Ts For Transmission Line

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SECTION - III
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SECTION-III
(PART-A)
TECHNICAL SPECIFICATIONS
1. GENERAL INFORMATION AND SCOPE
1.1 SCOPE
1.1.1 This Specification covers detailed survey, check survey, tower
spotting/optimization of tower location, soil resistivity measurements and
geotechnical investigation, fabrication and supply of all type of 220kV double
circuit transmission line towers (as per PSTCL design) including bolts, nuts
(normal & Anti-Theft) and washers, U-bolt, D-shackle and all type of tower
accessories like phase plate, circuit plate, number plate, danger plate, anti-
climbing device (with barbed wire) etc. and casting of foundation for tower
footing, erection of towers, tower earthing, fixing of insulator string, stringing
of conductors and earthwire along with all necessary line accessories and
testing and commissioning of the erected transmission lines.
1.1.2 This specification also covers the fabrication and supply of gantry structures
for under-crossing the 220kV and 400kV Transmission Lines including bolts,
nuts and washer, D-shackle and all type of accessories like phase plate,
circuit plate, number plate, danger plate, etc. casting of foundation for gantry
footing, erection of gantries, gantry earthing, fixing of Insulator string, stringing
of conductors and earth wires along with all necessary line accessories. All
the clauses in the specification will be relevant for the gantry structures also
unless stated otherwise.
1.1.3 This Specification includes the supply of insulators and their hard wares,
ACSR Zebra, earthwire of size 7/3.15 mm, earthwire suspension and tension
clamps and all other line accessories for conductor & earthwire like mid-span
compression joints for conductor and earth wire, repair sleeve for conductor,
vibration damper for conductor & Earth wire, flexible copper bond which shall
be supplied by the bidder during execution of the project.
1.1.4 All the raw materials such as steel, zinc for galvanizing, reinforcement steel
and cement for tower foundation, coke and salt for tower earthing etc. bolts,
nuts, washers, D-shackles, hangers, links, danger plates, phase plate, number
plate, circuit plate, anti climbing devices etc. required for tower manufacture
and erection shall be included in the bidders scope of supply. Bidder shall
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clearly indicate in the offer, the sources from where he proposes to procure
the raw materials and the components.
1.1.5 The entire stringing work of conductor shall be carried out by standard
stringing practice. The scope of the work includes both single circuit stringing
on DC towers and double circuit stringing on DC Towers and towers are
designed for this. The bidder shall indicate in the offer, the detail description of
the procedure to be deployed for stringing operation.
1.1.6 The Special River crossing towers or any other special type of tower required
as per approved route plan, if any shall be fabricated and supplied by the
Contractor. The construction of river crossing section including casting of
foundation shall also be in the scope of bidder.
1.1.7 The fabrication & inspection of Tower Proto assemblies, wherever required,
shall also be within the scope of the Bidder and no extra payment for the
same shall be made.
1.1.8 The following Package of 220KV transmission lines are included in the scope
of the bidder under this specification:
Package 1:
S.No Name of the line Aprx. Line
Length
(Km)
A 220 KV D/C line from 400 KV S/Stn. Mukatsar to 220
KV S/Stn Abohar on ACSR Zebra conductor.
46
B 220 KV D/C line from 400 KV S/Stn. Mukatsar to 220
KV S/Stn Kotkapura (new) on ACSR Zebra conductor.
35
C 220 KV S/C line on D/C towers from 400 KV S/Stn.
Mukatsar to 220 KV S/Stn Ghubaya on ACSR Zebra
conductor.
40

The proposed completion period for this package is 14 months from Letter of Award.
Package 2:
Length
(Km)
A LILO of both circuits of 220 KV Sunam Dhuri D/C line
at 400 KV S/Stn. Dhuri on ACSR Zebra conductor.
2 X 15
B 220 KV D/C line from 400 KV S/Stn. Dhuri to 220 KV
S/Stn Mandvi on ACSR Zebra conductor.
50
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C 220 KV S/C line on D/C towers from 400 KV S/Stn.
Dhuri to 220 KV S/Stn Nabha on ACSR Zebra
conductor.
50

Package 3:
Length
(Km)
A 220 KV D/C line from 400 KV S/Stn. Rajpura to 220 KV
S/Stn Devigarh on ACSR Zebra conductor.
20
B LILO of both circuits of 220 KV D/C Patiala
M.Gobindgarh line at 400 KV S/Stn. Rajpura on ACSR
Zebra conductor.
2 X 25
C 220 KV D/C line from 400 KV S/Stn. Rajpura to 220 KV
S/Stn Lalru on ACSR Zebra conductor.
20

Package 4:
Length
(Km)
A 220 KV D/C line from 400 KV S/Stn. Nakodar to 220
KV S/Stn Kartarpur on ACSR Zebra conductor.
45
B 220 KV D/C line from 400 KV S/Stn. Nakodar to 220
KV S/Stn Nur Mehal on ACSR Zebra conductor.
11
C 220 KV D/C line from 400 KV S/Stn. Nakodar to 220
KV S/Stn Rehana Jattan on ACSR Zebra conductor.
35


Package 5:
Length
(Km)
A 220 KV D/C line from 400 KV S/Stn. Makhu to 220 KV
S/Stn Majitha on ACSR Zebra conductor.
50
B 220 KV D/C line from 400 KV S/Stn. Makhu to 220 KV
S/Stn Taran Tarn on ACSR Zebra conductor.
30
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Package 6:
Length
(Km)
A 220 KV D/C line from 220 KV S/Stn. Goindwal Sahib
to 220 KV S/Stn Khassa on ACSR Zebra conductor.
50
B 220 KV D/C line from 220 KV S/Stn. Goindwal Sahib to
220 KV S/Stn Sultanpur on ACSR Zebra conductor.
20
C 220 KV D/C line from 220 KV S/Stn. Goindwal Sahib to
220 KV S/Stn Botianwala on ACSR Zebra conductor.
60


1.1.9 LOCATION DETAILS:
The 220KV transmission lines mentioned in the above packages pass
through the plain terrain of Punjab. The contractor shall have to erect the
220kV transmission line completely up to terminal arrangements as per
approved route of the line, based on the detailed & check survey to be
carried out by the Contractor.
1.2 DETAILS OF TRANSMISSION LINE ROUTES AND TERRAIN
The transmission line will be running partly through plain irrigated farm
lands/cultivated area and partly barren lands. There are few small rivers/
distributaries/ nalas, etc. to be crossed by lines in the above packages.
However, these Rivers /Nalas etc. are envisaged to be crossed by Normal
towers or strengthened Normal tower to suit specific locations.
1.3 PRELIMINARY AND DETAILED SURVEYS :
The details collected through preliminary surveys viz line route, general
soil characteristics, crossings, accessibility and infra-structure details & the
location of all obligatory points will be within the scope of the bidder. The
detailed survey shall be within the scope of the Contractor and the same
shall be carried out using the latest survey techniques such as Total
Station and GPS etc. along the approved route alignment based on
preliminary survey. Bidders may visit the line area to know about the
terrain details and the following officers may be contacted for the same:
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S.no Officer concerned Contact No. Area covered
(Circlewise)
1 The Sr.XEN, TLSC
Division, PSTCL, Patiala
096461-
17808
Patiala & Sangrur
2 The Sr.XEN, TLSC
Division, PSTCL, Mohali
096461-
17811
Mohali, Ropar,
Ludhiana, Khanna
3 The Sr.XEN, TLSC
Division,PSTCL,Bathinda
096461-
17809
Faridkot, Ferozpur,
Bathinda, Mukatsar
4. The Sr.XEN, TLSC
Division,PSTCL,Jalandhar
096461-
17812
Amritsar, Tarntaran,
Jalandhar, Gurdaspur

1.4 ACCESS TO THE LINE AND RIGHT OF WAY
Right of way and way leave clearance shall be arranged by the Employer
in accordance with work schedule. The Employer shall also secure way
leave and right of way in the forest area.
1.5 DETAILED SURVEY, OPTIMISATION OF TOWER LOCATION
1.5.1 The detailed survey for the line(s) route, optimisation of tower locations
alongwith profiling and tower spotting shall be carried out by successful
bidder as stipulated herein. The provisional quantity for detailed survey
has been indicated in Schedule of prices.
1.5.2 The bidder should note that Owner will not furnish the topographical maps
prepared by survey of India but will provide assistance that may be
required in obtaining the topographical maps.
1.5.3 Soil resistivity, along the route alignment, shall be measured in dry
weather by four-electrode method keeping inter-electrode spacing of 50
meters. The megger reading and soil characteristics shall also be
indicated in the soil resistivity results.
1.5.4 ROUTE MARKING:
At the starting point of the commencement of route survey, an angle iron
spike of 65 x 65 x 6 mm section and 1000 mm long shall be driven firmly
into the ground to project only 150 mm above the ground level. A punch
mark on the top section of the angle iron shall be made to indicate location
of the survey instrument. Teak wood peg 50x50x650 mm size shall be
driven at prominent position at intervals of not more than 750 meter along
the transmission line to be surveyed upto the next angle point. Nails of
100mm wire should be fixed on the top of these pegs to show the location
of instrument. The pegs shall be driven firmly into the ground to project
100mm only above ground level. At angle position stone/concrete pillar
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with PSTCL marked on them shall be put firmly on the ground for easy
identification.

1.5.5 PROFILE PLOTTING & TOWER SPOTTING:
From the field book entries, the route plan with enroute details and level
profile shall be plotted and prepared to scale of 1:1000 horizontal & 1:100
vertical on 1.0, 10 mm squared paper as per approved procedure.
Reference levels at every 20 meters along the profile are also to be
indicated on the profile besides, reduced levels at undulations. Areas
along the profile which in the view of the Contractor, are not suitable for
tower spotting, shall also be clearly marked on the profile plots. If the
difference in levels be too high, the chart may be broken up according to
requirement. A 10 mm overlap shall be shown on each following sheet.
The chart shall progress from left to right. Sheet shall be 594 mm wide in
accordance with the IS. For as built profile these shall be in A1 size.
1.5.6 TOWER LOCATION
1.5.6.1 SAG TEMPLATE
The print of the sag template as per PSTCL design will be provided to the
successful bidder.
1.5.6.2 TOWER SPOTTING
With the help of approved sag template and tower spotting data, tower
locations shall be marked on the profiles. While locating the towers on the
profile sheet, the following shall be borne in mind.
a. SPAN
The number of consecutive spans between the section points shall not
exceed 10. The section point shall comprise of tension point with B (2-D-
30) or C (2-D-60) type towers as applicable.
b. EXTENSION
An individual span shall be as near to the normal design span as
possible. In case an individual span becomes too short with normal
supports on account of undulations in ground profile, one or both the
supports of the span may be extended by inserting standard body
extension designed for the purpose according to technical specification.
c. LOADING
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There shall not be any upward force on suspension towers under
normal working conditions and the suspension towers shall support atleast
the minimum weight span as provided in the design. In case uplift is
unavoidable, it shall be examined if the same can be overcome by adding
standard body extensions to the towers failing which tension towers
designed for the purpose shall be employed at such positions.
d. ROAD CROSSING
At all important road crossings, the towers shall be fitted with normal
suspension or tension insulator strings depending on the type of towers
but the ground clearance at the roads under maximum temperature and in
still air shall be such that even with conductor broken in adjacent span,
ground clearance of the conductor from the road surface will not be less
than 7.015 meters. At all national highway tension towers with double
insulator strings on crossing side shall be used.
e. RAILWAY CROSSINGS
At the time of detailed survey, the railway crossings shall be finalized
as per the regulations laid down by the Railway Authorities. The following
are the important features of the prevailing rules & regulations:
i The crossing shall be supported on B(2-D-30) or C (2-D-60) type towers
on either side depending on the merits of each case and Double Tension
insulator string shall be used on both the towers on the side of the
crossing.
ii The crossing shall normally be at right angle to the railway track.
iii The minimum distance of the crossing tower shall be at least equal to the
height of the tower plus 6 meters away measured from the centre of the
nearest railway track.
iv No crossing shall be located over a booster transformer, traction switching
station, traction Sub Station or a track cabin location in an electrified area.
V Minimum ground clearance above rail level of the lowest portion of any
conductor under condition of maximum sag shall be maintained at 17.90
meters.
The approval for crossing railway track shall be obtained by the Employer
from the Railway Authorities, however six copies of profile and plan, tower
and foundation design and drawings / any other document required for the
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approval from the Railway Authorities shall be supplied by the Contractor
to the Employer.
F RIVER CROSSING
In case of Major River crossing, towers shall be of suspension type and
the anchor towers on either side of the main river crossing shall be C (2-D-
60) type tower. For navigable river, Clearance required by navigation
authority shall be provided. For non navigable river, clearance shall be
reckoned with respect to highest flood level (HFL).
G POWER LINE CROSSING
Where this line is to cross over another line of the same voltage or lower
voltage, the tower with suitable extensions shall be used. Where the line
is to cross under the power lines, gantries may be used. Provisions to
prevent the possibility of its coming into contact with other overhead lines
shall be made in accordance with the Indian Electricity Rules, 1956 as
amended upto date. In order to reduce the height of the crossing towers it
may be advantageous to remove the ground wire of the line to be crossed
(if this is possible and permitted by the Owner of the line to be crossed).
All the works related to the above proposal shall be deemed to be included
in the scope of the Contractor except if modifications are required to line
below, in which case, the conditions shall be as agreed upon.
H TELECOMMUNICATION LINE CROSSING
The angle of crossing shall be as near to 90
o
as possible. However,
deviation to the extent of 30
o
may be permitted under exceptionally
difficult situations.
When the angle of crossing has to be below 60
o
, the matter will be
referred to the authority in charge of the telecommunication system. On a
request from the Contractor, the permission of the telecommunication
authority may be obtained by the Employer. Also, in the crossing span,
power line support will be as near the telecommunication line as possible,
to obtain increased vertical clearance between the wires.
I DETAILS ENROUTE
All topographical details, permanent features, such as trees, buildings etc
17.5 m on either side of the alignment for 220kv Line shall be detailed on
the profile plan.

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1.5.7 CLEARANCE FROM GROUND BUILDING, TREES ETC.
Clearance from ground, buildings, trees and telephone lines shall be
provided in conformity with the Indian Electricity Rules 1956 as amended
upto date.
1.5.8 The tree cutting shall be the responsibility of the Employer except for that
required during survey. However, the Contractor shall count, mark and put
proper numbers with suitable quality of paint at his own cost on all the
trees that are to be cut by the Employer at the time of actual execution of
the work. Contractor may please note that Employer shall not pay any
compensation for any loss or damage to the properties or for tree cutting
due to Contractors work.
1.5.9 Any way leave, which may be required by the Contractor, shall be
arranged by the Employer as required by work programme.
1.5.10 To evaluate and tabulate the trees and bushes coming within 17.5 m on
either side of the central line alignment, the trees will be numbered and
marked with quality paint serially from angle point 1 onward and the
corresponding number will be painted on the stem of trees at a height of 1
meter from ground level. The tree list should contain the following:
a. Girth (circumference) measured at a height of 1 meter from ground level.
b. Approximate height of the tree with an accuracy of 2 meters.
c. Name of the type of the species/tree.
d. The bushy and under ground encountered within the 35m belt should also
be evaluated with its type, height, girth and area in square meters, clearly
indicating the growth in the tree/bush statement.
1.5.11 Payment of compensation towards the clearances etc. will be the
responsibility of the Employer.
1.5.12 PRELIMINARY SCHEDULE
The profile sheets, duly spotted, alongwith preliminary schedule indicating
type of towers, type of foundations, wind span, weight span, angle of
deviation, river or road crossing and other details shall be submitted for the
approval of the Employer. After approval, the Contractor shall submit six
more sets of the approved reports along with one set of reproducible copy
of final profile drawings to the Employer for record purpose.

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1.5.13 DETAILED SURVEY OF TOWER LOCATION
1.5.13.1 The detailed survey shall be conducted to locate and peg mark the tower
position on ground conforming to the approved profile and tower schedule.
In the process, it is necessary to have the pit centers marked according to
the excavation marking charts. The levels up or down of each pit center
with respect to the center of the tower location shall be noted and recorded
for determining the amount of earth work required to meet the approved
design parameters.
1.5.13.2 Changes, if required after detailed survey in the preliminary tower
schedule shall be carried out by the Contractor and he shall thereafter
submit a final tower schedule for the approval of Employer. The tower
schedule shall show position of all towers, type of towers, span length,
type of foundation for each towers and the deviation at all angles as set
out with other details.
1.6 ENVIRONMENTAL CONDITIONS
1.6.1 GENERAL CLIMATIC CONDITIONS
The area is in the extreme climate belt. Monsoons are generally active
from the months of July to September.
The maximum temperature during summer shall be of the order of 50
0
C

and the minimum temperature shall be of the order of () 2.5
0
C. Normal
everyday temperature is 32
0
C.
1.7 TECHNICAL DATA
Bidders shall furnish all technical data as per relevant schedules in four (4)
copies.
1.8 STATUTORY REGULATIONS AND STANDARDS
1.8.1 STATUTORY REGULATIONS
The contractor is required to follow local statutory regulations stipulated in
Electricity Act 2003, Electricity supply Act 1948 and Indian Electricity Rules
1956 as amended and other local rules and regulations referred to in this
specification.
1.8.2 REFERENCE STANDARDS
1.8.2.1 The codes and/or standards referred to in specification shall govern in all
cases wherever such references are made. In case of a conflict between
such codes and/or standards and the specification, latter shall govern.
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Such codes and/or standards, referred to shall mean the latest revision,
amendments/ changes adopted and published by the relevant agencies.
1.8.2.2 Other internationally acceptable standards which ensure equivalent or
better performance than those specified shall also be accepted.
1.9 QUALITY ASSURANCE, INSPECTION AND TESTING
1.9.1 QUALITY ASSURANCE
1.9.1.1 To ensure that the supply and services under the scope of this Contract
whether manufactured or performed within the Contractors works or at his
Sub-contractors premises or at 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. A quality assurance programme of the Contractor shall
generally cover but not limited to the following:
a. His Organisation structure for the management and implementation of the
proposed quality assurance programme.
b. Documentation control system.
c. Qualification data for bidders key personnel.
d. The procedure for purchases of materials, parts/components and selection
of sub-contractors including vendor analysis, source inspection, incoming
raw material inspection, verification of material purchase etc.
e. System for shop manufacturing including process controls and fabrication
and assembly controls.
f. Control of non-conforming items and system for corrective action.
g. Control of calibration and testing of measuring and testing equipments.
h. Inspection and test procedure for manufacture.
i. System for indication and appraisal of inspection status.
j. System for quality audits.
k. System for authorizing release of manufactured product to the Employer.
l. System for maintenance of records.
m. System for handling storage and delivery.
n. A quality plan detailing out the specific quality control procedure adopted
for controlling the quality characteristics relevant to each item of supply.
The Quality Plan shall be mutually discussed and approved by the
Employer after incorporating necessary corrections by the Contractor as
may be required.
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1.9.1.2 QUALITY ASSURANCE DOCUMENTS
The Contractor shall be required to submit all the Quality Assurance
Documents as stipulated in the Quality Plan at the time of Employers
inspection of material.
1.9.1.3 The Employer, through his duly authorised representatives, reserves the
right to carry out Quality Audit and Quality Surveillance of the system and
procedures of the Contractors/ his Sub-contractors Quality Management
and Control Activities.
1.9.2 INSPECTION, TESTING AND INSPECTION CERTIFICATE
The provision of the clause regarding Inspection, Testing and Inspection
Certificate as described in General Conditions shall be applicable to the
supply and erection portion of the works. The employer shall have the right
to re-inspect at his expenses any material though previously inspected
and approved by him at the Contractors works, before and after the same
are erected at site. If following the latter, material is found defective, then
the Contractor shall bear the cost of this inspection and reinstatement
according to specification.
1.10 TECHNICAL PARAMETERS 220kV LINE
Electrical System Data
a. Nominal voltage. 220kV
b. Maximum system voltage. 245kV
c. BIL (impulse) 1050kV (Peak)
d. Power frequency withstand voltage (wet). 460kV

2. DETAILS OF LINE MATERIAL FOR 220KV LINE
2.1 Particulars of Conductor and Earthwire.
Sr
No
Particulars.
Conductor Earthwire
1.
Type
ACSR Zebra
Galvanized
steel stranded.
2.
Stranding and wire dia
a. Aluminium
b. Steel

mm
mm

54/3.18
7/3.18

7/3.15
3.
Total sectional area Sq.mm
484.50 54.55
4.
Apprx. overall dia. mm
28.62 9.45
5.
Approximate mass Kg/km
1623 428
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6.
Calculated DC resistance
At 20
o
C (max)
Ohm/km
0.0680 3.41
7.
Ultimate Tensile Strength KN
130.30 54 KN
8.
Modulus of elasticity GN/sqm
68.9 186
9.
Co-efficient of linear
expansion
Per
degree
Centigrade
19.35 x10
6
11.5x10
-6

10
Mass of zinc coating gm/sq.m
250 240
11
Configuration of
conductor.
S/C on
D/C &
D/C on
D/C Line
Near vertical on
each side of tower.
12
Location of earthwire

One continuous
earthwire to run
horizontally
above the
conductor.

2.2 PARTICULARS OF INSULATOR STRINGS

2.3 INSULATOR STRING HARDWARE( FOR 220KV LINE)
a. Anchor shackle
b. Ball Hook
c. Chain link
d. Yoke plate
e. Ball clevis
f. Socket clevis
g. Clevis eye
Sr
no
Particulars.
Single
Suspension
string
Double
Suspension
string
Double
tension
string.
Single
tension
string
1.
No. of standard
insulator discs
1 x 14 2 x 14 2 x 15 1 x 15
2. Size of disc mm 255 x 145 255 x 145 255 x 145 255 x 145
3.
E&M Strength of
each insulator disc.
KN
70 70 160 160
4.
Size and designation
of ball & socket in
mm
16 16 20 20
5.
Minimum creepage
distance of each disc
mm (for Anti-Fog)
292 ( 432) 292 (432) 330 330
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h. Free center type suspension clamp.
i. Compression type dead end clamp.
2.4 ACCESSORIES FOR CONDUCTOR AND EARTHWIRE( for
220KVLINE)
a. Mid span compression joints
b. Repair sleeves for conductor
c. Flexible copper bonds
d. Vibration dampers
e. Suspension clamps for earthwire
f. Tension clamps for earthwire.
g. Preformed armour rods for Conductor

3. TRANSMISSION TOWERS
3.1 Qualifying Requirements &General Description of the Towers.
3.1.1 Incase the Contractor is a Conductor Manufacturer then the manufacturer
from whom he proposes to procure Tower material should have
manufacturing facility for Transmission Lines towers with minimum
manufacturing capacity of 4000 MT per financial year. The average
quantity manufactured per financial year during the last three financial
years should not be less than 2000 MT. Documentary proof in the form of
certificate from Chartered Accountant/ Engineer for the required
manufacturing capacity and performance certificate from any SEB / Utility
for at least 300 MT 132 KV or higher rating Transmission Lines Towers
during last 3 years shall be submitted. On Financial side, the average
Turnover of the manufacturer for the last three financial should be min.20
Crores and he should have liquid assets and / or evidence of access to or
availability of credit facilities of not less than Rs. 2 Crores. Documentary
proof for these shall also be attached with the bid.

3.1.2 The towers are of the following types:
a. Double Circuit (A, B,C, )
b. Special Towers ( if need be)

3.1.3 The towers are of self supporting lattice steel type, designed to carry the
line conductors with necessary insulators, earthwire and all fittings under
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all loading conditions. Outline diagrams of double circuit towers are
enclosed with the Specification.
3.1.4 The tower shall be fully galvanized structure.
3.2 Type of Towers
3.2.1 The towers are classified as given below for 220 KV Lines
Type Deviation Limit Typical use

A(`2-D-2) 0deg-2deg To be used as tangent tower
B( 2-D-30) 2 deg-30deg a)Angle tower with tension insulator
b) Also designed for any two of the
power cond. Broken the same side of
the span or any of the power
conductors & ground wire broken on
the same span.
c) Also designed for up-lift force
resulting from an up-lift span up to
280m
C(2-D-60) 30deg-60deg a) Angle tower with tension
String
b) Also designed for up-lift
forces resulting from an up-lift
span of 280m
c) Dead end with 0 deg.
deviation.
NOTE: - The above towers can also be used for longer span with smaller
angle of deviations.
3.2.2 SPECIAL TOWERS
The towers which will be specially designed for very long spans such as
Major River crossing etc. which can not be crossed by normal tower with
extension shall be called special tower.
3.2.3 EXTENSIONS
The B&C type towers have 3/6 Meter body extensions for maintaining
adequate ground clearances. Besides above 9/14/19 m body extensions
may also be used with appropriate reduction in spans in case of 2-D-2
tower type A.
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3.3 SPAN AND CLEARANCES
3.3.1 NORMAL SPAN
The normal ruling span of these towers shall be 350m.
3.3.2 WIND SPAN
Wind span is the sum of the two half spans adjacent to the support under
consideration. For normal horizontal spans this equals to the ruling span.
3.3.3 WEIGHT SPAN
The weight span is the horizontal distance between the lowest point of the
conductors on the two spans adjacent to the tower. For design of the
structures, the limits given below shall prevail (in meters).
TOWER NORMAL CONDITION BROKENWIRE CONDITION
TYPE
A,B&C 350X1.5 350X0.6

3.3.4 In case of certain locations actual spotting spans exceed the design spans
and cross arms and certain members of the tower shall be modified /
reinforced.
3.3.5 ELECTRICAL CLEARANCES
3.3.5.1 GROUND CLEARANCES
The min. ground clearances from the bottom conductor shall not be less
than 7015mm at the max. sag conditions i.e. at max. temperature and still
air. However to achieve the above clearance the height of the tower is
increased in the following manner.
a. A positive allowance of 150 mm shall be provided to account for error in
stringing.
b. Conductor creep shall be compensated by over tensioning the conductor
at temperature of 26
o
C lower than the stringing temperature for ACSR
ZEBRA.
For river crossing tower, the minimum electrical clearance including
ground clearance will be same as normal tower except an allowance of
4% of maximum sag of conductor instead of 150mm for normal towers
shall be provided to account for errors in stringing.
3.3.5.2 RAILWAY CROSSING
In case of railway crossing, the min. height above rail level to the lowest
portion of any conductor under condition of max. sag in accordance with
the regulations for Electrical Crossing of railway tracks as prevailing at the
Page 18 of 143

time of construction of line shall be applicable. However, as per existing
Indian Electricity Rules, the minimum clearance is stipulated as 15.40
meters.

3.3.5.3 POWER LINE CROSSING
Minimum clearance between the lowest at power conductor of crossing
line over the crossed line shall be in line with IS 5613 (Part II/ Sec1) as
follows.

