees
which may fail and foul the line.

The contractor shall take all possible steps to see that standing crops etc., are
not damaged while attending to tree cutting. When such damage is inevitable
the compensation will be borne by the APEPDCL provided the damage is with
the prior concurrence of the Engineer. The contractor shall bear the
compensation for damage caused by the gangs without prior concurrence of the
Engineer concerned.

No trees shall be cut until APEPDCL has made necessary arrangement with the
authorities concerned and permission is given to the contractor to cut such tree.
The contractor shall arrange to remove the obstacles as soon as possible.

At time however, it may not possible for the APEPDCL to arrange right-of-way
for excavation of pole pits or erecting the poles of stringing the line. At all such
times, the contractor shall shift his gangs to other areas. The rates quoted shall
cover all such contingencies and no extra payments shall be claimed for such
contingencies.

5.0 EXCAVATION OF POLE /STAY/STRUT/ DP /4-Pole PITS:

After the final survey of the line and after marking the pole locations with pegs,
excavation work has to be commenced in accordance to the approved route
map. Excavation is generally done by pick axes, crow V-bars and showers
although some times earth augers are used. Excavation of pole pits in very hard
or rocky soil or in rock beds may involve blasting of rock by suitable
explosives. The pits for the supports are excavated in the direction of the line
as this will facilitate the erection of support, in addition to giving greater lateral
stability, the depth of the foundation to be excavated for pole shall be in
accordance with relevant sketch for the erection of pole or strut or D.P/4P etc.

Excavation rates for poles, struts and D.P./4P pits shall be quoted by the
contractor for the following types of soil including dewatering of pits and
shoring and shuttering wherever necessary. No quotation for extra rate for
dewatering during excavation and shoring and shuttering will be entertained.

All soils other than hard rock.

Hard rock: Hard – Rock will be that which requires drilling and blasting by
any method. The cost of drilling and blasting shall be included in the quoted
rates. In certain cases, when the area around the location happens to be an
inhabited area consequent to which blasting cannot be restored to, the
 excavation may have, to be dug with or by the process of drilling wedging,
hammering and splitting or by the process of heating and splitting by sudden
cooling. The rate quoted shall take into consideration such contingencies also.
Whenever blasting is resorted to, the contractor shall make adequate
arrangements of safety precautions. The A.P.E.P.D.C.L. will not be responsible
for any damages or accidents arising out of process of blasting.

Note: For soils other than hard-rock excavation rate to be quoted shall include
back filling the pits with excavated soils after concreting wherever necessary.

For soils covered by hard rock variety, the excavation rate shall be including
back filling with excavated rock bits and borrowed earth duly reamed after
laying the designed rock foundation.

No extra charges shall admissible for the removal of the fallen earth in the pit,
when once excavated.

The quoted rates should cover all contingencies during the process of
excavation. For any reasons what so ever, no extra claim will be accepted.
4 Pole Strucutre:
Supply and erection of line 4 Pole structure with poles (fixing of
100x50mm MS channel cross arm at top and botom & 65x65x6mm MS angle
for brasing with necessary back clamps with 75x8mm, 50x6 mm MS flat at
various locations including supply and erection of 33KV Ploymer disc
insulators with hard ware including jumpering providing suitable size
alluminium T' clamps including supply and erection of 4nos No. GI earth pipe
with flange (40mm dia, 2.5Mt long) as per drawing, double earthing should be
done for all the structure parts including AB switches with 8mm GI wire and
coil earthing is to be done for AB switch handle, erection of earth pipe and
supply and refiling the earth pit with bentonite compound and black cotton soil
(in 1:6 ratio) and giving connections as per departmental standards as per
drawing enclosed. spun pipe of 2 feet dia. and 2 feet height (cement collar)
shall be provided around each earth electrode and all the earth wires should run
through 1"dia PVC pipe 3' above the ground level and 2' below the grond level
along the pole (wherever alluminium feerules are used, alluminium tape is to be
wound over the conductor to have better grip).
Line 4 pole structure with 12.5 Mts Spun poles, 3Nos A.B.Switches, Bus and
jumpers with Panther conductor and 4Nos 9.1M PSCC poles as struts and pole
concreting has to be done

6.0 FOUNDATION:
Classification of Foundation:
Depending on the type of soils, the subsoil water table and the presence of
surface water, four types of foundation designs will be used for each locations
classified in the following manner.
1) Wet type: To be used for locations:
Where sub-soil waters is wet at 1.5 meters or more below the ground level.

Which are in surface water for long period with water generation not exceeding
one meter below the ground level e.g. the paddy fields.

2) In black cotton soils.

a) Partially submerged type:

To be used at locations where sub-soils water table is met at more than 0.75
meters from the ground level.

b) Fully submerged type:

To be used at locations where sub-soil waters is met at less than 0.75 meters
from the ground level.

3) Rocky type:
To be used at location where hard rock is met with and where the bond strength
between the rock and the concrete will be very high.

7.0 ERECTION OF SUPPORTS:

11 Mtr Spun/PSCC poles for 33KV line and 9.1 Mtr poles for 11KV line are to
be used.
9.1Mtr PSCC poles for 33 KV and 8.0 Mtr PSCC poles for 11 KV line are to
be used as struts and wherever required stays also can be used.

After the excavation of pits is completed the supports to be erected may be

brought to the pit location. Then the pole may be erected inside the pit.
Wooden support may be utilized to facilitate lifting of the pole at the pit
locations.

Before the pole is put into the pit, RCC padding may be laid below the pole to
increase the surface contact between the pole and the soil. The padding will
distribute the density of the pressure due to weight of the pole on the soil.

Having lifted the pole, the same should be kept in a vertical position with the
help of manila rope of 25 mm dia. using the rope as a temporary anchor.
 As the poles are being erected say from the pole already erected to the next
location where the pole is being erected the alignment of the poles are to be
checked and set right by visual check. The verticality of the poles is to be
checked with a spirit level on both transverse and longitudinal directions.

Having satisfied that the verticality and alignment are all right earth filling or
concreting is to be done.

In swampy and special locations, however, before earth filling, the poles are to
be concreted up-to ground level of the pit.

After the poles have been set the temporary anchors are to be removed. The
supports shall be buried to a depth as per sketch enclosed.

8.0 ERECTION OF T.P./DP/4-Pole STRUCTURES FOR 33KV LINE AND D.P

STRUCTURES FOR 11KV LINES AT ANGLE LOCATIONS:

10 ft (3048 mm) & 7 ft (2134 mm) MS channel of size 100 x 50 mm line TP’s /
DP’s for 33KV & 11KV are to be erected one in three to five Km and AB
switch on the DP are to be erected at angle points. One AB switch is to be
erected at every 3 KM and depending on angle point as per field conditions and
as per the direction of the engineer.
Generally, for angles of deviation more than 200 double pole structures of
spacing 5ft may be erected. The pits are to be excavated as per the bisection of
the angle of deviation.

After the poles of DP are erected, the horizontal/cross bracings should be fitted
and the supports held in a vertical position with the help of temporary guys of
manila rope at least 25 mm dia. Ensuring that the poles are held in a vertical
position (this can be checked with a spirit level) the concreting of the poles with
cement, granite chips of size 20/30 mm mesh and sand in the ratio M400
conforming to ISS is to be done from the bottom of the support to the ground
level. Before lifting the pole in the pit, concrete padding of not less than 75
mm thickness may be put for the distribution of the load of the support on the
soil.

After the concreting is done, the pit may be filled with earth after the curing of
the concrete is completed.

Four stays or 2 struts & 2 stays along the line, two in each direction and two
stay/struts along the bisection of the angle of deviation, are to be provided.
Stay/Strut concreting may be done with M 400 mixture.
 The D. P. shall be erected as per the sketch enclosed.

9.0 ANCHORING AND PROVIDING GUYS FOR SUPPORTS:

Guys are to be provided to the supports at the following places (I) Angle
locations, (ii) Dead end locations, (iii) Tee-off points, (iv) Steep gradient
locations to avoid uplift on the poles.

The installation of guy will involve the following works:

Excavation of pit and fixing of stay rod.
Fastening guy wire to the support.
Tightening guy wire and fastening to the anchor.
The marking of the guy pit for excavation, the excavation of pits and setting of
the anchor rod must be carefully carried out. The stay rod should be placed in
the position such that the angle of inclination of the rod with the vertical face of
the pit is as the case may be. The concreting of the stay at the bottom should
then be carried out. The back filling and ramming must be well done thereafter,
and allowed to set for at least 7 days. The free end of the guy wire is passed
through the eye of the anchor rod, bent back parallel to the main portion of the
guy and bound after inserting the G.I. thimble. The G.I. thimble protects the
loop where it hears on the anchor rod. Where the existence of guy wire proves
hazardous, it should be protected with suitable asbestos pipe, filled with
concrete, of about 2Mtrs. length above the ground level, duly painted with
white and black stripes so that it may be visible at night. The turn buckle shall
be mounted at the pole end of the stay and guy wire so fixed that the eye bolt
turn buckle is half way in the working position thus giving the maximum
movement for tightening or loosening.

Guy insulators are placed to prevent the lower part of the guy from becoming
electrically energized by a contact of the guy when the conductors snap and fall
on them or due to leakage. No guy insulator shall be located less than 2.6Mtrs.
from the ground. The anchoring and providing guys for supports (Single guy
Bow guy an fly guy) shall be done as per sketch 3 enclosed. Bow guy and fly
guy shall have to be provided as per the field conditions.

10.0 FIXING OF CROSS ARMS AND INSULATORS

After the erection of supports and providing guys, the next step would be mount
the cross arms on the support. The cross arm is to be mounted after the support
is erected. The lineman should climb the support having requisite tools with
him and the cross arm is then tied to a hand line and pulled up by the ground
man, through a pulley till the cross arm reaches the linemen. The ground man
should station himself well to one side so that if any material drops from the top
of the pole it may not strike him. All the materials required should be lifted or
lowered by means of the hand line. In no case, the material or the tools should
be dropped or thrown from the pole top.
 The fixing of 33 KV and 11 KV cross arms shall be in accordance to spacing
detailed in Sketch G.I. bolts and nuts and spring washers of good quality only
shall be used which have to be procured by the contractor.

10.1 Back Clamps:

The back clamps for fixing of the “V” cross arms will have to be procured by
the contractor and shall be in accordance with sketch enclosed and the clamp
shall be fabricated with 75 X 8mm GI Flat for 33 KV and 50 X 6 mm GI Flat
for 11 KV.

10.2 Top Cleats:

The top cleat shall be got fabricated with GI. channel of 100x50mm and GI
angle of 65x65x6mm for 33 KV and 11KV respectively shall be in accordance
with sketches enclosed.

11. INSULATORS
The pins for insulators shall be fixed in the holes provided in the cross arms and
the pole top brackets. The insulators shall be mounted in their places over the
pins and tightened. In the case of strain or angle supports, where strain fittings
are provided for this purpose, on strap of the strain fittings is placed over the
cross arm before placing the bolts in the hole of the cross arms. The nut of
straps is so tightened that the strap can move freely in horizontal direction, as
this is necessary to fix the strain insulator.

Note: The insulators shall be cleaned and examined for defects before fixing.
It shall be ensured that all the current carrying parts are smooth and without
dirt, cracks or chips.

12.0 STRINGING OF THE LINE CONDUCTORS:

For the guidance of the contractor in handling the conductor and in stringing
certain Do’s and Don’ts are given below, before the workmen actually
commence the stringing work.

12.1 Do’s and Don’ts

Do’s:
Use proper equipment for handling aluminum conductors at all times.

Use skids, or similar method for lowering reels or coils from transport or
ground.
Examine reel before unreeling for presence of nails or any other object, which
might damage the conductor.
Rotate the reel or coil while unwinding conductor.
 Grip all strands while pulling out the conductor.
Control the unreeling speed with a suitable braking arrangement.
Use wooden guards of suitable braking arrangement.
Use long straight, parallel jaw grip with suitable liners when pulling conductor
thus avoiding nicking or kinking of the conductor.
Use free-running sleeves or blocks with adequate grooves for drawing/paving
conductors.
Use proper sag charts.
Mark conductors with crayons or adhesive tape of such (other) material which
will not damage the strand.
Make all splicing with the proper tools.
Use a twisting wrench for twisting the joints.
Chromate or graphite conducting oxide-inhibiting grease should be applied
before cleaning with wire brush.

Don’ts:
Do not handle conductors without proper tools at any stage.
Do not pull conductors without ensuring that there is no obstruction on the
ground.
Do not pull out excess quantity of conductor than required.
Do not make jumper connections on dirty or weathered conductor. Clean the
conductor using sand paper or wire brush.
Do not handle aluminum conductors in a rough fashion but handle it with care
it deserves.

12.2 Conductor Erections

The erection of overhead line conductor is a very important phase in

construction.
The erection of conductor’s can be sub-divided into 4 separate parts as follows:

Transport of conductors to work site.

Paving and stringing of conductors.
Tensioning and sagging of conductors.
Jointing of conductors.

At important crossing of roads, canals, navigable rivers, railways etc., flagmen

should be in attendance to ensure that normal services are not unduly
interrupted. These crossings should only be carried out in conjunction with and
with the approval of the proper authorities concerned.

The conductor drums shall be transported to the tension point without injuring
the conductor. If, it is necessary to roll the drum on the ground for a small
distance, it should be slowly rolled in the direction of the arrow marked on the
drum. The drum should be so supported that it can be rotated freely. For this
purpose the drum should either be mounted on the cable drum supports or jacks
or hung by means of chain pulley of suitable capacity, suspended from a tripod.
In case if it is not possible to raise the conductor drum by any of the above
methods, a trench of suitable depth slightly bigger than the conductor drum may
be dug, so as to facilitate free rotations of the drum when it is suspended in the
trench by means of M.S. Shaft. While paving, care should be taken to see that
conductor does not rub against any metallic fitting of the pole or on the
bad/rocky ground. Wooden tussles should be used for this purpose to support
the conductor.

The conductor should be passed over the poles on wooden or aluminum snatch
pulley blocks provided with low friction bearings. While conductor is being
paved out slowly, some braking arrangements should be made so that the
rotation of the drum may be stopped in emergency.

In case the length of one piece of the conductor is less than the length of the
section in which conductor paving is being done, it is easy to stretch one length
of all phases from one end and the remaining length from another end of the
section and thereafter jointing the two ends of the conductor where they meet
on no account any part of the conductor shall be left at a height of less than 5
meters. Above the ground over night and the work shall be so arranged that
before the end of the day, the conductor shall be raised to minimum height of 5
meters above the ground by rough sagging.

12.3 Mid Span Jointing of Conductors:

The mid span jointing of conductors should be carried out by using 2Nos.
aluminum ferrules of required size, one inner and one outer ferrule and the
crimping of the ferrules is to be done by using proper crimping tools.
Aluminum tape is to be wound over the conductor before insertion into the
ferrules to have better grip.

12.4 Sagging and Tensioning:

On the completion of the paving of the conductors and making mid-span joints
if any, tensioning operations will commence. Temporary stays will have to be
provided for both the anchoring supports in the section where the stringing has
to be done. At the tensioning end, one of the conductors is pulled manually up
to a certain point and then come along clamp is fixed to the conductor to be
tensioned. The grip to the come along clamp is attached to double sleeve pulley
block or the pulley lift machine and gradually tensioned.
The conductor should then be sagged in accordance with the sag-temperature
chart for the particular conductor and span. The sag should then be adjusted in
the middle span of the section. The Engineer will provide the sag chart.

The stretch of the conductor has to be taken out before stringing in order to
avoid the gradual increase in sag due to the setting down of the individual
wires. There are ways of accomplishing this.

12.5 Pre Stressing:

In this method the conductor is pulled up to a tension considerably above the
correct figure, but never exceeding fifty percent of breaking load for a short
period of say twenty minutes. As this method requires more time and involves
the use of stronger tackle to secure the higher tension the other method of over-
tensioning is commonly adopted.

12.6 Over tensioning:

This method consists of pulling up the conductor to a tension a little above the
theoretical tension for the prevailing temperature and fixed it up at that tension
with correspondingly reduced sag. After a certain time the conductor will settle
down to the correct sag and tension. A tension of five to eight percent more
than the theoretical value has been found to be suitable for the sizes of ACSR
and AAAC conductors standardized by REC. The ambient temperature during
sagging may be recorded correctly.

Conductors can be sagged correctly only when the tension is the same in each
span through out the entire length of the section. Use of snatch blocks reduces
the friction and chances of inequality of tension in various spans.

Sagging can be accomplished by several different methods but most commonly

used method is “sighting”. The sighting sag method of measuring sag is by the
use of targets placed on the supports below the cross arms. The targets may be
light strip of wood clamped to the pole at a distance equal to the sag below the
conductor when the conductor is placed in snatch block. The lineman sees the
sag from the next pole. The tension of the conductor is then reduced or
increased, until, the lowest part of the conductor in the span coincides with the
lineman’s line of sight.

When sagging is completed, the tension clamps shall be fixed. The clamp can
be fitted on the conductor without releasing the tension. A mark is made on the
conductor at a distance from the cross arms equal to the length of complete
strain insulator. Before the insulator sets is raised to position, all nuts should be
free. Come along clamp is placed on the conductor beyond the conductor
clamp and attached to the pulling unit. The conductor is pulled insufficiently to
allow the insulator assembly to be fitted to the clamp. After the conductor is
clamped to insulator, assembly unit may be released gradually. If the tension is
released with a jerk, an abnormal stress may be transferred to conductor and
support, which may result in the failure of the cross arms, stay or pole in some
 cases. After the stringing is completed, all poles, cross arms, insulators, fitting
etc., are checked up to ensure that there have been no deformities etc.

The next step is to place the conductor on the top of the pin insulator from the
snatch block and removing snatch blocks. Conductors are then fastened to
insulator by the use of aluminum wires. The following points should be
observed:

Proper size of the binding wire which can be readily handled and with
adequate strength to be used.

The length of tie wire should be sufficiently long for making complete tie
including the end allowance for gripping with the ends.

A good tie should provide a secure binding between the line conductor and
insulator and should reinforce the conductor on either side of the insulator.

The use of cutting pliers for binding the site wire should be avoided.

The tie wire, which has been used, previously should not be re-used.

Before tieing the conductor to the insulator two layers of aluminum tape should
be wrapped over the conductor in the portion where it touches the insulator.
The width and thickness of aluminum tape to be used for a specific size of
conductors has been specified in handbooks of aluminum conductor
manufactures and the same may be preferred to. The aluminum tapes should
also be used at the tension clamp and for proper grip.

Normally in straight runs of line, the conductors are run on the top of insulators,
when there is small angle of deviation the conductor is placed inside groove and
binded. Accordingly, there are two methods of tieing the conductors to
insulators. The binding wire/tie wire has to be procured by the contractor
and the bid price shall include the cost of this.

The contractor shall entirely responsible for any damage to the supports, other
accessories and conductor. He shall also be responsible for proper distribution
of the conductor drums to keep number and lengths of cut pieces of the
conductor to a minimum.

12.7 Conductor damage and repair:

If the conductor is damaged for whatever reasons and damage is not repaired
aluminum sleeves etc., it shall be brought to the notice of the Engineer and shall
not be used without his approval. Even repairing of conductor surfaces shall be
 done only in case of minor damages, scuff marks etc. which are safe from both
electrical and mechanical points of view. The final conductor surface shall be
clean, smooth, without any projections, sharp points, cut or abrasion etc., giving
satisfactory corona and R.I performance.

No joint or splice be made in spans crossing over main roads, railways, small
rivers or in tension spans. Not more than one joint per conductor shall be
allowed in one span. The strength of the joint shall confirm to I.E rule 75.
12.8 Stringing rate:

The stringing rate for stringing of the conductor per route length of line shall
include paving, stringing, clamping, jointing, tensioning, strain disc binding,
clamping and fitting of all necessary accessories. Wherever necessary ground
clearance have to be measured to ensure obtaining adequate line clearance as
per I.E. rule 77 (I).

12.9 Jumpering

The jumpering at all locations where it is required i.e. cut points and tapping
points etc. Should be done by using aluminum T-Clamps of suitable size
required for the conductor, and using aluminum tape over the conductor at the
T-clamp location to have a better grip. The bolts of the T-clamps should be
tightened to the required torque to prevent any loose contacts at the jumper
locations.

13.0 EARTHING

13.1 Pipe Earthing:

At T.P/D.P. Location pits are to be excavated, the steel and metal parts are to be
earthed by pipe earthling as per the drawing of sketch enclosed to this
specification. Duly filling the pits with bentonite compound and black cotton
soil (in1:6 ratio) and shall be maintained up-to a distance of 300 mm from the
pipe in all sides. The top edge of the pipe shall be at least 200 mm below the
ground level. The steel strips shall be fixed not less than 300 mm deep from the
ground level.

The tenders shall quote the charges for earthing inclusive of the cost of
bentonite compound and block cotton soil, excavation and back-filling.

13.2 Pole Earthing:

All supports shall be properly earthed with coil earthing.

 The earthing of TP/DP structures should be done in the presence of Deputy
Executive Engineer/ Construction only.

13.3 CROSSINGS:
Guarding shall be erected as per standards and as per sketch a, b, c, enclosed for
Railways, telephone lines and power lines.

14.0 EXECUTION OF WORKS RELATING TO POWER LINE CROSSINGS

AND RAILWAY CROSSINGS:

Work such as erection of support underneath an existing power line and paving
out of conductors and earth-wire and stringing the power line crossing span or a
railway crossing span, will have to be done only after receipt of line clear from
APEPDCL authorities and approval from the concerned officer, which some
times, may not match with program of the contractor. In such cases, the
contractor shall execute such works as and when approvals are received. His
rates for line erection and stringing shall take into consideration such
contingencies also.

15.0 CONCRETING:
Note: All TP/DP structures, Vertical formations, Single pole cut points
and Angle locations and every 5th pole as per the direction of Engineer-in-
Charge should be concreted. FOR 33KV & 11KV Line with Spun Poles, all
poles should be concreted.

The cement concrete used for the foundation shall be of ratio 1:3:6 using 40mm
HBG metal.
The sand used for the concrete shall be composed of hard silicon materials and
well sieved. It shall be clear and a sharp angular grit type of and free from
earthy or organic matter and deleterious salts.

The aggregate shall be of clean broken hard granite or other stone specified or
approved by the Engineer. It shall be hard, close grained quality. It shall also
be as far as possible cube like preferably angular, but not flaky, perfectly clean
and free from the earth organic or other deleterious matter, 40 mm aggregate
shall be of size as will pass through 40 mm square mesh measured in the clear.

The water used for mixing concrete shall be fresh and conform to ISI it should
be clean and free from oil, acids and alkali. Saltiest or brackish water should
not be used.

The concrete should be mixed as stiff as the requirements of placing the

concrete in the forms or moulds with as and the degree to which the concrete
 resists segregation will permit. Hence, the quantity of water used should not be
too much.

Proper forms of moulds adequately braced to retain proper shape while

concreting should be used. The mould should be made watertight so that
cement cream will not come out leaving only sand and jelly consequently
forming honeycombing in the concrete. The rate for concrete should be made
so that the works are not held up on this account.

After concerting to the required height, the top surface should be finished
smooth, with slight slope towards the outer edge to drain off the rainwater
falling on the copings. These copings and muffing should be done after the
stringing is completed in respect of tension locations and the Engineer at site
may decide such other locations as. For such locations an adhoc reduction of
Rs.100/- per location will be made while billing for concrete and this will be
released after the coping and muffing are completed.

In wet locations, the site must be kept completely dewatered both during the
placing of the concrete and for 24 hours after completion. There should be no
disturbance of concrete by water during this period. No extra rate will be paid
for the dewatering and the rate for concrete shall be inclusive of dewatering
charges.

The forms of moulds shall not be removed before a lapse of about 24 hours
after the completion of concreting. After removal of the form moulds, the
concreted surface, wherever required, shall be repaired with a rich cement and
sand motor in the shortest possible time.

The full concreting for the poles if erected in excavated pit shall be done so that
the complete block will be of the dimensions 0.7 x 0.7 x 2 Mtr for 11 Mtr and
0.6X0.6X1.5 Mts for 9.1 Mtr PSCC pole up to ground level including base
concreting of 75mm thick with 1:3:6 CC mix.

If augur is used for making pole pits, ramming shall be done after erection of
pole.

16. WORKMANSHIP:
The contractor shall entirely be responsible for the correct erection of all
support as per the approved drawings, and their correct setting and alignment,
as approved by the Engineer. If the supports and D. P. structures after the
erection are found to differ from approved route maps and drawings or to be out
of alignment, the contractor shall dismantle and re-erect them correctly at his
own cost without extension of time. The supports must be truly vertical and in
plumb after erection and so straining will be permitted to bring them to vertical
 position. Verticality of each support shall be measured by the contractor and
furnished to the Engineer.

17. Location numbers for each pole shall be painted on the pole.
Anti-climbing devices, and danger boards are to be provided at all railway
crossings and road crossings and DP locations. No extra charges shall be
admissible even though separate gangs may have to be sent by the contractor
for fitting these accessories and attachments on the support at the appropriate
time.

18. FINAL CHECKING, TESTING AND COMMISSIONING

After the completion of the works final patrolling and checking of the line shall
be done by the contractor to ensure that all the foundation works, pole erection
and stringing have been done as approved by the Engineer, and also to ensure
that they are complete in all respects. Contractor shall prepare pole schedules
and hand it over to the Engineer. All works shall be thoroughly inspected
keeping in view of the following main points.

i) Sufficient back filled earth is lying over each foundation pit and it is
adequately compacted.
ii)Concreting and coping of poles are in good and finally shaped conditions.
iii) All the accessories and insulators are strictly as per the drawings and
are free from any defects or damages, what so ever.
iv) All the bolts and nuts should be hot dip G.I. material and as per
contractual provisions.
v) The stringing of the conductor has been done as per the approved sag
and desired clearances are available.
vi) No damage, minor or major to the conductor, earth wire, accessories
and insulator strings will unattended are noticed.
vii) For all points double jumpers shall be provided to each phase. The
jumpers provided at the cut points are connected rigidly to the tension hardware
utilizing all the jointing bolts provided for the purpose.

The contractor shall submit a report to the above effect to the Engineer. In
case, it is noticed later that some or any of the above are not fulfilled the
engineer will get such items rectified through other agencies and recover
the cost of such works from the bills payable to the contractor against that
contract or any other contract executed by him for the APEPDCL

After final checking, the lines shall be tested for insulation in accordance with
tests prescribed by the Engineer. All arrangements for such testing or any other
test desired by the Engineer, shall be done by the contractor and necessary
labour, transport and testing equipment shall be provided by him. The
contractor defects found out as a result of such tests, shall rectify any,
forthwith, without any extra charges to the APEPDCL
 In addition to the above, the contractor shall be responsible for testing and
ensuring that the total and relative sags of the conductors are within the
specified tolerance. Such tests shall be carried out at selected points along the
route as required by the Engineer and the contractor shall provide all necessary
equipment and labour to enable the test to be carried out. After satisfactory
tests on the line and approval by the Engineer the line shall be energized at full
operating voltage before handling over.

19. SUPPLY OF MATERIALS BY APEPDCL

The material to be supplied by the APEPDCL will be delivered at APEPDCL stores

nearby. The contractor is responsible for handling, storage, and maintenance and safe
custody of the materials from the time of taking over until the date of issue of completion
certificate. No handling transport or storage charges shall be paid by the APEPDCL to the
contractor for the materials supplied by the APEPDCL for erection.

20. Supply of materials by the contractor:

The contractor has to make his own arrangements for procurement, supply and
use of materials and compliance of the following should be ensured.

