GETCO/E/TSLUC058/R0 DT.

09/03/2009

GUJARAT ENERGY TRANSMISSION CORPORATION LTD.

Sardar Patel Vidyut Bhavan, Race Course, Vadodara: 390 007

TECHNICAL SPECIFICATIONS OF LAYING 220KV POWER CABLE IN NATURAL VENTILATED TRENCH FOR 220 KV TRANSMISSION LINE

GETCO/E/TSLUC058/R0 DT. 09/03/2009

GETCO/E/TSLUC058/R0 DT. 09/03/2009

PART II
TECHNICAL SPECIFICATIONS FOR LAYING, TESTING AND COMMISSIONING OF 220KV XLPE POWER CABLE IN NATURAL VENTILATEDCONCRETE TRENCH

SECTION-I SPECIFICATION FOR LAYING OF CABLE The Cable Installation, jointing and termination shall generally conform to Manufacturers recommendation and Indian Electricity Rules. 1.1. LAYING, JOINTING AND INSTALLATION (GENERAL): 1.1.1. The successful Bidder shall have to arrange technical installation of cable laying and termination. supervision during

1.1.2.

The successful Bidder shall arrange for the services of fully qualified and competent supervising Engineer / Engineers and necessary minimum number of jointers, semi-skilled labourers, as he deems it absolutely necessary. Provision of special tools /Plants / appliances required for conductor jointing and stripping / dressing and application of XLPE insulation etc. shall be made by the successful Bidder. The successful Bidder shall furnish all necessary information, including drawings, manuals and instructions relating to both cable laying and jointing practice. The associated civil works, which are necessary for laying / installation of power cable, though not specifically mentioned, but shall be completely in the scope of successful Bidder. The route map showing the proposed installation of power cable will be issued to the successful Bidder. Cables are to be laid in Double natural ventilated trench as per instruction of E.I.C. Successful Bidder has to arrange at his own cost for first-aid, fire protection, electricity and water requirement at site. He shall also arrange for sign board, caution board GSECL, safety & security personnel etc. on cable route.

1.1.3.

1.1.4.

1.1.5.

1.1.6.

1.1.7.

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1.1.8. The successful Bidder has to bear with any temporary interruption that may occur during actual erection work, when the matter with other agency is involved. No idling charges or cost over run for the entire project shall be entertained. Approval for installation of the cable in a Double natural ventilated trench from Electrical Inspector shall be arranged by Purchaser. However, permission for commencement of work and permission for commissioning of cable after completion of laying has to be arranged by the successful Bidder. Successful Bidder shall arrange space for working office, workshop & store / yard for storing requisite materials like kits, cables etc. The Arbitration in the dispute shall be strictly as per standard commercial terms & conditions of the GETCO. Videography of entire process of laying of cable, jointing of cable and jointing of End terminations shall be done and submitted to Chief Engineer (Engg), Corporate Office, Vadodara.

1.1.9. 1.1.10.

1.1.11.

1.1.12.

1.1.13.

1.2. LAYING OF POWER CABLE: 1.2.1. The 220kv (E) XLPE cable shall be installed underground in two natural ventilated concrete trenches leaving spacing of 500mm in between two trenches and laying two circuits(Trefoil formation) in a trench in two tier. The vertical spacing between two tier should be sufficient to provide adequate natural ventilation, necessary design calculation shall be submitted in support and covering the trenches with perforated roof complying with all applicable standards and relevant IS & their amendments. The sealing of power cable ends during the storage; execution & completion of jointing work shall be in the scope of successful Bidder. Under no circumstances, the cable ends shall be kept open. The amount due to damages done because of water / moisture ingress OR penetration in the cable / conductors during execution shall be recovered from successful Bidder. It shall be responsibility of successful Bidder to repair OR replace free of cost without affecting the completion schedule. Three single core cables shall be laid in trefoil formation for one circuit. Two circuits in two tier form shall be laid in single trench. The maximum available width is 3000 mm. The single trench shall be 450mm inside width, the depth of the trench should be sufficient for two tier with adequate natural ventilation and spacing between two trenches shall be 500mm. Both the trenches shall be provided with support of required sizes of channel or angle section so as to bear the load of cables etc.Design calculation for selection of section shall be submitted and got approved from CE (ENGG), Corporate Office, Vadodara. The

1.2.2

1.2.3

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trenches shall be covered with perforated slab to provide adequate natural ventilation ,the design and selection is in the scope of Bidder but he should clearly come out with adequate supporting document in support of perforated slab offered. 1.2.4 The power cable shall be laid generally at a depth to provide natural air ventilation, design calculation in support shall be submitted. The cables shall be completely left open to get sufficient air for ventilation. The cable trench is to be constructed in two tier having 350mm inside width and height sufficient for two tier rack having free natural air ventilation. Type of cable trench to be design as per soil strata of sub station and is in the scope of Bidder.The soil investigation report is available for reference. Top slab of cable trench should be perforated and sufficient to with stand the live load as per Is 456 .Peforation shall be sufficient to provide adequate natural air vaentilation if necessary design calculation for the same shall be submitted in support.

