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REQUEST FOR PROPOSAL FOR DESIGN, ENGINEERING, SUPPLY, ERECTION TESTING & COMMISSIONING OF TRANSMISSION LINE(400 KV)

FOR EVACUATION OF POWER FROM 2X600 MW COAL BASED POWER PLANT AT DERANG, ANGUL, ORISSA

VOLUME II

Jindal India Thermal Power Limited


Plot No. 12, Sector B-1, Local Shopping Complex, Vasant Kunj, New Delhi 110 070, Telephone No. (011) 26139256-65 Fax No. (011) 26121734

INDEX (VOLUME-I)
SECTION 1 - INVITATION TO BID (ITB) SECTION II - INSTRUCTIONS TO BIDDERS SECTION III - GENERAL TERMS & CONDITIONS OF CONTRACT SECTION IV - TENDER SPECIFICATION

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

Schedule A : Schedule B : Schedule C : Schedule D : Schedule E : Schedule F : Schedule G: Schedule H: Schedule I : Schedule J : Schedule K : Schedule L: Schedule M: Schedule N: Schedule O:

Tower Schedule Tender Form Void Qualifying requirement data schedule (Form 1 to 8) Schedule of unit prices and tax break up Bid Security form Performance security form Proforma of Consortium Agreement Power of Attorney for Lead Member Power of Attorney for each of the other Members of the Consortium Performance Security form for Consortium Members Proforma of B.G. for Advance payment Proforma of Indemnity bond Format for Undertaking Format for Submission of Financial Bid

INDEX (VOLUME II)


SECTION I SECTION II SECTION III SECTION IV SECTION V : GENERAL INFORMATION & SCOPE : GENERAL TECHNICAL & ERECTION CONDITIONS : TOWER SPECIFICATION : PRE-COMMISSIONING PROCEDURES : TECHNICAL SPECIFICATION FOR ACSR MOOSE CONDUCTOR : TECHNICAL SPECIFICATIONS FOR 7/3.66MM GALVANISED STEEL EARTH-WIRE : TECHNICAL SPECIFICATIONS FOR PORCELAIN DISC INSULATORS

SECTION VI

SECTION VII

SECTION VIII : TECHNICAL SPECIFICATIONS FOR HARDWARE FITTINGS AND ACCESSORIES FOR CONDUCTOR AND EARTHWIRE SECTION IX : ANNEXURES

SECTION IX

: ANNEXURES (VOLUME-II)

a) ANNEXURE-1:- PROVISIONAL BILL OF QUANTITY FOR 400KV D/C TRANSMISSION LINE b) ANNEXURE-II:- BLANK c) ANNEXURE-III:- BLANK d) ANNEXURE-IV:- BLANK e) ANNEXURE-V:- STANDARDS FOR ACSR CONDUCTOR f) ANNEXURE-VI:- DRAWING CHARTS & DESIGN DATA TO BE SUBMITTED IN PHYSICAL FORM g) ANNEXURE-VII:- TESTS ON EARTHWIRE h) ANNEXURE-VIII:- TEST PROCEDURE FOR INSULATORS i) ANNEXURE-IX:- GUARANTEED TECHNICAL PARTICULARS FOR DISC INSULATOR UNIT j) ANNEXURE:- X:- TESTS ON COMPLETE STRINGS WITH HARDWARE FITTINGS k) ANNEXURE- XI:- ACCEPTANCE TESTS l) ANNEXURE-XII:- GUARANTEED TECHNICAL PARTICULARS OF SUSPENSION HARDWA RE FITTINGS FOR MOOSE ACSR CONDUCTOR m) ANNEXURE- XIII:- PRICE SCHEDULE FOR 400 KV D/C(ACSR TWIN MOOSE CONDUCTOR)

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SECTION I GENERAL INFORMATION & SCOPE

Jindal India Thermal Power Limited

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SECTION I

CONTENTS Clause Description 1.0 2.0 3.0 General Information and Scope Line Data Service Condition Page No 4 8 10

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TECHNICAL SPECIFICATIONS SECTION I GENERAL INFORMATION & SCOPE 1. 1.1. General Information and Scope

Scope 1.1.1. This Specification covers the following (i) Soil resistivity measurement, geotechnical investigation and check survey and detailed survey if required at the approaching reaches for any deviation during execution (Detailed survey including route alignment, profiling and tower spotting etc. has already been completed by the Owner) ; (ii) fabrication and supply of all type 400 kV double circuit transmission line towers, Body extensions and unequal leg extensions, as per Owners design/ drawings including bolts, nuts and washers, hangers, D- shackles and all types of tower accessories like phase plate, circuit plate, number plate, danger plate, anti-climbing device, and supply of Earthwire, Hardware Fittings and Conductor & Earthwire Accessories and design and supply of any special towers. In case the Contractor is having his own tested designs he may provide a separate quote (both techno commercial and price bids) for the same apart from the quote based on Owner supplied designs. (iii) Supply of Conductors and Insulators; (iv) Selecting type of foundation for different type of towers and casting of foundation for tower footings as per Owners/Contractors foundation design; (v) Erection of towers, tack welding of bolts and nuts including supply and application of zinc rich primer & enamel paint, painting of towers and other signaling arrangements for aviation requirements, tower earthing, fixing of insulator strings, stringing of conductors and earthwires along with all necessary line accessories; (vi) Testing and commissioning of the erected transmission lines, (vii) Arranging Right of Way; (viii) Supply of spares and Tools (ix) Any other items for the successful commissioning of the transmission line, unless specifically excluded in the Specification. 1.1.1.1. Contractor shall provide structural/fabrication drawings, shop drawings and Bill of materials of all 400 KV Double circuit towers and extensions suitable for Twin ACSR Moose Conductor after the placement of award, in sequence, suiting the project requirement. The construction drawings for all type of foundations for these towers shall also be provided by Contractor after the placement of award in sequence suiting the project requirement. The scope of this specification also provides for fabrication of prototype tower, its assembly and proto-inspection. 1.1.1.2. (a) The provisional quantities of various types of towers, foundations, conductor, earthwire, insulators etc., are provided in Annexure-1. However, contractor has to prepare his own estimates for bidding purpose after site visit. Page 4

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(b)

The various items provided in Annexure-1 shall be read in conjunction with the corresponding sections in the Technical Specifications including

amendments and, additions, if any. The Bidders unit rates shall be based on the description of activities in the Annexure-1 as well as necessary operations detailed in these Technical Specifications. (c) The bidder shall include in his bid the supply of mandatory spares, special tools and tackles, for erection, testing, commissioning of the transmission line. The list of such spares is provided in Annexure-14 special tools and tackles is provided in Annexure-15 and prices for supplying such items shall be deemed to be included in the bid price. The Unit rates quoted in the format given in Annexure 13 shall include minor details which are obviously and fairly intended, and which may not have been included in these documents but are essential for the satisfactory completion of the various works. The unit rate quoted shall be inclusive of all plant equipment, men, material, skilled and unskilled labor etc. essential for satisfactory completion of various works. All measurements for payment shall be in S.I. units, lengths shall be measured in meters corrected to two decimal places. Areas shall be computed in square meters & volume in cubic meters, rounded off to two decimals.

(d)

(e)

(f)

1.1.1.3. The Bidder shall submit his offer taking into consideration that the tower and foundation designs shall be provided by the Contractor. Further, the Bidder shall quote the unit rate for these items as per their units mentioned in Annexure-1. However, payment shall be made on per tower/foundation basis on completion of supply/erection as applicable to be worked out based on the approved Bill of Materials for towers and approved foundation drawings. 1.1.2. This specification also includes the supply of Conductor, earthwire, Insulators, hardware fittings and all type of accessories for conductor, earthwire and tower as detailed in the Specification. Contractor shall clearly indicate in their offer, the source from where they propose to procure these materials. The technical description of these items is given in relevant sections of this Bidding Document. The Contractor shall ensure the safe custody of Conductor, Insulator, tower parts and other line materials during construction. 1.1.3. 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 plates, number plates, Page 5

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Circuit Plates etc., required for tower manufacture and erection shall be included in the Contractors scope of supply. Bidder shall clearly indicate in the offer, the sources from where they propose to procure the raw materials and components. All the material procurement should be from the reputed manufacturers/suppliers who are in the PGCIL approved list of suppliers/manufacturers. However Vendor approval is required to commence the supply of items. 1.1.4. The entire stringing work of conductor and earthwire shall be carried out by tension stringing technique. The bidder shall indicate in the offer, the detail description of the procedure to be deployed for stringing operation. The Contractor shall indicate in their offer, the sets of tension stringing equipment he is having in his possession and the sets of stringing equipment he would deploy exclusively for this line. However, the Bidder having requisite experience has freedom to use helicopter for stringing. The Bidder intending to use helicopter shall furnish detailed description of the procedure, type and number of helicopter & accessories etc., to be deployed for stringing operation. 1.1.5. Special River Crossing towers/strengthening of available tower bodies/cross arms may be required to negotiate river crossing /valleys/hilly terrains . The Contractor has to develop the structural drawings, Bill of Materials and shop drawings of these river crossing towers at the time of execution. The rates quoted shall be inclusive of proto-assembly, type testing etc. N/A The following 400 kV Transmission line is included in the scope of the Contractor : Package 1 400 KV D/C (Twin ACSR Moose) Derang To Angul - 56 Kms. Transmission Line ( Line length is approximate)

1.1.6. 1.1.7.

1.1.8.

Location Details and Terminal Points

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400 KV D/C Derang To Angul Transmission Line This line shall emanate from 1200 MW Jindal Power Project 400 kV Sub-station of JITPL and shall terminate at 400 kV Sub-station of PGCIL.

1.1.9.

The Contractor shall have to Supply & Erect 400 KV DC (Twin ACSR) Transmission Line completely up to terminal arrangements/terminal points. Details of Transmission Line Routes and Terrain Bidders may visit the line route to acquaint themselves with terrain etc., of the proposed transmission lines. For this purpose they are requested to contact the following address : Jt. President - Projects Jindal India Thermal Power Limited Plot No. 12, Sector B-1, Local Shopping Complex, Vasant Kunj, New Delhi 110 070 Phone No. 011 2613 9256 to 9265 Access to the Line and Right of Way

1.2.

1.3.

The Contractor shall assist Owner for fixing the tree/crop compensation through Revenue/Horticulture Department or any other appropriate authorities. The compensation shall be paid subsequently by the Owner. The cost of cutting the trees, stacking of cut tree, clearing debris & transportation of cut trees (if required) would be borne by the Contractor. All statutory clearances including Forest clearance shall be arranged by the Owner. However, the Contractor shall be responsible for all the activities for obtaining the statutory clearances viz. collecting input details, preparation of documents etc. The Contractor shall be responsible for attending to any local issues related to Right of Way through private property, Government land etc. Right of way and way leave clearance shall be arranged by the Contractor in accordance with work schedules. Jindal India Thermal Power Limited Page 7

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2. 2.1.

Line Data Electrical System Data A Nominal Voltage B Maximum system voltage C BIL (Impulse) D Power frequency withstand voltage (wet) E Switching surge withstand voltage (wet) F Minimum Corona extinction voltage at 50 Hz AC system under dry condition
G Radio interference voltage at one MHz for phase to earth voltage of 305 KV under dry

kV kV kV (Peak) kV (rms) kV (peak) kV (rms) phase to earth Micro Volts

400 420 1550 680 1050 320 Min 1000 Max

condition
2.2.

Details of Line Materials A. Conductor and earthwire for 400 kV line Earthwire Conductor Galvanised steel ACSR Moose Mm 7/3.66 54/3.53 Aluminium +7/3.53 Steel No. N.A. 4 Mm N.A. 457 Unit

Sr.No. Description 1. Name/Type 2. Size 3. Conductor per phase 4. Spacing between conductor of same phase (sub conductor spacing) 5. Configuration

Two continuously to run horizontally on top of the towers and conductors Mm 10.98 Kg/Km. 583 KN 68.4 metres 400

Vertical (for D/C with 8000 mm min. inter phase spacing)

6. Overall diameter 7. Unit mass 8. Min. UTS 9. Ruling Design Span

31.77 2004 161.2 400

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2.3.

Details of Insulator Strings with disc insulator for 400 kV line Sr.N o. Particulars Single I Double Single I Single suspensio I suspensio tension n string suspensio n pilot string n String string Standard Standard Standard Standard Standard 120 120 120 120 160 Quad Tension String

1. Type of Disc 2. E&M Strength of


each Anti Fog

insulator in the string in KN 3. Nos. of Anti Fog 1x23 2x23 1x23 1x24 2x2x24 insulator disc per string 4. Size of disc in mm 280x145 280x145 280x145 280x145 5. Size and 20 20 20 20 20 designation of pin ball shank in mm. 6. Minimum creepage 315 315 315 315 330 distance of each disc in mm. 2.4. Insulator String Hardware (As may be applicable) a) b) c) d) e) f) g) h) i) j) k) l) m)
2.5.

280x170

Anchor Shackle Chain Link Ball Clevis Arcing horn holding plate Yoke plate Socket clevis Arcing horns Corona control ring/grading ring Clevis Eye Free centre type/Armour grip suspension clamp for suspension strings. Compression type dead end clamp Sag adjuster Balancing weight

Accessories for Conductor & Earthwire (As may be applicable) a) Performed Armour rods b) Mid Span compression joint c) Repair Sleeves d) T-Connector e) Flexible copper bonds f) Rigid spacers for twin moose Page 9

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Volume-II / Section - I g) h) i) j) k) 3. Twin Spacer dampers Vibration dampers for earth wires Quad Rigid Spacer Suspension clamp for earthwire Tension clamp for earthwire

EPC Tender for JITPL

Service Conditions Equipment/material to be supplied against this specification shall be suitable for satisfactory continuous operation under conditions as specified below : Maximum ambient temperature (Degree Celcius) : 50 Minimum ambient temperature (Degree Celcius) : 7.5 Relative humidity (% range) : 10-100 Maximum annual rainfall & short fall (Cm) : As per published meteriological/ climatological data Wind zone (as per IS : 875) :3 Maximum wind velocity (m / sec.) : 44 m/sec. (as per Is-875) Maximum altitude above mean sea level (Metres) : Upto 1000 m Isoceraunic level (days / years) : 50 Climate varies from moderately hot and humid tropical climate to cold climate.

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SECTION II GENERAL TECHNICAL & ERECTION CONDITIONS

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SECTION II CONTENTS Clause Description 1.0


2.0 Erection

Page No 13 20 29

General Technical Conditions Conditions JITPLS Environment and Social Policy and its Implementation

3.0

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TECHNICAL SPECIFICATIONS SECTION II GENERAL TECHNICAL & ERECTION CONDITIONS 1 1.1 General Technical Conditions General 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. 1.2 1.2.1 Engineering Data 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 Owner will cover only general conformance of the data to the
specifications and not a through review of all dimensions, quantities and details of

the materials, or items indicated or the accuracy of the information submitted. This review by the Owner 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. 1.2.2 All engineering data submitted by the Contractor after review by the Owner shall form part of the contract document. Drawings In addition to those stipulated in clause regarding drawings in GCC, the following also shall apply in respect of Contractor Drawings. 1.3.1 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. Each Drawing submitted by the Contractor shall be clearly marked with the name of the Owner, the specification title, the specification number and the name of the project. All titles, noting, markings and writings on the drawing shall be in English. All the dimensions should be to the scale and in metric units. The drawings submitted by the Contractor shall be reviewed by the Owner as far as practicable within 30 days and shall be modified by the Contractor if any modifications and/or corrections are required by the Owner. The Contractor shall Page 13

1.3

1.3.2

1.3.3

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incorporate such modifications and/or corrections and submit the final drawings

for approval. Any delays arising out of failure by the Contractor to rectify the drawings in good time shall not alter the contract completion date. 1.3.4 The Contractor should submit one plus four drawings for approval to the Owner. One print of such drawings shall be returned to the Contractor by the Owner marked approved/approved with corrections. The Contractor shall there upon furnish the Owner additional prints as may be required along with one reproducible in original of the drawings after incorporating all corrections. 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 Owner, if so required. 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 which are necessary to conform to the provisions and intent of the contract and such changes will again be subject to approval by the Owner. The approval of the documents and drawings by the Owner shall mean that the Owner 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). The works appear to comply with requirements of specifications.

1.3.5

1.3.6

1.3.7

(b)

In no case the approval by the Owner of any document does imply compliance with all technical requirements or 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. 1.3.8 The Owner may use AUTOCAD/PDF system in processing drawings. All drawings shall be suitable for AUTOCAD/PDF. Drawings which are not suitable for AUTOCAD/PDF will not be acceptable. A copy of each drawing reviewed will be returned to the Contractor as stipulated herein. 1.3.9 Copies of drawings returned to the Contractor will be in the form of a print with the Owners marking, or a print made from a AUTOCAD/PDF of the marked up drawing.

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1.3.10 The following is the general list of the documents and drawings that are to be

approved by the Owner. a) Work Schedule (Master Network) Plan. b) c)


d)

Checking of detail Survey already done by the owner Tower schedule and foundation classification for individual tower locations. Tower structural drawing and bill of materials. Soil Investigation report. Foundation working drawings/excavation Plan. Tower footing earthing drawing. Stub and stub-setting template drawings. Stringing procedure and stringing chart. Tower accessories drawings like design plate, name plate etc. Quality plan for fabrication and site activities including Quality System. Sub-vendors approval, etc.

e) f)
g) h)

i) j)
k)

l)

1.3.11 All rights of the design for all types of towers including special towers and
foundation designs Supplied by the Owner shall be strictly reserved with the Owner only and all the designs/drawings/data sheets submitted by the Contractor

from time to time after successful tower testing shall become the property of the Owner. Under no circumstances, the Contractor shall be allowed to use/offer above designs to any other authority without prior permission of the Owner. Any deviation to above is not acceptable and may be a cause of rejection of the Bid. 1.4 1.4.1 Design Improvements The Owner or the Contractor may propose changes in the specification and if the parties agree upon any such changes and the cost implication, the specification shall be modified accordingly. Design Co-ordination The Contractor shall be responsible for the selection and design of appropriate material/item to provide the best coordinated 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 it facilitates easy field assembly and maintenance. 1.6 Design Review Meeting The Contractor will be called upon to attend design review meetings with the Owner, and the consultants of the Owner during the period of contract. The Contractor shall attend such meetings at his own cost at Delhi or at mutually agreed venue as and when required.

1.5

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1.7 1.7.1

Quality Assurance, Inspection & Testing Quality Assurance


To ensure that the supply and services under the scope of this contract whether manufactured or performed within the Contractors works or at his SubContractors premises or at site or at any other place of work are in accordance with the specifications, the Contractor shall adopt suitable quality assurance program to control such activities at all points necessary. Such program shall be outlined by the Contractor and shall be finally accepted by the Owner after discussions before the award of contract. A quality assurance program of the

Contractor shall generally cover but not limited to the following:


(a) His organization structure for the management and implementation of the

(b) (c)
(d)

proposed quality assurance program. Documentation control system. Qualification data for Contractors key personnel.
The procedure for purchases of materials, parts components and, selection of sub-Contractors services including vendor analysis, source inspection,

incoming raw material inspection, verification of material purchases etc.


(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 Owner. (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

(o)

for controlling the quality characteristics relevant to each item of supply and Field Quality Plan and Manufacturing Quality Plan.

The Quality plan shall be mutually discussed and approved by the Owner after

incorporating necessary corrections by the Contractor as may be required. 1.7.1.1 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 Owners inspection of

equipment/material. 1.7.1.2 The Owner 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. Jindal India Thermal Power Limited Page 16

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1.7.2. Owners Supervision


1.7.2.1.To eliminate delays and avoid disputes and litigation it is agreed between the parties to the contract that all matters and questions shall be resolved in

accordance with the provisions of this document.


1.7.2.2.The manufacturing of the product shall be carried out in accordance with the specifications. The scope of the duties of the Owner, 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. Witness or authorise his representative to witness tests at the manufacturers works or at site, or at any place where work is performed under the contract. Inspect, accept or reject any equipment, material and work under the contract, in accordance with the specifications. Issue certificate of acceptance and/or progressive payment and final payment certificate. Review and suggest modification and improvement in completion schedules from time to time, and Supervise the Quality Assurance Program implementation at all stages of the works.

c)

d)

e)

f)

g)

1.7.3. Inspection & Inspection Certificate 1.7.3.1 The Owner, his duly authorized representative and/or outside inspection agency acting on behalf of the Owner shall have at all reasonable times access to the Contractors premises and 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 manufacture or assembled at other premises or works, the Contractor shall obtain from the Owner 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. 1.7.3.2 The Contractor shall give the Owner Inspector 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 Owner/inspector, unless witnessing of the tests is virtually waived, will attend such tests within fifteen (15) Jindal India Thermal Power Limited Page 17

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days of the date of which the equipment is notified as being ready for test/Inspection or 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 Inspector duly certified copies of tests in triplicate. 1.7.3.3 The Owner/Inspector shall, within fifteen (15) days from the date of inspection as defined herein give notice in writing to the Contractor, of any objection to any drawings and all or any equipment and workmanship which in his opinion is not in accordance with the contract. The Contractor shall give due consideration to such objections and shall make the modifications that may be necessary to meet the said objections. 1.7.3.4 When the factory tests have been completed at the Contractors or subContractors works, the Owner/inspector shall issue a certificate to this effect
within fifteen (15) days after completion of tests but if the test are not witnessed

by the Owner/inspector, the certificate shall be issued within fifteen (15) days of receipt of these tests or the issue of the certificate shall not bind the Owner to accept the equipment should it, on further tests after erection, be found not to comply with the contract. 1.7.3.5 In all cases where the contract provides for test 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 such item as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Owner/inspector or his authorized representative to carry out effectively such tests of the equipment in accordance with the contract and shall give facilities to the Owner/Inspector or to his authorized representative to accomplish testing. 1.7.3.6 The inspection by Owner and issue of Inspection Certificate thereon shall in no way limit the liabilities and responsibilities of the Contractor in respect of the agreed Quality Assurance Program forming a part of the Contract. 1.7.4. Tests and Standards 1.7.4.1 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. 1.7.4.2 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. These tests shall be carried out on samples prior to commencement of commercial production against the order. The Bidder shall indicate his schedule for carrying out these tests. Jindal India Thermal Power Limited Page 18

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1.7.4.3 Acceptance Tests shall mean those tests which are to be carried out on samples

taken from each lot offered for pre-dispatch inspection, for the purposes of acceptance of that lot. 1.7.4.4 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. 1.7.4.5 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. 1.7.4.6 The norms and procedure of sampling for these tests will be as per the Quality Assurance Program to be mutually agreed to by the Contractor and the Owner. 1.7.4.7 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-10 or as mutually agreed to between the Contractor and the Owner in the Quality Assurance Program. 1.7.4.8 For all type and acceptance tests, the acceptance values shall be the values specified in this Specification or guaranteed by the Bidder, as applicable. 1.8 1.8.1 Guaranteed Technical Particulars The Guaranteed Technical Particulars of the various items shall be furnished by the Bidders in one original plus four (4) copies in the prescribed format as provided in Annexure-6, Annexure-9 and Annexure12 of the Specifications. The Bidder shall also furnish any other schedule information as in their opinion is needed to give full description and details to judge the item(s) offered by them. The data furnished in Guaranteed 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 purpose 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 what so ever shall be given to the bidder offering better/more stringent values than those required as per specification. Packing All the materials shall be suitably protected, coated, covered or boxed and created to prevent damage or deterioration during transit, handling and storage at Site till

1.8.2

1.9 1.9.1

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the time of erection. The Contractor shall be responsible for any loss or damage during transportation, handling and storage due to improper packing. 1.9.2 The Contractor shall include and provide for securely protecting and packing the materials so as to avoid loss or damage during transport by air, sea, rail and road. All packing shall allow for easy removal and checking at site. Wherever necessary, proper arrangement for attaching slings for lifting shall be provided. All packages shall be clearly marked for with signs showing up and down on the sides of boxes, and handling and unpacking instructions as considered necessary. Special precaution shall be taken to prevent rusting of steel and iron parts during transit by sea. The cases containing easily damageable material shall be very carefully packed and marked with appropriate caution symbols, i.e. fragile, handle with care, use no hook etc. wherever applicable. 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 package, the name of the Contractor etc. Erection Conditions General 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. 2.2 2.2.1 Regulation of Local Authorities and Statutes 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 and the payment of Wages Act (both of the Government of India and Local State Govt.) and the rules made there under in respect of any employee or workman employed or engaged by him or his SubContractor. 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 Owner, shall be to the account of the Owner. Should any such inspection or registration need to be re-

1.9.3

1.9.4

1.9.5

2.0 2.1

2.2.2

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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. 2.3
2.3.1

Contractors Field Operation


The Contractor shall keep the Owner 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 Owner shall not relieve the Contractor of any of his responsibilities towards the field activities. Such reviews shall also not be considered as an assumption of any risk or liability by the Owner 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 of tools and plants and his erection methods. 2.4 Progress Report

2.4.1 Appropriate visual charts and photographs shall accompany the monthly progress

report detailing out the progress achieved on all erection activities as compared to the schedules in both hard and soft copies. 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. 2.5 2.5.1 Man Power Deployment Report The Contractor shall submit to the Owner, on the first day of every month, a man power deployment schedule for each activity. The Contractor shall also submit to the Owner on the first day of every month, a man power deployment report of the previous month detailing the number of persons scheduled to have been employed and actually employed. Facilities to be Provided by the Contractor

2.5.2

2.5.3

2.5.3.1 Tools, Tackle and Scaffoldings 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. He shall submit a list of all such materials to the Owner before the commencement of work at site. These tools and tackle shall not be removed from the site without the written permission of the Owner.

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2.5.3.2 First Aid and General Hygiene


The Contractor shall provide necessary first-aid facilities for all his employees, representatives and workmen working at the site. Enough number of Contractors

personnel shall be trained in administering first aid.


Similarly, the labor colony, the offices and the residential areas of the Contractors employees and workmen shall be kept clean and neat to the entire satisfaction of the Owner. Proper sanitary arrangements shall be provided by the

Contractor, in the work-areas, office and residential areas of the Contractor.


Waste oil shall be disposed of in a manner acceptable to the Owner. Under no

circumstances shall waste oil be dumped into uncontrolled drains. 2.6


2.6.1

Fire Protection
The work procedures that are to be used during the erection shall be those which

minimize fire hazards to the extent practicable. Combustible materials, combustible waste and rubbish shall be collected and removed from the site at least once each day. Fuels, oils and volatile or inflammable materials shall be stored away from the construction site and equipment and material stores in safe containers. 2.6.2 All the Contractors supervisory personnel and sufficient number of workers shall be trained for fire-fighting and shall be assigned specific fire protection duties. Enough of such trained personnel must be available at the site during the entire period of the contract. The Contractor shall provide enough fire protection equipment of the types and number for the ware-house, office, temporary structures, labour colony area etc. Access to such fire protection equipment, shall be easy and kept open at all time. Security 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. The Contractor shall make suitable security arrangements including employment of security personnel to ensure the protection of all materials, equipment and works from theft, fire, pilferage and any other damages and loss. 2.8 2.8.1 Materials Handling and Storage All the supplies under the contract arriving at site shall be promptly received, unloaded and transported and stored in the stores by the Contractor.

2.6.3

2.7

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2.8.2

Contractor shall be responsible for examining all the shipment and notify the Owner immediately of any damage, shortage, discrepancy etc. for the purpose of

Owners information only. The Contractor shall submit a report to the Owner every week, detailing all the receipts during the week. However, 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. 2.8.3 The Contractor shall maintain an accurate and exhaustive record detailing out the list of all items received by him for the purpose of erection and keep such record open for the inspection of the Owner.
All items shall be handled very carefully to prevent any damage or loss. The

2.8.4

materials stored shall be properly protected to prevent damage. The materials from the store shall be moved to the actual location at the appropriate time so as to avoid damage of such materials at site. 2.8.5 All the materials stored in the open or dusty location must be covered with suitable weather-proof and flameproof covering material wherever applicable. The Contractor shall be responsible for making suitable indoor storage facilities, to store all items/materials which require indoor storage. 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 failing behind the schedule for reasons attributable to him, he shall take necessary action to make good for such delays by increasing his work force or by working overtime or to otherwise to accelerate the progress of the work and to comply with schedule and shall communicate such actions in writing to the Owner, satisfying that his action will compensate for the delay. The Contractor shall not be allowed any extra compensation for such action. Field Office Records The Contractor shall maintain at his site office up-to-date copies of all drawings, specifications and other supplementary data complete with all the latest revisions thereto. The Contractor shall also maintain, in addition, the continuous record of all changes to the above Contractor Documents, drawings, specifications, supplementary data, etc. Effected at the field and on completion of his total assignment under the Contract shall incorporate data to indicate as installed conditions of the material supplied and erected under the contract. Such drawings

2.8.6

2.9 2.9.1

2.10

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and engineering data shall be submitted to the Owner in required number of

copies. 2.11 Protection of Property And Contractors Liability

2.11.1 The Contractor shall ensure provision of necessary safety equipment such as barriers, sign-boards, warning lights and alarms, etc., to provide adequate protection to persons and property. The Contractor shall be responsible to give

reasonable notice to the Owner and the Owners of public or private property and utilities when such property and utilities are likely to get damaged or injured during the performance of his works and shall make all necessary arrangements with such Owners, related to removal and/or replacement or protection of such property and utilities. 2.12 Insurance

2.12.1 In addition to the conditions covered under the title insurance in GCC the following provisions will also apply to the portion of works to be done beyond the Contractors own or his sub-Contractors manufacturing works. 2.12.2 Workmens Compensation Insurance This insurance shall protect the Contractor against all claims applicable under the workmens compensation Act, 1948 (Govt. of India). This policy shall also cover the Contractor against claims for injury, disability disease or death of his or his sub-Contractors employees, which for any reason are not covered under the workmens Compensation Act, 1948. The liabilities shall not be less that : Workmens Compensation Employees Liability 2.12.3 Comprehensive Automobile Insurance This insurance shall be in such a form to protect the Contractor against all claims for injuries, disability, disease and death to members of public including the Owners men and damage to the property of other arising from the use of motor vehicles during on or off the site operations, irrespective of the Ownership of such vehicles. The minimum liability covered shall be as herein indicated : a) Fatal Injury : : : Rs. 3,00,000 Each person Rs. 5,00,000 Each occurrence Rs. 5,00,000 Each occurrence As per Statutory Provisions As per Statutory Provisions

b)

Property Damage

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2.12.4 Comprehensive General Liability Insurance 2.12.4.1. The insurance shall protect the Contractor against all claims arising from injuries, disabilities, disease or death of members of public or damage to property of others, due to any act or omission on the part of the Contractor, its agents, its employees, its representative and sub-Contractors or from riots, strikes and civil commotion. 2.12.4.2. The hazards to be covered will pertain to all the works and areas where the Contractor, its sub-Contractors, its agents and employees have to perform work pursuant to the contract. 2.12.4.3. The above are only illustrative list of insurance covers normally required and it will be the responsibility of the Contractor to maintain all necessary insurance coverage to the extent both in time and amount to take care of all its liabilities either direct or indirect, in pursuance of the contract. 2.13 Protection of Monuments and Reference Points The Contractor shall ensure that any finds such as relics, antiques, coins fossils, etc. which he may come across during the course of performance of his works either during excavation or elsewhere, are properly protected and handed over to the Owner. Similarly, the Contractor shall ensure that the bench marks, reference points etc., which are marked either with the help of Owner or by the Owner shall not be disturbed in any way during the performance of its works. If any work, is to be performed which disturbs such reference, the same shall be done only after these are transferred to other suitable locations under the direction of the Owner. The Contractor shall provide all necessary materials and assistance for such relocation of reference points etc. 2.14 Work and Safety Regulations

2.14.1 The Contractor shall ensure safety of all the workmen, materials, plants and equipments belonging to him or to the others, working at the site. The Contractor shall also provide for all safety notices and safety equipment required by the relevant legislations and deemed necessary by the Owner. 2.14.2 The Contractor will notify, well in advance to the Owner, its intention to bring to the site any container filled with liquid or gaseous fuel or explosive or petroleum substance or such chemicals which may involve hazards. The Owner shall have the right to prescribe the conditions, under which such a container is to be stored, handled and used during the performance of the works and the Contractor shall strictly adhere to and comply with such instructions. The Owner shall also have the right at his sole discretion, in inspect any such container or such construction plant. Equipment for which materials in the container is required to be used and if in his opinion, its use is not safe, he may forbid its use. Jindal India Thermal Power Limited Page 25

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No claim due to such prohibition or towards additional safety provisions called

for by him shall be entertained by the Owner.


Further, any such decision of the Owner shall not, in any way, absolve the Contractor of his responsibilities and in case use of such a container or entry thereof into the site area is forbidden by the Owner, the Contractor shall use alternative methods with the approval of the Owner without any cost implication

to the Owner or extension of work schedule.


2.14.3 Where it is necessary to provide and/or store petroleum products or petroleum mixtures and explosives, the Contractor shall be responsible for carrying our such provision and/or storage in accordance with the rules and regulations laid down in Petroleum Act 1934, Explosives Act 1948 and amendments thereof, and petroleum and carbide of Calcium Manual published by the Chief Inspector of

Explosives of India. All such storage shall have prior approval of the Owner.
In case, any approval is necessary from the Chief Inspector (Explosives) or any

statutory authorities, the Contractor shall be responsible for obtaining the same. 2.14.4 All equipment used in construction and erection by Contractor shall meet Indian/International Standards and where such standards do not exist, the Contractor shall ensure these to be absolutely safe. All equipment shall be strictly operated and maintained by the Contractor in accordance with manufacturers operation manual and safety instructions and as per any existing Guidelines/Rules in this regard. 2.14.5 Periodical examinations and all tests for all lifting/hoisting equipment and tackle shall be carried out in accordance with the relevant provisions of Factories Act 1948, Indian Electricity Supply Act and associated Laws/Rules in force from time to time. A register of such examinations and test shall be properly maintained by the Contractor and will be promptly produced as and when desired by Owner or by the persons authorized by him. 2.14.6 The Contractor shall provide suitable safety equipment of prescribed standard to all employees and workmen according to the need, as may be directed by the Owner who will also have the right to examine these safety equipment to determine their suitability, reliability, acceptability and adaptability. 2.14.7 Where explosives are to be used, the same shall be used under the direct control and supervision of an expert, experienced and qualified licensed and competent person, strictly in accordance with the Code of Practices/Rules framed under Indian Explosives Act pertaining to handling, storage and use of explosive, with required licenses or permissions.

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2.14.8 The Contractor employing more than 250 workmen whether temporary, casual, probationer, regular or permanent or on contract, shall employ at least one full time officer exclusively as safety officer to supervise safety aspects of the equipment and workmen, such an officer will co-ordinate with the Project Safety

Officer of the Owner.


The name and address of such safety officer of the Contractor will be promptly

informed in writing to the Owner with a copy to the safety officer-in-charge before he starts work or immediately after any change of the incumbent is made during currency of the contract. 2.14.9 In case any accident occurs during the construction / erection or other associated activities undertaken by the Contractor, thereby causing any minor or major or fatal injury to his employees due to any reason whatsoever, it shall be the responsibility of the Contractor to promptly inform the same to the Owner and also to all the authorities envisaged under the applicable laws. 2.14.10The Owner shall have the right to stop the work, if in its opinion the work is being carried out in such a way as may cause accidents and endanger the informed in writing about the nature of hazards and possible injury/accident and he shall remove short-comings promptly. The Contractor after stopping the specific work, can if felt necessary, appeal against the order of stoppage of work to the Owner within 3 (three) days of such stoppage of work and the decision of the Owner in this respect shall be conclusive. 2.14.11The Contractor shall not be entitled for any damages/compensation for stoppage of work due to safety reasons as provided in Clause 2.14.10 above and the plea of such stoppage of work will not be taken as an extension of time, for completion of work and will not be the ground for waiver of any part of Supplies liability for timely completion of the works. 2.14.12The Contractor shall follow and comply with all Safety Rules, relevant provisions of applicable laws pertaining to the Safety of workmen, employees plant and equipment as may be prescribed from time to time without any demur, protest or contest or reservation. In case of any conflict between statutory requirement and Safety Rules referred above, the most stringent clause shall be applicable. 2.14.13If the Contractor fails in providing safe working environment as per Safely Rules or continues the work even after being instructed to stop work by the Owner as provided in Clause 2.14.10 above, the Contractor shall promptly pay to the Owner on demand, compensation at the rate of Rs.5,000/- (five thousand) per day or part thereof till the instructions are complied with and so certified by the Owner. However, in case of accident taking place causing injury, to any individual, the provisions contained in Clause 2.14.14 below shall also apply in addition to compensation mentioned in this para.

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2.14.14If the Contractor does not take all safety precautions and/or fails to comply with the Safety Rules as prescribed by the Owner or 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 Owner or any other person at site or adjacent thereto, the Contractor shall be responsible for payment of

compensation to the Owner as per the following schedule:a) Fatal injury or accident causing death b) Major injuries or accident causing 25 % or more permanent disability Rs.3,00,000.00 Applicable (Three lakhs only) Per death/ injury to any person person. Rs. 50,000/Whosoever (Fifty thousand only) Per person for

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 Owner is made to pay such compensation, the Contractor will be liable to reimburse the Owner such

amount(s) in addition to the compensation indicated above. 2.15 Foreign Personnel

2.15.1 In case necessary for the execution of the works, the Contractor shall bring foreign supervisors for the execution of the contract, at his own cost. The Contractor shall submit to the Owner, data on all personnel he proposes to bring into India for the performance of the works under the contract, at least sixty (60) days prior to their arrival in India. Such data shall include the name of each person, his present address, his assignment and responsibility in connection with the works, and a short resume of his qualification, experience etc., in relation to the work to be performed by him. 2.15.2 Any person, unsuitable and unacceptable to the Owner, shall not be brought to India. Any person brought to India, and found unsuitable or unacceptable to the Owner shall be immediately removed from site and repatriated back, if found necessary, he may be replaced by another personnel acceptable to the Owner. 2.15.3 No person brought to India by the contactor, for the works shall be repatriated without the consent of the Owner in writing, based on a written request from the Contractor for such repatriation giving reasons for such an action to the Owner. The Owner may give permission for such repatriation provided it is satisfied that the progress of work will not suffer due to such repatriation.

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2.15.4 The cost of passports, visas and all other travel expenses to and from India, shall be to the Contractors account. The Owner will not provide any residential

accommodation and/or furniture for any of the Contractors personnel including foreign personnel Contractor shall make his own arrangements for such facilities. 2.15.5 The Contractor and its expatriate personnel shall respect all Indian Acts, Laws,
Rules and Regulations and shall not, in any way, interfere with Indian political

and religious affairs and shall conform to any other rules and regulations which the Government of India, and the Owner may establish on them. The Contractors expatriate personnel shall work and live in close co-operation and co-ordination with their co-workers and the community and shall not engage themselves in any other employment either part-time or full-time nor shall they take part in any local politics. 2.15.6 The Owner shall assist the Contractor, to the extent possible in obtaining necessary permits to travel to India and back by issue of necessary certificates and other information needed by the Government agencies. 2.16 Code Requirements The erection requirements and procedures to be followed during the execution of the project shall be in accordance with the applicable India/International standards/Regulations, as indicated in Technical Specifications, good engineering practice, the Drawings and other applicable Indian codes, laws and regulations. JITPLs Environment and Social Policy and its Implementation Development and growth of mankind through Industrialization and unwarranted
use of natural resources has inflicted considerable impact on Environment and Society. As a result, Environmental and Social issues have emerged as the focal

3. 3.1.

point of global debate. In order to address environmental and social issues and to match the rising expectations of a cleaner, safer and healthier environment, Contractor needs to adhere to the following norms i) Avoidance of environmentally and socially sensitive areas while planning project activities.
Minimization of impacts when project activities occur in environmentally

ii)

and socially sensitive areas. iii) 3.2. Mitigation of any unavoidable adverse impacts arising out of its projects.

Basic issues to be kept in mind while carrying out construction activities are to

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EPC Tender for JITPL

Avoid socially sensitive areas with regard to human habitations and areas of cultural significance. Secure the interest of people affected due to project. Involve local people affected by transmission line project as per requirement and suitability. Consult affected people in decisions having implication to them if considered necessary. Apply, efficient and safe technology / practices. Keep abreast of all potential dangers to peoples health, occupational safety and safety of environment and the respective mitigatory measures. Establish preventive mechanisms to guarantee safety. Mitigation measures in case of accidents. Avoid unwarranted cutting of trees in forest area.

While constructing the lines through forest stretches the Contractor will provide
alternate fuel to its employee e.g. working labours /supervisors etc. in order to

avoid cutting of forest woods. 3.4. Contractor will ensure safety to the wild life. During working/camping near to the National park. Contractor during construction of lines in agricultural fields will ensure minimum damages to the crops, trees, bunds, irrigation etc. If the same is unavoidable, the decision of Engineer-in-charge shall be final. The waste/excess material/debris should be removed from the construction site including agricultural field, forest stretches, river etc. immediately after construction work and obtain a clearance certificate form the Owner of the land. The Contractor will ensure least disturbance to the hill slope and natural drainage so as to avoid soil erosion. Natural drainage in plain area if disturbed is to be trained to the satisfaction of Engineer-in-charge. As far as possible existing path/kachha road/approach shall be used for the construction. The Contractor will ensure supply of stone chips/sand from authorized/approved quarry areas who are having the required licenses/permits from the local authorities. Proper documentation of above, if any.

3.5.

3.6.

3.7.

3.8.

3.9.

3.10.

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SECTION III TOWER SPECIFICATION

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SECTION III CONTENTS Clause Description 1.0 2.0 3.0


4.0

Page No 33 38 38 54 75 83 91 92 Annexure-A Annexure-B Annexure-C Annexure-D Annexure-E 103 106 107 109 110

Detailed Survey, Optimization of Tower Location Environmental Conditions Transmission Tower


Geotechnical Investigations

5.0 6.0
7.0 8.0

Foundations Tower Erection, Stringing and Installation of Line Materials Special River Crossing Tower Field Quality Plan

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TECHNICAL SPECIFICATIONS SECTION III TOWER SPECIFICATION


1.0 1.1 Detailed Survey, Optimization of Tower Location Detailed survey for both the packages is completed. However near the approaches to sub-stations and if any deviations in line route, detailed survey including profiling, tower optimisation , tower spotting and check survey shall have to be carried out by the Contractor on the basis of Tower Spotting Data given by Owner as stipulated herein. The Contractor shall submit the proposal for detailed survey based on the preliminary route alignment given by the Owner. The Contractor shall finalize and submit results of detailed survey including any changes suggested within the time schedule as agreed at the time of award. The soil investigation for the obligatory points are to be carried out by the Contractor as detailed out in this specification. The Contractor should note that Owner will not furnish the topographical maps prepared by survey of India but will make available any assistance that may be required in obtaining the topographical maps. The detailed survey shall be made along the approved route alignment. Soil resistivity along the route alignment, shall be measured in dry weather by four electrode method keeping inter-electrode spacing of 50 meters. For calculating soil resistivity formula 2ar (where a = 50 metres and r = megger reading in ohms) shall be adopted. Measurement shall be made at every 2 to 3 kms along the route of transmission lines. In case soil characteristic, changes within 2 to 3 kms, the value shall also have to be measured at intermediate locations. The megger reading and soil characteristics shall also be indicated in the soil resistivity results. Route Making At the starting point of the commencement of route survey an angle iron spike of 65 x 65 x 6mm section and 1000mm 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 50x50x650mm six shall be driven at prominent position at intervals of not more than 750 meter along the transmission line to be surveyed up to the next angle point. Nails of 100mm wire length should be fixed on the top of these pegs
to show the location of instrument. The pegs shall be driven firmly into the

1.2

1.3

1.4 1.5

1.6

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stone/concrete pillar with JITPLPowerTransco marked on them shall be put

firmly on the ground for easy identification. 1.7 Profile Plotting & Tower Spotting
From the field book entries, the route plan with en-route details and level profile shall be plotted and prepared to scale of 1:2000 horizontal & 1:200 vertical in PLS-CADD software on 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, R/Ls at undulations. Areas along the profile Sheet, 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 accordingly to requirement. A 10mm 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 standard. For as built profile these shall be in A1 size. 1.8 1.8.1 Tower Location Sag Template & Tower Spotting Data Sag template curve drawing and Tower Spotting Data shall be supplied by the Owner to the successful Bidder on award of Contract. Sag template prepared based on the supplied sag-template curve drawing shall only be used for tower spotting on the profiles. Two numbers of the approved template, prepared on rigid transparent plastic sheet, shall be provided by the Contractor to the Owner for the purpose of checking the tower spotting. The templates shall be on the same scale as that of the profile. 1.8.2 Tower Spotting With the help of supplied 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 15

spans or 5 Kms in plain terrain and 10 spans or 3 Kms in hilly terrain. A section point shall comprise of tension point with DB type or DC type or DD 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

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extended by inserting standard body extension designed for the purpose according

to technical specification. (c) Loading


The towers shall be spotted such that wind & weight spans are within permissible limits (as per tower spotting data), to avoid any loading on towers beyond design

provisions. (d) Road Crossing


At all important road crossings, the ground clearance at the roads under maximum temperature and in still air shall be such that even with conductor broken an adjacent span, ground clearance of the conductor from the road surfaces will not be less than 8.84 m for 400 KV lines. At all national highways tension towers

shall be used and crossing span will not be more than 250 meters. (e) Railway Crossings
All the railway crossings coming en-route the transmission line have already been identified by the Owner. The railway crossings shall be finalized as per the regulation laid down by the Railway Authorities. The following are the important

features of the prevailing regulations (revised in 1987). i) ii) iii) iv) v) vi) The crossings shall be supported on DD type tower on either side depending on the merits of each case. The crossing shall normally be at right angle to the railway track. 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. No crossing shall be located over a booster transformer, traction switching station, traction sub-station or a track cabin location in an electrified area. Minimum ground clearance above rail level of the lower portion of any conductor under condition of maximum sag shall be maintained at 17.90 meters. The crossing span will be limited to 300 meters.

The approval for crossing railway track shall be obtained by the Owner from the
Railway Authority, however, six copies of profile and plan, tower and foundation design and drawings required for the approval from the Railway Authority shall

be supplied by the Contractor to the Owner. (f) River Crossings


Suitable type of tension tower shall be used for river crossings. Clearance required by navigation authority shall be provided. For non navigable river,

clearance shall be reckoned with respect to highest flood level (HFL).

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(g) Power line Crossings


Where this line is to cross over another line of the same voltage or lower voltage, suitable type of tension tower with suitable extensions shall be used for crossings.

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 to be agreed upon. Minimum clearance in meters between lines when crossing each other shall be as per stipulations of IE Rules. (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 by the Owner on intimation from the Contractor. If deviation of telecommunication line is required the same has to be executed by the Contractor at his own cost. 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. Contractor shall also be responsible for various activities viz. collecting input details, preparation of documents etc. as may be required, for processing of case for PTCC clearance for the transmission line(s) from the concerned authorities. (i) Details En-route All topographical details, permanent features, such as trees, building etc. 23m for 400KV on either side of the alignment shall be detailed on the profile plan. 1.9 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 up to date.

1.9.1. The tree cutting shall be the responsibility of the Contractor. 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 at the time of actual execution of the work as
detailed below. Contractor may please note that Owner shall not pay any

compensation for any loss or damage to the properties or for tree cutting due to Contractors work. Jindal India Thermal Power Limited Page 36

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1.9.2.

Any way leave which may be required by the Contractor, shall be arranged by the

Contractor as required by work program.


1.9.3. To evaluate and tabulate the trees and bushes coming within 23m for 400KV 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) b) c)


d)

Girth (circumstances) measured at a height of 1 meter from ground level. Approximate height of the tree with an accuracy of +2 meters. Name of the type of the species/tree.
The bushy and under growth encountered in the 46 m belt should also be evaluated with its type, height, girth and area in square meters, clearly

indicating the growth in the tree/bush statement.


1.9.4. Payment of compensation towards the clearance etc. will be the responsibility of the Owner. Contractor has to obtain the valuation of the trees/crops and pay the compensation as to the affected parties and get the receipts for reimbursement

from the Owner. 1.10 Preliminary Schedule


The profile sheets, duly spotted, along with preliminary schedules indicating type of towers, type of foundations, wind span, weight span, angle of deviation, river

of road crossing and other details shall be submitted for the approval of the Owner. After approval the Contractor shall submit six more sets of the approved reports along with one set of reproducible of final profile drawings to the Owner for record purpose. 1.11 Check Survey for Tower Location

1.11.1. The check survey shall be conducted to locate and peg mark the tower positions 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 centre with respect to the centre of the tower location shall be noted and recorded for determining the amount of earthwork required to meet the approved design parameters. 1.11.2. Changes in the preliminary tower schedule after check survey, if required, shall be carried out by the Contractor and he shall thereafter submit a final tower schedule for the approval of Owner. 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.

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2.0 2.1

Environmental Conditions Forest


The line route passing through forest stretches for various transmission lines

covered under this specification shall be furnished to the successful Bidder. 2.2 General Climatic Conditions
Climatic conditions shall be of tropical nature having summer period for 8 months and winter period for 4 months in a year. Working season shall be approximately

9 months/year and balance 3 months shall be monsoon period.


The maximum temperature during summer shall be of the order of 50oC and the minimum temperature in the winter shall be of the order of 7.5oC. Normal every

day temperature is 32C. 2.3 Statutory Regulations and Standards

2.3.1. Statutory Regulations


The Contractor is required to follow local statutory regulations stipulated in Electricity Act 2003, lndian Electricity Rules, 1956 as amended and other local

rules and regulations referred in these Specifications. 2.3.2. Reference Standards


2.3.2.1.The Codes and/or standards referred to in the 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. 2.3.2.2.Other internationally accepted standards which ensure equal or better performance than those specified shall also be accepted, subject to prior approval by the Owner. 3.0 3.1 Transmission Tower General Description of the Tower

3.1.1. The towers are of the following types: a) Double Circuit (DA, DB, DC & DD) b) Special towers

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3.1.2.