These materials should conform to the relevant Indian Standard specification.

These materials shall be supplied at least one month in advance of their
requirement manufactures test certificate for these materials shall be submitted
and got approved by Engineer before utilization. He shall guarantee the
materials so supplied by the contractor for satisfactory performance up to the
end of the maintenance and defects liability period.

All materials to be supplied should fully conform to provisions under clause 3

of Instructions to Bidders.

In procurement of these items the contractor shall follow all regulations of the
APEPDCL/Government of India in respect of import license etc., if he chooses
to procure these from imports. Further, the contractor shall be responsible for
the payment of applicable duties and taxes, port clearance inland transportation
etc.

The materials for which advance is given by APEPDCL is to be insured by the

contractor at his cost from the date of payment of advance to the date stated in
the certificate of completion for the whole of the works.

Material & Quality:

All the material used in the works shall be of the best quality of their respective
kinds as specified herein. They shall be obtained from sources and suppliers
approved by the Engineer or his representatives, and shall comply strictly with
the tests, specified herein after or, where tests are not specified in this
 specification, they should conform to the requirements of the latest issue of the
relevant Indian standards herein after abbreviated to as (I.S.) or other approved
National Standards authorized by the Engineer. The contractor has got the
obligation of showing the proof of source of any material procured by him, to
the APEPDCL on demand.

Inspection and Testing:

Any materials used in the works shall be subject to inspection and tests if
required by the Engineer. Unless otherwise stated, the costs of all tests required
by this specification shall be deemed to be included in the rates and prices
named by the contractor in the bill (schedule) of quantities.

Any material, which is prepared or manufactured without notice having been

given in writing to the Engineer, may be rejected if the Engineer considers that
his inspection was necessary during the process of manufacture of such
material.

Approvals: No material shall be used in the works unless the Engineer or his
representative has first approved it.

21 INFORMATION AND DATA:

The information furnished is the best available however, the APEPDCL does
not guarantee the correctness or interpretations, deductions or conclusions
which are given as supplementary information in the Bid Documents or in any
reports, maps, drawings, diagrams or in other reference information available to
the bidder from the APEPDCL of or otherwise.
The information have been produced as found, communicated to ascertained or
otherwise learned by the APEPDCL

It will be the Bidder’s responsibility to satisfy himself from the “Reference

Information” supplied and/or inspection of the site that sufficient quantities of
construction materials required for the works shall exists in the designated
borrow areas or quarry sites.

The APEPDCL does not accept any responsibility either in handing over the
quarries or procuring the materials or any other facilities. The Tenders will not
be entitled for any extra rate or claim for the misjudgment on his part for the
quantity and quality of materials available in the quarries.

Failure by the Bidder to have done all the timings, which is in accordance with
this condition he is deemed to have done, shall not relieve the successful Bidder
of the responsibility for satisfactorily completing the works as required at the
rates quoted by him.
22 CONSTRUCTION MATERIALS:

Cement: The contractor has to make his own arrangements for the
procurement of cement to required specifications required for the works
subjected to the followings:

a) The contractor shall procure cement, required for the works only from
reputed cement factories (Main producer) acceptable to the Engineer –in-
Charge. The contractor shall be required to furnish to the Engineer –in-Charge
bills of payment and test certificates issued by the manufactures to authenticate
procurement of quality cement from the approved cement factory. The
contractor shall make his own arrangement for adequate storage of cement.

b) The contractor shall procure cement in standard packing of all 50Kg per
bag from the authorized manufacturers. The contractor shall make necessary
arrangement at his own cost to the satisfaction of Engineer-in-Charge for actual
weighment of random sample from the available stock and shall conform with
the specification laid down by the Indian Standard Institution or other standard
foreign institutions as the case may be, Cement shall be got tested for all the
tests as directed by Engineer-in-Charge at-least one month in advance before
the use of cement bags brought and kept in site Godown.

The Contractor free of cost shall supply cement bags required for testing.
However, the testing charges for cement will be borne by the APEPDCL. If the
tests prove unsatisfactory, then the charges will be borne by the Contractor.

c) The Contractor should store the cement of 60 days requirement at

least one month in advance to ensure the quality of cement so brought to
site and shall not remove the same without the written permission of the
Engineer-in-Charge.

The Contractor shall forthwith remove from the works area any cement that the
Engineer-in-Charge may disallow for use, on account of failure to meet with
required quality and standard.

The contractor shall further, at all times satisfy the Engineer-in-charge on

demand, by production of records and books or by submission of returns and
other proofs as directed, that the cement is being used as tested and approved by
Engineer-in-charge for the purpose and the Contractor shall at all times, keep
his records up to date enable the Engineer-in-charge to apply such checks as he
may desire.

Cement which has been unduly long in storage with the Contractor or
alternatively has deteriorated due to in adequate storage and thus become unfit
for use in the works will be rejected by the department and no claim will be
 entertained. The Contractor shall forthwith remove from the work area, any
cement the Engineer-in-charge may disallow for use on work and replace it by
cement complying with the relevant Indian Standards.

23 STEEL:
The Contractor shall procure mild steel reinforcement bars, high yield strength
deformed (HYSD) bars, rods and structural steel etc., required for the works,
only from the main or secondary producers manufacturing steel to the
prescribed specifications of Bureau of Indian Standard or equivalent and
licensed to affix ISI or other equivalent certifications marks and acceptable to
the Engineer-in-Charge. Necessary ISI list certificates are to be produced to
Engineer-in-Charge before use on works. The unit weight and dimensions shall
be as prescribed in the relevant Indian standard specifications of steel. The steel
shall be painted with two coat of red oxide and two coats of aluminium paint.

24 WASTAGE:

The contractor will be allowed for the following materials to cover sag and wastage.
(i) Conductor Up to 2% of the route length for each of the conductor.
The contractor will further be allowed to claim additional quantities for materials as per
Actual quantity executed for jumpering and stiffener/reinforcement pieces
(ii) AB Cable Up to 3% route length for the 3x16+25 Sq.mm AB Cable.
Note: The contractor has to follow REC standard for the works wherever it is not
specifically mentioned above.
 24. PRESTRESSED CEMENT CONCRETE POLES
CONDITIONS AND SPECIFICATION (PSCC POLES)
The manufacture of PSCC Poles consists of the following operations

a. The metal and sand should be sieved and thoroughly washed as per the directions of the
Engineer in the center. The mixing of the concrete will be in proportion of (1:1:44:2.7)
(Nominal).
b. The mixing shall be done in a mixer. The proportion of the mix may be verified at the
discretion of the Engineer.
c. Stretching the 4 mm HT wire between the anchors employing manual labour and wrenches
etc to the required tension under the supervision and direction of the Engineer in-charge of
the center and gripping the wires with suitable grippers without any slip whatsoever. This
operation shall be done after setting the moulds in proper position. Before placing the HT
wire inside the form box, the form box is to be cleaned and thin film of oils is to be
applied.
d. Pouring the concrete in the moulds should be done in layers slowly and vibrating should be
done with vibrators.
e. Cutting the wires shall be done with gas cutters or electrical welding set after allowing the
concrete to set in the moulds for prescribed time. The poles shall then be lifted gently kept
in the curing ponds for curing in the site as shown by the Departmental Engineer at site.
f. Curing the poles shall be for 10 days thoroughly as directed by the Engineer.
g. The cured poles shall be stacked within the premises of the PSCC Center as directed by the
Engineer at site.
The cement concrete for casting of the PSCC poles should by M 400 grade using best river
sand and 10 mm to 20 mm HBG metal machine crushed metal should be used at the ratio
of

Sl.No. Description 9.1m/280 Kgs 8.0 m/200 Kgs

1 30% of 20 mm HBG metal 0.071 cum 0.0417 cum

2 35% of 12 mm HBG metal 0.083 cum 0.0486 cum

3 35% of 10 mm HBG metal 0.083 cum 0.0486 cum

0.237 cum 0.139 cum

Serial number of pole and date of manufacture should be marked clearly and neatly before
the concrete sets in indicating the center should also be marked Planting depth of 1500 m from
bottom to be made with out fail.

Earth wire shall be provided with No. 8 GI wire procured by the Contractor leaving 150
mm projections for giving earth connections, as directed by the Engineer at site, continuous wire
shall be run from top to bottom without any joints inside. Running maintenance for the machinery
supplied to the contractor has to be attended by the contractor only at his cost. The machinery
provided to the contractor has to be handled carefully. Any damages caused due to negligent
handling of the machinery will be made good from the contractor.

SPECIAL CONDITIONS FOR POLES MANUFACTURING

The course aggregate (metal) shall be free from dust and dirt and washed to ensure that all faces
are perfectly clean.The sand shall be screened before use. If the sand brought to site is dirty, it
must be washed clean in water. The metal used for manufacturing of poles should be graded metal
consisting the following percentages.

20 mm size 30%

12 mm size 35%

10 mm size 35%

The materials which do not comply with the standard specifications will be rejected and shall be
removed by the contractor from site, failing which the bills of the contractor cannot be processed.

The poles castled shall be covered with gunny bags and continuous, curing to be done till the poles
are kept in curing ponds for curing. The machinery and equipment handed over to the contractor
for manufacturing the poles shall be maintained properly and the same shall be handed over to the
department in good condition.

Note : 1

1. The pre-stressed concrete work shall be done as per specification No. 405 of APDSS.
2. Measurement boxes shall be used for feeding the concrete mixer for raw materials for
manufacturing of poles.

SPECIAL CONDITIONS
The requirement of materials as per the stand red data in force is detailed below per each pole.
DETAILS FOR MANUFACTURE OF PSCC POLES
Sl.No. Description of Material 8.00 M/200 Kgs 9.1M/280 Kgs

1 Cement 53 Grade 73.92 Kgs 126.50 Kgs

2 HT Steel Wire 4 mm dia 10.25 Kgs 16.00 Kgs

3 GI Wire No. 8 0.30 Kgs 0.30 Kgs

 4 Type of pole Solid 1. Section

5 Section a) at top 145 x 90 mm 130 x 150 mm

6 b) at bottom 290 x 90 mm 360 x 150 mm

Number of wire
7 12 (4 mm dia) 16 (4 mm dia)
a) tensioned

8 b) untensioned 2 (4 mm dia)

9 Quantity of concrete 0.157 cum 0.2687 cum

10 Concrete grade M 400 M 400

11 Metal 0.139 cum 0.237 cum

12 Cement 73.92 Kgs 126.50 Kgs

13 Sand 0.074 cum 0.126 cum

14 Steel 10.25 Kgs 16 Kgs

Point application of load

15 600 MM 600 MM
from top

Pretension applied to
16 1350 Kgs 1600 Kgs
each wire

17 Weight of pole 380 Kgs 680 Kgs

18 Factor of safety 2.5 2.5

19 Full tension applied 1750 Kgs.

Note:

1. The minimum ultimate tensile strength of HT wire is 175 Kgs/sq.mm

2. Stress in pre-stressing wire at the time of initial tensioning is taken as 80% of ultimate
tensile strength of HT steel wire.
Inspection
The APEPDCL may carry out inspection at any stage. The successful tenderer shall
grant free access to the representative of APEPDCL at a reasonable time when the
 work is in progress. Inspection and acceptance of any material under this specification
by the employer shall not relieve the supplier of his obligation of furnishing materials
in accordance with the specification and shall not prevent subsequent rejection if the
material is found to be defective.

Guarantee

a) The manufacturer shall guarantee the poles for a period of 18 months from the date of
manufacture or one year after they have been put in service in line, whichever is earlier. If
during the guarantee period, any poles are found to develop defects attributable to bad
materials and workmanship requiring withdrawal from service, the cost of replacement
shall be born by the bidder. The defective poles withdrawn from service shall be handed
over at site to the bidder for his disposal. The contractor shall make good the cost of
replacement within 60 days of advice of defects, during which period, the bidder or his
representative shall be given permission to inspect the poles, make his observations and
carry out check or examine jointly with the Engineer.
 25. 33 KV AB SWITCHES (ISOLATORS)
1.0 SCOPE:
This specification covers design, engineering, manufacture, assembly, stage
testing inspection and testing before supply and delivery at site of the
following:

a) 33 KV 800 A Air Break Switches (Isolators) with solid core insulators.

1.1 It is not the intent to specify completely herein all the details of the design and
construction of equipment. However the equipment shall conform in all
respects to high standards of engineering, design and workmanship and shall be
capable of performing in continuous commercial operation up to the Bidder's
guarantee, in a manner acceptable to the employer, who will interpret the
meanings of drawings and specification and shall have the power to reject any
work or material which, in his judgment is not in accordance there with. The
offered equipment shall be complete with all components necessary for their
effective and trouble free operation. Such, components shall be deemed to be
within the scope of Bidder's supply irrespective of whether those are
specifically brought out in this specification and/or the commercial order or not.

2.0 STANDARDS:
The materials shall conform in all respects to the relevant Indian Standard
Specifications with latest amendments indicated below.
International &
Indian
Title Internationally
Standard
recognized standard
IS- Switches & Switch isolators for Voltages
9920/1985 above 1000 V
Part I to IV
IS- Alternating Current disconnectors IEC – 62 271-102-2001
9921/1985 (isolators) and earthing switches for Alternating Current
Parts I to voltage above 1000 Volts. disconnectors (isolators)
IV for voltages from 1kV
to 52kV
IS- Alternating current Isolators
1881/1972 (disconnectors) and Earthing Switches
IS- Porcelain Post Insulators for systems
2544/1973 with normal voltage greater than 1000 V
IS- Dimensions of Indoor and Outdoor
5350/1970 Porcelain Post Insulators and Post
Insulator Units for Systems with nominal
Voltage greater than 1000 V
IS- Methods of Testing and Uniformity of
2633/1986 coating of zinc coated articles
 IS- Mild steel tubes, tubular & other rod
1239/1990 steel fittings and pipe fittings
2.1 CONFLICT OF STANDARDS:

Equipment conforming to other internationally accepted standards, which

ensure equal or higher quality than the standards mentioned above would also
be acceptable. In case the Bidders who wish to offer material conforming to the
other standards, salient points of difference between the standards adopted and
the specific standards shall be clearly brought out in relevant schedule. Four
copies of such standards with authentic English Translations shall be furnished
along with the offer. In case of conflict the order of precedence shall be (i) IS
(ii) IEC (iii) Other standards. In case of any difference between provisions of
these standards and provisions of this specification, the provisions contained in
this specification shall prevail.

3.0 CLIMATIC CONDITIONS:

The Voltage Transformers to be supplied against this Specification shall be

suitable for satisfactory continuous operation under the following climatic
conditions.

At various locations
Sl. in the
Location
No. state of Andhra
Pradesh
i) Max. ambient air temperature (deg.C) 50
ii) Min. ambient air temperature (deg.C) 7.5
iii) Average daily ambient air temperature 35
(deg.C)
iv) Max. Relative Humidity (%) 100
v) Max. altitude above mean sea level 1000
(Meters)
vi) Average Annual rainfall (mm). 925
vii) Max. wind pressure(kg/sq.m.) 200
viii) Isoceraunic level (days per year) 50
ix) Seismic level (Horizontal accn.) 0.3 g.

The equipment shall be for use in moderately hot and humid tropical climate,
conducive to rust and fungus growth.

4.0 PRINCIPAL PARAMETEERS :

4.1 Ratings: The Air Break Switches shall have the following ratings
Nominal System Voltage 33 kV
Rated Voltage 36 kV
Insulation levels for isolation As per
B.I.S
Rated impulse withstand 170 kV
voltage

Rated frequency 50 Hz +2% -

5%
Rated Current (for 800 A
isolator only)
Rated peak short circuit 50 kA
current
Rated short-time 20 KA
withstand current
Rated maximum 1 Sec
duration of Short circuit
Load break capacity 40 A

5.0 TECHNICAL REQUIREMENTS FOR 33kV AIR BREAK SWITCHES

(ISOLATORS)

5. 1 GENERAL TECHNICAL REQUIREMENTS:-

5.1.1 Construction:

Air Break Switches (Isolators) shall be 3 poles, gang operated, single or double
break type, without earthing contact blades. All Ferrous metal parts, except
those of stainless steel shall be hot dip galvanized and the uniformity of the
Zinc coating shall satisfy the requirements of relevant standard specification.
The parts shall be galvanized after machining. The finished galvanized surface
shall be smooth. Bearing housing shall be weather proof. Facility shall be
provided for lubrication of bearings.

5.1.2 Phase separation:

The phase separation for the different rated voltages shall be as given below:

Rated Voltage 36 kV
Phase separation 1524 mm
5.1.3 Blades:
The blades shall be made from a single length of rolled/extruded electrolytic
grade extruded hollow copper tube of adequate size matching with current
capacity, for 33 KV-800Amps Air Break Switches. These shall be capable for
carrying rated current continuously and fault current safely. The contact end
shall be tin or silver coated.

5.1.4 Fixed Contact:

The fixed contact element shall be made of rolled electrolytic grade copper flat
and with flexible ends, where required shall be made of soft electrolytic grade
copper sheet. The contact element shall be tin or silver coated. The contacts
assembly shall be so designed that while carrying the rated continuous current,
the temperature rise does not increase beyond the value specified in relevant
standards. The contact shall be self-relevance jaw-type and suitable stainless
steel SPRING of sufficient pressure shall be provided to ensure proper contact
in the closing position.

5.1.5 Arcing Horns:

The AB (Air Break) Switches shall be provided with 3 sets of removable spring
controlled rod type arcing horns with Make Before and Break After feature
Arcing Horns of GI material, one set for each phase, shall be provided. The
diameter of the arcing horn rods shall be not less than 10 mm for 33 kV
Isolators .

5.1.6 Terminal & Connector:

The terminal shall be made of rolled/extruded electrolytic grade copper flat
having a cross sectional area equal to that of the blade. It shall be so
constructed that an intimate contact with the contact elements ensured. The
connector should be suitable for ACSR Conductor up to Panther. The
Aluminum Alloy Connectors shall be supplied for each end and for each phase
of the switch. The terminal shall preferably be tin or silver coated

5.1.7 Bearing:
The operating shaft shall be supported with ball bearings, guide bearing and
universal joint in order to ensure smooth operation. Each rotating insulator
stack shall have thrust roller bearings and shall rotate into gunmetal bush
bearings contained in a suitable weatherproof housing. The housing shall be
fitted with the greasing nipple.
5.1.8 Phase Coupling Bar:
The bar is required for coupling the rotation of the 3 phases and should be fixed
in a manner to permit the smooth movement for operation of the witches.

5.1.9 Operation Mechanism:

The operating mechanism shall be suitable for normal operation by one man
without undue effort. This shall comprise of operating pipe of diameter 40 mm
 (Nominal Bore) for 33 kV and length 6 m with intermediate coupling and
operating handle. The mechanism shall provide adequate mechanical leverage
with minimum of loose/lost motion. The pipe shall conform to class 'B GI pipe
as per relevant standards. For single break switches, the rotating blades shall be
connected to the line side through a flexible copper connection of sufficient
length so that the strain on the live jumpers is avoided. These copper
connectors shall be made of tinned of braided copper strips. There should be
adequate clearance between HG fuse and AB switches operating handle when
the switch is erected on a transformer structure.
5.1.10 Mechanical strength:
The isolating switches shall be capable of withstanding the rated mechanical
terminal loads and electromagnetic forces, without affecting the operation and
current carrying properties. The switches, with or without earthing blades,
complete with the operating mechanism should not come out of their own in
closed position due to the effect of gravity, wind pressure, vibrations reasonable
shocks. Their construction should be such that they do not open under the
influence of the short circuit current.
5.1.11 Galvanising:
All ferrous parts should invariably be hot dip galvanised except the bolts, nuts,
washers spring washers and split pins, which shall be electro-galvanised,
conforming to relevant IS.

5.1.12 Locking Arrangements:

The Air Break Switches shall be constructed in such a manner to permit pad
locking in both open and close position.

5.1.13 Bolts and Nuts:

The required bolts and nuts (hot dip galvanised) for assembling the complete
air-break switch and for fixing the same to the structures shall be supplied with
the equipment at no extra cost. Bolts and nuts shall be provided with lock
washers and lock nuts wherever required. The switches shall be so designed
that the leakage current will pass to earth and not between terminals of the same
pole or between poles, when the insulators are fixed. A reliable earthing
terminal having a clamping bolt of at least 12 mm dia provided on the frame at
one end of the isolator, it shall be marked with the earth symbol in delible
manner on or adjacent to the terminal

5.1.14 Insulators:
Solid core Insulators for 33 kV 800 A AB switches conforming to the relevant
standards shall be supplied along with equipment.
 6.0 TESTS FOR 33kV AB SWITCHES (ISOLATORS) :

6.1.1 The tests indicated in IS : 9920 Part I to IV / IS-9921-1985 Part I to IV / IEC –

62 271-102-2001 with latest amendments shall constitute the type tests. The
certificates of type tests already not carried out (not more than 2 years old ) on
the day of bid opening by the tenderer in their lab or from any accredited test
house on the AB SWITCHES (ISOLATORS) identical in all respects being
quoted against this specification must be furnished by the manufacturer along
with this quotation as an evidence of compliance of this specification.

6.1.2 The AB SWITCHES (ISOLATORS) shall be fully type tested by the bidder as
per the relevant standard including the type tests mentioned in the above
standards. The type tests must have been conducted on 33kV AB SWITCHES
(ISOLATORS) from recognized NABL accredited test laboratories. The bidder
shall furnish two sets of type test reports as per relevant standards along with the
bid.

6.2 ACCEPTANCE AND ROUTINE TESTS :

6.2.1 All acceptance and routine tests stipulated in the relevant standards shall be
carried out by the supplier in presence of employer’s representative

6.2.2 The employer reserves the right to insist for witnessing the acceptance/routine
testing of the bought out items to pass tests.

6.2.3 Tests during manufacture: The Bidder shall furnish details of tests carried out
during the process of manufacture and end inspection by the bidder to ensure the
desired quality of the equipment to be supplied.

6.3 ADDITIONAL TESTS:

6.3.1 The employer reserves the right of having at his own expenses any other tests(s)
of reasonable nature carried out at Bidders premises, at site, or in any other place
in addition to the aforesaid type, acceptance and routine tests, to satisfy himself
that the material comply with the specifications.

6.3.2 In case of failure in any type test, the supplier is required to modify the design of
the material and the material shall be type tested again for the modified design,
without any extra cost to the employer. No delivery extension shall be given for
this additional testing.

6.3.3 The entire cost of testing for the acceptance and routine tests and tests during
manufacture shall be treated as included in the quoted unit price.
6.4. TEST REPORTS / TEST CERTIFICATES:
Record of routine test reports shall be maintained by the Bidder at his works for
periodic inspection by the employer’s representative. The Bidder shall maintain
test certificates of tests conducted during manufacture. These shall be produced
for verification as and when desired by the employer.

6.5 TEST FACILITIES:

The tests shall be carried out as per relevant Standards and test certificates shall
be furnished for approval. The Bidder shall indicate the details of the
equipment available with him for carrying out the various tests as per relevant
Standards. The bidder shall indicate the sources of all materials. He shall
indicate the name of the supplier and make of vacuum interrupters, meters,
relays, conductor, insulating oil, electrical steel laminations constructional steel
etc.

Note: The Meters used for conducting tests shall be calibrated periodically at reputed
Government Accredited Test Laboratories and test certificates shall be available at
works for verification by employers representative.

7.0 INSPECTION:
7.A The employer’s representative shall, at all times, be entitled to have access
to the works and at all places of manufacture where equipment offered shall be
manufactured and the representative shall have full facilities for unrestricted
inspection of the bidder’s works, raw materials and process of manufacture and
conducting necessary tests as detailed herein.

The Bidder shall keep the employer informed in advance of the time of starting
and of the progress of manufacture of the offered equipment in its various stages
so that arrangements can be made for inspection.

The supplier shall give 15 days (for Group A & B suppliers)/30 days (for Group C
Suppliers) advance intimation to enable the employer to depute his representative
for witnessing acceptance and routine tests.

No material shall be dispatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off, by the
employer in writing.

The acceptance of any quantity of material shall in no way relieve the Bidder of
any of his responsibilities for meeting all requirements of the specification, and
shall not prevent subsequent rejection if such material is later found to be
defective.
8.0 QUALITY ASSURANCE PLAN:

8.1 The bidder shall invariably furnish the following information along with his bid, failing
which his bid shall be liable for rejection. Information shall be separately given for
individual type of material offered.

i) The structure of organization.

ii) The duties and responsibilities assigned to staff ensuring quality of work.

iii) The system of purchasing, taking delivery and verification of materials.

iv) The system for ensuring quality of workmanship.

v) The quality assurance arrangements shall conform to be relevant requirements of

ISO 9001 or ISO 9002 as appropriate.

vi) Statement giving list of important raw materials names of sub-suppliers for the raw
materials, list of standards according to which the raw materials are tested. List of
test normally carried out on raw materials in presence of Bidder’s representative,
copies of test certificates.

vii) Information and copies of test certificates as in (vi) above in respect of bought out
accessories.

viii) List of manufacturing facilities available.

ix) Level of automation achieved and list of areas where manual procession exists.

x) List of areas in manufacturing process, where stage inspections are normally

carried out for quality control and details of such tests and inspections.

xi) Lists of testing equipment available with the bidder for final testing of equipment
specified and test plant limitation. If any, vis-a-vis the type, special acceptance and
routine tests specified in the relevant standards. These limitations shall be very
clearly brought out in schedule of deviations from specified test requirements.

8.2.1 The successful Contractor shall within 30 days of placement of order, submit following
information to the employer. List of raw materials as well as bought out accessories and
the names of sub suppliers selected from those furnished along with offers.

Type test certificates of the raw materials and bought out accessories if required by the
employer. Quality Assurance Plan (QAP) with hold points for employer’s inspection. The
quality assurance plan and employers hold points shall be discussed between the employer
and Contractor before the QAP is finalized.

8.3 The Contractor shall submit the routine test certificates of bought out
accessories and central excise asses for raw material at the time of routine
testing if required by the employer and ensure that the quality assurance
requirements of specification are followed by the sub-contractor.
8.4 The quality assurance programme shall give a description of the quality system and quality
plans with the following details.

A) Quality System :

The structure of the organisation.

The duties and responsibilities assigned to staff ensuring quality of work.

The system for purchasing, taking delivery and verification of materials.

The system for ensuring quality workmanship.

The system for control of documentation.

The system for the retention of records.

The arrangement for the contractor’s internal auditing.

A list of administration and work procedures required to achieve and verify contract’s
quality requirements. These procedures shall be made readily available to the employer for
inspection on request.

B) Quality Plans:

An outline of the proposed work and programme sequence.

The structure of the contractors organisation for the contract.

The duties and responsibilities assigned to staff ensuring quality of work.

Hold and Notification points.

Submission of Engineering documents required by the Specification.

The inspection of materials and components on receipt.

Reference to the contractors work procedures appropriate to each activity.

Inspection during fabrication/Construction.

Final inspection and test.

9.0 DOCUMENTATION :
9.1 All drawings shall conform to International Standards Organisation (ISO) ‘A’
series of drawings sheet/India Standards Specifications IS:656. All drawings
shall be in ink and suitable for micro filming. All dimensions and data shall be
in S.I.Units.
9.2 LIST OF DRAWINGS AND DOCUMENTS :
The bidder shall furnish four sets of following drawings along with his offer:
General outline drawing showing plan, elevation and end view dimensions,
assembly and constructional drawings of the equipment.
Name plate & schematic drawings.
Operation manuals, leafless literature etc.