Voltage level of crossed line (KV)
Voltage level of
crossing line
(kV) 33 KV 66 KV 132 KV
220
KV
400
KV
800
KV
220KV 4.58m 4.58m 4.58m 4.58m
5.49m
7.94m

3.3.5.4 LIVE METAL CLEARANCE
The minimum live metal clearance to be provided between the live parts
and steel work of super structure shall be as per IS: 5613 (Part-II/Sec-1)
1985 as given below:
Sr.No.
Type of Insulator string
Swing in
degree
Minimum live
metal clearance
in mm
Nil 2130
15 1980
30 1830
45 1675
1.
Single suspension insulator
string
60 -
2. Tension insulator string
Nil 2130
Nil 2130
10 2130
20 1675
3.
Jumper
30 -
Nil 2130
4.
Double suspension string
15 1980
Page 19 of 143

30 1830
45 1675

3.4 Drawings
3.4.1 After award of contract, the contractor shall made proto assembly as per
structural drawing of each type of tower as supplied by employer and get it
inspected and then prepare BOM and shop drawings. The contractor shall
furnish the following in ten (10) copies to the employer for necessary
within fifteen (15) days after approval of drawings.
a Bill of materials, indicating cutting and bending detail against each
member.
b Shop drawings showing all details relevant to fabrication
c. All the drawings for the tower accessories.
d. The contractor should also submit one copy of reproducible drawing/Bill of
materials as mentioned above within 15 days after final approval.
3.4.2 The Contractor is required to submit four copies of the drawings as
mentioned in clause 3.4.1 for employers approval. While submitting the
bill of material and any other drawings pertaining to the subject
transmission line, the Contractor shall clearly indicate on each drawing
PSTCL Specification No., Name of the transmission line and project, letter
reference No. and date on which the submission are made.
3.4.3 The design and drawings as covered in clause above shall be
approved/commented by the Employer as the case may be within 21
(twenty one) days of receipt of designs/drawings in PSTCL Transmission
Design Office. If the design /drawings are commented on by the employer,
the Contractor shall submit 4 sets of revised designs /drawings within 10
(ten) days of date of issue of comments.
3.4.4 The Contractor is required to furnish the progress of submissions and
approvals of drawings on twenty fifth of every month till the completion of
all the design activities.
3.4.5 The details shall include description of drawings, schedule date of
submission, actual date of submission, schedule date of approval, actual
date of approval, schedule date of submission of distribution copies, and
Remarks column. Provision of six additional columns shall also be made
Page 20 of 143

in the above progress report to indicate date of comments issued by the
Employer and details of submission of revised drawings.
3.5 GANTRIES
3.5.1 The entire clauses relating to towers will be relevant for gantries in general
unless otherwise stated.
3.5.2 The structural drawings for gantries will be provided by employer.
3.6 MATERIALS
3.6.1 TOWER STEEL SECTIONS
Indian Standard steel sections of tested quality in conformity with IS:2062
1980 (Grade A), with latest amendments, or any other equivalent grade of
structural steel angle sections and plates conforming to latest International
standard are to be used in towers, extensions and stub setting templates.
Preferably steel sections used should be as supplied by main producer
like SAIL/TISCO/IISCO etc. However, in case of non availability, if
purchased from secondary re-rollers, the re-rollers must ensure use of
billet of main producer used for manufacture of steel section. Also re-roller
should be a reputed manufacturer having ISI certification mark/license on
its product as per IS:2062 Grade-A. PSTCL reserves the right to witness
the rolling process and to test the billets & sections at the premises of the
Re-roller for which all testing facilities shall be ensured by the bidder free
of cost.
3.6.2 FASTENERS: BOLTS, NUTS AND WASHERS
3.6.2.1 All bolts and nuts (including Anti-Theft) shall conform to IS:12427-1988. All
bolts and nuts shall be galvanized as per IS 2629-1985 with coating as per
IS-1367 Part XIII 1983 and shall have hexagonal head (round in case of
Anti-Theft) and nuts, the heads being forged out of the solid steel rods and
shall be truly concentric, and square with the shank, which must be
perfectly straight. In case of Anti-Theft nuts , the shape & size shall be as
per the attached drawing. The difference between the two minimum
measurement from bolt head size edge on bearing face on the shank of
bolt taken for any to opposite side shall not exceed maximum limit of
0.84mm for M16 type bolts .Similarly the difference between the minimum
wall thickness measured between minor thread diameter and the flats of
any 2 opposite sides of nuts shall not exceed the maximum limit of 0.42
Page 21 of 143

mm for M 16 size of nuts .Further the bearing face shall be square to
shank with the tolerance of 2 degree.
3.6.2.2 The bolt shall be of 16 mm dia and of property class 5.6 as specified in IS:
1367 (part-III) 1979 and matching nut of property class 5 as specified in
IS:1367 (Part-VI) 1980.
3.6.2.3 Bolts upto M 16mm and having length upto 10 times the diameter of the
bolts should be manufactured by cold forging and thread rolling process to
obtain good and reliable mechanical properties and effective dimensional
control. The shear strength of bolts for 5.6 grade should be 310-MPa
minimum as per IS:12427, bolts should be provided with washer in
accordance with IS:1363 Part-1 to ensure proper bearing.
3.6.2.4 Nuts should be double chamfered as per the requirement of IS:1363 Part-
III, 1984. The manufacturer should ensure that nuts should not be over-
tapped beyond 0.4mm oversize on effective diameter for size upto M 16.
3.6.2.5 Fully threaded bolts shall not be used. The length of bolts shall be such
that the threaded portion will not extend into the place of contact of the
members.
3.6.2.6 All bolts shall be threaded to take the full depth of the nuts and threaded
for enough to permit firm gripping of the members, but not further. It shall
be ensured that the threaded portion of each bolt protrudes not less than
3mm and not more that 8 mm when fully tightened. All nuts shall fit and
tight to the point where the shank of the bolt connects to the head.
3.6.2.7 Flat and tapered washers shall be provided wherever necessary. Spring
washers shall be provided for insertion under all nuts. These washers shall
be of spring steel electro-galvanised steel, positive lock type and 3.5mm
in thickness for 16-mm dia bolt as per IS 3063 (latest edition)
3.6.2.8 To obviate bending stress in bolts or to reduce it to minimum, no bolt shall
connect aggregate thickness of more than three (3) times its diameter.
3.6.2.9 The bolt position in assembled towers shall be as per IS:5613 (Part-
II/Section-2-1976).
3.6.2.10 Bolts at the joints shall be so staggered that nuts may be tightened with
spanners without fouling.
3.6.2.11 The bidder shall use Anti-Theft nuts & bolts on the first storey of the tower
(Drg. attached)
Page 22 of 143

3.6.2.12 To ensure effective in-process Quality control, it is essential that the
manufacturer should have all the testing facilities for tests like weight of
zinc coating, shear strength, other testing facilities etc. in house. The bolts
should have ISI certification mark as per IS 12427-988 & Nuts as per
1363-Part III-1984 with latest amendments.
3.7 Tower Accessories
3.7.1 Step Bolts
Each tower shall be provided with step bolts conforming to IS:10238 of not
less than 16mm diameter and 175 mm long, spaced not more than 450
mm apart and extending from about 3.5metres above the ground level to
the top of the tower. For double circuit tower the step bolt shall be fixed on
one leg from 3.5M above ground level to top of the towers. Each step bolt
shall be provided with two nuts on one end to fasten the bolt securely to
the tower and button head at the other end to prevent the feet from
slipping away. The step bolts shall be capable of withstanding a vertical
load not less than 1.5 KN.
3.7.2 Insulator Strings and Earthwire Clamps Attachments
a. Suspension Insulator string assemblies under the bidders scope of supply
shall be used for suspension towers as per drawings enclosed with
Specification. For the attachment of suspension insulator string, a
swinging D-Shackle on the tower shall be provided as per drawings
enclosed with Specification. The supply of D-shackle is within scope of the
Bidder.
b. At tension towers, strain plates of suitable dimensions on the underside of
each cross arm tip and at the top of earthwire peak should be provided for
taking the hooks or D-Shackle of the tension insulator strings or earthwire
tension clamps, as the case may be.
3.7.3 Earthwire Clamps
a Suspension clamp :Earthwire suspension clamps will be supplied by the
bidder as per the reference drawing enclosed with specification.
b Tension Clamps:The bidder shall supply earthwire tension clamps for use
on the towers. The reference drawings for the same is enclosed with the
specification. However, the contractor shall supply the U-bolts wherever
required.
3.7.4 Anticlimbing Device
Page 23 of 143

Anticlimbing device/fencing as per enclosed drawings shall be provided
and installed by the Contractor for all towers/gantries. The height of the
anticlimbing device shall be provided approximately 3m above ground
level.
3.7.5 Danger, Number, Circuit and Phase plate
Danger, Number, Circuit and Phase Plates shall be provided and
installed by the Contractor with design & shape as per relevant IS.
a) Each tower shall be fitted with a number plate and danger plate. Each
tension tower shall be provided with a set of phase plates also. All the
double circuit towers are to be provided with circuit plate fixed near the
legs.
b) The letters, figures and the conventional skull and bones of danger plates
shall conform to IS:2551-1963 and shall be in a single red on the front of
the plate.

3.7.6 Bird Guards
To prevent birds perching immediately above the suspension insulator
strings and fouling the same with droppings, suitable bird guards shall be
provided at cross arm tips of all suspension towers. The bird guard
arrangement shall be such that it shall either prevent bird from perching in
position where they are liable to cause the damages or ensure that if birds
do perch, droppings will fall clear of the insulator string.
3.7.7 Aviation Requirements
3.7.7.1 The river crossing towers and any other towers in the vicinity of airport
shall be painted and the crossing span shall be provided with markers to
caution the low flying aircraft as per statutory provisions.
3.7.7.2 The full length of the towers shall be painted over the galvanized surface
in contrasting bands of orange or red and white. The bands shall be
horizontal. The width of the colour band shall be as per the relevant
aviation regulation clauses, prevalent at the time of execution of the
project.
a) Surface Preparation
The etching of galvanized surface of erected tower members with suitable
etching or wash primer is to be done as per IS:1477-1977 to enhance the
Page 24 of 143

adhesion of subsequently applied paint coating. After etching of
galvanized surface of tower one coat of zinc primer is to be applied.
b) Painting of Towers
Two coats of international orange or red and white paint at alternate
interval (bands) as explained above are to be applied. The painting of
towers shall generally confirm to relevant provisions in IS:1477-1977 Part I
& II. The paints to be used for painting shall be in accordance with
IS:2074-1962 with latest amendment.
c) Span Markers
Sphere type span marker of 600 mm diameter shall be provided on the
earthwire. The sphere shall be vertically divided into four quadrants and
each quadrants shall be alternatively painted in orange or red and white.
These markers shall be suspended from earthwire at interval of 36 meters.
The design of the markers and their fixing arrangement should be such
that they can withstand the wind pressure and shall not induce excessive
amount of vibration strain on earthwire. Detail of this arrangement shall be
submitted by the bidder along with Bid.
3.8 Tower Fabrication
The fabrication of towers shall be in conformity with the following:
3.8.1 Except where hereinafter modified, details of fabrication shall conform to
IS:802 (Part-II) 1978, with latest amendments or the relevant international
standards.
3.8.2 Butt splices shall be used and the inside cleat Angle and outside plate
shall be designed to transmit the load. The inside cleat Angle shall not be
less than half the thickness of the heavier member connected plus 2mm.
Lap splice may be used for connecting members of unequal size and the
inside angle of lap splice shall be rounded at the heel to fit the fillet of the
outside angle. All splices shall develop full stress in the member
connected through bolts. Butt as well as lap splice shall be made as above
and as close to the main panel point as possible. Pack plates of 3mm and
4mm thick can be used as per IS:1079 (1994) grade 0.
3.8.3 The use of filler in connection shall be avoided as far as possible. The
diagonal web members in tension may be connected entirely to the gusset
plate wherever necessary to avoid the use of filler and it shall be
connected at the point of intersection by one or more bolts.
Page 25 of 143

3.8.4 The tower structures shall be accurately fabricated to connect together
easily at site without any undue strain on the bolts.
3.8.5 All similar parts shall be made strictly inter-changeable. All steel sections
before any work is done on them, shall be carefully leveled, straightened
and made true to detailed drawings by methods that will not injure the
materials so that when assembled, the adjacent matching surfaces are in
close contact throughout. No rough edges shall be permitted in the entire
structure.
3.8.6 Drilling and Punching
3.8.7.1 Before cutting work is started, all steel sections shall be carefully
straightened and trued by pressure and not by hammering. They shall
again be trued after being punched and drilled.
3.8.7.2 Holes for bolts shall be drilled or punched with a jig but drilled holes shall
be preferred. Punching may be adopted for thicknesses upto 16mm.
Tolerances regarding punched holes are as follows:
a. Holes must be perfectly circular and no tolerance in this respect is
permissible.
b. The maximum allowable difference in diameter of the holes on the two
sides of plates or angle is 0.8mm i.e. the allowable taper in a punched
hole should not exceed 0.8mm in diameter.
c. Holes must be square with the plates or angles and have their walls
parallel.
3.8.7.3 All burrs left by drills or punch shall be removed completely. When the
tower members are in position, the holes shall be truly opposite to each
other. Drilling or reaming to enlarge holes shall not be permitted.
3.8.8 Erection mark
3.8.8.1 Each individual member shall have an erection mark conforming to the
component number given to it in the fabrication drawings. This mark shall
be made with marking dies of 16mm size before galvanising and shall be
legible after galvanising.
3.8.8.2 Erection Mark shall be
A-BB-CC-DDD
Where
A = Employers code assigned to the Contractor-Alphabet
BB = Contractors Mark-Numerical
Page 26 of 143

CC = Tower Type-Alphabet
DDD = Number mark assigned-Numerical.
3.8.9 Quantities and Weights
3.8.9.1 The provisional quantities required are mentioned in the schedule of
Prices. Final quantities shall be determined after completion and approval
of the detailed route survey. The final quantities of tower and line materials
shall be confirmed by the Employer based on the requirement of quantities
of various towers furnished by the Contractor after completion of detailed
survey. Hence, it will be responsibility of the Contractor to intimate the
exact requirements of all towers and various line materials required for line
immediately after the survey as per the attached Bill of Quantities (BOQ)
sheets. The Employer will order the final quantities at the unit rates quoted
in the Bid.
3.8.9.2 The estimated weight of tower material and Bolts & Nuts , given in Price
Schedules, is based on unit weight of each type of tower, stubs and
extensions as well as bolts and nuts along with spring washers and step
bolts to be supplied by the contractor .The weight of tower shall mean the
weight of tower calculated by using the black sectional (i.e. ungalvanised)
weight of steel members of the size indicated in the approved fabrication
drawings and bills of materials, without taking into consideration the
reduction in weights due to holes, notches and bevel cuts etc.The
payment of complete tower structure / Stub Set shall be made which will
include the weight of the structural members including pack washers, D-
shackle, U- Bolt & links to complete the tower / Stub Set as per the weight
of the respective item mentioned in the respective approved Bill of
Material. But anti climbing devices including cleats and barbed wire shall
be covered in ACD set, however, the procedure of calculation of weights
of cleat shall remain the same.
3.9 Galvanising
Fully galvanised towers and stub (partly galvanised) shall be used for the
lines. Galvanising of the member of the towers shall conform to IS:2629-
1985 and IS:4759-1968. All galavanised members shall withstand tests as
per IS:2633-1986. For fasteners, the galvanising shall conform to IS:1367
(Part-13). The galvanising shall be done after all fabrication work is
completed, except that the nuts may be tapped or re-run after galvanising.
Page 27 of 143

Threads of 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. Spring
washers shall be electro-galvanised as per Grade 4 of IS: 1573-1970.
3.10 Earthing
3.10.1 The footing resistance of all towers shall be measured by the Contractor in
dry weather after tower erection but before the stringing of earthwire. All
the towers are to be earthed, however, in no case tower footing resistance
shall exceed 10 ohms. Pipe type earthing and counterpoise type earthing
wherever required shall be provided in accordance with the stipulations
made in IS:3043-1987 and IS:5613 (Part-II/Section-2) 1985. The details
for pipe and counterpoise type earthing are given in drawing enclosed with
the specification.
3.10.2 The provisional quantities for pipe type earthing and counterpoise earthing
are furnished in Price Schedule. The Bidders are required to furnish unit
rates also for adjustment purpose with actual quantities. The quoted price
shall include fabrication, supply and installation of earthing material
including supply of coke, salt etc. In case of counterpoise type earthing,
the quotation shall be based on 100 meters of wire per tower.
3.11 Inspection and Tests
3.11.1 General
All standard tests, including quality control tests, in accordance with
appropriate Indian/International standard, shall be carried out unless
otherwise specified herein.
3.11.2 Inspection
In addition to the provision of Clause regarding Inspection in General
conditions, the following shall also apply:
3.11.2.1
a) The Contractor shall keep the Employer informed in advance about the
time of starting and of the progress of manufacture and fabrication of
various tower parts at various stages, so that arrangements can be made
for inspection.
b) The acceptance of any part of items, with or without inspection, shall in no
way relieve the Contractor of any part of his responsibility for meeting all
the requirements of the Specification.
Page 28 of 143

3.11.2.2 The Employer or his representative shall have free access at all
reasonable times to those parts of the Contractors works which are
concerned with the fabrication of the Employers material for satisfying
himself that the fabrication is being done in accordance with the provisions
of the specifications.
3.11.2.3 Unless specified otherwise, inspection shall be made at the place of
manufacture prior to despatch and shall be conducted so as not to
interfere unnecessarily with the operation of the work.
PSTCL reserves the right to re-inspect the material after it has reached
the site / has been erected to check that the material inspected has
reached the site and / or erected.
3.11.2.4 Should any member of the structure be found not to comply with the
approved design, it shall be liable to rejection. No member once rejected
shall be resubmitted for inspection, except in cases where the Employer or
his authorised representative considers that the defects can be rectified.
3.11.2.5 Defect which may appear during fabrication shall be made good with the
consent of and according to the procedure proposed by the Contractor and
approved by the Employer.
3.11.2.6 All gauges and templates necessary to satisfy the Employer shall be
supplied by the Manufacturer.
3.11.2.7 The correct grade and quality of steel shall be used by the Contractor. To
ascertain the quality of steel used, the inspector may at his discretion get
the material tested at an approved laboratory.
3.12 Packing
3.12.1 Angle section shall be wire bundled.
3.12.2 Cleat angles, gusset plates, brackets, fillet plate and similar loose pieces
shall be securely wired in multiples through holes.
3.12.3 Bolts, nuts, washers and other attachments shall be packed in double
gunny bags accurately tagged in accordance with the contents.
3.12.4 The packing shall be properly done to avoid losses/damages during
transit. Each bundle or package shall be appropriately marked.
3.13 Standards
3.13.1 The manufacturing, fabrication, galvanising, testing, erection procedure
and materials used for manufacture and erection of towers, design and
construction of foundations shall conform to the following Indian Standards
Page 29 of 143

(IS)/International Standards which shall mean latest revisions, with
amendments/changes adopted and published, unless specifically stated
otherwise in the specification. In the event of supply of material to
Standards other than specified, the Bidder shall confirm in his bid that
these 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 document will be provided by the
Contractor to establish their equivalence.
3.13.2 The material and services covered under these specifications shall be
performed as per requirements of the relevant standards/codes (with latest
revision) referred hereinafter against each set of equipment and services.
Other Internationally acceptable standards which ensure equal or higher
performance than those specified shall also be accepted.

Sr.
No.
Indian
Standards
Title International &
Internationally
recognized
Standards.
1. IS:209-Rev Specification for Zinc. ISO/R/752-1968
ASTM B6
2. IS:2062-1992 Steel for general structural
purpose.

3. IS:269-1976 Ordinary rapid hardening & low
heat Portland Cement.
ISO/R/597-1967
4. IS:383-1970 Coarse and find aggregates
from natural sources for
concrete.
CSA A23.1/A
23.2
5. IS:432-1966
(Part I&II)
Mild steel and medium tensile
bars and hard drawn steel wire
for concrete reinforcement.
BS-785-1938
CSA-G-30
6. IS:456-1978 Code of practice for plain and
reinforced concrete.

ISO/3893-1977
7. IS:800-1962 Code of practice for use of
structural steel in general
Building construction.
CSA S 16.1
8. a) IS:802

b)IS:802 (Part-
II)-1978

Code of Practice for use of
structural steel in overhead
transmission Line:
Part 1: Load and Permissible
stresses.
transmission line:
Fabrication, Galvanising,
IEC 826
ASCE 52
BS 8100

ACSE 52

Page 30 of 143

c) IS:802 Part-
III-1978

Inspection and packing.

transmission line towers:
Testing.

ASCE 52
9 IS:808 Dimensions for Hot Rolled
steel Beam, Column channel
and Angle sections.

10 IS:875 Code of practice for design
loads (other than earthquakes)
for Buildings & structures.

11. IS:1139-1966 Hot rolled mild steel, medium
tensile steel and high yield
strength deformed bars for
concrete reinforcements.
CAN/CSA
G 30.18
ASTM A615.
12. IS:1367-1967 Technical supply conditions for
threaded fasteners.(First
Revision).

13. IS:1489-1976 Portland Pozzolena Cement. ISO/R/863-1968
14. IS:1786-1966 Cold twisted steel bars for
concrete reinforcement.

15. IS:1893-1965 Criteria of Earthquake resistant
design of structures.
IEEE 693
16. IS:2016-1967 Plain Washers ISO/R/887-1968.
Ansi B 18.22.1
17. IS:2131-1967 Method of Standard
penetration test for soils.
ASTM D 1883.
18. IS:2251-1982 Danger Notice Plates.
19. IS:2629-1966 Recommended practice for hot
dip galvanising of iron & Steel.
ASTM A 123
CAN/CSA G 164
20. IS:2633-1972 Method of testing uniformity of
coating of zinc coated articles.
ASTM A 123
CAN/CSA G 164.
21 IS:3043-1972 Code of Practice for earthing
(with amendment No. 1 &2).

22. IS:3063-1972 Single Coil Rectangular
Section spring washers for
bolts, nuts, screws.
DIN-127-1970
23. IS:4091-1967 Code of practice for design
and construction of foundation
for transmission line towers
and poles.
ASCE/ IEEE 691
24. IS:5358-1969 Hot dip galvanized coatings on
fasteners.
ASTM A 153
CAN/CSA G 164.
25. IS:5613(Part-
II/Sec-1)1976
Code of practice for Design,
installation & maintenance of
overhead power lines(Section-
1: Designs).
ASCE 52.
26. IS:5613 (Part-
II/Sec-2)-1976
Code of practice for Design,
installation & maintenance of
over head power lines(Section

Page 31 of 143

2: installation & Maintenance).
27. IS: 6610-1972 Specification for heavy
washers for steel structures.

28. IS:6639-1972 Hexagonal bolts for steel
structures.
ASTM A 394
CSA B 33.4
29. IS:6745-1972 Methods for determination of
weight of zinc coating of zinc
coated iron and stel articles.
ASTM A90
30. Indian Electricity Rules-1956/
Electricity Act-2003.

31. Publication
No.19(N)/700-
1963
Regulation for Electrical
Crossing of Railway Tracks.

32. IS:8500-1977 Specification for weldable
structural steel(Medium and
High strength qualities).
BS:4360

4 Tower Foundations
4.1 Foundation Types
4.2.1 General
These specifications provide general guide lines for towers for
construction of foundations for transmission and gantry towers for the
transmission lines covered in the tender. The foundation shall be
constructed as per design/drawings to be supplied by the employer.
Drawings for foundations of various tower type upto 6 mtr. extension and
gantry towers are attached.
4.2.2 Before start of work, trial bore holes upto 6 mtr. below ground level shall
be carried out by successful bidder at every kilometer or as desired by
employer. The bore log data comprising of information like position of sub
soil water table, soil strata shall be submitted to the employer for
classification of foundation type to be provided at each location.
4.2.3 Reinforced Cement concrete or special foundations shall be used for all
types of normal towers in conformity with the present day practice followed
in the country and the specifications laid herein. All the four footings of the
tower and their extension shall be similar, irrespective of down thrust and
uplift.

Foundation includes supply of materials such as cement, reinforcement
steel, sand, coarse aggregates etc. Rates quoted for foundations in
appropriate schedules shall include all items of work related to supply and
Page 32 of 143

installation of foundations such as form work, excavation and backfilling,
stub setting, providing reinforcement etc.

