HINDUSTAN ORGANIC CHEMICALS LIMITED

(A Govt. of India Enterprise)

KOCHI UNIT, AMBALAMUGAL, PH: No. 0484 2720911, FAX NO-0484 2720893
NOTICE INVITING TENDER
No: HOC/ELECT/279 A

25.06.2010

Dear Sirs,
1)

Sealed quotations are invited by CHIEF ENGINEER (ELECTRICAL),

Hindustan Organic Chemicals Ltd., Ambalamugal for the works as detailed
below. A set of tender document is enclosed for submitting your quotation.

2)

Name of Work
SUPPLY, ERECTION AND COMMISSIONING OF 30 M HIGH MAST
LIGHTING SYSTEM. A brief description of the scope of works is attached
herewith.

3)

Last Date of Receipt of Quotations

Tenders will be received at the office of Deputy General Manager (P&A),
Hindustan Organic Chemicals Ltd., Ambalamugal - 682 302 on or before 28/07/10
upto 15.00 hrs. Bids received after the due date will not be considered.

4)

Earnest Money Deposit

Quotation shall accompany an EMD of Rs.12,000/- (Rupees Twelve Thousand
only) paid by crossed demand draft of State Bank of India drawn in favour of
M/s. Hindustan Organic Chemicals Ltd., payable at Ambalamedu branch of
SBI. Quotations not accompanied with EMD, are liable to be rejected.

Time of Completion
The time of completion of the work will be 6 Months from the date of issue of
work order or issue of instructions to start the work, which ever is earlier.
5)

Submission of Quotations
a) Bidders shall submit their offer in two separate sealed envelopes. Envelop No.
1 is to be addressed and superscribed as un priced bid and the name and
address of the bidder and to contain the Earnest Money and signed in all
pages of the offer and details asked for, for pre qualification along with a
forwarding letter containing all schemes with all technical details and
technical and commercial deviations if any.
b) Envelop No. 2 to be addressed and subscribed (PRICED BID) and the name
and address of the bidder and to contain price alone and signed in all pages.
Both envelopes No. 1 & 2 shall be put together in one envelop duly sealed and
shall be superscribed with Enquiry no. and offer for SUPPLY, ERECTION AND
COMMISSSIONING OF 30 M HIGH MAST LIGHTING SYSTEM Due date
28/07/10 and shall be submitted DEPUTY GENERAL MANAGER (P&A),
HINDUSTAN ORGANIC CHEMICALS LTD., AMBALAMUGAL - 682 302 by post or
deposited in the TENDER BOX kept in our Administrative Building. Bidders shall
print their address on all envelopes.

6)

BIDDERS shall go through all documents attached to the quotation and fill
in the blank spaces provided for and submit the same duly signed and
dated. Quotation should be complete in all respects and in accordance with the
various terms and conditions specified in the enquiry document.
Incomplete quotations are liable to be rejected.

7)

There will be public opening of quotations for the subject work.

8)

Taxes and duties: Rate quoted for supply portion shall be inclusive of all taxes
and duties. The extent of central excise duty included in the price for which
HOCL can avail of CENVAT credit shall be indicated separately. KVAT on
works ( For Installation) will be deducted at the applicable rate. Service tax on
erection part if any shall be charged extra as applicable .

9)

Security / Safety Regulations :

The contractor shall strictly follow all
the security and safety regulations and other relevant rules of HOC Ltd.
The work in the plant and other restricted specified areas shall be done only