9.2.1 The successful Bidder shall, within 2 weeks of placement of order, submit three
sets of final versions of all the above said drawings for employer’s approval.
The employer shall communicate his comments/approval on the drawings to the
supplier within four weeks. The supplier shall, if necessary, modify the
drawings and resubmit three copies of the modified drawings for their approval.
The supplier shall within two weeks, submit 23 prints and two good quality
report copies of the approved drawings for employer’s use.

9.2.2 Six sets of the type test reports, duly approved by the employer, shall be
submitted by the supplier for distribution before commencement of supply.
Adequate copies of acceptance and routine test certificates, duly approved by
the employer, shall accompany the dispatch consignment.

9.2.3 The manufacturing of the equipment shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written
approval of the employer. All manufacturing and fabrication work in
connection with the equipment prior to the approval of the drawing shall be at
the supplier’s risk.

9.2.4 Two set of nicely printed bound volumes of operation, maintenance and
erection manuals and approved drawings in English language shall be supplied
along with each circuit breaker, in addition to the five sets to be sent directly to
the employer.

9.2.5 Approval of drawings/work by employer shall not relieve the supplier of his
responsibility and liability for ensuring correctness and correct interpretation of
the drawings for meeting the requirements of the latest revision of application
standards, rules and codes of practices. The equipment shall conform in all
respects to high standards of engineering, design, workmanship and latest
revisions of relevant standards at the time of ordering and employer shall have
to power to reject any work or materials which, in his judgment is not in full
accordance therewith.

10.0 PACKING & FORWARDING:

10.1 The equipment shall be packed in crates suitable for vertical/horizontal
transport as the case may be, and suitable to withstand handling during
transport and outdoor storage during transit. The supplier shall be responsible
for any damage to the equipment during transit, due to improper and inadequate
 packing. The easily damageable material shall be carefully packed and marked
with the appropriate caution symbol. Wherever necessary, proper arrangement
for lifting, such as lifting hooks etc., shall be provided. Supplier without any
extra cost shall supply any material found short inside the packing cases
immediately.

10.2 Each consignment shall be accompanied with a detailed packing list containing
the following information.

Name of the consignee.

Details of consignment.
Destination.
Total weight of consignment
Handling and packing instructions.
Bill of Material indicating contents of each package.

10.3 The supplier shall ensure that the employer before dispatch approves the
packing list and bill of material.
10.4 The packing shall be done as per the manufacturer’s standard practice.
However, he should ensure the packing is such that, Rail/Road should not
damage the material during transit.

10.5 The marking on each package shall be as per the relevant standards and shall
also contain “APEPDCL WORKS”.

11.0 QUANTITY AND DELIVERY REQUIREMENTS: The quantity and

delivery requirement are indicated in Section-V
12.0 SUPERVISION SERVICES: The Employer will arrange for unloading of the
consignments.
13.0 MANDATORY SPARES & TOOLS: Not appilicable
14.0 TECHNICAL DEVIATIONS:
Any deviation in Technical Specification shall be specifically and clearly
indicated in the enclosed Technical deviation format as per Annexure – II or in
the schedule of deviation format – Schedule – ‘A’.
15.0 GUARANTEED TECHNICAL PARTICULARS
The Bidder shall furnish the guaranteed Technical Particulars as per Annexure
– I, enclosed and submit the same with the Tender.

ACRONYMS
------------------------------------------------------------------------------------------------------------

Reference Abbreviations Name and Address

------------------------------------------------------------------------------------------------------------
IEC International Electro Technical
Commission Bureau Central de la
Commission Electro Technique
 International, Rue de verembe

Geneva, Switzerland
ISO International Organisation for
Standardisation,
Danish Board of Standardisation
Aurehoegyej-12,
DK-2900, heel prup,
DENMARK.
ISS Indian Standard Bureau of
Indian Standards,
Nank Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi – 110 002, INDIA.
------------------------------------------------------------------------------------------------------------
 ANNEXURE – I
GUARANTEED TECHNICAL PARTICULARS FOR AIR BREAK SWITCHES
S S Details Guaranteed particulars
N
o.
Air Break Switches (Isolators) 3 33 kV
8 800 A
Name(s) of Manufacturer(s)
Whether single break or double break
No. of poles
Voltage rating
Frequency
Current rating in Amps.
i. Normal
ii. Max. with duration
Temperature rise of the following at full rated
current in Deg. C over ambient temperature
i. Copper contacts with coating
ii. Terminal of switches intended to be bolted to
the external conductors
Whether contracts are silver coated or tin coated
along with thickness of coating in mm
Voltage drop across terminals of poles
Short time current and duration
Material of fixed contact
Material of moving blade
m Material of terminal connector
Type, diameter and length of operating handle
Material of arcing horns
Size and length of mounting channel
Whether the Air break switch is complete with
all accessories
Whether dimensional drawing is enclosed with
the bid
Minimum clearance between phases (The centre
distance between the insulators of adjacent
phases in assembled position of switch)
Centre to centre distance between insulators of
the constructive poles of the same phase in the
assembled position of switch (in mm)
 Whether mechanical interlock has been provided 33KV
for EARTH Switches

Type of bearings used in 800A

i. Rotating insulator stack
ii. Operating shaft
Impulses withstand voltage with 1/50 Micro Sec.
wave positive and negative polarity
i. Across isolating distance
ii. To each and between poles
One minute power frequency withstand voltage
across isolating distance to earth and between
poles

Insulators
Type of Insulator
Name of Manufacturer of insulators
Height of the insulators
Diameter of the largest shell
No. of units per stack
2.1 Electrical characteristics (for one insulator)
Flash over voltage
Dry power frequency
Wet power frequency
Impulse voltage of 1/50 Micro-seconds (+ve)
Impulse voltage of 1/50 Micro-seconds (-ve)
Withstand voltage
i. Dry voltage
ii. Wet voltage
iii.Impulse voltage of 1/50 Micro-seconds (+ve)
iv. Impulse voltage of 1/50 Micro-seconds (-ve)
2.2 Power frequency puncture withstand voltage of
unit
2.3 Mechanical characteristics
Cantilever strength upright
Cantilever strength under hand
Torsional strength
Tensile strength
 2.4 General characteristics
Min. creepage distance
Weight of complete unit
2.5 Standard to which insulator conforms

ANNEXURE –II

(SCHEDULE OF DEVIATION)

Sl. Requirements/ Specification

Deviations Remarks
No. Equipment Clause No.

It is hereby conformed that except for deviations mentioned above, the offer
conforms to all the other features specified in Technical Specification Section III of this
Bid Document.

The additional features that are provided in the meters which have not been covered
in the specification are cited at Appendix ____________ of the bid.

Technical details/information enclosed with the bid as required in Technical

Specification Section-III of the bid document is listed at Appendix __________.

Place: Signature of the Bidder

Date: Name

Business address:

SECTION – IV

SCHEDULE ‘A’

DEPARTURE FROM SPECIFICATION

--------------------------------------------------------------------------------
 Sl. No. Reference to clause No. of this specification Departures

--------------------------------------------------------------------------------------------------------------
------

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SCHEDULE ‘B’

MANUFACTURER’S AND PLACES OF MANUFACTURE

TESTING & INSPECTION

-----------------------------------------------------------------------------------------------------------

Sl. Description Manufacturer Place of manufacture Place of testing and

No. inspection

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SCHEDULE ‘C’
LIST OF SUPPLIES MADE SO FAR WITH FULL DETAILS OF GOODS SUPPLIED
AND TO WHOM SUPPLIED

Sl. No. DETAILS OF GOODS SUPPLIED TO WHOM SUPPLIED

 SCHEDULE ‘D’

WEIGHT AND DIMENSIONS OF PACKAGES OF DESPATCH

------------------------------------------------------------------------------------------------------------

Sl. Equipment Contents of Weight Dimensions

No. individual
packages Kg

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----------------------------------------------------------------------------------

SCHEDULE ‘E’

DESCRIPTIVE LITERATURE AND FULL PARTICULARS OF THE EQUIPMENT

OFFERED

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Sl. No. Item No. Description

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SCHEDULE ‘F’
PERFORMANCE STATEMENT
Name and
Sl. Address of Order Name and
Qty (in Value Name and
Actual Dispatchin
authority No and description
Nos.) (in Rs.) Address of date of g
No who placed Date of material Consignee delivery Particulars
the order

SIGNATURE OF THE TENDERER

16.0. QUALITY ASSURANCE:

16.1. QUALITY ASSURANCE PROGRAME

To ensure that the equipment are in accordance with the specifications the contractor shall
adopt suitable quality assurance programme to control such activities at all points, as necessary
such programme shall be out lined by the contractor and shall be finally accepted by
owner/authorized representative after discussions before the award of contract. The QA
programme shall be generally in line with ISO-9000/IS-14000. A quality assurance programme of
the contractor shall generally cover the following.

a) His organization structure for the management and implementation of the proposed
quality assurance programme
b) Quality system manual.
c) Design control System
d) Documentation control system
e) Qualification data for bidder’s key personnel
f) The procedure for purchase of material, parts, components and selection of sub vendors
service including vendors analysis, source inspection, incoming raw material inspection,
verification of materials purchased etc.
g) System for shop manufacturing control including process controls, fabrication and
assembly controls
h) Control of non-conforming items and systems for corrective actions.
i) Inspection and test procedure
j) Control of calibration and testing of measuring and testing equipment.
k) System for indication and appraisal of inspection status.
l) System for quality audit
m) System for authorities’ release of manufactured product to owner.
n) System for maintenance of records
o) System for handling storage and delivery
p) All the plant standard/written down practices followed by the manufacturer/contractor
against the manufacturing activities in their works will be submitted in electronic media
preferably in at least one set of compact discs.

16.2. GENERAL REQUIREMENS – QUALITY ASSURANCE

1.1. All materials, components and equipment covered under the specification shall be
procedure manufactured and tested at all the stages, as per a comprehensive quality
programme. An indicative programme of inspection/tests to be carried out by the
contractor for some of the major items is given in this specification. This is however,
not intended to form a comprehensive programme as it is the contractor’s responsibility
to draw up and implement such programme duly approved by the Owner. The detailed
quality plans for the manufacturing activities should be drawn up by the bidder and
will be submitted to Owner for approval. Schedule for finalization of such quality plans
will be finalized before award.

1.2.Manufacturing quality plan shall detail out for all the components and equipments,
various tests, inspection, to be carried out as per the requirements to this specification
and standards mentioned therein and quality practices and procedures followed by
contractor’s Quality Control Organization, the relevant reference documents and
standards acceptance norms, inspection documents raised etc. during all stages of
material procurement manufacture, assembly and final testing/performance testing.
1.3. The Bidder shall also furnish copies of the reference documents/Plant
Standard/Acceptance norms/Test and inspection procedure etc. as referred in Quality
Plan along with Quality Plans .the Quality Plans and reference documents/standards
etc. will be subject to Owner’s approval and will form a part of the contract in these
approved Quality Plan, Owner shall identify customer hold points (CHP) which shall
be carried out in presence of the Owner’s Project Manager and beyond which work
shall not proceed without written consent of Owner’s Project Manager/Authorized
representative in writing. All deviation to this specifications approved quality plans and
applicable standard must be documented and referred to Owner along with technical
justification for approval and disposition.

1.4. No material shall be dispatched from the manufacture’s works before the
same is accepted subsequent to pre-dispatch final inspection including verification of
records of all previous tests/inspections by Owner’s Project manager/authorized
representative, and duly authorized for dispatch issuance of MDCC.

1.5. All materials used and supplied shall be accompanied by valid and
approved materials certificates and tests and inspection reports. These certificates and
reports shall indicate the heat numbers or other such acceptance identical numbers of
the material. The material certified shall also have the identification details stamped on
it.

1.6. All materials used for equipment manufacture including casting and forging
etc. shall be of tested quality as per relevant codes standard. Details of results of the
tests conducted to determine the mechanical properties chemical analysis and details of
heat treatment procedure recommended and actually followed shall be recorded on
certificates and time temperature chart. Tests shall be carried out as per applicable
material standards and/or agreed details

1.7. All welding and brazing shall be carried out as per procedure drawn and
qualified in accordance with requirements of ASME. Section IX/BS-4870 or other
international equivalent standard acceptable to the Owner.

1.8. All welding/brazing procedure shall be submitted to the Owner

authorized representative for approval prior to carrying out the welding/brazing.

1.9. All brazers, welders and welding operations employed on any part of the
contract either in Contract’s/his Sub-contractors works or at site elsewhere shall be
qualified as per ASME Section IX or BS 4871 or other equivalent international
Standards acceptable to the Owner.

1.10. Test results of qualification tests and specimen testing shall be furnished to
the Owner for approval. However where required by the Owner, tests shall be
conducted in presence of Owner/Authorized representative.
1.11. All the heat treatment results shall be recorded on time temperature charts
and verified with recommended regimes.

1.12. Results of all non-destructive testing shall be record on certificate.

1.13. All the sub-vendors proposed by the Contractor for procurement of major
bought out item including castings, forgings, semi-finished and finished
components/equipment, list of which shall be drawn up by the Contractor and finalized
with the Owner shall be subject to owner approval. The contractor proposal shall
include vendors facilities established at the respective works, the process capability
process stabilization, QC Systems followed experience list, etc along with his own
technical evaluation and shall be submitted to approval shall not relieve the contractor
from any obligation duty or responsibility under the contract.
1.14. For components/equipment procured by the Contractors for the purpose of
the Contract, after obtaining the written approval of the Owner, the Contractor’s
purchase specifications and enquiries shall call for quality plans to be submitted by the
suppliers along with their proposals. The quality plans called for from the vendors shall
set out, during the various stages of manufacture, the quality practices and procedures
followed by the vendor’s quality control organization, the relevant reference
documents/standards used acceptance level, inspection of documentation raised etc.
1.15. Such quality plans of the successful vendors shall be finalized with the
owner and such approved Quality Plans shall form a part of the purchase
order/contracts between the contractor and the vendor, within three weeks of the
release of the purchase order/contract for such bought out items. Components, a copy
of the same without price details but together with the detailed purchase specifications,
quality plans and delivery conditions shall be furnished to the Owner by the
Contractor.
1.16. The purchase specifications for the major bought out items, list of which
shall be drawn up by the Contractor and finalized with the Owner shall be furnished to
the Owner for comments and subsequent approval before orders are placed.
1.17. Owner reserves the right to carry out quality audit and quality surveillance
of the systems and procedures of the Contractor’s or their sub-vendor’s quality
management and control activities. The contractor shall provide all necessary
assistance to enable the Owner carry out such audit and surveillance.
1.18. The Contractors shall carry out an inspection and testing programme during
manufacture in his works and that of his sub-contractors and at site to ensure the
mechanical accuracy of components compliance with drawings, conformance to
functional and performance requirements, identity and acceptability of all materials
parts and equipment. He shall carry out all tests/inspections required to establish that
the items/equipments conform to requirements of the specifications and the relevant
codes/standards specified in the specifications, in addition to carrying out tests as per
the approved Quality Plan.
1.19. Quality audit/surveillance/approval of the results of the tests and inspection
will not, however, prejudice the right of the Owner to reject the equipment if it does
not comply with the specification when installed or does not comply with the
specification in service and the above shall in no way limit the liabilities and
responsibilities of the Contractor in ensuring complete conformance of the
materials/equipment supplied to relevant specification, standard data sheet, drawings
etc.
1.20. For all spares and replacement items, the quality requirements as agreed for
the main equipment supply shall be applicable.
 1.21. Repair/rectification procedures to be adopted to make the job acceptable
shall be subject to the approval of the Owner/authorized representative.

16.3. QUALITY ASSURANCE DOCUMENTS :

1. The Contractor shall be required to submit two sets of compact discs of the
following Quality Assurance documents within three weeks after dispatch of the
equipment.

2. The inspection plan with verification, inspection plan check points,

verification sketches, if used and methods used to verify that the inspection
and testing points in the inspection plan were performed satisfactorily.

3. Factory tests results for testing required as per applicable codes and standard
referred in the specification.

4. Inspection reports duly signed by QA personnel of the Owner and Contractor

for the agreed inspection hold points. During the course of inspection, the following
will also be recorded:
5. When some important repair work is involved to make the job acceptable
and
6. The repair work remains part of the accepted product quality
7. All the accepted deviations shall be included with complete technical details.
8. The contractor shall transfer all the guarantees/warranties of the equipment
purchased by him to the employer, which are supplied as a part of the contractor for
executing the works.
26. 11KV AB SWITCHES
 27. 11/33 KV COVERED CONDUCTORS
INTRODUCTION:

These Specifications lay down the Constructional, Dimensional and Performance

Requirements for Covered Conductors which consist of a Conductor surrounded by a Covering
made of Insulating Material (as described hereunder) as protection against Accidental Contacts
with other Covered Conductors and with Grounded Parts such as Tree Branches, etc.

CONSTRUCTION REQUIREMENTS:

1) CONDUCTOR:

CONDUCTOR MATERIAL: Aluminum Alloy (AAAC)

NOMINAL CROSS SECTION: 99 Sq mm for AAAC conductors for 11 KV and 120

Sq.mm for AAAC Conductors for 33 KV

CONDUCTOR DESIGN: The Conductor shall be stranded, round and should be Non-
Compacted. Non-Compacted Conductors shall comply with all the requirements of EN
50397-1-2006.

The D.C. Resistance of the conductor shall not exceed that given in EN 50397-1-2006
by more than 5%.
2) FILLING (WATER BLOCKING):
 The Stranded Conductor shall be longitudinally water tight by means of a water blocking
material incorporated during the extrusion process. The use of grease / water swellable
tape / water swellable powder etc is not permitted. The water blocking material shall be
stable at maximum operating conductor temperature of 90 Deg. Cent.

The water blocking compound shall be compatible with the conductor material as well as
the semi conducting polymer screen layer above it and not adversely affect its electrical or
mechanical properties.

3) SEMICONDUCTING SCREEN:

A semi conductive polymeric screen should be applied over the filled stranded conductor
to ensure a lower voltage stress on the Insulation applied over the screen. The thickness of
the semi conductive polymeric screen should be between 0.2 mm and 0.4 mm.

4) INSULATION:

The Insulation should be dual layered with the Inner Layer being XLPE with a nominal
thickness of 1.2 mm for Voltages up to 11 KV and the Outer Layer being a suitable
Polymer which is UV Resistant, Non Tracking and Erosion Resistant with a nominal wall
thickness of 1.1 mm for Voltages up to 11 KV. The minimum combined Insulation
Thickness of both Layers should be 2.3 mm for 11 KV.
Nominal thickness of 2.4 mm for Voltages for 33 KV and the Outer Layer being a suitable
Polymer which is UV Resistant, Non Tracking and Erosion Resistant with a nominal wall
thickness of 1.1 mm for Voltages 33 KV. The minimum combined Insulation Thickness of
both Layers should be 3.5 mm for 33 KV.

The conductor manufacturing and stranding process shall incorporate the longitudinal
water blocking also.

The Semi Conducting Screen, Inner Insulation and Outer Insulation should be extruded in
one step ie triple extrusion to ensure a good, permanent bond between the three layers and
also with the conductor.

It shall be possible to remove the Semi Conducting Screen, Inner and Outer Insulation
Layers without damage to the conductor.

Figure 1 shows the Cross Section of a Covered Conductor with AAAC Conductor
FIGURE 1 ( AAAC )
5) TYPE TESTS:

TEST FOR COVERED CONDUCTORS as per EN 50397-1-2006

Conductor Resistance Test

Thickness of Insulation & Covering

Tensile strength

%age Elongation at break of Insulation before ageing, after ageing & Completed Cable ageing

Carbon black content test on outer covering

Shrinkage test on outer covering

Shrinkage test on Insulation

Hot set test on Insulation

Water Absorption test on Insulation

Test for longitudinal water tightness

AC High Voltage test

Leakage Current Measurement

Tracking Resistance test

ELECTRICAL TESTS:
A) Conductor Resistance Test: To be done as a Routine as well as Type Test as per EN 50397-1-
2006.
B) High Voltage Test as per EN 50397-1-2006. – Type test
Test Voltage --- Phase to Phase Voltage of the System for which the Covered Conductor is
used.
No. of Specimens --- One
Length of Specimen (minimum) ---- 5 meters
Duration of Immersion in Water (minimum) ---- 1 Hour
Temperature of Water ---- (20 +/- 5) Degrees Centigrade
Test Duration --------------- 4 Hours for Routine Test
48 Hours for Type Test
Requirement: No Breakdown
C) Spark Test on Covering: Routine test
Test Voltage 0.7 X Phase to Phase Voltage of System (A, C,) or
Phase to Phase Voltage of System (D. C.)
 Requirement: No Breakdown
D) Leakage Current Test - Type test
Test Voltage 0.7 X Phase to Phase Voltage of System (A. C.)
Requirement: Maximum Leakage Current 1mA
E) Tracking Resistance: - Type test

NON – ELECTRICAL TESTS ON COVERING: Type tests

A) Mechanical Properties :
a) Before Ageing of Sample: As per Table 1 (as per EN 50397-1-2006)
b) After Ageing of Sample: As per Table 1 (as per EN 50397-1-2006)
c) Ageing of Complete Product Sample: As per Table 1 (as per EN 50397-1-2006)
d) Hot-Set-Test: As per Table 1 and in accordance to (as per EN 50397-1-2006)
e) Pressure Test at High Temperature: As per Table 1 and in accordance with EN 60811-3-1,
Sub Clause 6.1.
h) Water Absorption: As per Table 1 and in accordance with EN 50397-1-2006
TEST FOR LONGITUDINAL WATER TIGHTNESS
a) As Type Test with Heat Cycle and in accordance with 50397-1-2006.
No of Specimen – 1
Length of Specimen – 3 meters
Test Duration -- 24 hours
Bending Radius – 20 X Diameter of Covered Conductor

Requirement – No Leakage

b) As Routine Test without Heat Cycle and in accordance with IEC 60502 -2

No of Specimen – 1

Length of Specimen – 1 meter

Test Duration – 1 Hour

6) GTP
Bidder shall confirm by signing with stamp on the GTP

offered Values
Si.No. Parameters for 11KV 99
Sq.mm
1 Conductor type
2 Lay up of Conductors (mm)
3 Conductor Dia (mm)
4 Inner Semiconducting Layer thickness (mm)
5 Inner XLPE Layer thickness (mm)
6 Outer UV Resistance - XLPE Thickness (mm)
 7 Over all diameter (Min-Max) (mm)
8 Weight (Kg/Km)
9 Rated Operated Voltage (KV)
10 DC-resistance at 20 Degree C, Maximum (Ohm/KM)
11 Resistance Temperature coefficient (/0C)
12 Lightening Impulse withstand strength of XLPE Layer (KV)
13 Maximum Continuos Operating temperature (0C)
Max load(IEC 287), cond.temp 80 °C, air temp. 50 °C, wind
14
speed 0.5 m/s, Solar radiation 1200W/m², Approximate value (A)
15 Max short circuit current, 1 sec (KA)
16 Tensile Strength of Conductors (kN)
17 Aluminium Alloy

Offered Values
Si.No. Parameters for 33KV 120
Sq.mm
1 Conductor type
2 Lay up of Conductors (mm)
3 Conductor Dia (mm)
4 Inner Semiconducting Layer thickness (mm)
5 Inner XLPE Layer thickness (mm)
6 Outer UV Resistance - XLPE Thickness (mm)
7 Over all diameter (Min-Max) (mm)
8 Weight (Kg/Km)
9 Rated Operated Voltage (KV)
10 DC-resistance at 20 Degree C, Maximum (Ohm/KM)
11 Resistance Temperature coefficient (/0C)
12 Lightening Impulse withstand strength of XLPE Layer (KV)
13 Maximum Continues Operating temperature (0C)
Max load(IEC 287), cond.temp 80 °C, air temp. 50 °C, wind speed
14
0.5 m/s, Solar radiation 1200W/m², Approximate value (A)
15 Max short circuit current, 1 sec (KA)
16 Tensile Strength of Conductors (kN)
17 Aluminum Alloy

Prequalification Requirement
The offered triple extruded AAAC ( AlMgSi alloy ) conductor shall be suitable for use under
operating condition as specified below:
1. Ambient air temperature : 45 deg C
2. Maximum temperature of conductor at rated current : 90 deg C
3. Wind condition at site : 1 meter / sec
4. Solar radiation at site : 1200 watts / sq m
5. Maximum allowable temperature under
Short circuit condition : 250 deg C
Data sheet providing details of the conductor under data provided above shall be submitted along
with the offer.

2. Covered Conductor Accessories

2.1 Joint
The joint shall be suitable for the covered conductor for which they are designed. The joint
shall have the same basic insulation properties as the conductor covering. In this case, the test
shall be carried out according to EN 50397-1 table 2, ref. 1.2 “High Voltage (HV) test”. The
conductor shall have a sufficient length so that the joint is immersed and the test duration shall be
same as for sample test.
Mid Span Insulated Jointing Sleeves
The mid span Insulated jointing sleeves shall be of the tubular type, suitable for making
full tension joint between two conductors of same size, It shall be provided with a center stop
"indent" for correct positioning of the conductors to be joined. The tensile strength of the mid
span jointing sleeve after crimping/compression shall not be less than 95% of the strength of the
covered conductors. Heat shrinkable insulation tubing of adequate length shall be provided.
The jointing sleeves shall be pre-filled with any suitable oxide inhibiting compound and
their current rating shall not be less than that of the covered conductors.

2.2 TECHNICAL SPECIFICATION 11KV/33KV COMPOSITE INSULATORS

1.0 SCOPE:

This specification covers the design, manufacture, testing and supply of

11KV/33KV Composite Insulators. The composite insulators shall be of the following
type:

i) Disc insulators
ii) P in insulators

2.0 SERVICECONDITIONS:

The insulators to be supplied against this specification shall be suitable for

satisfactory continuous operation under the following tropical conditions.

2.1.1 Maximum ambient temperature(Degree C) … 50

2.1.2 Minimum ambient temperature(Degree C) … 3.5
2.1.3 Relative Humidity(%) … 10to100
2.1.4 Maximum Annual Rainfall(mm) … 1450
2.1.5. Maximum Wind pressure(kg/m.sq.) … 150
2.1.6 Maximum wind velocity(km/hour) … 45
2.1.7 Maximum altitude above mean sea level(meter) … 1000
2.1.8 Isoceraunic level (days/year) … 50
2.1.9 Seismic level(Horizontal acceleration) … 0.3g
2.1.10 Moderately hot and humid tropical climate
Conductive to rust and fungus growth
 3.0 SYSTEMPARTICULARS:
a)Nominal System Voltage 11kV 33kV
b)Corresponding highest system Voltage 12kV 36kV
c)Frequency 50Hzwith3%tolerance
d)Number of phase 3 3
e)Neutral earthing Effectively grounded.