4.2.4 Classifications of Foundations
The foundation designs shall depend upon the type of soil, sub-soil water
level and the presence of surface water which have been classified as
follows:
4.2.4.1 Normal dry
To be used for locations where normal dry cohesive or non-cohesive soils
are met & water table is at a depth equal to or more than the width of the
foundation below the foundation level.
4.2.4.2 Partially submerged
To be used at locations where sub-soil water table is met between 0.75 m
to 1.5 m below the ground level.
4.2.2.3 Fully Submerged:
To be used at locations where sub-soil water table is met at less than 0.75
m below ground level.
4.2.2.4 Special Foundation:
For the locations not covered above, the contractor shall refer to employer
soil details/ test results from a Govt. approved test house. The employer
will supply the result.
4.2.3 Properties of concrete & Reinforcement.
The cement concrete used for the foundations shall be of grade M-20.
All the properties of concrete regarding its strength under compression,
tension, shear, punching and bend etc as well as workmanship will
conform to IS:456-1978 (with latest amendments).
4.2.3.1 The Portland Cement used in concrete shall conform to IS:269-1967.
The Pozzolena cement used in concrete shall conform to IS:1489-1976.
4.2.3.2 Concrete aggregates shall conform to IS:383-1970
4.2.3.3 The water used for mixing concrete shall be fresh, clean and free from oil,
acids and alkalies, organic materials or other deleterious substances.
Potable water is generally preferred.
4.2.3.4 Reinforcement shall conform to IS:432-1966 for M.S. bars and hard drawn
steel wires and IS:1139-1966 and IS:1786-1966 for deformed and cold
twisted bars respectively. All reinforcement shall be clean and free from
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loose mill scales, dust, loose rust, and coats of paint, oil or other coatings,
which may destroy or reduce bond. Contractor shall supply, fabricate and
place reinforcement too shapes and dimensions and indicated or as
required to carry out the intent of drawings and specifications. Only one
type of steel shall be used for the design.
4.3 Design of foundations
The employer will provide the complete design of the foundation. Normally
following type of foundations are laid as per prevailing practice in PSTCL.
1 RCC open pit dry type
2 Semi Submerged type : Is laid where sub soil water is not permanent
and as such does not hinder in lying of foundations therefore the
foundation may be laid without de-watering otherwise de-watering is
required.
3 Fully Submerged : This foundations will cover de-watering etc. for lying
of this foundation.
4.3.1 Unit rates and measurements
The bidders are required to furnish unit rates in the Price Schedule.
4.3.1.1 The scope of work for foundation per tower shall include excavation, stub
setting, concreting, reinforcement, if any, timbering & shoring, shuttering,
dewatering, stock-pilling, dressing, curing, backfilling the foundation after
concreting with excavated/borrowed earth (irrespective of leads) and
consolidation of earth, carriage of surplus earth to the suitable point of
disposal as required by the Employer or any other activities related to
completion of foundation works.
4.3.1.2 The excavation volumes for each tower footing shall be estimated
assuming the faces of surrounding earth as vertical keeping a distance of
150mm clearance from the extreme edge of the base slab of footing.
4.3.1.3 The concrete volume and dimensions of the foundation shall be
determined from the PSTCL drawings. Measurement of concrete volume
shall be in cubic meters and shall be worked out to the second place of
decimal.
4.3.1.4 The Contractor shall provide the steel required for reinforcement of special
foundation. Measurement will be based on the calculated weights of steel
actually used in MT corrected to third place of decimal, no allowance being
made for wastage. No payments will be made for wire required for binding
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the reinforcement chairs, bolsters and spacers, as the cost of these is
deemed to be included in the unit rate quoted for the item of
reinforcement.
4.4 Construction of Tower Foundations
4.4.1 Excavation
4.4.1.1 Excavation work must not be started until the tower schedule and profile
has been approved by the Employer.
4.4.1.2 Except as specifically otherwise provided, all excavation for footing shall
be made to the lines and grades of the foundation. The excavation wall
shall be vertical and the pit dimensions shall be such as to allow a
clearance of 150 mm on all sides from the foundation pad. The Contractor
should ensure clearance of 150 mm from the foundation pad for quality
work. All excavation shall be protected so as to maintain a clean
subgrade, until the footing is placed, using timbering/ shuttering, shoring
etc., if necessary. Any sand, mud, silt or other undesirable materials which
may accumulate in the excavated pit shall be removed by the Contractor
before placing concrete. The water table shall be kept 0.5m below the
footing level for 24 hrs.from the last hour of concrete is placed.
4.4.1.3 No extra charge shall be admissible for the removal of the fallen earth in
the pit, when once excavated. Shoring and timbering/ shuttering as
approved by authorized representative of the Employer shall be provided
by the Contractor when the soil condition is so bad that there is likelihood
of accident due to the falling of earth.
4.4.2 Setting of Stubs
4.4.2.1 The stubs shall be set correctly in accordance with standard methods at
the exact location and alignment and precisely at correct levels with the
help of stub setting template and leveling instrument. Stubs shall be set in
the presence of Employers representative available at site and for which
adequate advance intimation shall be given to the Employer by the
Contractor. All precautions shall be taken that stubs once finally set are
not disturb. If these are disturbed due to any reasons the same shall be
re-set in the presence of Employers representative without any extra cost.
4.4.2.2 The Employers representative shall approve setting of stub at each
location.
4.4.4 Stub setting template
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4.4.4.1 Stub setting template shall be arranged by the contractor at his cost for all
types of tower with or without extension as per approved drawings. The
stub templates shall be red oxide painted.
4.4.4.2 The contractor will furnish sufficient number of templates for the timely
completion of line without any extra cost to employer.
4.4.4.3 Following number of stub setting templates shall be deployed by the
contractor for each Package:

Template For Tower Type Nos to be deployed
For A Type 12 Nos
For each of B and C Type 3 Nos each

However, if employer feels that more number of templates are
required for a timely completion of a particular line the contractor shall
have to deploy the same without any extra cost to employer.
4.4.5 MIXING, PLACING AND COMPACTING OF CONCRETE
4.4.5.1 The concrete shall be mixed in a mechanical mixer. However, in case of
difficult terrain hand mixing may be permitted at the discretion of
Employer. In case of hand mixing 10% extra cement shall be used without
any extra cost. The water for mixing concrete shall be fresh, clean and
free from oil, acids and alkalies. Saltish or blackish water shall not be
used.
4.4.5.2 Mixing shall be continued until there is uniform distribution of material and
the mix is uniform in colour and consistency, but in no case the mixing be
done for less than two minutes. Normally mixing shall be done close to the
foundation, but in case it is not possible, the concrete may be mixed at the
nearest convenient place. The concrete shall be transported from the
place of mixing to the place of final deposit as rapidly as practicable by
methods, which shall prevent the segregation or loss of any ingredient.
The concrete shall be placed and compacted before setting commences.
4.4.5.3 Form boxes shall be used for casting all type of foundations. The concrete
shall be laid down in 150 mm layers and consolidated well, so that the
cement cream works upto the top and no honey-combing is left in the
concrete. The mechanical vibrator shall be employed for compaction of
the concrete. However, in case of difficult terrain, manual compaction may
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be permitted at the discretion of Employer. After concreting the chimney
portion to the required height, the top surface should be finished smooth
with a slight slope towards the outer edge, to drain off any rainwater falling
on the coping.
4.4.5.4 In wet locations, the site must be kept complete dewatered, both during
the placing of the concrete and for 24 hours thereafter. There should be
no disturbance of concrete by water during this period.
4.4.5.5 After the formwork has been removed if the concrete surface is found to
be defective, the damage shall be repaired with rich cement and sand
mortar to the satisfaction of the Employers representative before the
foundation pits are backfilled at no extra cost.

4.4.6 Back-Filling and Removal of Stub Template
4.4.6.1 After opening of form work and removal of shoring and timbering, if any,
backfilling shall be started, after repairs, if any, to the foundation concrete.
Backfilling shall normally be done with excavated soil, unless it consists of
large boulders/stones, in which case the boulders shall be broken to a
maximum size of 80 mm. At such locations where borrowed earth is
required for backfilling, this shall be done by the Contractor at his own
cost, irrespective of lead.
4.4.6.2 The backfilling materials should be clean and free from organic or other
foreign materials. The earth shall be deposited in maximum 200 mm
layers, leveled and wetted and tampered properly before another layer is
deposited. Care shall be taken that the backfilling is started from the
foundation ends of the pits, towards the outer ends. After the pits have
been backfilled to full depth, the stub template may be removed.
4.4.6.3 The backfilling and grading shall be carried to an elevation of about 75
mm above the finished ground level to drain out water. After backfilling 50
mm high earthen embankment (bandh) will be made along the sides of
excavation pits and sufficient water will be poured in the backfilled earth
for at least 24 hours.
4.4.7 Curing
The concrete after setting for 24 hours shall be cured by keeping the
concrete wet continuously for a period of 10 days after laying. The pit may
be back filled with selected earth sprinkled with necessary amount of
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water and well consolidated in layers not exceeding 200 mm of
consolidated thickness after minimum period of 24 hours and thereafter
both the backfilled earth and exposed chimney top shall be kept wet for
the remainder of the prescribed time of 10 days. The uncovered concrete
chimney above the backfilled earth shall be kept wet by providing empty
cement bags dipped in water fully wrapped around the concrete chimney
for curing and ensuring that the bags are kept wet by the frequent pouring
of water on them.
4.4.8 Benching
When the line passes through hilly/undulated terrain, for a few tower
locations it may be required to level the ground for casting of tower
footings on same elevation. All the activities related to make the required
area of ground in same elevation for casting of foundation, shall be termed
as benching work. Benching work shall include cutting of excess earth and
removing the same to a suitable point of disposal as required by the
Employer. Benching shall be resorted to only after getting specific
approval from the Employer. Volume of the earth to be cut shall be
measured before cutting and got approved from the Employer. This
volume of earth shall be considered for the purpose of payment against
the head of benching work.
4.4.9 Protection of Tower Footing
4.4.9.1 The work shall include all necessary brick, stone masonry (in cement
mixture 1:5) revetments, concreting and earth filling above ground level
and the clearance from stacking on the site of all surplus excavated soil,
special measures for protection of foundation close to or in nallahas, river
bed hilly/undulated terrain etc, wherever required shall be done after
getting prior approval of the Employer.
4.4.9.2 The quantity of excavated earth obtained from a particular location shall
generally be utilised in back-filling work in protection of tower footing of
same location, unless it is unsuitable for such purpose. In the latter case,
the back filling shall be done with borrowed earth of suitable quality
irrespective of lead and the same shall be to the contractors account.
4.4.9.3 The unit rates shall be applicable for adjusting with the actual quantities of
protection works done.
5. Tower Erection, Stringing and Installation of Line Materials
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5.1 General
5.1.1 The details of the scope of erection work shall include the cost of labour,
all tools and plants and all other incidental expenses in connection with
erection and stringing work.
5.1.2 The Contractor shall be responsible for transportation of all the materials
to be provided by the Contractor as per the scope of work to site, proper
storage and preservation at their own cost till such time the erected line is
taken over by the Employer. The Contractor shall be responsible for
transportation, proper storage, safe custody, loss or damage of all
supplied items for incorporation in the lines and shall maintain and render
proper account for all such materials at all times.

5.1.3 Contractor shall set up required number of stores along the line at his own
cost and the exact location of such stores shall be discussed and agreed
to between the Contractor and the Employer. The employer shall not be
liable for any unpaid rents of the space taken for storing of material or any
damage or liability arising out of such arrangement.
5.2 Treatment of Minor Galvanising Damage
In case any minor damage to galvanising is noticed, the same shall be
treated with zinc rich paint (commercial grade) (having at least 90% zinc
content) before erection.
5.3 Assembly
5.3.1 The method followed for the erection of towers, shall ensure the points
mentioned below:
(a) Straining of the members shall not be permitted for bringing them into
position. It may, however, be necessary to match hole positions at joints
and to facilitate this, tommy bars not more than 450 mm long may be
used.
(b) Before starting erection of an upper section, the lower section shall be
completely braced and all bolts provided and tightened adequately in
accordance with approved drawings to prevent any mishap during tower
erection.
(c) All plan diagonals relevant to a section of tower shall be placed in position
before assembly of upper section is taken up.
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(d) The bolt position in assembled towers shall be as per IS:5613 (Part-
II/Section 2)-1976.
(e) Tower shall be fitted with number plate, danger plate, phase plate, circuit
plate and anti climbing device as described.
(f) All blank holes, if any left, after complete erection of the tower, are to be
filled up by bolts and nuts of correct size.
5.4 Tightening and Punching of Bolts and Nuts
5.4.1 All nuts shall be tightened properly using correct size spanner/torque
wrench. Before tightening, it will be seen that filler washers and plates are
placed in gaps between members wherever applicable bolts of proper size
and length are inserted, and one spring washer is inserted under each nut.
In case of step bolts, spring washers shall be placed under the outer nut.
The tightening shall progressively be carried out from the top downwards,
care being taken that all bolts at every level are tightened simultaneously.
The threads of bolts projecting outside the nuts shall be punched at their
position on the diameter to ensure that the nuts are not loosened in course
of time. If during tightening a nut is found to be slipping or running over the
bolt threads, the bolt together with the nut shall be replaced.
5.4.2 Anti-Theft type nuts & bolts shall be provided upto first storey of tower to
avoid pilferage of tower members.
5.5 Insulator Hoisting
5.5.1 Suspension insulator strings shall be used on suspension towers and
tension insulator strings on angle and dead end towers. These shall be
fixed on all the towers just prior to the stringing. Damaged insulators and
fittings, if any, shall not be employed in the assemblies. Before hoisting, all
insulators shall be cleaned in a manner that will not spoil, injure or scratch
the surface of the insulator, but in no case shall any oil be used for the
purpose. Torque wrench shall be used for fixing different line materials
and their components, like suspension clamp for conductor and earthwire
etc.
5.6 Handling of Conductor and Earthwire
5.6.1 The Contractor shall be entirely responsible for any damage to the towers
or conductors during stringing. While running out the conductors, care
shall be taken that the conductors do not touch or rub against the ground
or objects, which could cause scratches or damages to the strands. The
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conductors shall be run out of the drums from the top in order to avoid
damage due to chafing. Immediately after running out, the conductor shall
be raised at the supports to the levels of the clamps and placed into the
running blocks. The groove of the running blocks shall be of such a design
that the seat is semi-circular and larger than the diameter of the
conductor/earthwire and it does not slip over or rub against the sides. The
grooves shall be lined with hard rubber or neoprene to avoid damage to
conductor and shall be mounted on properly lubricated bearings.
5.6.2 The running blocks shall be suspended in a manner to suit the design of
the cross arm. All running blocks, especially those at the tension end, will
be fitted on the cross-arm with jute cloth wrapped over the steel work and
under the slings to avoid damage to the slings as well as to the protective
surface finish of the steel work. In case suspension, or section towers are
used even for temporary terminations, if this be unavoidable, they shall be
well guyed and steps shall be taken by the Contractor to avoid damage.
Guying proposal alongwith necessary calculations shall be submitted by
the Contractor to Employer for the approval. Proper T&P shall also be
made available to the Employer by the Contractor for checking the
tensions in the guy wires. The drums shall be provided with a suitable
braking device to avoid damages, loose running out and kinking of the
conductor. The conductor shall be continuously observed for loose or
broken strands or any other damage. When approaching end of a drum
length, at least three coils shall be left when the stringing operations are to
be stopped. These coils are to be removed carefully, and if another length
is required to be run out, a joint shall be made as per the
recommendations of the manufacturers.
5.6.3 Repairs to conductors, if necessary, shall be carried out during the running
out operations, with repair sleeves. Repairing of conductor surface shall
be done only in case of minor damage, scuff marks etc. keeping in view
both electrical and mechanical safe requirements. The final conductor
surface shall be clean smooth and without any projections, sharp points,
cuts, abrasions etc.
5.6.4 Conductor splices shall be so made that they do not crack or get damaged
in the stringing operation. The Contractor shall use only such
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equipment/methods during conductor stringing which ensures complete
compliance in this regard.
5.6.5 Derricks shall be used where roads, rivers, channels, telecommunication
or overhead power lines, railway lines, fences or walls have to be crossed
during stringing operations. It shall be seen that normal services are not
interrupted or damage caused to property. Shut down shall be obtained
when working at crossing of overhead power lines. The Contractor shall
be entirely responsible for the proper handling of the conductor, earthwire
and accessories in the field.

5.6.6 The sequence of running out shall be from top to downwards i.e. the
earthwire shall be run out first, followed by the conductors in succession.
Unbalances of loads on towers shall be avoided as far as possible.
5.6.7 The proposed transmission line may run parallel for certain distance with
the existing Transmission lines, which may remain, energised during the
stringing period. As a result there is a possibility of dangerous voltage
build up due to electromagnetic and electrostatic coupling in the pulling
wire, conductors and earthwires which although comparatively small
during normal operations can be severe during switching. It shall be the
Contractors responsibility to take adequate safety precautions to protect
his employees and others from this potential danger.
5.6.8 Towers during stringing shall be well guyed and steps may be taken by
Contractor to avoid damage. Proper T&P shall be made available to the
Employer by the Contractor for checking the tensions in the guy wires. All
the expenditure on account of the above work is deemed to be included in
the bid price and no extra payment shall be made for the same.
5.7 STRINGING OF CONDUCTOR AND EARTHWIRE
5.7.1 The stringing of the conductor shall be done by standard stringing method.
5.7.2 After being pulled, the conductor/earthwire shall not be allowed to hang in
the stringing blocks for more than 96 hours before being pulled to the
specified sag.
5.7.3 The stringing of Conductor shall be done as per initial stringing chart
provided by the Employer.
5.8 JOINTING
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5.8.1 All the joints on the conductor and earthwire shall be compression type, in
accordance with the recommendations of the manufacturer for which all
necessary tools and equipment like compressors, dies, processes etc.
shall have to be arranged by the Contractor. Each part of the joint shall be
cleaned by wire brush to make it free from rust or dirt etc. and properly
greased with anti corrosive compound if required, and as recommended
by the Contractor before the final compression is done with the
compressors.
5.8.2 All joints or splices shall be made at least 30 metres away from the
structures. No joints or splices shall be made in spans crossing over main
roads, Railways, small rivers with tension spans. During compression or
splicing operation the conductor shall be handled in such a manner as to
prevent lateral or vertical bearing against the dies. After pressing the joint
the aluminium sleeve shall have all corners rounded, burrs and sharp
edges removed and smoothened.
5.8.3 During stringing of conductor to avoid any damage to the joint, the
Contractor shall use a suitable protector with mid span compression joints
in case joints are to be passed over pulley blocks/aerial rollers. The size of
the groove of the pulley shall be such that the joint alongwith protection
can be passed over it smoothly.
5.9 Sagging-in-Operation
5.9.1 The conductor shall be pulled upto the desired sag and left in running
blocks for atleast one hour after which the sag shall be re-checked and
adjusted, if necessary before transferring the conductors from the running
blocks to the suspension clamps. The conductors shall be clamped within
36 hours of sagging in.
5.9.2 The sag will be checked in the first and the last span of the section in case
of sections upto eight spans and in one intermediate span also for
sections with more than eight spans. The sag shall also be checked when
the conductors have been drawn up and transferred from running blocks
to the insulator clamps.
5.9.3 The running blocks, when suspended from the transmission structure for
sagging shall be so adjusted that the conductors on running blocks will be
at the same height as the suspension clamp to which it is to be secured.
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5.9.4 At sharp vertical angles, the sags and tensions shall be checked on both
sides of the angle, the conductor and earthwire shall be checked on the
running blocks for equality of tension on both sides. The suspension
insulator assemblies will normally assume vertical positions when the
conductor is clamped.
5.9.5 Tensioning and sagging operations shall be carried out in calm weather
when rapid changes in temperatures are not likely to occur.
5.10 Tensioning and Sagging of Conductors and Earthwire
The tensioning and sagging shall be done in accordance with the
approved stringing charts before the conductors and earthwire are finally
attached to the towers through the earthwire clamps for the earthwire and
insulator strings for the conductor. The Initial stringing chart shall be used
for the conductor and final stringing chart for earthwire should be
employed for this purpose. Dynamometers shall be employed for
measuring tension in the conductor and earthwire. The dynamometers
employed shall be periodically checked and calibrated with the standard
dynamometer.
5.11 Clipping In
5.11.1 Clipping of the conductors in position shall be done in accordance with the
recommendations of the manufacturer. Conductor shall be fitted with
Preformed Armor Rods where it is made to pass through suspension
clamps.
5.11.2 The jumpers at the section and angle towers shall be formed to parabolic
shape to ensure maximum clearance requirements.
5.11.3 Fasteners in all fittings and accessories shall be secured in position. The
security clip shall be properly opened and sprung into position.
5.12 Fixing of Conductor and Earthwire Accessories
Vibration dampers for conductor & earthwire and other conductor &
earthwire accessories which are in bidders scope of supply, shall be
installed by the Contractor as per the design requirement and respective
manufacturers instructions within 24 hours of the conductor/earthwire
clamping. While installing the conductor and earthwire accessories, proper
care shall be taken to ensure that the surfaces are clean and smooth and
no damage shall occur to any part of the accessories.
5.13 Replacement
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If any replacements are to be effected after stringing and tensioning or
during maintenance, leg members and bracings shall not be removed
without reducing the tension on the tower with proper guying or releasing
the conductor. If the replacement of cross arms becomes necessary after
stringing, the conductor shall be suitably tied to the tower at tension points
or transferred to suitable roller pulleys at suspension points.
5.14 Permitted extra consumption of Line Materials
5.14.1 The bidder shall make every effort to minimise the breakages, losses, &
wastages of the line materials during erection. However while working out
the quantities of line materials, Employer shall permit the bidder extra
consumption of Conductor and Earthwire only upto the limit of 1%

The permitted extra consumption limit of 1% is inclusive of sag, stringing,
damage, losses & wastages etc. The quantity of conductor and earthwire
shall be worked out as per following norms.
(a) Quantity of Conductor = Line length as per detailed survey x
No. of phases (3) x No. of circuits.

(b) Quantity of Earthwire = line length as per detailed survey.

For other line materials, i.e. Disc Insulators, Hardware and Accessories for
Conductor and Earthwire, the actual quantity incorporated on transmission
line shall be approved.
5.14.2 The Contractor shall not be required to return to the Employer empty
Conductor and Earthwire drums as the same shall be deemed to become
his property.
5.15 Final Checking, Testing and Commissioning
After completion of the works, final checking of the line shall be done by
the Contractor to ensure that all the foundation works, tower erection, and
stringing have been done strictly according to the specifications and as
approved by the Employer. All the works shall be thoroughly inspected
keeping in view of the following main points:
(a) Sufficient backfilled earth is lying over each foundation pit and it is
adequately compacted.
(b) Concrete chimneys and their copings are in good finely shaped conditions.
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(c) All the tower members are correctly used, strictly according to final
approved drawing and are free of any defect or damage, whatsoever.
(d) All bolts are properly tightened and punched/tack welded.
(e) The stringing of the conductors and earthwire has been done as per the
approved sag and tension charts and desired clearances are clearly
available.
(f) All conductor and earthwire accessories are properly installed.
(g) All other requirements to complete the work like fixing of danger plate,
phase plate, number plate, anti climbing device, aviation signal (wherever
required) etc. are properly installed.
(h) Wherever required it should be ensured that revetment is provided.

(i) The original tracings of profile route alignment and tower, bill of material,
shop drawings of all towers are submitted to the Employer for reference
and record.
(j) The insulation of line as a whole is tested by the Contractor by providing
his own equipment, labour etc. to the satisfaction of the Employer.
(k) All towers are to be properly grounded as per requirements of the
specification.
(l) The line is tested satisfactorily for commissioning purpose.
6. General Technical Conditions
6.1 The following provisions shall supplement all the detailed technical
specifications and requirements brought out herein. The Contractors
proposal shall be based on the use of materials complying fully with the
requirements, specified herein.
6.2 Engineering Data
6.2.1 The furnishing of engineering data by the Contractor shall be in
accordance with the Schedule as specified in the Technical Specifications.
The review of these data by the Employer will cover only general
conformance of the data to the specifications and not a thorough review of
all dimensions, quantities and details of the materials, or items indicated or
the accuracy of the information submitted. This review by the Employer
shall not be considered by the Contractor, as limiting any of his
responsibilities and liabilities for mistakes and deviations from the
requirements, specified under these specifications.
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6.2.2 All engineering data submitted by the Contractor after review by the
Employer shall form part of the Contract document.
6.3 Drawings
In addition to those stipulated in clause regarding in general conditions,
the following also shall apply in respect of Contractors drawings.
6.3.1 All drawings submitted by the Contractor including those submitted at the
time of Bid shall be with sufficient detail to indicate the type, size,
arrangement, dimensions, material description, bill of materials, weight of
each component, break-up for packing and shipment, fixing arrangement
required, the dimensions required for installation and any other information
specifically requested in these specifications.
6.3.2 Each drawing submitted by the Contractor shall be clearly marked with the
name of the Employer, the specification title, the specification number and
the name of the Project. All titles, noting, markings and writings on the
drawings shall be in English. All the dimensions should be to the scale and
in metric units.
6.3.3 The drawings submitted by the Contractor shall be reviewed by the
Employer as far as practicable within 21 days and shall be modified by the
Contractor if any modifications and/or corrections are required by the
Employer. The Contractor shall incorporate such modifications and/or
corrections and submit the final drawings for approval within ten days. Any
delays arising out of failure by the Contractor to rectify the drawings in
good time shall not alter the contract completion date.
6.3.4 The drawings submitted for approval to the Employer shall be in
quadruplicate. One print of such drawings shall be returned to the
Contractor by the Employer marked "approved/approved with corrections".
The Contractor shall thereupon furnish the Employer additional prints as
may be required alongwith one reproducible in original of the drawings
after incorporating all corrections.
6.3.5 The work shall be performed by the Contractor strictly in accordance with
these drawings and no deviation shall be permitted without the written
approval of the Employer, if so required.
6.3.6 All manufacturing, fabrication and erection work under the scope of
Contractor, prior to the approval of the drawings shall be at the
Contractors risk. The Contractor may make any changes in the design
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which are necessary to conform to the provisions and intent of the
Contract and such changes will again be subject to approval by the
Employer.
6.3.7 The approval of the documents and drawings by the Employer shall mean
that the Employer is satisfied that:
(a) The Contractor has completed the part of the Works covered by the
subject document (i.e. confirmation of progress of Work).
(b) The Works appear to comply with requirements of Specifications.
In no case the approval by the Employer of any document does imply
compliance with all technical requirements nor the absence of errors in
such documents.
If errors are discovered any time during the validity of the Contract, then
the Contractor shall be responsible of their consequences.
6.3.8 Copies of drawings returned to the Contractor will be in the form of a print
with the Employers marking.
6.3.9 The following is the generic list of the documents and drawings that are to
be approved by the Employer:
(a) Detailed survey report and profile drawings showing ground clearance and
tower locations.
(b) Tower schedule for individual tower locations.
(c) Bill of material of towers and shop drawings.
(d) Soil investigation report.
6.4 Design Co-ordination
The Contractor shall be responsible for the selection and design of
appropriate material/item to provide the best co-ordinated performance of
the entire system. The basic design requirements are detailed out in this
Specification. The design of various components, sub-assemblies and
assemblies shall be so done that facilitates easy field assembly and
maintenance.
6.5 Design Review Meeting
The Contractor will be called upon to attend review meetings with the
Employer during the period of Contract. The Contractor shall attend such
meetings at his own cost at Patiala or at mutually agreed venue as and
when called for. Such review meeting will be held generally four times in a
year.
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6.6 Packing & Marking
6.6.1 All the materials shall be suitable protected, coated, covered or boxed and
crated to prevent damage or deterioration during transit, handling and
storage at Site till the time of erection. The Contractor shall be responsible
for any loss or damage during transportation, handling and storage due to
improper packing.
6.6.2 Each package shall be legibly marked by the Contractor at his expenses
showing the details such as description and quantity of contents, the name
of the consignee and address, the gross and net weights of the packages,
the name of the Contractor etc.
7. Erection Conditions
7.1 The following shall supplement the conditions already contained in the
other parts of these specifications and documents and shall govern that
portion of the work on this Contract to be performed at Site.
7.2 Regulation of Local Authorities and Statutes
7.2.1 The Contractor shall comply with all the rules and regulations of local
authorities during the performance of his field activities. He shall also
comply with the Minimum Wages Act, 1948, the payment of Wages Act
and of EPF act (all of the Government of India) and the rules made there
under in respect of any employee or workman employed or engaged by
him or his Sub-Contractor.
7.2.2 All registration and statutory inspection fees, if any, in respect of his work
pursuant to this Contract shall be to the account of the Contractor.
However, any registration, statutory inspection fees lawfully payable under
the provisions of the statutory laws and its amendments from time to time
during erection in respect of the transmission line, ultimately to be owned
by the Employer, shall be to the account of the Employer. Should any
such inspection or registration need to be re-arranged due to the fault of
the Contractor or his Sub-Contractor, the additional fees to such
inspection and/or registration shall be borne by the Contractor.
7.3 Contractors Field Operation
7.3.1 The Contractor shall keep the Employer informed in advance regarding his
field activity plans and schedules for carrying-out each part of the works.
Any review of such plan or schedule or method of work by the Employer
shall not relieve the Contractor or any of his responsibilities towards the
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field activities. Such reviews shall also not be considered as an
assumption of any risk or liability by the Employer or any of his
representatives and no claim of the Contractor will be entertained because
of the failure or inefficiency of any such plan or schedule or method of
work reviewed. The Contractor shall be solely responsible for the safety,
adequacy and efficiency or tools and plants and his erection methods.
7.4 Progress Report
7.4.1 Appropriate visual charts shall accompany the monthly progress report
detailing-out the progress achieved on all erection activities as compared
to the schedules. The report shall also indicate the reasons for the
variance between the scheduled and actual progress and the action
proposed for corrective measures, wherever necessary.
7.4.2 Facilities to be Provided by the Contractor
7.4.2.1 The Contractor shall provide all the construction equipment, tools, tackle
and scaffoldings required for construction, erection, testing and
commissioning of the transmission line covered under the Contract.
7.4.2.2 The Contractor shall provide necessary first-aid facilities for all his
employees, representatives and workmen working at the site.
7.5 Fire Protection
The work procedures that are to be used during the erection shall be
those, which minimise fire hazards to the extent practicable in line with
applicable laws, rules & regulations.
7.6 Security, Materials Handling and Storage
7.6.1 The Contractor shall have total responsibility for all equipment and
materials in his custody, stored, loose, semi-assembled and/or erected by
him at Site.
7.6.2.1 For all the supplies the Contractor shall be solely responsible for any
shortages or damages in transit, handling and/or in storage and erection at
Site. Any demurrage, wharfage and other such charges claimed by the
transporters, railways etc. shall be to the account of the Contractor.
7.7 Construction Management
Time is the essence of the Contract and the Contractor shall be
responsible for performance of his Works in accordance with the specified
construction schedule. If at any time, the Contractor is falling behind the
schedule for reasons attributable to him he shall take necessary action to
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make good for such delays by increasing his work force or by working
overtime or otherwise to accelerate the progress of the work and to comply
with schedule and shall communicate such actions in writing to the Employer,
satisfying that his action will compensate for the delay. The Contractor shall
not be allowed any extra compensation for such action.
7.8 Work and Safety Regulations
7.8.1 The Contractor shall ensure safety and well being of all the workmen,
materials plant and equipment belonging to him or to the others, working at
the Site and of Public at large. The Contractor shall comply with all safety
norms, rules & regulations as per Law / relevant legislations and as deemed
necessary by the Employer.