after
obtaining necessary safety permit/ work permit from competent
authority. Contractors shall inform the concerned department, the location of
work, nature of work etc. and obtain clearance before entering into the work.
Contractor shall strictly abide by the SAFETY REGULATIONS under Article9 of General Conditions of Contract.
a) The contractor shall strictly abide by the article 8 Labour laws of
General Conditions of Contract and 8.6 Employees State Insurance Act,
in particular.
b) A separate PF Code No. under the Employees PF act 1952 and also
furnish details of CPF contribution payment made with the Regional
Commissioner.
10) Defect Liability Period : The defect Liability Period for this work shall be
twelve (12) months.
11) Security Deposit : Security deposit shall be 10% of the order value. This shall
be deposit initially at 2.5% (two and half percent) of order value referred as
initial security deposit within ten days of the receipt by the party of the
notification of acceptance of the tender.
Balance 7.5% (seven and half percent) shall be recovered through deductions at
the rate of 10% (ten percent) of the value of each running account bill till the
total security deposit amount is collected, after which no further deductions
shall be made on this account. In case of only one bill the balance 7.5% (seven
and half percent) shall be ducted from the bill.
The contractor can furnish the initial or total security deposit amount through
bank guarantee from any scheduled or nationalized bank in the prescribed
form in favor of HOCL.
13) Payment Terms :
a) Supply : 75% against delivery of all items, 15% after erection and
commissioning. Balance 10% of value of supply shall be retained as security
deposit.
b) Erection and Commissioning: 90% after erection & commissioning, 10%
shall be retained as security deposit. After the completion of work security
deposit shall be refunded on submission of Performance Bank Guaranty
(PBG) valid for the defect liability period for equal amount.

14) Validity of Offer : The Offer shall be valid for a period of 120 Days from the
date of receipt of tender. The successful tenderer shall sign the Form of rate
list or execute an agreement in non- judicial stamp paper of appropriate value
(to be borne by the contractor) within 10 days from the date of issue of letter of
acceptance.
15) The tender notice may be read in conjunction with standard General Conditions
of Contract, Special Conditions of Contract, Technical Specification, Drawings
and other documents forming part of this enquiry (GCC is available in our web
site www.hoclkochi.com.
16) Unless otherwise stated all clauses of General Conditions of Contract and
Special Conditions of Contract shall generally be applicable to this contract.
17) Hindustan Organic Chemicals Ltd. reserves the right to accept other than the
lowest quotations, reject any or all quotations at the discretion without
assigning any reason thereof.
18) Quotations from vendors in our approved list shall alone be considered, others
may respond for enlistment.
19) Date, Time & Venue of Public Opening of the Tender.
Date

28/07/10

Time

4.00 p.m.

Venue :

Tender Room in Training Centre of HOCL, Ambalamugal

Following documents are enclosed.

1.
2.
3.
4.
5.

Scope of work /Technical specification for the high mast lighting

Technical Data Sheet for 30 M High Mast with Integral Power
Schedule of Rates for supply of 30 M High Mast lighting System.
Schedule of Rates for Erection and commissioning of 30 M High Mast
GCC

G.VENUGOPAL
CHIEF ENGINEER (ELECTRICAL)

TECHNICAL SPECIFICATION FOR THE HIGH MAST LIGHTING

Scope of work
SCOPE

1.0

The scope of this specification covers the design manufacture, transport, testing and
commissioning of the complete lighting system, using Raising and Lowering type of
High Mast Towers, including the Civil Foundation Works for civil foundation work
cement, steel, sand, stones etc has to be good quality as per IS standard. For mast
no.1, 10 nos. 2 x 400W luminaries has to be arranged asymmetrically in 180 0 degree
orientation and for mast no.2, 14 nos. 2 x 400W luminaries has to be arranged
asymmetrically in 2700 degree orientation. The owner will only provide the supply
point and the feeder cable of the required size, up to the bottom of the high mast.
However, all items required for the safe and efficient operation and maintenance of
the lighting system, including the high mast, whether explicitly stated in the
following pages or not, shall be included by the contractor.
It is the responsibility of the bidder to supply and erect all items and all labour that
are included and necessary for the completion of the work whether specifically
mentioned or not.
APPLICABLE STANDARDS

2.0

The following shall be the Reference Standards for the loading of High Mast:
Code No.