4.0 STANDARDS:

Unless otherwise specified elsewhere in the specifications insulators shall

confirmto the latest revisions of all relevant standards available at the time of
placement of the order. The standards are listed as below

Sr. Indian International

No. Standard Title Standard
Definition, test methods and acceptance criteria
1 - For composite insulators for A.C. over head lines IEC:61109
above1000V
Insulators for overhead lines –
- Composite line post insulators IEC:61952
2
for alternative current
with a nominal voltage >1 000 V
Porcelain insulators for overhead power lines
3
IS:731 with a nominal voltage greater than 1000V IEC:60383
IEC:60060-1
4
IS:2071 Methods of High Voltage Testing
Specification for Insulator fittings for Overhead
Power Lines with a nominal voltage greater IEC:60120
5
IS:2486 than1000VGeneralRequirements and Tests IEC:60372
Dimensional Requirements Locking Devices
Guide for the selection of insulators in respect
6
IS:13134 Of polluted condition IEC:60815
7 - Hydro phobicity Classification Guide STRIguide1.92/1
8 IS:8263 Methods of RI Test of HV insulators IEC:60437
Recommended Practice for Hot, Dip
9 IS:2629 Galvanization for iron and steel ISO:1461(E)
10 Determination of Weight of Zinc Coating on
 IS:6745 Zinc coated iron and steel articles ISO:1460
Methods of testing of local thickness of
11
IS:3203 Electroplated coatings ISO:2173
Testing of Uniformity of Coating of zinc coated
12
IS:2633 Articles
13 - Standard specification for glass fiber strands ASTM D578-05

5.0 GENERALREQUIREMENTS

5.1 The composite insulators shall generally conform to latest Standards as listed in
Clause 4.
5.2 The insulators should withstand the conductor tension, the reversible wind load
as well as the high frequency vibrations due to wind.
5.3 Biddermustbeanindigenousmanufacturerandsupplierofcompositeinsulatorsof
rating 11 kV or above OR must have developed proven inhouse technology and
manufacturing process for composite insulators of above rating OR possess
technical collaboration/association with a manufacturer of composite insulators
of rating 11kV or above. The Bidder shall furnish necessary evidence in support
of the above along with the bid, which can be in the form of certification from
the utilities concerned, or any other documents to the satisfaction of the owner.
5.4 Insulator shall be suitable for both the suspension and strain type of load &shall
be of Tongue & Clevis type .The diameter of Composite Insulator shall be less
than 200mm. The B&S insulators sockets should be 16B designation.
5.5 Insulators shall have sheds with good self-cleaning properties. Insulators
hedprofile; spacing, projection etc. and selection in respect of polluted conditions
shall be generally in accordance with the recommendation of IEC-
60815/IS:13134.

5.6 The size of Composite insulator, minimum creepage distance and mechanical
strength along with hardware fittings shall be as follows:
Nomin Highest Visible Wet
al Power Impulse Minimu
System System discharg Frequenc Withsta m SM Minimu
Sr. Type of
voltage voltage e test y nd Creepag L m FRP
No. composite
insulators kV(rms voltag Withstand voltage e (kN Rod Dia
kV e kV voltage Distance ) (mm)
) rms kV(rms kV(rms) (mm)
(rms) )
i. Disc 11 12 9 35 75 320 70 16
insulator 33 36 27 75 170 900 70 16

Nomin Wet
al Highest Visible Power Impulse Minimu
Type of System System discharg Frequenc Withsta m SC Minimu
Sr. voltage voltage e test y nd Creepag L
No. composite
insulators Kv(rms kV(rms voltage Withstand voltage e (kN m FRP
Rod Dia
kV(rms) voltage Distance )
) kV(rms kV(rms) (mm)
) )
ii. Pin 11 12 9 35 75 320 5 20.5
Insulator 33 36 27 75 170 900 10 33.5
 Disc Insulator – SML (Specified Tensile Load) should be applied in axial
direction to the insulator axis.

Pin Insulators – SCL (Specified Cantilever Load) should be applied in

transverse direction to Insulator axis.

5.7 Dimensional Tolerance of Composite Insulators

The tolerances on all dimensions
e.g.diameter,lengthandcreepagedistanceshallbeallowedasfollowsinlinewith-
IEC61109:
± (0.04d+1.5) mm when d≤300mm.
± (0.025d+6) mm when d>300mm.
Where,dbeingthedimensionsinmillimetersfordiameter,lengthorcreepagedistance as
thecasemaybe.Howevernonegativetoleranceshallbeapplicabletocreepagedistance.

5.8 Interchangeability:
Thecompositeinsulatortogetherwiththetongue&clevisfittingsshallbeofstandarddesi
gnsuitablefor use with the hardware of any other indigenous make conforming to
relevant standards referred above.

5.9 Corona and RI Performance

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part
shall be subjected to excessive localized pressure. The insulator and metal parts
shall be so designed and manufactured that it shall avoid local corona formation
and not generate any radiointe reference beyond specified limit under the
operating conditions.

6.0 TECHNICALDESCRIPTIONOF COMPOSITEINSULATORS

PolymericInsulatorsshallbedesignedtomeetthehighquality,safetyandreliabilit y
andarecapableofwithstandingawiderangeofenvironmentalconditions.
PolymericInsulatorsshallconsistofTHREEparts,atleasttwoof whichareinsulating
parts:-
(a)Core-theinternalinsulatingpart
(b)Housing-theexternalinsulatingpart
(c)Metalendfittings.
6.1 CORE
It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod).
Glassfibers and resin shall be optimized in the FRP rod. Glass fibers shall be
Boron free electrically corrosion resistant (ECR) glass fiber and shall exhibit
both high electrical integrity and high resistance to acid corrosion. The
matrix of the FRP rod shall be Hydrolysis resistant. The FRP rod shall be
manufactured through Pultrusion process. The FRP rod shall be void free.
6.2 POLYMER HOUSING:
The FRP rod shall be covered by a seamless sheath of high voltage grade Silicone
rubber housing of thickness 3mm minimum. It shall be one- piece housing using
only Injection Molding process to cover the core. Primer should be used to bond
the housing with FRP rod. The housing shall be designed to provide the necessary
creepage distance and protection against environmental influences. Housing shall
conform to the requirements of IEC 60815 with latest amendments.
 The high voltage grade Silicone rubber polymer material should be as per
requirement specified in clause 8.2.2
6.3 WEATHERSHEDS
The composite polymer weathersheds made of high voltage grade Silicone rubber
polymer shall be molded as part of the sheath and shall be free from imperfections.
It should protect the FRP rod against environmental influences, external pollution
and humidity. The strength of the weather shed to sheath interface shall be greater
than the tearing strength of the polymer. The interface, if any, between sheds and
sheath (housing) shall be free from voids.
The high voltage grade Silicone rubber polymer material should be as per
requirement specified in clause 8.2.2
6.4 METAL ENDFITTINGS:
Endfittingtransmitthemechanicalloadtothecore.Theyshallbemadeofspheroidal
graphitecastiron,malleablecastironorforgedsteeloraluminiumalloy.Theyshallbe
connectedtotherodbymeansofacontrolled compressiontechnique. Disc Insulator
Metal end fittings shall be suitable for Tongue & Clevis hard wares of
respective specified mechanical load and shall be hot dip galvanized
after,allfittingshavebeencompleted. Asthemaindutyoftheend
fittingsisthetransferofmechanicalloadstothecorethefittingsshouldbeproperly
attachedtothecorebyacoaxialor hexagonalcompressionprocess&should not
damagetheindividualfibersorcrackthecore.The dimensions of end fittings of
insulators shall be in accordancewiththestandarddimensions statedin
IEC:60120/IS:2486-Part-II/1989.

7.0 WORKMANSHIP

7.1 Allthematerials
shallbeoflatestdesignandconformtothebestengineeringpractices adopted in the
high voltage field. Bidders shall offer only such insulators as are
guaranteedbythemtobesatisfactoryandsuitableforcontinuedgoodserviceinpowe
r transmissionlines.

7.2
Thedesign,manufacturingprocessandmaterialcontrolatvariousstagesshallbes
uch as togivemaximum
workingload,highestmobility,bestresistancetocorrosion,good
finishandeliminationofsharpedges andcorners.

7.3
Thedesignoftheinsulatorsshallbesuchthatstressesduetoexpansionandcontrac
tion inanypartoftheinsulatorshallnotleadtodeterioration.

7.4 Thecoreshallbesoundandfreeof cracksandvoids thatmayadverselyaffectthe

insulators.

7.5 Weathersheds shallbeuniforminquality.They shallbe

clean,sound,smoothandshall befreefromdefects
andexcessiveflashingatpartinglines.

7.6 Endfittingsshallbefreefrom cracks,seams,shrinks,airholesandroughedges.End

 fittingsshouldbeeffectivelysealedtopreventmoistureingress;effectiveness
ofsealing systemmustbesupportedby testdocuments.Allsurfacesofthemetal
partsshallbe
perfectlysmoothwithoutprojectingpointsorirregularities,whichmaycausecoron
a.
Allloadbearingsurfacesshallbesoothanduniformsoastodistributetheloading
stresses uniformly.

7.7 Allferrouspartsshallbehotdipgalvanizedtogiveaminimumaveragecoatingofzinc
equivalentto610gm/sq.m.or87micron
thicknessandshallbeinaccordancewiththe requirementof
IS:4759.thezincusedforgalvanizingshallbeof purity99.5%asper IS:4699.
Thezinccoatingshallbeuniform,adherent,smooth,reasonablybright continuous
and free from imperfections such as flux, ash rust stains, bulky white
depositsandblisters.Thegalvanizedmetalpartsshallbeguaranteedtowithstandat
leastfoursuccessivedipseachlastingforone(1)minuteduration underthestandard
preecetest. Thegalvanizingshallbecarriedoutonlyafteranymachining.

8.0 TESTSANDSTANDARDS

Insulatorsofferedshallbemanufacturedwiththesameconfiguration &rawmaterials
asused in the insulatorsfor which typetest reportsaresubmitted. The
manufacturershallsubmitacertificateforthe same.typetestreports
submittedshallnotbemorethanfiveyears old.

8.1 TYPE TESTS:

The type tests are intended to verify the main characteristics of acomposite
insulator. The type tests shall be applied to composite insulators, the class
of which has passed the design tests.

8.1.1 FollowingTypetestshallbeconductedonasuitablenumberofindividualinsulator
units,components,materials orcompletestrings:

SI.
Descriptionoftypetest Testprocedure/ standard
No
1 Drylightningimpulsewithstandvoltagetest As perIEC61109(Clause6.1)
2 Wetpowerfrequencytest As perIEC61109(Clause6.2)
3 Mechanicalload-timetest As perIEC61109(Clause6.4)
4 Radiointerferencetest As perIEC61109(Clause6.5)
Revised
5 RecoveryofHydrophobicitytest Annexure–BThis testmaybe
repeatedevery3yrs
bythemanufacturer
6 Brittlefractureresistancetest Annexure–B
7 Cantilever Load withstand test for Pin IS 731
Insulators
Thebiddershallsubmit typetestreportsasperIEC61109 alongwith thebid.Additional
typetestsrequiredifanyshallbecarriedoutbythemanufacturer,afterawardof contract
forwhichnoadditional charges shallbepayable.In case,thetestshave already been
carriedout,themanufacturershall submitreports forthesame.
 8.1.2 Tests on the high voltage grade Silicone rubber material used inmanufacture of the
insulator housing and weather sheds:
The bidder shall furnish following type test reports conducted on High voltage
Silicone rubber material used for Polymer housing confirming following properties along
with their bid.

Sl.
Property Requirement Standard
No
1 Tensile Strength (MPa) 3 Mpa min ASTM D 412-06a
2 Elongation (%) 300% ASTM D 412-06a
3 Tear Strength 14 N/mm min ASTMD 624
Inclined plane Tracking &
4 (4.5KV 360 min) ASTM D2303
Erosion resistance test
5 Volume Resistivity (Ohm –cm) 2.5 x 10 3 ASTM D257
6 Dielectric constant 4 ASTM D150
7 Dielectric Strength (kv/mm) 10 kV /mm min ASTM D149
8 Density 1.5 min ASTM D792
9 Hardness (shore A) 60 nominal ASTM D 2240
10 Arc Resistance > 220 Seconds ASTM D 495-99
11 Silicone Content Min 30% BS: 2782-Pt10
12 Flammability V-0 UL 94

8.2 ACCEPTANCETESTS:

Thetestsamplesafterhavingwithstoodtheroutinetestshallbesubjecttothefollowing acceptance
tests inorder indicated below:

(a) Verificationofdimensions :Clause7.2IEC:61109,

(b) Verificationofthelockingsystem
(ifapplicable) :Clause7.3IEC:61109,
(c) Verificationoftightness oftheinterface :Clause7.4IEC:61109 amendment1of1995
Betweenendfittings &Insulatorhousing
(d) Verificationofthespecified : Clause7.4IEC:61109, amendment1of1995 /
mechanicalload & SCL IS 731
(e) Galvanizingtest :IS:2633/IS:6745

8.3 ROUTINE TESTS:

Sr.
Description Standard
No.
1 Identificationofmarking As perIEC:61109Clause8.1
2 VisualInspection As perIEC:61109Clause8.2
3 Mechanicalroutinetest As perIEC:61109Clause8.3

Every polymeric insulator shall withstand mechanical routine test at ambient

temperature tensile load at RTL corresponding to at least 50 % of the SML for at
 least10 sec.

8.4 TESTSDURINGMANUFACTURE:

Followingtests shallalsobecarriedoutonallcomponents as applicable

(a) Chemicalanalysis ofzincusedforgalvanizing

(b) Chemicalanalysis,mechanical,metallographictestandmagneticparticle
inspectionformalleablecastings.
(c) Chemicalanalysis,hardness tests andmagneticparticleinspectionfor
forgings.

8.5 SAMPLE TESTING:

8.5.1 Samples from offered inspection lot / production line shall be send to third
party NABL accredited laboratory for checking the SML / SCL withstand
capability.

9.0 QUALITYASSURANCEPLAN:

9.1 Thesuccessfulbiddershall submitfollowinginformationalongwiththebid:

9.1.1 Testcertificates oftherawmaterials andboughtoutaccessories.
9.1.2 Statementgivinglistofimportant
rawmaterial,theirgradesalongwithnamesof sub-
suppliersforrawmaterials,listofstandardsaccordingtowhich
therawmaterialsare tested. List oftestsnormallycarried out onraw
materials in presenceofbidder’s representative.
9.1.3 Listofmanufacturingfacilities available.
9.1.4 Levelofautomationachievedandlists ofareas
wheremanualprocessingexists.
9.1.5 Listof
areasinmanufacturingprocess,wherestageinspectionsarenormallycarri
edout forqualitycontrolanddetails ofsuchtests andinspections.
9.1.6 Listoftestingequipment availablewiththebidderforfinaltestingof
equipmentalong withvalidcalibrationreports.
9.1.7 The manufacturershallsubmit Manufacturing Quality Assurance
Plan (QAP) for
approval&thesameshallbefollowedduringmanufactureandtesting.
9.2 Thesuccessfulbiddershallsubmittheroutinetestcertificates of boughtoutraw
materials/accessories and central excise passes for raw material at the time
of inspection.
9.3 TheOwner’srepresentativeshallatalltimesbeentitledtohaveaccesstotheworks
and all places of manufacture, where insulator, and its component parts
shall be manufacturedandtherepresentativesshallhavefull
facilitiesforunrestrictedinspection of theSupplier’sandsub-
Supplier’sworks,rawmaterials,manufactureof thematerial
andforconductingnecessarytestas detailedherein.
9.4 Thematerialforfinalinspectionshallbeofferedby theSupplieronly
underpacked
condition.Theownershallselectsamplesatrandomfromthepackedlotforcarryin
g outacceptancetests. Thelot offeredforinspection
shallbehomogeneousandshall containinsulators manufacturedin3-
4consecutiveweeks.
 9.5 TheSuppliershallkeeptheOwnerinformedinadvanceof
thetimeofstartingandthe
progressofmanufactureofmaterialintheirvariousstagessothatarrangementsco
uld bemadeforinspection.
9.6 No materialshall be dispatched from its point of manufacture before it has
been satisfactorilyinspectedand testedunlesstheownerin
writingwaivesofftheinspection. In thelatercase
alsothematerialshallbedispatched only aftersatisfactory testing
specifiedhereinhas beencompleted.
9.7 Theacceptanceofanyquantityofmaterialshallinnowayrelievethe
Supplierofhis responsibilityformeetingalltherequirements
ofthespecificationandshallnotprevent
subsequentrejection,ifsuchmaterialarelaterfoundtobedefective

10.0 TESTCERTIFICATE:

ThetenderershallfurnishdetailedtypetestreportsoftheofferedcompositeInsulators
asperclause8.2oftheTechnical SpecificationsattheNABLapprovedlaboratoriesto
provethatthecompositeInsulatorsofferedmeettherequirements of thespecification.

Thepurchaserreserves righttodemand repetitionofsomeoralltheTypeTestin

presenceofpurchaser’srepresentativeatpurchaser’scost.Forthispurpose, thetenderer
shallquoteunitratesforcarryingouteach TypeTest.However,such unitrateswillnot
beconsideredforevaluationof theoffer.Incasetheunitfailsinthe TypeTests,the
completesupplyshallberejected.

11.0 TESTINGFACILITIES:

Thetenderermustclearlyindicatewhattestingfacilitiesareavailableintheworksof
themanufacturerandwhetherfacilitiesareadequatetocarry outallRoutine&acceptance
Tests. These facilitiesshould be available to Engineers if
deputedorcarryoutorwitnessthetestsinthemanufacturerworks. Ifanytestcannot
becarriedoutatthemanufacturer'swork, thereasonsshouldbeclearlystatedinthe
tender. Theinsulators
shallbetestedinaccordancewiththeproceduredetailedinIEC61109/92-93withlatest
amendments.

12.0. DRAWINGS :

12.1 TheBiddershallfurnishfulldescriptionandillustrationofthematerialoffered.
12.2 TheBiddershallfurnishalongwith thebid theoutlinedrawing(3copies)ofeach
insulator unit including a crosssectional view ofthe long rod insulator unit.
The drawingshallincludebutnotbelimitedtothefollowinginformation:
(a)Long roddiameter withmanufacturingtolerances
(b)MinimumCreepagedistancewithpositivetolerance
(c)Diameter of FRP Rod
(d)Unitmechanicalandelectricalcharacteristics
(e) Sizeandweightofballandsocket and Pin top and bottom.
(f)Weightofcompositelong rodunits
(g)Materials
(h)Identificationmark
12.3 Afterplacementof award,theSuppliershallsubmitthreesetsoffulldimensioned
 manufacturinginsulatordrawingscontainingallthedetails.
12.4
AfterplacementofawardtheSuppliershallalsosubmitfullydimensione
dinsulator cratedrawingfordifferenttypeofinsulators
forapprovaloftheowner.

13.0 RETEST AND REJECTION:

13.1
SampleProcedurefortestingofinsulatorsshallbeasperclause7.1to7.6of
IEC61109forAcceptance& RoutineTests.

Forthesamplingtests,twosamples areused,E1and E2. Thesizes ofthesesamples

are indicatedinthetablebelow.

LotSize(N) SampleSize
E E
N<300 Subjecttoagreement
300<N<2000 4 3
2000<N<5000 8 4
5000<N<10000 1 6

Ifmorethan10000insulatorsareconcerned, they shallbedividedintoanoptimum

numberoflots comprisingbetween2000and10000insulators. Theresults ofthetests
shallbeevaluatedseparatelyforeachlot.
Theinsulators shallbeselectedbythepurchaser’s representativefromthelotatrandom.
Thesamples shallbesubjectedtotheapplicablesamplingtests.
Thesamplingtests are:
Verificationofdimensions - (E1+E2)
Verificationofthelockingsystem - (E2)
Verificationoftightness oftheinterfacebetween - (E2)
endfittings &Insulatorhousing
VerificationofthespecifiedmechanicalloadSML - (E1)
Galvanizingtest - (E2)

Intheeventofafailureofthesampletosatisfyatest, theretestingprocedureshallbeas
follows :
Ifonlyoneinsulatorormetal partfailstocomplywith thesamplingtests,anew
sampleequaltotwicethequantityoriginallysubmittedtothetestsshallbesubjectedto
retesting.Theretestingshallcomprisethetestinwhichfailureoccurs. If twoormore
insulatorormetal partsfail tocomplywithanyofthesamplingtestsorifanyfailure
occurs duringtheretesting, thecompletelotis consideredasnotcomplyingwiththis
standardandshallbewithdrawnbythemanufacturer.

Providedthecauseofthefailurecanbeclearlyidentified,themanufacturermaysort
thelot toeliminate all theinsulatorswith thesedefects. Thesortedlot thenbe
resubmittedfortesting.Thenumberthenselectedshallbethree timesthefirstchosen
quantityfortests.If anyinsulatorsfailduringthisretesting,thecompletelotis
consideredasnotcomplyingwith thisstandardandshallbewithdrawnby the
manufacturer.

13.2 Verificationofdimensions (E1+E2)

Thedimensionsgivenin thedrawingsshallbeverified.Thetolerancesgivenin
 the drawingarevalid.Ifnotolerancesaregiveninthedrawingsthevaluesmentionedin
this specificationshallholdgood.

13.3Verificationofthelockingsystem(E2)
Thistestappliesonlytotheinsulatorsequippedwithsocketcouplingasspecifiedb
yIEC120andis performedaccordingto IEC383.

13.4Verificationoftightness oftheinterfacebetweenendfittings&Insulatorhousing (E2)

One insulator selected randomly fromthe sample E2, shall be subjected to
crackindicationby dyepenetration,inaccordance withISO3452,on thehousingin
thezone
embracingthecompletelengthoftheinterfacebetweenthehousingandmetalfitting
andincludinganadditionalarea,sufficientlyextendedbeyondtheendofthemetalpart.
Theindicationshallbeperformedinthefollowingway.
- thesurfaceshallbeproperlypre-cleanedwiththecleaner;
- the
penetrant,whichshallactduring20minutes,shallbeappliedonthecleanedsurface
;
-
within5minutesaftertheapplicationofthepenetrant,theinsulatorshallbe
subjected,attheambienttemperature,toa tensileloadof70%oftheSML,
appliedbetween themetalfittings;thetensileloadshallbeincreasedrapidlybut
smoothlyfromzeroupto70%ofthe
SML,andthenmaintainedatthisvaluefor1minute;
- thesurfaceshallbecleanedwiththeexcess penetrantremoved,anddried;
- thedevelopershallbeappliedifnecessary;
- thesurfaceshallbeinspected.
Some housingmaterials may bepenetrated by thepenetrant. Insuchcases
evidenceshallbeprovidedtovalidatetheinterpretationoftheresults.
Afterthe1min.testat70%ofthe SML,ifanycracks occur, thehousingand,if
necessary, themetalfittings andthecoreshallbecut,perpendicularlytothecrackinthe
middleof thewidestof theindicatedcracks,intotwohalves.Thesurfaceof thetwo
halves shallthenbeinvestigatedforthedepthofthecracks.

13.5 VerificationofthespecifiedmechanicalloadSML
Theinsulatorsof thesampleE1shallbesubjectedatambienttemperaturetoat
ensile load,appliedbetween thecouplings.Thetensileloadshallbeincreasedrapidly
butsmoothlyfrom zerotoapproximately75%oftheSML,andthenbegradually
increasedtothe SML inatimebetween30sec.to90sec.

If 100% of theSMLisreachedinlessthan90s, theload(100% of theSML)

shall bemaintained for the remainder ofthe 90 s. (This testis considered to be
equivalenttoa1minwithstandtestatthe SML.)
Theinsulators havepassedthetestat13.4&13.5aboveif:
-
Nofailure(breakageorcompletepulloutofthecore,orfractureofthemeta
lfitting)occurseitherduringthe1min.70%withstandtest(a)orduringthe1
min.100% withstandtest(b).
- No cracksareindicated afterthedyepenetration method described in 13.4
above.
- Theinvestigationofthehalvesdescribedin13.4aboveshowsclearlythatthe
cracks donotreachthecore.
13.6 Galvanizingtest
 This testshallbeperformedaccordingtoIS:2633/IS:6745ongalvanizedparts.
14.0 MARKINGS:

14.1
Eachinsulatorshallbelegiblyandindeliblymarkedwiththefollowingdetailsaspe
rIEC-61109:
a) Nameortrademarkofthemanufacturer. b) Voltage&Type
c) Monthandyearofmanufacturing.
d)
Min.failingload/guaranteedmechanicalstrengthinkiloNewtonfollowedbythe
word‘KN’tofacilitateeasyidentification.
15.0 PACKING:

15.1 Allinsulatorsshallbepackedinstrongcorrugatedbox ofmin.5 ply duly paletted

or woodencrates. Thegross weightofthecrates
alongwiththematerialshallnotnormally
exceed100Kgtoavoidhacklingproblem.Thecrates shallbesuitableforoutdoor
storageunderwetclimateduring rainy season.
15.2
Thepackingshallbeofsufficientstrengthtowithstandroughhandlingduringtran
sit,storageat siteandsubsequenthandlinginthefield.
15.3 Suitablecushioning,protectivepadding,orDunnageorspacersshall
beprovidedto preventdamageordeformationduringtransitandhandling.
15.4 Allpackingcasesshallbemarkedlegiblyandcorrectlysoastoensuresafearrivalat
theirdestinationandtoavoidthepossibilityof
goodsbeinglostorwronglydispatched
onaccountoffaultypackingandfaultyorillegiblemarkings.Eachwoodencase/cr
ate/corrugatedbox shallhaveallthemarkings stencilledonitinindelibleink.
15.5
Thebiddershallprovideinstructionsregardinghandlingandstorageprecautions
tobetakenat site.

16.0 GUARANTEE

The Supplierofinsulators
shallguaranteeoverallsatisfactoryperformanceofthe
insulators.Thetenderershallfurnishintheform attached(Schedule'A')all the
guaranteedtechnicalparticulars.
 Annexure-B

Tests on Insulator units

1 RIV Test(Dry)
The insulator string along with complete hardware fittings shall have a
radiointerferencevoltagelevelbelow100microvolts atoneMHzwhensubjectedto50Hz
ACvoltageof10kV&30kVfor11kV&33kVclassinsulators respectivelyunderdry condition.
ThetestprocedureshallbeinaccordancewithIS:8263/IEC:437/CISPR18-2.

2 Brittle Fracture Resistance Test

Brittlefracturetestshallbecarriedoutonnakedrodalongwithendfittingbyapplying“1nHNO3
acid”(63gconc.HNO3addedto937gwater)totherod.Therodshouldbe
held80%ofSMLforthedurationofthetest.Therodshouldnotfailwithinthe96-hour
testduration.Testarrangementshouldensurecontinuouswettingof therodwithNitric acid.

3 Recovery of Hydrophobicity & Corona test

Thetestshallbecarriedouton4mmthicksamples of5cmX7cm.

