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GENERAL CONSTRUCTION PRACTICES A. CONSTURCTIONAL PRACTICES FOR SUB-TRANSMISSION LINE

1.0

DETAILED SURVEY Successful bidder shall carry out detailed survey and prepare the detailed route of 33 KV lines, location of 33/11Kv Substations on topographical sheets / majmuli maps available from government agencies. The bidder shall make his own arrangements for obtaining the topographical maps / majmuli maps from the concerned agencies, the final route map of 33 KV lines shall be prepared and submitted by the bidder showing the proposed pole position, ground clearance, conductor sag and various crossings i.e. railway lines, communication lines, EHT lines, rivers, road and stream crossings on the map to a scale of 1:25000. All LT lines along with pole locations are to be marked on village / majmuli maps / patwari maps to a scale 1:5000. 1.1 Check Survey of Pole Locations The detailed survey shall be conducted to locate and peg mark the pole positions on ground conforming to the approved profile and pole schedule. In the process, it is necessary to have the pit centers marked according to the excavation marking charts. The levels up or down of each pit center with respect to the center of the pole locations shall be noted and recorded for determining the amount of earthwork required to meet the approved design parameters. Changes, if required, after detailed survey in the preliminary pole schedule shall be carried out by the Contractor and he shall thereafter submit a final pole schedule for the approval of employer. The pole schedule shall show position of all Poles, type of Poles, span length, type of foundation for each pole and the deviation at all angles as set out with other details. (i) Details En-route: All topographical permanent features, such as trees, telecommunication lines, buildings etc, 5.5 meter on either side of the alignment shall be detailed on the route plan. (ii) Clearance from ground building, trees etc.: Clearance from ground buildings, trees and telephones lines shall be provided in conformity with the Electricity Act, 2003, as amended up to date. The bidder shall select the height of the poles such that all the electrical clearances are maintained. (iii) The minimum planting depth of poles shall be governed by IS: 1678, However, if due to the ground conditions e.g. water logged area etc. depth of planting of poles shall be suitably increased, with appropriate extension arrangement in order to maintain the required clearances the vendor will submit the details of the same on case to case basis. (iv) Appropriate Guarding arrangement shall be used for crossings of electric line / telecom line / road / drain / canal crossing and at all points as per statutory requirements. The bidder shall provide install anti climbing devise and danger plates on all poles and DT stations. 1.2 Survey shall be carried out of the existing 33 KV lines net work. The survey shall be GPS based. It will cover mapping of 33 KV lines poles. The survey shall be carried out existing 33 KV feeder wise. 1.3 Preparation of single line diagram through suitable GIS & Electrical planning software indicating the location of each 33 KV lines poles, size of the conductors and locations. 1.4 The bidder shall hand over the software in CD media and corresponding license key to operate the system to the Employer after the completion of award. For Existing Line 1.5 Survey should also indicate the numbers of existing poles which are leaning and are required to be straightened. It should also indicate whether proper ground RAPDRP Part B Section 5 GCP

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clearance is available. In case it is necessary to provide guarding for the 33 KV line crossing the road, it should be indicated. 1.6 It shall also identify the spans where the conductor size is less than Raccoon for 33 KV Lines. For new line work 1.7 Based on the aforesaid survey tapping point of 33 KV lines is to be proposed giving the location of proposed Substations. 1.8 The survey shall clearly indicate the locations where road crossing guarding of telephone line is required. 1.9 The detail of survey which include pole location, distance between poles, reference point, size of conductor and other details as per above shall be provided to the Employer in Excel format or text format along with the data field name. 2.0 CLEARANCES - GENERAL For the purpose of computing the vertical clearance of an over-head line, the maximum sag of any conductor shall be calculated on the basis of the maximum sag in still air and at the maximum temperature, as per REC specifications. Similarly, for the purpose of computing any horizontal clearance of an over-head line, the maximum deflection of any conductor shall be calculated on the basis of the wind pressure, as per REC specifications. Following clearances shall be maintained by the contractor while executing the work, in conformation to the Indian Electricity Rules 1956:2.1 Clearance above Ground of The Lowest Conductor 1 No conductor of an over-head line, including service lines, erected across a street shall at any part thereof be at a height less than (a) (b) 2 For low and medium voltage lines For high voltage lines 5.8 meters 6.1 meters

No conductor of an over-head line, including service lines, erected along any street shall at any part thereof be at a height less than (a) (b) For low and medium voltage lines For high voltage lines 5.5 meters 5.8 meters

No conductor of an over-head line including service lines, erected elsewhere than along or across any street shall be at a height less than. (a) (b) (c) For low, medium and high voltage lines up to And including 11,000 volts, if bare For low, medium and high voltage lines Up to and including 11,000 volts, if insulated For high voltage lines above 11,000 volts 4.6 meters 4.0 meters 5.2 meters

For extra-high voltage lines the clearance above ground shall not be less than 5.2 meters plus 0.3 meter for every 33,000 volts or part thereof by which the voltage of the line exceeds 33,000 volts: Provided that the minimum clearance along or across any street shall not be less than 6.1 meters.

2.2

Clearance from Buildings of Low and Medium Voltage Lines and Service Lines

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Where a low or medium voltage over-head line passes above or adjacent to or terminates on any building, the following minimum clearances from any accessible point, on the basis of maximum sag, shall be observed:a. For any flat roof, open balcony, verandah roof and lean-to-roof (i) (ii) When the line passes above the building a vertical clearance of 2.5 meters from the highest point; and When he line passes adjacent to the building a horizontal clearance of 1.2 meters from the nearest point, and

b. For pitched roof (i) (ii) When the line passes above the building a vertical clearance of 2.5 meters immediately under the lines, and When the line passes adjacent to the building a horizontal clearance of 1.2 meters.

The horizontal clearance shall be measured when the line is at a maximum deflection from the vertical due to wind pressure. 2.3 Clearance from Buildings of High and Extra-High Voltage Lines i. Where a high or extra-high voltage over-head line passes above or adjacent to any building or part of building it shall have on the basis of maximum sag a vertical clearance above the highest part of a building immediately under such line, of not less than (a) (b) ii. For High Voltage Lines up to and including 33,000 volts For Extra High Voltage Lines 3.7 meters 3.7 meters plus 0.3 meters for every additional 33,000 volts or part thereof.

The horizontal clearance between the nearest conductor and any part of such building shall, on the basis of maximum deflection due to wind pressure, be not less than:(a) (b) (c) For high voltage lines up to and including 11,000 volts For high voltage lines above 11,000 volts and up to and including 33,000 volts For extra-high voltage lines 1.2 meters 2.0 meters 2.0 meters plus 0.3 meters for every additional 33,000 volts or part thereof.

3.0 CONSTRUCTION The construction of over head-lines may be divided into the following parts:1. Survey of lines, 2. Providing required line materials and shifting of these materials at site, 3. Erection of intermediate poles, cut point/ double pole (D.P.) locations. 4. Erection of Stay Sets and installation of strut poles as required, 5. Testing of line insulators and erection of insulators, 6. Execution of temporary jumpering at the terminal points to facilitate uninterrupted supply of power to the consumers. 7. Stringing of new conductor, tying of conductor on insulators, jumping at cut points locations. 8. Earthing of individual supports. 9. Provision of cradle guards at locations where possibilities of lines of different voltage gradient is likely to construct by other agency at a later date. Also providing earth mat / earthing cradle guard at various crossings as per prevailing rules, RAPDRP Part B Section 5 GCP

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10. 11. 12. 13.

Provision of anti-climbing device through wrapping of Barbed wire, Provision of danger notice board, Marking of each and every support, Special Crossing and its guarding i.e. P&T lines, building, line of other voltage grading, Road, other than Road/ Street, River crossing, Railway line crossing etc. 14. Jumpering of lines to existing system network. 15. Testing & commissioning of line with the existing system. 3.1 Maximum Intervals between Supports All conductors shall be attached to supports at intervals not exceeding the safe limits based on the ultimate tensile strength of the conductors and the factor of safety prescribed. Provided that in the case of over-head lines carrying low or medium voltage conductors, when erected in, over, along or across any street, the interval shall not without the consent in writing of the Engineer in Charge, exceed 65 meters. Average span of HT lines with proposed conductors is given in the table below: Sr. Line Support (height mtrs Nominal conductor Max span in Conductor type No. class /KG) size in sq mm mtrs 33 KV, 1 PCC (9.1m/280kg) AAAC 100 100 3 ph 3.2 Pit Marking and Digging Procedure After surveying, the pole location should be marked with the peg. The pits should not be too large than necessary, as otherwise, after erection of the pole and filling there remains a possibility of tilting of poles. For marking the pits, the dimensions of the pit and the centre to centre distance of pits are required. Pits having a dimension of about 1.2 mtr x 0.6 m should be excavated with its longer axis in the direction of the line or circular pit of size 0.6 mtr dia. The planting depth should be about 1/6 length of support i.e. 1.5 mtr in case of 8 mtr long PCC pole. the Excavation in generally done by using pickaxe crow bars, and shovel, very hard or rocky soil may require blasting of rock by small charges of gun power, etc. For hard rock location pit size of pole shall be excavated depth of 1 meter and dia is 1.2 times of bottom dimension of pole i.e. appox 350mm. 3.3 Erection of Poles and Concreting After excavation of pits is completed, the supports / poles to be erected may be brought to the pit location by manual labor or by cart. Then the pole may be erected inside the pit. Before starting Cement pole erection activities, requisite quantities of construction materials like boulders etc must be brought by the contractor near the pit. Issuance of Permit to Work (PTW) may be governed on inspection of construction materials in requisite quantities at site. Before erection the pole in the pit, concrete base-padding of not less than 75 mm thickness or stone block/ pre-casting of size 450x450x75mm shall be provided for the uniform distribution of the loads of the support on the soil. At least 48 hours should be allowed for setting of base padding concrete before placing the pole on it. Erection of poles can be done by using Bipod / Wooden horse made of 5 cm G.I. pipe and 6 m long. The spread of the legs should be 10 m. The tie wire for attachment of bipod to the pole is about 6 m long and is made of 7/10 SWG. Stay wire and this wire should be attached to the pole at 8 m. The pole is slid along the line route. The pole is tied with 3 ropes. The rope at the bottom prevents the pole from being dragged in the direction of the pull. To prevent the support from moving side in rising, two guy ropes are fixed on both sides and attached to temporary anchor. RAPDRP Part B Section 5 GCP

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For smooth sliding and perfect placement of pole in the pit, an inclined trench having 15.2 cm (6 in.) width and 10.2 cm (4 in.) length may be dug adjacent to the pit. A piece of M.S. channel may be placed in the inclined position at the other end of the pit for enabling the pole to slip smooth inside the pit. The trench would facilitate the pole to skid smoothly into the pit with jerks. The bipod is placed in position and attached to the pole by means of tie wire. The pull for lifting the poles is provided by rope pulley. When the pole has reached at an angle of 10.7 m to 12.2 m (35 to 40,) the bottom holding rope is slowly released. When the pole assumed the vertical position, the holding ropes should be tightened. It should be ensured that the time of erection, four men are at the ropes and the supervisor should be at a distance for guiding correct position so that in the event of breaking of rope, if pole falls, it will not result into an accident. Having lifted the pole the same should be kept in vertical position with the help of manila rope of 20/25 mm dia. using the rope as a temporary anchor. As the poles are being erected say from an anchor point to the next angle point, the alignment of the poles should be checked and set right by visual check. The verticality of the poles are to be checked with a spirit level. After the pole erection has been completed, and having satisfied that the verticality and alignments are all right, bolder filling and ramming is to be done. In case of PCC pole back filling by bolder shall be done. In swamp and special locations, before earth filling, the poles are to be concreted up to the ground level of the pit. In existing tilted pole location of line, pole shall require to make vertical by using extra bolder filling & ramming. Guy supports are to be provided wherever found missing or additionally required. After poles have been set, the temporary anchors are to be removed. 3.4 Earthing Earthing shall generally be carried out in accordance with the requirements of Indian Electricity Rules, 1956 and the relevant regulations of the Electricity Supply Authority concerned and as indicated below: (a) All metallic supports shall be earthed. (b) For PCC poles the metal cross-arms and insulator pins shall be bonded and earthed at every pole for HT lines. (c) All special structures on which switches, transformers, fuses, etc., are mounted / likely to mount should be earthed. (d) The supports on either side of the road, railway or river crossing should be earthed. (e) All supports (Steel & PCC) HT lines passing through inhabited areas, road crossings and along such other places, where Earthing of all poles is considered desirable from safety considerations should be earthed. In special locations and special structures, road crossings etc., pipe/rod Earthing should be done on either side of the construction . At other locations the coil earthing may be adopted. The coil earthing consists of 10 m length of 8 SWG. G.I. wire compressed into a coil 450 mm length and 50 mm dia and buried 1500 mm deep as per REC standard J-1. Following shall be the earthing requirements: Sl No 1 2 3 Description Single Pole PCC Double Pole PCC Road Crossing Type of Earthing 1 No. Coil Earthing at each SP 2 Nos. Coil Earthing at each DP GI Pipe earthing on either side one each RAPDRP Part B Section 5 GCP