Title

a) T.R. No.7

High Masts for Lighting and CCTV (2000 edition)

of ILE, U.K
Wind Loading
High Tensile Steel Sheets
Mild Steel
Galvanization
Stainless steel Wire rope
Trailing Cable
Motor

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

IS 875 Part 3
BS EN 10025:1993
IS 2062
BS EN ISO 1461
IS 3459 / 2266
IS 9968 Part 1
IS 325

HIGH MAST
2.1

Structure

The High mast shall be of continuously tapered, polygonal cross section, at least 20
sided, presenting a good and pleasing appearance and shall be based on proven InTension design conforming to the standards referred to the above, to give an assured
performance, and reliable service. The structure shall be suitable for wind loading as
per IS 875 part III 1987.
2.2

Construction

The mast shall be manufactured using special steel plates, conforming to BS-EN10025 and shall be delivered in multiple sections of effective length 10 metres. Thus a
30 m mast shall be delivered in three sections to site. Each section shall be fabricated
out of single plate duly folded and welded. There shall be only one longitudinal
seam weld per section. Section with more than one weld, circumferential or
longitudinal, shall not be accepted. At site the sections shall be joined together by
slip-stressed-fit method. No site welding or bolted joint shall be done on the mast.
The minimum overlap distance shall be 1.5 times the diameter at penetration. The
minimum top diameter shall be 150mm. Bottom diameter and plate thickness shall
be as per the structural requirements. Detailed design calculation of the mast shall
be submitted for verification.
The mast shall be provided with fully penetrated flange, which shall be free from any
lamination or incursion. The welded connection of the base flange shall be fully
developed to the strength of the entire section. The base flange shall be provided
with supplementary gussets between the blowholes to ensure of helical stress
concentration. For the environmental protection of the mast, the entire fabricated
mast shall be hot dip galvanized, internally and externally, having a uniform average
thickness of 86 microns for plate more than 5 mm and 70 microns for less than 5 mm.
Galvanizing shall be done in single dipping method for better adhesion and life.
3.02. 1. Door Opening
An adequate door opening shall be provided at the base of the mast and the opening
shall be such that it permits clear access to equipment like winches, cables, plug and
socket, etc. and also facilitate easy removal of the winch. The door opening shall be
complete with a close fitting, vandal resistant, weatherproof door, provided with a
heavy-duty double internal lock with special paddle key.
The door opening shall be carefully designed and reinforced with welded steel
section, so that the mast section at the base shall be unaffected and undue buckling

of the cut portion is prevented. Size of door opening shall not be more than 1200 X
250 mm. to avoid buckling of the mast section under heavy wind conditions.
3.03 Dynamic Loading for the Mast:
The mast structure shall be suitable to sustain an assumed maximum reaction arising
from a wind speed as per IS 185 (three second gust), and shall be measured at a
height of 10 metres above ground level. The design life of the mast shall be 25 years.
3.04

Lantern Carriage

3.04.1 Fabrication
A fabricated Lantern Carriage shall be provided for fixing and holding the flood
light fittings and control gear boxes. The Lantern Carriage shall be of special design
and shall be steel tube construction, the tubes acting as conduits for wires, with holes
fully protected by grommets. The Lantern Carriage shall be so designed and
fabricated to hold the required number of flood light fittings and the control gear
boxes and also have a perfect self balance. The Lantern Carriage shall be fabricated
in two halves and joined by bolted flanges with stainless steel bolts and nylon type
stainless steel nuts to enable easy installation or removal from the erected mast. The
inner lining of the carriage shall be provided with protective PVC arrangement, so
that no damage is caused to the surface of the mast during the raising and lowering
operation of the carriage. The entire Lantern Carriage shall be hot dip galvanized
after fabrication.
3.04. 2 Junction Box
Weather proof junction box, made of Cast Aluminum shall be provided on the
Carriage Assembly as required, from which the inter-connections to the designed
number of the flood light luminaries and associated control gears fixed on the
carriage shall be made.
3.05.1 Raising and lowering machanism
For the installation and maintenance of the luminaries and lamps, it will be
necessary to lower and raise the Lantern Carriage Assembly. To enable this, a
suitable Winch Arrangement shall be provided, with the winch fixed at the base of
the mast and the specially designed head frame assembly at the top. The lantern
carriage assembly shall reach 1 M from the base of the mast for easy access. There
shall be provision to disconnect the main towing cable going to Lantern carriage
before starting to lowering mechanism.