(i) Thesurfaceofselectedsamples shallbecleanedwithisopropylalcohol.Allowthe

surfacetodryandspraywithwater. RecordtheHydrophobicityclassificationinline
withSTRIguidefor Hydrophobicityclassification.Drythesamplesurface.
(ii) Thesampleshallbesubjectedtomechanical stress bybendingthesampleovera
groundelectrode. Coronais continuouslygeneratedbyapplying12kVtoaneedle
likeelectrodeplaced1mmabovethesamplesurface.Thetestshallbedonefor100 hrs.
(iii) Immediatelyafterthecoronatreatment,spraythesurfacewithwaterand recordthe
HCclassification.Drythesurfaceand repeatthecoronatreatmentas atclause2
above.NoteHCclassification.Repeatthecyclefor1000hrs. oruntilanHCof6or7is
obtained.Drythesamplesurface.
(iv) Allowthesampleto recoverand repeathydrophobicitymeasurementatseveraltime
intervals.Siliconerubbershould recovertoHC1–HC2within24to48hours,
dependingonthematerialandtheintensityofthecoronatreatment.
 Guaranteed TechnicalParticularsof11/33kV Disc Insulator
Sr. Offere
Description Unit Min.requirement
No. d
Polymeric Disc
1. TypeofInsulator
Insulator
Standardaccordingtowhichthe
2. IEC61109
insulators manufacturedand tested
High voltage grade
3. Material of Housing and Weather Sheds
Silicone rubber
ECR
(a) Material ofcore(FRProd)
BORRONFREE
(b) Material ofendfittings SGI Cast/Forged steel

(c) Sealingcompoundforendfittings Silicone sealent

4. Colour of housing Grey

5. Electricalcharacteristics

(a) Nominalsystemvoltage 11/33KV

(b) Highestsystemvoltage 12/36KV

WetPowerfrequency withstand
(c) 35/75KV
voltage
(d) Drylightingimpulsewithstandvoltage 75/170 kV

(e) Visible Discharge Test Voltage 9/27

(f) Creepage distance(Min.) 320/900MM

Inclined Plane Tracking and Erosion Resistance
(g) 4.5 kV for 360 minutes
of Housing
6. Mechanicalcharacteristics:
(a) SML (kN) 70KN
7. Dimensionsofinsulator
Kg.
(i) Weight
mm 16mm (min) for Disc
(ii) DiaofFRProd
Insulator
mm
(iii) LengthofFRProd
mm
(iv) Diaofweathersheds
mm
(v) Thicknessofhousing 3mm (min)
Dryarcdistance mm
Dimensioned drawings of insulator
(vi)
(includingweightwith
tolerancesinweight)enclosed.
 Method offixingofshedsto
Injection
8. housing(specify).Singlemouldor
Moulding
Modularconstruction(injection moulding)
9. Noofweathersheds

10. Typeofsheds

i) Aerodynamic Aerodynamic

11. Packingdetails

(a) Typeofpacking Corrugated Box

(b) No.ofinsulatorsineachpack

(c) Grossweightofpackage.
Anyotherparticularswhichthebiddermayliketogive
12.
.
Type Test as per requirement of Clause 8.2.1 and
13 Required
8.2.2

Signature:

Name:

Designation:

Date:

Place:

Guaranteed TechnicalParticularsof11/33kV Pin Insulator

Sr. Offere
No. Description Unit Min.requirement
d
Polymeric Pin Insulator
1. TypeofInsulator
Standardaccordingtowhichthe
2. IS 731& IEC 61109
insulators manufactured and tested.
high voltage grade
3. Material of Housing and weather Sheds
Silicone rubber
Material ofcore(FRProd)
(a) ECR
BORRONFREE

(b) Material ofendfittings SGI Cast/Forged steel

(c) Sealingcompoundforendfittings Silicone Sealent

4. Colour of housing Grey

5. Electricalcharacteristics

(a) Nominalsystemvoltage 11/33KV

(b) Highestsystemvoltage 12/36KV

WetPowerfrequency withstand
(c) 35/75KV
voltage
Drylightingimpulsewithstand
(d) voltage 75/170 kV

(e) Visible Discharge Test Voltage 9/27

(f) Creepage distance(Min.) 320/900MM

Inclined plane Tracking and Erosion Resistance
(g) of Housing 4.5 kV for 360 minutes

(h) FRP rod leakage Current at 175 V/mm < 0.05 mA

6. Mechanicalcharacteristics:
(a) SCL (kN) 5/10KN (11/33kv)
7. Dimensionsofinsulator

(i) Weight Kg.

11kV- 20.5mm
(ii) DiaofFRProd mm
33kV- 33.5mm
(iii) LengthofFRProd Mm

(iv) Diaofweathersheds mm

(v) Thicknessofhousing mm 3mm (min)

 Dryarcdistance
Dimensioned drawings of insulator
(vi) mm
(includingweightwith
tolerancesinweight)enclosed.
Method
8. offixingofshedstohousing(specify).Singlemoul Injectionmoulding
dor Modularconstruction(injection moulding)
9. Noofweathersheds

10. Typeofsheds

i) Aerodynamic Aerodynamic

11. Packingdetails

(a) Typeofpacking Corrugated Box

(b) No.ofinsulatorsineachpack

(c) Grossweightofpackage.
Anyotherparticularswhichthebiddermayliketogi
12.
ve.
Type Test as per requirement of Clause 8.2.1
13 Required
and 8.2.2

Signature:

Name:

Designation:

Date:

Place:
2.3 TECHNICAL SPECIFICATIONS FOR INSULATION PIERCING CONNECTORS
SUITABLE FOR 11 KV COVERED CONDUCTORS

1.0 Insulation Piercing Connector having 320 AMP Cu Carrying capacity with maximum Outline
size in mm: 97 x 63 x 54 for 50 sq mm & 393 AMP Cu Carrying capacity with maximum
Outline size in mm 131 x 82 x 57 for 99 sq mm Covered Conductor.

2.0 Bodies of Insulation Piercing Connector shall made of glass fibre reinforced polymer having
Insulated and Waterproof seals where Insulation material should be Weather, UV and
Corrosion resistant.

3.0 Insulation Piercing Connector should have Blades made of special tinned copper with End cup
Design suitable for Covered Conductor.

4.0 Insulation Piercing Connector should have Shear-head with one screw design to ensure good
contact properties and avoid damaging cables.

5.0 Insulation Piercing Connector should have Lowest Torque, easy to install & no special tools
necessary to operate.

6.0 Piercing of Insulation Piercing Connector should have structural design.

7.0 Insulation Piercing Connector should have a design such that there is no stripping of insulation
on the covered conductor. It shall be able to get the Lowest contact resistance& Superior
insulation as well as sealing performance.

8.0 Material of Insulation Piercing Connector should withstand for all routine & acceptance test as
per NFC 33 020-1998 listed below:

a. Flashover - 15 kV for 1 min in water.

b. Short circuit test,

c. Mechanical test

d. Heat cycle test

9.0 The superior material and process technology ensure operation regularity in corrosive
environment
 CLAUSE
2.4. TECHNICAL SPECIFICATION FOR
NO.
10kV 5kA Surge Arrester Distribution Class
FEATURES
1
GENERAL
1.1
This specification covers the design, manufacture, assembly, testing at
manufacturer's works, packing and delivery of Metal Oxide (gapless) Surge
1.2 arresters with Silicone Rubber housing.
The surge arresters shall conform in general to IEC-60099-4 and IS: 3070 part-
3
Arresters shall be completely molded units with absolutely no air volume
inside, suitable for mounting on bracket. Arresters of tubular construction i.e
arresters assembled in hollow core insulators with enclosed gas volume are
not acceptable due to abrupt short circuit performance and poor sealing
1.3 mechanism.
Surge arresters must be type tested as per relevant IEC at international
accredited laboratory.
1.4 The Test sequence should include all material and design test applicable for
polymeric housed surge arrester including Short Circuit Test, 1000 hrs Weather
Aging Test, Tracking & erosion resistance test etc.
2 Offer received without submission of valid type test reports shall be
ignored.
2.1

DUTY REQUIREMENTS

2.2
The surge arresters shall be capable of discharging over voltages occurring due
2.3 to switching on unloaded transformer, reactors and long lines. The arrester
should have minimum line discharge current withstand capability of 200A,
2000 micro sec.
2.4 The surge arrester shall be fully stabilized thermally, operating duty & TOV
tests should be done with equivalent thermal model of surge arrester.
2.5 The surge arresters shall protect transformers, circuit breakers, disconnecting
switches, instrument transformers, shunt reactors etc with insulation level
specified in the specifications.
The surge arresters shall be capable of withstanding meteorological and short
3 circuit forces under site conditions.
The surge arrester should have short circuit rating of 16kA & 600A as per
3.1 requirement of IEC 60099-4.

CONSTRUCTIONAL FEATURES

Polymer housing shall be free from lamination cavities or other flaws affecting
 CLAUSE
2.4. TECHNICAL SPECIFICATION FOR
NO.
10kV 5kA Surge Arrester Distribution Class
FEATURES
3.2 the mechanical and electrical strengths. Properties of the polymeric materials
shall be specified in the offer and test reports for the same from a reputed
Indian laboratory shall be submitted for approval of purchaser.
Polymeric housing shall be made of Silicone Rubber with min 30% silicone
3.3 content

3.4 The rain sheds / petticoats shall be of polymeric material and shall confirm to
the properties and test reports submitted. The petticoats shall not be pre-
molded push on type in view of weak interface between the housing and
3.5 assembled disc.
Each surge arrester shall be sealed single phase unit. The surge arrester shall
not have any air volume enclosed within.
The non linear blocks shall be sintered metal oxide material. The surge arrester

3.6 shall be robust with excellent mechanical and electrical properties.

Surge arresters shall be of cage type construction with no gas volume to

3.7 ensure that the arrester does not explode during the short circuit test
condition. The MOV blocks should be housed in cage of FRP rods
appropriately crimped at both end fittings. The housing should be directly
molded on stack of MOV blocks without any intermediate interface.
3.8 The surge arrester shall not fail due to housing contamination. TERT (Tracking
& Erosion resistance test) Test shall be carried out on the material used for
housing as per ASTM D 2303 and test report shall be submitted.
Housing shall be so coordinated that external flashover will not occur due to
application of any impulse or switching surge voltage up to maximum design
3.9 value of surge arrester. The polymer housing should comply with the
requirement of IEC 60815-3
The end fittings shall be non magnetic and of corrosion proof material.
The end fittings used in polymer arrester shall be made out of aluminum
through machining process/pressure die-casting process. Sand casted and
gravity casted end fittings are not acceptable due to poor microstructure and
porosity issues.
MOV blocks shall have full metallization to have full face contact and to
reduce contact resistance between adjacent discs. MOV blocks should be
100% tested for 200A, 2000 micro second LD.
MOV blocks shall have lead free insulating collar and The insulation
thickness must be consistent and of sufficient thickness to pass the 65kA,
4/10μs test.
MOV blocks shall be tested 100% at source and as a confirmation should
have the following values printed on Aluminium sprayed surface
3.10
a. Batch No.
b. AC reference voltage measured at reference current
c. Residual voltage measured at nominal discharge current
4 The manufacturer shall furnish the following for MOV discs:
 CLAUSE
2.4. TECHNICAL SPECIFICATION FOR
NO.
10kV 5kA Surge Arrester Distribution Class
FEATURES
4.1 The batch test reports with necessary quality checks used for individual blocks
along with insulation layer formed across each block.
Details of ageing test carried out on individual batch.
4.2 Detailed tests carried out on individual disc during routine tests
Fittings and accessories
4.3 Surge arresters should be supplied with suitable mounting bracket made of
SMC material.

4.4 TESTS
Surge arrester shall conform to all type tests as per IEC and shall be subjected
4.5 to routine and acceptance tests in accordance with IEC-99-4. All type test
reports should be within 5 yrs from the date of bidding.
The resistive current drawn by the arrester at rated voltage shall be indicated
4.6 in the routine test report.
The tenderer shall furnish detailed type test reports of the offered Surge
Arrester
All Type Tests shall be carried out at reputed and accredited laboratories to
prove that Surge Arresters offered meet the requirements of the specification.
There should be no change in the design of type tested Surge Arrester and those
offered against this tender
The surge arrester should be short circuit tested for 16kA & 600A as per
requirement of IEC 60099-4. The Surge Arrester Offered should have
same dimension as used for short circuit test.
The purchaser reserves the right to demand repetition of some or all the Type
Tests in presence of purchaser's representative at purchaser's cost. For this
purpose, the tenderer shall quote unit rates for carrying out each Type Test.
However, such unit rates will not be considered for evaluation of the offer. In
case the unit fails in the type tests, the complete supply shall be rejected.

List of type test Reports to be submitted along with offer

1) Residual Voltage test
2) Long duration discharge test 200A, 2000 micro sec
3) Operating duty test
4) Insulation withstand test
5) Power frequency voltage vs time characteristic
6) High current short circuit test 16kA
7) Low current short circuit test 600A
8) Accelerated aging test 1000 hrs
5 9) Weather aging test on full arrester 1000 hrs
10) Partial discharge test

Sample Testing
The bidder should submit 2 samples of offered surge arrester along with the
offer & same shall be tested for 200A, 2000 micro sec LD test to confirm the
line discharge capability. Alternatively this test to be repeated at third party
 CLAUSE
2.4. TECHNICAL SPECIFICATION FOR
NO.
10kV 5kA Surge Arrester Distribution Class
FEATURES
laboratory for each lot offered during inspection.

Drawings and Documentation

All dimensions and data shall be in System International Units.
The tenderer shall furnish one sets of following drawings along with this offer:
6 General outline drawings of the complete Arrester with technical parameters.
Drawing showing clearance from grounded and other live objects and between
adjacent poles of Surge arresters.
Mounting details, installation and commissioning instructions of Surge
arresters. Details of line terminal and ground terminals.

The offered surge arrester should meet or exceed the technical particulars
given below
General
System neutral earthing Effectively earthed
Installation Outdoor
Nominal discharge current 5kA of 8/20microsecond wave
Rated frequency 50Hz
Long duration discharge class Distribution

Prospective symmetrical fault current 16kA for 0.2 second

Partial discharge at 1.05MCOV not more than 10pico coulomb
(continuous operating voltage)
Reference ambient temperature 50 degree Celsius

Sl.No Particulars Value

1 Rating 10
(kVrms)
2 Continuous operating voltage 8
(kVrms)
3 Installation Outdoor
4 Class Distribution class
5 Arrester construction Polymeric cage design with FRP
rod crimped at end fittings
forming the cage
6 Nominal discharge current 5
(kAp)
7 Long duration line discharge
capability
Time(µs) 2000
Current (A) 200
8 Ratedfrequency (Hz) 50
 CLAUSE
2.4. TECHNICAL SPECIFICATION FOR
NO.
10kV 5kA Surge Arrester Distribution Class
FEATURES
9 Reference current (mAp) 5
10 Reference voltage (min) (kVrms) 10
11 Max residual voltage at (8/20 µs
impulse wave)
2.5KAp (kVp) 24.3
5KAp (kVp) 26.1
10 KAp (kVp) 28.5
12 Max steep current impulse 27.1
residual at 5kAp
(kVp)
13 Temporary overvoltage
withstand capability for
1 sec (kVrms) 10.5
10.0 sec (kVrms) 10
100.0 sec (kVrms) 9.5
14 Lightning impulse voltage 95
withstand capability (Dry)
(kVp)
15 Power frequency voltage 38
withstand capability (wet)
(kVrms)
16 Max Partial discharge (µC) < 10
17 High current impulse 65
withstandcapability (4/10µs
impulse wave) (kAp)
18 Total Creepage distance (min) 300
(mm)
19 Pull strength 1000 N (Min)
20 Cantilever strength 150NM (Min)
21 Torsion 30 Nm

2.5 33 KV Polymer Surge Arrestors:

Should have MOV (ZnO) Blocks of Line discharge Class I. This should be based on an overall
polymer housing directly moulded on to the ZnO discs and the reinforcement.

CLAUSE TECHNICAL SPECIFICATION FOR

NO. 30kV, 10kA Class-1 SURGE ARRESTER
FEATURES
1
GENERAL
1.1
This specification covers the design, manufacture, assembly, testing at
 CLAUSE TECHNICAL SPECIFICATION FOR
NO. 30kV, 10kA Class-1 SURGE ARRESTER
FEATURES
manufacturer's works, packing and delivery of Metal Oxide (gapless) Surge
arresters (polymer housed) along with Disconnector and mounting bracket
1.2
The surge arresters shall conform in general to IEC-60099-4 and IS: 3070 part-3
1.3
Arresters shall be completely molded units with absolutely no air volume
inside, The arresters should be suitable for bracket mounting. Arresters of
tubular construction i.e arresters assembled in hollow core insulators with
enclosed gas volume are not acceptable due to abrupt short circuit performance
and poor sealing mechanism.
1.4
Surge arresters must be type tested as per relevant IEC at international
2 accredited laboratory.

2.1 DUTY REQUIREMENTS

The surge arresters shall be capable of discharging over voltages occurring due
to switching on unloaded transformer, reactors and long lines. The surge
arrester should be of line discharge class-1 with minimum energy handling
2.2 capability of 2.5kJ/kV of Ur (Line discharge). The arrester should have
minimum line discharge current withstand capability of 325A, 2000 micro
sec.
The reference current of surge arresters shall be high enough to eliminate the
2.3
influence of grading and stray capacitance on the measured reference voltage.

2.4 Values and calculations shall be furnished with offer.

2.5
The surge arrester shall be fully stabilized thermally to give a life expectancy of
20 years under site conditions and take care of effect of direct solar radiation.

2.6 The surge arrester shall be suitable for circuit breaker duty cycle in the given
system.

2.7 The surge arresters shall protect transformers, circuit breakers, disconnecting
switches, instrument transformers, shunt reactors etc with insulation level
specified in the specifications.

2.8 The surge arresters shall be capable of withstanding meteorological and short
circuit forces under site conditions.

The surge arrester should have short circuit rating of 40kA & 600A as per
requirement of
2.9 IEC 60099-4.
Surge arrester shall be capable of discharging energy equivalent to class 1 of
IEC for a 33kV system on two successive operations followed immediately by
50Hz energisation with a sequential voltage profile as specified in TOV
2.10 characteristics.
 CLAUSE TECHNICAL SPECIFICATION FOR
NO. 30kV, 10kA Class-1 SURGE ARRESTER
FEATURES

The Surge Arresters should be provided with Disconnector to isolate the

arrester in the event of arrester failure. The Disconnector should be
2.11 suitable for Class 1 duty of surge arrester. The 5kA disconnectors supplied
for distribution class arresters are not acceptable.

The Surge Arrester should be suitable for bracket mounting. The Insulating
3 bracket should be made of SMC material. The bracket should be offered as
per technical specifications given in clause 7.
3.1
The Name plate should be able to withstand the outdoor conditions & UV
radiations. The marking on Name plate should not get erase due to outdoor
working conditions during life time of surge arrester.

3.2
CONSTRUCTIONAL FEATURES

Polymer housing shall be free from lamination cavities or other flaws affecting
3.3 the mechanical and electrical strengths. Properties of the polymeric materials
shall be specified in the offer and test reports for the same from a reputed
Indian laboratory shall be submitted for approval of purchaser.
3.4
The rain sheds / petticoats shall be of polymeric material and shall confirm to
the properties and test reports submitted. The petticoats shall not be pre-
3.5 molded push on type.

Each surge arrester shall be sealed single phase unit. The surge arrester shall not
3.6 have any air volume enclosed within.

3.7 The non linear blocks shall be sintered metal oxide material. The surge arrester
shall be robust with excellent mechanical and electrical properties.

3.8 Surge arresters shall be of cage or wrap type construction with no gas volume
to ensure that the arrester does not explode during the short circuit test
condition.
The surge arrester shall not fail due to housing contamination. TERT (Tracking
& Erosion resistance test) Test shall be carried out on the material used for
housing as per ASTM D 2303 and test report shall be submitted.
3.9
Housing shall be so coordinated that external flashover will not occur due to
application of any impulse or switching surge voltage up to maximum design
value of surge arrester. The polymer housing should comply with the
requirement of IEC 60815-3

The end fittings shall be non magnetic and of corrosion proof material.
The end fittings used in polymer arrester shall be made out of aluminum
through machining process/pressure die-casting process. Sand casted and
 CLAUSE TECHNICAL SPECIFICATION FOR
NO. 30kV, 10kA Class-1 SURGE ARRESTER
FEATURES
gravity casted end fittings are not acceptable due to poor microstructure and
porosity issues.

MOV blocks shall have full metallization to have full face contact and to
reduce contact resistance between adjacent discs.
MOV blocks shall have lead free insulating collar and The insulation
thickness must be consistent and of sufficient thickness to pass the 100kA,
4/10μs test.

MOV blocks shall be tested 100% at source and as a confirmation should have
the following values printed on Aluminium sprayed surface
a. Batch No.
3.10 b. AC reference voltage measured at reference current
c. Residual voltage measured at nominal discharge current
d. Power loss value measured at continuous operating voltage

The manufacturer shall furnish the following for MOV discs:

4 The batch test reports with necessary quality checks used for individual blocks
along with insulation layer formed across each block.
4.1
Details of ageing test carried out on individual batch.

4.2 Detailed tests carried out on individual disc during routine tests

Fittings and accessories

Surge arrester should be provided with terminal connection suitable for ACSR
single Zebra. Disconnector suitable for Class-1 arrester and insulating bracket
should be part of supply of surge arrester.

TESTS

Surge arrester shall conform to all type tests as per IEC and shall be subjected to
routine and acceptance tests in accordance with IEC-99-4.

Following type tests shall be conducted on as per relevant standard.

4.3
1. Insulation withstand test.
2. Residual voltage test.
4.4 3. Bending test on arrester housing assembly.
4. Long duration current impulse withstand test.
4.5 5. Operating duty test.
6. Short circuit test
7. Partial discharge test.
8. TERT testing on offered housing material as per ASTM D2303
9. Ageing test on MOV Blocks
10. Power frequency voltage vs time characteristics.
11. Weather ageing test on polymer housed surge arrester.
 CLAUSE TECHNICAL SPECIFICATION FOR
NO. 30kV, 10kA Class-1 SURGE ARRESTER
FEATURES
12. Moisture ingress test

5 The resistive current drawn by the arrester at rated voltage shall be indicated
in the routine test report.

The tenderer shall furnish detailed type test reports of the offered Surge Arrester

All Type Tests shall be carried out at reputed and accredited laboratories to
prove that Surge Arresters offered meet the requirements of the specification.

The purchaser reserves the right to demand repetition of some or all the Type
Tests in presence of purchaser's representative at purchaser's cost. For this
purpose, the tenderer shall quote unit rates for carrying out each Type Test.
However, such unit rates will not be considered for evaluation of the offer. In
case the unit fails in the type tests, the complete supply shall be rejected.

6
Drawings and Documentation

All dimensions and data shall be in System International Units.

The tenderer shall furnish one sets of following drawings along with this offer:

General outline drawings of the complete Arrester with technical parameters.

Drawing showing clearance from grounded and other live objects and between
7 adjacent poles of Surge arresters.

Mounting details, installation and commissioning instructions of Surge arresters.

Details of line terminal and ground terminals.

Technical specifications of mounting bracket

a) Wet power frequency withstand = 35kV
b) Lightning impulse withstand = 115kV
c) Dry arcing distance = Min 156 mm
d) Creepage = 325 mm
e) Material – SMC

The offered surge arrester should meet or exceed the technical particulars
given below

General

System neutral earthing Effectively earthed

Installation Outdoor
Nominal discharge current 10kA of 8/20microsecond wave
 CLAUSE TECHNICAL SPECIFICATION FOR
NO. 30kV, 10kA Class-1 SURGE ARRESTER
FEATURES
Rated frequency 50Hz
Long duration discharge class 1

Prospective symmetrical fault current 40kA for 0.2 second

Partial discharge at 1.05MCOV not more than 10pico coulomb

(continuous operating voltage)
Reference ambient temperature 50 degree Celsius

Sr.No Technical Particulars 30kV

1 Rated Voltage (kV) Ur 30

2 Continuous operating Voltage (kV) Uc 24
3 Nominal Discharge Current 10kA
4 Line Discharge Class Class-1
5 Energy absorption capability (kJ/kV of 2.5
Ur)
6 Long duration current impulse 325A, 2000 µSec
withstand
7 High current impulse withstand 4/10 100kA
µSec
8 Rated short circuit current High 40kA
Current
Rated short circuit current Low 600A
Current
9 Lightning impulse current residual
voltage 8/20 µSec
5kA 74.7 kVp
10kA 79.5 kVp
20kA 87.2 kVp
10 Steep current impulse residual voltage 83.6 kVp
@ 10kA 1/20 µSec
11 Switching current impulse residual
voltage
125A 59.8 kVp
500A 63.3 kVp
12 Lightning impulse withstand capability 273 kVp
of arrester housing 1.2/50 µSec
13 Power frequency withstand voltage of 122 kVp
arrester housing (Dry/Wet)
14 Creepage distance (min) 925 mm
15 Cantilever strength 350 N-M
16 TOV Capability with prior energy (kV
rms)
1 Sec 33.0
10 Sec 31.1
100 Sec 29.4
 Technical Specification:
Wedge Connectors for MV & HT Electrical Systems

1. SCOPE
This specification covers the design, manufacture, testing & supply of wedge type connectors
which are to be used for line jumpers, cut-points, T-connections, making connection to the
equipment’s like isolators, circuit breakers, CTs and PTs, Lightning Arresters, Busbars etc.
The connectors shall have maximum contact surface with the conductor, extremely low and
stable contact resistance, resulting proven minimum power loss. These shall maintain constant force
within the connection for the life of connector while compensating for thermal expansion and
increased life span.

2. STANDARDS
Unless otherwise specified elsewhere in this specification, the rating as well as performance and
testing of the HT & MV overhead line connectors shall conform to the latest revisions available at the
time of placement of order of all the relevant standards as listed below: -
1.0 ANSI C 119.4 and
1.1 IS 5561/1970.

3. HT & MV WEDGE CONNECTOR: “FIRED WEDGE CONNECTORS”

3.1 The connector shall confirm Electrically to Extra Heavy Duty, Class AA and Mechanically
to Class 1 as per ANSI C 119.4. It also shall confirm to Indian Standard - IS 5561. It consists
of a spring 'C' member and a Wedge, both made from a special Aluminium alloy of high
ductility and electrical conductivity. The 'C' member and a Wedge shall be factory coated with
a conductive inhibitor containing abrasive particles to help in cleaning the contact surface
during Installation.

The connector shall be useful for the conductor size of diameter more than 10mm such as
RABBIT, RACOON, DOG, COYATE, PANTHER and above.

It shall use a power tool with booster for installation to ensure installation quality and
repeatability. This is also needed to eliminate operator dependency. During the assembly, the
wedge shall be inserted at a speed of about 40 m/s using the specified tool. High-speed
insertion with the specified inhibitor shall be very effective in abrading all sliding surfaces and
in disrupting surface oxide film to generate large number of contact spot in the electrical
surfaces. When connected, this tap shall provide a reliable electrical and mechanical
connection for solid, stranded or compressed conductor combinations including AAC, AAAC
and ACSR. Wedge locking nothing but Notch formation at the end of wedge shall be
observed. This will ensure that in any case wedge will not loosen and come back.
During disassembly of connector, take-off clips are designed for use with the specified tool.
Upon disassembly, the conductor as well as connector can be reused.

3.2 ‘C’ MEMBER:

The C member shall be formed from extruded Aluminium so that the grain (extrusion
direction) runs perpendicular to the conductor (e.g. from C-groove end to C-groove end). This
orientation of grain direction provides for lower rates of stress relaxation in the metal and will
maintains the level of contact pressure at or near the value at initial installation for the life of
connection.
Susceptibility to stress corrosion cracking will also improve. The material used shall be
specially designed with tighter tolerances on the chemical composition to ensure consistency
of the C- member production regarding dimensions and mechanical properties.
 3.3 Wedge
The dimensions for the wedges are manufactured to close tolerances to ensure repeatability
and reliability of the connection.

3.4 Inhibitor
An oxidation inhibitor shall be applied to the surface there by elimination of oxidation of
metallic surface. The chemical composition of the inhibitor shall be synthetic and compatible
with the rubber gloves used by the utilities. This inhibitor shall contain special Aluminium
abrasive particles, optimized in size and quantity, to ensure repeatability and reliability of the
electrical contact made in every connection.

3.5 The connectors shall have maximum contact surface with conductor and, extremely low
and stable contact resistance and minimum power loss. These shall maintain constant force
within the connection for the life of the connector/clamp while compensating for thermal
expansion or creep and increased life span.
The mechanical stresses generated during the wedge insertion shall cause plastic deformation
of the C-clamp and shall increase the geometrical confirmation of the clamp to the conductor.

3.6 Installation Tool

Tool is to be used for HT Wedge Connectors installations, due to which operator dependency
& human errors in connector installations are eliminated.
(NOTE: “Wedge Connector to be installed manual efforts” i.e. by using tools like
hammer/spanner are NOT acceptable)
The tool is having 4 moving parts: the ram, the power unit, the breech cap and the gas release
knob. The gas produced by the power booster during the installation is captive inside the
power unit. This allows the tool to remain self-supporting on the lines during installations until
the gas release knob is turned counterclockwise. This allows the gas produced by the power-
booster to be released and the tool to be removed.