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4 5

Telephone Line Crossing DP with Isolating Switch

GI Pipe earthing on either side one each Coil earthing 2 Nos. and GI Pipe earthing 1 No

3.5

ERECTION OF DP STRUCTURE FOR ANGLE LOCATIONS For angles of deviations 10 degrees to 60 degrees, DP structure may be erected. The pit digging should be done along the bisection of angle of deviation. After the poles 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 20/25 mm dia. Ensuring that the poles are held in vertical position (by spirit level) or using plumb the concreting of poles with 1:3:6 @ 0.3 Cmt. per pole for PCC may be done from bottom of the support to the ground level. Before erection the pole in the pit, concrete basepadding of not less than 75 mm thickness shall be done for the uniform distribution of the loads of the support on the soil. At least 48 hours should be allowed for setting of base padding concrete before placing the pole on it.

3.6

CONCRETING The concreting mixture of one Cmt. 1:3:6 ratios would mean 1 part cement, 3 parts Coarse sand and 6 part 40 mm aggregate size stones . It may be noted that while preparing the concrete mixture, large quantities of water should not be used as this would wash away cement and sand.

3.7

PROVIDING OF GUYS TO SUPPORTS In spite of careful planning and alignment of line route, certain situations arise where the conductor tries to tilt the pole from its normal position due to abnormal wind pressure and deviation of alignment, etc. When these cases of strain arise, the pole is strengthened and kept in position by guys. One or more guys will have to be provided for all supports where there is unbalanced strain acting on the support, which may result in tilting/uprooting or breaking of the support. Guys are braces fastened to the pole. In this work anchor type guy sets are to be used. These guys are provided at (i) angle locations (ii) dead end locations (iii) T - off points (iv) Steep gradient locations and (v) where the wind pressure is more than 50 kg / Sq.mtrs. The fixing of guys stays will involve (i) pit digging and fixing stay rod (ii) fastening guy wire to the support (iii) Tightening guy wire and fastening to the anchor. The marking of guy pit, digging and setting of anchor rod must be carefully carried out. The stay rod should be placed in a position so that the angle of rod with the vertical face of the pit is 30/45 as the case may be. Before start of erection of Stay sets, required concreting materials like Cement, Sand, Stone Chips and Construction water need to be made available near the pit. For double pole structure (DP), four stays along the line, two in each direction and two stays along the bisection of the angle of deviation or as required depending on the angle of deviation are to be provided. After concreting of 0.2 cmt per stay, back filling and ramming must be done well and appropriate time / days shall be allowed for proper setting. Alternately stone block/ RCC base anchor plate of size 450x450x75mm as per REC standard K-1/ K-4 may be used. RAPDRP Part B Section 5 GCP

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The number of RCC base anchor plate / Pre-casting shall be 3 nos. per stay for 11Kv line and 2 nos. per stay for LT line. The free end of the guy wire/stay wire is passed through the eye of the anchor rod, bent back parallel to the main portion of the stay/guy and bound after inserting the G.I. thimble, where it bears on the anchor rod. If the guy wire proves to be hazardous, it should be protected with suitable asbestos pipe filled with concrete of about 2 m length above the ground level, painted with white and black strips 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 turn buckle is half way in the working position, thus giving the maximum movement for tightening or loosening. 3.8 Guy Stay Insulators Guy insulators are placed to prevent the lower part of the Guy from becoming electrically energized by a contact of the upper part of the guy when the conductor snaps and falls on them or due to leakage. No guy insulator shall be located less than 2.6 m from the ground. Guy insulators are to be used in stay wires only. When continuous earth wire is used guy insulator may not be required. 3.9 Fixing of Cross-Arms After the erection of supports and providing guys, the cross-arms are to be mounted on the support with necessary clamps, bolts and nuts. The practice of fixing the cross arms before the pole erection is also there. In case, the cross-arm is to be mounted after the pole is erected, the lineman should climb the pole with necessary tools. The cross-arm is then tied to a hand line and pulled up by the ground man through a pulley, till the crossarm reaches the line man. The ground man should station himself on one side, so that if any material drops from the top of the pole, it may not strike him. All the materials should be lifted or lowered through the hand line, and should not be dropped. 3.10 Insulators and Bindings Line conductors are electrically insulated from each other as well as from the pole or structure by Insulators. Following two types of insulators shall be used for the line insulation: (1) Pin type (2) Strain type The pin type insulators will be used for straight stretch of line. The strain insulators are used at terminal locations or dead end locations and where the angle of deviation of line is more than 10. The pins for insulators are fixed in the holes provided in the, cross-arms and the pole top brackets. The insulators are 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, one strap of the strain fittings is placed over the cross-arm before placing the bolt in the hole of cross-arms. The nut of the straps is so tightened that the strap can move freely in horizontal direction. 3.11 Tying of Conductor on Pin Insulators Conductors should occupy such a position on the insulator as will produce minimum strain on the tie wire. The function of the wire is only to hold the conductor in place, on the insulator, leaving the insulator and pin to take the strain of the conductor. In straight line, the best practice is to use a top groove insulator. These insulators will carry grooves on the side as well. When the conductor is placed on the top groove, the tie wire serves only to keep the conductor from slipping out.

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On corners and angles (below 5 degree deviations) the conductors should be placed on the outside of the insulators. On the far side of the pole, this pulls the conductor against the insulator instead of away from the insulator. 3.12 Kind and Size of Tie Wire to Be Used Aluminum tie wire should be used with aluminum line conductor. The tie should always be made of soft annealed wire so that it may not be brittle and injure the line conductor. A tie wire should never be used for second time. Good practice is to use no. 6 tie wires for line conductor. The length of the wire varies from 1 m for simple tie of a small insulator (11 kV Pin insulators). 3.13 Rules of Good Tying Practice: (i) Use only fully annealed tie wire. (ii) (iii) Use suitable size of tie wire which can be readily handled yet one which will provide adequate strength. Use length of tie wire sufficient for making the complete tie, including an allowance for gripping with the hands. The extra length should be cut from each end if the tie is completed. A good tie should; (a) (b) (c) (v) (vi) (vii) 3.14 Provide a secure binding between line wire insulator and tie wire. Have positive contacts between the line wire and the tie wire so as to avoid any chattering of the contacts. Re-enforce line wire in the vicinity of insulator.

(iv)

Tying to be done without use of pliers. Do not use the wire which has been previously used. Do not use hard drawn wires for tying.

Conductor Erection Conductor erection is the most important phase in construction. The main operations are:(a) (b) (c) (d) Transportation of Conductor to works site. Paying and Stringing of Conductor Jointing of Conductor Tensioning and Sagging of Conductor

The conductor drums are transported to the tension location. While transporting precautions are to be taken so that the conductor does not get damaged / injured. The drum could be mounted on cable drum support, which generally is made from crow-bar and wooden slippers for small size conductor drums. The direction of rotation of the drum has to be according to the mark in the drum so that the conductor could be drawn. While drawing the conductor, it should not rub causing damage. The conductor could be passed over poles on wooden or aluminum snatch block mounted on the poles for this purpose. The mid span jointing is done through compressions or if helical fittings are used the jointing could be done manually. After completing the jointing, tensioning operation could be commenced. The conductor is pulled through come-along clamps to stringing the conductor between the tension locations. Sagging of conductor has to be in accordance to the Sag Tension chart. In order to achieve it, it is preferred to pull the conductor to a tension a little above the theoretical value so that while transferring it from the snatch blocks to the pit insulators and to take care of temperature variation. Proper sag could achieve. Sagging for 11 KV line is mostly done by Sighting. A horizontal strip of wood is fixed below the cross-arm on the pole at the required sag. The lineman sees RAPDRP Part B Section 5 GCP

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from other end and the sag is adjusted by increasing or decreasing the tension. The tension clamps could then be finally fixed and conductor be fixed on pin-insulators. All fittings, accessories like guys, cross-arms, etc., could be checked as they should not have deform. The maximum permissible spans for all the lines of 11/0.4 KV are prescribed according to the design of the supports. Sag-tension charts for these conductors are to be followed. 3.15 Anti-Climbing Devices In order to prevent unauthorized persons from climbing any of the supports of HT & LT lines without the aid of a ladder or special appliance, anti-climbing devices are provided to the supports. Two methods generally adopted are (i) barbed wire binding, for a distance of 30 to 40 cm at a height of 3.5 to 4 m from ground level, (ii) clamps with protruding spikes at a height of 3 to 4 m. 3.16 Testing and Commissioning When the line is ready for charging, it should be thoroughly inspected in respect of the following:(i) (ii) (iii) (iv) (v) (vi) Poles-Proper alignment, concerting and muffing. Cross-arms Proper alignment. Binding, clamps and jumpers To check whether these are in reach. Conductor and ground wire Proper sag to check whether there are any cuts, etc. Guys: To check whether the Guy wire is tight and whether the Guy insulators are in-tact. Earthing System: To check whether the earthing connections of supports and fittings are intact. Measure earth resistance with earth tester.

After the visual inspection is over and satisfied, the conductor is tested for continuity/ground, by means of megger. At the time of testing through megger person should not climb on the pole or touch the guarding, conductor, guy wire etc. (1) Before charging any new line, it should be ensured that the required inspection fee for the new line is paid to the Electrical Inspector and approval obtained from him for charging the line. The line should be energized before the officer who has been authorized by the Company in this regard. Before energizing any new line, the officer-in-charge of the line shall notify to the workmen that the line is being energized and that it will no longer be safe to work on line. Acknowledgement of all the workmen in writing should be taken in token of having intimated them. Wide publicity, by issuing notice in the local news paper should be arranged, in all the localities through which the line, that is to be energized passes, intimating the time and date of energizing and warning public against the risk in meddling with the line. The Officer-in-charge of the line shall personally satisfy himself that the same is in a fit state to be energized. In case the lines cross-over the other lines or buildings, safe minimum clearances are to be maintained as per I E Regulations. These clearances should be maintained. The crossings could be for 1. 2. 3. 4. Telephone / telegraph lines Buildings Lines of other voltages Roads, Streets, Other than Roads/Streets. Extra steel structures and GI wire, if needed shall be provided by the agency. RAPDRP Part B Section 5 GCP

(2) (3)

(4)

(5) 3.17

Special Crossings (A)

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(B)

River Crossing: Data for the highest flood-level should be obtained for previous years. For medium voltage minimum clearance of 3 m is kept over the highest floor level. Double pole or 4 pole structure would be required to be specially designed, depending upon the span and conductor size for the river crossing. The structures should be located at such places that they could be approached under flood condition also. The foundation of structures should be sound so that it may not get eroded or damaged due to rain water.