3.05. 2 Winch
The winch shall be of completely self-sustaining type, without the need for brake
shoe, springs or clutches. Each driving spindle of the winch shall be positively
locked when not in use, gravity activated PAWLS. Individual drum also should be
operated for fine adjustment of lantern carriage. The capacity, operating speed, safe
working load, recommended lubrication and serial number of the winch shall be
clearly marked on each winch.
The gear ratio of the winch shall be 53 : 1. However the minimum working load shall
be not less than 750 kg. The winch shall be self-lubricating type by means of an oil
bath and the oil shall be readily available grades of reputed producers.
The winch drums shall be grooved to ensure perfect seat for stable and tidy rope lay,
with no chances of rope slippage. The rope termination in the winch shall be such
that distortion or twisting is eliminated and at least 5 to 6 turns or rope remains on
the drum even when the lantern carriage is fully lowered and rested on the rest pads.
It should be possible to operate the winch manually by a suitable handle or by an
integral power tool. It shall be possible to remove the double drum after
dismantling, through the door opening provided at the base of the mast. A test
certificate shall be furnished by the Contractor from the original equipment
manufacturer, for each winch in support of the maximum load operated by the
winch.
3.05. 3. Head Frame
The head frame which is to be designed as a capping unit of the mast, shall be of
welded steel construction, galvanized both internally and externally after assembly.
The top pulley shall be of appropriate diameter, large enough to accommodate the
stainless steel wire ropes and the multi-core electric cable. The pulley block shall be
made of non-corrodable material, and shall be of die cast Aluminum Alloy (LM-6).
Pulley made of synthetic materials such as Plastic or PVC are not acceptable. Selflubricating bearings and stainless steel shaft shall be provided to facilitate smooth
and maintenance free operation for a long period. The pulley assembly shall be fully
protected by a canopy galvanized internally and externally.
Close fitting guides and sleeves shall be provided to ensure that the ropes and cables
do not dislodged from their respective positions in the grooves. The head frame shall
be provided with guides and stops with PVC buffer for docking the lantern carriage.

3.05.4. Stainless Steel Wire Ropes

The suspension system shall essentially be without any intermediate joint and shall
consist of only non-corrodable stainless steel of AISI 316 grade.
The stainless wire ropes shall be of 7/19 construction, the central core being of the
same material. The overall diameter of the rope shall not be less than 6 mm. The
breaking load of each rope shall not be less than 2350 kg. giving a factor of safety of
over 5 for the system at full load as per the TR-7 referred to in the beginning of this
specification. The end constructions of ropes to the winch drum shall be fitted with
talurit. The thimbles shall be secured on ropes by compression splices. Two
continuous length of stainless wire ropes shall be used in the system and no
intermediate joints are acceptable in view of the required safety. No Intermediate
joints/terminations, either bolted or else, shall be provided on the wire ropes
between winch and lantern carriage.
3.6

Electrical System, Cable and Cable Connections

A suitable terminal box shall be provided as part of the contract at the base
compartment of the high mast for terminating the incoming cable. The electrical
connections from the bottom to the top shall be made by special trailing cable. The
cable shall be EPR insulated and PCP sheathed to get flexibility and endurance. Size
of the cable shall be minimum 5 core 4 sq mm copper. There shall be two cables per
mast, one for essential supply and the other for non-essential supply. The cable shall
be of reputed make. At the top there shall be two weather proof junction boxes to
terminate the trailing cable. Connections from the top junction box to the individual
luminaires shall be made by using 3 core 1.5 sq. mm. flexible PVC cables of required
make.
Also, suitable provision shall be made at the base compartment of the mast to
facilitate the operation of internally mounted, electrically operated power tool for
raising and lowering of the lantern carriage assembly. The trailing cables of the
lantern carriage shall be terminated by means of specially designed, metal clad,
multi pin plug and socket provided in the base compartment to enable easy
disconnection when required.
3.7

