Part-2 (A) Scope of Works
Part-2 (A) Scope of Works
Part-2 (A) Scope of Works
PART 2
EMPLOYER’S REQUIREMENTS
Part -2 : Employer’s Requirements 2
Table ofContents
PART 2 ..................................................................................................................................... 1
This specification intends to cover but not limited to the following activities, services and works:
• Providing engineering data, and drawing for review, approval and records.
• Supply, testing, packing, transportation and insurance from the manufacturer’s work to the site.
• Receipt, storage, insurance, preservation and conservation of equipments at the site.
• Fabrication, pre-assembly (if any), erection, testing and putting into satisfactory operation of all
the equipments/ materials including successful commissioning.
• In addition to the requirements indicated in this section, all the requirements as stated in Technical
specifications shall also be considered as a part of this specification as if completely bound
herewith.
• Providing all materials, equipments and services specified or otherwise, including survey, which
are required to fulfill the intent of ensuring operability, maintainability and the reliability of the
complete works covered under this specification.
• During warranty period the bidder is required to provide all the services and activities mentioned
in the contract.
• Preparation of project completion report/closure proposal along with a report clearly indicating
completion of any outstanding/ remedial work that needs to be carried out.
• Handing over the works to the employer for taking into commercial services.
It is not the intent to specify all aspects of design and construction of equipments mentioned
herein. The systems, subsystems and equipments shall conform in all respect to high standards of
engineering, design and workmanship and shall be capable of performing in continuous
commercial operation. Accordingly, scope of works under this contract is as under:
1.1 Execution of all other works as per tender document. All Steel structure except STPs shall be hot
dip galvanized as per relevant Indian Standard.
1.2 All the raw materials such as steel, zinc for galvanizing, reinforcement steel and cement for
foundation, coke for earthing, bolts, nuts & washers, danger plates, phase plate, number plate etc.
required for substations & its structures shall be included in the scope of supply. Bidders shall
Part -2 : Employer’s Requirements 4
clearly indicate in their offer, the sources from where they propose to procure the key raw
materials and the components.
1.3 All the Distribution Transformers procured under RDSS are procured with Standard ratings,
meeting at least Energy Efficiency Level-1 as specified in IS 1180 (Part-1):2014 and its
Amendment 1, 2, 3 & 4, should be manufactured by an authorised licensee and bear BIS
certification standard mark.
1.4 A set of drawings are enclosed with this bid document. These are tender drawings and are to be
approved by the Employer. These drawings are indicative in nature and therefore, must be referred
while preparing drawings for approval.
1.5 All the new assets created under RDSS to be properly GIS tagged with the help of mobile App
provided by the Employer.
1.6 The engraving of word “Developed under RDSS” in materials viz., Poles, Transformers (All types),
Cables, Energy Meter etc is mandatory requirement. The Employer shall ensure strict compliance of
this requirement. Also, while processing payments to the Contractor, suitable documentary evidence
/ photographs must be asked by the Employer in support of the compliance.
1.7 Major infrastructures like new primery substation, new Distribution Transformer, new lines etc
developed under RDSS needs to be clearly denoted by a signboard that should represent
1.7.1. About the Work
1.7.2. Date of Commissioning
1.7.3. Estimated cost
1.7.4. Scheme
1.7.5. Employer’s details
1.7.6. For Transformers, rating in kVA
The signboard shall comply to the technical specifications (REC) and shall reflect as a separate
billable item in the price schedule (REC). Colour coding of the DTs is essential.
1.8 The Manufacturing Quality Plan (MQP) shall be finalized by the Employer in consultation with the
contractor/manufacturer in line with the Technical Specifications and as per Employer’s practices
Supply of Plant and Services under this tender covers all interventions required for satisfactory
operations of the facilities unless specifically excluded. Scope includes Design, Supply, survey,
installation, erection testing and commissioning, on turnkey basis. The types of works envisaged in
the RDSS scheme are:
A. Loss Reduction :
• Feeder Bifurcation
• Reconductoring works
Part -2 : Employer’s Requirements 5
All items to be supplied and erected shall be strictly as per the specifications given in the Bid and
should comply the relevant standards and any amendments thereof.
Any deviation taken by the bidder and not specifically / clearly brought out in the price schedule will
not be considered as a valid deviation.
In addition to the works mentioned above the bidder is required to take care of the activities listed
below:-
2. Survey
The Contractor shall carry out, and be responsible for, final design of the works, including any site
surveys, subsoil investigations and all other things necessary for proper planning design and execution.
The initial site surveys will be carried out for tentative freezing of the material requirement and the
work content finalization, within one month of commencement of project, and this will be a joint
survey, along with the PMA and sample check by the employer. The same shall be reviewed
progressively on quarterly basis for freezing of the material requirement and work content. Design shall
be prepared by qualified designers who are engineers and experienced in design of transmission and
distribution systems. Employer shall provide all options proposed for loss reductions to the contractor.
Contractor, while surveying the execution of work, shall keep this requirement in view and suggest best
loss reduction options in decending order. Means, maximum loss reduction option shall be proposed on
priority. Also, while executing the works, same priority of works must be followed.. The changes in
design should be approved by Engineer-in-charge of Employer.
• Based on the finalized network design, the Bidder shall carry out the field survey for deciding
location of poles, distribution transformers etc. Besides, field survey will also cover the following:
a. Proposed route of 33 KV, 11KV and LT Line.
b. Proposed location of 33/11 KV sub-stations along with number, capacity of power
transformers and number of 11 KV feeders to be taken out.
c. Locations of new distribution transformers.
• Feeder wise Bill of Quantity (BOQ), for each proposed work will be prepared by the Bidder and
submitted to the Employer’s Engineer-in-charge for his approval before commencement of actual
work.
• All architectural and civil designs such as control room, foundation for equipment, transformer,
isolators, VCB shall be approved by the Employer’s Engineer-in-charge.
• Within substation yard, all clamps and connectors used for bus-bar will be crimped. All the clamps
and connectors connecting the equipments shall be of bolted type.
Part -2 : Employer’s Requirements 6
3. ProjectManagement System
3.1. General
The Contractor shall assign a project manager with the authority to make commitments and decisions
that are binding on the Contractor. Employer will designate an officer incharge to coordinate all
employer project related activities. All communications between employer and the Contractor shall be
coordinated through the project manager and officer incharge of Employer. The project managers shall
also be assisting employer in communicating project related information to other stake holders.
Bidder shall submit the manpower deployment plan along with the bids, describing the key roles of
each person.
a) To prepare, maintain and update project detailed Work Execution Plan for successful
implementation of project like approval of GTP, approval of sub-contractor, approval of
drawings, supply of materials, mobilization of men, material and equipment etc. at site for
successful completion of works, Compile and up-load physical as well as financial progresses,
compile the progress of works at Employer level and to assist in forwarding it to all stake
holders.
b) To actively participate with employer in resolving all issues relating to project implementation
including ROW, Forest Clearances and Railway Crossings.
c) To actively participate in monitoring, reviewing and analysing the physical, financial and quality
assurances works’ progress of RDSS works and also to take suitable measures on compliance of
observations being raised during monitoring/review meetings with employer.
d) To upload and up-date project wise physical progress in RDSS web portal. Physical as well as
financial progresses shall be uploaded in standard Bill of Material format of the contract. Also, to
submit invoices as per released RDSS guidelines to Employer for release of payments/funds.
e) To oversee the progress and compliance of the Quality Assurance Mechanism as per RDSS
guidelines.
The project schedule shall include the estimated period for completion of project and its linkage
with other activities etc. It is expected that the contractor should share updated project schedule
based on the actual progress done at site, priorities of the employer, availability of material etc
once per quarter along with the Progress report.
3.4. Transmittals
Every document, letter, progress report, change order, and any other written transmissions
exchanged between the Contractor and employer shall be assigned a unique transmittal number.
The Contractor shall maintain a correspondence index and assign transmittal numbers
consecutively for all Contractor documents. Employer will maintain a similar correspondence
numbering scheme identifying documents and correspondence that employer initiates.
Part -2 : Employer’s Requirements 8
The Quality Assurance (QA) will be carried out by Employer. The Employer may engage an
Authorised representative of employer responsible & accountable for assuring quality in RDSS
works. Key activities would include:
• Formulation of a detailed comprehensive Quality Assurance Mechanism (QAM)
plan/Guaranteed Technical Particulars as the case may be in the State for the works to be carried
out under RDSS scheme with an objective to create quality infrastructure works. The QAM and
Inspection Plan shall be integral part of the contract agreement with turnkey contractor or
equipment supplier and erection agency as the case may be in case of turnkey/ or departmental
execution of works.
• Ensuring that the quality of materials/equipment supplied at site and execution of works carried
out at field under RDSS scheme is in accordance to Manufacturing Quality Plan
(MQP)/Guaranteed Technical Particulars (GTP) and Field Quality Plan (FQP)/Approved
Drawings/Data Sheets respectively.
Turnkey Contractor shall strictly ensure QAM checks during the day to day course of project
execution, which are as follows:
a. Pre-dispatch inspections of all materials viz. as per MQP/GTP, Approved Drawings,
Technical Specifications, Datasheet, GTP, applicable national & international standards as
per GCC Clause 23.
b. 100% verification of all 66/11 or 33/11 kV sub stations (New & Augmented) for quality of
material as per MQP/GTP, Approved Drawings, Technical Specifications, Datasheet and
erection works in the field as per FQP/approved drawings.
c. 100% verification of feeders created under the scheme.
d. 100% verification of materials utilised under the scheme.
e. 100% verification of works done in Loss Reduction and Modernization & System
Strengthening.
4.1.1. Vendor approval: All the materials procured for RDSS works shall be purchased from the
authorised vendors approved by the Quality Assurance Department of Employer. Approved
vendors list is uploaded periodically on the Employer web portal.
4.1.2. FQP for Civil works: Employer shall prepare a separate FQP/field execution drawings which
Part -2 : Employer’s Requirements 9
shall be approved by their competent authority which shall be uploaded at web portal. The
turnkey shall adhere to this FQP/drawings while carrying out physical works.
4.1.3. FQP for testing & commissioning: Employer shall prepare a comprehensive Pre-
commissioning test Check-list for testing & commissioning of 33/11kV or 66/11kV substation,
Distribution transformer Substation etc. The electrical system shall be energized only after
performing all tests as described in the pre-commissioningtest checklist. and inspection from the
electrical inspector of the state (or as the practice may be). Proper records in this regard,
including tests on earth resistance, insulation resistance of 11 kV line & Distribution
Transformer etc. shall be maintained, jointly signed by Employer and turnkey representatives.
b. Some key indicative measures for effective implementation of the QAM by the Contractor
are given below. However, these are for reference and need to be followed as per relevant
provisions of the contract.
• Supply:
- Verification of qualifications of the subcontractor / manufacturer for supply of plant /
equipment and materials. Factory inspections may be conducted if required.
- Verification of material data, specifications, drawings and samples submitted by the
subcontractor / manufacturer including GTPs.
- Verification of type test reports including qualifications of the test laboratory,
completeness and acceptance of the type test reports.
- Witnessing acceptance tests carried out by the subcontractor/ manufacturer.
- Carrying out pre-dispatch inspections as per relevant guidelines of this tender/
contract.
Part -2 : Employer’s Requirements 10
c. It should be noted that no functional guarantees are applicable for equipment installed as a
part of this contract hence Guarantee Tests are not applicable.
d. The Employer may identify any third party agency including PMA/ TPQMA etc. who
would be responsible to monitor the QAM measures including verifications and inspections
mentioned above. The project manager may also engage third party inspectors for this
purpose in addition if required.
e. The Employer or its appointed third party shall design systems and procedures to
implement QAM system including formats for submittals by the Contractor in line with the
above requirements and provisions of the Contract.
f. The Contractor shall cooperate with and follow these QAM systems and procedures to
ensure proper implementation of an effective quality assurance and evaluation mechanism.
4.1.5. Pre-commissioning test record: All pre-commissioning test check list shall be documented
properly and signed by the quality engineer of the turnkey Contractor & countersigned by
Employer's representative and shall be kept for future reference. These documents shall be
maintained by Employers in proper order and shall be made available at site for verification by
Quality Monitors during inspection and finally be handed over to oser department O&M
department) at the time of handing over of energized assets.
4.1.6. Roles and responsibility of Contractor in ensuring Qualitity of Plant and Facilities:
1) Turnkey contractor shall be primarily be responsible for supply of quality materials. Hence,
turnkey contractor shall take all necessary actions including following:
a. To assess the capabilities and capacity of manufacturer to whom they intend to appoint as
sub-vendor,
Part -2 : Employer’s Requirements 11
5) Sampling from field: Any material, including materials listed below, may be picked from site for
testing at test laboratory chosen by inspecting official. 1. Distribution Transformer, 2. Overhead
Conductor, 3. Energy Meter, 4. Pole, 5. Insulators, 6. Cables, 7. Circuit Breaker.
a. Inspecting official will have right to pick any of the supplied equipment whether it is
lying in site stores, is under erection, is under local transportation from site stores to
erection location or is already commissioned. The equipment shall be sealed jointly in
presence of representatives of Employer, Employer’s appointed Third Party, Contractor,
and Supplier/manufacturer (if his representative is available at site). Employer at its
discretion may invite manufacturer’s representative to participate in sealing of materials.
b. Sealed equipment, on cost of turnkey contractor shall be sent to test laboratory for
verification of routine/type test results. At the time of sealing, details of equipment
available at site shall be recorded like cable/conductor drum number, power/distribution
transformer unique number, status of sequential legible embossing on cables, name of
manufacturer etc.
Part -2 : Employer’s Requirements 12
c. For testing of equipment, Employer/Nodal agency shall empanel test laboratories located
in or nearer to the state wherefrom sample is picked up.
d. Such picked up materials at a random shall be tested for all routine, acceptance and type
tests feasible to conduct in the empaneled laboratory. The laboratory expenses including
all other expenditures that shall incurred towards packing, transport, inspection, testing
charges etc. are to be borne by the Employer. At least one sample from a lot may be
subjected to inspection.
e. In cases, where pre-dispatch and factory test results/NABL accredited lab test report are
found mismatched with tests results on the sample picked from field; actions shall be
taken against willful defaulted manufacturer and turnkey contractor both.
f. Willful defaulter shall be those manufacturers and turnkey contractor whose material is
found to be manufactured using inferior quality raw materials, second hand core
materials, under-size/under-weight of cable/conductor in various parts of cable/conductor
drum, not conforming to transformer load losses as defined in agreed technical
specifications/contract conditions, improper or no sequential legible embossing on cable
etc.
g. This mismatch shall generally be, but not limited to the deviations in results from
guaranteed technical specifications of materials in terms of capacity (KVA capacity,
current carrying capacity, heating capacity, tensile strength, mechanical strength etc.,
operational efficiencies (errors in measurements of power, power/load losses, power
consumption etc., weights of key component materials (aluminum, copper, insulation
materials, steel components etc.), sub-standard specifications of key component
(measured specifications are in deviation from guaranteed specifications as per technical
specifications of the project and inferior/illegible embossing/sequential marking on
cables are found, following two actions shall be taken:
i. Sub-vendors/vendor registration of the manufacturer shall be discontinued in all
the power utilities of the country for a period of 5 years including in power utility
concerned where this act is found,
ii. Entire lot of materials/equipment supplied by the defaulting manufacturer shall be
rejected whether supplied materials/equipment is lying in site-stores, in transit,
under erection, testing & commissioning or has already been commissioned. All
costs related to removal of such rejected materials and reinstating fresh lot of
materials shall be borne by turnkey contractor without any cost implication to
power utility.
iii. Turnkey contractor shall be responsible for repetitive failures of materials in field
testing in a turnkey-contract. In such situations, registration of turnkey contractor
firm shall be discontinued in all the power utilities of the country for a period of 5
years including in power utility concerned where this act is found,
h. In cases, where field testing results are slightly mismatched with factory test results / pre-
dispatch test reports/NABL accredited lab test report but are in permissible limits as per
Part -2 : Employer’s Requirements 13
7) The Contractor should develop the quality assurance programme which shall generally cover the
following:
a. Organization structure for the management and implementation of the proposed quality
assurance programme :
b. Documentation control system;
c. Qualification data for bidder’s key personnel;
d. Procedure for purchases of materials, parts, components and selection of sub-Contractor’s
services including vendor analysis, source inspection, incoming raw material inspection,
verification of material purchases etc.
e. System for shop manufacturing and site erection controls including process controls and
fabrication and assembly control;
f. Control of non-conforming items and system for corrective actions;
g. Inspection and test procedure both for manufacture and field activities.
h. Control of calibration and testing of measuring instruments and field activities;
i. System for indication and appraisal of inspection status;
j. System for quality audits;
Part -2 : Employer’s Requirements 14
8) Electrical Inspector inspection: After successful completion of the work permission from State
Electrical Inspectorate is required. Necessary fee etc. shall be paid by the Employer. However if
Contractor pays such fee it shall be reimbursed on actual basis on documentary evidence. In case
of defects / in-complete works notified by Electrical Inspectorate, these shall be completed by
the agency at no extra cost implication to Employer.
4.2. Concurrent Quality Monitoring by Nodal agencies: In addition to the in-house quality checks
and processes followed by the Employer, the Nodal Agency of RDSS (REC/PFC) shall also
carry out concurrent inspection of works through Third Party Quality Monitoring Agency
(TPQMA). The Contractor needs to comply with the requirements and cooperate for effective
implementation.
4.2.1. Scope of Quality Assurance Mechanism by RDSS Nodal Agency (REC/PFC): The
Nodal Agency (REC/PFC) shall carry out concurrent inspection of works through TPQMA. To
enable the same, the Employers shall share the physical and financial progress of the works
through portal of the scheme or otherwise. In addition to the above, the Nodal Agencies may also
carry out concurrent quality monitoring on random sample basis as per the need through its own
manpower. TPQMA shall also verify quality of works carried out in the Project, which are as
follows:
• 100% New Power Substations or at least one in each district/circle.
• 5% Augmented Substations or at least five in each district/circle.
• 15 to 20 spans of 5% of HT feeders
• 2% of DTR Substations (11/0.4kV), including few spans of associated LT Lines
• 1% of Smart meters or 1,000 Meters in a project, whichever is less
• IT/OT/SCADA/DMS infrastructure – primarily at system level for highlevel functional
checks.
- Stage-II inspection of TPQMA shall commence in a project when 100% New & 70 %
of Augmentation substation works are completed in all respect.
(ii) HT Feeders: 5 % HT Feeder are to be inspected in 2 (two) stages. Stage-I & Stage-II
inspections shall cover 2.5 % of HT Feeder respectively.
- Stage-I Inspection of TPQMA shall commence in a project when 30% of HT Feeder works
are completed in all respect.
- Stage-II Inspection of TPQMA shall commence in a project when 70 % of HT Feeder
works are completed in all respect.
(iii) DTR Substations: 2% of DTR Substations (11/0.4kV), including few spans of associated
LT Lines are to be inspected in 2 (two) stages. Stage-I & Stage-II inspections shall cover 1 % of
DTR Substations respectively
- Stage-I Inspection of TPQMA shall commence in a project when 30% of DTR
Substation including LT Lines works are completed in all respect.
- Stage-II Inspection of TPQMA shall commence in a project when 70% of DTR
Substation including LT Lines works are completed in all respect.
(v) Deployment of mobile vans for quality inspection:The Employer/ Nodal Agency
reserves the right to also deploy mobile vans with Testing facility to test the plants and facilities
by selecting random samples from store or from site. The Employer may take sample from any
lot placed in store including the lot on which Pre-Dispatch Inspection was not carried out or
from the installed materials which it feels are not performing as it was intended to. In such a
case if the material/ facility fails, the same shall be replaced with new material, and one more
random sample would be selected from the same batch for testing. If the material fails the test
again, then the whole lot shall be replaced by the Contractor at its own risk and cost.
Part -2 : Employer’s Requirements 16
4.2.2. Cross verification of field /TPQMA works by Nodal Agency: The Nodal Agency also
reserves the right to monitor the field /materials to the tune of 1% of total inspections carried out
by TPQMA.
4.3. Material Inspection: For the purpose of inspection, materials have been segregated into two
categories as mentioned below:
4.3.1 Category – A (Pre-Dispatch Inspection & Testing at NABL accredited Labs):
a) This category shall include high ticket materials (Power Transformers, Distribution
Transformers, Circuit Breakers, AB/XLPE Cables, Overhead Conductor (AAAC/ACSR),
Insulator which involves more and important testing procedures and hence the inspection of
these materials will be carried out in the factory before the dispatch of the material.
b) In addition, Employer shall also ensure that for major materials as discussed above, samples
from 1st lot and one other lot randomly selected by the Employer shall be directly sent to NABL
acredited test labs for third party testing. It is also to be noted that material clearance of the lots
under testing shall only be given post receipt of successful test results. Contractor shall also
mandatorily depute its authorized official for pre – dispatch inspection at manufacturing facility
alongwith the Employer officials. The inspection and testing report would be jointly signed by
the Employer and the Contractor. All the expenses related to testing would be beared by the
Contractor.
c) Apart from the above mentioned protocol any one power transformer shall be selected by
Employeer from the supply schedule from the vendor, which shall be jointly sealed and tested for
short circuit testing on turnkey-Contractor’s expenses.
4.3.2 Category – B (On-site inspection): This category includes the materials for which a factory
inspection is not warranted and the material can be inspected upon arrival at the site before the
installation. In case the Employer is apprehensive about the quality of the material supplied it
reserves the right to send the selected lot to the NABL acredited testing lab for third party
testing.
4.3.3 Employer also reserves the right to send any installed equipment / materials to the NABL
acredited testing lab for testing. The Employer would have to reimburse the expenses related to
transportation of material from site to testing lab and all testing expenses in this regard.
4.3.4 The material which has to be tested at laboratory shall be sealed in the presence of authorized
official of Employer and Contractor.
4.3.5 If the materials tested at Laboratory fails then the entire lot would be rejected. Contractor shall
bear the responsibility of sending back such failed materials from site. Any subsequent delay in
contract performance due to failure of materials in the test laboratory would be on account of
Contractor and no time extension would be provided by the Employer in this regard. Any LD
levies in this regard would be borne by the Contractor.