The towers are of self supporting hot dip galvanised lattice steel type designed to carry the line conductors with necessary insulators, earth wires and all fittings under all loading conditions. Outline diagram of double circuit tower is enclosed

with the Specification.


3.1.3. The tower shall be fully galvanised using mild steel or/and high tensile steel sections as specified in clause no. 3.6. Bolts and nuts with spring washer are to be

used for connections. 3.2 Type of Towers

3.2.1. The towers for 400 kV Lines are classified as given below

Type of Tower Deviation Limit Typical Use DA 0 deg To be used as tangent tower. DB 0 deg 15 deg a) Angle towers with tension insulator string. b) Also to be used for uplift force resulting from an uplift span upto 200 m under broken wire condition. c) Also to be used for Anti Cascading Condition. DB 0 deg d) To be used as Section Tower DC 15 deg - 30 deg a) Angle tower with tension insulator string. b Also to be used for uplift forces resulting from an uplift span upto 200 m under broken wire condition. c) Also to be used for anti cascading condition. DC 0 deg d) To be used as section tower. Also to be used for transposition of transmission lines with modifications DD 30 deg-60 deg a) Angle tower with tension insulator string. b) Also to be used for uplift forces resulting from an uplift span upto 300 m under broken wire condition c) For river crossing anchoring with longer wind span & 0 deg. deviation on crossing span side and 0 deg to 30 deg. deviation on other side DDE 0 deg a) Complete dead end. b) Dead end with 0 deg to 15 deg deviation both on line side and sub station side (slack span). Note:- the above towers can also be used For longer span with smaller angle of deviations.

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3.2.2. Transposition tower


DC type towers with suitable modifications are to be used for transposition of the line maintaining all the required clearance and shielding. Two numbers of

transposition towers shall be required for double circuit line. 3.2.3. Special Towers
The towers which will be specially designed for very long spans which can not be

crossed by normal tower with extensions, like major river crossings etc. shall be treated as special towers. 3.2.4. Extensions 3.2.4.1.The Double Circuit towers are designed so as to be suitable for adding 3M, 6M and 9M body extensions/leg extensions for maintaining adequate ground clearances without reducing the specified factor of safety in any manner. 3.2.4.2.The provision for addition 18/25M body extension to tower types DA and DD is also kept by the Owner. For Power Line Crossing, River Crossings or any other obstacle, tower types DA or DD can be used with 18/25 M extensions depending,
upon the merit of the prevailing site condition. The maximum reduced spans for

DA and DD type towers shall be mentioned in the tower spotting data. 3.2.4.3.Provision for use or unequal leg extensions (upto max. 3m difference) has also been kept. The details of unequal leg extensions provided in the design shall be indicated to the Contractor during execution stage, so that proper optimisation of benching/revetment requirement can be done accordingly by the Contractor. 3.2.4.4.All above extensions provisions to towers shall be treated as part of normal tower only. 3.3 Span and clearances

3.3.1. Normal Span The normal ruling span of the line is 400m. 3.3.2. Wind Span The wind span is the sum of the two half spans adjacent to the support under consideration. For normal horizontal spans this equals to normal 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 spotting of structures, the span limits given in Table 3.1 for 400KV lines shall prevail.

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TABLE 3.1 (FOR 400 KV D/C LINE PORTION) TOWER TYPE NORMAL CONDITION MAX. (m) MIN. (m) DA 600 200 360 100 DB, DC 600 0 360 (-)200 DD 600 0 360 (-)300 BROKEN WIRE CONDITION MAX. (m) MIN. (m)

3.3.4. In case at certain locations where actual spotting spans exceed the design spans
then cross-arms and certain members of towers required to be modified /reinforced, in that case drawings of the modified/reinforced tower shall be

supplied to the Contractor as per requirement. 3.4 Electrical Clearances

3.4.1. Ground Clearance


The minimum ground clearance from the bottom conductor shall not be less than

8840 mm for 400KV at the maximum sag conditions and still air. a) An allowance of 150 mm shall be provided to account for errors in stringing.
b) Conductor creep shall be compensated by over tensioning the conductor at a

temperature of 26C, lower than the stringing temperature for ACSR MOOSE for 400KV transmission lines. 3.5
3.5.1

Design and Drawings


The relevant drawings for all the towers and their extension shall be furnished to

the Contractor by the Owner which shall include structural/ erection drawings, Shop floor drawings single line drawings/diagrams, foundation working drawings. In case the Contractors designs/drawings are approved by the Owner, the
Contractor is fully responsible for providing the Owner with structural/ erection

drawings, Shop floor drawings single line drawings/diagrams, foundation working drawings etc., after incorporating their weights/volumes etc. 3.5.2 The structural/erection drawings for the towers and their extensions shall be given
to the Contractor in two copies. The tower numbers shall be fabricated from the

shop drawings and BOM to be provided by Owner. However, before taking up the mass fabrication, the Contractor shall arrange for one number protoassembly for each type of towers and extensions which shall be inspected by Owner. However no separate charges will be paid by the Owner for proto assembly of towers along with its extensions. After successful proto assembly inspection the Contractor shall make reproducible from the given Jindal India Thermal Power Limited Page 41

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drawings/documents, add the required note for the subject line; change the revision number to the drawing documents and incorporate changes, if required to be made during proto-assembly. The revised drawing/documents (including

structural drawings, BOM etc.) shall be submitted in four copies and will be finally approved by the Owner. The mass/fabrication shall be taken up from the approved drawings. The overall responsibility of fabricating tower members correctly lies with the Contractor
only and the Contractor shall ensure that all the tower members can be fitted

while erecting without any undue strain on them. 3.5.3 Some drawings & documents such as BOM, shop drawings, structural drawings for some of towers/extensions based on single line design diagrams etc.; if any, required for proper and effective execution of the project may also be required to be developed by the Contractor. However, no extra cost for the same shall be payable to the Contractor. The drawings submitted by the Contractor shall be approved/commented by the Owner as the case may be within thirty (30) days of receipt of drawings in Owners office. It the designs/drawings are commented by the Owner, the Contractor shall submit revised design/drawings duly incorporating all comments within fifteen (15) days of date of issue of comments. The tower accessories drawings like number plate, circuit plate, danger plate, phase plate, anti-climbing device, step bolt, D-shackle, Hanger etc. including Earthing drgs. shall also be prepared by the Contractor and shall be submitted to the Owner, in three copies, along with one reproducible, for record: These drawings shall be prepared in A4 size only. Not Applicable While submitting the structural drawings, bill of materials and any other drawings pertaining to the subject transmission line, the Contractor shall clearly indicate on each drawing JITPL Specification No. Name of the transmission line and project, letter reference no. and date on which the submission are made. The same practice is also to be followed while submitting distribution copies. The Contractor shall require to submit 15 copies of all relevant drawings for necessary distribution. Materials Tower Steel Sections IS Steel Sections of tested quality of conformity with IS:2062 (Designated Y.S.250 MPa) or/and IS:8500 grade 490B (Designated Y.S.350 MPa) as per the tower designs are to be used in towers, extensions and stub setting templates. The Jindal India Thermal Power Limited Page 42

3.5.4

3.5.5

3.5.6 3.5.7

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Contractor can use other equivalent grade of structural steel angle sections and plates conforming to latest International Standards. However, use of steel grade having designated yield strength more than of EN 10025/BS-4360-50B grade (355MPa) is not permissible. Steel plates below 6mm size exclusively used for packing plates/packing washers produced as per IS: 1079 -1994 (Grade -0) are also acceptable. However, if below 6mm size plate are used as load bearing plates viz gusset plates, joint splices etc. the same shall conform to IS: 2062/IS 8500 or equivalent standard meeting mechanical strength/metallurgical properties corresponding to Fe-410 or above grade (designated yield strength not more than 355MPa), depending upon the type of grade incorporated into design: Flats of equivalent grade meeting mechanical strength and metallurgical properties may also be used in place of plates for packing plates packing washers. The chequered plates shall conform to IS:35021994. For designing of towers rationalised steel sections has been used. During execution of the project, if any particular section is not available, the same shall be substituted by higher section at no extra cost to Owner and the same shall be borne by the Contractor. However, design approval for such substitution shall be obtained from the Owner before any substitution. 3.6.2 Fasteners: Bolts, Nuts and Washers

3.6.2.1.All tower members shall be joined together with Bolts and nuts. The redundants of first two (2) panels from ground level shall be connected with Anti-theft bolts and nuts along with spring washers whereas the balance joints shall be connected with the hexagonal bolts & nuts. All hexagonal bolts and nuts shall conform to IS12427. They shall have hexagonal head and nuts, the heads being forged out of the solid, truly concentric, and square with the shank, which must be perfectly straight. Anti-theft bolts and nuts shall have round tapered heads with hexagonal shear nuts. They shall conform to IS: 12427 and IS: 1367 for property class 5.6/5 except for dimensions which shall be as per enclosed drawing no. O-0000-OO-X-X-X030. All bolts and nuts shall be galvanised as per IS: 1367 (Part-13)/IS: 2629. 3.6.2.2.The bolt shall be of 16/24 mm diameter and of property class 5.6 as specified in IS: 1367 (Part-III) and matching nut of property class 5.0 as specified in IS:1367 (Part-VI). 3.6.2.3.Bolts upto M16 and having length upto 10 times the diameter if 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 Jindal India Thermal Power Limited Page 43

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strength of bolts for 5.6 grade should be 310 MPa minimum as per IS: 12427. Bolts should be provided with washer face in accordance with IS: 1363 (Part-I) to

ensure proper bearing.


3.6.2.4.Nuts for hexagonal bolts should be double chamfered as per the requirement of IS: 1363 Part-III. It should be ensured by the manufacturer that nuts should not be overlapped beyond 0.4MM oversize on effective diameter for size upto M16. Nuts for Anti-theft bolts should be round tapered with hexagonal shear nuts. The hexagonal portion of shear nuts shall break away at specified torque recommended by the Contractor to ensure proper tightening of members and the fasteners shall not be opened subsequently with tools. The tightening torque and

shearing of anti-theft nuts shall be verified during proto-assembly.


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 than 8mm when fully tightened. All nuts shall fit 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 steel electrogalvanized, positive lock type and 3.5mm in thickness for 16mm dia. bolt and 4.5mm for 24mm bolt. 3.6.2.8.To avoid bending stress in bolts or to reduce it to minimum, no bolt shall connect aggregate thickness of members more than three (3) times its diameter. 3.6.2.9.The bolt positions in assembled towers shall be as per structural drawing. 3.6.2.10. Bolts at the joints shall be so staggered that nuts shall be tightened with spanners without fouling. 3.6.2.11. To ensure effective in-process Quality control it is essential that the manufacturer should have in house testing facility for all tests like weight of zinc coating, shear strength and other tests etc. The manufacturer should also have proper Quality Assurance System which should be in line with the requirement of this specification and IS: 14000 series Quality System Standard. 3.7 Tower Accessories Arrangement shall be provided for fixing of all tower accessories to the tower at a height between 2.5 meters and 3.5 meters above the ground level.

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3.7.1

Step Bolts & Ladders Each tower shall be provided with step bolts conforming to IS: 10238 of not less than 16mm diameter and 175mm long, spaced not more than 450mm apart and
extending from 2.5 meters above the ground level to the top of the tower. For

double circuit tower the step bolt shall be fixed on two diagonally opposite legs upto 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 with standing a vertical load not less than 1.5 KN. For special towers, where the height of the

super structure exceeds 50 meters, (ladders along with protection rings as per the Owner approved design shall be provided in continuation of the step bolts on one face of the tower from 30 metres above ground level to the top of the special structure. From 3.5m to 30m height of super structure stop bolts shall be provided. Suitable platform using 6mm thick perforated chequered plates alongwith suitable railing for access from step bolts to the ladder and from the ladder to each crossarm tip and the ground wire support shall also to be provided. The platform shall be fixed on tower by using counter-sunk bolts. 3.7.2 Insulator Strings Attachments a) For the attachment of suspension Insulator string, a suitable dimensioned swinging hanger on the tower shall be provided so as to obtain specified clearances under respective swinging condition of the strings. The hanger, extensions links, D-shackles etc. as required and considered in the design of the tower shall have minimum ultimate tensile strength of 2x120 KN = 240 KN UTS for double suspension string. The design and supply of hanger, D-shackles, strain plate etc. are also in the scope of Contractor. b) At tension towers strain plates of suitable dimensions under each crossarm tip, shall be provided for taking the hooks or D-shackles of the tension insulator strings with ultimate tensile strength of 4 X 160 KN. To achieve requisite clearances, if the design calls for providing extra D-shackles, link plate etc. before connecting the insulator string the same shall be supplied by the Contractor.

3.7.3

Earthwire Clamps Attachment a) Suspension Clamp Earthwire suspension clamps will be supplied by the Contractor. The drawing shall be submitted by the Contractor for Owners approval. The Contractor shall also supply U bolts/D-shackles, wherever required. b) Tension Clamps The Contractor shall supply earthwire tension clamps, for incorporation on the tower. Earth wire peaks of tension towers shall be provided with suitable plates to accommodate the shackle of tension clamps. The Contractor shall also supply the U-bolts wherever required and take

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Owners approval for details of the attachments before the mass

3.7.4

fabrication. Anticlimbing Device


Barbed wire type anti-climbing device, as per enclosed drawing shall be provided and installed by the Contractor for all towers. The barbed wire shall conform to IS-278 (size designation Al). The barbed wires shall be given chromating dip as

per procedure laid down in IS:1340. 3.7.5 Danger, Number, Circuit and Phase plate
Danger Plates, Number plates, circuit plates and phase plates shall be provided

and installed by the Contractor.


a) Each tower shall be fitted with a danger plate number plate and two sets of phase plates for double circuit tower. The transposition towers should have provision of fixing phase plates on both the transverse phase. Circuit

plates shall be provided on all the Double Circuit towers.


b) The letters, figures and the conventional skull and bones of danger plates shall conform to IS-2551 and shall be in a signal red on the front of the

plate. .
c) The corners of the danger, number and circuit plates shall be rounded off

to remove sharp edges.


d) The letters at number and circuit plates shall be red enameled with white

enameled background. 3.7.6 Aviation Requirements:

3.7.6.1.Aviation requirements, if required shall be in the scope of the Contractor and the

same shall conform to IS: 5613 (Part-2, Sec-I). 3.8 Tower Fabrication The fabrication of towers shall be in conformity with the following:
Except where hereinafter modified, details of fabrication shall conform to IS:802

3.8.1

(Part-Il) or the relevant international standards.


3.8.2 3.8.3 The tower structures shall be accurately fabricated to connect together easily at

site without any undue strain on the bolts.


No angle member shall have the two leg flanges brought together by closing the

3.8.4

angle. The diameter of the hole shall be equal to the diameter of bolt plus 1.5mm.

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3.8.5

The structure shall be designed so that all parts shall be accessible for inspection and cleaning. Drain holes shall be provided at all points where pockets of

depression are likely to hold water.


3.8.6 All identical parts shall be made strictly inter-changeable. All steel sections before any work is done on them, shall be careful leveled, straightened and made true to detailed drawings by methods which 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. 3.8.7 Drilling and Punching

3.8.7.1.Before any cutting work is started1 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. The punching may be adopted for thickness upto 16mm. Tolerances regarding punch holes are as follows:a) Holes must be perfectly circular and no tolerances in this respect are permissible. b) The maximum allowable difference in diameter of the holes on the two sides of plates or angle is 0.8 mm, i.e. the allowable taper in a punched holes should not exceed 0.8mm on diameter. c) Holes must be square with the plates or angles and have their walls parallel. 3.8.7.3.All burns 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 erection mark conforming to the component number given to it in the fabrication drawings. The mark shall be marked 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 A = Owners code assigned to the Contractors - Alphabet BB = Contractors Mark-Numerical CC = Tower Type Alphabet. Jindal India Thermal Power Limited Page 47

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DDD = Number mark to be assigned by the Contractor- Numerical. Erection mark for high tensile steel members shall be prefixed by the letter H 3.9
3.9.1

Quantities and weights


The quantities of the following items have been envisaged in Annexure-1 for

various types of towers: i) Basic Body. ii) Body Extensions. iii) Leg Extension. iv) Stubs & Cleats v) Bolts & Nuts including spring washers and step bolts etc.
During detail engineering, proto assembly of each of the above items shall be inspected and approved by Owner and subsequently shall be released for fabrication and manufacturing as per the Technical Specification by the Contractor. The manufacturing of the above items shall be taken up in such a

manner that the Equipment/Material offered for inspection to Owner are on completed tower basis for each type of tower, completed Stubs & Cleats set basis so as to facilitate availability of erectable tower of each type and erectable stubs & cleats set for casting to foundation. After inspection of the offered Equipment/ Material by Owner representative(s), a certificate for the inspected quantity shall be issued by Owner for the material meeting the requirements of Technical Specification. However, MICC shall be issued only on Completed Tower Basis for each type of tower (comprising the required Basic Body, body extensions wherever required, four (4) equal or defined unequal Leg Extension, Bolts & Nuts along with Packing and Spring Washers) and on completed Stubs & Cleats set basis for each type of tower foundation (comprising a set of stubs & Cleats, required Bolts and Nuts along with Spring Washers). Accordingly, the payment shall be released for completed Tower Basis for each type of tower (Comprising the Basic Body, body extensions, wherever applicable, bolts & nuts along with spring washer and step bolts, unequal leg extensions wherever applicable for a completed Tower) and on completed Stubs and Cleats set basis for each type of foundation (comprising a set of stubs & cleats, required Bolts and Nuts along with Spring Washers) based on the weight of the tower parts as calculated as per Clause 3.9.3 and Bolts & Nuts based on the unit rates incorporated in the contract. 3.9.2 Detail survey for both the packages is completed and tower schedule prepared based on the detailed survey is attached as Annexure-3. Contractor has to calculate all the quantities/volumes as per the details provided in Annexure-3 and quote the price accordingly. Unit volumes for the foundations and weights of the towers and bolts and nuts are provided in Annexure-4 for calculating the total quantities. However for benching, revetment and other tower protection works, Page 48

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contractor has to estimate the quantity during the site visit. Contractor is advised to have thorough site visit and understand the site conditions before submitting

the tender.
3.9.3 Though fully galvanised tower parts are to be supplied, 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 bill of materials, without taking into consideration the reduction in weights due to holes, notches and level cuts etc. but taking into

consideration the weight of the D-shackles, hangers, strain plates, pack plates, gusset plates and pack washers etc. The weight of stub and cleats also shall be calculated in similar manner. For bolts and nuts along with spring washers and step bolts, the weight per tower shall be calculated from the bolt schedule applicable to each type of towers and body extensions as approved by the Owner. The rate quoted by the bidder for tower/tower part supply is deemed to be inclusive of galvanising charges including the cost of zinc. 3.10 Galvanising Fully galvanised towers and stub shall be used for the lines. Galvanising of the member of the towers shall conform to IS: 2629 and IS: 4759. All galvanised members shall withstand tests as per IS: 2633. 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 taped or re-run after galvanising. 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 Clause 4 of IS: 1573. Earthing The Contractor shall measure the tower footing resistance (TFR) of each tower after it has been erected and before the stringing of the earthwire during dry weather. Each tower shall be earthed the tower footing resistance shall not exceed 10 ohms. Pipe type earthing and counter poise type earthing wherein required shall be done in accordance with the latest additions and revisions of: IS: 3043 Code of practice for Earthing.

3.11

IS: 5613 Code of practice for Design, Installation and maintenance (Part II/Section-2) of overhead power lines. 3.11.1 The details for pipe & counterpoise type earthing are given in the drawings enclosed with these specifications. 3.11.2 The provisional quantities for pipe type earthings and counterpoise earthing are furnished in Annexure-1. The bidders are required to quote unit rates for the same in appropriate schedule. The quoted price shall include fabrication, supply and Jindal India Thermal Power Limited Page 49

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installation of earthing material including supply of coke, salt etc In case of counterpoise type earthing, the quotation shall be based on 120 meters of wire per tower. 3.12 Inspection and Tests

3.12.1 General All standard tests, including quality control tests, in accordance with appropriate Indian/International Standard, shall be carried out unless otherwise specified. 3.12.2 Inspection 3.12.2.1. a) The Contractor shall keep the Owner 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 could be made for inspection.
b) The acceptance of any part of items shall in no way relieve the Contractor of any part of his responsibility for meeting all the requirements of the

Specification.
3.12.2.2. The Owner or his representative shall have-tree access at all reasonable times to

those parts of the Contractors works which are concerned with the fabrication of the Owners material for satisfying himself that the fabrication is being done in accordance with the provisions of the Specification. 3.12.2.3. Unless specified otherwise, inspection shall be made at the place of manufacture prior to dispatch and shall be concluded so as not to interfere unnecessarily with the operation of the work. 3.12.2.4. Should any member of the structure be found not to comply with the supplied design, it shall be liable to rejection. No member once rejected shall be resubmitted for inspection, except in cases where the Owner or his authorised representative considers that the defects can be rectified. 3.12.2.5. 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 Owner. 3.12.2.6. All gauges and templates necessary to satisfy the Owner shall be supplied by the Contractor. 3.12.2.7. The specified 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.

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3.13

Packing

3.13.1 Angle section shall be wire bundled. 3.13.2 Cleat angles, gusset plates, brackets, fillet plate, hanger and similar loose pieces shall be tested and bolted together in multiples or securely wired through holes.
3.13.3 Bolts, nuts washers and other attachments shall be packed in double gunny bags

accurately tagged in accordance with the contents. 3.13.4 The packing shall be properly done to avoid losses & damages during transit. Each bundle or package shall be appropriately marked. 3.14 Standards 3.14.1 The design, 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 (IS)/lnternational 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 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. 3.14.2 The material and services covered under these specifications shall be performed as per requirements of the relevant standard code 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.
Sl. No. Indian Standards (Is) Title Internationally recognized Standards/Guides ISO/R/752 ASTM B6 ASTM A131 CSA 6.1 ASCE 52 IEC 826 BS 8100 Section 1 Materials and loads Section 2 Permissible stresses Code of practice for use of structural steel in overhead Transmission Line : Fabrication, Galvanising, Inspection and

1. 2. 3. 4.

IS: 209-1992 IS 278-1991 IS 800-1991 (a) IS: 802 (Part 1) Sec 1-1995 Sec 2-1992

Specification for Zinc Galvanised Steel Barbed Wire Code of Practice for General Building Construction in Steel Code of Practice for General Building
Construction in Steel in Overhead

Transmission Line Towers : Materials, loads and Permissible Stresses

(b) IS : 802 1990 (Part 2)

ASCE 52

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(c) IS : 802-1990 (Part 3) IS : 808-1991 IS : 875-1992

5.
6.

7. 8.
9.

IS : 1363-1990 IS: 1367-1992 IS : 1477 1990

10.
11. 12.

IS: 1573-1991 IS: 1852-1993 IS: 1893-1991

Packing Code of practice for use of structural ASCE 52 Steel in overload Transmission Line Towers Testing IEC 652 Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle Sections. Code of Practice for Design Loads (other than Earthquakes) for Buildings and Structures Hexagon Nuts (size range M5 to M36) Technical Supply Conditions for Threaded Steel/Fasteners Code of practice for Painting of Ferrous Metals in Buildings : Part-I, Pretreatment: Part-II Painting. Electro-Plated Coatings of zinc on iron and steel Rolling and cutting Tolerances of Hot Rolled Steel Products IEEE 693 Criteria for Earthquake Resistant Design of Structures Plain Washers Steel for general structural purposes Ready Mixed Paint, Air Drying,
Red Oxide, Zinc Chrome, Prining

13. 14. 15.

IS : 2016-1992 IS: 2062-1992 IS: 2074-1992

ISO/R887 22.1

ANSIB18-

16. 17. 18. 19. 20. 21. 22.

IS: 2551-1990 IS : 2629-1990 IS : 2633-1992 IS : 3043-1991 IS : 3063-1994 IS: 3757-1992 IS : 4759-1990

23. 24.

IS : 5369-1991 IS : 5613-1993

25.

IS : 6610-1991

Specification Danger Notice Plates Recommended Practice for Hot Dip Galvanising of iron and steel Method of Testing Uniformity of coating of Zinc coated Articles Code of Practice for Earthing Single coil Rectangular section Spring Washers for Bolts, Nuts Screws High strength Structural Bolts Specification for Hot zinc coatings on structural steel and other Allied products General Requirements for Plain Washers Code of practice for design installation and Maintenance of overhead power lines section 1 Design Part 2, Section 2 Installation and Maintenance Specification for Heavy

ASTM A123 CSAG164

DIN-127

26. 27. 28.

IS : 6623-1992 IS : 6639-1990 IS : 6745-1990

Washers for steel structures. High Strength Structural Nuts ASTM A394 CSA B334 Hexagon Bolts for steel structure. Method for Determination of weight of ASTM A90

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29.

IS : 8500-1992

30. 31. 32. 33.

IS : 10238-1989 IS : 12427-1988 Publication 19(N)/700 No.

Zinc coated iron and steel articles Specification for weldable structural steel (Medium & High Strength Qualities) Step Bolts for steel structures Bolts for Transmission Line Towers Indian Electricity Rules Regulation for Electrical Crossing of Railway Tracks

3.14.3 The standards mentioned above are available from ________________________________________________________________________ Reference/Abbreviation Name and address from which the standards/guides are available ________________________________________________________________________ IS Bureau of Indian Standards Manak Bhawan, 9, Bahadur Shah Zafar Marg, New Delhi, India ISO International Organisation for Standardisation, Danish Board for Standardisation, Dansk Standardising Sraat, Aurehoegvei-12 DK-2900, Hellepruip, DENMARK Canadian Standard Association 178, Rexadale Boulevard, Rexdale (Ontario) Canada, M9W 1R3 Deutsches Institute Fiir Normung Burggrafenstrassee 4-10 Post Fach 1107 D-1000, Belin-30 GERMANY American Society for Testing and Material 1916 Race Street Philadelphia PA 19103-1187 USA Kitab Mahal Baba Kharak Singh Marg New Delhi-110001 INDIA Page 53

CSA

DIN

ASTM

Indian Electricity Rules Regulation for Electricity Crossing Of Railway Tracks Jindal India Thermal Power Limited

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ASCE

American Society of Civil Engineers 345 East 47th Street New York, NY 10017-2398 USA Institute of Electrical and Electronics Engineers 445 Hoes Lane NJ 0085-1331 USA International Electrotechnical Commission Bureau Central de la Commission 1 rue, de varembe Geneva Switzerland

IEEE

PIScataway,

IEC

4.0 4.1 4.1.1

Geotechnical Investigations General Owner requires that a detailed Geotechnical investigation be carried out at various
tower locations to provide the designer with sufficiently accurate information, both general and specific, about the substrata profile and relevant soil and rock parameters at site on the basis of which the foundation of transmission line towers

can be classified and designed rationally.


4.1.2 These specifications provide general guidelines for geotechnical investigation of normal soils. Cases of marshy locations and those affected by salt water or sulphate shall be treated as special locations and the corresponding description in

these specifications shall apply. Any other information required for such locations shall be obtained by Contractor and furnished to Owner. 4.2 4.2.1 Scope The scope of work includes detail soil investigations and furnishing bore log data at various tower locations. Along the line route detailed soil investigation has to be carried out at every 5.0 kM interval apart from the either side towers of River Crossing, Railway Crossings, Power line Crossings and any other critical points identified by owner. However, during actual execution of work the quantities shall be decided by the Engineer - in - Charge, depending upon the soil strata and terrain. Based on the bore log data/soil parameter /soil investigation results, the Contractor shall recommend the type of foundations suitable for these locations and the same shall be got approved by the Owner. For other tower locations, Trial

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pit is to be done in every locations for foundation classification up to

foundation depth. No separate payment for Trial pit shall be done.


4.2.2 These specifications cover the technical requirements for a detailed Geotechnical investigation and submission of a detailed Geotechnical Report. The work shall

include mobilization of all necessary tools and equipment, provision of necessary engineering supervision, and technical personnel, skilled and unskilled labour, etc. as required to carry out the entire field investigation as well as laboratory tests, analysis and interpretation of data collected and preparation of the Geotechnical Report. Contractor shall also collect data regarding variation of subsoil water table along the proposed line route. The aforementioned work shall be supervised by a graduate in Civil engineering having at least 5 years of site experience in geotechnical investigation work. 4.2.3 Contractor shall make its own arrangements to establish the co-ordinate system required to position boreholes, tests pits and other field test locations as per the drawings/sketches supplied by Owner. Contractor shall determine the reduced levels (R.Ls) at these locations with respect to benchmarks used in the detailed survey. Two reference lines shall be established based on survey data/details. Contractor shall provide at site all required survey instruments to the satisfactions of the Owner so that the work can be carried out accurately according to specifications and drawings. Contractor shall arrange to collect the data regarding change of course of rivers, major natural streams and nalas, etc., encountered along the transmission line route from the best available sources and shall furnish complete hydrological details including maximum velocity discharge, highest flood level (H.F.L), scour depth etc. of the concerned rivers, major streams and nalas (canals). The filed and laboratory data shall be recorded on the proforma recommended in relevant Indian Standards. Contractor shall submit to Owner two copies of field bore logs (one copy each to Owner site and Corporate Office) and all the field records (countersigned by the Owner) soon after the completion of each boreholes/test. Whenever Contractor is unable to extract undisturbed samples, it shall immediately inform the Owner. Payment for boring charges shall be subject to Owner being satisfied that adequate effort has been made to extract undisturbed samples. Special care shall be taken for locations where marshy soils are encountered and Contractor in such cases shall ensure that specified number of vane shear tests are performed and the results correlated with other soil parameters. One copy of all field records and laboratory test results shall be sent to Owner on a weekly basis. Owner may observe, at the laboratory testing procedures.

4.2.4

4.2.5

4.2.6

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4.2.7

The Contractor shall interact with the Owner to get acquainted with the different types of structures envisaged and in assessing the load intensities on the foundation for the various types of towers in order to enable him to make specific recommendation for the depth, founding strata, type of foundation and the

allowable bearing pressure.


4.2.8 After reviewing Contractors geotechnical investigation draft report, Owner will call for discussions, to be held normally within one week at Owners site Office, in order to comment on the report in the presence of Contractors Geotechnical Engineer. Any expenditure associated with the redrafting and finalising the report, travelling etc. shall be deemed included in the rates quoted for the geotechnical

investigations. 4.2.9 Contractor shall carry out all work expressed and implied in Clause 4.2. of these specifications in accordance with requirements of the specification. General Requirements Wherever possible, Contractor shall research and review existing local knowledge records of test pits, boreholes, etc., types of foundations adopted and the behaviour of existing structures, particularly those similar to the present project. Contractor shall make use of information gathered from nearby quarries, unlined wells excavation etc. Study of the general topography of the surrounding areas will often help in the delineation of different soil types. Contractor shall gather data regarding the removal of overburden in the project area either by performing test excavations, or by observing soil erosion or land slides in order to estimate reconsolidation of the soil strata. Similarly, data regarding recent land fills shall be studied to determine the characteristics of such land fills as well as the original soil strata. The water level in neighboring streams and water courses shall be noted. Contractor shall make enquiries and shall verify whether there are abandoned underground works e.g. worked out ballast pits, quarries, old brick fields, mines, mineral workings etc. It is essential that equipment and instruments be properly calibrated at the commencement of the work. If the Owner so desires, Contractor shall arrange for having the instruments tested at an approved laboratory at its cost and shall submit the test reports to the Owner. If the Owner desires to witness such tests, Contractor shall arrange for the same. Codes and Standards for Geotechnical Investigations All standards, specifications and codes of practice referred to herein shall be the latest editions including all applicable official amendments and revisions. In case Page 56

4.3 4.3.1

4.3.2

4.3.3

4.3.4

4.3.5

4.4 4.4.1

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of conflict between the present specifications and those referred to herein, the former shall prevail. Internationally accepted standards which ensure equal or

higher performance than those specified shall also be accepted. 4.4.2 All work shall be carried out in accordance with the following Indian Standards and Codes: International and Indian Internationally Title Standards (IS) Recognised Standard/Code IS:1080-1990 Codes of Practice for Design and Construction of Simple Spread Foundations. IS:1498-1992 Classification and Identification of Soils for ASTM D 2487 General Engineering purposes. ASTM D 2488 IS:1892-1992 Code of Practice for Subsurface Investigation for Foundation IS:1904-1986 Code of Practice for Design and Construction of foundation in Soils: General Requirements IS:2131-1992 ASTM D 1586 Method of Standard Penetration Test for Soils IS:2132-1992 ASTM D 1587 Code of Practice for Thin Walled Tube Sampling of Soils IS:2720-1992 ASTM D 420 Method of Test for Soils (Relevant Parts) IS:2809-1991 Glossary of Terms and symbols Relating to Soil ASTM D 653 Engineering IS:2911-1980 Code of Practice for Design and construction of Pile Foundations (Relevant Parts). IS:3025 Methods of Sampling and Testing (Physical and Chemical) for water used in Industry. IS:3043-1991 Code of Practice for Earthing IS:4078-1990 Code of Practice for Indexing and Storage of Drill Cores. IS:4091 -1987 Code of Practice for Design and Construction of Foundations for Transmission Line Towers and Poles. IS:4434-1992 Code of Practice for In-situ ASTM D 2573 Vane Shear Test for Soils ASTM D 4648 IS:4453-1992 Code of Practice for Exploration by Pits, Trenches. Drifts and Shafts. IS:4464-1990 Code of Practice for Presentation of Drilling information and core description in Foundation Investigation IS:4968 (Part-II) Method for Subsurface sounding for soils, 1992 dynamic method using cone and Bentonite slurry. IS:5313-1989 Guide for Core Drilling observations. Page 57

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Indian Standards (IS) IS:6403-1990 IS:6926-1990 IS:6935-1989 IS:7422-1990

Title Code of Practice for Determination of allowable Bearing Pressure on Shallow Foundation. Code of Practice for Diamond Core Drilling for Site Investigation for River Valley Projects. Method of Determination of Water level in a Bore Hole. Symbols and Abbreviations for use in Geological Maps Sections and subsurface Exploratory Logs (Relevant parts). Code of Practice for Calculation of Settlements of Foundations (Shallow Foundations subjected to symmetrical Vertical Loads). Method of Determination of Point Load Strength Index of Rocks Method of Determination of Unconfined Compressive Strength of Rock Materials. Method of Preparation of Rock Specimen for Laboratory Testing. Specification for Liquid Limit Apparatus Specification for Split Spoon Sampler. Method of Determination of Slake Durability Index of Rocks. Description of Discontinuities in Rock MassCore Recovery and Rock Quality.

International and Internationally Recognised Standard/Code ASTM D 194

IS:8009(Part-l)1993 IS:8764-1991 IS:9143-1991 IS:9179-1991 lS:9259-1992 IS:9640-1992 IS:10050-1991 IS:11315 (PartIl)-1991 4.5 4.5.1

ASTM D 2938 ASTM D 4543 ASTM D 4318 ASTM D 1586 ASTM D 4644

Field Investigation for Soils Boring Boreholes are required for detailed soil investigations.

4.5.1.1.General Requirements a) Boreholes shall be made to obtain information about the subsoil profile, its nature and strength and to collect soil samples for strata identification and for conducting Laboratory tests. The minimum diameter of the borehole shall be 150mm and boring shall be carried out in accordance with the provisions of IS:1892 and the present specification.

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b) All boreholes shall be 7m deep for normal soil conditions. If a strata is encountered where the Standard Penetration Test Records N values greater than 100, with characteristics of rock, the borehole shall be advanced by coring at least 3m further in normal locations with prior approval of the Owner. When the boreholes are to be terminated in soil strata an additional Standard Penetration Test shall be carried out at the termination depth. No extra payment shall be made for carrying out Standard Penetration Tests. c) Casing pipe shall be used when collapse of a borehole wall is probable. The bottom of the casing pipe shall at all times be above the test of sampling level but not more than 15cm above the borehole bottom. In case of cohesion less soils, the advancement of the casing pipe shall be such that it does not disturb the soil to be tested or sampled; The casing shall preferably be advanced by slowly rotating the casing pipe and not by driving. d) In-situ tests shall be conducted and undisturbed samples shall be obtained in the boreholes at intervals specified hereafter. Representative disturbed samples shall be preserved for conducting various identification tests in the laboratory. Water table in the borehole shall be carefully recorded and reported following IS:6935. No water or drilling mud shall be used while boring above ground water table. For cohesionless soil below water table, the water level in the borehole shall at all times be maintained slightly above the water table. e) The borehole shall be cleaned using suitable tools to the depth of testing or sampling, & ensuring least or minimum disturbance of the soil at the bottom of the borehole. The process of jetting through an open tube sampler shall not be permitted. In cohesive soils, the borehole maybe cleaned by using a
bailer with a flap valve. Gentle circulation of drilling fluid shall be done

when rotary mud circulation boring is adopted. f) On completion of the drilling, Contractor shall backfill all boreholes as directed by the Owner.

4.5.1.2.Auger Boring Auger boring may be employed in soft to stiff cohesive soils above the water table. Augers shall be of helical or post hole type and the cuttings brought up by the auger shall be carefully examined in the field and the description of all strata shall be duly recorded in the field borelog as per IS:1498. No water shall be introduced from the top while conducting auger boring.

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4.5.1.3.Shell and Auger Boring 4.5.1.3.1. Shell and auger boring may be used in all types of soil which are free from boulders. For cohesionless soil below ground water table, the water level in the borehole shall always be maintained at or above ground water level. The use of chisel bits shall be permitted in hard strata having SPT-N value greater than 100 Chisel bits may also be used to extend the bore hole through local obstructions such as old construction. Boulders rocky formations, etc. The requirements in Clause 4.5.1.2 shall apply for this type of boring also. Rotary method may be used in all types of soil below water table. In this
method the boring is carried out by rotating the bit fixed at the lower end of

the drill rod. Proper care shall be taken to maintain firm contact between the bit and the bottom of the borehole. Bentonite or drilling mud shall be used as drilling fluid to stabilise and protect the inside surface of the borehole. Use of percussion tools shall be permitted in hard clays and in dense sandy deposits. 4.5.2 Standard Penetration Test (SPT)

4.5.2.1.This test shall be conducted in all types of soil deposits encountered within a borehole, to find the variation in the soil stratification by correlating with the number of blows required for unit penetration of a standard penetrometer. Structure sensitive engineering properties of cohesive soils and sifts such as strength and compressibility shall not be inferred based on SPT values. The test shall be conducted at depths as follows: ________________________________________________________________ Location Depths (m) ________________________________________________________________ Normal Soils 2.0, 3.0, 5.0, 7.0 ________________________________________________________________ 4.5.2.2.The spacing between the levels of standard penetration testing and next
undisturbed sampling shall not he less than 1.0m Equipments, accessories and procedures for conducting the test and for the collection of the disturbed soil

samples shall conform to IS:2131.


4.5.2.3.The test shall be carried out by driving a standard split spoon sampler in the bore hole by means of a 650 N hammer having a free fall of 0.75 m. The sample shall be driven using the hammer for 450 mm recording the number of blows for every 150 mm. The number of blow for the last 300 mm drive shall be reported as N

value.

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4.5.2.4.This test shall be discontinued when the blow count is equal to 100 or the penetration is less than 25 mm for 50-blows. At the level where the test is discontinued, the number of blows and the corresponding penetration shall be reported. Sufficient quantity of disturbed soil samples shall be collected from the split spoon sampler for identification and laboratory testing. The sample shall be visually classified and recorded at the site as well as properly preserved without

loss of moisture content and labelled. 4.5.3 Sampling

4.5.3.1.General
a) Sufficient number of soil samples shall be collected. Disturbed soil samples shall be collected for soil identification and for conducting tests

such as sieve analysis, index properties, specific gravity, chemical analysis etc. Undisturbed samples shall be collected to estimate the physical bearing capacity and settlement properties of the soil. b) All accessories and sampling methods shall conform to IS:2132: all disturbed and undisturbed samples collected in the field shall be classified at site as per IS:1498: All samples shall be identified with date, borehole or test pit number, depth of sampling, etc. The top surface of these sample in-situ shall also be marked. Care shall be taken to keep the core and box samples vertical, with the mark directing upwards. The tube samples shall be properly trimmed at one end and suitably capped and sealed with molten paraffin wax. The Contractor shall be responsible for packing, storing in a cool place and transporting all the samples from site to the laboratory within seven days after sampling with probe, protection against loss and damage.

c)

4.5.3.2.Disturbed Samples a) Disturbed soil samples shall be collected in boreholes at regular intervals. Jar samples weighing approximately 1 kg shall be collected at 0.5m intervals starting from a depth of 0.5m below ground level and at every identifiable change of strata to supplement the boring records. Samples shall be stored immediately in air light jars which shall be filled to capacity as much as possible. In designated borrow areas, bulk samples, from a depth of about 0.5m
below ground level shall be collected to establish the required properties

b)

for use as a fill material. Disturbed samples weighing about 25 kg shall be collect at shallow depths and immediately stored in polythene bags as per

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IS:1892. The bags shall be sealed properly to preserve the natural moisture

content of the sample and placed in wooden boxes for transportation. 4.5.3.3.Undisturbed Samples
In each borehole undisturbed samples shall be collected at every change of strata

and at depths as follows: ________________________________________________________________ Location Depths (m) ________________________________________________________________ Normal Soils 1.0, 4.0, 6.0 ________________________________________________________________ 4.5.3.3.1. The spacing between the top levels of undisturbed sampling and standard
penetration testing shall not be less than 1.0m. Undisturbed samples shall be at 100mm diameter and 450mm in length. Samples shall be collected in a

manner to preserve the structure and moisture content of the soil Accessories and sampling procedures shall conform to IS:1892 and IS:2132. a) Undisturbed sampling in cohesive soil: Undisturbed samples in soft to stiff cohesive soils shall be obtained using a thin walled sampler. In order to reduce the wall friction, suitable precautions, such as oiling the surfaces shall be taken. The sampling tube shall have a smooth finish on both surfaces and a minimum effective length of 450mm. The area ratio of sampling tubes shall be less than 12.5%. However, in case of very stilt soils area ratio up to 20% shall be permitted. b) Undisturbed sampling in very loose, saturated, sandy and silty soils and very soft clays: Samples shall be obtained using a piston sampler consisting of a cylinder and piston system. In soft clays and silty clays, with water standing in the casing pipe, piston sampler shall be used to collect undisturbed samples in the presence of expert supervision. Accurate measurements of the sampling depth, dimensions of sampler, stroke and length of sample recovery shall be recorded. After the sampler is pushed to the required depth, the cylinder and piston system shall be drawn up together, preventing disturbance and changes in moisture content of the sample; c) Undisturbed sampling in cohesionless soils

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Undisturbed samples in cohensionless soils shall be obtained in accordance with IS:8763. Sampler operated by compressed air shall be

used to sample cohesionless soils below ground water table. 4.5.4 Ground Water

4.5.4.1.One of the following methods shall be adopted for determining the elevation of

ground water table in boreholes as per 15:6935 and the instructions of the Owner:
a) In permeable soils, the water level in the borehole shall be allowed to stabilise after depressing if adequately by bailing before recording its level. Stability of sides-and bottom of the boreholes shall be ensured at all

times; b) For both permeable and impermeable soils, the following method shall be suitable. The borehole shall be filled with water and then bailed out to various depths. Observations on the rise or tall of water level shall be made at each depth. The level at which neither fall nor rise is observed shall be considered the water table elevation and confirmed by three successive readings of water level taken at two hours interval.

4.5.4.2.If any variation of the ground water level is observed in any specific boreholes the water level in these boreholes shall be recorded during the course of the field investigation. Levels in nearby wells, streams, etc., if any, shall also be noted parallelly. 4.5.4.3.Subsoil water samples
a) Subsoil water samples shall be collected for performing chemical analysis.

Representative ground water samples shall be collected when first encountered in boreholes and before the addition of water to aid boring or drilling. b) Chemical analysis of water samples shall include determination of pH value, turbidity, sulphate, carbonate, nitrate and chloride contents,
presence of organic matter and suspended solids. Chemical - preservatives may be added to the sample for cases as specified in the test methods or in

applicable Indian Standards. This shall only be done if analysis cannot be conducted within an hour of collection and shall have the prior written permission and approval of the Owner. 4.5.5 Dynamic Cone Penetration Test (For marshy locations) Dynamic cone penetration test shall be conducted to predict stratification, density,
beating capacity of granular soils, etc. The test shall be conducted to the specified

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depth or refusal, whichever comes first. Refusal shall be recorded when the blow count exceeds 150 for 300mm penetration. Equipment, accessories, test procedures, field observations and reporting of results shall conform to IS:4968,

Part-II. The driving system shall comprise of a 650kg weight having a free fall of 0.75m. The cone shall be of 65mm diameter provided with vents for continuous flow of bentonite slurry through the cone and rods in order to avoid friction
between the rods and soil. On completion of the test the results shall be presented

as a continuous record of the number of blows required for every 300mm penetration of the cone into the soil in a suitable chart supplemented by a graphical plot of blow count for 300mm penetration vs. depth. On completion of the test, the results shall be presented on the proforma approved by the Owner.
4.5.6 Vane Shear Test (required for boreholes where UDS is not possible in

marshy locations) Field vane shear test shall be performed inside the borehole to determine the shear
strength and bearing capacity of cohesive soils. Equipment, accessories, test

procedures, field observations shall correspond to IS:4434. Tests may also be conducted by direct penetration from ground surface. If the cuttings at the test depth in the borehole show any presence of gravel, sand shells, decomposed wood, etc., which are likely to influence the test results substantially, the test at that particular depth may be omitted with the permission of the Owner. However, the test shall be conducted at a depth where these obstructions cease to occur. On completion of the test, the results shall be reported in an approved proforma as specified in IS:4434, Appendix- A. 4.6 4.6.1 Field Investigation for Rock Rock Drilling

4.6.1.1.If, during the investigations, large hard fragments or natural rock beds are encountered, work shall proceed with core drilling methods. The equipment and procedures for this operation shall conform to IS:1892. The starting depth of drilling in rock shall be certified by the Owner. At the end of the investigation, the hole drilled in rock shall be backfilled with grout consisting of 1 part cement and 3 parts sand by weight. 4.6.1.2.Drilling shall be carried out with NX size tungsten carbide (TC) or diamond tipped drill bits, depending on the type of rock and according to IS:6926. Suitable type of drill bit (TC/Diamond) and core catchers shall be used to ensure continuous and good core recovery. Core barrels and core catchers shall be used for breaking off the core and retaining it when the rods are withdrawn. Double tube core barrels shall be used to ensure better core recovery and to retrieve cores from layers of bedrock. Water shall be circulated continuously in the hollow rods and the sludge conveying the rock cuttings to the surface shall be collected. A very high core recovery ratio shall be aimed at in order to obtain a satisfactory Jindal India Thermal Power Limited Page 64

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undisturbed sample. Attempt shall be made to recover cores of 1.5m in length. Normally TC bit shall be used. Change over to a diamond bit shall require the

specific written approval of the Owner, and his decision as to whether a TC or a diamond bit is to be used shall be final and binding on Contractor. 4.6.1.3.No drilling run shall exceed 1.5m in depth, if the core recovery is less than 80% in any run the length of the subsequent run shall be reduced to 0.75m. During drilling operations observations on return water, rate of penetration etc. shall be made recorded and recorded as per IS:5313. a) The colour of return water at regular intervals, the depth at which any change of colour of return water is observed, the depth of occurrence and amount of flow of hot water, if encountered, shall be recorded. The depth through which a uniform rate of penetration was maintained,
the depth at which marked change in rate of penetration or sudden fail on drill rod occurs, the depth at which any blockage of drill bit causing core

b)

loss, if any, shall be recorded.


c) Any heavy vibration or torque noticed during the drilling should be

recorded together with the depth of occurrence. d) Special conditions like the depth at which grouting was done during drilling, presence of artesian conditions, loss of drilling fluid, observations of gas discharge with return water, etc., shall also be observed and recorded. All the observations and other details shall be recorded as per daily drill and reported in a proforma as given in IS:5313, Appendix A.

e)

4.6.2 Core Sampling 4.6.2.1.Core samples shall be extracted by the application of a continuous pressure at one end of the core with the barrel held horizontally without vibration. Friable cores shall be extracted from the barrel directly into a suitably sized half round plastic channel section. Care shall be taken to extrude the samples in the direction of coring to avoid stress reversal. 4.6.2.2.Immediately after withdrawal from the core barrel, the cores shall be placed in a tray and transferred to boxes specially prepared for this purpose. The boxes shall be made from seasoned timber or any other durably material and shall be indexed on top of the lid according to IS:4078. The cores shall be numbered serially and arranged in the boxes in a sequential order. The description of the core samples shall be recorded as instructed in IS:4464. Where no core is recovered, it shall be recorded as specified in the standard. Continuous records of core recovery and

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rock quality designation (RQD) are to be mentioned in the borelog in accordance

with IS: 1315 (Part-Il). 4.7 4.7.1 Laboratory Testing Essential Requirements
a) Depending on the types of substrata encountered, appropriate laboratory tests shall be conducted on soil and rock samples collected in the field. Laboratory tests shall be scheduled and performed by qualified and experienced personnel who are thoroughly conversant with the work. Tests indicated in the schedule of items shall be performed on soil, water and rock samples as per relevant IS codes. One copy of all laboratory test data records shall be submitted to Owner progressively every week. Laboratory tests shall be carried out concurrently with the field investigations as initial laboratory test results could be useful in planning

the later stages of field work. A schedule of laboratory tests shall be established by Contractor to the satisfaction of the Owner within one week of completion of the first borehole. b) Laboratory tests shall be conducted using approved apparatus complying with the requirements and specification of Indian Standards or other approved standards for this type of work. It shall be checked that the apparatus are in good working condition before starting the laboratory tests. Calibration of all the instruments and their accessories shall be done carefully and precisely at an approved laboratory. All samples, whether undisturbed or disturbed shall be extracted, prepared and examined by competent personnel properly trained and experienced in soil sampling, examination, testing and in using the apparatus in conformance with the Specified standards. Undisturbed soil samples retained in liners or seamless tube samplers shall be removed, without causing any disturbance to the samples, using suitably designed extruders just prior to actual testing. If the extruder is horizontal, proper support shall be provided to prevent the sample from breaking. For screw tube extruders, the pushing head shall be free from the screw shaft so that no torque is applied to the soil sample in contact with the pushing head. For soft clay samples, the sample tube shall be cut by means of a high speed hacksaw to proper test length and placed over the mould before pushing the sample into it with a suitable piston. While extracting a sample from a liner or tube, care shall be taken to assure that its direction of movement is the same as that during sampling to avoid stress reversal.

c)

d)

e)

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4.7.2

Tests

4.7.2.1.Tests as indicated in these specifications and as may be requested by the Owner, shall be conducted. These tests shall include but may not be limited to the

following a) Tests of undisturbed and disturbed samples Visual and engineering classification; Sieve analysis and hydrometric analysis Liquid, plastic and shrinkage limits; Specific gravity; Chemical analysis Swell pressure and free swell index determination Proctor compaction test b) Tests of undisturbed samples Bulk density and moisture content; Relative density (for sand), Unconfined compression test; Box shear test (for sand); Triaxial shear tests (depending on the type of soil and field conditions on undisturbed or remolded samples): i)Unconsolidated undrained; ii) consolidated drained test; -Consolidation. c) Tests on rock samples Visual classification; Moisture content, porosity and density; Specific gravity; -Hardness; Stake durability; Unconfined compression test (both saturated and at in-situ water content): Point load strength index; Deformability test(both saturated and dry samples). d) Chemical analysis of sub soil water. 4.7.3 Salient Test Requirement a) Triaxial shear tests shall be conducted on undisturbed soil samples, saturated by the application of back pressure. Only if the water table is at Page 67

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sufficient depth so that chances of its rising to the base of the footing are small or nil, the triaxial tests shall be performed on specimens at natural moisture content. Each test shall be carried out on a set of three test specimens from one sample at cell pressures equal to 100, 200 and 300

kPa respectively or as required depending on the soil conditions:


b) Direct shear test shall be conducted on undisturbed soil samples. The three normal vertical stresses for each test shall be 100, 200 and 300 kPa or as

required for the soil conditions;


c) Consolidation test shall have loading stages of 10,25,50,75, 100, 200, 400 and 800 kPa. Rebound curve shaft be recorded for all samples by unloading the specimen at its in-situ stress. Additional rebound curves

shall also be recorded wherever desired by the Owner; d) Chemical analysis of subsoil shaft include determination of PH value, carbonate, sulphate (both SO3 and SO4). chloride and nitrate contents, organic matter, salinity and any other chemicals which may be harmful to the foundation material. Their contents in the soil shall be indicated as percentage (%);

e) Chemical analysis of subsoil water samples shall include the determination of properties such as colour, odour, turbidity, PH value and specific conductivity, the last two chlorides, nitrates, organic matter and any other chemical harmful to the foundation material. The chemical contents shall be indicated as parts per million (PPM) based on weight. 4.8 4.8.1 Geotechnical Investigation Report General a) Contractor shall submit a formal report containing geological information of the region, procedures adopted for geotechnical investigation, field observations, summarised test data, conclusions and recommendations. The report shall also include detailed borelogs, subsoil sections, field test results, laboratory observations and test results both in tabular as well as graphical form, practical and theoretical considerations for the interpretation of test results, supporting calculation for the conclusions drawn etc. Initially, Contractor shall submit three copies of the report in draft form for Owners review; Contractors Geotechnical engineer shall visit Owners Corporate Office for a detailed review based on Owners comments in order to discuss the nature of modifications, if any, to be done in the draft report. Contractor shall incorporate in the report, the agreed modifications and resubmit the revised draft report for approval. One Plus Four copies of the detailed final Page 68

b)

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approved report shall be submitted to Owner together with one set of reproducible of the graphs, tables etc. c) The detailed final report based on field observations, in-situ and laboratory tests shall encompass theoretical as well as practical considerations for foundations for different types of structures as discussed in Clause 5.3.