3.18

Guarding Guarding is an arrangement provide for the lines, by which a live conductor, when accidentally broken, is prevented to come in contact with other electric lines, telephone or telegraph lines, railway lines, roads, and persons or animals and carriages moving along the railway line or road, by providing a sort of cradle below the main electric line. Immediately after a live conductor breaks, it first touches this cradle guard of G.I. Wires before going down further, this in turn, trips the circuit breakers or H.T. /L.T. fuses provided for the protection purposes, and the electric power in the conductor or the line is cut off, and danger to any living object is averted. Guarding is not required for crossings of 66 KV and higher voltage lines where the transmission line is protected by fast acting relay operated circuit breaker of modern design with a tripping time of the order of 0.25 sec. from occurrence of fault to its clearance. For all other crossings, guarding is essential for Railway Telecommunication lines and major road crossing. The minimum height between any guard wire and live crossing conductor shall not be less then 1.5 m in case of a railway crossing. The guarding consists of 2 G.I., bearer wires strung between the two line supports, and G.I. Cross-lacings connecting two-bearer wires at definite intervals. The bearer fixed to the guarding cross-arms on the line supports by means of threaded eyebolts for proper tightening.

4.0

DESIGN PARAMETERS: (i) (ii) (iii) (iv) (v) (vi) (vii) Factor of safety 2.0 in normal conditions for 2.5 for 33 KV Lines PCC supports. 2 Wind pressure on pole & conductor 75 kg/m for 33 KV lines. In addition to wind load on cross arm insulators guy-wire etc shall be considered. Wind load on full projected area of conductors and poles is to be considered for design. Ground clearance shall be minimum 5.2m for 33 KV Lines for bare conductor at locations other than road crossings. The live metal clearance shall be as per IS: 5613 Pole accessories like danger plates phase plates and number plates shall be provided.

5.0

STRINGING OF CONDUTOR i) The works include spreading of conductors or HT/LT cables without any damages and stringing with proper tension without any kinks / damages including binding of conductor at pin points, jumper at cut points etc, The ground and line clearances at road crossings along roads. LT crossing and others shall be as per the relevant I.E. rules. While transporting conductors drums to site precautions are to be taken so that the conductor does not get damaged. The drum shall be mounted on cable drum support, The direction of rotation o the drum shall be according to the mark in RAPDRP Part B Section 5 GCP

ii)

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the drum so that the conductor could be drawn, While drawing the conductor, it shall not rub causing damage, the conductor shall be passed over poles on wooden or aluminium snatch block (pulley) mounted on the poles for this purpose. iii) iv) The conductor shall be pulled through come-along clamps to stringing the conductor between the tension locations. Conductor splices shall not crack or otherwise be susceptible to damage in the stringing operation. The contractor shall be used only such equipment/ methods during conductor stringing which ensures complete compliance in this regard. All the joints including mid span joints on the conductor and earth wire shall be of the compression type in accordance with the recommendations of the manufacturer, for which all necessary tools and equipment like compressors dies, etc, shall be obtained by the contractor, each part of the joint shall be cleaned by wire brush till it is free of rust or dirt, etc, and be properly greased with anti corrosive compound, before the final compression is carried out with the compressors. After completing the jointing, tensioning operation shall be commenced. All the joints or splices shall be made at least 15 meters away form the pole No. joints of splices shall be made in spans crossing over main roads, railways and small rivers, spans. Not more than one joint per sub conductor span shall be allowed. The compression type fittings shall be of the self centering type. After compressing the joint the aluminium sleeve shall have all corners rounded; burrs and sharp edges removed and smoothened. During stringing of conductor to avoid any damages to the joint the contractor shall use a suitable protector for mid span compression joints in case they are to be passed over pulley blocks / aerial rollers. The pulley groove size shall be such that the joint along with protection can be passed over it smoothly.

v)

vi)

6.0

PERMITTED EXTRA CONSUMPTION OF CONTRACTOR SUPPLIED MATERIALS The quantities of conductor, insulator, earth wire, hardware fitting, conductor and earth wire accessories indicated in BPS are tentative and actual quantity will depend upon final survey. The payment for contractor supplied line materials shall be made for the quantities incorporated in the works plus permitted extra quantities as mentioned below: Contractor shall make every effort to minimize the breakage, losses and wastage of the line material during erection. However the contractor shall be permitted the extra consumption up to the limit as specified in the table below and shall be permitted to dispose of the scrap, if any . Sr. No. 1 2 3 Item Conductor HT & LT Cable Cable (Power & Service Wire) % of permitted extra consumption 1 1 1

In case of conductor the permitted extra consumption limit of 1% is inclusive of sag, jumper, damage, losses and wastage. The contractor shall not be required to return to the purchaser, empty conductor / earth wire left over drums and shall dispose of the same at his cost. 7.0 TENSIONING AND SAGGING OPERATIONS (i) The tensioning and sagging shall be done in accordance with the approved stringing charts or sag tables. The initial stringing chart shall be sued for the RAPDRP Part B Section 5 GCP

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conductor and final stringing chart for the earth wire. The conductors shall be pulled up to the desired sag and left in running blocks for at least one hour after which the sag shall be re-checked and adjusted, if necessary before transferring the conductor from the running blocks to the suspension clamps. The conductor shall be clamped within 36 hours of sagging in. (ii) The sag will be checked in the first and the last section span for sections up to eight spans and in one additional intermediate span for sections with more than eight spans. The sag shall also be checked when the conductors have been drawn up and transferred form running blocks to the insulator clamps. At sharp vertical angles, conductor and earth wire sags and tensions shall be checked for equality on both sides of the angel and running block. The suspension insulator assemblies will normally assume verticality when the conductor is clamped. Tensioning and sagging operations shall be carried out in calm whether when rapid changes in temperature are not likely to occur.

(iii)

7.1

Clipping in Clipping of the conductors in to position shall be done in accordance with the manufacturers recommendations, jumpers at section and angle towers shall be formed to parabolic shape to ensure maximum clearance requirements, Fasteners in all fittings and accessories shall be secured in position. The security clip shall be properly opened and sprung into position.

7.2

Fixing of conductor and earth wire accessories Conductor and earth wire accessories supplied by the contactor shall be installed by contractor as per the design requirements and manufacturers instruction within 24 hours, of the conductor / earth wire clamping. While installing the conductor and earth wire accessories, proper case shall be taken to ensure that the surfaces are clean and smooth and that no damage occurs to any part of the accessories or of the conductors.

7.3

Replacement If any replacements are to be effected after stringing and tensioning or during maintenance e.g. replacement of cross arms, the conductor shall be suitably tied to the pole at tension points or transferred to suitable roller pulleys at suspension points.

8.0

FINAL CHECKING, TESTING AND COMMISSIONING After completion of the works, final checking of the line shall be carried out by the Contractor to ensure that all foundation works, pole erecting and stringing have been done strictly according to the specifications and as approved by the Owner. All the works shall be thoroughly inspected in order to ensure that: 1 2 3 4 5 6 7 8 Sufficient backfilled earth covers each foundation pit and is adequately compacted. All poles are used strictly according to final approved drawing and are free of any defect or damage whatsoever. The stringing of the conductors have been done as per the desired clearances. All conductor accessories are properly installed. All other requirements for completion of works such as fixing of danger plate and anti-climbing device have been fulfilled. The insulation of the line as a whole is tested by the Contractor through provision of his own equipment, labor, etc. to the satisfaction of the purchaser. All poles are properly grounded. The line is tested satisfactorily for commissioning purpose. RAPDRP Part B Section 5 GCP

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9.0

ELECTRICAL SYSTEM DATA

Sr. No. 1 2 3 4 5 Description of the Parameter System Operating Voltage Maximum operating voltage of the systems (rms) Rated frequency No. of phases Rated Insulation levels (i) Full wave impulse withstand voltage (1.2/50 micro-sec.) (ii) One minute power frequency dry and wet withstand voltage (rms) 6 7 Min. creepage distance Min. clearance (i) Phase to earth (ii) Phase to phase (iii) Sectional 8 9 Rated short circuit current System neutral earthing 320 mm 320 mm 3000 mm 25 KA for 1 sec. Effectively earthed 140 mm 280 mm Clearances 25 KA for 1 sec. Effectively earthed 33 kV System 33 kV 36 kV 50 Hz 3 11 kV System 11 kV 12 kV 50 Hz 3

170 kVp 80 KV 25 mm/KV (900 mm)

75 kVp 28 KV 25 mm/KV (300 mm)

10.0

REPAIR TO CONDUCTORS The conductor shall be continuously observed for loose or broken strands or any other damage during the running out operations. Repair to conductors, if necessary, shall be carried out with repair sleeves. Repairing of the conductor surface shall be carried out only in case of minor damage, scuff marks, etc. The final conductor surface shall be clean, smooth and free from projections, sharp points, cuts, abrasions, etc. The Contractor shall be entirely responsible for any damage to the poles during stringing.

(B)

CONSTRUCTION PRACTICE FOR 33/11KV TRANSFORMER SUB-STATION

Following are the works owner intends to execute with installation of various equipments, apparatus and associated accessories so that all should function properly in co-ordination with each other. 1. Providing foundation, supporting structures, operation & maintenance platform for each equipments, apparatus and associated accessories strictly as per recommendation of Original Equipments Manufacturer (OEM) and Indian Electricity Rules, 2. Providing ISMC100 Channel on the cable trench and installation of control panels in the Control Room. 3. Installations and Commissioning of each equipments, apparatus and associated accessories with control panels for protection alarm circuits of equipments / feeders at substations, which shall invariably include Transformer protection, Feeder Protection and Incomer protection. 4. Installation testing and commissioning of Current Transformers. 5. Testing & Pre - Commissioning checks shall be made in association with representative of Engineer in Charge as per Original Equipments manufacturer recommendations / standard check list as approved by EIC. 6. Providing control / power cables between Breaker, CT, PT, Power Transformer and Indoor / outdoor control panels. The cable shall be laid in trenches provided by owner. RAPDRP Part B Section 5 GCP

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Control supply of 30V DC at the substation control room shall be extended to VCB control panels (Out door panel and Indoor panel) by the agency. 7. VCBs are to be connected with substation earthing mesh using 50X6 mm GS flat. Two distinct connections shall be required for this purpose. Approximately 25 running feet GS flat shall be required for this purpose. 8. For indoor panel earthing, separate 2 Nos. 3 metres long pipe earthing pits shall be provided with 50X6 mm GS flat. Two distinct earth connections shall be provided in the panel earthing. Approximately 30 running feet GS flat shall be required for indoor panel earthing. 1. EXECUTION OF CONSTRUCTION WORKS: Contractor shall jointly conduct a detailed survey site selected for 33/11 kV substations of the Circle with CSPDCL representative and prepare presentable document showing status of work required to be executed. This status report shall be examined by SE (O&M) for issuance of necessary advice for taking up the work at site. On finalizing the program, agency shall start execution of work at defined work place in planned manner. Work shall not be executed in haphazard manner without planning. Record of procured materials for execution of works at site shall be jointly made by representative of agency, representative of Substation O&M deptt. and the representative of SE(O&M). Materials shall be properly tagged, documented and stacked in the store yard. Loading, unloading, cartage and handling of materials in stores etc all shall be in the scope of the agency. The REC construction standard practice should be followed while execution of works. 2. 33/11 KV Power Transformer: a. The power transformer shall be oil immersed, naturally air cooled (type ON), outdoors type, three phase, 50 Hz, 33/11 KV step down power transformers of 1.6 MVA (as per requirement) capacity as per the technical specification detailed at vol-II of the Bid Document shall be tested and inspected before dispatch and delivery at places as per list of sites. The Power Transformer as per technical specifications detailed in vol-II of the Bid Document is required to be installed and commissioned alongwith exercising the test checks as recommended by OEM (original equipment manufacturer). b. The metallic breathers should be provided. The alignment of breather should be vertical. Breather pipe should be cleaned for proper connection. c. Transformer neutral should be solidly grounded with two different earth connections. The transformer body should be grounded at two different locations.

d. Transformer oil should be tested for insulation resistance, sludge, and acidity and gas content checks. Results should be compiled and furnished in the o/o concerned Executive Engineer (STM) and EIC. e. Operation of Buchholz relay, OTI and WTI are to be checked with representative of Engineer in Charge. The connecting cable should be checked for healthiness. The cables are to be neatly dressed, clamped with the transformer, buried in the ground using protection covering of bricks and sand as per CPWD specifications / laid in the cable trench, provided with ferrules, provided with proper size double compression gland made of brass at entry points of control panel and marshalling box and lugged. Operation of OTI, WTI and Buchholz relay is to be checked, calibrated thereafter in association with the representative of EIC and checked for local & remote alarm and tripping. f. Cable connection / termination details, equipments details, terminal block details, tags details etc should be prepared and submitted to EIC & STM Division of CSPDCL.