Part -2 : Employer’s Requirements 17
4.3.6.2. Tests to be conducted during the Pre-dispatch Inspection: All the tests shall be carried out
in accordance with the latest relevant IS published from time to time by BIS. An indicative list of IS
specification and tests for some of the materials are given below:
Power Transformers
Standards Applicable:-
IS:2026 Power Transformer
(Part I to IV)
IS:5 Colour for ready mixed paints
IS:325 Three Phase Induction Motors
IS:335 New insulating oil for transformers, switch gears
IS:1271 Classification of insulating materials for electrical machinery and apparatus in relati
on to their stability in services
IS:2071 Method of high voltage testing
IS:2099 High voltage porcelain bushings
IS:2147 Degree of protection
IS:2705 Current Transformers
IS:3202 Code of practice for climate proofing of electrical equipment
IS:3347 Dimensions for porcelain Transformer Bushings
IS:3637 Gas operated relays
IS:3639 Fittings and accessories for power Transformers
IS:5561 Electric Power Connectors
IS:6600/BS:C Guide for loading of oil immersed Transformers
P‟10:0
IS:10028 Code of practice for selection, installation and maintenance
of transformers, Part I. II and III
C.B.I.P. Public Manual on Transformers
ation
Part -2 : Employer’s Requirements 18
Distribution Transformers
Standards Applicable:-
IS 2026: (Part 1 to 10) as General Specification of Transformer
applicable
IS 1180 (Part1) Outdoor type oil immersed Distribution transformer upto including 2500
(Including Amendment 1, kVA & 33 kV
2, 3 & 4)
IS 3347 (Part 1) Specification upto 1.1 kV Voltage Bushing (for Porcelain)
IS 3347 (Part 3) Specification upto 17.5 kV Voltage Bushing (for Porcelain)
Type Test • A valid Type test report within 5 years of supply
• 3 star rated transformer as per BEE
IS -5484 Specification for Aluminum wire rods
IS 12444 Specification for Copper wire Rods
Proposed Tests as per IS
1 Measurement of Winding resistance at all Tap Positions
2 Ratio of Tap Position Polarity & Phase Position
3 % Impedance at 75 degree Celsius at 50Hz
4 Load losses at 50% and at 100% Loading on Energy efficiency Level -5 as per IS 1980 (Part-
1) 2014 and its amendment 1.2. 3 and 4
5 No Load Loss at 50Hz and No load current at rated voltage
6 Insulation Resistance
7 Induced Overvoltage Withstand
8 Separate source voltage Withstand
9 Magnatizing Current at Rated voltage and frequency an 112.5% of rated voltage
10 Temperature rise test
11 Pressure Test
12 Oil Leakage Test
Circuit Breaker
Standards Applicable:-
IS: 13118 Specification for HV AC Circuit Breaker
IS: 14658 HV AC Circuit Breakers - Guide for Short-circuit and Switching Test Procedures for
Part -2 : Employer’s Requirements 19
XLPE Cables
Standards Applicable:-
IS : 7098 (Part-I) : 1988 Specification for Crosslinked Polyethylene Insulated PVC sheathed
Cables for working Voltage upto& including 1100 Volt
IS: 8130 : 1984 Specification for Conductors for insulated electric cables and flexible
cords
IS:5831 : 1984 PVC insulation & sheath of electric cables
IS: 3975 : 1970 Specification for Low Carbon Galvanized steel wires, Formed Wires
and tapes for armouring of Cables
IS:10810 : 1984 Methods of test for Cables.
IS:10418 : 1982 Cable Drums for Electric Cables.
IS : 694 : 2010 PVC unsheathed and Sheathed cables / Chords with rigid and flexible
conductor for rated voltages uptoand including 450/ 750 V
Proposed Tests as per IS
1 Resistance Test on conductor
2 Test for thickness of insulation and sheath
3 Tensile strength and elongation at break test for insulation & outer sheath.
4 Hot set test for insulation.
5 Insulation resistance (Volume resistivity) Test
6 High voltage test
Standards Applicable:-
IS 14255 : 1995 Specification for Aerial Bunched Cables for working Voltage up to &
including 1100 Volts.
IS : 8130 : 1984 Specification for Conductors for Insulated Electric Cables and flexible
Cords.
IS : 398 (Part-IV) : 1994 Specification for Aluminum Conductors for overhead transmission
purposes: Aluminum Alloy Stranded Conductors (Aluminum
Magnesium –Silicon type).
IS:10418:1982 Specification for Drums for Electric Cables
Proposed Tests as per IS
1 Breaking Load Test for messenger Conductor.
2 Elongation test for messenger conductor.
3 Conductor resistance test for both messenger and XLPE conductor
4 Test for thickness of insulation of XLPE conductor
5 Tensile Strength and Elongation at Break Test for both messenger and XLPE conductor
6 Hot Set Test for XLPE insulation.
7 Insulation resistance test for XLPE conductor
8 High Voltage Test for XLPE conductor
Porcelein Insulators
Standards Applicable:-
IS 1445 : 1977 Porcelain insulators for overhead power lines with a nominal voltage up
to and including 1000 V
IS 2486 (Part 1) : 1993 Metal fittings of insulators for overhead power lines with nominal
voltage greater than 1000 V: Part 1 General requirements and tests
IS 2486 (Part 2) : 1989 Insulator fittings for overhead power lines with nominal voltage greater
than 1 000 V: Part 2 Dimensional requirements
IS 2486 (Part 4) : 1989 Insulator Fittings for Overhead Power Lines with a Nominal Voltage
Greater than 1 000 V - Part IV : Tests for Locking Devices
Part -2 : Employer’s Requirements 21
The above list of tests is only indicative in nature and if the Employer feels, it can add some tests based
on latest IS Standards. If the Employer faces any inssues with respect to actual performance of a
material then it can issue a notice to the Contractor for testing of that material at its sole descrition.
4.3.6.3. The Contractor shall ensure receipt of material at site within 21 days from date of receipt of
dispatch instructions. In case materials are not received within 21 days from date of issue of dispatch
instruction, the dispatch instruction shall stand cancelled. All expenditure incurred by Employer in
performance of dispatch instruction shall be recovered from turnkey Contractor. A fresh pre – dispatch
inspection would be required to issue a dispatch instruction for supplying the same lot at the site.
4.3.6.4. The turnkey Contractor shall ensure that pre-dispatch inspection for materials are intimated
only when the material is completely ready for inspection. On due date of inspection, if it is found that
materials are not ready in required quantities or the inspection could not be carried out due to non-
availability of requisite calibrated certificate of instruments with manufacturer, closing of works on
scheduled date of inspection, non-availability of sufficient testing/material handling staff at
manufacturer works etc, all expenditures incurred on deployment of various inspecting officials along
with a fine of Rs 50,000/- shall be recovered from the bills of the agency and re-inspection shall be
carried out on expense of the Contractor. 2nd such situation at same manufacturer/supplier shall result in
rejection of name of manufacturer from list of approved vendors/sub-vendors. In case sub-standard
materials (old component, re-cycled materials, re-used core material, re-used transformer coil material
etc) offered for inspection and are noticed during the inspection, materials shall be rejected and
approval of sub-vendor shall also be cancelled for all RDSS projects.
4.4. Implications for not meeting quality requirements by Contractor
4.4.1. In case of failures in testing:
a) The turnkey Contractor shall ensure that pre-dispatch inspection for materials is intimated only
when the material is completely ready for inspection. On due date of inspection, if it is found that
materials are not ready in required quantities or the inspection could not be carried out due to
non-availability of requisite calibrated certificate of instruments with manufacturer, closing of
works on scheduled date of inspection, non-availability of sufficient testing/material handling
staff at manufacturer works etc, all expenditures incurred on deployment of various inspecting
officials along with a fine of Rs 50,000/- inclusive of GST shall be recovered from the bills of
the agency and re-inspection shall be carried out on expense of Contractor.
Part -2 : Employer’s Requirements 22
b) 2nd such situation at same manufacturer/supplier shall result in rejection of name of manufacturer
from list of approved vendors/sub-vendors. In case sub-standard materials (old component, re-
cycled materials, re-used core material, re-used transformer coil material etc) offered for
inspection and are noticed during the inspection, materials shall be rejected and approval of sub-
vendor shall also be cancelled for all RDSS projects.
c) In case, a material fails the pre-dispatch inspection as per GCC Clause 23, and also fails the
subsequent repeat inspection of the rectified/replaced material, the complete lot of material under
inspection will be required to be replaced by the manufacturer/supplier. If in subsequent
inspection of the new lot, the material again fails the inspection, then materials shall be rejected
and approval of vendor/sub-vendor shall also be cancelled for all RDSS projects.In such scenario
any subsequent delay in contract performance due to failure of materials in the test laboratory
would be on account of Contractor and no time extension would be provided by the Employer in
this regard. Any LD levies in this regard would be borne by the Contractor.
d) Apart from the above, in case of default by vendors/manufacturers, Contractor shall also be
penalized based on the no. of materials/lots get rejected as per below table:
No. of Material/lot rejected in a
Sr. No. % Penalty imposed on contract price
project/district
1 >5 5.0%
2 >3 2.5%
3 >1 1.0%
4.4.2. In case of defects found during Field inspection:There are three categories of defects found in
field inspection as defined below:
a) CRITICAL DEFECTS: These defects must be rectified before charging. Critical defects are
those which endanger life and property. Dangerous deficiencies on safety, ground clearances,
equipment earthing and protection would come this category. These are defects in presence of
which the Electrical Inspector would not allow charging of the electrical installation. That is, if
equipment are already energized, it should be de-energized and rectified without delay. If
critical equipment like distribution transformer HT and LT line have been installed dangerously,
the defect type would fall under critical category of defect. Example : LA is not connected , DT
neutral earth is missing , Earth electrodes not installed, Ground clearance not as per IE rule,
Oil level low in transformer etc.
b) MAJOR DEFECTS: These defects must be rectified before operational handover (to Operation
and Maintenance wing).These are major deviations from drawing and specification. These are
serious deviation with respect to contract. The electrical installation can be charged temporarily.
However, the defects should preferably be rectified before charging. Example : Pole not pitched
at proper depth, Brick-bats/ foundation inadequate, use of undersized earth wire, precariously
loose electrical connections and mechanical fitting.,
Part -2 : Employer’s Requirements 23
c) MINOR DEFECTS: These defects are very minor in nature. Such defects in electrical
installations keep surfacing during operation and maintenance. The installation may be charged
with these defects. However they must be rectified Example: Danger board not proper, energy
meter not installed before contractual handover (before final payment is released and contract is
closed), missing barbed wire, stay wire loose, loose fasteners, vegetation too close to HT/Lt line.
Note:
1. These defects are broad in nature. Actual field defects need to be defined more accurately by
inspectors.
2. All pictures depicting defects should be numbered. Their number mentioned in the report shown
in the table
3. An infrastructure schematic (single line diagram) showing DTRs, HT and LT poles duly
numbered by the inspector shall be submitted along with the report. Their number shall be used
to describe location of defects to be rectified subsequently.
Annexure-A
Location
Status Picture
S.N. Description Observation as per
(Yes/No) No.
SLD
13 Gravel size proper
Earthing of main equipment, fence etcdone
14
properly
15 Sub Station fencing provided
Cable trench made with cable trays – or
16
cables lying on trench floor
Whether Cable trenches have suitable slope
17
to ensure automatic draining of rainwater
18 Proper storage of equipment
19 Cables tied on cable trays
Glands, lugs used (wherever need - at cable
20
entries)
21 Dead end marking for cables is done
22 Earth mat provided
23 Undersized conductor/ cables used
Correct size of earthing conductor - flats, GI
24
wires etc used
25 Acid proof floor used in battery room
Fasteners (nut, bolts, clamps connectors,
26
hardwaresetc) as per specification
Switchgear rubber mats, chequer plates not
27
provided
FQP for material receipt and storage
28
maintained by Employer
29 Name of Feeder on Control Panel.
30 Name of Feeder on Outgoing DP structure
Working platform on 33 KV and 11 KV
31
outdoor VCB
32 Name of Substation board on the entrances
Painting of control room, water supply
33
position in Substation
General sanitation arrangement in the
34
control room building
Internal Lighting in the substation control
35
room
36 Closed fencing of the substation yard
Part -2 : Employer’s Requirements 37
Location
Status Picture
S.N. Description Observation as per
(Yes/No) No.
SLD
Approach road to Power Transformer
37
foundation
Water logging/ Earth filling in the yard
38
trench
Partition wall between two Power
39
Transformers
Availability of Earthing Rod in the
40
substation
41 Availability of Permit & Work Book
Tracing of Earth connection of Power/
42
Distribution Transformer up to Earth Pit
43 Connection at Earth Pit
44 Jointing & Clamping of Earth Conductors
All Terminal Blocks at
45
CTs/PTs/Breaker/Panels/Junction Box
46 Earthing& Fencing is as per specification
Cable trench cover inside the control room
47
and in the yard.
48 Exhaust Fan in the Battery Room
49 Inter Battery connections
50 Battery Charger connection
51 Earthing of Control Panel
Termination of power cables at 11 KV
52 sides/LT sides of Power and Station
Transformer.
Inside pic of distribution board of station
53
transformer
54 Take Overall picture of station transformer
55 Connection of Lightning arrestor
Approximate clearance of live part in the
56
substation
57 Oil leakage in Power/Station Transformer
58 Area lighting in the substation
Material diagram of substation in the control
59
room
60 List of authorized operational personnel in
Part -2 : Employer’s Requirements 38
Location
Status Picture
S.N. Description Observation as per
(Yes/No) No.
SLD
the substation
61 Connection at the bus-bar jumpers
62 Loop cables LT/HT/Control
63 Tagging on cable terminals
Work clearance on control panels and
64 sufficient lightening on the control panel
Part -2 : Employer’s Requirements 39
The following type, acceptance and routine tests and tests during manufacture shall be carried-out
on the material. For the purpose of this clause:
5.1. Contractor shall supply the materials of type & design which has already been Type Tested.
Contractor shall provide copy of such tests at site in support of type-tested materials supplied under
the contract. No extra payment or time shall be granted for type testing of materials. In exceptional
case to case basis, employer will decide to permit type testing of material at Contractor’s cost.
5.2. 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 purposes of acceptance of that lot.
5.3. Routine Tests shall mean those tests, which are to be carried out on the material/equipment to check
requirements which are likely to vary during production.
5.4. Tests during Manufacture shall mean those tests, which are to be carried out during the process of
manufacture and end inspection by the Contractor to ensure the desired quality of the end product to
be supplied by him.
5.5. The norms and procedure of sampling for these tests will be as per the Quality Assurance
Programme to be mutually agreed to by the Contractor and the Employer.
5.6. The standards and norms to which these tests will be carried out are listed against them. Where a
particular test is a specific requirement of this Specification, the norms and procedure of the tests
shall be as per IS/IEC Standard this specification or as mutually agreed to between the Contractor
and the Employer in the Quality Assurance Programme.
5.7. For all type test and acceptance tests, the acceptance values shall be the values specified in this
Specification, Approved Quality Plan or guaranteed by the Bidder, as applicable.
6.1 All equipment being supplied shall conform to type tests including additional type tests, if any as
per technical specification and shall be subject to routine tests in accordance with requirements
stipulated under respective sections. The Contractor shall intimate the Employer the detailed
program about the tests at least three (3) weeks in advance in case of domestic supplies & six (6)
weeks in advance in case of foreign supplies.
6.2 The reports for all type tests and additional type tests as per technical specification shall be
furnished by the Contractor alongwith equipment/material drawings. The type tests conducted
earlier should have either been conducted in accredited laboratory (accredited based on ISO/IEC
Part -2 : Employer’s Requirements 40
Guide 25/17025 or EN 45001 by the national accreditation body of the country where laboratory is
located) or witnessed by the representative(s) of Employer or Utility. The test-reports submitted
shall be of the tests conducted within last 5 (five) years prior to the date of bid opening. In case the
test reports are of the test conducted earlier than 5 (five) years prior to the date of bid opening, the
Contractor shall repeat these test(s) at no extra cost to the Employer, however the delay in supply
due to type-test will not be acceptable during the project.
6.3 In the event of any discrepancy in the test reports i.e. any test report not acceptable due to any
design/manufacturing changes (including substitution of components) or due to non-compliance
with the requirement stipulated in the Technical Specification or any/all additional type tests not
carried out, same shall be carried out without any additional cost implication to the Employer.
6.4 The Employer, his duly authorized representative and/or outside inspection agency acting on behalf
of the Employer shall have at all reasonable times free access to the Contractor’s/sub-vendors
premises or Works and shall have the power at all reasonable times to inspect and examine the
materials and workmanship of the Works during its manufacture or erection if part of the Works is
being manufactured or assembled at other premises or works, the Contractor shall obtain for the
Engineer and for his duly authorized representative permission to inspect as if the works were
manufactured or assembled on the Contractor’s own premises or works. Inspection may be made at
any stage of manufacture, dispatch or at site at the option of the Employer and the equipment if
found unsatisfactory due to bad workmanship or quality, material is liable to be rejected.
6.5 The Contractor shall give the Employer/Inspector ten (10) days written notice of any material being
ready for joint testing including Contractor and Employer. Such tests shall be to the Contractor’s
account except for the expenses of the Inspector. The Employer/Inspector, unless witnessing of the
tests is virtually waived, will attend such tests within thirty (30) days of the date of which the
equipment is notified as being ready for test /inspection, failing which the Contractor may proceed
alone with the test which shall be deemed to have been made in the Inspector’s presence and he
shall forthwith forward to the Inspector duly certified copies of tests in triplicate.
6.6 The Employer or Inspector shall, within seven (07) days from the date of inspection as defined
herein give notice in writing to the Contractor, of any objection to any drawings and all or any
equipment and workmanship which in his opinion is not in accordance with the Contract. The
Contractor shall give due consideration to such objections and shall either make the modifications
that may be necessary to meet the said objections or shall confirm in writing to the
Employer/Inspector giving reasons therein, that no modifications are necessary to comply with the
Contract. If any modification is made on the equipment on the basis of test results not in conformity
with the contract, the modified equipment shall be subject to same sequence of test again without
any additional cost to Employer.
6.7 When the factory tests have been completed at the Contractor’s or Sub-Contractor’s works, the
Employer/Inspector shall issue a certificate to this effect within seven (07) days after completion of
Part -2 : Employer’s Requirements 41
tests but if the tests are not witnessed by the Employer/Inspector, the certificate shall be issued
within seven (07) days of receipt of the Contractor’s Test certificate by the Engineer/Inspector.
Failure of the Employer/Inspector to issue such a certificate shall not prevent the Contractor from
proceeding with the Works. The completion of these tests or the issue of the certificate shall not
bind the Employer to accept the equipment should, it, on further tests after erection, be found not to
comply with the Contract. The equipment shall be dispatched to site only after approval of test
reports and issuance of dispatch instruction by the Employer.
6.8 In all cases where the Contract provides for tests whether at the premises or at the works of the
Contractor or of any Sub-Contractor, the Contractor except where otherwise specified shall provide
free of charge such items as labour, materials, electricity, fuel, water, stores, transport, loading &
unloading, packing, apparatus and instruments as may be reasonably demanded by the
Employer/Inspector or his authorized representative to carry out effectively such tests of the
equipment in accordance with the Contract and shall give facilities to the Employer/Inspector or to
his authorized representative to accomplish testing.ContractorContractorContractor
6.9 The inspection by Employer and issue of Inspection Certificate thereon shall in no way limit the
liabilities and responsibilities of the Contractor in respect of the agreed quality assurance
programme forming a part of the Contract.
6.10 The Employer will have the right of having at his own expenses any other test(s) of reasonable
nature carried out at Contractor’s premises or at site or in any other place in addition of aforesaid
type and routine tests, to satisfy that the material comply with the specification.
6.11 The Employer reserves the right for getting any field tests not specified in respective sections of the
technical specification conducted on the completely assembled equipment at site. The testing
equipment for these tests shall be provided by the Employer.
7. Pre-Commisioning Tests
On completion of erection of the equipment and before charging, each item of the equipment shall
be thoroughly cleaned and then inspected jointly by the Employer and the Contractor for
correctness and completeness of installation and acceptability for charging, leading to initial pre-
commissioning tests at Site. The list of pre-commissioning tests shall be provided by the
Employer as per its standard practices. or as included in the Contractor’s quality assurance
programme.
8. Commisioning Tests
All required instrumentation and control equipment will be used during such tests and the
Contractor will use all such measuring equipment and devices duly calibrated as far as
practicable. However, the Contractor, for the requirement of these tests, shall take immeasurable
Part -2 : Employer’s Requirements 42
parameters into account in a reasonable manner. The tests will be conducted at the specified load
points and as near the specified cycle condition as practicable. The Contractor will apply proper
corrections in calculation, to take into account conditions, which do not correspond to the
specified conditions.
8.1 Any special equipment, tools and tackles required for the successful completion of the
Commissioning tests shall be provided by the Contractor, free of cost.
8.2 The specific tests to be conducted on equipment have been brought out in the respective chapters of
the technical specification. However where the pre-commissioning tests have not been specified
specifically they shall be as per relevant IS code of practice or as mutually agreed.
8.3 The Contractor shall be responsible for obtaining statutory clearances from the concerned
authorities for commissioning and operation of the equipment including the Electrical Inspector.
Necessary fee to perform these works shall be paid by Employer.
The State owned power distribution utilities have implemented GIS based asset tagging activities in
the past and migrated asset information into GIS platform. Bidder should update various attributes
of new / upgraded infrastructure created under RDSS over the same platform. Various electrical
assets i.e Power Transformers, Distribution Transformer, HT & LT lines with over head conductor,
poles, insulators, stay wire etc and Underground distribution system consists of Feeder pillar, UG
cable etc; automation devises like RMU’s FPI, Auto-reclosures etc needs to be updated in the
existing GIS platform. The GIS platform and the associated mobile-app will be provided by the
Employer. The scope of the bidder is limited to updating the GIS co-ordinates and the associated
mapping information of the new assets created/upgraded on the platform provided by the Employer
using the mobile app. However no additional payment shall be made to the Contractor for these
works.
4. Vendor will start collecting intended data from newly commissioned and / or upgraded
infrastructure commissioned in RDSS and submit the same with the Employer nodal / team for
approval.
5. The Employer’s project in charge would get these data verified through their team, once completed
they will get duly verified by Executive Engineer and circle SE and shall submit same to IT office
for further review.
6. It is to be noted that updating of GIS asset information is mandatory requirement for the issuance of
completion certificate by the employer.
10. Documentation
10.1. General
10.1.1. To ensure that the proposed systems conform to the specific provisions and general intent of the
Specification, the Contractor shall submit documentation describing the systems to employer for
review and approval. The Contractor shall obtain approval of employer for the relevant document
at each stage before proceeding for manufacturing, system development, factory testing, site
testing, training etc. The schedule for submission/approval of each document shall be finalised
during the discussions before placement of the contract, this schedule shall be in line to overall
project schedule.
