HARYANA VIDYUT PRASARAN NIGAM LIMITED SECTION-V

TECHNICAL BIDDING DOCUMENT No. REC-112

FOR SUPPLY, ERECTION AND COMMISSIONING OF
LILO OF ONE CIRCUIT OF 400KV SAMAYPUR- GREATER NOIDA LINE WITH QUAD BERSIMIS CONDUCTOR AT 400KV SUBSTATION NAWADA (FARIDABAD)

ON TURNKEY BASIS

TECHNICAL
VOLUME II
Chief Engineer/MM, Haryana Vidyut Prasaran Nigam Limited Shakti Bhawan, Sector-6, Panchkula-134113 Ph:- 0172-2583724, 2583744, Fax:- 0172-2583724

JUNE, 2011

PART- I

SCOPE AND BOQ OF LILO OF ONE CIRCUIT OF

400KV G.NOIDA SAMAYPUR LINE

AT 400KV S/STN. NAWADA.

PART -1 (GENERAL)
1.1 INTRODUCTION: The scope of this specification covers Engineering and Construction of termination arrangement of LILO of one ckt. of 400kV SamaypurG-Noida Quad Bersimis line on Bersimis ACSR / Aluminum Tubes at 400kV S/Stn. Nawada as per arrangement shown in the indicative sketch (Annexure-1 attached with the bid). The detailed Engineering of the Termination arrangement is in the scope of the bidder, which shall be submitted to HVPN for getting concurrence of PGCIL before execution of the work. SCOPE The detailed scope of work shall be as under: 1 2. 3. 4. 5. Loop in loop out arrangement at tower No. 108 of one ckt. of 400kV Samapur-GNoida Quad Bersimis line of PGCIL at 400kV S/Stn. Nawada Supply and erection of Bersimis conductor. Supply and erection of special T-clamps for taking in connection from the existing Quad Bersimis line in line with PGCIL practice. Fabrication, supply and erection of 400kV S/Stn. Gantries / Beam Structures as per Drawing / BOM to be supplied by HVPN. Supply and erection of IPS 4 Aluminum tube along with corona ring and welding sleeves. Supply and erection of Bus Post Insulator alongwith their structure for supporting 4 Aluminum tube as per Sr. No. 5 above. Supply and erection of spacers and connectors as per BOQ. Supply and erection of various S/Stn. and Line Hardware fittings as per BOQ Supply and erection of 160kN Polymer Insulators as per BOQ Supply and erection of 390 KV Gapless L.A. alongwith structures. Supply and erection of Earthwire (size 3.66mm) alongwith required clamps and connector as per BOQ / as per site requirement. The existing Earthmat of the S/Stn. shall be extended in the area of proposed LILO arrangement as per PART (Switchyard Erection) alongwith Risers & Electrodes Supply and erection of lightning mast as per DSLP calculation to be carried out by the Bidder. Lighting with 2x400W, HPSV lamp with high flood lighting fixture suitable for outdoor mounting with aluminum enclosure along with LT AC copper cables for connections from existing ACPs / DBs. The termination arrangement for PGCIL TL No. 108 to gantries shall be with slack span and restricting the angle of deviation at Gantries to max. 150 only. The electrical clearance of aluminum pipes on BPI from existing 400kV PGCIL line shall be maintained and the ground level of BPI structure shall be decided accordingly during detailed Engineering. The crossing arrangement profile shall be prepared and got supplied for concurrence of PGCIL. The detailed scope of Civil part, its technical specification has been shown in PART-VI. SCHEDULE OF QUANTITIES The detailed description of various items/equipment are indicated at Annexures attached with the bid. The bill of quantity of major equipment is also indicated and wherever the quantities are not indicated the bidder is required to compute the quantity. Bidder is required to indicate unit rate and total price of the items under a particular head in bid proposal sheets. Bidder should include all such items in the bid proposal sheets, which may not be specifically mentioned but are essential for the execution of the contract. The Technical specification / BOQ is also attached with the bid.

1.2

6.
7. 8. 9. 10. 11. 12. 13. 14. 15.

16 17.

18. 1.2.3

Page-1

1.3

1.4

GENERAL ELECTRICAL LAYOUT The GELO for 400kV S/Stns. Nawada and the indicative sketch for termination arrangement of LILO of one ckt. of 400kV SamaypurG-Noida Quad Bersimis line at 400kV S/Stn. Nawada is attached with the bid (GELO drg. No. HSD-1/3157 and indicative sketch drg. No.-1) along with earthmat layout drawing No. 5257 PN088NWD-E-SYD-EAR-0017. LOCATIONS OF THE SUBSTATION The location of the substation along with the nearest Railhead is indicated at Annexure-II METEOROLOGICAL DATA. The meteorological data of the substation is indicated at Annexure-III. However, for design purpose, ambient temperature should be considered as 50 C. DRAWING 1. The bidder shall maintain inter equipment distances, bay length, bay width etc. in accordance with the enclosed general/electrical layouts of the respective substations while doing so the bidder will ensure that the statutory electrical clearances required for substation are maintained as per General Technical Requirements. 2. The drawing enclosed gives the basic scheme, layout of substation, substation buildings, associated service etc. In case of any discrepancy between the drawing and text of specification the bidder is advised to get these clarified before submission of bid. No claim what-so-ever on this score shall be entertained after award of contract. 3. The bidder shall adopt the design of galvanised steel structure for tower, beam and equipment supporting structures for 400kV S/Stns. supplied by HVPNL.

1.5

1.6

1.8 1.8.1

SPARES MANDATORY SPARES The following quantities shall be supplied by the bidder as spares:i) 10% spares of total Quantity of items at Sr.No.-2.2 to 2.5 & 1.1 of BOQ (Annexure-A1) ii) One number each of items at Sr. No. 3.1 to 3.4 of BOQ (Annexure-A1) iii) Four number each of items at Sr. No. 2.1 & 5.1 of BOQ (Annexure-A1) 1. The bidder or his authorized representative should visit the site of works and its surroundings to obtain himself at his responsibility and expenses, all information regarding general site characteristics, accessibility, infrastructure details and factual position in respect of scope of work vis--vis GELO drg. and indicative LILO arrangement drg. attached with the bid document. Any alteration/addition envisaged in the document must be got clarified before submission of the bid. 2. No extra payment shall be made on account of any change in the layout drgs. required for providing DSLP as per Rezvik method. 3. Any other items not specifically mentioned in the specification but which are required for erection, testing, commissioning and satisfactory operation of LILO arrangement are to be considered as included in the scope of the specification unless specifically excluded

Notes:

Page-2

Sr. No.

ANNEXURE-I TERMINATION ARRANGEMENT AT 400KV SUB-STATIONS Name of Scope of Work Indicative Termination S/Stn. arrangement Drg. No.

1. (A)

400 kV S/Stn. Nawada

The scope of this specification covers construction of termination arrangement of LILO of one ckt. of 400kV SamaypurG-Noida Quad Bersimis line at 400kV S/Stn. Nawada as per arrangement shown in the indicative sketch (attached with the Bid)

GELO Drawing No.- HSD1/3157

Indicative Termination Arrangement Drawing No.-1

ANNEXURE-II LOCATION OF SUB-STATIONS Sr. No. 1. Name of Substation 400 kV S/Stn. Nawada Nearest Rail Head Faridabad

ANNEXURE-III METEOROLOGICAL DATA Equipment to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) Location Max. Ambient air temp. (deg. C) Min ambient air temp. (deg. C) Daily average air temp. (deg. C) Average no. of Thunder storm days per Annum Maximum Relative Humidity (%) Minimum Relative Humidity (%) Average annual rain fall (mm) Max. wind pressure (kg/sq m) Max. altitude above mean sea level (meters) Isoceraunic level (days/year) Seismic level (horizontal acceleration) Average no. of rainy days per Annum In the state of Haryana 50 -2.5 35 45 100 26 900 195 1000 45 0.3 g 120

NOTE: Moderately hot and humid tropical climate conductive to rust and fungus growth. The climate conditions are also prone to wide variations in ambient condition. Smoke is also present in the atmosphere. Heavy lightening also occurs during June to October.

Page-3

Annexure-A1
BILL OF QUANTITIES
Sr.No 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 Item Description CONDUCTORS/ TUBE supply ACSR Bersimis conductor 4" IPS Al tube suitable for Quad Bersimis Welding sleeves for 4" IPS Al tube (Included in 1.2) Corona cap for 4" IPS Al tube (Included in 1.2) SPACERS & CONNECTORS supply Spacer for Quad ACSR Bersimis - Rigid type - 400 kV Special T- clamp for single Bersimis to single Bersimis for taking in arrangement at the Tower C-Wedge connectors for Bersimis ACSR Terminal connector for BPI suitable for 4" IPS Al Tube Rigid/ flexible Inter connector suitable for 4" IPS Al tube to quad Bersimis Uom Mtr Mtr Nos Nos Qty 8000 750 120 35

Nos Nos No. Nos Nos

320 24 150 120 30

3 3.1

400kV HARDWARE supply 400 KV QUAD TENSION LINE HARDWARE FITTINGS SUITABLE FOR 160 KN POLYMER INSULATORS COMPLETE WITH ALL ASSOCIATED HARDWARE, ACCESSORIES INCLUDING CORONA RINGS ETC. (TO BE USED AT LILO GANTRIES) 400 KV DOUBLE TENSION S/STN. STRING HARDWARE SUITABLE FOR 160 KN POLYMER INSULATOR STRING WITH ALL HARDWARE, ACCESSORIES FOR QUAD ACSR BERSIMIS CONDUCTORS WITH TENSION CLAMP SET WITH TURN BUCKLE (DOUBLE ANCHORING) 400 KV DOUBLE TENSION S/STN. STRING HARDWARE SUITABLE FOR 160 KN POLYMER INSULATOR STRING WITH ALL HARDWARE, ACCESSORIES FOR QUAD ACSR BERSIMIS CONDUCTORS WITH TENSION CLAMP SET WITHOUT TURN BUCKLE (DOUBLE ANCHORING) 400 KV SINGLE SUSPENSION S/STN. PILOT HARDWARE FITTINGS SUITABLE FOR 160 KN POLYMER INSULATOR STRING COPLETE WITH ALL HARDWARE ACCESSORIES FOR QUAD ACSR BERSIMIS CONDUCTORS 390kV Surge Arrester (Gapless) 390kV Surge Arrester (Gapless) Polymer insulator 160 KN Polymer insulator string with corona ring & other accessories ( Complete String)

SET

3.2

SET

24

3.3

SET

18

3.4

SET

24

4 4.1 5 5.1

Nos

Nos

156

6 6.1 6.2 6.3 6.4

EARTHING supply Earth wire of size 3.66 mm 75 x 12 mm Flat Cleat type clamps for earthing down conductors Earth wire tension clamps with D-shackle assembly Mtr Mtr Nos Nos 1250 1000 450 41

Page-4

6.5 6.6 6.7 7 7.1 8. 8.1 8.2

PG-clamps for GS earth wire Pad type compressive clamp for earth wire down conductor 40mm dia MS rod conductor 420kV BPI Supply 420kV Bus post insulator Lighting arrangement 2x400W, HPSV lamp in high flood lighting fixture suitable for outdoor mounting with aluminum enclosure LT AC copper cables for connections from existing ACPs / DBs, for Lightning arrangement at termination area. Mandatory spares as per Clause No.-1.8

Nos Nos Mtr

26 18 3000

Nos

125

No. Lot

25 Lot

Lot

Lot

Note: 1

The quantities given in BOQ are approx. and for evaluation purpose. In case of variation in Quantities at the time of Detailed Engineering , the actual quantities shall be payable as per Quoted rates. The detailed Engineering of the Termination arrangement is in the scope of the bidder, which shall be submitted to HVPN for getting concurrence of PGCIL before execution of the work.

Page-5

ANNEXURE B-I Schedules of items for associated steel structure works to be quoted. The bidder is required to estimate the quantities and furnish the unit rate for each item/ works and the total price for each item in the bid proposal sheets. The list may not be exhaustive, and the bidder may modify/ append the same as required. Item for associated structure work Sr. No.

DESCRIPTION

LILO arrangement at 400 kV S/Stn. Nawada

Lattice type steel structure of 400kV kV: Supply of material, preparation of fabrication drawing, galvanizing and delivery of lattice type steel structure for tower and beams for 400kV switchyard fabricated from steel conforming to IS: 2062 including nuts-bolts gusset plates foundation bolts and other accessories as per drawings supplied by the owner. Main S/Stn. tower and Beam
A STRUCTURE supply along with earthing material

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 B 2.1 2.2 Note -

Tower type TI Tower type TH Tower type TN Tower type TC Tower type TJ Beam type G1 Beam type G2 LM along with DSLP Calculations Equipment structure 400kV BPI structure 390 kV Surge Arrester (Gap)

Nos Nos Nos Nos Nos Nos Nos Nos

3 4 2 3 3 2 8 2

No. No.

125 6

1. The quantity given above are as approximate. and for evaluation purpose . In case of variation of quantities at the time of detailed engineering, actual quantities shall be payable as per quoted price. 2 The detailed Engineering of the Termination arrangement is in the scope of the bidder, which shall be submitted to HVPN for getting concurrence of PGCIL before execution of the work.

Page-6

MODEL TECHNICAL SPECIFICATION

PART-GTR (GENERAL TECHNICAL REQUIREMENT)

PART-GTR (GENERAL TECHNICAL REQUIREMENTS) CLAUSE NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 23.0 24.0 25.0 26. 0 PARTICULARS PAGE NO. Foreword General Requirement Standards Services to be performed by the Equipment being furnished Engineering Data and Drawings Material/Workmanship Design Improvements/Coordination Quality Assurance Programme Type Testing, Inspection & Inspection Certificate Tests Packaging & Protection Finishing of Metal Surfaces Handling, Storing & Installation Tools and Tackles Auxiliary Supply Support Structure Clamps and Connectors including Terminal Connectors Control Cabinets, Junction Boxes, Terminal Boxes & Marshalling Boxes for Outdoor Equipment Auxiliary Switches Terminal Blocks and Wiring Lamps and Sockets Bushings, Hollow Column Insulators, Support Insulators Motors Technical Requirement of Equipments Testing and adjustment Monthly Progress Reports 23 23 24 24 26 29 30 42 23 23 23 23 22 16 16 16 18 20 20 20 20 6 9 12 12 13 1 1 2 2

Annexure-A Corona and Radio Interference Voltage(RIV) Test Annexure-B Seismic Withstand Test Procedure Annexure-C List of Specifications Annexure-D List of Drawings/Documents

PART-II GTR (GENERAL TECHNICAL REQUIREMENTS) 1.0 1.1 FOREWORD The provisions under this Part are intended to supplement general requirements for the materials, equipments and services covered under other Parts of tender documents and is not exclusive. However in case of conflict between the requirements specified in this Part and requirements specified under other Parts, the requirements specified under respective Parts shall prevail. GENERAL REQUIREMENT The bidders shall submit the technical requirements, data and information as per the technical data sheets provided in the Volume III of bid documents. The bidders shall furnish catalogues, engineering data, technical information, design documents, drawings etc. It is recognized that the bidders may have standardized on the use of certain components, materials, processes or procedures different from those specified herein. Alternate proposals offering similar equipment based on the manufacturers standard practice will also be considered provided such proposals meet the specified designs, standard and performance requirements and are acceptable to the Employer. Except for lighting fixtures, wherever a material or article is specified or defined by the name of a particular brand, Manufacturer or Vendor, the specific name mentioned shall be understood as establishing type, function and quality and not as limiting competition. For lighting fixtures , makes shall be as defined in Part- Lighting System. Equipment furnished shall be complete in every respect with all mountings, fittings, fixtures and standard accessories normally provided with such equipment and/or needed for erection, completion and safe operation of the equipment as required by applicable codes though they may not have been specifically detailed in the Technical Specifications unless included in the list of exclusions. Materials and components not specifically stated in the specification but which are necessary for commissioning and satisfactory operation of the switchyard/substation unless specifically excluded shall be deemed to be included in the scope of the specification and shall be supplied without any extra cost. All similar standard components/parts of similar standard equipment provided, shall be inter-changeable with one another. Page-1

2.0 2.1

2.2 2.3

2.4

2.5

3.0

STANDARDS

3.1

The works covered by the specification shall be designed, engineered, manufactured, built, tested and commissioned in accordance with the Acts, Rules, Laws and Regulations of India. The equipment to be furnished under this specification shall conform to latest issue with all amendments (as on the date of bid opening) of standard specified under Annexure -C of this Part, unless specifically mentioned in the specification. The Bidder shall note that standards mentioned in the specification are not mutually exclusive or complete in themselves, but intended to compliment each other. The Bidder shall also note that list of standards presented in this specification is not complete. Whenever necessary the list of standards shall be considered in conjunction with specific IS/IEC. When the specific requirements stipulated in the specifications exceed or differ than those required by the applicable standards, the stipulation of the specification shall take precedence. Other internationally accepted standards which ensure equivalent or better performance than that specified in the standards specified under Annexure C / individual parts for various equipments shall also, be accepted, however the salient points of difference shall be clearly brought out in additional information schedule of Vol III along with English language version of such standard. The equipment conforming to standards other than specified under Annexure C / individual parts for various equipments shall be subject to Employers approval. The bidder shall clearly indicate in his bid the specific standards in accordance with which the works will be carried out. SERVICES TO BE PERFORMED BY THE EQUIPMENT BEING FURNISHED The 400kV system is being designed to limit the switching surge over voltage to 2.5pu and the power frequency over voltage to 1.5 pu. In case of the 400kV system, the initial value of the temporary overvoltage could be 2.0 pu for 1 - 2 cycles. he equipment furnished under this specification shall perform all its functions and operate satisfactorily without showing undue strain, restrike etc under such over voltage conditions. All equipments shall also perform satisfactorily under various other electrical, electromechanical and meteorological conditions of the site of installation. Page-2

3.2

3.3

3.4

3.5

3.6

3.7 4.0 4.1

4.2

4.3

All equipment shall be able to withstand all external and internal mechanical, thermal and electromechanical forces due to various factors like wind load, temperature variation, ice & snow, (wherever applicable) short circuit etc for the equipment. The bidder shall design terminal connectors of the equipment taking into account various forces that are required to withstand. The equipment shall also comply to the following: a) b) All outdoor EHV suitable for hot line washing. equipments shall be

4.4 4.5

To facilitate erection of equipment, all items to be assembled at site shall be match marked.

4.6 4.6.1

EHV equipments and system shall be designed to meet the following major technical parameters as brought out hereunder. System Parameter 400 kV System 400kV 50Hz 3

S.NO Description of parameters 1. 3. 4. 5. i) System operating voltage Rated frequency No. of phase Rated Insulation levels Full wave impulse withstand voltage(1.2/50 micro sec.)

1550kVp

ii)

Switching impulse 1050kVp withstand (250/2500 sec.) dry and wet One minute power frequency dry and wet withstand voltage (rms) Corona extinction voltage 630kV

Iii)

6.

320kV Page-3

7.

Max. radio 1000 microinterference volt voltage for frequency between 0.5 MHz and 2 MHz at 320kV rms for 400kV system and 156kV rms for 220kV system & 92 kV rms for 132kV system Minimum creepage distance Min. clearances Phase to phase 25 mm/kV (10500 mm) 4200 mm (for Rod conductor configuration) 4000 mm (for conductor onductor configuration)

8. 9. i)

ii) iii) 10.

Phase to earth 3500 mm Sectional clearances Rated short circuit current for 1 sec. duration System neutral earthing 6500 mm 40 kA

11.

Effectively earthed

Note : The insulation and RIV levels of the equipments shall be as per values given in the respective chapter of the equipments. 4.7.2 Major Technical Parameters The major technical parameters of the equipments are given below. For other parameters and features respective technical parts should be referred.

Page-4

FOR 420 kV SA) Rated voltage (kV, rms) Rated frequency (Hz) No. of poles Design ambient temperature (C) Rated Insulation levels : 1) Full Insulation levels : 2) For arrester housing 1425 kV peak Switching impulse withstand voltage (250/2500 micro second) dry and wet For arrester housing 1050 kV peak 420 50 1 50

3) One minute power frequency dry and wet withstand voltage For arrester housing -630kVrms 4) Min. Creepage distance :Phase to ground (mm) Seismic acceleration Partial discharge :-for arrester at 1.05 COV Not exceeding 50 p.c. 5) System neutral - Effectively earthed 10500. 0.3g Horizontal 320 (min)

(E) Technical Parameters of Bushings/Hollow Column insulators/support insulators : For 400 kV System (a) Rated Voltage (kV) 420 Page-5

(b) Impulse withstand voltage(Dry& Wet) (kVp)

1425

(c) Switching surge 1050 withstandvoltage (dry and wet) (kVp) (d) Power frequency 630 withstand voltage (dry and wet) (kV rms) (e) Total creepage distance (mm) 10500

(f) Pollution Class-III Heavy (as per IEC 71) and as specified in Part-2 for all class of equipment. (g) Insulator shall also meet requirement of and IEC-815 for 400 kV, 220 kV system, as applicable having alternate long & short sheds. 5.0 5.1 ENGINEERING DATA AND DRAWINGS The engineering data shall be furnished by the Contractor in accordance with the Schedule for each set of equipment as specified in the Technical Specifications. The list of drawings/documents which are to be submitted to the Employer shall be discussed and finalised by the Employer at the time of award. The Contractor shall necessarily submit all the drawings/ documents unless anything is waived. The Contractor shall submit 4 (four) sets of drawings/ design documents /data/ test reports as may be required for the approval of the Employer. 5.3 5.3.1 Drawings All drawings submitted by the Contractor including those submitted at the time of bid shall be in sufficient detail to indicate the type, size, arrangement, material description, Bill of Materials, weight of each component, break-up for packing and shipment, dimensions, internal & the external connections, fixing arrangement required and any other information specifically requested in the specifications. Each drawing submitted by the Contractor shall be clearly marked with the name of the Employer, the unit designation, the specifications title, the specification number and the name of the Project. If standard catalogue pages are submitted, the applicable items shall be indicated therein. All titles, noting, markings and writings on the drawing shall be in English. All the dimensions should be in metric units. Page-6

5.2

5.3.2

5.3.3

Further work by the Contractor shall be in strict accordance with these drawings and no deviation shall be permitted without the written approval of the Employer, if so required. The review of these data by the Employer will cover only general conformance of the data to the specifications and documents, interfaces with the equipment provided under the specifications, external connections and of the dimensions which might affect substation layout. This review by the Employer may not indicate a thorough review of all dimensions, quantities and details of the equipment, materials, any devices or items indicated or the accuracy of the information submitted. This review and/or approval by the Employer shall not be considered by the Contractor, as limiting any of his responsibilities and liabilities for mistakes and deviations from the requirements, specified under these specifications and documents. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawings shall be at the Contractors risk. The Contractor may make any changes in the design which are necessary to make the equipment conform to the provisions and intent of the Contract and such changes will again be subject to approval by the Employer. Approval of Contractors drawing or work by the Employer shall not relieve the contractor of any of his responsibilities and liabilities under the Contract. All engineering data submitted by the Contractor after final process including review and approval by the Employer shall form part of theContract Document and the entire works performed under thesespecifications shall be performed in strict conformity, unless otherwise expressly requested by the Employer in Writing. Approval Procedure The scheduled dates for the submission of the drawings as well as for, any data/information to be furnished by the Employer would be discussed and finalised at the time of award. The following schedule shall be followed generally for approval and for providing final documentation. i) Approval/comments/ by Employer on initial submission Resubmission (whenever required) Approval or comments Furnishing of distribution copies in bound volume (5 copies per substation and one copy for Corporate Centre) As per agreed schedule Within 3 (three) weeks from date of comments including both ways postal time). Within 3 weeks of receipt of resubmission. 2 weeks from the date of final approval

5.4

5.5

5.6

5.7

ii)

iii) iv)

Page-7

v)

Furnishing of distribution copies of test reports (a) Type test reports (one copy per substation plus one copy for corporate centre) (b) Routine Test Reports (one copy for each substation) 2 weeks from the date of final approval

-doAs per agreed schedule

vi)

Furnishing of instruction/ operation manuals (4 copies per substation and two copies for corporate centre)

vii) RTFs of drawings (one set per substation and one set for corporate centre) (viii) Video Cassette (VHS-PAL) highlighting installation and maintenance techniques/ requirements of circuit breaker & isolators (one per substation plus one for corporate centre) (ix) As built drawings & RTFs (Two sets per substation plus one set for corporate centre) (x) ROM optical disks for all As built drawings (one per substation plus one for corporate centre)

-do-

-do-

On completion of entire works -do-

Page-8 P a g e 7

NOTE: (1) The contractor may please note that all resubmissions must incorporate all comments given in the earlier submission by the Employer or adequate justification for not incorporating the same must be submitted failing which the submission of documents is likely to be returned. The drawings which are required to be referred frequently during execution should be submitted on cloth lined paper. The list of such drawings shall be finalised with the Contractor at the time of Award. All major drawings should be submitted in Auto Card Version 12 or better. The instruction Manuals shall contain full details of drawings of all equipment being supplied under this contract, their exploded diagrams with complete instructions for storage, handling, erection, commissioning, testing, operation, trouble shooting, servicing and overhauling procedures. If after the commissioning and initial operation of the substation, manuals require any modifications/ the instruction additions/changes, the same shall be incorporated and the updated final instruction manuals shall be submitted by the Contractor to the Employer.

(2)

(3) (4)

(5)

(6) The Contractor shall furnish to the Employer catalogues of spare parts. 6.0 6.1 6.1.1 MATERIAL/ WORKMANSHIP General Requirement Where the specification does not contain references to workmanship, equipment, materials and components of the covered equipment, it is essential that the same must be new, of highest grade of the best quality of their kind, conforming to best engineering practice and suitable for the purpose for which they are intended. Incase where the equipment, materials or components are indicated in the specification as similar to any special standard, the Employer shall decide upon the question of similarity. When required by the specification or when required by the Employer the Contractor shall submit, for approval, all the information concerning the materials or components to be used in manufacture. Machinery, equipment, materials and components supplied, installed or used without such approval shall run the risk of subsequent rejection, it being understood that the cost as well as the time delay associated with the rejection shall be borne by the Contractor. Page-9

6.1.2

6.1.3

The design of the Works shall be such that installation, future expansions, replacements and general maintenance may be undertaken with a minimum of time and expenses. Each component shall be designed to be consistent with its duty and suitable factors of safety, subject to mutual agreements. All joints and fastenings shall be devised, constructed and documented so that the component parts shall be accurately positioned and restrained to fulfill their required function. In general, screw threads shall be standard metric threads. The use of other thread forms will only be permitted when prior approval has been obtained from the Employer. Whenever possible, all similar part of the Works shall be made to gauge and shall also be made interchangeable with similar parts. All spare parts shall also be interchangeable and shall be made of the same materials and workmanship as the corresponding parts of the Equipment supplied under the Specification. Where feasible, common component units shall be employed in different pieces of equipment in order to minimize spare parts stocking requirements. All equipment of the same type and rating shall be physically and electrically interchangeable. All materials and equipment shall be installed in strict accordance with the manufacturers recommendation(s). Only first-class work in accordance with the best modern practices will be accepted. Installation shall be considered as being the erection of equipment at its permanent location. This, unless otherwise specified, shall include unpacking, cleaning and lifting into position, grouting, levelling, aligning, coupling of or bolting down to previously installed equipment bases/foundations, performing the alignment check and final adjustment prior to initial operation, testing and commissioning in accordance with the manufacturers tolerances, instructions and the Specification. All factory assembled rotating machinery shall be checked for alignment and adjustments made as necessary to reestablish the manufacturers limits suitable guards shall be provided for the protection of personnel on all exposed rotating and / or moving machine parts and shall be designed for easy installation and removal for maintenance purposes. The spare equipment(s) shall be installed at designated locations and tested for healthiness. The Contractor shall apply oil and grease of the proper specification to suit the machinery, as is necessary for the installation of the equipment. Lubricants used for installation purposes shall be drained out and the system flushed through where necessary for applying the lubricant required for operation. The Contractor shall apply all operational lubricants to the equipment installed by him. All oil, grease and other used in the Works/ Equipment shall be purchased in India unless the Contractor has any special requirement for the specific application of a type of oil or grease not available in India. Page-10

6.1.4

6.1.5

6.1.6

6.1.7

6.1.8

A cast iron or welded steel base plate shall be provided for all rotating equipment which are to be installed on a concrete base unless otherwise agreed to by the Employer. Each base plate shall support the unit and its drive assembly, shall be of design with pads for anchoring the units, shall have a raised up all around and shall have threaded in air connections, if so required. Corona and radio interference voltage test and seismic withstand test procedures for equipments shall be in line with the procedure given at Annexure-A and B respectively. Provisions For Exposure to Hot and Humid climate Outdoor equipment supplied under the specification shall be suitable for service and storage under tropical conditions of high temperature, high humidity, heavy rainfall and environment favourable to the growth of fungi and mildew.

6.1.9

6.2

6.2.2

FUNGI STATIC VARNISH Besides the space heaters, special moisture and fungus resistant varnish shall be applied on parts which may be subjected or predisposed to the formation of fungi due to the presence or deposit of nutrient substances. The varnish shall not be applied to any surface of part where the treatment will interfere with the operation or performance of the equipment. Such surfaces or parts shall be protected against the application of the varnish.

6.2.4

Degree of Protection The enclosures of the Control Cabinets, Junction boxes and Marshalling Boxes, panels etc. to be installed shall provide degree of protection as detailed here under: Installed out door: IP- 55 The degree of protection shall be in accordance with IS:13947 (Part-I) / IEC-947 (Part-I) / IS 12063 / IEC 529. Type test report for degree of protection test, on each type of the box shall be submitted for approval.

6.3 6.3.1

RATING PLATES, NAME PLATES AND LABELS Each main and auxiliary item of substation is to have permanently attached to it in a conspicuous position a rating plate of non-corrosive material upon which is to be engraved manufacturers name, year of manufacture, equipment name, type or serial number together with details of the loading conditions under which the item of substation in question has been designed to operate, and such diagram plates as may be required by the Employer. The rating plate of each equipment shall be according to IEC requirement. All such nameplates, instruction plates, rating plates of SA shall be bilingual with Hindi inscription first followed by English. Alternatively two separate plates one with Hindi and the other with English inscriptions may be provided. Page-11

6.3.2

7.0 7.1

DESIGN IMPROVEMENTS / COORDINATION The bidder shall note that the equipment offered by him in the bid only shall be accepted for supply. However, the Employer or the Contractor may propose changes in the specification of the equipment or quality thereof and if the Employer & contractor agree upon any such changes, the specification shall be modified accordingly. If any such agreed upon change is such that it affects the price and schedule of completion, the parties shall agree in writing as to the extent of any change in the price and/or schedule of completion before the Contractor proceeds with the change. Following such agreement, the provision thereof, shall be deemed to have been amended accordingly. The Contractor shall be responsible for the selection and design of appropriate equipments to provide the best co-ordinated performance of the entire system. The basic design requirements are detailed out in this Specification. The design of various components, subassemblies and assemblies shall be so done that it facilitates easy field assembly and maintenance. The Contractor has to coordinate designs and terminations with the agencies (if any) who are Consultants/Contractor for the Employer. The names of agencies shall be intimated to the successful bidders. The Contractor will be called upon to attend design co-ordination meetings with the Engineer, other Contractors and the Consultants of the Employer (if any) during the period of Contract. The Contractor shall attend such meetings at his own cost at New Delhi or at mutually agreed venue as and when required and fully cooperate with such persons and agencies involved during those discussions. QUALITY ASSURANCE PROGRAMME To ensure that the equipment and services under the scope of this Contract whether manufactured or performed within the Contractors Works or at his Sub-contractors premises or at the Employers site or at any other place of Work are in accordance with the specifications, the Contractor shall adopt suitable quality assurance programme to control such activities at all points necessary. Such programme shall be broadly outlined by the contractor and finalised after discussions before the award of contract. The detailed programme shall be submitted by the contractor after the award of contract and finally accepted by POWERGRID after discussion. However, in case detailed valid programme approved by POWERGRID for the equipment already exist, same would be followed till its validity. A quality assurance programme of the contractor shall generally cover the following: (a) His organization structure for the management and implementation of the proposed quality assurance programme. Page-12

7.2

7.3

7.4

7.5

8.0 8.1

(b) Documentation control system; (c) (d) Qualification data for bidders key personnel; The procedure for purchases of materials, parts components and selection of sub-Contractors services including vendor analysis, source inspection, incoming raw material inspection, verification of material purchases etc. System for shop manufacturing and site erection controls including process controls and fabrication and assembly control; Control of non-conforming items and system for corrective actions; Inspection and test procedure both for manufacture and field activities. Control of calibration and testing of measuring instruments and field activities; System for indication and appraisal of inspection status; System for quality audits; System for authorising release of manufactured product to the Purcahser. System for maintenance of records; A quality plan detailing out the specific quality control measures and procedures adopted for controlling the quality characteristics relevant to each item of equipment furnished and/or services rendered.

(e) (f) (g) (h) (i) (j) (k) (l) (n)

(m) System for handling storage and delivery; and

The Employer or his duly authorised representative reserves the right to carry out quality audit and quality surveillance of the system and procedure of the Contractor/his vendors quality management and control activities. 8.2 Quality Assurance Documents The contractor would be required to submit all the Quality Assurance Documents as stipulated in the Quality Plan at the time of Employers inspection of equipment/material. 9.0 9.1 TYPE TESTING, INSPECTION, TESTING & INSPECTION CERTIFICATE All equipment being supplied shall conform to type tests including additional type tests as per technical specification and shall be subject to routine tests in accordance with requirements stipulated under respective parts. Employer reserves the right to witness any or all the type tests. The Contractor shall intimate the Employer the detailed program about the tests atleast three (3) weeks in advance in case of domestic supplies & six (6) weeks in advance in case of foreign supplies. Page-13

9.2

The reports for all type tests and additional type tests as per technical specification shall be furnished by the Contractor alongwith equipment / material drawings. The type tests conducted earlier should have either been conducted in accredited laboratory (accredited based on ISO / IEC Guide 25 / 17025 or EN 45001 by the national accredition body of the country where laboratory is located ) or witnessed by the representative(s) of HVPNL or Utility. The test reports submitted shall be of the tests conducted within last 5 (five) yearsprior to the date of bid opening. In case the test reports are of the test conducted earlier than 5 (five) years prior to the date of bid opening, the contractor shall repeat these test(s) at no extra cost to the Employer. In the event of any discrepancy in the test reports i.e. any test report not acceptable due to any design / manufacturing changes (including substitution of components) or due to non-compliance with the requirement stipulated in the Technical Specification or any/all additional type tests not carried out, same shall be carried out without any additional cost implication to the Employer. For outdoor clamps, type testing and type test reports are not required to be submitted for the makes of POWERGRID approved list of subvendors. For the new makes (other than those POWERGRID approved list of subvendors), type test reports as per relevant standard shall be submitted for Employers approval.

9.4

The Employer, his duly authorised representative and/or outside inspection agency acting on behalf of the Employer shall have at all reasonable times free access to the Contractors/sub-vendors premises or Works and shall have the power at all reasonable times to inspect and examine the materials and workmanship of the Works during its manufacture or erection if part of the Works is being manufactured or assembled at other premises or works, the Contractor shall obtain for the Engineer and for his duly authorised representative permission to inspect as if the works were manufactured or assembled on the Contractors own premises or works. Inspection may be made at any stage of manufacture, despatch or at site at the option of the Employer and the equipment if found unsatisfactory due to bad workmanship or quality, material is liable to be rejected. The Contractor shall give the Employer /Inspector thirty (30) days written notice of any material being ready for joint testing. Such tests shall be to the Contractors account except for the expenses of the Inspector. The Employer /inspector, unless witnessing of the tests is virtually waived, will attend such tests within thirty (30) days of the date of which the equipment is notified as being ready for test/inspection, failing which the Contractor may proceed alone with the test which shall be deemed to have been made in the Inspectors presence and he shall forthwith forward to the Inspector duly certified copies of tests in triplicate. Page-14

9.5

9.6

The Employer or Inspector shall, within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Contractor, of any objection to any drawings and all or any equipment and workmanship which in his opinion is not in accordance with the Contract. The Contractor shall give due consideration to such objections and shall either make the modifications that may be necessary to meet the said objections or shall confirm in writing to the Employer /Inspector giving reasons therein, that no modifications are necessary to comply with the Contract. When the factory tests have been completed at the Contractors or Sub-Contractors works, the Employer/inspector shall issue a certificate to this effect within fifteen (15) days after completion of tests but if the tests are not witnessed by the Employer /Inspector, the certificate shall be issued within fifteen (15) days of receipt of the Contractors Test certificate by the Engineer/Inspector. Failure of the Employer /Inspector to issue such a certificate shall not prevent the Contractor from proceeding with the Works. The completion of these tests or the issue of the certificate shall not bind the Employer to accept the equipment should, it, on further tests after erection, be found not to comply with the Contract. The equipment shall be dispatched to site only after approval of test reports and issuance of CIP by the Employer . In all cases where the Contract provides for tests whether at the premises or at the works of the Contractor or of any Sub-Contractor, the Contractor except where otherwise specified shall provide free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Employer /Inspector or his authorised representative to carry out effectively such tests of the equipment in accordance with the Contract and shall give facilities to the Employer /Inspector or to his authorised representative to accomplish testing. The inspection by Employer and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the agreed quality assurance programme forming a part of the Contract. The Employer will have the right of having at his own expenses any other test(s) of reasonable nature carried out at Contractors premises or at site or in any other place in addition of aforesaid type and routine tests, satisfy that the material comply with the specification. The Employer reserves the right for getting any field tests not specified in respective parts of the technical specification conducted on the completely assembled equipment at site. The testing equipments for these tests shall be provided by the Employer. Page-15

9.7

9.8

9.9

9.10

9.11

10. 10.1

TESTS Pre-commissioning Tests On completion of erection of the equipment and before charging, each item of the equipment shall be thoroughly cleaned and then inspected jointly by the Employer and the Contractor for correctness and completeness of installation and acceptability for charging, leading to initial pre-commissioning tests at Site. The list of pre-commissioning tests to be performed are given in respective chapters and shall be included in the Contractors quality assurance programme.