1.1 Power Transformer foundation: Digging of transformer foundation i) Hard Soil excavation and digging 7.2 x 0.6 x 0.7 = 3.04 cmt ii) Black Cotton Soil - excavation and digging 2.0 x 2.0 x 2.0 = 8.0 cmt RAPDRP Part B Section 5 GCP

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1.2 Concreting of foundation: The concreting shell be provided for foundation with mix ratio of 1:3:6 of cement ,sand and metals. A total concreting of 7.7 CMT shall be provided in black cotton soil location as per drawing. A total concreting of 5.5 CMT shall be provided in hard rock/hard soil as per drawing . A masonry work with bricks 1.5x0.3x8.4=3.78 CMT shall be also provided after above concreting as per drawing A plastering with 15 mm thick bricks of size 1x2.4x4=9.6 CMT of ratio of 1:6 of cement and sand mixture shall also be provided over the above masonry work as per drawing. 1.3 Foundation of 33 kv and 11kv VCBs:The Excavation for each VCB shall be as per foundation design prescribed by manufacturer of VCB and as per their foundation drawing. The concreting for each VCB shall have a ratio of 1:3:6 of mix of cement, sand, and metals for foundation and grouting of structures and foundation bolts as per drawing. 3. Bus Bar. 3.1 Bus Bar arrangement: The Bus Bar arrangement shall be as per drawing enclosed with documents to meet the requirement of the individual sub- station and shall conform to the IEE rules. 3.2 Structures for 33 kv and 11 KV bus bar :H-Beam of lenths 8 mtr. Shall be provided for bus bar structures as per drawing. The concreting @0.45 cmt per structure is required in ratio of 1:3:6. 4. VCB: The VCBs are required to be installed at the locations listed in this bid. The CTs are also to be installed by the agency in separate/same locations in accordance with the recommendations of the breakers manufacturer. General arrangement drawings shall be submitted by the agency for Owners approval before start of work of installation of breakers. The agency shall install foundations, supporting structures and O&M platform. Required drawings shall be provided by agency for owners approval before execution of works at site. 4.1 Current Transformer : Along with the Vacuum Circuit Breakers, Current Transformers are to be provided. CTs are to be erected on suitable structure provided by the bidder. Testing and pre commissioning checks shall be conducted in accordance with OEM recommendations and as approved by the owner. Terminal components at HT as well as LT & Earthing side shall also be the part of the CT. 4.2 Control Panels: i. The panels as per the requirement of protection like feeder protection, transformer protection or incomer protection are to be provided with each breaker: ii. Panel should be erected on ISMC75 (75x40x6 mm) MS channel duly welded on MS angle inserted on indoor trench. Panels should then be properly aligned, iii. Cables should enter with double compression glands, codified, lugged, dressed iv All alarm, annunciation and trip circuits / indication & alarm circuits should be tested and made operative, v. The indication should be made operable, vi. Breaker should be remotely operated, vii. Indicating instruments should be calibrated, viii. Grounding of panel at two different locations should be provided. ix. Control relays should be calibrated and checked for tripping and closing operations. x. Pick up time / trip time and tripping at normal and reduced voltages should be checked. RAPDRP Part B Section 5 GCP

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xi.

Latching arrangement of relays should be checked for safe operation.

5. Station Battery & Charger: Station battery is to be provided at each substation. The battery connections / terminals are to be cleaned and provided with petroleum jelly. Terminals hardware is to be provided with connecting cables. The cable should be neatly dressed, clamped and wired using ferrules, tag marks, double compression glands. The new cable supplied should conform to IS: 1554 specification and must be suitable for DC utilization and having current carrying capacity 50 A current rating. Connecting cable and associated materials needed for commissioning of battery shall be treated as part of the battery. The Station battery are to be supplied with wooden racks made of Sal wood planks of thickness not less than 25mm, support legs made of size not less than 2 inches X 2 inches. The battery may be placed on two-tier formation of stand. The construction of battery rack should suit site conditions of their placement. The rack should be painted with three coat of acid proof paint of reputed make as approved by Engineer in Charge. No metal fasteners / nails should be used for construction of battery racks. The stand should be supported on insulators to obtain necessary insulation from the earth and there should be insulators between each cell and stand. The battery sets are to be provided with battery chargers as per detail specifications enclosed. Interconnecting cables and power supply cables originating / terminating at the battery charger, should be neatly dressed, clamped and wired using ferrules, tag marks, double compression glands etc as applicable. Connecting cable and associated materials needed for commissioning of charger shall be treated as part of the battery charger. The agency shall provide following equipments at all the substations: 1. Two copies of battery instruction sheet duly laminated, 2. One cell testing voltmeter 3 0 3 volts, 3. Two syringe hydrometers 4. One thermometer with specific gravity correction scale, 5. One set of suitable spanners, 6. Two acid resistant funnel, 7. One acid resisting jar of 2 liters capacity. 6. Isolator / AB Switch / Drop out Fuse: Isolator, AB switches and DO Fuses should be supplied with base steel structure, terminals bi metallic connectors / PG clamps / earth connectors. They should be checked for proper alignment and free & smooth operation. The insulators should be cleaned before commissioning. The linkage of contacts should be checked for free and adequate grip. The isolator should be checked for fully OPEN / CLOSED positions. Contact between two movable points should be checked and recorded. The contacts should be adequately lubricated before commissioning. Connection of terminal connectors shall be checked for proper tightness. Operating handle should be separately grounded. Equipments should be supplied with detail technical specifications enclosed. 7. Lightning Arrester: LAs should be supplied with base steel structure, terminals bi metallic connectors / PG clamps and earth connectors. LAs are to be connected with separate earth connection using GS flat. All LA terminals / connections are to be tightened. 8. Lighting: The substation area inside the fencing should be illuminated with flood light fittings provided with 250 Watts Sodium Vapory Lamps. Each fitting and its Junction box enclosures should be IP 55 protection type. Water and vermin proof-ness is a must. At least 4 Nos. fittings at all RAPDRP Part B Section 5 GCP

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the four corners should be provided. Acceptable make of fitting, fixtures and lamp are Philips, Crompton, Alsthom, and Bajaj only. Area light supply from Substation DB to be extended through 2X16 Sq.mm PVC insulated PVC Sheathed aluminum stranded armoured power cable laid in underground trench of nd width 300 mm wide, provided with 2 class brick protection (Approx. 10 bricks per metre length of laying) and sand protective covering (200 mm thick) and laid at the depth of 750mm minimum. Laying specification of cable shall be as detailed in CPWD specification of laying power cables. Suitable loop length of 1.5 metre to be kept at the end points. Pole mounted junction box (and not the Control Gear Box supplied with the fitting) should be made of 2mm thick CR steel sheet of size 300X450X200mm fitted with SPN terminal block of 32A capacity, 10A SPN miniature circuit breaker of ISI mark and reputed manufacture. The JB should be applied with suitable anti rusting treatment and painted with 2 or more coats of zinc oxide paint followed by 2 or more coats of enamel paint of approved make and shade. The JB should also conform to IP 55 protection for enclosure. Neoprene gasket should be used in JB. 2 Nos. earthing terminals of 10 mm dia should be provided with 25X6mm size of mounting clamps. Bidders shall get JB drawing approved before start of manufacturing. 4 Sq.mm, 1100V grade, weather proof three core (One core for phase, one core for Neutral and one core for earthing) aluminum stranded conductor PVC sheathed and PVC insulated cable conforming to IS 694 should be used for connection of fitting and its Control Gear Box from pole mounted Junction Box. Control Gear box must provide ISI approved components. Copper wound heavy chokes shall be acceptable. Tubular poles 12m high as per IS: 2713 (Latest Version) embossed with ISI certification mark and pole designation shall be used for installation of area light fixtures in Urban as well as Rural substations. Pole should be designated as 410 SP - 60. Poles and fitting structures should be painted with two coat of anti rusting bitumen paint inside and out side up to the planting depth and two coat zinc oxide paint followed by 2 or more coats of aluminum paint of approved make, brand and shade on portion of pole which will remain above ground level. 9. Station Transformer & Distribution Boxes: The Station Transformer should be commissioned with fresh Silica Jel, Breather, Cabling Network, Bimetallic Clamp, Lugs, Earthing and Lightning Arrester. Station Transformer Distribution Box (DB) is required to be provided with handles, cover, locking arrangements, fixing knobs etc. and shall be free from rust. Approved brand of red oxide paint in two coats shall be applied followed by two or more coats of approved brand and colour of enamel paint making the surface perfect finish. The DBs are required to be provided with neoprene gaskets for making them water-resistant. Entry of cables inside the box shall be through gland so that no vermin or insects may enter inside the DBs. The cables should be terminated with proper size lugs and gland. Necessary tagging, identification of cores and dressing of cables with nylon cable ties shall be in the scope of work. Locking arrangement shall be provided in all locations. 5 Lever brass Pad- Lock to be provided shall be of Godrej make and the keys shall be handed over to representatives of Engineer in Charge in writing. All materials required to perform this work shall be in the scope of agency. 10. Insulators: All supplied insulators should be clean and without cracks / chipping etc before mounting. Chipped or cracked insulators will not be acceptable. 11. AAA Conductor: The AAA conductors required for formation of bus, jumpers and interconnection of various equipments apparatus and associated accessories shall be 100 sq mm AAA DOG conductor and shall be provided with necessary hardware / strain fitting. 12. Steel structure / supports: The steel supports / structures / clamps shall to be provided with necessary hardware using following sections: ISMC 100 Channel (100x50x6 mm), RAPDRP Part B Section 5 GCP

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ISA 65x65x6 mm MS angle, 50x8 mm MS Flat Steel sections are to be fabricated in such a way that no gas cutting, gas drilling, sharp edges workmanship are found on finished items. Properly drilled holes of circular / elliptical shape, smooth edges are to be ensured. Hardware is to be used as per specifications enclosed. 13. Connections: Suitable Bi metallic clamps should be provided at bushings of the transformers and circuit breakers. Also at all those points where joining of two different materials is required, bi metallic clamps should be provided. T Clamps should be provided on each jumper on bus bars. Line jumpers should be provided with adequate size of PG Clamps (Two numbers PG Clamps at each end of jumper). Clamp should be made of aluminium grade T-1F as per IS 8309 having good electrical quality aluminum material and should not be brittle in nature. Suitable PG clamps should be provided on the jumpers of bus bar wherever it is required. 14. Cabling: The control cables between outdoor breaker panel and indoor control panel, transformer marshalling box and breaker indoor / out door control panels etc shall be provided and laid in the open trenches. Trenches are to be provided by the agency. The cable inside control room shall be laid in existing concrete trench. Cables shall be properly tagged, bunched and tied using cable ties inside trench. At the entry point of trench in control room, proper sealing arrangement should be provided so as to stop entry of reptiles and rain water inside control room through trench. 15. Labeling: All the equipments and circuits should be labeled using yellow base and black indication marks (number or name). 40 / 50 mm height digits / words should be used for this purpose. Colour coding of phases at breaker, bus and transformer and feeder end should be marked with colour circles. Sample should be approved by EIC before execution. Painting and marking of digits etc should be performed by a skilled / trained painter. Labeling of following informations is intended by the owner preferably in local HINDI language: Transformer capacity and designated name like T - 1 or T 2, VCB designated name Identification of CT & PT Colour coding of bus bars, transformer terminals, feeders phases, Name of feeder Warning instruction, if any, of availability of two sources of HT supply on same structure. 16. Earthing of Sub Station :Earthing work is to be executed on all the substations. Earthing should be provided with GI earth pipe, GS solid rod 25 mm dia and 50X6 mm GS flat forming earth grid and riser along with GI wires / Stay wires as per requirement of Engineer. Engineer shall approve arrangement of earthing network. Following arrangement envisaged for grid/earth rod/ earth pipe: (Indicative drawing is enclosed with the document) Description of equipment Earth Pit 3 m long, 40 mm dia Earth rod GS solid 25 mm dia Semi Urban / Rural Substation 3 Nos. 19 Nos. RAPDRP Part B Section 5 GCP Urban Substation 3 Nos. 16 Nos.