10.1.2. Each document shall be identified by a Contractor document number, the employer document
number, and the employer purchase order number. Where a document is revised for any reason,
each revision shall be indicated by a number, date, and description in a revision block along with
an indication of official approval by the Contractor's project manager. Each revision of a
document shall highlight all changes made since the previous revision.
10.1.3. All technical description, specifications, literature, correspondence, prints, drawings, instruction
manuals, test reports( both factory and at site), progress photographs, booklets, schedules and all
supplementary data or documents furnished in compliance with the requirements of the Contract,
shall become the property of the Employer and the costs shall be considered as included in the
Contract price.
10.1.4. The Contractor shall be responsible for any time delay, misinterpretation, error and conflict
during design, manufacturing, testing and erection of the Works resulting from non-compliance
with the requirements of this Specification.
10.1.5. The Employer shall have the right to make copies of any documents, data, reports, information
etc. supplied by the Contractor in connection with the Works. The Employer shall not impart the
information of these documents to any other manufacturer or competitor but he shall be free to
use these for preparation of technical papers, reports etc.
Part -2 : Employer’s Requirements 44
10.2. Requirements for submission of documents, information and data by the Contractor
10.2.1. The Contractor shall submit to the Employer all documents in accordance with an approved
schedule of submissions and shall submit any further information (in the form of drawings,
documents, manuals, literature, reports etc.) when asked by the Employer while
commenting/approving any drawings/documents etc.
10.2.2. The documents which are subject to the approval of the Employer shall be identified by the
Contractor with the stamp "FOR APPROVAL". All other documents shall be submitted to the
Employer for information and shall be identified by the Contractor with the stamp "FOR
INFORMATION".
10.2.3. The sequence of submission of the documents shall be subject to the approval of the Employer.
The sequence of submissions of all documents shall be such that the necessary information is
available to enable the Employer to approve or comment the document.
10.2.4. The Contractor shall supply 4 hard copies of all drawings and documents.
10.2.5. In case a "SUBSEQUENT" revision of any document is made due to any reason whatsoever, a
revision of the same, highlighting the changes shall be resubmitted for the Employer's specific
approval/ information.
10.3.1. The Employer shall be allowed fifteen (15) calendar days to approve the Contractor's
submissions. The submissions for approval, shall be returned to the Contractor marked in one of
the following ways :
Category I: Approved
Category II: Approved with Comments.
Category III: Returned for correction.
Category IV : For information
10.3.2. The first notations "I" or "II" shall be deemed to permit the Contractor to proceed with the work
shown on the document, except in the case of notation "III" the work shall be done subject to the
corrections indicated thereon and/or described in the letter of transmittal. The Contractor shall
bear the full responsibility for proceeding with the Works prior to receipt of the release in
notation "I" from the Employer.
Part -2 : Employer’s Requirements 45
10.3.3. In case of notation "II", the Contractor shall include the alterations required & resubmit the
document within fifteen (15) days from date of Employer's letter of transmittal.
10.3.4. In case of notation "III", the Contractor shall include the alterations required and resubmit the
document to the Employer, within fifteen (15) days, from date of letter of transmittal, so that such
document can be returned with the notation "I" or "II".
10.3.5. It may also be noted that the approval/commenting by the Employer does not relieve the
Contractor of any of his contractual obligations and his responsibilities for correctness of
dimensions, materials, weights quantities or any other information contained therein, as well as
the conformity of designs with Indian Statutory Laws and the Technical Specifications as may be
applicable. The approval also does not limit the Employer's rights under the Contract.
10.3.6. The approved documents shall be considered as the working documents. However the Technical
Specification and connected documents shall prevail over these documents in case a decision is
required on interpretation.
The Contractor shall not delay the Works pending the receipt by the Contractor of the comments
on documents submitted to the Employer for information. However, the Employer shall have the
right to comment on all the documents submitted by the Contractor, when, in the opinion of the
Employer the document does not comply with the Contract or otherwise. The Contractor shall
satisfactorily demonstrate that the information contained in the aforesaid document does meet the
requirements of the Contract or revise the document in order that the information shall comply
with the requirements of the Contract.
10.5.1. The reference drawings are enclosed with the bid document, which forms a part of the
specification. The Contractor shall develop a new layout in line with the specification and take the
approval of the EMPLOYER. The Contractor shall maintain the overall dimensions of the
substation, buildings, bay length, bay width, phase to earth clearance, phase to phase clearance
and sectional clearances, clearances between buses, bus heights but may alter the locations of
equipment to obtain the statutory electrical clearances as required for the substation.
10.5.2. All drawings submitted by the Contractor including those submitted at the time of bid shall be in
sufficient detail to indicate the type, size, arrangement, material description, Bill of Materials,
weight of each component, break-up for packing and shipment, dimensions, internal & the
external connections, fixing arrangement required and any other information specifically
Part -2 : Employer’s Requirements 46
10.5.3. Each drawing submitted by the Contractor shall be clearly marked with the name of the
Employer, the unit designation, the specifications title, the specification number and the name of
the Project. If standard catalogue pages are submitted, the applicable items shall be indicated
therein. All titles, noting, markings and writings on the drawing shall be in English. All the
dimensions should be in metric units.
10.5.4. Further work by the Contractor shall be in strict accordance with these drawings and no deviation
shall be permitted without the written approval of the Employer, if so required.
10.5.5. The review of these data by the Employer will cover only general conformance of the data to the
specifications and documents interfaces with the equipment provided under the specifications.
This review by the Employer may not indicate a thorough review of all dimensions, quantities and
details of the equipment, materials, any devices or items indicated or the accuracy of the
information submitted. This review and/or approval by the Employer shall not be considered by
the Contractor, as limiting any of his responsibilities and liabilities for mistakes and deviations
from the requirements, specified under these specifications and documents.
10.5.6. All manufacturing and fabrication work in connection with the equipment prior to the approval of
the drawings shall be at the Contractor’s risk. The Contractor may make any changes in the
design which are necessary to make the equipment conform to the provisions and intent of the
Contract and such changes will again be subject to approval by the Employer. Approval of
Contractor’s drawing or work by the Employer shall not relieve the Contractor of any of his
responsibilities and liabilities under the Contract.
10.5.7. All engineering data submitted by the Contractor after final process including review and
approval by the Employer shall form part of the Contract Document and the entire works
performed under these specifications shall be performed in strict conformity, unless otherwise
expressly requested by the Employer in Writing.
• Materials released due to bay capacity augmentation and/or due to replacement like power
transformers, distribution transformers, insulator, meter board, cut outs etc are also required to be
returned to Employer’s stores through proper documentation.
• All other line materials released like, conductors, poles, cross arms; fabricated material, etc. shall
be properly accounted for and returned to Employers store after recording all necessary details
including weight, length etc. wherever necessary. A detailed procedure for return of the old
materials shall be prescribed by Project Management Agency.
• In respect of accountal of devolution of released material, the process as formulated by Employer
time to time shall be followed by the Contractor
12. Miscellaneous activities
• Commencement of Supply & Works: The Contractor shall ensure that the supply and installation
of material and service under the contract is as per approved PERT / completion schedule of
works. The Contractor is to commence supply with the type tested materials with necessary routine
test/ acceptance test certificates for a particular lot duly approved by EMPLOYER or the
EMPLOYER’s authorized agencies.
• The Contractor shall submit Type test and routine test certificates as applicable, issued by NABL
accredited / third party independent standard laboratories like CPRI, NPL etc.
• Unit rates: The unit rates quoted shall include 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 work. The unit rate quoted shall be inclusive of deployment of all plants,
equipments, men, materials, skilled & unskilled labour etc. essential for satisfactory completion of
work.
• The prices for fabricated materials shall include all works relating to fabrication,
galvanizing,insurance, storage and delivery ex-Contractors stores, unloading and loading. The
quoted prices shall also include the cost of necessary quantity of steel and zinc, freight charges up
to site store and other indirect charges incurred in connection with supply of finished materials.
• Quantities/ length of 33 KV, 11 KV line and LT line, distribution transformers sub stations, 33/11
KV sub-station etc. indicated in the price schedules are provisional. Any quantity variation in
individual item and in contract value shall be governed as per GCC clause 39. The Contractor shall
execute the work based on the actual survey and as approved by the Engineer-in-charge or person
authorized by him.
• The scope of work also covers supply of other items, not specifically mentioned in this
specification and/or bill of materials but are required for the successful installation, testing,
commissioning and satisfactory performance of the 33 KV & 11 KV lines, 33/11 KV sub stations,
distribution transformer sub stations, LT lines, service lines etc.
Thefollowingworks&servicesshallalsobeprovidedbytheContractor.
a) Unloading theequipmentsfrom therailorroad transport andmoving
thosetostoragearea.Demurrage/wharfagecharge,ifanyincurred,shall bepaidbytheContractor
Part -2 : Employer’s Requirements 48
b) Openingofpackingcases,inspectionandcheckingofmaterialsforany damageor
lossintransitshallbetheresponsibilityoftheContractor.All claimswiththeconcernedauthorities
e.g.rail,transport,insurance etc. shallbelodgedbytheContractor.
c) Complete erection of equipments, etc covered under the contract, final preparation for testing,
commissioning, final run and acceptance tests and putting the sub-station/ plant/line etc. into
operation.
d) All consumable, stores required for the above erection and commissioning works.
e) Allerectiontools,liftingtackles,andallequipments,tools&tacklesfor transportationatsite.
f) Workshop, as required within the work area.
g) Thirdpartyinsurance [1]atsiteandinsuranceofpersonnelemployedatsite
[1]
Note: Before receipt of equipment at site but without limiting his obligations and responsibilities
under this clause hereof, the Contractor shall insure against his liability for any equipment,
material or physical damage, loss or injury which may occur to any property, including that of
EMPLOYER and project management agency, or to any person including employee of the
EMPLOYER, by or arising out of the execution of the contract or in the carrying out of contract.
The third party insurance cover shall be provided for the period from date of Ex-factory dispatch
till taking over of the entire equipment after testing, commissioning and trial operation, if any.
Third party insurance shall be affected for an adequate amount to cover for all marine,
transportation, field transportation, erection, testing and commissioning till handing over to
Employer,. Terms shall include a provision whereby, in the event of any claim being brought or
made against EMPLOYER in respect of which the Contractor would be entitled to receive
indemnity under the policy, the insurer will indemnify EMPLOYER and project management
agency against such claims and any costs, charges and expenses in respect hereof. Contractor
shall lodge the claim if need so arise, the employer shall be the Employer of the
equipment/materials and the claims shall be settled in the name of Employer.
Part -2 : Employer’s Requirements 49
1.00 Survey
a. 9.1 meter long /280 KG PCC Poles (PCC Pole as per state practice)
b. 11/13 m long galvenised H-Beam 152x152 mm 37.1 kg/m
c. 11 M long steel Tubular poles of Designation 540 SP 52 (IS 2713, Pt I, II, III 1980)
d. 13 M long steel Tubular poles of Designation 540 SP 72 (IS 2713, Pt I, II, III 1980)
e. 11/33 m Wide Galvanised Parallel Beam GI Poles (160x160 mm) extendable with jointing
plates – 30.44kg per meter
In rural area, PCC poles are to be used. In urban area, PCC or H-Beam or STP or Wide
Parallel Beam supports are to be used of suitable length. In hilly areas where handling of
material is a challenge, tubular poles or Wide Parallel Beam GI poles expandable with
jointing plaes may be used. In location specific conditions like forest area, vicinity of other
existing overhead lines or permanent structures etc, H- beam or tubular poles or Wide
Parallel Beam supports may be used of suable length.Steel bottom plate shall be used in steel
tubular poles/H-Beam / Wide parallel Beam and cement concrete reinforced plate shall be
used as base plate for PCC poles.Steel tubular poles shall be cleaned till good surface finish
and painted with 2 or more coats of red oxide paint and 2 or more coats of aluminium paint
till good finish. Steel tubular poles and H-Beams shall also be painted with 2 or more coats
till good surface finish with anti-corrosive paint (in case of tubular poles shall also be painted
on the inner walls) which goes in to the foundation. Project Manager shall approved brand
and shade of paints.
Part -2 : Employer’s Requirements 50
steel tubular poles shall be cleaned till good surface finish and painted with 2 or more coats
of red oxide paint and 2 or more coats of aluminium paint till good finish. Steel tubular poles
and H-Beams shall also be painted with 2 or more coats till good surface finish with anti-
corrosive paint (in case of tubular poles shall also be painted on the inner walls) which goes
in to the foundation. Project Manager shall approved brand and shade of paints.
Painting of H-Beams and Steel Tubular Poles shall be performed at stores. Before shifting to
site for erection, poles shall be offered for inspection and approval by Project Manager. In
water bound areas and in NE areas, galavenized poles may be used. The minimum coating of
the zinc on steel tubular poles or Wide Parallel Beam supports shall comply with IS: 2629
and IS: 2633 (with latest amendments). Galvanizing shall be checked and tested in
accordance with IS: 2633.
Add
The H beam poles shall be hot-dip galvanized thoroughly internally and externally as per
according to IS: 2629 and IS: 2633 (with latest amendments). Galvanizing shall be checked
and tested in accordance with IS: 2633.
Poles and other hollow items shall be galvanized both inside and out. The zinc coating shall
be smooth, continuous and uniform. It shall be free from acid spots and shall not scale, blister
or be removable by handling or packing. There shall be no impurities in the zinc or additives
to the smelter bath that could have a detrimental effect on the durability of the zinc coating.
Before pickling, all welding, drilling, cutting and grinding shall be completed and all grease,
paint, varnish, oil and welding slag shall be completely removed.
All protuberances which could affect the life of galvanizing shall also be removed. To avoid
the formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
Testing of galvanizing shall be performed for Uniformity of thickness as per IS 2633/1986,
Mass of coating as per IS 6745/1972 and quantity of zinc, water quenching ¢riguging as
per IS 2629/1985.
Fabricated steel structure items shall be galvanized both inside and out. The zinc coating
shall be smooth, continuous and uniform. It shall be free from acid spots and shall not scale,
blister or be removable by handling or packing. There shall be no impurities in the zinc or
additives to the smelter bath that could have a detrimental effect on the durability of the zinc
Part -2 : Employer’s Requirements 51
coating. Before pickling, all welding, drilling, cutting and grinding shall be completed and all
grease, paint, varnish, oil and welding slag shall be completely removed.
All protuberances which could affect the life of galvanizing shall also be removed. To avoid
the formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
4.00 Hardware:
MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used
for tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing,
strain plates etc.
While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall
be hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
them to site for erection, they shall be offered for inspection and approval by Project
Manager.
Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (2Nos.), anchor plate
(300x300x8mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 20 mm diameter solid GS stay
rod & 7/4.00 mm dia GI stranded wire complete.
Stay set shall be used at all turning locations, conductor dead end location, double pole
structure, triple pole structure, four pole structure to nullify the tension of conductor. At dead
end locations, stay sets shall be used in pairs in separate foundations. Erection of storm guys
at suitable location in straight line may also be provided.
0.3 cmt cement concreting in mixture 1 part cement, 3 part coarse sand, 6 part 40mm size
aggregate stone chips (1:3:6) shall be provided in each stay set foundation. 2 Nos. guy
insulator shall be provided in stranded GI wire at middle location between two turn buckles.
Shuttering and vibrator shall be used for cement concreting works.
Part -2 : Employer’s Requirements 52
6.00 Earthing:
a. 40 mm dia., 3000 mm long GI pipe earth electrode with test link, RCC pit, RCC cover plate
on GI frame, bentonite powder and other accessories complete
b. GI Earthing spike made of 20mm solid rod
c. Chemical rod earthing using Carbon powder/Bentonite powder / Conductive concrete powder
including electrode with 2000mm long, 50 mm diameter GI pipe, GI Strip of 24x3mm
minimum.
d. 8 SWG GI Earthing Coil.
e. 6 SWG GI wire for earthing and guarding
f. 8 SWG GI wire for earthing and guarding
Each 33 kV line support shall be provided with one GI earthing spike made of 20 mm solid
rod or 8 SWG GI Earthing Coil and connected with 8 SWG GI wire. Overhead line structure
shall be connected to GI earthing spike or GI Earthing Coil using 8 SWG GI wire. GI nuts,
bolts & washers shall be used to join two GI wires and 20 mm solid spike rod. Project
Manager shall decide use of GI Earthing Coil or GI Solid earth Road for earthing of
individual poles.
At railway crossing, line crossing and other specific locations 40 mm dia, 3000 mm long GI
pipe earth electrode with test link, RCC pit, RCC cover plate on GI frame, bentonite powder
and other accessories shall be used. Overhead line structure at these locations shall be
connected to GI earth pipe using 8 SWG GI wire. GI nuts, bolts & washers shall be used to
join two GI wires and 40 mm GI earth pipe.
In rocky soil where getting required earth resistance is a challenge, chemical rod earthing
shall be used. Overhead line structure shall be connected to chemical earth electrode using
8SWG GI wire. GI nuts, bolts & washers shall be used to join two GI wires and 20 mm solid
spike rod.
GI flats and GI wires must be properly dressed, bundled and fixed on supporting structure at
1 to 2 feet intervals.
The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator should properly be cleaned before installation. No damage/crack
insulator should be used.
Following ACSR Conductors (or equivalent AAAC conductor) are envisaged for new 33 kV
lines:
Care should be taken while drawing conductor from the drum. Proper roller should be used
while handling conductors during erection. Jointing sleeves, binding materials, PG clamps,
bi-metallic conductor shall be used for conductor jointing, insulators fixing, jumpering and
termination at equipment respectively.
Proper sag should be maintained using sag chart table. While tensioning, care should be
taken to avoid tension on pin insulator. Therefore, proper alignment of line to be ensured.
Conductor joint should not be in the middle span but may be planned nearer the support.
At terminal location, care should be taken while connecting two sections to avoid bird faults.
Therefore, pin insulator is to be used to handle the conductor on DC cross arm (as per state
practice).
Each support pole should be numbered properly labelled using yellow base and black
indication marks (number or digits). 40/50 mm height digits/words should be used for this
purpose. Base shall be made using 2 or more coats of yellow enamel paint till good surface
finish. Base preparation shall be completed before shifting of poles to site for erection. Base
painting and marking of digits should be performed by a skilled and trained painter using
branded enamel paint, Project Manager shall approve type and brand of enamel paint.
Warning instruction, if any, of availability of two sources of 33 kV supply on same structure,
at source structure, at cut points should exclusively be provided as per state practice.
3.5 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each 33 kV support.
Galvanized barbed wire should be properly dressed and crimped at termination. While
wrapping the wire on support, proper tension should be maintained.
Each support should be provided with a danger board with pole clamps as per approved
drawing. Danger board should be in bi-lingual languages (local language and English).
Clamp for danger board, nut-bolts and washers shall be painted with two or more coats of
red-oxide and aluminium paints respectively till smooth surface before installation.
12.00 33 KV AB Switch:
33 kV, 3-ph, 600 A, 3 Pin type, Vertical/Horizontal Mounting type, Gang Operated, AB
Switch shall be installed at cut points and at suitable locations as per instructions of Project
Manager. B Class GI pipe shall be used (without any joints) for operation of switch. AB
Switch structure and handle must be earthed using 8 SWG GI wire.
Cement concrete in mixture 1 part cement, 3 part coarse sand, 6 part 40mm size aggregate
stone chips (1:3:6) shall be used in all the types of 33 kV line supports.
While erecting supports (poles), shuttering must be used for concreting so that proper
quantity of cement concrete mixture be used and assessed during inspection. During
concreting proper compaction by means of mobile vibrator be provided. While starting work
of support erection, gang wise shuttering and mobile vibrator shall be offered for inspection
to Project Manager. While erecting support, mercury level gauge must be used to ensure
vertical erection of support.
250mm dia X 12” inch size muffing shall be provided on steel tubular/ H-Beam poles/wide
parallel beam support to prevent direct entry of rain water along the poles. Cement Concrete
of 1:2:4 (1 part Cement, 2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall
be used for individual poles
Steel plate shall be used in steel tubular poles/Wide parallel Beam/ H-beam supports and
cement concrete reinforced plate shall be used as base plate for PCC poles.
Part -2 : Employer’s Requirements 55
A separate composite item of railway crossing is kept in BoQ. 2 Nos. separate cables shall be
laid in separate GI pipe enclosures. At a time, one shall be used and another shall be kept idle
as spare in ready to join condition. Cable termination, cable identification, protective
covering, laying of jumpering cable etc shall all be completed in this head. This composite
item shall contain following key items:
a. 3Cx300 Sqmm XLPE armored cable (approx. length is 0.3 km each) – 2 sets
b. 150mm dia GI pipe of A class (red color painted on edges) for cable protection in
underground laying – 2 sets
c. 150mm dia GI pipe of B class (blue color painted on edges) for cable support at DP structure
– 2 sets
d. Outdoor heat shrinkable cable jointing kits for main cable and jumpering cable – 4 Nos for
main cable, 8 Nos for jumpering cables.
e. 33 kV lightening arrestor station class 10kA (6 nos.),
f. 4 Nos GI 3-meters long pipe earthing/chemical earthing,
g. 6 SWG GI wires with GI nuts, bolts & washers,
h. Cable markers,
i. Bi-metallic clamps,
j. Jumpering with 33 kV Arial Bunched Cables 200 Sqmmdia (10 mtr) etc – 4 sets
Horizontal drilling machine shall be used for horizontal bore below railway tracks.
observations with supporting photographs in digital form within one month from receipt of
observations.
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/trim to obtain required tree clearance. Contractor
shall pay compensation for any loss or damage for tree cutting due to Contractor’s work.
Wherever forest clearance is envisaged for execution of work, clearance of forest department
for tree cutting, if required, shall be arranged by the Project Manager and compensation shall
also be paid by the Project Manager. Necessary fee if required to pay to Govt. dept. for
arranging such clearances shall paid by Project Manager. However, the Contractor would
require to provide all necessary assistance for execution of this work.
During execution of 33 KV Line work, all statutory clearances shall be ensured for ground
clearance, line-to-line clearance, road crossing clearance, horizontal and vertical clearances
from buildings/objects etc. All road crossings and line crossings shall be guarded as per
specifications. Conductor joint should not be provided in mid span length. Instead, it should
be nearer to the support.