10.2 Commissioning Tests 10.2.1 The testing equipments required for testing and commissioning shall be arranged by the Contractor. 10.2.2 The specific tests requirement on equipment have been brought out in the respective chapters of the technical specification. 10.2.3 The Contractor shall be responsible for obtaining statutory clearances from the concerned authorities for commissioning the equipment and the switchyard. However necessary fee shall be reimbursed by HVPNL on production of requisite documents. 11.0 11.1 PACKAGING & PROTECTION All the equipments shall be suitably protected, coated, covered or boxed and crated to prevent damage or deterioration during transit, handling and storage at Site till the time of erection. On request of the Employer, the Contractor shall also submit packing details/associated drawing for any equipment/material under his scope of supply, to facilitate the Employer to repack any equipment/material at a later date, in case the need arises. While packing all the materials, the limitation from the point of view of availability of Railway wagon sizes in India should be taken into account. The Contractor shall be responsible for any loss or damage during transportation, handling and storage due to improper packing. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor. Employer takes no responsibility of the availability of the wagons. All coated surfaces shall be protected against abrasion, impact, discolouration and any other damages. All exposed threaded portions shall be suitably protected with either a metallic or a non-metallic protecting device. All ends of all valves and pipings and conduit equipment connections shall be properly sealed with suitable devices to protect them from damage. All metal surfaces shall be subjected to treatment for anti-corrosion protection. All ferrous surfaces for external use unless otherwise stated elsewhere in the specification or specifically agreed, shall be hot-dip galvanized after fabrication. High tensile steel nuts & bolts and spring washers shall be electro galvanized to service condition . All steel conductors including those used for earthing/grounding (above ground level) shall also be galvanized according to IS: 2629. Page-16

11.2

12.0 FINISHING OF METAL SURFACES 12.1

12.2 12.2.1

HOT DIP GALVANISING The minimum weight of the zinc coating shall be 610 gm/sq. m and minimum thickness of coating shall be 85 microns for all items thicker than 6mm. For items lower than 6mm thickness requirement of coating thickness shall be as per relevant ASTM. For surface which shall be embedded in concrete, the zinc coating shall be 610 gm/sq. m minimum. The galvanized surfaces shall consist of a continuous and uniform thick coating of zinc, firmly adhering to the surface of steel. The finished surface shall be clean and smooth and shall be free from defects like discoloured patches, bare spots, unevenness of coating, spelter which is loosely attached to the steel globules, spiky deposits, blistered surface, flaking or peeling off, etc. The presence of any of these defects noticed on visual or microscopic inspection shall render the material liable to rejection. After galvanizing. no drilling or welding shall be performed on the galvanized parts of the equipment excepting that nuts may be threaded after galvanizing. Sodium dichromate treatment shall be provided to avoid formation of white rust after hot dip galvanization. The galvanized steel shall be subjected to six one minute dips in copper sulphate solution as per IS-2633. Sharp edges with radii less than 2.5 mm shall be able to withstand four immersions of the Standard Preece test. All other coatings shall withstand six immersions. The following galvanizing tests should essentially be performed as per relevant Indian Standards. Coating thickness Uniformity of zinc Adhesion test Mass of zinc coating

12.2.2

12.2.3

12.2.4 12.2.5

12.2.6

Galvanised material must be transported properly to ensure that galvanised surfaces are not damaged during transit. Application of zinc rich paint at site shall not be allowed. PAINTING All sheet steel work shall be degreased, pickled, phosphated in accordance with the IS-6005 Code of practice for phosphating iron and sheet. All surfaces, which will not be easily accessible after shop assembly, shall beforehand be treated and protected for the life of the equipment. The surfaces, which are to be finished painted after installation or require corrosion protection until installation, shall be shop painted with at least two coats of primer. Oil, grease, dirt and swaf shall be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with dilute acid followed by washing with running water, rinsing with slightly alkaline hot water and drying. Page-17

12.3 12.3.1

12.3.2

After phosphating, thorough rinsing shall be carried out with clean water followed by final rinsing with dilute dichromate solution and oven drying. The phosphate coating shall be sealed with application of two coats of ready mixed, stoving type zinc chromate primer. The first coat may be flash dried while the second coat shall be stoved. After application of the primer, two coats of finishing synthetic enamel paint shall be applied, each coat followed by stoving. The second finishing coat shall be applied after inspection of first coat of painting. The exterior colour of the paint shall be as per shade no: 697 (for outdoor) & 692 (for indoor) of IS-5 and inside shall be glossy white for all equipment, marshalling boxes, junction boxes, control cabinets, panels etc. unless specifically mentioned under respective parts of the equipments. Each coat of primer and finishing paint shall be of slightly different shade to enable inspection of the painting. A small quantity of finishing paint shall be supplied for minor touching up required at site after installation of the equipments. In case the Bidder proposes to follow his own standard surface finish and protection procedures or any other established painting procedures, like electrostatic painting etc., the procedure shall be submitted alongwith the Bids for Employers review & approval. HANDLING, STORING AND INSTALLATION In accordance with the specific installation instructions as shown on manufacturers drawings or as directed by the Employer or his representative, the Contractor shall unload, store, erect, install, wire, test and place into commercial use all the equipment included in the contract. Equipment shall be installed in a neat, workmanlike manner so that it is level, plumb, square and properly aligned and oriented. Commercial use of switchyard equipment means completion of all site tests specified and energisation at rated voltage. Contractor may engage manufacturers Engineers to supervise the unloading, transportation to site, storing, testing and commissioning of the various equipment being procured by them separately. Contractor shall unload, transport, store, erect, test and commission the equipment as per instructions of the manufacturers supervisory Engineer(s) and shall extend full cooperation to them. In case of any doubt/misunderstanding as to the correct interpretation of manufacturers drawings or instructions, necessary clarifications shall be obtained from the Employer. Contractor shall be held responsible for any damage to the equipment consequent to not following manufacturers drawings/instructions correctly. Page-18

12.3.3

12.3.4

12.3.5

13.0 13.1

13.2

13.3

13.4

Where assemblies are supplied in more than one part, Contractor shall make all necessary mechanical and electrical connections between parts including the connection between buses. Contractor shall also do necessary adjustments/alignments necessary for proper operation of circuit breakers, isolators and their operating mechanisms. All components shall be protected against damage during unloading, transportation, storage, installation, testing and commissioning. Any equipment damaged due to negligence or carelessness or otherwise shall be replaced by the Contractor at his own expense. Contractor shall be responsible for examining all the shipment and notify the Employer immediately of any damage, shortage, discrepancy etc. for the purpose of Employers information only. The Contractor shall submit to the Employer every week a report detailing all the receipts during the weeks. However, the Contractor shall be solely responsible for any shortages or damages in transit, handling and/or in storage and erection of the equipment at Site. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor. The Contractor shall be fully responsible for the equipment/material until the same is handed over to the Employer in an operating condition after commissioning. Contractor shall be responsible for the maintenance of the equipment/material while in storage as well as after erection until taken over by Employer, as well as protection of the same against theft, element of nature, corrosion, damages etc. Where material / equipment is unloaded by Employer before the Contractor arrives at site or even when he is at site, Employer by right can hand over the same to Contractor and there upon it will be the responsibility of Contractor to store the material in an orderly and proper manner. The Contractor shall be responsible for making suitable indoor storage facilities, to store all equipment which require indoor storage. The words erection and installation used in the specification are synonymous. Exposed live parts shall be placed high enough above ground to meet the requirements of electrical and other statutory safety codes. The design and workmanship shall be in accordance with the best engineering practices to ensure satisfactory performance throughout the service life. If at any stage during the execution of the Contract, it is observed that the erected equipment(s) do not meet the above minimum clearances, the Contractor shall immediately proceed to correct the discrepancy at his risks and cost. Page-19

13.5

13.6

13.7

13.8 13.9 13.10 13.11

13.12 Equipment Bases A cast iron or welded steel base plate shall be provided for all rotating equipment which is to be installed on a concrete base unless otherwise agreed to by the Employer. Each base plate shall support the unit and its drive assembly, shall be of a neat design with pads for anchoring the units, shall have a raised lip all around, and shall have threaded drain connections. 14.00 15.00 16.0 16.1 Tools and Tackles Not Applicable Auxiliary Supply Not Applicable SUPPORT STRUCTURE Employer has standardized the design of support structure and other control dimensions as given in standard structural (design) drawings enclosed with Section-Project. The Bidder shall strictly adhere to these dimensions. The Contractor is required to supply standard structures of various equipment. Bidder may also refer relevant Clauses of Part (Structure) in this regard. Any substructure or adopter plate required to meet the above bus termination height other than the standard structure will be supplied by the Contractor as part of the equipment. All brackets, angels, stool or other members necessary for attaching the operating mechanism to the supporting structure shall be engineered and supplied by the Contractor. The Support structures for all equipments shall be supplied by the Contractor. The support structures should be hot dip galvanised with minimum 610 gram/sq.m net of zinc. In case of any deviation in this regard the bid is liable to be considered technically non responsive and shall be liable to be rejected. Support structure shall meet the following mandatory requirements : The minimum vertical distance from the bottom of the lowest porcelain part of the bushing, porcelain enclosures or supportinginsulators to the bottom of the equipment base, where it rests on the foundation pad shall be 2.55 metres. CLAMPS AND CONNECTORS INCLUDING TERMINAL CONNECTORS All power clamps and connectors shall conform to IS:5561 & NEMA CC1 and shall be made of materials listed below : Each equipment shall be supplied with the necessary terminals and connectors, as required by the ultimate design for the particular installation. The conductor terminations of equipment shall be either expansion, sliding or rigid type suitable for 4" IPS (OD : 114.2 mm, ID: 97.18 mm) aluminum tube or suitable for Quad Bersimis Conductor(.The requirement regarding external corona and RIV as specified for any equipment shall include its terminal fittings and the equipment shall be factory tested with the connectors in position. If corona rings are required to meet these requirements they shall be considered as part of that equipment and included in the scope of work. Page-20

16.2 16.3

16.4 16.4.1

17.0 17.1 17.2

17.3

Where copper to aluminum connections are required, bi-metallic clamps shall be used, which shall be properly designed to ensure that any deterioration of the connection is kept to a minimum and restricted to parts which are not current carrying or subjected to stress. The design details of the joint shall be furnished to the Employer by the Contractor. Low voltage connectors, grounding connectors and accessories for grounding all equipment as specified in each particular case, are also included in the scope of Work. No current carrying part of any clamp shall be less than 10 mm thick. All ferrous parts shall be hot dip galvanised. Copper alloy liner of minimum 2 mm thickness shall be cast integral with aluminum body for Bi-metallic clamps. All casting shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be blurred and rounded off. Flexible connectors, braids or laminated straps made for the terminal clamps for bus posts shall be suitable for both expansion or through (fixed/sliding) type connection of 4" IPS AL. tube as required. In both the cases the clamp height (top of the mounting pad to centre line of the tube) should be same. Clamp shall be designed to carry the same current as the conductor and the temperature rise shall be equal or less than that of the conductor at the specified ambient temperature. The rated current for which the clamp/connector is designed with respect to the specified reference ambient temperature, shall also be indelibly marked on each component of the clamp/connector, except on the hardware. All current carrying parts shall be designed and manufactured to have minimum contact resistance. Clamps and connectors shall be designed to be corona controlled. Corona extinction voltage for 400kV class clamps shall not be less than 320kV (rms) respectively and R.I.V. level shall not be more than 1000 micro volts at the test voltage specified in respective Parts. Tests Clamps and connectors should be type tested as per IS:5561 and shall also be subjected to routine tests as per IS:5561. Following type test reports on three samples of similar type shall be submitted for approval for which type test once conducted shall be applicable (i.e. the requirement of test conducted within last five years shall not be applicable). i) ii) Temperature rise test (maximum temperature rise allowed is 35C over 50C ambient) Short time current test Page-21

17.4

17.5

17.6 17.7

17.8

17.9 17.10

17.11 17.11.1

iii) iv) 18.0 18.1

Corona (dry) and RIV (dry) test (for 220 KV and above voltage level clamps) Resistance test and tensile test

Bushings, Hollow Column Insulators, Support Insulators: Bushings shall be manufactured and tested in accordance with IS: 2099 & IEC: 137 while hollow column insulators shall be manufactured and tested in accordance with IEC 233/IS 5621. The support insulators shall be manufactured and tested as per IS 2544/IEC 168 and IEC 273. The insulators shall also conform to IEC 815 as applicable. Support insulators, bushings and hollow column insulators shall be manufactured from high quality porcelain. Porcelain used shall be homogeneous, free from laminations, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified tough and impervious to moisture. Glazing of the porcelain shall be uniform brown in colour, free from blisters, burrs and similar other defects. Support insulators/bushings/hollow column insulators shall be designed to have ample insulation, mechanical strength and rigidity for the conditions under which they will be used. When operating at normal rated voltage there shall be no electric discharge between the conductors and bushing which would cause corrsion or injury to conductors, insulators or supports by the formation of substances produced by chemical action. No radio interference shall be caused by the insulators/bushings when operating at the normal rated voltage. Bushing porcelain shall be robust and capable of withstanding the internal pressures likely to occur in service. The design and location of clamps and the shape and the strength of the porcelain flange securing the bushing to the tank shall be such that there is no risk of fracture. All portions of the assembled porcelain enclosures and supports other than gaskets, which may in any way be exposed to the atmosphere shall be composed of completely non hygroscopic material such as metal or glazed porcelain. All iron parts shall be hot dip galvanised and all joints shall be air tight. Surface of joints shall be trued up porcelain parts by grinding and metal parts by machining. Insulator/bushing design shall be such as to ensure a uniform compressive pressure on the joints. Tests In bushing, hollow column insulators and support insulataors shall conform to type tests and shall be subjected to routine tests in accordance with IS: 2099 & IS: 2544 & IS : 5621. The type test reports shall be submitted for approval. Page-22

18.2

18.3 18.4

18.5

18.6

18.7

18.8

19.1

TESTING AND COMMISSIONING An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the field Q.P./Instructions of the equipment Contractor or Employer without any extra cost to the Employer. The Contractor shall arrange all instruments required for conducting these tests along with calibration certificates and shall furnish the list of instruments to the Employer for approval. (a) Insulation resistance. (b) Phase sequence and proper direction of rotation. (c) Any motor operating incorrectly shall be checked the cause and the conditions corrected. to determine

20.1

Surge Arresters The manufacturer whose Surge Arresters are offered should have designed, manufactured and tested as per IEC/IS or equivalent standard and supplied the Surge Arrester for the specified energy capability with rated system voltage and which are in satisfactory operation for at least 2 (two) years as on the date of bid opening. Operating and maintenance instructions: These instructions shall give sufficient details to enable the employer to maintain, dismantle, reassemble and adjust all parts of the equipment and shall contain the following information.
table of content list of illustration introduction

21.1

22.1

23.1 24.1

the instruction shall contain: - General technical characteristics - a brief general description of the equipment and - a definition of the technical terms used in subsequent pharagraphs of the instruction book Detail description: This shall contain a complete and accurate description of the equipment, its assembly and dismantling, as well as components and accessories. An accurate list stating clearance, tolerances, temperatures, fits, etc. is required. Operating principles: A brief summary of the technical operating basis of the equipment, including diagrams, circuit diagrams and similar ones. Operating instructions: The instructions shall be accurate and easy to understand and shall contain the sequence of individual manipulations required for operation of the equipment, table lists and graphic presentation, should be used as far as possible for making the description understood more readily. The operating and maintenance instructions shall be written and prepared in English by the Contractor. All labels, instructions on equipment shall be written in English by the Contractor. The following information for secondary equipment (distance relays, bus bar and breaker failure relay, differential relay, pilot wire differential relay, over current relays etc) shall be given in CD-ROMs in English:Page-23

1.Operating manuals 2. Maintenance and setting instructions 3. Electrical circuits 4. Soft ware required for local and remote setting, testing, tele metering and getting information from the relays. 5. Contractor shall give 5 sets of CD-ROM equipment. for secondary and primary

25.1 Testing and adjustment: The entire testing and adjustment procedure for equipment after overhauls and during operation shall be dealt with Maintenance instructions are to be divided in to three parts. 1. Preventive maintenance indicating the inspection required at regular intervals, the inspection procedure, the routine cleaning and lubricating operations, the regular safety check and similar steps. Repair and adjustment, describing the inspections fitting and dismantling of parts, fault tracing as well as repair and adjustment procedure. Spare parts list, containing all the necessary data for ordering spare part. MONTHLY PROGRESS REPORTS For the control of the works by the Employer, the Contractor shall prepared detailed monthly progress reports in following form: These reports show the progress of material orders and procurement, material shipments, construction and assembly works included in the contract. It will also include but not limited to commencement dates, percentage of completion (with regards to the affected payments vs. Total contract amount excluding escalation and to the physical realisation of works) and expected completion dates. Progress reports shall show manufacture of goods and construction operations for each item of work the time work under the contract started to the anticipated completion date, there by indicating the periods during which was previously underway as well as estimated future periods of manufacture and construction operations. Monthly progress reports which are prepared at the end of each calendar month by the Contractor shall be submitted to the Employer in three (3) copies and two (2) of them shall be given to the Employer after approval of the regional department not later than seven (7) days after the close of the reporting period. The Employer has the right to withhold an amount not exceeding 1000 US$ or equivalent Rs which are calculated by using selling exchange rates of the Central Bank of India per month from the earnings of the Contractor if proper monthly progress report are not submitted to the Employer in due course Page-24

2. 3. 26.

MONTHLY PROGRESS REPORT 1st page Contractor Sub-Contractor Contract No Contractors Site Engineering(s) name, telephone and fax number 1. Civil Engineer(s) 2. Electrical Engineer (s) 3. Supervisor(s) 4. Site test engineer(s) 5. Commissioning engineer(s) Employers Control Engineer(s) name, Telephone and fax number 1.Civil Engineer: 2.Electrical Engineer Second and the following page Project Report No: Month from.......to..... CHAPTER-I CHAPTER-II a) List of letters submitted by Consortium b) List of letters send by the Employer c) Photocopies of minutes of meeting d) list of project submitted and stage (indicate revision) Work activity CHAPTER-III Delivery of goods (shipped, arrived to port, At customs, arrived to side in good condition not) * Supplied by Contractor a) Local b) Civil Works Erection Site test Overall function test CHAPTER-IV Problem and difficulties confronted with indicating agreements and disagreements CHAPTER V Work program expected to be done next month CHAPTER VI Monetary realization of the project and monthly monetary projection up to completion. Page-25 General

ANNEXURE-A CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) TEST 1. General Unless otherwise stipulated, all equipment together with its associated connectors, where applicable, shall be tested for external corona both by observing the voltage level for the extinction of visible corona under falling power frequency voltage and by measurement of radio interference voltage (RIV). 2. Test Levels: The test voltage levels for measurement of external RIV and for corona extinction voltage are listed under the relevant clauses of the specification. 3. 3.1 Test Methods for RIV: RIV tests shall be made according to measuring circuit as per International Special-Committee on Radio Interference (CISPR) Publication 16-1(1993) Part -1. The measuring circuit shall preferably be tuned to frequency with 10% of 0.5 Mhz but other frequencies in the range of 0.5 MHz to 2 MHz may be used, the measuring frequency being recorded. The results shall be in microvolts. Alternatively, RIV tests shall be in accordance with NEMA standard Publication No. 107-1964, except otherwise noted herein. In measurement of, RIV, temporary additional external corona shielding may be provided. In measurements of RIV only standard fittings of identical type supplied with the equipment and a simulation of the connections as used in the actual installation will be permitted in the vicinity within 3.5 meters of terminals. Ambient noise shall be measured before and after each series of tests to ensure that there is no variation in ambient noise level. If variation is present, the lowest ambient noise level will form basis for the measurements. RIV levels shall be measured at increasing and decreasing voltages of 85%, 100%, 115% and 130% of the specified RIV test voltage for all equipment unless otherwise specified. The specified RIV test voltage for 400 kV is listed in the detailed specification together with maximum permissible RIV level in microvolts. Page-26

3.2 3.3

3.4

3.5

The metering instruments shall be as per CISPR recommendation or equivalent device so long as it has been used by other testing authorities. The RIV measurement may be made with a noise meter. A calibration procedure of the frequency to which noise meter shall be tuned shall establish the ratio of voltage at the high voltage terminal to voltage read by noisel meter. Test Methods for Visible Corona The purpose of this test is to determine the corona extinction voltage of apparatus, connectors etc. The test shall be carried out in the same manner as RIV test described above with the exception that RIV measurements are not required during test and a search technique shall be used near the onset and extinction voltage, when the test voltage is raised and lowered to determine their precise values. The test voltage shall be raised to 130% of RIV test voltage and maintained there for five minutes. In case corona inception does not take place at 130 %, test shall be stopped, otherwise test shall be continued and the voltage will then be decreased slowly until all visible corona disappears. The procedure shall be repeated at least 4 times with corona inception and extinction voltage recorded each time. The corona extinction voltage for purposes of determining compliance with the specification shall be the lowest of the four values at which visible corona (negative or positive polarity) disappears. Photographs with laboratory in complete darkness shall be taken under test conditions, at all voltage steps i.e. 85%, 100%, 115% and 130%. Additional photographs shall be taken at corona inception and extinction voltages. At least two views shall be photographed in each case using Panchromatic film with an ASA daylight rating of 400 with an exposure of two minutes at a lens aperture of f/5.6 or equivalent. The photographic process shall be such that prints are available for inspection and comparison with conditions as determined from direct observation. Photographs shall be taken from above and below the level of connector so as to show corona on bushing, insulators and all parts of energised connectors. The photographs shall be framed such that test object essentially, fills the frame with no cut-off. The test shall be recorded on each photograph. Additional photograph shall be taken from each camera position with lights on to show the relative position of test object to facilitate precise corona location from the photographic evidence. In addition to photographs of the test object preferably four photographs shall be taken of the complete test assembly showing Page-27

3.6

4.

4.1

4.2

relative positions of all the test equipment and test objects. These four photographs shall be taken from four points equally spaced around the test arrangement to show its features from all sides. Drawings of the laboratory and test set up locations shall be provided to indicate camera positions and angles. The precise location of camera shall be approved by Employers inspector, after determining the best camera locations by trial energisation of test object at a voltage which results in corona. 4.3 4.4 The test to determine the visible corona extinction voltage need not be carried out simultaneously with test to determine RIV levels. However, both test shall be carried out with the same test set up and as little time duration between tests as possible. No modification on treatment of the sample between tests will be allowed. Simultaneous RIV and visible corona extinction voltage testing may be permitted at the discretion of Employers inspector if, in his opinion, it will not prejudice other test. Test Records: In addition to the information previously mentioned and the requirements specified as per CISPR or NEMA 107-1964 the following data shall be included in test report: a) b) c) d) e) f) Background noise before and after test. Detailed procedure of application of test voltage. Measurements of RIV levels expressed in micro volts at each level. Results and observations with regard to location interference sources detected at each step. Test voltage shall be recorded when measured through 100 microvolts in each direction. and type of RIV passes

5.

Onset and extinction of visual corona for each of the four tests required shall be recorded.

Page-28

ANNEXURE - B SEISMIC WITHSTAND TEST PROCEDURE

The seismic withstanding test on the complete equipment (except Auto Transformer and Shunt Reactor) shall be carried out along with supporting structure. The bidder shall arrange to transport the structure from his contractors premises/ Power Grid sites for the purpose of seismic withstand test only. The seismic level specified shall be applied at the base of the structure. The accelerometers shall be provided at the terminal pad of the equipment and any other point as agreed by the employer. The seismic test shall be carried out in all possible combinationations of the equipment. The seismic test procedure shall be furnished for approval of the employer.

Page-29

ANNEXURE - C LIST OF SPECIFICATIONS GENERAL STANDARDS AND CODES Wherever Indian Standards have been mentioned, equivalent IEC or any other Internationally recognized standard will also be applicable. India Electricity Rules Indian Electricity Act Indian Indian Factories Act IS-5, IS-335, IS-617, IS-1448 (P1 to P 145) IS-2071 (P1 to P3) IS-12063 Colors for Ready Mixed Paints and Enamels. New Insulating Oils. Aluminium and Aluminium Alloy Ingots and Castings for General Engineering Purposes Methods of Test for Petroleum and its Products. Methods of High Voltage Testing. Classification of degrees provided by enclosures equipment. Insulation Coordination. Code of Practice for Earthing Method of Test for Specific Resistance (Resistivity) of Electrical Insulating Liquids Method of Test for Interfacial Tension of Oil against Water by the Ring Method Method of test for Power factor & Dielectric Constant of Electrical Insulating Liquids. Method for determination of electric strength of insulating oils. Guide for marking of insulated conductors. Guide for uniform system of marking & identification of conductors & apparatus terminals. Methods for Radio Interference Test on High voltage Insulators. Page-30 of protection of electrical Electricity (Supply) Act

IS-2165 P1:1997 P2:1983 IS-3043 IS-6103 IS-6104 IS-6262 IS-6792 IS-5578 IS-11353 -

IS-8263

IS-9224 (Part 1,2&4) IEC-60060 (Part 1 to P4) IEC 60068 IEC-60117 IEC-60156, IEC-60270, IEC-60376 IEC-60437 IEC-60507 IEC-60694 IEC-60815 IEC-60865 (P1 & P2) ANSI-C.1/NFPA.70 ANSI-C37.90A ANSI-C63.21, C63.3 C36.4ANSI-C68.1 ANSI-C76.1/EEE21 ANSI-SI-4 ANSI-Y32-2/C337.2 ANSI-Z55.11 NEMA-107T NEMA-ICS-II

Low Voltage Fuses High Voltage Test Techniques Environmental Test Graphical Symbols Method for the Determination of the Electrical Strength of Insulation Oils. Partial Discharge Measurements. Specification and Acceptance of New Sulphur Hexafloride Radio Interference Test on High Voltage Insulators. Artificial Pollution Tests on High Voltage Insulators to be used on AC Systems. Common Specification for High Voltage Switchgear & Controlgear Standards. Guide for the Selection of Insulators in respect of Polluted Conditions. Short Circuit Current - Calculation of effects. National Electrical Code Guide for Surge Withstand Capability (SWC) Tests Specification for Electromagnetic Noise and Field Strength Instrumentation 10 KHz to 1 GHZ Techniquest for Dielectric Tests Standard General Requirements and Test Procedure for Outdoor Apparatus Bushings. Specification for Sound Level Metres Drawing Symbols Gray Finishes for Industrial Apparatus and Equipment No. 61 Light Gray Methods of Measurements of RIV of High Voltage Apparatus General Standards for Industrial Control and Systems Part ICSI-109 Page-31

Clamps & connectors IS-5561 NEMA-CC1 NEMA-CC 3 -

Hexagon headbolts, screws and nuts of product grade C. Hexagon head bolts, screws and nuts of products grades A and B. Hexagonal Bolts and Nuts (M42 to M150) Fasteners: Bolts, screws and studs Specification and tests for materials Electric power connectors. Electric Power connectors for sub station Connectors for Use between aluminium or aluminum- Copper Overhead Conductors Fittings for Aluminum and steel cored Al conductors for overhead power lines. Porcelain insulators for overhead power lines with a nominal voltage greater than 1000 V. Insulator fittings for overhead power lines with a nominal voltage greater than 1000 V. Dimensions of Ball and Socket Couplings of string insulator units. Insulated bushings for alternating voltages above 1000 V.

Bus hardware and insulators IS: 2121 IS-731 IS-2486 (P1 to P4) IEC-60120 IEC-60137 IEC-60168 -

IEC-60233 IEC-60273

IEC-60305

Tests on indoor and outdoor post insulators of ceramic material or glass for Systems with Nominal Voltages Greater than 1000 V. Tests on Hollow Insulators for use in electrical equipment. Characteristices of indoor and outdoor post insulators for systems with nominal voltages greater than 1000V. Insulators for overhead lines with nominal voltage above 1000V-ceramic or glass insulator units for a.c. systems Characteristics of String Insulator Units of the cap and pintype. Page-32

IEC-60372 (1984)

Locking devices for ball and socket couplings of string insulator units : dimensions and tests. Insulators for overhead lines with a nominal voltage above 1000 V. Characteristics of string insulator units of the long rod type. Dimensions of Clevis and tongue couplings of string insulator units. Wet process proelain insulators Test methods for electrical power insulators For insulators, wet-process porcelain and toughened glass suspension type For wet-process apparatus, post-type Iron and steel hardware Recommendations of the CISPR, tolerances of form and of Position, Part 1 Zinc Coating (Hot-Dip) on iron and steel hardware Dimensions & tolerances for Wrought Aluminum and Aluminum Alloys drawn round tube. Wrought Aluminum and Aluminum Alloy Bars. Tubes and Sections for Electrical Rods, purposes. Aluminum purposes 1350 H19 Wire for electrical porcelain insulators

IEC-60383 (P1 and P2) IEC-60433 IEC-60471 ANSI-C29 ANSI-C29.1 ANSI-C92.2 ANSI-C29.8 ANSI-G.8 CISPR-7B ASTM A-153

Strain and rigid bus-conductor IS-2678 -

IS-5082

ASTM-B 230-82 ASTM-B 231-81 ASTM-B 221 ASTM-B 236-83

Concentric - lay - stranded, aluminum 1350 conductors Aluminum - Alloy extruded bar, road, wire, shape Aluminum bars for electrical purpose (Busbars) Page-33

Galvanizing IS-209 IS-2629 IS-2633 ASTM-A-123 -

Zinc Ingot Recommended Practice galvanizing on iron and steel. for Hot-Dip

Methods for testing uniformity of coating of zinc coated articles. Specification for zinc (Hot Galavanizing) Coatings, on products Fabricated from rolled, pressed and forged steel shapes, plates, bars and strips. Zinc-coated (Galvanized) steel barbed wire

ASTM-A-121-77

Page-34

Steel structures IS-228 (1992) IS-802 (P1 to 3:) IS-806 IS-808 IS-814 IS-816 IS-817 Method of Chemical Analysis of pig iron, cast iron and plain carbon and low alloy steels. Code of practice for use of structural steel in overhead transmission line towers. Code of practice for use of steel tubes in general building construction Dimensions for hot rolled steel beam, column channel and angle sections. Covered electrodes for manual arc welding of carbon of carbon manganese steel. Code of Practice for use of metal arc welding for general construction in Mild steel Code of practice for training and testing of metal arc welders. Part 1 : Manual Metal arc welding. Code of practice for design loads (other than earthquake) for buildings and structures. Steel tubes for structural purposes. Recommended practice for radiographic examination of fusion welded butt joints in steel plates. Hexagonal head bolts, screws & nuts of products grade C. Hexagon headbolts, screws and nuts of product grades A and B. Technical supply condition for threaded steel fasteners. Methods for bend test. Method for tensile testing of steel products. Criteria for earthquake resistant design of structures. Line Pipe. Steel coil for general structural purposes. Code of practice for Radiographic testing. Single rectagular section spring washers for Page-35 bolts, nuts and screws.

IS-875 (P1 to P4) IS-1161 IS-1182

IS-1363 (P1 to P3) IS-1364 IS-1367 (P1 to P18) IS-1599 IS-1608 IS-1893 IS-1978 IS-2062 IS-2595 IS-3063

IS-7205 IS-9595 ANSI-B18.2.1 ANSI-B18.2.2 ANSI-G8.14 ASTM-A6

Recommendations for metal arc welding of carbon and carbon manganese steels. Inch series square and Hexagonal bolts and screws Square and hexagonal nuts Round head bolts Specification for General Requirements for rolled steel plates, shapes, sheet piling and bars of structural use Specifications of structural steel Specification for malleable iron castings Practice for safeguarding against embilement of Hot Galvanized structural steel products and procedure for detaching embrilement Specification for high strength low alloy structural steel Specification for low and intermediate tensile strength carbon steel plates of structural quality Specification for Galvanized steel transmission tower bolts and nuts Specification for High strength low alloy structural manganese vanadium steel. Specification for High strength low alloy colombium- Vanadium steel of structural quality Code for welding in building construction welding inspection Structural welding code American institute of steel construction Manufactured graphite electrodes Mild steel tubes, tubulars and other wrought steel fittings Page-36

ASTM-A36 ASTM-A47 ASTM-A143

ASTM-A242 ASTM-A283

ASTM-A394 ASTM-441 ASTM-A572

AWS D1-0 AWS D1-1 AISC NEMA-CG1

Other civil works standards IS-269 IS2721 IS-278 IS-383 33 grade ordinary steel chain portland link fence cement. fabric Galvanized

Galvanized steel barbed wire for fencing. Coarse and fine aggregates from natural sources for concrete. Mild steel and medium tensile steel bars and hard-dawn steel wire for concrete reinforcement. Code of practice for plain and reinforced concrete. Method of test for strength of concrete. Code of practice for general construction in steel. Steel tubes for structural purposes. Basic requirements for water supply, drainage and sanitation. Methods of sampling and analysis of concrete. Hard-dawn steel wire fabric for concrete reinforcement. Code of Practice for Building drainage.

IS-432 (P1 and P2)

IS-456 IS-516 IS-800 IS-806 IS-1172

IS-1199 IS-1566 IS-1742 IS-1785

Plain hard-drawn steel wire for prestressed concrete. Page-37

IS-1786 IS-1811 IS-1893 IS-2062 IS-2064 IS-2065 IS-2090 IS-2140 IS-2470 (P1 & P2) IS-2514 IS-2645 IS-3025 (Part 1 to Part 48) IS-4091

High strength deformed Steel Bars and wires for concrete reinforcement. Methods of sampling Foundry sands. Criteria for earthquake resistant design of structures. Steel for general structural purposes. Selection, installation and maintenance of sanitary appliances-code of practices. Code of practice for water supply in buildings. High tension steel bars used in prestressed concrete. Standard Galvanized steel wire for fencing. Code of practice for installation of septic tanks. Concrete vibrating tables. Integral cement waterproofing compounds. Methods of sampling and test (Physical and chemical) for water and waste water. Code of practice for design and construction of foundations for transmission line towers and poles. Code of practice for ancillary structures in sewerage system. Plywood for concrete shuttering work. Sewage and drainage pumps. Earth Manual by United States Department of the interior Bureau of Reclamation Zinc/Coated steel chain link fence fabric test for moisture-density relation of soils using 10-lb (4.5 kg) rame land 18-in. (457 mm) Drop.

IS-4111 (Part 1 to P5) IS-4990 IS-5600 USBR E12 ASTM-A392-81 ASTM-D1557-80 -

National buiding code of India 1970

ASTM-D1586

Penetration Test and Split-Barrel

Page-38

(1967) ASTM-D2049-69 ASTM-D2435 BS-5075 -

Sampling of Soils Relative Density of

Test Method for Cohesionless Soils

Test method for Unconsolidated, (1982) Undrained Strengths of Cohesive Soils in Triaxial Compression. Specification for accelerating Part I Admixtures, Retarding Admixtures and Water Reducing Admixtures. Latest CPWD specifications Methods for Determination of Mass of zinc coating coated Iron and Steel Articles BS:443-1969 on zinc

CPWD IS:6745

ACSR BERSIMIS CONDUCTOR

IS:8263

Methods for Radio Interference IEC:4371973 Test on High Voltage Insulators NEMA:107-1964 CISPR Zinc Ingot BS:3436-1961 Aluminum Conductors for IEC:209-1966 Overhead Transmission Purposes Aluminium Conductors galvanized IEC:2091966 steel reinforced extra high voltage (400 kV and above) Reels and Drums forBS:1559-1949 Bare Conductors ISO/R89for Iron

IS:209 IS:398 Part - V BS:215(Part-II) BS:215(Part-II) IS:1778 IS:1521 IS:2629

Method for Tensile Testing 1959 of steel wire Recommended Hot dip and Steel. Method of coating for of

practice Galvanising on Testing zinc Coated

IS:2633 IS:4826

Uniformity Articles.

Hot dip galvanised coatings on round steel wires ASTMA-472-729 Page-39

GALVANISED STEEL EARTHWIRE IS:1521 IS:1778 IS:2629 IS:2633 Method for Tensile Testing ISO/R:89-1959 of Steel Wire Reels and Drums for Bare Conductors Recommended practice forHot Dip Galvanising on Ironand Steel. Methods for testing Uniformityof Coating of Zinc Coated Articles. ASTM:A 475Hot dip Galvanised Coatings 72a on Round Steel Wires BS:443-1969 Method for Determination BS:443-1969of mass of Zinc Coating on Zinc coated Iron and Steel Articles. Zinc ingot BS:3463-1961 Aluminum Conductors for BS:215 (Part-II) overhead transmission purposes. General and safety requirements for electric lighting fittings. Water Dust Dust proof proof tight electric electric proof lighting lighting electric fittings fittings lighting lighting lighting with with fittings. fittings. fittings. metal plastic

IS:4826 IS:6745

IS:209 IS:398 (Pt. I to P5:1992) Lighting Fixtures and Accessories (i) (ii) IS:1913 IS:3528

(iii) IS:4012 (iv) IS:4013 (v) IS:10322 (vi) IS:10322 (vii) IS:2206 (viii) IS:10322 (ix) IS:10322 (x) IS:10322 (xi) IS:2418 (xii) IS:9900 (xiii) IS:1258

Industrial reflectors. Industrial reflectors.

Well glass lighting fittings for use under ground in mines (non-flameproof type). Specification for flood light. Specification for decorative lighting outfits. Lumanaries for street lighting Tubular flourescent lamps High pressure mercury vapour lamps. Specification for Bayonet lamp flourescent lamp. Page-40

(xiv) IS:3323 (xv) IS:1534

Bi-pin lamp holder tubular flourescent lamps. Ballasts for use in flourescent lighting fittings. (Part-I)

(xvi) IS:1569 (xvii)IS:2215 (xviii)IS:3324 (xix) IS:418 (xx) IS:3553 (xxi) IS:2713 (xxii)IS:280

Capacitors for use in flourescent lighting fittings. Starters for flourescent lamps. Holders for starters for tubular flourescent lamps GLS lamps Water tight electric fittings Tubular steel poles MS wire for general engg. Purposes

Page-41

PART - III

CHAPTER - SA SURGE ARRESTORS

CONTENTS

Clause. No. Description

Page No.

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0

General Duty Requirements Constructional Features Fittings & Accessories Tests Spare Parts & Mandatory Maintenance Equipment Technical Parameters Testing & Commissioning

1 1 2 3 4 5 5 8

SURGE ARRESTERS 1.0 1.1 GENERAL : The Surge arresters shall conform to IEC : 99-4 except to the extent modified in the specification and shall also be in accordance with requirements under Chapter-GTR. Arresters shall be of hermetically sealed units, self supporting construction, suitable for mounting on tubular support structures to be supplied by the Contractor. The Surge Arrestors shall be designed for use in the geographic and meteorological conditions as given in the Chapter-GTR. DUTY REQUIREMENTS : a. The surge arresters shall be of heavy duty station class and gapless type without any series or shunt gaps. The surge arresters shall be capable of discharging over-voltages occurring during switching of unloaded transformers, reactors and long lines. 420 kV class Surge arresters shall be capable of discharging of severe reenergisation switching surges on a 400 kV, 450 km long line with Surge impedance of 300 ohms and capacitance of 11986 nF/km and over voltage factor of 2.3 p.u. 420 kV class arrester shall be capable of discharging energy equivalent to class 3 of IEC for a 420 kV system on two successive operation followed immediately by 50 Hz energisation with a sequential voltage profile as specified below : 705 kVp for 3 peaks 580 565 kVp kVp for for 1 0.1 Sec seconds

1.2

1.3

2.0

b.

c.

d.

550 kVp for 10 seconds e. The surge arresters shall be suitable for withstanding Chapter-GTR. forces as defined in

f.

The reference current of the arresters shall be high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage. The surge arresters are being provided to protect the following equipment whose insulation levels are indicated in the table given below:-

g.