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Earth mat Laying of earth mat

50X6 mm GS Flat 50X6 mm GS Flat Below ground 0.5 meter

Standard requirements / provisions of earthing of CSPDCL are enclosed herewith. Connections of earth-grid / earth pit with Lightning Arrester and Power Transformer Neutral and Transformer body (at two distinct points) are to be made using 50X6mm GS flat. Connections of other equipments may be provided with 8 SWG GI wire or GI Stay wire as per approval of Engineer in charge. Following arrangements are envisaged for earth connection: Power Transformer Neutral(Two distinct connections) Transformer Body Breaker body / legs (Two distinct connections) Lightning Arrester Station transformer Neutral (Two distinct connections) Fencing Control Panels (Two distinct connections) Isolator handle Steel structure of substation Line meters GS Flat GI Stay wire GS Flat GI wire GI Stay wire GI wire GI flat GI wire GS Flat GS wire

Fencing and gate should be grounded. Moving portion of gate should be grounded with flexible braided conductors of equivalent aluminum 25 Sq.mm size of conductors duly lugged and bolted. Substation wise measurement of earth resistance of earth pits/mesh and corresponding drawing of existing earthing arrangement shall be recorded and submitted by the agency. 17. Painting of Over head structures: RS joist, tubular pole, fencing, main gate etc shall be done as under: De-rusting shall be performed using wire brush, emery paper etc. The surface shall be cleaned and painted with two or more coats of red oxide zinc chromate primer paint using painting brush. On smooth surface finish, two or more coats of aluminium paints using painting brush shall be applied till final smooth surface finish and even shade on surface appears. 17.1 Enclosure boxes / panels: The Engineer in Charge shall approve the make of paint. It shall be reputed make and shade. The brush shall only be used for painting. The quality of painting shall be examined at the time of final handing over of installation and also at the time of completion of defect. In event of detoriation of paint, the surface cleaning and re painting shall be performed by the agency without any extra cost. After application of two or more coats of red oxide zinc chromate paint, the installation shall be offered to owner for clearance to apply final finish paint either aluminium paint or synthetic enamel paint. 18. Metering equipments and Line Meters: 33 KV metering units (combined CT & PT unit) for incoming and outgoing 33 KV feeder and 11 KV metering units (combined CT & PT unit) on all outgoing 11 KV feeders are to be installed along with electronic meters on the substation structures in the substation to record line parameters of 33 KV and 11 KV incomer as well out going feeders. These meters are to be installed inside the control room. The work shall involve provision and installation of metering unit on substation structure (out side) and meter box and meters in control room, laying, tagging and tagging of control cables. Meters shall be commissioned in associations with representative of EIC. The installation details needs to be submitted by the agency for approval of owner before start of work. 19. SITE TESTING AND PRE COMMISSIONING CHECKS: RAPDRP Part B Section 5 GCP

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An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the Field Quality Plan/ instructions of the equipments manufacturer or owner without any extra cost to the Owner. The Contractor shall arrange all instruments required for conducting these tests alongwith calibration certificates and shall furnish the list of instruments to the Owner for approval. Detail test certificates duly signed by CSPDCL representative & agency representative of tests jointly carried out at site before putting the equipments in use, shall be submitted by the contractor in three copies as per following distribution: A. O/o the STM, Circle headquarters, B. O/o the Executive Engineer (O&M), c. Concern Substation 19.1 GENERAL CHECKS:

Check for physical damages. Visual examination of zinc coating/ planting. Check from name plate that all items are as per order/ specification. Check tightness of all bolts, clamp and connecting terminals using torque wrenches. For oil filled equipments check for oil leakage, if any. Also check oil level and top up. Check ground connections for quality of weld and application of zinc rich paint over weld joint of galvanized surfaces. Check cleanliness of insulator and bushings. All checks and tests specified by the manufacturers in their drawings and manuals as well as tests specified in the relevant code of erection. 19.2 CIRCUIT BREAKERS:

Insulation resistance of each pole. Check adjustment, if any, suggested by manufacturer. Breaker closing and tripping time. Slow and power closing operation and opening. Trip free and anti pumping operation. Minimum pick up volts of coils Contact resistance. Functional checking of all accessories. Functional checking of control circuits, interlocks, tripping through protective relays and autoreclose operation. Insulation resistance of control circuits, motor etc. Resistance of closing and tripping coils. 19.3 ISOLATORS:

Insulation resistance of each pole. Manual and electrical operation on interlocks. Insulation resistance of control circuit and motors. Ground connections Contact resistance Proper alignment to minimize the vibration to the extreme possible during operation. Measurement of operating torque for isolator and earth switch Resistance of operating and interlocking coils. 19.4 CURRENT TRSFORMERS:

Insulation Resistance Test Polarity test. Ratio identification test-checking of all ratios on all cores by primary injection of current. Dielectric test of oil Magnetizing characteristics test. 19.5 VOLTAGE TRANSFORMERS RAPDRP Part B Section 5 GCP

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Insulation resistance test Polarity test. Ratio test Dielectric test of oil 19.6 SURGE ARRESTER

Grading leakage current Resistance of ground connection 19.7 PHASING OUT

The phasing out of all supplies in the Sub station system shall be carried out. 19.8 STATION EARTHING

Check soil Resistively Check continuity of grid wires Check earth resistance of the entire grid as well as various sections of the same. Check for weld joint and application of zinc rich paint on galvanised surface. Dip test on earth conductor prior to use. 19.9 CONDUCTOR STRINGING AND POWER CONNCTORS Physical check for finish Electrical clearance check Testing of torque by torque wrenches on all bus power connectors and other accessories. Milli volt drop test on all power connectors Sag and tension check on conductors. 19.10 INSULATORS Visual examination for finish damage, creepage distance, etc.

20.
20.1

CIVIL WORKS AND SOIL INVESTIGATION GENERAL The provisions of this section of specification shall only be applicable to the extent of scope of works indicated in Bid Proposal Sheet (BPS). The intent of specification covers the following: Design, engineering, and construction of all civil works at sub-station. All civil works shall also satisfy the general technical requirements specified in other Sections 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. 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. 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. 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. RAPDRP Part B Section 5 GCP

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In case of R&M of existing substations, Contactor shall visit site to ascertain the amount of repair and strengthening of structures and foundations, dismantling and new construction of structures and foundations works are to be done before quoting. Contractor must furnish the design and drawings in support of the activities mentioned above that are to be carried out in the R&M of existing substation site. However, the Contractor shall quote according to the complete requirements. 20.2 GEOTECHNICAL INVESTIGATION

20.2.1 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.So 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 Owners specific approval giving details regarding data proposed to be utilised for civil structures design. 20.2.2 The Contractor should visit the site to ascertain the soil parameters before submitting the bid. The topography is uneven steeply sloping at few places requiring cutting and filling operations including slope stability and protection measures (if slopes encountered). Any variation in soil data shall not constitute a valid reason for any additional cost & shall not affect the terms & condition of the Contract. Tests must be conducted under all the critical locations i.e. Control Room Building. Tower locations, transformer etc. 20.3 SCOPE OF WORK This specification covers all the work required for detailed soil investigation and preparation of a detailed report. The work shall include mobilisation 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 Geotechnical 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. 20.3.1 Bore Holes Drilling of bore holes of 150 mm dia. in accordance with the provisions of IS: upto 10 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). For a new substation, minimum three (3) bore holes shall be done to find out the geological profile of the area. If any unconformity encountered then more bore holes shall be drilled with the approval of Engineer-in-charge for the new projects. However in case deep pile foundations are envisaged the depths have to be regulated as per codal provisions. In cases where rock is encountered, coring in one borehole per bay shall be carried out to 1.5 M in bedrock and continuous core recovery is achieved. Performing Standard Penetration Tests at approximately 1.5 m interval in the borehole 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.

RAPDRP Part B Section 5 GCP

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Collecting undisturbed 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 Contractors 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 bore log shall be handed over to the Engineer-in-charge. 20.3.2 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 resistivity test, the test procedure, and reporting of field observations shall confirm to IS: 3043. The test shall be conducted using Wagners 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 coordinate 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 upto a distance of 10.0 m. 20.3.3 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. 20.3.4 Back Filling of Bore Holes On completion of each hole, the Contractor shall backfill all bore holes as directed by the Owner. The backfill material can be the excavated material and shall be compacted properly. 20.3.5 Laboratory Test 1. The laboratory tests shall be carried out progressively during the field work after sufficient number of samples have reached the laboratory in order that the test results of the initial bore holes 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 a) b) c) d) Visual and Engineering Classification Liquid limit, plastic limit and shrinkage limit for C- soils. Natural moisture content, bulk density and specific gravity. Grain size distribution.

2.

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e) f) g)

Swell pressure and free swell index determination for expensive soil only. Consolidated un-drained test with pore pressure measurement. Chemical tests on soil and water to determine the carbonates, sulphates, nitrates, chlorides, Ph value, and organic matter and any other chemical harmful to the concrete foundation. C.B.R value Rock quality designation (RQD), RMR in case of rock is encountered

h) i)

20.3.6 Test Results and Reports 20.3.6.1 The Contractor shall submit the detailed report in two (2) copies wherein information regarding the geological detail of the site, summarised 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 two (3) copies shall be submitted. The test data shall bear the signatures of the Investigation Agency, Vendor and also site representative of CSPDCL.

20.3.6.2. a)

The report shall include but not limited to the following: A plan showing the locations of the exploration work i.e. bore holes, dynamic cone penetration tests 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 summarised 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.

b)

20.3.7 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: a) 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. RAPDRP Part B Section 5 GCP

b)

c)

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d)

Recommendations regarding slope of excavations and dewatering schemes, if required. Required protection measures for slope stability for cut & 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 effects of the same on concrete and steel and recommendations for protective measures. If expansive soil is met with, recommendations on removal or retaining the same under the structure, road, drains, etc. shall be given. In the latter 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.

e)

f)

g)

20.4

SITE PREPARATION The contractor shall be responsible for proper leveling of switchyard site as per layout and levels of switchyard finalised 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 personnel 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. If HFL is not available, then nearby road level shall be assumed as HFL. Whenever for bay extension works the existing substation are to be modified or strengthen, contractor should keep same as EGL of existing sub-station so that FFL shall be same for both and all the necessary arrangements are to be carried out in this regard by the contractor.

20.5

SCOPE OF WORKS This clause covers the design and execution of the work for site preparation, such as clearing of the site, the 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 brick soling/stone filling.

20.5.1

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. Contractor shall also carry out necessary protection of slope of switchyard area and approach road. The fill material if required shall be suitable for the above requirement. The fill shall be such 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. Material unsuitable for founding of foundations shall be removed and replaced by suitable fill material and to be approved by the Owner. Backfill material around foundations or other works shall be suitable for the purpose for which it is used and compacted to the density described under RAPDRP Part B Section 5 GCP

2)

3) 4)

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Compaction. Excavated material not suitable or not required for backfill shall be disposed off in areas as directed by owner upto a maximum lead of 1 km. 20.5.2 Excavation and backfill 1. 2. Excavation and backfill for foundations shall be in accordance with the relevant code. Whenever water table is met during the excavation, it shall be dewatered and water table shall be maintained below the bottom of the excavation level during excavation, concreting and backfilling. 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. Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be constructed by compacting the material in successive uniform horizontal layers not exceeding 20 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. 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. The land required for borrowing earth shall be arranged & selected by contractor. The identified land shall be got approved by site in charge. The quoted rates shall include cost of earth, taxes, duties, royalty, compensation for the land identified for borrow earth. The rate shall also be inclusive of all leads, lifts, ascent, descent and testing required for completion of work in all respect. The ground levels for all measurements shall be taken at every 5 meter distance in uniformly sloping ground and at closer distance where pits/undulations are met with. In fairly leveled area, levels shall be taken at 15 mt. apart at the discretion of Engineer in Charge. The ground levels shall be recorded and plotted on plans. The same is signed by the contractor and the Engineer in Charge before the earth work is started. All labor, material, tool, equipment etc required for the above work shall be arranged by the contractor at his own cost.