3.7 Power-Booster
Power charge repeatability (PCR) is critical to the supply of a reliable product, which can be
applied safely and consistently every time. These power-boosters are designed with the primer
cap enclosed to ensure that it can only be used with the specified tool and to ensure that there
is no incorrect installations.

4. FREEDOM FROM DEFECTS: -

4.1 The wedge type connectors shall be smooth and free from cavities, blowholes, and such
other defects, which would likely cause them to be unsatisfactory in service.
4.2 The wedge type connectors shall be so designed and proportioned that they are capable of
safely withstanding stresses to which they may be subjected (including those due to short
circuit and climatic conditions) and that the effects of vibration both on conductor and
connector itself are minimized.
They shall be designed, manufactured, and finished to avoid sharp radius of curvature, ridges
and excrescences, which might lead to, localized pressure on or damage to the conductor in
service.
Sufficient contact pressure should be maintained at the joint by the provision of the required
number of bolts or other fixing arrangements. But the contact pressure should not be so great
as to cause relaxation of the joint by cold flow. The joint should be such that the pressure is
maintained within this range under all conditions of service.

5. TESTS:
5.1 TYPE TESTS
The following Type Tests shall be carried out as specified in respective standard as per
ANSI C119.4 for any one of the connector from same design
 a) Current Cycle Test (CCT) or Current Cycle Submersion Test (CCST)
b) Mechanical test / Wire Pull-out Test

As per IS5561
c) Tensile Test.
d) Resistance Test
e) Temperature Rise Test.
f) Short Time Current Test.
- For Raccoon and Dog conductors: 25KA for 3 secs
- For higher sizes: as per electrical fault system requirements
g) Dimensional Check

Special Test:
Corona RIV Test on any one of the wedge connector for conductor dia higher
than 30mm.
Salt fog test as per ASTM B117 for any one of the connector

5.2 TEST CERTIFICATE

The tenderer shall furnish detailed type test reports of the offered Wedge Type Connector for
the tests as per this specification. All the above Type Tests shall be carried out as per the
relevant standards at National or International labs, capable of carrying out specified tests.
These type tests should have been carried out as per respective standards. Testing for family of
connector shall be as per standard, if applicable.

5.3 ACCEPTANCE TESTS

a) Tensile Test.
b) Resistance Test.
c) Dimensional
The acceptance tests are to be carried out in presence of Company's representative. The
supplier shall, therefore, give sufficient notice to the Company for arranging witnessing of the
tests.

5.4 ROUTINE TESTS

a) Visual inspection.
b) Dimensional Check.

5.5 TESTING FACILITIES AND DETAILS OF EQUIPMENTS

The supplier / tenderer shall clearly state as to what testing facilities are available in the works
of manufacturer and whether the facilities are adequate to carry out type, routine and
acceptance tests as per specification. The bidder shall provide the facilities to purchaser’s
representative for witnessing the tests in the manufacturer’s works. If any test cannot be
carried out at manufacturer’s works reason should be clearly stated in the tender.

6. DRAWING
The bidders shall supply the material as per drawing approved by customer/testing lab.

7. Guaranteed Technical Particulars (GTP)

GTP of LT & HT Wedge Connectors shall be as per Annexure 1 & 2 respectively.

8. MARKING
Each C- member and wedge is marked with distinct identification code. This identification
code is also marked on the packaging to ensure that the correct parts are used for the application. The
installer can make a quick visual check before installing.
9. PACKING
For packing, Polythene Bags, Corrugated Boxes, Wooden Boxes shall be used. The packing
shall be fit to withstand rough handling during transit and storage at destination. The heads and
threaded portion of fasteners fitting should be properly protected against damage. The gross weight of
the packing shall not normally exceed 50 kg per box or case. All different fitting components shall be
packed in different cases and shall be completed with minor accessories fitted in places. The tenderer
should be approved the packing list before dispatching the material.

10. PERFORMANCE OF WEDGE CONNECTORS

Bidder shall submit performance certificates/Purchase orders to prove satisfactory
performance of connectors for minimum 10 years after installation.

Annexure-1
 28. 33V 10 KN COMPOSITE SILICON RUBBER POLYMER PIN
INSULATORS WITH GI PINS

1.0 SCOPE:
This specification covers design, manufacture, testing and supply of Composite Polymer Pin
Insulators for use in the 33KV overhead transmission lines. The Composite Pin Insulators
shall be of the following type:-

Long rod type Pin Insulators intended to be mounted rigidly on a supporting structure to
support for 33KV AAAC Dog:-

2.0 APPLICABLE STANDARDS:

2.1 Standards:-
Following Indian/International Standards, which shall mean latest revision, with
amendments/changes adopted and published, unless specifically stated otherwise in the
Specification, shall be referred while accessing conformity of Insulators with these
specifications.

i. In the event of supply of Insulators conforming to standards other than specified, the Bidder
shall confirm in his bid that these standards are equivalent or better to those specified. In case
of award, salient features of comparison between the standards proposed by the Bidder and
those specified in this document will be provided by the Supplier to establish equivalence.

Sr. Indian Title International

Standard Standard
No.
Standard

1 Definition, test methods and acceptance criteria for IEC:61109

composite Insulators for a. c. overhead lines above
1000V.

2 IS: 731 Porcelain insulators for overhead power lines with a IEC: 60383
nominal voltage greater than 1000V.
3 IS:2071 Methods of High Voltage Testing. IEC:60060-1

4 IS:2486 Specification for Insulator fittings for overhead power IEC:60120

lines with a nominal voltage greater than 1000V General
IEC:60372
Requirements and Tests Dimensional Requirements
locking devices.

5 - Thermal Mechanical performance test and mechanical IEC:60575

 Sr. Indian Title International
Standard Standard
No.
Standard

performance test on string Insulators units.

6 IS: Guide for the selection of insulators in respect of polluted IEC: 60815
13134 condition.

7 Characteristics of string insulator units of the long rod

- IEC: 60433
type.

8 - Hydrophobicity Classification Guide. STRI guide

1.92/1

9 - Radio interference characteristics of overhead power CISPR 18.2

lines and high voltage equipment. Part 2

10 IS:8263 Methods of RI Test of HV Insulators. IEC:60437

11 Standard for Insulators- Composite- Distribution Dead-end ANSI C 29.13-

Type. 2000

12 IS:4759 Hot dip zinc coatings on structural steel & other allied ISO:1459
products.

13 IS:2629 Recommended practice for Hot Dip galvanization for ISO:1461(E)

iron and steel

14 IS:6745 Determination of weight of zinc coating on zinc coated ISO:1460

Iron and steel articles.

15 IS:3203 Methods of testing of local thickness of electroplated ISO:2178

coatings.

16 IS:2633 Testing of Uniformity of coating of zinc coated articles.

17 - Standard specification for glass fiber standards. ASTM D

578-05

18 - Standard specification for compositional analysis by ASTM D

Thermo-gravimetery.
578-05

19 IS:4699 Specification for refined secondary zinc

The addresses of organizations who offer the above standards are given at Annexure-A
 3.0 Technical Description of Composite Insulators:
3.1 Service condition:-
The polymer Insulators to be supplied shall be suitable for satisfactory continuous operation
under condition s as specified below:

Maximum ambient temperature : 480C

Minimum ambient temperature : -50C

Relative humidity : 0 to 100%

3.2 Composite Insulators long rod type to support conductor on 33KV Over head
Power Lines:-

3.2.1 The Insulators shall be suitable for 3 , 50 Hz, effectively earthed 33 KV O/H distribution
system in a moderately / heavily polluted atmosphere.

3.2.2 Bidder must be an indigenous manufacturer and supplier of composite Insulators of rating
33KV or above OR must have developed proven in house technology and manufacturing
process for composite Insulators of above rating OR possess technical collaboration/
association with a manufacturer of composite Insulators of rating 33KV or above. The Bidder
shall furnish necessary evidence in support of the above along with the bid, which can be in
the form of certification from the utilities concerned, or any other documents to the
satisfaction of the owner.

3.2.3 Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing,
projection etc, and selection in respect of polluted conditions shall be generally in accordance
with the recommendation of IEC-60815/IS: 13134.

3.2.4 The size of Composite insulator, minimum creepage distance and mechanical strength along
with hardware fittings shall be as follows:

S Type of Nomina Highes Visible Wet Impulse Weather Minimu Min. Pin
N composit l t discharg power withstan shed m failin rod
e system system e test frequency d creepage g shank
Insulator voltage voltag diameter
voltage withstand voltage distance load diam
KV e KV KV voltage KV (mm) (mm) KN eter
(rms) (rms) (rms) KV (rms) (rms) (mm)

i. 33KV
Pin 33 36 27 75 170 100 900 10 33.5
Insulator
Note: Creepage distances have been considered in line with IS-13134 (which specifies 20mm/ KV
for moderately polluted environment and 25mm/KV for heavily polluted area)

3.3 Dimensional Tolerance of Composite Insulators :-

The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed
as follows in line with IEC 61109:

± {0.04d+1.5) mm when d<300 mm,

± (0.025d+6J mm when d>300 mm.

Where, d being the dimensions in millimeters for diameter, length or creepage distance as the
case may be,

However, no negative tolerance shall be applicable to creepage distance.

3.4 Corona and Rl Performance:-

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part
shall be subjected to excessive localized pressure. The insulator and metal parts shall be so
designed and manufactured that it shall avoid local corona formation and not generate any
radio interference beyond specified limit under the operating conditions.

4.0 BASIC FEATURES:

4.1 Design and construction:-
The Composite Pin Insulator shall have a core, housing & weather shed of insulating material
and steel/aluminum alloy hardware components for attaching it to the support/conductor.

4.1.1 Core:-

It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass
fibers and resin shall be optimized in the FRP rod. Glass fibers shall be Boron free
electrically corrosion resistant (ECR) glass fiber or Boron free E-Glass and shall exhibit both
high electrical integrity and high resistance to acid corrosion. The matrix of
the FRP rod shall be Hydrolysis resistant. The FRP rod shall be manufactured through
Pultrusion process. The FRP rod shall be void free. The diameter of FRP rod should be 24 mm
only
4.1.2 Housing (Sheath):-

The FRP rod shall be covered by a seamless sheath of a silicone electrometric compound or
silicone alloy compound of a thickness of 3mm minimum uniformly measurable including on
weather sheds. It shall be one-piece housing using Injection Molding Principle to cover the
core. The elastomer housing shall be designed to provide the necessary creepage distance
and protection against environmental influences. Housing shall conform to the requirements of
IEC 61109/92-93 with latest amendments.
4.1.3 Weather sheds:-
The composite polymer weather sheds made of a silicone elastomeric compound or silicone
alloy compound shall be firmly bonded to the sheath, vulcanized to the sheath or molded as
part of the sheath and shall be free from imperfections It should protect the FRP rod against
environmental influences, external pollution and humidity. The weather sheds should have
silicon content of minimum 30% by weight. The strength of the weather shed to sheath
interface shall be greater than the tearing strength of the polymer. The interface, if any,
between sheds and sheath (housing) shall be free from voids.

4.1.4 End Fittings:-

End fittings transmit the mechanical load to the core. They shall be made of spheroidal
graphite cast Iron, malleable cast iron or forged steel or aluminum alloy. They shall be
connected to the rod by means of a controlled compression technique. The material used in
fittings shall be corrosion resistant. As the main duty of the end fittings is the transfer of
mechanical loads to the core the fittings should be properly attached to the core by a coaxial or
hexagonal compression process & should not damage the individual fibers or crack the core.
The gap between fitting and sheath shall be sealed by a flexible silicone electrometric
compound or silicone alloy compound sealant. System of attachment of end fitting to the rod
shall provide superior sealing performance between housing, i.e. seamless sheath and metal
connection. The sealing must be moisture proof.

The dimensions of end fittings of Insulators shall be in accordance with the standard
dimensions stated in IS: 2486/IEC60120.

5.0 Workmanship:

5.1 All the materials shall be of latest design and conform to the best engineering practices
adopted in the high voltage field. Bidders shall offer only such Insulators as are guaranteed
by them to be satisfactory and suitable for continued good service in power transmission lines.

5.2 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.

5.3 The design of the Insulators shall be such that stresses due to expansion and contraction in
any part of the insulator shall not lead to deterioration.

5.4 The core shall be sound and free of cracks and voids that may adversely affect the Insulators.
5.5 Weather sheds shall be uniform in quality. They shall be clean, sound, smooth and shall be
free from defects and excessive flashing at parting lines.

5.6 End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings
should be effectively sealed to prevent moisture ingress; effectiveness of sealing system must
be supported by test documents. All surfaces of the metal parts shall be perfectly smooth with
out 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.

5.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc
equivalent to 610 gm/Sq.m, or 87 m thickness and shall be in accordance with the requirement
of IS: 4759, The zinc used for galvanizing shall be of purity 99.5% as per IS: 4699. 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 galvanized
metal parts shall be guaranteed to withstand at least four successive dips each lasting for one H)
minute duration under the standard preece test. The galvanizing shall be carried out only after
any machining.

6.0 Equipment Marking:

6.1 Each insulator unit shall be legibly and indelibly marked with the following details as per IEC-
61109:

(a) Month &Year of manufacture

(b) Min. failing toad/guaranteed mechanical strength in kilo Newton followed by
the word 'KN' to facilitate easy identification.

(c) Manufacturer’s name/Trade mark

(d) “APEPDCL” name shall be inscripted on the insulator similar to the supplier’s name
inscription on the insulator

7.0 Bid Drawings:

7.1 The Bidder shall furnish full description and illustration of the material offered.

7.2 The Bidder shall furnish along with the bid the outline drawing (3 copies) of each insulator unit
including a cross sectional view of the long rod insulator unit. The drawing shall include but
not be limited to the following information:

(a) Long rod diameter with manufacturing tolerances

(b) Minimum Creepage distance with positive tolerance

(c) Protected creepage distance

(d) Eccentricity of the long rod unit

(i) Axial run out
(ii) Radial run out

(e) Unit mechanical and electrical characteristics

(f) Weight of composite long rod unit.

(g) Materials
 (i) Identification mark

(ii) Manufacturer's catalogue number

7.3 After placement of award, the supplier shall submit full dimensioned manufacturing insulator
drawing containing all the details in four (4) copies to Owner for approval. After getting
approval from Owner and successful completion of all the types tests, the supplier shall submit
10 more copies of the drawing to the Owner for further distribution and field use.

7.4 After placement of award the Supplier shall also submit fully dimensioned insulator crate
drawing for different type of Insulators for approval of the owner.

8.0 Tests and Standards:

Insulators offered shall be manufactured with the same configuration & raw materials as used
in the Insulators for which design & type test reports are submitted. The manufacturer shall
submit a certificate for the same. The design & type test reports submitted shall not be more
than 5 years old.

8.1 Design Tests:-

For polymeric insulators it is essential to carry out design test as per clause 4.1 of IEC 61109 /
92-93 with latest amendments. The design tests are intended to verify the suitability of the
design, materials and method of manufacture (technology). When a composite insulator is
subjected to the design tests, the result shall be considered valid for the whole class of
insulators, which are represented by the one tested and having the following characteristics:

• Same materials for the core, and sheds and same manufacturing method;

• Same material of the fittings, the same design, the same method of attachment;

• Same or greater layer thickness of the shed material over the core (including a
sheath where used);
• Same or smaller ratio of the highest system voltage to insulation length;
• Same or smaller ratio of all mechanical loads to the smallest core diameter
between fittings
• Same or greater diameter of the core.

The tested composite insulators shall be identified by a drawing giving all the
dimensions with the manufacturing tolerances.

Manufacturer should submit test reports for Design Tests as per IEC-61109 (clause- 5)
along with the bid. Additionally following tests shall be carried out or reports for the tests
shall be submitted after award of contract: UV test: the test shall be carried out in line with
clause 7.2 of ANSI C29.13.
8.2 Type Tests:-

The tenderer shall furnish detailed type test reports of the offered composite Insulators as per
clause 8.2 of the Technical Specifications at the NABL approved laboratories to prove that the
composite Insulators offered meet the requirements of the specification. These Type Tests
should have been carried out within five years prior to the date of opening of this tender.
The following type tests shall be conducted on a suitable number of individual insulator units,
components & materials and the test report should invariably be submitted with the bid:-

SN Description of type test Ten procedure/standard

1. Dry lightning impulse withstand voltage test As per IEC 61109

2. Wet power frequency test As per IEC 61 109

3. Mechanical failing load test As per IS:731

4. Radio interference test As per IEC 61109

5. Recovery of Hydrophobicity test Annexure-B

This test may be repealed every

3 yrs by the manufacturer

6. Chemical composition test for silicon content Annexure-B

Or any other test method

acceptable to the owner

7. Brittle fracture resistance test Annexure - B

Note:- The purchase may like to conduct any other test(s) in addition to above tests at bidder’s
cost to establish the performance of material as per system requirement.

8.2.2 It shall be the option of the owner to accept the Insulators based on type test reports submitted
by the manufacturer. The owner shall be free to repeat the type test & may witness the same.

Note: The owner, for the purpose of facilitating the type tests, may ask the bidders to quote test
charges separately

8.2.3 All the type test given in Clause No. 8.2 in addition to routine & acceptance test shall be
carried out on Pin Insulators wherever required.

8.3 Acceptance (sample) Tests

a. Verification of dimensions IEC: 61109

b. Verification of the locking system (if applicable) IEC: 61 109

c. Galvanizing test IS:2633/IS:6745

 c. Verification of tightness of the interface between IEC:61109 amendment
end fittings & Insulator housing 1 of 1995

d. Verification of the specified mechanical load 4 IEC: 611 09 / IS:731

The test samples after having withstood the routine test shall be subjected to the
following acceptance tests:-

8.4 Routine Tests:-

SN Description Standard

1. Identification of marking As per IEC: 61109

2. Visual Inspection As per IEC 61109

3. Mechanical routine test As per IEC: 61109 / IS:731

8.5 Tests during Manufacture

Following tests shall also be carried out on all components as applicable:-

a) Chemical analysis of zinc used for galvanizing

b) Chemical analysis, mechanical, metallographic test and magnetic particle

inspection for malleable castings.

c) Chemical analysis, hardness tests and magnetic particle inspection for forgings

a) Chemical analysis of zinc used for galvanizing

b) Chemical analysis, mechanical, metallographic test and magnetic particle inspection for
malleable castings.

c) Chemical analysis, hardness tests and magnetic particle inspection for forgings.

8.6 Additional Tests:-

8.6.1 The Owner reserves the right at his own expenses, for carrying out any other test(s) of
reasonable nature carried out at Supplier's premises, at site, or in any other place in addition to
the aforesaid type, acceptance and routine tests to satisfy himself that the material comply with
the Specifications.

8.6.2 The Owner also reserves the right to conduct all the tests mentioned in this specification at his
own expense on the samples drawn from the site at Supplier's premises or at any other test
center. In case of evidence of non compliance, it shall be binding on the part of the Supplier to
prove the compliance of the items to the technical specifications by repeat tests or correction
of deficiencies or replacement of defective items, all without any extra cost to the Owner,
 9.0 Quality assurance plan:-

9.1 The successful bidder shall submit following information to the owner:

9.1.1 Test certificates of the raw materials and bought out accessories.

9.1.2 Statement giving list of important raw materials, their grades along with names of sub-
suppliers for raw materials, fist of standards according to which the raw materials are tested.
List of tests normally carried out on raw materials in presence of bidder's representative.

9.1.2 List of manufacturing facilities available.

9.1.3 Level of automation achieved and lists of areas where manual processing exists.

9.1.4 List of areas in manufacturing process, where stage inspections are normally carried out for
quality control and details of such tests and inspections.

9.1.5 List of testing equipments available with the bidder for final testing of equipment along with
valid calibration reports.

9.1.6 The manufacturer shall submit Manufacturing Quality Plan (MQP) for approval & the same
shall be followed during manufacture and testing,

9.1.7 The successful bidder shall submit the routine test certificates of bought out raw materials /
accessories and central excise passes for raw material at the time of inspection.

10.0 GUARANTEE:-
The Supplier of Insulators shall guarantee overall satisfactory performance of the Insulators
for the period of 18 months from the date of supply.

11.0 Inspection:

11.1 The owner's representative shall at all times be entitled to have access to the works and all
places of manufacture, where insulator, and its component parts shall be
manufactured and the representatives shall have full facilities for unrestricted
inspection of the Supplier's and sub-Supplier's works, raw materials, manufacture
of the material and for conducting necessary test as detailed herein.

11.2. The material for final inspection shall be offered by the Supplier only under packed condition.
The owner shall select samples at random from the packed lot for carrying out acceptance
tests. The lot offered for inspection shall be homogeneous and shall contain Insulators
manufactured in 3-4 consecutive weeks.

11.3 The Supplier shall keep the Owner informed in advance of the time of starting and the
progress of manufacture of material in their various stages so that arrangements could be made
for inspection.

11. 4 No material shall be dispatched from its point of manufacture before it has been satisfactorily
inspected and tested unless the inspection is waived off by the owner in writing. In the later
case also the material shall be dispatched only after satisfactory testing specified herein has
been completed.
11.5 The acceptance of any quantity of material shall in no way relieve the Supplier of his
responsibility for meeting all the requirements of the specification and shall not prevent
subsequent rejection, if such materials are later found to be defective.

12.0 Packing:
12.1 All Insulators shall be packed in strong corrugated box of min, 7 ply duly paletted or wooden
crates. The gross weight of the crates along with the material shall not normally exceed 100
Kg to avoid handling problem. The crates shall be suitable for outdoor storage under wet
climate during rainy season.

12.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage
at site and subsequent handling in the field.

12.3 Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent
damage or deformation during transit and handling.

12.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their
destination and to avoid the possibility of goods being lost or wrongly dispatched on account
of faulty packing and faulty or illegible markings. Each wooden case/crate/corrugated box
shall have all the markings stenciled on it in indelible ink.

12.5 The bidder shall provide instructions regarding handling and storage precautions to be taken at
site.

Annexure – A

The standards mentioned in this specification are available from:

Reference Name and address

abbreviation

IEC/CISPR International Electro technical commission, Bureau Central de la

commission, electro technique international, 1 rule de verembe,
Geneva, SWITZERLAND

BIS/IS Bureau of Indian Standards, Manak Bhavan, 9, Bahadur Shah

Zafar Marg, New Delhi – 110 001, INDIA

ISO International organization for standardization, Danish Board of

Standardization Danish Standardizing Sraat, Aurehoegvej-12 DK-
2900, Heeleprup, DENMARK

NEMA/ANSI National Electric Manufacture Association, 155, East 44th Street,

New York, NY: 10017 U.S.A

ASTM American Society for Testing and Materials, 1916 Race St.
Phelledelphia, PA19103 U.S.A.

STRI guide STRI, Sweden, Website : www.stri.se

 ANNEXURE – B

Tests on Insulator units :

1. RIV Test (Dry) :

The insulator string along with complete hardware fittings shall have a radio interference
voltage level below 100 micro votls at one MHz when subjected to 50 Hz A.C. voltage of 10KV for
11KV class insulators respectively under dry condition. The test procedure shall be in accordance
with IS:8263/IEC : 437/CISPR 18-2.

2. Brittle Fracture Resistance Test

Brittle fracture test shall be carried out on naked rod along with end fittings by applying “In
HNO3 acid” (63 g. conc.HNO3 added to 937 g water) to the rod. The rod should be held at 80% of
SML for the duration of the test. The rod should not fail within the 96-hour test duration. Test
arrangement should ensure continuous wetting of the rod with Nitric acid.

3. Recovery of Hydrophobicity & Corona test

The test shall be carried out on 4mm thick samples of 5cm X 7 cm.

i) The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface
to dry and spray with water. Record the Hydrophobicity classification in line with STRI
guide for Hydrophobicity classification (Extract enclosed at Annexure-D). Dry the
samples surface.
ii) The sample shall subjected to mechanical stress by bending the sample over a ground
electrode. Corona is continuously generated by applying 12KV to a needle like electrode
placed 1mm above the sample surface. Tentative arrangement shall be as shown in
Annexure-E. The test shall be done for 100 hrs.

iii) Immediately after the corona treatment, spray the surface with water and record the HC
classification. Dry the surface and repeat the corona treatment as at clause 2 above. Note
HC classification. Repeat the cycle for 1000 hrs. or unitl an HC of 6 or 7 is obtained. Dry
the sample surface.

iv) Allow the sample to recover and repeat hydrophobicity measurement at several time
intervals. Silicone rubber should recover to HC1-HC2 within 24 to 48 hours, depending on
the material and the intensity of the corona treatment.

3. Chemical composition test for silicon content

The content of silicon in the composite polymer shall be evaluated by EDX (Energy
Dispersion X-ray) Analysis or Thermo-gravimetric analysis. The test may be carried out at
CPRI or any other NABL accredited laboratory.
 ANNEXURE – C

Guaranteed Technical Particulars of 33 KV-10KN composite

Silicon rubber polymer pin insulators with GI Pins

Sl. Description Unit 33 KV 10

No. KN Pin

1. Type of Insulators

2. Standard specification to which the Insulators manufactured

and tested

3. Name of material used in manufacture of the Insulator

(with class / grade)

(a) Material of core rod (FRP rod)

(b) Material of Housing & weather sheds (silicon content by > 30%
weight)

(c) Sealing compound for end fitting

4. Colour Glaze of Insulator

5. Electrical Characteristics:

(a) Nominal system Voltage KV rms

(b) Highest System Voltage KV rms

(c) Dry power frequency withstand KV rms

(d) Wet power frequency withstand KV rms

(e) Dry flash over voltage KV rms

(f) Wet flash over voltage KV rms

(g) Dry lighting impulse withstand voltage

(a) Positive kV(peak)

(b) Negative kV(peak)

(h) Dry lighting impulse flashover voltage

(a) Positive (KV peak) kV(peak)

(b) Negative (KV peak) kV(peak)

Sl. Description Unit 33 KV 10
No. KN Pin

(i) RIV at 1 MHz when energized at 10kV/30kV (rms) under dry Microvolt
condition

(j) Creepage distance (min) mm 900 mm

6. Mechanical Characteristics:

Minimum failing load (KN) KN 10KN

7. Dimensions of Insulator:

(a). Weight (Approx) Kg 2.5Kgs ± 2%

(b). Dia of FRP rod mm 33.5

(c) Length of FRP rod mm

(d). Dia of weather sheds mm

(e). Thickness of housing mm 3

(f). Dry arc distance (Approx) mm

(g). Dimensioned drawings of Insulator (including weight with Yes/no

tolerances in weight) enclosed.

8. Method of fixing of sheds to housing specify ):- single mould

or modular construction (injection moulding/compression
moulding)

9. No. of weather sheds Nos.

10. Sectional Length mm

11. Type of sheds

(i) Aerodynamic

(ii) With under ribs

12. Packing details

(a) Type of packing.

(b) No. of Insulators in each pack

(c ) Gross weight of package

13. Any other particulars which the bidder may like to give.
 29.11KV POLYMER PIN INSULATOR WITH GI PINS

1.0. Scope

This specification covers design, manufacture, testing and supply of composite insulators for
use in the 11KV overhead transmission lines and substations.

The composite insulator will be used on lines on which the conductor will be AAA/ACSR of
size up to 100 sq.mm.

2.0. APPLICABLE STANDARDS

2.1. Standards

Following Indian/International Standards, which shall mean latest revision, with

amendments/changes adopted and published, unless specifically stated otherwise in the
specification, shall be referred while accessing conformity of insulators with these
specifications.