7.8.2 If the Contractor does not take all safety precautions and/or fails to comply
with the Safety Rules as prescribed under the applicable law for the safety of
the equipment, plant and personnel and the Contractor does not prevent
hazardous conditions which may cause injury to his own employees or
employees of other Contractors, or Employer or any other person at Site or
adjacent thereto, the Contractor shall be responsible for payment of
compensation to the Employer as per the following schedule:-

a) Fatal injury or Rs. 1,00,000/-
Accident causing Death
b) Major injuries or Rs. 20,000/-
accident causing 25% per person
or more permanent disability.
The above compensation will be applicable for death/ Injury to
any person whosoever.
Permanent disability shall have the same meaning as indicated in
Workmens Compensation Act. The compensation mentioned above shall
be in addition to the compensation payable to the workmen/employees
under the relevant provisions of the Workmens Compensation Act and
rules framed there under or any other applicable law as applicable from
time to time. In case the Employer is made to pay such compensation, the
Contractor will be liable to reimburse the Employer such amount (s)
addition to the compensation indicated above.
8.0 MANDATORY CONDITION
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The bidder or the authorised representative must visit the site of works
and its surroundings and obtain himself at his own responsibility and
expense, all information regarding terrain of the proposed lines, line route,
general site characteristics, crossings, accessibility, infrastructure details
and the factual position in respect of existing foundations/substations for
coordination purpose. The bidder is essentially required to furnish a
certificate in support of his having visited the site and acquainted himself
fully with the related conditions as per above, without which his tender will
not be considered.

The employer will assist the interested bidder to see and inspect the
site of works. For this purpose bidders are requested to contact the
following office:

CHIEF ENGINEER/TL,
Design Directorate Transmission,
B-2, Shakti Vihar, PSTCL,
Patiala.

Page 52 of 143

Activity Schedule for Package 1
The activity schedule, stating tentative completion period of each activity is
given below. In case the bidder wants to change this schedule, the
reasons for the same should be given.
Sr.No. Description of work. Tentative Completion Period.

1. Establishment of site
office
1 month from the date of award of contract.
2. Detailed survey 3 month from the date of award of contract.
3. Approval of detailed
survey maps/profiles by
PSTCL
2 weeks from the date of submission of correct
route plan after removing objections, if any of
this office.
4. Geo-technical & Soil
Investigation and
submission of reports.
2 weeks from the date of approval of survey
maps/profiles.
5. Approval of soil
investigation reports.
1 week from receipt of soil investigation
reports.
6. Fabrication & testing of
prototype of each type of
tower/structure.(if req.)
2 months from the date of award of contract.
7. Submission of BOM &
shop drawing of towers.
1 week from the approval of proto type.
8. Approval of BOM & shop
floor drawings.
1 week from the date of submission.
9. Completion of foundation
work.
Within 10 months of award of contract.
10. Completion of erection of
towers and supply of
complete line material.
11. Completion of stringing
work.
12. Testing & Commissioning Within 14 months of award of contract.

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office
PSTCL
this office.
Investigation and
maps/profiles.
5. Approval of soil
1 week form receipt of soil investigation
reports.
floor drawings.
work.
11 Completion of stringing
work.

Page 54 of 143

Page 55 of 143




office
PSTCL
this office.
Investigation and
maps/profiles.
5. Approval of soil
reports.
tower/structure(if req.)
floor drawings.
work.
work.

Page 56 of 143




office
PSTCL
this office.
Investigation and
maps/profiles.
4. Approval of soil
reports.
floor drawings.
work.
work.


Page 57 of 143



office
PSTCL
this office.
Investigation and
maps/profiles.
4. Approval of soil
reports.
floor drawings.
work.
work.


Page 58 of 143



office
PSTCL
this office.
Investigation and
maps/profiles.
4. Approval of soil
reports.
floor drawings.
work.
work.

Page 59 of 143

SECTION III
PART B

SCOPE FOR CONTRACTOR SUPPLIED LINE MATERIALS

1. General Information
The general scope for supply of all the material / equipment to be used for
complete execution of the 220 KV transmission lines packages is given in
this section.
2. Scope
2.1 The material to be supplied as covered in this volume shall be designed,
manufactured and tested as per the requirement specified.
2.2 The materials covered shall be supplied complete in all respects,
including all components, fittings and accessories which are necessary or
are used for their efficient performance and satisfactory maintenance
under the various operating and atmospheric conditions. Such parts shall
be deemed to be within the scope of the Contract, whether specifically
included or not in the Specification or in the Contract Schedules. The
Contractor shall not be eligible for any extra charges for such fittings etc.
The details of the material required for the above mentioned lines
under this specification are as follows and the tentative quantity of the
same are mentioned in Price Schedules of respective Packages on line-
wise basis.
i) Conductor / Tower material
ii) Earthwire
iii) Insulators
iv) Hardware Fittings
v) Accessories for Conductor and Earthwire
3 Weights and Measures
All weights and measures shall be in System International (S.I.) units. All
fasteners shall be of Metric size only.
4 General Technical Conditions
4.1 The following provisions shall supplement all the detailed technical
specifications and requirements brought out in the accompanying
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Technical Specifications. The Bidders proposal shall be based on the use
of equipment and materials complying fully with the requirements,
specified herein

4.2 Equipment Performance Guarantee
4.2.1 The performance requirements of the items are detailed separately in this
Specification. These guarantees shall supplement the general
performance guarantee provisions covered under General Terms and
conditions of Contract in stipulated in the bidding documents.
4.2.2 Penalties for not meeting specified performance shall be assessed and
recovered from the Contractor. Such penalties shall be in addition to
damages, if any payable under any other clause of Conditions of Contract.
4.3 Engineering Data
4.3.1 The furnishing of engineering data by the Contractor shall be in
accordance with the provisions of the contract specifications. The review
of these data by the Employer will cover only general conformance of the
data to the specifications and drawings. This review by the Employer may
not indicate to thorough review of all dimensions, quantities and details of
the equipment, materials, any devices or items indicated or the accuracy
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 this Specifications and documents.
4.3.2 All engineering data submitted by the Contractor after final process
including review and approval by the Employer shall form part of the
Contract Document and the entire works performed under these
Specifications shall be performed in strict conformity, unless otherwise
expressly requested by the Employer in writing.
4.4 Drawings
4.4.1 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, dimensions, material description. Bill of Materials, weight of
each component, break-up for packing and shipment, fixing arrangement
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required, the dimensions required for installation and any other information
specifically requested in the Specifications.
4.4.2 Each drawing submitted by the Manufacture shall be clearly marked with
the name of the Employer, the unit designation, the specification title, the
specification number and the name of the Project. All titles, notings,
markings and writings on the drawing shall be English. All the dimensions
should be to the scale and in metric units.
4.4.3 The drawings submitted by the Manufacturer shall be reviewed by the
Employer as far as practicable within three (3) weeks and shall be
modified by the Manufacturer if any modifications and/or corrections are
required by the Employer. The Manufacturer shall incorporate such
modifications and/or corrections and submit the final drawings for approval
within shortest possible time / as per directions of the PSTCL.
4.4.4 The drawings submitted for approval to the Employer shall be in
quadruplicate. One print of such drawings shall be returned to the
Manufacturer by the Employer marked approved/approved with
corrections. The Manufacturer shall there upon furnish the Employer
additional print, as stipulated in Technical Specification, of the drawings
after incorporating all corrections.
4.4.5 Further work by the Manufacturer shall be strictly in accordance with these
drawings and no deviation shall be permitted without the written approval
of the Employer, if so required.
4.4.6 All manufacturing and fabrication work in connection with the
equipment/material prior to the approval of the drawings shall be at the
Manufacturers risk. The Manufacture 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 Manufacturers drawing
or work by the Employer shall not relieve the Manufacturer of any of his
responsibilities and liabilities under the Contract.
4.5 Manufacturing Schedule
The Manufacturer shall submit to the Employer his manufacturing, testing
and delivery schedules of various items within thirty (30) days from the
date of the Letter of Award in accordance with the delivery requirements
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stipulated. Schedules shall also include the materials and items purchased
from outside Manufacturers, if any.
4.6 Reference Standards
4.6.1 The Codes and/or Standards referred to in Specifications shall govern, in
all cases wherever such references are made. In case of a conflict
between such codes and/or Standards and the specifications, latter shall
govern. Such codes and/or Standards, referred to shall mean the latest
revisions, amendments/changes adopted and published by the relevant
agencies. In case of any further conflict in this matter, the same shall be
referred to the Employer whose decision shall be final and binding.
4.6.2 Other internationally acceptable Standards which ensure equipment or
better performance than those specified shall also be accepted. The
copies of the same shall have to be furnished by the Bidder.
4.7 Quality Assurance
To ensure that the equipment under the scope of this Contract whether
manufactured within the Contractor Works or at his Sub-Contractors
premises is in accordance with the specifications, the Contractor shall
adopt suitable Quality Assurance Programme to control such activities at
all points necessary.
4.7.1 A Quality Assurance Programme of the Contractor shall generally cover but
not be limited to the following:-
a) His organization structure for the management and implementation
of the proposed Quality Assurance Programme
b) Documentation control system.
c) Qualification data for key personnel.
d) 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.
e) System for shop manufacturing including process controls.
f) Control of non-conforming items and system for corrective action
g) Control of calibration and testing of measuring and testing
equipments.
h) Inspection and test procedure for manufacture.
i) System for indication and appraisal of inspection status.
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j) System for quality audits.
k) System for authorizing release of manufactured product to the
Employer.
l) System for maintenance of records.
m) System for handling, storage and delivery and
n) A Quality Plan detailing out the specific quality control procedure
adopted for controlling the quality characteristics of the product.
4.7.2 Quality Assurance Documents
The Contractor shall be required to submit all the Quality Assurance
Documents as stipulated in the Quality Plan at the time of Employers
inspection of equipment/material. The Employer or his duly authorized
representatives reserves the right to carry out Quality Audit and Quality
surveillance of the systems and procedures of the Contractors/his
vendors Quality Management and Control Activities.
4.7.3 Employers Supervision
To eliminate delays and avoid disputes and litigation, it is agreed between
the parties to the Contractor that all matters and questions shall be
resolved in accordance with the provisions of this document.
The manufacturing of the product shall be carried out in accordance with
specifications. The scope of the duties of the Employer, pursuant to the
contract, will include but not be limited to the following:-
a) Interpretation of all the terms and conditions of these Documents and
Specifications.
b) Review and interpretation of all the Contractors drawings, engineering
data, etc.
c) Witness or authorize his representative to witness tests at the
manufactures works or at site, or at any place where work is
performed under the Contract.
d) Inspect, accept or reject any equipment, material and work under the
Contract, in accordance with the Specifications.
e) Issue certificate of acceptance and/or progressive payment and final
payment certificate.
f) Review and suggest modification and improvement in completion
schedules from time to time; and
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g) Supervise the Quality Assurance Programme Implementation at all
stages of the works.
4.7.4 Inspection, Testing and Inspection Certificate
i) The Employer, his duly authorized representative and/or outside
inspection agency acting on behalf of the Employer shall have at all
reasonable times access to the Contractors premises or works and shall
have the power at all reasonable times to inspect and examine the
materials and workmanship of the product during its manufacture and if
part of the product is being manufactured or assembled at other premises
or works, the Contractor shall obtain from the Employer and/or his duly
authorized representative permission to inspect as if the
equipment/materials were manufactured or assembled on the Contractors
own premises or works.
ii) The Contractor shall give the Employer fifteen (15) days written notice
of any material being ready for testing. Such tests shall be to the
Contractors account except for the expenses of the Inspector. The
Employer , unless witnessing of the tests is virtually waived, will attend
such tests within fifteen(15) days of the date of which the equipment is
notified as being ready for test/inspection of on a mutually agreed date,
failing which the Contractor may proceed with the test which shall be
deemed to have been made in the Inspectors presence and he shall
forthwith forward to the Employer duly certified copies of tests in triplicate.
iii) In case of any objection to any drawings and all or any equipment and
workmanship which in Employers opinion is not in accordance with the
Contract the same shall be brought out in the Inspection Report by the
Employer at the time of Inspection and the Contractor shall give due
consideration to such objections and shall make the modifications that
may be necessary to meet the said objections / offer the material afresh.
iv) In all cases where the Contractor provides for tests, whether at the
premises or works of the Contractor or of any Sub-Contractor, the
Contractor except where otherwise specified shall provide free of charge
items such as labour, materials, electricity, fuel, water, stores, apparatus
and instruments, as may be reasonably demanded by the Employer
Inspector or his authorized representative to carry out effectively such
tests of the equipment in accordance with the Contract and shall provide
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facilities to the Employer Inspector or to his authorized representative to
accomplish testing.
v) The inspection by Employer and acceptance of material shall in no way
limit the liabilities and responsibilities of the Contractor in respect of the
requirements of the Contract.
5. Technical Description
The technical description of Conductor, Earthwire, Insulators, Hardware
fittings and Accessories shall be as specified in other parts of the
Technical Specifications .
6 Tests and Standards
6.1 Tests
The following type, acceptance and routine tests and tests during
manufacture shall be carried out on the material. For the purpose of this
clause:
6.1.1 Type Tests shall mean those tests which are to be carried out to prove the
process of manufacture and general conformity of the material to this
Specification. Type test certificates indicating conformity of the material as
per relevant Standard/PSTCL specification are required to be submitted
alongwith the bid as per requirement of this specification.
6.1.2 Acceptance Tests shall mean those tests which are to be carried out on
samples taken from each lot offered for pre-despatch inspection, for the
purposes of acceptance of that lot.
6.1.3 Routine Tests shall mean those tests, which are to be carried out on the
material to check requirements which are likely to vary during production.
6.1.4 Tests during Manufacture shall mean those tests, which are to be carried
out during the process of manufacture and end inspection by the
Contractor to ensure the desired quality of the end product to be supplied
by him.
6.1.5 The norms and procedure sampling for these tests will be as applicable
ISS / these specifications.
6.1.6 The standards and norms to which these tests will be carried out are listed
against them. Where a particular test is a specific requirement of this
Specification, the norms and procedure of the test shall be as specified in
Annexure-A .
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6.1.7 For all type and acceptance tests, the acceptance values shall be the
values specified in this Specification or guaranteed by the Bidder, as
applicable. The tests and standards are specified in the other
parts of the Technical Specification.
7.0 Technical Particulars.
7.1 Technical Particulars of the various items shall be furnished as per the
relevant schedules in all copies of bid. The Bidders shall also furnish any
other schedule informations as in their opinion is needed to give full
description and details to judge the items(s) offered by them.
7.2 The data furnished in Technical Particulars should be the minimum or
maximum value (as per the requirement of the specification) required. A
Bidder may guarantee a value more stringent than the specification
requirement. However, for testing purposes or from performance point of
view, the material shall be considered performed successfully if it achieves
the Minimum/Maximum value required as per the technical specification.
No preference whatsoever shall be given to the bidder offering,
better/more stringent values than those required as per specification.
8.0 Service Condition
Equipment/material to be supplied against this specification shall be
suitable for satisfactory continuous operation under tropical conditions as
specified below:

1. Max. ambient temperature (Celsius) 50
2. Min. ambient temperature (Celsius) (- )2.5
3. Relative humidity (%) Range 10-100
4. Max. wind velocity (m/sec) 47
5. Max. altitude above mean sea level (meters) 1000
6. Isokeraunic level 50
7. Moderately hot and humid tropical climate Yes
conducive to rust and fungus growth.

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SECTION III
Part -C
SURVEY & SOIL INVESTIGATION

1. General Information & Scope Of Work
1.1 The technical specifications covers detailed survey including route
alignment, profiling, tower spotting, optimization of locations, check
survey, contouring, and soil investigation for the transmission lines/ part
of the transmission lines covered under this specification .
1.1.1 The scope of work inter-alia shall include the following:-
a. Detailed Survey using GPS, Total Work stations, long range scanners
& Digital theodolites of reasonable accuracies , inter-alia including :
i. Digitised profiling along the selected route along with plan details.
ii. Computer aided tower spotting & optimization
iii. Soil resistivity measurement along the route
b. Check survey with contouring wherever required
c. Soil Investigation
d. Preparation of Survey reports including estimation of Bill of Quantities,
identification and explanation of route constraints (like Forest,
Animal/Bird sanctuary,oil pipe line/underground inflammable pipe lines
etc.), infrastructure details available en-route etc.
1.2 The Provisional quantities for the scope of work are indicated in relevant
Price Schedules. The final quantities for route alignment & detailed survey
(quantities in kms unit) shall be the route length along the approved route
alignment. For contouring at undulated/hilly tower locations and soil
investigations (quantities in Locs. unit), the actual quantities to be
executed shall be decided by Site Engineer-in-charge (Sr.XEN of
Concerned TLSC Division) during execution stage and the final quantities
shall be as approved by Superintending Engineer of concerned TLSC
Circle. The route alignment, detailed survey, including profiling & tower
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spotting, contouring, soil investigation etc shall be carried out by the
Contractor as per the technical specifications stipulated herein.
1.3 The Contractor must note that the Employer shall not be responsible for
loss or damage to properties, trees etc. due to contractors work during
survey. The Contractor shall indemnify the Employer for any loss or
damage to properties, trees etc. during the survey work.
1.4 The Contractor should note that Employer will not furnish the NRSA
satellite imageries or topographical maps prepared by survey of India but
will make available assistance that may be required in obtaining these by
providing letters of recommendation to the concerned authorities.
1.5 The work shall be carried out by the contractor using modern surveying
techniques. The bidder shall indicate in his offer, the detailed description of
the procedure to be deployed. The details of the equipment & facilities
including soft wares for image processing, computer aided tower spotting
etc. available with the bidder or his associates shall also be furnished with
the bid.
1.8 After carrying out the detailed survey and soil investigations, the contractor
shall estimate complete BOQ (Bill of Quantities) of the transmission lines
on Package-wise basis and submit the same (as per the BOQ format
enclosed with the Specifications) to the Employer.
2. Route Alignment
2.1 Wherever the route Alignment has already been carried out for the line
using satellite imageries of NRSA (PAN & LISS-III merged product) and
Survey of India topographical maps (scale 1:50000), any changes
necessitated during execution stage in the route alignment, same shall be
carried out by the contractor using satellite imageries / topographical
maps.
2.2 Requirement of Transmission Line Routing (for changes if any
necessitated on account of site constrains etc.):
2.2.1. The Re-alignment, if any required, of the transmission line shall be most
economical from the point of view of construction and maintenance. The
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contractor shall identify & examine alternative route alignments and
suggest to the Employer the optimal route alignment.
2.2.2. Routing/Re-routing of transmission line through protected/reserved forest
area should be avoided. In case it is not possible to avoid the forests or
areas having large trees completely, then keeping in view of the overall
economy, the route should be aligned in such a way that cutting of trees is
minimum.
2.2.3. The route should have minimum crossings of Major river, Railway lines,
National/State highways, overhead EHV power line and communication
lines.
2.2.4. The number of angle points shall be kept to minimum.
2.2.5. The distance between the terminal points specified shall be kept shortest
possible, consistent with the terrain that is encountered.
2.2.6. Marshy and low lying areas, river beds and earth slip zones shall be
avoided to minimize risk to the foundations.
2.2.7. It would be preferable to utilize level ground for the alignment.
2.2.8. Crossing of power lines shall be minimum. Alignment will be kept such as
to avoid induction problems on the lower voltage lines.
2.2.9. Crossing of communication line shall be minimized and it shall be
preferably at right angle. Proximity and parallelism with telecom lines shall
be eliminated to avoid danger of induction to them.
2.2.10. Areas subjected to flooding such as nalah shall be avoided.
2.2.11. Restricted areas such as civil and military airfield shall be avoided. Care
shall also be taken to avoid aircraft landing approaches.
2.2.12. All alignment should be easily accessible both in dry and rainy seasons to
enable maintenance throughout the year.
2.2.13. Certain areas such as quarry sites, gardens & nurseries which will present
the Employer problems in acquisition of right of way and way leave
clearance during construction and maintenance should be avoided.
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2.2.14. Angle points should be selected such that shifting of the point within 100 m
radius is possible at the time of construction of the line.
2.2.15. The line routing should avoid large habitations, densely populated areas,
Forest, Animal/Bird sanctuary, reserve coal belt areas, oil pipe
line/underground inflammable pipe lines etc. to the extent possible.
2.2.16. The areas requiring special foundations and those prone to flooding
should be avoided.
2.3 For examination of the alternatives & identification of the most appropriate
route, besides making use of information/data/details available/extracted
through Survey of India Topographical maps and computer-aided
processing of NRSAs satellite imagery, the contractor shall also carryout
reconnaissance/preliminary survey as may be required for verification &
collection of additional information /data /details.
2.4 The contractor shall submit his preliminary observations & suggestions
along with various information/ data / details collected and also processed
satellite imagery data, scanned topographical map data marked with the
alternative routes etc. The final evaluation of the alternative routes shall be
conducted by the contractor in consultation with concerned Sr.XEN/ SE
TLSC and optimal route alignment shall be proposed by the contractor.
During Site visit and field verification to be conducted by the contractor the
Employers representative may join for the proposed route alignment.
2.5 Final digitized route alignment drawing with latest topographical and other
details/features including all rivers, railway lines, canals, roads etc. up to 4
kms on both sides of selected route alignment shall be submitted by the
contractor for Employers approval along with report containing other
information/details as mentioned above.
2.6 Changes in the route alignment, if any, during detail survey, shall be
incorporated in the final digitized route alignment drawings.
3. Detailed Survey
3.1 The detailed survey shall be carried out using GPS, Total stations, digital
theodolites etc. along the approved route alignment.
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3.2 Soil resistivity, along the route alignment shall be measured in dry weather
by four electrode method keeping inter-electrode spacing of 50 mtrs. For
calculating soil resistivity formula 2ar ( Where a=50 m and r= megger
reading in ohms) shall be adopted. Measurement shall be made at every 2
to 3 km along the length of the route. In case soil characteristics changes
within 2 to 3 km, values shall have to be measured at intermediate
locations also. Megger reading and soil characteristics should also be
indicated in the soil resistivity results.
3.3 Route Marking
3.3.1. The route of the transmission line shall be recorded using GPS of
positional accuracy less than 3m.
3.3.2. The co-ordinates of all the angle points as well as other important
crossings, landmarks etc. shall be recorded using GPS for easy relocating.
3.3.3. At the starting point of the commencement of route survey the co-
ordinates shall be recorded. The co-ordinates of the location of the survey
instrument shall also be recorded. Further, the co-ordinates at prominent
position at intervals of not more than 750 meter along the transmission line
to be surveyed up to the next angle point shall also be recorded. Wherever
the line alignment crosses the EHT line, Railway line, P&T line or roads,
the contractor shall record co-ordinates on the points of crossing.
Wherever line route alignment passes over permanent land marks such
as rock, boulders, culverts etc. suitable white paint marks with directional
markings shall be made and co-ordinates recorded.
3.4 Profiling
3.4.1. The complete profiling along the route shall be carried out using modern
surveying equipments viz. total stations, GPS, digital theodolite, long
range scanners etc. Reference levels at every 20 metres along the route
are to be recorded. R/Ls at other undulations along the route as well as in
the route plan and other enroute details viz. crossings, building &
structures, trees & other infrastructure etc shall also be recorded. Areas
along the route, which in the view of the contractor, are not suitable for
tower spotting, shall also be marked.
Page 72 of 143

3.4.2. The complete profiling details shall be digitized and the data shall be
prepared & stored in the format compatible to computer-aided tower
spotting software.
A printed/plotted output of the digitized profiling shall be submitted by the
contractor to Employers site-in-charge (Sr.XEN of concerned TLSC Divn.)
for review before taking up computer-aided tower spotting.
3.5 Optimisation of Tower Location / Tower Spotting
3.5.1. Optimisation of tower locations shall be done by the contractor using
computer-aided tower spotting software .
3.5.2. The sag-tension characteristics of the conductor as well as tower spotting
data shall be furnished by the Employer to the contractor during execution
stage. Sag template curves, if any required for tower spotting, shall be
prepared by the contractor.
3.5.3. Tower Spotting
While profiling & spotting the towers, the following shall be borne in mind:

a) Span
The number of consecutive spans between the section points shall not
exceed 10 spans. A section point shall comprise of tension point with B
type (2-D-30) or C Type (2-D-60) as applicable.
b) Extension/Truncation
An individual span shall be as near to the normal design span as possible.
In case an individual span becomes too short with normal supports on
account of undulations in ground profile, one or both the supports of the
span may be extended by inserting standard body.
c) Loading
There shall not be any upward force on suspension towers under normal
working conditions and the suspension towers shall support at least the
minimum weight span as provided in the designs. In case uplift is
unavoidable, it shall be examined if the same can be overcome by adding
Page 73 of 143

standard body extensions to the towers failing which tension towers
designed for the purpose shall be deployed at such positions.
d) Road Crossing
At all important road crossings, the tower shall be fitted with tension
insulator strings but the ground clearance at the roads under maximum
temperature and in still air shall be such that even with conductor broken
in adjacent span, ground clearance of the conductor from the road
surfaces will not be less than specified. At all national highways crossing
span will not be more than 250 meters.