Part -2 : Employer’s Requirements 57
The scope of works include on turnkey basis for design, engineering, manufacturing, shop
testing, transportation, supply, storage, erection, testing & commissioning of the following:
a) Complete design and engineering of all the systems, sub-systems, equipment, material and
services.
b) Providing engineering data, drawings and O&M manuals for Employer’s review, approval
and records.
c) Manufacturing, supply, testing, packing, transportation and insurance from the manufacturer’s
work to the site including port and customs clearance, if required.
d) Receipt, storage, insurance, preservation and conservation of equipment at site.
e) All civil and structural works as required.
f) Fabrication, pre-assembly (if any), erection, testing and putting into satisfactory
operation of all the equipment/material including successful commissioning
g) Satisfactory conclusion of the contract.
h) Enabling work as per the site requirement.
In addition to the requirements indicated herein, all the requirements as stated in other
sections shall also be considered as a part of this specification as if completely bound
herewith.
The Bidder shall be responsible for providing all material, equipment and services specified or
otherwise which are required to fulfill the intent of ensuring operability, maintainability and
the reliability of the complete work covered under this specification.
It is not the intent to specify all aspects of design and construction of equipment mentioned
herein. The systems, sub-systems and equipment shall conform in all respect to high standards
of engineering, design and workmanship, and shall be capable of performing in continuous
commercial operation.
The scope of work shall comprise, but not limited to the design, engineering, manufacture,
testing and inspection at manufacture’s works, packing, supply, transportation, transit
insurance, delivery to site, unloading, and storage and equipment erection including
associated civil and structural works. Further it
Part -2 : Employer’s Requirements 59
shall include the cabling, lighting, earthing, supervision, site testing, inspection and
commissioning of Sub-Station. The scope shall also include all enabling works required for
modification to existing facilities within the project area.
a. Bay Details:
The equipment and materials to be supplied by the Bidder shall form a complete 66 kV Sub-
Station.
Any items though not specifically mentioned but which are required to make the switchyard
complete in all respects for its safe, efficient, reliable and trouble free operation shall also be
deemed to be included and the same shall be supplied and erected by the Bidder without any
additional cost to Employer. The following items of works are covered under scope-
The scope includes but not limited to the following services/items described herein and
elsewhere in specification:
i. The Bidder shall be responsible for detailed design and engineering of overall system, sub-
systems, elements, system facilities, equipments, auxiliary services, etc. It shall include
proper definition and execution of all interfaces with systems, equipment, material and
services of Employer for proper and correct design, performance and operation of the project.
ii. Bidder shall provide complete engineering data, drawings, reports, manuals etc. for Employer’s
review, approval and records.
iii. The scope shall also include the design and engineering as per details elaborated elsewhere in
this specification.
iv. The Bidder shall carry out earth resistivity measurements at the switchyard site
v. Relay setting calculations shall also be submitted by the Bidder for approval.
vi. For all civil and structural works, the Bidder shall carry out design calculations; prepare all the
detailed construction and fabrication drawings.
4.00 Arrangement by the Contractor
Contractor shall make his own necessary arrangements for the following and for those not
listed anywhere else:
Details scope under civil works have been provided in this Part 2, Section 6 – “Civil Works
and Soil Investigation” mentioned subsequently.
The reference drawings, which are indicative of the type of specifications Employer intends to
accept, shall be developed by Contractor and approved by Project Manager. The Contractor
shall maintain the overall dimensions of the substation, buildings, bay length, bay width,
phase to earth clearance, phase to phase clearance and sectional clearances, clearances
between buses, bus heights but may alter the locations of equipment to obtain the statutory
electrical clearances required for the substation.
Nos of proposed
Name of Proposed 33KV line
No Division Capacity in KVA 11 KV outgoing
Substation LILO or Radial
feeders
2.00 Following works are in the scope of Employer and shall be executed by Project Manager:
a) Acquisition of land for the substation and its possession to start constructional activities,
b) Approach road to the substation land,
c) Leveling of the substation land,
d) Construction of retaining wall wherever required including cutting, digging or filling of earth
as required,
e) Availability of up-stream source and plan for incomer 33 KV line (if the same is not part of
package)
f) General layout of the substation
g) Three (3phase) 415V AC power supply at one point on Contractor’s expense & as per
prevailing electricity tariff provided LT network is available in the vicinity of the proposed
substation.
Part -2 : Employer’s Requirements 63
h) Space for construction office & store yard for agency provided free of charge provided it is
available at site.
Since above works are not covered under substation works, Employer/Employer shall provide
all above input before start of substation work by turnkey Contractor. A format protocol note
for handing over/taking over of sub-station land, approach road, retaining wall(wherever
needed) and layout plan shall be signed between Project Manager and authorized
representative of Turnkey Contractor.
3.00 Types of substation: Two types of substations are envisaged under this head as per following:
a. Partly-Outdoor substation – in this type, 33KV section comprising breakers, isolators, 11/0.4
KV station transformer, CTs, PT, Lightening Arrester, Power Transformer & 11 KV Capacitor
Bank, 33KV gantry shall be installed in out-door switch yard. Control panels of breakers shall
be installed inside the control room. All 11KV equipment like CTs, Breakers and control
panels, feeder meter shall be installed inside the control room. 11 KV cables shall be used for
connection of power transformer and breaker and Breaker to outgoing isolators. 11KV feeder
isolators and 11KV Lightening Arresters shall be installed outdoor.
Power Transformers shall be 33/11 kV, 3 ph, 50 Hz, ONAN, Cu Wound, Outdoor
Conventional type Power Transformer along with transformer oil, Buchholtz relay, breather,
OTI & WTI, Marshalling Box, Conservator tank, oil level indicator, valves, Vent explosion
plug, control wiring between sensing equipment and marshalling box, cable supporting tray on
the body of transformer, transformer wheels, LV/HV bushing etc as required. Following type
and capacity of power transformers are envisaged under the scheme:
2 sets of 50x8 mm galvanized neutral earthing strips shall be supplied with the transformer
along with braided copper conductor links for connections at bushing ends. Two distinct earth
connection shall be provided for neutral earthing. The earthing strips shall be mounted on
11KV post insulators. An isolating link shall be provided on individual earth strips for testing
purposes.
Transformer protective equipment like OTI, WTI and Buchholtz relay shall be tested during
pre-commissioning stage. Their electric connection upto marshalling box shall be performed as
per Original Equipment Manufacturer recommendations. Cable tray shall be installed for
laying of control cable shall be laid on cable tray on transformer body so that cable shall not
get heated by transformer temperature. While commissioning the transformer tripping of
breaker through all these equipment must be checked.
5.00 Breaker:
33 kV & 11 kV Vacuum Circuit Breakers shall be used for protection and control of power
circuits. In partly outdoor substation, all 11 KV switchgears shall be indoor mounted type and
33 KV breakers shall be outdoor mounting type whereas in fully outdoor substation, 11 KV as
well as 33 KV breakers shall be outdoor mounting type. In both the type of substation, control
panels shall be indoor type. Outdoor breakers are to be supplied with Current Transformers.
The outdoor mounting type breakers shall be supplied with its mounting galvanized steel
structures.
Detailed cable schedules, termination details and circuit diagrams of control panels,
transformer marshalling box, breaker marshalling box, and capacitor banks equipment shall be
prepared and submitted by turnkey Contractor for approval of Project Manager before
commencing the work.
Part -2 : Employer’s Requirements 65
Cement concrete including reinforcement steel shall be used for the foundation. Project
Manager shall approved design and drawings of foundations. Proper shuttering, vibrator,
curing shall be performed while constructing the foundations for breaker.
Permanent maintenance platform shall be constructed for outdoor breakers and CT. Project
Manager shall approve design of platform.
Control wiring between CT/breaker and control panel for outdoor mounting breakers/CT shall
be routed through Junction box. Metallic Junction box shall be installed on support gantry
structure of substation or on MS angle (50x50x6 mm) support. The boxes are to be erected,
electrically connected with the existing system, properly earthed, and labeled. The test report
of pre-commissioning checks shall be prepared and submitted. All CT terminals are to be ring
type and other terminals are of fork type. 2.5 sqmm copper multi stands wiring 1.1 KV grade,
ISI marked, IS 694 shall be used for control wiring. A terminal block be provided between CT
and Meter keeping 20% spare terminals. The Junction box are to be earthed using 8 SWG GI
wire direct connection to the earthing. 2 Nos Earthing bolts on the Distribution Box/SMC
Distribution Box shall be provided of 10mm dia.
100 KVA, aluminium / copper wound, 11/0.4 KV (or 33/0.4 KV) Station Transformers shall be
installed on DP structure made of H-Beam 152x152 mm 37.1 kg 8 meter long or parallel
flanged beams WPB 160X30.44. Outdoor type Distribution Box/SMC Distribution Box/SMC
Distribution Box/SMC Distribution Box complying to IS 13410 for station transformer shall
be comprising of 200 A switch fuse unit, 6 Nos SP MCCB– 90 A, 2 Nos 32 A SP MCCB, 3-
ph, 63A, contactor controlled yard lighting timer unit, tri-vector electronic energy meter
(mounted in separate metallic LTCT cum meter box) with suitable CT, control/power cabling
and terminals, 1 No 20 A Industrial socket and switch for local power supply requirements,
mounting channel, clamps and hardware.
The Station Transformer substation shall be provided with Station Class LA, 33KV / 11KV AB
Switch and 33KV / 11KV DO Fuse. Except type of Distribution Board, Lightening Arresters,
and DP Structures, all other scope of work as mentioned under 100 KVA capacity Distribution
Transformer work shall be the scope of work under 100 KVA Station Transformer on LT side.
There are two type of gantry structures envisaged under the scheme.
Part -2 : Employer’s Requirements 66
a) Gantry structures made of H-Beam 152x152 mm 37.1 kg 8 meter long or parallel flanged
beams WPB 160X30.44 kg/m, double MS Channel 100x50mm for bus bar supports (Beam),
65x65x6mm angle for cross arms/supporting structures and 50x8mm flats for clamps along
with hardware items duly painted etc., and
b) Gantry structures made of Lattice structures of equal angles sections, flat as per approved
drawings. State practices are to be adopted in the design. All structural steel members and bolts
shall be galvanized after fabrication as per IS:4759 and zinc coating shall not be less than
610gm/sq. meter for all structural steel members. All L45x45x5 will have 23 mm back mark.
All L50x50x6 will have 28mm back mark. 3.5mm spring washers are to be used under each
nut, structural steel shall conform to IS 2026. All weld shall be 6mm filled weld unless
specified otherwise. All nuts and bolts shall be of property class 5.6 of IS 1367. Plain washers
shall be as per IS 2016 & spring washers shall be IS: 3063.
The gantry steel structures materials shall be hot-dip galvanized thoroughly internally and
externally as per according to IS: 2629 and IS: 2633 (with latest amendments). Galvanizing
shall be checked and tested in accordance with IS: 2633.
The gantry steel structure items shall be galvanized both inside and out. The zinc coating shall
be smooth, continuous and uniform. It shall be free from acid spots and shall not scale, blister
or be removable by handling or packing. There shall be no impurities in the zinc or additives to
the smelter bath that could have a detrimental effect on the durability of the zinc coating.
Before pickling, all welding, drilling, cutting and grinding shall be completed and all grease,
paint, varnish, oil and welding slag shall be completely removed.
All protuberances which could affect the life of galvanizing shall also be removed. To avoid
the formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
0.5m3 cement concrete in mixture 1 part cement, 3 part coarse sand, 4 part 20mm size
aggregate stone chips (1:3:4) shall be used in all the types of gantry supports.
While erecting supports (poles), shuttering must be used for concreting so that proper quantity
of cement concrete mixture be used and assessed during inspection. During concreting proper
compaction by means of mobile vibrator be provider. While starting work of support erection,
gang wise shutting and mobile vibrator shall be offered for inspection to Project Manager.
Part -2 : Employer’s Requirements 67
While erecting support, mercury level gauge must be used to ensure vertical erection of
support.
300x300mm X 12” inch height muffing shall be provided on gantry support to prevent direct
entry of rain water along the support. Cement Concrete of 1:2:4 (1 part Cement, 4 parts coarse
sand and 4 parts 20mm aggregate stones chips) shall be used for individual poles.
415 Volts, ACDB (IP 54 protection) shall be indoor floor mounted with mounting
arrangements, three phase-neutral voltmeter, three phase ammeter and Selector switches, 63
Amps TPN switch fuse unit in incomer circuit, 32 Amps TPN switches in outgoing circuits
equals the number of indoor breaker control panels plus number of outdoor VCB kiosk panel
and having 20% spare outgoing circuits, etc. Alternatively, ACDB can also be erected on
separate MS frame made of 50x50x6 angle.
Substation flooring shall be provided with suitable inserts to fix ISMC 75 channel. This
channel shall hold ACDB board. The board shall be installed on indoor trench. Cables shall
have bottom entry. The board shall be grounded by 50x6mm GI strip at two distinct
connections.
Indoor floor mounted,IP 54 protection, two pole 100 Amp 2 pole DC Switch Fuse unit as
incomer, two pole 40 Amp Switch Fuse units in outgoing circuits equals the numbers of indoor
breaker control panels plus numbers of outdoor VCB kiosks panels plus control room lighting
panel and 20% spares outgoing circuits. Direct Current Distribution Board shall be installed in
each substation. It would comprises of DC volt meter including mounting arrangements etc as
required as per technical specifications, approved drawings and scope of works. Alternatively,
DCDB can also be erected on separate MS frame made of 50x50x6 angle.
Substation flooring shall be provided with suitable inserts to fix ISMC 75 channel. This
channel shall hold DCDB board. The board shall be installed on indoor trench. Cables shall
have bottom entry. The board shall be grounded by 50x6mm GI strip at two distinct
connections.
10.00 Cables:
a. Control cables: 1.1 KV grade 2.5 mm2 PVC insulated and PVC sheathed, armored, stranded,
copper control cable with 2 core, 6 core and 10 core are envisaged in the substation.
Part -2 : Employer’s Requirements 68
b. HT Power Cables: In partly outdoor substation, 11KV XLPE Cables shall be used as per
following requirements;
• Between Power Transformer and Main transformer breaker
• Between Feeder breaker and outdoor feeder DP structures
• Between capacitor bank switch and capacitor bank
c. LT Power cables: 1.1 KV grade, armored, stranded, aluminum power cable PVC insulated and
PVC sheathed with complete accessories as per detailed engineering
d. LT cable for Internal Electrification works: following cables shall be used for internal
electrification purpose:
• 1.1 KV PVC insulated PVC sheathed ISI marked, IS 694, 10mm2, copper conductor, stranded,
for internal electrification works between main DB and Sub DB or Sub DB to switch board,
• 1.1 KV PVC insulated PVC sheathed ISI marked, IS 694, 2.5mm2 /4.00mm2, copper conductor,
stranded, for internal electrification works light & Fan and Power circuits respectively,
• 1.1 KV PVC insulated PVC sheathed ISI marked, IS 694, 4.00mm2, copper conductor, stranded
weather proof cable for connection between outdoor area lighting luminary fixtures and its
junction boxes,
Power Cables are to be laid as per best engineering practices. Power and control cables are to
be laid in different alignments in cable trench. However, in case power/control cable is
required to extend up to the equipment where cable trench is not constructed, they shall be laid
in underground trench of width 300 – mm wide, provided with 2nd class brick protection
(Approx. 10 bricks per meter length of laying) and sand protective covering (200 mm thick)
and laid at the depth of 750mm minimum for LT cables and 1000mm for 11 kV cables. Laying
specification of cable shall be as detailed in CPWD specification of laying power cables.
Suitable loop length of 1.5 meter to be kept at the end points. Excessive loop lengths shall not
be paid.
Part -2 : Employer’s Requirements 69
Following two types of metering equipment are envisaged in the work comprising of:
Meter shall be HT trivector DLMS compliant category suitable for substation/feeder metering.
Meter shall be 3 ph 4 w 110 V 5 A accuracy class 0.5s with GSM (GPRS compatible) modem.
All CT terminals are to be ring type and other terminals are of fork type. 2.5 sqmm copper
multi stands wiring 1.1 KV grade, ISI marked, IS 694 shall be used for control wiring. A
terminal block be provided between CT and Meter keeping 20% spare terminals.
The Meter-cum-meter box are to be earthed using 8 SWG GI wire direct connection to the
earthing. 2 Nos Earthing bolts on the distribution boards shall be provided of 10mm dia.
Capacitor banks of 600 KVAr, 1200 KVAr and 1500 KVAr capacity shall be provided with
3.15 MVA, 5.0 MVA and 8.0 MVA capacity power Transformer respectively. Capacitor bank
shall comprises of switching vacuum circuit breaker, current transformers (100-50/5-5A), fully
automatic control panel mounted inside the substation buildings, 11 KV residual voltage
transformer, 11 KV three phase Isolator, Earthing system, capacitor banks complete with
individual fuses, interconnection mounting rakes, external fuses mounting arrangement, base
insulators & accessories, 3 Nos. 11 KV single phase Metal oxide (Gap less) lighting arresters,
isolators etc as per requirements. Hot dip galvanized mounting structure made of sections of
100x50x6 mm channel or 75x40x6 mm channel or 75x75x8 mm equal angles only.
At-least four Philips make LED bulbs are to be provided of 7 watts {2 Nos in control room, 1
No in station battery room, 1 No in yard area). These bulbs shall be fed by DC station battery.
The wiring of these bulbs shall be so designed that it will automatically turn ON in event of
failure of normal power supply. Provision for putting these bulbs OFF by operator is also to be
provided. Wiring is to be performed concealed using PVC insulated PVC sheathed 2.5 mm2
stranded copper wire. An automatic change over switch is envisaged for this purpose. This may
be installed at prominent location, generally easily approachable by operator in the substation
control room.
Station battery are to be supplied with wooden racks made of teak/sal wood planks of thickness
not less than 25mm, support legs made of size not less than 2 inches X 2 inches. The battery
may be placed on two-tier formation of stand. The construction of battery rack shall suit site
conditions of their placement. The rack shall be painted with three coat of acid proof paint of
reputed make as approved by Project Manager. No metal fasteners / nails shall be used for
construction of battery racks. The stand shall be supported on insulators to obtain necessary
insulation from the earth and there shall be insulators between each cell and stand.
Initial charging of stationary battery shall strictly be as per Original Equipment Manufacturer
(OEM) recommendations. Detail charging and discharging cycle readings shall be recorded
and submitted to Project Manager for approval.
Battery room shall be provided with exhaust fan of air displacement capacity more than six
times volume of battery room per hour. Wooden doors and windows shall be provided in the
battery room. Anti-acid tiles shall be used in the floor and upto six feet height of the wall of the
battery room.
The battery connections / terminals are to be cleaned and provided with petroleum jelly.
Terminals hardware is to be provided with connecting cables. The inter-battery wiring cable
shall be neatly dressed using cable ties, clamped and wired using ferrules, tag mark. New
battery sets are to be provided with battery chargers as per detail specifications enclosed.
Interconnecting cables and power supply cables originating / terminating at the battery charger,
shall be neatly dressed using cable ties, clamped and wired using ferrules, tag marks, double
compression glands etc as applicable. Connecting cable and associated materials needed for
commissioning of charger shall be treated as part of the battery charger. 1.1 KV multi-strands,
30 sqmm, copper conductors, PVC insulated and PVC sheathed cable for DC wiring between
DCDB and Battery bank.
Outdoor type CTs are to be erected on supporting structure provided on the breaker structure or
suitable structure as per state practices. Potential Transformers shall be erected on gantry
structures and connected with bus. In both the case, separate metallic Junction Box shall be
installed on support gantry structure of substation or erected on separate galvanized steel
structures in the yard nearer to equipment. The boxes are to be erected, electrically connected
with the existing system, properly earthed, and labeled. The test report of pre-commissioning
checks shall be prepared and submitted for approval of Project Manager.
All CT terminals are to be ring type and other terminals are of fork type. 2.5 sqmm copper
multi stands wiring 1.1 KV grade, ISI marked, IS 694 shall be used for control wiring. A
terminal block be provided in the junction box keeping 20% each spare ring type/fork type
terminals.
The junction box shall be earthed using 8 SWG GI wire direct connection to the earthing. 2
Nos Earthing bolts on the junction box of 10mm dia.
Testing and pre commissioning checks shall be conducted in accordance with OEM
recommendations and as approved by the Employer. Terminal connectors at HT as well as LT
side shall be provided with the CT/PT equipment.
New panels as per the requirement of protection like feeder protection, transformer protection
or incomer protection are to be supplied with each newly supplied breaker:
a. In case of fully outdoor type substation, control Panel to be erected on ISMC75 (75x40x6 mm)
MS channel duly welded on MS angle inserted on indoor trench. Panels shall then be properly
aligned, Cables shall enter with double compression glands, codified, lugged, and dressed.
Part -2 : Employer’s Requirements 72
b. Breaker cum control panel shall be erected on ISMC 100(75x50x6 mm) MS channel duly
welded on MS angle inserted on indoor trench. Panels shall then be properly aligned, Cables
shall enter with double compression glands, codified, lugged, and dressed.
c. Functional checks shall be performed on the control panel as per control wiring diagram.
d. All alarm, annunciation and trip circuits / indication & alarm circuits shall be tested and made
operative,
e. The indication lamp shall be LED type lamp as per given specifications and shall be made
operative,
f. Indicating instruments shall be calibrated,
g. Grounding of panel at two different locations by 50x6mm flat shall be provided. ,
h. Control relays shall be calibrated and checked for tripping and closing operations,
i. Pick up time / trip time and tripping at normal and reduced voltages shall be checked, properly
adjusted and recorded,
j. Latching arrangement of relays shall be checked for operation,
Station Class LAs will be used in 33 KV and 11 KV with base steel structure, terminals bi –
metallic connectors / PG clamps and earth connectors. LAs are to be connected with separate
earth connection using 50x6mm GS flat. All LA terminals / connections are to be tightened.
All lightening arresters installed in grid substations shall be Station Class Lightening Arresters.
Indoor Distribution Board having 63A TPN MCB, outgoing MCBs of suitable ratings for
power and light & fan circuits are to be installed. Internal electrification of the control room
includes provision of fans, exhaust fans, LED illumination fixtures, switches and sockets.
Two nos separate 3 m long 40 mm dia earthing shall be provided for internal electrification
works. 8 SWG GI wires shall connect following equipment:
Internal Electrification works’ wiring shall be provided with single core PVC insulated & PVC
sheathed 2.5 mm2 stranded ISI 694 marked copper flexible wire (for light and fan circuits) and
4.0 mm2 stranded ISI 694 marked copper flexible wire (for power points) in conceal
arrangement in 25 mm dia 2 mm thick PVC ISI marked pipe and 2.5mm thick switch boards in
flash arrangement. Neutral links are to be used in each switchboards. Jointing in neutral
conductor other than at switching board shall not be permitted.