4.8.2

Data to be furnished

4.8.2.1.The report shall also include the following a) A plot plant/location plan showing the locations and reduced levels of all field test e.g. boreholes, trial pits, static cone penetration tests, dynamic cone penetration tests, etc., property drawn to scale and dimensioned with reference to the established grid lines; A true cross section of all individual boreholes and test pits with reduced levels and co-ordinates showing the classification and thickness of individual stratum, position of ground water table, various in-situ tests conducted, samples collected at different depths and the rock stratum, if encountered; Geological information of the area including geomorphology, geological structure, lithology, stratigraphy and tectonics, core recovery and rock quality designation (RQD), etc., Observations and data regarding change of course of rivers, velocity, scour depths, slit factor, etc., and history of flood details for mid stream and river bank locations; Past observations and historical data, if available, for the area or for other areas with similar soil profile, or with similar structures in the surrounding areas; Plot of Standard Penetration Test (uncorrected and corrected N values) with depth for each test site; Results of all laboratory test summarised according to Table 4.0 (i) for each sample as well as (ii) for each layer, alongwith all the relevant charts, tables, graphs, figures, supporting calculations, conclusions and photographs of representative rock cores, For all triaxial shear tests, stress vs. strain diagrams as well as Mohrs circle envelopes shall be furnished. If back pressure is applied for saturation, the magnitude of the same shall be indicated. The value of Page 69

b)

c)

d)

e)

f)

g)

h)

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modulus of elasticity (E) shall be furnished for all tests along with relevant

calculations; i) For all consolidation tests, the following curves shall be furnished i) ii) iii) e vs. log p; e vs. p; Compression vs log t or vs t

depending upon the shape of the plot, for proper determination of coefficient of consolidation. The point showing the initial condition (eo, po) of the soil shall be marked on the curves; j) The procedure adopted for calculating the compression index from the field curve and settlement of soil strata shall be clearly specified. The time required for 50% and 90% primary consolidation along with secondary settlements, if significant, shall also be calculated.

Table 4.0 SUMMARY OF RESULTS OF LABORATORY TESTS ON SOIL AND WATER SAMPLES
1. 2. 3. 4. Bore hole test pit no. Depth (m) Type of sample Density (kg/m3) a. Bulk b. Dry Water content (%) Particle Size (%) a. Gravel b. Sand c. Silt d. Clay Consistency properties a. LL b. PL c. PI

5. 6.

7.

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Volume-II / Section - III d. LI Soil a. Classification-IS b. Description c. Specific gravity Strength Test a. Type b. C (Cohesion) c. (angle of internal friction) Consolidation Test a. eo b. Pc c. Cc d. DP e. Mv f. Cv Shrinkage limit (%) Swell Test a. S.Pr b. FS Relative Density (%) Remarks

EPC Tender for JITPL

8.

9.

10.

11. 12.

13. 14.

Notations : I. For type of Sample : DB Disturbed bulk soil sample. DP Disturbed SPT soil sample DS Disturbed samples from cutting edge of undisturbed soil sample RM Remoulded soil sample UB Undisturbed block soil sample US Undisturbed soil sample by sampler W Water sample II. For Strength Test : SCPT Static Cone Penetration Test UCC Unconfined Compression Test

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Volume-II / Section - III VST Vane Shear Test Tuu Unconsolidated Undrained Triaxial Test Note : Replace T by D for Direct Shear Test Tod Consolidation Drained Triaxial Test III. For Others : LL Liquid Limit (%) PL Plastic Limit Pl Plasticity Index Li Liquidity Index C Cohesion (kPa) Angle of Internal Friction (degrees) S-Pr. Swelling Pressure (kPa) e0 Initial Void Ratio Pc Reconsolidation Pressure (kPa) Cc Compression Index DP Change in Pressure (kPa) mv Coefficient of Volume Compressibility (m2/KN) Cv Coefficient of Consolidation (m2/hr)
IV.

EPC Tender for JITPL

For Chemical Test As per Specifications Clause 4.8.4

4.8.3 Recommendations 4.8.3.1 Recommendations shall be provided for each tower location duly considering soil
type and tower spotting data. The recommendations shall provide all design parameters and considerations required for proper selection, dimensioning and future performance of tower foundations as discussed in part but not limited to

Clause 4.2 of these specifications and the following : a) The subsurface material must provide safe bearing capacity and uplift resistance by incorporating safety factors specified in Clause 4.2 all the while experiencing small deformations throughout, thereby avoiding rupture under ultimate loads; Movement of the foundation, including short and long term components under transient and permanent loading, shall be strictly controlled with regard to settlement, uplift, lateral translation and rotation;

b)

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d)

e)

f)

g)

h)

Co-efficient of permeability of various sub soil and rock strata based on in-situ permeability tests. Core resistance, frictional resistance total resistance, relation between core resistance, Standard Penetration Test N value and settlement analysis for different sizes of foundation based on static cone penetration test. For shallow foundation the following shall be indicated with comprehensive supporting calculations : i) Net safe allowable bearing pressure for isolated square footing of sizes 2.0 m, 3.0 m and 4.0 m at three different foundation depths of 1.0 m, 2.0 m and 3.0 m below ground level considering both shear failure and settlement criteria giving reasons for type of shear failure adopted in the calculation. ii) Net safe allowable bearing pressure for raft foundations of widths greater than 5.0 m at 2.0 m, 3.0 m and 4.0 m below ground level considering both shear failure and settlement criteria. iii) Rate and magnitude of settlement expected of the structure. iv) Net safe bearing capacity for foundation sizes mentioned in para (i) above, modulus of subgrade reaction, modules of elasticity from plate load test results along with time settlement curves and load settlement curve in both natural and log graph, variation of Modulus of subgrade reaction with size, shape and depth of foundation. The stable slopes for shallow and deep excavations, active and passive earth pressure at rest and angle of repose for sandy soils shall be furnished. The loading of the foundations shall not compromise the stability of the surrounding subsurface materials and the stability of the foundation shall be ensured against sliding or overturning. Depending on the subsurface material, water table level and tower type, and either reinforced concrete isolated pad and chimney, cast-in-situ bored pile of special foundations shall be installed at a given location as discussed in Clause 4.2. Net safe allowable bearing pressure and uplift resistance shall be provided for the various sizes of isolated square footings founded at various depths below ground level considering both shear failure and movement criteria; rate and magnitude of movement expected of the structure (settlement, uplift, and rotation) shall also be given. In cases where normal open cast/pile foundations appear to be impractical, special pile foundations shall be given due consideration along with the following : i) Type of pile foundation and reasons for recommending the same duly considering the soil characteristics. ii) Suitable founding strata for the pile : Page 73

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EPC Tender for JITPL

i)

j)

k)

l) m)

n)

Estimated length of pile for 500, 750 and 1000 KN and 4500 KN capacities; end bearing and frictional resistance shall be indicated separately: Magnitude of negative skin friction or uplift forces due to soil iv) swelling. Where the subsoil water and soil properties are found to be chemically aggressive. Contractor shall take suitable precautions during construction including any protective coating to be applied on the foundations; susceptibility of soil to termite action and remedial measures for the same shall be dealt with; Suitability of locally available soils at site for filling, backfilling and adequate compaction shall be investigated. If expansive soil such as black cotton soil is encountered recommendation of removal or retainment of the same shall be given in the latter case, detailed specifications of special requirements shall also be given; Susceptibility of subsoil strata to liquefaction in the event of earth quake and remedial measures, if required, shall be considered. Any other information of special significance such as dewatering schemes, etc. which may have a bearing on the design and. construction shall be provided. Recommendations for additional soil investigations, beyond the scope of the present work, shall be given if Contractor considers such investigations necessary.

4.8.4 Hydrogeological Conditions 4.8.4.1 The maximum elevation of ground water table, amplitudes of its fluctuations and data on water aggressivity with regard to foundation structure materials shall be reported. While preparing ground water characteristics the following parameters should be specified for each acquifier: a) bicarbonate alkalinity mg-eq/(deg), b) pH value c) content of aggressive carbon dioxide, mg/l; d) content of magnesia salts. mg/l, recalculated in terms of ions Mg+2 e) content of ammonia salts, mg/l, recalculated in terms of ions NH4+ f) content of caustic alkalis, mg/l, recalculated in terms of ions Na+ and K g)contents of chlorides,mg/l recalculated in terms of ions Cl h) contents of sulphates, mg/I, recalculated in terms of ions SO4-2 I) aggregate content of chlorides, sulphates, nitrates, carbonates and other salts. mg/I.

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4.9 4.9.1

Rates and Measurements Rates


The Contractors quoted rates shall be inclusive of making observations,

establishing the ground level and co-ordinates at the location of each borehole, test pit etc. No extra payments shall be made for conducting Standard Penetration Test, collecting, packing, transporting of all samples and cores, recording and submittal of results on approved formats. 5.0 5.1 5.2 Foundations Foundation includes supply of materials such as cement, sand, coarse aggregates and reinforcement steel etc. Foundations designs for various tower types & their extensions and for foundation classification as described in Clause 5.3 shall be provided by Owner during execution stage based on site requirement. 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 (except pile foundation). 5.3.1 Normal Dry To be used for locations where normal dry cohesive or non-cohesive soils are met. 5.3.2 Sandy Dry Soil Not Applicable 5.3.3 Wet To be used for locations: a) b) 5.3.4 Where sub-soil water is met at 1.5 meters or more below the ground level. Which are in surface water for long periods with water penetration not exceeding one meter below the ground level e.g. the paddy fields.

5.3

Partially Submerged
To be used at locations where sub-soil water table is met between 0.75 meter to

1.5meter below the ground level.

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5.3.5

Fully Submerged.
To be used at locations where sub-soil water table is met at less than 0.75 meter

below the ground level. 5.3.6 Black Cotton Soil


To be need at locations where soil is clayey type, not necessarily black in colour, which shrinks when dry and swells when wet, resulting in differential movement. For designing foundations, for such locations the soil is to be considered

submerged in nature. 5.3.7 Fissured - Rock


To be used at locations where decomposed or fissured rock, hard gravel, kankar, limestone, laterite or any other soil of similar nature is met. Under cut type

foundation is to be used for fissured rock locations.


In case of fissured rock locations, where water table is met at 1.5M or more below ground level, wet fissured rock foundations shall be adopted. In case of dry

locations dry fissured rock foundations shall be adopted. 5.3.8 Hard Rock
The locations where chiselling, drilling and blasting is required for excavation, Hard rock type foundations are to be used. For these locations rock anchoring is to be provided to resist uplift forces. For design purpose, rock level shall be considered at ground level and no overburden soil weight shall be considered for

resisting the uplift.


5.3.9 In addition to the above, depending on the site conditions other types of foundations shall also be designed and provided by the Owner suitable for

Intermediate conditions under the above classifications to effect more economy.


5.3.10 The proposal for these types of foundations shall be submitted by the Contractor based on the detailed soil investigation and approval for the same shall be

obtained from the Owner. 5.4 Type of Foundations


Reinforced Cement Concrete footing shall be used for all type of normal towers. All the four footings of the tower and their extension shall be similar. The total depth of foundation except Hard Rock type below the ground level shall not be more than 3.0 meters. For foundation shape details refer drawing enclosed with the specification. The working drawing of all type of foundations for all type of towers shall be provided by the Owner to the Contractor during execution stage

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5.5

Soil Investigation
The Contractor shall undertake soil investigation as per clause 4.1 at tower

locations as approved by the Owner. The provisional number of testing locations are furnished in schedule of prices. Unit rates for the same are to be furnished by the bidder in appropriate schedules of price, for adjustment purpose with actual quantities required for soil testing. 5.6 5.6.1 Properties of Concrete For open cast type foundation The cement concrete used for the foundations shall be Nominal Mix Concrete of grade M-20 having 1:1.5:3 nominal mix ratio with 20mm. coarse aggregate for chimney portion and 40 mm aggregates for pyramid or slab portion. The quantity of cement to be used per cubic meter shall be as per CPWD specification (DSP). All the properties of concrete regarding its strength under compression, tension, shear, punching and benching etc. as well as workmanship will conform to IS: 456. 5.6.2 5.6.3
5.6.4

a)

The Portland Cement used in concrete shall conform to 33 grade (IS: 269) or 43 grade (IS: 8112) or 53 grade (IS:12269). .

Concrete aggregates shall confirm to IS:383.


The water used for mixing concrete shall be fresh, clean and free from oil, acids

& alkalies, organic materials or other deletarious substances. Portable water is generally preferred. 5.6.5 Reinforcement shall confirm to IS:432 for MS bars and hard drawn steel wires and to IS:1139 and IS:1786 for deform and cold twisted bars respectively. Thermo mechanically Treated (TMT) bars (equivalent grade) in place of cold twisted bars are also accepted. All reinforcement shall be clean and free from
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 to shapes and dimensions as indicated or as required to carry out the intent of drawings and Specifications. 5.7 Design of Foundations The working drawing of all type of foundations for all towers shall be provided by the Owner to the Contractor during execution stage based on site requirements. 5.8 5.8.1 Unit Rates and Measurement for Foundation The bidder is required to quote the unit rates for different types of foundation after considering activities like excavation for different types of soil, concreting, supply and placement of reinforcement and stub setting in the relevant Unit Price Page 77

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Schedule as provided in Annexure-13. The payment for various types of foundations will be released on composite rate of total unit cost of foundation as provided by the bidder in Annexure-13. 5.8.2 Excavation for each type of soil shall include excavation along with all associated activities like shoring, shuttering, dewatering-till completion of foundation work, stock piling, dressing, back filling of foundations after concreting with excavated/borrowed earth (irrespective of lead) and consolidation of earth, carriage of surplus earth to the suitable point of disposal as required by the Owner or any other activity related to completion foundation work. Form boxes shall be used for casting of foundations. The unit rate of foundation shall also include the cost of supply, fabrication and placement of form boxes, cement, water, coarse and fine aggregates mixing and placing of concrete, curing of concrete and any other activities related to completion of concreting works of foundation. The unit rate of foundation shall also include supply and placement of reinforcement steel, stirrups, wire for binding the reinforcement chairs, bolsters and spacers etc. as required to complete the foundation work as per the drawing. Construction of Tower Foundation, Stub Setting and Earthing General Design of tower foundations is treated in Clause 5.2 & 5.3 and the required geotechnical investigation and geotechnical investigation report in Clause 4.1. The Contractor shall furnish soil resistivity values to the Owner along with the line alignment. 5.9.2 Excavation

5.8.3

5.8.4

5.9 5.9.1

5.9.2.1 Excavation work in a section must not be started until the tower scheduled and profile of that section has been approved by the Owner. 5.9.2.2 Except as specifically otherwise provide, all excavation for footings shall be made to the lines and grades of the foundations. For estimation purposes, the excavation wall shall be vertical and the pit dimensions shall be based on an assumed clearance of 150mm on all sides of the foundation pad. For footings without undercut, this clearance will actually be established in practice for facilitating work. For footings with undercut, no such clearance will be allowed. All excavation shall be protected so as to maintain a clean subgrade and provide worker safety until the footing is placed, using timbering, shoring, dewatering etc. as approved by the Owner. Contractor shall especially avoid disturbing the bearing surface of the pad. Any sand, mud, silt or other undesirable materials which may accumulate in the excavated pit or borehole shall be removed by Contractor before placing concrete. 5.9.2.3 The soil to be excavated for tower foundations shall be classified as follows :

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EPC Tender for JITPL

Soil removable by means of a spade and shovel. This type of excavation will also include excavation for dry soil in case of wet, partially submerged, fully submerged and wet black cotton type of foundations. b)Wet Soil Where the subsoil water table is encountered within the range of foundation depth or land where pumping or bailing out of water is required due to presence of
surface water shall be treated as wet soil. This type of excavation will also include

excavation for wet soil in case of wet, partially submerged, fully submerged and wet black cotton type of foundations. c) Dry Fissured Rock

Limestone, laterite, hard conglomerate or other soft or fissured rock in dry condition which can be quarried or split with crow bars, wedges or pickaxes. However; if required, light blasting may be resorted to for loosening the material but this will not in any way entitle the material to be classified as hard rock. d)Wet Fissured Rock Above fissured rock, when encountered with subsoil water within the range of foundation depth or land where pumping or bailing out of water is required, shall be treated as wet fissured rock. e) Hard Rock

Any rock excavation, other than specified under fissured rock above, for which blasting, drilling, chiselling are required. The unit rate quoted for hard rock
excavation shall be inclusive of all costs for such drilling (including drilling

required for anchoring), chiselling and blasting. 5.9.2.4 No extra charge shall be admitted for the removal of fallen earth into a pit or borehole once excavated shoring and shuttering/timbering as approved by Owner shall be provided by the Contractor when the soil condition is so bad and that there is likelihood of accident due to the falling of earth. 5.9.2.5 Where rock is encountered, the holes for tower footings shall preferably be drilled. Blasting where resorted to as an economy measure, shall be done with utmost care to minimise fracturing rock and using extra concrete for filling the blasted area. All necessary precautions for handling and use of blasting materials shall be taken. In cases where unnecessarily large quantities are excavated/blasted, resulting in placement of large volumes of concrete, payment of concrete shall be limited to design volumes of excavation, concreting, Jindal India Thermal Power Limited Page 79

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reinforcement etc. In case where drilling is done, the stubs may be shortened

suitably with the approval of the Owner.


5.9.2.6 The Contractor shall supply requisite blasting material and be responsible for its

storage and use. 5.9.2.7 Indian Standard IS:3764 shall be followed regarding safety of excavation work. 5.10 Setting of Stubs setting of stubs.
5.10.2 The stubs shall be set correctly and precisely in accordance with approved method at the exact location, alignment and levels with the help of stub setting templates and leveling instruments. Stubs shall be set-in the presence of Owners representative available at site where required and for which adequate advance intimation shall be given to Owner by Contractor. Tolerances as per provisions of

5.10.1 For all towers the Contractor shall submit for approval the proposed method for

IS :5613 shall be allowed for stub-setting. 5.10.3 Setting of stub at each location shall be approved by Owner. 5.10.4 However, in hilly region for towers with unequal leg extensions and for river crossing towers, props may be used with complete accuracy and high skilled supervision, subject to prior approval from Owner. 5.10.5 Stub Setting Templates 5.10.5.1 Stub setting templates shall be arranged by the Contractor at his own cost for all heights of towers. Stub templates shall be of adjustable type and painted. 5.10.5.2 The Contractor shall deploy sufficient number of templates for timely completion of the line without any extra cost to Owner. 5.10.5.3 One set of each type of stub setting template in good working condition shall be supplied to the Owner, on completion of the project, at no extra cost to Owner. 5.10.5.4 The following number of stub setting templates shall be deployed by the Contractor for each package : Templates for tower type i) for DA type ii) for DB, iii) forDC iv) forDD v) For tower with + 18/25 M Extn. Jindal India Thermal Power Limited For Pkg. 1 5 2 1 4 1 each Page 80

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However, if Owner feels that more templates are required for timely completion of the lines, the Contractor shall have to deploy the same without

any extra cost to Owner. 5.11 Mixing, Placing and Compacting of Concrete concrete shall be fresh, clean and free from oil, acids and alkalis. Saltish or brackish water shall not be used. 5.11.2 Mixing shall be continued until there is uniform distribution of material and mix is uniform in color and consistent, but in no case the mixing be carried out for less than two minutes. Normal mixing shall be done close to the foundation but exceptionally 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. 5.11.3 To avoid the possibility of reinforcement rods being exposed due to unevenness
of the bottom of the excavated pit, a, pad of lean concrete 50mm thick and

5.11.1 The concrete shall be mixed in the mechanical mixer. The water for mixing

corresponding to a 1:3:6 nominal mix shall be provided at the bottom of the pad. 5.11.4 Form boxes shall be used for casting all types of foundations except at an undercut interface for which the adjoining subsurface material shall provide adequate support. 5.11.5 The concrete shall be laid down in 150mm layers and consolidated well, so that the cement cream works, up to the top and no honey-combing occurs in the concrete. A mechanical vibrator shall be employed for compacting the concrete. Monolithic casting of foundations must be carried out. However, in case of unavoidable circumstances, a key construction joint can be provided at the chimney-pad interface subject to approval of the Owner. After concreting the chimney portion to the required height, the top surface should be finished smooth
with a slight slope towards the outer edge for draining rain water. However

nothing extra shall be paid to the Contractor for providing such construction joints. 5.11.6 Wet locations shall be kept completely dewatered, both during and 24 hours after placing the concrete, without disturbance of the concrete. 5.11.7 If the concrete surface is found to be defective after the form work has been removed, the damage shall be repaired with a rich cement sand mortar to the satisfaction of the Owner before the foundation is back filled. 5.12 Backfilling and Removal of Stub Templates 5.12.1 After opening of form work and removal of shoring, timbering, etc., back- filling shall be started after repairs, if any, to the foundation concrete. Backfilling shall normally be done with the excavated soil, unless it is a clay type or it consists of large boulders/stones, in which case the boulders shall be broken to a maximum Jindal India Thermal Power Limited Page 81

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EPC Tender for JITPL

size of 80-mm. At locations where borrowed earth is required for backfilling, Contractor shall bear the cost irrespective of lead & lift. 5.12.2 The backfilling materials shall be clean and free from organic or other foreign materials. A clay type soil with a grain size distribution of 50% or more passing the # 200 sieve as well as a black cotton soil are unacceptable for backfilling. The earth shall be deposited in maximum 200 mm layers, levelled, wetted if necessary and compacted properly before another layer is deposited. The moisture content for compaction shall be based on the Proctor compaction test results given in the Geotechnical Report, Clause 4.1. The density of the compacted backfill material may further be verified to the satisfaction of the Owner based on the sand-cone method described in the ASTM D1556-82 standard. 5.12.3 The backfilling and grading shall be carried to an elevation of about 75mm above the finished ground level to drain out water. After backfilling 50mm high, earthen embankment (bund) will be made along the sides of excavation pits an sufficient water will be poured in the backfilling earth for at least 24 hours. After the pits have been backfilled to full depth the stub template can be removed. 5.13 Curing The concrete shall be cured by maintaining the concrete wet for a period of atleast
10 days after placing. Once the concrete has set for 24 hours the pit may be

backfilled with selected moistened soil and well consolidated in, layers not exceeding 200mm thickness and thereafter both the backfill earth and exposed chimney shall be kept wet for the remainder of the prescribed 10 days. The exposed concrete chimney shall also be kept wet by wrapping empty cement bags around it and wetting the bags continuously during the critical 10 days period. 5.14 Benching . When the line passed through hilly/undulated terrain, leveling the ground may be required for casting of tower footings. All such activities shall be termed benching and shall include cutting of excess earth and removing the same to a suitable point of disposal as required by Owner. Benching shall be resorted to only after approval from Owner. Volume of the earth to be cut shall be measured before cutting and approved by Owner for payment purposes. Further, to minimise benching, unequal leg extensions shall be considered and provided if found
economical. The proposal shall be submitted by the Contractor with detailed

justification to the Owner. 5.15 Protection of Tower Footing

5.15.1 Tower spotting shall endeavor to minimise the quantity of revetment required. 5.15.2 The work shall include all necessary stone revetments, concreting and earth filling above ground level, the clearing from site of all surplus excavated soil, special measures for protection of foundation close to or in nallahs, river bed undulated Jindal India Thermal Power Limited Page 82

Volume-II / Section III

EPC Tender for JITPL

terrain, etc., including suitable revetment or galvanised wire netting and meshing packed with boulders. The top cover of stone revetment shall be sealed with M-15 concrete (1:2:4 mix). Contractor shall recommend protection at such locations

wherever required. Details of protection of tower footing are given in drawing enclosed with these specifications for reference purpose only.
5.15.3 Tower footings shall generally be backfilled using soil excavated at site unless

deemed unsuitable for backfilling In the latter case, backfilling shall be done with borrowed earth of suitable quality irrespective of lead at the cost of the contractors. The unit rate for backfilling quoted in Unit Price Schedule shall include the required lead and consolidation and leveling of earth after backfilling. 5.15.4 The provisional quantities for protection work of foundations are furnished in Annexure-1. However the contractor has to make a site visit and estimate the quantities to include the same in his quote for the tower protection works as per the general drawings attached. The unit rates shall also be applicable for adjusting with the actual quantities of protection works done. These unit rates shall hold good for protection work carried out on down hills or uphills slopes applicable for the tower locations. 5.15.5 While quoting the tower protection unit rates contractor shall also consider the random rubble masonry revetment, excavation & (1:5) random masonry and top sealing with M-15 concrete. No extra rates shall be paid for allied work such as excavation, for revetment, packed stone at head of weep holes etc. However no deduction shall be made for the volume enclosed by weep holes. The locations where both benching and protection of tower footing are envisaged, an economy got to be established against providing unequal leg extension. 5.15.6 For some of the locations in nalas, river bed or undulated terrain etc., maximum size boulders of min. 150 mm dimension bounded and packed in galvanised wire net/mesh of 8 SWG wire 152 square mesh are to be provided. These stones shall be provided in crates size of 2.0 m x2.0 m or as deemed suitable for a particular location. Measurement shall be taken in cubic meters and 15% deduction will be made for void from cage/ stack measurements. 6.0 6.1 6.1.1 Tower Erection, Stringing and Installation of Line Materials General The scope of erection work shall include the cost of all labour, tools and plant such as tension stringing equipment and all other incidental expenses in connection with erection and stringing work. The bidders shall indicate in the offer the sets of stringing equipment he would deploy exclusively for each transmission line package, sets which shall be of sufficient capacity to string a bundle of 2 (Twin) ACSR MOOSE Conductors.

Jindal India Thermal Power Limited

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Volume-II / Section - III

EPC Tender for JITPL

6.1.2

The Contractor shall be responsible for transportation to site of all the materials to be provided by the Contractor as well as proper storage and preservation of the same at his own cost, till such time the erected line is taken over by the Owner. Similarly, the Contractor shall be responsible for transportation, proper storage,

safe custody, and loss or damage of all Owners supplied items for incorporation in the lines and shall maintain and render proper account of all such materials at all times. The Contractor shall, reimburse the cost of any of the materials lost or damaged during storage and erection. 6.1.3 Contractor shall set up required number of stores along the line and the exact location of such stores shall be discussed and agreed upon with the Owner. Owner supplied items shall be dispatched to the railway stations situated nearest to the
stores set up by the Contractor. Form these railway stations, receipt, unloading

and transportation to the stores shall be the entire responsibility of the Contractor. 6.1.4 Payment for stringing shall be done on the basis of per kilometer and irrespective of number of tension/suspension towers. However, stringing for river crossing spans, if applicable, have been given separately in schedule of Prices. Treatment of Minor Galvanisation Damage Minor defects in hot-dip galvanised members shall be repaired by applying At least two coats of zinc rich Primer (having approx. 90% zinc content) and two coats of enamel paint to the satisfaction of the Owner before erection. 6.3 Assembly The Contractor shall give complete details of the erection procedures he proposes to follow. 6.3.1 The method for the erection of towers shall ensure the following a) Straining of the members shall not be permitted for positioning. It may however, be necessary to match hole positions at joints using tommy bars not more than 450mm in length; b) Prior to erection of an upper section, the tower section shall be completely braced, and all bolts provided tightened adequately in accordance with approved drawings to prevent any mishap during tower erection. c) All plan diagonals relevant section of tower shall be in place prior to assembly of an upper Section; d) The bolt positions in assembled towers shall be as per lS-5613 (Part II/Section 2);

6.2

Jindal India Thermal Power Limited

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Volume-II / Section - III

EPC Tender for JITPL

e) Tower shall be fitted with number, danger and phase plates as well as anticlimbing device, as described; f) After complete erection of the tower, all blank holes, if any, are to be filled by bolts and nuts of correct size. 6.4 6.4.1 Tightening of Bolts and Nuts All nuts shall be tightened properly using correct size spanner and torque wrench. Before tightening, it will be verified that filler washers and Plates are placed in relevant gap between members, 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 nuts. 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. The threads of all the bolts except for Anti-theft bolts projected outside the nuts shall be welded at two diametrically opposite places, the circular length of each welding shall be at least 10mm. The welding shall be provided from ground level to bottom cross arms for double circuit towers. However, for river crossing towers, the welding shall be provided from ground level to 30 m height from stub level. After welding zinc-rich primer having approximately 90% zinc content shall be applied the welded portion. At least two coats of the paint shall be applied. The surface coated with zinc rich primer shall be further applied with two finish coats of high build enamel of the grade recommended by the manufacturer of the zinc rich primer. The cost of welding and paint including application of paint shall be deemed to he included in the erection price. Not Applicable Insulator Hoisting Double suspension insulator strings shall be used for suspension towers and Quad tension Insulator strings on tension towers. Damaged insulators and strings, if any, shall not be employed in the assemblies. Prior to 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 that purpose. For checking the soundness of insulators, IR measurement using 5 kV (DC) Megger shall be carried out on insulators. Corona control rings/arcing horn shall be fitted in an approved manner. Torque wrench shall be used for fixing various line materials and components, such as suspension clamp for conductor and earthwire, etc., whenever recommended by the manufacturer of the same.

6.4.2

6.4.3 6.5

Jindal India Thermal Power Limited

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Volume-II / Section - III

EPC Tender for JITPL

6.6 6.6.1

Handling of Conductor and earthwire Running Out of the Conductors

6.6.1.1 The conductors shall be run out of the drums form the top in order to avoid damage. The Contractor shall be entirely responsible for any damage to tower or

conductors during stringing.


6.6.1.2 A suitable braking device shall be provided to avoid damaging, loose running out and kinking of the conductors. Care shall be taken that the conductors do not touch and rub against the ground or objects which could scratch or damage the

strands.
6.6.1.3 The sequence of running out shall be from the top down i.e. the earthwire shall be run out first followed in succession by the conductors. Unbalanced loads on

towers shall be avoided as far as possible.


6.6.1.4 The Conductor shall take adequate steps to prevent clashing of sub conductors until installation of the spacers/spacer dampers. Care shall be taken that sub-

conductors of a bundle are from the same Contractor and preferably from the same batch so that creep behavior of sub conductors remains identical. During sagging, care shall be taken to eliminate differential sag in sub-conductors as far as possible. However, in no case shall sag mismatch be more than 25mm. 6.6.1.5 Towers not designed for one sided stringing shall be well guyed and steps taken by the Contractor to avoid damage. Guying proposal along with necessary calculations shall be submitted by the Contractor to Owner for approval. All expenditure related to this work is deemed to be included in the bid price and no extra payment shall be made for the same. 6.6.1.6 When the 400 kV transmission lines runs parallel to existing energised power lines, the Contractor shall take adequate safety precautions to protect personnel; from the potentially dangerous voltage built up due to electromagnetic and electrostatic coupling in the pulling wire, conductors and earthwires during stringing operations. 6.6.1.7 The Contractor shall also take adequate safety precautions to protect personnel from potentially dangerous voltage build up due to distant electrical storms. 6.6.2 Running Blocks

6.6.2.1 The groove of the running blocks shall be of such a design that the seat is semicircular and larger than the diameter of the conductor/earthwire and it does not slip over or rub against the slides. The grooves shall be lined with hard rubber or neoprene to avoid damage to conductor and shall be mounted on properly lubricated bearings. 6.6.2.2 The running blocks shall be suspended in a manner to suit the design of the crossarm. All running blocks, especially at the tensioning end will be fitted on the Jindal India Thermal Power Limited Page 86

Volume-II / Section - III

EPC Tender for JITPL

cross-arms 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. 6.6.3 Repairs to Conductors other damage during the running out operations. 6.6.3.2 Repairs to conductor if necessary, shall be carried out with repair sleeve. 6.6.3.3 Repairing of the conductor surface shall be carried out only in case of minor damage, scuff marks, etc. The final conductor surface shall be clean, smooth and free from projections, sharp points, cuts, abrasion, etc. 6.6.3.4 The Contractor shall he entirely responsible for any damage to the towers during stringing. 6.6.4 Crossings Derricks or other equivalent methods ensuring that normal services need not be interrupted nor damage caused to property shall be used during stringing operations where roads, channels, telecommunication lines, power lines and railway lines have to be crossed. However, shut down shall be obtained when working at crossings of overhead power lines. The Contractor shall be entirely responsible for the proper handling of the conductor, earthwire and accessories in the field. 6.7 6.7.1 Stringing of Conductor and Earthwire The stringing of the conductor for 400kV shall be done by the control tension method. The equipment shall be capable of maintaining a continuous tension per bundle such that the sag for each conductor is about twenty percent greater than the sags specified in the stringing sag table. The bidder shall give complete details of the stringing methods he proposes to follow. Prior to stringing the Contractor shall submit the stringing charts for the conductor and earthwire showing the initial and final sags and tension for various temperatures and spans along with equivalent spans in the lines for the approval of the Owner. A controlled stringing method suitable for simultaneous stringing of the sub conductors shall be used. The Four conductors making up one phase bundle shall be pulled in and paid out simultaneously. These conductors shall be of matched length. Conductors or earthwires shall not be allowed to hang in the stringing blocks for more than 96 hours before being pulled to the specified sag. Conductor creep are to be compensated by over tensioning the conductor at a temperature of

6.6.3.1 The conductor shall be continuously observed for loose or broken strands or any

6.7.2

6.7.3

Jindal India Thermal Power Limited

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EPC Tender for JITPL

260 C lower than the ambient temperature or by using the initial sag and tensions

indicated in the tables. 6.8 6.8.1 Jointing When, approaching the end of a drum length at least three coils shall be left in place when the stringing operations are 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 accessories manufacturer. Conductor splices shall not crack or otherwise be susceptible to damage in the stringing operation. The Contractor shall use only such equipment/methods during conductor stringing which ensures complete compliance in this regard. All the joints on the conductor and earthwire shall be of the compression type, in accordance with the recommendations of the manufacturer. for which all necessary tools and equipment like compressors , dies etc., shall be obtained by the Contractor. Each part of the joint shall be cleaned by wire brush till it is free of dust or dirt etc., and be properly greased with anti-corrosive compound. If required and as recommended by the .manufacturer, before the final compression is carried out with the compressors. All the joints of splices shall be made at least 30 meters away from the tower structures. No joints or splices shall be made in spans crossing over main roads, railways and small river tension spans. Not more than one joint per sub conductor per span shall be allowed. The compression type fittings shall be of the self centering type or care shall be taken to mark the conductors to indicate when the fitting is centered properly. 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 compressing the joint the aluminium sleeve shall have all corners rounded, burrs and sharp edges removed and smoothened. During stringing of conductor to avoid any damage to the joint, the Contractor shall use a suitable protector for mid span compression joints in case they are to be passed over pulley blocks/aerial rollers. The pulley groove size shall be such that the joint alongwith protection can be passed over it smoothly. Tensioning and Sagging Operations The tensioning the sagging shall be done in accordance with the approved stringing charts or sag tables. The initial stringing chart shall be used for the conductor and final stringing chart for the earthwire. The conductors shall be pulled up to the desired sag and left in running blocks for at least one hour after which the sag shall be rechecked and adjusted, if necessary, before transferring the conductors from the running blocks to the suspension clamps. The conductor shall be clamped within 96 hours of sagging in.

6.8.2

6.8.3

6.8.4

6.8.5

6.9 6.9.1

Jindal India Thermal Power Limited

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Volume-II / Section - III 6.9.2

EPC Tender for JITPL

The sag will be checked in the first and the last section span for sections up to eight spans, and in one additional intermediate span for sections with more than eight spans. The sag shall also be checked when the conductors have been drawn up and transferred from running blocks to the insulator clamps. 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

6.9.3

height as the suspension clamp to which it is to be secured. 6.9.4 At sharp vertical angles, conductor and earthwire sags and tensions shall be checked for equality on both sides of the angle and running block. The suspension insulator assemblies will normally assume verticality when the conductor is clamped. Tensioning and sagging operations shall be carried out in calm whether when rapid changes in temperature are not likely to occur. Clipping In

6.9.5 6.10

6.10.1 Clipping of the conductors into position shall be done in accordance with the manufacturers recommendations. 6.10.2 Jumpers at section and angle towers shall be formed to parabolic shape to ensure maximum clearance requirements. Pilot suspension insulator strings shall be used, if found necessary, to restrict jumper swing to design values. 6.10.3 Fasteners in all fittings and accessories shall be secured in position. The security clip shall be properly opened and sprung into position. 6.11 Fixing of Conductors and Earthwire Accessories Conductor and earthwire accessories including spacers, spacer dampers (for bundle conductor) and vibration dampers shall be installed by the Contractor as per the design requirements and manufacturers instruction 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 that no damage occurs to any part of the accessories or of the conductors. Torque wrench shall be used for fixing the Dampers/Spacer Dampers, Suspension Clamps etc. and torque recommended by the manufacturer of the same shall be applied. 6.12 Replacement If any replacement are to be effected after stringing and tensioning or during maintenance, leg member and bracing shall not be removed without first reducing the tension on the tower by proper guying techniques or releasing of the conductor. For replacement of cross arms, the conductor shall be suitably tied to

Jindal India Thermal Power Limited

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Volume-II / Section - III

EPC Tender for JITPL

the tower at tension points or transferred to suitable roller pulleys at suspension

points. 6.13 6.14 Not Applicable Final checking, Testing and Commissioning
After completion of the works, final checking of the line shall he carried out by the Contractor to ensure that all foundation works, tower erection and stringing have been done strictly according to the specifications and as approved by the

Owner. All the works shall be thoroughly inspected in order to ensure that:
a) Sufficient backfilled earth covers each foundation pit and is adequately

compacted;
b) Concrete chimneys and their copings are in good condition and finely

shaped.
c) All tower members are used strictly according to final approved drawing

and are free of any defect or damage whatsoever.


d) All bolts are properly tightened, punched, tack welded and painted with

zinc rich paint;


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) g) All conductor and earthwire accessories are properly installed; All other requirements for completion of works such as fixing of danger plate, phase plate, number plate, anti-climbing device, aviation signal have been fulfilled.
Wherever required, that proper revetment (erosion protection) is provided;

h)

i)

The original tracings of profile and route alignment as well as tower


design, structural drawings, bill of material and shop drawings of all.

towers are submitted to the Owner for reference and record. j) The insulation of the line as a whole is tested by the Contractor through provision of his own equipment, labour etc., to the satisfaction of the Owner. All towers are properly grounded.

k)

Jindal India Thermal Power Limited

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Volume-II / Section - III l) 7.0 8.0

EPC Tender for JITPL

The line is tested satisfactorily for commissioning purpose.

Special River Crossing Towers Not Applicable Field Quality Plan All field activity shall be carried out in accordance with Standard Field Quality plan given in the Specification.

Jindal India Thermal Power Limited

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EPC Tender for JITPL

STANDARD FIELD QUALITY PLAN FOR TRANSMISSION LINES

iption of

Items to be Checked

Tests/Checks to be

Ref. documents

Check/Testing

Counter Check/Test by Owner

Activity

done Agency N/A


Extent

au

ed Survey

k Survey

Tower Location & Final Length

i) Alignment ii) Final Length

a. Route b. Tower

alignment
Schedule

Contractor -do-

100% at Field -do-

i) All angle towers in plains and


50% in hilly terrains. ii) Final length to be checked on

En

c. Profile
Soil

100% basis based on records/documents


Contractor 100% at Field

a. Borelog

1. Depth of bore log 2. SPT Test

As per Owner
Specification

To witness 20% at Field

En

gation

3. Collection samples

of

dal India Thermal Power Limited

Page

92

Volume-II

EPC Tender for JITPL

iption of

Items to be Checked

Tests/Checks to be

Ref. documents Agency

Check/Testing Extent

Counter Check/Test by Owner

Activity

done

au

b. Tests on samples

As per tech. Specs.

As per Owner
Specification

Lab appd. By Owner

100% by testing lab

Review of lab test results

Lin based

review

ation

1. Source approval
A. Materials 1. Cement

Source meeting Owner Specification/Approved


vendor

Contractor

As proposed by
Contractor

To verify the proposal based on the supply made and factory test
results.

En

2. Physical tests

As per document at Annexure-I of this FQP at Pg. 12, 13 & 14.

Samples to be taken jointly with Owner and tested at Owner approved lab

Review of all MTCs


and one sample for every 500 MT

100% review of lab test results

En

3.

Chemical Chemical

Tests

-do-

Contractor to submit
MTC

100%% review of
MTC by Contractor

100% review of MTC

En

composition of Cement

2.
Steel

Reinforcement

1. Source approval

To be procured from main producers only.

Contractor

As proposed by
Contractor

To review the proposal based on


the documents.

En

2.

Physical

and

As per annexure-2 of

Contractor to submit
MTC

All MTCs

100% review of MTC

En

Chemical analysis
test

this FQP at pg. 15

dal India Thermal Power Limited

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93

Volume-II / Section-III

EPC Tender for JITPL

iption of

Items to be Checked

Tests/Checks to be

Ref. documents Agency

Check/Testing Extent

Counter Check/Test by Owner

Activity

done

au

3.

Coarse

1. Source approval

Source meeting Owner


Specification

Contractor

Proposed by the
Contractor, indicating

To review the proposal based on


the documents

En

Aggregates

the location of the quarry and based on the test results of Joint samples tested in Owner approved lab 2. Physical tests As per document at Annexure-3 of this FQP
at page 16 4. Fine

Samples to be taken jointly and tested in Owner approved lab


Contractor

One sample per lot of


200 cum or part

100% review of lab test results

En

thereof Proposed by the


Contractor, indicating

aggregate

1. Source approval

Source meeting Owner


Specification

To review the proposal based on


the documents.

En

the location of the quarry and based on the results of Joint samples tested in Owner approved lab.
2. Physical test

As per Annexure-4 of this FQP at page 17

Samples to be taken jointly and tested in Owner approved lab

One sample per lot of


200 cum or part

100% review of lab test results

En

thereof
100% visual check at Field Verification at random

5. Water

1. Cleaniness (Water

Owner Specification

Contractor

En

shall be fresh and clean)

dal India Thermal Power Limited

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94

Volume-II / Section-III

EPC Tender for JITPL

iption of

Items to be Checked

Tests/Checks to be

Ref. documents Agency

Check/Testing Extent

Counter Check/Test by Owner

Activity

done

au

2. Suitability of water for concreting 1. Visual observation B. Classification


of soil strata

Owner Specification

Contractor

100% Visual Check


at Field

Verification at random

En

Owner Specification

Contractor

100% at Field

100% at Field

a. Sectio

b. In ca

2. Ground water level 3. History of water


table in adj.

WBC/

accepta

Engine

Area/surface water
4. Soil Investigation

charge

c. For S

wherever required

Fdns./p

Accep

Engine

charge

C. Concrete Works a. Before 1. Bottom of

concreting Depth of foundation Appd. Drgs.


Contractor 100% at Field

100% check by Owner

En

excavated earth 2. Stub setting


1) Centre Line -do-do-do-do-

2) Diagonals 3) Level of stubs 3.


steel Reinforcement Placement

Bar bending schedule

-do-

-do-

-do-

dal India Thermal Power Limited

Page

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Volume-II / Section-III

EPC Tender for JITPL

b.

During

concreting

iption of

Items to be Checked

Tests/Checks to be

Ref. documents Agency

Check/Testing Extent

Counter Check/Test by Owner

Activity

done

au

1. Workability

Slump test

Range 25 mm to 55 mm refer document at

Contractor

100% at field

20% check at random

Eng

Annexure-5 of this FQP at Pg. 18 2.


Concrete

Cubes Comp Strength

CPWD SPEC as
referred in document at annexure-5 of this page

Casting of cubes at site. Cubes to be tested at Owner appd. Lab for 28 days strength

One sample of 3 cubes


in each tower locations

100% review of lab test results. Cubes at 20% location are to be taken in presence of Owner
officials

Eng

Strength

at 18
1. All materials like cement, steel Coarse/fine aggregate, water 2. Before concreting 1. Check for center
line of each pile

To be tested as per procedure enumerated in the respective columns above

tions

Appd. Drawings

Contractor

100%

100%

Eng

c
-do-do-do-do-

2.

Check

for

dia/verticality of each pile 3. Check for depth of each pile -do-do-do-do-

3.

During

Concreting

dal India Thermal Power Limited

Page

96

Volume-II

EPC Tender for JITPL

a. Workability

1. Slump test

100-150 mm as per

Contractor

Every one hour. For each pile

100% at field

Eng

Owner Specn.

c
100% cubes for piles, 20% Pile caps, beams, chimney etc. to be taken in presence of Owner officials. 100% review of test results.

b.

Concrete

2. Cubes compressive strength

As per Owner Specn.

Contractor. One set of cubes (Min. 6 nos.) to be taken and tested for 7&28 days strength at Owner appd. Lab.

One set for each pile. For Pile caps, beams, Chimney, one sample for every 20 Cu.m. or part thereof for each day of concreting.