Page-1

Equipment to Lightning be protected impulse (kVp) for 420 kV system Power transformer Instrument Transformer Reactor + 1300

Switching Surge (kVp) for 420 kV system + 1050

+ 1425

+ 1050

+ 1300

+ 1050

CB/Isolator Phase to ground + 1425 Across open contacts + 1425 (-/+240)

+ 1050 + 900 (-/+345)

h)

The duty cycle of CB installed in 420/245/145 kV System of the Employer shall be O-0.3 sec-CO-3 min-CO. The Surge Arrester shall be suitable for such circuit breaker duties in the system.

3.0

CONSTRUCTIONAL FEATURES : The features and constructional details of surge arresters shall be in accordance with requirement stipulated hereunder : a) The non-linear blocks shall be of sintered metal oxide material. These shall be provided in such a way as to obtain robust construction, with excellent mechanical and electrical properties even after repeated operations. The surge arresters shall be fitted with pressure relief devices suitable for preventing shattering of porcelain housing and providing path for flow of rated fault currents in the event of arrester failure. Details shall be furnished in the bids alongwith quality checks. The arresters shall not fail due to arrester porcelain contamination. Seals shall be provided in such a way that these are always effectively maintained even when discharging rated lightning current. Outer insulator shall be porcelain conforming to requirements stipulated in Chapter-GTR. Terminal connectors shall conform to requirements stipulated under Chapter-GTR. Porcelain housing shall be so coordinated that external flashover will not occur due to application of any impulse or switching surge voltage upto the maximum design value for arrester. Page-2

b)

c) d)

e)

f)

The end fittings shall be made of corrosion proof material and preferably be nonmagnetic. The name plate shall conform to the requirements of IEC incorporating the year of manufacture. The heat treatment cycle details alongwith necessary quality checks used for individual blocks alongwith insulation layer formed across each block are to be furnished. Metalizing coating thickness for reduced resistance between adjacent discs is to be furnished with additional information schedule of bid proposal sheets alongwith procedure for checking the same. Details of thermal stability test for uniform distribution of current on individual disc is to be furnished. The manufacturer will submit Data for rejection rate of ZnO blocks during manufacturing/operation for the past three years.

g)

h)

i)

4.0

FITTINGS AND ACCESSORIES : a) 390/216/120 kV Arresters shall be complete with insulating base having provision for bolting to flat surface of structure. Self contained discharge counters, suitably enclosed for outdoor use and requiring no auxiliary or battery supply for operation shall be provided for each single pole unit alongwith necessary connection. Suitable leakage current meters should also be supplied within the same enclosure. The reading of milliammeter and counters shall be visible through an inspection glass panel. The terminals shall be robust and of adequate size and shall be so located that incoming and outgoing connections are made with minimum possible bends. The design of the surge monitor shall be such that it is possible to tilt the surge monitor downwards by an angle of up to 45 degrees from Horizontal plane. Micro processor based instruments for monitoring resistive current or wattloss of the arrester shall have to be supplied, if required. Surge monitor consisting of discharge counters and milliammeters should be suitable to be mounted on support structure of the arrester and should be tested for IP55 degree of protection. The standard supporting structure for surge arrester should be provided with a mounting pad, for fixing the surge monitor. The surge monitor should be suitable for mounting on this standard mounting pad. Also all nuts, bolts, washers etc. required for fixing the surge monitor shall have to be supplied by the Contractor. e) Grading/corona rings shall be provided on each complete arrester unit as required. Suitable terminal connectors shall be supplied by the Contractor. Page-3

b)

c)

d)

5.0 5.1

TESTS : In accordance with the requirements stipulated under Chapter-GTR, the surge arresters should have been type tested as per IEC/IS and shall be subjected to routine and acceptance tests in accordance with IEC document. In the switching surge operating duty test, the samples shall be pre-heated to 70 deg. C, (instead of 60 deg. C. as given in IEC) prior to application of long duration surges for contamination test procedures outlined in ANSI : 062-11-1987 may be followed until IEC brings out alternate test procedure for the same. The test reports of the type tests and the following additional type tests shall also be submitted for the Employers review. i) ii) iii) Radio interference voltage test as per Annexure-A of Chapter-GTR. Seismic withstand test as per Annexure-B of Chapter-GTR. Contamination test.

iv) Temporary over voltage withstand test procedure to be mutually agreed) Each metal oxide block of surge arresters shall be tested for the guaranteed specific energy capability in addition to the routine/acceptance test as per IEC-99. 5.2 (a) Acceptance Tests : 1. 2. 3. Measurement of power frequency reference voltage of the arrester units. Lightning Impulse Residual voltage on arrester units (IEC clause 6.3.2). Internal Ionisation or partial Discharge test.

(b) Special Acceptance Test : 1. 2. 3. Thermal stability test on three sections (IEC Clause 7.2.2). Aging & Energy Capability test on blocks (procedure to be mutually agreed). Wattloss test.

(c) Routine Tests : 1. 2. 3. 4. 5. Measurement of reference voltage. Residual voltage test of arrester unit. Internal Ionisation test or partial discharge test. Sealing test. Verticality check on completely assembled Surge arresters as a sample test on each lot. Page-4

(d) Test on Surge Monitors : The Surge monitors shall also be connected in series with the test specimens during residual voltage and current Impulse withstand tests to verify efficacy of the same. Additional routine/ functional tests with one 100A and 10kA current impulse, (8/20 micro sec.) shall also be performed on the Surge monitor. (e) Test on insulators All routine tests shall be conducted on the hollow column insulators as per IEC 233. The following additional tests shall be carried out on 420 kV, 245 kV and 145 kV Insulators: i) Ultrasonic test as a routine test. ii) Pressure test as a routine test. iii) Bending load test in 4 directions at 50% specified bending load as a routine test. Bending load test in 4 directions at 100% specified bending load as a sample test on each lot. Burst pressure test as a sample test on each lot.

iv)

v) 6.0

SPARE PARTS AND MAINTENANCE EQUIPMENT : Bidder shall include in his proposal spare parts and maintenance equipment, as mentioned in Section-Project.

7.0 A. A7.0(a) A7.0(b)

TECHNICAL PARAMETERS : 420 kV CLASS SURGE ARRESTER Rated arrester voltage i) Nominal discharge current 390 kV 10kA of 8/20 microsecond wave.

ii)

Discharge current at which insulation coordination will be done.

20kA of 8/20 microsecond wave

A7.0(c)

Minimum discharge capability arrester voltage and at minimum characteristics whichever is higher. Continuous operating voltage at 50 deg.C

8kJ/kV or corresponding to clause-2.0(d) referred to rated discharge

A7.0(d)

303 kV (rms) Page-5

A7.0(e)

(i)

Min. switching surge residual voltage (1kA)

730 kVp

(ii) Max. switching surge residual voltage (1kA) A7.0(f) Max. residual voltage at i) 10kA nominaL discharge current 20kA nominal discharge current Steep fronted wave residual voltage at 10 kA

780 kVp

900 kVp

ii)

975 kVp

iii)

1050 kVp

A7.0(g)

Long duration discharge class High current short duration test value (4/10 micro second wave) Current for pressure relief test Low current long duration test value (2000 micro sec) Prospective symmetrical fault current Pressure relief class

As per clause 2.0(d)

A7.0(h)

100 kAp

A7.0(i)

40 kA rms

A7.0(j)

As per IEC.

A7.0(k)

40kA (rms) for 0.2 Sec. A

A7.0(l)

Page-6

8.0 8.1

TESTING AND COMMISSIONING An indicative list of tests is given below. Contractor shall perform any additional test based on specialties of the items as per the field Q.P./Instructions of the equipment Contractor or Employer without any extra cost to the Employer. The Contractor shall arrange all instruments required for conducting these tests alongwith calibration certificates and shall furnish the list of instruments to the Employer for approval. (a) Leakage current measurement. (b) Resistance of ground connection. For details, refer O.S. Document no. OS/T&C/BAY/95

Page-7 .

PART-(SE) SWITCHYARD ERECTION

PART- IV

TECHNICAL SPECIFICATION

PART-(SE)

SWITCHYARD ERECTION

PART-(SE) SWITCHYARD ERECTION 1.0

GENERAL The detailed scope of work includes design, detailed engineering, manufacture, testing at works, supply on FOR destination site basis, insurance, handling, storage, erection testing and commissioning of various items and works as detailed in the scope of Part -1. This Part covers the description of the following items. A Supply of B. 1.1 String insulators and hardware including clamps/ connectors ACSR conductor Galvanised Steel Earthwire Aluminium Tubular Bus Bars Spacers Bus post insulators Earthing & Earthing material Lightning protection material Cabling material Other items Erection of all items String Insulators & Hardware The insulators for suspension and tension strings shall conform to IEC383 . Insulator hardware shall conform to IS:2486. 1.1.1 1.1.1.1 Construction Features Suspension and tension insulators shall be wet process porcelain with ball and socket connection. Insulators shall be interchangeable and shall be suitable for forming either suspension or tension strings. Each insulator shall have rated strength markings on it. Page-1

PART-(SE) SWITCHYARD ERECTION 1.1.1.2 When operating at normal rated voltage there shall be no electric discharge between conductor and insulator which would cause corrosion or injury to conductors or insulators by the formation of substances due to chemical action. No radio interference shall be caused when operating at normal rated voltage. The design of the insulator shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. All ferrous parts shall be hot dip galvanized in accordance with the latest edition of IS:2629. The zinc used for galvanizing shall be of grade Zn-99.95 as per IS209. the zinc coating shall be uniform, adherent, smooth, reasonable bright, continuous and free from imperfections such as flux, ash, rust stains bulky white deposits and blisters. Bidder shall make available data on all the essential feature of design including the method of assembly of discs and metal parts, number of discs per insulator string insulators, the manner in which mechanical stresses are transmitted through discs to adjacent parts, provision for meeting expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions. Clamps for insulator strings and Corona Control rings shall be of aluminum alloy as stipulated for clamps and connectors. Insulator hardware shall be of forged steel. Malleable cast iron shall not be accepted except for insulator disc cap. The surface of hardware must be clean, smooth, without cuts, abrasion or projections. No part shall be subjected to excessive localized pressure. The metal parts shall not produce any noise generating corona under operating conditions. The tension Insulator hardware assembly shall be designed for 11500 kg. tensile load. Earth wire tension clam shall be designed for 1000kg tensile load with a factor of safety of two (2) for sub station Hardware Fittings.

1.1.1.3

1.1.1.4

1.1.1.5 1.1.1.6

1.1.1.7

1.1.1.8

The specification of Terminal connector /Interconnector for Bersimis / BPI/ 4 Alum. tube shall be conforming to relevant Standards as practice adopted in PGCIL . The tension string assemblies shall be supplied alongwith suitable turn buckle. Sag compensation springs if required may also be provided.

1.1.1.9

1.1.1.10 All hardware to be used at S/Stn. Gantries shall be bolted type. However, for Termination Gantries Quad Tension fittings of 4X160kN shall be used, the Technical specification of which is attached in the last of this specification. Page-2

PART-(SE) SWITCHYARD ERECTION 1.2

Tests In accordance with the stipulations of the specification, the suspension and tension strings, insulator and hardware shall be subjected to the following type test, acceptance tests and routine tests :

1.2.1

Type Tests on Insulator Strings ( Bolted Type ) : The test reports for following type tests shall be submitted for approval . a) Power frequency voltage withstand test with corona control rings under wet condition as per IEC 383. b) Switching surge voltage withstand test [400 KV class only] under wet condition as per IEC 383. c) Lightning Impulse voltage withstand test with corona control rings under dry condition as per IEC 383. Corona Extinction Voltage test (Dry) The sample assembly when subjected to power frequency voltage shall have a corona extinction voltage of not less than 320KV (rms) for 400KV line to ground under dry condition. There shall be no evident of Corona on any part of the sample. The atmospheric condition during testing shall be recorded and the test results shall be accordingly corrected with suitable correction factor as stipulated in IEC 383. d) RIV Test (Dry) Under the conditions as specified under (e) above the insulator string alongwith complete hardware fittings shall have a radio interference voltage level below 1000 microvolts at 1 MHz when subjected to 50 Hz AC line to ground voltage of 320Kv for 400KV string under dry conditions. The test procedure shall be in accordance with IS 8263/IEC 437. e) Mechanical strength test The complete insulator string alongwith its hardware fitting excluding arcing horn, corona control ring, grading ring, tension/suspension clamps shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string components shall not show any visual deformation and it shall be possible to dismantle them by hand. Hand tools may be sued to remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the Page-3

PART-(SE) SWITCHYARD ERECTION load shall be further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded. 1.2.2 Acceptance Test on Hardware Fitting ( Bolted type only) : a) b) c) d) e) f) Visual examination as per Cl. 5.10 of IS:2486 (Part-I). Verification of Dimensions as per Cl. 5.8 of IS:2486 (Part-I). Galvanizing/Electroplating tests as per Cl. 5.10 of IS:2486 (Part-I). Slip strength test as per Cl. 5.4 of IS:2486 (Part-I). Shore hardness test for the Elastometer (If applicable as per the value guaranteed by the Bidder) Mechanical strength test for each component (including corona control rings and arcing horns). The load shall be so applied that the component is stressed in the same way as it would be in actual service and the procedure as given in 1.2.13.1 (g) above should be followed. g) Test on locking device for ball and socket coupling as per IEC 372(2)

1.2.3 Routine Test on hardware Fittings( Bolted type only) : a) b) a) Visual examination as per Cl 5.10 of IS:2486 (Part-I) Mechanical strength Test as per Cl 5.11 of IS:2486 (Part-I) Chemical analysis and mechanical hardness tests and magnetic particle inspection for fabricated hardware : -

The chemical analysis, hardness tests and magnetic particle inspection for malleable casting will be as per the internationally recognized procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding tests will be as discussed and mutually agreed to by the Contractor and Employer in Quality Assurance Program. 1.3 INSULATOR STRING a) Power frequency withstand voltage of the complete string with Corona Control ring (wet) KV rms 400KV 680 Page-4

PART-(SE) SWITCHYARD ERECTION b) c) d) e) Lightning impulse withstand Voltage of string with Corona Control rings (dry) KVp Switching surge withstand voltage of string with Corona Control rings (wet) KVp Minimum corona extinction voltage level of string with Corona Control rings (dry) KV rms RIV level in micro volts of string with Corona Control rings at 320KV (rms) for 400KV string and 156 KV for 220KV string across 300 Ohms resistor at 1 MHz Total creepage distance of the insulator string (mm) +1550 +1050 320 1000 (Max.)

f)

10500

For termination gantries near TL No. 108, Quad tension fittings of Bersimis conductor of Transmission lines will be used and For S/Stn. Gantries, double insulator strings of tension type and Single suspension Pilot fittings of Suspension type shall be used. 2.0 2.1

ACSR BERSIMIS CONDUCTOR Details of Conductor

2.1.1 The Conductor shall conform to IS:398 (Part V) 1982 except where otherwise specified herein. 2.1.2 The details of the conductor are tabulated below : a) Stranding and wire diameter b) Number of Strands Steel Steel core 1st Steel Layer 2nd steel layer 1st Aluminum Layer 2nd Aluminum Layer 3rd Aluminum Layer c) Sectional area of aluminium d) Total sectional area e) Overall diameter : 42/4.57mmAll+7/2.54 mm steel : :1 :6 :0 :8 : 14 : 20 : 689.5 sq mm : 725.0 sq mm : 35.05 mm Page-5

PART-(SE) SWITCHYARD ERECTION f) Approximate weight g) Calculated d.c. resistance at 20 deg C h) Minimum UTS : 2181 kg/km : .04242 ohm/km : 154 KN

2.1.3 The details of aluminium strand are as follows : i) Minimum breaking load of strand before stranding : 2.64 KN ii) Minimum breaking load of strand after stranding : 2.51 KN iii) Maximum D.C. resistance of : 0.001738 Ohms strand at 20 deg C 2.1.4 The details of steel strand are as follows : i) Minimum breaking load : of strand before stranding ii) Minimum breaking load of strand after stranding : iii) Minimum number of twist : to be withstood in torsion test when tested on a gauge length of 100 times diameter of wire 2.2 2.2.1` Workmanship The finished conductor shall be smooth, compact, uniform and free from all imperfections including spills and splits, die marks, scratches, abrasions, scuff marks, kinks (protrusion of wires), dents, press marks, cut marks, wire cross over, over riding, looseness (wire being dislocated by finger/hand pressure and/or unusual bangle noise on tapping), material inclusions, white rust, power formation or black spots (on account of reaction with trapped rain water etc.), dirt, grit etc. All the aluminium and steel strands shall be smooth, uniform and free from all imperfections, such as spills and splits, die marks, scratches, abrasions and kinks after drawing. `The steel strands shall be hot dip galvanized and shall have a minimum zinc coating o f260 gm/sq m after stranding of the uncoated wire surface. The zinc coating shall be smooth, continuous and of uniform thickness, free from imperfections and shall withstand minimum three dips after stranding in standard Preece test. The finished strands and the individual wires shall be of uniform quality and have the same properties and characteristics as prescribed in ASTM designation : B 498-74. Page-6 6.87 KN 6.53 KN 18 before stranding 16 after stranding

2.2.2`

2.2.3

PART-(SE) SWITCHYARD ERECTION 2.2.4 `The steel strands shall be preformed and postformed in order to prevent spreading of strands in the event of cutting of composite core wire. Care shall be taken to avoid damage to galvanization during performing and postforming operation. Joints in Wires Aluminium Wires No joints shall, be permitted in the individual wires in the outermost layer of the finished conductor. However, joints in the 12 wire and 18 wire inner layers of the conductor shall be allowed but these joints shall be made by cold pressure butt welding and shall be such that no such joints are within 15 meters of each other in the complete stranded conductor. 2.3.2 Steel Wires There shall be no joint of any kind in the finished wire entering into the manufacture of the strand. There shall also be no strand splices in any length of the completed stranded steel core of the conductor. Tolerances The manufacturing tolerances to the extent of the following limits only shall be permitted in the diameter of individual aluminum and steel strands and lay-ratio of the conductor. a) Diameter of Aluminum and steel strands : Aluminium Steel b) Standard 4.57 mm 2.54 mm Maximum 4.61 mm 2.57 mm Maximum 4.53 mm 2.51 mm

2.3 2.3.1

2.4

Lay ratio of Conductor : Steel Aluminium 7 Wire Layer 8 Wire Layer 14 Wire Layer 20 Wire Layer Maximum 24 17 16 13 Minimum 16 10 10 10

2.5 2.5.1

Materials Aluminium The aluminum strands shall be hard drawn from electrolytic aluminium rods having purity not less than 99.5% and a copper content not exceeding 0.04%. Page-7

PART-(SE) SWITCHYARD ERECTION 2.5.2 Steel The steel wire strands shall be drawn from high carbon steel wire rods and shall conform to the following chemical composition : Element Carbon Manganese Phosphorus Sullphur Silicon 2.5.3 Zinc The Zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity. It shall conform to and satisfy all the requirements of IS:209-1979. 2.6 2.6.1 2.7 2.7.1 2.7.2 Standard Length The Conductor shall be supplied in standard length of 1500 metres as required. No joint shall be allowed within a single span of stringing. Tests : The following type, acceptance & routine tests and tests during manufacturing shall be carried out on the conductor. Type Tests The equipment should be offered type tested. Test reports should not be more than seven years old reckoned from the date of bid opening in respect of all the tests carried out in accredited laboratories ( based on ISO/IEC) by a reputed accreditatic body or witnessed by HVPNL or another electric power utility and be submitted by the successful Bidder to HVPNL for approval as per schedule given in Bar chart.:a) UTS test on stranded Conductor b) Corona extinction voltage test (dry) ) ) ) ) ) c) Radio Interference ) voltage test (dry) ) ) d) DC resistance test ) on stranded conductor ) % Composition 0.50 to 0.85 0.50 to 1.10 not more than 0.035 not more than 0.045 0.10 to 0.35

As per Annexure-A

Page-8

PART-(SE) SWITCHYARD ERECTION 2.7.3 Acceptance Tests a) Visual check for joints, scratches etc. and lengths of conductor lengths of conductor b) ) ) ) ) Dimensional check on steel and aluminum ) steel and aluminium strands ) strands ) ) Check for lay ratios of various layers ) of various layers ) ) Galvanising test on steel strands ) strands ) ) Torsion and Elongation test on steel ) strands )

As per Annexure-A

c) d) e)

- do

f) Breaking load test on steel and aluminium ) strands ) ) g) Wrap test on steel and ) aluminium strands ) ) h) DC resistance test on aluminium strands ) ) i) UTS test on welded joint of aluminium ) strands

IS:398 (Part-V) 1982 Clauses 12.5.2, 12.7 & 12.8 As per Annexure-A

NOTE : All the above tests except test mentioned at (a) shall be carried out on aluminium and steel strands after stranding only. 2.7.4 Routine Tests a) Check to ensure that the joints are as per specification. b) c) 2.7.5 Check that there are no cuts, fins etc. on the strands All acceptance test as mentioned in Clause-2.7.3 above to be carried out on each coil Tests During Manufacture a) Chemical analysis of zinc used for galvanizing b) Chemical analysis of aluminium used for making aluminium strands b) Chemical analysis of aluminium used for making aluminium strands ) ) ) ) ) ) ) )

As per Annexure-A

Page-9

PART-(SE) SWITCHYARD ERECTION 2.7.6 Sample Batch for Type Testing The Contractor shall offer material for selection of samples for type testing, only after getting quality assurance plans approved from Employers Quality Assurance Department. The sample shall be manufactured strictly in accordance with the Quality Assurance Plan approved by Employer. 3.0 3.1 GALVANISED STEEL EARTHWIRE Details of Earthwire

3.1.1 The galvanized steel earth wire shall generally conform to the specification of ACSR core wire as mentioned in IS:398 (Part-II) except where otherwise specified herein. 3.1.2 The details of the earth wire are tabulated below: a) b) c) d) e) f) g) h) Stranding and wire diameter Number of strands Steel core Total sectional area Overall diameter Approximate weight Calculated d.c.resisTance at 200C Minimum ultimate tensile Strength Direction of lay of outer layer 3.2 WORKMANSHIP : Right hand : 68.4kN : : : : : 1 6 73.65mm2 583 kg/km 2.5 ohms/km : 7/3.66 mm steel

3.2.1 All steel strands shall be smooth, uniform and free from all imperfections, such as spills and splits, die marks, scratches, abrasions and kinks after drawing and also after stranding. 3.2.2 The finished material shall have minimum brittleness as it will be subjected to appreciable vibration while in use. 3.2.3 The steel strands shall be hot dip galvanized (and shall have a minimum zinc coating of 275 gms/sq.m) after stranding of the uncoated wire surface. The zinc coating shall be smooth, continuous, of uniform thickness, free from imperfections and shall withstand three and a half dips after stranding in standard Preece test. The steel wire rod shall be of such quality and purity that, when drawn to the size of the strands specified and coated with zinc, the finished strands shall be of uniform quality and have the same properties and characteristics in ASTM designation B498-74. Page-10

PART-(SE) SWITCHYARD ERECTION 3.2.4 The steel strands shall be performed and postformed in order to prevent spreading of strands while cutting of composite earthwire. Care shall be taken to avoid damage to galvanization during performing and postforming operation. 3.2.5 To avoid susceptibility towards wet storage stains (white rust), the finished material shall be provided with a protective coating of boiled linseed oil. 3.3 JOINTS IN WIRES There shall be no joint of any kind in the finished steel wire strand entering into the manufacture of the earth wire. There shall be no strand joints or strand splices in any length of the completed stranded earth wire. 3.4 TOLERANCES The manufacturing tolerances to the extent of the following limits only shall be permitted in the Diameter of the individual steel strands and lay length of the earth wire: Standard Diameter Lay length 3.5 3.66mm 181mm Maximum 3.75mm 198mm Minimum 3.57mm 165mm

MATERIALS

3.5.1 Steel The steel wire strands shall be drawn from high carbon steel rodes and shall conform to the following requirements as to the chemical composition: Element Carbon Manganese Phophorous Sulphur Silicon % Composition Not more than 0.55 0.4 to 0.9 Not more than 0.04 Not more than 0.04 0.15 to 0.35 Page-11

PART-(SE) SWITCHYARD ERECTION 3.5.2 Zinc The Zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity. It shall conform to and satisfy all the requirements of IS:209-1979. 3.6 STANDARD LENGTH

3.6.1 The earthwire shall be supplied in standard drum length of manufacturer. 3.7 TESTS

3.7.1 The following type, routine & acceptance tests and tests during manufacturing shall be carried out on the earthwire. 3.7.2 TYPE TESTS In accordance with the stipulation of specification, the following type tests reports of the earthwire shall be submitted for approval as per clause 9.2 of Part-GTR. a) b) a) UTS Test DC resistance test Visual check for joints scratches etc. and length of Earthwire Dimensional check Galvanising test Lay length check Torsion test Elongation test Wrap test DC resistance test Breaking load test Chemical Analysis of steel ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) As per Annexure-B

3.7.3 ACCEPTANCE TESTS

b) c) d) e) f) g) h) i) j)

As per Annexure-B

IS:398 (Part-III) 1976

Page-12

PART-(SE) SWITCHYARD ERECTION 3.7.4 ROUTINE TESTS a) b) Check that there are no cuts, fins etc. on the strands. Check for correctness of stranding.

3.7.5 TESTS DURING MANUFACTURE a) Chemical analysis of zinc used for galvanizing Chemical analysis of steel ) ) ) ) ) ) As per Annexure-B

b)

3.7.6 SAMPLE BATCH FOR TYPE TESTING The Contractor shall offer material for sample selection for type testing, only after getting quality assurance programme approved by the Employer. The samples for type testing shall be manufactured strictly in accordance with the Quality Assurance Programme approved by the Employer. 4.0 4.1 TUBULAR BUS CONDUCTORS General Aluminium used shall be grade 63401 WP (range 2) conforming to IS:5082. 4.2 Constructional Features

4.2.1 For outside, diameter (OD) & thickness of the tube shall be no minus tolerance, other requirements being as per IS:2678 and IS:2673. 4.2.2 The aluminium tube shall be supplied in suitable cut length to minimize wastage. 4.2.3 The welding of aluminium tube shall be done by the qualified welders duly approved by the Employer. 4.2.4 The welding sleeves and corona caps as per requirement shall be suitable for 4 aluminum tube and shall be conforming to relevant IS/IEC. Page-13

PART-(SE) SWITCHYARD ERECTION 4.3 Tests In accordance with stipulations of the specification, Routine tests shall be conducted on tubular bus conductors as per IS:5082. Also the wall thickness and ovality of the tube shall be measured by the ultrasonic method. In addition to the above tests, 0.2% proof tests on both parent metal and Aluminium tube after welding shall be conducted. 4.4 Parameters a) b) c) d) e) 5.0 5.1 Size Outer diameter (mm) Thickness (mm) Cross-sectional area (sq.mm) Weight (kg/m) 4IPS (EH Type) 114.2 8.51 2825.61 7.7

EARTHING CONDUCTORS General All conductors buried in earth and concrete shall be of mild steel. All conductors above ground level and earthing lads shall be of galvnaised steel, except for cable trench earthing.

5.2

Constructional Features

5.2.1 Galvanised Steel a) b) c) Steel conductors above ground level shall be galvanised according to IS:2629. The minimum weight of the zinc coating shall be 618 gm/sq.m. and minimum thickness shall be 85 microns. The galvanized surfaces shall consist of a continuous and uniformly thick coating of zinc, firmly adhering to the surfaces of steel. The finished surface shall be clean and smooth and shall be free from defects like discoloured patches, bare spots, unevenness of coating, spelter which is Loosely attached to the steel globules, spiky deposits, blistered surfaces, flaking or peeling off etc. The presence of any of these defects noticed on visual or microscopic inspection shall render the material liable to rejection. Page-14

PART-(SE) SWITCHYARD ERECTION 5.3

Tests In accordance with stipulations of the specifications galvanized steel shall be subjected to four one minute dips in copper sulphate solution as per IS:2633.

6.0 6.1

SPACERS General Spacers shall conform to IS:10162. The spacers are to be located at a suitable spacing to limit the short circuit forces as per IEC 865. Wherever 400 kV standard gantry structures are being used, the spacer span(s) for different conductor/span configurations and corresponding short circuit forces shall be as per Annexure-D.

6.2 6.2.1 6.2.2 6.2.3 6.3

Constructional Features No magnetic material shall be used in the fabrication of spacers except for GI bolts and nuts. Spacer design shall be made to take care of fixing and removing during installation and maintenance. The design of the spacers shall be such that the conductor does not come in contact with any sharp edge. Tests Each type of spacers shall be subjected to the following type tests, acceptance tests and routine tests:

6.3.1 a)

Type Tests: Following type test reports shall be submitted for approval as per clause 9.2 of Part-GTR. Clamp slip tests The sample shall be installed on test span of twin conductor bundle string or quadruple conductor bundle string (as applicable) at a tension of 44.2 KN. One of the clamps of the sample when subjected to a longitudinal pull of 2.5 KN parallel to the axis of the conductor shall not slip on the conductor. The permanent displacement between the conductor and the clamp of sample measured after removal of the load shall not exceed 1.0 mm. Similar tests shall be performed on the other clamp of the same sample. Page-15

PART-(SE) SWITCHYARD ERECTION b) c) Fault current test as per CL 5.14.2 of IS : 10162. Corona Extinction voltage test (dry) This test shall be performed on 400 kV and 220 kV equipment as per procedure mentioned at Annexure C, minimum corona extinction voltage shall be 320 kV (rms) line to ground and 156 kV (rms) line to ground for 400 kV and 220 kV spacers respectively. RIV test (Dry) This test shall be performed as per procedure mentioned at Annexure C, Maximum RIV level at 305 kV (rms) line to ground and 156 kV (rms) line to ground for 400 kV and 220 kV spacers respectively shall be 1000 micro volts, across 300 ohm resistor at 1 MHz. Resilience test (if applicable) Tension test, f) g) h) 6.3.2 a) b) c) d) e) f) g) h) i) j) Log decrement test (if applicable) Compression Test Galvanizing test Acceptance Test Visual Examination Dimensional verification Movement test Clamp slip test Clamp bolt torque test (if applicable) Assembly torque test Compression test Tension test Galvanizing test Hardness test for neoprene (if applicable) The shore hardness of different points on the elastometer surface of cushion grip clamp shall be measured by shore hardness meter. It shall be between 65 to 80. Page-16

d)

e)

PART-(SE) SWITCHYARD ERECTION k) Ultimate tensile strength test The UTS of the relating rods shall be measured. It shall not be less than 35 kg /sq. mm

6.3.3 ROUTINE TEST a) Visual examination b) Dimensional verification. 6.0 BUS POST INSULATORS The post insulators shall conform in general to latest IS: 2544, IEC-168 and IEC -815. 7.1 7.1.1 Constructional features: Post type insulators shall consist of a porcelain part permanently secured in a metal base to be mounted on the supporting structures. They shall be capable of being mounted upright. They shall be designed to withstand any stocks to which they may be subjected to by the operation of the associated equipment. Only solid core insulators will be acceptable. Porcelain used shall be homogeneous, free from lamination, cavities and other flaws or imperfections that might effect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. Glazing of the porcelain shall be of uniform brown in colour, free from blisters, burrs and other similar defects. The insulator shall have alternate long and short sheds with aerodynamic profile. The shed profile shall also meet the requirements of IEC -815 for the specified pollution level. When operating at normal rated voltage there shall be no electric discharge between conductor and insulators which would cause corrosion or injury to conductors to insulators by the formation of substance produced by chemical action. The design of the insulators shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. All ferrous parts shall be hot dip galvanized in accordance with the latest edition of IS : 2633 & IS : 4579. The zinc used for galvanizing shall be grade Zn 99.95 as per IS : 209. The zinc coating shall be uniform, adherent, smooth, reasonably, bright, continuous and free from imperfection such as flux ash, rust stains, bulky white deposits and blisters. The metal parts shall not produce any noise generating corona under the operating conditions: Page-17

7.1.2 7.1.3 7.1.4

7.1.5

7.1.6 7.1.7

PART-(SE) SWITCHYARD ERECTION 7.1.8 a) Every bolt shall be provided with a steel washer under the nut so that part of the threaded portion of the bolts is within the thickness of the parts bolted together. Flat washer shall be circular of a diameter 2.5 times that of bolt and of suitable thickness. Where bolt heads/ nuts bear upon the beveled surface they shall be provided with square tapered washers of suitable thickness to afford a seating square with the axis of the bolt. All bolts and nuts shall be of steel with well formed hexagonal heads forged from the solid and shall be hot dip galvanized. The nuts shall be good fit on the bolts and two clear threads shall show through the nut when it has been finally tightened up.

b)

c)

7.1.9

Bidder shall make available data on all the essential features of design including the method of assembly of shells and metals parts, number of shells per insulator, the manner in which mechanical stresses are transmitted through shells to adjacent parts, provision for meeting expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions. Tests In accordance with the stipulations of the specifications, the post insulators shall be subject to type, acceptance, sample and routine tests as per IS: 2544 and IEC-168. In addition to acceptance / sample / routine test as per IS: 2544 and IEC 168, the following tests shall also be carried out. a) b) c) d) Ultrasonic test as an acceptance test. Soundness test, metallurgical tests and magnetic test on MCI caps and pedestal tests as acceptance test All hot dip galvanized components shall be subject to check for uniformity of thickness and weight of zinc coating on sample basis. The bending test shall be carried out at 50% minimum failing load in four directions as a routine test and at 100% minimum failing load in four directions as an acceptance test. Acceptance norms for visual defects allowed at site and also at works shall be agreed in the quality plan. Page-18

7.2

7.2.1

e)

PART-(SE) SWITCHYARD ERECTION 7.2.2 In accordance with the stipulation of specification, the following type tests reports of the post insulators shall be submitted for approval as per clause 9.2 of Part GTR. a) b) c) d) e) f) g) 7.3 Power frequency withstand test (dry & wet) Lighting impulse test (dry) Switching impulse test (wet ) (for 420 kV insulator only) Measurement of RIV (dry) (As per annexure C) (As per annexure C)

Corona extinction voltage test (dry ) Test for deflection under load Test for mechanical strength

Technical parameters for Bus Post Insulators: a) b) c) d) e) f) g) h) i) j) k) Voltage class (kV ) Dry and wet one minute power frequency withstand voltage (kV rms) Dry lighting impulse withstand voltage (kVp) Wet switching surge withstand voltage (kVp) Max. ratio interference voltage (in microvolts) at voltage of 305 kV (rms) and 156 (rms) for 400 kV & 220 kV respectively between phase to ground Corona extinction voltage (kV rms) Total minimum cantilever strength (kg) Minimum torsional moment Total height of insulator (mm) PCD Top (mm) Bottom (mm) 127 300 Page-19 3650 Type Solid core 420 680 1425 1050 500 320 (min) 800

PART-(SE) SWITCHYARD ERECTION l) No. of bolts Top Bottom m) Diameter of bolts /holes (mm) Top Bottom dia n) o) Pollution level as per IEC -815 M16 18 Heavy (III) 4 8

Minimum total creepage distance for heavy pollution 10500 (mm)

7.3.1 if corona extinction voltage is to be achieved with the help of corona ring or any other similar device, the same shall be deemed to be included in the scope of the contractor. 8.0 8.1 EARTHING The earthing shall be done in accordance with requirements given hereunder and drawing titled Earthing Details enclosed with the specification. The earthmat design shall be done by the contractor as per IEEE-80. The soil resistivity measurement shall also be done by the contractor. The main earthmat shall be laid in the switchyard area in accordance with the approved design requirement. Neutral points of system of different voltages, metallic enclosures and frame works associated with all current carrying equipments and extraneous metalworks associated with electric system shall be connected to a single earthing system unless stipulated otherwise. Earthing and lighting protection system installation shall be in strict accordance with the latest editions of Indian electricity rules, relevant Indian standards and codes of practice and regulations existing in the locality where the system is installed : a) b) c) d) Code of practice for earhing IS : 3043 Code of practice for the protection of building and allied structures against light lighting IS : 2309. Indian electricity rules 1956 with latest amendments. National electricity safety code IEEE-80. Page-20

8.2

8.3

PART-(SE) SWITCHYARD ERECTION 8.4

Details of Earthing system a) b) c) d) Item Main earhhing conductor to be buried dia ground Conductor above ground & earthing leads (for equipment) Conductor above ground & earthing leads (for columns & aux. structures) Earthing of indoor LT panels, control panels and outdoor marshalling boxes, MOM boxes & lighting panels etc. Rod earth electrode Pipe earth electrode (in treated earth pit) as per IS. Earthing for motors Earthing conductor along conductor cable trenches Earrhing of lighting poles Size 40 mm dia 75 X 12 mm GS flat 75 X 12 mm GS flat 50 X 6 mm GS flat Material Mild steel rod Galvanized steel Galvanized steel Galvanized steel

e) f)

40 mm dia, 3000 mm long 40 mm dia, 3000 mm long 25X3 mm GS flat 50 X 6 mm MS flat 20 mm dia 3000 mm long

Mild steel Galvanized steel

g) h) i)

Galvanized steel Mild steel Mild steel rod

The sizes of the earthing conductor indicated above are the minimum sizes. 8.5 8..5.1 8.5.2 Earthing Conductor Layout Earthing conductors in outdoor areas shall be buried at least 600 mm below finished ground level unless stated otherwise. Wherever earthing conductor crosses cable trenches, underground service ducts pipes, tunnels, railway tracks etc, it shall be laid minimum 300 mm below them and shall be circumvented in case it fouls with equipment / structure foundations. Tap connections from the earthing grid to the equipment / structures to be earthed, shall be terminated on the earthing terminals of the equipment/structures as per Earthing details (drawing enclosed). Page-21

8.5.3

PART-(SE) SWITCHYARD ERECTION 8.5.4 Earthing conductor or leads along their run on cable trench, ladder, walls etc shall be supported by suitable welding /clearing at intervals of 750 mm. wherever, it passes through walls, floors etc. galvanized iron sleeves shall be provided for the passage of the conductor and both ends of the sleeve shall be prevent the passage of water through the sleeves. Earthing conductor around the building shall be buried in earth at a minimum distance of 1500 mm from the outer boundary of the building. In case, high temperature is encountered at some location, the earthing conductor shall be laid minimum 1500 mm away from such location. Earthing conductors crossing the road shall be laid 300 mm below road or at greater depth to suit the site conditions. Earthing conductors embedded in the concrete shall have approximately 50 concrete cover. Equipment and Structures Earthing Earthing pads shall be provided for the apparatus / equipment at accessible position. The connection between earthing pads and the earrhing grid shall be made by two short earthing lead (one direct and another through the support structures) free from kinks and splices. In case earthing pads are not provided on the item to be earthed, same shall be provided in consultation with Employer. Whether specifically shown in drawings or not, steel /RCC columns, metallic stairs etc. shall be connected to the nearby earthing grid conductor by two earthing leads. Electrical continuity shall be ensured by bonding different sections of hand rails and metallic stairs. Mettallic pipes, conduits and cable tray sections for cable installation shall be bonded to ensure electrical continuity and connected to earthing conductors at regular interval. Apart from intermediate connections, beginning points shall also be connected to earthing system. Mettalic conduits shall not be used as earth continuity conductor. Wherever earthing conductor crosses or runs along metallc structures such as gas, water, steam conduits etc and steel reinforcement in concrete it shall be bonded to the same. Light poles, junction boxes on the poles, cable and cable boxes /glands, lockout switches etc shall be connected to the earthing conductor running along with the supply cable which inturn shall be connected to earthing grid conductor at a minimum two points whether specifically shown or not. Page-22

8.5.5

8.5.6 8.5.7 8.6 8.6.1

8.6.2

8.6.3

8.6.4 8.6.5

8.6.6

PART-(SE) SWITCHYARD ERECTION 8.6.7 8.6.8 Railway tracts within switchyard area shall be earthed at a spacing of 30 m and also at both ends. Earrhing conductor shall be buried 2000 mm outside the switchyard fence. All the gates and every alternate post of the fence shall be connected to earthing grid. The stone spreading shall be restricted to switchyard fence only i.e. the stone spreading shall not be done outside switchyard fence. The criterian for stone spreading shall be followed in line with requirement specified elsewhere in the specification. 8.6.9 Flexible earthing connectors shall be provided for the moving parts.