Part -2 : Employer’s Requirements 73
Iron junction box made of 18 gauges CRCA sheet shall be used for switchboard; 2 mm thick
cotton impregnated hylum sheet is to be used for the purpose of switch board. ISI marked
switched and sockets are to be used for Internal Electrification works. Earth wire must be made
available duly connected with earth circuit for Earthing in each and every switchboard.
Reputed make indoor double door Miniature circuit breaker DB fitted with Miniature Circuit
Breakers of MDS/ Havells/ Standard make or equivalent ISI marked shall be used for the
protection. Reputed make LED fittings and 5-star energy efficient BLDC fans are to be used
for the substation. These materials are to be procured from authorized dealer of the materials
manufacturers only. Documentary evidence may be submitted for source of supply of all
electrical materials. Before procurement of materials Project Manager shall approve make, type
and quality of materials.
Control Room lighting shall be designed to ensure 300 lux illumination level through LED
lamp fittings. The bidder shall submit calculation for achieving the above illumination before
start of lighting work for approval of project manager.
20.00Yard Lighting:
The substation area inside the fencing shall be illuminated provided with 100 Watts LED flood
light fittings. Each fitting and its Junction box enclosures shall be IP 55 protection type. Water
and vermin proof-ness is a must. At least 4 Nos. fittings at all the four corners shall be
provided. Acceptable make of fitting, fixtures and lamp are Philips, Crompton, Alstom, and
Bajaj only.
Area light supply from Substation DB to be extended through 2X16 mm2 PVC insulated PVC
Sheathed aluminum stranded armored power cable laid in underground trench of width 300 –
mm wide, provided with 2nd class brick protection (Appro. 10 bricks per meter length of
laying) and sand protective covering (200 mm thick) and laid at the depth of 750mm minimum.
Laying specification of cable shall be as detailed in CPWD specification of laying power
cables. Suitable loop length of 1.5 metre to be kept at the end points.
Pole mounted junction box (and not the Control Gear Box supplied with the fitting) shall be
made of 2mm thick CR steel sheet of size 300X300X200mm fitted with SPN terminal block of
32A capacity, 10A SPN miniature circuit breaker of ISI mark and reputed manufacture. The JB
shall be hot dip galvanized. The JB shall also conform to IP 55 protection for enclosure.
Neoprene gasket shall be used in JB. 2 Nos. earthing terminals of 10 – mm dia shall be
provided with 25X6mm size of mounting clamps. Bidders shall get JB drawing approved
before start of manufacturing.
Part -2 : Employer’s Requirements 74
4 Sq.mm, 1100V grade, weather proof three core (One core for phase, one core for Neutral and
one core for earthing) aluminum stranded flexible conductor PVC sheathed and PVC insulated
cable conforming to IS 694 shall be used for connection of fitting and its Control Gear Box
from pole mounted Junction Box. Control Gear box must provide ISI approved components.
Copper wound heavy chocks shall be acceptable.
Tubular poles 12m high as per IS: 2713 (Latest Version) or WPB 160x23.83 kg/m parallel
flanged beams. embossed with ISI certification mark and pole designation shall be used for
installation of area light fixtures in Urban as well as Rural substations. Pole shall be designated
as 410 – SP - 60. Poles and fitting structures shall be painted with two coat of anti – rusting
bitumen paint inside and outside up to the planting depth and two coat zinc oxide paint
followed by 2 or more coats of aluminum paint of approved make, brand and shade on portion
of pole which will remain above ground level.
Steel tubular Poles/Wide Parallel Beams shall be hot-dip galvanized thoroughly internally and
externally as per according to IS: 2629 and IS: 2633 (with latest amendments). Galvanizing
shall be checked and tested in accordance with IS: 2633.
Steel tubular Poles/Wide Parallel Beams shall be galvanized both inside and out. The zinc
coating shall be smooth, continuous and uniform. It shall be free from acid spots and shall not
scale, blister or be removable by handling or packing. There shall be no impurities in the zinc
or additives to the smelter bath that could have a detrimental effect on the durability of the zinc
coating. Before pickling, all welding, drilling, cutting and grinding shall be completed and all
grease, paint, varnish, oil and welding slag shall be completely removed.
All protuberances which could affect the life of galvanizing shall also be removed. To avoid the
formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
Following ACSR conductors (or equivalent AAAC conductor) are envisaged for bus bars,
jumpers, droppers:
Part -2 : Employer’s Requirements 75
Conductor shall be provided with hardware fittings, T-clamps, bi-metallic clamps and PG
clamps as per requirements. T – Clamps shall be provided on each jumper on bus bars. Line
jumpers shall be provided with adequate size of PG Clamps (Two numbers PG Clamps at each
end of jumper). Clamp shall be made of aluminium grade T-1F as per IS – 8309 having good
electrical quality aluminium material and shall not be brittle in nature. Suitable Bi – metallic
clamps shall be provided at bushings of transformers and circuit breakers. Also at all those
points where joining of two different materials is found, bi –metallic clamps shall be provided.
Care shall be taken while drawing conductor from the drum. Proper roller shall be used while
handling conductors during erection.
The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator shall properly be cleaned before installation. No damage/crack insulator
shall be used.
23.00Power receptacles:
Two power receptacles are envisages in switch yard area to provide power supply to
Transformer Oil Filtration machine and other testing and commissioning related works. Each
receptacles shall house 63A MCCB as incomer, 40A 3 phase socket/switch and 1 No, 20A
single phase Industrial type socket/switch of reputed brand and type.
24.00Tube well:
Deep Tube is envisaged for all the substations. Depending on the depth of the bore, suitable
capacity of submerged pump shall be installed. Bore diameter shall be 6” which must be
penetrated vertically in all type of soil condition. Before digging the bore, soil Resistivity
needs to be checked to ascertain the location of the best site for the tube well. Following works
are envisaged under this scope:
Part -2 : Employer’s Requirements 76
• Digging bore of diameter six inches. Providing MS casing on bore up to the suitable depth
finalized during detailed engineering.
• Providing new 3 phase submersible pump 32 stages or 30 stages depending on technical
requirements.
• Providing Start Panel of reputed make like L&T, Havells or equivalent make having single
phase protection, Over load protection, Pre – set timer of L&T make, Star Delta Starter,
Indications for Load currents in all three phases, Indications for Supply voltages in all three
phases etc. Starting panel must conform to IP 52 protection for enclosure. It shall be mounted
indoor inside the Control room on 50x50x6 mm GS angle supports. Start panel must be earthed
with 2 Nos 8 SWG wires. 4 core 16 Sq mm aluminum armored cable must be used for
energizing this Start Panel.
• Three phase, 4 wires, copper flexible supply cables suitable for submersible pump operations,
ISI marked, 1100V grade shall be connected to submersible pump through underground trench
up to the well as per CPWD specifications duly protected from brick and sand cushioning.
• A Heavy-duty gunmetal wheel valve (tap) may be provided on the discharge line for drinking
water requirements.
• Provision for lifting the pump in case of overhauling / breakdown maintenance may also be
provided.
• ISI marked PVC or 2nd GI Pipes are to be used for suction as well as discharge water lines.
• An open drain must be provided in the vicinity of the tube well. Detail arrangement shall be
finalized in detailed engineering.
25.00Yard Earthing:
Earthing shall be provided with GI earth pipe, GS solid rod 25 mm dia and 75x8mm GS flat
forming earth mat. 50x6mm GI flat shall be used for earth-riser along with GI wires / Stay
wires as per requirement of Project Manager. Project Manager shall approve arrangement of
earthing network. Following arrangement envisaged for grid/earth rod/ earth pipe: (Indicative
drawing is enclosed with the document)
Fencing and gate shall be grounded. Moving portion of gate shall be grounded with flexible
braided conductors of equivalent aluminum 25 mm2 sizes of conductors duly lugged and
bolted.
In rocky soil where getting required earth resistance is a challenge, chemical rod earthing shall
be used. Overhead line structure shall be connected to chemical earth electrode using 8SWG
GI wire. GI nuts, bolts & washers shall be used to join two GI wires and 20 mm solid spike
rod.
In areas with poor with poor earth resistance where it is generally difficult to perform
maintenance activities, maintenance free earth pits shall be provided.
GI flats and GI wires must be properly dressed, bundled and fixed on supporting structure at 1
to 2 feet intervals.
33 KV & 11 kV, 3-ph, 3 Pin type, Horizontal Mounting type, Gang Operated, Isolator Switch
shall be installed at suitable locations as per instructions of Project Manager to isolate line
section, power transformer, bus bars etc. B Class GI pipe shall be used (without any joints) for
operation of isolator switch. Isolator Switch structure and handle must be earthed using 50x6
GI flat.
Isolator cum earth switch – The employer may also opt for 33kV and 11kV Isolator cum earth
switch, In this case the Contractor is required to make provision for its power supply, control
supply and indications in control panel.
The fabricated steel structures materials shall be hot-dip galvanized thoroughly internally and
externally as per according to IS: 2629 and IS: 2633 (with latest amendments). Galvanizing
shall be checked and tested in accordance with IS: 2633.
Fabricated steel structure items shall be galvanized both inside and out. The zinc coating shall
be smooth, continuous and uniform. It shall be free from acid spots and shall not scale, blister
or be removable by handling or packing. There shall be no impurities in the zinc or additives to
the smelter bath that could have a detrimental effect on the durability of the zinc coating.
Before pickling, all welding, drilling, cutting and grinding shall be completed and all grease,
paint, varnish, oil and welding slag shall be completely removed.
Part -2 : Employer’s Requirements 79
All protuberances which could affect the life of galvanizing shall also be removed. To avoid
the formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
Testing of galvanizing shall be performed for Uniformity of thickness as per IS 2633/1986, Mass
of coating as per IS 6745/1972 and quantity of zinc, water quenching ¢riguging as per IS
2629/1985. galvanized.
28.00Hardware:
MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used for
tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing, strain
plates etc.
While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall be
hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS: 2633.
Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting them to
site for erection, they shall be offered for inspection and approval by Project Manager.
Fire Buckets filled with sand: The fire buckets confirming to IS 2546/1974 filled with sand
shall be installed at two places in new s/s – in control room and in switchyard near power
transformer. There shall be 4 no. of buckets at each location in a s/s. The buckets shall be
hanging on a steel stand. The buckets and the stand shall be as per relevant standards and will
be filled with sand.
In case of 66 kV power substation, The Contractor is required to make the provision of
sprinkler system, deluge valves, jockey pumps, Diesel pump etc including oil sock pits etc.
Carbon dioxide type and Dry chemical powder type fire extinguishers are also to be installed in
newly constructed substation. All the portable extinguishers shall be of free standing type and
shall be capable of discharging freely and completely in upright position. Each extinguisher
shall have the instructions for operating the extinguishers on its body itself. All extinguishers
shall be supplied with initial charge and accessories as required. Portable type extinguishers
shall be provided with suitable clamps for mounting on walls or columns. All extinguishers
shall be painted with durable enamel paint of fire red color conforming to relevant Indian
Part -2 : Employer’s Requirements 80
Standards. Capacities of each type shall be as indicated in the schedule of quantities. Carbon
dioxide (CO2, type) extinguisher shall of 4.5 kg for control room conform to IS:2878. Dry
chemical powder type extinguisher shall be of 6 kg capacity for control room conform to
IS:2171.
The substation shall be equipped with one following equipment for smooth operation and
maintenance:
For suitable information to operating staff or the other related persons visiting the substation,
following facilities shall be provided before commissioning of substation or on date of
inauguration of the substation.
• Sketch of substations electrical circuit inside the substation in white cotton impregnated 2 mm
thick hylum sheet 2x2 feet size installed on the wall,
• Notice board 3x3 feet made out of 10 mm thick water proof ply, painted suitably and provided
with 1st class teak wood ribs at the sides of 2 x ½ inches size,
• Electrical safety charts,
Part -2 : Employer’s Requirements 81
• Provision for notifying name, address, telephone numbers, qualification details etc of the
operational staff Employer intends to post at the substations and their officials in hierarchy,
• Depicting working drawings of cable terminals details and cable laying details in laminated
sheets
• Color coding of bus bars and terminal conductors of the feeders using enamel painting round
marks and labeling name of feeders, equipment, etc as defined.
33.00Others:
Buildings for substation control room – shall be 10mx12m size. Details are enclosed in the
tender drawing. The buildings should also has provision for dedicated washrooms for female
employees in addition to male washrooms.
Indoor trenches covered with 6 mm thick chequirred plates: Concrete trench are required inside
control room with 50x50x6 mm GS angle inserted at the edges for erection of control panels.
Unused part of cable trench shall be covered with 6mm thick MS chequirred plates inside
control room. At the entry point of trench in control room, proper sealing arrangement shall be
provided so as to stop entry of reptiles and rainwater inside control room through trench.
Bi-metallic connectors shall be provided wherever there is a connection between two metal
parts on all electrical equipment like 33/11 KV Power transformer, 11/0.4 KV station
transformer, vacuum circuit breakers, isolators, DO Fuse, Lighting Arrester, etc.
34.00Labelling:
Each substation equipment shall be labelled using yellow base and black indication marks
(number or digits). 40/50 mm height digits/words shall be used for this purpose. Base shall be
made using 2 or more coats of yellow enamel paint till good surface finish. Base preparation
shall be completed before shifting of poles and equipment to site for erection. Base painting
and marking of digits shall be performed by a skilled and trained painter using branded enamel
paint, Project Manager shall approve type and brand of enamel paint. The identification of
phases through Red, Yellow and Blue circles shall be provided on transformer, CT, PT, 33 KV
and 11 KV feeder Double Pole structures.
Control panels shall be labelled from front as well as from the back by providing serial number
and name of feeder/transformer. The color coding sign on two adjacent panels shall also be
provided with 100mm dia color circle overlapping two adjacent panel sheet for safety purpose.
Part -2 : Employer’s Requirements 82
35.00Danger board:
Each substation equipment and structures shall be provided with a danger board as per
approved drawing. Danger board shall be in bi-lingual languages (local language and English).
Clamp for danger board, nut-bolts and washers shall be painted with two or more coats of red-
oxide and aluminium paints respectively till smooth surface before installation.
An indicative list of tests is given below. Contractor shall perform any additional test based on
specialties of the items as per the Field Quality Plan/ instructions of the equipment
manufacturer or Employer without any extra cost to the Employer. The Contractor shall
arrange all instruments required for conducting these tests along with calibration certificates
and shall furnish the list of instruments to the Employer for approval. Detail test certificates
duly signed by Employer’s representative & agency representative of tests jointly carried out at
site before putting the equipment in use, shall be submitted by the Contractor in three copies.
Agency shall also be responsible to prepare Single Line Diagram of substations and an overall
power distribution network of the circle showing 400KV, 220KV, 132KV, 33 KV network and
point of metering. A set of drawings which includes drawing of Single phasing AB Switch,
Substation earthing arrangement are enclosed for basic information. These drawings are not
necessarily showing the exact dimensions of the substations.
Factory test certificates of equipment, test certificates at the time of pre-dispatch inspections,
pre-dispatch inspection reports, pre-commissioning check results and post commissioning
check results shall be compiled and provided in three sets to Project Manager for his approval
and records.
Part -2 : Employer’s Requirements 83
A copy of such test record shall be offered to electrical inspector and other inspecting officials
during his/her visit to substation for inspection.
Contractor shall project-wise make his own separate arrangements for the following:
40.00Civil works:
Details scope under civil works have been provided in “Civil Works and Soil Investigation”
at Section 6 of Part 2.
Foundation design for power transformer, outdoor type vacuum circuit breaker, control room
building, fencing, gantry structure etc shall be submitted by Contractor. While designing OEM
recommendations must be considered. Foundation for power transformer, outdoor type vacuum
circuit breaker, control room building and fencing shall be provided with reinforcement steel.
Project Manager shall approve foundation designs.
The reference drawings, which are indicative of the type of specifications Employer intends to
accept, are annexed with the specification. The Contractor shall maintain the overall
dimensions of the substation, buildings, bay length, bay width, phase to earth clearance, phase
to phase clearance and sectional clearances, clearances between buses, bus heights but may
Part -2 : Employer’s Requirements 84
alter the locations of equipment to obtain the statutory electrical clearances required for the
substation.
The enclosed drawings give the basic scheme, layout of substation, associated services,
earthing arrangement. These drawings are provided for general information only.
Note: The insulation and RIV levels of the equipment shall be as per values given in the
respective chapter of the equipment.
42.00Commissioning spares:
The Contractor shall supply spares, which he expects to consume during installation testing
and commissioning of system. The quantity of these spares shall be decided based on his
previous experience, such that site works shall not be hampered due to non-availability of these
spares. Contractor shall submit a complete list of such spares along with the bid, the cost of
which shall be deemed to have been included in the lump-sum proposal price of the package.
The Contractor, if so agreed at a cost to be negotiated may leave the unused commissioning
spares at the site for use of Employer.
43.00Recommended spares:
The Contractor shall provide a list of recommended spares giving unit prices and total prices
for 3 years of normal continuous operation of equipment. This list shall take into consideration
and shall be given in a separate list. The Employer reserves the right to buy any or all the
recommended spares. The recommended spares parts shall be delivered at the site. The list of
recommended spares to be furnished by the Bidder shall also contain the following:
Price of recommended spares will not be used for evaluation of bids. The prices of these spares
will remain valid for a period of not less than 120 days after the date on which the validity of
main bid expires. Whenever recommended spares are the same as mandatory spares, then the
prices of the mandatory spares and such common recommended spares shall be the same.
Further, the prices of any recommended spares shall be subject to review by the Employer and
shall be finalized after mutual discussions.
Part -2 : Employer’s Requirements 85
1.00 Survey
In case of feeder separation, existing agriculture load shall be mapped during survey. A
report to be presented indicating location wise pumps to be fed through separate feeder.
Percentage voltage regulation at farthest point on various spur sections shall be examined
during survey and submitted to project manager who will take a decision for feeder
separation works.
<In rural area, Employers may use PCC poles are to be used. In urban area, Employer may
use PCC or Galvanized H-Beam or STP or Wide Parallel Beam supports of suitable length.
In hilly areas where handling of material is a challenge, tubular poles or Wide Parallel Beam
GI poles expandable with jointing plaes may be used. In location specific conditions like
forest area, vicinity of other existing overhead lines or permanent structures etc, H- beam or
tubular poles or Wide Parallel Beam supports may be used of suable length.
Part -2 : Employer’s Requirements 86
Steel bottom plate shall be used in steel tubular poles/H-Beam / Wide parallel Beam and
cement concrete reinforced plate shall be used as base plate for PCC poles>.
Steel tubular poles shall be cleaned till good surface finish and painted with 2 or more coats
of red oxide paint and 2 or more coats of aluminium paint till good finish. Steel tubular poles
and H-Beams shall also be painted with 2 or more coats till good surface finish with anti-
corrosive paint (in case of tubular poles shall also be painted on the inner walls) which goes
in to the foundation. Project Manager shall approved brand and shade of paints.
Fabricated steel items like V cross arm, top clamp, DC cross arm, bracket, clamps, cross
bracings, bracings, strain plate, guarding channels, back clamp, transformer mounting
structure etc shall be made of MS Channels, MS angle, MS flats as per approved drawings.
While fabricating, good quality electrical cutting tools and drill machine shall be used to
ensure no sharp edges and perfect holes as per approved drawings. Gas cutting set should not
be used for fabrication of MS steel items. Weld material shall be distributed equally between
the two materials that were joined. The weld shall be free of waste materials such as slag.
The weld surface should not have any irregularities or any porous holes (called porosity).
The joint shall be tight. Most welds need to demonstrate the required strength. One way to
ensure proper strength is to start with a filler metal and electrode rating that is higher than
your strength requirement.
The fabricated steel structures materials shall be hot-dip galvanized thoroughly internally and
externally according to IS: 2629 and IS: 2633 (with latest amendments). Galvanizing shall
be checked and tested in accordance with IS: 2633.
Fabricated steel structure items shall be galvanized both inside and out. The zinc coating
shall be smooth, continuous and uniform. It shall be free from acid spots and shall not scale,
blister or be removable by handling or packing. There shall be no impurities in the zinc or
additives to the smelter bath that could have a detrimental effect on the durability of the zinc
coating. Before pickling, all welding, drilling, cutting and grinding shall be completed and all
grease, paint, varnish, oil and welding slag shall be completely removed.
All protuberances which could affect the life of galvanizing shall also be removed. To avoid
the formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
Part -2 : Employer’s Requirements 87
4.00 Hardware:
MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used
for tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing,
strain plates etc.
While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall
be hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
them to site for erection, they shall be offered for inspection and approval by Project
Manager.
Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (2Nos.), anchor plate
(200x200x6mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay
rod & 7/3.15 mm dia GI stranded wire complete.
Stay set shall be used at all turning locations, conductor dead end supports, double pole
structure, triple pole structure, four pole structure to nullify the tension of conductor. Erection
of storm guys at suitable location in straight line may also be provided. Erection of storm
guys at suitable location in straight line may also be provided.
0.2 cmt cement concreting in mixture 1 part cement, 3 part coarse sand, 6 part 40mm size
aggregate stone chips (1:3:6). 2 Nos. guy insulator shall be provided in stranded GI wire at
middle location between two turn buckles.
6.00 Earthing:
a) 40 mm dia., 3000 mm long GI pipe earth electrode with test link, RCC pit, RCC cover plate
on GI frame, bentonite powder and other accessories complete
b) GI Earthing spike made of 20mm solid rod, Chemical rod earthing using Carbon
powder/Bentonite powder / Conductive concrete powder including electrode with 2000mm
Part -2 : Employer’s Requirements 88
long, 50 mm diameter GI pipe, GI Strip of 24x3mm minimum.6 SWG GI wire for earthing
and guarding
c) 8 SWG GI wire for earthing and guarding
d) Maintenance free type earthing
Each 11 kV line support shall be provided with one GI earthing spike made of 20 mm solid
rod or GI Earth Coil and connected with 8 SWG GI wire. Overhead line structure shall be
connected to GI earthing spike or GI Earth Coil using 8 SWG GI wire. GI nuts, bolts &
washers shall be used to join two GI wires and 20 mm solid spike rod. Project Manager shall
decide use of GI Earth Coil or 20mm dia GI Solid Rod for individual pole earthing.