3.

4.

5.

6.

7.

20.5.3 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 Proctors density at OMC. The su b-grade for the roads and embankment filling shall be compacted to minimum 95% of the Standard Proctors density at OMC. Cohesion less material sub grade shall be compacted to 70% relative density (minimum). 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. 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. RAPDRP Part B Section 5 GCP

2.

3.

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Rolling will also be required on rock fills. No compaction shall be carried out in rainy weather. 20.5.4 Requirement for fill material under foundation All foundations shall rest below virgin ground level and the minimum depth of foundation below the virgin ground level shall be at least 500 mm. For small equipment and minor foundations like marshalling kiosk, Switch board stand, earth switch and main box support etc. may be reduced to 300 mm with specific approval of the owner. 20.6 STONE FILLING 20.6.1 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 filling shall be done in the areas of the switchyard wherever equipments and or structures are to be provided under present scope of work covering entire fencing area. Prevailing practice of stone filling is to be adopted for the bay extension works of existing substations. Contractor shall verify the existing practice prevailing at site before quoting. 20.7 GENERAL REQUIREMENT 20.7.1 The material required for site surfacing 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 (single sized) conforming to table 2 of IS: 3831970. Hardness, flakiness shall be as required for wearing courses are given below. (a) Sieve analysis limits/Gradation Sieve size % passing by weight 40mm 20mm 10mm 4.75mm 100 85-100 0-20 0-5

(b) Hardness Abrasion value (IS: 2386 part-IV) not more than 40% Impact value (IS: 2386 part-IV) not more than 30% (c) Flakiness Index As per (IS: 2386 part-IV) and maximum value is 25. 20.7.2 After all the structures/equipments are erected, the surface of the switchyard area shall be maintained, rolled/compacted to the lines and grades as decided by Engineer-in-Charge. De-weeding including removal of roots shall be done before rolling is commenced. Engineer-in-Charge shall decide final formation level so as to ensure that the site appears uniform. 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. 20.7.3 A base layer of uncrushed/crushed/broken stone of 20 mm nominal size (single sized) shall be spread and rolled/compacted by using half ton roller with 4 to 5 passes and water sprinkling to form a minimum 50 mm layer on the finished ground level of the specified switchyard area excluding roads, drains, cable trench and tower and equipment foundations as indicated in the drawing. 20.7.4 Over the base layer of site surfacing material, a final surface course of minimum 50 mm thickness of 20 mm nominal size (single sized) broken stone as specified above shall be RAPDRP Part B Section 5 GCP

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spread and compacted by light roller using half tones steel roller (width 30" and 24" dia meter) with water sprinkling as directed by the Engineer-in-Charge. The water shall be sprinkled in such a way that bulking does not take place. 20.7.5 In areas that are considered by the Engineer-in-Charge 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.

20.8

SITE DRAINAGE 1. Adequate site drainage system shall be provided by the Contractor in new and existing substation. In case of bay extension of existing substation, drainage layout shall be prepared by the contractor in such away that it should satisfy the technical parameters stated below while designing the drainage system so that flow of water of the existing part of substation remain uninterrupted and the same should be approved by the owner. The technical parameters stated below also to be taken into account while designing the drainage system for new substation as well. The Contractor shall obtain rainfall data and design the storm water drainage system, (culverts, ditches, drains etc.) to accommodate run off due to the most intense rainfall that is likely to occur over the catchments area in one hour period on an average of once in ten years. The surface of the site shall be sloped to prevent the ponding of water. 2. The maximum velocity for pipe drains and open drains shall be limited to 2.4m/sec and 1.8m/sec respectively. However, minimum non-silting velocity of 0.6m/sec shall be ensured. Longitudinal bed slope shall not be milder than 1 in 1000. 3. The drains shall be constructed using Brick masonry except at road crossings etc. where RCC pipe shall be used. The RCC pipe for drains and culverts shall be as per IS:456 and IS:783. 4. The Contractor shall ensure that water drains are away from the site area and shall prevent damage to adjacent property by this water. Adequate protection shall be given to site surfaces, roads, ditches, culverts, etc. to prevent erosion of material by water. 5. The drainage system shall be adequate without the use of cable/pipe trenches. (Pipe drains shall be provided in areas of switchyard where movement of crane will be necessary in operating phase of the substation). 6. For pipe drains, concrete pipe of class NP2 shall be used. However, for road crossings etc. higher strength pipe of class NP3 shall be provided. For rail crossings, pipes conforming to railway loading standards or at least NP4 class shall be provided. Manholes shall be provided at every 30m interval, at connection points and at every change of alignment. 7. Open surface drains for new s/s shall be provided with brick masonry in 1:6 (1 cement: 6 coarse sand) cement mortar with 12 mm thick, 1:4 (1 cement: 4 sand) cement plaster inside and exposed surface of drains as per approved drawing. For bay extension at existing substations, prevailing practice of the respective substation shall be adopted. 8. Pipe drains shall be connected through manholes at an interval of max. 30m. Effluents shall be suitably treated by the Contractor to meet all the prevalent statutory requirements and local pollution control norms and treated effluents shall be conveyed to the storm water drainage system at a suitable location for its final disposal. 9. Invert of the drainage system shall be decided in such a way that the water can easily be discharged above the High Flood Level (HFL) outside substation boundary at suitable location upto a maximum 50M beyond boundary wall of substation or actual whichever occurs earlier and approved by Owner. RAPDRP Part B Section 5 GCP

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10.All internal site drainage system, including the final connection/disposal to owner acceptance points shall be part of Suppliers scope including all required civil works. The Contractor shall connect his drain(s) at one or more points to outfall points as feasible at site. 11.The drainage scheme and associated drawings shall be got approved and constructed as per enclosed drawing no.C/DMS/005-Rev-0. . 20.9 ROADS AND CULVERTS 1.The main approach road including modification of existing road to meet the site conditions, roads for access to equipment and buildings with in substations (including bay extension in existing substations) are in the scope of bidder. Layout of the roads shall be based on General detail & Arrangement drawing for the substation. If extra road is required for functional point of view, which has not been mentioned in the layout drawing, Contractor should provide the same with out extra cost to the owner. 2.All substation roads shall be constructed so as to permit transportation of all heavy equipment. The roads shall have min. 3.0 m wide RCC road as per enclosed drawing no.C/DMS/005-Rev-0. 3.Road construction shall be as per IRC standards. 4.Adequate provision shall be made for road drainage. Protection of cut and embankment slopes of roads as per slope stability requirement shall be made. 5.All the culverts and its allied structure (required for road/rail, drain trench crossings etc.) shall be designed for class A loading as per IRC standard / IS code and should be checked for loading. 6.All roads shall be designed for class D of traffic as per IRC -37 Guide-lines for the design of rigid pavements.

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20.10

TRANSFORMER FOUNDATION The Contractor shall provide a road system integrated with the transformer foundation to enable installation and the replacement of any failed unit by the spare unit located at the site. This system shall enable the removal of any failed unit from its foundation to the nearest road. If existing/failed transformer is required to be replaced by new one in augmentation/bay extension works of existing substations then the foundation supporting that equipment shall be strengthen by modifying the foundation itself or the foundation shall be dismantle and recast new foundation as per site conditions. However, contractor must furnish the design calculation incorporating all those changes so that safety of the structure and foundation remain adequate. Similarly all types of equipment foundations with /without supporting structures shall be treated in similar manner as stated for transformer foundations. Contractor must access the amount of work involve for augmentation/bay extension of existing substations while quoting.

20.11 CABLE & PIPE TRENCHES 1. The cable trenches and precast removable RCC cover (with lifting arrangement) shall be constructed using RCC of M20 grade for new substation whereas for bay extension of existing substation size and material of cable trenches shall be same as the existing one and pre-cast removable RCC cover (with lifting arrangement) shall be constructed using RCC of M20 grade. Cable trenches must be designed for the design criteria stated below, whether it is of concrete or brick for both new substations and bay extension works in existing substations. The cable trench walls shall be designed for the following loads. (i) (ii) 3. 4. 5. 6. Dead load of 100 kg/m length of cable support + 75 Kg on one tier at the end. Triangular earth pressure + uniform surcharge pressure of 1T/m2.

2.

Cable trench covers shall be designed for self-weight of top slab + concentrated load of 200 kg at centre of span on each panel. Cable trench crossing the road/rails shall be designed for class A. 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 for the new substation. The top of cable trench shall be such that the surface rainwater does not enter the trench. The top of trench shall be kept same as existing one to maintain uniformity of the cable trenches structure in case of bay extension works of existing substations.

7. 8. 9.

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.

10. The trench bed shall have a slope of 1/500 along the run & 1/250 perpendicular to the run. 11. Cable trenches shall be blocked at the ends if required with brick masonry in cement sand mortar 1:6 and plaster with 12mm thick 1:6 cement sand mortar. 12. Cable trench contains cable trey that shall be supported on ISA. The size and spacing of angle section shall be as per design criteria mentioned above. RAPDRP Part B Section 5 GCP

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13. Cable trench shall be constructed as per enclosed drawing no.C/DMS/002-Rev-0. .

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20.12

FOUNDATION /RCC CONSTRUCTION 1. Work covered under this Clause of the Specification comprises the design and construction of foundations and other RCC constructions for switchyard structures, equipment supports, trenches, drains, control cubicles, bus supports, transformer, marshalling kiosks, auxiliary equipments & 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 RCC constructions. However, for the augmentation/bay extension works of existing substation, type of RCC structures and foundations etc. shall be similar to one already existing at the existing substation and for which design shall be furnished in support of safety of those RCC structures and foundations etc. Contractor must access the amount of work involved for the construction of switchyard structures, equipment supports, trenches, drains, control cubicles, bus supports, transformer, marshalling kiosks, auxiliary equipments & systems, buildings, tanks, boundary wall or for any other equipment or service and any other foundation required to complete the work for the existing substations. 2. Concrete shall conform to the requirements mentioned in IS: 456 and all the tests shall be conducted as per relevant Indian Standard Codes as mentioned in Standard field quality plan appended with the specification A minimum grade for PCC and RCC shall be used for all structural/load-bearing members as per latest IS 456. 3. 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. 4. The switchyard foundations plinths and building plinths shall be minimum 300mm and 500 mm above finished ground level respectively. 5. Minimum 75mm thick lean concrete shall be provided below all underground structures, foundations, trenches etc. to provide a base for construction. 6. 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. 7. 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. 8. If pile foundations are adopted, the same shall be cast-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.

20.12.1 General

20.12.2 Design 1. Foundations shall be of reinforced cement concrete for new substation but for the augmentation / bay extension works of existing substation it could be of RCC/ PCC depending on type of structures and materials used for the similar type of structures in those bay extension works of existing substation. Design requirement shall be fulfilled by the contractor and furnished for approval for both new substation and existing substation (for bay extension works) as specified in the scope of work. The design and construction of RCC/ PCC / Masonry structures shall be carried out as per IS: 456 and relevant IS code/CBIP manual/NBC etc and minimum grade of RAPDRP Part B Section 5 GCP

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concrete shall be as per relevant IS code. Higher grade of concrete than specified above may be used at the discretion of Contractor without any additional financial implication to the Owner. 2. Limit state method of design shall be adopted unless specified otherwise in the specification. 3. For detailing of reinforcement IS: 2502 and SP: 34 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 & slab sections having thickness more than 150 mm. Clear cover to reinforcement towards the earth face shall be minimum 40 mm. 4. RCC water retaining structures like storage tanks, etc. shall be designed as uncracked section in accordance with IS: 3370 (Part I to IV) by working stress method. However, water channels shall be designed as cracked section with limited steel stresses as per IS: 3370 (Part I to IV) by working stress method. 5. 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 or isolated /combined footings proposed to be used. 6. Design shall consider any sub-soil water pressure that may be encountered following relevant standard strictly. 7. 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/masonry foundations. 8. RCC columns /pedestals shall be provided with rigid connection at the base. 9. 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. 10. 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).