8.6.10 All lighting panels, junction boxes, receptacles fixtures, conduits etc shall be grounded in compliance with the provision of I.E. rules. 8.6.11 A continuous ground conductor of 16 SWG GI wire shall be run all along each conduit run. The conductor shall be connected to each panel ground bus. All junction boxes, receptacles, switches, lighting fixtures etc shall be connected to this 16 SWG ground conductor. 8.6.12 50 mm X 60 mm MS flat shall run on the top tier and all along the cable trenches and the same shall be welded to each of the racks. Further, this flat shall be earthed at both ends and at an interval of 30 mtrs. The MS flat shall be finally painted with two coats of red oxide primer and two coats of post office red enamel paint. 8.6.13 A 40 mm dia, 3000 mm long MS earth electrode with test link, CI frame and cover shall be provided to connect down conductor of lighting mast and towers with peak. 8.7 8.7.1 Jointing Earthing connections with equipment earthing pads shall be bolted type. Contact surfaces shall be free from scale, paint, enamel, grease, rust or dirt. Two bolts shall be provided for making each connection. Equipment bolted connections, after being checked and tested, shall be painted with anti corrosive paint. Compound.

8.7.2 Connection between equipment earthing lead and main earthing conductors and between main earthing conductors shall be welded type. For rust protections, the weld should be treated with red lead and afterwards coated with two layers bitumen compound to prevent corrosion. 8.7.3 Steel to copper connections shall be brazed type and shall be treated to prevent moistures ingression. Page-23

PART-(SE) SWITCHYARD ERECTION 8.7.4 Resistance of the joint shall not be more than the resistance of the equivalent length of the conductor. 8.7.5 All ground connections shall be made by electric arc welding. All welded joints shall be allowed to cool down gradually to atmospheric temperature before put ting any load on it. Artificial cooling shall not be allowed. 8.7.6 Bending or earthing rod shall be done preferably by gas heating. 8.7.7 All arc welding with large dia, conductor shall be done with low hydrogen content electrodes. 8.7.8 The 75x12mm GS flat shall be clamped with equipment support structures at 1000mm interval. 8.9 Specific Requirement for Earthing Systems

8.9.1 Each earthing lead from the neutral of the power transformer/Reactor shall be directly connected to two pipe electrodes in treated earth pit (as per IS) which in turn, shall be buried in Cement Concrete pit with a cast iron cover hinged to a cast iron frame to have an access to the joints. All accessories associated with transformer/reactor like cooling banks, radiators etc. shall be connected to the earthing grid at minimum two points. 8.9.2 Earthing terminal of each lightning arrester & capacitor voltage transformer shall be directly connected to rod earth electrode which in turn, shall be connected to station earthing grid. 8.9.3 Auxiliary earthing mat comprising of 40mm dia M.S. rods closely spaced (300mmX 300mm) conductors shall be provided at depth of 300mm from ground level below the operating handles of the M.O.M. Box of the isolators. M.O.M. boxes shall be directly connected to the auxiliary earthing mat. 9.0 Main Bus Bars The brief description of the bus switching scheme, bus bar layout and equipment connection to be adopted are indicated elsewhere in the specification. The bus bar arrangements are shown in drgs enclosed with the bid documents. 9.1 The Contractor shall furnish supporting calculations for the bus bars/conductors to show adequacy of design parameters for: a) b) c) Fibre-stress Cantilever strength of post insulators Aeolain vibrations Page-24

PART-(SE) SWITCHYARD ERECTION d) e) 9.1.1 Vertical deflection of bus bars Short circuit forces in bundle conductor an spacer location for each span of ACSR Conductor stringing as per layout drawings.

The welds in the aluminium tubes shall be kept to the minimum and there shall not be more than one weld per span. The procedure and details of welding shall be subject to Employers approval. Material for welding sleeve shall be same as that of Aluminium tube. Welding sleeve shall be of 600mm length. Corona bells shall be provided wherever the bus extends beyond the clamps and on free ends, for sealing the ends of the tubular conductor against rain and moisture and to reduce the electrostatic discharge loss at the end points. There shall be a small drain hole in the corona bell. The material of Corona bell shall be Aluminium alloy similar to that of clamps & connectors. To minimize the vibrations in the aluminium tubes, damping conductor shall be provided inside the aluminium tubes. For this purpose, the cut pieces of ACSR Conductor which otherwise are considered wastages, shall be used as damping conductor. Details of past experience of the persons proposed to be employed for Aluminium tube welding and the test reports of the welded pieces to prove the electrical and mechanical characteristics shall also be furnished along with the bid. Welding at site shall be done by adopting a qualified procedure and employing qualified welders as per ASME-Section IX. BAY EQUIPMENT The disposition of various bay equipments shall be as per single line diagrams and layout drawings. To distribute minimum ten outgoing 240V, 10Amps, 10 Amps single phase supplies to be controlled by MCB to be drawn from above 3 phase incomers Alternatively, AC Distribution arrangement in bay kiosk (meant for sub-station automation system) is also acceptable subject to HPNL approval.

9.1.2

9.1.3

9.1.4

10.0 10.1

11.0 11.1

LIGHTNING PROTECTION Direct stroke lightning protection (DSLP) shall be provided in the EHV switchyard by lightning masts and shield wires. The layout drawings enclosed indicate the tentative arrangement. The final arrangement shall be decided after approval of the DSLP calculations. The lightning protection system shall not be in direct contact with underground metallic service ducts and cab. Page-25

11.2

PART-(SE) SWITCHYARD ERECTION 11.3 11.4 11.5 Conductors of the lightning protection system shall not be connected with the conductors of the safety earthing system above ground level. Down conductors shall e cleated on the structures at 2000 mm interval. Connection between each down conductor and rod electrodes shall be made via test joint (pad type compression clamp) located approximately 1500mm above ground level. The rod electrode shall be further joined with the main earthmat. Lightning conductors shall not pass through or run inside G.I.conduits. EQUIPMENT ERECTION DETAILS For equipment interconnection, the surfaces of equipment terminal pads, Aluminium tube, conductor & terminal clamps and connectors shall be properly cleaned. After cleaning, contact grease shall be applied on the contact surfaces of equipment terminal pad, aluminium tube/conductor and terminal clamps to avoid any air gap in between. Subsequently bolts of the terminal pad/terminal connectors shall be tightened and the surfaces shall be cleaned properly after equipment interconnection. Muslin or leather cloth shall be used for cleaning the inside and outside of hollow insulators. All support insulators, circuit breaker interrupters and other fragile equipment shall preferably be handled with cranes having suitable booms and handling capacity. Bending of Aluminium tube and compressed air piping if any should be done by a bending machine and through cold bending only. Bending shall be such that inner diameter of pipe is not reduced. Cutting of the pipes wherever required shall be such as to avoid flaring of the ends. Hence only a proper pipe cutting tool shall be used. Hack saw shall not be used. Handling of equipment shall be done strictly as per manufacturers/Contractors instructions/instruction manual. Handling equipment, sling ropes etc.should be tested periodically before erection for strength. The slings shall be of sufficient length to avoid any damage to insulator due to excessive swing, scratching by sling ropes etc. Page-26

11.6 12.0 12.1

12.2 12.3 12.4

12.5 12.6 12.7 12.8

PART-(SE) SWITCHYARD ERECTION 13.0 13.1

STORAGE The Contractor shall provide and construct adequate storage shed for proper storage of equipments, where sensitive equipments shall be stores indoors. All equipments during storage shall be protected against damage due to acts of nature or accidents. The storage instructions of the equipment manufacturer/Employer shall be strictly adhered to. JUCTION BOX a) The Contractor shall supply and install junction boxes complete with terminals as required. The brackets, bolts, nuts, screws etc required for erection are also included in the scope of the Contractor. Junction boxes having volume less than 1600 cubic centimeters may be installed without any support other than that resulting from connecting conduits where two or more rigid metallic conduits enter and accurately position the box. Boxes shall be installed so that they are level, plumb and properly aligned to present a pleasing appearance. Boxes with volumes equal to or greater than 1600 cubic cm, and smaller boxes terminating on less than two rigid metallic conduits or for other reasons not rigidly held, shall be adequately supported by auxiliary steel or standard steel shapes or plates to be fabricated and installed. The Contractor shall perform all drilling, cutting, welding, shimming and bolting required for attachment of supports. TESTING AND COMMISSIONING An indicative list of tests for testing and commissioning is given below. Contractor shall perform any additional test based on specialties of the items as per the field Q.P./instructions of the equipment Contractor or Employer without any extra cost to the Employer. The Contractor shall arrange all equipments instruments and auxiliaries required for testing and commissioning of equipments along with calibration certificates and shall furnish the list of instruments to the Employer for approval. GENERAL CHECKS (a) Check for physical damage. (b) Visual examination of zinc coating/plating (c) Check from name plate that all items are as per order/specification (d) Check tightness of all bolts, clamps and connecting terminals using torque wrenches. Page-27

14.0

b)

c)

15.0 15.1

15.2

PART-(SE) SWITCHYARD ERECTION (e) (f) (g) (h) (i) (j) 15.3 For oil filled equipment, check for oil leakage, if any. Also check oil level and top up wherever necessary. 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 all tests specified in the relevant code of erection. Check for surface finish of grading rings (Corona Control Ring) Pressure test on all pneumatic lines at 18.5 times are rated pressure shall be conducted.

15.4

STATION EARTHING a) Check soil resistivity b) Check continuity of grid wires c) Check earth resistance of the entire grid as well as various sections of the same d) Check for weld joint and application of zinc rich paint on galvanized surfaces. e) Dip test on earth conductor prior to use. BERSIMIS ACSR STRINGING WORK, TUBULAR BUS WORK AND POWER CONNECTORS a) Physical check for finish b) c) d) e) Electrical clearance check Testing of torque by torque wrenches on all bus bar power connectors and other accessories. Millivolt drop test on all power connectors. Sag and tension check on conductors. Physical check Millivolt drop test on all joints Dye penetration test & Radiography test on 10% sample basis on weld joints. d) Test check on 5% sample joints after cutting the weld piece to observe any voids etc.

15.5

ALUMINIMUM TUBE WELDING a) b) c)

15.6

POLYMER INSULATOR The Detailed specification of Polymer insulators of 160kN is attached separately in the last of this specification of switchyard erection.

Page-28

PART-(SE) SWITCHYARD ERECTION ANNEXURE A (Testing Procedure for ACSR BERSIMIS Conductor) 1.0 UTS Test on Stranded Conductor Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor of minimum 5 m length suitably compressed with dead end clamps at either end. The load shall be increased at a steady rate upto 80 kN and held for one minute. The circles drawn shall not be distorted due to Relative movement of strands. Thereafter the load shall be increased at a steady rate to 16.12 kN and held for one minute. The applied load shall then be increased until the failing load is reached and the value recorded. 2.0 Corona Extinction Voltage Test Two samples of conductor of 5m length shall be strung with a spacing of 450 mm between them at a height not exceeding 8.0 m above ground. This assembly shall be tested as per Annexure-C, Corona extinction voltage shall not be less than 320 kV (RMS) Line to ground. 3.0 Radio Interference Voltage Test The sample assembly similar to that specified under (2.0) above shall be tested as per annexure-C. Maximum RIV level (across 300ohm resistor at 1 MHz) at 305 KV (RMS) line to ground voltage shall be 1000 micro volts. 4.0 D.C. Resistance Test on Stranded Conductor On a conductor sample of minimum 5 m length two contact clamps shall be fixed with a pre-determined bolt torque. The resistance shall be measured by a Kelvin double bridge by placing the clamps initially zero meter and subsequently one meter apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 200C as per clause no. 12.8 of IS:398 (Part V)-1982. The resistance corrected at 200C shall conform to the requirements of this specification. 5.0 Chemical Analysis of Zinc Samples taken from the zinc ingots shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this specification. 6.0 Chemical Analysis of Aluminium and Steel Samples taken from the Aluminium ingots/coils/strands shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this specification. Page-29

PART-(SE) SWITCHYARD ERECTION 7.0 Visual Check for Joints, Scratches etc. Conductor drums shall be rewound in the presence of the inspector. The inspector shall visually check for scratches, joints, etc. and that the conductor generally conform to the requirements of this specification. The length of conductor wound on the drum shall be measured with the help of counter meter during rewinding. 8.0 Dimensional Check for Steel and Aluminium Strands The individual strands shall be dimensionally checked to ensure that they conform to the requirements of this specification. 9.0 Check for Lay-ratios of various layers The lay-ratios of various layers shall be checked to ensure that they conform to the requirements of this specification and clause no. 9.4 and 9.5 of IS-398 (Part-V) 1982. 10.0 Galvanising Test The test procedure shall be as specified in IS:4826-1968. The material shall conform to the requirements of this specification. 11.0 Torsion and Elongation Tests on Steel Strands The test procedures shall be as per relevant clause of IS:398 (Part-V), 1982. In torsion test, the number of complete twists before fracture shall not be less than 18 on a length equal to 100 times the standard diameter of the strand before stranding & 16 after stranding. In case test sample length of less or more than 100 times the standard diameter of the strand, the minimum number of twist will be proportionate to the length and if number comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the elongation of the strand shall not be less than 4% for a gauge length of 200mm. 12.0 Breaking load test on welded Aluminium Strand: Two Aluminium wires, shall be welded as per the approved quality plan and shall be subjected to tensile load. The welded point of the wire shall be able to withstand the minimum breaking load of the individual strand guaranteed by the bidder. Page-30

PART-(SE) SWITCHYARD ERECTION ANNEXURE B (Testing Procedure for Galvanised Steel Earthwire) 1. UTS TEST Circles perpendicular to the axis of the earthwire shall be marked at two places on a sample of earthwire of minimum 5 m length suitably compressed with dead end clamps at either end. The load shall be increased at a steady rate upto 34 kN and held for one minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter, the load shall be increased at a steady rate of 68.4 kN and held for one minute. The applied load shall then be increased until the failing load is reached and the value recorded. 2. D.C. RESISTANCE TEST ON STRANDED CONDUCTOR On a earthwire sample of minimum 5 m length two contact clamps shall be fixed with a pre-determined bolt torque. The resistance shall be measured by a Kelvin doublebridge by placing the clamps initially zero meter and subsequently one meter apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 200C shall conform to the requirements of this specification. 3. VISUAL CHECK FOR JOINTS, SCRATCHES ETC. Earthwire drums shall be rewound in the presence of the inspector. The inspector shall visually check for joints, scratches, etc. and see that the earthwire generally conforms to the requirements of this specification. The length of earthwire wound on the drum shall be measured with the help of counter meter during rewinding. 4. TORSION AND ELONGATION TESTS ON STEEL STRANDS The test procedures shall be as per relevant clause of IS:398 (Part-V). The minimum number of twists which a single steel strand shall withstand during torsion test shall be eighteen for a length equal to 100 times the standard diameter of the strand. In case test sample length is less or more than 100 times the standard diameter of the strand, the minimum number of twists will be proportionate to the length and if number comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the elongation of the strand shall not be less than 64% or a gauge length of 200 mm. Page-31

PART-(SE) SWITCHYARD ERECTION 5.

DIMENSIONAL CHECK The individual strands shall be dimensionally checked to ensure that they conform to the requirements of this specification.

6.

LAY LENGTH CHECK The lay length shall be checked to ensure that they conform to the requirements of this specification.

7.

GALVANISING TEST The test procedure shall as specified in IS:4826-1968. The material shall conform to the requirements of this specification.

8.

CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING Samples taken from zinc ingots shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this specification.

9.

CHEMICAL ANALYSIS OF ZINC Samples taken from the steel ingots/coils/strands shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this specification.

Page-32

PART-(SE) SWITCHYARD ERECTION ANNEXURE-C CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) TEST 1. General Unless otherwise stipulated, all equipment together with its associated connectors, where applicable, shall be tested for external corona both by observing the voltage level for the extinction of visible corona under falling power frequency voltage and by measurement of radio interference voltage (RIV). 2. Test Levels: The test voltage levels for measurement of external RIV and for corona extinction voltage are listed under the relevant clauses of the specification. 3. 3.1 Test methods for RIV: RIV tests shall be made according to measuring circuit as per International SpecialCommittee on Radio Interference (CISPR) Publication 16-1 (1993) Part-1. The measuring circuit shall preferably be tuned to frequency with 10% of 0.5 Mhz but other frequencies in the range of 0.5 MHz to 2 MHz may be used, the measuring frequency being recorded. The result shall be in microvolts. Alternatively, RIV tests shall be in accordance with NEMA standard Publication No. 107-1964, except otherwise noted herein. In measurement of , RIV temporary additional external corona shielding may be provided. In measurements of RIV only standard fittings of identical type supplied with the equipment and a simulation of the connections as used in the actual installation will be permitted in the vicinity within 3.5 meters of terminals. Ambient noise shall be measured before and after each series of tests to ensure that there is no variation in ambient noise level. If variation is present, the lowest ambient noise level will form basis for the measurements. RIV levels shall be measured at increasing and decreasing voltages of 85%, 100%, 115% and 130% of the specified RIV test voltage for all equipment unless otherwise specified. The specified RIV test voltage for 400kV, 220 kV is listed in the detailed specification together with maximum permissible RIV level in microvolts. The metering instruments shall be as per CISPR recommendation or equivalent device so long as it has been used by other testing authorities. The RIV measurement may be made with a noise meter. A calibration procedure of the frequency to which noise meter shall be tuned shall establish the ratio of voltage at the high voltage terminal to voltage read by noisel meter. Page-33

3.2 3.3

3.4

3.5 3.6

PART-(SE) SWITCHYARD ERECTION 4.

Test Methods for Visible Corona The purpose of this test is to determine the corona extinction voltage of apparatus, connectors etc. The test shall be carried out in the same manner as RIV test described above with the exception that RIV measurements are not required during test and a search technique shall be used near the onset and extinction voltage, when the test voltage is raised and lowered to determine their precise values. The test voltage shall be raised to 130% of RIV test voltage and maintained there for five minutes. In case corona inception does not take place at 130%, test shall be stopped, otherwise test shall be continued and the voltage will then be decreased slowly until all visible corona disappears. The procedure shall be repeated at least 4 times with corona inception and extinction voltage recorded each time. The corona extinction voltage for purposes of determining compliance with the specification shall be the lowest of the four values at which visible corona (negative or positive polarity) disappears. Photographs with laboratory in complete darkeness shall be taken under test conditions, at all voltage steps i.e. 85%, 100%, 115% and 130%. Additional photographs shall be taken at corona inception and extinction voltages. At least two views shall be photographed in each case using Panchromatic film with an ASA daylight rating of 400 with an exposure of two minutes at a lens aperture of f/5.6 or equivalent. The photographic process shall be such that prints are available for inspection and comparison with conditions as determined from direct observation. Photographs shall be taken from above and below the level of connector so as to show corona on bushing, insulators and all parts of energized connectors. The photographs shall be framed such that test object essentially, fills the frame with no cut-off. In case corona inception does not take place at 130%, voltage shall not be increased further and corona extinction voltage shall be considered adequate.

4.1

The test shall be recorded on each photograph. Additional photograph shall be taken from each corona position with lights on to show the relative position of test object to facilitate precise corona location from the photographic evidence. In addition to photographs of the test object preferably four photographs shall be taken of the complete test assembly showing relative positions of all the test equipment and test objects. These four photographs shall be taken from four points equally spaced around the test arrangement to show its features from all sides. Drawings of the laboratory and test set up locations Shall be provided to indicate camera positions and angles. The precise location of camera shall be approved by Employers inspector, after determining the best camera locations by trial energisation of test object at a voltage which results in corona. The test to determine the visible corona extinction voltage need not be carried out simultaneously with test to determine RIV levels. Page-34

4.2

4.3

PART-(SE) SWITCHYARD ERECTION 4.4 However, both test shall be carried out with the same test set up and as little time duration between tests as possible. No modification on treatment of the sample between tests will be allowed. Simultaneous RIV and visible corona extinction voltage testing may be permitted at the discretion of Employers inspector if, in his opinion, it will not prejudice other test.

5.

Test Records: In addition to the information previously/mentioned and the requirements specified as per CISPR or NEMA 107-1964 the following data shall be included in test report: a) b) c) d) e) f) Background noise before and after test Detailed procedure of application of test voltage Measurements of RIV levels expressed in micro volts at each level Results and observations with regard to location and type of interference sourced detected at each step. Test voltage shall be recorded when measured RIV passes through 100 microvolts in each direction. Onset and extinction of visual corona for each of the four tests required shall be recroded

Page-35

PART-(SE) SWITCHYARD ERECTION ANNEXURE-D SHORT CIRCUIT FOCES AND SPACER SPAN FOR 400 KV GANTRY STRUCTURE

Sl.No. Max. Span 1. 2. 3. 4. 54 Mtr 54 Mtr 70 Mtr 70 Mtr

Conductor Ph-Ph Configuration Spacing QUAD QUAD TWIN TWIN 7 mtr 6 mtr 7 mtr 6 mtr

Normal Tension 4T 4T 4T 4T

Short circuit Spacer force per Span Phase 5.64 T 6 mtr 5.1 T 5.64 T 5.1 T 5 mtr 5 mtr 5 mtr

Page-36

PART-(SE) SWITCHYARD ERECTION Technical Description of Composite Long Rod Insulators 1.1 Details of Composite Long Rod Insulators

1.1.1 The insulators of the strings shall consist of composite long rod insulators for a three phase, 50 Hz, effectively earthed 400kV transmission system application in a very heavy polluted environment. Couplings shall be ball and socket type. 1.1.2 Bidder shall quote such composite insulators which have proven use under foggy/humid operational conditions in polluted industrial environment combined with smoke and dust particles. The Bidder shall furnish evidence in the form of certification from the power utilities that the similar type of product supplied to them had been performing satisfactory. The Bidder shall also submit certified test report for an accelerated ageing test of 5000 hours such as that described in Appendix-C of IEC61109. 1.1.3 Insulators shall have sheds of the open aerodynamic profile without any under ribs with good self-cleaning properties. Insulator shed profile, spacing projection etc. shall be strictly in accordance with the recommendation of IEC-60815. 1.1.4 The size of long rod insulator, minimum creepage distance, the number to be used in different type of strings, their electromechanical strength and mechanical strength of insulator string alongwith hardware fittings shall be as follows:
S.No Type of String *Size of Composite Insulator (Core dia x Nominal length) (mm) Minimum Creepage Distance No. of individual Units per String ElectroMechanical Strength of Insulator Unit (kN) Mechanical Strength of Insulator String along with Hardware Fittings (kN)

(mm)

(Nos.)

1
1.

2
Quadruple Tension String of Bersimis ACSR ( To be used at Termination Gantries only from TL No.-108 ) Double Tension Bolted Type fitting of Bersimis ACSR ( to be used at S/Stn. Gantries)

3
24x3910

4
13020

5
4x1

6
160

7
4x160

24x3910

13020

2x1

160

2x160

Page-37

PART-(SE) SWITCHYARD ERECTION

3 Bolted type Single Suspension Pilot Bolted Type fitting of Bersimis ACSR ( to be used at S/Stn. Gantries) 24x3335 13020 1x1 160 160

Note: *The core dia of composite insulators mentioned at column No.3 is minimum requirement. The bidder shall offer composite long rod insulators of suitable core dia to meet specified E&M strength requirements. For offered core dia, the bidder shall submit documentary evidence of past supplies & satisfactory operation of the same for minimum period of three years. However, the overall string length shall be within the limits specified in the drawing. 1.2 Pin and Cap

1.2.1 Pin and cap shall be designed to transmit the mechanical stress and develop uniform mechanical strength in the insulator. The cap shall be circular with the inner and outer surfaces concentric of such design that it will not yield or distort under load conditions. 1.2.2 The design shall be such as to permit easy removal of replacement of either insulator units or fittings under the live line conditions. 1.3 Ball and Socket Designation The dimensions of the Ball and Socket shall be of 20mm for 160 kN Insulators in accordance with the standard dimensions stated in IEC:120/ IS:2486 (Part-II). 1.4 Dimensional Tolerance of Composite Insulators The tolerances on all dimensions e.g. diameter, length and creepage distance shall be allowed as follows: (0.04d+1.5) mm when d300 mm. (0.025d+6) mm when d>300 mm. Where, d being the dimensions in millimeters for diameter, length or creepage distance as the case may be. However, no negative tolerance shall be applicable to creepage distance. Page-38

PART-(SE) SWITCHYARD ERECTION 1.5 Interchangeability The composite long rod insulators inclusive of the ball & socket connection shall be standard design suitable for use with the hardware fittings of any make conforming to relevant IEC standards. 1.6 Corona and R1 Performance All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall be subjected to excessive localized pressure. The insulator and metal parts shall be so designed and manufactured that it shall avoid local corona formation and shall not generate any radio interference beyond specified limit under the operating conditions. 1.7 Maintenance

1.7.1 The long rod insulators offered shall be suitable for employment of hot line maintenance technique so that usual hot line operation can be carried out with ease, speed and safety. 1.7.2 All insulators shall be designed to facilitate cleaning and insulators shall have the minimum practical number of sheds and grooves. All grooves shall be so proportioned that any dust deposit can be removed without difficulty either by wiping with a cloth or by remote washing under live line condition. 1.8 Materials

1.8.1 Core It shall be a glass-fiber reinforced (FRP rod) epoxy resin rod of high strength. Glass fibers and resin shall be optimized. The rod shall be electrical grade corrosion resistant (ECR), boron free glass and shall exhibit both high electrical integrity and high resistance to acid corrosion. 1.8.2 Housing & Weathersheds The FRP rod shall be covered by a seamless sheath of a silicone rubber compound of a thickness of minimum 3mm. The housing & weathersheds should have silicon content of minimum 30% by weight. It should protect the FRP rod against environmental influences, external pollution and humidity. It shall be extruded or directly molded on the core. The interface between the housing and the core must be uniform and without voids. The strength of the bond shall be greater than the tearing strength of the polymer. The manufacturer shall follow non-destructive technique (N.D.T.) to check the quality of jointing of the housing interface with the core. The technique being followed with detailed procedure and sampling shall be furnished along with the bid. The details for this shall be finalized during detailed engineering and finalization of MQP. Page-39

PART-(SE) SWITCHYARD ERECTION The weathersheds of the insulators shall be of alternate shed profile. The weathersheds shall be vulcanized to the sheath (extrusion process) or molded as part of the sheath (injection moulding process) and free from imperfections. The vulcanization for extrusion process shall be at high temperature and for injection moulding shall be at high temperature & high pressure. Any seams / burrs protruding axially along the insulator, resulting from the injection moulding process shall be removed completely without causing any damage to the housing. The track resistance of housing and shed material shall be class 1A4.5 according to IEC60587. The strength of the weathershed to sheath interface shall be greater than the tearing strength of the polymer. The composite insulator shall be capable of high pressure washing. 1.8.3 End Fittings End fittings transmit the mechanical load to the core. They shall be made of malleable cast iron spheroidal graphite or forged steel. They shall be connected to the rod by means of a controlled compression technique. The manufacturer shall have inprocess Acoustic emission arrangement or some other arrangement to ensure that there is no damage to the core during crimping. This verification shall be in-process and done on each insulator. The gap between fitting and sheath shall be sealed by a flexible silicone rubber compound. The system of attachment of end fitting to the rod shall provide superior sealing performance between housing and metal connection. The sealing must be humidity proof and durable with time. 1.8.4 Grading Rings Grading rings shall be used at both ends of each composite insulator unit for reducing the voltage gradient on and within the insulator and to reduce radio and TV noise to acceptable levels. The size and placement of the metallic grading rings shall be designed to eliminate dry band arcing/corona cutting/ exceeding of permissible electrical stress of material. The bidder shall furnish calculations along with the proposed placement and design of corona ring in support of the above. Grading rings shall be capable of installation and removal with hot line tools without disassembling any other part of the insulator assembly. The supply of grading rings shall be in the scope of the composite insulator supplier. 1.9 Workmanship 1.9.1 All the materials shall be of latest design and conform to the best modern practices adopted in the extra high voltage field. Bidders shall offer only such insulators as are guaranteed by him to be satisfactory and suitable for transmission lines specified and will give continued good service. Page-40

PART-(SE) SWITCHYARD ERECTION 1.9.2 The design, manufacturing process and material control at various stages shall be such as to give maximum working load, highest mobility, best resistance to corrosion, good finish and elimination of sharp edges and corners to limit corona and radio interference. 1.9.3 The design of the insulators shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. 1.9.4 The core shall be sound and free of cracks and voids that may adversely affect the insulators. 1.9.5 Weathersheds shall be uniform in quality. They shall be clean, sound, smooth and free from gross defects and excessive flashing at parting lines. 1.9.6 End fittings shall be free from cracks, seams, shrinks, air holes and rough edges. End fittings should be effectively, sealed to prevent moisture ingress, effectiveness of sealing system must be supported by test documents. All surfaces of the metal parts shall be perfectly smooth with the projecting points or irregularities which may cause corona. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly. 1.9.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to 600 gm/sq.m. and shall be in accordance with the requirement of ISO:1461 (E) and shall satisfy the tests mentioned in ISO:1460 (E). The zinc used for galvanizing shall be of purity of 99.95%. The zinc coating shall be uniform, adherent, smooth, reasonably bright continuous and free from imperfections such as flux, ash rust stains, bulky white deposits and blisters. The galvanized metal parts shall be guaranteed to withstand at least six successive dips each lasting for one (1) minute duration under the standard preece test. The galvanizing shall be carried out only after any machining. 2.0 2.1 Equipment Marking Each composite long rod unit shall be legibly and indelibly marked with the trade mark of the manufacturer, name of HVPNL and month & year of manufacture. The guaranteed combined mechanical and electrical strength shall be indicated in kilo Newton followed by the word kN to facilitate easy identification and to ensure proper use. One 10 mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on the cap/end fitting of each composite long rod of particular strength for easy identification of the type of insulator. The paint shall not have any deteriorating effect on the insulator performance. Following codes shall be used as identification mark : For 160 kN long rod unit : Green Page-41

2.2

PART-(SE) SWITCHYARD ERECTION 3.0 3.1 3.2 Bid Drawings The Bidder shall furnish full description and illustration of the material offered. The Bidder shall furnish along with the bid the outline drawing (6 copies) of each insulator unit including a cross sectional view of the long rod insulator unit. The drawing shall include but not limited to the following information : (a) (b) (c) (d) Long rod diameter and ball to ball spacing with manufacturing tolerances Minimum Creepage distance with positive tolerance Protected creepage distance Eccentricity of the long rod unit (i) (ii) (e) (f) (g) (h) Axial run out Radial run out

Unit mechanical and electrical characteristics Size and weight of ball and socket parts Weight of composite long rod units Materials (i) (ii) Identification mark Manufacturer's catalogue number

3.3

After placement of award, the Supplier shall submit full dimensioned insulator drawings containing all the details as given in Clause No. 3.2 above, in four (4) copies to Employer for approval. After placement of award the Supplier shall also submit fully dimensioned insulator crate drawing for different type of insulators. After placement of award, the Supplier shall submit full dimensioned manufacturing drawing of composite long rod insulator unit in six (6) copies to the Employer for reference and record. Tests and Standards Type Tests The following type tests shall be conducted on long rod units, components, materials or complete strings:

3.4 3.5

4.0 4.1

Page-42

PART-(SE) SWITCHYARD ERECTION

4.1.1 On the complete composite Long Rod Insulator String with Hardware (a) (b) (c) (d) (e) (f) (g) Power frequency voltage withstand test with corona control rings/grading ring and arcing horns under wet condition Switching surge voltage withstand test under wet condition Impulse voltage withstand test under dry condition Corona and RIV test under dry condition Mechanical Strength test Vibration test Salt-fog pollution withstand test IEC:383-1993/ Annexure A IEC:383-1993 IEC:383-1993 Annexure-A Annexure-A Annexure-A Annexure-A

Fittings

4.1.2 On Composite Insulator Units (a) Tests on interfaces and connections of metal fittings (Tests to be performed on the same samples in the sequence given below) i) Dry power frequency voltage test ii) Sudden load release test iii) Thermal mechanical test iv) Water immersion test v) Steep front impulse voltage test vi) Dry power frequency voltage test Assembled core load time test i) Determination of the average failing load of the core of the assembled unit ii) Control of the slope of the strength time curve of the insulator Brittle fracture resistance test Test of housing, Tracking and erosion test Tests for the core material i) Dye penetration test ii) Water diffusion test Flammability test Recovery of Hydrophobicity test Mechanical Load Time test and test of tightness between end firings and insulator housing Silicone content test High Pressure washing test IEC: 61109

(b)

IEC: 61109

(c) (d) (e) (f) (g) (h) (i) (j)

Annexure-A IEC: 61109 IEC:61109 IEC:61109 Annexure-A IEC:61109 Annexure-A Annexure-A Page-43

PART-(SE) SWITCHYARD ERECTION 4.1.4 All the type test given in Clause No. 4.1.1 shall be conducted on Single I suspension, Double tension, Double I suspension & Quadruple tension insulator string string along with hardware fittings. All the type tests given in Clause No. 4.1.1 (a) to (e) shall also be conducted on Single 'I' Pilot suspension & Single tension insulator string along with hardware fittings. 4.2 Acceptance Tests:

4.2.1 For Composite Long Rod Insulators (a) (b) (c) (d) Verification of dimensions Galvanising test Verification of locking system Verification of tightness of interface between end fittings and insulator housing and of specified mechanical load Recovery of Hydrophobicity ) ) ) ) ) ) ) ) IEC : 61109 IEC : 60383 IEC : 60383 IEC : 61109

(d) (e)

Annexure-A

Tests on interfaces and connections of ) IEC: 61109 metal fittings (Tests to be performed on ) the same samples in the sequence given below) i) ii) iii) iv) v) vi) Dry power frequency voltage test Sudden load release test Thermal mechanical test Water immersion test Steep front impulse voltage test Dry power frequency voltage test Annexure-A

(f)

Silicone content test

The test 4.2.1.(e) shall be carried out in case total quantity of insulators of a particular rating exceeds 5000 nos. The test 4.2.1.(f) shall be done against each lot or against every 5000 nos. of insulators whichever is less. In the event of failure of the sample to satisfy the acceptance test(s) specified in 4.2 above, the retest procedure shall be as per clause 7.6 of IEC 61109. Page-44

PART-(SE) SWITCHYARD ERECTION 4.3 4.3.1 Routine Tests For Composite Long Rod Insulator Units a) b) 4.4 Visual Inspection As per IEC:61109 Mechanical routine test As per IEC:61109

Tests During Manufacture On all components as applicable a) b) Chemical analysis of zinc used for galvanising Chemical analysis, mechanical, metallographic test and magnetic particle inspection for malleable castings. Chemical analysis hardness tests and magnetic particle inspection for forgings Tracking and erosion test on insulating material Testing Expenses The entire cost of testing for acceptance and routine tests and tests during manufacture specified herein shall be treated included in the quoted Ex-works price except for the expenses of the inspector/HVPNL s representative. As per AnnexureA As per AnnexureA As per AnnexureA IEC 60587

c) d) 4.5

4.6 4.6.1

Schedule of testing and additional tests The bidder has to indicate the schedule of following activities in their bids: a) Submission of drawing for approval. b) Submission of Quality Assurance programme for approval.

4.6.2

The HVPNL reserves the right of having at his own expense any other test (s) of reasonable nature carried out at manufacturers premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the material comply with the specifications. The HVPNL also reserves the right to conduct all the tests mentioned in this specification at his own expense on the samples drawn from the site at manufacturers premises or at any other test center. In case of evidence of non compliance, it shall be binding on the part of the manufacture to prove the compliance of the items to the technical specifications by repeat tests or correction of deficiencies, or replacement of defective items, all without any extra cost to the HVPNL . Page-45

4.6.3

PART-(SE) SWITCHYARD ERECTION 4.7 Co- ordination for testing The Bidder/insulator manufacturer shall have to co-ordinate testing of hardware fittings with and shall have to also guarantee overall satisfactory performance of the insulators with the hardware fittings. 4.5 Test Reports

4.10.1 Copies of type test reports shall be furnished in at least six (6) copies along with one original. One copy shall be returned duly certified by the Employer only after which the commercial production of the concerned material shall start. 4.10.2 Copies of acceptance test reports shall be furnished in at least six (6) copies. One copy shall be returned duly certified by the Employer, only after which the material shall be dispatched. 4.10.3 Record of routine test reports shall be maintained by the Supplier at his works for periodic inspection by the Employers representative. 4.10.4 Test certificates of test during manufacture shall be maintained by the Supplier. These shall be produced for verification as and when desired by the Employer. 4.11 Inspection 4.11.1 The Employers representative shall at all times be entitled to have access to the works and all places of manufacture, where insulator, and its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection of the Suppliers and sub-Suppliers works, raw materials, manufacture of the material and for conducting necessary test as detailed herein. 4.11..2 The material for final inspection shall be offered by the Supplier only under packed condition as detailed in clause No.4.13 of the specification. The Employer shall select samples at random from the packed lot for carrying out acceptance tests. The lot should be homogeneous and should contain insulators manufactured in 3-4 consecutive weeks. 4.11.3 The Supplier shall keep the Employer informed in advance of the time of starting and the progress of manufacture of material in their various stages so that arrangements could be made for inspection. 4.11.4 No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the Employer in writing. In the latter case also the material shall be dispatched only after satisfactory testing for all tests specified herein have been completed. 4.11.5 The acceptance of any quantity of material shall be no way relieve the Supplier of his responsibility for meeting all the requirements of the specification and shall not prevent subsequent rejection, if such material are later found to be defective.