At railway crossing, line crossing and other specific locations 40 mm dia, 3000 mm long GI
pipe earth electrode with test link, RCC pit, RCC cover plate on GI frame, bentonite powder
and other accessories shall be used. Overhead line structure at these locations shall be
connected to GI earth pipe using 8 SWG GI wire. GI nuts, bolts & washers shall be used to
join two GI wires and 40 mm GI earth pipe.
In rocky soil where getting required earth resistance is a challenge, chemical rod earthing
shall be used. Overhead line structure shall be connected to chemical earth electrode using
8SWG GI wire. GI nuts, bolts & washers shall be used to join two GI wires and 20 mm solid
spike rod.
In road crossings and line crossings, 6 SWG GI wire shall be used for cross lacing and 8
SWG wire shall be used for guard wires.
GI flats and GI wires must be properly dressed, bundled and fixed on supporting structure at
1 to 2 feet intervals.
The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator should properly be cleaned before installation. No damage/crack
insulator should be used.
Following ACSR Conductors (or equivalent AAAC Conductor) are envisaged for new 11 kV
lines:
Care should be taken while drawing conductor from the drum. Proper roller should be used
while handling conductors during erection. Jointing sleeves, binding materials, PG clamps,
bi-metallic conductor shall be used for conductor jointing, insulators fixing, jumpering and
termination at equipment respectively. There must not be uneven sag between
conductor/spans.
Proper sag should be maintained using sag chart table. While tensioning, care should be
taken to avoid tension on pin insulator. Therefore, proper alignment of line to be ensured.
At terminal location, care should be taken while connecting two sections to avoid bird faults.
Therefore, pin insulator is to be used to handle the conductor on DC cross channel.
9.00 11 KV AB Switch:
11 kV, 3-ph, 600 A, 3 Pin type, Vertical/Horizontal Mounting type, Gang Operated, AB
Switch shall be installed at cut points and at suitable locations as per instructions of Project
Manager. B Class GI pipe shall be used (without any joints) for operation of switch. AB
Switch structure and handle must be earthed using 8 SWG GI wire.
Each support pole shall be numbered properly labelled using yellow base and black
indication marks (number or digits). 40/50 mm height digits/words should be used for this
purpose. Base shall be made using 2 or more coats of yellow enamel paint till good surface
finish. Base preparation shall be completed before shifting of poles to site for erection. Base
painting and marking of digits should be performed by a skilled and trained painter using
branded enamel paint, Project Manager shall approve type and brand of enamel paint.
Warning instruction, if any, of availability of two sources of 33 kV supply on same structure,
at source structure, at cut points should exclusively be provided as per state practice.
Part -2 : Employer’s Requirements 90
3.5 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each 11 kV support.
Galvanized barbed wire should be properly dressed and crimped at termination. While
wrapping the wire on support, proper tension should be maintained.
Each support shall be provided with a danger board with pole clamps as per approved
drawing. Danger board should be in bi-lingual languages (local language and English).
Clamp for danger board, nut-bolts and washers shall be painted with two or more coats of
red-oxide and aluminium paints respectively till smooth surface before installation.
0.5m3Cement concrete in mixture 1 part cement, 3 part coarse sand, 6 part 40 mm size
aggregate stone chips (1:3:6) shall be used in steel tubular poles and H-Beam 11 kV line
supports.
In rural areas, PCC pole pit shall be refilled with 200 mm average size of bolder mixed with
excavated earth. Proper ramming shall be performed for better compaction. All Double pole
(DP), Triple pole (TP), cut point poles, Distribution Transformer substation poles and poles
erected on water logging area shall be grouted using cement concrete mixture similar to H-
beams/STP/Wide Parallel Beams . Prior approval of Project Manager shall be obtained for
concreting of PCC poles in water logging area. While preparing route survey report, water
logging areas shall be earmarked.
While erecting supports (poles), shuttering must be used for concreting so that proper
quantity of cement concrete mixture be used and assessed during inspection. During
concreting proper compaction by means of mobile vibrator be provided. While starting work
of support erection, gang wise shuttering and mobile vibrator shall be offered for inspection
to Project Manager. While erecting support, mercury level gauge must be used to ensure
vertical erection of support.
250mm dia X 12” inch size muffing shall be provided on H- beams / STP/ Wide Parallel
Beams to prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part
Cement, 2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for
individual poles.
Part -2 : Employer’s Requirements 91
Steel plate shall be used in steel tubular poles and cement concrete reinforced plate shall be
used as base plate for PCC poles.
Two separate composite items of 11 kV line railway crossing is kept in BoQ. One is with 300
sq.mm cable & another one with 185 sq.mm cable.
2 Nos. separate cables shall be laid in separate GI pipe enclosures. At a time, one shall be
used and another shall be kept idle as spare in ready to connect condition. Cable termination,
cable identification, protective covering, laying of jumpering cable etc shall all be completed
in this head. These composite items shall contain following sub-items:
a) 3Cx185 (3Cx300) sqmm XLPE armored cable (approx. length is 0.3 km each) – 2 sets
b) 150mm dia GI pipe of A class (red color painted on edges) for cable protection in
underground laying – 2 sets
c) 150mm dia GI pipe of B class (blue color painted on edges) for cable support at DP structure
– 2 sets
d) Outdoor heat shrinkable cable jointing kits for main cable and jumpering cable – 4 Nos for
main cable and 8 Nos for jumpering cables.
e) 11 kV lightening arrestor station class 10kA (6 nos.),
f) 4 Nos GI 3-meters long pipe earthing,
g) 6 SWG GI wires with GI nuts, bolts & washers,
h) Cable markers,
i) Bi-metallic clamps,
j) Jumpering with 11 kV Arial Bunched Cables 200 Sqmmdia (10 mtr) etc – 4 sets
k) Maintenance free type earthing
Horizontal drilling machine shall be used for horizontal bore below railway tracks.
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/trim to obtain required tree clearance. Contractor
shall pay compensation for any loss or damage for tree cutting due to Contractor’s work.
Wherever forest clearance is envisaged for execution of work, clearance of forest department
for tree cutting, if required, shall be arranged by the Project Manager and compensation shall
also be paid by the Project Manager. Necessary fee if required to pay to Govt. dept. for
arranging such clearances shall paid by Project Manager. However, the Contractor would
require to provide all necessary assistance for execution of this work.
During execution of 11 KV Line work, all statutory clearances shall be ensured for ground
clearance, line-to-line clearance, road crossing clearance, horizontal and vertical clearances
from buildings/objects etc. All road crossings and line crossings shall be guarded as per
specifications. Conductor joint should not be provided in mid span length. Instead, it should
be nearer to the support.
Part -2 : Employer’s Requirements 93
Based on survey report, Project Manager shall decide type, capacity and location of
Distribution Transformer sub-station.
2.00 Following types of support are envisaged for 11/0.4 or 11/0.25 KV Distribution Transformer
Substation support:
a) 8 m/140 kgs PCC Poles - (PCC Pole as per state practice) – up to 100 KVA rating only
b) 13 m long H-Beam 152x152 mm, 37.1 kg/mtr
c) 11 m long H-Beam 152x152 mm, 37.1 kg/mtr
d) 11 M long Steel Tubular poles of Designation 540 SP 52 (IS 2713, Pt I, II, III 1980)
e) 9 M long Steel Tubular poles of Designation 540 SP 28 (IS 2713, Pt I, II, III 1980)
f) For DTR Substation up to 63 KVA WPB 160x23.83 kg/m beams of 11 meter or 13meter
length
Part -2 : Employer’s Requirements 94
g) For DTR Substation above 63 KVA up to 315 KVA WPB 160x30.44 kg/m beams of 11 meter
or 13meter length
In rural area, Employer may use PCC poles are to be used. In urban area, Employer may use
PCC or H-Beam or STP or Wide Parallel Beam supports of suitable length. In hilly areas
where handling of material is a challenge, tubular poles or Wide Parallel Beam GI poles
expandable with jointing plaes may be used. In location specific conditions like forest area,
vicinity of other existing overhead lines or permanent structures etc, H- beam or tubular poles
or Wide Parallel Beam supports may be used of suable length.Steel bottom plate shall be used
in steel tubular poles/H-Beam / Wide parallel Beam and cement concrete reinforced plate
shall be used as base plate for PCC poles.
PCC supports shall be used for distribution transformer substation up to 100 KVA capacity
only. Beyond 100 KVA rating, Galvanized Wide parallel beams 160x30.44 kg/m supports
shall be used for mounting of distribution transformer.
Steel tubular poles shall be cleaned till good surface finish and painted with 2 or more coats
of red oxide paint and 2 or more coats of aluminium paint till good finish. Steel tubular poles
and H-Beams shall also be painted with 2 or more coats till good surface finish with anti-
corrosive paint (in case of tubular poles shall also be painted on the inner walls) which goes
in to the foundation. Project Manager shall approved brand and shade of paints.
Fabricated steel items like DC cross arm (100x50x6 mm), back clamps (65x8 mm), pole
clamp (65x8 mm), DO mounting channel (100x50x6 mm), transformer mounting channel
(100x50x6 mm), transformer clamping set (50x50x6 mm), transformer belting set (50x50x6
mm), V cross arm, top clamp, DC cross arm, bracket, clamps, cross bracings, bracings, strain
plate, back clamp, transformer mounting structure etc shall be made of MS Channels, MS
angle, MS flats as per approved drawings.
While fabricating, good quality electric cutting tools and drill machine shall be used to ensure
no sharp edges and perfect holes as per approved drawings. Gas cutting set should not be used
for fabrication of MS steel items. Weld material shall be distributed equally between the two
materials that were joined. The weld shall be free of waste materials such as slag. The weld
surface should not have any irregularities or any porous holes (called porosity). The joint shall
be tight. Most welds need to demonstrate the required strength. One way to ensure proper
strength is to start with a filler metal and electrode rating that is higher than your strength
requirement.
Part -2 : Employer’s Requirements 95
The minimum coating of the zinc on steel tubular poles or Wide Parallel Beam supports shall
comply with IS: 2629 and IS: 2633 (with latest amendments). Galvanizing shall be checked
and tested in accordance with IS: 2633.
Poles and other hollow items shall be galvanized both inside and out. The zinc coating shall
be smooth, continuous and uniform. It shall be free from acid spots and shall not scale, blister
or be removable by handling or packing. There shall be no impurities in the zinc or additives
to the smelter bath that could have a detrimental effect on the durability of the zinc coating.
Before pickling, all welding, drilling, cutting and grinding shall be completed and all grease,
paint, varnish, oil and welding slag shall be completely removed.
All protuberances which could affect the life of galvanizing shall also be removed. To avoid
the formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
Testing of galvanizing shall be performed for Uniformity of thickness as per IS 2633/1986,
Mass of coating as per IS 6745/1972 and quantity of zinc, water quenching ¢riguging as
per IS 2629/1985.
4.00 Hardware:
MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used for
tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing, strain
plates etc.
While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall
be hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
them to site for erection, they shall be offered for inspection and approval by Project Manager.
Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (2Nos.), anchor plate
(200x200x6mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay
rod & 7/3.15 mm dia GI stranded wire complete.
Stay set shall be used at all sub-station location to nullify the tension of
conductor/cable/transformer on the supports. 0.2 cmt cement concreting in mixture 1 part
cement, 3 part coarse sand and 6 part 40mm size aggregate stone chips (1:3:6) shall be
provided in the foundation of the stay set. 2 Nos. guy insulator shall be provided in 7/3.15 mm
dia stranded GI wire at middle locations between two turn buckles.
Following type and sizes of minimum 3 star rated {as per Bureau of Energy Efficiency
(BEE)}, BIS stamped, distribution transformers are standardized in the project:
The distribution transformers shall be supplied with transformer oil filled up-to maximum
permissible level and breather with silica gel.
The distribution transformers must have been successfully type tested within five years from
date of Letter of Intent and the designs should have been in satisfactory operation for a period
not less than two years as on the date of bid opening. Compliance shall be demonstrated by
submitting, (i) authenticated copies of the type test reports and (ii) performance certificates
from the users, specifically from Central Govt./State Govt. or their undertakings.
T-Clamps should be provided on each jumper on bus bars. Line jumpers should be provided
with adequate size of PG Clamps (Two numbers PG Clamps at each end of jumper). Clamp
should be made of aluminum grade T-1F as per IS-8309 having good electrical quality
aluminum material and should not be brittle in nature.
ACSR raccoon conductor (or equivalent AAAC Conductor) is to be used for connection
between overhead lines to transformer studs/bushing upto 100 KVA ratings. For transformers
having ratings more then 100KVA, higher size of conductors matching with its current
carrying rating be used.
All CT terminals are to be ring type and other terminals are fork type. 2.5 sqmm copper multi
stands wiring 1.1 KV grade, ISI marked, IS 694 shall be used for control wiring. A terminal
block be provided between CT and Meter keeping 20% spare terminals.
The Distribution Box/SMC Distribution Boxes are to be earthed using 8 SWG GI wire direct
connection to the earthing. 2 Nos Earthing bolts on the distribution boards should be provided
of 10mm dia.
Part -2 : Employer’s Requirements 98
The single core power cables should be terminated with proper size lugs and gland. Necessary
tagging, identification of cores and dressing of cables with nylon cable ties shall be in the
scope of work. The unutilized holes in the DBs provided for cable entry needs to be plugged
properly in a manner that it must stop access to reptiles, dust and water ingress.
The Low Tension bus bars are to be painted with two or more coats of brush-able epoxy
compound suitable to insulate the bus bars for 415 volts exposure.
The Distribution Box/SMC Distribution Box, for transformers upto and including 25 KVA,
should also house three phase tri-vector energy meter / single phase meter depending on
capacity and type of distribution transformer as per specifications. For higher capacity
transformers where CT operated meters are to be installed, separate LTCT cum Meter Box at
eye height shall be installed for housing of meter, CTs, terminal block and wiring.
The single core un-armored power cables shall be used for connection from Distribution
Transformer to Distribution Box/SMC Distribution Box and Distribution Box/SMC
Distribution Box to Outgoing LT lines. Cable should not be used in underground laying
arrangement. Cables should be dressed & tied properly using clamps /cable ties at 1 meter
intervals and tied with substation structure/poles. At-least one meter cable is to be kept as
spare at the individual ends.
Following arrangements shall be made for LT Distribution Transformers and LT Cables:
1.1 KV XLPE Aluminium Conductor, Stranded, un-armored cable be used for connection of
transformer LV bushing to Distribution Box/SMC Distribution Box and Distribution
Box/SMC Distribution Box to overhead line.
9.00 Earthing:
Distribution Transformer Earthing shall be provided with 3 Nos earthing and making earth
mat /risers using 50X6mm GI Flat. Earthing should be provided with GI earth pipe or
Chemical Earthing depending of strata of soil in the location. Project Manager shall decide the
type of earthing.
25x3mm GI Flat and 8 SWG GI shall be used for making earthing connection to various sub-
station equipment as per given details. GI Flat and GI wire shall be properly dressed, bunched
and clamped with the support at 2 feet intervals. An overlapping of 35mm shall be used at the
place of flat to flat joint. Two sets of GI nuts, bolts and washers shall be used for flat-to-flat
joints. GI nuts, bolts and washers must be used for GI Flat–to-GI wire & GI wire-to-GI wire
joints.
Substation wise measurement of earth resistance of earth pits / mesh and corresponding
drawing of existing earthing arrangement shall be recorded and submitted to Project Manager.
The location of earth pits should be at-least 3m apart, so that they their earth conductive areas
do not overlap. In rocky soil where getting required earth resistance is a challenge, chemical
rod earthing shall be used in place of normal GI pipe type earthing. Project Manager shall
decide type of earthing pits.
The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator should properly be cleaned before installation. No damage/crack
insulator should be used.
Each Substation should be numbered properly labelled using yellow base and black indication
marks (number or digits). 40/50 mm height digits/words should be used for this purpose. Base
shall be made using 2 or more coats of yellow enamel paint till good surface finish. Base
preparation shall be completed before shifting of poles to site for erection. Base painting and
marking of digits should be performed by a skilled and trained painter using branded enamel
paint, Project Manager shall approve type and brand of enamel paint.
3.5 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each sub-station
support. Galvanized barbed wire should be properly dressed and crimped at termination.
While wrapping the wire on support, proper tension should be maintained.
Each support should be provided with a danger board with pole clamps as per approved
drawing. Danger board should be in bi-lingual languages (local language and English). Clamp
for danger board, nut-bolts and washers shall be painted with two or more coats of red-oxide
and aluminium paints respectively till smooth surface before installation.
0.5 m3 Cement concrete in mixture 1 part cement, 3 part coarse sand, 6 part 40 mm size
aggregate stone chips (1:3:6) shall be used in PCC Pole, steel tubular poles and H-Beam
support foundation.
While erecting supports (poles), shuttering must be used for concreting so that proper quantity
of cement concrete mixture be used and assessed during inspection. During concreting proper
compaction by means of mobile vibrator be provided. While starting work of support erection,
gang wise shuttering and mobile vibrator shall be offered for inspection to Project Manager.
While erecting support, mercury level gauge must be used to ensure vertical erection of
support.
250mm dia X 12” inch size muffing shall be provided on steel tubular and H-Beam poles to
prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part Cement, 2
parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for individual poles.
Steel plate shall be used in steel tubular poles and cement concrete reinforced plate shall be
used as base plate for PCC poles.
15.00 11 KV AB Switch:
11 kV, 3-ph, 200 A, 3 Pin type, Horizontal/Vertical Mounting type, Gang Operated, AB
Switch shall be installed on 100 KVA and more capacity distribution transformer substation
only. B Class GI pipe shall be used (without any joints) for operation of switch. AB Switch
structure and handle must be earthed using 8 SWG GI wire.
11 kV, 3-ph, Drop Out fuse units (set of 3 units) along with Support Insulators, Base Channel,
fuse barrel etc. shall be used for all capacity Distribution Transformer Substations. DO Fuse
structure shall be earthed using 8 SWG GI wire.
Distribution Class LAs on each phase shall be provided in the sub-station with base steel
structure, terminals bi – metallic connectors / PG clamps and earth connectors. LAs are to be
connected with separate earth connection. 25x3 mm GI flat shall be used for earth connection.
1. Survey:
Mapping of route of proposed new LT line by foot survey in rural/urban areas be performed
mentioning various milestones. While surveying, existing electrical infrastructure in the
locality should also be mapped. Line alignment (single line diagram) on political map with
fair correctness, be prepared. SLD and foot survey report shall be approved by Project
Manager and shall be used as basic document for assessment of works under the contract. On
completion of line work, as built Single Line Diagram and pole wise line diagram showing
pole wise materials used and pole-to-pole span should be submitted to Project Manager. This
details shall be used as reference documents by Quality & Quantity Inspecting officials to
execute inspection works.
2. The LT line between distribution transformer and consumers shall be on LT Areal Bunched
cables.
In rural area, Employer may use PCC poles are to be used. In urban area, Employer may use
PCC or H-Beam or STP or Wide Parallel Beam supports are to be used of suitable length. In
hilly areas where handling of material is a challenge, tubular poles or Wide Parallel Beam GI
Part -2 : Employer’s Requirements 103
poles expandable with jointing plaes may be used. In location specific conditions like forest
area, vicinity of other existing overhead lines or permanent structures etc, H- beam or tubular
poles or Wide Parallel Beam supports may be used of suable length.Steel bottom plate shall
be used in steel tubular poles/H-Beam / Wide parallel Beam and cement concrete reinforced
plate shall be used as base plate for PCC poles.Steel tubular poles shall be cleaned till good
surface finish and painted with 2 or more coats of red oxide paint and 2 or more coats of
aluminiumpaint till good finish. Steel tubular poles and H-Beams shall also be painted with 2
or more coats till good surface finish with anti-corrosive paint (in case of tubular poles shall
also be painted on the inner walls) which goes in to the foundation. Project Manager shall
approved brand and shade of paints.
Fabricated steel items like clamps, stay clamp, etc shall be made of MS Channels, MS angle,
MS flats as per approved drawings.
While fabricating, good quality electrical cutting tools and drill machine shall be used to
ensure no sharp edges and perfect holes as per approved drawings. Gas cutting set should not
be used for fabrication of MS steel items. Weld material shall be distributed equally between
the two materials that were joined. The weld shall be free of waste materials such as slag.
The weld surface should not have any irregularities or any porous holes (called porosity).
The joint shall be tight. Most welds need to demonstrate the required strength. One way to
ensure proper strength is to start with a filler metal and electrode rating that is higher than
your strength requirement.
The fabricated steel structures materials shall be hot-dip galvanized thoroughly internally and
externally according to IS: 2629 and IS: 2633 (with latest amendments). Galvanizing shall
be checked and tested in accordance with IS: 2633.
Fabricated steel structure items shall be galvanized both inside and out. The zinc coating
shall be smooth, continuous and uniform. It shall be free from acid spots and shall not scale,
blister or be removable by handling or packing. There shall be no impurities in the zinc or
additives to the smelter bath that could have a detrimental effect on the durability of the zinc
coating. Before pickling, all welding, drilling, cutting and grinding shall be completed and all
grease, paint, varnish, oil and welding slag shall be completely removed.
All protuberances which could affect the life of galvanizing shall also be removed. To avoid
the formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
Part -2 : Employer’s Requirements 104
5. Hardware:
MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used
for tying of overhead structure wherever required.
While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall
be hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
them to site for erection, they shall be offered for inspection and approval by Project
Manager.
6. Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (1 No.), anchor plate
(200x200x6mm), nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay
rod shall be used with 7/3.15 mm dia GI stranded wire.
Stay set shall be used at all turning locations, cable dead end locations to nullify the tension
of the cable. Erection of storm guys at suitable location in straight line may also be provided.
Erection of storm guys at suitable location in straight line may also be provided.
0.2 cmt cement concreting in mixture 1 part cement, 3 part coarse sand, 6 part 40mm size
aggregate stone chips (1:3:6). 2 Nos. guy insulator shall be provided in stranded GI wire at
middle location between two turn buckles.
7.1.1. 40 mm dia., 3000 mm long GI pipe earth electrode with test link, RCC pit, RCC cover plate
on GI frame, bentonite powder and other accessories complete
7.1.2. GI Earthing spike made of 20mm solid rod or 8 SWG, 50 turns earthing coil
7.1.3. Chemical rod earthing using Carbon powder/Bentonite powder / Conductive concrete powder
including electrode with 2000mm long, 50 mm diameter GI pipe, GI Strip of 24x3mm
minimum.8 SWG GI wire for earthing and guarding
Part -2 : Employer’s Requirements 105
Every sixth LT line support shall be provided with one GI earthing spike made of 20 mm
solid rod or GI Earth Coil and connected with 8 SWG GI wire. Overhead steel items shall be
connected to GI earthing spike or GI Earth Coil using 8 SWG GI wire. GI nuts, bolts &
washers shall be used to join two GI wires and 20 mm solid spike rod. Project Manager shall
decide use of GI Earth Coil or 20mm dia GI Solid Rod for individual pole earthing.