e) Railway Crossings
All the railway crossings coming-enroute the transmission line shall be
identified by the Contractor. At the time of detailed survey, the railway
crossings shall be finalised as per the regulation laid down by the Railway
Authorities / Indian Electricity Rules. The following are the important
features of the prevailing rules & regulations :
i) The crossings shall be supported on B(2-D-30) or C(2-D-60) type tower
on either side depending on the merits of each case.
ii) The crossing shall normally be at right angle to the railway track.
iii) The minimum distance of the crossing tower shall be at least equal to
the height of the tower plus 6 meters away measured from the centre
of the nearest railway track.
iv) No crossing shall be located over a booster transformer, traction
switching station, traction sub-station or a track cabin location in an
electrified area.
v) Minimum ground clearance above rail level of the lowest portion of any
conductor under condition of maximum sag shall be maintained at
15.40 m for 220 kV transmission lines.
vi) The crossing span will be limited to 300 meters.
f) River Crossings
In case of major river crossing, towers shall be of suspension type along
with anchor towers of C type tower on either side of the main river
crossing. For navigable rivers, clearance required by navigation authority
shall be provided. For non navigable river, clearance shall be reckoned
with respect to highest flood level (HFL).
Page 74 of 143

g) Power line Crossings
Where the line is to cross over another line of the same voltage or lower
voltage, A type tower with suitable extensions shall be used. Provisions to
prevent the possibility of its coming into contact with other overhead lines
shall be made in accordance with the Indian Electricity Rules, 1956 as
amended up-to-date. In order to reduce the height of the crossing towers,
it may be advantageous to remove the ground-wire of the line to be
crossed (if this is possible and permitted by the Employer of the line to be
crossed).
Minimum clearance in meters between lines when crossing each other:
Sl.
No.
Nominal System
Voltage
66 KV 132KV 220KV 400KV 765KV/
800 KV
1 66 KV 2.44 3.05 4.58 5.49 7.94
2 132KV 3.05 3.05 4.58 5.49 7.94
3 220KV 4.58 4.58 4.58 5.49 7.94
4 400KV 5.49 5.49 5.49 5.49 7.94
5 765 / 800 KV 7.94 7.94 7.94 7.94 7.94

For power line crossings of voltage level of 132 kV and above, angle
towers shall be provided adjacent to A type tower on either side of the
Power line crossing which can be used in temporary dead end condition
with proper guying to facilitate stringing of the power line crossing
sections separately on obtaining line shutdowns.
h) Telecommunication Line Crossings
The angle of crossing shall be as near to 90 degree possible. However,
deviation to the extent of 30 degree may be permitted under exceptionally
difficult situations.
When the angle of crossing has to be below 60 degree, the matter will be
referred to the authority in charge of the telecommunication System. On a
request from the Contractor, the permission of the telecommunication
authority may be obtained by the Employer.
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Also, in the crossing span, power line support will be as near the
telecommunication line as possible, to obtain increased vertical clearance
between the wires.
i) Details En-route
All topographical details, permanent features, such as trees, building etc.
17.5 m for 220 KV D/C line on either side of the alignment shall be detailed
on the profile plan.
3.6 Clearance from Ground, Building, Trees etc.
Clearance from ground, buildings, trees and telephone lines shall be
provided in conformity with the Indian Electricity Rules, 1956 as amended
upto date.
3.6.1. The Contractor shall count, mark and put proper numbers with suitable
quality of paint at his own cost on all the trees that are to be cut by the
Employer at the time of actual execution of the work as detailed below.
Contractor may please note that Employer shall not pay any compensation
for any loss or damage to the properties or for tree cutting due to
Contractors work.
3.6.2. To evaluate and tabulate the trees and bushes coming within 17.5 m for
220 KV D/C line on either side of the central line alignment the trees will
be numbered and marked with quality paint serially from angle point 1 (I)
onwards and the corresponding number will be painted on the stem of
trees at a height of 1 meter from ground level. The trees list should contain
the following:
a) Girth (circumferences) measured at a height of 1 meter from ground
level.
b) Approximate height of the tree with an accuracy of +2 meters.
c) Name of the type of the species/tree.
d) The bushs and under growth encountered within the 35 m for 220 kV
line should also be evaluated with its type, height, girth and area in
square meters, clearly indicating the growth in the tree/bush statement.
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3.6.3. The contractor shall also intimate the Employer his assessment about the
likely amount of tree & crop compensation etc. required to be paid by the
Employer during execution stage. This assessment shall be done
considering prevailing practices/guidelines, local regulations and other
enquiries from local authorities.
3.6.4. The Contractor shall also identify the forest/non forest areas involved duly
authenticated by concerned authorities.
a) A statement of forest areas with survey/compartment Nos.(all type of
forest RF/PF/Acquired forest/Revenue forest/Private forest/Forest as
per dictionary meaning of forest etc.)
b) A statement of non-forest areas with survey/compartment nos.
c) Tree cutting details(Girth wise & specie wise)
d) Marking of forest areas with category on topo sheets 1:2,50,000
showing complete line route, boundaries of various forest divisions and
their areas involved.
e) Village forest maps of affected line and affected forest area and
marking of the same.
f) Forest division map showing line and affected forest area.
3.6.5 The Contractor shall finalize the forest clearance proposal on the
prescribed format duly completed in all respects for submission by the
Employer to the Forest Department.
3.7 Preliminary Schedule
The profile sheets showing the locations of the towers together with
preliminary schedules of quantities indicating tower types, spans, angle of
deviation, crossing & other details etc. shall be submitted by the contractor
for review & approval by the Employers site-in-charge ( concerned
Sr.XEN /TLSC)
3.8 Check Survey of Tower Locations
3.8.1. The check survey shall be conducted to locate tower locations on ground
conforming to the approved profile and tower schedule.
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3.8.2. The co-ordinates of all the tower locations shall also be recorded using
GPS of positional accuracy less than 3 m for easy relocating. The position
of all tower locations shall be marked in the final digitized route alignment
drawing with relative distances from any permanent bench mark area.
3.9 Contouring at hilly/undulated locations
3.9.1. The levels up or down of each pit centre with respect to centre of tower
location shall be recorded at intervals of 2m using total
stations/GPS/digital theodolite and digitized contour plans shall be made.
Based on the digitized elevation plans, the quantities of benching &
protection work shall be optimized using suitable computer-aided
techniques/software.
3.10 The changes desired by the Employer in the preliminary tower schedule
or as may be required based on detailed survey of tower locations &
contouring by the contractor, shall be carried out by the contractor and the
final tower schedule shall be submitted for approval of Employer. The
tower schedule shall show position of all type of towers, span length, type
of foundation for each tower, benching & revetment requirement, deviation
at all angles, crossings & other details etc.
3.11 Survey Report
3.11.1. Complete BOQ of the transmission lines as per format enclosed with this
technical specifications shall be furnished in the survey report.
3.11.2. Each angle point locations shall be shown with detailed sketches showing
existing close by permanent land marks such as specific tree(s), cattle
shed, homes, tube wells, temples, electric pole/tower, telephone pole,
canal, roads, railway lines etc. The relative distance of land marks from the
angle points and their bearings shall be indicated in the sketch. These
details shall be included in the survey report.
3.11.3. Information w.r.t infrastructure details available en-route, identification and
explanation of route constraints, etc shall also be furnished in the Survey
report and shall inter-alia include the following:
3.11.3.1. Information regarding infrastructural facilities available along the final route
alignment like access to roads, railway stations, construction material
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sources (like quarry points for stone, sand and availability of construction
water), labour, existing transport facilities , fuel availability etc. shall be
furnished in the survey report.
3.11.3.2. All observations which the Contractor thinks would be useful to the
construction of the transmission lines mentioned under scope of work are
to be reported.
3.11.3.3. Suggestions regarding location for setting up stores during line
construction in consultation with Employers representative shall also be
provided by the contractor.
3.11.3.4. Some portions of the line may require clearance from various authorities.
The Contractor shall indicate the portion of the line so affected, the nature
of clearance required and the name of concerned organizations such as
local bodies, municipalities, P&T (name of circle), Inland navigation,
Irrigation Department, Electricity Boards and Zonal railways, Divisional
Forest Authorities etc.
3.11.4. All the requisite data for processing the case for statutory clearances such
as PTCC, Forest and Railway shall be provided along with the report.
4. Geotechnical Investigations
4.1 General
4.1.1. These specifications provide general guidelines for geotechnical
investigation of normal soils. Information required for locations with special
foundations shall be obtained by Contractor and furnished to Employer.
4.2 Scope
4.2.1. The scope of work includes soil investigations/ furnishing bore log data at
various tower locations. The Soil investigation report/ bore log data will be
submitted to the SE/ Transmission Design, PSTCL, Patiala for foundation
decision in case sub-soil water level is found to be above 6 m. The bore
log data shall indicate the sub-soil water level, nature of soil strata and
bearing capacity of the soil. The bore log data shall be furnished for all
locations on the approved route plan.
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4.2.2. Contractor shall carry out all work expressed and implied in these
specifications in accordance with requirements of the specification.
4.2.3. It is essential that equipment and instruments be properly calibrated at the
commencement of the work. If the Employer desires to witness such tests,
Contractor shall arrange for the same.
4.3 Codes and Standards for Geotechnical Investigations
All work shall be carried out in accordance with the relevant Indian
Standards and Codes.

Page 80 of 143

SECTION III
PART D

TECHNICAL SPECIFICATION OF ACSR ZEBRA

1. SCOPE & QUALIFYING CRITERIA :
This specification covers manufacture, testing before dispatch, supply
& delivery of ACSR Zebra having Nominal Aluminium Area 420 mm sq.,
54/7/3.18mm to be delivered in good condition at any destination railway
station in Punjab. The supplier shall be responsible for the said delivery of
material to the correct railhead in accordance with the dispatch instructions to
be issued after successful material inspection. The conductor should bear
either ISI certification or PQM (Punjab Quality Mark)
The tendered prices shall cover the cost of material utilized/destroyed
while carrying out various tests as specified in this specification or in the
relevant ISS to which the material offered shall conform and no extra payment
shall be due for the material so destroyed during testing .
In case the Contractor is a Tower Manufacturer then the manufacturer
from whom he proposes to procure Conductor should have capacity to
manufacture at least 2000 Km 61 strand ACSR / AAAC per year and should
have supplied at least 500 Km ACSR Zebra and/or Moose during the last two
years. Certificate of a Chartered Accountant / Engineer for capacity shall be
furnished with the bid. In addition to this Performance Certificate for supply of
at least 300 Km ACSR Zebra and/or Moose from any SEB / utility shall also
be furnished with the Bid. On Financial side, the average Turnover of the
manufacturer for the last three financial should be min.20 Crores and he
should have liquid assets and / or evidence of access to or availability of
credit facilities of not less than Rs. 2 Crores. Documentary proof for these
shall also be attached with the bid.

2. STANDARDS:
The conductor shall comply in all respects with the IS-398 (Part-2):1996 with
latest amendments, if any, and also the technical specification detailed
therein. Offers conforming to the standard other than IS-398(Part-2): 1996
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shall be accompanied by the English version of the relevant standard in
support of the guaranteed particulars as given in GTPs.

3. MATERIAL:
3.1 The conductor shall be constructed of hard drawn aluminium and
Galvanized steel wires which have the mechanical and electrical properties
specified in table 1&2 of IS 398 (Part-2) 1996. The conductor to be procured
against this specification is to be installed on 220 KV transmission lines,
hence special care shall be taken during its manufacture to avoid any defects
on conductor. The raw material used for the manufacture of the conductor
shall be EC Grade Aluminium rods conforming to IS-5484, 1978 and
Galvanised steel wire drawn from high carbon steel rods procured by either
acid or base open hearth process, electric furnace or basic oxygen process.
The Mechanical properties of wire shall comply with requirements, given in
table 2 of IS-398(Part-2)1996. The zinc used for galvanizing should be
electrolyte high grade zinc having purity not less than 99.95%. It shall conform
to satisfy all the requirements. IS 209:1992. Zinc coating on steel wire may
be applied by the hot process or electrolytic Process. The stranding of
conductor be completed in single operation . The tenderer shall submit
documentary proof of their capability of making 54 strands conductor in single
operation. The conductor drum should bear ISI Monogram mark or PQM
mark in conformation to ISI/PQM material supplied.

3.2 The responsibility for procurement of good quality raw material shall be
solely of supplier and in any case assistance for the procurement of raw
material not controlled by the Govt. shall not be provided by the Board and
delivery programme shall not be affected due to non supply of raw material.
The supplier will have to ensure adequate quantity of good quality un-
controlled raw material in their stock so that the progress of work is not
hampered. No extension in delivery period will be allowed on the pretext of
non-availability of or short supply of raw material not controlled by Govt. and
this will not constitute a valid reason of Force Majeure. The material used for
finished product shall be of best quality and shall conform to specific details
as laid down in IS:398(Part-2):1996 for tolerances, mechanical properties,
surface conditions, joints in wire and stranding.
Page 82 of 143

3.3 The aluminium wires(strands) shall be hard drawn from electrolytic aluminium
rod having purity not less than 99.5% and shall conform to relevant ISS. Cut ends
of the conductor shall be properly treated to avoid ingress of moisture. The producer
test certificate in respect of impurity contents of Aluminium conductivity etc. shall
have to be furnished in order to assess whether Aluminium rod of correct quality
has been used for aluminium strands.

The steel wires(strands) shall be drawn from steel produced by either acid or
basis open hearth process by the electric furnace process or basic oxygen
process and shall conform to the requirement as regards to chemical
composition. The steel produced by BESSEMER process shall not be used
for drawing the steel wire strands.

3.4 The steel core wire shall hot dip galvanised conforming to IS:2629/1980
and shall have zinc coating of minimum 250 gms/m2 of the un-coated inner wire
surface as per IS:4826/1968 for hard heavily coated wires. The zinc coated
steel wire after stranding shall successfully withstand 2 dips of one minute duration
and 1 dip of minute duration under Preece test. The zinc coating shall be
reasonably smooth, continuous and of reasonably uniform thickness and free from
imperfections, consistent with good commercial practice and shall meet all the
relevant tests as per the standards. The steel wires shall be for such quality and
purity that when drawn to the size of wire specified and coated with zinc, the
finished strands shall have the same properties and characteristics as prescribed
in the relevant Indian standards. The quality of zinc used for coating of steel wire
shall be as-per IS-209/1992 i.e. electrolytic High grade zinc of 99.95 purity.
3.5 The responsibility to arrange raw material shall be solely of the firm. EC
grade Aluminium ingots or rods of relevant size shall be procured only from
the main producers such as Hindalco , Balco & Nalco. Similarly in case of
HTGS wire of relevant size, the material shall be procured main / reputed
producers like Ratlam Wires, Tata Steel, Usha Martin, Arti Steels, Bajrang
Wires, Bharat Wires & Ropes and Ramsarup industrial Corp.
4. SURFACE CONDITIONS:
The wires used for standard conductor shall be smooth and free from
all imperfections, such as spills and splits. The surface of the conductor shall
Page 83 of 143

be free from sharp edges, abrasion or other departures from smoothness of
uniformity of surface counter that would increase radio interference and
corona losses. When subjected to tension upto 50% of the ultimate strength of
conductor the surface shall not depart from its cylindrical form nor any part of
the component parts, or strands move relative to each other in such a way so
as to get out of place and disturb the longitudinal smoothness of the
conductor.
The defects like scratches, die marks, surface cuts, abrasion, stuff
mark and deposition of dust, dirt and grit, non-uniformity in diameter, un-even
and loose stranding, discontinuity in steel core wire, overlapping of strands,
joints in individual wires in the outer most layer of the conductor, etc. should
be avoided during manufacturing.
Even though the conductor may pass the relevant tests specified in
this specification or IS but if any of the above defects during visual inspection
are found to exist in the conductor offered, the same shall not be accepted.

5. JOINT IN WIRE:

I) ALUMINIUM WIRES: It would be preferable if no joints are made in Aluminium wires.
However, in case joints are made ,no two joints in any layer are permitted within
15 meters of each other in complete stranded conductor. The joint shall be made by
cold pressure welding as per IS:398/1996(Part-II). There will be no joints in
outermost layer of conductor.

II) GALVANISED/STEEL CORE WIRE:
There shall be no joints or weld of any kind in the finished wire entering into
constructions of strands. There shall also be no strand joints or strand splices
in any length of the completed stranded steel core wire of conductor.

6. LENGTHS AND VARIATION IN LENGTHS.
The conductor shall be supplied in standard length of 1300 meters. 90%
of the total ordered quantities of the conductor can be supplied in standard
lengths with +/- 5% tolerances. Further supply of 10% ordered quantities can
be supplied in shorter lengths but none of which shall be less than 650 meters
or 50% of the standard length.
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7. TEST CERTIFICATES AND TEST :
a) The firm shall supply the following type test certificates for ACSR ZEBRA
carried out as per the relevant ISS from Govt. Test House/Govt. Accredited
Test House/Tag Corporation, Chennai alongwith the tender. Type test
certificates from any other agency will not be acceptable:
i) Surface condition
ii) Test for ultimate breaking load on stranded conductor.
iii) Stress strain Tests

b) Individual wire and finished steel cored Aluminium conductor shall be
subjected, before dispatch from the works, to the test as specified in the IS-
398(Part-2) 1996 with latest amendments or any other authoritative standard.
Samples of individual wire for test shall be taken before stranding from
not less than 10% of the spools in the case of Aluminium wires and 10% of
the wire coiled in the case of steel wires. If samples are taken after stranding,
they shall be obtained by cutting 1.2 meters lengths from the outer end of the
finished conductor from not more than 10% of the finished reels or drums.
The tests will have to be performed in the presence of Employer upto
his entire satisfaction without any extra charges. Steel wire shall be tested
both for torsion and elongation and it shall pass both the tests.

8. REJECTION AND RE-TESTS
Should any one of the test pieces first selected fails to pass the tests,
three further samples from the same batch shall be selected for testing one of
which shall be from the length from which the original test samples was taken
unless that length has been withdrawn by the supplier.
Should all of the three test pieces from these additional samples satisfy
the requirements of the tests, the batch represented by these samples shall be
deemed to comply with the standard, should the test piece from any of the
three additional samples fail, the batched represented shall be deemed not to
comply with the standards and shall be rejected.
9. PACKING & MARKING:
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a) Supplier will be required to pack and protect the material securely so as to
avoid damage in transit under normal conditions. The conductor in the drum
shall be properly lagged due to abrasion during transport.
b) Supplier shall also be responsible for all losses or damages caused or
occasioned to by defect in the packing drum. The conductor shall be wound
in non-returnable wooden reels or drums.
c) The wooden drum and reels shall be manufactured according to Drg.
No.DD/TS-990R1 (Attached) and as per details given hereafter.

The drums shall be marked with the following:
i) Trade Name, if any
ii) Name of the manufacture
iii) Contract/Specification No.
iv) Size and type of conductor
v) Length of conductor
vi) Net weight
vii) Gross weight
viii) Certification mark ISI/PQM as per Approved ISI Monogram.
ix) Name and address of the consignee.
x) Drum Number and lot No.
xi) To check the sturdiness (or otherwise) of the packing reels a few
drums selected at random would be subjected to rolling for distance of
50 Mtrs. on the floor out of which 20 Mtrs. would be bricked floor. The
protective lagging should not break and drum should not get distorted
from the original shape during this process.
xii) The direction of rolling of drum shall be marked on the drum .
xiii) The conductor shall be tightly and uniformly spooled in the drum. Each
wrap shall be laid snugly against the side of the proceeding wrap.
xiv) The outside surface of the conductor drum flanges shall be painted with
double coat of enamel paint, the inner surface of the flanges including
the Barrel the inner surface of the flanges including the Barrel shall be
painted with double coat of Aluminium paint and thereafter bituminised
paper shall be provided.

d) No extra charges will be paid for these reels or drums.
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e) The reels shall be sufficiently strong to ensure delivery of conductor in
field free from displacement and damage shall be able to with stand all
stresses due to handling and stringing operations so that conductor surface
is not dented scratched or damaged in any way during manufacture,
transport and erection. It shall be notched to suite the conductor and to be
held in place by steel strapping. The drum shall be suitable for wheel
mounting. Before reeling the card board or other suitable material shall be
secured to the drum along the inside flange. The outside flange surface shall
be painted with two coats of paint. The conductor wound on the drum shall
be covered with polythene paper. The drum shall be properly lagged with at
least 50mm thick wood so as to avoid damage due to abrasion during
transport. Any loose space between top conductor layer and cross-wooden
battens shall be securely filled with straw or other waste packing material.
The protective lagging shall be closely fitted. There shall be hoop iron or
galvanized steel wire outside the protective lagging. A gap of min. 100mm
shall be kept between last conductor layer and wooden battens to avoid any
damage to conductor.

11. GUARANTEED TECHNICAL PARTICULARS:
The Bidder shall submit the GTPs with his bid.

IMPORTANT : Material shall be accepted only from those manufacturers who
have got the ISI/PQM mark and facility to manufacture 54 strands conductor
in single operation. Documentary proof for having such facility shall be
submitted with the tender.

WOODEN DRUM DETAILS

1. WOODEN COMPONENTS:
Wood used for manufacture of drum shall be seasoned wood preferably soft
wood. It shall be sound and free from visual defects, which may impair its
strength.
2. FLANGES;
All Flanges shall be constructed with two thickness of timber, each ply being
at approximately right angle to the other, nailed, clenched together. Nails shall
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be driven from the inside face of flange, punched and the clenched on the
outer face. Flange boards shall be not less than the nominal thickness by
more than 2mm. There shall be not less than two nails per Board in each
circle. Where a slot is cut in the flange to receive the inner end of the
conductor, the entrance shall be in line with the periphery of the barrel. The
flanges of drum shall be large enough to prevent any possible contact
between the conductor and the ground during handling or transport. The
projection of flanges beyond the outer-most of the conductor shall be at least
100mm.
3. SPINDLE HOLE:
The spindle hole shall be cut through the centre of the middle flange board
and either spindle steel plates or cast iron bushings shall be fitted by bolts and
nuts.
4. BARREL END SUPPORTS
The supports shall be securely fixed to the flanges by nailing and shall be of
segmental type.
5. BARREL
Each batten shall be nailed to the barrel end support with one nail at each
side for 50mm wide Boards and at least two nails for all wider boards. The
battens shall be closely butted & provided with a smooth and round external
surface to the barrel. The edges of the battens shall be chamfered.

6. STRETCHERS;
Stretchers shall be used in the construction of drums and the middle end
supports when provided shall be slotted to receive them.

7. The protective lagging shall be closely fitted. Out-side the protective lagging there shall
be hoop iron or galvanized steel wire. A gap of min.(100mm) shall be kept between last
conductor layer and wooden battens to avoid any damage to conductor. The wooden
battens shall be nailed to the flanges.

8. PROTECTION TO CONDUCTOR;
The barrel surface and inner surfaces of the flanges of the drums shall be
painted with Aluminium Paint. A layer of water proof material shall be provided
over the barrel and inner surfaces of flanges. Another layer of water proof
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material shall be provided over the last layer of conductor and under the
laggings.
The wooden drum shall be constructed as per following details
(All dimensions in mm).

Drum dimension suitable Zebra
for conductor size
Flange diameter 1725 mm
Barrel diameter 710 mm

Transverse 900 mm
Flange thickness 3x33 mm
Bore diameter 90 mm
Nail circle -
Nail length 89 mm
Nail size 3.65 mm
Thickness of barrel end lagging 50 mm
No. of stretchers 6 mm
Stretcher size 100x50 mm
No. of bolts 6 mm
Diameter of spindle plate hole 90 mm
No. of spindle bolt plate 4
Spindle plate diameter 12 mm
Thickness of external lagging 50 mm
No. of binders over the external lagging. 3

Page 89 of 143

GUARANTEED TECHNICAL PARTICULARS OF ACSR ZEBRA
1. CONDUCTOR
a) Nominal Alumn. Area 420mm
2

b) Stranding 54/3.18Al.+7/3.18 Steel
2. Sectional area of aluminium 428.9mm
2

3. Total sectional area 484.5mm
2

4. Appx. Overall diameter 28.62mm
5. Appx. Mass 1621Kg/Km.
6. Calculated resistance at 20
0
0.06868 /km
7. Appx. Calculated breaking load 130.32KN
8. Lay ratio
a)Steel core Min.-13
Max.-28
b)Aluminium Wires
1. 12 wire layers
Min.-10
Max.-17
2. 18wire layers
Min.-10
Max.-16
3. 24wire layers
Min.-10
Max.-14
9. Modulus of elasticity 69GN/m
2
10. Co-efficient of linear expansion 19.3x10
-6
/
0
C
2.DATA FOR INDIVIDUAL WIRE OF ALUMINIUM AND STEEL
USED IN ACSR ZEBRA
1. DIAMETER STEEL ALUMINIUM
Max. 3. 24mm 3.21mm
Min. 3.12mm 3.15mm
2. Cross sectional Area 7.942mm
2
7.942mm
2
3. Weight 61.95kg/km 21.47kg/km
4. Breaking Load
Before stranding 10.43KN 1.29KN
After stranding 9.91KN 1.23KN
5. Resistance at 20
0
C 3.626/km
6. Zinc Coating.
a) No. & duration of dips 2 dips of One minute each &
1 dip of half minute
b) Min. weight of coating gm/mm
2
250gm/m
2

Page 90 of 143

SECTION-III
PART - E
SPECIFICATIONS FOR DISC INSULATORS

1.0 Scope & Qualifying Criteria :
2.1 The scope of the Bidder includes the supply of Normal and Anti-Fog
Porcelain Disc Insulators complete in all respect. The use of Anti-fog
type disc insulators is envisaged at those suspension points where the
level of pollution is very high. Areas having high pollution level are to
be identified by the bidder during detailed survey so as to ascertain the
actual quantum of Anti-fog type insulators required on the lines under
the packages covered by this specification.
2.2 The bidder shall ensure that the manufacturer of the Disc Insulators
fulfills the following Qualifying Criteria:
i) The manufacturer should have production capacity of at least
2,00,000 nos. porcelain disc insulators of 70 KN and above
voltage rating per annum. A certificate to this effect from a
Chartered Accountant / Engineer must accompany the Bid.
ii) The manufacturer must have supplied a total of at least 1,00,000
nos.70 KN & 160 KN porcelain insulators during the last three
years. A certificate to this effect from a Chartered Accountant /
Engineer must accompany the Bid.
iii) Performance certificate(s) from SEBs/ Utilities for satisfactory
supply & operation of at least 20,000 nos. porcelain disc
insulators of 70 KN and above ratings for normal type & 5,000
nos. for Anti-Fog type must be furnished with the Bid .
iv) The average annual turnover of the manufacturer for the last
three years shall not be less than Rs. 10 crores. He should have
liquid assets and / or evidence of access to or availability of
credit facilities of not less than Rs. 2 Crores. Documentary proof
for these shall also be attached with the bid.