Page-46

PART-(SE) SWITCHYARD ERECTION 4.12 Packing and Marking

4.12.1 All insulators shall be packed in suitable PVC/ plastic tubes/any other suitable packing along with temporary wrap-on shields/shrouds for each insulator unit. The packing shall provide protection against rodent. The shields/shrouds shall be for protection during transport and for preventing bird pecking during erection. Further, the shields/shrouds shall be made of opaque, weather proof material of adequate strength and shall be colour coded. The shields/shrouds shall have smaller diameter than the insulator to stay in place against winds & weather and shall be designed so as to leave only the end fittings exposed for attachment of insulator to tower and line hardware until line construction is complete. The shield/shroud shall have suitable pull off loop for easy detachment just prior to charging of the line without causing any damage to the insulator. The bidderSupplier shall furnish detailed design of the packing and shield/shroud along with attachment and detachment procedure in this regard. For marine transportation, crates shall be palleted. 4.12.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and subsequent handling in the field. 4.12.3 Suitable cushioning, protective padding, or dunnage or spacers shall be provided to prevent damage or deformation during transit and handling. 4.12.4 The Supplier shall guarantee the adequacy of the packing and shall be responsible for any loss or damage during transportation, handling, storage and installation due to improper packing. 4.12.5 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings. Each case/crate shall have all the markings stenciled on it in indelible ink. 4.13 Standards The insulator strings and its components shall conform to the following Indian/ International Standards which shall mean latest revision, with amendments/ changes adopted and published, unless specifically stated otherwise in the Specification. 4.13.1 In the event of supply of insulators conforming to standards other than specified, the Supplier shall confirm in his bid that these standards are equivalent or better to those specified. In case of award, salient features of comparison between the standards proposed by the Supplier and those specified in this document will be provided by the Supplier to establish equivalence. Sl. No. 1. 2. Indian Standard IS:2091992 IS:4061991 Title Specification for zinc Internationa l Standard BS:3436

Method of Chemical Analysis of Slab BS:3436 Zinc Page-47

PART-(SE) SWITCHYARD ERECTION 3. 4. IS:731-1991 IS:2071 Part (I) 1993 (Part(II)- 1991 Part(III)- 1991 IS:2486 Part- I-1993 Part- II-1989 Part-III-1991 IS:2629-1990 IS:2633-1992 IS:3188-1988 IS:6745-1990 IS:8263-1990 Porcelain insulators for overhead Power lines BS:137with a nominal voltage greater than 1000 V (I&II) IEC:60383 Methods of High Voltage Testing IEC:60060-1

5.

6. 7. 8. 9. 10.

Specification for Insulator fittings for Overhead Power Lines with a nominal voltage greater than 1000V General Requirements and Tests Dimensional Requirements Locking Devices Recommended Practice for Hot, Dip Galvanisation for iron and steel Testing of Uniformity of Coating of zinc coated articles Dimensions for Disc Insulators Determination of Weight of Zinc Coating on Zinc coated iron and steel articles Methods of RI Test of HV insulators

BS:3288 IEC:60120 IEC:60372 ISO-1461 (E) IEC:60305 BS:433-1969 ISO:14601973 IEC:60437 NEMA Publication No.07/ 1964/ CISPR IEC:60506 IEC: 60575 IEC:60507 IEC 61109

11. 12. 13. 14.

IS:8269-1990

15. 16. 17.

Methods for Switching Impulse test on HV insulators Thermal Mechanical Performance test and mechanical performance test on string insulator units Salt Fog Pollution Voltage Withstand Test Composite insulators for A.C. Overhead lines with nominal voltage greater than 1000V Definitions, test methods and acceptance criteria Guide for the selection of insulators in respect of polluted conditions Tests on insulators of Ceramic material or glass or glass for overhead lines with a nominal voltage greater than 1000V Characteristics of string insulator units of the long rod type

IEC:60815 IEC:60383 IEC : 60433 Page-48

PART-(SE) SWITCHYARD ERECTION The standards mentioned above are available from: Reference Abbreviation BS Name and Address British Standards, British Standards Institution 101, Pentonvile Road, N - 19-ND, UK International Electro technical Commission, Bureau Central de la Commission, electro Technique international, 1 Rue de verembe, Geneva, SWITZERLAND Beureau Of Indian Standards. Manak Bhavan, 9, Bahadur Shah Zafar Marg, New Delhi - 110001. INDIA International Organisation for Standardization. Danish Board of Standardization Danish Standardizing Sraat, Aurehoegvej-12 DK-2900, Heeleprup, DENMARK National Electric Manufacture Association, 155, East 44th Street. New York, NY 10017 U.S.A. American Society for Testing and Materials, 1916 Race St. Philadelphia, PA19103 USA

IEC/CISPR

BIS/IS

ISO

NEMA

ASTM

Page-49

PART-(SE) SWITCHYARD ERECTION ANNEXURE-A 1.0 1.1 Tests on Complete Strings with Hardware Fittings Corona Extinction Voltage Test (Dry) The sample assembly when subjected to power frequency voltage shall have a corona extinction voltage of not less than 320 kV (rms) line to ground under dry condition. There shall be no evidence of corona on any part of the sample. The atmospheric condition during testing shall be recorded and the test results shall be accordingly corrected with suitable correction factor as stipulated in IEC : 383. RIV Test (Dry) Under the conditions as specified under (1.A.1) above, the insulator string along with complete hardware fittings shall have a radio interference voltage level below 1000 micro volts at one MHz when subjected to 50 Hz AC voltage of 305 kV line to ground under dry condition. The test procedure shall be in accordance with IS:8263 /IEC : 60437. Mechanical Strength Test The complete insulator string along with its hardware fitting excluding arcing horn, corona control ring, grading ring and suspension assembly/dead end assembly shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string components shall not show any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to, remove cotter pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded. Vibration Test The suspension string shall be tested in suspension mode, and tension string in tension mode itself in laboratory span of minimum 30 metres. In the case of suspension string, a load equal to 600 kg shall be applied along the axis of the suspension string by means of turn buckle. The insulator string along with hardware fittings and the sub-conductors each tensioned at 43 kN shall be secured with clamps. The system shall be suitable to maintain constant tension on each sub-conductors throughout the duration of the test. Vibration dampers shall not be used on the test span. AllAll the sub-conductors shall be vertically vibrated simultaneously at one of the resonance frequencies of the insulators string (more than 10 Hz) by means of vibration inducing equipment. The peak to peak displacement in mm of vibration at the antinode point, nearest to the string, shall be measured and Page-50

1.2

1.3

1.4

PART-(SE) SWITCHYARD ERECTION the same shall not be less than 1000/f1.8 where f is the frequency of vibration in cycles/sec. The insulator string shall be vibrated for not less than 10 million cycles without any failure. After the test the insulators shall be examined for looseness of pins and cap or any crack in the cement. The hardware shall be examined for looseness, fatigue failure and mechanical strength test. There shall be no deterioration of properties of hardware components and insulators after the vibration test. The insulators shall be subjected to the Mechanical performance test followed by mechanical strength test as per relevant standards. 1.5 Salt-fog pollution withstand test This test shall be carried out in accordance with IEC : 60507. The salinity level for composite long rod insulators shall be 160 Kg/m3 NACL. 2.0 2.1 Composite Longrod Insulator Units Brittle Fracture Resistance Test Assembled core load time test with container that contains1n-HNO3 concentric acid that is applied at the naked rod. The rod should be held at 80% of SML for the duration of the test. The rod should not fail within the 96 hour test duration 2.2 (1) Recovery of Hydrophobicity Test The surface of selected samples shall be cleaned with isopropyl alcohol. Allow the surface to dry and spray with water. Record the HC classification. Dry the sample surface. Treat the surface with corona discharges to destroy the hydrophobicity. This can be done utilizing a high frequency corona tester, Holding the electrode approximately 3mm from the sample surface, slowly move the electrode over an area approximately 1 x 1. Continue treating this area for 2 3 minutes, operating the tester at maximum output. Immediately after the corona treatment, spray the surface with water and record the HC classification. The surface should be hydrophilic, with an HC value of 6 or 7. If not, dry the surface and repeat the corona treatment for a longer time until an HC of 6 or 7 is obtained. Dry the sample surface. Allow the sample to recover and repeat the hydrophobicity measurement at several time intervals. Silicone rubber should recover to HC 1 HC 2 within 24 to 48 hours, depending on the material and the intensity of the corona treatment. Page-51

(2)

(3)

(4)

PART-(SE) SWITCHYARD ERECTION 2.3 Silicone content test Minimum content of silicone as guaranteed by supplier shall be verified through FT-IR spectroscopy & TGA analysis or any other suitable method mutually agreed between Employer & Supplier in Quality Assurance Programme . 2.4 High Pressure washing test The test is to be carried out at 3800 kPa with nozzles of 6 mm diameter at a distance of 3m from nozzles to the insulator, followed by a dry power frequency voltage test as per IEC 61109. 3. 3.1 Tests on All components (As applicable) Chemical Analysis of Zinc used for Galvanizing Samples taken from the zinc ingot shall be chemically analysed as per IS:209-1979. The purity of zinc shall not be less than 99.95%. 3.2 Tests for Forgings The chemical analysis hardness tests and magnetic particle inspection for forgings, will be as per the internationally recognised procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Supplier and Employer in Quality Assurance Programme. 3.3 Tests on Castings The chemical analysis, mechanical and metallographic tests and magnetic, particle inspection for castings will be as per the internationally recognised procedures for these tests. The samplings will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Supplier and Employer in Quality Assurance Programme.

Page-52

PART-(SE) SWITCHYARD ERECTION

1.0 1.1 1.1.1

TechnicalDescriptionofTensiontypeHardwareFittingofTransmissionLines (TobeusedatTerminalGantries) DetailsofHardwareFittings The hardware fittings shall be suitable for use with Polymer insulators having ball and socket fittings.. Each hardware fitting shall be supplied complete in all respects and shall includethefollowinghardwareparts: Suitablearcinghornasspecified. Suitableyokeplatescomplyingwiththespecificationsgivenhereinafter. Coronacontrolrings/gradingringwithfittingsforattachmenttolinesideyokeplate. SagadjustmentplateforQuadrupletensionhardwarefittings. Deadendassemblytosuitconductorsize. Other necessary fittings viz Dshackles, eye links, extension links, ball clevis, socket clevis,cleviseye,Uclevisandchainlinketc.tomakethehardwarefittingscomplete. 2.5%extrafasteners. DimensionsofInsulatorStringAlongwithHardwareFitting Foreverysetofquadtensionhardwarefittings,onenumberrigidspacersuitableforQuad ACSR BERSIMIS conductor shall also be provided to ensure that there is no fouling of conductors or any component of the fittings while bringing down top two conductor throughbottomtwoconductorsofquadbundle,atthejumperconnection. Interchangeability The hardware for insulator strings with disc insulators / porcelain long rod insulators together with ball and socket fittings shall be of standard design, so that these hardwares are inter changeable with each other and suitable for use with insulators of any make conformingtorelevantIndian/InternationalStandard. CoronaandRIPerformance Sharpedgesandscratchesonallthehardwarefittingsshallbeavoided.Allsurfacesmust beclean,smooth,withoutcutsandabrasionsorprojections.The Contractor must give suitable assurance about the satisfactory corona and radio interferenceperformanceofthematerialsofferedbyhim.

1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.9 1.2 1.2.1

1.3 1.3.1

1.4

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PART-(SE) SWITCHYARD ERECTION

1.5 1.5.1 Maintenance The hardware fittings offered shall be suitable for employment of hot line maintenance technique so that usual hot line operations can be carried out with ease, speed and safety. The technique adopted for hot line maintenance shall be generally bare hand method & hot stick method. The Bidder should clearly establish in the bid, the suitability of his fittingsforhotlinemaintenance. Thelinesideyokeplateshallhaveanotch&aworkingholeofsuitablesize.Thedesignof coronacontrolrings/gradingringshallbesuchthatitcanbeeasilyreplacedbyemploying hotlinemaintenancetechnique. Designation BallandSocketDesignation Thedimensionsoftheballandsocketshallbeinaccordancewiththestandarddimensions stated in IS:2486(PartII)/IEC:120. The dimensions shall be checked by the appropriate gaugeaftergalvanizingonly. SecurityClipsandSplitPins Security clips for use with ball and socket coupling shall be Rshaped, hump type which provides positive locking of the coupling as per IS:2486(PartIII)/ IEC : 372. The legs of the security clips shall be spread after assembly in the works to prevent complete withdrawalfromthesocket.Thelockingdeviceshouldberesilient,corrosionresistantand of suitable mechanical strength. There shall be no risk of the locking device being displacedaccidentallyorbeingrotatedwheninposition.Undernocircumstancesshallthe lockingdevicesallow,separationoffittings. The hole for the security clip shall be countersunk and the clip should be of such design that the eye of clip may be engaged by a hot line clip puller to provide for disengagement under energised conditions. The force required to pull the security clip into its unlocked positionshallnotbelessthan50N(5kg)ormorethan500N(50kg). Splitpinsshallbeusedwithbolts&nuts. ArcingHorn/IntermediateArcingHorn The arcing horn / Intermediate Arcing Horn shall be either ball ended rod type or tubular type. The arcing horn shall be provided as shown on the drawing of the hardware fittings, in thisspecification. Theairgapshallbesoadjustedtoensureeffectiveoperationunderactualfieldconditions.

1.5.2

1.6 1.6.1

1.7 1.7.1

1.7.2

1.7.3 1.8 1.8.1 1.8.2 1.8.3

Page-54 .

PART-(SE) SWITCHYARD ERECTION

1.9 YokePlates The strength of yoke plates shall be adequate to withstand the minimum ultimate tensile strengthasspecifiedinthebiddrawings. The plates shall be either triangular or rectangular in shape as may be necessary. The designofyokeplateshalltakeintoaccountthemostunfavorableloadingconditionslikely to be experienced as a result of dimensional tolerances for disc insulators as well as components of hardware fittings within the specified range. The plates shall have suitable holes for fixing corona control rings/grading ring/arcing horn. All the corners and edges shouldberoundedoffwitharadiusofatleast3mm.Designcalculationsi.e.forbearing& tensilestrength,fordecidingthedimensionsofyokeplateshallbefurnishedbythebidder. The holes provided for bolts in the yoke plate should satisfy shear edge condition as per ClauseNo.8.10ofIS:8001984.. CoronaControlRings/GradingRing The Corona control rings/grading ring shall be provided with hardware fittings and shall beofsuchdesignthatitshouldcoveratleastonediscinsulatorindiscinsulatorstringsso that they will reduce the voltage across the insulator units. It shall also improve corona and radio interference performance of the complete insulator string along with hardware fittings. The corona control rings/grading ring shall be made of high strength heat treated aluminium alloy tube of minimum 2.5 mm wall thickness. If mild steel brackets are used then the brackets shall not be welded to the pipe but shall be fixed by means of bolts and nuts on a small aluminium plate attachment welded to the pipe. The welded center of the corona control ring/grading ring shall be grinded before buffing. Alternately, Aluminium tube/flats of suitable dimensions welded to the corona control rings/grading rings may be usedforconnectiontoyokeplate. The Corona control rings/grading ring should have a brushed satin finish and nota bright glossysurface.Noblemishshouldbeseenorfeltwhenrubbingahandoverthemetal. Thelimitingdimensionsofcoronacontrolringshallbeasperthespecificationdrawings. Bidder may quote for grading ring with armour grip suspension assembly. The grading ring shall be of open type design with a gap of 125 mm. The open ends shall be suitably terminated. The outside diameter of the tube shall be 60 mm. The ends of grading ring tubeshallbesealedwithweldedaluminiumcapdulybuffed.

1.10 1.10.1

1.10.2

1.10.3 1.10.4 1.10.5

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PART-(SE) SWITCHYARD ERECTION

1.11 1.11.1 SagAdjustmentPlate The sagadjustment plate to be provided with the Quad tension hardware fitting shall be of three plate type. The sag adjustment plate shall be provided with a safety locking arrangement. The device shall be of such design that the adjustment is done with ease, speedandsafety. The maximum length of the sag adjustment plate from the connecting part of the rest of the hardware fittings shall be 520 mm. The details of the minimum and maximum adjustment possible and the steps of adjustment shall be clearly indicated in the drawing. An adjustment of 150 mm minimum at the interval of 6 mm shall be possible with the sag adjustmentplate. Designcalculationsfordecidingthedimensionsofsagadjustmentplateshallbefurnished by bidder. The hole provided for bolts should satisfy shear edge condition as per Clause No.8.10ofIS:8001984. DeadendAssembly ThedeadendassemblyshallbesuitableforspecificConductor. The dead end assembly shall be compression type with provision for comprising jumper terminal at one end. The angle of jumper terminal to be mounted should be 30 with respect to the vertical line. The area of bearing surface on all the connections shall be sufficient to ensure positive electrical and mechanical contact and avoid local heating due to I2R losses. The resistance of the clamp when compressed on Conductor shall not be morethan75%oftheresistanceofequivalentlengthofConductor. 1.15.3 Die compression areas shall be clearly marked on each deadend assembly designed for continuous die compressions and shall bear the words COM PRESS FIRST suitably inscribed near the point on each assembly where the compression begins. If the dead end assembly is designed for intermittent die compressions it shall bear identification marks COMPRESSION ZONE AND NONCOMPRESSION ZONE distinctly with arrow marks showing the direction of compressions and knurling marks showing the end of the zones. The letters, number and other markings on the finished clamp shall be distinct and legible. The dimensional tolerances of the cross section of aluminium and steel dead end; for dead end assembly for the specific conductor shall be as stipulated in the Standard TechnicalParticulars. Theassemblyshallnotpermitslippingof,damageto,orfailureofthecompleteconductor or any part there of at a load less than 95% of the ultimate tensile strength of the conductor.

1.11.2

1.11.3

1.15 1.15.1 1.15.2

1.15.4

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PART-(SE) SWITCHYARD ERECTION

1.17 1.17.1 Fasteners:Bolts,NutsandWashers AllboltsandnutsshallconformtoIS:6639.AllboltsandnutsshallbegalvanisedasperIS 1367 (Part 13)/IS2629. All bolts and nuts shall have hexagonal heads, the heads being forged out of solid truly concentric, and square with the shank, which must be perfectly straight. Bolts up to M16 and having length up to 10 times the diameter of the bolt should be manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. The shear strength of bolt for 5.6 grade should be 310 MPa minimum as per IS 12427. Bolts should be provided with washerfaceinaccordancewithIS:1363Part1toensureproperbearing. Nuts should be double chamfered as per the requirement of IS:1363 PartIII. It should be ensuredbythemanufacturerthatnutsshouldnotbeovertappedbeyond0.4mmoversize oneffectivediameterforsizeuptoM16. Fully threaded bolts shall not be used. The length of the bolt shall be such that the threadedportionshallnotextendintotheplaceofcontactofthecomponentparts. Allboltsshallbethreadedtotakethefulldepthofthenutsandthreadedenoughtopermit the firm gripping of the component parts but no further. It shall be ensured that the threaded portion of the bolt protrudes not less than 3 mm and not more than 8 mm when fullytightened.Allnutsshallfitandtighttothepointwhereshankoftheboltconnectsto thehead. Flat washers and spring washers shall be provided wherever necessary and shall be of positive lock type. Spring washers shall be electrogalvanised. The thickness of washers shallconformtoIS:20161967. TheBidder shallfurnishboltschedulesgivingthicknessofcomponentsconnected,thenut andthewasher,thelengthofshankandthethreadedportionofboltsandsizeofholesand anyotherspecialdetailsofthisnature. To obviate bending stress in bolt, it shall not connect aggregate thickness more than three timeitsdiameter. Bolts at the joints shall be so staggered that nuts may be tightened with spanners without fouling. To ensure effective inprocess Quality control it is essential that the manufacturer should have all the testing facilities for tests like weight of zinc coating, shear strength, other testing facilities etc, inhouse. The manufacturer should also have proper Quality Assurance system, which should be in line with the requirement of this specification and IS.14000servicesQualitySystemstandard. Fastenersofgradehigherthan8.8arenottobeused.

1.17.2

1.17.3

1.17.4 1.17.5

1.17.6

1.17.7

1.17.8 1.17.9 1.17.10

1.17.11

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PART-(SE) SWITCHYARD ERECTION

1.18 Materials The materials of the various components shall be as specified hereunder. The Bidder shall indicate the material proposed to be used for each and every component of hardware fittings stating clearly the class, grade or alloy designation of the material, manufacturing process&heattreatmentdetailsandthereferencestandards. ThedetailsofmaterialsfordifferentcomponentarelistedasinTableI
TABLE1:(DetailsofMaterials) Nameofitem Materialtreatment Processof Reference Remarks Standard SecurityClips StainlessSteel/ AISI302or PhospherBronze 304L/IS1385 ArcingHorn MildSteelRod/ Hotdip AsperIS226 TubeType galvanised orIS2062 BallFittings, ClassIVSteel Dropforged& AsperIS:2004 Socket,all normalizedHot shackleslinks dipgalvanised cleves YokePlate MildSteel Hotdip AsperIS226 galvanized orIS2062 SagAdjustment MildSteel Hotdip AsperIS226 plate galvanized orIS2062 CoronaControl HighStrengthAl. HeattreatedHot ASTMB429oras Mechanical ring/Grading Alloytube(6061/ dipgalvanized perIS strengthof ring 6063/1100typeor weldedjointshall 65032/63400Type) notbelessthan 20KN Supporting HighStrentgthAl HeattreatedHot ASTMB429oras Brackets& Alloy7061/6063/ dipgalvanized perIS:226or MountingBolts 65032/63400Type) IS:2062 orMildSteel TurnBuckle ClassIISteel Forgedhotdip IS:2004 galvanized Freecentretype HighStrengthAl. Castedorforged IS:617orASTM clamp/Envelope Alloy4600/LM6 &Heattreated B429 typeClamp: or6061/65032 ClampBody, KeeperPiece Envelopetype MildSteel Hotdip AsperIS226 Clamp:Cotter galvanised orIS2062 bolts/Hangers, Shackles, Brackets Envelopetype StainlessSteel Forged&&Heat AISI302or304L Clamp: orHighStrength treated ASTMB429 UBolts Alalloy6061/6063 or65032/63400 P.A.rod High strength Al Heattreatment ASTM:B429 Min.tensile alloy type 6061 or during strengthof35 equivalent manufacturing kg/mm2

1.18.1

Sl. No. 1. 2. 3.

4. 5. 6(a).

6(b).

7. 8(a).

8(b)

8(c)

9.

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PART-(SE) SWITCHYARD ERECTION

10. AGSclamp (a)Supporting house (b)Alinsertand retainingstrap (c)Elastomer cushion DeadEnd Assembly:Outer Sleeve SteelSleeve Balancing weights High strength corrosion resistant Al. alloy LM6, 4600 orequivalent6061 High strength Al alloy type 6061 or equivalent Moulded on Al reinforcement EC grade Al of purity not less than 99.50% MildSteel Cast iron machined Steel Cast/forgedheat treated. IS:617or equivalent

ForgedandHeat treated

ASTM:B429

11(a).

11(b). 12.

HotDip Galvanised MCI/ Hotdip Mild galvanised

IS:226/IS2062 IS:226/2062or equivalent

Note : Alternate materials conforming to other national standards of other countries also may be offered provided the properties and compositions of these are close to the properties and compositions of material specified.Biddershouldfurnishthedetailsofcomparisionofmaterialofferedvisavisspecifiedinthebidorelse thebidsareliabletoberejected. 1.19 1.19.1 Workmanship All the equipment shall be of the latest design and conform to the best modernpracticesadoptedintheExtraHighVoltagefield.TheBiddershallofferonlysuch equipment as guaranteed by him to be satisfactory and suitable for the rated transmission linesandwillgivecontinuedgoodperformance. The design, manufacturing process and quality control of all the materials shall be such as to give the specified mechanical rating, highest mobility, elimination of sharp edges and corners to limit corona and radiointerference, best resistance to corrosion and a good finish. All ferrous parts including fasteners shall be hot dip galvanised, after all machining has been completed. Nuts may, however, be tapped (threaded) after galvanising and the threads oiled. Spring washers shall be electro galvanised. The bolt threads shall be undercut to take care of the increase in diameter due to galvanising. Galvanising shall he done in accordance with IS 2629 :1985/ IS 1367 (Part 13) and shall satisfy the tests mentionedinIS2633:1986. Before ball fittings are galvanised. all die flashing on the shank and on the bearing surface of the ball shall be carefully removed without reducing the dimensions below the design requirements. The zinc coating shall be perfectly adherent, of uniform thickness, smooth, reasonably bright, continuous and free from imperfections such as flux, ash rust, stains, bulky white deposits and blisters. The zinc used for galvanising shall be Zinc of any grade in IS 209:1992ingot(fourthrevision)orIS13229:1991.

1.19.2

1.19.3

1.19.4

1.19.5

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PART-(SE) SWITCHYARD ERECTION

1.19.6 Pin balls shall be checked with the applicable GO gauges in at least two directions. one of which shall be across the line of die flashing, and the other 90o to this line.NO GO gaugesshallnotpassinanydirection. 1.19.7 Socket ends, before galvanising, shall be of uniform contour. The bearing surface of socket ends shall be uniform about the entire circumference without depressions of high spots. The internal contours of socket ends shall be concentric with the axis of the fittings as per IS:2486/IEC:120. The axis of the bearing surfaces of socket ends shall be coaxial with the axis of the fittings. Thereshallbenonoticeabletiltingofthebearingsurfaceswiththeaxisofthefittings. In case of casting, the same shall be free from all internal defects like shrinkage, inclusion, blow holes, cracks etc. Pressure die casting shall not be used for casting of components withthicknessmorethan5mm. All current carrying parts shall be so designedand manufactured thatcontact resistance is reducedtominimum. No equipment shall have sharp ends or edges, abrasions or projections and cause any damage to the conductor in any way during erection or during continuous operation which would produce high electrical and mechanical stresses in normal working. The designofadjacentmetalpartsandmatingsurfacesshallbesuchastopreventcorrosionof thecontactsurfaceandtomaintaingoodelectricalcontactunderserviceconditions. All the holes shall be cylindrical, clean cut and perpendicular to the plane of the material. Theperipheryoftheholesshallbefreefromburrs. All fasteners shall have suitable corona free locking arrangement to guard against vibrationloosening. Welding of aluminium shall be by inert gas shielded tungsten arc or inert gas shielded metal arc process. Welds shall be clean, sound, smooth, uniform without overlaps, properly fused and completely sealed. There shall be no cracks, voids incomplete penetration, incomplete fusion, undercutting or inclusions. Porosity shall be minimised so that mechanical properties of the aluminium alloys are not affected. All welds shall be properlyfinishedaspergoodengineeringpractices. BidDrawings TheBiddershallfurnishfulldescriptionandillustrationsofmaterialsoffered. Fully dimensioned drawings of the complete insulator string hard wares and their component parts showing clearly the following arrangements shall be furnished along with the bid. Weight, material and fabrication details of all the components should be includedinthedrawings.

1.19.8

1.19.9 1.19.10

1.19.11 1.19.12 1.19.13

1.20 1.20.1 1.20.2

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(i) Attachmentofthehangerorstrainplate.

(ii) Deadendassembly. (iii) ArcinghornattachmenttothestringofthistechnicalSpecification. (iv) Yokeplates (v) Hardware fittings of ball and socket type for inter connecting units to the top and bottomYokeplates. (vi) Corona control rings/grading ring attachment to conductor and other small accessories. (vii)Linkswithsuitablefittings. 1.20.3 All drawings shall be identified by a drawing number and contract number. All drawings shall be neatly arranged. All drafting & lettering shall be legible. The minimum size of lettering shall be 3 mm. All dimensions & dimensional tolerances shall be mentioned in mm. Thedrawingsshallinclude: (i) Dimensionsanddimensionaltolerance.

(ii) Material, fabrication details including any weld details & any specified finishes & coatings. Regarding material designation & reference of standards are to be indicated. (iii) CatalogueNo. (iv) Marking (v) Weightofassembly (vi) Installationinstructions (vii) Designinstallationtorquefortheboltorcapscrew. (viii) Withstand torque that may be applied to the bolt or cap screw without failure of componentparts. (ix) Thecompressiondienumberwithrecommendedcompressionpressure. (x) 1.20.4 Allotherrelevantterminaldetails.

After placement of award, the Contractor shall submit fully dimensioned drawing includingallthecomponentsinfour(4)copiestotheOwnerforapproval.

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2.5 2.5.1 SpacerDamper Suitable spacer dampers for four bundle ACSR BERSIMIS conductor for 400 kV (Quad) line shall be offered. The spacer damper covered by this specification shall be designed to maintain the bundle spacing of 457 mm under all normal operating conditions and to effectively control Aeolian vibrations as well as sub span oscillation and to restore conductor spacing after release of any external extraordinary load. The nominal sub conductorspacingshallbemaintainedwithin5mm. Thespacerdampershallrestorethenormalsubconductorspacingduetodisplacementby wind, electromagnetic and electrostatic forces including the specified short circuit level without permanent deformation or damage either to bundle conductors or to spacer damperitself. The design offered shall be presented as a system consisting of spacer dampers and their staggering scheme for spans ranging from 100 m to 1100 m. A vibration performance test shall be carried out on an experimental test line. The systems tested should be those specified by the Supplier for the 400 kV line conditions. Only systems satisfying the performancecriteriaunderAnnexureAshallbesubmittedbyBidderalongwithbid. The test line selected for the performance evaluation shall have been designed for that purpose,beadequatelyexposedtowindandproperlyinstrumented. Sl. Description TechnicalParticulars Doublecircuitfor400kVline: 1. Configuration Four ACSR Quad BERSIMIS conductor bundle per phase and all three phases in vertical configuration. Refer sectionI for mechanicalpropertiesofconductor 2. Spanlengthinmetres i)Rulingdesignspan 400metres ii)Maximumspan 1100metres iii)MinimumSpan 100metres 3. Tensile load in each sub Aspersagtensioncalculations. conductor 4. Armourrodsused Yes 5. Maximum permissible 150microstrains dynamicstrains

2.5.2

2.5.3

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2.6.4 Under the operating conditions specified, the spacer damper system shall adequately control Aeolian vibrations throughout the life of the transmission line with wind velocity ranging from0to30kmperhourinordertopreventdamagetoconductoratsuspensionclamps,dead endclampsandspacerdamperclamps. The spacer damper system shall also control the subspan oscillations in order to prevent conductordamageduetochaffingandseverebendingstressesatthespacerdamperclampsas wellassuspensionanddeadendclampsandtoavoidweartospacerdampercomponents. The spacer damper shall consist of a rigid central body called the frame linked to the conductor by four articulated arms terminated by suitable clamping system. The articulation shallbedesignedtoprovideelasticanddampingforcesunderangularmovementofthearms. The dynamic characteristics of the articulations shall be maintained for the whole life of the transmissionline. The clamping system shall be designed to provide firm but gentle and permanent grip while protecting the conductor against local static or dynamic stresses expected during normal operatingconditions.Theclampingsystemshallbedesignedtocompensateforanyreduction ofconductordiameterduetocreep. Bolted type clamps shall allow installation without removal of the bolts or the clamps from clamp body. Locking mechanism shall be suitable to prevent bolt loosening. Clamp locking devices with small loose components shall not be accepted. Nut cracker, hinged open or boltless type clamps are acceptable provided adequate grip can be maintained on the conductor. Bolts and nuts shall be of mild steel, stainless steel, or high strength steel in accordance with thedesignofthespacerdamper.

2.6.5

2.6.6

2.6.7

2.6.8

2.6.9

2.6.10 Where elastomer surfaced clamps are used, theelastomer elements shall be firmly fixed to the clamp. The insert should be forged from aluminium alloy of type 6061 or equivalent aluminiumalloyhavingminimumtensilestrengthof25kg/mm2.Theinsertshallbemoulded on the insert surface. The insert shall be duly heat treated and aged to retain its consistent characteristics during service. The grain flow of the forged insert shall be in the direction of themaximumtensionandcompressionloadsexperienced. 2.6.11 If clamps involving preformed rods are used, these rods shall be designed for specific conductor size. They shall be made of high strength aluminium alloy of type 6061 or equivalent aluminium alloy having a minimum tensile strength of 35 kg/mm3. The rods shall be ball ended. The rods shall be heat treated and aged to achieve specified mechanical properties and to retain the same during service. The length of the rods shall be such that the endsfallinsidetheimaginarysquarewhosesidesareverticalandhorizontaloutertangentsto theconductorsections.

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2.6.12 The spacer damper body shall be cast/forged from suitable high strength corrosion resistant aluminumalloy.Thealuminiumalloyshallbechoseninrelationwiththeprocessused. 2.6.13 The rubber components involved in the design such as damping elements shall be made with rubbercompoundselectedspecificallyforthatparticularapplication.TheBiddershallsubmit a complete list of physical and mechanical properties of the elastomer used. This list shall makereferencetoallapplicableASTMstandards. 2.6.14 The rubber components used shall have good resistance to the effects of temperature up to 95C and to ultraviolet radiation, ozone and other atmospheric contaminants. The rubber shallhavegoodwearandfatigueresistanceandshallbeelectricallysemiconductive. 2.6.15 The spacer damper involving ferrous material shall not have magnetic power loss more than that stipulated in the Standard Technical Particulars at 600 A, 50 Hz alternating current per subconductor. 2.6.16 Thespacerdamperassemblyshallhaveelectricalcontinuity.Theelectricalresistancebetween thesubconductorsacrosstheassemblyincaseofspacerdamperinvolvingelastomersurfaced clamps shall be suitably selected by the manufacturer to ensure satisfactory electrical performanceandavoiddeteriorationofelastomerunderserviceconditions. 2.6.17 The spacer damper assembly shall have complete ease of installation and shall be capable of removal/reinstallationwithoutanydamage. 2.6.18 The spacer damper assembly shall be capable of being installed and removed from the energized line by means of hot line techniques. The Bidder shall supply with the bid the completedescriptionoftheinstallation,removalandreinstallationprocedure. 2.6.19 The Bidder shall recommend the staggering scheme for installation of spacer dampers on the line which shall ensure most satisfactory fatigue performance of the line as specified. The scheme shall indicate the number of spacer dampers per phase per span and the sub span lengths to be maintained between spacer dampers while installing on the four bundle conductors. 2.6.20 The staggering scheme shall be provided for spans ranging from 100 m to 1100 m. The numberofspacerdampersforanominalrulingspanof400mshallnotbelessthansix. 2.6.21 Nosubspanshallbegreaterthan70mandnoendsubspanshallbelongerthan40m.

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2.6.22 The staggering scheme shall be such that the spacer dampers be unequally distributed along thespantoachievesufficientdetuningofadjacentsubspansforoscillationsofsubspanmode andtoensurebundlestabilityforwindspeedsupto60km/hr. 2.6.23 The Bidder shall furnish all the relevant technical documents in supports of the staggering schemerecommendedforthespacerdamper. 2.7 RigidSpacerforJumperforQuadConductor 2.7.1 Jumpersattensionpointsshallbefittedwithspacerssoastolimitthelengthoffreeconductor to 3.65 m and to maintain the sub conductor spacing of 457 mm. Bidder shall quote for rigid spacer for jumper. It shall meet all the requirements of spacer used in line except for its vibrationperformance.Spacersrequiringretainingrodsshallnotbequotedforjumpers. ThespacerofferedbytheBiddershallsatisfythefollowingrequirements. Spacer shall restore normal spacing of the sub conductors after displacement by wind, electromagnetic and the electrostatic forces under all operating conditions including the specified short circuit level without permanent deformation damage either to conductor or to theassemblyitself.Theyshallhaveuniformgripontheconductor For spacer requiring retaining rods, the retaining rods shall be designed for the specified conductorsize.Thepreformedrodsshallbemadeofhighstrength,specialaluminiumalloyof type 6061/65032 and shall have minimum tensile strength of 35 kg/sq.mm. The ends of retaining rods should be ball ended. The rods shall be heattreated to achieve specified mechanicalpropertiesandgiveproperresilienceandretainthesameduringservice. Four number of rods shall be applied on each clamps to hold the clamp in position. The minimum diameter of the rods shall be 7.87 + 0.1 mm and the length of the rods shall not be lessthan1100mm. Where elastomer surfaced clamp grooves are used, the elastomer shall be firmly fixed to the clamp. The insert should be forged from aluminium alloy of type 6061/65032. The insert shall bedulyheattreatedandagedtoretainitsconsistentcharacteristicsduringservice. Anynutusedshallbelockedinanapprovedmannertopreventvibrationloosening.Theends of bolts and nuts shall be properly rounded for specified corona performance or suitably shielded. Clamp with cap shall be designed to prevent its cap from slipping out of position when being tightened. The clam grooves shall be in uniform contact with the conductor over the entire surface, except for rounded edges. The groove of the clamp body and clamp cap shall be smooth and free of projections, grit or other material. which cause damage to the conductor when the clampisinstalled.

2.7.2 2.7.2.1

2.7.2.2

2.7.2.3

2.7.2.4

2.7.2.5

2.7.2.6 2.7.2.7

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2.7.2.8 For the spacer involving bolted clamps, the manufacturer must indicate the clamp bolt tightening torque to ensure that the slip strength of the clamp is maintained between 2.5 kN and 5 kN. The clamp when installed on the conductor shall not cause excessive stress concentration on the conductor leading to permanent deformation of the conductor strands andprematurefatiguefailureinoperation. Universaltypeboltedclamps,coveringarangeofconductorsizes,willnotbepermitted.

2.7.2.9

2.7.2.10 No rubbing, other than that of the conductor clamp hinges or clamp swing bolts, shall take placebetweenanypartsofthespacer.Jointincorporatingaflexiblemediumshallbesuchthat thereisnorelativeslipbetweenthem. 2.7.2.11 The spacer shall be suitably designed to avoid distortion or damage to the conductor or to themselvesduringservice. 2.7.2.12 Rigidspacersshallbeacceptableonlyforjumpers. 2.7.2.13 The spacer shall not damage or chafe the conductor in any way which might affect its mechanicalandfatiguestrengthorcoronaperformance. 2.7.2.14 The clamping system shall be designed to compensate for any reduction in diameter of conductorduetocreep. 2.7.2.15 The spacer assembly shall not have any projections, cuts, abrasions etc. or chattering parts whichmightcausecoronaorRIV. 2.72.16 The spacer tube shall be made of aluminium alloy of type 6061/65032. If fasteners of ferrous material are used, they shall conform to and be galvanised conforming to relevant Indian Standards. The spacer involving ferrous fasteners shall not have magnetic power loss more thanonewattat600Amps50Hzalternatingcurrentpersubconductor. 2.7.2.17 Elastomer, if used, shall be resistant to the effects of temperature up to 95 deg.C, ultraviolet radiationandotheratmosphericcontaminantslikelytobeencounteredinservice.Itshallhave good fatigue characteristics. The physical properties of the elastomer shall be of approved standard. 2.7.2.18 Thespacerassemblyshallhaveelectricalcontinuity.Theelectricalresistancebetweenthesub conductor across the assembly in case of spacer having elastomer clamp grooves shall be suitably selected by the manufacturers to ensure satisfactory electrical performance and to avoiddeteriorationofelastomerunderallserviceconditions. 2.7.2.19 The spacer assembly shall have complete ease of installation and shall be capable of removal/reinstallationwithoutanydamage. 2.7.2.20 The spacer assembly shall be capable of being installed and removed from the energised line bymeansofhotlinetechnique.