Eng

strength

1. Materials
a. Tower

Visual checking for 1. Stacking 2. Cleanliness 3. Galvanizing 4. Damages 1. Sequence of erection

Appd. Drgs./BOM

Contractor

100% at stores

100% verification of records

Eng

ion

member/bolts & nuts/washers/acces sories

2. Erection of Super-structure

As per Appd. Drgs./Owner specification

Contractor

100% at field

100% check

Eng

2. Check for completeness 3. Tightening of nuts and bolts 4. Check for verticality

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

dal India Thermal Power Limited

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97

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EPC Tender for JITPL

iption of

Items to be Checked

Tests/Checks to be

Ref. documents Agency

Check/Testing Extent

Counter Check/Test by Owner

Activity

done

au

5. Tack welding for bolts & nuts 3. Tower footing resistance (TFR) TFR at locations before and after earthing. 1. Materials a. Insulators 1. Visual check for cleanliness/glazing/ cracks/and white
spots. 2. IR Value

Owner Specification

Contractor

100% at Field

100% Check

Eng

c
Owner Specification Contractor 100% at Field

20% locations to be verified

Eng

ging

Owner Specification

Contractor

100% at Field

100% verification of records and to carry random checks 10%

Eng

(min. 50M Ohms)

-do-

One test per sample size of 20 for every


lot of 10,000

To verify Contractors records 100% and joint check 20% of total tests Collection of samples, sealing them and handing over by Owner to Insulator supplier 100% Review of records

3. E&M test

Insulator supplier

a. 20 per 10,000 for

Te

discs
b. 3 per 1500 for

Appd

long rod

at M

rer

4. Traceability (Make/batch

Packing list/CIP

Contractor

100% at field

Eng

dal India Thermal Power Limited

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98

Volume-II/ Section-III

EPC Tender for JIT

No./Locations where installed)


b.

Conductor

On

receipt,

Packing list

Contractor

100% at stores

20% check

Eng

1. Visual check of
drum.

2. Check for seals at both ends, and Owner sticker on outer end 3. Check depth from top of flange to the top of the outer most layer c. Earthwire Check for seals at both ends 2. Field activity
a. Before

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

Packing list

Contractor

100% at stores

20% check

Readiness for stringing

Stringing procedures as per Owner specification

Contractor

Readiness certificate to be submitted by the Contractor

Review of Certificate

Eng

Stringing

b.

During

(Conductor/Earthwire)

stringing

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iption of

Items to be Checked

Tests/Checks to be

Ref. documents Agency

Check/Testing Extent

Counter Check/Test by Owner

Activity

done

au

1. Scratch/cut check (Visual) 2. Repair sleeve 3. Mid span Joints 4. Guying


(in case

Appd. Drawings/ Owner Specn.


-do-do-

Contractor

100% at Field

100% record & Field check 20%


-do-do-

Eng

-do-do-

-do-do-

Appd. Guying arrangement/Owner specn.

-do-

-do-

100%

Eng

of towers not designed for one side stringing) c. After stringing Check for, 1. Sag/Tension

Sag tension chart/tower Spotting


data

-do-

-do-

100% record & Field check 20%

Eng

2. Electrical clearances

As per appd. Drgs./Owner specifications

-do-

-do-

-do-

i) Ground clearance ii) Live metal clearance etc. 3. Jumpering

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

-do-

dal India Thermal Power Limited

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100

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EPC Tender for JITPL

iption of

Items to be Checked

Tests/Checks to be

Ref. documents Agency

Check/Testing Extent

Counter Check/Test by Owner

Activity

done

au

4. Copper bond

As per Appd. Drgns./Owner Specification

Contractor

100% at Field

100% record & Field Check 20%

Eng

5. Placement of spacer/damper Testing a. Readiness of lines for precommissioning 1. Completeness of


line.

As per Specn./drgs/ placement chart

-do-

-do-

-do-

Owner latest precommissioning procedures (Doc. No. D-2-01-70-01-00)

Contractor

100%

100% joint checking

Eng

missionin

ines

2. Meggar test of
line

mmi-

Readiness of lines for commissioning

2. Digital

a.

Owner latest precommissioni

-do-

-do-

-do-

ing of

photograph of each tower to ascertain the completeness of


tower.
b. Pre-

ng procedures
(Doc. No. D-

2-01-70-0100)

commissioning
Report

c. CEA clearance 3. Electrical Inspectors clearance


-do-do-

-do-

dal India Thermal Power Limited

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from CEA.

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Annexure

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR CEMENT

ARY PORTLAND CEMENT


Ordinary Portland Cement 33 grade as per IS 269 Ordinary Portland Cement 43 grade as per IS 8112 Ordinary Portland Cement 53 grade as per IS 12269 Remarks

me of the test

hysical tests Specific surface area shall not be less than 225 sq.m. per Kg. or 2250 Cm2/gm. 72+/- 1 hour : Not less than 16 Mpa (16 N/mm2) 168+/-2 hour : Not less than 22 Mpa (22 N/mm2) 672+/-4 hour : Not less than 33 Mpa (33 N/mm2) Initial setting time : Not less than 30 minutes Final setting time : Not more than 600 minutes Unaerated cement shall not have an expansion of more than 10mm when tested by Le chatlier and 0.8% Autoclave test. Specific surface area shall not be less than 225 sq.m. per Kg or 2250 Cm2/gm. 72+/- 1 hour : Not less than 23 Mpa (23 N/mm2) 168+/-2 hour : Not less than 33 Mpa (33 N/mm2) 672+/-4 hour : Not less than 43 Mpa (43 N/mm2) Initial setting time : Not less than 30 minutes Final setting time : Not more than 600 minutes Unaerated cement shall not have an expansion of more than 10mm when tested by Le chatlier and 0.8% Autoclave test Specific surface area shall not be less than 225 sq.m. per Kg or 2250 Cm2/gm. 72+/- 1 hour : Not less than 27 Mpa (27 n/mm2) 168+/-1 hour : Not less than 37 Mpa (37 N/mm2) 672+/-1 hour : Not less than 53 Mpa (53 N/mm2) Initial setting time : Not less than 30 minutes Final setting time : Not more than 600 minutes Unaerated cement shall not have an expansion of more than 10mm when tested by Le chatlier and 0.8% Autoclave test.

To be conducted in apprd.

eness

Blaines air permeability m as per IS 4031 (Part-2)

mpressive ength

As per IS 4031 (Part-6)

ial & Final ing time

As per IS 4031 (Part-5)

-do-

undness

Le chatlier and Autoclave te per IS 4031 (Part-3)

dal India Thermal Power Limited

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EPC Tender for JIT

me of the test

Ordinary Portland Cement 33 grade as per IS 269

Ordinary Portland Cement 43 grade as per IS 8112

Ordinary Portland Cement 53 grade as per IS 12269

Remarks

emical composition tests


a) Ratio of percentage of lime to percentage of silica, alumina & iron oxide 0.66 to 1.02 b) Ratio of percentage of alumina to that of iron oxide Minimum 0.66% c) Insoluble percentage by mass 4.00% d) Magnesia percentage by mass Max. 6% e) Total sulphur content calculated as sulphuric anhydride (SO3),
percentage by mass Not

Review of MTCC onl a) Ratio of percentage of lime to percentage of silica, alumina % iron oxide to 1.02 a) Ratio of percentage of alumina to that of iron oxide Minimum 0.66 c) Insoluble percentage by mass 4.00% d) Magnesia percentage by mass Max. 6% e) Total sulphur content calculated as sulpuric anhydride (SO3),
percentage by mass Not a)

Ratio of percentage of lime to percentage of silica, alumina % iron oxide 0.66 to 1.02%

0.66

a) Ratio of percentage of alumina to that of iron oxide Minimum 0.66% c) Insoluble residue, percentage by mass Max. 4.00%

residue, Max.

residue, Max.

d) Magnesia percentage Max. 6%


e)

by

mass

more than 2.5 and 3.0 when tri-calcium aluminate percent by mass is 5 or less and greater than 5 respectively. Not more than 5 percent

more than 2.5 and 3.0 when tri-calcium aluminate percent by mass is 5 or less and greater than 5 respectively. Not more than 5 percent

Total sulphur content calculated as sulpuric anhydride (SO3), percentage by mass Not more than 2.5 and 3.0 when tri-calcium aluminate percent by mass is 5 or less and greater than 5 respectively.

al loss on tion

Not more than 5 percent

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me of the test

Remarks

ZZOLANA PORTLAND CEMENT AS PER IS 1489


i) Fineness Specific surface area shall not be less than 300 sq.m. per Kg. or 3000 Cm2/gm 168+/- 2 hour : Not less than 22 Mpa (22 N/mm2) 672+/- 2 hour : Not less than 33 Mpa (33 N/mm2) iii) Initial & Final setting time Initial setting time : Not less than 30 minutes Final setting time : Not more than 600 minutes iv) Soundness Unaerated cement shall not have an expansion of more than 10mm

sical tests

ii) Compressive strength

Le chatlier and Autoclave te per IS 4031 (Part-3)

mical position tests


a)

Magnesia percentage by mass Max. 6%

Review of MTCC onl


-do-

b) Insoluble material, percentage by mass x + 2 (100-x)/100 where x is the declared % of pozzolana in the PPC c) Total sulphur content calculated as sulpuric anhydride (SO3), percentage by mass 2.75 and 3.0 when tri-calcium aluminate percent by mass is 7 or less and greater than 7 respectively. Not more than 5 percent Not more than

-do-

al loss on tion

dal India Thermal Power Limited

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Annexure

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR REINFORCEMENT STEEL


Mild and medium tensile steel as per IS 432 Cold twisted Deformed bars Fe 415 as per IS 1786 Carbon (For 20 mm dia and below) 0.23% Max. Remarks

me of the test

mical analysis

Carbon (For over 20 mm dia) 0.25% Sulpher Phosphorus 0.055% 0.055%

Carbon Sulpher Phosphorus

0.30% Max 0.060% 0.060%

Sulpher & Phosphorus 0.11%


a)

sical tests

Ultimate Tensile stress For all dia bars 410 N/Sq.mm. (min.)

a)

Ultimate Tensile stress 10% more than actual 0.2% proof stress but not less than 485 N/Sq.mm.)

Testing in approved lab

b)

Yield stress (N/Sq.mm) min. 250 240

For bars upto 20 mm dia For bars above 20 mm dia


c)

b) 0.2% of proof stress/Yield stress (N/Sq.mm) min. For bars upto 20 mm dia
c)

Testing in approved lab

415

Percentage of elongation 23% Pass

Percentage of elongation 14.5% (min.) Pass Testing in approved lab

& Rebend

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Annexure

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR COARSE AGGREGATES AS PER IS 383

arse Aggregates
Tests

etermination

a. IS Sieve Designation

f particles size

%age passing for Single-Sized Aggregate of nominal size 40 mm 20 mm 16 mm 12.5 mm


10

Percentage Passing for grades Aggregate of nominal size 40 mm 20 mm 16 mm

mm 63 mm 40 mm
20 mm 16 mm 100 -

85 to 100 0 to 20
-

100 85 to 100
-

95 to 100 30 to 70
-

100 95 to 100
-

100 85 to 100
-

100 90-100
-

100 85 to 100

12.5 mm

100

10 mm

0 to 5

0 to 20

0 to 30

0 to 45

85 to 100
0 to 20

10 to 35

25 to 35

30 to 70

4.75 mm

0 to 5

0 to 5

0 to 10

0 to 5

0 to 10

0 to 10

2.36 mm

0 to 5

Flakiness index

Not to exceed 25%

dal India Thermal Power Limited

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Crushing Value Presence of deletrious material Soundness test (for concrete work subject to frost action)

Not to exceed 45% Total presence of deleterious materials not to exceed 5% 12% when tested with sodium sulphate and 18% when tested with magnesium sulphate

dal India Thermal Power Limited

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Annexure

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR FINE AGGREGATES AS PER IS 383

e aggregates
Tests

Percentage passing for graded aggregate of nominal size IS Sieve Designation F.A. Zone I
10 mm 100

Determination of particle size

F.A. Zone II
100

F.A. Zone II
100

4.75 mm 2.36 mm 1.18 mm 600 microns 12.5 mm 300 microns 150 microns

90-100 60-95 30-70 15-34 5 to 20 0-10 Not to exceed 8%

90-100 75-100 55-90 35-59 8 to 30 0-10 Not to exceed 8%

90-100 85-100 75-100 60-79 12 to 40 01-0

ilt content Presence of deleterious material

Not to exceed 8

Total presence of deleterious materials shall not exceed 5% 12% when tested with sodium sulphate and 15% when tested with magnesium sulphate

oundness Applicable to concrete work subject to frost action

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Annexure

ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR CONCRETE WORK


Concrete a) Workability b) Compressive strength Slump shall be recorded by slump cone method and it shall between 2555 mm. Three samples of 15 cm cube for 28 days compressive strength for all concrete works except pile foundation work shall be taken. For pile foundation works, six cubes, three for 7 days testing and balance three for 28 days testing shall be taken.

es :

For nominal (volumetric) concrete mixes, compressive strength for 1:1.5:3 (Sand : Fine aggregates : Coarse aggregates) concrete shall be 265 kg/Sq.cm. for 28 days and for 1:2:4 nominal mix, it shall be 210 kg/Sq.cm. ACCEPTANCE CRITERIA BASED ON 28 DAYS COMPRESSIVE STRENGTHS FOR NOMINAL MIX CONCRETE : the average of the strength of three specimen be accepted as the compressive strength of the concrete, provided the strength of any individual cube shall neither be less than 70% nor higher than 130% of the specified strength. If the actual average strength of accepted sample exceeds specified strength by more than 30%, the Engineer-in-charge, if he so desires, may further investigate the matter. However, if the strength of any individual cube exceeds more than 30% of the specified strength, it will be restricted to 30% only for computation of strength. If the actual average strength of accepted sample is equal to or higher than specified upto 30%, the strength of the concrete shall be considered in order and the concrete shall be accepted at full rates. If the actual average strength of accepted sample is less than specified strength but not less than 70% of the specified strength, the concrete may be accepted at reduced rate at the discretion of Engineer-in-charge.

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If the actual average strength of accepted sample is less than 70% of specified strength, the Engineer-in-charge shall reject the defective portion of work represent by sample and nothing shall be paid for the rejected work. Remedial measures necessary to retain the structure shall taken at the risk and cost of contractor. If, however, the Engineer-in-charge so desires, he may order additional tests to be carried out to ascertain if the structure can be retained. All the charges in connection with these additional tests shall be borne by the Contractor. This standard Field Quality Plan is not to limit the supervisory checks which are otherwise required to be carried out during execution of work as per drawings/Technical specifications etc. All materials should have Cat-A CIP before they are erected. Contractor shall be responsible for implementing/documenting the SFQP. Documents shall be handed over by the contractor to Owner after the completion of the work. Project incharge means over all incharge of work. Line Incharge means incharge of the line. Section in-charge means incharge of the section. In case of deviation the approving authority will be one step above the officer designated for acceptance in this quality plan subject to minimum level of Line incharge. Acceptance criteria and permissible limits for tests are indicated in the Annexures. However for further details/tests Owner specification and relevant Indian standards shall be referred. Tests as mentioned in this FQP shall generally be followed. However E.I.C. reserves the right to order additional tests wherever required necessary at the cost of the agency. All counter checks/tests by Owner shall be carried out by Owners officials atleast at the level of Jr. Engr.

neral Notes :

PL PowerTransco Limited

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SECTION IV PRE-COMMISSIONING PROCEDURES

Jindal India Thermal Power Limited

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SECTION IV CONTENTS Clause Description 0.0 1.0 2.0 3.0 4.0 5.0 6.0
7.0

Page No 114 115 115 116 116 Requirement Over System Procedure Procedure 124 124 125 125 125 126 130 130 130 130 131

Introduction Definitions Overall Procedure Safety Procedures Inspection Statutory Handing


Protective

8.0 9.0 10.0 11.0 12.0 13.0

Dispatch Switching

Testing and Measurement Procedures Energization De-Energisation Observation and Duration Criteria Documentation

14.0 Passing 15.0

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TECHNICAL SPECIFICATIONS SECTION IV PRE-COMMISSIONING PROCEDURES FOR TRANSMISSION LINES 0.0 INTRODUCTION Over all procedure, safety rules, Statutory Requirements, dispatch procedures, switching sequences, observations, passing criteria and documentation of test results have been documented in this report. The detailed inspection and handing over documents are required to be checked for the entire length of transmission line before energization. The detailed inspection/test procedures for each activity has been elaborated in separate section of this documentation. The contents of this report are as following 1. Definition 2. Overall Procedures. 3. Safety procedures 4. Inspection 5. Statutory Requirements 6. Handing over 7. Protective system 8. Dispatch procedures 9. Switching procedures 10. Testing 11. Energization 12. De-energization 13. Observations and duration 14. Passing criteria 15. Documentation

Jindal India Thermal Power Limited

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1.0

DEFINITION
Main Transmission Lines means all high pressure cables and overhead lines

(not being an essential part of the distribution system of a licensee) transmitting electricity from a generating station to another generating station or a sub-station, together with any step-up and step- down transformers, switch-gear and other works necessary to and used for the control of such cables or overhead lines, and such buildings or part thereof as may be required to accommodate such transformers, switch-gear and other works and the operating staff thereof; Power System means a system under the control of the Government or any Board of Generating Company or other agency and having one or more i) generating station; or ii) main transmission lines and sub-stations; or iii) generating stations and main transmission lines and substations; Regional Electricity Board means any of the Boards as constituted immediately before the commencement of the Electricity Laws (Amendment) Act, 1991, by resolution of the Central Government for ensuring integrated operation of constituent system in the region; Regional Load Dispatch Centre means the Centre so designated where the operation of each of the Regional Electricity Grids constituting the countrys power system is coordinated Sub-Station means a station for transforming or converting electricity for the transmission or distribution thereof and includes transformers, convertors, switchgear, capacitors, synchronous condensers, structures cables and other appurtenant equipments and any buildings used for that purpose and the site thereof, a site intended to be used for any such purpose and any buildings used for housing the staff of the sub section; Tie-Line means a line for the transfer of electricity between two power systems together with switchgear and other works necessary to, and used for the control of such line. 2.0 OVERALL PROCEDURE
First it is to be ascertained that the transmission line to be energized is ready for

operation and has been properly handed over (released) in writing. This will include all safety aspects, Electrical inspector clearance, PTCC clearance, Statutory clearance, and final inspection, if any.

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Instructions for the work and supervision is given by the test leader (Line in charge). However all switching and all operational activities will be executed by

the regular operators.


Line charging instructions received from Owner are clearly understood by the Line in charge and doubts, if any, are to be got clarified prior to the energisation

of the line.
Once the line is handed over for charging no work shall be permitted without a

valid WORKPERMIT.
When the whole system has been energized, including the AC line, it will be kept in this state for 8 hours or more for soaking with continuous inspection and monitoring. However recommendations of the Owner may be checked. Otherwise

it may be put into continuous operation. 3.0 SAFETY PROCEDURES


Energization implies an abrupt and serious change of the working conditions in

the plant.
In order to avoid serious accidents, thorough information must be imparted to all personnel involved in the construction of transmission line. Incharge of the Transmission line (Group head OR Divisional head) must ensure that due publicity has been made to the public in all the villages/areas along the line route cautioning them against climbing the towers etc. and that the line is proposed to be charged on so and so date. It is also to be confirmed that the AGENCIES involved in the construction activities shall not carry out any job on the said line

without a valid WORK PERMIT.


It shall be ensured before charging that all men, material, Tools and plants and

any temporary earthing on any part of the entire length of line are removed.
It must be ensured that any power supply / low voltage charging used as anti-theft

measure must be disconnected and isolated to avoid accidental connection.


All equipment tests and pre-commissioning tests must have been completed,

reterminated (in case cables were isolated for testing purpose) and documented.
The system must be formally declared ready for energization and handed over for

operation in writing. 4.0 INSPECTION Before the line is scheduled to be handed over for the pre commissioning/energization the same shall be inspected by representatives of Owner and Construction Agency as follows: Jindal India Thermal Power Limited Page 116

Volume-II / Section-IV Such an inspection shall include: i) Right of way/way leave/electrical clearance ii) Foundation and Revetments/Protection Work iii) Tower and Tower accessories iv) Hardware Fittings v) Insulators vi) Conductors and Earthwire vii) Accessories for conductor and Earthwire viii) Aviation Warning Signals (Lights/globules/painting) 4.1 4.1.1

EPC Tender for JITPL

RIGHT OF WAY/WAY LEAVE/ELECTRICAL CLEARANCE Right of way/Way leave clearance


Ensure that no tree/tree branches are falling within the zone of minimum

clearance specified as per Fig. 1.

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Guidelines of forest/environmental rules shall be followed to avoid excessive tree cutting i.e. all the trees should be cut from ROUTE level in the 3 meter corridor below each line Conductor/Earthwires. In the balance corridor, Trees branches are

only to be lopped to attain the specified clearance as per Table no 1. TABLE NO. 1 CLEARANCE FOR RIGHT OF WAY TRANSMISSION VOLTAGE IN KV 132 220 400 400 4.1.2 Electrical Clearance In case of line crossings, clearance between lowest conductor of line and top conductor of the other line shall be adequate as follows: (Minimum clearances in mm between lines when crossing each other) SI. No. 1. 2. 220 3. 132 KV KV 400 KV 3050 4580 5490 4580 4580 5490 5490 5490 5490 Nominal System Voltage 132 kV 220 kV 400 kV MINIMUM RIGHT OF WAY (IN MTRS) 27 35 52 (S/C) 46 (D/C)

Jumpers in the tension tower are properly intact with conductor and form a parabolic shape in order to achieve adequate clearance from super steel structure. 4.1.2.1 Ground clearance Normally at the time of construction adequate clearance is provided between lowest conductor and ground, but due to delay in charge/commissioning there are chances of dumping/heaping soil, either concrete etc. or staking bricks etc. which Jindal India Thermal Power Limited Page 118

Volume-II / Section-IV

EPC Tender for JITPL

may cause reduction in ground clearance. In such cases the stored materials shall

be removed.
Ensure that there is no temporary or permanent construction of houses or shades below the line. If the same has been constructed they shall be removed before

charging. s indicated by Approved Drawings by Owner are to be referred. ces

The ground profile at the time of commissioning shall be checked with the profile approved at the time of check survey. Ground clearance of lowest conductors at critical points/wherever the lowest conductor is touching the ground shall be checked in the field from any of the prevalent method and the values of ground clearance at these critical points shall be recorded in the prescribed format. In case of hilly Terrain and for building clearance, the side clearance from conductors and jumpers at critical points shall also be checked and recorded for all phases of conductor/earthwire towards hill/building side. The permissible minimum ground clearances for different voltages are as given below. VOLTAGE (KV) 132 220 400 4.1.2.2 Clearance for Telephone line crossings The minimum clearances between the conductors of the power line and telecommunication lines are specified as follows: VOLTAGE (KV) 132 220 400 CLEARANCE (MM) 2745 3050 4880 GROUND CLEARANCE (MM) 6100 7015 8840

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The vertical clearances between conductors and between conductor and earth-

wire shall be checked randomly say in any one span of all sections and 10 sections of hilly areas from single line diagram of the towers. 4.2 FOUNDATION AND REVETMENTS/PROTECTION WORK FOUNDATION: There shall not be any damage/uneven settlement of founda io t ns. For this, tolerances in levels of all four stubs should not exceed the criteria provided in the Annexure-C of IS -5613 (Part -3/Section 2):1989. It is to be ensured that back filling of foundation is properly done. Soil shall be filled over all legs upto ground level. Extra surface earth after foundation back filling shall be removed from legs of the tower beyond a lead distance of 30 m. Any crack or break in chimney, if found, shall be repaired. REVETMENTS / PROTECTION : Cracks/damages to revetments shall be repaired. Wherever revetments are provided, weep holes shall have slope such as to flush out the deposited water away from tower platform. In case of hill terrain, the benching area should be leveled properly. The area around tower shall have proper slope for drainage of rain water. 4.3 4.3.2 TOWER AND TOWER ACCESSORIES Normal Tower After completion of a transmission line, all the towers shall be thoroughly checked before charging the line. Special attention shall be given to the points as mentioned below: Deformed/Buckled/missing/Rusted Members and Nuts and Bolts It is to be ensured that no members are bend, deformed or rusted have been used in towers and if so, the same shall be replaced. If any member is found missing, a new member shall be fixed as per erection drawing of Towers. Nuts shall be sufficiently tightened for the required Torque specified by Owner Approved Drawing. Minimum 2/3 complete threads shall be projected outside Jindal India Thermal Power Limited Page 120

Volume-II / Section-IV

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the nut. All bolts shall have their nuts facing outside of the tower for Horizontal connection and Downwards for Vertical connections. Nuts & bolts shall be properly tack welded/punched as per the specification and proper zinc rich paint shall be applied. It shall be ensured that the circular length of each welding shall be at least 10mm. It shall also be ensured that all extra blank holes provided on tower members are filled with correct size of nuts & bolts. 4.3.2 Special Towers In addition to the above checks for towers, ladders and platforms provided in special towers shall be properly tightened and no foreign material shall be left out on such platforms. Earthing of Towers
Ensure that proper earthing of tower has been done and earthing strip is neither

damaged nor broken and is properly fixed to the stub. In case of counter poise earthing, it is to be ensured that earth wire is sufficiently buried in the ground and no where it has drag out during cultivation. The length of counter-poise is normally 30 m as per TS. Before charging of the line, ensure that resistance is below 10 ohms. If the value (before stringing) has been recorded higher than 10 ohm earthing shall be changed to counterpoise type. Earthing of special towers shall be verified as per approved drawings applicable for special towers/special foundation. (In case of anchor foundation bolt/anchor plate welded with last leg of special tower.) 4.3.3. Tower accessories All the danger plates, number plates, circuit plates, and phase plates shall be in position & and as per the specification. All plates shall be properly tightened. It shall be ensured that phase plates are fixed in correct phase sequence. Specially at transposition towers, the phase plates in the correct phase sequence shall be provided at each towers or end tower as per the specification of the line. It shall be ensured that the anti-climbing device (ACD) is provided, at the suitable height of tower. In case of barbed wire ACD, barbed wire shall be tightly

Jindal India Thermal Power Limited

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fixed. In case of spike type ACD, all spikes shall be properly fixed and oriented

towards outer face of tower.


It shall be ensured that the step bolts (for normal towers) are provided upto the

peak of tower. Any missing step bolts shall be replaced. Fixing of birds guards (upto 220 kV/wherever applicable) shall be ensured. 4.4. HARDWARE FITTINGS Tightening of all bolts and nuts are to be checked upto specified torque. Check the fixing of all security clips. Surface condition of corona control rings and distance/alignment between
Tower side arcing horn (wherever applicable) and line side arcing horn/corona

control ring to be checked as per approved drawings. To restrict the swing of jumpers, the provision of Pilot strings in case of Tension Towers shall be verified from the approved drawings. 4.5 INSULATORS All the damaged/broken insulator discs shall be replaced. Unusual deflection in suspension strings if observed shall be rectified. The insulators shall be cleaned before charging. IR value of individual disc of at least 5 insulators at random shall be checked by 5/10 kV Megger. 4.6. CONDUCTORS and EARTHWIRES Surface Condition Surface of the conductors shall be free from scratches/rubs Ensure that conductor strands are not cut and opened up. Wherever strands are found cut/damaged/scratched, they must be repaired with repair sleeves/repair protective rods in case the nos. of damaged strands are within specified limits (normally upto l/6th nos. of strands in the outer layer). 4.7 4.7.1 ACCESSORIES FOR CONDUCTORAND EARTHWIRES Joints All joints on conductor/earthwires shall be away from the tower at a distance of at least 30 meters or as provided in the Technical specification (TS). Ensure that not more than one joint in a conductor is provided in one span or as provided in the Technical specification (TS). Jindal India Thermal Power Limited Page 122

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Ensure that no mid span joint is provided in major crossings for main roads, railway crossing and major rivers etc. or as provided in TS. Ensure that all mid span joints on conductors/earthwire and repair sleeves of compression type are free from sharp edges, rust and dust. Wherever grease are specified the same shall be applied in the joints. 4.7.2. Clipping Ensure that conductor is not over tightened in the suspension clamps. 4.7.3 Spacers, vibration dampers and copper bonds Placement and no. of spacers/dampers between four sub conductors on each phase shall be verified as per spacer/damper placement chart. Damaged/missing spacers shall be replaced and loose/displaced spacers shall be tightened/relocated. Spacing of Vibration dampers from the tower and spacing between damper to damper in case two Vibration Dampers (VD) were provided, shall be verified as per the damper placement chart. All loose/displaced VD shall be properly tightened/relocated and missing VDs shall be provided. To be ensured that no copper bond is loose/missing.
4.7.4

Jumpers Verify Electrical clearance of jumpers to tower body as per design. All the jumpers shall be checked properly. In case, jumpers (conductor/earthwire) is found loose, it shall be tightened sufficiently.

4.7.5

Foreign material Ensure that all foreign materials viz dead bird. fallen tree branches, bird nests etc. on conductors, earthwires, Jumper, insulator string, cross arms are removed.

4.7.6.

Others It shall be ensured that all temporary/local earthing. guys, T & P (Tools and Plants), foreign material and other loose material which were used during stringing/tower erection have been removed. In case there is any change in the ground profile before commissioning of line from the approved profile, the extra earth/obstruction/temporary sheds/any other construction shall be removed.

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4.8

AVIATION WARNING / OBSTRUCTION SIGNALS (LIGHTS/GLOBULES/PAINTING). It shall be ensured that following measures have been taken in the line/Towers falling within obstruction zone of civil aviation and defense establishments as per their requirement and our specification. Day markers Painting of Full/Top portion of Towers with Red/Orange and White Paints. Globules on earthwires have been provided. Night markers It shall be ensured that proper aviation lights at the peak level/at specified heights of towers have been provided along with Solar panels/Battery banks/Control cubicles and other accessories as per specification. The functioning of lights with simulation to be checked/verified.

5.0 5.1.

STATUTORY REQUIREMENT The concerned authorities shall be informed before commissioning the lines and their approval obtained in accordance with Indian Electricity Act, 2003 and Indian Electricity Rule, 1956 . Before charging of the line PTCC approval from P&T Dept. shall be obtained. HANDING OVER The transmission line shall be inspected prior to energization and a formal handing over document to be jointly signed by the representative of the EPC Contractor and JITPL. However all contractual taking over has to be resolved separately as per the terms and conditions of the contract. The Handing over shall be limited to the completion of Erection and ready for Energization. Any outstanding points or remaining activities are to be listed jointly by the EPC Contractor and JITPL and signed jointly. The remaining activities/outstanding points are classified in the following category. Details of the SECTIONS: A. B. C. D. List of outstanding activities remaining in any part of the line A list of temporary arrangements introduced. Check list records properly documented, completed and signed. Original tracing of Profile, Route Alignment, Tower Design, Structural Drawings, Bill of Materials, Shop Drawings, Stringing charts (initial and final as applicable) etc. of all towers/line submitted to Owner. Page 124

5.2 6.0

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With the outstanding activities mentioned above are solved or with only minor points without influence on the charging remain (minor issues handing over of the transmission line shall be accepted by the pre-commissioning team. This handing over for energization with or without remaining activities shall be made by the group head to the commissioning in charge in writing. Shortcomings noticed during the inspection, List of outstanding activities shall be recorded and a copy of the format is to be given to the EPC Contractor for corrective action to be taken on a time schedule. 7.0 PROTECTIVE SYSTEM Before energization it must be ascertained that all protective systems for the unit to be energized are operative. This includes confirmation that the protections have been properly tested and that the tests have been documented. It also includes verification by inspection or otherwise, if necessary by
repetition of trip test, that the protections are actually functionally enabled. This verification serves to prevent that energization takes place of a unit where a

protection has been disabled for test or other reason.


8.0

DISPATCH PROCEDURES All operational activities (switching etc.) must be coordinated and communicated with the system dispatcher i.e. PGCIL. In this respect the general procedures already established by PGCIL will be followed.

9.0

SWITCHING PROCEDURES
For each activity the instructions to the operators and the communications to the dispatchers will be made in writing or by confirmed telephone messages. The

switching procedures first to be properly documented step by step and understood by everybody involved in the switching operation prior to the
enerzisation. Any clarification required in the procedures must be resolved. The

format established by Owner for switching orders and operational data logging shall be followed. The implication of this is that each and every activity must be listed and described, so that complete information is available for detail investigation, if required in future.

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10.0 10.1.

TESTING AND MEASUREMENT PROCEDURES Earth Resistance Measurement Normally Earth tester is used for measuring a) soil resistivity. b) earth resistance a. Prior to the testing of soil resistivity and earth resistance the operation
manual of the testing instrument available at site may be referred and procedures to be adopted for measurement of soil resistivity and earth

resistance.
A typical Earth tester has 4 terminals. C1, P1, C2, P2 and 4 similar electrodes are driven in the ground at equal distances and connected to the instruments in the order of C1 P1 and P2, C2. Then the handle is rotated or button is pressed and the reading of the resistance is read on the megger

scale. If R is the resistance measured then the Specific resistivity = 2aR


where a is the distance between the electrode and R is the resistance in

ohms measured on the megger. b) In order to measure earth resistance of electrode of the substation it could be connected to C1 and the value of R could be read in the scale with the rotation of the handle of the megger. This will give the earth resistance. The value as far as possible shall be below 10 Ohm. To improve the value, water shall be sprinkle at the earthing pit.

10.2

Before commissioning of the lines following tests maybe carried out.

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10.2.1

Insulation Resistance Test This test may be carried out with the help of a 10 OR 12 KV megger preferably power driven to ascertain the insulation condition of the line. In case 5 kV megger is used for insulation resistance measurement it shall be ensured that the induced voltage (CVT reading) is LESS than the instrument withstanding capacity otherwise it is likely that the instrument maybe damaged. This Test is to be carried out First prior to the continuity test. Measurement of Insulation Resistance One of the most common devices used for testing electrical insulation is the Megger Insulation Tester. The DC test voltage is generated by a permanent magnet generator. This generator is turned either by hand, or by an electric motor. In either case a slip clutch maintains the generator speed at constant value so long as the slipping speed is exceeded. A constant voltage is important when the insulation under test has a high capacitance. Common generator output voltage are 500, 1000, 2500 and 5000 volts. Many Meggers have a guard terminal as well as line and earth. The guard terminal is useful shall one wish to exclude part of the insulation under test from the measurement. This is possible since current flowing to the generator via the guard circuit does not pass through the deflecting coil. Another use of the guard circuit is to shield the line lead between the Megger and the apparatus under test. This prevents leakage to ground from the line lead which would invalidate the Megger reading. Insulation resistance is the ratio VDC/ IDC . VDC is applied across two conductors separately by the insulation under test. IDC is the current flowing through/over the insulation. For a healthy and clean insulation the megger reading is in mega-Ohms to infinity. For dirty in, insulation and defective, moist insulation the meggers shows a very low insulation resistance value. Megger test gives clear indication about the health, cleanliness and dryness of the line/equipment insulation. 2 e used for the Transmission line keeping all safety requirements, Permit to work, clearance
from statutory bodies and other conditions prevailing at the Sub-station where

charging of the line is being co-ordinated.

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10.2.2

Conductor Continuity Test

10.2.2.1 The objective of this test is to verify that each conductor of the overhead line properly connected electrically (the value of electrical resistance of line does not vary abnormally from that of a continuous conductor of the same size and length). The electrical resistance of the conductor shall be measured with a Whetstone bridge or other suitable instrument, if available taking the safety aspects of Equipment as well as testing Engineer. A simple method of continuity test is illustrated below Once the insulation is completed and the results confirms no short circuit carry the following SENDING END CLOSER R-Ph GS OPEN Y Ph GS OPEN B-Ph GS RECEIVING END MEGGER R-Ph MEGGER Y-Ph MEGGER B-Ph RESULTS (OHMS) ZERO/LOW HIGH HIGH

OPEN R-Ph GS

MEGGER R-Ph MEGGER Y-Ph MEGGER B-Ph

HIGH ZERO/LOW HIGH

CLOSE Y-Ph GS OPEN B-Ph GS

OPEN R-Ph GS

MEGGER R-Ph MEGGER Y-Ph MEGGER B-Ph

HIGH HIGH ZERO/LOW (ALL GS OPEN CONDITIONS)

CLOSE Y-Ph GS OPEN B-Ph GS

GS means GROUND SWITCH If the above test results are OK it confirms the continuity of the line. 10.2.2.2 The continuity Test of the line with proper phase indication or phase marking can be checked by continuity test as described below:

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SENDING END

RECEIVING END MEGGER BETWEEN

RESULTS (OHMS)

CONNECT R&Y PHASE

R PHASE & YPH

ZERO OR LOW HIGH HIGH HIGH HIGH ZERO OR LOW HIGH ZERO OR LOW HIGH

B-PHASE & ALL GS Y PHASE & B PH OPEN B PHASE & R PH CONNECT R & B PHASE R PHASE & Y PH

Y PHASE & ALL GS Y PHASE & B PH OPEN B PHASE & R PH CONNECT Y & B PHASE R PHASE & Y PH

R-PHASE & ALL GS Y PHASE & B PH OPEN B PHASE & R PH

If the test results are OK it confirm that marking of the phases are in order. 10.2.2.2. Phase Sequence Once the line is charged from one end, without closing the Breaker at the other end the Phase sequence is to he checked from the CVT output by the help of Phase Sequence Meter. In case there is other feeders available Phase sequence is to be RECHECKED by the measurement of secondary voltage of both the Feeders. (New line & available charged line). Let the secondary Voltage of CVT is 110 volts (ph to ph) for both the Circuit. In case of correct Phase Sequence the voltage reading shall he as follows : NEW CIRCUIT R-Phase R-Phase R-Phase Y-Phase OLD CIRCUIT R-Phase Y-Phase B-Phase R-Phase 110 VOLTAGE 0 110 110

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Y-Phase
Y-Phase

Y-Phase B-Phase R-Phase

0 110 110

B-Phase B-Phase Y-Phase 110 B-Phase

B-Phase

In case the resu1ts are not matching the phase sequence in to be rechecked and reconfirmed before closing the breaker. 11.0. ENERGIZATION Execution of the energization is simply the last event in the switching sequence, switching of the close control button for the relevant circuit breaker. 12.0 DE-ENERGIZATION Instructions about de-energization will be given only if this is part of the test. Otherwise de-energization will be considered part of regular operation. 13.0 OBSERVATION AND DURATION Visual and audible inspection (look and listen) of the relevant equipment and reading of permanent instrumentation will be made. The system shall be charged at least for 8 hours. During this time continuous monitoring and inspection will be maintained in control room, auxiliary systems areas and switch yards. This will include frequent, scheduled inspection of all equipment and reading of all permanent instruments and recorders, and surge arrester counters, especially system parameters as per standard procedures adopted by Owner. 14.0 PASSING CRITERIA Neither insulation breakdown nor protective system actions must occur. No irregular equipment behaviour noise, vibration, high temperature is permitted. Corona discharges may not be unreasonable. Local discharges that may be attributable to sharp points shall be carefully located and recorded. After termination of the energization the equipment shall be closely inspected and the points rounded or covered.

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No unscheduled changes of system nor of equipment is permitted during the 8

hour energized condition. 15.0 DOCUMENTATION


Switching and operational activities will be recorded in regular manner in the

operators log. Likewise all readings of permanent instruments. Copies of this log, notes on special observations from inspections ad other measurements will constitute the test records.

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SECTION V TECHNICAL SPECIFICATIONS FOR ACSR MOOSE CONDUCTOR

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SECTION V CONTENTS Clause Description 1.0 2.0 3.0


4.0

Page No 135 135 135 136 138 139 139 Cleaning Temperature Curve 139 139 140 141 141 141 141 141 144 145

General Environmental Data Electrical System Data Technical Particulars of ACSR MOOSE Conductor Material Surface Conditions

5.0 6.0
7.0

8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 17.0 19.0 20.0
21.0 22.0

Tests Testing Expenses Additional Tests

Sample Batch for Type Testing Test Reports Test Facilities Description of Tests Re-Test and Rejection Insepction

Length of the Conductor Packing and Marking Approval of Drawings, Sag Tension Charts and

145 145 147

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23.0 24.0

N/A N/A

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TECHNICAL SPECIFICATION SECTION V FOR ACSR MOOSE CONDUCTOR 1.0 GENERAL This specification covers manufacture, testing, supply and delivery of ACSR MOOSE conductors required for construction/maintenance of 400 KV lines & substation works of JITPLPowerTransco Limited. The conductor shall conform to the Indian Standards enlisted in Annexure-5. SCHEDULE -A DESCRIPTIVE TECHNICAL INFORMATIONS:
2.0

ENVIRONMENTAL DATA Following are the salient parameters of the environmental data (a) Maximum ambient temperature degree C (b) Minimum ambient temperature degree C : 50 : 7.5

(c) Maximum daily average temperature degree C : 32 (d) Maximum relative humidity % (e) Number of rainy days/year (f) Average number of thunder storm, days/year (g) Pollution level category
3.0

: 90 : 90 : 50 : Moderately Polluted.

ELECTRICAL SYSTEM DATA (a) Nominal System Voltage (b) Frequency (c) System Highest Voltage (d) Number of Conductor per phase (e) Conductor type & size : 400 KV : 50 Hz : 420 KV : 4 : ACSR Moose 520 Sq. mm. nominal. (f) Spacing between the two conductors of same phase (sub- conductor spacing) : 457 mm

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EPC Tender for JITPL : Vertical 44 m/sec 400 meters

(h) Maximum wind speed considered for line design: (i) Ruling design span 4.0 :

TECHNICAL PARTICULARS OF ACSR MOOSE CONDUCTOR The line conductor shall meet the following requirements: (a) Nominal Aluminium area (b) Stranding & Wire diameter : : 520 Sq.mm Al : 54/3.53 mm Steel : 7/3.53 mm (c) No. Of Aluminium strands: 1st layer 2nd layer 3rd layer : 12

: 18 : 24 : : : : : : : : 528.50 Sq.mm 597 Sq.mm 31.77 mm 2004* Kg/Km 0.05552 ohm/Km 161.20 KN (Min) 19.3 x 10-6 per deg.C. 0.703 x 106 Kg/Sq.mm. sq

(d) Sectional area of aluminium (e) Total sectional area (f) Approximate overall diameter (g) Approximate weight (h) Calculated d.c. resistance at 20 deg. C. (i) Approximate calculated breaking load (1) Co-efficient of linear expansion (k) Final modulus of elasticity (1) Resistivity of Aluminium wire at 20 deg. C. (m) Electrical conductivity at 20 deg. C.

: 0.028264 ohms mm/m (maximum)

: 53.3% (standard) of IACS(International Annealed Copper Standard).

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*This weight is that of ungreased conductor. This figure will change depending on the

density and thickness of coating of the grease. (n) Lay Ratio of Conductor: . Steel Core (1 Centre core & layer of 6 wires) Aluminium 1st layer of 12 wires 2nd layer of 18 wires 3rd layer of 24 wires 14 13 12 12 11 10 Max. 18 16 Min

(o)

Strand Details : Materials Steel Diameter Standard Maximum Minimum 3.53 3.60 3.46 9.787 sq.mm 76.34 kg/km 12.86 KN 12.22 KN 2.921 ohms/Km Not permitted Not Permitted Joints by cold butt pressure 3.53 3.55 3.51 9.787 sq.mm 26.45 kg/km 1.57 KN 1.49 KN Aluminium

(p)
(q)

Cross Sectional area for nominal Diameter of wire Weight Minimum Breaking Load: (i) Before stranding (ii) After stranding

(r)

(s) (t) Joints

D.C. resistance at 20 deg. C. : Aluminium(ii) Outer Layer Inner Layer (i) Steel

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No two joints shall be less than 15 meters apart in a complete stranded conductor (u) Stranding There shall be no tendency to untwist or spring apart, when the 6 wire & 12 wire layers. One conductor length per drum To be submitted along with offer 1800 meters +/- 5%

(v) (w) (x) (y) (z)

Packing Temperature rise curve Standard length/drum

Corona Extinction Voltage at 50 Hz (AC) Minimum 320 KV phase to ground RIV at 1 MHz for phase to ground voltage (i) 266 KV (dry condition) Not to exceed 500 micro volt (ii) 100 KV (wet condition) Not Exceeding 1000 micro volt

5 5.1

MATERIAL Aluminium The Aluminium strands shall be hard drawn from electrolytic aluminium rods having purity not less than 99.5% and copper content not exceeding 0.04%.

5.2

Steel The steel wire strands shall be drawn from high carbon steel wire rods produced by either the acid or basic open hearth process. The electric furnace process shall conform to requirements as to chemical composition given in latest relevant IS. The chemical composition of high carbon steel wire is given below: Element (i) Carbon (ii) Manganese (iii) Phosphorous (iv) Sulphur (v) Silicon % Composition 0.50 to 0.85 0.50 to 1.10 Not more than 0.035 Not more than 0.045 0.10 to 0.35

5.3

Zinc The zinc used for galvanizing shall be electrolytic high grade zinc of 99.95% pure .it shall conform to and satisfy all the requirements of IS-209. Galvanising may be done by hot process. Neutral grease may be applied between the layers of wires.

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Volume-II / Section-V 5.3.1 Zinc coating of steel core: (i) Number of 1 minute dip: (ii)Minimum weight of Zinc coating: (iii)Process of Galvanising: 6.0 SURFACE CONDITIONS: 3

EPC Tender for JITPL

260 gm/sq.lnt. Hot dip

The surface of the conductor shall be smooth and free from dents, sharp edges,
abrasion or other departures from smoothness or uniformity of surface contour

that would appreciably increase radio interference and corona loss when used as
phase conductor. When subjected to tension up to 50% of the ultimate tensile strength of the conductor, the surface shall neither depart from its general cylindrical form nor any of the component parts or strands shall move relative to each other in such a way so as to get out of place and disturb the longitudinal

smoothness of the conductor. 7.0 CLEANING The conductor shall be free from excessive amount of die grease, metal particles
and dirt. The Bidder shall describe in complete details, the method which he

proposes to use in production to clean the conductor. 8.0 TEMPERATURE RISE CURVE
The Bidder shall furnish curves showing relation between current in amperes at

50 cycles and temperature rise in degree Celsius for ACSR 61/3.53mm.The ambient temperature shall be taken as 40 degree C. The graph shall specifically indicate current values, for conductor temperature of 60 degree C ( ambient temperature 40 degree + temperature rise of 20 degree C above ambient), 65 degree C, 70 degree C etc. upto 100 degree C in steps of 5 degree C. 9.0
9.1

TESTS The conductor offered in the tender should have been successfully type tested in line with the standard and technical specification within the last five years from the date of opening of tender. The bidder shall be required to submit copies of the type test reports along with the offer in electronic document form. The type tests, acceptance tests, routine tests and tests during manufacture shall be carried out on the conductor. 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. These tests shall be carried out on sample prior to commencement

9.2

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of commercial production against the order. The bidder shall indicate his schedule for carrying out these tests in the offer. (b) Acceptance tests shall mean those tests, which are to be carried out on
sample taken from each lot, offered for pre-despatch inspection, for the

purposes of acceptance of that lot. (c) Routine tests shall mean those tests, which are to be carried out on each strand/spool/length of the conductor 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 by the Contractor, to ensure the desired quality of the end product to be supplied by him. 9.3 The norms and procedures of sampling for these tests will be as per the Quality Assurance Plan/Programme to be mutually agreed-to by the Contractor and Owner as per relevant clause of General Conditions of Contract. 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 procedures of the test shall be as specified in Annexure-I, or as mutually agreed to, between the Contractor and the Owner, in the Quality Assurance Programme. For all type tests 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. TESTING EXPENSES: The Owner may opt for repetition of Type Test at his own expenses prior to manufacture. In case of failure in any type test, the bidder is either required to modify the design of the material or repeat the particular type test successfully, at his own expenses. The decision of the Owner, in this regard shall be final and binding. Bidder shall indicate the laboratories, in which he proposes to conduct the type test. He shall ensure that the tests can be completed in these laboratories, within the time schedule, guaranteed by him, in the appropriate schedule. The entire cost of testing for the acceptance tests, routine tests, and tests during manufacture, specified herein, shall be treated as included in the quoted unit price of conductor, except, for the expenses of the inspector/ Owners representative.

9.4

9.5

10.0 10.1 10.2

10.3

10.4

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EPC Tender for JITPL

The Owner reserves the right of having, at his own expenses, any other test(s) of reasonable nature carried out at Contractors premises, at site, or at any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself, that the materials complies with the specification. 12.0 12.1 SAMPLE BATCH FOR TYPE TESTING The Contractor shall offer at least five (5) drums for selection of samples required for conducting all the type tests. TEST REPORTS (DOCUMENTS IN PHYSICAL FORM) One original plus four copies of type test reports shall be furnished to the Owner within one month of conducting the tests. One copy will be returned duly certified by the Owner to the Contractor within three weeks thereafter and on receipt of the same, Contractor shall commence commercial production of the conductor. One original plus four copies of the acceptance test reports shall be furnished to the Owner. One copy will be returned, duly certified by the Owner and only thereafter, Contractor shall dispatch the conductor. All records of routine test reports shall be maintained by the Contractor at his works for periodic inspection by the Owner. All test reports of tests conducted during manufacture, shall be maintained by the Contractor. These shall be produced for verification as and when requested for by the Owner. TEST FACILITIES The following additional test facilities shall be available at Contractors works: The testing equipments with Valid Calibration certificate of various testing equipments including tensile testing machine, resistance measurements facilities, burette, thermometer, barometer etc. Standard resistance for calibration of resistance bridges. DESCRIPTION OF TESTS TYPE TESTS The following type tests shall be conducted on the samples of conductor in presence of Owners representative. The sample for type tests shall be selected
by Owners representative. The type test shall be conducted once on

13.0 13.1

13.2

13.3 13.4

14.0 14.1 (i)

(ii) 15.0 15.1

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sample/samples of conductor for every 400 Kms or part thereof of production

from each manufacturing facility. 15.1.1 Ultimate Tensile Strength Test: Circles perpendicular to the axis of the conductor shall be marked at two places on a sample conductor of minimum 5 metre length, suitably compressed with Tension Clamps at either end. Tensile load shall be applied to the sample and shall be increased at a steady rate up to 50 % of the Ultimate Tensile Strength of the conductor and held for one minute. The circles drawn, shall not be distorted due to relative movement of strands. The applied load shall then be increased at steady rate until the failing load is reached. This value shall not be less than the guaranteed breaking load of the conductor. 15.1.2 Corona Extinction Voltage Test Four samples of conductor of 5 meters length shall be strung with a spacing of 457 mm. between them. This sample assembly when subjected to power frequency voltage, shall have a corona extinction voltage of not less than 320 KV line to ground under dry conditions. There shall be no evidence corona on any part of the samples when photographed in a darkened room. Corresponding corona inception and extinction voltage shall also be measured. 15.1.3 Radio Interference Voltage Test Under the conditions as specified under Clause 15.1.2 above, the conductor samples shall have a radio interference voltage level below 500 microvolts at one MHz when subjected to 50 Hz AC voltage of 266 KV line to ground under dry condition. 15.1.4 D.C.Resistance Test On a conductor sample of minimum 5 metre length, two contact clamps shall be fixed The resistance shall be measured by a Kelvin Double Bridge by placing the clamps initially zero meter and subsequently one meter apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 20 degree C as per IS:398 (Part V). The resistance corrected at 20 degree C shall conform to the requirements of this specification. 15.1.5 Stress-Strain Test (i) Test loads for Complete Conductor
The loading conditions for repeated stress- strain tests for a complete

conductor shall be as follows: Load initially to 1 KN tension to straighten the conductor. After straightening, remove the load and set the strain gauge to zero at zero tension.