2.0 Details of Disc Insulators
a) The insulator strings shall consist of standard discs for a three phase, 50 Hz,
effectively earthed 220KV transmission system in a moderately polluted
Page 91 of 143

atmosphere and Anti-fog type for heavily polluted areas at suspension points.
The discs shall be cap and pin, ball and socket type.
b) Bidder may quote for disc insulators made of electro-porcelain .
c) The size of disc insulator, minimum creepage distance, the number to be
used in different type of strings & their electromechanical strength shall be as
follows :

S No. Type of string Size of disc
insulator
(mm)
Minimum
creepage
distance of
each disc
(mm)
No. of
discs
Electro-
mechanical
strength of
insulator disc
(KN)
1. Single
suspension
255 X 145 292 (432 for
Anti-fog)
1x14 70
2. Single Tension 280 X 145 330 1x15 160
3. Double Tension 280 X 145 330 2x15 160
4. Double
Suspension
255 X 145 292 (432 for
Anti-fog)
2x14 70

2.1 Pin and Cap
i) Pin and Cap shall be designed to transmit the mechanical stresses to the
shell by compression 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.
ii) The pin shall move freely in the cap socket but without danger of accidental
uncoupling during erection or in position. The design of the disc should be
such that stresses due to expansion or contraction in any part of the insulator
shall not lead to deterioration.

2.2 Security Clip
2.2.1 Security clip for use with ball and socket coupling shall be of R-shaped hump
type which shall provide positive locking of the coupling as per IS:2486-(Part-
iii)/IEC:372. The legs of the security clips shall be spread after installation to
prevent complete withdrawal from the socket. The locking device should be
resilient, corrosion resistant and of suitable mechanical strength. There shall
be no risk of the locking device being displaced accidentally or being rotated
Page 92 of 143

when in position. Under no circumstances shall locking device allow
separation of insulator units or fittings. 3% extra clips are to be provided.

2.2.2 The hole for the security clip shall be countersunk and the clip shall be of such
design that the eye of clip may be engaged by a hot line clip puller to provide
for disengagement under energized conditions. The force required to pull the
security clip into its unlocked position shall not be less than 50 N (5 Kg) or
more than 500 N (50 Kg).

2.3 Ball and Socket Designation
The dimensions of the balls and sockets shall be of 16 mm
designation, for 70 KN disc insulator and 20 mm designation for 160 KN discs
in accordance with the standard dimensions stated in IS:2486-(Part-II)/IEC :
120.

2.4 Dimensional Tolerance of Insulator Disc
It shall be ensured that the dimensions of the disc insulators for both 70
KN and 160 KN( Normal Type) are within the limits specified below:

For Standard type disc
Std. Max. Min.
a) Diameter of Disc (mm)
70 KN
160 KN

255
280

266
293

244
267
b) Ball to ball spacing
between discs
70 KN
160 KN
145
170
149
175
141
165

2.5 Interchangeability
The disc insulators inclusive of the ball and socket fittings shall be of standard
design suitable for use with the hardware fittings of any make conforming to
relevant Indian/International Standards.
2.6 Corona And RI Performance
All surfaces must be clean, smooth, without cuts, abrasions or projections.
No part shall be subjected to excessive localized pressure. The metal parts shall
Page 93 of 143

be so designed and manufactured that it shall not generate any Radio
Interference beyond specified limit and not produce any noise generating corona
under the operating conditions.
2.7 Maintenance
2.7.1 The disc insulators offered shall be suitable for employment of hot line
maintenance techniques so that the usual hot line operations can be carried
out with ease, speed and safety.
2.7.2 Bidders shall indicate the methods generally used in the routine hot and dead
line maintenance of EHV Lines for which similar disc insulators have been
supplied by them. Bidders shall also indicate the recommended periodicity of
such maintenance.
2.8 Materials
2.8.1 Porcelain
The porcelain used in the manufacture of shells shall be sound, free
from defects thoroughly vitrified and smoothly glazed.
2.8.2 Glaze
The finished porcelain shall be glazed in brown colour. The glaze shall
cover all exposed parts of the insulator and shall have a good luster, smooth
surface and good performance under the extreme weather conditions of a
tropical climate. It shall not be cracked or chipped by ageing under the
normal service conditions. The glaze shall have the same co-efficient of
expansion as of the porcelain body throughout the working temperature
range.
2.8.3 Cement
Cement used in the manufacture of the insulator shall not cause
fracture by expansion or loosening by contraction. The cement shall not give
rise to chemical reaction with metal fittings and its thickness shall be as small
and uniform as possible. Proper care shall be taken to correctly centre and
locate individual parts during cementing.
2.8.4 Pins and Caps.
Pins and Caps shall be made of drop forged steel and malleable cast
iron/spheriodal graphite iron respectively, duly hot dip galvanized and shall
not be made by jointing, welding, shrink fitting or any other process from more
than one piece of material.
2.8.5 Security Clips
Page 94 of 143

Security clips shall be made of good quality stainless steel or phosphor
bronze as per IS:1385-1968.
3.0 Workmanship
3.1 All the material shall be of the latest design and conform to the best
modern practices adopted in the extra High voltage field. Bidders shall
offer only such insulators as are guaranteed by him to be satisfactory and
will give continued good service.
3.2 The design, manufacturing process and material control at various stages
shall be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish and elimination of sharp edges and
corners to limit corona and radio interference.
3.3 The design of the insulators shall be such that stresses due to expansion
and contraction in any part of the insulator shall not laed to deterioration.
3.4 Metal caps shall be free from cracks, seams, shrinks, air holes, burrs and
rough edges. All surfaces of the metal parts shall be perfectly smooth with
no projecting points or irregularities which may cause corona. All load
bearing surfaces shall be smooth and uniform so as to distribute the
loading stresses uniformly.
3.5 All ferrous parts shall be hot dip galvanized to give a minimum average
coating of zinc equipment to 600 gm/sq.m. and shall be in accordance with
the requirement of IS:2629-1966 and shall satisfy the tests mentioned in
IS:2633-1972. The zinc used for galvanising shall be as per IS:209-1979.
The zinc coating shall be uniform, adherent, smooth, reasonably bright,
continuous and free from imperfections such as flux, ash, rust stains, bulky
white deposits and blisters. The galvanised metal parts shall be
guaranteed to withstand atleast four successive dips each lasting for one
(1) minute duration under the standard preece test.
3.6 Before ball fittings are galvanized, all die flashing on the shank surface of
the ball shall be carefully removed without reducing the dimensions below
the design requirements.
3.7 The design of the insulators shall be such that the shell shall not engage
directly with hard metal. The design shall also be such that when units are
coupled together there is no contact between the shell of one unit and
metal of the next adjacent unit. The design of the shell ribs shall be such
Page 95 of 143

that the security clip of the insulator can be engaged and disengaged
easily with hot stick without damaging the shell ribs.
3.8 Insulator units after assembly shall be concentric and co-axial within limits
as permitted by the relevant Indian Standards.
3.9 The manufacturer of the disc insulators shall guarantee an insulator failure
rate not exceeding 1 (one) per 10000 (ten thousand) per year. In case the
annual failure rate during the first ten years of service exceeds the above
figure, under normal operating condition, as will be determined by check to
be conducted as per mutually agreed procedure and conditions upto ten
years (as permitted by the operating situation). The manufacturer shall
supply to the Owner free of cost spare insulators equal to 10 times excess
of the failure.
3.10 The manufacturer shall guarantee that there shall not be any
decapping of insulators on line under normal operating conditions. In event
of any decapping and subsequent line drop, during the first ten years of
service the manufacturer shall have to pay Rs. 50,000/- (Rs. Fifty
thousand) per dropped string towards expenditure to be incurred by
PSTCL for this line repair.
4.0 Equipment marking
4.1 Each insulator disc shall be legibly and indelibly marked with the trade
mark of the manufacturer and year of manufacture. The guaranteed
combined mechanical and electrical strength shall be indicated in kilo
newtons followed by the word kN to facilitate easy identification and to
ensure proper use.
4.2 For porcelain insulator, the marking shall be on porcelain. The marking
shall be printed, not impressed and shall be applied before firing.
5.0 Bid Drawings
5.1 The bidder shall furnish full description and illustration of the material
offered.
5.2 The bidder shall furnish along with the bid the outline drawing (4 copies) of
each insulator unit including a cross sectional view of the insulator shell.
The drawing shall include but not limited to the following information:
(a) Shell diameter and ball to ball spacing with manufacturing tolerances
(b) Minimum Creepage distance with positive tolerance
(c) Protected creepage distance.
Page 96 of 143

(d) Eccentricity of the disc
(i) Axial run out
(ii) Radial run out
(e) Unit mechanical and electrical characteristics
(f) Size and weight of ball and socket parts.
(g) Weight of unit insulator disc
(h) Materials
(i) Indentification mark
(j) Manufacturers catalogue number

5.3 After placement of award, the Contractor shall submit full dimensioned
insulator drawings containing all the details as given in Clause above, in
four (4) copies to Employer for approval. After getting approval from
Employer , the Contractor shall submit 10 more copies of the same
drawing to the Employer for further distribution and field use at Employers
end.
6.0 Tests and Standards
6.1 Tests
The following type, acceptance, routine tests and tests during
manufacture shall be carried out on the disc insulator individually . For the
purpose of this clause:-
6.1.1 Type tests shall mean those tests which are to be carried out to prove
the design, process of manufacture and general conformity of the
material to this specification. Type test certificate indicating conformity
of the material as per relevant standard/PSTCL specification are
required to be submitted along with the bid as per requirements of this
specification.
6.1.2 Acceptance tests shall mean those tests which are to be carried out on
samples taken from each lot offered for pre-despatch inspection for the
purpose of acceptance of that lot.
6.1.3 Routine tests shall mean those tests, which are to be carried out on
each disc insulator/hardware fitting to check requirements which are
likely to vary during production.
6.1.4 Tests during manufacture shall mean those tests which are to be
carried out during the process of manufacture and end inspection by
Page 97 of 143

the Contractor to ensure the desired quality of the end product to be
supplied by him.
6.1.5 The norms and procedure of sampling for these tests will be as per
applicable ISS / IEC standards.
6.1.6 The standard and norms to which these tests will be carried out are
listed against them.
6.1.7 For all types and acceptance tests, the acceptance values shall be the
values guaranteed by the Bidder in the Guaranteed Technical
Particulars of this proposal or the acceptance value specified in this
specification whichever is more stringent for that particular test.
6.1.8 For all type and acceptance tests, the Bidder shall guarantee only
minimum values in the Guaranteed Technical Particulars. Bidder shall
be required to achieve the same or higher values, as guaranteed,
during testing for all type and acceptance tests except for voltage
distribution test. Bidder shall be required to achieve the same or lower
values during testing.
6.2 Type Tests
The type test are meant to demonstrate conformity to the specification of design &
material used in the manufacture of goods. The disc insulators to be offered by
the bidders should have successfully passed the type test (As per IS 731 / relevant
IEC) given below :
a) Visual examination
b) Verification of dimension
c) Visible discharge test
d) Impulse voltage withstands test
e) Wet power frequency voltage withstand test
f) Temperature cycle test
g) Electro-mechanical failing load test
h) 24 hrs. Mechanical strength test/Electro mechanical strength test
i) Puncture test
j) Porosity test
k) Galvanising test
6.3 Acceptance Tests
a)
b)
Visual examination.
Verification of dimensions.

IS :731-1971
c) Temperature cycle test.
Page 98 of 143

d)
e)

f)

g)
h)
i)

Galvanising test.
Electro Mechanical Strength
test/24 hrs. Mechanical Strength
test.
Test on locking device for ball
and socket coupling.
Puncture test
Porosity test
Electro-mechanical failing load
test

}IEC:575-1975,
Clause
4.0
}IEC:373(2)-
1976

6.4 Routine Tests

a)
b)
c)

Visual Inspection.
Mechanical routine test.
Electrical routine test (for
porcelain insulator only)

IS-731-1971 Clause-
10.13, 10.14 & 10.15

6.5 Testing Expenses
The entire cost of testing for acceptance and routine tests and tests during
manufacture specified herein shall be treated as included in the quoted Ex-
works/CIF Price except for the expenses of the Inspector/Employers
representative.
6.6 Additional Tests.
i) The Employer 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 afore said type,
acceptance and routine tests to satisfy himself that the material comply
with the Specifications.
ii) The Employer 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 Contractors premises or at any other test centre. In case of
evidence of non-compliance, it shall be binding on the part of the
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 cost to the
Employer.
6.7 Test Reports.
Page 99 of 143

i) Copies of type test reports, conducted within last five years from CPRI/ ERDA
or equivalent lab/ test house of national repute , shall be furnished alongwith
the bid.
ii) Record of routine test reports shall be maintained by the Contractor at his
works for periodic inspection by the Employers representative.
iii) Test Certificate of test during manufacture shall be maintained by the
Contractor. These shall be produced for verification as and when desired by
the employer.
7.0 Inspection
7.1 The Employers representative shall at all times be entitled to have access to
the works and all places of manufacture, where insulators, and its component
parts shall be manufactured and the representatives shall have full facilities for
unrestricted inspection of the Contractors and sub-contractors works, raw
materials, manufacture of the material and for conducting necessary test as
detailed herein.
7.2 The material for final inspection shall be offered by the Contractor only under
packed condition. The Employer shall select samples at random from the
packed lot for carrying out acceptance tests.
7.3 The contractor shall keep the Owner informed in advance of the time of starting
and the progress of manufacture of material in their various stages so that
arrangements could be made for inspection.
7.4 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.
7.5 The acceptance of any quantity of material shall be no way relieve the
Contractor 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.
8.0 Packing and Marking
8.1 All insulators shall be packed in strong seasoned wooden crates. The gross
weight of the crates alongwith the material shall not normally exceed 50 Kg to
avoid handling problem.
Page 100 of 143

8.2 The packing shall be of sufficient strength to withstand rough handling during
transit, storage at site and subsequent handling in the field. The heads of the pins
should be properly protected against damage.
8.3 Suitable cushioning, protective padding or spacers shall be provided to prevent
damage or deformation during transit and handling.
8.4 All packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and to avoid the possibility of goods being lost or
wrongly dispatched on account of faulty packing and faulty or illegible markings.
Each wooden case/crate shall have all the markings stenciled on it in indelible
ink.
9.0 Standards
9.1 The insulators strings and its components shall conform to the following
Indian/International Standards which shall mean latest revision, with
otherwise in the Specification.
9.2 In the event of supply of insulators conforming to standards other than specified
the Bidder shall confirm in his bid that these standards are equivalent to those
specified. In case of award salient features of comparison between the standards
proposed by the Contractor and those specified in this document will be provided
by the Contractor to establish equivalence.
Sr.
No.
Indian Standard Title International
Standard
1. IS:209-1979 Specification for Zinc BS:3436-1986
2. IS:406-1964 Method of Chemical
Analysis of Slab Zinc.

3. IS:731-1971 Porcelain insulators for
overhead Power lines with
a nominal voltage greater
than 1000 V
BS:137-
1982(I&II)
4. IS:2071 Part(I)-
1974 (Part(ii)-1974
(Part(iii)-1976
Methods of High Voltage
Testing
IEC:60-1-1989
5. IS:2486 Specification for insulator
fittings for Overhead
Power Lines with a
nominal voltage greater
than 1000V

Page 101 of 143

Part-I-1971 General Requirements
and Tests)
BS:3288-1979
Part-II-1974 Dimensional
Requirements
IEC:120-1984
Part-III-1974 Locking Devices IEC:372-1984
6. IS:2629-1985 Recommended Practice
for Hot, Dip Galvanization
for iron and steel
ISO-1461(E)
7. IS:2633-1986 Testing of Uniformity of
Coating of zinc coated
articles.

8. IS:3188-1965 Dimensions for Disc
Insulators.
IEC:305-1978
9. IS:6745-1972 Determination of Weight of
Zinc coated iron and steel
articles.
ISO:1460(E)
10. Thermal Mechanical
Performance test and
mechanical performance
test on string insulator
units.
IEC:575-1977
11. Guide for the selection of
insulators in respect of
polluted conditions
IEC:815-1986
12. IS-731-1971 Tests on insulators of
Ceramic material or glass
for overhead lines with a
than 1000V

13. IS-3188 For characteristic of string
insulator units

14. IEC-383/1983 For tests on insulators of
ceramics material for
overhead lines with a
than 1000V

Page 102 of 143

15. IS:13305-1992 Permissible limits of visual
defects for insulating
porcelain.

16. Specification for ceramic
insulating material
IEC-672
(Part-I, II &III)

Page 103 of 143

SECTION-III
PART - F
SPECIFICATIONS FOR EARTH WIRE
1. Technical Description of Earthwire
1.1 Scope & Qualifying Criteria:
i) The bidder is to arrange for supply of HTGSS wire (Earth Wire) of size
7/3.15 mm to be used on 220 KV Transmission Lines.
ii) The bidder shall ensure that the manufacturer fulfills the following
Qualifying Criteria:
a) The manufacturer must have capacity to make at least 2000 MT Earthwire
of size 7/3.15 mm & above per annum. Documentary proof in form of a
certificate from a chartered Accountant / Engineer must be attached with
the Bid.
b) The manufacturer must have supplied at least 1000 MT Earthwire of size
7/3.15mm & above during the last three years. Documentary proof in form
of a certificate from a chartered Accountant / Engineer must be attached
with the Bid.
c) Performance Cetificate(s) from any SEB/ Utility for supply of at least 250
MT Earthwire of size 7/3.15 mm or above shall be funished with the Bid.
d) The average annual turnover of the manufacturer shall not be less than
Rs. 10 crores per annum and he should have liquid assets and / or
evidence of access to or availability of credit facilities of not less than Rs. 2
Crores. Documentary proof for these shall also be attached with the bid.
1.2 Details of Earthwire
1.2.1 The galvanised steel earthwire shall generally conform to the
specification of ACSR core wire as mentioned in IS:12776-1989 & IS:
4826-1979 (latest) except where otherwise specified herein.
1.3 Workmanship
1.3.1 All steel strands shall be smooth, uniform and free from all
imperfections, such as spills and splits, die marks, scratches, abrasions
and kinks after drawing and also after stranding.
1.3.2 The finished material shall have minimum brittleness as it will be
subjected to appreciable vibration while in use.
Page 104 of 143

1.3.3 The steel strands shall be Hot dip galvanised and shall have a
minimum zinc coating of 240 gms/sqm. After stranding of the uncoated
wire surface. The zinc coating shall be smooth, continuous, of uniform
thickness, free from imperfections and shall withstand three and a half
dips after stranding in standard Preece test.
1.3.4 The steel strands shall be preformed and post formed in order to
prevent spreading of strands while cutting of composite earthwire.
Care shall be taken to avoid damage to galvanization during
preforming and post forming operation.
1.3.5 To avoid susceptibility towards wet storage strains (while rust), the
finished material shall be provided with a protective coating of boiled
linseed oil.
1.4 Joints in Wires
There shall be no joint of any kind in the finished steel wire strand
entering into the manufacture of the earth wire. There shall be no
strand joints or strand splices in any length of the completed stranded
earthwire.
1.5 Tolerances
The tolerances shall be as per the relevant ISS.
1.6 Materials
1.6.1 Steel
The steel wire strands shall be drawn from high carbon steel rods and
shall conform to the following requirements as to the chemical composition
:-
Element % Composition
Carbon Not more than 0.55
Manganese 0.4 to 1.10
Phosphorous Not more than 0.05
Sulphur Not more than 0.05
Silicon 0.15 to 0.35
1.6.2 Zinc
The zinc used for galvanising shall be electrolytic High Grade Zinc of
99.95% purity. It shall conform to and satisfy all the requirements of
IS:209-1979
1.7 Standard length
Page 105 of 143

1.7.1 The standard length of the earthwire shall be 2000 meters. The
tolerance on length shall be 5% on the standard length.
1.7.2 Random length will be accepted provided no length is less than 50% of
standard length and the total quantity of random lengths is not more
than ten(10)percent of the total quantity in each shipment.
2.1 Tests
The following type, acceptance and routine tests and tests during
manufacture shall be carried out on the earthwire. For the purpose of this
clause:
2.1.1 Type Tests shall mean those test which are to be carried out to prove
the process of manufacture and general conformity of the material to
this Specification. Type test certificates indicating conformity of the
material as per relevant Standard/PSEB specification are required to
be submitted alongwith the bid as per requirements of section II of this
specification.
2.1.2 Acceptance Tests shall mean those tests which are to be carried out
on samples taken from each lot offered for pre-despatch inspection, for
the purposes of acceptance of that lot.
2.1.3 Routine Tests shall mean those tests, which are to be carried out on
each strand/spool/length of the earthwire to check requirements which
are likely to vary during production.
2.1.4 Tests during Manufacture shall mean those tests, which are to be
carried out during the process of manufacture and end inspection by
the Contractor to ensure the desired quality of the end product to be
supplied by him.
2.1.5 The norms and procedure of sampling for these tests will be as per the
Quality Assurance Programme to be mutually agreed to by the
Contractor and the Employer.
2.1.6 The standards and norms to which these tests will be carried out are
listed against them.
2.1.7 For all type and acceptance tests, the acceptance values shall be the
values guaranteed by the Bidder in the guaranteed technical particulars
of his proposal or the acceptance value specified in this Specification,
whichever is more stringent for that particular test.
Page 106 of 143

2.2 Type Tests, Acceptance Tests, Routine Tests and Test During
Manufacture.
2.2.1 Type Tests on Earthwire
All the tests under clause 2.2.2 (Acceptance Tests)
2.2.2 Acceptance Test on Earthwire

a) Visual and dimensional check on drum
b) Visual check for joints scratches etc. and
lengths of earth wire.
c) Dimensional check
Annexure-A
d) Lay length check

e) Galvanising test

f) Torsion test

g) Elongation Test

h) Wrap test.
i) DC resistance test. IS:398(Part-III)
j) Breaking load test
k) Chemical Analysis of steel

2.2.3 Routine Test on Earth wire.
a) Check for correctness of stranding.
b) Check that there are no cuts, fins etc. on the strands.
c) Check that drums are as per Specification.
2.2.4 Tests During Manufacturer on Earthwire.
a) Chemical analysis of zinc used for galvanising.
b) Chemical analysis of steel.
2.3.1 The entire cost of testing for the type, acceptance and routine tests and
tests during manufacture specified herein shall be treated as included
in the quoted unit price except for the expenses of the
inspector/Employers representative.
2.4 Additional Tests.
2.4.1 The Employer reserves the right of having at his own expenses any
other test(s) of reasonable nature carried out at Contractors premises,
Page 107 of 143

at site, or in any other place in addition to the aforesaid type,
acceptance and routine tests to satisfy himself that the materials
comply with the Specifications.
2.4.2 The Employer 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 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 item all without any extra cost to the
Employer.
2.5 Test Reports
2.5.1 Copy of type test reports ,conducted at Govt. approved / NABL
accredited labs not older than five years at the time of bid submission,
shall be furnished alongwith the Bid.
2.5.2 Record of routine test reports shall be maintained by the Contractor at
his works for periodic inspection by the Employers representative.
2.5.3 Test Certificates of tests during manufacture shall be maintained by the
Contractor. These shall be produced for verification as and when
desired by the Employer.
2.6 Inspection
2.6.1 The Employers representative shall at all times be entitled to have
access to the works and all places of manufacture, where conductor
shall be manufactured and representative shall have full facilities for
unrestricted inspection of the Contractors works, raw materials and
process of manufacture for conducting necessary tests as detailed
herein.(also see annex A)
2.6.2 The Contractor shall keep the Employer informed in advance of the
time of starting and of the progress of manufacture of conductor in its
various stages so that arrangements can be made for inspection.
2.6.3 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
earthwire shall be dispatched only after satisfactory testing for all tests
specified herein have been completed.
Page 108 of 143

2.6.4 The acceptance of any quantity of material shall in no way relieve the
Contractor of any of his responsibilities for meeting all requirements of
the Specification, and shall not prevent subsequent rejection if such
material is later found to be defective.
2.7 Packing for Earthwire in wooden drum
The Contractor shall be responsible for any loss or damage during
transportation handling and storage due to improper packing. The
drums shall generally conform to IS:1778-1980, except as otherwise
specified hereinafter. The empty drums will be the property of the
Contractor and should be disposed at Contractors cost.
2.7.1 The drums shall be suitable for wheel mounting and for letting off the
earthwire under a minimum controlled tension of the order of 5KN.
2.7.2 For Earthwire two standard lengths shall be wound on each drum.
2.7.3 For Earthwire, each strand shall be individually welded to prevent
parting of two lengths at a tension less than 15 KN. The two ends
where the first length finishes and the second length starts, shall be
clearly marked with adhesive tape and no weld should be present
outside these marks. The length between the two marks shall be
treated as scrap and will not be taken into account for measurement
purposes.
2.7.4 All wooden components shall be manufactured out of seasoned soft
wood free from defects that may materially weaken the component
parts of the drums.
2.7.5 The flanges shall be of two ply construction with each ply at right
angles to the adjacent ply and nailed together. The nails shall be
driven from the inside face flange, punched and then clenched on the
outer face. The thickness of each ply shall not vary by more than 3mm
from that required. There shall be at least 3 nails per plank of ply with
maximum nail spacing of 75 mm. Where a slot is cut in the flange to
receive the inner end of the earthwire the entrance shall be in line with
the periphery of the barrel.
2.7.6 The wooden battens used for making the barrel of the earthwire shall
be of segmental type. These shall be nailed to the barrel supports with
at least two nails. The battens shall be closely butted and shall provide
Page 109 of 143

a round barrel with smooth external surface. The edges of the battens
shall be rounded or chamfered to avoid damage to the earthwire.
2.7.7 Barrel studs shall be used for the construction of drums. The flanges
shall be holed and the barrel studs shall be threaded over a length on
either end, sufficient to accommodate washers, spindle plates and nuts
for fixing flanges at the required spacing.
2.7.8 Normally, the nuts on the studs shall stand protruded of the flanges.
All the nails used on the inner surface of the flanges and the drum
barrel shall be counter sunk. The ends of barrel shall generally be
flushed with the top of the nuts.
2.7.9 The inner cheek of the flanges and drum barrel surface shall be
painted with a bitumen based paint.
2.7.10 Before reeling, card board or double corrugated or thick bituminised
waterproof bamboo paper shall be secured to the drum barrel and
inside of flanges of the drum by means of a suitable commercial
adhesive material. After reeling the conductor and exposed surface of
the outer layer of earthwire shall be wrapped with water proof thick
bituminised bamboo paper to preserve the earthwire from dirt, grit and
damage during transport and handling.
2.7.11 A minimum space of 50 mm for earthwire shall be provided between
the inner surface of the external protective lagging and outer layer of
the earthwire.
2.7.12 Each batten shall be securely nailed across grains as far as possible to
the flange, edges with at least 2 nails per end. The length of the nails
shall not be less than twice the thickness of the battens. The nails
shall not protrude above the general surface and shall not have
exposed sharp, edges or allow the battens to be released due to
corrosion.
2.7.13 The nuts on the barrel studs shall be tack welded on the one side in
order to fully secure them. On the second end, a spring washer shall
be used.
2.7.14 Outside the protective lagging, there shall be minimum of two binder
consisting of hoop iron/galvanised steel wire. Each protective lagging
shall have two recesses to accommodate the binders.
Page 110 of 143

2.7.15 The earthwire ends shall be properly sealed and secured on the side of
one of the flanges to avoid loosening of the earthwire layers during
transit and handling.
2.8 Marking
Each drum shall have the following information stenciled on it in
indelible ink alongwith other essential data:
a) Contract/Award letter number.
b) Name and address of consignee.
c) Manufacturers name and address.
d) Drum number
e) Size of earthwire.
f) Length of earthwire in meters.
g) Gross weight of drum with earthwire.
h) Weight of empty drum with lagging.
i) Arrow marking for unwinding.
j) Position of the earthwire ends.
2.9 Verification of Earthwire Length
The Employer reserves the right to verify the length of earthwire after
unreeling at least ten (10) percent of the drums in a lot offered for
inspection.
2.10 Standards
The earthwire shall conform to the following Indian/International
Standards, which shall mean latest revision, amendments/changes
adopted and published, unless otherwise in the Specification.
In the event of the supply of earthwire conforming to standards other
than specified, the Bidder shall confirm in his bid that these 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 documents will be provided by the Contractor to
establish their equivalence.
Sl.
No.
Indian
Standard
Title International
Standards
1 IS:209-
1979
Specification for Zinc BS:3436-1986
2. IS:398-
1982
Specification for
Aluminium Conductors
for Overhead
IEC:209-1966
BS:215-1970
Page 111 of 143

Transmission Purposes.
3. IS:398-
1982 Part-
II
Aluminium Conductor
Galvanised Steel
Reinforced.