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2.8 TConnector TConnector of compression type shall be used for jumper connection at tower for making LILO termination . It shall be manufactured out of 99.5% pure aluminium and shall be strong enough to withstand normal working loads. The Tconnector shall have a resistivity across jumper less than 75% resistivity of equivalent length of conductor. The Tconnector shall not permitslippingoff,damagetoorfailureofcompleteconductor.Theweldedportionsshallbe designed for 30 kN axial tensile load. Leg sleeve of Tconnector should be kept at an angle of 15 deg. from vertical and horizontal plane of the conductor in order to minimise jumper pull at the welded portion. The dimensions and dimensional tolerances of Tconnector shall be as perStandardTechnicalParticulars. MaterialandWorkmanship Alltheequipmentshallbeofthelatestprovendesignandconformtothebestmodernpractice adopted in the extra high voltage field. The Bidder shall offer only such equipment as guaranteed by him to be satisfactory and suitable for 400 kV transmission line application withbundleconductorsandwillgivecontinuedgoodperformance. The design, manufacturing process and quality control of all the materials shall be such as to achieve requisite factor of safety for maximum working load, highest mobility, elimination of sharpedgesandcorners,bestresistancetocorrosionandagoodfinish. All ferrous parts shall be hot dip galvanised, after all machining has been completed. Nuts may, however, be tapped (threaded) after galvanising and the threads oiled. Spring washers shallbeelectrogalvanisedaspergrade4ofIS15731970.Theboltthreadsshallbeundercutto take care of increase in diameter due to galvanising. Galvanising shall be done in accordance with IS:2629/IS1367 (Part13) and satisfy the tests mentioned in IS2633. Fasteners shall withstand four dips while spring washers shall withstand three dips. Other galvanised materialsshallhaveaminimumoverallcoatingofZincequivalentto600gm/sq.mandshallbe guaranteed to withstand at least six dips each lasting one minute under the standard Preece testforgalvanisingunlessotherwisespecified. The zinc coating shall be perfectly adherent, of uniform thickness, smooth, reasonably bright, continuousandfreefromimperfectionssuchasflux,ash,ruststains,bulkywhitedepositsand blisters.ThezincusedforgalvanisingshallbeofgradeZn.99.95asperIS:209. In case of castings, the same shall be free from all internal defects like shrinkage, inclusion, blowholes.cracksetc. All current carrying parts shall be so designed and manufactured that contact resistance is reducedtominimumandlocalisedheatingphenomenonisaverted. Noequipmentshallhavesharpendsoredges,abrasionsorprojectionsandshallnotcauseany damage to the conductor in any way during erection or during continuous operation which would produce high electrical and mechanical stresses in normal working. The design of adjacent metal parts and mating surfaces shall be such as to prevent corrosion of the contact surfaceandtomaintaingoodelectricalcontactunderallserviceconditions.

2.9 2.9.1

2.9.2

2.9.3

2.9.4

2.9.5 2.9.6 2.9.7

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PART-(SE) SWITCHYARD ERECTION

2.9.8 2.9.9 2.10 Particular care shall be taken during manufacture and subsequent handling to ensure smooth surfacefreefromabrasionorcuts. ThefastenersshallconformtotherequirementsofIS:6639.Allfastenersandclampsshallhave coronafreelockingarrangementtoguardagainstvibrationloosening. CompressionMarkings Diecompressionareasshallbeclearlymarkedoneachequipmentdesignedforcontinuousdie compressions and shall bear the words COMPRESS FIRST suitably inscribed on each equipment where the compression begins. If the equipment is designed for intermittent die compressions, it shall bear the identification marks COMPRESSION ZONE and NON COMPRESSION ZONE distinctly with arrow marks showing the direction of compression andknurlingmarksshowingtheendofthezones.Theletters,number andothermarkingson finishedequipmentshallbedistinctandlegible. BidDrawings TheBiddershallfurnishdetaileddimensioneddrawingsoftheequipmentsandallcomponent parts. Each drawing shall be identified by a drawing number and Contract number. All drawings shall be neatly arranged. All drafting and lettering shall be legible. The minimum size of lettering shall be3 mm. All dimensions and dimensional tolerances shall be mentioned inmm. Thedrawingsshallinclude (i) Dimensionsanddimensionaltolerances (ii) Material. fabrication details including any weld details and any specified finishes and coatings.Regardingmaterial,designationsandreferenceofstandardsaretobeindicated. (iii) CatalogueNo. (iv) Marking (v) Weightofassembly (vi) Installationinstructions (vii)Designinstallationtorquefortheboltorcapscrew viii)Withstand torque that may be applied to the bolt or cap screw without failure of componentparts (ix) Thecompressiondienumberwithrecommendedcompressionpressure. (x) Allotherrelevanttechnicaldetails 2.11.3 The above drawings shall be submitted with all the details as stated above along with the bid document. After the placement of award. the Contractor shall again submit the drawings in fourcopiestothePurchaserforapproval.

2.11 2.11.1

2.11.2

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PART-(SE) SWITCHYARD ERECTION

2. Sl. 1. 2. 3. 4. TENSIONHARDWAREFITTINGSQUADACSRBERSIMISCONDUCTOR Description Unit Particulars/Value MechanicalStrengthofTension fittings(excludingdeadendclamp) TypeofDeadEndassembly CompressionPressure Maximumelectricalresistanceof deadendassemblyasapercentage ofequivalentlengthofConductor Slipstrengthofdeadendassembly PurityofZincusedforgalvanizing Min.No.ofdipsinstandardpreece testtheferrouspartscanwithstand. kN MT % 640 Compression 100 75

5. 6. 7.

kN % Nos

Min.95%ofUTSofBersimis AsperIS:209/IS13229 a)Fasteners:4dipsof1min b)Springwashers:3dipsof1min c)Allothers:6dipsof1min

TCONNECTORFORACSRBERSIMISCONDUCTOR Sl. Description Unit Material 1. DimensionofAluminumsleeveBeforecompression 2. i)Insidediameter mm ii)Outsidediameter mm iii)Length mm DimensionsofAluminumSleeveaftercompression 3. i)Outsidedimension(Cornertocorner) mm ii)Outsidedimension(facetoface) mm 5. Maximumresistanceofthecompressedunit % expressed,aspercentageoftheresistanceof equivalentlengthofbareconductor. 6. MinimumcoronaExtinctionvoltagekV(rms) kV underdrycondition 7. MaximumRadioInterferenceVoltageat1 Micro MHzforphasetoearthvoltageof305kV(rms) Volts underdrycondition

Particulars/Value Aluminiumofpurity99.5% 37.40.5 58.41.0 630.005.0 57.40.5 49.70.5 75

320 1000

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PART-(SE) SWITCHYARD ERECTION QUADSPACERDAMPERFORQUADACSRBERSIMISCONDUCTOR Sl. Description 1. 2. 3. TypeofClamps TypeofDampingelement Materialof (a)Clamp (b)Body (c)Keeperpiece (d)ArmwithPivot Elastomer(ifused) (a)Shorehardness (b)Temp.rangeforwhich designed Minimumultimatetensile strengthofspacer (a)Compressiveload (b)Tensileload Unit C kN kN Particulars/Value Bolted/Nutcracker/Hingedopen/Boltless /Preformedrods. Spring/Elastomer/EPDM AlAlloyIS:4600 AlAlloy4600 AlAlloy4600 AlAlloy4600 5080 Upto95C 15 5 2.5kN 2.0kN Below1watt.

4.

5.

6 7.

Slippingstrengthofspacer clamp (a)Beforevibrationtest (b)Aftervibrationtest Maximummagneticpowerloss ofatsubconductorcurrentof 600amperes,50HzAC

Wat t

Page70

PART-(SE) SWITCHYARD ERECTION

8.

9.

MinimumcoronaExtinction voltagekV(rms)underdry condition RadioInterferenceVoltageat1 MHzforphasetoearthvoltage of305kV(rms)Microvolts underdrycondition

kV

320

Below1000

QUADRIGIDSPACERFORQUADACSRBERSIMISCONDUCTOR Sl. Description Unit Particulars/Value

1.

Materialof (a)Clamp (b)Body (c)Keeperpiece (d)Tube Minimumultimatetensilestrength ofspacer (a)Compressiveload (b)Tensileload Maximummagneticpowerlossof atsubconductorcurrentof600 amperes,50HzAC MinimumcoronaExtinction voltagekV(rms)underdry condition TightningTorque RadioInterferenceVoltageat1 MHzforphasetoearthvoltageof 305kV(rms)Microvoltsunderdry condition

AlAlloyIS:4600 AlAlloy4600 AlAlloy4600 AlAlloy63400

3 5.

kN 15 kN 5 Watts Below1watt.

6.

kV

320

7 7.

6kgm Below1000 Page71

PART-(SE) SWITCHYARD ERECTION 2.FLEXIBLECOPPERBONDFOR7/3.66MMGSEARTHWIRE Sl. 1. 2. 3. 4. 5. 6. Description Stranding Crosssectionalarea Minimumcopperequivalentarea Lengthofcoppercable Materialoflugs BoltSize i)Diameter ii)Length SlipStrength Unit Sq.mm Sq.mm mm mm mm kN Particulars/Value 37/7/0.417 35.4 34 500+5 Tinnedcopper 16 40 3 3.VIBRATIONDAMPERFOR7/3.66MMGSEARTHWIRE Sl. 1. 2. Description TypeofDamper Materialsofcomponents a)Dampermasses Unit Particulars/Value 4RStockbridgetype Castiron/mildsteel/Zinc alloydulyhopdip galvanised Aluminumalloy4600 Hightensilestrength galvanizedsteel 19 135 2.5 2.5 2 10to60 +/40(Maximum)

7.

3. 4. 5. 6. 7. 8.

b)Clamp c)Messengercable Numberofstrandsinstranded messengercable Minimumultimatetensilestrength ofstrandedmessengercable Slipstrengthofstrandedmessenger cable(masspulloff) Slippingstrengthofdamperclamp (a)Beforefatiguetest (b)Afterfatiguetest Resonancefrequenciesrange Percentagevariationinreactance afterfatiguetestincomparisonwith that.beforefatiguetest

Nos. Kg/mm 2 kN kN kN Hz %

Page-72

PART-(SE) SWITCHYARD ERECTION

9.

10.
a)

b) c)

Percentagevariationinpower dissipationafterfatiguetestin comparisonwiththatbeforefatigue test Galvanising MinimumweightofZinccoatingfor steelparts PurityofZincusedforgalvanising Min.No.ofdipsinstandardpreece testtheferrouspartscanwithstand.

+/40(Maximum)

gm/m 2 % Nos.

600 99.95(IS209)or98.5(IS 13229) a)Fasteners:4dipsof1 minute b)Springwashers:3dips of1minute c)allothers:6dipsof1 minute

4.SUSPENSIONCLAMPFOR7/3.66MMGSEARTHWIRE Sl. Description 1. Materialofcomponents (a)Shackle (b)ClampBody&Keeper 2. 3. 4. 5.

a)

Unit mm kN kN gm/m 2 % Nos.

Particulars/Value ForgedSteel Malleablecastiron/SGI/ AlAlloy4600 MildSteel 150 25 12to17 600 99.95(IS209)or98.5(IS 13229) a)Fasteners:4dipsof1 minute b)Springwashers:3dips of1minute c)allothers:6dipsof1 minute Page-73

b) c)

IUBolt TotalDrop(Maximum) BreakingStrength(Minimum) SlippingStrength Galvanising MinimumweightofZinccoatingfor steelparts PurityofZincusedforgalvanising Min.No.ofdipsinstandardpreece testtheferrouspartscanwithstand.

PART-(SE) SWITCHYARD ERECTION 5.TENSIONCLAMPFOR7/3.66MMGSEARTHWIRE Sl. 1. 3. Description Unit Materialofcomponents (i)AnchorShackle (ii)CompressionClamp a)SteelSleeve b)Aluminiumsleeve c)AluminiumFillersleeve RangeofHardnessofthesteelsleeve BH (Brinnelhardness) N 4. DimensionofsleeveBeforecompression i) ii) iii) 5. i) ii) 6. 7. 8. 9.
a)

Particulars/Value ForgedSteel MildSteel Aluminiumofpurity99.5% Aluminiumofpurity99.5% 120200

Aluminium Sleeve

SteelSleeve

Alufiller sleeve

b) c)

Insidediameter mm 22.000.5 11.500.2 11.500.2 Outsidediameter mm 30.000.5 21.000.5 21.000.5 2055 25.0 Length mm 2455 DimensionsofSleeveaftercompression AluminiumSleeve SteelSleeve 20.200.5 Outsidedimension(CornertoCorner) mm 29.400.5 17.500.5 Outsidedimension(facetoface) mm 25.000.5 Slipstrength KN 65 MinimumBreakingstrengthof KN 70 assembly(excludingclamp) CompressionPressure Ton 100 Galvanising MinimumweightofZinccoatingfor gm/m 600 steelparts 2 PurityofZincusedforgalvanising % 99.95(IS209)or98.5(IS 13229) Min.No.ofdipsinstandardpreece Nos. a)Fasteners:4dipsof1 testtheferrouspartscanwithstand. minute b)Springwashers:3dipsof 1minute c)allothers:6dipsof1 minute Page-74

PART-(SE) SWITCHYARD ERECTION

5.0 5.1 5.1.1 5.1.1.1

TestsandStandardsforLineHardwarefittings TypeTests OnthecompleteInsulatorStringwithHardwareFittings OnthecompleteDiscInsulatorStringwithHardwareFittings a) Powerfrequencyvoltagewithstandtest :AsperIEC:383 withcoronacontrolrings/gradingringand arcinghornsunderwetcondition Switchingsurgevoltagewithstandtest underwetcondition Impulsevoltagewithstandtestunderdry condition Impulsevoltageflashovertestunderdry condition Voltagedistributiontest CoronaandRIVtestunderdrycondition MechanicalStrengthtest Vibrationtest PowerArcTest :AsperIEC:383 :AsperIEC:383 :AsperIEC:383 :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA

5.1.1.2

b) c) d) e) f) g) h) i)

OnthecompletestringwithHardwareFittings a) Powerfrequencyvoltagewithstandtest :AsperIEC:383 withcoronacontrolrings/gradingringand arcinghornsunderwetcondition Switchingsurgevoltagewithstandtest underwetcondition Impulsevoltagewithstandtestunderdry condition Impulsevoltageflashovertestunderdry condition :AsperIEC:383 :AsperIEC:383 :AsperIEC:383 Page-75

b) c) d)

PART-(SE) SWITCHYARD ERECTION 5.1.3 5.1.7 5.1.8 5.1.9 e) f) g) h) OnTensionHardwareFittingonly a) b) c) d) Electricalresistancetestfordeadend Assembly Heatingcycletestforfordeadend Assembly Slipstrengthtestfordeadendassembly Mechanicalstrengthtest :AsperIS:2486 (PartI) :AsperIS:2486 (PartI) :AsperIS:2486 (PartI) :AsperAnnexureA CoronaandRIVtestunderdrycondition MechanicalStrengthtest Vibrationtest PowerArcTest :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA

FlexibleCopperBond a) Slipstrengthtest :AsperAnnexureA

VibrationDamperforEarthwire a) b) c) d) e) f) QuadSpacerDamperforConductor a) Chemicalanalysisofmaterials :AsperAnnexureA Page-76 Chemicalanalysisofmaterials Dynamiccharacteristicstest Vibrationanalysis Clampsliptest Fatiguetests Damperefficiencytest :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperIS:9708

PART-(SE) SWITCHYARD ERECTION 5.1.11 5.1.12 b) c) d) e) f) g) h) i) j) Clampsliptest Performancetest i)Aeolian ii)subspanoscillations Magneticpowerlosstest(ifapplicable) DynamicCharacteristictest Fatiguetest TensioncompressionTest Coronaextinctionvoltagetest(dry) Radiointerferencevoltagetest(dry) Ozonetestonelastomer :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA

RigidSpacerforjumper a) b) c) d) e) f) Chemicalanalysisofmaterials Clampsliptest Magneticpowerlosstest(ifapplicable) TensioncompressionTest Coronaextinctionvoltagetest(dry) Radiointerferencevoltagetest(dry) :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA

OnEarthwireSuspensionclampAssembly a) b) c) Chemicalanalysisofmaterials ClampslipstrengthVstorquetestfor suspensionclamp MechanicalstrengthTest :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA Page-77

PART-(SE) SWITCHYARD ERECTION 5.1.13

5.1.14

OnEarthwireTensionclampAssembly a) b) c) d) Chemicalanalysisofmaterials :AsperAnnexureA

Mechanicalstrengthtest(excludingclamp) :AsperAnnexureA Slipstrengthtestfortensionassembly Electricalresistancetestfortensionclamp :AsperAnnexureA :AsperAnnexureA

All the type tests given under clause no. 5.1.1 above shall be conducted on Quadruple tension insulator string along with hardware fittings for 400 kV lines with Quad ACSR BERSIMISconductor. ThetestsspecifiedunderClauseNo.5.1.1.1(a)to(g)/5.1.1.2(a)to(f)shallbeconductedon for400kVlineswithQuadACSRBERSIMISconductor. Heating cycle test on dead end assembly, and performance test for Quad spacer damper shall not be required to be carried out if a valid test certificate is available for a similar design, i.e., test conducted earlier should have been conducted in accredited laboratory (accredited based on ISO/IEC guide 25/17025 or EN 45001 by the National Accreditation body of the country where laboratory is located) or witnessed by the representative (s) of OWNER or Utility. The test reports submitted shall be for the tests conducted within the last5(five)yearspriortothedateofBidopening. In case the tests have been conducted earlier than the above stipulated period or in the event of any discrepancy in the test report (i.e., any test report not applicable due to any design / manufacturing change including substitution of components or due to non compliance with the requirement stipulated in the Technical Specification) the tests shall beconductedbytheContractoratnoextracosttotheOwner. TypetestsspecifiedunderClause5.1.1.1(a)to(d)/5.1.1.2(a)to(d)shallnotberequiredto be carried out if a valid test certificate is available for a similar design, i.e., tests conducted earlier should have been conducted in accredited laboratory (accredited based on ISO/IEC guide 25/17025 or EN 45001 by the National Accreditation body of the country where laboratory is located) or witnessed by the representative (s) of OWNER or Utility. The test reports submitted shall be for the tests conducted within the last 5 (five) years prior to the dateofBidopening. In case the tests have been conducted earlier than the above stipulated period or in the event of any discrepancy in the test report (i.e., any test report not applicable due to any design / manufacturing change including substitution of components or due to non compliance with the requirement stipulated in the Technical Specification) the tests shall beconductedbytheContractoratnoextracosttotheOwner.

5.1.15 5.1.16

5.1.17

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PART-(SE) SWITCHYARD ERECTION

5.2 5.2.1 AcceptanceTests OnTensionHardwareFittings a) b) c) VisualExamination Verificationofdimensions Galvanising/Electroplatingtest :AsperIS:2486(PartI) :AsperIS:2486(PartI) :AsperIS:2486(PartI) :AsperAnnexureA

d) Mechanicalstrengthtestofeachcomponent (excludingcoronacontrolringsgradingring andarcinghorn) e) f) MechanicalStrengthtestofweldedjoint Mechanicalstrengthtestforcoronacontrol ring/gradingringandarcinghorn

:AsperAnnexureA BS:3288(PartI)

g) h)

Testonlockingdeviceforballand socketcoupling Chemicalanalysis,hardnesstests,grainsize, inclusionrating&magneticparicle inspectionforforgings/castings Slipstrengthtestfordeadendassembly

:AsperIEC:372(2) :AsperAnnexureA

5.2.7

i)

:AsperIS:2486(PartI) Clause5.4

FlexibleCopperBond a) b) Visualexaminationanddimensional verification Slipstrengthtest :AsperIS:2121(PartII) Clause6.2,6.3 :AsperannexureA

5.2.8

VibrationDamperforEarthwire a) b) Visualexaminationanddimensional verification Galvanisingtest (i)Ondampermasses :AsperIS:2121(PartII) Clause6.2,6.376.7 :AsperAnnexureB :AsperAnnexureB

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PART-(SE) SWITCHYARD ERECTION

5.2.9 5.2.10 c) d) e) f) g) h) ii)Onmessengercable Verificationofresonancefrequencies Clampsliptest Clampbolttorquetest Strengthofthemessengercable Masspullofftest Dynamiccharacteristicstest :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB

QuadSpacerDamperforline/RigidspacerforJumper a) b) Visualexaminationanddimensional verification Galvanisingtest :AsperIS:2121(PartII) Clause6.2,6.376.7 :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB :AsperAnnexureB

c) Movementtest(exceptforspacerjumpers) d) e) f) g) h) EarthwireTensionClampAssembly a) b) c) d) e) Visualexaminationanddimensional verification Galvanisingtest Slipstrengthtestfortensionclamp Mechanicalstrengthtestoneachcomponent (excludingclamp) Hardnesstest Clampsliptest Clampbolttorquetest Compressiontensiontest Assemblytorquetest Hardnesstestforelastomer(ifapplicable)

:AsperIS:2121(PartII) :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA

Page-80

PART-(SE) SWITCHYARD ERECTION

5.2.11 5.3 5.3.1 5.3.1 5.4 EarthwireSuspensionClampAssembly a) b) c) d) Visualexaminationanddimensional verification Galvanisingtest Clampslipstrengthtest Mechanicalstrengthtestoneachcomponent (excludingclamp) :AsperIS:2121(PartII) :AsperAnnexureA :AsperAnnexureA :AsperAnnexureA

RoutineTests ForHardwareFittings a) b) Visualexamination ProofLoadTest IS:2486(PartI) :AsperAnnexureA

Forconductorandearthwireaccessories a) Visualexaminationanddimensional verification :AsperIS:2121(PartII) Clause6.2,6.376.7

TestsDuringManufactureonallcomponentsasapplicable a) b) ChemicalanalysisofZincusedfor galvanising Chemicalanalysismechanical metallographictestandmagneticparticle inspectionformalleablecastings Chemicalanalysis,hardnesstestsand magneticparticleinspectionforforging IS:2486(PartI) :AsperAnnexureA

5.5 5.5.1 5.5.2

c)

:AsperAnnexureA

TestingExpenses Testing charges for the type test specified shall be indicated separately in the prescribed schedule. Bidder shall indicate charges for all type tests covered under Clause No. 5.1.2 to 5.1.12 separately.Thechargesforeachtypetestshallbeseparatelyindicated.

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PART-(SE) SWITCHYARD ERECTION

5.5.3 Testing charges for all type tests specified under clause no. 5.1.1 shall be indicated only by insulator Suppliers as the charges for these tests shall be paid to them duly by the Owner toavoidduplicationandshallnotbeindicatedbythehardwareSuppliers. For type tests which involve the tests on the complete insulator string with hardware fittings, the Contractor of hardware fittings shall supply the necessary number of sets of hardwarefittingsattheplaceoftestingfreeofcost. Incaseoffailureinanytypetest,theBidderwhosematerialhasfailediseitherrequiredto modify the design of the material & successfully carryout all the type tests as has been detailed out in Clause 5.1 of this specification or to repeat that particular type test at least threetimessuccessfullyathisownexpenses.Incaseoffailureofthecompletestringinany type test, the manufacturer whose product has failed in the test shall get the test repeated at his cost. The Supplier whose material has not failed in the test shall be required to supplytherequisitequantityofmaterial(thatis,insulatordiscsorhardwarefittingsasthe case may be) required for repeat testing at the place of testing and the cost of supply shall bebornebytheContractorwhosematerialhasfailedintesting. Bidder shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that adequate facilities for conducting the tests are available in the laboratory and the tests can be completed in these laboratories within the time schedule guaranteedbythemintheappropriateschedule. The entire cost of testing for acceptance and routine tests and tests during manufacture specifiedhereinshallbetreatedasincludedinthequotedExworks/CIFPrice. In case of failure in any type test, repeat type tests are required to be conducted, then, all the expenses for deputation of Inspector Owners representative shall be deducted from the contract price. Also if on receipt of the Contractors notice of testing, the Owners representative/Inspector does not findplant to be ready for testing the expenses incurred bytheOwnerforredeputationshallbedeductedfromcontractprice. The Contractor shall intimate the Owner about carrying out of the type tests along with detailed testing programme at least 3 weeks in advance (in case of Domestic Contractor andatleast6weeksadvanceincaseofForeignContractor)ofthescheduleddateoftesting duringwhichtheOwnerwillarrangetodeputehisrepresentativetobepresentatthetime ofcarryingoutthetests. ScheduleofTestingandAdditionalTests TheBidderhastoindicatethescheduleoffollowingactivitiesintheirbids (a) Submissionofdrawingforapproval.

5.5.4

5.5.5

5.5.6

5.5.7 5.5.8

5.5.9

5.7 5.7.1

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PART-(SE) SWITCHYARD ERECTION

(b) SubmissionofQualityAssuranceprogrammeforapproval. The Owner reserves the right of having at his own expense any other test(s) of reasonable nature carried out at Contractors premises, at site, or in any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the material comply withthespecifications. TheOwneralsoreservestherighttoconductallthetestsmentionedinthisspecificationat his own expense on the samples drawn from the site at Contractors premises or at any other test center. In case of evidence of non compliance, it shall be binding on the part of Contractor to prove the compliance of the items to the technical specifications by repeat tests, or correction of deficiencies, or replacement of defective items, all without any extra costtotheOwner. Coordinationfortesting The Contractors shall have to coordinate testing of their hardware fittings with insulators to be supplied by other Supplier to the Owner and shall have to also guarantee overall satisfactoryperformanceofthehardwarefittingswiththeinsulators. TestReports Copies of type test reports shall be furnished in at least six copies along with one original. One copy shall be returned duly certified by the Owner, only after which the commercial productionoftheconcernedmaterialshallstart. Copies of acceptance test report shall be furnished in at least six copies. One copy shall be returned,dulycertifiedbytheOwner,onlyafterwhichthematerialswillbedispatched. Record of routine test report shall be maintained by the Contractor at his works for periodicinspectionbytheOwnersrepresentative. Test certificates of tests during manufacture shall be maintained by the Contractor. These shallbeproducedforverificationasandwhendesiredbytheOwner. Inspection

5.7.3

5.8

5.9 5.9.1

5.9.2 5.9.3 5.9.4 5.10

5.10.1 TheOwnersrepresentativeshallatalltimesbeentitledtohaveaccesstotheworksandall places of manufacture, where the material and/or its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection of the Contractors, subContractors works raw materials. manufacturers of all the materialandforconductingnecessarytestsasdetailedherein. 5.10.2 The material for final inspection shall be offered by the Contractor only under packed condition as detailed in clause 5.11 of this part of the Specification. The engineer shall selectsamplesatrandomfromthepackedlotforcarryingoutacceptancetests.

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PART-(SE) SWITCHYARD ERECTION

5.10.3 The Contractor shall keep the Owner informed in advance of the time of starting and of theprogressofmanufactureofmaterialinitsvariousstagessothatarrangementscouldbe madeforinspection. Material shall not be despatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the Owner in writing.Inthelattercasealsothematerialshallbedespatchedonlyafteralltestsspecified hereinhavebeensatisfactorilycompleted. The acceptance of any quantity of material shall in no way relieve the Contractor of his responsibility for meeting all the requirements of the Specification, and shall not prevent subsequentrejection,ifsuchmaterialarelaterfoundtobedefective.

5.10.4

5.10.5

5.11 5.11.1 5.11.2 5.11.3 5.11.4 PackingandMarking All material shall be packed in strong and weather resistant wooden cases/crates. The grossweightofthepackingshallnotnormallyexceed200Kgtoavoidhandlingproblems. The packing shall be of sufficient strength to withstand rough handling during transit, storageatsiteandsubsequenthandlinginthefield. Suitable cushioning, protective padding, dunnage or spacers shall be provided to prevent damageordeformationduringtransitandhandling. Bolts, nuts, washers, cotter pins, security clips and split pins etc. shall be packed duly installed and assembled with the respective parts and suitable measures shall be used to preventtheirloss. Each component part shall be legibly and indelibly marked with trade mark of the manufacturer. All the packing cases shall be marked legibly and correctly so as to ensure safe arrival at theirdestinationandtoavoidthepossibilityofgoodsbeinglostorwronglydespatchedon account of faulty packing and faulty or illegible markings. Each wooden case/crate shall haveallthemarkingsstenciledonitinindelibleink. Standards The Hardware fittings; conductor and earth wire accessories shall conform to the following Indian/International Standards which shall mean latest revisions, with amendments/ changes adopted and published, unless specifically stated otherwise in the Specification.

5.11.5 5.11.6

5.12 5.12.1

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PART-(SE) SWITCHYARD ERECTION

5.12.2 In the event of the supply of hardware fittings; conductor and earth wire accessories conformingtostandardsotherthanspecified,theBiddershallconfirminhisbidthatthese standards are equivalent to those specified. In case of award, salient features of comparison between the Standards proposed by the Contractor and those specified in this documentwillbeprovidedbytheContractortoestablishtheirequivalence.

Sl. IndianStandard 1. 2. IS:2091992 IS:3981992 PartV IS1573 IS:2121(PartII)

Title Specificationforzinc AluminumConductorGalvanised SteelReinforcedForExtraHigh Voltage(400KV)andabove ElectroplatedCoatingofZincon ironandSteel SpecificationforConductorand EarthwireAccessoriesfor OverheadPowerlines: MidspanJointsandRepairSleeves forConductors SpecificationforInsulatorFittings forOverheadpowerLineswith NominalVoltagegreaterthan 1000V: GeneralRequirementsandTests RecommendedPracticeforHot DipGalvanisingofIronandSteel MethodofTestingUniformityof CoatingonZincCoatedArticles OzonetestonElastomer TestsoninsulatorsofCeramic materialorglassforoverheadlines withanominalvoltagegreater than1000V GalvanisedCoatingonRound SteelWires MethodsofDeterminationof WeightofZincCoatingofZinc CoatedIronandSteelArticles

International Standard BS:34361986 IEC:10891991 BS:2151970

3. 4.

5.

IS:2486(PartI)

6. 7. 8. 9.

IS:2629 IS:2633

ASTMD1171 IEC:3831993

10. IS:4826 11. IS:6745

ASTMA472729 BS:4431969 BS:433 ISO:1460(E) Page-85

PART-(SE) SWITCHYARD ERECTION

12. IS:8263

13. IS:6639 14. IS:9708 15. IS:10162

Methodof Radio InterferenceTests IEC:437 onHighVoltageInsulators NEMA:107 CISPR Hexagonal Bolts for Steel ISO/R272 Structures SpecificationforStock Specification for Spacers Dampers for Twin Horizontal Bundle Conductors

Thestandardsmentionedaboveareavailablefrom: ReferenceAbbreviation BS NameandAddress BritishStandards, BritishStandardsInstitution 101,PentonvileRoad, N19NDUK InternationalElectrotechnicalCommission, BureauCentraldelaCommission, electroTechniqueinternational, 1Ruedeverembe, Geneva SWITZERLAND BeureauOfIndianStandards. ManakBhavan, 9,BahadurShahZafarMarg, NewDelhi110001. INDIA InternationalOrganisationforStandardization. DanishBoardofStandardization DanishStandardizingSraat, Aurehoegvej12 DK2900,Heeleprup, DENMARK. NationalElectricManufactureAssociation, 155,East44thStreet. NewYork,NY10017 U.S.A. Page86

IEC/CISPR

BIS/IS

ISO

NEMA

PART-(SE) SWITCHYARD ERECTION

ANNEXUREA 1.0 1.1 TestsonCompleteStringswithHardwareFittings VoltageDistributionTest(ForInsulatorString) Thevoltageacrosseachinsulatorunitshallbemeasuredbyspheregapmethod.Theresult obtained shall be converted into percentage. The voltage shall not exceed 10% for tension insulatorstringsfor400kVline. CoronaExtinctionVoltageTest(Dry) The sample assembly when subjected to power frequency voltage shall have a corona Extinction voltage of not less than 320 kV (rms) line to ground for 400 kV lines under dry condition. There shall be no evidence of corona on any part of the sample. The atmospheric condition during testing shall be recorded and the test results; shall be accordinglycorrectedwithsuitablecorrectionfactorasstipulatedinIEC:60383. RIVTest(Dry) Under the conditions as specified under (1.2) above, the insulator string along with complete hardware fittings shall have a radio interference voltage level below 1000 micro voltsatoneMHzwhensubjectedto50HzACvoltageof305kVlinetogroundunderdry conditionfor400kVline.ThetestprocedureshallbeinaccordancewithIS:8263/IEC:437. MechanicalStrengthTest The complete insulator string along with its hardware fitting excluding arcing horn, corona control ring, grading ring and suspension assembly/dead end assembly shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string components shall not show any visual deformation and it shall be possible to disassemble thembyhand.Handtoolsmaybeusedtoremovecotterpinsandloosenthenutsinitially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be furtherincreasedatasteadyratetillthespecifiedminimumUTSandheldforoneminute. No fracture should occur during this period. The applied load shall then be increased untilthefailingloadisreachedandthevaluerecorded.

1.2

1.3

1.4

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PART-(SE) SWITCHYARD ERECTION

1.5 VibrationTest The tension string in tension mode itself in laboratory span of minimum 30 meters. In the case of suspension string a load equal to 600 kg shall be applied along the axis of the suspension string by means of turn buckle. The insulator string along with hardware fittings and four sub conductors each tensioned at 43 KN shall be secured with clamps. The system shall be suitable to maintain constant tension on each subconductors throughout the duration of the test. Vibration dampers shall not be used on the test span. Boththesubconductorsshallbeverticallyvibratedsimultaneouslyatoneoftheresonance frequencies of the insulators string (more than 10 Hz) by means of vibration inducing equipment. The peak to peak displacement in mm of vibration at the antinode point nearesttothestringshallbemeasuredandthesameshallnotbelessthan1000/f18wheref isthefrequencyofvibrationincycles/sec.Theinsulatorstringshallbevibratedfornotless than 10 million cycles without any failure. After the test the disc insulators shall be examined for looseness of pins and cap or any crack in the cement. The hardware shall be examined for looseness, fatigue failure and mechanical strength test. There shall be no deterioration of properties of hardware components and disc insulators after the vibration test.Theinsulatorsshallbesubjectedtothefollowing,testsasperrelevantstandards: Sl. Test

a) b) 1.6

Temperaturecycletestfollowedbymechanical performancetest Puncturetest/steepwavefronttest(Onlyforglassinsulators)

PowerArctest This test shall be performed on the complete string in accordance with IEC Technical ReportIEC:614671997withthefollowingtestseries: Testcircuit B Shortcircuitcurrent In=Isys=40KA Numberanddurationoftest Twooftn=0.2sand oneoftn=0.5s

Theacceptancecriteriaafterthecompletionoftestseriesshallbefollowing. a) Insulatorseparationnotpermitted.

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PART-(SE) SWITCHYARD ERECTION

1.7 2.0 2.2 b) Burning/melting of metal components, breaking of insulator sheds, glaze removal are permitted. c) The complete insulator string along with its hardware fittings including arcing horn, coronacontrolring/gradingringshallwithstand80%ofUTS. AssemblyTest This test shall be carried out to ensure that the cotter pins, bolts, clamps etc., fit freely and properly. TestsonHardwareFittings Galvanising/ElectroplatingTest Thetestshallbecarried outasperClauseno.5.9ofIS:2486(Part1)1972exceptthatboth uniformity of zinc coating and standard preece test shall be carried out and the results obtainedshallsatisfytherequirementsofthisspecification. MechanicalStrengthTestofEachComponent Each component shall be subjected to a load equal to the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. The component shallthenagainbeloadedto50%ofUTSandtheloadshallbefurtherincreasedatasteady rate till the specified UTS and held for one minute. No fracture should occur. The applied loadshallthenbeincreaseduntilthefailingloadisreachedandthevaluerecorded. MechanicalStrengthTestofWeldedJoint The welded portion of the component shall be subjected to a Load of 2000 kgs for one minute. Thereafter, it shall be subjected to diepenetration/ultrasonic test. There shall not beanycrackattheweldedportion. ProofLoadTest Each component shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength which shall be increased at a steady rate to 67% of the UTS specified. The load shall be held for one minute and then removed. After removal of the loadthecomponentshallnotshowanyvisualdeformation. TestsforForgingCastingandFabricatedHardware The chemical analysis, hardness test, grain size, inclusion rating and magnetic particle inspection for forging, castings and chemical analysis and proof load test for fabricated hardware shall be as per the internationally recognised procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding testwillbeasintheQualityAssuranceprogramme.

2.3

2.4

2.7

2.8

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2.9 MechanicalStrengthTest The complete string without insulators excluding arcing horn, corona control rings/grading ring and suspension assembly/dead end assembly shall be subjected to a loadequalto50%ofthespecifiedminimumultimatetensilestrength(UTS)whichshallbe increasedatasteadyrateto67%oftheminimumUTSspecified.Thisloadshallbeheldfor fiveminutesandthenremoved.Afterremoval oftheload,thestringcomponentshallnot show any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to remove cotter pins and loosen thenuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS is reached and held for the one minute. No fracture should occur during this period. The applied load shall then be increased until thefailingloadisreachedandthevaluerecorded. TestsonConductorandEarthwireAccessories FlexibleCopperBond SlipStrengthTest Onapplyingaloadof3kN betweenthetwoends,strandedflexiblecoppercableshallnot come out of the connecting lugs and none of its strands shall be damaged. After the test, thelugsshallbecutopentoascertainthatthegrippingofcablehasnotbeenaffected. VibrationDamperforEarthwire (a) DynamicCharacteristics,Test The damper shall be mounted with its clamp tightened with torque recommended by the manufacturer on shaker table capable of simulating sinusoidal vibrations for aeolian vibration frequency band ranging from 5 to 40 Hz for damper for ACSR BERSIMIS Conductor and from 10 to 60 Hz fordamper for earth wire.The damper assembly shall be vibrated vertically with a + 1 mm amplitude from 5 to 15 Hz frequency and beyond 15 Hz at 0.5mm to determine following characteristics with the help of suitable recording instruments: (i) (ii) (iii) ForceVsfrequency PhaseangleVsfrequency PowerdissipationVsfrequency

3.0 3.3

3.4

The Force Vs frequency curve shall not show steep peaks at resonance frequencies and deep troughs between the resonance frequencies. The resonance frequencies shall be suitably spread within the aeolian vibration frequencyband between the lower and upper dangerous frequency, limits determined by the vibration analysis of conductor/earth wire withoutdampers.