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For non-continuous stress-strain data recordings, take the strain readings at

1KN intervals at the lower tension and at 5 KN intervals above 30 % UTS.


Load to 30 % UTS and hold for 0.5 hour. Take readings after 5, l0, l5 and

30 minutes during the hold period. Release to initial load.


Reload to 50% UTS and hold for 1 hour. Take readings after 5, 10, 15, 30,

45 and 60 minutes. Release to initial load.


Reload to 70% UTS and hold for 1 hour. Take readings after 5, 10, 15, 30,

45 and 60 minutes. Release to initial load.


Reload to 85% UTS and hold for 1 hour. Take readings after 5, 10, 15, 30,

45 and 60 minutes. Release to initial position as per previous loading


After the fourth application of load, again apply tension, increasing uniformly until the actual breaking strength is reached. Simultaneous

reading of tension and elongation shall be taken-up to 90% UTS at the same intervals as for previous loading. (ii) Test Loads For Steel Core only The loading conditions for the repeated stress-strain tests for the Steel Core of ACSR shall be as follows: The test shall consists of successive application of load applied in a manner similar to that for the complete conductor at 30%, 50%, 70% and 85% UTS. The steel core shall be loaded until the elongation at the beginning of each hold period corresponds to that obtained on the complete conductor at 30%, 50%, 70% and 85% of UTS respectively. (iii) Stress-Strain Curves Obtain the design stress- strain curve by drawing a smooth curve through the 0.5 and hour points at 30%, 50% and 70% UTS loading. Remove from the lower end at the design curves, the presence of any conductor slack, that can be related to any observed extrusion entering the span from the compression dead-end. Both the laboratory and design stress-strain curves shall be submitted to the Owner. 15.2 Routine/Acceptance Tests The following acceptance tests shall be conducted on the samples in presence of the Owners representative and the test values shall conform to IS:398-V. (i) Visual and Dimensional Check on Drum The drums shall be visually and dimensionally checked to ensure that they conform to the requirements of this specification. (ii) Visual Check for Joints, Scratches etc.

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Conductor drums shall be rewound in the presence of Owners representative. The Owners representative shall visually check for scratches, joints etc. and that the conductor generally conforms to the

requirements of this specification. (iii) Dimensional Check on Aluminium and Steel Strands
The individual strands shall be dimensionally checked to ensure that they

conform to the requirement of this specification. (iv) Lay- Ratio Test of Various Layers
The Lay-ratios of various layers shall be checked to ensure that they

conform to the requirements of this specification. (v) Elongation and Torsion Test
The test procedure shall be as specified in IS-398 (Part-V)-1992. The

material shall conform to the requirements of this specification. (vi) Breaking Load Test on Individual Aluminium and Steel Strand
For the purpose of acceptance test, this test shall be made on both

aluminium and steel. The tensile test shall apply to all wires of ACSR conductors. The tensile strength of any of the wires shall not be less than the values given in the technical particulars mentioned in this specification. When an automatic tensile testing machine is used, the load shall be applied gradually and rate of separation of the jaws of the testing machine shall not be less than 25 mm/minute and not greater than 100 mm/minute. (vii) Resistance Test As per Clause 13.8 of IS-398-V, the measurement of resistance shall be made on strands of ACSR conductor, and shall be carried out to an accuracy of at least one part in a thousand and conform to the specified values. Certificates as to the accuracy of the apparatus shall be provided. 16.0 Contractor shall conduct all the type tests mentioned above in presence of Owners representative on the samples selected by him for every 1000 KMs of conductor or part thereof at Contractors cost. RE-TEST AND REJECTION Each drum or reel selected for testing, shall be tested for compliance with the requirements of IS-398-V. Should any selected drum or reel not fulfill any of the test requirements, that particular drum or reel shall be withdrawn. In respect of each failure, two test pieces shall be selected from two different drums in the lot and subjected to the test under which the failure occurred. If either of the two re-test pieces fails to pass that test, the drum or reel concerned shall be rejected. All rejected drums shall be marked and segregated. Jindal India Thermal Power Limited Page 144

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18.0

The Owner reserves the right to have carried out any/all type tests mentioned under Clause No 15.1 at his own expenses on samples of conductor selected

from the lot supplied at site. The entire conductor shall be rejected if the test results are not satisfactory. 19.0 INSPECTION The Owners representative shall, at all time, be entitled to have access to the works and all places of the manufacturer, where the conductor shall be made or prepared and the representative shall have full facilities for unrestricted inspection of Contractors works, the raw materials, the manufacture of the conductor and for conducting necessary tests as detailed herein before. The Contractor shall keep the Owner informed, well in advance, of the time starting and of progress of manufacture of conductor at its various stages, so that arrangement could be made for inspection. No conductor shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested and release order is issued by the Inspecting Officer for dispatch. 20.0 LENGTH OF THE CONDUCTOR STADARD LENGTH The standard length of the conductor shall be minimum 1800 meters. Tolerance of +/- 5 % in standard length offered by the bidder shall be permitted. All length outside this limit of tolerance shall be treated as random length. RANDOM LENGTH Random length will be accepted provided no length is less than 70 % of the standard length specified and the total quantity of such random lengths shall not be more than 7 % of the total quantity allotted to each consignee and 5 % of total quantity ordered. If required for special applications, the successful bidder shall supply 6 (six) nos. of 2500 meters long continuous conductor. Bidder shall also indicate the maximum single length, above the standard length, he can manufacture, in the guaranteed technical particulars. This is required for special stretches like river crossings etc. The Owner reserves the right to place orders for the above length on to the extent of 10 % of the total ordered quantity on the same terms and conditions applicable for the standard lengths during the pending period of the contract. 21.0 PACKING AND MARKING (i) The conductor shall be wound on non-returnable reels or drums of well seasoned wood, conforming to Indian Standard-1778 specification for

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Reels and Drums for bare wire. Only one conductor length shall be packed

on each drum.
The reels shall be of such construction as to assure delivery of conductor free from displacement and damage and should be able to withstand all stresses during subsequent Road or rail transport, storage, handling and stringing operations, so that conductor surface is not dented, scratched or

damage in any way during transport and erection. The conductor shall be preferably lagged on the drums and the proposed method of lagging shall be clearly stated by the bidder in the tender. The conductor should be stocked to suit the reel and held in place by steel strapping. The conductor drum should be suitable for wheel mounting. Before reeling, the cardboard or other suitable material shall be secured to the drum and inside flanges of the drum. After reeling the conductor, the exposed surfaces should be wrapped with suitable soft material to protect the conductor from dirt and grit. Any space between drum lagging and conductor should be suitably filled with soft, filler material compactly packed. All the drums shall be painted inside and outside with aluminium paint. All reels shall have a layer of water proofs polyethylene film around the drums under the conductor and another layer over the conductor and under the lagging. The wooden drums shall be capable of being mounted on tension stringing equipment which shall be power operated. The conductor drum shall be made as per enclosed drawing. (ii) Each drum shall have following information stenciled on it, in indelible ink, along with other essential data: (a) Contract/Specification No. (b) Name and address of the Consignee. (c) Name of the destination. (d) Makers name and address or trade-mark. (e) Drum number. (f) Name and size of the conductor. (g) Length of the conductor in meters. (h) Gross weight of the drum with protective lagging including conductor. (i) Weight of the empty drum with protective lagging. (j) Net weight of the conductor. (k) Arrow marking for unwinding. (1) Position of the conductor end. (m)Lot Number. Jindal India Thermal Power Limited Page 146

Volume-II / Section-V (n) Date of Packing. (o) I.S.I.Marking. 22.0


22.1

EPC Tender for JITPL

APPROVAL OF DRAWINGS, SAG TENSION CHARTS & QUALITY ASSURANCE PLAN


The successful Bidder (Contractor) shall submit drum drawing for approval of

the Owner before commencement of production. 22.2


22.3

The Contractor shall d9iscuss & finalise Quality Assurance Plan in consultation with Owner before commencement of production.
The Contractor shall submit sag-tension charts for approval of the Owner before

commencement of supply. SCHEDULE B 23.0 QUALIFYING REQUIREMENTS : N/A

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EPC Tender for JITPL

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BLANK

Jindal India Thermal Power Limited

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EPC Tender for JITPL

BLANK

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SECTION VI TECHNICAL SPECIFICATIONS FOR 7/3.66MM GALVANISED STEEL EARTH-WIRE

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SECTION VI CONTENTS Clause Description 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 General Climatic and ISO CERAUNIC Conditions System Particulars Technical Particulars Tests Test Reports Inspection Packing Marking Page No 153 153 153 154 157 160 161 161 162

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EPC Tender for JITPL

TECHNICAL SPECIFICATION SECTION VI 7/3.66MM GALVANISED STEEL EARTH-WIRE 1.0 GENERAL


This specification covers manufacture, testing, supply & delivery of Galvanized Steel (G.S.) earthwire, required for 400 KV lines, proposed to be erected by the Owner. The earthwire offered, shall conform to the technical requirements

covered under this specification and latest Indian Standard Specifications. 2.0 CLIMATIC AND ISOCERAUNIC CONDITIONS
The offered earthwire shall be suitable for satisfactory operation under following

environmental conditions. (i) Temperature a) Minimum b) Maximum c) Everyday average (ii) Relative Humidity maximum : 7.5 deg. C : 50 deg. C : 32 deg. C : 90 % : 75 : 1500 mm to 3800 mm : Not more than 1000 Mtrs. above sea level. (v) Pollution level (v) Isoceraunic level : Moderately polluted. : 20/50

(iii) No. of rainy days per year (iv) Rainfall per year (v) Altitude

3.0

SYSTEM PARTICULARS The 7/3.66 mm size G.S. earthwire is required for shielding of 400 KV Transmission Lines with conductor configuration as follows: . Conductor configuration: Double circuit : Vertical

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4.0 4.1

TECHNICAL PARTICULARS OF EARTHWIRE SIZE 7/3.66 mm Physical properties i) Material ii) iii) No. of wires in strand (Nos.) Normal diameter of galvanized strand wire (mm.) Total sectional area (mm.sq.) Approximate weight (kg/ Km) Minimum breaking load of strand (KN)
Elongation of strand after

: : :

Steel Steel core Outer layer 1 6 Std. 3.66 73.65 3.74 Total 7 3.58

Max. Min.

iv) v) vi)

: :
583

:
4%

68.4

vii)

breakage shall not be less than


-6

viii) Co-efficient of expansion (per deg.C) ix) Modulus of (Kg/sq.mm.)

linear

11.5 x 10
3

elasticity

19 x 10

x) Permissible variation in diameter of individual zinc


coated wires for a nominal

+/- 2%

diameter of 3.66 mm (percent) xi) Overall diameter of earthwire (mm) of zinc : 10.98

xii) Minimum weight

275 (should withstand

Jindal India Thermal Power Limited

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Volume-II / Section-VI coating (g/M sq.)

EPC Tender for JITPL one minute dips = 4 Nos, 1/2minute dips =1 No. : 2.5

xiii)

Calculated D.C. resistance at 20 deg. C (ohm/km)

xiv) Lengths a) Standard length (M) b) Random lengths (M)

: 2000 Random lengths will be accepted provided no length is less than 70 % of standard length and total quantity of random lengths is not more than 10% of the total quantity in each shipment. +/- 5% of the standard length. Minimum : 165 Maximum : 198 : : Right hand 7.8

c) Tolerance in length d) Strand lay and lay length

xv) xvi)

Direction of lay of outer layer Density at 20 deg.C (g/cm3)

4.2

Detailed Technical Particulars

4.2.1 Material The basic metal shall be steel made by the open heart basic oxygen or electric
furnace process and of such quality and purity that when drawn to size of wire

specified and coated with zinc, the finished strand and individual wires shall be of uniform quality and have the properties and characteristics as prescribed in this specification. The steel shall have following composition as per IS-12776: 1989 Element Carbon Manganese Phosphorous Jindal India Thermal Power Limited Composition 0.55 Max 0.40 to 0.9 0.04 Max Page 155

Volume-II / Section-VI Sulphur Silicon 4.1.2 Galvanizing: 0.04 Max 0.15 to 0.35

EPC Tender for JITPL

The slab zinc, when used for zinc coating, shall be of any grade of zinc conforming to ASTM specification, B-6, for zinc metal (slab Zinc) process Hot dip. 4.1.3 Stranding All steel strands shall be smooth, uniform and free from all imperfections such as spills and split die marks, scratches, abrasions and kinks after drawing and also after stranding. The finished material shall have minimum brittleness. Unless
otherwise specified, the strand shall right hand lay. All wires shall be stranded

with uniform tension. Stranding shall be sufficiently close to ensure no appreciable reduction in diameter when stressed to 10% of the specified strength. The 7-wire strand shall consist of central wire with 6-wire layer concentrically twisted over it with a uniform pitch not more than 16 times the specified nominal diameter of the strand. 4.1.4 Ductility of steel The zinc coated wire shall not fracture when wrapped at a rate not exceeding 15 turns per minute in a close helix of at least two turns around a cylindrical mandrel. The mandrel diameter for extra high strength strand shall be equal to three times the nominal diameter of the individual wire of the strand. 4.1.5 Joints and splices There will be no joint/splice in any of the wires of the strand in the standard length of 2000 meters. The tenders should explicitly mention in their offers that there will be no joint in any of the wires constituting the ground wire not withstanding the provisions, otherwise, if any, in the IS. 4.1.6 Weight of coating The weight of zinc coating shall be not less than 275 gm/sq.mtr. 4.1.7 Tests of coating The weight of the zinc coating shall be determined by stripping test in accordance with ASTM methods A90, test for weight of coating on zinc coated iron or steel articles.

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4.1.8

Adherence of coating
The zinc coated wire shall be capable of being wrapped at a rate not exceeding 15 turns per minute in close helix of at least two turns round a cylindrical mandrel equal to three times the nominal diameter of the wire under test without cracking of flaking the zinc coating to such an extent that any zinc can be removed by

rubbing with the bare fingers. 4.1.9 Finish


The zinc-coated wire shall be free from imperfections not consistent with good commercial practice. The zinc coating shall be continuous and of reasonably

uniform thickness. 4.3 Tests


All type tests and routine tests as per standard methods shall be carried out by the bidder. The bidder shall however, shall indicate in the tender the tests proposed by him and also quote the same. Three copies of the Type test certificates shall be

submitted with the tender . 4.4 Standards


The Groundwire shall confirm to the provisions of the latest edition of ASTM Designation A 475-72(a) pertaining to Standard Specification for Zinc coated steel wire strand or any other authoritative standard (as amended upto date) except where specified otherwise, in the specification. The materials conforming to any

international standard, which ensure equal or better performance, shall also be acceptable. 4.5 Sag Tension Charts The Contractor shall be required to submit five sets of stringing charts for earthwire, showing initial and final sags and tensions for various temperatures and spans. One set of chart shall be in ink on tracing cloth. 4.6 Guaranteed Technical Particulars The bidder shall fill in the guaranteed technical particulars in the pro-forma as provided in Annexure-6 and submit the same with this tender. 5 TESTS This section details out the tests of the earthwire.

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5.1

The earthwire offered in the tender should have been successfully type tested in line with the standard and technical specification within the last five years from

the date of opening of tender.


5.2 The following type, acceptance and routine tests and tests during manufacture shall

be carried out on the earthwire for the purpose of this clause.


5.2.1 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 these specifications. These tests shall be carried out on samples prior to commencement of commercial production. 5.2.2 Acceptance tests 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. 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. 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. The norms and procedures of sampling for these tests will be as per the Quality Assurance Programme to be mutually agreed to, by the Contractor and Owner or as per relevant IS/International Standard. The standards and norms to which these tests will be carried out are listed against them. Where a particular tests is a specific requirement of this specification, the norms and procedures of these tests shall be as specified in Annexure-7 or as mutually agreed by the Contractor and the Owner in the Quality Assurance Programme. For all type and acceptance tests, the 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 these specifications, whichever is more stringent for that particular test.

5.2.3

5.2.4

5.2.5

5.2.6

5.2.7

5.3 Type Tests The following tests shall be conducted once on sample/samples of earthwire for every 200 kms of production from each manufacturing facility. (a) (b) UTS Tests DC Resistance Test )
)

Owner Specification Annexure-7 Page 158

Jindal India Thermal Power Limited

Volume-II / Section-VI (c) Surface Condition Test )

EPC Tender for JITPL

5.4 Acceptance Tests a) Visual check for joints etc. : : : : : : : : : : Owner Specification Annexure-7 - do - do - do - do - do IS-12776:1989 - do - do *IS-4826-1979

b) c)
d)

Dimensional check on steel strands Check for Lay Length of 6 wire Layer Wrap test on steel strands DC resistance test on steel strands Visual check on drum Breaking load test on steel strands Elongation test on steel strand Test

e) f)
g) h)

i) Torsion j) *Note:

Galvanizing tests on steel strands

Although the tests will be as specified in IS: 4826-1979, no allowance or


relaxation will be given for galvanization tests done on steel wires after stranding

for the purpose of acceptance of any material covered by these specifications. 5.5 Routine Tests (a) (b) (c)
(d)

Check to ensure that there are no joints as per specification. Check that there are no cuts, fins etc. on the strands. Check for correctness of stranding. Check that drums are as per specification.

5.6 Test During Manufacture (a) Chemical analysis of Zinc used for galvanizing )
) )

Owner Specification Page 159

Jindal India Thermal Power Limited

Volume-II (b) Chemical analysis of steel for making steel strands )


)

EPC Tender for JITPL Annexure-7

5.7 Testing Expenses 5.7.2 The Owner may opt for repetition of Type test at his own expenses, prior to manufacture.
In case of failure in any type test the bidder is either required to modify the design

5.7.3

of the material or repeat the particular type test successfully at his own expense. The decision of the Owner in this regard shall be final and binding. 5.7.4 Bidder shall indicate the laboratories in which he proposes to conduct the type tests. He shall ensure that the tests can be completed in these laboratories within the time schedule guaranteed by him in the appropriate schedule. The entire cost of testing for the acceptance and routine tests and tests during manufacture specified herein shall be treated as included in the quoted unit price of conductor, except for the expenses of the inspector/Owners representative.

5.7.5

5.8 Additional Tests The Owner reserves the right of having at his own expenses any other test(s) of reasonable nature carried out at Contractors premises, at site, or any other place in addition to the aforesaid type, acceptance and routine tests to satisfy himself that the materials comply with the specification. 5.9 Sample Batch for Type Testing 5.9.2 The Contractor shall offer at least five (5) drums for selection of samples required for conducting all the type tests. The Contractor is required to carry out all the acceptance tests successfully in the presence of Owners representative before dispatch. TEST REPORTS (DOCUMENTS IN PHYSICAL FORM). At least 3 (three) copies of type test reports should be furnished. One copy of type test reports will be returned duly certified by the Owner, only after receipt of this report, the commercial production of the said material should start. Page 160

5.9.3

6 6.1

Jindal India Thermal Power Limited

Volume-II / Section-VI

EPC Tender for JITPL

6.2

At least 3 (three) copies of acceptance test reports shall be furnished. One copy

will be returned duly certified by the Owner, only after receipt of which, the materials should be dispatched. 6.3 Record of routine test reports should be maintained by the Contractor at his works for periodic inspection by the Companys representatives. INSPECTION

7.2 The Companys representative shall at all times be entitled to have access to the works and all places of manufacture, where earthwire shall be made or prepared and the representatives shall have full facilities for unrestricted inspection of the Contractors works, raw materials, manufacture of the earthwire and for conducting necessary tests detailed herein. 7.3 The Contractor shall keep the Company informed in advance of the time of starting and of the progress of manufacture of earthwire in its various stages so that arrangements can be made for inspection. 7.4 No earthwire shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested, unless the inspection is waived off by the Owner in writing. In the later case also, the earthwire 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 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 materials are later found to be defective. 8 8.1 PACKING The earthwire shall be suitably packed before dispatch in strong, non-returnable wooden drums suitable for ocean/local rail and road transportation, rough handling and stringing and shall conform in all respects to the latest edition of IS 1778-1961 except as otherwise specified herein.

8.1.1 Standard Length The standard length of the galvanized steel earth strand shall be 1800 m 2000 m. A tolerance of + 5% on the standard length shall be permitted. Jindal India Thermal Power Limited Page 161

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EPC Tender for JITPL

8.1.2 8.1.3 9
9.1

Only two lengths of earthwire shall be wound on each drum. Boiled linseed oil should be applied to earthwire to avoid white rust. MARKING
Each drum shall have the following information stenciled on it in indelible ink

alongwith other essential data. (a) (b) (c)


(d)

(e) (f)
(g) (h)

(i) (j)
(k)

(l)

Contract / LOI No. Name and Address of Consignee Manufacturers Name and Address Drum No. & Lot No. Size of Earthwire Length of Earthwire in mtrs. Gross weight of the drum with earthwire. Weight of empty drum with laggings. Arrow marking for unwinding. Position of the earthwire ends. Number of lengths on the reel/or drum. The product may be marked with the standard mark.

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SECTION VII TECHNICAL SPECIFICATIONS FOR PORCELAIN DISC INSULATORS

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SECTION VII CONTENTS Clause Description 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0
12.0

Page No 165 165 166 167 169 169 171 171 171 172 172 172 172 173 173

General Standards Applicable General Requirement Details of Insulators Drawings Specific Technical Requirements Galvanising Ball and Socket Design Dimensional Tolerance Interchangeability Corona and RIV Performance Suitability for Live Line Maintenance Freedom from Defects String Characteristics Test Test Values Test Procedures and Sampling of Norms Additional Tests Identification marks Guaranteed Technical Particulars for Insulators

13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0

178 178 179 179 179

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TECHNICAL SPECIFICATION SECTION VII PORCELAIN DISC INSULATORS 1.0 GENERAL


This section details the technical particulars of porcelain disc insulators for 400

KV Transmission Lines. The Insulators shall conform in all respects to high standards of Engineering, design, workmanship and latest revisions of relevant standards 2.0 2.1 STANDARDS APPLICABLE: Except as modified in this specification, the disc insulators to be supplied shall conform to the latest version, with amendments thereof, of the following Bureau of Indian Standards and equivalent International Standards. Sr. Indian No. Standard 1. IS: 406 Title Method for Chemical Analysis of Slab Zinc Specification for Zinc Porcelain insulators for overhead power lines with a nominal voltage greater than 1000V Method of High Voltage Testing BS:3436 BS:137(I&II) IEC:274 IEC:383 International Standard

2. IS: 209 3. IS:731

4. IS:2071 Part(I to III) 5. IS:2486

Specification for Insulator fittings for overhead power lines with a nominal
voltage greater than 1000V

Part I Part II Part III Part IV

General Requirements and Tests Dimensional Requirements Locking Devices Tests for Locking Devices

BS:3288 IEC:120 IEC:372 IEC:372

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Volume-II / Section-VII 6. IS:2629 Recommended practice for Hot Dip Galvanization for iron and steel Testing for Uniformity of Coating of Zinc coated articles Dimensions for Disc Insulators Determination of Weight of Zinc coating on Zinc coated iron and steel articles Methods of RIV Test of HV Insulators

EPC Tender for JITPL

7. IS:2633

8. IS:3188 9. IS:6745

IEC:305

10. IS:8263

IEC:437, NEMA Publication No. 107/1964 CISPR IEC:506 IEC: 575

11. IS:8269 12.

Methods for Switching impulse test on HV insulators Thermal Mechanical performance test and mechanical performance test on string insulator units

2.2

Insulators conforming to any other International standards are also acceptable


provided always that such standards are equivalent to or better than the corresponding standards specified in 2.1 above. However, in such an event the salient points of comparison between the standards adopted and the standards quoted herein shall be detailed in the offer. One copy of authentic English version

of such standards shall be submitted (in physical form) alongwith the offer. 3.0 a) GENERAL REQUIREMENTS: All raw materials to be used in the manufacture of insulators shall be subject to strict raw material quality control and to stage testing/quality control during manufacturing stage to ensure the quality of the final end product. Manufacturing shall conform to the best engineering practices adopted in the field of extra high voltage transmission. Bidders shall therefore offer insulators as are guaranteed by them for satisfactory performance on transmission Lines.

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b)

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, elimination of sharp edges and corners to limit corona and

radio interference voltages.


c) The design of the insulator shells shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. Shells with

cracks shall be eliminated by temperature cycle test followed by mallet test. Shells shall be dried under controlled conditions of humidity and temperature. d) The cap and pin 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 and of such design that it will not yield or distort under loaded conditions. The head portion of the pinball shall be suitably designed so that when the insulator is under tension the stresses are uniformly distributed over the pinhole portion of the shell. The pinball shall move freely in the cap socket either during assembly of a string or during erection of a string or when a string is placed in position. permitted by Indian/International standards. The insulator design shall be such that when units are coupled together to form a string, there shall be no contact between the shell of one unit and metal of the adjacent unit. Metal caps shall be free from cracks, seams, shrinks, air holes, blowholes and rough edges. All metal surfaces shall be perfectly smooth with no projecting parts or irregularities, which may cause corona. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly. Pins shall not show any microscopically visible cracks, inclusions and voids. Cap, Pin shall not be manufactured by joining, welding, shrink fitting or by any other process from more than one piece of metal. The insulator design shall be such that the insulating medium shall not directly engage with hard metal. The surface of porcelain shall be coated with resilient paint to offset the effect of difference in thermal expansion of these materials. DETAILS OF DISC INSULATORS: The insulator strings shall consist of standard discs for a three phase 50 Hz, effectively earthed 400 KV transmission system in a moderately polluted atmosphere. The discs shall be cap and pin, ball and socket type.

e) Insulator units after assembly shall be concentric and coaxial within limits as

f)

g)

h) i)

4.0 a)

b) The size of disc insulator, minimum creepage distance, the number to be used in different type of strings, their electromechanical strength; and mechanical strength of insulator string alongwith hardware fitting shall be as follows:

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EPC Tender for JITPL

Type of string

Size of disc insulator unit (mm)

Minimum No. of creepage standard distance disc in of each String (No) disc (mm)

Mechanical strength of of insulator string with H/W fitting(KN)

400 KV Single Suspension I string


Double Susp-

(AF) 280x145

430

23

120

(AF) 280x145

430

2x23

2x120

ension I string Quad Tension string (AF) 305x170 475 4x24 4x160

Type of string (400 KV)

Type Of insulator (AF) (AF) (AF)

Length of disc insulator string (mm) 3335 9890 3335 9890 4075 11400

Minimum creepage distance of disc insulator string (mm)

Single suspension I

string Double suspension I string Quad tension string

c) The electro-mechanical strength of individual disc unit in strings mentioned above is as follows:

Sr. No . A) 1)

Type of String

Electro-Mechanical strength of individual disc insulator

400 KV Single/Double Suspension I string 120 KN 2) Quad Tension string 160 KN

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5.0 5.1

DRAWINGS: The bidder shall furnish outline drawings of disc insulator unit indicating all dimensions for scrutiny and approval. All drawings shall be neatly arranged, and all drafting and lettering shall be standard and legible. Dimensions shall be in SI units. The drawings shall give following information: The bill of material indicating quantity and nature of material used for various parts. Details like Ball and Socket designation, Maximum Axial & Radial Runout, Minimum & Protected Creepage distance, Colour of Glaze, Electro-mechanical strength, Identification mark and weight of insulator. Electrical characteristics like One minute power frequency withstand and flashover voltage under dry and wet conditions, Lightening impulse withstand and flashover voltage, Switching surge impulse withstand voltage, Visible discharge and Radio Interference Voltage. SPECIFIC TECHNICAL REQUIREMENTS: NON-METALLIC PARTS PORCELAIN The porcelain used in the manufacture of the shells shall be ivory white,
nonporous, of high dielectric, mechanical and thermal strength, free from internal stresses, blisters, laminations, voids, foreign matter, imperfections or other defects which might render it in any way unsuitable for insulator shells. Porcelain shall remain unaffected by climatic conditions, ozone, acid, alkalis, zinc or dust. The manufacturing shall be by the wet process and impervious character obtained by

1)

2)

3)

6.0 I) a)

thorough vitrification. b) PORCELAIN GLAZE


Surfaces to come in contact with cement shall be made rough by sand glazing. All

other exposed surfaces shall be glazed with ceramic materials having the same temperature coefficient of expansion as that of the insulator shell. The thickness of glaze shall be uniform throughout and the colour of glaze shall be brown. The glaze shall have a visible luster, shall be smooth on surface and be capable of satisfactory performance under extreme tropical climatic weather conditions and prevent ageing of the porcelain. The glaze shall remain under compression on the porcelain body throughout the working temperature range.

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Volume-II / Section-VII c) FILLER MATERIAL

EPC Tender for JITPL

Cement to be used, as a filler material shall be quick setting, fast curing portland cement. It shall not cause fracture by expansion or loosening by contraction. Cement shall not react chemically with metal parts in contact with it and its thickness shall be as small and as uniform as possible. II) a) METALLIC PARTS BALL PINS These shall be made of forged steel of grade EN-8D (BS:970)/CL-IV(IS:2004) or equivalent, by drop forging method and normalized. They shall not be manufactured by joining, welding, and shrink fitting or by any other process from more than one piece of metal. The ball pins shall be free from forging defects. The bidder shall specify the grade, composition and mechanical properties of steel used in manufacture of ball pin, in Quality Assurance Plan. b) METAL CAP The caps shall be cast from black heart malleable cast iron of grade BM 320 (IS: 14329) or equivalent and annealed. The caps shall be made in single piece and shall be free from casting defects like misrun, cold shut etc. The bidder shall specify the grade, composition and mechanical properties of steel used in manufacture of caps, in Quality Assurance Plan. c) i) SECURITY CLIPS These shall be made of Stainless Steel grade AISI 304/316 (ASTM A276) or Phosphor Bronze.

ii) The security clips to be used as locking device for ball and socket coupling shall be 'R' shaped hump type to provide for positive locking of the coupling as per IS:2486 (Part IV). The legs of the security clips shall allow for spreading after installation to prevent complete withdrawal from the socket. The locking device shall be resilient, corrosion resistant and of sufficient mechanical strength. There shall be no possibility of the locking device to be displaced or be capable of rotation when placed in position and under no circumstances shall it allow separation of insulator units. iii) The hole for the security clip shall be countersunk and the clip shall be of such design that the eye of the clip may be engaged by a hot line clip puller to provide for disengagement under energized conditions.

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iv)

The force required for pulling the R-clip into its unlocked position shall not be

less than 50 N (5 Kgs) or more than 500 N (50 Kgs). 7.0 a) GALVANISING: All ferrous parts shall be hot dip galvanized in accordance with IS: 2629 and IS:
2633. Before galvanization, the steel section shall be thoroughly cleaned of any paint, grease, rust, scale, acid/alkali or such other foreign matters as are likely to

interfere with the galvanizing process or with the quality and durability of the zinc coating. Pickling shall be very carefully done and shall be proper. b) Before ball fittings are galvanized, all die flashing on the shank and on bearing surface of the ball shall be carefully removed without reducing the designed dimensional requirements. The zinc used for galvanizing shall be of grade Zn 98 (% of zinc 99.95%) as per IS: 209. The mass of zinc coating shall not be less than 610 gm/m2(86 microns). The galvanized surface shall consist of continuous and uniformly thick coating of zinc, firmly adhering to the surface of steel. The finished surface shall be clean and smooth and shall be free from defects like discolored patches, bare spots, unevenness of coating, spelter which is loosely attached to the steel, globules, spiky deposits, blistered surface, flaking or peeling off etc. The presence of any of these defects noticed on visual or microscopic inspection shall render the material liable to rejection. There shall be no flaking or loosening when struck squarely with a chisel faced hammer. The galvanized components shall withstand minimum four one minute dips in standard copper sulphate solution as per IS: 2633. Defect in any component indicating presence of impurities in the galvanizing bath in quantities larger than that permitted by the specifications, or lack of quality control in any manner in the galvanizing plant, shall render the entire production in the relevant shift liable to rejection. BALL AND SOCKET DESIGNATION: The dimensions of ball and socket for 120 KN and 160 KN discs shall be 20 mm in accordance with the standard dimensions stated in IS: 2486 (Part II)/IEC: 120. 9 .0 DIMENSIONAL TOLERANCE: The dimensions of the disc insulators shall be within the limits specified below:

c)

d)

e)

f)

8.0

Jindal India Thermal Power Limited

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Standard Diameter of Disc (in mm) 120 KN (AF)


160 KN (AF)

Maximum

Minimum

280 305

293 318

267 292 Minimum

Standard Maximum Ball to Ball Spacing between Discs (in mm) 120 KN (N, AF) 160 KN (N, AF) 145 170 149 175

141 165

10.0

INTERCHANGEABILITY: The insulators inclusive of ball and socket fittings shall be of standard design
suitable for use with hardware fittings of any make conforming to relevant Indian

Standards. 11.0 CORONA AND RIV PERFORMANCE:


All surfaces shall be even, smooth, without cuts, abrasions or projections. No part shall be subjected to excessive localized pressure. The metal parts and porcelain shall not produce any noise-generating corona under all operating conditions. The insulators and metal parts shall be so designed and manufactured that it shall avoid local corona formation and not generate any radio interference beyond

specified limit under operating conditions. 12.0


a)

SUITABILITY FOR LIVE LINE MAINTENANCE:


The insulators shall be compatible for use with hot line or live line maintenance

techniques so that usual hot line operations can be carried out with ease, speed and safety. b) All insulators shall be designed to facilitate cleaning and insulators shall have minimum practical number of sheds and grooves. All grooves shall be so proportioned that any dust deposit can be removed without difficulty either by wiping with cloth or by remote washing under live line condition. FREEDOM FROM DEFECTS: Insulators shall have none of the following defects: a) Ball pin shake b) Cementing defects near the pin like small blowholes, hair cracks, lumps, etc. Jindal India Thermal Power Limited Page 172

13.0

Volume-II / Section-VII c) 14.0 Sandfall defects on the surface of the insulator. STRING CHARACTERISTICS: The characteristic of the complete string shall be as follows:
Sr.
No

EPC Tender for JITPL

STRING TYPE 400 KV Suspension string 1050 1050 400 KV Tension String

PARTICULARS

1 Switching Surge Withstand Voltage (Dry & Wet) (KVp) 2 Dry Lightning Impulse Withstand Voltage (KVp) 3 4 50% Lightning Impulse flashover voltage (KVp) Dry Power frequency withstand voltage (KV rms) Wet Power frequency withstand voltage (KV rms) Corona extinction Voltage (KV rms) Maximum RIV for complete string Including corona Rings, arcing horns, clamps etc. at 1.1 times max. Line to Ground Voltage (V) Maximum voltage across any disc

1600 1700 1650 1770 740 740

690 690

6 7

320 320 500 500 500 500

9% 10%

15.0

TEST The Contractor shall offer the disc Insulator that are already type tested within the
last five years and manufactured by reputed manufacturer approved by PGCIL/PGCIL. In case the insulators are not type tested within 5 (five) years as on the date of opening of bids, fresh type test as per relevant IS shall be carried

out in presence of Owners representative before supply of materials


Jindal India Thermal Power Limited Page 173

Volume-II / Section-VII

EPC Tender for JITPL

15.1

TYPE TESTS: The list of type tests to be conducted is as follows:

I)

On Disc Insulator Unit:

Sr. No. a) b)

Particulars of test

Reference Standard }IS:731 } IS:731

Visual examination Verification of dimensions test

Sr. No. c)

Particulars of test

Reference Standard } } } } } }
}

Thermal-Mechanical performance test

IEC:575 and Annexure-8 of this specification IEC:60383 IEC:60383

d)

Power frequency voltage flashover test i) Dry ii) Wet Lightning Impulse voltage withstand test (Dry) 50% Lightning Impulse voltage flashover test (Dry) Visible Discharge test (Dry) Radio Interference Voltage test (Dry) Residual strength test (On 120KN &160KN disc insulator) Steep wave front test (On 120KN &160KN disc insulator)

e)

}
}

f)

IEC:60383

} }
} } }

g) h)

IS:731 IEC:60437 & Annex.-8 of this specification As per Annex.-8 of this specification As per Annexure 8 of this specification

i)

} } } }

j)

Jindal India Thermal Power Limited

Page 174

Volume-II / Section-VII II) On complete insulator string with hardware fittings: a)

EPC Tender for JITPL

The type tests on 400 KV strings specified hereunder, shall be conducted on Double I Suspension (2x120 KN) and Quad tension (2x2x160 KN) insulator strings alongwith hardware fittings.

On 400KV String of 120KN & 160KN insulators I) a) On 1st sample Power frequency voltage withstand test with corona control/grading rings and arcing horn i) Dry ii) Wet Switching Surge voltage withstand test (Wet) Lightning Impulse voltage withstand test (Dry) 50% Lightning Impulse voltage flashover test (Dry) Voltage distribution test (For Disc Insulator only) Corona and RIV test under dry condition Mechanical strength test i) Double I suspension string ii) Quad Tension string On 2nd sample Dynamic test (Vibration test) } } As per Annexure8 of this specification

} } } } } } } }
}

IEC:60383 and Annexure-8 of this specification IEC:60383 and Annexure-8of this specification IEC:60383 and Annexure-8 of this specification IEC:60383 and Annexure-8 of this specification IEC:383 and Annexure-8 of this specification As per Annexure-8 of this specification As per Annexure-8 of this specification

b)

c)

}
}

d)

} } } } } } } } } }
}

e)

f)

g)

II) h)

III) i)

On 3rd sample Time Load test } As per Annexure8 Page 175

Jindal India Thermal Power Limited

Volume-II / Section-VII }

EPC Tender for JITPL of this specification

15.2

ACCEPTANCE TESTS: This shall mean those tests, which are to be carried out on samples taken from
each lot offered for predespatch inspection for the purpose of acceptance of the

lot. 15.2.1 LIST OF ACCEPTANCE TESTS:


The following acceptance tests shall be conducted on 120KN and 160KN disc

insulators in presence of Owners representative for the purpose of acceptance of a lot: Sr. No. a) b) c)
d)

Particulars of test Visual examination Verification of dimensions Temperature cycle test Galvanising test Mechanical performance test Test on locking device for ball and socket coupling Electro-mechanical Puncture test Porosity test Power frequency voltage withstand test (Dry) strength test }
} }

Reference Standard IS:731 IS:731 IS:731 IS:731 IEC:60575 IS:2486(IV)

} }
}

e) f)

} } } } } } IS:731 IS:731 IS:731 IEC:60383

g) h) i) j)

. 15.3 ROUTINE TESTS:

Jindal India Thermal Power Limited

Page 176

Volume-II / Section-VII

EPC Tender for JITPL

This shall mean those tests, which are to be carried out on each insulator to

check the requirements which are likely to vary during production. 15.3.1 LIST OF ROUTINE TESTS:
The following routine tests shall be conducted on each insulator and results

certified by the manufacturer: Sr. No. a) b) c) Particulars of test Reference Standard } } } IS:731 IS:731 IEC:60383

Visual Inspection Mechanical routine test Electrical routine test

15.4

TESTS DURING MANUFACTURING: Stage tests during manufacturing shall mean those tests, which are to be carried out during the process of manufacturing to ensure quality control such that the end product is of the designed quality conforming to the intent of this specification.

15.4.1 LIST OF TESTS DURING MANUFACTURING: The following tests, including but not limited to, shall be conducted on raw and in process material during the process of manufacturing: Sr. No. a) Particulars of test Fineness, Raw appearance, Fired appearance, Free Magnetic Iron content, Grain size, Chemical Analysis, Free Moisture Content on
raw materials like Quartz Powder, Feldspar Powder, China Clay, Ball } } }

Reference Standard }
}

} }

Relevant Indian /International/ Plant standard

Clay etc. b) Raw appearance, Fired appearance, Chemical Analysis of Glaze material Visual inspection, Grain size, Compressive Strength, Optimum water content, Initial and final setting

} } } }
}

Relevant Indian /International/ Plant standard Relevant Indian /International/ Page 177

c)

Jindal India Thermal Power Limited

Volume-II / Section-VII time, Auto Clave Expansion of Cement d) Hydraulic Pressure Proof load test, High Frequency test on Porcelain Shell } } } } } } } } } } } } } } } } } } } }

EPC Tender for JITPL Plant standard Relevant Indian /International/ Plant standard As per Annexure-8 of this specification

e)

Visual inspection, Dimension/Guage Checking, Chemical Analysis, Tensile Strength, Hardness, Grain size, Inclusion rating, Heat treatment, Magnetic Particle Inspection on ball pins Visual inspection, Dimension/ Guage Checking, Chemical Analysis, Tensile Strength, Hardness, Microstructure, Magnetic Particle Inspection on MCI caps Visual inspection, Dimensional verification, Resistance to Bending, Operation test, Hardness test on Security Clip Chemical analysis of Zinc used for galvanizing

f)

As per Annexure-8 of this specification

g)

As per Annexure-8 of this specification As per Annexure-8 of this specification

h)

16.0

TEST VALUES: For all type and acceptance tests, the acceptance values shall be the values guaranteed by the Bidder in the guaranteed technical particulars or the acceptance value specified in this specification or the relevant standard whichever is more stringent for that particular test.

17.0

TEST PROCEDURE AND SAMPLING NORMS:

a) The test procedure and sampling norms for carrying out type tests; acceptance tests and routine tests shall be as per reference standards specified under clause No. 15.0 of this specification. b) The test procedure and sampling norms for carrying out tests during manufacturing shall be as per relevant Indian/ International Standard where applicable and plant standard for others. The sampling norm for conducting tests on bought out items shall be as outlined in Annexure-8 of this specification.

Jindal India Thermal Power Limited

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EPC Tender for JITPL

c) The bidder shall furnish details regarding sampling norm and reference standard

followed, in Quality Assurance Plan. 18.0 ADDITIONAL TESTS:


The Owner reserves the right for carrying out any other test(s) of a reasonable nature at the works of the Contractor or at any other recognized laboratory/research institute in addition to the above mentioned type, acceptance and routine tests at the cost of the Owner to satisfy himself that the material

complies with the intent of this specification. 19.0


a)

IDENTIFICATION MARK:
The porcelain shell of each disc insulator shall be legibly and indelibly marked with the trade mark/name of the manufacturer, the month and year of manufacture, country of manufacture, guaranteed electro-mechanical strength in

kilo-newtons abbreviated by 'KN' to facilitate easy identification and proper use. The marking shall be printed and not impressed and the same shall be applied before firing. b) The metal cap of each disc insulator shall bear the name of manufacturer by embossing. The identifying letters shall be at least 5 mm high. The characters shall be distinct, durable, and conspicuous after galvanizing.

20.0 Guaranteed Technical Particulars for Insulators The Guaranteed Technical Particulars for Insulators enclosed as Annexure-9 shall be duly filled in and submitted along with the offer.

Jindal India Thermal Power Limited

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EPC Tender for JITPL

SECTION VIII TECHNICAL SPECIFICATIONS FOR HARDWARE FITTINGS AND ACCESSORIES FOR CONDUCTOR AND EARTHWIRE

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SECTION VIII CONTENTS Clause 1.0 2.0 3.0 4.0 Description Technical Description of Hardware Fittings Accessories for ACSR MOOSE Conductor G.S. Earthwire Accessories Tests and Standards Page No 182 194 202 206

Jindal India Thermal Power Limited

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EPC Tender for JITPL

TECHNICAL SPECIFICATIONS SECTION VIII HARDWARE FITTINGS AND ACCESSORIES FOR TWIN ACSR MOOSE CONDUCTOR & 7/3.66MM EARTHWIRE FOR 400KV LINES 1.0 1.1. Technical Description of Hardware Fittings Details of Hardware Fittings The hardware fittings shall be suitable for use with Disc Insulators or porcelain long rod insu1ators having ball and socket fittings. 1.1.1. The hardware fittings shall be as per the specification drawings enclosed with the specification. Hardware fittings shall be supplied suitable for attaching to hanged/strain plate fixed to tower. Each hardware fittings shall be supplied complete in all respects and shall include the following hardware parts. Suitable arcing horn as specified in clause 1.8 hereinafter. Suitable yoke plates for suspension and tension hardware fittings for the quad bundle arrangement complying with the specifications given hereinafter. Corona contro1 rings/grading ring with fittings for attachment to line side yoke p1ate. Sag adjustment plate for double tension hardware fittings and turn buckle for single suspension pilot hardware fittings. Suspension and dead end assembly to suit conductor size as detailed in clause 1.13, 1.14 and 1.15 hereinafter. Provisions for attaching balancing weights on the line side yoke plate of single suspension pilot hardware fittings. Other necessary fittings viz D-shackles, eye links, extension links, ball clevis, socket clevis, clevis eye, U clevis and chain link etc. to make the hardware fittings compete. 2.5% extra fasteners and aluminium filler plugs. Dimensions of Insulator String along with Hardware Fittings The various limiting dimensions of the insulator strings alongwith hardware fittings shall be as per the specification drawings enclosed with the specification. For every set of quad tension/sing1e tension hardware fitting for quad bundle conductor, one number of 250 mm rigid spacer suitable for twin ACSR MOOSE conductor shall be provided to ensure that there is no fouling of conductors or any component of the fittings while bringing

1.1.2. 1.1.3.

1.1.4. 1.1.5. 1.1.6. 1.1.7. 1.1.8.

1.1.9.

1.2.

Jindal India Thermal Power Limited

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down two top conductors through bottom two conductors of quad bundle

1.3. 1.3.1.

at the jumper connection. Interchangeability The hardware for insulator strings with disc insulators or porcelain long rod insulators together with ball and socket fittings shall be of standard design, so that these hardware are interchangeable with each other and suitable for use with disc insulators of porcelain long rod insulators of any make conforming to relevant Indian/International Standard. Corona and RI Performance Sharp edges and scratches on all lie hardware fittings shall be avoided. All surfaces must be clean, smooth, without cuts and abrasions or projections. The Contractor shall be responsible about the satisfactory corona and radio interference performance of the materials offered by him. Maintenance The hardware fittings offered shall be suitable for employment of hot line maintenance technique so that usual hot line operations can be carried out with ease, speed and safety. The technique adopted for hot line maintenance shall be generally bare hand method & hot stick method. The Bidder should clearly establish in the bid, the suitability of his fittings for hot line maintenance. The line side yoke plate shall have a notch & a working hole of suitable size. The design of corona control rings/grading ring shall be such that it can be easily replaced by employing hot line maintenance technique. Designation Ball and Socket Designation The dimensions of the ball and socket shall be of 20 mm wherever 120 KN and 160 KN insulators are used. The designation should be in accordance with the standard dimensions stated in IS: 2486 (Part-II)/ IEC: 120. The dimensions shall be checked by the appropriate gauge after galvanising only. Security Clips and Split Pins 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)/ IEC: 372. 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.

1.4.

1.5.
1.5.1.

1.5.2.

1.6.
1.6.1.

1.7.
1.7.1.

Jindal India Thermal Power Limited

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Volume-II / Section-VIII 1.7.2.

EPC Tender for JITPL

The hole for the security clip shall be countersunk and the clip should be of such design that the eye of clip may be engaged by a hot line clip puller to provide for disengagement under energised conditions. The force required to pull the security clip into its unlocked position shall not be less than 50 N (5 kg) or more than 500 N (50kg). Split pins shall be used with bolts & nuts Arcing Horn The arcing horn shall be either ball ended rod type or tubular type. For insulator strings with disc insulators the arcing horn shall be provided as shown on the drawing of the hardware fittings, in this specification. The air gap shall be so adjusted to ensure effective operation under actual field conditions. The arcing distance between arcing horn and corona control rings/grading ring shall be 3050 mm under nominal dimensions of insulator for insulator strings with disc insulators/long rod insulators. Yoke Plates 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 take into account the most unfavourable 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 corona control rings/grading ring/arcing horn. All the corners and edges should be rounded off with a radius of atleast 3 mm. Design calculations i.e. for bearing & tensile strength, for deciding the dimensions of yoke plate shall be furnished by the bidder. The holes provided for bolts in the yoke plate should satisfy shear edge condition as per IS-800. Corona Control Rings/Grading Ring The Corona control rings/grading ring shall be provided with hardware fittings and shall be of such design that it should cover atleast one disc insulator in disc insulator strings so that they will reduce the voltage across the insulator units. It shall also improve corona and radio interference performance of the complete insulator string alongwith hardware fittings. The corona control rings/grading ring shall be made of high strength heat treated aluminium alloy tube of minimum 2.5 mm wall thickness. If mild steel brackets are used then the brackets shall not be welded to the pipe but shall be fixed by means of bolts and nuts on a small aluminium plate attachment welded to the pipe. The welded centre of the corona control ring/grading ring shall be grinded before buffing. Alternately, Aluminum Page 184

1.7.3.