1.2.5

1.2.6

The cable drum must be handled correctly and with care during transport and laying of the power cables, in order to avoid damage to the cables. Any damages done because of poor handing of the cables to the properties of corporation, private OR to anybody shall be responsibility of successful bidder & the GETCO reserves the right to recover the amount due to such damages. The minimum bending radius of the cable shall be 20xD where D is diameter of the cable. Erection of structures shall be created by piece meal method on the foundations after allowing the required curing time for the foundations.The members shall not be strained or bent during course of erection. Care shall taken to see that the joining surfaces are clear and free from dirt or grit and fit properly.The structures shall be erected strictly in accordance with the approved drawings. The structures must be truly vertical after erection.The design of lattice type support structure and its foundation design is also in the scope of Bidder.

1.2.8

1.2.9

1.2.10 The contractor has to keep allotted 220kv power cable, material supplied by him in safe custody and transport to the respective sites and will be fully responsible for any damage to or loss of any or all allotted equipments or materials supplied by him at any stage during transportation or erection or taking over of the sub station/ line by the GETCO. The contractor has to return empty cable drum as instructed by E.I.C. The route map for cable will be issued free of cost to the contractor before commencement of work, however the changes made by Engineeer in charge i.e. Ex. Engr. (Const.) shall be incorporated.

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The Contractor has to open site store at sub station site or at place near by the sub station site and ensure for safe custody of all the stored materials at his own cost. The Contractor shall have total responsibility for the entire materials stored, loose, semi assembled and/or erected by him at site in his custody. The Contractor shall make suitable security arrangements at his own cost to ensure the protection of all materials, equipment and works from theft, fire pilferage and any other damages and loss. It shall be the responsibility of the contractor to arrange for security till the works are finally taken over by the GETCO/GSECL.

1.3. CROSSINGS: 1.3.1 (a) Where road crossing comes in way of laying power cable, the power cable shall be laid through NP-4 RCC Hume pipes. The required length of Hume pipe shall be arranged by the successful Bidder at no extra cost. (b) The RCC Hume pipe inner dia-meter shall not be less than 800 mm. (c) The RCC pipes to be laid shall have minimum depth in such a way that the back filling on top surface of the pipe shall be at least 700mm in depth. The pipe joints shall be smooth so that cables are not damaged during pulling & operation. (d) During the crossing of utilities like water line, drainage lines, telephone lines, gas lines etc, sufficient care shall be taken & protection shall be made available so that other utilities do not damage the cable mechanically and / or electrically or do not effect the performance of the cable. (e) NALA CROSSINGS / CULVERT CROSSINGS: The Nala crossings are to be made with separate fly-over bridges of adequate sizes to carry all the cables in required formation. The bridges are to be made at the sufficient distances from the edge of Nala considering the further expansions of roads. The strength shall be such that it should not wash away with the flow of water during heavy rain.

1.4

IDENTIFICATION, MARKING AND WARNING:

1.4.1

The identification Board shall be placed on all four side of the trench with warnings as shown below with letter sizes in line with relevant IS. GSECL - 220KV CABLE LINE DO NOT WALK

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1.4.2 The cable trench roof should be duly embossed on top side as under:

GSECL 220 kV CABLE LINE DO NOT WALK

1.4.3

BILL OF QUANTITIES:

1.4.3.1 The Bill of Quantities shall be read in conjunction with the Technical Specifications, laying of cable and drawings. 1.4.3.2 The quantities given in the Bill of Quantities are estimated and provisional, and are given to provide a common basis for Bidders.
1.5 TEST AFTER INSTALLATION: 1.5.1 Pre-commissioning tests on site, to be undertaken by the successful Bidder shall include the following: a)Insulation Resistance of each cable drum length after laying and before jointing.

b) Tests for detection of damage to outer sheath, if any. c) Serving insulation resistance after laying each cable length shall withstand a voltage of 10kv DC for one minute between each reinforcement and external conducting surface; In addition, the serving insulation resistance shall be measured and checked with the values obtained during routine factory tests. d) On completion of the cable laying and jointing work, the complete installation shall be checked with a D.C. voltage of 3 Uo applied for 15 minutes between each conductor and sheath. e) Conductor resistance of each cable of each complete circuit. f) Test for 5 min. with system voltage applied between the conductor and the screen. g) Test for 24 hours with normal operating voltage of the system. h) Continuity & Phase confirmation. NOTE : The pre-commissioning test at (f) or (g) at site to be undertaken as an alternative to the test (d). 1.6 GENERAL: 1. The cable laying shall have to be done, as per actual site condition at the time of execution, and as per the instruction of the engineer-incharge.