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Acceptancecriteriaforvibrationdamper. (i) (ii) (iii) (iv) (v) (vi) (b) Theabovedynamiccharacteristicstestonfivedampershallbeconducted. The mean reactance andphaseangleVs frequency curves shall be drawn with the criteriaofbestfitmethod. Theabovemeanreactanceresponsecurveshouldliewithinfollowinglimits: V.D.forBERSIMIS:0.191fto0.762fgf/mm V.D.for7/3.66Earthwire:0.060fto0.357fgf/mm WherefisfrequencyinHz. The above mean phase angle response curve shall be between 25o to 130o within thefrequencyrangeofinterest. Iftheabovecurvelieswithintheenvelope,thedamperdesignshallbeconsidered tohavesuccessfullymettherequirement. Visual resonance frequencies of each mass of damper is to be recorded and to be comparedwiththeguaranteedvalues. VibrationAnalysis

The vibration analysis of the earthwire shall be done with and without damper installed on the span. The vibration analysis shall be done on a digital computer using energy balanceapproach.Thefollowingparametersshallbetakenintoaccountforthepurposeof analysis: (i) Theanalysisshallbeborneforsingleconductor/earthwirewithoutarmourrodsas per the parameters given under clause 2.5.13 and 3.3.8 of this part of the Specification. The tension shall be taken as 43 kN and 14 kN for ACSR BERSIMIS conductor and 7/3.66 mm earth wire respectively for a span ranging from 100 m to 1100m. Theselfdampingfactorandflexuralstiffness(El)forearthwireshallbecalculated onthebasisofexperimentalresults.Thedetailsofexperimentalanalysiswiththese datashouldbefurnished. The power dissipation curve obtained from Dynamic Characteristics Test shall be usedforanalysiswithdamper. Examine the aeolian vibration level of the earthwire with and without vibration damper installed at the recommended location or wind velocity ranging from 0 to 30Kmperhour,predictingamplitude,frequencyandvibrationenergyinput.

(ii)

(iii) (iv)

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(v) From vibration analysis of earthwire without damper, antinode vibration amplitude and dynamic strain levels at clamped span extremities as well as antinodesshallbeexaminedandthuslowerandupperdangerousfrequencylimits between which the aeolian vibration levels exceed the specified limits shall be determined. From vibration analysis of earthwire with damper/dampers installed at the recommended location, the dynamic strain level, at the clamped span extremities, damper attachment point and the antinodes on the earthwire shall be determined. In addition to above damper clamp vibration amplitude and antinode vibration amplitudesshallalsobeexamined.

(vi)

The dynamic strain levels at damper attachment points, clamped span extremities and antinodes shall not exceed the specified limits. The damper vibration amplitude shall not bemorethanthatofthespecifiedfatiguelimits. c) ClampSlipandFatigueTests (i) TestSetUp

Theclampslipandfatiguetestsshallbeconductedonalaboratorysetupwithaminimum effective span length of 30 m. The 7/3.66 mm earth wire at 14 and shall not be equipped with protective armour rods at any point. Constant tension shall be maintained within the span by means of lever arm arrangement. After the earthwire has been tensioned, clamps shall be installed to support the earthwire at both ends and thus influence of connecting hardware fittings are eliminated from the free span. The clamps shall not be used for holding the tension on the earthwire. There shall be no loose parts, such as suspension clamps, U bolts on the test span supported between clamps mentioned above. The span shall be equipped with vibration inducing equipment suitable for producing steady standingvibration.Theinducingequipmentshallhavefacilitiesforsteplessspeedcontrol as well as stepless amplitude arrangement. Equipment shall be available for measuring the frequency, cumulative number of cycles and amplitude of vibration at any point along thespan. (ii) ClampSliptest

Thevibrationdampershallbeinstalledonthetestspan.Thedamperclamp,afterlightning with the manufacturers specified tightening torque, when subjected to a longitudinal pull of2.5kNparalleltotheaxisofearthwireforaminimumdurationofoneminuteshallnot slip i.e. the permanent displacement between earthwire and clamp measured after removal of the load shall not exceed 1.0 mm. The load shall be further increased till the clampstartsslipping.Theloadatwhichtheclampslipsshallnotbemorethan5kN.

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(iii) FatigueTest

The vibration damper shall be installed on the test span with the manufacturers specified tightening torque. It shall be ensured that the damper shall be kept minimum three loops awayfromtheshakertoeliminatestraysignalsinfluencingdampermovement. Thedampershallthenbevibratedatthehighestresonantfrequencyofeachdampermass. For dampers involving torsional resonant frequencies, tests shall be done at torsional modes also in addition to the highest resonant frequencies at vertical modes. The resonance frequency shall be identified as the frequency at which each damper mass vibrates with the maximum amplitude on itself. The amplitude of vibration of the damper clampshallbemaintainednotlessthan25/fmm,wherefisthefrequencyinHz. The test shall be conducted for minimum ten million cycles at each resonant frequency mentionedabove.Duringthe,testifresonanceshiftisobservedthetestfrequencyshallbe tunedtothenewresonantfrequency. The clamp slip test as mentioned hereinabove shall be repeated after fatigue test without retorquingoradjustingthedamperclamp,andtheclampshallwithstandaminimumload equalto80%oftheslipstrengthforaminimumdurationofoneminute. After the above tests, the damper shall be removed from conductor/earthwire and subjected to dynamic characteristics test. There shall not be any major deterioration in the characteristicofthedamper.Thedamperthenshallbecutopenandinspected.Thereshall not be any broken, loose, or damaged part. There shall not be significant deterioration or wear of the damper. The conductor/earthwire under clamp shall also be free from any damage. Forthepurposeofacceptance,thefollowingcriteriashallbeapplied. (1) There shall not be any frequency shift by more than +2 Hz for frequencies lower than 15 Hz and 3 Hz for frequencies higher than 15 Hz. The force response curve shall generally lie within guar anteed % variation in reactance after fatigue test in comparison with that before fatigue test by the Contractor. The power dissipation of the damper shall not be less than guaranteed % variation in power dissipation before fatigue test by the Contractor. However, it shall not be less than minimum power dissipation which shall be governed by lower limits of reactanceandphaseangleindicatedintheenvelope.

(2)

(3)

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3.5 (a) SpacerDamper PerformanceTest One very important quality of a spacer damper is its ability to control Aeolian vibrations and subspan oscillations within acceptable limits. Performance testing shall be carried out on an experimental test line, as described in Clause 2.5.3, SectionVI. After testing, there shall not be any slippage greater than 3mm on conductors, loosening of components ordamagetoconductorsorspacerdampercomponents. i) AeolianVibrations Under the specified operating conditions, the spacer damper shall control Aeolian vibrations in order to prevent damage to conductors either at suspensions clamp or atthespacerdamperclamps. Formeasurementsandevaluationpurpose,thefollowingcriteriashallapply: The peak to peak amplitude of any vibration cycle shall never exceed 1.5 Yb, whereYbisthesafeBendingAmplitude. The RMS value of any vibration measurement sample shall be lower than 0.6 Yb/2,at89mmfromlastpointofcontactwithsuspensionorspacerclamp.

ii)

SubspanOscillations The spacer damper system shall control subspan oscillations in order to prevent conductor damage due to clashing or to severe bending stresses at the spacer damperclamp,andavoidwearofspacerdamperselements. In order to achieve that performance level, subspan oscillation shall be controlled withinthefollowinglimits,foranywindspeedbelow60km/hr. In any individual subspan, the peak to peak amplitude of each subconductor shallneverexceed350mm. In any individual subspan, the RMS value (Y rms) of each oscillation measurementsampleshallbesuchthat: f.Yrms<80mm/sec. Where Y(rms)=antinodeamplitude(mm) f=frequencyoftheoscillation(cycle/sec.) f=(1/2L)sqrt(T/m) L=subspanlength(m)

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PART-(SE) SWITCHYARD ERECTION

T=Conductortension(N) m=conductormass(kg/m) For any set of 10 or more measurement samples associated with a given wind sectorandagivensubspan,theYrmsvalueshallbesuchthat: f.Yrms<70mm/sec. The wind sector is defined as a combination of 5 km/hr wind speed range and 10winddirectionrange. Eachmeasurementsampleshallbeatleastone(1)minutelong. (b) ClampSlipTest(forspacerforjumperalso) The spacer damper assembly shall be installed on a four conductors bundle string at a tensionof43kN.Incaseofspacerforjumper,theclampofsampleshallbetightenedwith aspecifiedtighteningtorque.Oneofthesampleclamps,whensubjectedtoalongitudinal pullparalleltotheconductoraxisforaminimumdurationofoneminute,shallnotslipon the conductor, i.e. the permanent displacement between the conductor and the clamp of the sample measured after removal of the load shall not exceed specified values. The minimum slip under longitudinal pull varies with clamp type according to the following table. CLAMPTYPE LONGITUDINAL LOAD(kN) MetalMetalbolted Rubberloaded Clampusing Preformedrods In order to determine the effect of conductor creep with the spacer dampers only, the conductor shall be retensioned to 68 kN without further tightening the spacer damper clamps and the clamp slip test shall be reperformed. The minimum slip under longitudinalloadsshallnotbelessthan80%ofthevaluesgivenintheabovetable. Similar testing shall be performed of the other clamps of the same sample. For spacer dampersonly,suchclampsliptestsshallalsobeconductedaftereachofthevibrationtests mentioned in Clause 3.5 (a) but under longitudinal loading corresponding to 80% of the valuesgivenintheabovetable. 2.5 12 6.5 2.5 MAXIMUM SLIP(mm) 1 2.5

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PART-(SE) SWITCHYARD ERECTION

c) DynamicCharacteristicTestforSpacerDamper The purpose of this test is to obtain quantitative information regarding the dynamic characteristic of the spacer damper. The values obtained during this test will serve as referencestoevaluatethebehaviourofthesamespacerdamperunderthefatiguetest. The test will consist in the application of sinusoidal movement to the spacer damper articulation and measurement of the force (F), displacement (X) and phase angle () between these two. From these values, the stiffness (K) and damping faction (n) shall be calculatedas: The test frequency shall not be higher than 3 Hz. The test shall be performed at five different displacement amplitudes. The amplitudes shall be selected to reproduce 10, 20, 40, 60 and 90 percent of the maximum displacement permitted by the spacer damper design. Thetestshallbeperformedonthreesamples. In case ofspacer dampers with asingle articulation for eacharm, the central body shall be applied between two arms corresponding to a horizontal pair of conductors. In this case, one spacer clamp may be fixed and the other displaced in its direction, the central body beingfreetomove. FatigueTestforSpacerDamper Thepurposeofthistestistoevaluatethecapacityofthespacerdampertosustainwithout damagethecyclicmovementswhichcanbeinducedbyvibrations. Thespacerdamperarticulationshallbesubjectedtocyclicmotionsforatotalof10million cycles. The test frequency shall be between 2 and 3 Hz. The amplitude of motion shall be establishedonthefollowingbasis: theloadappliedonthespacerdamperclampshallnotbelessthan300N; The clamp displacement under the applied load shall not be less than 60% of the maximumdisplacementpermittedbythedesign; If the 300 N load generates movement exceeding the maximum permitted displacement, the load can be reduced to limit the movement to 95% of the maximumdisplacement.

d)

After the test, the sample shall be subjected to a second dynamic characteristic test. The testshallbeperformedattwoamplitudes,10%and60%ofthemaximumdisplacement. The spacer damper shall show no signs of cracks or detoriation, loosening of bolts or abnormalwear.

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The dynamic characteristics (k and n) shall not be less than 75% of the values measured before the fatigue test. The test shall be performed on three samples which have been previously subjected to dynamic characteristics test. Motion shall be as described in DynamicCharacteristicTest. OzoneTest This test shall be performed on elastomer/rubber components in accordance with ASTM D1171bytheozonechamberexposuremethod(methodB).Thetestdurationshallbe500 hours and the ozone concentration 50 PPHM. At the test completion, there shall be no visiblecrackundera2xmagnification. CompressionandTensileTests Three samples of spacer dampers shall be subjected to a tension compression test. The load shall be applied between each pair of diagonally opposed conductors. Under the compressive load, the arms shall be allowed to rotate until they reach their mechanical stops.Acompressiveloadof15kNshallfirstbeappliedandheldforfiveminutes.Then atensileloadof5kNshallbeappliedonthesamepairofarms.Thetestshallberepeated on the other pair of arms. After the test, the spacer damper must be dismantled and the components examined. There should not be any failure of components or damage impairing the reusability of the spacer damper such as permanent deformation. The spacergeometryshallbemaintainedwithin5%oftheoriginaldimensions. MagneticPowerLossTestforSpacerDamper/Spacerforjumper The sample involving ferrous parts shall be tested in a manner to simulate service conditions for 50 Hz pure sinewave. The test should be carried out at various currents ranging from 400 amperes to 800 amperes for 400 kV line and the magnetic power loss at various currents should be specified in tabulated graphical form. The difference between the power losses without and with sample at room temperature shall be limited to 1 watt for 600 amperes current (rms) for ACSR BERSIMIS Conductor. The losses shall be determinedbyaveragingtheobservationsobtainedfromatleastfoursamples. MechanicalStrengthTestforEarthwireSuspension/TensionClamp (a) The suspension assembly/tension assembly (excluding tension clamp) shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. This load shall be held for five minutes and then removed. After removal of the load, thecomponentsshallnotshowanyvisualdeformationand

e)

f)

3.6

3.7

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PART-(SE) SWITCHYARD ERECTION

itshallbepossibletodisassemblethembyhand.Handtoolsmaybeusedtoloosenthe nuts initially. The assembly shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS is reached and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded. (b) ClampSlipStrengthVsTorqueTestforSuspensionAssembly The suspension assembly shall be vertically suspended by means of a flexible attachment.AsuitablelengthofEarthwireshallbefixedintheclamps.Theclampslip strengthatvarioustighteningtorquesshallbeobtainedbygraduallyapplyingtheload at one end of the earthwire. The clamp slip strength Vs torque curve shall be drawn. The clamp slip strength at the recommended tightening torque shall be more than 12 kNbutlessthan17kNfor7/3.66mmearthwire.

(c) SlipStrengthTestofTensionClamp Tension clamps shall be compressed on a 5 m length of earthwire on both ends. The assembly shall be mounted on a tensile testing machine and anchored in a manner similar to the arrangement to be used in service. A tensile load of 50% of the specified breakingloadoftheearthwireshallbeapplied&thesampleshallbemarkedinsucha way that movement relative to the fitting can easily be detected. Without any subsequent adjustment of the fitting, the load shall be steadily increased to 95% of the specified breaking load and maintained for one minute. There shall be no movement of the earthwire relative to the fitting during this one minute period and no failure of thefittingalso.

(d) ElectricalResistanceTestofTensionClamp The tension clamp and the jumper shall be compressed on two suitable lengths of earthwire.Theelectricalresistanceshallbemeasuredbetweenpointsonearthwirenear the clamp and near the jumper mouth keeping 25 mm clearance of the fitting and should not exceed 75% of the measured resistance of equivalent length of earthwire. The test shall be conducted with direct current. The current connections shall be at a distance not less than 50 times the diameter of earthwire from the fitting and shall be made so that effective contact is ensured with all those strands of theearth wire which would be taken into account in calculating its equivalent resistance. The test shall be repeated with the polarity reversed and the average of the two results considered as themeasuredvalue.

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PART-(SE) SWITCHYARD ERECTION

3.8 CoronaExtinctionVoltageTest(Dry) The sample when subjected to power frequency voltage shall have a corona extinction voltage of not less than 320 kV (rms) line to ground for 400 kV lines under dry condition for 400 kV line. There shall be no evidence of corona on any part of the sample. The atmospheric condition during testing shall be recorded and the test results shall be accordinglycorrectedwithsuitablecorrectionfactorasstipulatedinIS:731. RadioInterferenceVoltageTest(Dry) Under the conditions as specified under (3.8) above, the sample shall have a radio interferencevoltagelevelbelow1000micro volts atoneMHzwhensubjectedto50HzAC voltage of 305 kV rms line to ground under dry condition for 400 kV line. The test procedureshallbeinaccordancewithIS:8263. ChemicalAnalysisTest Chemical analysis of the material used for manufacture of items shall be conducted to checktheconformityofthesamewithTechnicalSpecificationandapproveddrawing. TestsonAllcomponents(Asapplicable) ChemicalAnalysisofZincusedforGalvanizing Samples taken from the zinc ingot shall be chemically analysed as per IS2091979. The purityofzincshallnotbelessthan99.95%. TestsforForgings The chemical analysis hardness tests and magnetic particle inspection for forgings, will be as per the internationally recognised procedures for these tests. The, sampling will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Contractor and Purchaser in Quality Assurance Programme. TestsonCastings The chemical analysis, mechanical and metallographic tests and magnetic particle inspection for castings will be as per the internationally recognised procedures for these tests. The samplings will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Contractor and PurchaserinQualityAssuranceProgramme.

3.9

3.10 4.0 4.1 4.2

4.3

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PART-(SE) SWITCHYARD ERECTION

ANNEXUREB AcceptanceTests 1. 2. FlexibleCopperBond (a) SlipStrengthTest Sameasclause3.3ofAnnexureA.

VibrationDamperforEarthwire (a) VerificationofResonanceFrequencies Thedampershallbemountedonashakertableandvibrateatdamperclampdisplacement of +/0.5 mm to determine the resonance frequencies. The resonance shall be visually identified as the frequency at which damper mass vibrates with maximum displacement on itself. The resonance frequency thus identified shall be compared with the guaranteed value. A tolerance of 1 Hz at a frequency lower than 15 Hz and 2 Hz at a frequency higherthan15Hzonlyshallbeallowed. (b) ClampSlipTest SameasClause3.4(c)(ii)ofAnnexureA. (c) ClampBoltTorqueTest The clamp shall be attached to a section of the earthwire. A torque of 150 percent of the manufacturers specified torque shall be applied to the bolt. There shall be no failure of componentparts.ThetestsetupisasdescribedinClause3.4(c)(i),AnnexureA. (d) StrengthoftheMessengerCable Themessengercableshallbefixedinasuitabletensiletestingmachineandthetensileload shall be gradually applied until yield point is reached. Alternatively, each strand of message caste may be fixed in a suitable tensile testing machine and the tensile load shall be gradually applied until yield point is reached. In such a case, the 95% of yield strength of each wire shall be added to get the total strength of the caste. The load shall be not less thanthevalueguaranteedbytheContractor (e) MassPulloffTest Each mass shall be pulled off in turn by fixing the mass in one jaw and the clamp in the other of a suitable tensile testing machine. The longitudinal pull shall be applied graduallyuntilthemassbeginstopulloutofthemessengercable.Thepulloffloadsshall notbelessthanthevalueguaranteedbytheContractor.

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PART-(SE) SWITCHYARD ERECTION

(f) DynamicCharacteristicsTest The test will be performed as acceptance test with the procedure mentioned for type test withsamplingmentionedbelow VibrationDamper: 1Samplefor1000Nos.&belowConductor 3Samplesforlotabove1000&upto5000nos.

Additional1sampleforeveryadditional1500piecesabove5000.

Theacceptancecriteriawillbeasfollows (i) The above dynamic characteristics curve for reactance & phase angle will be done for frequencyrangeof10Hzto60Hzforvibrationdamperfor7/3.66mmearthwire. (ii) If all the individual curve for dampers are within the envelope as already mentioned fortypetestforreactance&phaseangle,thelotpassesthetest. (iii) If individual results do not fall within the envelope, averaging of characteristics shall bedone. (a) Force of each damper corresponding to particular frequency shall be taken & averageforceofthreedampersatthefrequencycalculated.

(b) Similaraveragingshallbedoneforphaseangle. (c) Average force Vs frequency and average phase Vs frequency curves shall be plottedongraphpaper.Curvesofbestfitshallbedrawnfortheentirefrequency range.

(d) Theabovecurvesshallbewithintheenvelopespecified. 3. SpacerDamper/Spacerforjumper (a) DynamiccharacticsTest Thetestshallbecarriedoutasperclause3.5(c)ofAnnexureA.

(b) MovementTest The spacer assembly shall be capable of the following movements without damaging theconductor,assumingoneconductorisfixedandtheothermoving: (i) (ii) Longitudinalmovement paralleltotheconductor Verticalmovementina verticaldirectionatright angletotheconductor 50mm 25mm

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(iii) Torsionalmovement/angular movementinaverticalplane paralleltotheconductor 5deg.

(c) CompressiveandTensileTest The spacer assembly shall withstand ultimate compressive load of 14 kN and tensile loadof7.0kNappliedbetweensubconductorbundleandheldforoneminutewithout failure. Line distance between clamps shall be recorded during each of the compression and tension test. Measurement shall be recorded at (i) no load (ii) with load (iii) after release of load. The center line distance under load shall be within 100 mm of the nominal design spacing. After release of load it shall be possible to retain the clamps at their original position using only slight hand pressure. There shall be no deformation or damage to the spacer assembly which would impair its function of maintainingthenormalspacing. (d) ClampSlipTest Sameasclause3.5(b)ofAnnexureA.

(e) ClampBoltTorqueTest The spacer assembly shall be attached to conductor. A torque of 150 per cent of the manufacturers specified tightening torque shall be applied to the clamp bolts or cap screws.Thereshallbenofailureofthecomponentparts. (f) AssemblyTorqueTest The spacer assembly shall be installed on conductor. The same shall not rotate on eitherclamponapplyingatorqueof0.04kNinclockwiseoranticlockwisedirection. (g) HardnesstestforElastomer The shore hardness at different points on the elastomer surface of cushion grip clamp shallbemeasuredbyshorehardnessmeter.Theyshallliebetween65to80. (h) UTSofRetainingRods Theultimatetensilestrengthoftheretainingrodsshallbemeasured.Thevalueshall notbelessthan35kg/sq.mm.

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PART -V

TECHNICAL SPECIFICAITON OF STRUCTURE (STR)

THIS TECHNICAL SPECIFICATON IS EXCLUSIVELY APPLICABLE FOR 400KV LEVEL

PART:STRUCTURE

Table of contents Clause No. Description Page No.

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0

GENERAL 1 DESIGN REQUIREMENTS FOR STRUCTURES 2 NOT COVERED IN STAND ARDISED LIST DESIGN DRAWINGS, BILL OF MATERIALS 4 AND DOCUMENTS FABRICATION OF STEEL MEMBERS 5 PROTO-ASSEMBLY BOLTING WELDING FOUNDATION BOLTS STABILITY OF STRUCTURE GROUTING GALVANISING TOUCH-UP PAINTING INSPECTION BEFORE DISPATCH TEST CERTIFICATE ERECTION MODE OF MEASUREMENT SAFETY PRECAUTIONS 5 6 6 6 7 7 7 7 7 8 9 9 9

PART: STRUCTURES 1.0 1.1 GENERAL The scope of specification covers fabrication, proto-assembly, supply and erection of galvanized steel structures for towers, girders, lightning masts and equipment support structures. Towers, girders and lightning masts shall be lattice type structure fabricated from structural steel conforming to IS 2062 (latest). All equipment support structures shall be fabricated from GI pipe conforming to YST 22 or of higher grade as per IS 806 except for 132kV and below for which the equipment structure shall be of lattice type. Line diagrams of tower, girders, lighting mast, equipment support structures for standard 400kV/220kV structures are enclosed with the tender document. The fabrication drawings alongwith BOM shall be provided to the successful bidder after the award. Contractor shall only use these standard drawings for fabrication. Support structure for circuit breaker is not standardized and shall be designed by the contractor and approved by the Employer. Any other structures of 400/220kV class necessary to suit the layout for a particular S/Stn. to complete the work in all its requirements shall be designed by the Employer at detailed Engineering stage. Design & drawing of structure other than 400/220KV class shall also be prepared by the Employer at detailed engineering stage. It is the intent of the Employer to provide structures which allow interchangeability of equipments at a later stage. Accordingly equipment support structure standardization has been carried out with the provision of stool. Stools shall be provided by the contractor between the equipment and its support structure to match the bus bar height. The top of stool shall be connected to the equipment and the bottom of the stool shall be connected to the support structure. Details of the stools shall be submitted to Employer for approval. The scope shall include supply and erection of all types of structures including bolts, nuts, washers, hangers, shackles, clamps anticlimbing devices, bird guards, step bolts, inserts in concrete, gusset plates, equipment mounting bolts, structure earthing bolts, foundation bolts, spring washers, fixing plates, ground mounted marshalling boxes (AC/DC marshalling box and equipment control cabinets), structure mounted marshalling boxes and any other items as required to complete the job. Page-1

The connection of all structures to their foundations shall be by base plates and embedded anchor/foundation bolts. All steel structures and anchor/ foundation bolts shall be fully galvanized. The weight of the zinc coating shall be at least 0.610 kg/m2 for anchor bolts/ foundation bolts and for structural members. One additional nut shall be provided below the base plate which may be used for the purpose of leveling. Suitable modification shall be carried out in the drawings of equipment support structures by the contactor in order to suit fixation of accessories such as marshalling boxes, MOM boxes, control cabinets, junction box, surge counter, etc. in the standard structure fabrication drawings. Drawings of fixing of such accessories shall be submitted by the contractor for approval. 2.0 DESIGN REQUIREMENTS FOR STRUCTURES NOT COVERED IN STANDARDISED LIST For design of steel structures loads such as dead loads, live loads, wind loads etc. shall be based on IS:875, parts I to V. 2.2 For materials and permissible stresses IS:802, part-I, part 2 shall be followed in general. However, additional requirements given in following paragraphs shall be also considered. 2.3 Minimum thickness of galvanized tower member shall be as follows: Members Leg members, ground wire peak members/main members Other members Redundant members 2.4 minimum thickness (mm) 5 4 4

2.1

Maximum slenderness ratios for leg members, other stressed members and redundant members for compression force shall be as per IS:802. Minimum distance from hole center to edge shall be 1.5 x bolt diameter. Minimum distance between center to center of holes shall be 2.5 x bolt diameter. Page-2

2.5

2.6 2.7

All bolts shall be M16 or higher as per design requirement. Step bolts In order to facilitate inspection and maintenance, the structures shall be provided with climbing devices. Each tower shall be provided with M16 step bolts 175 mm long spaced not more than 450 mm apart, staggered on faces on one leg extending from about 0.5 meters above ground level to the top of the tower. The step bolt shall conform to IS: 10238. Ladders along with safety guard shall be provided for the lightening mast tower.

2.8

Design criteria (to be referred only for structures for which design is included in the scope of the contractor) a) All structures shall be designed for the worst combination of dead loads, live loads, wind loads as per code IS: 875, seismic forces as per code IS:1893 (latest), importance factor of 1.5, loads due to deviation of conductor, load due to unbalanced tension in conductor, torsional load due to unbalanced vertical and horizontal forces, erection loads, short circuit forces including snatch in the case of bundled conductors etc. short circuit forces shall be calculated considering a fault level of 40.0 kA. IEC-864 may be followed for evaluation of short circuit forces. b) Switchyard gantry structures shall be designed for the two conditions i.e. normal condition and short circuit condition. In both conditions the design of all structures shall be based on the assumption that stringing is done only on one side i.e. all the three phase conductors broken on the other side. Factor of safety of 2.0 under normal conditions and 1.5 under short circuit conduction shall be considered on al external loads for the design of switchyard structures. c) Vertical load of half the span of conductors/string and the earth wires on either side of the beam shall be taken into account for the purpose of design. Weight of man with tools shall be considered as d150 kgs. For the design of structures. Page-3

d)

Terminal/line take of gantries shall be designed for a minimum conductor tension of 4 mtr. tones per phase of r400kV and 2 mtr. tones per phase for 200kV, 1 tonne per phase for 132kV or as per requirements whichever is higher. The distance between terminal gantry and dead end tower shall be taken as 200 mtr. the design of these terminal gantries shall also be checked considering+/-30 deg. Deviation of conductor in both vertical and horizontal planes. For other gantries the structural layout requirements shall be adopted in design.

e) f)

The girders shall be connected with lattice columns by bolted joints. All pipe support used for supporting equipments shall be designed for the worst combination of dead loads, erection load. Wind load/seismic forces, short circuit forces and operating forces acting on the equipment and associated bus bars as per IS:806. The material specification shall be as per IS:1161 read in conjunction with IS:806.

g)

If luminaries are proposed to be fixed on gantries/towers, then the proper loading for the same shall be considered while designing. Also holes for fixing the brackets for luminaries should be provided wherever required.

h)

Foundation bolts shall be designed for the loads for which the structures are designed. Lightning mast shall be 50m in height (47.5m lattice structure plus 2.5 m pipe) and designed for diagonal wind condition. Lightning masts shall be provided with a structural steel ladder within its base up to a height of 25 m. the ladder shall be provided with protection rings. Two platforms shall be provided one each at 12.5 m and 25.0 m height for mounting of lighting fixtures. The platforms shall also have protection railing. The details of lighting fixtures would be as per the approved drawings. Page-4

i)

3.0 3.1

Design drawings, bill of materials and documents For standard structures

3.1.1 Tower, girders, lightning masts, equipment support structures etc of 400/220kV class have all been standardized by the Employer and fabrication drawings (structure assembly drawing) alongwith bill of material shall be provided by the Employer for all these standard structures to the successful bidder after the letter of award based on which structures shall be supplied. 3.1.2 Contractor shall however not be relieved of his responsibility for the safety of the structure and good connections and any loss or damage occurring due to defective fabrication, erection or workmanship shall be borne by the Contractor. 3.2 FOR STRUCTURES DESIGNED BY CONTRACTOR ( To be referred only for structures for which design is included in the scope of the Contractor)

3.2.1 The Contractor shall furnish design, drawing and BOMs and shop manufacturing drawings for every member to the Employer after award of the contract. The design drawing should indicate not only profile, but section, numbers and sizes of bolts and details of typical joints. In case Employer feels that any design drawing, BOM are to be modified even after its approval, Contractor shall modify the designs & drawings and resubmit the design drawing, BOM as required in the specification. 3.2.2 The fabrication drawings to be prepared and furnished by the Contractor shall be based on the design approved by the Employer. These fabrication drawings shall indicate complete details of fabrication and erection including all erection splicing details and typical fabrication splicing details, lacing details, weld sizes and lengths. Bolt details and all customary details in accordance with standard structural engineering practice whether or not given by the Employer. The fabrication drawings shall be submitted to the Employer. Proto shall be made only after approval of fabrication drawings. 3.2.3 Such approval shall, however, not relieve the Contractor of his responsibility for the safety of the structure and good connections and any loss or damage occurring due to defective fabrication, design or workmanship shall be borne by the Contractor. Page-5

3.3

The Mass fabrication work shall start only after the final approval to the proto corrected fabrication drawing is accorded by the Employer. Proto assembly shall be required to be carried out only for those structures that have not been proto-assembled by the fabricators for this contract or for earlier contracts from POWERGRID. Wherever proto-assembly is not to be repeated, proto-corrected drawings shall be submitted directly with a note on the drawing stating that proto-assembly has been carried out under a particular previous contract.

4.0 4.1

FABRICATION OF STEEL MEMBERS The fabrication and erection works shall be carried out generally in accordance with IS 802. A reference however may be made to IS 800 in case of non-stipulation of some particular provision in IS 802. All materials shall be completely shop fabricated and finished with proper connection material and erection marks for ready assembly in the field.

5.0

PROTO-ASSEMBLY i) The component parts shall be assembled in such a manner that they are neither twisted nor otherwise damaged and shall be so prepared that the specified camber, if any, is provided. In order to minimize distortion in member the component parts shall be positioned by using the clamps, clips, dogs, jigs and other suitable means and fasteners (bolts and welds) shall be placed in a balanced pattern. If the individual components are to be bolted, paralleled and tapered drifts shall be used to align the part so that the bolts can be accurately positioned. Sample towers, beams and lightning masts and equipment support structures shall be trial assembled in the fabrication shop and shall be inspected and cleared by Contractor based on the approved fabrication drawing before mass fabrication. Employer may opt to witness such trial assembly. For all structures, B.O.Ms along with proto corrected fabrication drawings shall be prepared and submitted to Employer as document for information. Such BOM, which shall be duly certified by the Contractor for its conformity to the drawings issued by Employer, shall be the basis for Employer to carry out inspection. Page-6

ii)

6.0

BOLTING i) Every bolt shall be provided with a washer under the nut so that no part of the threaded portion of the bolt is within the thickness of the parts bolted together. ii) All steel items, bolts, nuts and washers shall be hot dip galvanized. iii) 2.0% extra nut and bolts shall be supplied for erection.

7.0

WELDING The work shall be done as per approved fabrication drawings which shall clearly indicate various details of joints to be welded, type of weld, length and size of weld, whether shop or site weld etc. Symbols for welding on erection and shop drawings shall be according to IS:813. Efforts shall be made to reduce site welding so as to avoid improper joints due to constructional difficulties.

8.0 8.1

FOUNDATION BOLTS Foundation bolts for the towers and equipment supporting structures and elsewhere shall be embedded in first stage concrete while the foundation is case. The Contractor shall ensure the proper alignment of these bolts to match the holes in the base plate. The Contractor shall be responsible for the correct alignment and leveling of all steel work on site to ensure that the towers/structures are plumb. All foundation bolts for lattic structure, pipe structure are to be supplied by the contractor. All foundation bolts shall be fully galvanized so as to achieve 0.61 kg. per sq.m. of Zinc Coating as per specifications. All foundation bolts shall conform to IS 5624 but the material, however shall be MS conforming to IS:2062. STABILITY OF STRUCTURE The Contractor shall be responsible for the stability of the structure at all stages of its erection at site and shall take all necessary measures by the additions of temporary bracings and guying to ensure adequate resistance to wind and also a loads due to erection equipment and their operations. Page-7

8.2 8.3 8.4 8.5

9.0

10.0

GROUTING The method of grouting the column bases shall be subject to approval of Employer and shall be such as to ensure a complete uniformity of contact over the whole area of the steel base. The Contractor will be fully responsible for the grouting operations.

11.0 11.1 11.2 11.3

GALVANISING All structural steel works and pipe supports shall be galvanized after fabrication. Zinc required for galvanizing shall have to be arranged by the manufacturer. Purity of zinc to be used shall be 99.95% as per IS:209. The Contractor shall be required to make arrangement for frequent inspection by the Employer as well as continuous inspection by a resident representative of the Employer, if so desired for fabrication work.

12.0

TOUCH-UP PAINTING The touch up primers and paints shall consist of Red Oxide/Zinc chromate conforming to the requirements of IS:2074 with a pigment to be specified by the Employer.

13.0

INSPECTION BEFORE DISPATCH Each part of the fabricated steel work shall be inspected as per approved quality plans and certified by the Employer or his authorized representative as satisfactory before it is dispatched to the erection site. Such certification shall not relieve the Contractor of his responsibility regarding adequacy and completeness of fabrication.

14.0

TEST CERTIFICATE Copies of all test certificates relating to material procured by the Contractor for the works shall be forwarded to the Employer.

Page-8

15.0

ERECTION The Contractor should arrange on his own all plant and equipment, welding set, tools and tackles, scaffolding, trestles equipments and all other accessories and ancillaries required for carrying out erection without causing any stresses in the members which may cause deformation and permanent damage.

16.0

MODE OF MEASUREMENT The measurement of the standard lattice and pipe structures for towers, beams, equipment support structure etc. shall be made in numbers for each type of structures. This will include foundation bolts and nuts and therefore no separate payment shall be made for the same. The unit rate quoted for each type of structure shall be inclusive of supply, fabrication, galvanizing, erection, nuts, bolts , wastages etc. complete. Nothing extra shall be payable for substitution necessitated due to non-availability of sections indicated in the standard drawing. Nothing extra shall be payable for modifications or steel added to suit the contractors fixing arrangements for accessories etc.

17.0

SAFETY PRECUATIONS The Contractor shall strictly follow at all stages of fabrication, transportation and erection of steel structures, raw materials and other tools and tackles, the stipulations contained in Indian Standard Code for Safety during erection of structural steel work IS:7205.

18.0

All tests mentioned in standard field quality plans have to be carried out and conformity of materials and workmanship shall be ascertained.

Page-9

Part -VI

TECHNICAL SPECIFICAITON OF CIVIL PART

REC-112

PART-6
CIVIL WORKS 1.0 GENERAL The intent of specification covers the following: Design, Engineering, Construction of all specified Civil Works of the proposed substation covered under the scheme. All Civil Works shall also satisfy the general technical requirements specified in other Parts of this specification and as detailed below. All the specified designs shall be carried out to the required service conditions/loads as specified elsewhere in the specifications or implied as per National/International Standards and as specified by manufacturers. All Civil Works shall be carried out as per applicable Indian Laws, latest Standards and Codes. All material shall be of best quality conforming to relevant Indian Standards and Codes. The successful bidder shall furnish all design, (unless otherwise specified), drawings, labour, tools, equipment, material, temporary works, construction plant and machinery, supply fuel, transportation and all other incidental items not shown or specified but are required for complete performance of the works in accordance with approved drawings, specifications and direction of HVPNL. The work shall be carried out according to the design/drawings to be developed by the successful bidder and submit the same for approval of the HVPNL or shall be supplied to the bidder by the HVPNL as detailed in the schedule of quantities. The design/drawing so approved shall become the property of the Nigam and the Nigam shall be free to use these designs/drawings at any of its upcoming/future station. For all structures, buildings, foundations etc. necessary layout and details shall be developed by the bidder keeping in view the functional requirement of the sub-station facilities and providing enough space and access for operation, use and maintenance based on the input provided by the HVPNL. Certain minimum requirements are indicated in this specification for guidance purposes only. However, the bidders shall quote considering all the requirements essential for functional purposes. All the civil works covered under the said scheme shall be constructed under the supervision of experienced degree/diploma holder civil engineers as mentioned under GCC.

2.0

SOIL DATA For the guidance of the bidders, the general soil data around proposed sub-station at Nawada is specified below. Type of soil Dry bulk density Angle of internal friction Cohesion Safe allowable B.C Depth of water table : : : : : : Silty sand 1700 kg/m2 28 00 6t/m2 (F.O.S=2.5) Below 6M from N.S.L

2.1

GENERAL SITE DESCRIPTION The site is part of 400kV Nawada sub-station. The sub-station is presently under construction. The plot except portion fouling under 400kV Samaypur-Greater Noida LILO arrangement shall be filled as per FGL of the sub-station. To achieve desired mandatory clearance for the proposed LILO & existing 400kV Samaypur-Greater Noida PGCIL line, earth filling or cutting may be required. The quantities of earth filling/cutting indicated in the BoQ are only tentative and may vary based on finalization of LILO arrangement engineering. The bidders are, however, advised to visit the site before quoting.

2.2

The successful bidder shall use the soil data mentioned above for designing the equipment structure foundations. Minimum depth of foundation in natural ground so designed shall not be less than 1.0 meter excluding lean concrete. SITE PREPARATION The site as available shall be handed over to the selected bidder. Clearing of the site from bushes including its roots shall be carried out by the successful bidder. The Contractor shall prepare the `CONTOURS` of land at suitable intervals. The spot levels shall be taken at a distance not more the 5.0M interval. The contours shall extend upto sufficient distance (approx. 50M) around the land so as to have fair idea of existing feature and topography of the area. On submission of contour plan by the successful bidder and upon finalization of LILO requirement etc., the HVPNL shall fix the Formation Level. The contractor, as per specifications shall carry out the necessary earth cutting/filling in layers, compaction, leveling and dressing to reach the desired formation level.