1.8.
1.8.1. 1.8.2. 1.8.3.

1.9.

1.10. 1.10.1.

1.10.2.

Jindal India Thermal Power Limited

Volume-II / Section-VIII

EPC Tender for JITPL

tube/flats of suitable dimensions welded to the corona control

rings/grading rings may be used for connection to yoke plate. 1.10.3. The Corona control rings/grading ring should have a brushed satin finish and not a blight glossy surface. No blemish should be seen or felt when rubbing a hand over the metal. The limiting dimensions of corona control ring shall be as per the specification drawings. Bidder may quote for grading ring with armour grip suspension assembly. The grading ring shall be of open type design with a gap of 125 mm. The open ends shall be suitably terminated. The outside diameter of the tube shall be 60mm. The ends of grading ring tube shall be sealed with welded aluminium cap duly buffed. Sag Adjustment Plate The sag adjustment plate to be provided with the double tension hardware fitting shall be of three plate type. The sag adjustment plate shall be provided with a safety locking arrangement. The device shall be of such, design that the adjustment is done with ease, speed and safety. The maximum length of the sag adjustment plate from the connecting part of the rest of the hardware fittings shall be 435 mm. The details of the minimum and maximum adjustment possible and the steps of adjustment shall be clearly indicated in the drawing. An adjustment of 150 mm minimum at the interval of 6 mm shall be possible with the sag adjustment plate. Design calculations for deciding the dimensions of sag adjustment plate shall be furnished by bidder. The hole provided for bolts should satisfy shear edge condition as per IS-800. Turn Buckle The turn buckle is to be provided with single tension hardware fitting. The threads shall be of sufficient strength to remain unaffected under the specified tensile load. The maximum length of the turn buckle from the connecting part of the rest of the hardware fittings shall be 520 mm. The details of the minimum and maximum adjustment possible shall be clearly indicated in the drawing. An adjustment of 150 mm minimum shall be possible with turn buckle. Suspension Assembly The suspension assembly shall be suitable for ACSR MOOSE Conductor. The suspension assembly pilot insulator string shall include suitable Envelope type suspension c1amps. Page 185

1.10.4. 1.10.5.

1.11.
1.11.1.

1.11.2.

1.11.3.

1.12.
1.12.1.

1.12.2.

1.13.
1.13.1. 1.13.2.

Jindal India Thermal Power Limited

Volume-II / Section-VIII 1.13.3.

EPC Tender for JITPL

The suspension clamp 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. The suspension damp shall have a slip strength between 20 to 29 KN. 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 excrescence which might damage the conductor. The suspension assembly/clamp shall be designed so that it shall minimise the static & dynamic stress developed in the conductor under various loading conditions as well as during wind induced conductor vibrations. It shall also withstand power arcs & have required level of Corona/RIV performance. There shall be a differential price loading for comparison of bids, of Rs.67.50 per suspension assembly for each watt of magnetic power loss at a sub-conductor current of 600 amps. The lowest losses quoted by any Bidder shall be used to arrive at the differential price loading to be applied for that bid. However, bids offering suspension assemblies with magnetic power loss more than 4 watts except for envelope type clamps for which magnetic power loss more than 8 watts at sub conductor current of 600 amps. shall be liable to be rejected. The Bidders are requested to enclose test certificates for magnetic power loss test alongwith the bid. In case, the magnetic power loss of the suspension assembly obtained during type testing of the same exceeds the value guaranteed by the Bidder in his bid, the material shall be rejected outright or the same shall be accepted after suitable liquidated damages for non-performance are assessed, which shall be recovered from the contract price. The liquidated damages thus assessed shall not be less than twice the differential price loading indicated in Clause 1.13.7, i.e. Rs.135 per watt/suspension assembly. Free Centre Type Suspension Clamp For the Free Centre Suspension Clamp seat 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. Standard Preformed Armour Rod Set The Preformed Armour Rods Set suitable for ACSR MOOSE Conductor shall be used to minimize the stress developed in the sub-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 Page 186

1.13.4. 1.13.5.

1.13.6.

1.13.7.

1.13.8.

1.13.9.

1.13.10. 1.13.10.1.

Jindal India Thermal Power Limited

Volume-II / Section-VIII

EPC Tender for JITPL

also withstand power arcs, chafing and abrasion from suspension clamp and localised heating effect due to magnetic power losses from suspension

clamps as well as resistance losses of the conductor. 1.13.10.2. 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 to have gentle but permanent grip on the conductor. The surface of the armour rod when fitted on the conductor shall be smooth and free from projections, cuts and abrasions etc. The pitch length of the rods shall be determined by the Bidder but shall be less than that of the outer layer of conductor and the same shall be accurately controlled to maintain uniformity and consistently reproducible characteristic wholly independent of the skill of linemen. The length each rod shall be 2540 25mm and diameter shall be 927 0.10 mm. The tolerance in length of the rods in complete set should be within 13mm between the longest and shortest rod. The ends of armour rod shall be parrot billed. The number of armour rods in each set shall be twelve. Each rod shall be marked in the middle with paint for easy identification. The armour rod shall not loose their resilience even after five applications. The conductivity of each rod of the set shall not be less than 40% of the conductivity of the International Annealed Copper Standard (IACS) Armour Grip Suspension Clamp. The armour grip suspension clamp shall comprise of retaining strap, support housing, elastomer inserts with aluminium reinforcements and AGS preformed rod set. Elastomer insert shall be resistant to the effects of temperature up to 85C, Ozone, ultraviolet radiations and other atmospheric contaminants likely to be encountered in service. The physical properties of the elastomer shall be of approved standard. It shall be electrically shielded by a cage of AGS preformed rod set. The elastomer insert shall be so designed that the curvature of the AGS rod shall follow the contour of the neoprene insert. The AGS preformed rod set shall be as detailed in clause 1.13.10.1 to 1.13.10.7 in general except for the following. The length of the AGS preformed rods shall be such that it shall ensure sufficient slipping strength as detailed under clause 1.13.4 and shall not introduce unfavourable stress on the conductor under all operating conditions. However the length of AGS preformed rods shall not be less than 2235 25 mm.

1.13.10.3.

1.13.10.4.

1.13.10.5. 1.13.10.6. 1.13.10.7.

1.13.11.
1.13.11.1.

1.13.11.2.

1.13.11.3. 1.13.11.4.

Jindal India Thermal Power Limited

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EPC Tender for JITPL

1.14. 1.14.1.

Envelope type Suspension Clamp The scat of the envelope type suspension clamp shall be smoothly rounded & suitably curved at the ends. The edges shall have rounded bead. There shall be atleast two U-bolts for tightening of clamp body and keeper pieces together. Hexagonal bolts and nuts with, split-pins shall be used for attachment of the clamp. Dead end Assembly The dead end assembly shall be suitable for ACSR Moose Conductor. 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 300 with respect to the vertical line. The area of bearing surface on all the connections shall be sufficient to ensure positive electrical and mechanical contact and avoid local heating due to I2R losses. The resistance of the clamp when compressed on Conductor shall not be more than 75% of the resistance of equivalent length of Conductor. 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 compressions 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 fillet 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 and steel dead end; allow for dead end assembly for ACSR MOOSE shall be as per the table given below: Dimensions before Compression Inner dia (mm) Outer dia (mm) i) Aluminium Sleeve 340.5 541 ii) Steel Sleeve 11.10.2 210.5 Sl. Item No. Dimensions after compression Corner to Face to face corner (mm) width (mm) 5305 460.5 20.20.5 17.50.5

1.15.
1.15.1. 1.15.2.

1.15.3.

1.15.4.

The assembly shall not permit slipping of, damage to, or failure of the complete conductor or any part there of at a load less than 95% of the ultimate tensile strength of the conductor.

Jindal India Thermal Power Limited

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1.16.

Balancing Weights For holding the single suspension pilot insulator string used for jumper connections at the transposition towers from excessive deflection, suitable balancing weights, weighting 200 kg are to be suspended through the line side yoke plate. It shall consist of four weights, each weighting 50 Kg and shall be connected to yoke plate by means of bolts/eye bolts and shackle arrangement. The bottom weight shall be provided with recess to shield the ends of eye bolts. The same shall be suitable for use on 400 KV transmission lines.

1.17.

Fasteners: Bolts, Nuts and Washers All bolts and nuts shall conform to IS:6639. All bolts and nuts shall be galvanised as per IS 1367 (Part 13)/IS:2629. All bolts and nuts shall have hexagonal heads and nuts, the heads being forged out of solid truly concentric and square with the shank, which must be perfectly straight. 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 minimum as per IS: 12427. Bolts should be provided with washer face in accordance with IS: 1363, Part-I to ensure proper bearing. Nuts should be double chambered as per the requirement of IS: 1363, PartIII. It should be ensured by the manufacturer that nuts should not be overtapped beyond 0.4mm oversize on effective diameter for size upto M16. Fully threaded bolts shall no 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. 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 8 mm when fully tightened. All nuts shall fit and tight to the point where shank of the bolt connects to the head. Flat washers and spring washers shall be provided wherever necessary and shall be of positive lock type. Spring washers shall be electro-galvanised. The thickness of washers shall conform to IS:2016. The Bidder shall furnish bolt schedules giving thickness of components connected, the nut and the washer and the length of shank and the threaded portion of bolts and size of holes and any other special details of this nature. To obviate bending stress in bolt, it shall not connect aggregate thickness more than three time its diameter. Page 189

1.17.1.

1.17.2.

1.17.3.

1.17.4.

1.17.5.

1.17.6.

1.17.7.

1.17.8.

Jindal India Thermal Power Limited

Volume-II / Section-VIII 1.17.9. 1.17.10.

EPC Tender for JITPL

Bolts at the joints shall be so staggered that nuts may be tightened with spanners without fouling. 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., inhouse. The manufacturer should also have proper Quality Assurance system which should be in line with the requirement of this specification and IS: 14000 services Quality System Standard. Fasteners of grade higher than 8.8 are not to be used and minimum grade to bolts shall be 5.6. Materials The material of the various components shall be specified hereunder. The Bidder shall indicate the material proposed to be used for each and every component of hardware fittings stating clearly the class, grade or alloy designation of the material, manufacturing process & heat treatment details and the reference standards. The details of materials for different component are listed as in Table NoI Workmanship All the equipment shall be of the latest design and conform to the best modern practices adopted in the Extra High Voltage field. The Bidder shall offer only such equipment as guaranteed by him to be satisfactory and suitable for 400 kV transmission lines and will give continued good performance. The design, manufacturing process and quality control of all the materials shall be such as to give the specified mechanical rating; highest mobility, elimination of sharp edges and corners to limit corona and radiointerference, best resistance to corrosion and a good finish. All ferrous parts including fasteners shall be hot dip galvanized, after all machining has been completed. Nuts may, however, be tapped, (threaded) alter galvanising and the threads oiled. Spring washers shall be electro galvanised. The bolt threads shall be undercut to take care of the increase in diameter due to galvanising; Galvanising shall be done in accordance with IS:2629/IS:1367 (Part 13) and shall satisfy the tests mentioned in IS:2633. Fasteners shall withstand four dips while spring washers shall withstand three dips of one minute duration in the standard Preece test. Other galvanised materials shall have a minimum average coating of zinc equivalent to 600 gm/sq.m., shall be guaranteed to withstand at least six successive dips each lasting one (1) minute under the standard preece test for galvanising.

1.17.11. 1.17.12.

1.17.13.

1.18. 1.18.1.

1.18.2.

1.18.3.

Jindal India Thermal Power Limited

Page 190

Volume-II / Section - VIII 1.18.4.

EPC Tender for JITPL

Before ball fittings are galvanised, all die flashing on the shank and on the bearing surface of the ball shall be carefully removed without reducing the dimensions below the design requirements. The zinc coating shall be perfectly adherent, of uniform thickness, smooth, reasonably bright, continuous and free from imperfections such as flux, ash rust, stains, bulky white deposits and blisters. The zinc used for galvanising shall be of any grade in IS-209:1992 ingot (fourth amendment) or IS-13229:1991. 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 to this line. NO GO gauges shall not pass in any direction. Socket ends before galvanising, shall be of uniform contour. The bearing surface of socket ends shall be uniform about the entire circumference without depressions or high spots. The internal contours of socket ends shall be concentric with the axis of the fittings as per IS:2486/IEC: 120. The axis of the bearing surfaces of socket ends shall be coaxial with the axis of the fittings. 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, blow holes, cracks etc. Pressure die casting shall not be used for casting of components with thickness more than 5mm. All current carrying parts shall be so designed and manufactured that contact resistance is reduced to minimum. 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 condition. 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. All fasteners shall have suitable corona free locking arrangement to guard against vibration loosening. Welding of aluminium shall be by inert gas shielded tungsten arc or inert gas shielded metal arc process. Welds shall be clean, sound, smooth uniform-without overlap, properly fused and completely sealed. There shall be no cracks, voids incomplete penetration, incomplete fusion, under-cutting or inclusions. Porosity shall be minimised so that mechanical properties of the aluminium alloys, are not affected. All welds shall be properly finished as per good engineering practices.

1.18.5.

1.18.6.

1.18.7.

1.18.8.

1.18.9.

1.18.10.

1.18.11. 1.18.12. 1.18.13.

Jindal India Thermal Power Limited

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Volume-II / Section - VIII

EPC Tender for JITPL

1.19. 1.19.1.
1.19.2.

Bid Drawings The Bidder shall furnish full description and illustrations of materials offered. Fully dimensioned drawings of the complete insulator string hardwares and their component parts showing clearly the following arrangements shall be furnished in five (5) copies along with the bid. Weight of material and fabrication details of all the components should be included in the drawings. (i) (ii) (iii) (iv) (v) (vi) (vii) Attachment of the hanger or strain plate. Suspension or dead end assembly. Arcing horn attachment to the string as specified in clause 1.8 of this Technical Specification. Yoke plates Hardware fittings of ball and socket type for inter connecting units to the top and bottom Yoke plates. Corona control rings/grading ring attachment to conductor and other small accessories. Links with suitable fillings.

1.19.3.

(viii) Details of balancing weights and arrangements for their attachment in the single suspension pilot insulator string. All drawings shall be identified by a drawing number and contract number. All drawings shall be neatly arranged. All drafting & lettering shall be legible. The minimum size of lettering shall be 3 mm. All dimensions & dimensional tolerances shall be mentioned in mm. The drawings shall include (ix) (x) Dimensions and dimensional tolerance Material fabrication details including any weld details & any specified finishes & coatings. Regarding material designation & reference of standards are to be indicated. Catalogue No. Marking Installation instructions Design installation torque for bolt or cap screw.

(xi) (xii) (xiv) (xv) (xvi)

(xiii) Weight of assembly

Withstand torque that may be applied to the bolt or cap screw without failure of component parts. (xvii) The compression die number with recommended compression pressure. Jindal India Thermal Power Limited Page 192

Volume-II / Section - VIII (xviii) All other relevant terminal details 1.19.4.

EPC Tender for JITPL

After placement or award, the Contractor shall submit fully dimensioned drawing including all the components in four (4) copies to the Owner for approval After getting approval from the Owner and successful completion of all the type tests, the Contractor shall submit thirty (30) more copies of the same drawings to the Owner for further distribution and field use at Owners end. TABLE I Details of Materials

Sr. No. 1. 2. 3.

Name of item Security Clip Arcing Horn Ball Fittings, Socket, all shackles links cleves Yoke Plate Sag Adjustment Plate Supporting Brackets & Mounting Bolts

Material treatment Stainless Steel/ Phospher Bronze Mild Steel Road / Tube Type Class-IV Steel

Process of Standard Hot dip galvanized Drop forged & normalized Hot dip galvanized Hot dip galvanized Hot dip galvanized Heat treated Hot dip galvanized

Reference AISI 302 or 304-L/IS 1385 As per IS-226 or IS-2062 As per IS 2004

Remarks

4. 5. 6(a)

Mild Steel Mild Steel High Strength A1 Alloy 6061/6063/65032/63 400 Type) High Strength A1, Alloy 4600/LM-6 or 6061/65032 Mild Steel

As per IS-226 or IS-2062 As per IS-226 or IS-2062 ASTM-B429 or as per IS226 or IS-2062

Mechanical Strength of welded joint shall not be less than 20 KN

7(a)

7(b)

7(c)

Envelope type Clamp Clamp Body, Keeper piece Envelope type Clamp : Cotter bolts/Hangers, Shackles, Brackets Envelope type Clamp : U Bolts Dead End

Casted or forged & Heat treated Hot dip galvanised

IS:617 or ASTM-B429 As per IS-226 or IS-2062

8(a)

Stainless Steel or High Strength A1 alloy 6061/6063 or 65032/63400 ECgrade A1 of

Forged & Heat treated

AISI 302 or 304-L ASTMB429

Jindal India Thermal Power Limited

Page 193

Volume-II / Section - VIII Assembly Outer Sleeve Steel Sleeve purity not less than 99.50% Mild Steel

EPC Tender for JITPL

8(b)

Hot dip Galvanised

IS : 226/IS2062

Note :

2.0 2.1. 2.1.1. 2.1.2. 2.2. 2.2.1.

Alternate materials conforming to other national standards of other countries also may be offered provided the properties and compositions of these are close to the properties and compositions of material specified. Bidder should furnish the details of comparison of material offered viz a viz specified in the bid or else the bids are liable to be rejected. Accessories for ACSR MOOSE Conductor General
This portion (under clause 2) details the technical particulars of the

accessories for ACSR MOOSE Conductor. 2.5% extra fasteners and retaining rods shall be provided. Mid Span Compression Joint
Mid Span Compression joint shall be used for joining two lengths of conductor. 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. 2.2.2.
The joint shall be made of steel and aluminium sleeves for jointing the steel core and aluminium wires respectively. The steel sleeve should not crack or fail during compression The Brinnel Hardness of steel sleeve shall not exceed 200. The steel sleeve shall be hot dip galvanised. 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, dimensions and dimensional tolerances of mid span compression joint shall be as per Table II Table II Dimensions & Dimensional Tolerances for Mid Span Compression Joint, Tconnector and Repair Sleeve Sr. Item Dimensions before compression Dimensions after No. compression Inner Dia Outer Dia Length Corner Face to face (mm) (mm) (mm) to Corner width (mm) (mm) 1. Mid Span Compression Joint Jindal India Thermal Power Limited Page 194

Volume-II / Section - VIII

EPC Tender for JITPL

i) ii) 2. 3.

Aluminium Sleeve Steel Sleeve T-connector Sleeve Repair Sleeve Repair Sleeve

340.5 11.10.2 340.5 340.5

541 210.5 541 541

7355 2505 4005 3005

530.5 20.20.5 530.5 530.5

460.5 17.50.5 460.5 460.5

2.3.

Repair Sleeve of compression type shall be used to repair conductor with


not more than two strands broken in the outer layer. The sleeve shall be manufactured from 99.5% pure aluminium and shall have a smooth

2.4.

surface. The Repair sleeve shall comprise of two pieces with a provision of seat for sliding of the keeper piece. The edges of the seal as well as the 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. T-Connector T-Connector of compression type shall be used for jumper connection at transposition tower. It shall be manufactured out of 99.5 pure aluminium and shall be strong enough to withstand normal working loads. The Tconnector shall have a resistivity across jumper less than 75% resistivity of equivalent length of conductor. The T-connector shall not permit slipping off, damage to or failure of complete conductor. The welded portions shall be designed for 30 KN axial tensile load. Leg sleeve of Tconnector should be kept at an angle of 15 deg. from vertical and horizontal plane of the conductor in order to minimize jumper pull at the welded portion. The dimensions and dimensional tolerances of Tconnector shall be as per Table-II. Spacer Damper for quad bundle conductor. Suitable spacer dampers for four bundle ACSR MOOSE conductor shall be offered. The spacer damper covered by this specification shall be designed to maintain the bundle spacing of 457 mm under all normal operating conditions and to effectively control Aeolian vibrations as well as sub-span oscillation and to restore conductor spacing after release of any external extraordinary load. The nominal sub conductor spacing shall be maintained within 5mm. The spacer damper shall restore the normal sub-conductor spacing due to displacement by wind, electromagnetic and electrostatic forces including the specified short circuit level without permanent deformation or damage either to bundle conductors or to spacer damper itself.

2.5.

2.5.1.

2.5.2.

Jindal India Thermal Power Limited

Page 195

Volume-II / Section - VIII 2.5.3.

EPC Tender for JITPL

The design offered shall be presented as a system consisting of spacer dampers and their staggering scheme for spans ranging from 100 m to 1100 m. A vibration performance test shall be carried out on an experimental test line. The systems tested should be those specified by the Contractor for the 800kV line conditions. Only systems satisfying the performance criteria under Annexure-10 shall be submitted by Bidder alongwith bid. The test line selected for the performance evaluation shall have been designed for that purpose, be adequately exposed to wind and properly instrumented. S. Description Technical Particulars No Double Circuit 1 Configuration Twin ACSR MOOSE conductors bundle per phase and all three phases per Circuit in near vertical configuration on both side of tower 2 Span length in metres 400 meters a. Ruling design span b. Maximum Span 1100 meters c. Minimum Span 100 meters 3 Tensile load in each subSag-tension calculation shall be provided conductor 4 Maximum permissible 150 microstrains dynamic strains

2.5.4.

Under the operating conditions specified the spacer damper shall adequately control Aeolian vibrations throughout the life of the transmission line with wind velocity ranging from 0 to 30 km per hour in order to prevent damage to conductor at suspension clamps, dead end clamps and spacer damper clamps The spacer damper system shall also control the sub-span oscillations in order to prevent conductor damage due to chaffing and severe bending stresses at the spacer damper clamps as well as suspension and dead end clamps and to avoid wear to spacer damper components. Not Applicable The spacer damper shall consist of a rigid central body called the frame linked to the conductor by four articulated arms terminated by suitable clamping system. The articulation shall be designed to provide elastic and damping forces under angular movement of the arms. The dynamic

2.5.5.

2.5.6. 2.5.7.

Jindal India Thermal Power Limited

Page 196

Volume-II / Section - VIII

EPC Tender for JITPL

characteristics of the articulations shall be maintained for the whole line of the transmission life. The damping system shall be designed to provide Firm but gentle and permanent grip while protecting the conductor against local static or dynamic stresses expected during normal operating conditions. The clamping system shall be designed to compensate for any reduction of conductor diameter due to creep. Bolted type clamps shall allow installation without removal of the bolts or the clamps from clamp body. Locking mechanism shall be suitable to prevent bolt loosening. Clamp locking devices using small, loose components shall not be accepted. Nut cracker, hinged open or boltless type clamps are acceptable provided, adequate grip can be maintained on the conductor. Bolts and nuts shall be of mild steel stainless steel, or high strength steel in accordance with the design of the spacer damper,: Clamp tightening bolt shall be of shear type and clearly marked so that after the correct torque has been applied the correctly installed bolts may be clearly identifiable from the ground. Where elastomer surfaced clamps are used, the elastomer elements shall be firmly fixed to the clamp. The, insert should be forged from aluminium alloy of type6061 or equivalent aluminium alloy having minimum tensile strength of 25 kg/mm2. The insert shall be moulded on the insert surface. The insert shall be duly heat treated and aged to retain its consistent characteristics during Service. The grain flow of the forged insert shall be in the direction of the maximum tension and Compression loads experienced. If clamps involving preformed rods are used, the rods shall be designed for specific conductor size, They shall be made of high strength aluminium alloy of type 6061 or equivalent aluminium alloy having a minimum tensile strength of 35 kg/mm2. The rods shall be ball ended. The rods shall be heat treated and aged to achieve specified mechanical properties and to retain the same during service. The length of the rods shall be such that the ends fall inside the imaginary square whose sides are vertical and horizontal outer tangents to the conductor sections The spacer damper body shall be cast/forged from suitable high strength corrosion resistant aluminum alloy. The aluminium alloy shall be chosen in relation with the process used. However a combination of aluminium alloy and steel shall also be accepted. The rubber components involved in the design such as damping elements shall be made with rubber compound selected specifically for that particular application. The bidder shall submit a complete list of physical Page 197

2.5.8.

2.5.9.

2.5.10.

2.5.11.

2.5.12.

2.5.13.

Jindal India Thermal Power Limited

Volume-II / Section - VIII

EPC Tender for JITPL

and mechanical properties of the elastomer used. This list shall make reference to all applicable ASTM standards. 2.5.14. The rubber components used shall have good resistance to the effects of temperature upto 850C and to ultraviolet radiation, ozone and other atmospheric contaminants. The rubber shall have good wear and fatigue resistance and shall be electrically semi-conductive. The spacer damper involving ferrous material shall not have magnetic power loss more than one watt at 500 A, 50 Hz alternating current pre subconductor. The spacer damper assembly shall have electrical continuity. The electrical resistance between the sub-conductors across the assembly in case of spacer damper involving elastomer surfaced clamps shall be suitably selected by the manufacturer to ensure satisfactory electrical performance and avoid deterioration of elastomer under service conditions The spacer damper assembly shall have complete ease of installation and shall be capable of removal/reinstallation without any damage. The spacer damper assembly shall be capable of being installed and removed from the energized line by means of hot line techniques. The Bidder shall supply with the bid the complete description of the installation, removal and reinstallation procedure. The Bidder shall recommend the staggering scheme for installation of spacer dampers on the line which shall ensure most satisfactory fatigue performance of the line as specified: -The scheme shall indicate the number of spacer dampers per phase per span and the sub-span lengths to be maintained between spacer dampers while installing on the four bundle conductors. The staggering scheme shall be provided for spans ranging from 100 m to 1100m. The number of spacer dampers for a nominal ruling span of 400 m shall not be less than six. No sub-span shall be greater than 70 m and no end sub-span shall be longer than 40 m. The staggering theme shall be such that the spacer dampers be unequally distributed along the span to achieve sufficient detuning of adjacent subspans for oscillation or sub-spans mode and to ensure bundle stability for wind speeds upto to 60 km/hr. The Bidder shall furnish all the relevant technical documents in supports of the staggering scheme recommended for the spacer damper. Bundle Spacer for jumper Jumpers tension points shall also be fitted with spacers so as to limit the length of free conductor to 3.65 m and to maintain the sub conductor Page 198

2.5.15.

2.5.16.

2.5.17. 2.5.18.

2.5.19.

2.5.20.

2.5.21. 2.5.22.

2.5.23.

2.6. 2.6.1.

Jindal India Thermal Power Limited

Volume-II / Section - VIII

EPC Tender for JITPL

spacing of 457 mm. Bidder shall quote for rigid spacer for jumper. It shall meet all the requirements of spacer used in line except for its vibration performance. Spacers requiring retaining rods shall not be quoted for

jumpers. 2.6.2. 2.6.2.1. The space offered by the Bidder shall satisfy the following requirements. Spacer shall restore normal spacing of the sub-conductors after displacement by wind, electromagnetic and the electrostatic forces under all operating conditions including the specified short circuit level without permanent deformation damage either to conductor or to the assembly itself. They shall have uniform grip on the conductor. Where elastomer surfaced clamp grooves are used, the elastomer shall be firmly fixed to the clamp. The insert should be forged from aluminium alloy of type 6061/65032. The insert shall be duly heat treated and aged to retain its consistent characteristics during service. Any nut used shall be locked in an approved manner to prevent vibration loosening. The ends of bolts and nuts shall be properly rounded for specified corona performance or suitably shielded. Clamp with cap shall be designed to prevent its cap from slipping out of position when being tightened. The clam grooves shall be in uniform contact with the conductor over the entire surface, except for rounded edges. The groove of the clamp body and clamp cap shall be smooth and free of projections, grit or other material, which cause damage to the conductor when the clamp is installed. For the spaces involving bolted clamps, the manufacturer must indicate the clamp bolt tightening torque to ensure that the slip strength of the clamp is maintained between 2.5 kN and 5 kN. The clamp when installed on the conductor leading to permanent deformation of the conductor strands and premature fatigue failure in operation. Universal type bolted clamps covering a range of conductor sizes will not be permitted No rubbing, other than that of the conductor clamp hinges or clamp swing bolts, shall take place between any parts of the spacer. Joint incorporating a flexible medium shall be such that there is no relative slip between them. The spacer shall be suitably designed to avoid distortion or damage to the conductor or to themselves during service. Rigid spacers shall be acceptable only for jumpers. The spacer shall not damage or chafe the conductor in anyway which might affect its mechanical and fatigue strength or corona performance.

2.6.2.2.

2.6.2.3.

2.6.2.4. 2.6.2.5.

2.6.2.6.

2.6.2.7. 2.6.2.8.

2.6.2.9.

2.6.2.10.
2.6.2.11.

Jindal India Thermal Power Limited

Page 199

Volume-II / Section - VIII 2.6.2.12.


2.6.2.13. 2.6.2.14.

EPC Tender for JITPL

The clamping system shall be designed to compensate for any reduction in diameter of conductor due to creep. The spacer assembly shall not have any projections, cuts, abrasions etc. or chattering parts which might cause corona or RIV. The spacer tube shall be made of aluminium alloy of type 6061:65032. If fasteners of ferrous material are used, they shall conform to and be galvanized conforming to relevant Indian Standards. The spacer involving ferrous fasteners shall not have magnetic power loss more than one watt at 600 Amps 50Hz alternating current per sub-conductor. Elastomer, if used, shall be resistant to the effects of temperature upto 85 deg. C ultraviolet radiation and other atmospheric contaminants likely to be encountered in service. It shall have good fatigue characteristics. The physical properties of the elastomer shall be of approved standard. The spacer assembly shall have electrical continuity. The electrical resistance between the sub-conductor across assembly in case of spacer having elastomer clamp grooves shall be suitably selected by the manufacturers to ensure satisfactory electrical performance and to avoid deterioration of elastomer under all service conditions. The spacer assembly shall have complete ease of installation and shall be capable of removal/reinstallation without any damage The spacer assembly shall be capable of being installed and removed from the energised line by means of hot line technique. Material and Workmanship All the equipment 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 400 kV transmission line application with bundle conductors and will give continued good performance. 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. All ferrous parts shall be hot dip galvanised, after all machining has been completed. Nuts may however, be tapped (threaded) after galvanising and the threads oiled. Spring washers shall be electro galvanised as per grade 4 of IS:1573. The bolt threads shall be undercut to take care of increase in diameter due to galvanising. Galvanising shall be done in accordance with IS:2629/IS-1367 (Part-13) and satisfy the tests mentioned in IS:26331986. Fasteners shall withstand four dips while spring washers shall withstand three dips. Other galvanised materials shall have a minimum average coating of Zinc equivalent to 600 gm/sq.m and shall be Page 200

2.6.2.15.

2.6.2.16.

2.6.2.17. 2.6.2.18.

2.7. 2.7.1.

2.7.2.

2.7.3.

Jindal India Thermal Power Limited

Volume-II / Section - VIII

EPC Tender for JITPL

guaranteed to withstand at least six dips each lasting one minute under the

standard Peerce test for galvanising unless otherwise specified. 2.7.4. 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 galvanising shall be of any grade in IS-209:1992 ingot (fourth amendment) or IS-13229:1991. In case of castings, the same shall be free from all internal defects like shrinkage, inclusion, blow holes, cracks etc All current carrying parts shall be so designed and manufactured that contact resistance is reduced to minimum and localised heating phenomenon is averted. No equipment shall have sharp ends or edges, abrasions or projections 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. Particular care shall be taken during manufacture and subsequent handling to ensure smooth surface free from abrasion or cuts. The fasteners shall conform to the requirements of IS: 6639. All fasteners and clamps shall have corona free locking arrangement to guard against vibration loosening. Compression Markings Die compression areas shall be clearly mark 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 NONCOMPRESSlON 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. 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 drawings shall be neatly arranged. All drafting and lettering shall be legible. The minimum size of lettering shall be 3 mm. All dimensions and dimensional tolerances shall be mentioned in mm. Page 201

2.7.5. 2.7.6.

2.7.7.

2.7.8. 2.7.9.

2.8.

2.9.
2.9.1.

Jindal India Thermal Power Limited

Volume-II / Section - VIII 2.9.2. The drawings shall include: (i) (ii) Dimensions and dimensional tolerances

EPC Tender for JITPL

Material, fabrication details including any weld details and any


specified finishes and coatings. Regarding material, designations

(iii) (iv) (v) (vi) (vii)

and reference of standards are to be indicated. Catalogue No. Marking Weight of assembly Installation instructions 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
2.9.3. 2.9.4.

Placement charts for spacer/spacer damper and damper. The above drawings shall be submitted in five copies with all the details as stated above along with, the bid document. After the placement of award the Contractor shall again submit the drawings in four copies to the Owner for approval. After Owners approval and successful completion of all type tests, 20 (twenty) more sets of drawings shall be submitted to the Owner for further distribution and field use at Owners end. G.S. Earthwire Accessories General This portion (under clause 3) details the technical particulars of the accessories for Galvanized Steel Earthwire. 2.5% extra fasteners shall be supplied. 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 with aluminium encasing. The steel sleeve should not crack or fail during compression. The Brinnel Hardness of steel should not exceed 200. The steel sleeve shall be hot dip galvanized. The aluminium sleeve shall have aluminium of purity not less than 99.5%. Filler aluminium sleeve shall also be provided at the both ends. The joints shall not permit slipping off, damage to or failure of the 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

3.0 3.1.
3.1.1. 3.1.2.

3.2.

Jindal India Thermal Power Limited

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Volume-II / Section - VIII

EPC Tender for JITPL

dimensions and the dimensional tolerances of the joint shall be as per the

table-III. Table III Dimensions & Dimensional Tolerances for Mid Span Compression Joint and Repair Sleeve Sr. No Item Dimensions before compression Inner Dia (mm) For 7/3.66 mm GS Earthwire 1. Aluminium Sleeve 22 0.5 2. Steel Sleeve 11.50.2 3. Filler Aluminium 11.50.2 Sleeve 3.3. 3.3.1. Vibration Damper Vibration dampers of 4R-Stockbridge type with four (4) different frequencies spread within the specified Aeolian frequency band-width corresponding to wind speed of 1 m/sec 7 m/sec shall be used for suspension and tension points on each earthwire in each span to damp out Aeolian vibrations as mentioned herein after. Alternate damping systems or Dogbone dampers offering equivalent or better performance also shall be acceptable, provided the manufacturer meets the qualifying requirements stipulated in the Specifications. Relevant technical documents to establish the technical suitability of alternate systems shall be furnished by the bidder along with the bid. One damper minimum on each side per earthwire at suspension points and two dampers on each side per earth wire at tension points shall be used for ruling design span of 400 meters for 400 kV line. No vibration damper shall be provided in slack span (in line take off / between dead end tower and gantry structure). The bidder may offer damping system involving more number of dampers per ruling design span than the specified. However price compensation shall be considered for evaluation. For the purpose of price compensation 80 % of towers as suspension locations and 20 % of towers as tension locations and all the spans assumed to be ruling design spans. The clamp of the vibration damper shall be made of aluminium alloy. It shall be capable of supporting the damper during installation and prevent damage or chafing of the earthwire during erection or continued operation. The clamp shall have smooth and permanent grip to keep the damper in position on the earthwire without damaging the strands or causing Page 203 Outer Length Dia (mm) (mm) Dimensions after compression Corner to Face to Corner (mm) face with (mm) 29.40.5 20.20.5 25.00.5 17.50.5

320.5 210.5 210.5

4005 2305 605

3.3.2.

3.3.3.

3.3.4.

3.3.5.

Jindal India Thermal Power Limited

Volume-II / Section - VIII

EPC Tender for JITPL

premature fatigue failure of the earthwire under the clamp. The clamp groove shall be in uniform contact with the earthwire 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. 3.3.6. 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 of preformed and post formed quality in order to prevent subsequent droop of weights and to maintain consistent flexural stiffness of the cable in service. The number of standards in the messenger cable shall be 19. The messenger cable ends shall be suitably and effectively sealed to prevent corrosion. 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. The vibration analysis of the system, with and without damper, dynamic characteristic of the damper as detailed under Annexure-10, shall have to be submitted by the Bidder alongwith his bid. The technical particulars for vibration analysis and damping design of the system are as follows: SNo. Description For 7/3.66 mm GS Earthwire 1. Span length in meters i) Ruling design span ii) Maximum span iii) Minimum Span 2. Tensile load in Conductor at temperature of 0 deg. C and still air 3. Armor rod s used
4.

3.3.7.

3.3.8.

Technical Particulars

Maximum permissible dynamic strain

400 meters 1100 meters 100 meters As per sag tension calculations. Standard preformed armor s/AGS +/- 150 micro strains

3.3.9.

The damper placement chart for spans ranging from 100 m to 1100 m 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) Locations of the damper for various combinations for spans and line tensions clearly indicating number of damper of dampers to be installed per earthwire per span.

3.3.10.

Jindal India Thermal Power Limited

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EPC Tender for JITPL

(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 centre type/triunion type etc.) (4) The influence of mid span compression joints in the placement of dampers. 3.4. 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 500 mm in length. It shall consist of 259 wires of 0.417 mm 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 12mm, dia. bolt and the other for 16 mm dia bolt. The complete assembly shall also include one 16 mm dia., 40mm long HRH MS Bolt hot dip galvanised with nut and lock washer. Suspension Clamp Standard anchor shackle/twisted shackle for earthwire suspension clamp shall be supplied for attaching to the hanger plate of tower. At all suspension towers, suitable suspensions clamps shall be used to support the earthwire of 7/3.66 mm size. The clamps shall be of either free centre type or triunion type and shall provide adequate area of support to the earthwire. The groove of the clamp shall be smooth, finished in an uniform circular or oval shape and shall slope downwards in a smooth curve to avoid edge support and hence to reduce the intensity of bending moment on earthwire. 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. The clamping piece and the clamp body shall be clamped by at least two U-bolts of size not less than 12 mm diameter having one nut and one 3mm thick lock nut with washer on each of its limbs. Suspension clamps shall be provided with inverted type U-bolts. One limb of the U-bolt shall be long enough to accommodate the lug of the flexible copper bond. 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 attachment to the centre point of the earthwire shall not exceed 150 mm. The design of

3.5.

3.5.1.
3.5.2.

3.5.3.

3.5.4.

3.5.5.

Jindal India Thermal Power Limited

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EPC Tender for JITPL

he assembly shall be such that the direction of run of the earthwire shall be

same as that of the Conductor. 3.5.6. The complete assembly shall be guaranteed for slip strength of not less than 12 kN and not more than 17 kN. The breaking strength of the assembly shall not be less than 25 kN. Tension Clamp At all tension towers suitable compression type tension clamps shall be used to hold 7 / 3.66 mm Galvanised Steel Earthwire. Anchor shackle shall be supplied which shall be suitable for attaching to the tension clamps to strain plates. The clamps shall have adequate area of bearing surface to ensure positive electrical and mechanical contact and shall not permit any slip to earthwire under working tension and vibration conditions. The angle of jumper terminals to be mounted should be 30 deg. with respect to the vertical line. The clamps shall be made of mild steel with aluminium encasing. 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 galvanised. The aluminium encasing shall have aluminium of purity not less than 99.5%. Filler aluminium sleeve shall also be provided at the end. 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. The slip strength of the assembly shall not be less than 95% of the ultimate strength of the earthwire. The clamps shall be complete with all the component including anchor shackle, bolts, nuts, washers, split pin, jumper arrangement etc. Material Workmanship Same as Clause 2.7 of this section 3.8. 3.9. 4.0 4.1.
4.1.1.

3.6.
3.6.1.

3.6.2.

3.6.3.

3.6.4.

3.6.5. 3.6.6.

3.7.

Compression Marking Same as clause 2.8 of this section Bid Drawings Same as Clause 2.9 of this section Tests and Standards Type Tests On the complete Insulator String with Hardware Fittings On the complete Disc Insulator String with Hardware Fittings

4.1.1.1.

Jindal India Thermal Power Limited

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EPC Tender for JITPL

a)

b) c)
d)

e) f)
g) h)

i) 4.1.1.2.

Power frequency voltage withstand test with corona control rings / grading ring and arcing horns under wet condition Switching surge voltage withstand test under wet condition Impulse voltage withstand test under dry condition Impulse voltage flashover under dry condition Voltage distribution test Corona and RIV test under dry condition Mechanical Strength test Vibration test Power Arc Test

As per IEC:383

As per IEC:383 As per IEC:383 As per IEC:383 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10

On the complete Porcelain long rod Insulator siring with Hard ware Fittings a) Power frequency voltage withstand test with corona control rings / grading ring and arcing horns under wet condition Switching surge voltage withstand test under wet condition Impulse voltage withstand test under dry condition Impulse voltage flashover under dry condition Corona and RIV test under dry condition Mechanical Strength test Vibration test Power Arc Test As per IEC:383

b)

As per IEC:383

c)
d)

As per IEC:383 As per IEC:383 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10

e) f)
g) h)

4.1.2.

On suspension Hardware fitting only a) b) c) Magnetic power loss test for suspension assembly
Clamp slip strength Vs torque test for

As per Annexure-10
As per Annexure-10

suspension clamp Mechanical strength Test As per Annexure-10

Jindal India Thermal Power Limited

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EPC Tender for JITPL

d) 4.1.3.

Ozone Test on elastomer

As per Annexure-10

On Tension Hardware Fitting only a) b) c) d) Electrical resistance test for dead end assembly Heating cycle test for dead end Assembly Slip Strength test for dead end assembly Mechanical strength test As per IS:2486(Part-I) As per IS:2486(Part-I) As per IS:2486(Part-I) As per Annexure-10

4.1.4.

Mid Span Compression Joint for Conductor and Earthwire a) Chemical analysis of materials b) Electrical resistance test c) Heating cycle test d) Slip strength test e) Corona extinction voltage test (dry) f) Radio interference voltage test (dry) As per Annexure-10 As per IS:2121 (part-II) As per IS:2121 (part-II) As per Annexure-10 As per Annexure-10 As per Annexure-10

4.1.5.

Note: Tests mentioned at (c), (e) & (f) are not applicable to mid span compression joints for earthwire. Repair Sleeve for conductor (a) Chemical analysis of materials (b) Corona extinction voltage test (dry) (c) Radio interference voltage test (dry) As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per IS:2121 (Part-II) Clause 6.5 & 6.6 (c) Heating cycle test (d) Axial tensile load test on welded portion (e) Corona extinction voltage test (dry) (f) Radio interference voltage test (dry) As per IS:2121 (Part-II) As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 Page 208

4.1.6.

T-connector for conductor and Earthwire (a) Chemical analysis of materials (b) Electrical resistance test

4.1.7.

Flexible Copper Bond (a) Slip strength test

Jindal India Thermal Power Limited

Volume-II / Section - VIII 4.1.8. Vibration Damper for Earthwire (a) Chemical analysis of materials (b) Dynamic characteristics test (c)Vibration analysis (d) Clamp Slip test (e) Fatigue tests (f) Damper efficiency test
4.1.9.

EPC Tender for JITPL

As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per IS:9708 As per Annexure-10 As per Annexure-10 As per Annexure-10 i) Aeolian vibration As per Annexure-10 ii) Sub-span oscillation As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 As per Annexure-10 Page 209

Spacer Damper for quad bundle conductor a) Chemical analysis of materials b) Clamp slip test c) Performance test

d) Dynamic characteristics test e) Fatigue tests d) Magnetic power loss test (if applicable) e) Compressive and Tension-Tests f) Corona extinction voltage test (dry) g) Radio interference voltage test (dry) h) Ozone test on elastomer 4.1.10. Rigid spacer for jumper a) Chemical analysis of materials b) Clamp slip test c) Magnetic power loss test (if applicable) d) Tension-compression test e) Corona extinction voltage test (dry) f) Radio interference voltage test (dry)
4.1.11.

On Earthwire Suspension clamp Assembly a) Chemical analysis of materials b) Clamp slip strength Vs torque test for suspension clamp c) Mechanical strength Test

Jindal India Thermal Power Limited

Volume-II / Section - VIII 4.1.12. On Earthwire Tension clamp Assembly a) Chemical analysis of materials c) Slip strength test for tension assembly d) Electrical resistance test for tension clamp 4.1.13.

EPC Tender for JITPL

As per Annexure-10 As per Annexure-10 As per Annexure-10

b) Mechanical strength test (excluding clamp) As per Annexure-10

All the type tests given under clause no.4.1.1 above shall be conducted on double suspension and Quadruple tension insulator string along with hardware fittings as applicable. The test specified under clause no. 4.1.1.1 (a) to (f) / 4.1.1.2 (a) to (e) shall be conducted on single suspension pilot string and single tension string aIongwith hardware fittings. Heating cycle test on dead end assembly and mid span compression joint & T-connector for conductor and performance test on spacer dampers shall not be required to be carried out if a valid test certificate is available for a similar design i.e. tests conducted earlier should have been conducted in accredited laboratory (accredited based on ISO/IEC guide 25/17025 or EN 45001 by the National accreditation body of the country where laboratory is located) or witnessed by the Owners representative(s). The test reports submitted shall be for the tests conduced within last 5 (five) years prior to the date of bid opening. In case the tests have been conducted earlier than the above stipulated period or in the event of any discrepancy in the test report (i.e. any test report not applicable due to any design / manufacturing change including substitution of components or due to non-compliance with the requirement stipulated in the technical specifications) the tests shall be conducted by the Contractor at no extra cost to the Owner. Acceptance Tests On Both Suspension and Tension Hardwar Fittings a) b) c) d) Visual Examination Verification of dimension Galvanising/Electroplating test (excluding corona control rings grading ring and arcing horn) e) f) g) Mechanical Strength test of welded joint ring/grading ring and arcing horn Test on locking device for ball and socket coupling As per IEC:372(2) As per Annexure-10 Mechanical strength test for corona control BS-3288 (Part-I) As per IS:2486 (Part-I) As per IS:2486 (Part-I) As per IS:2486 (Part-I)

4.1.14.

4.2. 4.2.1.

Mechanical strength test of each component As per Annexure-10

Jindal India Thermal Power Limited

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Volume-II / Section - VIII h)

EPC Tender for JITPL

Chemical analysis, hardness tests, grain size As per Annexure-10 inclusion rating & magnetic paride inspection for forgings/castings

4.2.2.

On Suspension Hardware Fittings only a) b) c) Clamp Slip strength Vs Torque test for suspension clamp Shore hardness test of elastomer cushion for AG suspension clamp Bend test for armour rod set Resilience test for armour rod set Conductivity test for armour rods set As per IS:2121 (Part-I) Clause 7.5,7.10 & 7.11 As per IS:2121 (Part-I) Clause 7.5,7.10 & 7.11 As per IS:2121 (Part-I) Clause 7.5,7.10 & 7.11 As per Annexure-10 As per Annexure-10

4.2.3.

On Tension Hardware Fittings only a) Slip strength test for dead end assembly As per IS : 2486 (Part-I) Clause 5.4

4.2.4.

On Mid Span Compression Joint for Conductor and Earthwire a) b) c) Visual examination and dimensional Verification Galvanising test Hardness test Visual examination and dimensional verification b) Axial tensile load test for welded portion Visual examination and dimensional verification As per Annexure-10 As per IS:2121 (Part-II) Clause 6.2, 6.3 As per IS:2121(Part-II), Clause 6.2, 6.3 7,6.7 As per Annexure-11 As per Annexure-11 As per IS:2121 (Part-II)

4.2.5.

T-Connector for conductor a)

4.2.6.

Repair Sleeve for Conductor a)

4.2.7.

Flexible Copper Bond a) Visual examination and dimensional verification As per IS:2121 (Part-II) Clause 6.2, 6.3

Jindal India Thermal Power Limited

Page 211

Volume-II / Section - VIII b) 4.2.8. a) b) Slip strength test Visual examination and dimensional verification Galvanising test i) On damper masses ii) On messenger cable c) d) e) f) g) h)
4.2.9.

EPC Tender for JITPL As per annexure 10 As per IS:2121 (Part-II) Clause 6.2, 6.3 7 6.7 As per annexure 11 As per annexure 11 As per annexure 11 As per annexure 11 As per annexure 11 As per annexure 11 As per annexure 11 As per annexure 11 As per annexure 11 As per IS:2121 (Part-II) Clause 6.2, 6.3 7 6.7 As per annexure 11 As per annexure 11 As per annexure 11 As per annexure 11 As per annexure 11 As per annexure 11

Vibration Damper for Earthwire

Verification of resonance frequencies Clamp slip test Clamp bolt torque test Strength of the messenger cable Mass pull off test Dynamic characteristics test Visual examination and dimensional verification Galvanising test Clamp slip test Clamp bolt torque test Compression-tension test Assembly torque test UTS of retaining rods (if applicable) Visual examination and dimensional verification

Spacer Damper for conductor/Rigid spacer for Jumper a) b) c) d) e) f) g) h) i)

Movement test (except for spacer jumpers)As per annexure 11

Hardness test for elastomer (if applicable) As per annexure 11

4.2.10.

4.2.10 Earthwire Tension Clamp Assembly a) b) c) d) e) As per IS : 2121 (Part-II) As per annexure 11 As per Annexure 10 As per Annexure 10 As per Annexure 10

Galvanising test Slip strength test for tension clamp Mechanical strength test on each component (excluding clamp) Hardness test

4.2.11.