2.1.1 In the event of supply of insulators conforming to standards other than specified, the Bidder
shall confirm in his bid that these standards are equivalent or better to those specified. In case
of award, salient features of comparison between the standards proposed by the bidder and
those specified in this document will be provided by the Supplier to establish equivalence.

Sl. Indian Title International

No. Standard Standard
1. Definition, test methods and acceptance criteria for IEC : 61109
composite insulators for a.c. overhead lines above
1000V
2. IS : 731 Porcelain insulators for overhead power lines with a IEC : 60383
nominal voltage greater than 1000V
3. IS : 2071 Methods of High Voltage Testing IEC : 60060-1
4. IS : 2486 Specification for insulator fittings for overhead power IEC : 60120
lines with a nominal voltage greater than 1000V IEC : 60372
General Requirements and Tests Dimensional
Requirements Locking Devices
5. Thermal Mechanical Performance test and mechanical IEC : 60575
performance test on string insulator units
6. IS : 13134 Guide for the selection of insulators in respect of IEC : 60815
polluted conditions
7. Characteristics of string insulator units of the long rod IEC : 60433
type
8. Hydrophobicity classification guide STRI guide 1.92/1
9. Radio interference characteristics of overhead power CISPR:18-2 part 2
lines and high-voltage equipment
10. IS : 8263 Methods of RI Test of HV Insulators IEC : 60437
11. Standard for insulators – Composite-Distribution Dead- ANSI C29 13-2000
end type
12. IS : 4759 Hot dip zinc coatings on structural steel & other allied ISO : 1459
products ISO : 1461
13. IS : 2629 Recommended Practice for Hot, Dip Galvanization for ISO-1461 (E)
iron and steel
14. IS : 6745 Determination of weight of zinc coating on zinc coated ISO : 1460
 iron and steel articles
15. IS : 3203 Methods of testing of local thickness of electroplated ISO : 2178
coatings
16. IS : 2633 Testing of Uniformity of coating of zinc coated articles
17 Standard specification for glass fiber strands ASTMD 578-05
18 Standard test method for compositional analysis by ASTM E 1131-03
Thermogravimetry
19 IS : 4699 Specification for refined secondary zinc

The addresses of organizations who offer the above standards are given at Annexure-A

3.0. Technical Description of Composite Insulators :

3.1. Service condition

The polymer insulators to be supplied shall be suitable for satisfactory continuous operation
under conditions as specified below:

Maximum ambient temperature : 500C

Minimum ambient temperature : -50C
Relative humidity : 0 to 100%

3.2. Composite Insulators long rod type for tension locations and pin/ post type for suspension
locations

3.2.1. The insulators shall be suitable for 3Ph. 50Hz, effectively earthed 11KV O/H distribution
system in a moderately/heavily polluted atmosphere.

3.2.2. Bidder must be an indigenous manufacturer and supplier of composite insulators of rating
11KV or above or must have developed proven in house technology and manufacturing
process for composite insulators of above rating OR posses technical collaboration/association
with a manufacturer of composite insulators of rating 11KV or above. The Bidder shall furnish
necessary evidence in support of the above along with the bid, which can be in the form of
certification from the utilities concerned, or any other documents to the satisfaction of the
owner.

3.2.3. Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing,
projection etc., and selection in respect of polluted conditions shall be generally in accordance
with the recommendation of IEC-60815/IS : 13134.

3.2.4. The size of composite insulator, minimum creepage distance and mechanical strength along
with hardware fittings shall be as follows.

Sl. Type of Nomi Highe Visibl Wet Dry Mini Weat Min. Thick Bar
No compos nal st e power lighting mum her failing ness e
. ite syste system discha frequen Impulse creep Shed load of FRP
insulato m voltag rge cy withsta age Dia KN Silico RO
rs volta e KV test withsta nd distan (mm) ne D
ge (rms) voltag nd voltage ce Sheat Dia
KV e KV voltage KV (mm) h met
(rms) (rms) KV (rms) Mini er(
(rms) mum mm
(mm) )
 Pin 95 3
1 Insulato 11 12 9 35 75 320 5 24
r

3.3. Dimensional Tolerance of Composite Insulators

The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed
as follows in line with-IEC 61109 :
± (0.04d + 1.5)mm when d300mm
± (0.025d+6)mm when d>300mm

Where, d being the dimensions in millimeters for diameter, length or creepage distance as the
case may be.

However, no negative tolerance shall be applicable to creepage distance.

3.4. Interchangeability

The composite insulators including the end fitting connection shall be standard design suitable
for use with the hardware fittings of any make conforming to relevant IEC/IS standards.

3.5. Corona and RI performance

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be
subjected to excessive localized pressure. The insulator and metal parts shall be so designed
and manufactured that it shall avoid local corona formation and not generate any radio
interference beyond specified limit under the operating conditions.

3.6. Maintenance

3.6.1. The composite insulators offered shall be suitable for use of hot line maintenance technique so
that usual hot line operation can be carried out with ease, speed and safety.

4.0. Technical description of composite Insulators.

4.1 Design and construction

The composite insulator shall have a core, housing & weathershed of insulating material and
steel/aluminum hardware components for attaching it to the support/conductor.

4.1.1. Core

It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass fibers and
resin shall be optimized in the FRP rod. Glass fibers shall be boron free electrically corrosion resistant
(ECR) glass fiber or boron free E-Glass and shall exhibit both high electrical integrity and high
resistance to acid corrosion. The matrix of the FRP rod shall be Hydrolysis resistant. The FRP rod
shall be manufactured through Pultrusion process. The FRP rod shall be void free. The diameter of
FRP rod should be 24 mm only.

4.1.2 Housing (Sheath)

The FRP rod shall be covered by a seamless sheath of a silicone elastomeric compound or
silicone alloy compound of a thickness of 3 mm minimum measurable everywhere including on
weathersheds.
 It should protect the FRP rod against environmental influences, external pollution and
humidity. It shall be extruded or directly molded on the core and shall have chemical bonding with the
FRP rod. The strength of the bond shall be greater than the tearing strength of the polymer. Sheath
material in the bulk as well as in the sealing/bonding area shall be free form voids.

4.1.3. Weathersheds

The composite polymer weathersheds made of silicone elastomeric compound or silicon alloy
shall be firmly bonded to the sheath, vulcanized to the sheath or molded as part of the sheath and shall
be free from imperfections. The weathersheds should have silicon content of minimum 30% by
weight. The strength of the weathershed to sheath interface shall be greater than the tearing strength
of the polymer. The interface, if any, between sheds and sheath (housing) shall be free from voids.

4.1.4. End Fittings

End fittings transmit the mechanical load to the core. They shall be made of spheroidal
graphite cast iron, malleable cast iron or forged steel or aluminium alloy. They shall be connected to
the rod by means of a controlled compression technique. The gap between fittings and sheath shall be
sealed by a flexible silicone elastomeric compound or silicone alloy compound sealant. System of
attachment of end fitting to the rod shall provide superior sealing performance between housing, i.e.,
seamless sheath and metal connection. The sealing must be moisture proof.

The dimensions of end fittings of Insulators shall be in accordance with the standard
dimensions stated in IS: 2486/IEC60120.
5.1 Acceptance (sample) tests

The test samples after having with stood the routine test shall be subjected to the following acceptance
test.

a) Verification of dimensions : IEC : 61109

b) Verification of the locking system : IEC : 61109
(if applicable)
c) Galvanizing test : IS : 2633/IS : 6745
d) Verification of the specified : IEC : 61109
Mechanical load (if applicable)

5.2 Routine Tests

Sl.No. Description Standard

1. Identification of marking As per IEC : 61109
2. Visual inspection As per IEC : 61109
3. Mechanical routine test As per IEC : 61109

5.3 Test during manufacture

Following test shall also be carried out on all components as applicable

a) Chemical analysis of zinc used for galvanizing

b) Chemical analysis, mechanical, metallographic test and magnetic particle
inspection for malleable castings.
c) Chemical analysis, hardness tests and magnetic particle inspection for forgings.
The standards mentioned in this specification are available from:

Reference Name and address

abbreviation
IEC/CISPR International Electro technical commission, Bureau Central de la
commission, electro technique international, 1 rule de verembe,
Geneva, SWITZERLAND
BIS/IS Bureau of Indian Standards, Manak Bhavan, 9, Bahadur Shah
Zafar Marg, New Delhi – 110 001, INDIA
ISO International organization for standardization, Danish Board of
Standardization Danish Standardizing Sraat, Aurehoegvej-12 DK-
2900, Heeleprup, DENMARK
NEMA/ANSI National Electric Manufacture Association, 155, East 44th Street,
New York, NY: 10017 U.S.A
ASTM American Society for Testing and Materials, 1916 Race St.
Phelledelphia, PA19103 U.S.A.
STRI guide STRI, Sweden, Website : www.stri.se

Tests on Insulator units :

1. RIV Test (Dry) :

The insulator string along with complete hardware fittings shall have a radio interference
voltage level below 100 micro votls at one MHz when subjected to 50 Hz A.C. voltage of 10KV for
11KV class insulators respectively under dry condition. The test procedure shall be in accordance
with IS:8263/IEC : 437/CISPR 18-

2. Brittle Fracture Resistance Test

Brittle fracture test shall be carried out on naked rod along with end fittings by applying “In
HNO3 acid” (63 g. conc.HNO3 added to 937 g water) to the rod. The rod should be held at 80% of
SML for the duration of the test. The rod should not fail within the 96-hour test duration. Test
arrangement should ensure continuous wetting of the rod with Nitric acid.

3. Recovery of Hydrophobicity & Corona test

The test shall be carried out on 4mm thick samples of 5cm X 7 cm.

i) The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface
to dry and spray with water. Record the Hydrophobicity classification in line with STRI
guide for Hydrophobicity classification (Extract enclosed at Annexure-D). Dry the
samples surface.
ii) The sample shall subjected to mechanical stress by bending the sample over a ground
electrode. Corona is continuously generated by applying 12KV to a needle like electrode
placed 1mm above the sample surface. Tentative arrangement shall be as shown in
Annexure-E. The test shall be done for 100 hrs.

iii) Immediately after the corona treatment, spray the surface with water and record the HC
classification. Dry the surface and repeat the corona treatment as at clause 2 above. Note
HC classification. Repeat the cycle for 1000 hrs. or unitl an HC of 6 or 7 is obtained. Dry
the sample surface.
 iv) Allow the sample to recover and repeat hydrophobicity measurement at several time
intervals. Silicone rubber should recover to HC1-HC2 within 24 to 48 hours, depending on
the material and the intensity of the corona treatment.

4. Chemical composition test for silicon content

The content of silicon in the composite polymer shall be evaluated by EDX (Energy
Dispersion X-ray) Analysis or Thermo-gravimetric analysis. The test may be carried out at
CPRI or any other NABL accredited laboratory.
 30. 33KV POLYMER DISC INSULATORS (B&S)

1.0. Scope
This specification covers design, manufacture, testing and supply of composite insulators for
use in the 33KV overhead transmission lines and substations. The composite insulators shall
be of the following type:

Long rod insulators for conductors in tension application at angle/cut points. The
insulators shall be of ball and socket type.

2.0. APPLICABLE STANDARDS

2.1. Standards
Following Indian/International Standards, which shall mean latest revision, with amendments/
changes adopted and published, unless specifically stated otherwise in the specification, shall be
referred while accessing conformity of insulators with these specifications.

2.1.1 In the event of supply of insulators conforming to standards other than specified, the Bidder
shall confirm in his bid that these standards are equivalent or better to those specified. In case
of award, salient features of comparison between the standards proposed by the bidder and
those specified in this document will be provided by the Supplier to establish equivalence.
Sl. Indian Title International
No. Standard Standard

1. Definition, test methods and acceptance criteria for composite IEC : 61109
insulators for a.c. overhead lines above 1000V

2. IS : 731 Porcelain insulators for overhead power lines with a nominal IEC : 60383
voltage greater than 1000V

3. IS : 2071 Methods of High Voltage Testing IEC : 60060-1

4. IS : 2486 Specification for insulator fittings for overhead power lines IEC : 60120
with a nominal voltage greater than 1000V General
IEC : 60372
Requirements and Tests Dimensional Requirements Locking
Devices

5. Thermal Mechanical Performance test and mechanical IEC : 60575

performance test on string insulator units

6. IS : 13134 Guide for the selection of insulators in respect of polluted IEC : 60815
conditions

7. Characteristics of string insulator units of the long rod type IEC : 60433

8. Hydrophobicity classification guide STRI guide 1.92/1

9. Radio interference characteristics of overhead power lines and CISPR:18-2 part 2

 high-voltage equipment

10. IS : 8263 Methods of RI Test of HV Insulators IEC : 60437

11. Standard for insulators – Composite-Distribution Dead-end ANSI C29 13-2000

type

12. IS : 4759 Hot dip zinc coatings on structural steel & other allied ISO : 1459
products
ISO : 1461

13. IS : 2629 Recommended Practice for Hot, Dip Galvanisation for iron ISO-1461 (E)
and steel

14. IS : 6745 Determination of weight of zinc coating on zinc coated iron ISO : 1460
and steel articles

15. IS : 3203 Methods of testing of local thickness of electroplated coatings ISO : 2178

16. IS : 2633 Testing of Uniformity of coating of zinc coated articles

17 Standard specification for glass fiber strands ASTMD 578-05

18 Standard test method for compositional analysis by ASTM E 1131-03

Thermogravimetry

19 IS : 4699 Specification for refined secondary zinc

The addresses of organizations who offer the above standards are given at Annexure-A

3.0. Technical Description of Composite Insulators :

3.1. Service condition

The polymer insulators to be supplied shall be suitable for satisfactory continuous operation
under conditions as specified below :

Maximum ambient temperature : 480C

Minimum ambient temperature : -50C

Relative humidity : 0 to 100%

3.2. Composite Insulators long rod type for tension locations and pin/ post type for suspension
locations
 3.2.1. The insulators shall be suitable for 3Ph. 50Hz, effectively earthed 33KV O/H distribution
system in a moderately/heavily polluted atmosphere. Long rod insulators shall be of ball &
socket.

3.2.2. Bidder must be an indigenous manufacturer and supplier of composite insulators of rating
33KV or above or must have developed proven in house technology and manufacturing
process for composite insulators of above rating OR posses technical collaboration/association
with a manufacturer of composite insulators of rating 33KV or above. The Bidder shall furnish
necessary evidence in support of the above along with the bid, which can be in the form of
certification from the utilities concerned, or any other documents to the satisfaction of the
owner.

3.2.3. Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing,
projection etc., and selection in respect of polluted conditions shall be generally in accordance
with the recommendation of IEC-60815/IS : 13134.

3.2.4. The size of composite insulator, minimum creepage distance and mechanical strength along
with hardware fittings shall be as follows.

Minimu
Wet m
Nomi creepag
Visible power Impul Pin
nal Highes e
Type of discha frequen se Weat Thickn Min. ball
syste t distanc
Sl. composit rge cy withst her ess of failin shan
m system e (mm
No e test withsta and Shed silicon g k
volta voltag Heavily
. insulator voltag nd voltag dia sheath load diam
ge e KV pollute
s e KV voltage e KV (mm) (mm) KN eter
KV (rms) d
(rms) KV (rms) mm
(rms) (25mm/
(rms)
kv)

33KV
composit
1 e 33 36 27 75 170 100 900 70 16
3
polymer
insulator (minimu
m)

Note : 1. Creepage distances have been considered in line with IS-13134 (which specifies 20mm/kv
for moderately polluted & 25mm/kv for heavily polluted environment)
3.3. Dimensional Tolerance of Composite Insulators

The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed
as follows in line with-IEC 61109 :

± (0.04d + 1.5)mm when d 300mm

± (0.025d+6)mm when d>300mm

Where, d being the dimensions in millimeters for diameter, length or creepage distance as the
case may be.

However, no negative tolerance shall be applicable to creepage distance.

3.4. Interchangeability

The composite insulators including the end fitting connection shall be standard design suitable
for use with the hardware fittings of any make conforming to relevant IEC/IS standards.

3.5. Corona and RI performance

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be
subjected to excessive localized pressure. The insulator and metal parts shall be so designed
and manufactured that it shall avoid local corona formation and not generate any radio
interference beyond specified limit under the operating conditions.

3.6. Maintenance
3.6.1. The composite insulators offered shall be suitable for use of hot line maintenance technique so
that usual hot line operation can be carried out with ease, speed and safety.

4.0. BASIC FEATURES

4.1. Design and construction

The composite insulator shall have a core, housing & weathershed of insulating material and
steel/aluminum hardware components for attaching it to the support/conductor.

4.1.1. Core

It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass fibers and
resin shall be optimized in the FRP rod. Glass fibers shall be boron free electrically corrosion
resistant (ECR) glass fiber or boron free E-Glass and shall exhibit both high electrical integrity
and high resistance to acid corrosion. The matrix of the FRP rod shall be Hydrolysis resistant.
 The FRP rod shall be manufactured through Pultrusion process. The FRP rod shall be void
free. The diameter of FRP rod should be 16 mm only

4.1.2 Housing (Sheath)

The FRP rod shall be covered by a seamless sheath of a silicone elastometric compound or
silicone alloy compound of a thickness of 3mm minimum uniformly measurable including on
weather sheds.

It should protect the FRP rod against environmental influences, external pollution and
humidity. It shall be extruded or directly molded on the core and shall have chemical bonding
with the FRP rod. The strength of the bond shall be greater than the tearing strength of the
polymer. Sheath material in the bulk as well as in the sealing/bonding area shall be free form
voids.

a. Weathersheds
The composite polymer weathersheds made of silicone elastomeric compound or silicon alloy
shall be firmly bonded to the sheath, vulcanized to the sheath or molded as part of the sheath
and shall be free from imperfections. The weather sheds should have silicon content of
minimum 30% by weight. The strength of the weather shed to sheath interface shall be greater
than the tearing strength of the polymer. The interface, if any, between sheds and sheath
(housing) shall be free from voids.

b. End Fittings
End fittings transmit the mechanical load to the core. They shall be made of spheroidal
graphite cast iron, malleable cast iron or forged steel or aluminium alloy. They shall be
connected to the rod by means of a controlled compression technique. The gap between
fittings and sheath shall be sealed by a flexible silicone elastomeric compound or silicone
alloy compound sealant. System of attachment of end fitting to the rod shall provide superior
sealing performance between housing, i.e., seamless sheath and metal connection. The sealing
must be moisture proof.

The dimensions of end fittings of Insulators shall be in accordance with the standard
dimensions stated in IS: 2486/IEC60120.

5.0. Workmanship

1. All the materials shall be of latest design and conform to the best engineering practices
adopted in the high voltage filed. Bidders shall offer only such insulators as are guaranteed
by them to be satisfactory and suitable for continued good service in power transmission lines.
1. 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.
2. The design of the insulators shall be such that stresses due to expansion and contraction in any
part of the insulator shall not lead to deterioration.
3. The core shall be sound and free of cracks and voids that may adversely affect the insulators.
4. Weathersheds shall be uniform in quality. They shall be clean, sound, smooth and shall be free
from defects and excessive flashing at parting lines.
5. End fittings shall be free form cracks, seams, shrinks, air holes and rough edges. End fittings
should be effectively sealed to prevent moisture ingress; effectiveness of sealing system must be
supported by test documents. All surfaces of the metal parts shall be perfectly smooth without
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.
6. All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc
equivalent to 610 gm/sq.m. or 87 m thickness and shall be in accordance with the requirement
of IS:4579. The zinc used for galvanizing shall be of purity 99.5% as per IS : 4699. 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 galvanized
metal parts shall be guaranteed to withstand at least four successive dips each lasting for one (1)
minute duration under the standard preece test. The galvanizing shall be carried out only after any
machining.
6.0. Equipment Marking :

6.1. Each insulator unit shall be legibly and indelibly marked with the following details as per IEC-
61109 :

(a) Month & Year of manufacture

(b) Min. failing laod/guaranteed mechanical strength in kilo Newton followed by the
word ‘kN’ to facilitate easy identification.
(c) Manufacturer’s name/Trade mark.
(d) “APEPDCL” name shall be inscripted on the insulator similar to the supplier’s
name inscription on the insulator

6.2.One 10 mm thick ring or 20mm thick spot of suitable quality of paint shall be marked on the end
fitting of each composite long rod of particular strength in case of 33KV insulators for easy
identification in case both types of insulators are procured by the utility. The paint shall not have
any deteriorating effect on the insulator performance. Following codes shall be used as
identification mark :
For 70KN long rod unit : Red

7.0. Bid Drawings :

6.0. The Bidder shall furnish full description and illustration of the material offered.

6.1. The bidder shall furnish along with the bid the outline drawing (3 copies) of each insulator unit
including a cross sectional view of the long rod insulator unit. The drawing shall include but not
be limited to the following information :
(a) Long rod diameter with manufacturing tolerances
(b) Minimum Creepage distance with positive tolerance
(c) Protected creepage distance
 (d) Eccentricity of the long rod unit
(i) Axial run out
(ii) Radial run out
(e) Unit mechanical and electrical characteristics
(f) Size and weight of ball and socket/tongue & clevis
(g) Weight of composite long rod units
(h) Material
(i) Identification mark

(ii) Manufacturer’s catalogue number

6.2. After placement of award, the supplier shall submit full dimensioned manufacturing insulator
drawing containing all the details in four (4) copies to Owner for approval. After getting approval
from Owner and successful completion of all the types tests, the supplier shall submit 10 more
copies of the drawing to the Owner for further distribution and field use.

6.3. After placement of award the supplier shall also submit fully dimensioned insulator crate drawing
for different type of insulators for approval of the owner.

8.0. Tests and Standards

Insulators offered shall be manufactured with the same configuration & raw materials as used
in the insulators for which design & type test reports are submitted. The manufacturer shall
submit a certificate for the same. The design & type test reports submitted shall not be more
than 5 years old.

8.1. Design tests

Manufacturer should submit test reports for Design Tests as per IEC- 61109 (clause -5) along
with the bid. Additionally following tests shall be carried out or reports for the tests shall be
submitted after award of contract .

UV Test: The test shall be carried out in line with clause 7.2 of ANSI C29.13

8.2. Type Tests

The following type tests shall be conducted on a suitable number of individual insulator units,
components, materials or complete strings :

8.2.1. The bidder shall submit type test reports as per IEC 61109 along with the bid. Additional type
tests as required above shall be carried out by the manufacturer, after award of contract for
 which no additional charges shall be payable. In case, the tests have already been carried out,
the manufacturer shall submit reports for the same.
Sl. Description of type test Test procedure/standard
No.

1. Dry lightning impulse withstand voltage test As per IEC 61109

2. Wet power frequency test As per IEC 61109

3. Mechanical load-time test As per IEC 61109

4. Radio interference test As per IEC 61109

5. Recovery of Hydrophobicity test Annexure-B (This test may be

repeated every 3 years by the
manufacturer)

6. Chemical composition test for silicon content Annexure-B (or any other test
method acceptable to the owner)

7. Brittle fracture resistance test Annexure-B

8.2.2. It shall be the option of the owner to accept the insulators based on type test reports submitted
by the manufacturer. The owner shall be free to repeat the type test & may witness the same.
Note : The owner, for the purpose of facilitating the type tests, may ask the bidders to quote
test charges separately.

8.2.3. All the type test given in clause No. 8.2 in addition to routine & acceptance test shall be
carried out on insulator along with hardware fittings wherever required.

8.3. Acceptance (sample) tests

8.3.1. For composite insulators

a) Verification of dimensions : IEC : 61109

b) Verification of the locking : IEC : 61109

system (if applicable)

c) Galvanizing test : IS : 2633/IS : 6745

d) Verification of the specified : IEC : 61109

8.4. Routine Tests
Sl.No. Description Standard

1. Identification of marking IEC : 61109

2. Visual inspection IEC : 61109

3. Mechanical routine test IEC : 61109

8.5. Test during manufacture

Following test shall also be carried out on all components as applicable

a) Chemical analysis of zinc used for galvanizing

b) Chemical analysis, mechanical, metallographic test and magnetic particle

inspection for malleable castings.

c) Chemical analysis, hardness tests and magnetic particle inspection for forgings.

8.6. Sample Batch for Type Testing

8.6.1. The bidder shall offer material for sample selection for type testing only after getting Quality
Assurance Programme approved by the owner. The bidder shall offer at least three times the
quantity of materials required for conducting all the type tests for sample selection. The
sample for type testing will be manufactured strictly in accordance with the Quality Assurance
Programe approved by the owner.

8.7. Additional Tests :

8.7.1 The owner reserves the right at his own expenses, for carrying out any other tests (s) of
reasonable nature carried out at supplier’s premises, at site, or in any other place in addition to
the aforesaid type, acceptance and routine tests to satisfy himself that the material comply with
the specifications.

8.7.2 The owner also reserves the right to conduct all the tests mentioned in this specification at his
own expense on the samples drawn from the site at Supplier’s premises or at any other test
center. In case of evidence of non compliance, it shall be binding on the part of the Supplier to
prove the compliance of the items to the technical specifications by repeat tests or corrections
of deficiencies or replacement of defective items, all without any extra cost to the owner.

8.8. Co-ordination for Testing

8.8.1. The supplier shall have to co-ordinate testing of insulators with hardware fittings to be
supplied by other supplier and shall have to guarantee overall satisfactory performance of the
insulators with the hardware fittings.

8.8.2. The bidder shall intimate the owner about carrying out of the type tests along with detailed
testing programme at least 3 weeks advance of the scheduled date of testing during which the
owner will arrange to depute his representative to be present at the time of carrying out the
tests.
9.0 Quality assurance plan:-
9.1 The successful bidder shall submit following information to the owner:

9.1.1 Test certificates of the raw materials and bought out accessories.

9.1.2 Statement giving list of important raw materials, their grades along with names of sub-
suppliers for raw materials, fist of standards according to which the raw materials are tested.
List of tests normally carried out on raw materials in presence of bidder's representative.

9.1.2 List of manufacturing facilities available.

9.1.3 Level of automation achieved and lists of areas where manual processing exists.

9.1.4 List of areas in manufacturing process, where stage inspections are normally carried out for
quality control and details of such tests and inspections.

9.1.5 List of testing equipments available with the bidder for final testing of equipment along with
valid calibration reports.

9.1.6 The manufacturer shall submit Manufacturing Quality Plan (MQP) for approval & the same
shall be followed during manufacture and testing,

9.1.7 The successful bidder shall submit the routine test certificates of bought out raw materials /
accessories and central excise passes for raw material at the time of inspection.

10.0 GUARANTEE:-

The Supplier of Insulators shall guarantee overall satisfactory performance of the Insulators
for the period of 18 months from the date of supply.
 11.0 Inspection::

11.1 The owner's representative shall at all times be entitled to have access to the works and all
places of manufacture, where insulator, and its component parts shall be
manufactured and the representatives shall have full facilities for unrestricted
inspection of the Supplier's and sub-Supplier's works, raw materials, manufacture
of the material and for conducting necessary test as detailed herein.

11.2. The material for final inspection shall be offered by the Supplier only under packed condition.
The owner shall select samples at random from the packed lot for carrying out acceptance
tests. The lot offered for inspection shall be homogeneous and shall contain Insulators
manufactured in 3-4 consecutive weeks.

11.3 The Supplier shall keep the Owner informed in advance of the time of starting and the
progress of manufacture of material in their various stages so that arrangements could be made
for inspection.

11. 4 No material shall be dispatched from its point of manufacture before it has been satisfactorily
inspected and tested unless the inspection is waived off by the owner in writing. In the later
case also the material shall be dispatched only after satisfactory testing specified herein has
been completed.

11.5 The acceptance of any quantity of material shall in no way relieve the Supplier of his
responsibility for meeting all the requirements of the specification and shall not prevent
subsequent rejection, if such materials are later found to be defective.