In rocky soil where getting required earth resistance is a challenge, chemical rod earthing
shall be used. Overhead line structure shall be connected to chemical earth electrode using
8SWG GI wire. GI nuts, bolts & washers shall be used to join two GI wires and 20 mm solid
spike rod.
GI wires must be properly dressed and fixed on supporting structure at 1 to 2 feet intervals.
8.01 1X16 (Ph) + 1X25 (bare messenger cum neutral) SQ. MM.
1X16 (Ph) + 1X25 (bare messenger cum neutral) + 1x16
8.02
(insulated Street lighting)SQ. MM.
8.03 3X16(Ph)+1X25 (bare messenger cum neutral) SQ. MM.
3 X 16(Ph) +1x25 (bare messenger cum neutral) + 1x16
8.04
(insulated Street lighting) SQ. MM.
8.05 1X25(Ph)+1x25 (bare messenger cum neutral) SQ. MM.
1X25(Ph) + 1X25 (bare messenger cum neutral) + 1x16
8.06
(insulated Street lighting) SQ. MM.
8.07 3X25(Ph)+1X25 (bare messenger cum neutral) SQ. MM.
3 X 25(Ph) +1x25 (bare messenger cum neutral) + 1x16
8.08
(insulated Street lighting) SQ. MM.
8.09 1X35(Ph)+1X25 (bare messenger cum neutral) SQ. MM.
1x35(Ph) + 1X25 (bare messenger cum neutral) + 1x16
8.10
(insulated Street lighting) SQ. MM.
8.11 3X35(Ph)+1X25 (bare messenger cum neutral) SQ. MM.
3X35 (Ph) + 1x25 (bare messenger cum neutral)+ 1x16
8.12
(insulated Street lighting) SQ. MM.
8.13 3X50(Ph)+1X35 (bare messenger cum neutral) SQ. MM.
3X50 (Ph)+1x35 (bare messenger cum neutral) +1x16
8.14
(insulated Street lighting) SQ. MM.
8.15 3X95(Ph)+1X70 (bare messenger cum neutral) SQ. MM.
3X95(Ph)+1X70 (bare messenger cum neutral) +1x16
8.16
(insulated Street lighting) SQ. MM.
Part -2 : Employer’s Requirements 106
Single phase DB shall be suited for two core 25 sqmmaluminium conductor cable as incomer
and 8 nos. two core 10 sqmm conductor cables as outgoing cables. Three phase DB shall be
suited for four core 35 sqmmaluminium conductor cable as incomer and 4 nos. four core 16
sqmm conductor cables as outgoing cables.
The Distribution Box/SMC Distribution Box shall be installed only at locations where BPL
connections are provided.
2Cx25 sqmmstranded cable or 4Cx35 sqmmstranded cable shall be used between LT line
and Distribution Box/SMC Distribution Box. T-connector shall be used at LT line for
tapping. While tapping connection from ABC cable, highly skilled lineman/wireman shall be
deployed along with sophisticated cutting plier/tool so that no damage should result in AB
cable conductor. T-connector should be crimped properly for resistance free/maintenance
free electric connection. Alternately, piercing type connector may be used for tapping of LT
connection from ABC cable conductor.
Each support pole should be numbered properly labelled using yellow base and black
indication marks (number or digits). 40/50 mm height digits/words should be used for this
purpose. Base shall be made using 2 or more coats of yellow enamel paint till good surface
finish. Base preparation shall be completed before shifting of poles to site for erection. Base
painting and marking of digits should be performed by a skilled and trained painter using
branded enamel paint, Project Manager shall approve type and brand of enamel paint.
3.5 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each LT line support.
Galvanized barbed wire should be properly dressed and crimped at termination. While
wrapping the wire on support, proper tension should be maintained.
13. Danger board:
Part -2 : Employer’s Requirements 107
Each support should be provided with a danger board with pole clamps as per approved
drawing. Danger board should be in bi-lingual languages (local language and English).
Clamp for danger board, nut-bolts and washers shall be painted with two or more coats of
red-oxide and aluminium paints respectively till smooth surface before installation.
Cement concrete in mixture 1 part cement, 3 part coarse sand, 6 part 40 mm size aggregate
stone chips (1:3:6) shall be used in steel tubular poles and H-Beam LT line supports and wide
parallel beam supports.
In rural areas, PCC pole pit shall be refilled with 200 mm average size of bolder mixed with
excavated earth. Proper ramming shall be performed for better compaction. PCC pole at cut
point and PCC poles erected on water logging area shall be grouted using cement concrete
mixture similar to H-Beam & Tubular poles. Prior approval of Project Manager shall be
obtained for concreting of PCC poles in water logging area. While preparing route survey
report, water logging areas shall be earmarked.
While erecting supports (poles), shuttering must be used for concreting so that proper
quantity of cement concrete mixture be used and assessed during inspection. During
concreting proper compaction by means of mobile vibrator be provided. While starting work
of support erection, gang wise shuttering and mobile vibrator shall be offered for inspection
to Project Manager. While erecting support, mercury level gauge must be used to ensure
vertical erection of support.
250mm dia X 12” inch size muffing shall be provided on steel tubular and H-Beam poles to
prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part Cement,
2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for individual
poles.
Steel plate shall be used in steel tubular poles and cement concrete reinforced plate shall be
used as base plate for PCC poles.
the observations with supporting photographs in digital form within one month from receipt
of observations.
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/trim to obtain required tree clearance. Contractor
shall pay compensation for any loss or damage for tree cutting due to Contractor’s work.
Wherever forest clearance is envisaged for execution of work, clearance of forest department
for tree cutting, if required, shall be arranged by the Project Manager and compensation shall
also be paid by the Project Manager. Necessary fee if required to pay to Govt. dept. for
arranging such clearances shall paid by Project Manager. However, the Contractor would
require to provide all necessary assistance for execution of this work.
During execution of LT Line works, all statutory clearances shall be ensured for ground
clearance, line-to-line clearance, road crossing clearance etc.
18. The earthing point of distribution transformer should be extended to the single phase
beneficiary premises having en-route earth connection at every 6th supports. The earth
conductor is to be connected with earth point provided in the premises of single phase
consumers. The bearer wire shall be earthed at every sixth pole.
19. Bearer wire of LT AB cable shall be anchored through eyehook or dead end (anchor) clamps.
20. Extra length of continuous AB cable along with messenger / bearer wire shall be properly
dressed and clamped.
a. Installation of additional 3.15 MVA Transformer with two additional bay on 11 KV side.
b. Installation of additional 5 MVA Transformer with two additional bay on 11 KV side.
c. Installation of additional 6.3 MVA Transformer with three additional bay on 11 KV side.
d. Installation of additional 8 MVA Transformer with four additional bay on 11 KV side.
Part -2 : Employer’s Requirements 109
2. Renovation/Augmentation of 33 kV line
1.00 Augmentation of 3 phase 33 kV line using additional supports matching with length and type of
existing support is envisaged on following type of supports:
i. 9.1 meter long /280 KG PCC Poles (PCC Pole as per state practice)
ii. 11 m or 13 m long H-Beam 152x152 mm 37.1 kg/m
iii. 11 M long steel Tubular poles with welded steel base plate of Designation 540 SP 52 (IS 2713,
Pt I, II, III 1980)
iv. 13 M long steel Tubular poles with welded steel base plate of Designation 540 SP 72 (IS 2713,
Pt I, II, III 1980)
2.00 Augmentation of existing conductor with following type of new ACSR conductor including
jointing sleeves, binding materials and helical formed fittings etc as required are envisaged under
this work-
i. 6/4.72 mm+7/1.57 mm (100 mm² Al. Area) - Dog replacing existing raccoon conductor
ii. 6/4.09 + 1/4.09 mm (80 mm² Al. Area) - Raccoon replacing existing rabbit/weasel conductor
iii. 30/2.59 + 7/2.59 mm (150 mm² Al. Area) - Wolf replacing existing dog/raccoon conductor
iv. 30/3.00 + 7/3.00 mm (200 mm² Al. Area) - Panther replacing existing dog/raccoon/wolf
conductor
3.00 While executing this work, mid span pole with all fittings may be provided matching with
existing poles of the line.
4.00 Following works shall also be executed by Contractor under this head –
3. Renovation/Augmentation of 11 kV line
1.00 Augmentation of 3 phase 11 kV line using additional supports matching with length and type of
existing support is envisaged on following type of supports:
a. 8 meter long /140 KG PCC Poles (PCC Pole as per state practice)
b. 9 m or 11 m or 13 m long H-Beam 152x152 mm 37.1 kg/m
c. 11 M long steel Tubular poles with welded steel base plate of Designation 540 SP 52 (IS 2713,
Pt I, II, III 1980)
d. 13 M long steel Tubular poles with welded steel base plate of Designation 540 SP 72 (IS 2713,
Pt I, II, III 1980)
2.00 Augmentation of existing conductor with following type of new ACSR conductor including
jointing sleeves, binding materials and helical formed fittings etc as required are envisaged under
this work-
a. 6/3.35 + 1/3.35 mm (50 mm² Al. Area) - Rabbit by replacing existing weasel/squirrel conductor
b. 6/4.09 + 1/4.09 mm (80 mm² Al. Area) - Raccoon by replacing existing rabbit/weasel/squirrel
conductor
c. 6/4.72 mm+7/1.57 mm (100 mm² Al. Area) - Dog by replacing existing raccoon/rabbit conductor
3.00 While executing this work, mid span pole with all fittings may be provided matching with
existing poles of the line.
4.00 Following works shall also be executed by Contractor under this head –
h. Removal of old conductor in coil form, removal of old steel structure, removal of old conductor
fittings, removal of any other worn out/defective material and deposit them in Employer’s store
within a reasonable time as decided by Project Manager
a) Optimistic lengths of LT lines needed to feed the existing consumers, existing un-connected
consumers and future growth in electrical loading,
b) Space available for installation of support/transformers,
c) Probable load expected to come on the transformer due to existing BPL beneficiaries /others
connected /un-connected probable beneficiaries in the locality taking care of their expected load
growth in next 5 years.
d) Distribution Transformers of capacity 16 KVA to 315 KVA (single phase as well as three phase)
shall be decided as per standard rating of distribution transformer as depicted in IS
specifications. Nonstandard ratings of DTR shall not be installed.
e) Distribution Transformers of capacity 16 KVA to 315 KVA (single phase as well as three phase)
shall be installed on existing structures/plinth.
Based on survey report, Project Manager shall decide type, capacity and location of Distribution
Transformer sub-station for augmentation/R&M works.
2.00 Following types of works are envisaged for Distribution Transformer sub-station for
augmentation/R&M works:
a. Replacement of defective materials of DTR substations
b. Re-erection/re-concreting of substation supports
c. Dismantling of defective/worn-out steel structure materials, 11 kV/LT equipment like Lightening
Arrester, DO Fuse, Distribution Box/SMC Distribution Box, LT cable, jumpering conductor,
Part -2 : Employer’s Requirements 113
terminal clamps, insulators etc as required. Shifting of dismantled material to Employer’s store
within reasonable period of time.
d. Installation of stay set for strengthening of DTR substation structure.
e. Topping up of new and filtered transformer oil wherever required.
f. De-moisturizing of silica gel, filling of transformer oil in silica gel breather.
g. Providing new DTR substation equipment like steel structure materials, 11 kV/LT equipment
like Lightening Arrester, DO Fuse, Distribution Box/SMC Distribution Box, LT cable,
jumpering conductor, terminal clamps, insulators etc
h. Renovation of DTR substation earthing by providing new earth pits, inter connection of earth
pits and their connection to various equipment
i. Cleaning of metallic structure items by rubbing through emery paper and re-painting using two
codes of red oxide paint and two coats of aluminium oxide paints of reputed type and make as
approved by Project Manager using painting brush.
Fabricated steel items like DC cross arm (100x50x6 mm), back clamps (65x8 mm), pole clamp
(65x8 mm), DO mounting channel (100x50x6 mm), transformer mounting channel (100x50x6
mm), transformer clamping set (50x50x6 mm), transformer belting set (50x50x6 mm), V cross
arm, top clamp, DC cross arm, bracket, clamps, cross bracings, bracings, strain plate, back
clamp, transformer mounting structure etc shall be made of MS Channels, MS angle, MS flats as
per approved drawings.
While fabricating, good quality electric cutting tools and drill machine shall be used to ensure no
sharp edges and perfect holes as per approved drawings. Gas cutting set should not be used for
fabrication of MS steel items. Weld material shall be distributed equally between the two
materials that were joined. The weld shall be free of waste materials such as slag. The weld
surface should not have any irregularities or any porous holes (called porosity). The joint shall be
tight. Most welds need to demonstrate the required strength. One way to ensure proper strength
is to start with a filler metal and electrode rating that is higher than your strength requirement.
The fabricated steel structures materials shall be hot-dip galvanized thoroughly internally and
externally according to IS: 2629 and IS: 2633 (with latest amendments). Galvanizing shall
be checked and tested in accordance with IS: 2633.
Fabricated steel structure items shall be galvanized both inside and out. The zinc coating
shall be smooth, continuous and uniform. It shall be free from acid spots and shall not scale,
blister or be removable by handling or packing. There shall be no impurities in the zinc or
additives to the smelter bath that could have a detrimental effect on the durability of the zinc
Part -2 : Employer’s Requirements 114
coating. Before pickling, all welding, drilling, cutting and grinding shall be completed and all
grease, paint, varnish, oil and welding slag shall be completely removed.
All protuberances which could affect the life of galvanizing shall also be removed. To avoid
the formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
4.00 Hardware:
MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used for
tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing, strain
plates etc.
While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads only
be visible of the bolt after full tightening of nut on requisite torque. The hardware shall be hot
dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS: 2633.
Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting them to site
for erection, they shall be offered for inspection and approval by Project Manager.
Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (2Nos.), anchor plate
(200x200x6mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay rod
& 7/3.15 mm dia GI stranded wire complete.
Stay set shall be used at all sub-station location to nullify the tension of
conductor/cable/transformer on the supports. 0.2 cmt cement concreting in mixture 1 part
cement, 3 part coarse sand and 6 part 40mm size aggregate stone chips (1:3:6) shall be provided
in the foundation of the stay set. 2 Nos. guy insulator shall be provided in 7/3.15 mm dia
stranded GI wire at middle locations between two turn buckles.
Following type and sizes of Energy efficiency Level 1 rated DT as per IS 1980 (Part-1) 2014
with Amendments 1, 2, 3, & 4. , distribution transformers are standardized in the project for
augmentation
Part -2 : Employer’s Requirements 115
The new distribution transformers shall be supplied with transformer oil filled up-to maximum
permissible level and breather with silica gel.
The distribution transformers must have been successfully type tested within five years from
date of Letter of Intent and the designs should have been in satisfactory operation for a period
not less than two years as on the date of bid opening. Compliance shall be demonstrated by
submitting, (i) authenticated copies of the type test reports and (ii) performance certificates from
the users, specifically from Central Govt./State Govt. or their undertakings.
The losses in Distribution Transformer should be as per Energy Efficiency Level 1 as specified
in IS 1180 (Part-1):2014 and amendement 1,2,3 &4 for all kVA ratings of distribution
transformers .Bimetallic connectors of suitable capacities are to be provided on LT side and on
HT side of the transformer.
T-Clamps should be provided on each jumper on bus bars. Line jumpers should be provided
with adequate size of PG Clamps (Two numbers PG Clamps at each end of jumper). Clamp
should be made of aluminum grade T-1F as per IS-8309 having good electrical quality
aluminum material and should not be brittle in nature.
Part -2 : Employer’s Requirements 116
ACSR raccoon conductor (or equivalent AAAC conductor) is to be used for connection between
overhead lines to transformer studs/bushing.
Distribution Box/SMC Distribution Boxes are to be installed as per specifications enclosed. The
boxes are to be erected, electrically connected with the existing system, properly earthed, and
labeled. The test report of pre-commissioning checks should be prepared and submitted.
All CT terminals are to be ring type and other terminals are fork type. 2.5 sqmm copper multi
stands wiring 1.1 KV grade, ISI marked, IS 694 shall be used for control wiring. A terminal
block be provided between CT and Meter keeping 20% spare terminals.
The Distribution Box/SMC Distribution Boxes are to be earthed using 8 SWG GI wire direct
connection to the earthing. 2 Nos Earthing bolts on the distribution boards should be provided of
10mm dia.
The single core power cables should be terminated with proper size lugs and gland. Necessary
tagging, identification of cores and dressing of cables with nylon cable ties shall be in the scope
of work. The unutilized holes in the DBs provided for cable entry needs to be plugged properly
in a manner that it must stop access to reptiles, dust and water ingress.
The Low Tension bus bars are to be painted with two or more coats of brush-able epoxy
compound suitable to insulate the bus bars for 415 volts exposure.
The Distribution Box/SMC Distribution Box 16 KVA should also house three phase tri-vector
energy meter / single phase meter depending on capacity and type of distribution transformer as
per specifications.
Part -2 : Employer’s Requirements 117
For higher capacity transformers where CT operated meters are to be installed, separate LTCT
cum Meter Box at eye height shall be installed for housing of meter, CTs, terminal block and
wiring.
The single core un-armored power cables shall be used for connection from Distribution
Transformer to Distribution Box/SMC Distribution Box and Distribution Box/SMC Distribution
Box to Outgoing LT lines. Cable should not be used in underground laying arrangement. Cables
should be dressed & tied properly using clamps /cable ties at 1 meter intervals and tied with
substation structure/poles. At-least one meter cable is to be kept as spare at the individual ends.
1.1 KV XLPE Aluminium Conductor, Stranded, un-armored cable be used for connection of
transformer LV bushing to Distribution Box/SMC Distribution Box and Distribution Box/SMC
Distribution Box to overhead line.
9.00 Earthing:
Part -2 : Employer’s Requirements 118
Distribution Transformer Earthing shall be provided with 3 Nos earthing and making earth mat
/risers using 50X6mm GI Flat. Earthing should be provided with GI earth pipe or Chemical
Earthing depending of strata of soil in the location. Project Manager shall decide the type of
earthing.
25x3mm GI Flat and 8 SWG GI shall be used for making earthing connection to various sub-
station equipment as per given details. GI Flat and GI wire shall be properly dressed, bunched
and clamped with the support at 2 feet intervals. An overlapping of 35mm shall be used at the
place of flat to flat joint. Two sets of GI nuts, bolts and washers shall be used for flat-to-flat
joints. GI nuts, bolts and washers must be used for GI Flat–to-GI wire & GI wire-to-GI wire
joints.
Substation wise measurement of earth resistance of earth pits / mesh and corresponding drawing
of existing earthing arrangement shall be recorded and submitted to Project Manager.
The location of earth pits should be at-least 3m apart, so that they their earth conductive areas do
not overlap. In rocky soil where getting required earth resistance is a challenge, chemical rod
Part -2 : Employer’s Requirements 119
earthing shall be used in place of normal GI pipe type earthing. Project Manager shall decide
type of earthing pits.
The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator should properly be cleaned before installation. No damage/crack insulator
should be used.
Each Substation should be numbered properly labelled using yellow base and black indication
marks (number or digits). 40/50 mm height digits/words should be used for this purpose. Base
shall be made using 2 or more coats of yellow enamel paint till good surface finish. Base
preparation shall be completed before shifting of poles to site for erection. Base painting and
marking of digits should be performed by a skilled and trained painter using branded enamel
paint, Project Manager shall approve type and brand of enamel paint.
3.5 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each sub-station support.
Galvanized barbed wire should be properly dressed and crimped at termination. While wrapping
the wire on support, proper tension should be maintained.
Each support should be provided with a danger board with pole clamps as per approved drawing.
Danger board should be in bi-lingual languages (local language and English). Clamp for danger
board, nut-bolts and washers shall be painted with two or more coats of red-oxide and aluminium
paints respectively till smooth surface before installation.
Cement concrete in mixture 1 part cement, 3 part coarse sand, 6 part 40 mm size aggregate stone
chips (1:3:6) shall be used in PCC Pole, steel tubular poles, WPB Poles and H-Beam support
foundation.
While erecting supports (poles), shuttering must be used for concreting so that proper quantity of
cement concrete mixture be used and assessed during inspection. During concreting proper
compaction by means of mobile vibrator be provided. While starting work of support erection,
gang wise shuttering and mobile vibrator shall be offered for inspection to Project Manager.
While erecting support, mercury level gauge must be used to ensure vertical erection of support.
250mm dia X 12” inch size muffing shall be provided on steel tubular, WPB poles and H-Beam
poles to prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part
Cement, 2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for
individual poles.
Steel plate shall be used in steel tubular poles and WPB poles and cement concrete reinforced
plate shall be used as base plate for PCC poles.
15.00 11 KV AB Switch:
11 kV, 3-ph, 200 A, 3 Pin type, Horizontal/Vertical Mounting type, Gang Operated, AB Switch
shall be installed on 100 KVA and more capacity distribution transformer substation only. B
Class GI pipe shall be used (without any joints) for operation of switch. AB Switch structure and
handle must be earthed using 8 SWG GI wire.
11 kV, 3-ph, Drop Out fuse units (set of 3 units) along with Support Insulators, Base Channel,
fuse barrel etc. shall be used for all capacity Distribution Transformer Substations. DO Fuse
structure shall be earthed using 8 SWG GI wire.
Distribution Class LAs on each phase shall be provided in the sub-station with base steel
structure, terminals bi – metallic connectors / PG clamps and earth connectors. LAs are to be
connected with separate earth connection. 25x3 mm GI flat shall be used for earth connection.
5. Renovation/Augmentation of LT line
Part -2 : Employer’s Requirements 121
1.00 Conversion of LT line using additional supports with all fittings matching with length and type
of existing support is envisaged on following type of supports:
2.00 Conversion of existing LT line of bare conductor with following type of new ABC cable LT
line as required are envisaged under this work-
2.01 1X16 (Ph) + 1X25 (bare messenger cum neutral) SQ. MM.
1X16 (Ph) + 1X25 (bare messenger cum neutral) + 1x16 (insulated Street
2.02
lighting)SQ. MM.