Earthwire Suspension Clamp Assembly

Jindal India Thermal Power Limited

Page 212

Volume-II / Section - VIII a) b) c) d) 4.3 4.3.1 Visual examination and dimensional verification Galvanising test Clamp slip strength test (excluding clamp) Routine Tests For Hardware Fittings a) b)
4.3.2

EPC Tender for JITPL

As per IS : 2121 (Part-II) As per Annexure 11 As per Annexure-10

Mechanical strength test on each component As per Annexure-10

Visual examination Proof Load Test Visual examination and dimensional verification

As per IS : 2121 (Part-II) As per Annexure-10 As per IS:2121 (Part-II) Clause 6.2, 6.3.7 6.7

For conductor and earthwire accessories a)

4.4

Tests During Manufacture on all components as applicable a) b) Chemical analysis of Zinc used for galvanizing IS:2486 (Part-I) Chemical analysis mechanical metallographic test and magnetic particle inspection for malleable castings c) Chemical analysis, hardness tests and magnetic particle inspection for forging As per Annexure-10 As per Annexure-10

4.5
4.5.1 4.5.2

Testing Expenses Testing charges for all type/routine tests shall be borne by the Contractor In case of failure in any such type tests, the Contractor whose material has failed is either required to modify the design of the material & successfully carryout all the type tests or to repeat that particular type test at least three times successfully at his own expense. In case of failure of the complete string in any type test, Contractor shall get the test repeated at his cost. The Contractor whose material has not failed in the test shall be required to supply the requisite quantity of material. Contractor shall indicate the laboratories in which they propose to conduct the type tests. They shall ensure that adequate facilities for conducting the tests are available in the laboratory and the tests can be completed in these laboratories within the time schedule guaranteed by them in the appropriate schedule.
The entire cost of testing for acceptance and routine tests and tests during

4.5.3

4.5.4

manufacture specified herein shall be treated as included in the quoted Exworks / CIF Price.

Jindal India Thermal Power Limited

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Volume-II / Section - VIII 4.5.5

EPC Tender for JITPL

4.5.6

4.6
4.6.1

In case of failure in any type test, repeat type test are required to be conducted, Then, all the expenses for deputation of Inspector/Owners representative shall be deducted from the contract price. Also if on receipt of the Contractors notice of testing, the Owners representative/ lnspector does not find plant to be ready for testing the expense incurred by the Owner for re-deputation shall be deducted from contract price. The Contractor shall intimate the Owner about carrying out of the type tests alongwith detailed testing programme at least 3 weeks in Advance (in case of testing in India) and at least 6 weeks advance (in case of testing abroad) of the scheduled date of testing during which the Owner will arrange to depute his representative to be present at the time of carrying out the tests. Sample Batch for Type Testing The Contractor shall offer material for sample selection for type testing only after getting Quality Assurance Programme approved by the Owner. The Contractor shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. The sample for type testing will be manufactured strictly in accordance with the Quality Assurance Programme approved by the Owner. Before sample selection for type testing the Contractor shall be required to conduct all the acceptance tests successfully in presence of Owners representative. Schedule of Testing and Additional Tests The Bidder has to indicate the schedule of the following activities in their bids (a) Submission of drawing for approval (b) Submission of Quantity Assurance programme for approval (c) Offering of material for sample selection for type tests (d) Schedule of type testing

4.6.2

4.7
4.7.1

4.7.2

4.7.3

The Owner reserves the right of having at his own expense any other test(s) of reasonable nature carried out at Contractors premises, at site, or in any other place in addition to the aforesaid type acceptance and routine tests to satisfy himself that the material comply with the specifications. The Owner also reserves the right to conduct all the tests mentioned in this specification at his own expense on the sample 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 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 Owner

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EPC Tender for JITPL

4.8 4.8.1

Co-ordination for testing The Contractor shall have to co-ordinate testing of hardwire fittings with insulators and shall have to also guarantee overall satisfactory performance of the hardware fittings with the insulators. Test Reports Copies of type test reports shall be furnished in at least six copies-alongwith one original - One copy shall be returned duly certified by the Owner, only after which the commercial production of the concerned material shall start. Copies of acceptance test report shall be furnished in atleast six copies. One copy shall be returned, duly certified by the Owner, only after which the materials will be dispatched. Record of routine test report shall be maintained by the Contractor at his works for Periodic inspection by the Owners representative Test certificates of tests during manufacture shall be maintained by the Contractor. These shall be produced for verification as and when desired by the Owner. Inspection The Owners 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

4.9
4.9.1

4.9.2

4.9.3 4.9.4

4.10 4.10.1

4.10.2

4.10.3

4.10.4

4.10.5

parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection or the Contractors, sub-Contractors works raw materials, manufacturers of all the material and for conducting necessary tests as detailed herein. The material for final inspection shall be offered by the Contractor only under packed condition as detailed in clause 4.11 of this part of the Specification. The engineer shall select samples at random from the packed lot for carrying out acceptance tests. The Contractor shall keep the Owner informed in advance of the time of starting and of the progress of manufacture of material in its various stages so that arrangement could be made for inspection. Material shall not be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived of by the Owner in writing. In the latter case also the material shall be dispatched only after all tests specified herein have been satisfactorily completed. The acceptance of any quantity of material shall in no way relieve the Contractor of his responsibility for meeting all the requirements of the specification, and shall not prevent subsequent rejection, if such material are later found to be defective.

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EPC Tender for JITPL

4.11 4.11.1

Packing and Marking All material shall be packed in strong and weather-resistant wooden cases/crates. The gross weight of the packing shall not normally exceed 200 Kg to avoid handling problems. The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and subsequent handling in the field. Suitable cushioning, protective padding, dunnage or spacers shall be provided to prevent damage or deformation during transit and handling. Bolts, nuts, washers, cotter pins, security clips and split pins etc shall be packed duly installed and assembled with the respective parts and suitable measures shall be used to prevent their loss. Each component part shall be legibly and indelibly marked with trade mark of the manufacturer and year of manufacture All the 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 stencilled on it in indelible ink Standards The Hardware fittings; conductor and earthwire accessories shall conform to the
following Indian/International Standards which shall mean latest revisions, with

4.11.2 4.11.3 4.11.4

4.11.5 4.11.6

4.12 4.12.1

amendments/changes adopted and published, unless specifically stated otherwise in the Specification
4.12.2 In the event of the supply of hardware fittings; conductor and earthwire accessories 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 their equivalence. Sr No 1 2 3 4 Indian Standard IS: 209-1992 IS: 398-1992 Part-V IS 1573 IS: 2121 (Part I)
IS: 2486 (Part

Title

International Standard

I)

Specification for zinc BS:3436-1986 Aluminium Conductor Galvanised SteelBS:215-1970 Reinforced for Extra High Voltage (400 KV) and above Electrolated Coating of Zinc on iron and Steel Specification for Conductor and Earthwire Accessories for Overhead Power Lines: MidSpan Joints and Repair Sleeves for Conductors Specification for Insulator Fittings for Overhead power Lines with Nominal Voltage greater than Page 216

Jindal India Thermal Power Limited

Volume-II / Section - VIII

EPC Tender for JITPL

6
7

IS:2629
IS:2633

8 9

10 11 12 13 14

IS:4826 IS:6745 IS:8263 IS:6639 IS:9708

1000 V: General Requirements and Tests Recommended Practice for Hot Dip Galvanising of Iron and Steel Method of Testing Uniformity of Coating on Zinc Coated Articles Ozone Test on Elastomer Tests on insulators of Ceramic material or glass for overhead lines with nominal voltage greater than 1000V Galvanised Coating on Round Steel Wires Methods of Determination of Weight of Zinc Coating of Zinc Coated Iron and Steel Articles Method of Radio Interference Tests on High Voltage Insulators Hexagonal Bolts for Steel Structures Specification for Stock Bridge Vibration Dampers for Overhead Power Lines Specification for Spacers Dampers for Twin Horizontal Bundle Conductors

ASTM-D1171 IEC:383-1993 ASTM A472-729 BS:443-1969 BS:433 ISO:1460 (E) IEC:437 NEMA:107 CISPR ISO/R-272

15

IS:10162

The standards mentioned above are available from: Reference Abbreviation BS Name and Address British Standards, British Standards Institution, 101, Pentonvile Road, N-19-ND, UK International Electro technical Commission, Bureau Central de la Commission, Electro Technique international, 1 Rue de verembe, Geneva SWITZERLAND Bureau of Indian Standards, Manak Bhavan, 9, Bahadur Shah Zafar Marg, New Delhi 110001 INDIA International Organisation for Standardization, Danish Board of Standardization, Danish Standardizing Sraat, Aurehoegvej-12, Page 217

IEC/CISPR

BIS/IS

ISO

Jindal India Thermal Power Limited

Volume-II / Section - VIII

EPC Tender for JITPL

NEMA

DK-2900, Heeleprup, Denmark National Electric Manufacture Association, 155, East 44th Street, New York, NY 10017, U.S.A.

Jindal India Thermal Power Limited

Page 218

Volume-II / Section-IX

EPC Tender for JITPL

SECTION IX ANNEXURES

Jindal India Thermal Power Limited

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Volume-II / Section-IX
ANNEXURE -1

EPC Tender for JITPL

Provisional Bill of Quantity for 400KV D/C Transmission Line from Derang to Angul

Sl.No

Particulars Total Length of the Line kMs Check Survey HT Unit Wt. (kg) 5150 350 630 980 9800 800 1700 2500 11900 15000 950 1700 2600 5400 7500

Total Quantity 56.24 56.24 MS Unit Wt.(kg) Nos

A 1

SUPPLY OF MATERIALS Supply of tower parts a) (i) 'A' Type towers Normal (ii) 3 M Extension pieces (iii) 6 M Extension pieces (iv) 9 M Extension pieces b) (i) 'B' Type towers Normal (ii) 3 M Extension pieces (iii) 6 M Extension pieces (iv) '9 M Extension pieces c) 'C' Type towers d) (i) 'D' Type towers Normal (ii) 3 M Extension pieces (iii) 6 M Extension pieces (iv) 9 M Extension pieces (v) 18 M Extension pieces (vi) 25 M Extension pieces 2 3 Supply of Bolts and Nuts (3% of total tower Wt. Of towers) Supply of tower accessories a) Danger plate (one per tower) b) Number plate (one per tower) c) Phase plate (set of three per tower) x No. of Ckts. d) Anti climbing device (one set per tower) e) Circuit plate (one per circuit in case of two or more ckt) d) Supply of pipe type earthing (60% of total No.) e) Supply of Counter poise earthing (40% of total No.)

6200 1220 1900 2500 6600 1800 2250 3100 6100 10000 3100 3800 5100 12400 19900 68761

111 31 14 1 15 1 1 1 11 16 1 2 4 1 2

Nos 153 153 306 153 306 100 53

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4 Supply of ACSR Moose Conductor (kM)
(=Route kM x 3 x No. of Ckts x 2 x 1.015)

EPC Tender for JITPL


685.003

5 6

Supply of 7/3.66mm GSS Ground wire (kM)


(=Route kM x 2 x 1.015)

114.2 Nos 630 48 504 36 17250 24192 Nos 228 14 112 390 5508 504 612 222 168 7344

Supply of Insulators with Hardware a) 'I' Suspension Insulator Sring (No. Suspn. X 3) x Ckts b) Single 'I' suspn. Pilot string (No. of 'D' type x 1) c) Double Tension string (No. of anchor x 2 x 3 x No. of Ckts) d) Double 'I'' suspn. Insulator string (Special Locations) 120 kN Insulators 160 kN Insulators Supply of Conductor and GW Accessories a) Mid span compression Joint for condr. (one No. for 3 kM) b) Mid span compression joint for GW (one No. for 8 kM) c) Repair sleeves for Conductor (2 Nos. for every Route kM) d) Flexible copper Earth bonds (2x 'A' type + 2x2xNo. of Anchor) e) Bundle Spacers for Conductor (6x No. of towers x 3 x Ckts) f) Rigid spacer for Conductor (2 x No. of
anchor x 2 x 3x Ckts)

g) Vibration Damper for GW (No. Of towers x 2 x2) h) Earth wire suspension clamp ( No. 'A' towers x 2) I) Earth wire tension clamps (No. of Anchor x 2 x 2) j) Vibration dampers for conductor (No. towersx4xCktsx3x Condr)

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ERECTION

1 2 C 1 2 3

Erection of tower,Stringing of Conductor and Ground wire (Route kM) Erection of Tower parts(MT) CIVIL WORKS Geotechnical investigation for towers foundation(Nos) Excavations(Cu.M) M20 Concrete (1:1:3 Concrete) (Cu.M) 1:3:6 Concrete (15% of M20 Concrete) in Cu.M Reinforcements (4% of weight of M20) in MT Benching a) All kinds of soil except fissured rock b) Fissured rock Revetment works a) Random Rubble Masonry (1:5 cement mortar) in Cu.M b) 1:2:4 Cement Concrete revetment c) Back filling and levelling (Included above)

56.24 298

153 37842 5567

601

5 6

417

150 1500

2500 250 2500

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ANNEXURE 2 :

BLANK

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ANNEXURE 3 :

BLANK

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ANNEXURE 4 :

BLANK

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ANNEXURE-5 STANDARDS FOR ACSR CONDUCTOR


The 520 Sq.mm. ACSR Moose conductor shall conform to the following Indian

Standard which shall mean latest revision/amendments/changes adopted and published: (i) (ii) (iii)
(iv)

IS :398 Part I to V as relevant IS : 1521 :1972 IS :1778 :1980


IS :8263 : 1976

Specification for Aluminium Conductors for overhead transmission purposes Method of Tensile Testing of Steel. Reel and Drums for bare conductors Method of Radio Interference tests on High Voltage Insulators Specification for Zinc EC grade Aluminium rod produced by rolling Hot Dipped Galvanised coatings on round steel Specification for Lithium soap grease

(v) (vi) (vii)

IS :209 IS : 1841 IS : 4826

(viii) IS : 7623

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ANNEXURE 6 DRAWING CHARTS & DESIGN DATA TO BE SUBMITTED IN PHYSICAL FORM

(A)

Bidder shall furnish full details of earthwire drum offered. The drawing shall

indicate: i) iii) iv) (B) Size & weight of drum ii)Materials used. Identification marks. Any other information, which may be useful to the user.

Successful bidder during the execution of contract shall submit the sag tension charts of earthwire for approval. GUARANTEED TECHNICAL PARTICULARS Unit Specified values 4 Offered Values 5

Sr.No 1 1.
2.

DescrIption 2 Makers name, address and country Percentage composition of steel wire element i) Carbon ii) iii) iv) v) Sulphur Phosphorus Manganese Silicon 3

% % % % %

Not more than 0.55 Not more than 0.04 Not more than 0.04 0.4 to 0.9 0.15to 0.35

3.

Particulars of steel strand: a) b) No. of strands Diameter of strand Standard Nos. Mm 7

3.66 Page 227

Jindal India Thermal Power Limited

Volume-II / Section-IX Maximum Minimum c) 4. Sectional area of strand Mm Mm

EPC Tender for JITPL 3.75 3.57

sq.mm.

Zinc coating of steel strand: a) Uniformity of coating (number and duration of dips withstood) Minute duration of dips i) One ii) Half b) Minimum weight of coating

No. No. g/m.sq. mm sq.mm.

4 1 275 10.98 73.65

5.
6. 7. 8.

Standard overall diameter of steel wire Total area of cross section of steel wire. Guaranteed ultimate tensile strength of steel wire D.C. resistance in ohms per km. At 20 deg.C Standard length of steel wire (minimum) Tolerance if any of standard length Random length of steel wire Random lengths in No. Modulus of elasticity of steel wire Co-efficient of linear expansion 1) Strand lay and lay length a) Maximum b) Standard c) Minimum Direction of lay of outer layer

N/mm2 1100 2.5 Km % Km No. Kg/mm 19x10 /deg.C 11.5x10-6 2.0 +/-5

9. 10.
11. 12. 13. 14. 15.

mm mm mm

198 181 165

2)

Right/L Right hand eft Kg/Km 583 Page 228

16.

Weight of steel wire

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17. 18.
19.

Standard length of steel wire in each drum Standard weight of steel wire on the drum Weight of empty drum Gross weight of the drum Dimension of the drum in cms. Initial and final sags and tension and stringing charts, whether furnished. Standard according to which the steel wire will be manufactured Other particulars, if any Separate winding & unwinding facilities for inspection purpose whether available.

Meter Kg. Kg. Kg. GWB Yes/No

2000

20.
21. 22.

23.

IS or equival ent

24. 25.

Yes/No

Name of the Firm: Signature of the Bidder: Designation: Date:

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ANNEXURE 7 TESTS ON EARTHWIRE 1 UTS Test on Earthwire


A sample of earthwire of about 5 m length will be subjected to the ultimate

Tensile strength test. The earthwire shall not fail at a value less than 68.4 KN. 2 Surface Condition Test

A sample of earthwire of 5 m length shall be subjected to a load of 50% of the UTS of the earthwire. Neither shall the surface depart from its cylindrical form nor the strands move relative to each other so as to get out of place or disturb the

longitudinal smoothness of the earthwire. 3 D.C. Resistance Test

On strand of minimum 5 m length, two contact clamps shall be fixed. The

Resistance shall be measured by Kelvin bridge by placing the clamps initially from one end and subsequently one meter apart. The test shall be repeated at each meter length and the value recorded. The value obtained shall be corrected to the value at 20 deg.C. 4 Visual Check for joints/lengths

Two drums from each lot/50Km. whichever is less, shall be selected at random and rewound in the presence of the inspector and actual length of earthwire measured. The weight of the earthwire also will be measured by weighing empty drum and drum with earthwire. The inspector shall visually check for scratches, joints etc. and see that the earthwire generally conforms to the requirements of this specification. The expenditure for above measurements, if any, will be to the bidders account. The firm should have separate facility for winding and unwinding for inspection purpose. 5 Visual Check on Drums The drums shall be visually and dimensionally checked to ensure that they conform to these specifications. 6 Chemical analysis of Zinc used for galvanizing

Samples taken from the zinc ingots shall be chemically/ spectrographically analyzed as per IS-209. The purity of zinc shall not be less than 99.95%.

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Wrapping Test

One specimen cut from each of the samples of galvanized steel wire shall be wrapped round a mandrel of diameter equal to 4 times the wire of diameter to form a close helix of 8 turns. Six turns shall be unwrapped and again closely wrapped in the same direction as before. The wire shall not break. 8 Lay Length Check The lay length shall be checked to ensure that they confirm to the requirement of the specification.

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ANNEXURE - 8 TEST PROCEDURE FOR INSULATORS 1.0 PROCEDURE FOR MOUNTING INDIVIDUAL DISC AND COMPLETE STRING FOR MEASUREMENT OF RIV, VOLTAGE DISTRIBUTION & VISIBLE DISCHARGE: The insulator unit or insulator string shall be suspended vertically by
means of an earthed wire rope or other suitable means from a supporting structure. The distance between the upper most point of the insulator metal work and the supporting structure shall be not less than 1 meter. No other object shall be nearer to the insulator than 1 meter or 1.5 times the length of the insulator string, whichever is greater. A length of conductor in the

a)

form of a straight smooth metal rod or tube shall be attached to the lower integral fitting of the insulator unit or insulator string so that it lies in a horizontal plane and the distance from the lowest shed of porcelain part to the upper surface of the conductor shall be as short as possible but greater than 0.5 times the diameter of the lowest insulator. b) c) The diameter of the conductor shall be about 1.5% of the length of the insulator unit or insulator string with a minimum of 25 mm. The length of the conductor shall be at least 1.5 times that of the insulator unit or insulator string and it shall extend at least 1 meter on each side of the vertical axis. Precaution shall be taken to avoid flashover from the ends of the conductor. The test voltage shall be applied between the conductor and earth. MOUNTING PROCEDURE FOR COMPLETE STRING FOR WET POWER FREQUENCY, WET SWITCHING SURGE AND DRY IMPULSE WITHSTAND TESTS: The insulator string shall be suspended vertically in an arrangement
simulating a tower body and cross arm. The cross arm is simulated by a horizontal member, the insulator string being at one end and the vertical member simulating the tower body at the other. Both members and the link supporting the insulator string shall be earthed. The width of each member facing the insulator string shall be from 400 mm minimum to at least 20% of the length of the insulator string. The distance between the

d)

e) 2.0

a)

axis of the insulator string and the vertical member simulating the tower Jindal India Thermal Power Limited Page 232

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body shall be between 1.2 and 1.5 times the length of the insulator string. The distance between the upper most point of the insulator string and the lower part of the horizontal member simulating the cross arm shall be equal to about 300 mm. The member simulating the tower body shall extend to at least twice the length of the insulator string below the member simulating the tower cross arm. b) A bundle consisting of two/quad sub conductors in the form of straight smooth metal rods or tubes shall be attached to the lower integral fittings of the insulator string at right angles to the cross arm. The two/quad sub conductors of the bundle shall be maintained parallel by means of horizontal spacers, the sub conductor spacing shall be equal to about one tenth of the length of the insulator string. The bundle shall extend approximately for the length of the insulator string on each side of the axis of the insulator string and diameter of each sub conductor shall be between 0.75% and 1.25% of the length of insulator string. To avoid spark over from the two ends of the bundle, each end shall be protected by means of a suitable device (for instance by means of metal ring). The height of the conductor above ground shall be equal to about 1.5 times the length of the insulator string but not less than 6 meters. The test voltage shall be applied between the conductor bundle and earth, the H.V. connection being made at one end of the conductor bundle. During the test, no object other than those described in this clause shall be nearer to the live end of the insulator string than 1.5 times the length of string. The insulator string shall be complete with those parts, which are considered necessarily associated with the string and are specified as such by the manufacturer. TESTING PROCEDURE FOR DYNAMIC TEST (VIBRATION TEST): Complete string is to be subjected to aeolian vibrations by suitable arrangement, while keeping the tension at every day stress (e.d.s). The string shall be vibrated at frequencies and double amplitude as already agreed between Owner and Contractor for 10 million cycles. After 5 million cycles, the string shall be rotated through 90 in horizontal plane. For 'V'/'I' suspension string & quad tension string, the e.d.s. will be 4600 kgs per conductor. All discs shall be thoroughly checked for any damage, cracks, loosening of pins/caps. Thereafter, all the discs will be subjected to electrical routine test, electro mechanical failing load test and porosity test. The string shall be deemed to have passed the dynamic test if it withstands all these tests. Jindal India Thermal Power Limited Page 233

c)

d)

e)

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4.0

TESTING PROCEDURE FOR WET POWER FREQUENCY WITHSTAND TEST:(As per IEC: 60383/IS: 731) The insulator string shall be mounted as per mounting arrangement given above in Clause 2.0. The characteristics of artificial rain shall be in accordance with Clause 3.3 of IS 2071 (Part-I). The test voltage to be applied to the insulator string shall be the wet power frequency withstands voltage adjusted for atmospheric conditions at the time of test. A voltage of about 75% of the test voltage so determined shall be applied and then increased gradually with a rate of rise of about 2% of this voltage per second. The test voltage at full value shall be maintained for one minute. No flashover or puncture shall occur during this period. TESTING PROCEDURE FOR WET SWITCHING SURGE WITHSTAND TEST: (As per IEC: 60381/IS: 731) The insulator string shall be mounted as per mounting arrangement given above (Clause 2.0). The impulse generator shall be adjusted to produce a 250/2500 second impulse wave. Impulse waves of both positive and negative polarity shall be used. Wet tests shall be made under the conditions prescribed in specified standards. The withstand test shall be performed at a specified switching impulse voltage with application of corrections for atmospheric conditions. Fifteen impulses shall be applied to the insulator string under test. If the number of flashovers on the external insulation does not exceed two, the insulator string shall be deemed to have complied with this test requirement. The insulators shall not be damaged by the test but slight marks on the surface of the insulating parts or chipping of the cement or other material used for assembly is permitted. TESTING PROCEDURE FOR DRY LIGHTNING IMPULSE VOLTAGE WITHSTAND TEST: (As per IEC: 60383/IS: 731) The insulator string shall be arranged as per mounting arrangement given above (Clause 2.0). Impulse waves of both positive and negative polarity

a)

b)

c)

d)

5.0 a)

b)

c.

6.0

a)

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shall be used. However, when it is evident which polarity will give the

lowest flashover voltage it will suffice to test with that polarity. b) The impulse generator shall be adjusted to produce a standard 1.2/50 second impulse wave of a value equal to the specified value of the impulse withstand voltage corrected for atmospheric conditions. Five such impulses shall be applied. If there is no flashover or puncture, the insulator shall be considered to have passed the test. If during the application of these five impulses, puncture occurs or if there is more than one flashover, the insulator shall be considered to have failed to comply with the test requirement. If only one flashover occurs, a new series of ten impulses shall be applied. The insulator will be considered to have passed the test only if during this new series of impulses there is no flashover or puncture. The insulators shall not be damaged by the test but slight marks on the surface of the insulating parts or chipping of the cement or other material used for assembly is permitted. TESTING PROCEDURE FOR MECHANICAL STRENGTH TEST: The complete disc insulator string consisting of number of units as stipulated alongwith its hardware fitting excluding arcing horn, corona control ring/grading ring and suspension/dead end assembly shall be mounted in the Tensile Testing Machine. The assembly shall then be subjected to a tensile load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. This load shall be maintained on the string for five minutes and then removed. After removal of the load the string shall be unloaded and dismantled with hand or small hand tools and the string components shall be inspected for visual deformation. Should any difficulty be experienced in dismantling and re-assembling the string with hand or small hand tool and/or if there is any visual deformation caused by the application of the above load, the string shall be deemed to have failed in this test. If the string can be re-assembled, it shall again be mounted in the tensile testing machine and loaded up to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS is reached and held there for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded. The string shall be deemed to have passed the test if the breakage occurs at a load not lower than guaranteed E&M strength.

c)

d)

7.0 a)

b)

c)

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8.0 a)

TESTING PROCEDURE FOR TIME LOAD TEST: The insulator string shall first be subjected to 5 minutes power frequency routine test. After successful completion of this test, the insulator string shall be mounted vertically/horizontally and subjected to a load equal to 66% of the specified mechanical strength for duration of 24 hours. After the completion of above period if the string is found to be intact on visual examination, it shall again be subjected to 5 minutes power frequency routine test. The string shall be deemed to have passed the time load test if it successfully withstands 5 minutes power frequency routine test. TESTING PROCEDURE FOR VOLTAGE DISTRIBUTION TEST: The voltage across each insulator unit shall be measured by sphere gap method. The result obtained shall be converted into percentage and proportionate correction be applied so as to give a total of 100% distribution. The voltage across any disc shall not exceed the specified values.

b)

9.0

10.0

TESTING PROCEDURE VOLTAGE TEST (Dry):

FOR

CORONA

EXTINCTION

The sample assembly when subjected to power frequency voltage shall have a corona extinction voltage of not less than the value specified under dry condition. There shall be no evidence of corona on any part of the sample when all possible sources of corona are photographed in a darkened room.
11.0

TESTS ON INDIVIDUAL DISCS: VISUAL EXAMINATION: Visual examination shall be made at random on the lot of insulators. The color of the insulator shall approximate to the color specified. Some variation of color shade is permitted and shall not justify rejection of the insulator. The insulator shall be free from physical distortion of shape within tolerance specified. Defects such as looseness of pins/caps, cracks etc. in the metal part shall be checked.

11.1

a)

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The area specified as glazed on the drawing shall be covered by a smooth hard glaze, free from cracks and other defects prejudicial to satisfactory performance in service. Out of the areas specified as glazed on the drawing the total area not covered by glaze shall not exceed. 1 + DF . cm2 2000 Also the area of any single glaze defect shall not exceed: 0.5 + DF . cm2 20000 Where: D is the greatest diameter of the insulator in cm. F is the creepage distance of the insulator in cm.

c)

11.2

VERIFICATION OF DIMENSIONS: The dimension of the insulator shall be checked with the approved drawing. Unless otherwise specified, the tolerance in the diameter shall be: (0.04D + 1.5) mm for D less than or equal to 300 mm and (0.03D + 6) mm for D more than 300 mm. Where: D = Specified insulator diameter in mm. The tolerance in spacing shall be (0.03S + 0.3) mm. Where: S = Specified insulator spacing in mm.

11.3

ECCENTRICITY TEST (AXIAL RUNOUT & RADIAL RUNOUT): The insulator shall be vertically mounted on a fixture using dummy pin and socket. A vertical scale with horizontal slider shall be used for the axial run out. The pointer shall be positioned in contact with the bottom of the outermost petticot of the disc. The disc insulators shall be rotated with reference to the fixture and the slider shall be allowed to move up and down on the scale but always maintaining contact with the bottom of the outermost petticot. After one full rotation of the disc the maximum and minimum position the slider has reached on the scale can be found out.

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Difference between the above two readings shall satisfy the guaranteed

value for axial run out.


Similarly, using a horizontal scale with vertical slider the radial run out shall be measured. The slider shall be positioned on the scale to establish contact with the circumference of the disc insulator and disc insulator rotated on its fixture always maintaining the contact. After one full rotation the maximum and minimum position of the slider reached on the scale are found out. The difference between the above readings shall

satisfy the guaranteed value for radial run out. 11.4 DRY LIGHTNING IMPULSE VOLTAGE WITHSTAND TEST: Please refer to Clause No. 6.0 for Testing Procedure.
11.5

WET POWER FREQUENCY WITHSTAND TEST: Please refer to Clause No. 4.0 for Testing procedure.

11.6

RADIO INTERFERENCE VOLTAGE TEST:(As per IS 8263) Insulator string or insulators shall be mounted as per mounting arrangement given above (Clause 1). As radio interference level may be
affected by fibres or dust setting on the insulator, the insulators may be

a)

wiped with a clean cloth before taking a measurement. The atmospheric conditions during tests shall be recorded. It is not known what correction factors apply to radio interference testing, but it is known that test may be sensitive to high relative humidity exceeding 80%. b) The test circuits may be either NEMA-107 or as per Fig.1 of IS: 8263. The measuring set shall be tuned to 0.5MHz + 10% frequency and the results shall be expressed as dB above 1 volt across a resistance of 300 Ohm. A voltage of 10% higher than the specified test voltage shall be applied to the object under test and maintained for at least 5 minutes. The voltage shall then be decreased by steps down to 30% of the specified test voltage, raised again by steps to the initial value and finally decreased by steps to the 30% value. At each step, a radio interference level as recorded during third run v/s the applied voltage shall be plotted. The curve so obtained is the radio interference characteristics of the insulator. Each voltage step shall be approximately 10% of the specified test voltage.

c)

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The insulator unit passes the radio interference test if the radio interference level at the specified test voltage, as read from the radio interference characteristic, does not exceed the specified radio interference level. Furthermore, no sudden increase shall be found on the radio interference characteristic between the specified test voltage and 1.1 times the specified test voltage. Because of high variability, it is preferable to make radio interference measurements on a number of insulators. The radio interference characteristic is the mean corona obtained after taking into account all measurements made on insulators of one type. TEST PROCEDURE FOR THERMAL-MECHANICAL PERFORMANCE TEST (As per IEC 575) The test shall be conducted on string of 5 or 10 or 15 units.

11.7

a)

This test has an initial stage of thermal cycles together with mechanical loading and unloading and a concluding stage of testing the insulator units to failure. Such a failing load test constitutes the basis of the thermal mechanical performance test in judging the test results. During the initial stage of test, the insulator units shall be subjected to four 24 hours cycles of cooling and heating and to a tensile load equal to 60% of the specified electro-mechanical failing load. The tensile load shall be applied to the insulator units at room temperature before starting the first thermal cycle. Each 24 hours cycle shall comprise a cooling to -30 50C and a heating to +40 50C. The temperature limits for temporary range of 400C may be suitably changed where the prevailing conditions so require. The temperature sequence shall be first cooling, then heating. The temperature equipment shall be such as to permit keeping of minimum and maximum temperatures each for at least four consecutive hours of the temperature cycle. The tensile load shall be completely removed and reapplied towards the end of each heating period, the last one excepted. On completion of the fourth 24 hours cycle and cooling to room temperature the tensile load shall be removed on the same day. After this load removal, the insulator units shall be subjected individually to an electromechanical strength test. The performance of insulator unit will be determined by comparison of the failing load values and the fracture pattern obtained during the electromechanical strength test. Page 239

b)

c)

d) e)

f)

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11.8

RESIDUAL STRENGTH TEST The test shall be conducted in accordance with clause No. 4.4 and 4.5 of IEC: 797 proceeded by temperature cycle test. The sample size shall be 25 and the evaluation of results and acceptance criteria shall be as per Clause No. 4.6 of IEC: 797.

12.0

HYDRAULIC INTERNAL PRESSURE TEST ON SHELLS: The test shall be carried out on 100% disc insulator shells before assembly. The insulator should withstand required pressure for the preset time of one second (min.) without breaking.

13.0

HIGH FREQUENCY TEST ON SHELLS: The test shall be carried out on 100% disc insulator shells before assembly. The insulators should withstand applied High Frequency voltage for 5 minutes without puncture.

A)

TESTS ON BOUGHT-OUT ITEMS: Forged Components (Ball Pins):

1)

a) Visual inspection: All material (100% samples) shall be visually checked for forging defects and general appearance. b) c) Dimensional check: At random check of not less than 1 sample per lot. The acceptance norm shall be dimensions as per drawing. Guage Check: The test shall be conducted on 100% samples with GO and NO GO gauges. The acceptance norm shall be dimensions as per approved drawing/relevant IS. Normalising: Time temperature chart/Graph from output of recorder shall be verified. The same shall conform to required standard. Hardness test: The test shall be conducted on minimum of 2 samples per lot of 1000 nos. The acceptance norm shall be hardness as per IS:1500/175-210 BHN. Grain Size: The test shall be conducted on minimum of 2 samples per lot of 1000 nos. The acceptance norm shall be grain size of 6 microns and above (ASTM No. 6 and above).

d)

e)

f)

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Inclusion rating : The test shall be conducted as per IS:4163 on minimum of 1 sample per lot of 1000 nos. The acceptance norm shall be inclusion rating of ASTM 2 thick series or less. Chemical analysis: The test shall be conducted on minimum of 1 sample per lot per heat no. The acceptance norm shall be chemical composition as per BS:970 for EN-8D steel or equivalent. Failing Load test: At random check of not less than 2 samples per lot of 1000 nos. The sample shall be subjected to proof load limit and held for one minute. The load shall be released and there shall not be any crack or permanent deformation. Thereafter, the sample shall be subjected to further loading up to its recommended breaking load and actual breaking load shall be noted. Magnetic Particle Examination: The test shall be conducted on 100% samples as per IS:3703 for detection of longitudinal and transverse cracks. There shall not be any surface or sub-surface cracks. Malleable Cast Iron Cap:

h)

i)

j)

2)

a) Visual inspection: All material (100% samples) shall be visually checked for freedom from casting defects and identification mark. The surface shall be free from casting defects and shall be cleanly fettled. The cap shall bear identification mark of the manufacturer. b) c) Dimensional check: At random check of not less than 1 sample per lot of 1000 nos. The acceptance norm shall be dimensions as per drawing. Guage Check: The test shall be conducted on 100% samples with GO and NO GO gauges. The acceptance norm shall be dimensions as per approved drawing/relevant IS. Hardness test: The test shall be conducted on minimum of 2 samples per lot of 1000 nos. The acceptance norm shall be hardness as per IS:2108/150 BHN max. Chemical analysis: The test shall be conducted on minimum of 1 sample per 5000 nos. The acceptance norm shall be chemical composition confirming to grade BM:320 or equivalent. Failing Load test: At random check of not less than 2 samples per lot of 1000 nos. The sample shall be subjected to proof load limit and held for one minute. The load shall be released and there shall not be any crack or permanent deformation. Thereafter, the sample shall be subjected to

d)

e)

f)

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further loading upto its recommended breaking load and actual breaking

load shall be noted. g) Magnetic Particle Examination: The test shall be conducted on 100% samples as per IS:3703 for detection of longitudinal and transverse cracks. There shall not be any surface or sub-surface cracks. Security clip:

3)

a) Visual inspection: All material (100% samples) samples shall be inspected


for corrosion and surface irregularities. The acceptance norm shall be as

per IS:3063. b) Dimensional check: At random check of not less than 1% sample per lot. The acceptance norm shall be dimensions as per IEC:372/ IS:2486(IV). Resistance to bending: At random check of not less than 1 sample per lot. The acceptance norm shall be as per IEC:372/IS:2486(IV). Operation test: At random check of not less than 1 sample per lot. The acceptance norm shall be as per IEC:372/IS:2486(IV). Hardness test: At random check of not less than 2 samples per lot. The acceptance norm shall be hardness not less than 152 BHN for R-clip and 143 BHN for W-clip. Chemical analysis: At random check of not less than 1 sample per lot. The acceptance norm shall be chemical composition confirming to AISI:304/316 grade as per ASTM A 276. Hot Dip Galvanized components: Test on Raw material Chemical analysis of Zinc: At random check of not less than one sample per lot. The acceptance norm shall be grade Zn98 (% of zinc > 99.95%) as per IS:209. Galvanizing checking: Visual inspection: All material (100% samples) shall be visually checked as per IS: 2629. The finished surface shall be clean, smooth and shall be free from defects like discoloured patches, bare spots, unevenness of coating, spelter which is loosely attached to the steel, globules, spiky deposits, blistered surface, flaking or peeling off etc.

c)

d)

e)

f)

B) I) 1)

II)

1)

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Uniformity of zinc coating: At random check of not less than 2 samples per lot. The test shall be conducted as per IS: 2633 and the samples shall withstand minimum 4 dips of 1 minute each in standard CuSO4 solution without showing signs of red deposits of copper. Thickness of zinc coating: At random check of not less than 1 sample per lot. The acceptance norm shall be thickness of coating not less than 610 gms/mm2. Adherence of zinc coating: At random check of not less than 2 samples per lot. There shall be no flaking or loosening when struck squarely with a chisel faced hammer.

3)

4)

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ANNEXURE-9 a) GUARANTEED TECHNICAL PARTICULARS FOR DISC INSULATOR UNIT Sr. No. INSULATOR TYPE PARTICULARS Manufacturers name, address and country Size and designation of Ball & Socket and standard to which it will conform (mm) Outside diameter of disc (mm) Spacing (mm) Eccentricity of disc Axial runout(mm) Radial runout(mm) Creepage distance of disc (mm) Electro-mechanical strength of disc(KN) Withstand voltage of disc Power frequency Dry (kV rms) Wet (kV rms) 160 KN (N) 160 KN (AF) 120 KN (N) 120 KN (AF)

1)

2)

3)

4) 5) a)
b)

6)

7)

8) 8.1 a) b)

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8.2 a) b)

Impulse voltage (1.2/50 sec) +ve (kV peak) ve (kV peak) Flashover voltage of Disc Power frequency Dry (kV rms) Wet (kV rms) 50% Lightning impulse voltage (1.2/50 (sec) (ve (kV peak) (ve (kV peak) Corona inception voltage (kV rms) Corona extinction voltage (kV rms) Max. RIV at 1 MHz and 10 KV AC (rms) Weight of each disc (kgs)

9 9.1 a) b) 9.2 a) b) 10)

11)

12)

13)

Signature of the Bidder.......... Name............................. Designation...................... Date.............................

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EPC Tender for JITPL Common authorized seal of the bidder...............

b) GUARANTEED TECHNICAL PARTICULARS FOR DISC INSULATOR STRING (400 KV) Sr. No. STRING TYPE PARTICULARS No. of insulator discs per string Withstand voltage of complete string Power frequency Dry (kV rms) Wet (kV rms) Impulse voltage (1.2/50 sec) +ve (kV peak) ve (kV peak) Flashover voltage of complete string Power frequency Dry (kV rms) Wet (kV rms) 50% Lightning impulse voltage (1.2/50 sec) +ve (kV peak) ve (kV peak) SINGLEI SUSPENSION (120 KN) N/AF DOUBLEI SUSPENSION (120KN) N/AF QUAD TENSIO N (160KN) N/AF

1)

2) 2.1 a) b) 2.2 a) b) 3) 3.1 a) b) 3.2 a) b)

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4)

Corona inception voltage (kV rms)

5) Corona extinction voltage (kV rms) 6) Max. RIV for complete string including corona rings, arcing horns, clamps etc. at 1.1 times maximum line to ground voltage (in (volts) Max. voltage (%) across any disc in the string Electromechanical strength of complete string (KN)

7)

8)

Signature of the Bidder.......... Name............................. Designation...................... Date............................. Common authorized seal of the bidder...............

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ANNEXURE 10 1.0 1.1. Tests on Complete Strings with hardware Fittings Voltage Distribution Test The voltage across each insulator unit shall be measured by sphere gap method. The result obtained shall be converted into percentage. The voltage across any disc shall not exceed 9% for suspension insulator strings and l0% for tension insulator strings. Corona Extinction Voltage Test (Dry)
The sample assembly when subjected to power frequency voltage shall have a

1.2.

1.3.

corona Extinction voltage of not less than 320 kV (rms) line to ground under dry condition. There shall be no evidence of corona on any part of the sample. The atmospheric condition during testing shall be recorded and the test results; shall be accordingly corrected with suitable correction factor as stipulated in IEC:383. RIV Test Under the conditions as specified under (2) above, the insulator string alongwith complete hardware fittings shall have a radio interference voltage level below 1000 micro volts at one MHz when subjected to 50 Hz AC voltage of 305kV line to ground under dry condition. The test procedure shall be in accordance with IS:8263/IEC-437 Mechanical Strength Test
The complete insulator string alongwith its hardware fitting excluding arcing

1.4.

horn, corona control ring, grading ring and suspension assembly /dead end assembly shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. After removal of the load, the string components shall not show any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to remove cotter pins and loosen the nuts initially. The string
shall then be reassembled and loaded to 50% of UTS and the load shall be

1.5.

further increased at a steady rate till the specified minimum UTS and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded. Vibration Test The suspension string shall-be tested in suspension mode, and tension string in
tension mode itself in laboratory span of minimum 30 meters. In the case of

suspension string a load equal to 600 kg shall be applied along the axis of the suspension string by means of turn buckle. The insulator string alongwith Jindal India Thermal Power Limited Page 248

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hardware fittings and two/four sub-conductors each tensioned at 43KN incase of ACSR Moose/AAAC Moose shall be secured with clamps. The system shall be suitable to maintain constant tension on each sub- conductors throughout the duration of the test. Vibration dampers shall not be used on the test span. Both the sub-conductors shall be vertically vibrated simultaneously at one of the resonance frequencies of the insulators string (more than 10 Hz) by means of vibration inducing equipment. The peak to peak displacement in mm of vibration at the antinode point nearest to the string shall be measured and the same shall not be less than 1000/f1.8 where f is the frequency of vibration in cycles/sec. The insulator string shall be vibrated for not less than 10 million cycle; without any failure. After the test the disc insulators shall be examined for looseness of pins and cap or any crack in the cement. The hardware shall be examined for looseness, fatigue failure and mechanical strength test. There shall be no deterioration of properties of hardware components and disc insulators after the vibration test. The disc insulators shall be subjected to the following tests as per relevant standards: Sr.No. Test a) b) Temperature cycle test followed 60 by mechanical performance test Puncture test/steep wave front test (only for glass insulators) Power Arc test This test shall be performed on the complete string in accordance with IEC Technical Report IEC:61467-1997 with the following test series: Test circuit B Short circuit current In = Isys = 40 KA Number and duration of test Two of tn = 0.2s and One of tn = 0.5 s The acceptance criteria after the completion of test series shall be following a) Insulation separation not permitted. b) Burning/Melting of metal components, breakage of insulator sheds, glaze removal are permitted. c) The complete insulator string alongwith its hardware fittings including arcing horn, corona control ring/grading ring shall withstand 80% of UTS. Tests on Hardware Fittings Magnetic Power Loss Test for Suspension Assembly
40

Percentage of insulator units to be tested Disc Insulators Long Rod Insulators 100

1.6.

2.0 2.1.

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Four hollow aluminium tubes of 32 mm diameter shall be placed 457 mm apart respectively and alternating current over the range of 400 to 800 amps shall be passed through each tube. The reading of the watt meter with and without two suspension assembly alongwith line side yoke plate, clevis eye shall be recorded. Not less than three suspension assemblies shall be tested. The average power loss for suspension assembly shall be plotted for each value of current. The value of the loss corresponding to 600 arnperes shall be read off from the graph. 2.2. Galvanising/Electroplating Test The test shall be carried out as per.Clause no. 5.9 of lS:2486-(Part-l) except that both uniformity of zinc coating and standard preecee test shall be carried out and the results obtained shall satisfy the requirements of this specification. Mechanical strength Test of Each Component Each Component shall be subjected to a load equal to the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for five minutes and then removed. The component shall then again be loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified UTS and held for one minute. No fracture should occur. The applied load shall then, be increased until the failing load is reached and the value recorded. Mechanical Strength Test of Welded Joint The welded portion of the component shall be subjected to a Load of 2000 kgs for one minute. Thereafter, it shall be subjected to die-penetration / ultrasonic test. There shall not be any crack at the welded portion. Clamp Slip Strength Vs Torque Test for Suspension Clamp The suspension assembly shall be vertically suspended by means of a flexible attachment. A suitable length of ACSR MOOSE Conductor shall be fixed in the clamp. The clamp slip strength at various tightening torques shall be obtained by gradually applying the load at one end of the conductor. The Camp slip strength vs torque curve shall be drawn. The clamp slip strength at the recommended torque shall be more than 20kN but less than 29kN
2.6.

2.3.

2.4.

2.5.

Shore HardnessTest for Elastomer Cushion The shore hardness at various points on the surface of the elastomer cushion shall be measured by a shore hardness meter and the shore hardness number shall be between 65 to 80 Proof Load Test Each component shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength which shall be increased at a steady rate to 67% of the UTS specified. The load shall be held for one minute and then removed. After removal of the load the component shall not show any visual deformation.

2.7.

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2.8.

Tests for Forging Casting and Fabricated hardware The chemical analysis, hardness test, grain size, inclusion rating and magnetic
particle inspection for forging, castings and chemical analysis and proof-load

test for fabricated hardware shall be as per the internationally recognized


procedures for these tests. The sampling will be based on heat number and heat

2.9.

treatment batch. The details regarding test will be as in the Quality Assurance programme. Mechanical Strength test for suspension/tension hardware fittings The complete string without insulators- excluding arcing horn, corona control rings/grading ring and suspension assembly/dead end assembly shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. This load shall be held for five minutes and then removed. After removal of the load, the string component shall not show any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to remove cotter-pins and loosen the nuts initially. The string shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS is reached and held for one minute. No fracture should occur during this period. The applied load shall then be increased until the failing load is reached and the value recorded.

2.10.

Ozone Test for Elastomer This test shall be performed in accordance with ASTM D-1171 by the Ozone chamber exposure method (method B). The test duration shall be 500 hours and the ozone concentration 50 PPHM. At the test completion, there shall be no visible crack under a 2x magnification.

3.0 3.1.

Tests on Conductor and Earthwire Accessories Mid Span Compression Joint for Conductor and Earthwire Slip Strength Test The fitting compressed on conductor/earthwire shall not be less than one meter in length. The test shall be carried out as per IS:2121 (Part-II) Cause 6.4 except that the load shall be steadily increased to 95% of minimum ultimate tensile strength of conductor/earthwire and retained for one minute at this load. There shall be no movement of the conductor/earthwire relative to the fittings and no failure of the fittings during this one minute period.

3.2.

T-Connector Axial Tensile load test for welded portion The sleeve portion of the T-Connector shall be compressed on Conductor. The compressed portion shall be held rigidly on some fixtures and axial load shall be applied alongwith the jumper terminal. The load shall be increased gradually till breaking of welded joint occurs. The breaking load should be above 30 KN

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3.3.

Flexible Copper Bond Slip Strength Test On applying a load of 3 kN between the two ends, stranded flexible copper cable shall not come out of the connecting lugs and none of its strands shall be damaged. After the test the lugs shall be cut open to ascertain that the gripping of cable has not been affected.

3.4.