12.0 Packing:

12.1 All Insulators shall be packed in strong corrugated box of min, 7 ply duly paletted or wooden
crates. The gross weight of the crates along with the material shall not normally exceed 100
Kg to avoid handling problem. The crates shall be suitable for outdoor storage under wet
climate during rainy season.

12.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage
at site and subsequent handling in the field.
12.3 Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent
damage or deformation during transit and handling.

12.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their
destination and to avoid the possibility of goods being lost or wrongly dispatched on account
of faulty packing and faulty or illegible markings. Each wooden case/crate/corrugated box
shall have all the markings stenciled on it in indelible ink.

12.5 The bidder shall provide instructions regarding handling and storage precautions to be taken at
site.

13.0 .Samples:

Two samples shall be submitted along with the tender

Annexure – A

The standards mentioned in this specification are available from :

Reference Name and address

abbreviation

IEC/CISPR International Electro technical commission, Bureau Central de la

commission, electro technique international, 1 rule de verembe,
Geneva, SWITZERLAND

BIS/IS Bureau of Indian Standards, Manak Bhavan, 9, Bahadur Shah

Zafar Marg, New Delhi – 110 001, INDIA

ISO International organization for standardization, Danish Board of

Standardization Danish Standardizing Sraat, Aurehoegvej-12 DK-
2900, Heeleprup, DENMARK

NEMA/ANSI National Electric Manufacture Association, 155, East 44th Street,

New York, NY: 10017 U.S.A

ASTM American Society for Testing and Materials, 1916 Race St.
Phelledelphia, PA19103 U.S.A.

STRI guide STRI, Sweden, Website : www.stri.se

 ANNEXURE – B

Tests on Insulator units :

1. RIV Test (Dry) :
The insulator string along with complete hardware fittings shall have a radio interference
voltage level below 100 micro votls at one MHz when subjected to 50 Hz A.C. voltage of 30KV for
33KV class insulators respectively under dry condition. The test procedure shall be in accordance
with IS:8263/IEC : 437/CISPR 18-2.

2. Brittle Fracture Resistance Test

Brittle fracture test shall be carried out on naked rod along with end fittings by applying “In
HNO3 acid” (63 g. conc.HNO3 added to 937 g water) to the rod. The rod should be held at 80% of
SML for the duration of the test. The rod should not fail within the 96-hour test duration. Test
arrangement should ensure continuous wetting of the rod with Nitric acid.

3. Recovery of Hydrophobicity & Corona test

The test shall be carried out on 4mm thick samples of 5cm X 7 cm.

i) The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface
to dry and spray with water. Record the Hydrophobicity classification in line with STRI
guide for Hydrophobicity classification (Extract enclosed at Annexure-D). Dry the
samples surface.
ii) The sample shall subjected to mechanical stress by bending the sample over a ground
electrode. Corona is continuously generated by applying 12KV to a needle like electrode
placed 1mm above the sample surface. Tentative arrangement shall be as shown in
Annexure-E. The test shall be done for 100 hrs.
iii) Immediately after the corona treatment, spray the surface with water and record the HC
classification. Dry the surface and repeat the corona treatment as at clause 2 above. Note
HC classification. Repeat the cycle for 1000 hrs. or unitl an HC of 6 or 7 is obtained. Dry
the sample surface.
iv) Allow the sample to recover and repeat hydrophobicity measurement at several time
intervals. Silicone rubber should recover to HC1-HC2 within 24 to 48 hours, depending on
the material and the intensity of the corona treatment.

4. Chemical composition test for silicon content

The content of silicon in the composite polymer shall be evaluated by EDX (Energy
Dispersion X-ray) Analysis or Thermo-gravimetric analysis. The test may be carried out at
CPRI or any other NABL accredited laboratory.
 ANNEXURE – C

Guaranteed technical particulars of 33 KV Polymer (B&S) Insulator

Sl. Description Unit 33KV

No. 70KN

1. Type of insulators

2 Standard according to which the insulators manufactured and tested

3. Name of material used in manufacture of the insulator with

class/grade)

a) Material of core (FRP rod)

i) E-glass or ECR-glass

ii) Boron content

b) Material of housing & weather sheds (silicon content by weight)

c) Material of end fittings

d) Sealing compound for end fittings

4 Colour

5 Electrical characteristics :

a) Nominal system voltage kV(rms)

b) Highest system voltage kV(rms)

c) Dry Power frequency withstand voltage kV(rms)

d) Wet power frequency withstand voltage kV(rms)

e) Dry flashover voltage kV(rms)

f) Wet flash over voltage kV(rms)

g) Dry lighting impulse withstand voltage

a) Positive kV(peak)

b) Negative kV(peak)

h) Dry lighting impulse flashover voltage

a) Positive kV(peak)
 b) Negative kV(peak)

i) RIV at 1 MHz when energized at 10KV/30KV (rms) under dry Microvolt

condition

j) Creepage distance (Min.) mm 900 mm

6 Mechanical characteristics :

a) Minimum failing load KN 70KN

7 Dimensions of insulator

i) Weight Kg. 1.4 Kgs ±

2%

ii) Dia. Of FRP rod mm 16 mm

iii) Length of FRP rod mm

iv) Dia. of weathersheds mm 95

v) Thickness of housing mm

vi) Dry arc distance mm

Dimensioned drawings of insulator (including weight with Yes/No

tolerances in weight) enclosed

8 Method of fixing of sheds to housing (specify) : Single mould or

modular construction (injection moulding/compression moulding)

9 No. of weathersheds

10 Type of sheds

i) Aerodynamic

ii) With underribs

11 Packing details

a) Type of packing

b) No. of insulators in each pack

c) Gross weight of package

12 Any other particulars which the bidder may like go give

 31. 33 KV METAL PARTS (B&S TYPE)

1. SCOPE:
The specification covers design, manufacture, testing at manufacturer’s works before dispatch
supply and delivery of Hardware fittings for 33 KV String Insulators as per the “Schedule of
Requirements” attached.

2. Standards:-
The fittings shall confirm to the IS specification No. IS-2486- Part-I-1971 and IS-2486 Part-II-
1989 and IS 2486- Part-III-1974 (the latest version there of) – These fittings shall suit the 33 kV
String Insulators (B&S Type) covered in IS 731-1971(the latest versions there of) and IS-3188-
1965(the latest version there of).

3. Design and type :-

The fittings shall be Ball and Socket type. The normal dimensions of ball shall be those
shown against 16 mm and those of socket shall be shown against 16mm alternative(B) (Vide fig. 8
and 9 of IS-2486-part II-1989) respectively. The minimum failing load of the fittings shall not be less
than 4590Kgs.

4. Materials:-
The components of the fitting shall be of materials specified in clause 5.1 of IS 2486-part-I-
1971 (the latest issue). Fittings comprising tension clamps of Alluminium alloy shall be offered. The
composition of Alluminium alloy may be declared giving references to the relevant IS. The exact
weight of the clamp shall be mentioned.

5. Testing:-

Type Tests:- The following type test certificates showing the results of type tests done as per clause
5.3.1. of IS 2486 PartI-1971 (the latest issue) with the dimensional drawings shall invariably
accompany the tender.

Tests to be conducted

1. Slip strength test

2.Mechanical tests

3.Verification of dimensions

4.Galvanizing test

5.Visual examination test.

b) The following tests shall be conducted on the fittings ordered in accordance with IS and Test
Certificates shall be submitted in duplicate. The test samples shall be selected by the “ EASTERN
POWER DISTRIBUTION COMPANY OF A.P. LIMITED”. Inspecting Officers in the event of
inspection is done at the manufacturer’s works.

b-i) Acceptance tests:-

As per Clause 5.3.2 of IS 2486 PartI-1971 ( the latest issue) sampling should follow the
procedure laid down in Appendix-A of IS 2486 – Part-I-1971 ( the latest issue).

b-ii) Routine tests:-

As per clause 5.3.3 of IS 2486-Part I-1971 ( the latest issue) on each and every fittings.

6. Packing:- For packing of fittings double gunny bags shall be employed. The gross weight of the
packing shall not normally exceed 50 kgs. All nuts shall be hand tightened over the bolts and screwed
up to the farthest point.

7. Guaranteed Technical particulars:-The technical particulars as specified in the IS shall be

guaranteed and statements of guaranteed particulars shall be furnished along with tender in the form
given in Annexure.

7. SAMPLES:-

Two samples of Hardware fittings for 33 kV String Insulators (B&S Type) shall be submitted along
with the tender.

8. Embossing:- The samples shall be engraved with your trade mark.

10. All bids submitted will also include the following information:

i. Copies of original documents defining the constitution or legal status, place of

registration and principle place of business of the company or firm or partnership, etc.,
 ii. The bidder should furnish a brief write-up, backed with adequate data, explaining his
available capacity and experience (both technical and commercial) for the manufacture and supply of
the required equipment within the specified time of completion after meeting all their current
commitments.

iii. The bidder should clearly confirm that all the facilities exist in his factory for
inspection and testing and these will be made available to the employer or his representative for
inspection..

iv. Reports on financial standing of the Bidder such as profit and loss statement, balance
sheets and auditor’s report for the past three years, bankers certificates etc.

11. GUARANTEED TECHNICAL PARTICULARS OF HARDWARE FITTINGS

SUITABLE FOR 33 KV STRING INSULATORS
Sl.No. Characteristic
1 Type of manufacture:
The materials used for various components parts like
cross arm straps, tension clamps, ball eye, rivet pin,
security clip etc. should also be furnished.
Makers’s name and company
2

Size of Ball and Socket

3

Type of galvanizing
4

Minimum failing load

5

Slip strength (KN)

6

Electrical resistance of fittings

7

Maximum size of conductor for which the fittings are

8 suitable

9 Weight of the metal parts

10 Drawings to scale (drawings of all components parts as

well as the assembly drawings) to be enclosed.
 32.11KV POLYMER DISC INSULATORS (C&T)
1.0 Scope

This specification covers design, manufacture, testing and supply of composite insulators for use in
the 11KV overhead transmission lines and substations. The composite insulators shall be of the
following type.

Long rod insulators for conductors in tension application at angle/cut points. The insulators shall be
of tongue & clevis type, as desired by the purchaser.

2.0.APPLICABLE STANDARDS

2.1.Standards

Following Indian/International Standards, which shall mean latest revision, with

amendments/changes adopted and published, unless specifically stated otherwise in the specification,
shall be referred while accessing conformity of insulators with these specifications.

2.1.1 In the event of supply of insulators conforming to standards other than

specified, the Bidder shall confirm in his bid that these standards are equivalent or
better to those specified. In case of award, salient features of comparison between the
standards proposed by the bidder and those specified in this document will be provided
by the Supplier to establish equivalence.
Sl. Indian Title International
No. Standard Standard
1. Definition, test methods and acceptance IEC : 61109
criteria for composite insulators for a.c.
overhead lines above 1000V
2. IS : 731 Porcelain insulators for overhead power lines IEC : 60383
with a nominal voltage greater than 1000V
3. IS : 2071 Methods of High Voltage Testing IEC : 60060-1
4. IS : 2486 Specification for insulator fittings for IEC : 60120
overhead power lines with a nominal voltage IEC : 60372
greater than 1000V General Requirements
andTestsDimensionalRequirements
Locking Devices
5. Thermal Mechanical Performance test and IEC : 60575
mechanical performance test on string
insulator units
6. IS : 13134 Guide for the selection of insulators in IEC : 60815
respect of polluted conditions
7. Characteristics of string insulator units of the IEC : 60433
long rod type
8. Hydrophobicity classification guide STRI guide
1.92/1
9. Radio interference characteristics of overhead CISPR:18-2 part
power lines and high-voltage equipment 2
10. IS : 8263 Methods of RI Test of HV Insulators IEC : 60437
11. Standard for insulators – Composite- ANSI C29 13-
Distribution Dead-end type 2000
12. IS : 4759 Hot dip zinc coatings on structural steel & ISO : 1459
other allied products ISO : 1461
 Sl. Indian Title International
No. Standard Standard
13. IS : 2629 Recommended Practice for Hot, Dip ISO-1461 (E)
Galvanisation for iron and steel
14. IS : 6745 Determination of weight of zinc coating on ISO : 1460
zinc coated iron and steel articles
15. IS : 3203 Methods of testing of local thickness of ISO : 2178
electroplated coatings
16. IS : 2633 Testing of Uniformity of coating of zinc
coated articles
17 Standard specification for glass fiber strands ASTMD 578-05
18 Standard test method for compositional ASTM E 1131-03
analysis by Thermo-gravimetric
19 IS : 4699 Specification for refined secondary zinc

3.0.Technical Description of Composite Insulators :

3.1.Service condition

The polymer insulators to be supplied shall be suitable for satisfactory continuous operation
under conditions as specified below:

Maximum ambient temperature : 550C

Minimum ambient temperature : -50C
Relative humidity : 0 to 100%

3.2.Composite Insulators long rod type for tension locations.

3.2.1. The insulators shall be suitable for 3Ph. 50Hz, effectively earthed 11KV O/H distribution
system in a moderately/heavily polluted atmosphere. Long rod insulators shall be of tongue &
clevis type as specified.

3.2.2. Bidder must be an indigenous manufacturer and supplier of composite insulators of rating
11KV or above or must have developed proven in house technology and manufacturing process
for composite insulators of above rating OR posses technical collaboration/association with a
manufacturer of composite insulators of rating 11KV or above.

The Bidder shall furnish necessary evidence in support of the above along with the bid, which
can be in the form of certification from the utilities concerned, or any other documents to the
satisfaction of the owner.

3.2.3. Insulators shall have sheds with good self-cleaning properties. Insulator shed profile, spacing,
projection etc., and selection in respect of polluted conditions shall be generally in accordance
with the recommendation of IEC-60815/IS : 13134.

3.2.4. The size of composite insulator, minimum creepage distance and mechanical
strength along with hardware fittings shall be as follows.
Sl. Typ Nomi Highes Visible Wet Dry Minim Weat Min. Thickn Pin
No e of nal t dischar power lighting um her failing ess ball
. com syste system ge test frequenc Impulse creepa Shed load of shank
posi m voltage voltage y withstan ge Dia KN Silicon dia
te volta KV KV withstan d distan (mm) e (mm)
insu ge (rms) (rms) d voltage ce Sheath
lato KV voltage KV (mm) Minim
rs (rms) KV (rms) um
(rms) (mm)
Pin
Insu
1 11 12 9 35 75 320 95 45 3 16
lato
r

3.3.Dimensional Tolerance of Composite Insulators

The tolerances on all dimensions e.g. diameter, length and creepage distance
shall be allowed as follows in line with-IEC 61109:

± (0.04d + 1.5) mm when d 300mm

± (0.025d+6) mm when d>300mm

Where, d being the dimensions in millimeters for diameter, length or creepage

distance as the case may be.

However, no negative tolerance shall be applicable to creepage distance.

3.4.Interchangeability

The composite insulators including the end fitting connection shall be standard
design suitable for use with the hardware fittings of any make conforming to
relevant IEC/IS standards.

3.5.Corona and RI performance

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No

part shall be subjected to excessive localized pressure. The insulator and metal
parts shall be so designed and manufactured that it shall avoid local corona
formation and not generate any radio interference beyond specified limit under
the operating conditions.

3.6.Maintenance

The composite insulators offered shall be suitable for use of hot line
maintenance technique so that usual hot line operation can be carried out with
ease, speed and safety.
 4.0.BASIC FEATURES

4.1 Design and construction

The composite insulator shall have a core, housing & weather shed of insulating
material and steel/aluminum hardware components for attaching it to the
support/conductor.

4.1.1. Core

It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Glass
fibers and resin shall be optimized in the FRP rod. Glass fibers shall be boron free
electrically corrosion resistant (ECR) glass fiber or boron free E-Glass and shall
exhibit both high electrical integrity and high resistance to acid corrosion. The matrix
of the FRP rod shall be Hydrolysis resistant. The FRP rod shall be manufactured
through Pultrusion process. The FRP rod shall be void free.

4.1.2 Housing (Sheath)

The FRP rod shall be covered by a seamless sheath of a silicone elastomeric

compound or silicone alloy compound of a thickness of 3mm minimum measurable
uniformly everywhere including on weather sheds.

It should protect the FRP rod against environmental influences, external pollution and
humidity. It shall be extruded or directly molded on the core and shall have chemical
bonding with the FRP rod. The strength of the bond shall be greater than the tearing
strength of the polymer. Sheath material in the bulk as well as in the sealing/bonding
area shall be free form voids.

4.1.3. Weather sheds

The composite polymer weather sheds made of silicone elastomeric compound or

silicon alloy shall be firmly bonded to the sheath, vulcanized to the sheath or molded
as part of the sheath and shall be free from imperfections. The weather sheds should
have silicon content of minimum 30% by weight. The strength of the weather shed to
sheath interface shall be greater than the tearing strength of the polymer. The interface,
if any, between sheds and sheath (housing) shall be free from voids.

4.1.4. End Fittings

End fittings transmit the mechanical load to the core. They shall be made of spheroidal
graphite cast iron, malleable cast iron or forged steel or aluminium alloy. They shall be
connected to the rod by means of a controlled compression technique. The gap
between fittings and sheath shall be sealed by a flexible silicone elastomeric
compound or silicone alloy compound sealant. System of attachment of end fitting to
the rod shall provide superior sealing performance between housing, i.e., seamless
sheath and metal connection. The sealing must be moisture proof.

The dimensions of end fittings of Insulators shall be in accordance with the standard
dimensions stated in IS: 2486/IEC60120.

a. Acceptance (sample) tests For composite insulators

a) Verification of dimensions : Clause 7.2 IEC : 61109
b) Verification of the locking system : Clause 7.3 IEC : 61109
 (if applicable)
c) Galvanizing test : IS : 2633/IS : 6745
d) Verification of the specified : Clause 7.4 IEC : 61109
Mechanical load

b. Routine Tests

Sl.No. Description Standard

1. Identification of marking As per IEC : 61109 Clause 8.1
2. Visual inspection As per IEC : 61109 Clause 8.2
3. Mechanical routine test As per IEC : 61109 Clause 8.3

5.3 Test during manufacture

Following test shall also be carried out on all components as applicable

a) Chemical analysis of zinc used for galvanizing

b) Chemical analysis, mechanical, metallographic test and magnetic particle inspection

for malleable castings.

c) Chemical analysis, hardness tests and magnetic particle inspection for forgings.

Tests on Insulator units :

1. RIV Test (Dry) :

The insulator string along with complete hardware fittings shall have a radio
interference voltage level below 100 micro volts at one MHz when subjected to 50 Hz A.C.
voltage of 10KV & 30KV for 11KV class insulators respectively under dry condition. The test
procedure shall be in accordance with IS:8263/IEC : 437/CISPR18-2.

2. Brittle Fracture Resistance Test

Brittle fracture test shall be carried out on naked rod along with end fittings by
applying “In HNO3 acid” (63 g. conc.HNO3 added to 937 g water) to the rod. The rod should
be held at 80% of SML for the duration of the test. The rod should not fail within the 96-hour
test duration. Test arrangement should ensure continuous wetting of the rod with Nitric acid.

3. Recovery of Hydrophobicity & Corona test

The test shall be carried out on 4mm thick samples of 5cm X 7 cm.

i) The surface of selected samples shall be cleaned with isopropyl alcohol. Allow
the surface to dry and spray with water. Record the Hydrophobicity
classification in line with STRI guide for Hydrophobicity classification (Extract
enclosed at Annexure-D). Dry the samples surface.

ii) The sample shall be subjected to mechanical stress by bending the sample over a
ground electrode. Corona is continuously generated by applying 12KV to a
needle like electrode placed 1mm above the sample surface. Tentative
 arrangement shall be as shown in Annexure-E. The test shall be done for 100
hrs.

iii) Immediately after the corona treatment, spray the surface with water and record
the HC classification. Dry the surface and repeat the corona treatment as at
clause 2 above. Note HC classification. Repeat the cycle for 1000 hrs. or unitl an
HC of 6 or 7 is obtained. Dry the sample surface.

iv) Allow the sample to recover and repeat hydrophobicity measurement at several
time intervals. Silicone rubber should recover to HC1-HC2 within 24 to 48
hours, depending on the material and the intensity of the corona treatment.

4. Chemical composition test for silicon content

The content of silicon in the composite polymer shall be evaluated by EDX (Energy
Dispersion X-ray) Analysis or Thermo-gravimetric analysis. The test shall be carried
out at any NABL accredited laboratory.

GUARANTEED TECHNICAL PARTICULARS

Name of Manufacturer :
Address of work :

11KV 45 KN
Sl. Characteristics of insulators Unit (C&T)
No.

Composite Disc
Type
1 Type of Insulator (Long Rod )
Insulators

Standard according to which the insulators

2 As per IEC 61109
manufactured and tested

Silicon rubber,
fibre glass
Name of material used in manufacture of rod (FRP Rod)
ECR
the insulator with class/grade)
grade, end fittings

a) Material of core (FRP rod)

3
ECR Glass
i) E-glass or ECR – glass
ii) Boron content Boron Free Epoxy

b) Material of housing & weather sheds b) 30% to 45% by

weight
(silicon content by weight) c) HDG SGI
c) Material of end fittings Casting
 d) RTV Silicon
alloy
d) Sealing compound for end fittings
Sealant

4 Colour Grey

5 Electrical characteristics

a) Nominal system voltage KV (rms) 11 KV

KV (rms) 12 KV
b) Highest system voltage

KV (rms) 45 KV
c) Dry Power Frequency withstand voltage

KV (rms) 35 KV
d) Wet Power Frequency withstand voltage

KV (rms) 50 KV
e) Dry flash over voltage

KV (rms) 40 KV
f) Wet flash over voltage

g) Dry lightning impulse withstand voltage KV (Peak) 75 KV

i) Positive KV (Peak) 75 KV
ii) Negative

h) Dry lightning impulse flash over

KV (Peak) 110KV
withstand voltage
KV (Peak) 110KV
i) Positive
ii) Negative
 i) RIV at 1 MHz when energized at Microvolt <50
10KV/30KV (rms) under dry condition

mm 320 mm
j) Minimum creepage distance (mm)

Mechanical characteristics
6. 45 KN
a) Minimum failing load
mm

Dimensions of insulators

i) weight Kgs. 0.8 kg (min)

ii) Dia FRP Rod mm 16

iii) Length of FRP Rod mm 200(min)
7. iv) Dia of weather sheds mm -
v) Thickness of housing mm 3 (minimum)
vi) Dry arc distance mm 167
vii) Dimensional drawings of insulator
(including weight with tolerances in Yes / No
weight) enclosed
Method of fixing of sheds to housing Single mould and
8.
(specify) : Single mould and injection injection moulding
moulding.

9. No. of weather sheds -

Type of sheds Aero dynamic

10.
i) Aero dynamic
ii) With under ribs
Packing details
11. i) Type of packing As per spec
ii) No. of insulators in each pack
iii) Gross weight of package
12. Any other particulars which the bidder may
like to give
33.11KV METAL PARTS (C&T)
 34. GI Stay Wire
1. SCOPE:
The specification provides for the manufacture, testing before despatch, supply and delivery
of G.I. stay wire.
2. STANDARDS:
The G.I. Stay Wire shall confirm to IS 2141-1979 with latest amendments unless otherwise
modified in this specification.
3. MATERIAL:
The wire shall be drawn from steel made by the open hearth basic oxygen or electric
Furnace process and of such quality that when drawn to the size of wire specified and coated
with zinc, the finished strand and the individual wires shall be of uniform quality and have
the properties and characteristics as specified in this specification. The wires shall not
contain sulphur and phosphorous exceeding 0.060 percent each.

3.1 The wires shall be coated with zinc of Grade Zn 98 (IS:209-1966).

3.2 The wires shall be circular and shall be free from scale, irregularities imperfection, split
surface flaws, rough jagged and imperfect edges. The zinc coating shall be smooth, even
and, bright.
3.3 Joints shall be permitted in the individual wires during stranding but these stranding joints
shall not be less than 15 metres apart in the finished strands.

4. Construction:

4.1 The wires shall be of grade 4 having minimum tensile strength of 70 Kgf./mm sq.

4.2 The constructional details shall be as specified in table give below. The galvanized stay
strand shall be of 7 (seven) wires and the wires shall be so stranded together that when an evenly
distributed pull is applied at the ends of the completed wire, each strand will take an equal share
of the pull.

No. of
Single wire before stranding Strand
wires
Min Min breaking Minimum
Diameter Length of
Tolerance % Elongation load breaking load
(mm) lay
% KN/Sq.mm KN/sq.mm
12 to 18
+ 0.06 mm, times the
7 3.15 6 5.46 34
- 0.03 mm strand
diameter
5. Sampling Criteria:

Sampling criteria and the tests shall be in accordance with IS:2141-1979.

6. Tests:

6.1 i) Tests on wires before manufacture ductility test in accordance with IS-1755.
ii) Chemical analysis of sample from each lot.
iii) Coating test.

The uniformity of zinc coating shall be tested by the method specified IS:2633-1964. The
wire shall with stand the number of dips as specified in IS:4826 – 1968 indicated below:.
Weight of coating and number of Dips Heavily – Coated Wire.

Nominal diameter of Hard Weight of coating No. of dips 1

Galvanized wire (mm) g/sq.m Min.
3.15 240 3

Hard: Galvanized after drawing, without annealing.

General:

Weight of coil

The wire shall be supplied in 50 Kg. coils.

7. Marking:

Each coil shall carry a brand or be stamped with the following information:

a) Manufacturer name or trade mark.

b) Lot number & coil number
c) Size
d) Construction
e) Tensile designation
f) Lay
g) Coating
h) Length
i) Mass
j) Contract No. (PO No.)
k) ISI Certification work if any
l) Identification mark APEPDCL.
The above shall be legible stamped upon a metallic tape securely attached to the coil.
 35.11 KV GUY INSULATORS (HT)

1. SCOPE:- The specification provides for the manufacture, testing at manufacturer’s works,
before despatch, supply and delivery of 11 KV Guy Insulators (HT) as per “Schedule of
Requirements” attached .

2. STANDARDS:-
The Guy Insulators shall be of as per Fig.3 designation ‘C’ of the I.S 5300 ( the latest issue).

3. GENERAL REQUIREMENT:- The porcelain shall be sound, free from defects thoroughly
verified and smoothly glazed. The design of Insulator should be such that, stresses due to
expansion or and contraction in any part of the insulator shall not lead to its deterioration.

4. TYPE AND DIMENSIONS:-

The Guy Insulators shall be of as per Fig.3 designation ‘C’ of the I.S 5300 ( the latest issue).
And unless otherwise specified a tolerance of +/- 5% shall be allowed on all the dimensions.

5. TESTS & TEST CERTIFICATES:-

The tests shall be carried out as per the relevant IS before dispatch and the Test
Certificates shall be furnished for approval. Type Test Certificates showing the results of
Type Tests on identical materials as per relevant I.S.S. shall accompany the tender.

6. MARKING:- The Insulators shall be legibly and indelibly marked as stipulated in para (6)
of the I.S.

a) Name of trade-mark of the manufacturer.

b) Month and year of manufacture and.
c) Porosity test.
Markings on porcelain shall be printed and shall be applied before firing.
7. GUARANTEED TECHNICAL PARTICULARS:-

The technical particulars as specified in the IS shall be guaranteed and statement of

guaranteed particulars shall be furnished along with tender in the form given in the Annexure.

8. PACKING: Supplies shall be done in wooden crates suitable for rough handling.

10) Embossing:- The material shall be engraved with your trade mark and “APEPDCL” name
shall be in scripted on the insulator similar to the supplier name inscription on the insulator.