BS:215-1970
IEC:1089-1991

4. IS:1778-
1980
Reels and Drums for
Bare Conductors.
BS:1559-1949
5. IS:1521-
1972
Method of Tensile
Testing of Steel Wire.
ISO6892-1984
6. IS:2629-
1985
Recommended Practice
for Hot Dip Galvanising
of Iron and Steeel.

7. IS:2633-
1972
Method of Testing
Uniformity of Coating on
Zinc Coated Articles.

8. IS:4826-
1979
Galvanised Coating on
Round Steel Wires.
IEC:888-1987
BS:443-1969
9. IS:6745-
1972
Methods of
Determination of Weight
of Zinc Coating of Zinc
Coated Iron and Steel
Aticles.
BS:433-1969
ISO:1460-1973
10. Zinc Coated steel wires
for stranded
Conductors.
IEC:888-1987

Page 112 of 143

ANNEXURE-A (Earthwire)

1.1 Chemical Analysis of Steel :Samples taken from the Steel ingots
coils/strands shall be chemically/ spectrographically analysed. The same shall
be in conformity with the requirements stated in this specification.
1.2 Visual and Dimensional Check on Drums:The drums shall be visually and
dimensionally checked to ensure that they conform to the requirements of this
specification.
1.3 Visual Check for Joints, Scratches, etc.:Earth wire drums shall be rewound
in the presence of the Purchaser. The purchaser shall visually check for
scratches, joints, etc. and that the conductor generally conforms to the
requirements of this specification.
1.4 Dimensional Check on Steel :The individual strands shall be dimensionally
checked to ensure that they conform to the requirements of this specification.
1.5 Check for Lay Ratios of various Layers :The lay ratios of various layers
shall be checked to ensure that they conform to the requirements of this
specification.
1.6 Galvanising Test :The test procedure shall be as specified in IS:4826. The
material shall conform to the requirements of this specification. The
adherence of zinc shall be checked by wrapping around a mandrel four times
the diameter of the steel wire.
1.7 Torsion and Elongation Tests on Steel Strands :The test procedures shall
be as per of IS:398 (Part-II ).

Page 113 of 143

SECTION III
PART - G
SPECIFICATIONS FOR HARDWARE FITTINGS

1. Scope & Qualifying Requirements:
1.1 This specification covers design manufacture testing supply & delivery of
ACSR Zebra accessories like Single suspension and Tension string
hardware fitting, PA Rods, Straight Joints, Repair Sleeve and 4R Stock
Bridge Dampers with security clips etc. for 220KV overhead Power
transmission lines in the state of Punjab
1.2 Technical specifications contained herein are for the guidance of the
Bidders. Any deviation from Purchasers specification will be considered
on their relative merits in respect of performance, efficiency, durability and
overall economy, consistent with the requirements stipulated herein after.
1.3 Equipment carrying ISI Mark would be preferred.
1.4 The Bidders may not furnish particulars of Manufacturer who are not in a
position to offer material according to Purchasers specification.
1.5 The details / particulars of Manufacturer who have genuine facilities to
manufacture single piece forged fitting & galvanizing need only be
submitted.
1.6 The tendered prices shall cover the cost of material utilized/destroyed
while carrying out various tests as specified in this specification or in the
relevant ISS to which the material offered shall conform and no extra
payment shall be due for the material so destroyed during testing.
1.7 The manufacturer should have adequate capacity to manufacture
Hardware Fittings & accessories suitable for ACSR Zebra / Moose and
should have supplied at least 2000 nos. Tension Fittings, 4000 nos.
Suspension Fittings, 2000 sets of PA rods and 3000 nos. 4-R Dampers for
ACSR Zebra and/or Moose during the last two years. Certificate of a
Chartered Accountant / Engineer for the same shall be furnished with the
bid. In addition to this, Performance Certificate for supply of at least 1500
nos. Tension Fittings, 2500 nos. Suspension Fittings, 2500 sets of PA rods
and 4000 nos. 4-R Dampers for ACSR Zebra and/or Moose during the last
two years from any SEB / utility shall also be furnished with the Bid. On
Page 114 of 143

Financial side, the average Turnover of the manufacturer for the last three
financial should be min.2 Crores and he should have liquid assets and / or
evidence of access to or availability of credit facilities of not less than Rs.
50 lakhs. Documentary proof for these shall also be attached with the bid.
2.0 Technical Description of Hardware Fittings:
2.1 Details of Hardware Fittings:
The hardware fittings shall be as per the specification drawings
enclosed with this part of the specification. Each hardware fitting shall be
supplied complete in all respects and shall include the following hardware
parts:
a) Single/Double suspension and Tension hardware fittings, shall be supplied
suitable for attaching to strain plate fixed to tower.
b) Suspension and dead end assembly to suit conductor size of ACSR
ZEBRA.
c) Other necessary fittings as eye links, ball clevis, socket clevis, clevis eye,
U-clevis and chain link etc. to make the hardware fittings complete.
d) 2.5% extra fasteners.
2.2 Dimensions of Insulators String alongwith Hardware Fitting:
The various limiting dimensions of Single/Double Suspension and
Single/Double Tension insulator strings alongwith hardware fitting shall be
as per the specification drawing enclosed with this part of the specification
2.3 Interchangeability:
The hardware for insulator strings with disc insulators together with ball &
socket fitting shall be of standard design, so that these hardware are
interchangeable with each other and suitable for use with disc insulators of
any make conforming to relevant Indian standard.
2.4 Corona and RI Performance:
Sharp edges and scratches on all the hardware fittings shall be avoided.
All surfaces must be clean, smooth, without cuts and abrasions or
projections to avoid Corona and Radio Interference.
2.5 Maintenance:
The hardware fittings offered shall be suitable for employment of hot line
maintenance techniques so that usual hot line operations can be carried
out with ease, speed and safety. The techniques adopted for hot line
maintenance shall be generally bare hand method & hot stick method.
Page 115 of 143

2.6Ball and Socket Designation
The dimensions of the ball and socket shall be of 16mm for 70 KN disc
insulators & 20mm for 160KN disc insulators. The designation should be in
accordance with the standard dimensions shall be checked by the
appropriate gauge after galvanizing only.
2.7 Security clips and Split Pins
i) Security clips for use with ball and socket coupling shall be R-shaped, hump
type, which provides positive locking of the coupling as per IS: 2486(Part-III)
1974 shall be made of Phosphorous bronze conforming to IS: 7814-1975. The
legs of the security clips shall be spread after assembly in the works to prevent
complete withdrawal from the socket. The locking device should be resilient,
corrosion resistant and of suitable mechanical strength. There shall be no risk
of the locking device being displaced accidentally or being rotated when in
position. Under no circumstances shall the locking devices allow separation of
fittings.
ii) 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 energized conditions. The force required to
pull the security clip into its unlocked position shall not be less than 50 N (5Kg)
or more than 500 N (50 Kg).
iii) Split pins shall be used with bolts & nuts.

2.8 Suspension Assembly:
i) The suspension assembly shall be suitable for ACSR Zebra (54/7/3.18
Conductor).
ii) The suspension assembly shall include free centre type suspension clamp
alongwith standard preformed Armour rods. The suspension clamp
alongwith standard preformed Armour rods set shall be designed to have
maximum mobility in any direction and minimum moment of inertia so as to
have minimum stress on the conductor in the case of oscillation of the
same.
iii) The suspension clamp alongwith standard preformed armour rods set
shall have a slip strength between 8-15% of breaking load of ACSR
zebra. The conductor should not slip at a load of 8% of breaking load of
conductor. The slip strength shall not exceed 15% of breaking load of
Page 116 of 143

conductor as per specification
iv) The suspension assembly shall be designed, manufactured and finished to
give it a suitable shape, so as to avoid any possibility of hammering
between suspension assembly and conductor due to vibration. The
suspension assembly shall be smooth without any cuts, grooves,
abrasions, projections, ridges or excrescences, which might damage
the conductor.
v) The suspension assembly/clamp shall be designed so that it shall
minimize the static & dynamic stress developed in the conductor under
various loading conditions as well as during wind induced conductor
vibrations.
2.9 Free Centre Type Suspension Clamp:
i) Free Centre Suspension Clamp shall be smoothly rounded and curved
into a bell mouth at the ends. The lip edges shall have rounded bead.
There shall be at least two U-bolts for tightening of clamp body and keeper
pieces together.
ii) The Suspension Clamp required for use on ACSR Zebra shall be of
Aluminium alloy only. The clamp body and the keeper pieces shall be of
high strength aluminium alloy, while base cotter bolt, U-bolts and nuts shall
be of stainless steel (IS: 6603-1972)
iii) The ball mouth of the Suspension Clamp shall be so designed as to
take into the account, the hypothetical catenarys angle of the conductor
vibrations.
iv)The clamp body and the conductor groove of the keeper pieces shall
hold the conductor at mutually suitable curvature, so that the conductor
receives the maximum compression at the clamp centre, with gradually
lessening compression as it reaches the ball mouth in order that any
damage to conductor due to vibration is minimized.
v)The suspension clamp when suspended vertically by means of flexible
attachment shall not slip upto a minimum load of 2200 kg i.e 50% of the
maximum working tension of the conductor.
vi) Supplier shall indicate the tightening torque with which Nuts should be
tightened so that conductor in suspension clamps should not slip at a load
of 2200 kg i.e 50% of the maximum working tension of the conductor so as
to have the required slip strength.
Page 117 of 143

2.10 Dead end Assembly:
i) The dead end assembly shall be suitable for ACSR Zebra.
ii) 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
0
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 I
2
R losses. The
resistance of the clamp when compressed on Conductor shall not be more
than 75% of the resistance of equivalent length of Conductor.
iii) Die compression areas shall be clearly marked on each dead-end
assembly designed for continuous die compressions and shall bear the words
COMPRESS FIRST suitably, inscribed near the point on each assembly
where the compression begins. If the dead end assembly is designed for
intermittent die compression it shall bear identification marks
COMPRESSION ZONE and NON COMPRESSION ZONE distinctly with
arrow marks showing the direction of compressions and knurling marks
showing the end of the zones. Tapered aluminium filler plugs shall also be
provided at the line of demarcation between compression & non-compression
zone. The letters, number and other markings on the finished clamp shall be
distinct and legible. The dimensional tolerances of the cross section of
aluminium /aluminium alloy for dead end assembly for ACSR Zebra shall be
as per the table given below:
Sr
No.
Item Dimensions before
Compression
Dimensions after
Compression
Inner
Dia
(mm)
Outer Dia
(mm)
Corner to
corner
(mm)
Face to
face (mm)
1 Aluminium 31 48 46 40
2 Steel 10.7 28.8 20.2 17.5

iv) The assembly shall not permit slipping or damage to, or failure of the
complete conductor or any part thereof at a load less than 95% of the ultimate
tensile strength of the conductor.
2.11 Yoke Plates
Page 118 of 143

The strength of yoke plates shall be adequate to withstand the minimum
ultimate tensile strength, as specified in the bid drawings. The plates shall be
either triangular or rectangular in shape as may be necessary. The design of
yoke plate shall into account the most unfavorable loading conditions likely to
be experienced as a result of dimensional tolerances for disc insulators as
well as components of hardware fittings within the specified range. The plates
shall have suitable holes for fixing arcing horn. All the corners and edges
should be rounded off with a radius of atleast 3mm. The holes provided for
bolts in the yoke plate should satisfy shear edge condition as per Clause
No.8.10 of IS:800-1984.

3.0 Fasteners: Bolts, Nuts and Washers:
i) All bolts and nuts shall confirm to IS:12427-1988. All bolts and nuts shall
be hot dip galvanized. 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.
ii) Bolts upto M16 and having length upto 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 min.
as per IS: 12427.Bolts should be provided with washer face in accordance
with IS: 1363 Part-1 to ensure proper bearing.
iii) Nuts should be double chamfered as per the requirement of IS:1363 Part-
III,1984.It should be ensured by the manufacturer that nuts should not be
over tapped beyond 0.4mm oversize on effective diameter for size upto
M16.
iv) Fully threaded bolts shall not be used. The length of the bolt shall be such
that the threaded portion shall not extend into the place of contact of the
component parts.
v) All bolts shall be threaded to take the full depth of the nuts and threaded
enough to permit 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 8mm when fully tightened. All nuts shall fit
and tight to the point where shank of the bolt connects to the head.
vi) Flat washers and spring washers shall be provided wherever necessary
Page 119 of 143

and shall be of positive lock type. Spring washers shall be electro-
galvanised. The thickness of washers shall conform to IS:2016-1967.
vii) To obviate bending stress in bolt, it shall not connect aggregate thickness
more than three time its diameter.
viii) Bolts at the joints shall be so staggered that nuts may be tightened with
spanners without fouling.
ix) To ensure effective in-process quality control it is essential that the
manufacturer should have all the testing facilities for tests like weight of
zinc coating, shear strength, other testing facilities etc, in-house.
x) Fasteners of grade higher than 8.8 are not to be used.

4.0 Materials:
i) The materials of the various components shall be as specified hereunder.
However components made of alternative materials giving equivalent or
better performance shall also be considered. The Bidder shall indicate the
material proposed to be used for each and every component of hardware
fittings stating clearly the class, grade or alloy designation of the material,
manufacturing process & heat treatment details and the reference
standards.
ii) Raw material to be used for the manufacture of various hardware fittings
made of mild steel, forged steel and aluminium alloy, nuts and bolts, cotter
pins, security clips, galvanizing or electro-plating shall conform to relevant
Indian standard and may be tested by purchaser according to the tests laid
therein.
4.1 Mild Steel:
Raw material to be used for the manufacture of various hardware
fittings made of mild steel shall be tested according to the tests laid in the
relevant Indian standard, if so desired by the purchaser.
4.2 Aluminium or Aluminium Alloy fittings:
The Aluminium or Aluminium Alloy fittings shall be of extruded sections
as mentioned against each. The type of Aluminium/ Aluminium Alloy, its
mechanical properties and chemical composition shall be indicated in the
tender.
4.3 Forgings:
Page 120 of 143

All the forged fitting shall be made from forged steel and all the tests
specified in the corresponding IS shall be performed on the test bars, if
desired by the purchaser. The Bidder shall specify whether cold or hot
process shall be used and the forging done with drop hammer or press,
alongwith the size and capacity of the forging equipment. All the forged
fittings shall be made out of one piece and these shall not be made by
joining welding or shrunk fitted or with any other process.
The Bidder shall indicate type of forging steel and its mechanical
properties, which will be used for producing forged hardware fittings.
The details of materials for different component are listed as in Table No.1
5.0 Workmanship:
i) All the equipment shall be of the latest design and conform to the best modern practices
adopted in the Extra High Voltage field.
ii) All ferrous parts including fasteners shall be hot dip galvanized, after all
machining has been completed. Nuts may, however, be tapped (threaded)
after galvanizing and the threads oiled. Spring washers shall be electro-
galvanized. The bolt threads shall be undercut to take care of the increase in
diameter due to galvanizing. Galvanizing shall be done in accordance with
IS:2629-1985 and shall satisfy the tests mentioned in IS:2633-1986.
Fasteners shall withstand four dips while spring washers shall withstand three
dips of one-minute duration in the standard preece test. Before ball fittings are
galvanized, all die flashing on the shank and on the bearing surface of the ball
shall be carefully removed without reducing the dimensions below the design
requirements.
iii) The zinc coating shall be perfectly adherent, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux,
ash, rust stains, bulky white deposits and blisters. The zinc used for
galvanizing shall be grade Zn 99.95 as per IS: 209-1979.
iv) Pin balls shall be checked with the applicable GO gauges in at least two
directions, one of which shall be across the line of die flashing and the
other 90
0
to this line. NO GO gauges shall not pass in any direction.
v) Socket ends, before galvanizing, shall be of uniform contour. The bearing
surface of socket ends shall be uniform about the entire circumference
without depressions of high spots. The internal contours of socket ends
shall be concentric with the axis of the fittings as per IS: 2486.
Page 121 of 143

vi) The axis of the bearing surfaces of socket ends shall be coaxial with the
axis of the fittings. There shall be no noticeable tilting of the bearing
surfaces with the axis of the fittings.
vii) In case of casting, the same shall be free from all internal defects like
shrinkage inclusion, blowholes, cracks etc. Pressure die-casting shall not
be used for casting of components with thickness more than 5 mm.
viii) All current carrying parts shall be so designed and manufactured that
contact resistance is reduced to minimum & localized heating
phenomenon is averted.
ix) No equipment shall have sharp ends or edges, abrasions or projections
and cause any damage to the conductor in any way during erection or
during continuous operation, which would produce high electrical and
mechanical stresses in normal working. The design of adjacent metal parts
and mating surfaces shall be such as to prevent corrosion of the contact
surface and to maintain good electrical contact under service conditions.
x) All the holes shall be cylindrical, clean cut and perpendicular to the plane
of the material. The periphery of the holes shall be free from burrs.
xi) All fasteners shall have suitable corona free locking arrangement to guard
against vibration loosening.
xii) Welding of aluminium shall be by inert gas shielded tungsten arc or inert
gas shielded metal arc process. Welds shall be clean, sound, smooth, and
uniform without overlaps, properly fused and completely sealed. There
shall be no cracks, voids incomplete penetration, incomplete fusion, under-
cutting or inclusions. Porosity shall be minimized so that mechanical
properties of the aluminium alloys are not affected. All welds shall be
properly finished as per good engineering practices.
xiii) The particular care shall be taken during manufacture & subsequent
handing to ensure smooth surface free from abrasion or cuts.
6.0 Bid Drawings:
i) The Bidder shall furnish full description and illustrations of materials offered.
ii) Fully dimensioned drawings of the complete insulator string hardwares and
the component parts showing clearly the following arrangements shall be
furnished in four (4) copies alongwith the bid. Weight, material and fabrication
details of all the components should be included in the drawings.
(a) Attachment of the hanger or strain plate.
Page 122 of 143

(b) Suspension or dead end assembly.
(c) Links with suitable fittings.
iii) All drawing shall be identified by a drawing number and contract number. All
drawings shall be neatly arranged. All drafting & lettering shall be legible. The
minimum size of lettering shall 3 mm. All dimensions & dimensions tolerances
shall be mentioned in mm:
The drawing shall include:
(a) Dimensions and dimensional tolerance.
(b) Materials, fabrication details including any weld details & any
specified finishes & coatings. Regarding material, designation &
reference of standards are to be indicated.
(c) Catalogue No.
(d) Marking
(e) Weight of assembly
(f) Installation instructions
(g) Design installation torque for the bolt or cap screw.
(h) Withstand torque that may be applied to the bolt or cap screw
without failure of component parts.
(i) The compression die number with recommended compression
pressure.
(j) All other relevant terminal details.
iv) After placement of award, the Contractor shall submit fully dimensioned
drawing including all the components in four (4) copies to the Purchaser for
approval. After getting approval from the Purchaser and successful
completion of all the type tests, the Contractor shall submit 10 more copies
of the same drawings to the Purchaser for further distribution and field use
at Purchasers end.
Table-1
Details of Materials for ACSR Zebra
Sr.
No.
Name of item. Material Reference
Standard
1. Security Clips SS/Phosphor Bronze IS: 7814:1975/
IS:6603-1972
2. U-clevis/ Anchor
shackle
Forged Steel Grade-4 As per IS:2004
1978 or
equivalent.
3. Ball Eye/ Ball clevis Forged Steel Grade-4 As per IS:2004
1978 or
Page 123 of 143

equivalent.
4. Socket clevis /
Clevis-clevis
Forged Steel Grade-4 As per IS:2004
1978 or
equivalent.
5. Tension Clamp Extruded Aliminium
(99.5% pure)
As per IS:2004
1978 or
equivalent.
6. Suspension Clamp High Strength Al. Alloy IS: 6051:1910
7. Dead End
Assembly

(a)Outer Sleeve (of
dead end
assembly)
EC grade of Extruded
Aluminium (99.5%
pure)

(b) Steel Sleeve Mild Steel/FS As per IS:226-
1975
8. Jumper Bolts / U-
bolts with flat
washer & nut

Stainless Steel IS: 6603:1972
9. Bolt, Nut & Flat
washer for outer
parts
Mild Steel HDG
10. Spring Washer Spring steel
11. Split pin Brass with min
hardness of 160HV

7.0 Tolerance in Dimensions
The tolerance, if any, in all important dimensions, shall be indicated on
each of the drawing, otherwise the purchaser shall stick to the dimensions
given in the specification drawings, in case the offer is accepted.
8.0 Samples
The bidder who has not supplied /executed order earlier for these items to
PSTCL may submit samples within 15 days of opening of the tender free of
cost. Ordinary samples will not be returned to supplier. However expensive
samples will be returned to him & should be collected by him within 1 month
of opening of the tender at his own risk & cost .

9.0 Accessories For ACSR Zebra conductor
9.1 General
i) This portion details the technical particulars of the accessories for ACSR
Zebra.
ii) 2.5% extra fasteners shall be provided.
9.2 Standard Preformed Armour Rod Set
Page 124 of 143

1) The Preformed Armour Rods Set suitable for ACSR Zebra shall be used to
minimize the stress developed in the conductor due to different static and
dynamic loads because of vibration due to wind, slipping of conductor from
the suspension clamp as a result of unbalanced conductor tension in
adjacent spans and broken wire condition. It shall also withstand power arcs;
chafing and abrasion from suspension clamp and localized heating effect due
to magnetic power losses from suspension clamps as well as resistance
losses of the conductor.
2) The preformed armour rods set shall have right hand lay and the inside
diameter of the helices shall be less than the outside diameter of the
conductor (conductor being manufactured according to IS; 398-1961-Part II)
to have gentle but permanent grip on the conductor and the loading stress
shall be evenly distributed over the entire length of the conductor through out
the length of contact. The surface of the armour rod when fitted on the
conductor shall be smooth and free from projections, cuts and abrasions etc.
3) The armour rods shall not have the tendency of loosening at the ends during
use. The armour rods shall conform to IS: 2121-1981 (Part-I) with latest
amendments.
4) The manufacture of armour rods should be free of machine marks or any
surface distortions and the ends must be smooth, so as not to cause damage
to the conductor and that corona effect is minimum.
5) The number of armour rods in each set shall be twelve. Each rod shall be
marked in the middle with paint for easy application on the line.
6) The armour rod shall not loose their resilience even after five applications.
7) Material will be supplied as per following particulars:
1. Type Performed
2. Suitable for ACSR Zebra conductor
3. Material Aluminium Alloy (High strength in
accordance with IS: 739-1996)
4. UTS 35 kg/mm
2
5. Dimensions As per IS: 2121-1981 (Part-I)
6. Tolerance in dimensions As per IS: 2121-1981 (Part-I)
7. Number of Rods in each
set
12 Nos.
8. Direction of Lay Right Hand Lay
9. Shape of ends & centre
marking
Ball ended, Centre to be marked
with Black paint
10. Conductivity Not less than 39% of the
conductivity of the IACS.
11. Slip strength 25% of UTS of conductor
Page 125 of 143

9.3 Mid Span Compression Joint
1.Mid Span Compression Joint shall be used for joining two lengths of conductor
shall be made out of extruded aluminium tubing and of circular to hexagonal pattern.
The joint shall have a resistively less than 75% of the resistivity of equivalent length
of conductor. The joint shall not permit slipping off, damage to, or failure of the
complete conductor or any part thereof at a load less than 95% of the ultimate tensile
strength of the conductor.
2.The joint shall be made of aluminium sleeves for jointing the conductor. The
aluminium sleeve shall have aluminium of purity not less than 99.5%. Tapered
aluminium filler plugs shall also be provided on the line of demarcation between
compression and non-compression zone. The Mid Span Compression Joint should
be so designed that when installed, no air space is left within the finished joint. The
dimensions and dimensional tolerances of mid span compression joint shall be as
per Table-II.
3.The tender must accompany dimensional sketches separately for steel and
aluminium portion of the joint before and after it is installed on the conductor, along
with the inner and outer dimensions of steel and aluminium portions of the joint.
4.The Mid Span Compression Joint in all respects must comply with the
requirements laid down for such joints in IS:2121-1981(Part-II) (with latest
amendments). Tender shall be accompanied with copies of the type tests mentioned
in relevant IS in support of the guaranteed technical particulars.