11. In addition to earth pressure and ground water pressure etc., a surcharge load of 1T/Sq.m shall also be considered for the design of all underground structures including channels, sumps, tanks, trenches, substructure of any underground hollow enclosure etc., for the vehicular traffic in the vicinity of the structure. 12. 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 & ground water pressure & surcharge pressure from outside (application only to structures, which are liable to be filled up with water or any other liquid). Full earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside. 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.

b) c)

13. 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. RAPDRP Part B Section 5 GCP

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14. The foundations of transformer and circuit breaker shall be of block type foundation. Minimum reinforcement shall be governed by IS: 2974 and IS: 456. 15. The tower and equipment foundations shall be checked for a factor of safety of 2.0 for normal condition and 1.5 for short circuit condition against sliding, overturning and pullout. 20.12.3 Admixtures & additives 1. 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. 2. Admixtures in concrete shall conform to IS: 9103. The water proofing cement additives shall conform to IS: 2645. Owner shall approve concrete Admixtures/ Additives. 3. The Contractor may propose and the Owner may approve the use of a waterreducing 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. 4. The water-reducing set-retarding admixture shall be an approved brand of Lignosulphonate type admixture. 5. 20.13 The waterproofing cement additives shall be used as required / advised by the Owner.

GATES AND BOUNDARY WALL 1. The Gate frame shall be made of medium duty MS pipe conforming to relevant IS with welded joints. 2. The gates shall be fabricated with welded joints to achieve rigid connections. The gate frames shall be painted with one coat of approved steel primmer and two coats of synthetic enamel paint. 3. Gates shall be fitted with approved quality iron hinges, latch and latch catch. Latch and latch catch shall be suitable for attachment and operation of pad lock from either side of gates. Hinges shall permit gates to swing through 180 degree back against fence. Gates shall be earthed by G I wire. 4. Gates shall be fitted with galvanized chain hook or gate hold back to hold gates open. Double gates shall be fitted with centre rest and drop bolt to secure gates in closed position. 5. Gates shall be installed in locations shown on drawings. Next to the main gate, a men gate (1.25 m wide, single leaf) shall also be provided. 6. Bottom of gates shall be set approximately 40mm above ground surface and necessary guiding mechanism shall be fitted. 7. The Contractor shall design and construct boundary wall around substation area as per requirements. The boundary wall shall be of height 2.0M and shall be made of RCC frame construction with RCC column and plinth beam arrangement and panels filled with one brick thick wall in cement sand mortar 1:6. The boundary wall shall be plastered on both external and internal faces with cement and sand plaster 1:6 of thickness 18 mm and 12 mm respectively. An additional barbed Y-shaped arm of MS angle 50x50x6 with 3-rows (6 nos) barbed wire A-4 IS: 278. Expansion joints shall be provided as per codal requirements. MS grating shall be provided at required locations for drainage purposes. The boundary wall shall be painted with minimum two coats of color wash over a base coat of white wash with lime. The front portion of boundary wall shall however be with a RC jail and 12 mm square MS bar top above brick work and pebble dash plaster finish with colour pigment. The steel work shall be given two coats of synthetic enamel paint of approved make over one coat of primer. Boundry wall and gate shall be constructed as per enclosed Drawing no. C/DMD/003-Rev-0 RAPDRP Part B Section 5 GCP

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RAPDRP Part B Section 5 GCP

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20.14

BUILDINGS - GENERAL REQUIREMENTS

20.14.1 General The scope for new control room building includes the design, engineering and construction including anti-termite treatment, plinth protection, DPC of Building including sanitary, water supply, electrification, false ceiling etc. of control room building. The buildings shall be of RCC framed structure of concrete of M20 grade (Min.). Following design criteria shall be adopted for design purposes for new substation. If any extension of the Control Room building is required in augmentation / bay extension works of existing substation then extension part shall be compatible to existing one structurally and architecturally but following design criteria shall be adopted for design purposes for R&M of existing substation. 20.14.2Control room Building Minimum floor area requirements shall be 12x10 sq. mts. which may be increased at the time of detailed engineering to suit project requirements. The layout of the control room shall be finalised as per detailed engineering to suit project requirements .The minimum dimension of different rooms required for C.R.building shall be as per drawing. The CR building shall consist of the following: Control room S/s In-charge room Battery room Storeroom Toilet Portico An open space of 1 m minimum shall be provided on the periphery of the rows of panel and equipment generally in order to allow easy operator movement and access as well as maintenance. Any future possibility of annexe building shall be taken care of while finalizing the layout of the control room building. Minimum headroom of 3 M below soffit of beams/false ceiling shall be considered for rooms. The roof shall have four side sloping roof or flat roof as finalised during detailed engineering. 20.14.2.1 Design a) The buildings shall be designed: 1. 2. 3. To the requirements of the National Building Code of India, and the standards quoted therein. For the specified climatic & loading conditions. To adequately suit the requirements of the equipment and apparatus contained in the buildings and in all respects to be compatible with the intended use and occupancy. With a functional and economical space arrangement. For a life expectancy of structure, systems and components not less than that of the equipment, which is contained in the building, provided regular maintenance is carried out. RAPDRP Part B Section 5 GCP

4. 5.

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6. 7.

Be aesthetically pleasing. Different buildings shall show a uniformity and consistency in architectural design. To allow for easy access to equipment and maintenance of the equipment. With, wherever required, fire retarding materials for walls, ceilings and doors, which would prevent supporting or spreading of fire. Suitable expansion joints shall be provided in the longitudinal direction wherever necessary with provision of twin columns. Individual members of the buildings frame shall be designed for the worst combination of forces such as bending moment, axial force, shear force, torsion etc. Permissible stresses for different load combinations shall be taken as per relevant IS Codes. The building lighting shall be designed in accordance with the requirements of relevant section.

8. 9. 10.

11. 12.

20.14.2.2 Design loads Building structures shall be designed for the most critical combinations of dead loads, super- imposed loads, equipment loads, crane load, wind loads, seismic loads, and temperature loads. Dead loads shall include the weight of structures complete with finishes, fixtures and partitions and should be taken as per IS: 1911. Super-imposed loads in different areas shall include live loads, minor equipment loads, cable trays, small pipe racks/hangers and erection, operation and maintenance loads. Equipment loads shall constitute, if applicable, all load of equipments to be supported on the building frame. The wind loads shall be computed as per IS 875, Seismic Coefficient method shall be used for the seismic analysis as per IS 1893 with importance factor 1.5. Wind and Seismic forces shall not be considered to act simultaneously. Floors/slabs shall be designed to carry loads imposed by equipment, cables piping, equipment and other loads associated with building. Floors shall be designed for live loads as per relevant IS. Cable and piping loads shall also be considered additionally for floors where these loads are expected. For consideration of loads on structures, IS: 875 shall strictly adhere to. Any other load coming in the structure, not mentioned in IS 875 shall be calculated as per relevant IS code and NBC. 20.14.2.3 Submission The following information shall be submitted for review and approval to the Owner: 1. Design criteria shall comprise the codes and standards used, applicable climatic data including wind loads, earthquake factors maximum and minimum temperatures applicable to the building locations, assumptions of dead and live loads, including equipment loads, impact factors, safety factors and other relevant information. Structural design calculations and drawing (including construction/fabrication) for all reinforced concrete and structural steel structures. Fully, dimensioned concept plan including floor plans, cross sections, longitudinal sections, elevations and perspective view of each building. These drawings shall be drawn at a scale not smaller than 1:75 and shall identify the major building components. Fully dimensioned drawings showing details and sections drawn to scales of sufficient size to clearly show sizes and configuration of the building components and the relationship between them. RAPDRP Part B Section 5 GCP

2. 3.

4.

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5. 6. 7.

Product information of building components and materials, including walls partitions flooring ceiling, roofing, door and windows and building finishes. A detailed schedule of building finishes including colour schemes. A door & window schedule showing door types and locations, door lock sets and latch sets and other door hardware.

Approval of the above information shall be obtained before ordering materials or starting fabrication or construction as applicable. 20.14.2.4 Finish Schedule (a) The finishing schedule is given in subsequent clauses. (b) M.S. Ladder should be provided to access the control room roof from outside. Ladder shall be made up of ISMC 75x40 which will run as beam one meter apart and intermediate steps will be made up of 45x45x5 angle with rise of 300 mm. Red oxide premier shall be applied initially, then two coats of rich zinc paint shall be applied to avoid corrosion. 20.14.2.5 Flooring Flooring in various rooms of control room building shall be as for detailed schedules given in Table -1 20.14.2.6 Walls Control room buildings shall be of framed superstructure. All walls shall be non-load bearing walls. Min. thickness of external walls shall be 230 mm (one brick) with 1:6 cement sand mortar. 20.14.2.7 Plastering All internal walls shall have minimum 12mm and 15 mm thick 1:6 cement sand plaster on either side of wall. The ceiling shall have 6mm thick 1:4 cement sand plaster. 20.14.2.8 Finishing All external surfaces shall have 18 mm cement plaster in two coats, under layer 12 mm thick cement plaster 1:5 and finished with a top layer 6 mm thick cement plaster 1:6 (DSR 13.19) with water proofing compound. The paint shall be antifungal quality of reputed brand suitable for masonry surfaces for high rainfall zone. White cement primer shall be used as per manufacturers recommendation. Internal finish Schedule is given Table - 1 below: Sl.No . 1. Location Flooring & Skirting 150mm high Precast Terrazo tiles (DSR02, item no. 11.29A.2 & 11.31.2 TABLE-1 Wall Internal Ceiling Doors, Windows, Ventilators 1) Standard steel rolled section frames with 5 mm glass. DSR02 10.12, 10.13 & 10.14 2) Flush door shutters - DSR02 9.25.2 White Wash (DSR02 13.70.1) 1) Standard steel rolled section frames with 5 mm glass. DSR02 10.12, 10.13 & 10.14 2) Flush door shutters - DSR02 9.25.2 1) Standard steel rolled section frames

Control Room, Relay Room

2.

Sub-station Incharge, Office, corridor, staff room.

Precast Terrazo tiles (DSR02, item no. 11.29A.2 & 11.31.2

3.

Battery room

Acid and Alkali

Oil bound washable distemper on smooth surface applied with 2mm thick Plaster of Paris putty. (DSR02 13.40 A & 13.77.2) Oil bound washable distemper on smooth surface applied with POP putty. (DSR02 13.40 A & 13.77.2) Dado of acid resistant tile 1.2 M RAPDRP Part B Section 5 GCP

White Wash (DSR02 13.70.1)

Acid resistant

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Sl.No .

Location

Flooring & Skirting 150mm high Resistant tiles. DSR02 11.36 C. 1 & 11.36 C.1.1

Wall Internal

Ceiling

Doors, Windows, Ventilators with 5 mm glass. DSR02 10.12, 10.13 & 10.14 2) Flush door shutters - DSR02 9.25.2 Painted with acid resistant Paint. DSR02 13.96.1 1) Standard steel rolled section frames with 5 mm glass. DSR02 10.12, 10.13 & 10.14 2) Flush door shutters - DSR02 9.25.2

high & Paint above 1.2 M to ceiling. DSR02 11.36 C. 2.1, 11.36C.2 & 13.96.1

Paint. DSR02 13.96.1

4.