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2. The structures for termination of the cable , LAs and stringing of section connecting Gantry structure of existing Switch yard shall be arranged by the Bidder. 3. The Bidder has to submit the Bar chart in MS Project format and FQP for approval during commencement period before actually starting the work. 4. The scope of work shall also include obtaining required permission / approval from various statutory authorities i.e. Municipal Corporation, Gram Panchayat (if any), PWD, Electrical Inspector, Telecom Department etc. Payment demanded by any statutory authority as a compensation shall be reimbursed by GETCO on submission of documentary evidence i.e. receipt of such payment made. 5. The Un-priced schedule of the offered item shall also be submitted in technical Bid. 6. The successful bidder has to complete the work i.e. Supply of Power Cable, Laying, Testing, Charging and Commissioning within EIGHT MONTHS after commencement period of one month. 7. The end of cut pieces of cables left out during executions shall be sealed to prevent ingress of any moisture in the cable before handing over to consignee. 8. No straight joint is permitted. The section length should be single, the Bidder may decide the length of single drum after verifying site conditions. 9. The consignee shall be Executive Engineer (const.),Rajkot, Gujarat Energy Transmission Corporation Limited, 10. Detailed route for laying cables is available and may be collected. 11. The rate of laying of 220 KV Cable covers the cost of fixing of 3 phase earth box. 12. Civil work for all nala crossings, road crossing etc. for all the above lines shall be considered in scope of bidder. 13. Contractor shall observe all labour laws and maintain records for the same 14. Such parts as may have not been specifically included but otherwise form part of the job are deemed to be included unless otherwise specifically mentioned.

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1.7 GENERAL PROCEDURE FOR LAYING OF EHV CABLES IN TRENCHES

ON SUPPORTMEMBER OR CABLE TRAY

1. Check that the cable trench and support member or cable trays in the trench are dry (not water logged), clean and dressed. If required, pumps should be used to drain out water from the trench. 2. There should be no sharp stone or hard particle on the route of cable in trench or on the support member or cable tray that may damage the cable outer sheath. 3. Depending upon the site conditions, rollers could be placed on support member or cable tray or on the ground in the walk way. The rollers should be placed at a distance of 3 4 Metres. At bends, special corner rollers should be placed so that the cable does not touch the side wall of trench. 4. Drum should be mounted on the cable jacks and should rotate freely. The jack could be positioned near the end of trench at a levelled hard surface. 5. A man should be stationed near the drum with a plank wedged against the flange so that overrunning of the drum could be prevented if pulling stops. 6. Ensure the drum is rolled against the direction of marked ROLL THIS WAY on the drum and the cable is laid out from the top of the drum.

7.

Lay a strong rope from the other end to cable drum on the route from where the cable has to pass. Attach the end of the pulling rope to the leading end of cable using a cable stocking on pulling eye to pull the cable.

8. One man should be provided at each roller and a gang of men should be provided at the pulling rope attached to pulling eye/cable stocking. All the persons should face towards the drum site. The total number of persons required for pulling should be decided depending upon weight per metre of cable and route conditions.

9.

One Supervisor should be positioned near the drum. He should make evenly timed calls for pulling or stopping the pulling operation. If required, and local body allows, two to three loud speakers could be used by the supervisor for making the call.

10. .There should be signal men carrying red & green flags placed at every 50 Metres. These signal men should show green flag when the pulling of cable has to be done and red flag when the pulling of cable has to be stopped.

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11. .Ensure that when the supervisor gives call for pulling the cable, all the men grip and pull the cable simultaneously. 12. If possible, three to four foreman/supervisor equipped with walkie-talkie sets should be placed at cable laying area. One of them should be placed near the drum and one should walk along with the cable pulling eye/cable stocking when the cable laying is being done while others should be positioned at vulnerable bends, road crossings etc. to ensure that cable pulled is not getting damaged or bent at a shorter radius at bends. 13. For heavy cables with complicated route, apply graphite grease on cable at the end of the ramp (after the drum), before the cable enters the trench. If the site conditions requires, the graphite grease should be applied by the men at rollers during the course of pulling. 14. During laying, if outersheath damage is observed, the portion of cable which is damaged should be marked with red PVC tape. After laying of the cable when cable is still on the rollers, visual check for any outersheath damage should be done. The bottom portion of the cable should be checked with the help of a mirror. The damaged sheath should be repaired before outersheath testing. 15. Remove rollers and other pulling equipment from site. 16. If the cable had been laid on rollers on walkway, place the cable on support member or cable tray. 17. Dress the cable and do the snaking as per advice of cable manufacturer, if required. 18. Fix clamps on the cable as required. 19. After laying the cables, it should be checked again to see that all cable ends are undamaged and sealed. If cable has to be cut, both the cable ends should be re-sealed immediately by good quality heat shrinkable cap. 20. A sample drawing for cable trench laying (drg. no. GETCO/C/02/SIKKA/CBLT-19 R0) is attached for reference to the bidder. However, the successful bidder shall submit his own drawing with strength calculation & in accordance with safety norms for approval to GETCO.

Signature of the Bidder: __________ Name: _______________________ Designation: ___________________ Date: _____________

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Authorised common rubber Stamp / seal of the bidder: _________