2.3

The contractor at his own cost shall make the layout and levels of all structures/buildings as per the general grid of the plot and the Benchmark given by the concerned Executive Engineer/Civil Works Division. The permanent Benchmark and all the change points shall be established at the proposed site and the same shall be got authenticated before taking any further levels. The contractor shall provide all help including instruments, materials and personnel to the Executive Engineer/Civil Works Division or his representative for checking the detailed layout and shall solely be responsible for the correctness of the layouts and levels. 3.0 SCOPE This clause covers the design, engineering, supply of labour, material and execution of civil items including contouring, dismantling of the existing foundations/structures/roads wherever required, clearing the site, site preparation, supply and compaction of fill material to achieve formation level, foundations, excavation and compaction of backfill for foundation, etc., retaining wall complete in all respects. 3.1 WATER SAMPLE The successful bidder shall arrange water supply connection from Local Govt. (Village Panchyat, Public Health Deptt., Municipal Committee/Council etc.) to meet the construction requirement. HVPNL will facilitate the successful bidder for obtaining connection from the concerned govt. department. In case water supply connection is not available, the successful bidder shall arrange at his own cost sufficient quantity and good quality water along with required pumping arrangements for construction, curing and other purposes. For construction/curing purposes, the successful bidder shall provide a temporary underground water storage tank of atleast 10,000ltr. capacity for storage of water. Nothing shall be paid extra on account of obtaining water connection/water supply/provision of U/G storage tank for arranging/collection of water. In case good quality water is available at existing sub-stations, the same shall be provided to the successful bidder free of cost. 3.2 GENERAL

3.2.1 Material including excavated material unsuitable for founding of foundations shall be removed and replaced by suitable fill material and the same is required to be got approved from the HVPNL.

3.2.2 Fill/Backfill material around foundations or other works shall be free from harmful salts viz. sulphates, chlorides and or any organic/inorganic materials. The Fill/Backfill material should be compacted as described under clause 3.4. 3.3 EXCAVATION AND BACKFILL

3.3.1 Excavation and backfill for foundations shall be in accordance with the relevant IS code and as per approved design/drawings. 3.3.2 Whenever water table/seepage water is met during excavation, it shall be dewatered and foundation pit shall be maintained dry i.e. free of water during the excavation, concreting and back filling. No extra payment on this count shall be admissible. 3.3.3 When embankments are to be constructed on slopes of 15% or greater, benches or steps with horizontal and vertical faces shall be cut in the original slope prior to placements of embankment material. The vertical faces shall measure not more than 1.0 m in height. 3.3.4 Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be constructed by compacting the material not exceeding 15cm in thickness of loose material before compaction in successive uniform horizontal layers. Each layer shall be compacted as required by means of mechanical tempers approved by the HVPNL. Rocks larger than 10 cm shall not be placed in embankment adjacent to structures. 3.3.5 Earth embankments of roadways and site areas adjacent to buildings shall be placed in successive uniform horizontal layers not exceeding 20 cm in thickness in loose stage measurements 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. 3.3.6 In case the switchyard area needs leveling & dressing only, to maintain the final formation level as fixed by HVPNL, same shall be done with utmost care and with proper compaction. If the top crest of earth (30 cm depth) is containing harmful salts and organic/inorganic materials, it shall be scraped and disposed off at a place outside substation as directed by Executive Engineer/ Civil Works Division. . 3.4 COMPACTION

3.4.1 The method and equipment used to compact the fill material shall be suitable to achieve the density that will give the allowable soil bearing pressure required for the foundations, roads etc. in each layer of fill material. Each layer of earth embankment when compacted shall be as

close to optimum moisture content as practicable. Embankment material that does not contain sufficient moisture to obtain proper compaction shall be wetted. If the material contains excess moisture, then it shall be allowed to dry before rolling. The rolling shall begin at the edges overlapping half the width of the roller each time and progress to the center of the road or towards the building as applicable. Rolling will also be required on rock fills. No compaction shall be carried out in rainy season/during rains. 3.4.2 At all times, the unfinished construction shall have adequate drainage. Upon completion of the road's surface course, adjacent shoulders shall be given a final shaping, true alignment and grade. 3.4.3 The density to which fill materials shall be compacted shall be as per relevant IS and as per direction of HVPNL. All compacted sand filling shall be confined as far as practicable. Backfilled earth shall be compacted to minimum 95% of the Standard Proctor's density at Optimum Moisture Content (OMC). The sub-grade for the roads and embankment filling shall be compacted to minimum 95% of the Standard Proctor's density at OMC. 3.5 EARTH WORK FOR ACHIEVING FORMATION GROUND LEVEL (FGL)

3.5.1 To maintain the formation level (FL) as fixed by HVPNL, earth filling/cutting or both filling/cutting may be required. Before earth work is started, the site shall be clear from bushes/trees including roots, existing structures etc. by the successful bidder 3.5.2 In case earth is to be imported (earth filling), the area from where the earth is to be imported should be pre-determined so as to ensure good quality of earth i.e. earth imported should be free from shrubs, ranks, vegetation, grass, brushwood, stone shingle and boulders (longer than 75mm in any direction), organic or any other foreign matter. Earth containing deleterious materials salt peter earth etc. shall not be used for filling. All clods and lumps of earth exceeding 8cm in any direction shall be broken or removed before the earth is used for filling. Imported earth shall be measured for payment as per x-sections based on initial and final levels at the substation. 3.5.3 In case the earth work is required in cutting, the cut earth shall be spread in sub-station areas requiring filling and the surplus earth, if any shall be disposed of to a suitable undisputed place outside the substation. The successful bidder shall be responsible in case some dispute arises on account of disposal of earth at a disputed site. Cutting shall be measured and payment shall be made on actual basis as per x-sections based on initial and final levels at the substation.

3.5.4 In case both cutting of earth (including spreading) & filling (import of earth) are required, each item will be measured separately and payment made on actual basis for both as per x-sections based on initial and final levels at the substation. 3.5.5 The rates for earth filling/cutting and spreading of earth shall include site clearance, laying of earth in layers (as per specification briefly brought out under compaction), dressing, carriage, lead, loading and unloading, watering and compaction with roller including compensation of earth etc. as per specification complete for the substation as a whole, including under roads. 3.5.6 In case only dressing is required for maintaining FGL, nothing shall be paid extra on this account. 3.5.7 In case earth contains harmful salts, deleterious materials etc. and top layer of 300mm layer requires cutting and disposal only, nothing shall be paid extra on this account. This earth shall be disposed outside substation area and shall not be used for filling anywhere in the substation area. 4.0 4.1 SITE SURFACING SCOPE OF WORK 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 Executive Engineer/ Civil Works Division. Stone spreading along with cement concrete layer shall be done in areas presently in the scope of the scheme. 4.2 GENERAL REQUIREMENT

4.2.1 The material required for site surfacing/gravel filling should be free from all types of organic materials and shall be of standard approved quality as directed by the Executive Engineer/Civil Works Division. 4.2.2 The material to be used for stone filing/site surfacing shall be crushed/broken stone of 40mm nominal size (ungraded single size) conforming to table 2 of IS: 383 1970. Hardness, flakiness shall be as required for wearing courses are given below:a) Sieve Analysis Limits (Gradation) (IS: 383 Table 2) Sieve Size % passing by weight 63mm 100 40mm 85-100 20mm 0-10 (upto 90% retained on sieve) One Test shall be conducted for every 500 cum per source.

b)

Hardness Abrasion Value (IS: 2386 Part-IV) not more than 40% Impact value (IS: 2386 Part-IV) not more than 30% One test per 500 cum with a minimum of one test per source.

4.2.3 The Contractor, after all the structures and equipment have been erected and accepted, shall furnish and install the site surfacing to the lines and grades as shown in the drawing and in accordance with the requirements and direction of the Executive Engineer/Civil Works Division. The site shall be maintained to the lines and grades indicated in the drawing by using 3 ton roller with suitable water sprinklers to form a smooth and compact surface condition which shall match with finished ground level of the switchyard area. 4.2.4 200mm thick base layer of cement concrete in 1:4:8 (1 cement: 4 fine aggregates conforming to zone-II as per IS:583: 8 coarse aggregate nominal size 20MM) shall be provided in the areas excluding roads, drains, cable trenches as per detailed engineering drawing. For easy drainage of water, the slope of 1:1000 is to be provided towards the drain. The above slope shall be provided at the top of base layer of cement concrete in 1:4:8. A layer of cement slurry of mix 1:4 (1 cement: 4 fine aggregates) shall be laid uniformly over cement concrete layer. The cement consumption for cement slurry shall not be less than 150kg per 100 sq.m. 20mm single size coarse aggregate should be used for base concrete. 4.2.5 The sub grade shall be in moist condition at the time the cement concrete is placed. If necessary, it should be saturated with water for not less than 6 hours but not exceeding 20 hours before placing of cement concrete. If it becomes dry prior to the actual placing of cement concrete, it shall be sprinkled with water and it shall be ensured that no pools of water or soft patches are formed on the surface. 4.2.6 Areas where the Executive Engineer/Civil Works Division is satisfied that proper filling of the base course material by normal rolling equipment is not possible due to closely laid foundations and structures, the filling of the base course material shall be compacted by hand. Due care shall be exercised to avoid any damage to the foundations, structures, equipments during rolling compaction or otherwise. 4.2.7 A final layer of 100mm thick uncrushed/crushed/broken stone of 40mm nominal size (ungraded size) shall be spread uniformly over cement concrete layer after curing is complete.

4.2.8 Generally site surfacing will be restricted upto 2.0m beyond the last structure/equipment foundation. However, depending upon actual engineering requirement, same can be extended. All visible outer portion of toe/retaining wall shall be plastered and cement painted. Steel grating shall be provided in the toe/retaining wall for draining out the rain water. 5.0 SITE DRAINAGE SCOPE Adequate site drainage system shall be provided by the Contractor within the LILO arrangement & existing 400kV Samaypur-Greater Noida PGCIL line under the present scope including connection at one or more points with the settlement tank, recharge bore well & the outfall point located outside the substation boundary wall is in the scope of contractor. Invert level of drainage system at outfall point shall be decided in such a way that the water can easily be discharged outside the substation boundary wall. Outfall point shall be got approved from Executive Engineer/Civil Works Division before commencement of construction. The contractor shall obtain rainfall data and design the storm water drainage system including culverts, ditches, drains etc. to accommodate the most intense rainfall that is likely to occur over the catchments area in one hour period on an average of once per ten years. While designing the drainage system following points shall taken care of: 5.1 The surface of the switchyard shall be sloped to prevent pounding of water. Longitudinal slope shall generally be not less than 1 in 1000. However, keeping in view the discharge, the same can be increased to 1:2000. Open surface drains shall be constructed in first class brick masonry in 1:4 cement sand mix laid over 100mm thick PCC of 1:4:8 (1cement; 4 coarse aggregates; 8 stone aggregate 20mm nominal size). The side walls shall be plastered with 1:5 cement sand mix The trapezoidal drains, if proposed shall have 300mm bottom width and sides slope of 1 horizontal; 1.5 vertical. For design of lined drain IS: 10430 and for construction of cast-in-situ cement lining IS: 3873 shall be followed. Maximum spacing between two drains shall not be more than 100meter. It will be ensured that no area is left un-drained.

5.2

5.3

5.4

5.5

5.6

The side wall(s) of the drains as per site conditions shall be 25mm above the gravel level to prevent spilling gravels. Suitable mild steel grating be provided for drainage of surface water. RCC pipe drains shall be provided in area of switch yard where movement of crane will be necessary in operating phase of the substation. For pipe drains, RCC concrete pipe of class NP3 shall be used. However, for road crossings rail crossings etc., RCC pipes of class NP4 shall be provided. For design of RCC pipes for drains and culverts, IS: 456 and IS: 783 shall be followed. Pipe drains shall be connected through manholes at an interval of max. 30m. Sum pit of suitable size to hold water for 5 minutes discharge has to be constructed within the substation boundary at suitable site as per the design evolved by the successful bidder and approved by HVPNL. The drainage scheme and associated drawings shall be developed by the successful bidder and shall be got approved from HVPNL before commencement of work. Two non clog pumps (of reputed make) and of suitable capacity (depending upon maximum discharge and capable of lifting particle size upto 65mm) shall be provided at sum pit by the contractor without any extra cost. RAINWATER HARVESTING. In addition to drainage of rainwater in accordance with clause 5.0 of Part civil of Technical specification, the contractor shall make arrangement for rainwater harvesting also as per drawing supplied by the HVPNL with the bid document. Rainwater harvesting shall not be done if the depth of water table is within 8.0 m from finished ground level. Rainwater harvesting shall be done by providing one number recharge structures with bore well. The recharge structure shall be suitably located within the sub-station. Branch drains from the main drain carrying rainwater from entire switchyard, constructed in accordance with clause 5.0 shall be connected to the recharge structures. The internal diameter of recharge shafts shall be 4.5 meter as per HVPNL drawing with 230mm thick lining of brick work upto a depth of 2.0 meter from ground level and 345mm thick brickwork below 2.0 meter depth. The brickwork shall be constructed with cement mortar 1:6 (1 cement: 6 coarse

5.7

5.8

5.9

5.10

5.11

5.12

6.0 6.1

6.2

6.3

sand). The overall depth of shaft shall be 5.0 meter below invert level of drain. The shaft shall be covered with RCC slab for a live load of 300kg per sq m. Two openings of size 0.7x0.7 meter shall be provided in the RCC cover slab as shown in the drawing. An iron cover made of 5mm thick chequerred plate with hinges shall be provided on the openings. Galvanized M.S. rungs of 20mm diameter at spacing of 300mm shall be provided in the wall of shaft below the opening in the RCC slab to facilitate cleaning of shaft. 6.4 A 300 mm diameter bore well shall be drilled in the centre of the shaft. The depth of bore well shall be 5.0 meter more than the depth of sub soil water or as per directions of the Executive Engineer/ Civil Works Division. A 150 mm dia. class 3 PVC pipe conforming to IS 4985-1981 with latest revision shall be lowered in the bore well keeping bail plug towards bottom of bore well. The pipe shall have 1.58 mm holes for 4.0 meter length starting from 1.0 meter from bottom of bore well. Holes of 3.0 mm dia shall be provided for a length of 2.0 meter starting from the bottom level of coarse sand and down wards. The overall length of pipe shall be equal to total depth of bore well plus depth of shaft. Gravel of size 3mm to 6mm shall be filled around 150 dia PVC pipe in the bore well. The shaft shall be filled with 500mm thick layers each from the bottom of shaft with boulders of seize 50mm to 150mm, gravel of size 5mm to 10mm coarse sand having particle size 1.5mm to 2.0 mm and boulders of size not less than 200mm respectively.

6.5

6.6

7.0 FOUNDATION FOR RCC CONSTRUCTION (GENERAL) 7.1 Work covered under this clause comprises the design, engineering, supply and construction of foundations and other RCC constructions for LILO arrangement structures, equipment supports, sump pit, drains or for any other equipment or service and any other foundation required to complete the work. This clause is as well applicable to other RCC constructions. In case of overlapping of foundations, deeper foundation shall be constructed first. The foundations resting on filled up soil, the fill material under foundation/trenches shall be such that the maximum pressure from the footing transferred through fill material will not exceed the allowable soil bearing pressure of original undistributed soil. In case earth filling is involved due to high fixation of formation level, all foundation shall rest below virgin ground level and the minimum depth excluding lean concrete of all foundations below virgin ground level shall not be less than 1000mm.

7.2

7.3

10

7.4

All the properties of concrete regarding its strength under compression, tension, shear, punching and bond strength etc. as well as workmanship will conform to IS: 456. The concrete used as lean concrete or base concrete under the structure/equipment/trench/walls foundations etc. shall be minimum 100 mm thick (1:4:8). The successful bidder shall also use above mentioned thickness and grade of lean concrete for equipments foundation/sump pit design. The aggregate size shall be 20mm nominal for 100mm thickness and 40mm nominal for thickness more than 100mm. Base concrete shall be well compacted. The top surface of base concrete shall be leveled before placing the reinforcement. During excavation if excavation exceeds than the required depth or if any loose pocket of earth is met below the base then the loose earth shall be removed or excavation depth be increased till normal hard soil is met as per satisfaction of Executive Engineer/Civil Works Division. This extra depth shall be filled with lean concrete. No extra shall be payable an account of this extra excavation and lean concrete. 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. The tower/equipment foundations shall be 300mm above the finished ground level. 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 or pile foundation may be required based on soil/sub-soil conditions and superimposed loads. The cement concrete used for foundation shall be of grade M-20 (irrespective of any grade mentioned on the drawings). The mix-design (conforming to IS-Standards) shall be done prior to start of work, as per specifications, got approved from HVPNL and shall be used for the construction, provided there is no change in the source and the quality of materials. The source of materials shall be intimated to the HVPNL and shall be ensured that Mix design is with the materials from intimated source only and it is not changed during construction. In case source of material changes or quality of material differs from the earlier approved parameters the Mix design shall be done again. The Coarse aggregate used shall be of 20 mm graded or two types of single size aggregate mixed in some fixed ratio to have graded 20mm aggregate. The Coarse aggregate shall conform to IS 383.

7.5

7.6

7.7

7.8

7.9

7.10

11

7.11

Grading of Fine aggregate shall conform to Zone-II of Table - 4 of IS: 383 and shall be free from deleterious materials. The environmental exposure condition considered for mix design shall be MILD. For Mix-design, the degree of quality control shall be considered as FAIR. The Water cement ratio shall be minimum 0.50 and maximum 0.55. The minimum slump shall be 25mm and maximum 75mm. For Volumetric use of ingredients for concrete mix, the contractor shall intimate the size of measuring boxes along with the Mix-design.

7.12

7.13 7.14 7.15 7.16

7.17 Ordinary Portland Cement (OPC) of Grade 43 conforming to IS: 8112 manufactured by major cement manufacturer shall be used. 7.18 The water used for preparing concrete and for curing purpose shall be fresh, clean and free from oil, acids and alkalis, organic materials or suspended or other deleterious substances. Saltish or brackish water shall not be used. Water used for construction & curing etc. shall be conforming to requirements of IS: 456 Clause 5.4. Contractor shall arrange at his own cost sufficient quantity and good quality water for construction and curing and other purposes. In case good quality water is available at existing sub-stations, it can be used by the successful contractor free of cost (also refer clause 3.1). 7.19 No admixtures shall be used except water proofing cement additives conforming to IS 2645 with the approval of the HVPNL. 7.20 Reinforcement steel (including TMT) Bars manufactured by main producers or their authorized re-rollers in India or abroad shall be used and certificates in this regard shall be submitted by the Contractor to the entire satisfaction of the HVPNL. The steel used shall conform to IS: 1786 for deformed and cold twisted bars. Required grade of steel shall be Fe415. All reinforcement shall be clean and free from loose mill scale, dust, loose rust and coats of paint, oil or other coating, which may destroy or reduce bond with concrete. Reinforcement bars should be fresh. Bidder shall supply, fabricate and place reinforcement to shapes and dimensions as indicated on the drawings or as required to carry out the intent of drawings and specifications. Adequate nos. of chairs, spacers of required size shall be provided to ensure the proper placement of reinforcement. The reinforcement bars crossing one another should be tied together at every intersection with two strands of annealed steel wires 0.9 to 1.6 mm

12

thick twisted and tied to make the skeleton of the steel work rigid so that the reinforcement does not get displaced during concrete placement. All the reinforcement steel should be placed/stacked at site store on raised (at least 0.5 meter from near surroundings) pucca/brick platform or reinforcement steel should be placed on MS/GI sheets. The reinforcement steel after stacking should be covered with Tarpaulin to avoid corrosion. Immediately before concreting (portion of reinforcement to be embedded in concrete) shall be painted with cement slurry after removing any rust/corrosion/any other foreign material. Overlaps in more than 30% of bars will not be allowed at a section. Fabricated Reinforcement bars shall be placed in position as shown in the drawing or as directed by Executive Engineer/Civil Works Division. 7.21 The bars crossing one another shall be tied together at every intersection with two strands of annealed steel wires 0.9 to 1.6mm dia. twisted and tied to make the skeleton of steel work rigid so that reinforcement does not get displaced during placement of concrete. Two types of steel shall not be used. All the foundation bolts used for equipment foundations & for main gantry tower foundations shall be galvanized. The foundation bolts shall be embedded in concrete during concreting and no grout holes shall be left for this purpose. Excavation shall extend minimum 150 mm around foundation (from RCC portion and not from lean concrete). Proper shuttering & shoring shall be provided to support the excavated earth face to avoid falling of earth. No extra charges shall be admissible for the removal of fallen earth in the pit, once excavated. MIXING, PLACING AND COMPACTION OF CONCRETE The concrete shall be mixed in a mechanical mixer. The mixer shall comply with IS: 1791 & 12119. The mixer shall be fitted with water measuring devices. Mixing shall be continued until there is uniform distribution of material and the mix is uniform in colour and consistency. If there is segregation after unloading from mixer, the concrete should be re-mixed, but in no case the mixing shall be done close to the foundation, or place of work but in case it is not possible the concrete may be mixed at the nearest convenient place. From mixer, concrete shall be put on pucca platform or steel

7.22 7.23

7.24

7.25

7.26

8.0 8.1

8.2

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troughs, which shall be leak proof to avoid any loss of water/slurry. The concrete shall be transported from the place of mixing to the place of final deposit as rapidly as practicable, which shall prevent the segregation before any setting commences. 8.3 Proper shuttering shall be used for the construction of all type of PCC/RCC works. Shuttering shall be rigidly tightened so that there are no distortions in the shape. Shuttering shall be made sufficiently strong to with stand all the loads and vibrations. Vibrators shall be used to ensure thorough compaction. After the shuttering has been removed, if the concrete surface is found to be slightly damaged, same shall be repaired with rich cement sand mortar to the satisfaction of the HVPNL's representative before the foundation pits are back-filled. CURING The concrete after setting for 24 hours shall be cured by keeping the concrete wet continuously for a period of 10 days (minimum) after laying. The foundation be back filled with selected good earth free from harmful salts, organic material, sprinkled with necessary amount of water and well consolidated in layers not exceeding 200 mm of consolidated thickness after a minimum period of 72 hours and thereafter both backfilled earth and exposed top shall be kept wet for the remainder of the prescribed curing time. The uncovered concrete portion above the backfilled earth or vertical columns etc. shall be kept wet by providing empty cement jute bags dipped in water fully wrapped around the concrete for curing and ensuring that the bags are kept wet by the frequent pouring of water on them. In case Portland Pozzolona cement has been used, curing period shall be increased by Executive Engineer/ Civil Works Division. 10.0 DISMANTLING The contractor wherever required, shall carry out dismantling PCC/RCC/brickwork etc. & dispose it of at a suitable undisputed place outside substation. The successful bidder shall be responsible in case some dispute arises on account of disposal of dismantled material at a disputed site. 11.0 11.1 DESIGN All the foundations except open drain shall be of Reinforced Cement Concrete. The design and construction of RCC structures shall be carried out as per IS: 456-2000 using minimum grade of concrete as M-20 (M-25 for water retaining structures). Higher grade of concrete than specified

8.4

9.0

14

above may be used by the contractor without any additional cost to the HVPNL with proper mix design. 11.2 Limit state method of design shall be adopted unless specified otherwise in the specification/IS Codes. For design and construction of steel-concrete composite beams IS: 11384 shall be followed. For detailing of reinforcement, IS: 2502 and SP: 34 shall be followed. Two layers of reinforcement (on inner and outer shall be provided for wall & slab sections) having thickness of 150 mm and above. Clear cover to reinforcement towards the earth face shall be minimum 50 mm and for other components, same shall be as per IS: 456. The procedure used for design of the foundations shall be the most critical loading combination of 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. The contractor, for approval of drawings shall submit detailed design calculations along with drawings. Designer shall consider sub-soil water pressure that may be encountered, following relevant standard strictly. Necessary protection to the foundation work, if required shall be provided to take care of any special requirements for aggressive alkaline soil, black cotton soil or any other type of soil which is detrimental/harmful to the concrete foundations without extra cost to the HVPNL. RCC column shall be provided with rigid connection at the base. All sub-structures shall be checked for sliding and overturning stability during both construction and operating conditions for various combinations of loads. Factor 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. In case of trench passing above the footing base then for over turning only dead weight of trench shall be considered.

11.3

11.4

11.5

11.6

11.7

11.8 11.9

11.10 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). However, for the design of substructures of any underground enclosures, earth pressure at rest shall be considered.

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11.11 In addition to earth pressure and ground water pressure etc. a surcharge load of 2T/sq. m shall 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 or otherwise. 11.12 Following conditions shall be considered for the design of water tank in pumps house, channels, sumps and trenches and other underground structures. a) Full water pressure from inside and no earth pressure and ground water pressure & surcharge pressure from outside, (applicable only to structures which are liable to be filled up with water or any other liquid). b) Full earth pressure, surcharge pressure from outside and no water pressure from inside. c) For any water retaining structure or any member submerged in water the minimum grade and concrete shall be M-25. d) 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 super imposed loadings. 11.13 Base slab of the any underground enclosure like water storage tank shall also be designed for empty condition during construction and maintenance stages with maximum ground water table (GWT) at 2.0 m. below ground level. Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the super-imposed loading. Intermediate dividing piers of such enclosures shall be designed considering water in one pump sump only & the other pumps sump being empty for maintenance. 11.14 The foundations shall be proportioned so that the estimated total and differential movements of the foundations are greater than the movements that the structure or equipment is designed to accommodate. 11.15 The foundations of transformer/reactor and circuit breaker shall be of block type foundation. Minimum reinforcement shall be governed by IS: 2974 and IS:456-2000. 11.16 The tower and equipment foundations shall be checked for a factor of safety of 2.2 for normal condition and 1.65 for short circuit condition against sliding, overturning and pullout. The same factors shall be used as partial safety factor over loads in limit state design also.

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12.0

OTHER FOUNDATIONS

12.1 All foundations shall be designed in accordance with the provisions of the relevant parts of latest revisions of Indian Standards IS: 456 and other relevant Indian Standards. 12.2 Type of foundation system i.e. isolated footing or raft etc. shall be decided based on the load intensity and soil strata. 13.0 MATERIALS The brief requirement regarding various materials to be used for construction of building are detailed below or specified in respective drawings. However, materials not specifically mentioned in the specifications/drawings, the same shall also conform to the relevant IS codes and got approved from the HVPNL before being used. The contractor shall remove from site any material not conforming of IS Standards or rejected by the representative of HVPNL/Executive Engineer/ Civil Works Division. 13.1 BRICKS AND TILES The bricks used shall be first Class bricks of nominal size (230x110x70) mm so that every four courses shall measure 30.48 cm in height. A tolerance upto 80mm in length 40mm in width and 40mm in thickness/height shall be permitted per 20 bricks. The bricks shall be made from good brick earth free from efflorescence/kankar, thoroughly burnt and uniform deep red colour, regular in size and shape with parallel faces and sharp corners, uniform in colour, free from flaws etc, and shall have all the qualities of a good brick. Bricks and tiles shall have ringing sound when struck with each other. Bricks shall have a minimum crushing strength of 105 kg/per sq. cm and shall not absorb water more than 20% of its own dry weight after 24 hours immersion in cold water. For tile terracing and tile facing, size of tile shall be (230x110x30) mm having permissible tolerance of IS Standards for length, width & height 40mm. 13.2 SAND (FOR MASONRY MORTAR & PLASTER) Sand for masonry work and plaster shall preferably consist of natural sand, However crushed stone sand or crushed gravel sand or a combination of any of them be used. Sand shall be hard, durable, clear and free from harmful impurities like iron pigments, mica salts, coal or

17

other organic impurities. Grading of sand for use in masonry mortar shall be conforming to IS: 2116 and for use in plaster shall conform to IS: 1542 tabulated as below: IS Sieve Designation 10.0 mm 4.75 mm 2.36 mm 1.18 mm 600 micron 300 micron 150 micron For mortar For Plaster Percent passing by mass 100 100 95 to 100 90 to 100 95 to 100 70 to 100 90 to 100 40 to 100 80 to 100 5 to 70 20 to 65 0 to 15 0 to 50

The maximum quantities of clay, fine silt, fine dust and organic impurities shall not exceed limits described in IS: 2386 (Part II). Clay, fine dust and silt in natural sand or crushed gravel sand or crushed stone sand not more then 5% by mass. 13.3 BRICK WORK All brickwork shall strictly be according the specifications and notes specified in the drawings. All bricks shall be soaked in stacks by spraying clean water at regular intervals to keep them wet to the satisfaction of Executive Engineer/ Civil Works Division. Each brick shall be set (with frog upwards) with bed and vertical joints completely filled with mortar. Thickness of mortar joint shall be 6.25 mm and shall not be more than 9.4 mm. For exposed brickwork, bed joint will be 7.81 mm thick and vertical joint 6.28 mm. All brickwork shall be true in plumb, straight edge, for exposed brickwork or face work bricks shall be selected for purpose. The face joints shall be duly racked to minimum depth of 13 mm when mortar is green for providing key to plaster or pointing. The mortar used for brick work/ plasterwork shall be machine mixed only. All fixtures, doors/windows/CI pipes, outlet for water, hold fasts etc. which are required to be built/laid in brickwork shall be embedded simultaneously. Each day work done shall not be more than 1m in height and no portion of the work shall be left more than 1m lower than the other. The height of brick courses shall be kept uniform. All the half brick thick walls shall be provided with 2 numbers - 6 mm bars at every fourth layer.

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In case of difference in the natural ground level and formation level, no extra payment on account of extra brick work whether in building or boundary wall shall be paid extra. The contractor may, therefore, visit the site before quoting rates for the brick work. 13.4 DAMP PROOF COURSE On outer walls horizontal DPC shall be provided at level with plinth protection and on inner face vertical DPC 20 mm thick, shall be provided. On all inner walls horizontal DPC shall be provided at floor/plinth level. Horizontal DPC shall consist of cement concrete (1:1.5:3) 50 mm thick. Edge of DPC shall be straight, even and vertical. It shall be cured for at least 7 days, after which it shall be allowed to dry. Vertical DPC shall consist of two layers of plaster (1:3) with total thickness of 20 mm. Hot bitumen shall be applied over dried up surface in thin layer. 13.5 PAINTING, ACRYLIC EMULSION DISTEMPER/WHETHER PROOF ACRYLIC PAINT The internal wall including ceiling of sump pit-cum -pump chamber (building) shall be provided with dry distemper/white wash. The outer face of building shall have peach colour cement based whether proof exterior (acrylic paint) coating. All the steel work, wire mesh, doors & windows etc., shall have first quality paints of approved make/shades. 13.6 MATERIALS The lime for white washing shall be unslaked lime of good quality which shall be slaked at spot, mixed with water at least for 24 hours, than stained through coarse cloth, Indigo & some binding material like gum be added in proper quantity before use. The Priming Paint shall conform to IS: 109 (Alkali resistant priming paint). The dry distemper and whether exterior acrylic paint shall be of superior quality manufactured by standard firms like ASIAN, NEROLEC, BERGER, DULUX, SHALIMAR etc. The material should be brought to site in sealed condition and stored properly. All paints and allied materials shall be of superior quality manufactured by standard firms like ASIAN, NEROLEC, BERGER, DULUX, SHALIMAR etc. and meet the requirements of following Indian Standards for wooden and metallic surfaces and shall be of approved brands and manufacturer and of approved shade. Synthetic enamel paint shall be conforming to IS: 117, IS: 133 and IS: 137 of first quality.

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13.7

DOORS/WINDOWS The contractor shall provide & fix steel chowkhats/doors and aluminum /windows/ventilators (single/double leaf) including vertical styles, top rails, lock (middle) rails and bottom rails with metal fastener & screws fitted with nuts & bolts or using rawl plugs & screws. The Aluminum section to be used shall be of 10 gauge (3mm) anodized (15 micron) of reputed makes such as HINDALCO/JINDAL conforming to IS: 1968-1983. The doors & windows shall be fitted with 5.0 mm thick glass of reputed make like TATA FLOAT/SAINT GOBBAIN, high-class rubber gasket & aluminum beading complete so to make the glass airtight. The toilet doors shall, however, be fitted with pre-laminated board (NOVAPAN/KIT/DECCO) panels of appropriate size with aluminum beading to make it airtight. The door/floor springs, locks (six lever of Godrej or equivalent), handles, tower bolts, stoppers with rubber cushion, screws etc. shall be of 1st quality ISI make as approved by Executive Engineer/Civil Works Division.

13.8

ELECTRICAL ITEMS The bidder shall prepare the design and detail of circuits to be provided and layout of pipes. 28W (T-5) CFL tubes shall be used. The wiring shall be recessed conduit wiring. Heavy duty PVC conduits of 20/25/30mm size and wires 2.5/4/6 sq. mm copper for circuit wiring & 1.5 sq. mm copper for earth including wiring for sub-mains, modular switch boards, junction boxes, switches/sockets 5 Amp, 5/16 Amp and 16 Amp, 240V indoor and outdoor receptacle including 2T split/window ACs, electronic step regulator mounted on the switch boards, provision for telephone wires including telephone junction boxes/tap blocks, sockets. Depth of inspection/junction boxes shall be 80 mm in ceiling and 28 mm on wall surface which may vary as per requirement of modular switches/regulator.

13.9

ROOFING On top of RCC slab of sump pit-cum-pump chamber building, terracing shall be done with tile brick paving. The top surface of RCC slab when thoroughly dry shall be painted uniformly with bitumen of penetration 80/25, hot cut back bitumen, the quantity of bitumen shall be 1.7 kg per sq. m of roof surface. Immediately after painting dry, clean sharp coarse sand shall be evenly sprayed and leveled over the surface after bitumen is still hot. Over the layer of bitumen the good soil with optimum moisture content shall be laid on roof to requisite thickness and slope, well compacted.

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After laying the mud surface shall be given a coat of mud plaster 25 mm thick and allowed to dry. Over the mud plaster flat tile bricks shall be laid using the minimum amount of plain mud mortar as bedding. The tiles shall be laid close to each other; the thickness of joints shall not be less than 6 mm and more then 12 mm in width. After tiles are well set and bedding mortar has dried joints of tiles shall be grouted with cement mortar of mix 1:3 (1 cement: 3 fine sand) such that all the joints of tiles are completely filled with mortar and the joints should be finished neatly by providing flush pointing in 1:3 cement mortar (1 cement: 3 sand). The surface shall be cured for at least 7 days. The tiles surface as completed shall be even and true to slopes of 1 in 48. 14.0 TOE/RETAINING WALL Toe/Retaining wall as proposed in the GELO/CLO for the LILO arrangement shall be constructed as per HVPNL drawing enclosed herewith. Top of DPC of toe/retaining wall shall be 100mm above the FGL of sub-station which has been fixed as 199.70M assuming BM as 198.200M situated on brick pillar near N65, E120 Tower Location No. 108 or 198.415M situated on brick pillar near N415, E250 Tower Location No. 107. The brick work in foundation upto DPC level including 100mm thick 1:4:8 PCC below brick foundation and 25mm thick horizontal DPC (without bitumen coating), cement plaster with cement paint on outer face (vertical face) of the wall shall be in the scope of work. The measurement shall, however, be done only for brick work. Nothing shall be paid for 100mm thick lean & 25mm thick DPC. 15.0 YARD CHAIN LINK FENCING AND GATE Fencing & Gates shall be provided as per General Electrical Layout Plan/Civil layout plan and any other specified area along the lines shown. The design shall be as per drawings attached with the tender except the toe/retaining wall payment of which shall be covered under relevant item mentioned in the BoQ and item 14.0 above. Chain link fence fabric shall of size 75mm; coated wire shall be of 3.15mm dia. having zinc coating after weaving. The chain link fabric shall be fixed to the intermediate parts and at top & bottom of fence by welding/fixing 50x6mm M.S. flat all through its length. All structural steel manufactured by TISCO, SAIL, IISCO and RASHTRIYA ISPAT (primary manufacturers) shall conform to IS: 20621786 shall only be used. The bidders shall, however, be allowed to use Amba steel, Rathi steel, Kamdhenu steel, Barnala steel, P.R.S steel, Shidbali steel (manufactured by secondary manufacturers) only after obtaining nonavailability certificate from the primary manufacturers. Before using secondary steel, the selected bidder would require to conduct all physical

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& chemical tests (lot wise & dia. wise) to establish its conformity to IS Standards conforming to IS 2062. The barbed wire shall consist of two splices per reel. The barbed wire shall be formed by twisting two line wires, one containing barbs. The barbed wire shall be of 12 SWG galvanized steel with its weight 155-186 gm/m length of wire. Distance between two barbs shall be 75mm. The barbs shall carry four points and shall be formed by twisting two point wires, each two turn tightly round one line wire making altogether 4 complete turn. The barbs shall be finished in such a way that four points are set and locked at right angles to each other. The barbs shall have a length of not less than 13mm and not more than 18mm. The points shall be sharp and well pointed. Fasteners Single strand aluminum or galvanized steel, wire conforming to requirements for fence fabric 4mm diameter. Tension wires - Single strand, high tensile, galvanized steel wire 4mm diameter. Fittings and Hardware Cast aluminum alloy or galvanized steel malleable or ductile steel. Cast iron D-Clamp to be drop forged with bolt, Check nut, Thimble and other material required for stretching the Barbed wire complete in all respect. Generally the drawing attached with the tender shall be applicable. However, if due to difference of levels between formation level and Switchyard and outside, normal foundations have to be changed in some portion and retaining wall have to be provided below due to site requirements. Successful bidder for approval before execution will submit the suitable design. Nothing extra shall be payable on this account. All the structural steel shall be galvanized (conforming to IS 2629-1985 and IS 4759-1968 and withstand tests as per IS 2633-1986). The galvanizing shall be done after fabrication work is complete. However for touch-ups of damaged spots, cold galvanizing be done with paints/sprays such as ZINKOTE -20 Zinc rich paint or Zinc metal spray after cleaning the damaged spots of rust, oil, grease, dirt, moisture, water etc 16.0 FIELD QUALITY CONTROL PLAN The contractor shall submit the field quality control plan for effective control on quality of civil works for approval from HVPNL before the start of work. All cost of testing as per approved field Quality control plan or as directed by HVPNL shall be borne by the Contractor.

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17.0

After completion of civil works, a completion plan giving all details of foundations, trenches, culverts, fencing budding etc. as built shall be submitted with original tracing.

18.0 Any material or activity not covered under the specifications or drawings shall be, as governed by relevant IS specification/National Building Code of India. 19.0 GENERAL The work shall be carried out by specialists in the trade. Workers shall be provided with gum boots and hand gloves. Minimum overlaps of 100mm shall be given at the ends and sides of the strips of the felts/tissue and properly bonded with bitumen. Joints in the successive layers of the fibre glass based felt/tissue shall be staggered. There shall be no air pockets. Corners shall be treated flush without any air pockets or voids. a. The materials and the sub-contractors executing the work shall be duly approved by the Executive Engineer/Civil Works Division. b. Adequate covering shall be provided during work to avoid splashing or staining of adjacent works and surfaces. Any surface or work splashed or stained shall be thoroughly cleaned to the full satisfaction of the Executive Engineer/ Civil Works Division. 20.0 SPECIAL NOTE Fully galvanized angles, flat, nut & bolts etc. shall be used in all the items covered under this scheme. Galvanizing of the steel section shall confirm to IS 2629-1985 and IS 4759-1968. All galvanizing members shall withstand test as per IS 2633-1986. The galvanizing shall be done after all fabrication work is completed, except that the nuts may be tapped or rerun after galvanizing. Threads of the bolts and nuts shall have a neat fit and shall be such that they can be turned with finger throughout the length of the threads of bolts and they shall be capable of developing full strength of the bolts.

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