Vibration Damper for Earthwire (a) Dynamic Characteristic Test The damper shall be mounted with its clamp tightened with torque recommended by the manufacturer on shaker table capable of simulating sinusoidal vibrations for aeolian vibration frequency band ranging from 10 to 60 Hz for damper for earthwire. The damper assembly shall be vibrated vertically with a1 mm amplitude from 5 to 15 Hz frequency and beyond 15 Hz at 0.5mm to determine following characteristics with the help of suitable recording instruments (i) Force Vs frequency (ii) Phase angle Vs frequency (iii) Power dissipation Vs frequency The Force Vs frequency curve shall not show steep peaks at resonance frequencies and deep troughs between the resonance frequencies. The resonance frequencies shall be suitably spread between the Aeolian vibration frequency band between the lower and the upper dangerous frequency limits determined by the vibration analysis of earthwire without dampers. Acceptance criteria for vibration damper (i) The above dynamic characteristic tests on five dampers shall be conducted (ii) The mean reactance and phase angle Vs frequency curves shall be drawn with the criteria of best fit method. (iii) The above mean reactance response curve should lie within 0.060f to 0.357f kgf/mm limits for earthwire damper where f is frequency in Hz. (iv) The above mean phase angle response curve shall be between 25 to 130 within the frequency range of interest (v) If the above curve lies within the envelope, the damper design shall be considered to have successfully met the requirement (vi) Visual resonance frequencies of each mass of damper is to be recorded and to be compared with the guaranteed values. (b) Vibration Analysis The vibration analysis of the earthwire - shall be done with and without damper installed on the span. The vibration analysis shall be done on a digital computer

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using energy balance approach. The following parameters shall be taken into account for the purpose of analysis:
(i) The analysis shall be borne for single earthwire without armour rods as per the parameters given under clause 2.7.13 and 3.3.8 of this part of the Specification. The tension shall be taken as 14 kN for earthwire for as span

ranging from 100m to 1100m. (ii) The self damping factor and flexural stiffness (El) for conductor and
earthwire shall be calculated on the basis of experimental results. The details of

experimental analysis with these data should be furnished. (iii) The power dissipation curve obtained from Dynamic Characteristics Test shall be used for analysis with damper. (iv) Examine the aeolian vibration level of the earthwire with and without vibration damper installed at the recommended location or wind velocity ranging from 0 to 30 Km per hour predicting amplitude, frequency and vibration energy input. (vi) From vibration analysis of earthwire without damper, antinode vibration amplitude and dynamic strain levels at clamped span extremities as well as antinodes shall be examined and thus lower and upper dangerous frequency limits between which the aeolian vibration levels exceed the specified limits shall be determined. (vi) From vibration analysis of earthwire with the damper/dampers installed at the recommended location, the dynamic strain level, at the clamped span extremities, damper attachment point and the antinodes on the earthwire shall be determined in addition to above damper clamp vibration amplitude and anti node vibration amplitude shall also be examined The dynamic strain levels al damper attachment points, clamped span extremities and the antinodes shall not exceed the specified limits. The damper clamp vibration amplitude shall not be more than that of the specified fatigue limits. (c) Clamp Slip and Fatigue Tests (i) Test Set Up The clamp slip and fatigue tests shall be conducted on a laboratory set up with a minimum effective span length of 30 m. The earthwire shall be tensioned at 14 kN and shall not be equipped with protective armour rods at any point Constant tension shall be maintained within the span by means of lever arm arrangement After the earthwire has been tensioned, clamps shall be installed to support the earthwire at both ends and thus influence of connecting hardware fittings are eliminated from the free span. The clamps shall not be used for holding the tension on the earthwire. There shall be no loose parts, such as suspension clamps, U bolts on the test span supported between clamps mentioned above. The span shall be equipped with vibration inducing equipment suitable for producing steady standing vibration. The inducing equipment shall have Jindal India Thermal Power Limited Page 253

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facilities for stepless speed control as well as stepless amplitude arrangement. Equipment shall be available for measuring the frequency, cumulative number of cycles and amplitude of vibration at any point along the span. (ii) Clamp Slip test The vibration damper shall be installed on the test span. The damper clamp, after lightning with the manufacturers specified tightening torque, when
subjected to a longitudinal pull of 2.5 kN parallel to the axis of earthwire for a minimum duration of one minute shall not slip i.e. the permanent displacement between conductor/earthwire and clamp measured after removal of the load shall not exceed 1.0 mm. The load shall be further increased till the clamp starts

slipping. The load at which the clamp slips shall not be more than 5 kN. (iii) Fatigue Test The vibration damper shall be installed on the test span with the manufacturers specified tightening torque It shall be ensured that the damper shall be kept minimum three loops away from the shaker to eliminate stray signals influencing damper movement. The damper shall then be vibrated at the highest resonant frequency of each damper mass. For dampers involving torsional resonant frequencies, tests shall be done at torsional modes also in addition to the highest resonant frequencies at vertical modes. The resonance frequency shall be identified as the frequency at which each damper mass vibrates with the maximum amplitude on itself. The amplitude of vibration of the damper clamp shall be maintained not less than 25/f mm, where f is the frequency in Hz. The test shall be conducted for minimum 10 million cycles at each resonant frequency mentioned above. During the test, if resonance shift is observed the test frequency shall be tuned to the new resonant frequency. The clamp slip test as mentioned hereinabove shall be repeated after fatigue test without re-torquing or adjusting the damper clamp, and the clamp shall withstand a minimum load equal to 80% of the slip strength for a minimum duration of one minute. After the above tests, the damper shall be removed from conductor/ earthwire and subjected to dynamic characteristics test. There shall not be any major deterioration in the characteristic of the damper. The damper then shall be cut open and inspected. There shall not be any broken, loose or damaged part. There shall not be significant deterioration or wear of the damper. The earthwire under clamp shall also be free from any damage. For the purpose of acceptance, the following criteria shall he applied (1) There shall not be any frequency shift by more than 2 Hz for frequencies lower than 15 Hz and 3 Hz for frequencies higher than 15 Hz. (2) The force response curve shall generally lie within guaranteed % variation in reactance after fatigue test in comparision with that before fatigue test by the Contractor Jindal India Thermal Power Limited Page 254

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(3) The power dissipation of the damper shall not be less than guaranteed %
variation in power dissipation before fatigue test by the Contractor. However, it shall not be less than minimum power dissipation which shall be governed by

3.5.

lower limits of reactance and phase angle indicated in the envelope. Spacer Damper a) Performance Test One very important quality of a spacer damper is its ability to control Aeolian vibrations and sub-span oscillations within acceptable limits. Performance
testing shall be carried out on an experimental test line, as described in Clause2.5.5 of this Section. After testing there shall not be any slippage greater than 3mm on conductors loosening of component or damage to conductors or

spacer damper components. i) Aeolian Vibrations Under the specified operating conditions the spacer damper shall control
Aeolian vibrations in order to prevent damage to conductors either at

suspensions clamp or at the spacer damper clamps. For measurements and evaluation purpose, the following criteria shall apply
The peak to peak amplitude of any vibration cycle shall never exceed 1.5 yb,

where yb is the safe Bending Amplitude.


The RMS value of any vibration measurement sample shall be lower than 0.6

yb/2, at 89 mm from last point of contact with suspension or spacer clamp. Sub-span Oscillationsii) The spacer damper system shall control sub-span oscillations in order to prevent
conductor damage due to clashing or to severe bending stresses at the spacer

damper clamp, and avoid wear of spacer dampers elements.


In order to achieve the performance level sub-span shall be controlled within the

following limits for any wind speed below 60km/hr. In any individual sub-span the peak to peak amplitude of each sub-conductor shall never exceed 350mm. In any individual sub-span, the RMS value (Yrms) of each oscillation measurement sample shall be such that: f Yrms<80mm/sec. Where Yrms=anti-node amplitude(mm) f=frequency of the oscillation (cycles/sec) f=(1/2) L=Sub-span length (m) T=Conductor tension (N) Jindal India Thermal Power Limited Page 255

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For any set of 10 or more measurement samples associated with a given wind sector and a given sub-span, the Yrms value shall be such that: f.Yrms The wind sector is defined as a combination of 5 km/hr wind speed range and 10 deg.C wind direction range Each measurement sample shall be at least one (1) minute long. b) Clamp Slip Test (for spacer for jumper also) The spacer damper assembly shall be installed on a four conductors bundle string at a tension of 41 kN. In case of spacer for juniper, the clamps of sample shall be tightened with a specified tightening torque. One of the sample clamps, when subjected to a longitudinal pull of 2.5 KN parallel to the conductor axis for a minimum duration of one minute, shall not slip on the conductor i.e. the permanent displacement between the conductor and the clamp of the sample measured after removal of the load shall not exceed 1.0 mm. Similar testing shall be performed of the other clamps of the same sample. For spacer dampers only, such clamp slip tests shall also be conducted after each of the vibration tests mentioned in Clause 5 (a) but under longitudinal load of 2 KN for a minimum duration of one minute after vibration test without any adjustment of sample. Dynamic Characteristic Test for Spacer Damperc) The purpose of this test is to obtain quantitative information regarding the dynamic characteristic of the spacer damper. The values obtained during this test will serve as references to evaluate the behaviour of the same spacer damper under the fatigue test The test will consist in the application of sinusoidal movement to the spacer damper articulation and measurement of the force (F), displacement (X) and phase angle between these two. From these values, the stiffness (K) and damping factor (n) shall be calculated as: K = F cos / Xn = cos The test frequency shall not be higher than 3 Hz. The test shall be performed at five different displacement amplitudes. The amplitudes shall be selected to reproduce 10, 20, 40, 60 and 90 per cent of the maximum displacement permitted by the spacer damper design. The test shall be performed on three samples. In case of spacer dampers with a single articulation for each arm, the central body shall be fixed and the arm rotated around the axis of the articulation in a plane perpendicular to the conductor. For spacer dampers using double articulated arms, the sinusoidal movement shall be applied between two arms corresponding to a horizontal pair of

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conductors. In this case, one spacer clamp may be fixed and the other displaced in its direction, the central body being free to move. d) Fatigue Test for Spacer Damper The purpose of this test is to evaluate the capacity of the spacer damper to sustain without damage the cyclic movements which can be induced by vibrations. The spacer damper articulation shall be subjected to cyclic motions for a total of 10 million cycles. The test frequency shall be between 2 and 3 Hz. The amplitude of motion shall be established on the following bases. the load applied on the spacer damper clamp shall not be less than 300N; the clamp displacement under the applied load shall not be less than 60% of the maximum displacement permitted by design; if the 300N toad generates movement exceeding the maximum permitted displacement, the load can be reduced to limit the movement to 95% of the maximum displacement. - After the test, the sample shall be subjected lo a second dynamic characteristic test. This test shall be performed at two amplitudes, 10% and 60% of the maximum displacement - The spacer damper shall show no signs of cracks or deterioration, loosening of bolts or abnormal wear The dynamic characteristics (k and n) shall be less than 60% of the values measured before the fatigue test. The test shall be performed on three samples. Ozone Teste)
-

This test shall be performed on elastomer/rubber components in accordance with ASTMD-1171 by the ozone chamber exposure method (method B). The test duration shall be 500 hours and the ozone concentration 50 PPHM. At the test completion, there shall be no visible crack under a 2x magnification. f) Compression and Tensile Tests Three samples of spacer dampers shall be subjected to a tension compression test. The load shall be applied between each pair of diagonally opposed conductors. Under the compressive load, the arms shall be allowed to rotate until they reach their mechanical stops. A compressive load of l5kN shall first be applied and held for five minutes. Then a tensile load of 5kN shall be applied on the same pair of arms. The test shall be repeated on the other pair of arms. After the test, the spacer damper must be dismantled and the components examined. There should not be any failure of components or damage impairing the reusability of the spacer damper such as permanent deformation. The spacer geometry shall be maintained within 5 % of the original dimensions. Magnetic Power Loss Test for Spacer Damper/Spacer for Jumper

3.6.

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The sample involving ferrous parts shall be tested in a manner to simulate

3.7.

service conditions for 50 Hz pure sine-wave. The test should be carried out at various currents ranging from 300 amperes to 900 amperes and the magnetic power loss at various currents should be specified in tabulated graphical form. The difference between the power losses without and with sample at room temperature shall be limited to 1 watt for 600 amperes current (rms) for ACSR MOOSE conductor. The losses shall be determined by averaging the observations obtained from atleast four Samples. Earthwire Suspension/Tension Clamp a) Mechanical Strength Test The suspension assembly/tension assembly (excluding tension clamp) shall be subjected to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be increased at a steady rate to 67% of the minimum UTS specified. This load shall be held for five minutes and then removed. After removal of the load, the components shall not show any visual deformation and it shall be possible to disassemble them by hand. Hand tools may be used to loosen the nuts initially. The assembly shall then be reassembled and loaded to 50% of UTS and the load shall be further increased at a steady rate till the specified minimum UTS is reached and held for one minute. No fracture should
occur during this period. The applied load shall then be increased until the

failing load is reached and the value recorded. b) Clamp Slip Strength Vs Torque Test for Suspension Assembly The suspension assembly shall be vertically suspended by means of a flexible attachment. A suitable length of Earthwire shall be fixed by the clamps. The clamp slip strength at various tightening torques shall be obtained by gradually applying the load at one end of the earthwire. The clamp slip strength Vs torque curve shall be drawn. The damp slip strength at the recommended tightening torque shall be more than 12kN but less than l7kN for7/3.66mm earthwire. c) Slip Strength Test of Tension Clamp Tension clamps shall be compressed on a 5 m length of earthwire on both ends. The assembly shall be mounted on a tensile testing machine and anchored in a manner similar to the arrangement to be used in service. A tensile load of 50% of the specified breaking load of the earthwire shall be applied & the sample shall be marked in such a way that movement relative to the fitting can easily be detected. Without any subsequent adjustment of the fitting, the load shall be steadily increased to 95% of the specified breaking load and maintained for one minute. There shall be no movement of the earthwire relative to the fitting during this one minute period and no failure of the fitting also. d) Electrical Resistance Test of Tension Clamp The tension clamp and the jumper shall be compressed on two suitable lengths of earthwire. The electrical resistance shall be measured between points on earthwire near the clamp and near the jumper mouth keeping 25 mm clearance Jindal India Thermal Power Limited Page 258

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of the fitting and should not exceed 75% of the measured resistance of
equivalent length of earthwire. The test shall be conducted with direct current.

The current connections shall be at a distance not less than 50 times the
diameter, of earthwire from the fitting and shall be made so that effective

contact is ensured with all those strands of the earthwire which would be taken
into account in calculating its equivalent resistance. The test shall be repeated with the polarity reversed and the average of the two results considered as the

measured value. 3.8. Corona Extinction Voltage Test (Dry) The sample when subjected to power frequency voltage shall have a corona extinction voltage of not less than 320 kV rms line to ground under dry condition. There shall be no evidence of corona on any part of the sample. The
atmospheric condition during testing shall be recorded and the test results shall 3.9.

he accordingly corrected with suitable correction factor as stipulated in IS: 731. Radio Interference Voltage Test (Dry) Under the conditions as specified under (3.8) above, the sample shall have a radio interference voltage level below l000 microvolts at one MHz when subjected to 50 Hz AC voltage of 305 kV rms line to ground, under dry condition. The test procedure shall be in accordance with IS: 8263 Chemical Analysis Test Chemical analysis of the material used for manufacture of items shall be conducted to check the conformity of the same with Technical Specification and approved drawing.

3.10.

4.0 4.1.

Tests on All components (As aplicab1e) Chemical Analysis of Zinc used for Galvanizing Samples taken from the zinc ingot shall be chemically analysed as per IS-2091979. The purity of zinc shall not be less than 99.95%. Tests for Forgings The chemical analysis hardness tests and magnetic particle inspection for forgings will be as per the internationally recognised procedures for these tests. The sampling will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance Programme. Tests on Castings The chemical analysis mechanical and metallographic tests and magnetic particle inspection for castings will be as per the internationally recognized procedures for these tests. The samplings will be based on heat number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance Programme.

4.2.

4.3.

Jindal India Thermal Power Limited

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EPC Tender for JITPL

ANNEXURE-11 ACCEPTANCE TESTS 1. Mid Span Compression Joint for Conductor and Earthwire Hardness Test The Brinnel hardness at various points on the steel sleeve of conduction core and of the Earthwire compression point and tension clamp shall be measured. T-Connector for Conductor (a) Axial Tensile Load Test for Welded Portion Same as clause 3.2 of Annexure - 10
3.

2.

Flexible Copper Band (a) Slip Strength Test Same as clause 3.3 of Annexure-10

4.

Vibration Damper for Earthwire (a) Verification of Resonance Frequencies


The damper shall be mounted on a shaker table and vibrate at damper

clamp displacement of +/- 0.5 mm to determine the resonance frequencies. The resonance shall be visually identified as the frequency at which damper mass vibrates with maximum displacement on itself. The resonance frequency thus identified shall be compared with the guaranteed value. A tolerance of 1 Hz at a frequency lower than 15 Hz and 2 Hz at a frequency higher than 15 Hz only shall be allowed. (b) Clamp Slip Test Same as Cause 3.4 (c) (ii) of Annexure 10 (c) Clamp Bolt Torque Test The clamp shall be attached to a section of the earthwire. A torque of 150 percent of the manufacturers specified torque shall be applied to the bolt. There shall be no failure of component parts. The test set up is as described in Clause 3.4 (c) (i), Annexure-10. (d) Strength of the Messenger Cable The messenger cable shall be fixed in a suitable tensile testing machine and the tensile load shall be gradually applied until yield point is reached.. Alternatively each strand of message caste may be fixed in a suitable tensile testing machine and the tensile load shall be gradually applied until yield point is reached. In such a case, the 95% of yield strength of each wire shall be added to get the total strength of the caste. The load shall be not less than, the value guaranteed by the Contractor (e) Mass Pull off Test

Jindal India Thermal Power Limited

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EPC Tender for JITPL

Each mass shall be pulled off in turn by fixing the mass at one jaw and the
clamp in the other of a suitable tensile testing machine. The longitudinal pull shall be applied gradually till the mass begins to pull out of the messenger cable.

(f)

The pull off loads shall not be less than the value guaranteed by the Contractor. Dynamic Characteristics Test The test will be performed as acceptance lest with the procedure mentioned for type test with sampling mentioned below Vibration Damper of 1 Sample for 1000 No,. & below Conductor nos
3 Samples for lot above 1000 & upto 5000

Additional 1 sample for every additional 1500 pieces above 5000.

The acceptance criteria will be as follows: (i) The above dynamic characteristics curve for reactance & phase angle will be done for frequency range of 10Hz to 60Hz for vibration damper for 7/3.66-mm earthwire. (ii) If all the individual curves for dampers are within the envelope as already mentioned for type test for reactance & phase angle, the lot passes the test. (iii) If individual resu1ts do not fall within the envelope, averaging of characteristics shall be done. (a) force of each damper corresponding to particular frequency shall be taken & average force of three dampers at the frequency calculated. (b) Similar averaging shall be done for phase angle. (c) Avenge force Vs frequency and avenge phase Vs frequency curves shall be plotted on graph paper. Curves of best fit shall be drawn for the entire frequency range. (d) The above curves shall be within the envelope specified. 5. Spacer Damper/ spacer for jumper (a) Test Set-up. The test set-up shall be as per Clause 3.4 (c) (i) of Annexure-10. (b) Movement Test The spacer assembly shall be capable of the following movements without damaging the conductor, assuming one conductor is fixed and the other moving (i) Longitudinal movement 50mm parallel to the conductor (ii) Vertical movement in a vertical direction at right angle to the conductor Jindal India Thermal Power Limited Page 261 25 mm

Volume-II / Section - IX (iii) Torsional movement/angular movement in a vertical plane parallel to the conductor (c) Compressive and Tensile Test

EPC Tender for JITPL 5 deg.

Test procedure shall be same as specified in Clause 3.5 (c) of Annexure-10. (d) Clamp Slip Test Same as clause 3.5(b) of Annexure-10 (e) Clamp Bolt Torque Test The spacer assembly shall be attached to conductor. A torque of 150 per cent of
the manufacturers specified tightening torque shall be applied to the clamp bolts

or cap screws. There shall be no failure of the component parts. (f) Assembly Torque Test
The spacer assembly shall be installed on conductor. The same shall not rotate

on either clamp on applying a torque of 0.04 kN in clockwise or anti clockwise direction. (g) Hardness test for Elastomer
The shore hardness at different points on the elastomer surface of cushion grip clamp shall be measured by shore hardness meter. They shall lie between 65 to

80. (h) UTS of Retaining Rods


The ultimate tensile strength of the retaining rods shall be measured. The value

shall not be less than 35 kg/sq. mm.

Jindal India Thermal Power Limited

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Volume-II / Section - IX

EPC Tender for JIT

ANNEXURE-12 GUARANTEED TECHNICAL PARTICULARS OF SUSPENSION HARDWARE FITTINGS FOR MOOSE ACSR CONDUCTOR `Description Unit Value Specified by the
Owner

Double I Suspension
AGS

Twin ACSR

Single Suspension (Pilot) Envelope


Twin ACSR

Moose Name of Manufacture Address of Manufacturer

Moose Office Works Watt / ASS KN Less than 4


watt

Value Guaranteed by the Bidder Double I Single Suspension Suspension AGS (Pilot) Twin ACSR Envelope Moose Twin ACSR Moose

Maximum magnetic power loss of suspension assembly at conductor current of 600 amps. Slipping Strength of suspension assembly (clamp torque Vs slip curve shall be enclosed) Particulars of standard / AGS preformed armour rod set for suspension assembly No. of rods per set Direction of lay Overall length after fitting on conductor Mm Actual length of each rod along its helix Mm

Less than 8
watt

20 to 29 KN

No.

12

Right Hand 2235 2385 Approx

N.A. N.A. N.A. N.A.

dal India Thermal Power Limited

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263

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EPC Tender for JIT

`Description Unit

Value Specified by the


Owner

Double I Suspension
AGS

Twin ACSR

Single Suspension (Pilot) Envelope


Twin ACSR

Moose Diameter of each rod Tolerance in


Diameter of each rod Mm 9.27 0.10 25

Moose N.A. N.A. N.A. N.A.

Value Guaranteed by the Bidder Single Double I Suspension Suspension AGS (Pilot) Twin ACSR Envelope Moose Twin ACSR Moose

+-mm +-mm +-mm 13

Length of each rod Difference of length between the longest and shortest rod in a set Type of Aluminium alloy used for manufacture of PA rod set UTS of each rod Particulars of Elastomer (for AGS Clamp only) Contractor of elastomer Type of elastomer Shore hardness of elastomer

Alu-Alloy 6061
Kg/sq.mm

35

N.A.

Owner Approved supplier Neoprene Rubber 65 To 85


B.H.N.

N.A.

Temperature range for which elastomer is designed Moulded on insert

UPTO 85oC Yes/No


Yes

N.A. N.A.

dal India Thermal Power Limited

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264

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EPC Tender for JI

`Description Unit

Value Specified by the


Owner

Double I Suspension
AGS

Twin ACSR

Single Suspension (Pilot) Envelope


Twin ACSR

Moose UTS of Hardware Component indicated in the drawings enclosed with the bid Purity of Zinc used for galvanizing Min No of dips in standard precee test the ferrous parts can withstand Yes/No
Yes Yes 99.95
i) Fasteners 4
dips

Moose

Value Guaranteed by the Bidder Single Double I Suspension Suspension AGS (Pilot) Twin ACSR Envelope Moose Twin ACSR Moose

99.95
i) Fasteners 4
dips

ii) Sp. Washers 3 dips iii) Other

ii) Sp. Washers 3


dips

iii) Other Ferrous

Ferrous parts 6
dips

parts 6 dips

dal India Thermal Power Limited

Page

265

Volume-II / Section - IX

EPC Tender for JIT

GUARANTEED TECHANICAL PARTICULARS OF TENSION HARDWARE FITTINGS FOR MOOSE ACSR CONDUCTOR Unit Value Specified by the Owner

No. Description

Value Guaranteed b the Bidder

Name

of manufacturer

Address of manufacturer Dimensional Drawing of Insulator Strings (with Disc/Long Rod Insulator) enclosed Detailed dimensioned drawings of all Hardware Components enclosed Material of Component enclosed in the drawing Electrical resistance of dead end assembly as a percentrage of equivalent length of conductor. Slip strength of dead end assembly Total weight of Tension Assembly

Quad Tension / Single Tension Yes/No Yes Yes/No


% Yes

Less Than 75
154 260

KN
Kg

UTS of hardware components indicated in the drawing enclosed with the bid Purity of Zinc used for galvanizing Min No. of dips in standard process test the ferrous parts can withstand

KN

(Approx)/91 (Approx) 640 for QT/120 for ST 99.95


4

Fasteners

Dips & Spring

dal India Thermal Power Limited

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266

Volume-II / Section - IX

EPC Tender for JITP

Washers

Dips, Other Ferrous parts 6 Dips Yes, shall be submitted Design calculation of Yoke Plates and Sag Adjustment Plate enclosed Yes/No Yes

PL PowerTransco Limited

Page

267

Volume-II / Section - IX

EPC Tender for JITPL

GUARANTEED TECHANICAL PARTICULARS OF MID SPAN COMPRESSIOIN JOINT FOR ACSR MOOSE CONDUCTOR Sr.No . 1. 2. 3. 4. 5. i) ii) Description Unit Value Specified by the Owner Value Guaranteed by Bidder

Manufacturers Name and Address Drawing enclosed Suitable for conductor size Purity of Aluminium Aluminium alloy used for Aluminium sleeve Material of steel sleeve Type of material with chemical composition Range of Hardness of material (Brinnel Hardness) Weight of zinc coating Outside diameter of sleeve before compression Aluminium Steel Inside diameter of sleeve before compression Aluminium Steel Length of sleeve before compression Aluminium Steel Dimensions of sleeve after compression Aluminium Corner to corner Surface to surface mm mm 541 210.5 gm/m2 Yes 31.77 E.C grade Aluminium purity not Less than 99.5% Mild Steel (H.D.G) Mild Steel Fe-410, As per IS : 2062 From : 120 To : 200 610

mm

iii) 6) a) b) 7) a) b) 8) i) ii) 9) a) i) ii)

mm mm

340.5 11.10.2

mm mm

7355 2505

mm mm

530.5 460.5

Jindal India Thermal Power Limited

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Volume-II / Section - IX

EPC Tender for JITPL

Sr.No . b) i) ii) 10) i) ii) 11) a) b) c) 12) 13)

Description

Unit

Value Specified by the Owner 20.20.5 17.50.5 785 (Approx) 286 (Approx) 2.56 (Approx) 0.49 (Approx) 3.05 (Approx) 154 (Min) 75

Value Guaranteed by Bidder

Steel Corner to corner Surface to surface

mm mm

Length of sleeve after compression mm Aluminium Steel mm Weight of sleeve Aluminium Steel Total Slip Strength Resistance of the compressed unit expressed as percentage of the resistivity of equivalent length of bare conductor Minimum Corona extinction voltage under dry condition kg kg kg KN %

14) 15)

KV (rms)

320 phase to earth

Micro Radio interference voltage at IMHZ for phase to earth voltage of volts 305 KV under dry condition

Less than 1000

Jindal India Thermal Power Limited

Page 269

Volume-II / Section - IX

EPC Tender fo

GUARANTEED TECHANICAL PARTICULARS OF REPAIR SLEEVE FOR ACSR MOOSE CONDUCTOR Description Manufacturers Name and Address Drawing enclosed Suitable for conductor size Purity of Aluminium Aluminium alloy used for Aluminium sleeve Inside diameter of sleeve before compression Outside diameter of sleeve before compression Diameter before compression Diameter after compression
Yes

No

Unit

Value Specified by the Owner

Value Guaranteed by the Bidder

mm

31.77 E.C grade Aluminium purity not Less than 99.5%


341

mm

mm mm

541

Corner to Corner 31 Before Compression 3005 1.060 (approx)


75

Surface to Surface 461 After Compression 340(approx)

Length of sleeve

mm

Weight of sleeve Resistance of the compressed unit expressed as percentage of the resistivity of equivalent length of

kg

dal India Thermal Power Limited

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270

Volume-II / Section - IX

EPC Tender for JITP

No

Description bare conductor Minimum Corona extinction voltage under dry condition

Unit

Value Specified by the Owner

Value Guaranteed by the Bidder

KV (rms)

320 phase to earth

Radio interference voltage at 1 MHZ for phase to earth voltage of 305 KV under dry condition

Micro volts

Less than 1000

PL PowerTransco Limited

Page

271

Volume-II / Section - IX

EPC Tender for JITPL

GUARANTEED TECHANICAL PARTICULARS OF SPACER DAMPER FOR TWIN ACSR MOOSE CONDUCTOR Sr. No. 1. Description Unit Value Specified by the Owner Value Guaranteed by the Bidder

Manufacturers Name and Address Office Works

2. a) b) 3. 4. a) b) c) d) 5. a) b) c) d)

Drawing enclosed Design Drawing Placement Chart Suitable for Conductor size Material of Component parts Insert Damping Ball/Clamp Main Body Retaining Rods (if any) Manufacturing process for Insert Damping Ball/Clamp Main Body Retaining Rods (If any)

Yes/No
Yes/No

Yes Yes 31.77 --Aluminium Alloy Aluminium Alloy ---

Mm

----Die Casting Die Casting -------

6. a) b) c) d) e) f) 7.

Retaining Rods (if any) Type of Alloy used Number of retaining rods used for Each Spacer Damper Diameter Length Weight Minimum ultimate tensile strength For retaining rods Elastomer (if used)

N.A. N.A. N.A. N.A. N.A. N.A.

Jindal India Thermal Power Limited

Page 272

Volume-II / Section - IX

EPC Tender for JITPL

Sr. No. a) b) c) d) e) f) 8. a) b) 9. 10. 11. a) b) 12.

Description Unit

Value Specified by the Owner PGCIL/PGCIL approved supplier Synthetic Rubber No 50 to 60 N.A. Upto 85

Value Guaranteed by the Bidder

Contractor Type Moulded on insert Shore hardness Thickness on insert Temp. range for which designed Minimum ultimate tensile strength Of Spacer Compressive load Tensile load Weight of Spacer Damper Designed Clamping torque (if applicable) Slipping strength of Before Vibration Test After Vibration Test Magnetic Power Loss per Spacer for 600 Amps. 50 Hz Alternating Current Electrical Resistance of Elastomer cushioned Spacer Maximum Minimum Minimum Corona Extinction Voltage (phase to earth) under Dry condition Radion Interference Voltage at 1 MHz for phase to earth voltage of 305 KV under Dry condition

mm
oC

KN KN Kg. Kg.m

14 7 5.7 (approx) 4 6.5 5.2 Less than 1

KN KN Watts

13. i) ii) 14. 15.

KOhm
KOhm

1000 10 320 Below 1000

KV(rms ) Micro Volts

Jindal India Thermal Power Limited

Page 273

Volume-II / Section - IX

EPC Tender for JITPL

GUARANTEED TECHANICAL PARTICULARS OF RIGID SPACER DAMPER FOR TWIN ACSR MOOSE CONDUCTOR Sr.No. Description 1. Manufacturers Name and Address Unit Office Works Value Specified by the Owner Value Guaranteed by the Bidder

2. a) b) 3. 4. a) b) 5. a) b) 6. a) b) c) d) e) f) 7. a) b) 8. a) 9. a)

Drawing enclosed Design Drawing Placement Chart Suitable for Conductor size Material of Component parts (Indicate i.e. of alloy) Insert / (clamp) Main Body Manufacturing process for Insert / (clamp) Main Body Elastomer (if used) Contractor Type Moulded on insert Shore hardness Thickness on insert Temp. range for which designed Minimum ultimate tensile strength Of spacer Compressive load Tensil load Weight of Spacer for jumper Slipping strength of spcer clamp Before vibration test

Yes/No Yes Yes/No Yes 31.77 mm --Aluminium Alloy LM-6 Aluminium Alloy LM-6 Die Casting Die Casting N.A. N.A. N.A. N.A. N.A. N.A.

Mm Deg.C

KN KN Kg

14 7 4.0 (approx)

KN

2.5

Jindal India Thermal Power Limited

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Volume-II / Section - IX

EPC Tender for JITPL

b) 10.

After vibration test Magnetic power loss per spacer for 600 Amps. 50 Hz Alternating Current Electrical resistance of elastomer cushioned spacer Minimum corona extinction voltage (phase to earth) under Dry condition Radio interference voltage at 1 MHz for phase to earth voltage of 305 Kv under dry condition

KN Watts

2.0 Below 1

11.

N.A.

12.

Kv (rms) Micro volts

320

13.

Below 1000

Jindal India Thermal Power Limited

Page 275

Volume-II / Section - IX

EPC Tender for JITPL

GUARANTEED TECHANICAL PARTICULARS OF T CONNECTOR FOR TWIN ACSR MOOSE CONDUCTOR Sr.No. Description 1. Manufacturers Name and Address Unit Value Specified by the Owner Value Guaranteed by the Bidder

2. 3. 4. 5.
6. a)

Drawing enclosed Suitable for conductor size Purity of Aluminium used for Tconnector Inside diameter of sleeve before compression Outside dimensions of sleeve Diameter before compression After compression Corner to Corner Surface to Surface Length of sleeve Before compression After compression Angle of leg sleeve of T-Conductor From vertical axis Weight of sleeve Axial Tensile strength of welded portion of T-conductor Resistivity of the compressed jumper as a percentage of equipment length of bare conductor Minimum corona extinction voltage under dry conduction. Radio interference voltage at 1MHZ for phase to earth voltage of 305 KV (dry condition)

mm

Yes 31.77 99.5% 340.5

mm

mm

541

b) i) ii) 7. a) b) 8. 9. 10.
11.

mm mm mm mm

530.5 460.5 4005 420 (Approx) 15o (Approx)

Kg

4.4 (Approx) 30 KN 75%

12. 13.

Not less than 320 KV (rms) Micro Less than 1000 Volts Micro Volts

Jindal India Thermal Power Limited

Page 276

Volume-II / Section - IX

EPC Tender for JITPL

GUARANTEED TECHANICAL PARTICULARS OF MID SPAN COMPRESSION JOINT FOR 7/3.66 MM GALVANISED STEEL EARTHWIRE Sr.No. Description 1. Manufacturers Name and Address Unit Value Specified by the Owner Value Guaranteed by the Bidder

2. 3. i)

Drawing enclosed Material of joint Type of material with chemical composition Range of hardness of the steel sleeve (Brinnel hardness) Inside diameter of sleeve before compression Steel sleeve Aluminium sleeve Aluminium filler sleeve Outside dimensions of sleeve Steel sleeve Aluminium sleeve Aluminium filler sleeve Outside dimension of sleeve after compression Steel sleeve Corner to corner Surface to surface Aluminium cover Corner to corner Surface to surface Length of steel sleeve Before compression

Yes Mild Steel Mild Steel Fe410, As per IS:2062 Not exceeding 200

ii)

4. i) ii) iii) 5. a) b) c) 6. a) i) ii) b) i)


ii)

Mm Mm Mm

11.5 0.2 22 0.5 11.5 0.2

Mm Mm Mm

21 0.5 32 0.5 21 0.5

Mm Mm Mm Mm Mm

20.20.5 17.50.5 29.4 0.5 25.0 0.5 230 5

7. a)

Jindal India Thermal Power Limited

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Volume-II / Section - IX

EPC Tender for JITPL

b) 8.

After compression Length of Aluminium sleeve

Mm Mm

265 (Approx) Before Compression 400 5 After Compression 435 (Approx) 1 (Approx)

9. a)
b)

c) 10.
11.

Weight of sleeve Steel Aluminium Aluminium filler sleeve Slip strength Resistance of the compressed unit expressed as a percentage of the resistivity of equivalent length of bare earthwire

Kg. Kg Kg KN %

65 Less than 75

Jindal India Thermal Power Limited

Page 278

Volume-II / Section - IX

EPC Tender for JITPL

GUARANTEED TECHANICAL PARTICULARS OF FLEXIBLE COPPER BOND Sr.No. Description 1. 2. 3. 4. 5. 6. 7. 8. i) ii) 9. 10. Manufacturers Name and Address Drawing enclosed Stranding Cross sectional area Minimum copper equivalent area Length of copper cable Material of lugs Bolt Size Diameter Length Resistance Total weight of flexible copper bond Yes 37/7/0.417 Sq.mm 35 Sq.mm 34 500 / +5-0 Mm Tinned Copper Mm Mm Ohm Kg 16mm 40mm 0.001429 (Approx) 0.55 kg (Approx) Unit Value Specified by the Owner Value Guaranteed by the Bidder

Jindal India Thermal Power Limited

Page 279

Volume-II / Section - IX

EPC Tender for JITPL

GUARANTEED TECHANICAL PARTICULARS OF VIBRATION DAMPER FOR 7/3.66 MM EARTHWIRE Sr.No. Description Unit Value Specified by the Owner Value Guaranteed by the Bidder

1. 2. a) b) 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. a) b) 16. 17. a) b) 18.

Manufacturers Name and Address Drawing enclosed Design drawing Placement chart Suitable for earthwire size Total weight of one damper Diameter of each damper mass Length of each damper mass Weight of each damper mass Material of damper masses Material of clamp Material of stranded messenger cable Number of strands in stranded messenger cable Lay ratio of stranded messenger cable
Minimum ultimate tensile strength of

Yes/No Yes/No Mm Kg Mm Mm Kg

Yes Yes 10.98 2.3 (Approx) Right Left 452 402 1355 1255 0.953% 0.73% Cast Iron Aluminium Alloy A-6 High Tensile Steel Wire 19 9 to 11

19.

stranded messenger cable Slip strength of stranded messenger cable (Mass pull off) Resonance frequencies First frequency Second frequency Designed clamping torque Slip strength of damper clamp Before fatigue test After fatigue test Percentage variation in Reactance after fatigue test in comparision with that before fatigue test. Percentage variation in power dissipation after fatigue test in comparision with that before fatigue test.

Kg/sq. mm KN Hz Hz Kg-m KN KN % %

135 2.5 Right 18.52 462 4 2.5 2.0 20 20 Left 121 302

Jindal India Thermal Power Limited

Page 280

Volume-II / Section - IX

EPC Tender for JITPL

GUARANTEED TECHANICAL PARTICULARS OF SUSPENSION CLAMP FOR 7/3.66mm GALVANISED STEEL EARTHWIRE Sr.No. Description Unit Value Specified by the Owner Value Guaranteed by the Bidder

1. 2. 3. i) ii) iii) 4. 5. 6. 7. 8.

Manufacturers Name and Address Drawing enclosed Material Shackle Clamp Body & Keeper U-Bolt Total drop (maximum) Weight Breaking strength (minimum) Slipping strength Tightening Torque Yes Forged Steel Malleable Iron H.D.G Mild Steel H.D.G. 150 3.2 (Approx) 2550 12 to 17 5

Mm Kg Kgf KN Kgm

Jindal India Thermal Power Limited

Page 281

Volume-II / Section - IX

EPC Tender for JITPL

GUARANTEED TECHANICAL PARTICULARS OF TENSION CLAMP FOR 7/3.66 MM EARTHWIRE Sr.No. Description Unit Value Specified by the Owner Value Guaranteed by the Bidder

1. 2. 3. i) ii)

Manufacturers Name and Address Drawing enclosed Material Shackle a) Compression clamp Yes/No Yes Forged steel Mild Steel with Aluminium encasing Not exceed 200

4. i) ii) iii) 5. a) i) ii) iii)

b) Hardness of the material (BHN) Inside diameter of the sleeve before compression Steel Sleeve Aluminium Sleeve Aluminium filler sleeve Outside dimension of sleeve Before compression Steel sleeve Aluminium Sleeve Aluminium filler sleeve

Mm Mm Mm Mm Mm mm

11.50.2 22.00.5 11.50.2 210.5 320.5 210.5

Jindal India Thermal Power Limited

Page 282

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EPC Tender for JITPL

ANNEXURE-13 PRICE SCHEDULE FOR 400 KV D/C(ACSR TWIN MOOSE CONDUCTOR) DERANG- ANGUL TRANSMISSION LINE
S. No A I II III Particulars Total Length of the Line KMs Statutory clearances and charges. Check Survey (Rs. Per kM) Design and testing of towers TOTAL OF DESIGN AND OTHER EXP. B 1 SUPPLY OF MATERIALS Supply of tower parts a) (i) 'A' Type towers Normal (ii) 3 M Extension pieces (iii) 6 M Extension pieces (iv) 9 M Extension pieces b) (i) 'B' Type towers Normal (ii) 3 M Extension pieces (iii) 6 M Extension pieces (iv) '9 M Extension pieces c) 'C' Type towers d) (i) 'D' Type towers Normal (ii) 3 M Extension pieces (iii) 6 M Extension pieces (iv) 9 M Extension pieces (v) 18 M Extension pieces (vi) 25 M Extension pieces 2 Supply of Bolts and Nuts (3% of total tower Wt. Of towers) TOTAL OF TOWERS AND B&N Supply of tower accessories 3 a) Danger plate (one per tower) b) Number plate (one per tower) c) Phase plate (set of three per tower) x No. of Ckts. Nos 153 153 306 Unit Rate * * * Total Cost in Rs. * * * 5150 350 630 980 9800 800 1700 2500 11900 15000 950 1700 2600 5400 7500 6200 1220 1900 2500 6600 1800 2250 3100 6100 10000 3100 3800 5100 12400 19900 68761 111 31 14 1 15 1 1 1 11 16 1 2 4 1 2 * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * * HT Unit Wt. (kg) MS Unit Wt.(kg) Nos Unit Rate HT/MT Unit RateMS/MT Total Cost in Rs. Total Quantity 56.24 LS 56.24 LS LS * LS * * * * Unit Rate Total Cost in Rs.

Jindal India Thermal Power Limited

Page 283

Volume-II / Section - IX
d) Anti climbing device (one set per tower) e) Circuit plate (one per circuit in case of two or more ckt) d) Supply of pipe type earthing (60% of total No.) e) Supply of Counter poise earthing (40% of total No.) TOTAL OF TOWERS ACCESSORIES 153 306 100 53 * * * *

EPC Tender for JITPL


* * * * * * *

Supply of ACSR Moose Conductor (kM)


(=Route kM x 3 x No. of Ckts x 2 x 1.015)

685.003

Supply of 7/3.66mm GSS Ground wire (kM)


(=Route kM x 2 x 1.015) TOTAL OF TOWERS CONDUCTER AND GSS GROUND WIRE

114.2

Supply of Insulators with Hardware a) 'I' Suspension Insulator Sring (No. Suspn. X 3) x Ckts b) Single 'I' suspn. Pilot string (No. of 'D' type x 1) c) Double Tension string (No. of anchor x 2 x 3 x No. of Ckts) d) Double 'I'' suspn. Insulator string (Special Locations) (Three Road crossings) 120 kN Insulators 160 kN Insulators
TOTAL OF INSULATOR & HARDWARE

Nos 630 48 504 36 17250 24192


* * * * * * * * * * * * * *

Supply of Conductor and GW Accessories a) Mid span compression Joint for condr. (one No. for 3 kM) b) Mid span compression joint for GW (one No. for 8 kM) c) Repair sleeves for Conductor (2 Nos. for every Route kM) d) Flexible copper Earth bonds (2x 'A' type + 2x2xNo. of Anchor) e) Bundle Spacers for Conductor (6x No. of towers x 3 x Ckts) f) Rigid spacer for Conductor (2 x
No. of anchor x 2 x 3x Ckts)

228 14 112 390 5508 504 612

* * * * * * *

* * * * * * *

g) Vibration Damper for GW (No. Of towers x 2 x2)

Jindal India Thermal Power Limited

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Volume-II / Section - IX

EPC Tender for JITPL

h) Earth wire suspension clamp ( No. 'A' towers x 2) I) Earth wire tension clamps (No. of Anchor x 2 x 2) j) Vibration dampers for conductor (No. towersx4xCktsx3x Condr)
TOTAL OF CONDUCTER AND GW ACCESSORIES TOTAL COST OF SUPPLY

222 168 7344

* * *

* * *

* *

Excise Duty@ * * CST/VAT@ * *

Total Cost of Design, supply, ED & CST

* * *

SUPPLY COST PER KM C D 1 2 E 1 FREIGHT & INSURANCE ERECTION Erection Of towers, Stringing of Conductor and Ground wire (LS) Erection of Tower parts (LS) Sub-total cost of Erection CIVIL WORKS Excavations(Cu M) M20 Concrete (1:1:3 Concrete) (Cu.M) 1:3:6 Concrete (15% of M20 Concrete) in Cu.M Reinforcements (4% of weight of M20) in MT Benching a) All kinds of soil except fissured rock b) Fissured rock

1 1

* * * * *

37842

5567

601

4 5

417

150 1500

* *

* *

Jindal India Thermal Power Limited

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Volume-II / Section - IX
6 Revetment works a) Random Rubble Masonry (1:5 cement mortar) in Cu M b) 1:2:4 Cement Concrete revetment c) Back filling and levelling (Included above) Sub-total cost of Civil Works
TOTAL COST OF F&I, ERECTION AND CIVIL WORKS F&I, ERECTION AND CIVIL WORKS COST PER KM

EPC Tender for JITPL

2500 250 2500

* * *

* * * * * * *

TOTAL COST PER KM OF THE LINE

* TO BE FILLED BY THE CONTRACTOR

Jindal India Thermal Power Limited

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Volume-II / Section - IX ANNEXURE-14 SPARES FOR DERANG TO ANGUL 400 KV DC (TWIN) TRANSMISSION LINE
SL. NO. I ITEM DESCRIPTION
STUBS AND CLEATS WITH COMPLETE BOLTS, NUTS, PACK

EPC Tender for JITPL

UNIT

QUANTITY

WASHERS and SPRING WASHERS Sets Sets Sets Sets


Sets

1 2 3 4 5 II

Stubs with cleats for A Type Towers suitable from (+0) to (+9) extensions Stubs with cleats for B Type Tower suitable from (+0) to (+9) Extensions Stubs with cleats for C Type Tower suitable from (+0) to (+9) Extensions Stubs with cleats for D Type Tower suitable from (+0) to (+9) Extensions Stubs with cleats for D Type Tower suitable from (+18) to (+25) Extensions TEMPLATES WITH COMPLETE BOLTS, NUTS, PACK WASHERS and SPRING WASHERS

10 2 2 2
1

6 Templates for A Type Towers suitable from (+0) to (+9) extensions 7 Templates for B Type Tower suitable from (+0) to (+9) Extensions 8 Templates for C Type Tower suitable from (+0) to (+9) Extensions 9 Templates for D Type Tower suitable from (+0) to (+9) Extensions 10 Templates for D Type Tower suitable from (+18) to (+25) Extensions III TOWER PARTS WITH COMPLETE BOLTS, NUTS, PACK WASHERS and SPRING WASHERS 11 FOR NORMAL A TYPE TOWER 12 FOR (+) 3M Extension of DA Type Tower 13 FOR (+) 6M Extension of DA Type Tower 14 FOR (+) 9M Extension of DA Type Tower 15 FOR (+) 18M Extension of DA Type Tower 16 FOR (+) 25M Extension of DA Type Tower 17 FOR NORMAL B TYPE TOWER 18 FOR (+) 3M Extension of DB Type Tower 19 FOR (+) 6M Extension of DB Type Tower 20 FOR (+) 9M Extension of DB Type Tower 21 FOR NORMAL C TYPE TOWER 22 FOR (+) 3M Extension of DC Type Tower 23 FOR (+) 6M Extension of DC Type Tower 24 FOR (+) 9M Extension of DC Type Tower 25 FOR NORMAL D TYPE TOWER 26 FOR (+) 3M Extension of D Type Tower 27 FOR (+) 6M Extension of D Type Tower

Sets Sets Sets Sets Sets 1

2 1 1 1

Sets Sets Sets Sets Sets Sets Sets Sets Sets Sets Sets Sets Sets Sets Sets Sets Sets

10 1 1 1 1 1 2 1 1 1 2 1 1 1 2 1 1

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Volume-II / Section - IX

EPC Tender for JITPL

28 29
30

FOR (+) 9M Extension of DD Type Tower FOR (+) 18M Extension of DD Type Tower
FOR (+) 25M Extension of DD Type Tower

Sets Sets Sets

1 1 1

IV 31 32 33 34 35 36 37 39 V

TOWER ACCESSORIES WITH COMPLETE BOLTS, NUTS, PACK WASHERS and SPRING WASHERS Name Plate No. Plate Circuit Plate Phase Plate Step Bolts Anti-Climbing Device PipeType Earthing Hangers for A Type Towers (IF REQUIRED)
ACSR MOOSE CONDUCTOR ACCESSORIES WITH COMPLETE

Nos. Nos. Nos. Sets Nos. Sets Sets Sets Nos.

10 10 10 10 1000 10 5 5 30

38 Counter Poise Earthing

BOLTS, NUTS, PACK WASHERS and SPRING WASHERS 40 Twin Spacers Dampers 41 Twin Spacers Dampers Rigid 42 43 44 45 46 47 48
VI

Nos. Nos. Nos. Sets Sets Nos. Nos. Nos. Sets

500 50 50 250 50 50 50 24 2

Vibration Dampers Dead End Compression Joint Mid-Span Joint Repair Sleeves Jumper Cones T - Connectors Balancing Weight
7/3.66 EARTHWIRE ACCESSORIES WITH COMPLETE BOLTS,

NUTS, PACK WASHERS and SPRING WASHERS 49 50 51 52 VII 53 54 55 VIII58 IX 59 X 60 XI 61 Copper Bonds Tension Clamp with dead end joint Mid-Span Joint Vibration Dampers INSULATORS HARDWARE COMPLETE WITH BOLTS & NUTS Twin Tension Set including Corona Control rings, Arcing Horn etc. Twin Single Suspension including Grading rings, Arcing horn etc. Twin Double Suspension including Grading rings, Arcing horn etc.
ACSR MOOSE CONDCUTOR (To be supplied in Steel Drums) 7/3.66 GS Earth Wire ( To be supplied in Steel Drums)

Nos. Sets Sets Nos. Sets Sets Sets kMs. kMs. Nos Nos.

24 12 12 48 24 24 6 48 4 1000 1000

120 KN DISC INSULATORS 160 KN DISC INSULATORS

Jindal India Thermal Power Limited

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Volume-II / Section - IX

EPC Tender for JITPL

ANNEXURE-15 TOOLS FOR DERANG TO ANGUL 400 KV DC (TWIN) TRANSMISSION LINE


Sl. No. 1 2 3 4 5 6 7 DESCRIPTION OF ITEM UNIT Aerial Rollers suitable for Quad Moose Earthwire Rollers Come-Along Clamp suitable for ACSR Moose Auto Type Come-Along Clamp suitable for ACSR Moose Bolt & Nut Type Come-Along Clamp suitable for Earthwire Auto type Come-Along Clamp suitable for Earthwire Bolt & Nut type SLINGS A) 16MM 30 mtrs Long B) 12mm 6 mtrs Long C) 16mm 2 mtrs Long D) 12mm 2 mtrs Long 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Four Sheave Pullies Set with 12mm flexible steel rope of 350 mtrs length Double sheave pullies Single Sheave Pullies 12mm Flexible steel rope Stay set including steel wire rope and turn buckle set. D-shackles different sizes Spacer cycle suitable for Quad Conductor Tomy Bars CrowBars Safety Belts Helmets First Aid Kit Tool Box Derrick Manila Ropes A) 16mm B) 12mm C) 20mm 23 24 25 26 Drum lifting Jacks for Conductor Turn Table for Earthwire End Socks for ACSR Moose Mid Span Socks for ACSR Moose Hydraulic Compressor 100T capacity for Jointing including die-sets suitable for ACSR moose and Earthwire Bundles Bundles Bundles Sets Sets Nos. Nos. 4 4 2 1 1 2 2 Nos. Nos. Nos. Nos. Sets Nos. Nos. Mtrs. Sets Nos.
Nos.

Nos. Nos. Nos. Nos. Nos. Nos.

QUANTITY 30 15 6 6 2 2 12 12 12 12 4 4 10 2000 6 24 1 4 8 8 20 2 4 2

Nos. Nos. Nos. Nos. Nos. Nos. Nos.

27

Sets

Jindal India Thermal Power Limited

Page 289