1. Type Compression
2. Material
i) Outer Sleeve Aluminium (Extruded tube) 99.5%
pure
II) Inner Sleeve Steel (Hot Dip galvanized)
3. Shape of cross section
i) Before compression Round
ii) After compression Hexagonal
4. Min. failing load Not less than 95% of the breaking
load of the conductor
5. Electrical resistance of the
joint after installation
Not more than 75% of measured
resistance of the equivalent length
Page 126 of 143

of conductor
6. Marking Compression & non compression
zone to be marked clearly of the
Aluminium sleeve
7. Weight 0.4 kg (indicative only)

Page 127 of 143

Table II
Dimensions & Dimensional Tolerances for Mid Span Compression Joint
and Repair Sleeve for ACSR Zebra
Sr
No.
Item Dimensions before
Compression
Dimensions after
Compression
Inner
Dia

(mm)
Outer
Dia

(mm)
Length

(mm)
Corner
to
Corner
(mm)
Face to
Face

(mm)
1 Mid Span Compression joint for ACSR Zebra
A

Aluminium
Sleeve
31+0.5 48+1 710+5 46+0.5 40+0.5
B Steel Sleeve 10.7 28.8 20.2 17.5
2 Repair Sleeve 31+0.5 48+1 275+5 46+.5 40+.5

9.4 Repair Sleeve
1. Repair Sleeve of compression type shall be used to repair conductor with not
more than one sixth of the strands broken in the outer layer. The sleeve shall be
manufactured from 99.5% pure aluminium and shall have a smooth surface. The
repair sleeve shall comprise of two pieces with a provision of seat for sliding of the
keeper piece. The edges of the seat as well as keeper piece shall be so rounded that
the conductor strands are not damaged during installation. The dimensions and
dimensional tolerances of repair sleeve shall be as per Table-II.
2. Repair sleeves suitable for ACSR Conductor shall be of circular to hexagonal
pattern and are required to make good the severed strands of the conductor. The
repair sleeves shall be suitable for applying with 100 Ton press. The material to be
used for repair sleeve shall satisfy the requirement laid down in IS-2121-1981 (Part-
II) for ACSR Zebra conductor.

Table III
1. Type Compression type, in two parts
with provision of seat for sliding of
keeper piece
2. Shape of cross section
i) Before compression Generally round
ii) After compression Hexagonal
3. Dimensions As per given in Table II
Page 128 of 143

4. Suitable for ACSR ZEBRA conductor
5. Material Extruded Aluminium 99.5% pure
6. UTS Not less than 95% of UTS of
conductor

7. Standard IS: 2121-1981 (Part-II)
8. Max. Electrical resistance
of repaired portion
Not more than 75% of measured
resistance of the equivalent length
of conductor
9. Min. failing load 95% of breaking load of conductor
10. Length As per given in Table II

9.5 Vibration Damper
1. Vibration dampers of 4R-stockbridge type with four (4) different resonances
spread within the specified aeolian frequency band width corresponding to wind
speeds of 1m/s to 7 m/s shall be used at suspension and tension points on each
conductor in each span to damp out aeolian vibrations as mentioned hereinafter.
2. One damper minimum on each side per conductor for suspension points and
for tension points shall be used for ruling design span of 350 meters.
3. The clamp of the vibration damper shall be made of high strength aluminium
alloy of designation 4600 as per IS:617-1994. It shall be capable of supporting the
damper and prevent damage or chafing of the conductor during erection or
continued operation. The clamp shall have smooth and permanent grip to keep the
damper in position on the conductor without damaging the strands or causing
premature fatigue failure of the conductor under the clamp. The clamp groove shall
be in uniform contact with the conductor over the entire clamping surface except for
the rounded edges. The groove of the clamp body and clamp cap shall be smooth,
free from projections, grit or other materials, which could cause damage to the
conductor when the clamp is installed. Clamping bolts shall be provided with self-
locking nuts and designed to prevent corrosion of threads of loosening in service.
4. The messenger cable shall be made of high strength galvanized
steel/stainless steel with a minimum strength of 135 Kg/mm
2
. It shall be of preformed
and post formed quality in order to prevent subsequent droop of weight and to
maintain consistent flexural stiffness of the cable in service. The number of strands
in the messenger cable shall be 19. The messenger cable other than stainless steel
Page 129 of 143

shall be hot dip galvanized in accordance with the recommendations of IS: 4826-
1979 for heavily coated wires.
5. The damper mass shall be made of hot dip galvanized cast iron . All castings
shall be free from defects such as cracks, shrinkage, inclusions and blowholes etc.
The surface of the damper masses shall be smooth. The bidder should indicate the
composition of the material so used for casting and give its
6. The damper mass shall be so designed so as to avoid accumulation of
rainwater in it. If necessary damper masses may be provided with holes before
galvanizing for draining out the rainwater.
7. The damper clamp shall be casted over the messenger cable and offer
sufficient permanent grip on it. The tightening torque for fitting the Damper with the
conductor shall be indicated in the tender. The clamping bolts shall be provided with
suitable locking devices to prevent loosening during service due to electrical and
mechanical stresses.
8. The threads in nuts & tapped holes shall be cut after galvanizing and shall be
well lubricated or greased. All other threads shall be cut before galvanizing.
9. The damper clamp shall be capable of being removed and reinstalled on the
conductor at the designated torque without damaging the fasteners or the conductor
surface.
10. The messenger cable shall not slip out of the grip at a load less than the mass
pull-off value of the damper. The damper masses made of material other than zinc
alloy shall be fixed to the messenger cable in a suitable manner in order to avoid
excessive stress concentration on the messenger cables, which shall cause
premature fatigue failure of the same. The messenger cable ends shall be suitably
and effectively sealed to prevent corrosion. The damper mass made of zinc alloy
shall be casted over the messenger cable and have sufficient and permanent grip on
the messenger cable under all service conditions.
11. The vibration damper shall be capable of being installed and removed from
energized line by means of hot line techniques. In addition, the clamp shall be
capable of being removed and reinstalled on the conductor at the designated torque
without shearing or damaging of fasteners & conductor.
12. 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
Page 130 of 143

concentration on the conductor leading to permanent deformation of the conductor
strands and premature fatigue failure in operation.
13. The vibration damper shall not have magnetic power loss more than 1 watt at
500 Amps. 50 Hz alternating current per conductor.
14. The technical particulars for damping design of the system are as follows:
----------------------------------------------------------------------------------------------
Sr. No. Description Technical Particulars.
Zebra
----------------------------------------------------------------------------------------------
Configuration Double /Single Circuit
1. Span length in meters
(i) Average span 350 m
ii) Max. span 500 m
2. Tensile load in Wind Zone 4
(As per IS:875,1987 (47m/s)
a) At temperature of 2.5
o
C 4133 kg
and Still air
b) At temperature of 2.5
0
C 4428 kg
and 2/3rd full wind
b) At temperature of 32
0
C 3951 kg
and full wind
3. Armour rods used Standard performed Armour rods
4. Maximum permissible 150 micro strain
dynamic strain
5. Max. working temperature 75
o
C
6.. Ultimate breaking load 130.32 KN
----------------------------------------------------------------------------------------------
18. The Contractor shall submit the damper placement chart for spans ranging
from 100m to 500m. Placement charts should be duly supported with
relevant technical documents and sample calculations.
19. The damper placement charts shall include the following:
(1) Location of the dampers for various combinations of spans and
line tensions clearly indicating the number of dampers to be
installed per span.
(2) Placement distance clearly identifying the extremities between
which the distances are measured.
Page 131 of 143

(3) Placement recommendation depending upon type of suspension
clamps (viz Free centre type)
(4) The influence of mid span compression joints, repair sleeves
and Armour rods in the placement of dampers.
(5) The dampers shall be suitable for installation and replacement
with hot line tools.
9.6 Material and Workmanship
9.6.1 All the equipments shall be of the latest proven design and conform to the
best modern practice adopted in the extra high voltage field. The Bidder
shall offer only such equipment as guaranteed by him to be satisfactory
and suitable for 220KV lines and will which give continued good
performance.
9.6.2 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 sharp edges and corners, best
resistance to corrosion and a good finish.
9.6.3 All ferrous parts shall be hot dip galvanized, after all machining has been
completed. Nuts may, however, be tapped (threaded) after galvanizing
and threads oiled. Spring washers shall be electro-galvanized. The bolt
threads shall be undercut to take care of increase in diameter due to
galvanizing. Galvanizing shall be done in accordance with IS: 2629-1985
and satisfy the tests mentioned in IS: 2633-1986. Fasteners and other
galvanized materials shall be guaranteed to withstand at least four dips
each lasting one minute under the standard Preece test for galvanizing
unless otherwise specified.
9.6.4 The zinc coating shall be perfectly adherent, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux,
ash, rust, stains, bulky white deposits and blisters. The zinc used for
galvanizing shall be of grade Zn.99.95 as per 209-1979.
9.6.5 In case of castings, the same shall be free from all internal defects like
shrinkage inclusion, blowholes, cracks etc.
9.6.6 All current carrying parts shall be so designed and manufactured that
contact resistance is reduced to minimum and localized heating
phenomenon is averted.
9.6.7 No equipment shall have sharp ends or edges, abrasions or projections
Page 132 of 143

and shall not cause any damage to the conductor in any way during
erection or during continuous operation which would produce high
electrical and mechanical stresses in normal working. The design of
adjacent metal parts and mating surfaces shall be such as to prevent
corrosion of the contact surface and to maintain good electrical contact
under all service conditions.
9.6.8 Particulars care shall be taken during manufacture and subsequent
handling ensure smooth surface free from abrasion or cuts.
9.6.9 The fasteners shall conform to the requirement of IS: 6639-1972. All
fasteners and clamps shall have corona free locking arrangement to guard
9.6.10 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 90 deg. to this line. NO GO gauges shall not pass in any direction.
9.6.11 Socket ends, before galvanising shall be of uniform contour. The bearing
surface of socket ends shall be uniform about the entire circumference.
9.6.12 The axis of the bearing surfaces of socket ends shall be coaxial with the
axis of the fittings. There shall be no noticeable tilting of the bearing
surfaces with the axis of the fittings.
In case of casting, the same shall be free from all internal defects like
shrinkage inclusion, blowholes, cracks etc. Pressure die-casting shall not
be used for casting of components with thickness more than 5 mm.
9.6.13 All the holes shall be cylindrical, clean cut arid perpendicular to the plane
of the material. The periphery of the holes shall be free from burrs.
9.6.14 All fasteners shall have suitable corona free locking arrangement to guard
9.6.15 Welding of aluminium shall be by inert gas shielded tungsten arc or inert
gas shielded metal arc process. Welds shall be clean, sound, smooth, and
uniform without overlaps, properly fused and completely sealed. there
shall be no cracks, voids, incomplete penetration, incomplete fusion, under
cutting or inclusions. Porosity shall be minimized so that mechanical
properties of the aluminium alloys are not affected. All welds shall be
properly finished as per good engineering practices.

9.7 Compression Markings
Page 133 of 143

Die compression areas shall be clearly marked on each equipment
designed for continuous die 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 and knurling marks showing the end
of the zones. The letters, number and other markings on finished
equipment shall be distinct and legible.
9.8 Bid Drawings
The Bidder shall furnish detailed dimensioned drawings of the equipments
and all component parts. Each drawing shall be identified by a drawing
number and Contract number. All drawing shall be neatly arranged. All
drafting and lettering shall be legible. The minimum size of lettering shall
be 3mm. All dimensions and dimensional tolerances shall be mentioned in
mm.
The drawings shall include:
(i) Dimensions and dimensional tolerances.
(ii) Material, fabrication details including any weld details and any
specified finishes and coatings. Regarding material,
designations and reference of standards are to be indicated.
(iii) Catalogue No.
(iv) Marking.
(v) Weight of assembly.
(vi) Installation instructions.
(vii) Design installation torque for the bolt or cap screw.
(viii) Withstand torque that may be applied to the bolt or cap screw
without failure of component parts.
(ix) The compression die number with recommended compression
pressure.
(x) All other relevant technical details.
9.8.1 Placement charts for spacer/spacer damper and damper.
9.8.2 The above drawing shall be submitted in 4 copies with all the details as
stated above alongwith the bid document. After the placement of award,
the Contractor shall again submit the drawings in four copies to the
Page 134 of 143

Purchaser for approval. After Purchasers approval and successful
completion of all type tests, 10 more sets of drawings shall be submitted to
Purchaser for further distribution and field use at Purchasers end.
The type, acceptance and routine tests and tests during manufacture shall be
carried out. For the purpose of this clause:
a) Type tests shall mean those tests, which are to be carried out to prove the
design process of manufacture and general conformity of the material to
this Specification.
b) Acceptance test shall mean those tests, which are to be carried out on
samples taken from each lot offered for pre-dispatch inspection for the
purpose of acceptance of that lot.
c) Routine test shall mean those tests, which are to be carried out on each item
of the material to check requirements, which are likely to vary during
production.
d) Tests during Manufacture shall mean those tests which are to be carried out
during the process of manufacturing and end inspection by the Purchaser to
ensure the desired quality of the end product to be supplied by him.
e) The standards & norms to which these tests shall be carried out are listed
against them.
f) For all type and acceptance tests, the acceptance values shall be the values
guaranteed by the Bidder in the data requirement sheets of this proposal or
the acceptance value specified in this specification, whichever is more
stringent for that particular test.
10.0 Earthwire Accessories for 7/3.15 mm Earthwire
10.1 General
1. This portion details the technical particulars of the accessories for
Galvanised Steel Earthwire.
2. 2.5% extra fasteners shall be supplied.
10.2 Mid Span Compression Joint
Mid Span compression joint shall be used for joining two lengths of
earthwire. The joint shall be made of mild steel. The steel sleeve should
not crack or fail during compression. The Brinnel Hardness of stainless
steel should not exceed 200. The steel sleeve shall be hot dip galvanized.
The joints shall not permit slipping off, damage to, or failure of the
Page 135 of 143

complete earthwire or any part thereof at a load not less than 95% of the
ultimate tensile strength of the earthwire. The joint shall have resistivity
less than 75% of resistivity of equivalent length of earthwire. The
dimensions and the dimensional tolerances of the joint shall be as per the
table given below;
Sr.
No
Item Dimension before
compression
Dimensions after compression
Inner dia
(mm)
Outer dia
(mm)
Corner to corner
width (mm)
Face to face
width (mm)
1. Steel
Sleeve
10+/-0.2 20+/-.2 19+/-0.5 16+/- 0.5

10.3 Vibration Dampers
i)Vibration Dampers of 4R stock bridge type with four (4) different
frequencies spread within the specified Aeolian frequency bandwidth
corresponding to wind speed of 4m/s to 7 m/s shall be used for suspension &
tension points on which each earth wire in each span to damp out Aeolian
vibration as mentioned herein after.
ii)One damper min on each side per earth wire at suspension points and at
tension points shall be used for ruling design span of 350 mtr. for Earthwire of
size 7/3.15.
iii)The bidder may offer damping system involving more number of dampers
per ruling design span than the specified.
iv)The clamp of the Vibration Dampers shall be made of aluminum alloy. It
shall be capable of supporting the damper during installation and prevent
damage or chafing of earth wire during erection or continued operation.
The clamp shall have smooth and permanent grip to keep the damper in
position on the earth wire without damaging the strands or causing
premature fatigue failure of the earthwire under the clamp. The clamp
grooves shall be in uniform contact with the conductor over the entire
clamping surface except for the rounded edges. The groove of the clamp
body and clamp cap shall be smooth, free from projections, grit or
materials which could cause damage to the earthwire when the clamp is
installed. Clamping bolts shall be provided with self locking nuts designed
to prevent corrosion of the threads or loosening during service.
v) The messenger cable shall be made of high strength galvanised
steel/stainless steel with a minimum strength of 135 kg/sq.mm. It shall be
Page 136 of 143

of preformed and post formed quality in order to prevent subsequent drop
of weights and to maintain consistent flexural stiffness of the cable in
service. The number of strands in the messenger cable shall be 19. The
messenger cable ends shall be suitably and effectively sealed to prevent
corrosion.
vi) The damper mass shall be made of hot dip galvanised mild steel/cast iron
or a permanent mould cast zinc alloy. All castings shall be free from
defects such as cracks, shrinkages inclusions and blow holes etc. the
inside and outside surfaces of the damper masses shall be smooth.
vii) The technical particulars for vibration analysis and damping design of the
system are as follows :
Sr.
No.
Description Technical Particulars
1. Configuration One galvanised steel earth wires in
horizontal configuration 7/3.15mm
2. Span length meters
i) Ruling design span
ii) Maximum span

350m
500m
3. tensile load in
i) At temperature of -
2.5
o
C
ii) At temperature of
2.5
o
C and 2/3
rd
full wind
iii) At temperature of 32
o
C
and full wind
Wind zone 4(As per
IS:875,1987(47m/s)
1290 Kg
1415 kg

1369 kg
4. Max. permissible Dynamic
strain
+/- 150 micro strain
5. Ultimate Breaking load 5710 kg.
6. Max. working temperature 75
o
C

viii) The damper placement chart for spans ranging from 100m to 500m shall
be submitted by the bidder. All the placement charts should be duly
supported by relevant technical documents.
The damper placement charts shall include the following :
1) Location of the dampers for various combinations as spans and lien
tension clearly indicating numbers of dampers to be installed per
earthwire per span.
2) Placement distances clearly identifying the extremities between which
the distances are to be measured.
3) Placement recommendation depending upon type of suspension
clamps (viz, free center type/trunion type etc.)
Page 137 of 143

4) The influence of mid span compression joints in the placement of
dampers.
10.4 Flexible Copper Bond
The flexible copper bond shall be circular in cross section of minimum
34 sq. mm equivalent copper area and not less than 500mm in length, it shall
consist of 259 wires of 0.417mm dia. Tinned copper conductor, it shall be laid
up as 7 stranded ropes, each of 37 bunched wires. The tinning shall be as per
relevant Indian Standard. Two tinned copper connecting lugs shall be press
jointed to either ends of the flexible copper cable. One lug shall be suitable for
122mm dia bolt and the other for 16mm dia bolt. The complete assembly shall
also include one 16mm dia 40mm long HRH MS Bolts hot dip galvanized with
nut and lock washer.
10.5 Suspension Clamp
1. Standard suspension clamp for Earthwire size 7/3.15 mm as per PSTCL
deign shall be supplied.
2. The clamps shall be of free-centre type and shall provide adequate area of
support to the earthwire. The groove of the clamp shall be smooth,
finished in a uniform circular or oval shape and shall slope downwards in
the smooth curve to avoid edge support and hence to reduce the intensity
of bending moment on earthwire.
3. There shall be no sharp point in the clamps coming in contact with
earthwire. There shall not be any displacement in the configuration of the
earthwire strands nor shall the strands be unduly stressed in final
assembly during working conditions.
4. The clamping piece and the clamp body shall be clamped by at least two
U-Bolts of size not less than 10mm diameter having one nut and one 3
mm thick lock nut with washer on each of its limbs. Suspension clamps
shall be provided with inverted type U-bolts.
5. The Contractor shall supply all the components of the suspension
assembly including shackles, bolts, nuts, washers, split pin etc. The total
drop of the suspension assembly from the centre point of the earthwire
shall not exceed 150mm. The design of the assembly shall be such that
the direction of run of the earthwire shall be same as that of the conductor.
10.6 Tension Clamp
Page 138 of 143

1. At all tension towers suitable compression type tension clamps shall be
used to hold 7/3.15mm galvanized steel earthwire. Anchor shackle shall
be supplied which shall be suitable for attaching the tension clamp to
strain plates.
2. The clamps shall have adequate area of bearing surface to ensure
positive electrical and mechanical contact and shall not permit any slip to
the earthwire under working tension and vibration conditions. The angle of
jumper terminal to be mounted should be 30 deg. with respect to the
vertical line.
3. The clamp shall be made of mild steel . The steel should not crack or fail
during compression. The Brinnel hardness of steel sleeve shall not exceed
200. The steel sleeve shall be hot dip galvanized.
4. The complete assembly shall be so designed as to avoid undue bending in
any part of the clamp and shall not produce any hindrance to the
movements of the clamps in horizontal or vertical directions.
5. The slip strength of the assembly shall not be less than 95% of the
ultimate strength of the earthwire.
6. The clamps shall be complete with all the components including anchor
shackle, bolts nuts washers, split pin, jumper arrangement etc.
11.1 Type tests
On suspension Hardware Fittings only
a) Visual Inspection IS: 2486(Part-I)
b) Verification of Dimensions
c) Slip strength test
d) Ultimate Tensile Strength test
e) Mechanical strength test
f) Magnetic power loss test for suspension
assembly

g) Clamp slip strength Vs torque test for
suspension clamp

h)
i)
Galvanizing/Electroplating tests
Chemical composition test
IS: 2633
On Tension Hardware fittings only
a) Visual Inspection IS: 2486(Part-I)
Page 139 of 143

c) Slip strength test for dead-end assembly
d) Heating cycle test for dead end Assembly
e) Electrical resistance test for dead end
Assembly

f) Ultimate Tensile Strength test
g) Mechanical strength test
h) Chemical composition test
i) Galvanizing/Electroplating tests IS: 2633
Mid Span Compression joint for Conductor and Earthwire
a) Visual Inspection IS: 2121(Part-II)
c) Heating cycle test
d) Failing Load Test
e) Electrical resistance test
f) Slip strength test
g) Chemical analysis of materials
i) Galvanizing tests IS: 2633
Repair Sleeve for Conductor
a) Chemical analysis of materials
Vibration Dampers
a) Visual Inspection IS: 9708-1993
c) Resonance frequency Test
d) Fatigue tests
e) Mass Pull off Test
f) Dynamic characteristics test
g) Damper efficiency test
h) Clamp Slip Test
i) Clamp Bolt Tightening Test
j) Chemical analysis of materials
k) Magnetic power loss test
l) Galvanizing/Electroplating tests IS: 2633

11.2 Acceptance Tests
On Both Suspension and Tension Hardware Fittings
Page 140 of 143

a) Visual Examination IS:2486-(Part-I)
b) Verification of dimensions
c) Galvanizing/Electroplating test
d) Mechanical strength test of each
component.

e) Ultimate Tensile Strength test
f) Chemical composition test
On Tension Hardware Fittings only
Electrical resistance test for dead end
Assembly
IS:2486-(Part-I)
Mid Span Compression joint for conductor and Earthwire
Visual examination and dimensional
verification
IS:2121-(Part-II)-1981
Galvanising/Electroplating test IS: 2633
Failing Load Test IS: 2121
Repair Sleeve for Conductor
Visual examination and dimensional
verification
IS:2121-(Part-II)-1981
Vibration Damper for Conductor
a) Visual examination and dimensional
verification
IS: 9708-1993
b) Fatigue Test
c) Mass pull off test
d) Verification of resonance frequencies
e) Clamp slip test
f) Clamp bolt torque test
g) Strength of messenger cable
h) Dynamic characteristics test
i) Galvanizing test IS: 2633
Routine Tests
For Hardware Fittings
a) Visual examination IS:2486-(Part-I) 1993
For Conductor and Earthwire Accessories
a) Visual examination and dimensional
verification
IS:2121-(Part-II)1981
Clause 6.2 & 6.3
Page 141 of 143

Tests During Manufacture
a) Chemical analysis of zinc used for
galvanizing

b) Chemical analysis, mechanical,
metallographic test and magnetic paprticle
inspection for malleable castings.

c) Chemical analysis hardness tests and
magnetic particle inspection for forgings

a) All the requisite Type Test Certificates of the material to be arranged by
the Bidder from qualifying manufacturers must be furnished with the bid and no
charges for the same shall be payable.
b) The Purchaser reserves the right of having at his own expense any other
tests(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 with the specification.
c) The Purchaser 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
Contractors premises. 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
specification by repeat tests, or correction of deficiencies, or replacement of
defective items all without any extra cost to the Purchaser.
11.4 Tests Reports
11.4.1 Record of routine test report shall be maintained by the Contractor at his
works for periodic inspection by the Purchasers representative.
11.4.2 Test Certificates of tests during manufacture shall be maintained by the
Contractor. These shall be produced for verification as and when desired by
the Purchaser.
12.0 Inspection
12.1 The Purchasers representative shall at all times be entitled to have
access to the works and all 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 Contractors, sub-
Page 142 of 143

Contractors works, raw materials, manufacturers of all the material and
for conducting necessary tests as detailed herein.
12.2 The material for final inspection shall be offered by the Contractor only
packed condition as the Employer shall select samples at random from the
packed lot for carrying out acceptance tests.
12.3 The Contractor shall keep the Purchaser informed in advance of the time
of starting and of the progress of manufacture of material in its various
stages so that arrangements could be made for inspection.
12.4 Material shall not be dispatched from its point of manufacture before it
has been satisfactorily inspected and tested, unless the inspection is
waived off by the Purchaser in writing. In the latter case also the material
shall be dispatched only after all tests specified herein have been
satisfactorily completed.

13 Packing and Marking.
1. All material shall be packed in strong and weather resistant wooden
cases/crates or double gunny bags. The gross weight of the packing shall not
normally exceed 50 Kg to avoid handling problems.
2. The packing shall be of sufficient strength to withstand rough handling during
transit, storage at site and subsequent handling in the field. The bidder shall
be fully responsible for defects observed in the material on account of
improper packing.
3. All the packing cases / bags 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.
4. The fittings made of extrusions shall have the following identification mark
embossed/punched on them and those made of forged mild steel shall be
stamped/marked wherever possible. Castings and Forging which shall be
done at works other than that of the supplier, shall bear identification mark,
both of the manufacturer and supplier.
i) Name and trade mark of the manufacturer.
ii) Size of the conductor for which it is to be used.
iii) Month & year of manufacture.
14.0 Standard
Page 143 of 143

1. The Hardware fittings, conductor accessories shall conform to the following
Indian Standards, which shall mean latest revisions, with
otherwise in the Specification.
2. In the event of the supply of hardware fittings; accessories conforming to
standards other than specified, the Bidder shall confirm in his bid that these
standards are equivalent to those specified and acceptance of the same shall
be solely in the domain of PSTCL. In case of award, salient features of
comparison between the Standards proposed by the Contractor and those
specified in this document will be provided by the Contractor to establish their
equivalence, alongwith certified copies of those standards.
Sr
No
Indian Standard
1. IS: 209-1979 Specification for Zinc
2. IS: 398-1996 (Part-2) Specification for ACSR for overhead
Transmission Purpose
3. IS: 1573-1976 Electroplated Coating of Zinc on Iron and
Steel
4. IS: 2121-1981 Part-I Specification for Conductors and Earth
wire Accessories for overhead power lines
Part-II Mid-Span Joints and Repair Sleeve for
Conductors
5. IS: 2486 Specification for Insulator Fitting for
overhead power lines with nominal Voltage
greater than 1000V
Part-I, 1971 General requirements and tests
6. IS: 2629-1985 Recommended practice for Hot Dip
Galvanizing of Iron and Steel
7. IS: 2633-1986 Method of testing Uniformity of coating on
Zinc Coated Articles.
8. IS: 4826-1979 Galvanized Coating on Round Steel Wires
9. IS: 6745-1972 Methods of Determination of Weight of Zinc
Coating of Zinc Coated Iron and Steel
Articles.
10 IS: 6639-1976 Hexagonal Bolts for Steel Structures
11 IS: 9708-1980 Specification for Stock Bridge Vibration
Dampers for Overhead Power Lines

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