Power Tool for the winch

A suitable, high-powered, electrically driven, internally mounted power tool, with

manual over ride shall be supplied for the raising and lowering of the lantern
carriage maintenance purposes. The speed of the power tool shall be to suit the
system. The power tool shall be single speed, provided with a motor of the required
rating. The power tool shall be supplied complete with suitable control. The capacity

and speed of the electric motor used in the power tool shall be suitable for the lifting
of the design load installed on the lantern carriage.
The power tool mounting shall be so designed that it will be not only self-supporting
but also aligns the power tool perfectly with respect to the winch spindle during the
operations. Also, a handle for the manual operation of the winches in case of
problems with the electrically operated tool, shall be provided and shall incorporate
a torque limiting device.
The power tool operation shall always be through a separate torque-limiting device
to protect the wire ropes from over stretching. It shall be mechanical with suitable
load adjusting device. The torque limiter shall trip the load when it exceeds the
adjusted limits. There shall be suitable provision for warning the operator once the
load is tripped off. The torque limiter is a requirement as per the relevant standards
in view of the over all safety of the system. Each mast shall have its own power tool
motor. The motor shall have over load relay and fuse protection
3.8

Lightning Finial

One number heavy duty hot dip galvanised lightning finial shall be provided for
each mast. The lightning finial shall be minimum 1.2 M in length and shall be
provided at the Centre of the head frame. It shall be bolted solidly to the head frame
to get a direct conducting path to the earth through the mast. The lightning finial
shall not be provided on the lantern carriage under any circumstances in view of
safety of the system.
3.09 Aviation Obstruction Lights:
Suitable Aviation Obstruction Lights or reliable design and reputed manufacturer
shall be provided on top of mast.
3.10 Earthing Terminals:
Suitable earth terminal using 12mm diameter stainless steel bolts shall be provided
at a convenient location on the base of the Mast, for lightning and electrical earthing
of the mast.
3.11 Feeder Pillar
Each mast shall be provided with a feeder pillar fabricated out of 14 SWG CRCA
sheet and finished with two coats of red oxide primer and gray enamel paint of
shade 631 of IS-5. The feeder pillar shall comprise of two compartments, one for

essential supply and the other for non-essential supply. Switchgears shall be to suit
the power loading. The motor shall also house control contractors for the power tool
motor.
3.12. Incoming Power Cable
A cable of size 4 X 16 sq.mm. Aluminum conductor, Armoured cable for power
supply and 4 X 1.5 sq.mm. Copper conductor Armoured cable for motor supply shall
be provided to the base compartment of the highmast. Cable shall be taken to the
base compartment of the highmast through the provision made in the foundation.
Power cable of suitable size upto the supply point shall be provided by purchaser.

3.0

LUMINAIRES

Luminaries shall be specially designed with cast aluminium housing suitable lamp
housing and control gears for 400 W HPSV lamps. The luminaries shall be tested as
per Indian standards and test reports shall be submitted along with the materials.
The luminaries shall be suitable for installation on high masts.
Make of luminaries shall be BAJAJ/PHILIPS/CROMPTON only

TECHNICAL DATA SHEET FOR 30 MTR HIGH MAST WITH INTEGRAL

POWER
TOOL AND COMPONENTS
HIGHMAST SYSTEM
a)
b)
c)
d)
e)
f)
g)
h)

Height of mast
No. of Sections
Make of high mast
Material construction
Thickness of sections
No. of longitudinal welds/section
No. of circumferential welds/section
Make of luminaire/lamp

:
:
:
:
:
:
:

i) Cross section of Mast

j) Base dia. And top diameter A/F

:
:

k) Type of joints
l) Length of overlap
m) Metal protection treatment for

:
:
:

n)
o)
p)
q)
r)

:
:
:
:
:
:
:
:
:
:
:

s)
t)
u)
v)
w)
x)
y)

Method of hot dipping

Average thickness of galvanisation
Size of opening and door at base
Type of locking arrangement
Details of slack board inside the base
Compartment.
Provision for cable termination
Diameter of base plate
Thickness
of base plate
Size of anchor plate and thickness
Details of template
Weight of 30 mtr. Mast
:
(without accessories)
Lightning Protection finial