Toilet

Ceramic glazed tiles in flooring DSR02 11.74

DADO glazed tile 2.1M high for toilet (DSR 02 11.73)

White Wash (DSR02 13.70.1)

5.

Other areas not specified

Terrazo tiles (DSR02 11.29A.2 & 11.31.20

Oil bound distemper, DSR02 - 13.40A & 13.77

White Wash (DSR02 13.70.1)

Note: DSR item references (DSR-2002) to be read with CPWD specifications are only for material and workmanship guidance of the Contractors. 20.14.2.9 Roof Roof of the C.R. Building shall consist of Cast-in-situ RCC slab treated with a water proofing system which shall be an integral cement based treatment conforming to CPWD specification (item no. 25.8 of DSR 2002). The water proofing treatment shall be of following operations: (a) Applying and grouting a slurry coat of neat cement using 2.75 kg/m 2 of cement admixed with proprietary water proofing compounds conforming to IS: 2645 over the RCC slab including cleaning the surface before treatment. (b) Laying cement concrete using broken bricks/brick bats 25mm to 100mm size with 50% of cement mortar 1:5 (1 cement: 5 coarse sand) admixed with proprietary water proofing compound conforming to IS: 2645 over 20mm thick layer of cement mortar of min 1:5 (Cement: 5 coarse sand) admixed with proprietary water proofing compound conforming to IS: 2645 to required slope and treating similarly the adjoining walls upto 300mm height including rounding of junctions of walls and slabs. (c) After two days of proper curing applying a second coat of cement slurry admixed with proprietary water proofing compound conforming to IS: 2645. (d) Finishing the surface with 20mm thick joint less cement mortar of mix 1:4 (1 cement: 4 course sand) admixed with proprietary water proofing compound conforming to IS: 2645 and finally finishing the surface with trowel with neat cement slurry and making of 300 x 300 mm square. (e) The whole terrace so finished shall be flooded with water for a minimum period of two weeks for curing and for final test. All above operations to be done in order and as directed and specified by the Engineer-in-charge. With average thickness of 120 mm and minimum thickness at khurra at 65 mm. 20.14.2.10 Glazing Minimum thickness of glazing shall be 5.0 mm. as per IS: 2835. 20.15.2.11 Doors and Windows RAPDRP Part B Section 5 GCP

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The details of doors and windows of the control room building shall be as per finish schedule Table-1 and tender drawing with the relevant IS code. Rolling steel shutters and rolling steel grills shall be provided as per layout and requirement of buildings. Paints used in the work shall be of best quality specified in CPWD specification.

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20.14.2.12 Plumbing & Sanitation (i) All plumbing and sanitation shall be executed to comply with the requirements of the appropriate byelaws, rules and regulations of the Local Authority having jurisdiction over such matters. The Contractor shall arrange for all necessary formalities to be met in regard to inspection, testing, obtaining approval and giving notices etc. PVC syntax or equivalent make Roof water tank of adequate capacity depending on the number of users for 24 hours storage shall be provided. Minimum 1 Nos. 500 liters capacity shall be provided. Galvanized MS pipe of medium class conforming to IS: 1239 shall be used for internal & external piping work for potable water supply. Sand CI pipes with lead joints conforming to IS: 1729 shall be used for sanitary works above ground level. Each toilet shall have the following minimum fittings. (a) WC (Western type) 390 mm high with toilet paper roll holder and all fittings Or WC (Indian Type) Orissa Pattern (580 x 440 mm) with all fittings (both types of WCs shall be provided at alternate locations). (b) Urinal (430 x 260 x 350 mm size) with all fittings. (c) Wash basin (550 x 400 mm) with all fittings. (d) Bathroom mirror (600 x 450 x 6 mm thick) hard board backing (e) CP brass towel rail (600 x 20 mm) with C.P. brass brackets (f) Soap holder and liquid soap dispenser. (vi) (vii) All fittings, fastener, grating shall be chromium plated. All sanitary fixtures and fittings shall be of approved quality and type manufactured by well known manufacturers. All items brought to site must bear identification marks of the type of the Manufacturer. Soil, waste and drain pipes, for underground works shall be stoneware for areas not subject to traffic load. Heavy-duty cast iron pipes shall be used otherwise. In case of Augmentation & R&M of existing substation, amount of work shall be envisaged by contract for lump sum quotation.

(ii)

(iii) (iv) (v)

(viii)

(ix)

20.15

MISCELLANEOUS GENERAL REQUIREMENTS

20.15.1 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. 20.15.2 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. 20.15.3 All steel sections and fabricated structures that are required to be transported on sea shall be provided with anti corrosive paint to take care of sea worthiness. 20.15.4 All mild steel parts used in the water retaining structures shall be hot-double dip galvanised. The minimum coating of the zinc shall be 750 gm/sq. m. for galvanised 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 BS: 3416. RAPDRP Part B Section 5 GCP

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20.15.5 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. 20.15.6 Bricks having minimum 75kg/cm2 compressive strength can only be used for masonry work. Contractor shall ascertain himself at site regarding the availability of bricks of minimum 75kg/cm2 compressive strength before submitting his offer. 20.15.7 Doors and windows on external walls of the buildings (other than areas provided, with insulated metal claddings) shall be provided with RCC sunshade over the openings with 300 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. 20.15.8 Service ladder shall be provided for access to all roofs. 20.15.9 Angles 45x45x5 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. 20.15.10 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. 20.15.11 All rungs for ladder shall also be galvanised as per IS: 277 medium classes. 20.15.12 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: -----------------------------------------------------------------------------------------Sl.No. Mix Cement Sand Coarse aggregate of 20 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. 20.15.13 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. 20.15.14 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. 20.16 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 sole 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. 20.17 WATER SUPPLY (i) (ii) Contractor shall make its own arrangement for construction water. The contractor shall carry out all the plumbing/erection works required for supply of water in control room building. RAPDRP Part B Section 5 GCP

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(iii) (iv)

The details of tanks, pipes, fittings, fixtures etc for water supply are given elsewhere in the specification under respective sections. A scheme shall be prepared by the contractor indicating the layout and details of water supply which shall be got approved by the Owner before actual start of work including all other incidental items not shown or specified but as may be required for complete performance of the works. Bore wells and pumps for water supply are in the scope of contractor meeting the day-to-day requirement of the water supply. If the water is supplied by Municipal Corporation then bore well for water supply purposes is not required to be carried out by contractor. Contractor shall also make necessary arrangement /formalities to receive water connection from corporation.

(v) (vi)

20.18

SEWERAGE SYSTEM (i) (ii) Sewerage system shall be provided for control room building. The Contractor shall construct septic tank and soak pit suitable for 5 users if outside of Municipal Corporation zone. Otherwise, all necessary arrangement for the disposal of sewerage to the Municipal Corporations end shall be arranged by the contractor at his own cost for regularizing the disposal activity. The septic tank and soak pit shall be constructed as per enclosed Drawing no. C/DMD/006-Rev-0 .

(iii)

20.19 20.19.1

STATUTORY RULES Contractor 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. 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. Statutory clearance and norms of State Pollution Control Board shall be followed as per Water Act for effluent quality from plant. 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 out by the Bidder. Foundation system adopted by Bidder shall ensure that relative settlement and other criteria shall be as per provision in IS: 1904 and other Indian Standards All water retaining structures designed as 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). Construction joints shall be as per IS: 456. All underground concrete structures like water retaining structures etc. shall have plasticizer cum water proofing cement additive conforming to IS: 9103. 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 coat of bituminous painting for water/damp proofing. In case of water leakage in the above structures, Injection Method shall be applied for repairing the leakage. All building/construction materials shall conform to the best quality specified in CPWD specifications if not otherwise mentioned in this specification.

20.19.2

20.19.3 20.19.4

20.19.5 20.19.6 20.19.7 20.19.8

20.19.9

20.19.10 All tests as required in the standard field quality plans have to be carried out.

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20.20 20.20.1

FENCING Product materials for fencing The minimum requirements are as follows:

20.20.2

Chain Link fence fabric in accordance to IS-2721 1. 2. 3. 4. 5. Size of mesh Nominal wire size Width of chain link Class of zinc coating Zinc coated after weaving. : : : : 75 mm 3.15 mm dia 2000 mm medium

20.20.3 Posts Intermediate Straining posts Stay post 1. 2. 3. 4. Angle Section : L 50 x 50 x 6 : L 65 x 65 x 6 : L 50 x 50 x 6

5. 6. 7. 8. 9. 10.

11.

All structural steel shall conform to IS: 2062 and shall be painted with a coat of approved steel primer and two coats of synthetic enamel paint. The Chain Link fabric shall be fixed to the post at the top and bottom of the fence by welding/fixing 50 mm MS flat all through its length. Fencing top shall be either of galvanised barbed wire or tape. Barbed wire shall conform to IS: 278. The barbed wire may consist of not more than two splices per reel. The barbed wire shall be formed by twisting two line wires, one containing the barbs. The barbed wire shall be designated as A-4 IS: 278 and shall be galvanized. Above chain link, 3-rows (6 nos) of barbed tape/wire shall be provided in each arm of the Y shaped barbed arm at top. With barbed tape/wire above the chain link fence, the total fence height shall be minimum 2500 mm above finished gravel level. Barbed tape/wire arms shall be same as intermediate and straining post. Tension wire: single strand, high tensile, galvanised steel wire, 4 mm diameter. Fittings and hardware: cast aluminum alloy or galvanized steel, malleable or ductile cast iron turnbuckles to be drop forged. For every 50 reels or part there of samples of the barbed wire/tape and the individual line wires shall be put to tensile test and in case of failure to conform to the tensile properties given below, two additional tests of each kind shall be made on the samples cut from other reels. GI chain link mesh shall be as per IS: 2721. Mesh size 75 mm and nominal wire size shall be 3.15 mm diameter. Tensile properties Tensile strength of line wire Minimum Breaking load of Complete barbed wire/tape : : 40 to 60Kgs/Sq.mm 375Kgs.

On the results of these additional tests, the whole or portion of the barbed wire/tape shall be accepted or discarded by the Purchaser, as the case may be. 20.20.4 1. INSTALLATION Contractor shall submit the fencing drawing Fence shall be installed along lines shown on approved drawings. RAPDRP Part B Section 5 GCP

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2. 3. 4. 5. 6. 7.

8. 9. 10.

Post holes shall be excavated by approved methods. Intermediate posts shall be spaced 2.5 m apart measured parallel to ground surface. Straining posts shall be installed at equal intervals not exceeding 25.0 m. Straining posts shall be installed at sharp changes in grade, at corners, at change of direction and where directed. All corner post will have two-stay post and every tenth post will have a transverse stay post. Posts shall be set in 1:2:4 plain cement concrete Blocks of minimum dimension 400 mm x 400 mm x 1000 mm deep Concrete work shall conform to relevant clause. Post shall be braced and held in plumb position and true alignment and elevation until concrete has set. Fence fabric shall not be installed until concrete has cured a minimum of 7 days. Bottom and top of the fence fabric shall be fixed with MS flats of 50 mm x 6mm (min). Fence fabric shall be laid out with barbed edge on top, stretched tightly and shall be fastened to intermediate, post gate and straining post with 50 x 6 flats. Fabric shall be secured to tension wires with tie wires at 400 mm intervals. Tie wires shall be given not less than two twists. Barbed tape shall be spliced with standard wire splices. Barbed tape shall be stretched to have uniform tension. Barbed tape shall be attached to barbed wire arms with approved metal clips. Toe wall of one Brick/Random Rubble masonry, with notches over 75 mm thick PCC (1:4:8) shall be provided below all fencing and shall be minimum 200 mm above and 200 mm below finished ground level. All exposed surfaces of brick toe wall shall be provided with 1:6 cement sand plaster and coated with two coats of colour wash with a base coat of white wash with lime. Rubble masonry toe wall shall be with raised & cut pointing and 50 mm PCC (1:2:4) band coping. Proper earthing shall be done for fencing also.

11. 12. 13. 14. 15.

16.

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++++++ RAPDRP Part B Section 5 GCP