2. DYNAMIC LOADING AS PREVAILING AT SITE

a) Max. wind speed
b) Max. gust speed time
c) Height above ground level these two
Factors are measured
d) Factor of safety for wind load
e) Factor of safety for other load

:
:
:
:
:

3. FOUNDATION DETAILS
a) Type of foundation
b) Size of foundation
c) Soil bearing capacity at site
d) Design Safety factor
e) Considered wind pressure (Kg/Mt2)
f) Depth of foundation
g) Number of foundation bolts
h) PCD of foundation bolts
i) Type of foundation bolts
:
j) Bolt diameter

:
:
:
:
:
:
:
:
:

4. LANTERN CARRIAGE
a) Material of construction
b) Diameter of carriage ring (mm)
c) Construction
d) Number of joints
e) Buffer between carriage and masts
f) Load carrying capacity
g) Total weight of assembly with fittings
h) Number of fittings
i) Type of fittings/fixture

:
:
:
:
:
:
:
:
:

5. CABLE
a)
b)
c)
d)
e)
f)

Type
Material
Current carrying capacity
Conductor size
No. of cores
No. of circuits

:
:
:
:
:
:

6. WINCH
a) Make of winch
b) Number of drums/winch
c) Gear Ratio
d) Capacity
e) Method of operation
f) Lubrication arrangement
g) Type of lubricant

:
:
:
:
:
:
:

7. STAINLESS STEEL WIRE ROPE

a) Make
b) Grade
c) Number of ropes
d) Construction
e) Centre core material
f) Diameter (mm)
g) Thimbles & Talurit
h) Braking load capacity
i) Factor of Safety

:
:
:
:
:
:
:
:
:

8.
a)
b)
c)
d)
e)

POWER TOOL
Model
Input Supply
Wattage/HP
Number of speeds
Operating speed (Average)

:
:
:
:
:

9.
a)
b)
c)

TORQUE LIMITER
Lifting capacity
Adjustable/Non- adjustable
Tripping device

:
:
:

SCHEDULE OF RATES FOR SUPPLY OF 30 M HIGH MAST LIGHTING SYSTEM

Sl. DESCRIPTION OF EQUIPMENT/
No. ACTIVITY
1.0

SUPPLY OF ITEMS

1.1

Supply of 30 M high mast system

totally hot dip galvanized and
suitable for 45mt/s wind velocity.
The mast shafts shall be in three
sections with no circumferential
weld on each sections with
integral power tool. Accessories
for 30 M High mast including
head frame, steel wire rope 6mm
dia (7/19 construction) double
drum winch, Galvanized Lantern
carriage arrangement suitable for
10 luminaries and 14 luminaries
asymmetrically arranged for 2
mast respectively and its control
gear boxes and lighting finial.

1.2

1.3

1.4

1.5

Supply of foundation bolts

manufactured from special steel
along with nuts, washers, anchor
plates and templates
Supply of specially designed Non
integral flood light luminaire type
BGENF 22 R or equivalent with
two nos 400 W SON T/HPSV
lamps and its control gear boxes.
Supply of Control panel housing
suitable timer contractor circuit
for Automatic switch ON and
switch OFF of the mast at a preset time
Supply of LED type single twin
aviation obstruction light

UNIT

QTY

No.

No.

No.

24

No.

No.

UNIT
RATE
(Rs.)

AMOUNT
(Rs.)

( BENOY/BAJAJ/CG/PHILIPS
make)

SCHEDULE OF RATES FOR ERECTION & COMMISSIONING OF 30 M

HIGH MAST

2.0

ERECTION AND COMMISSIONING

2.1

Erection and commissioning of the

High Mast with the help of
suitable equipment

No.

2.2

Design and casting of suitable

foundation for the high mast
considering the safe soil bearing
capacity at site .

No.

2.3

Pipe earthing station for high mast (2

per mast is mandatory, 1 for
lightning and one for electrical) as
per IS standard

No.

2.4

Installation of the above panel on

suitable foundation

No.