2.03 3X16(Ph)+1X25 (bare messenger cum neutral) SQ. MM.
3 X 16(Ph) +1x25 (bare messenger cum neutral) + 1x16 (insulated Street lighting)
2.04
SQ. MM.
2.05 1X25(Ph)+1x25 (bare messenger cum neutral) SQ. MM.
1X25(Ph) + 1X25 (bare messenger cum neutral) + 1x16 (insulated Street lighting)
2.06
SQ. MM.
2.07 3X25(Ph)+1X25 (bare messenger cum neutral) SQ. MM.
3 X 25(Ph) +1x25 (bare messenger cum neutral) + 1x16 (insulated Street lighting)
2.08
SQ. MM.
2.09 1X35(Ph)+1X25 (bare messenger cum neutral) SQ. MM.
1x35(Ph) + 1X25 (bare messenger cum neutral) + 1x16 (insulated Street lighting)
2.10
SQ. MM.
2.11 3X35(Ph)+1X25 (bare messenger cum neutral) SQ. MM.
3X35 (Ph) + 1x25 (bare messenger cum neutral)+ 1x16 (insulated Street lighting)
2.12
SQ. MM.
2.13 3X50(Ph)+1X35 (bare messenger cum neutral) SQ. MM.
3X50 (Ph)+1x35 (bare messenger cum neutral) +1x16 (insulated Street lighting) SQ.
2.14
MM.
2.15 3X95(Ph)+1X70 (bare messenger cum neutral) SQ. MM.
3X95(Ph)+1X70 (bare messenger cum neutral) +1x16 (insulated Street lighting) SQ.
2.16
MM.
Part -2 : Employer’s Requirements 122
3.00 While executing this work, mid span pole with all fittings may be provided matching with
existing poles of the line or wherever the sag is high and need so arise.
4.00 Following works shall also be executed by Contractor under this head –
Item-wise scope of works of LT line is detailed out under scope of new LT line. It shall be
utilized on item to item requirement under renovation/augmentation of LT line also.
Part -2 : Employer’s Requirements 123
b. In areas where length of LT line is more than 300 meters causing line losses and in theft
prone areas where unauthorized hooking is observed, HVDS is recommended. Existing LT
line supports shall be used for erection of 11 kV lines.
c) Probable load expected to come on the transformer due to existing BPL beneficiaries /others
connected /un-connected probable beneficiaries in the locality taking care of their expected
load growth in next 5 years.
d) Distribution Transformers of capacity 16 KVA to 25 KVA (single phase as well as three
phase as per detailed given) shall be installed on double pole structures. Hence, three phase
11 KV lines shall be laid for 16 KVA to 25 KVA (single phase as well as three phase)
capacity sub-stations. Single phase 11 KV lines (2-wire) shall only be permitted for 10 KVA
single phase transformers mounted on single pole structure. However, V-cross arms and top
clamp shall be used on each line support so that whenever needed, this 2-wire line may be
converted to 3-phase 11 kV line by erecting an additional conductor.
e) Double pole support steel structures for 16 KVA and 25 KVA distribution transformers
shall be designed in such a way that they can be augmented to 63 KVA transformer
structures without any addition in near future on technical requirements.
f) Single phase 10 KVA distribution transformer shall be installed on single pole structure.
Based on survey report, Project Manager shall decide type, capacity and location of
Distribution Transformer sub-station.
Existing LT lines’ conductor and fittings shall be dismantled. Tilted supports, if any, shall
be straightened. Poles erected in water logging areas or loose soil areas shall be provided
with cement concrete foundation.
Requirement of mid span pole with all fittings, to suit 11 kV line conductor shall be
examined during survey. Project Manager shall approve requirement of mid span poles and
extra concreting on existing poles.
While deciding mid span poles, project manager shall decide type and length of poles
matching with existing supports available in the field. Stay set wherever required in existing
line to be converted may be provided.
6.00 Support for conversion of existing LT line into 11 KV overhead line and for new 11 kV
line:
iii. 9 M long Steel Tubular poles of Designation 540 SP 28 (IS 2713, Pt I, II, III 1980)WPB
160/30.44kg/m of similar lenth as per existing support in LT line. This will improve
mechanical strength of 11 KV line. And also facilitate line to line crossing clearance.
Steel plate shall be used in steel tubular poles and cement concrete reinforced plate shall be
used as base plate for PCC poles.
Fabricated steel items like DC cross arm (100x50x6 mm), back clamps (65x8 mm), pole
clamp (65x8 mm), DO mounting channel (100x50x6 mm), transformer mounting channel
(100x50x6 mm), transformer clamping set (50x50x6 mm), transformer belting set (50x50x6
mm), V cross arm, top clamp, DC cross arm, bracket, clamps, cross bracings, bracings,
strain plate, guarding channels, back clamp, transformer mounting structure etc shall be
made of MS Channels, MS angle, MS flats as per approved drawings.
While fabricating, good quality electric cutting tools and drill machine shall be used to
ensure no sharp edges and perfect holes as per approved drawings. Gas cutting set should
not be used for fabrication of MS steel items. Weld material shall be distributed equally
between the two materials that were joined. The weld shall be free of waste materials such
as slag. The weld surface should not have any irregularities or any porous holes (called
porosity). The joint shall be tight. Most welds need to demonstrate the required strength.
One way to ensure proper strength is to start with a filler metal and electrode rating that is
higher than your strength requirement.
The fabricated steel structures materials shall be hot-dip galvanized thoroughly internally and
externally according to IS: 2629 and IS: 2633 (with latest amendments). Galvanizing shall
be checked and tested in accordance with IS: 2633.
Fabricated steel structure items shall be galvanized both inside and out. The zinc coating
shall be smooth, continuous and uniform. It shall be free from acid spots and shall not scale,
blister or be removable by handling or packing. There shall be no impurities in the zinc or
additives to the smelter bath that could have a detrimental effect on the durability of the zinc
coating. Before pickling, all welding, drilling, cutting and grinding shall be completed and all
grease, paint, varnish, oil and welding slag shall be completely removed.
All protuberances which could affect the life of galvanizing shall also be removed. To avoid
the formation of white rust all galvanized material shall be packaged in such a way to ensure
adequate ventilation between parts during shipping and storage.
Part -2 : Employer’s Requirements 126
8.00 Hardware:
MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used
for tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing,
strain plates etc.
While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall
be hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
them to site for erection, they shall be offered for inspection and approval by Project
Manager.
Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (1No.), anchor plate
(200x200x6mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay
rod & 7/3.15 mm dia GI stranded wire complete.
Stay set shall be used at all sub-station location to nullify the tension of
conductor/cable/transformer on the supports. 0.2 cmt cement concreting in mixture 1 part
cement, 3 part coarse sand and 6 part 40mm size aggregate stone chips (1:3:6) shall be
provided in the foundation of the stay set. 2 Nos. guy insulator shall be provided in 7/3.15
mm dia stranded GI wire at middle locations between two turn buckles. Erection of storm
guys at suitable location in straight line may also be provided.
Following type and sizes of minimum 3 star rated {as per Bureau of Energy Efficiency
(BEE)}BIS stamped, distribution transformers are standardized in the project :
The distribution transformers shall be supplied with transformer oil filled up-to maximum
permissible level and all accessories viz. breather with silica gel etc.
The distribution transformers must have been successfully type tested within five years
from date of Letter of Intent and the designs should have been in satisfactory operation for a
period not less than two years as on the date of bid opening. Compliance shall be
demonstrated by submitting, (i) authenticated copies of the type test reports and (ii)
performance certificates from the users, specifically from Central Govt./State Govt. or their
undertakings.
T-Clamps should be provided on each jumper on bus bars. Line jumpers should be provided
with adequate size of PG Clamps (Two numbers PG Clamps at each end of jumper). Clamp
should be made of aluminum grade T-1F as per IS-8309 having good electrical quality
aluminum material and should not be brittle in nature.
Part -2 : Employer’s Requirements 128
12.00 11 KV AB Switch:
11 kV, 3-ph, 600 A, 3 Pin type, Vertical/Horizontal Mounting type, Gang Operated, AB
Switch shall be installed at cut points and at suitable locations as per instructions of Project
Manager. B Class GI pipe shall be used (without any joints) for operation of switch. AB
Switch structure and handle must be earthed using 8 SWG GI wire.
The Distribution Box/SMC Distribution Boxes are to be earthed using 8 SWG GI wire
direct connection to the earthing. 2 Nos Earthing bolts on the Distribution Box/SMC
Distribution Box should be provided of 10mm dia.
Part -2 : Employer’s Requirements 129
The single core power cables should be terminated with proper size lugs and gland.
Necessary tagging, identification of cores and dressing of cables with nylon cable ties shall
be in the scope of work. The unutilized holes in the DBs provided for cable entry needs to
be plugged properly in a manner that it must stop access to reptiles, dust and water ingress.
The Low Tension bus bars are to be painted with two or more coats of brush-able epoxy
compound suitable to insulate the bus bars for 415 volts exposure.
The Distribution Box/SMC Distribution Box should also house three phase tri-vector
energy meter / single phase meter depending on capacity and type of distribution
transformer as per specifications.
The single core un-armored power cables shall be used for connection from Distribution
Transformer to Distribution Box/SMC Distribution Box and Distribution Box/SMC
Distribution Box to Outgoing LT lines. Cable should not be used in underground laying
arrangement. Cables should be dressed & tied properly using clamps /cable ties at 1 meter
intervals and tied with substation structure/poles. At-least one meter cable is to be kept as
spare at the individual ends.
1.1 KV XLPE Aluminium Conductor, Stranded, un-armored cable be used for connection
of transformer LV bushing to Distribution Box/SMC Distribution Box and Distribution
Box/SMC Distribution Box to overhead line.
14.00 Earthing:
Distribution Transformer Earthing shall be provided with 3 Nos earthing and making earth
mat /risers using 50X6mm GI Flat. Earthing should be provided with GI earth pipe or
Chemical Earthing depending of strata of soil in the location. Project Manager shall decide
the type of earthing.
25x3mm GI Flat and 8 SWG GI wire shall be used for making earthing connection to
various sub-station equipment as per given details. GI Flat and GI wire shall be properly
dressed, bunched and clamped with the support at 2 feet intervals. An overlapping of 35mm
shall be used at the place of flat to flat joint. Two sets of GI nuts, bolts and washers shall be
used for flat-to-flat joints. GI nuts, bolts and washers must be used for GI Flat–to-GI wire &
GI wire-to-GI wire joints.
Substation wise measurement of earth resistance of earth pits / mesh and corresponding
drawing of existing earthing arrangement shall be recorded and submitted to Project
Manager.
The location of earth pits should be at-least 3m apart, so that they their earth conductive
areas do not overlap. In rocky soil where getting required earth resistance is a challenge,
chemical rod earthing shall be used in place of normal GI pipe type earthing. Project
Manager shall decide type of earthing pits.
The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator should properly be cleaned before installation. No damage/crack
insulator should be used.
Each Substation should be numbered properly labelled using yellow base and black
indication marks (number or digits). 40/50 mm height digits/words should be used for this
purpose. Base shall be made using 2 or more coats of yellow enamel paint till good surface
finish. Base preparation shall be completed before shifting of poles to site for erection. Base
painting and marking of digits should be performed by a skilled and trained painter using
branded enamel paint, Project Manager shall approve type and brand of enamel paint.
3.5 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each sub-station
support. Galvanized barbed wire should be properly dressed and crimped at termination.
While wrapping the wire on support, proper tension should be maintained.
Each support should be provided with a danger board with pole clamps as per approved
drawing. Danger board should be in bi-lingual languages (local language and English).
Part -2 : Employer’s Requirements 132
Clamp for danger board, nut-bolts and washers shall be painted with two or more coats of
red-oxide and aluminium paints respectively till smooth surface before installation.
While erecting supports (poles), shuttering must be used for concreting so that proper
quantity of cement concrete mixture be used and assessed during inspection. During
concreting proper compaction by means of mobile vibrator be provided. While starting work
of support erection, gang wise shutting and mobile vibrator shall be offered for inspection to
Project Manager. While erecting support, mercury level gauge must be used to ensure
vertical erection of support.
250mm dia X 12” inch size muffing shall be provided on steel tubular and H-Beam poles to
prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part Cement,
2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for individual
poles.
Steel plate shall be used in steel tubular poles and cement concrete reinforced plate shall be
used as base plate for PCC poles.
11 kV, 3-ph, Drop Out fuse units (set of 3 units) along with Support Insulators, Base
Channel, fuse barrel etc. shall be used for all capacity Distribution Transformer Substations.
DO Fuse structure shall be earthed using 8 SWG GI wire.
Distribution Class LAs shall be provided in the sub-station with base steel structure,
terminals bi – metallic connectors / PG clamps and earth connectors. LAs are to be
connected with separate earth connection. 25x3 mm GI flat shall be used for earth
connection.
Part -2 : Employer’s Requirements 133
1.00 General
The provisions of this section of specification shall only be applicable to the extent of scope of
works indicated in Bid Proposal Sheet (BPS). The intent of specification covers the following:
Design, engineering, and construction of all civil works at power sub-station, 66 kV line, 33 kV line,
11 kV line, DTR substation, LT line, HVDS, augmentation/renovation of system etc. All civil works
shall also satisfy the general technical requirements specified in other Sections of this Specification
and as detailed below. They shall be designed to the required service conditions/loads as specified
elsewhere in this Specification or implied as per National/ International Standards.
All civil works shall be carried out as per applicable Indian Laws, Standards and Codes. All
materials shall be of best quality conforming to relevant Indian Standards and Codes.
The Contractor shall furnish all design, drawings, labour, tools, equipment, materials, temporary
works, constructional plant and machinery, fuel supply, transportation and all other incidental items
not shown or specified but as may be required for complete performance of the Works in accordance
with approved drawings, specifications and direction of Employer.
The work shall be carried out according to the design/drawings to be developed by the Contractor
and approved by the Project Manager based on Tender Drawings Supplied to the Contractor by the
Project Manager and Original Equipment Manufacturer recommendation. For all buildings,
structures, foundations etc. necessary layout and details shall be developed by the Contractor
keeping in view the functional requirement of the substation facilities and providing enough space
and access for operation, use and maintenance based on the input provided by the Project Manager.
Certain minimum requirements are indicated in this specification for guidance purposes only.
In case of R&M of existing substations, Contactor shall visit site to ascertain the amount of repair
and strengthening of structures and foundations, dismantling and new construction of structures and
foundations works are to be done before quoting. Contractor must furnish the design and drawings in
support of the activities mentioned above that are to be carried out in the R&M of existing substation
site.
The rate quoted by the bidder for all type of civil work shall be firm irrespective of the type of
terrain and depth of filling.
Part -2 : Employer’s Requirements 134
This specification covers all the work required for detailed soil investigation and preparation of a
detailed report. The work shall include mobilisation of necessary equipment, providing necessary
engineering supervision and technical personnel, skilled and unskilled labour etc. as required to
carry out field investigation as well as, laboratory investigation, analysis and interpretation of data
and results, preparation of detailed Geo-technical report including specific recommendations for the
type of foundations and the allowable safe bearing capacity for different sizes of foundations at
different founding strata for the various structures of the substation. The Contractor shall make his
own arrangement for locating the co-ordinates and various test positions in field as per the
information supplied to him and also for determining the reduced level of these locations with
respect to the benchmark indicated by the Project Manager.
All the work shall be carried out as per latest edition of the corresponding Indian Standard Codes.
a. Geotechnical Investigation
The Contractor shall perform a detailed soil investigation to arrive at sufficiently accurate, general as
well as specific information about the soil profile and the necessary soil parameters of the site. So
that the foundation of the various structures can be designed and constructed safely and rationally.
A report to the effect will be submitted by the Contractor for Project Manager’s specific approval
giving details regarding data proposed to be utilised for civil structures design.
The Contractor should visit the site to ascertain the soil parameters before submitting the bid. The
topography is uneven steeply sloping at few places requiring cutting and filling operations including
slope stability and protection measures (if slopes encountered). Any variation in soil data shall not
constitute a valid reason for any additional cost & shall not affect the terms & condition of the
Contract. Tests must be conducted under all the critical locations i.e. Control Room Building. Tower
locations, transformer etc.
b. Bore Holes
Drilling of bore holes of 150 mm dia. in accordance with the provisions of IS: upto 10 m depth or to
refusal which ever occur earlier. (By refusal it shall mean that a standard penetration blow count (N)
of 100 is recorded for 30 cm penetration). For a new substation, minimum three (3) bore holes shall
be done to find out the geological profile of the area. If any unconformity encountered then more
bore holes shall be drilled with the approval of Project Manager for the new projects. However in
case deep pile foundations are envisaged the depths have to be regulated as per codal provisions. In
Part -2 : Employer’s Requirements 135
cases where rock is encountered, coring in one borehole per bay shall be carried out to 1.5 M in
bedrock and continuous core recovery is achieved.
Performing Standard Penetration Tests at approximately 1.5 m interval in the borehole starting from
1.5 m below ground level onwards and at every change of stratum. The disturbed samples from the
standard penetrometer shall also be collected for necessary tests.
Collecting undisturbed samples of 100/75 mm diameter 450 mm long from the boreholes at intervals
of 2.5 m and every change of stratum starting from 1.0 m below ground level onwards in clayey
strata.
All samples, both disturbed and undisturbed, shall be identified properly with the borehole number
and depth from which they have been taken.
The sample shall be sealed at both ends of the sampling tubes with wax immediately after the
sampling and shall be packed properly and transported to the Contractor’s laboratory without any
damage or loss.
The logging of the boreholes shall be compiled immediately after the boring is completed and a copy
of the bore log shall be handed over to the Project Manager.
This test shall be conducted to determine the Electrical resistivity of soil required for designing safe
grounding system for the entire station area. The specifications for the equipments and other
accessories required for performing electrical resistivity test, the test procedure, and reporting of
field observations shall confirm to IS: 3043. The test shall be conducted using Wagner’s four
electrode method as specified in IS: 1892, Appendix-B2. Unless otherwise specified at each test
location, the test shall be conducted along two perpendicular lines parallel to the coordinate axis. On
each line a minimum of 8 to 10 readings shall be taken by changing the spacing of the electrodes
from an initial small value of 0.5 m upto a distance of 10.0 m.
d. Water Sample
Representative samples of ground water shall be taken when ground water is first encountered before
the addition of water to aid drilling of boreholes. The samples shall be of sufficient quantity for
chemical analysis to be carried out and shall be stored in airtight containers.
Part -2 : Employer’s Requirements 136
On completion of each hole, the Contractor shall backfill all bore holes as directed by the Project
Manager. The backfill material can be the excavated material and shall be compacted properly.
f. Laboratory Test
1. The laboratory tests shall be carried out progressively during the field work after sufficient
number of samples have reached the laboratory in order that the test results of the initial bore holes
can be made use of in planning the later stages of the field investigation and quantum of laboratory
tests.
2. All samples brought from field, whether disturbed or undisturbed shall be extracted/prepared
and examined by competent technical personnel, and the test shall be carried out as per the
procedures laid out in the relevant I.S. Codes.
1. The Contractor shall submit the detailed report in two (2) copies wherein information regarding
the geological detail of the site, summarized observations and test data, bore logs, and conclusions
and recommendations on the type of foundations with supporting calculations for the
recommendations. Initially the report shall be submitted by the Contractor in draft form and after the
draft report is approved, the final report in two (3) copies shall be submitted. The test data shall bear
the signatures of the Investigation Agency, Vendor and also site representative of Employer.
i.A plan showing the locations of the exploration work i.e. bore holes, dynamic cone penetration tests
etc.
ii.Bore Logs: Bore logs of each bore holes clearly identifying the stratification and the type of soil
stratum with depth. The values of Standard Penetration Test (SPT) at the depths where the tests were
conducted on the samples collected at various depths shall be clearly shown against that particular
stratum.
Test results of field and laboratory tests shall be summarised strata wise as well in combined tabular
form. All relevant graphs, charts tables, diagrams and photographs, if any, shall be submitted along
with report. Sample illustrative reference calculations for settlement, bearing capacity, pile capacity
shall be enclosed.
a. Recommendations: The report should contain specific recommendations for the type of
foundation for the various structures envisaged at site. The Contractor shall acquaint himself about
the type of structures and their functions from the Project Manager. The observations and
recommendations shall include but not limited to the following:
i.Geological formation of the area, past observations or historical data, if available, for the area and
for the structures in the nearby area, fluctuations of water table etc. Slope stability characteristics and
landslide history of the area shall be specifically highlighted. Remedial measures to be adopted shall
also be given.
ii.Recommended type of foundations for various structures. If piles are recommended the type, size
and capacity of pile and groups of piles shall be given after comparing different types and sizes of
piles and pile groups.
iii.Allowable bearing pressure on the soil at various depths for different sizes of the foundations based
on shear strength and settlement characteristics of soil with supporting calculations. Minimum factor
of safety for calculating net safe bearing capacity shall be taken as 3.0 (three). Recommendation of
liquefaction characteristics of soil shall be provided.
v.Comments on the Chemical nature of soil and ground water with due regard to deleterious effects of
the same on concrete and steel and recommendations for protective measures.
Part -2 : Employer’s Requirements 138
vi.If expansive soil is met with, recommendations on removal or retaining the same under the structure,
road, drains, etc. shall be given. In the latter case detailed specification of any special treatment
required including specification or materials to be used, construction method, equipment to be
deployed etc. shall be furnished. Illustrative diagram of a symbolic foundation showing details shall
be furnished.
vii.Recommendations for additional investigations beyond the scope of the present work, if considered
such investigation as necessary.
The Employer shall be responsible for proper leveling of switchyard site as per layout and levels of
switchyard finalised during detailed engineering stage. The Employer at his own cost shall make the
layout and levels of all structure etc from the general grids of the plot and benchmarks set and
approved by the Project Manager. The Contractor shall give all help in instruments, materials and
personnel to the Project Manager for checking the detailed layout and shall be solely responsible for
the correctness of the layout and levels. Site leveling shall be in the scope of the Employer. Bidder
may decide the level of the sites. However, the level shall be such that it is 300 mm higher than the
highest flood level (HFL) of the site. If HFL is not available, then nearby road level shall be assumed
as HFL.
Whenever for bay extension works the existing substation are to be modified or strengthen,
Contractor should keep same as EGL of existing sub-station so that FFL shall be same for both and
all the necessary arrangements are to be carried out in this regard by the Contractor.
This clause covers the design and execution of the work for site preparation, such
as clearing of the site, the supply and compaction of fill material, slope protection by stone
pitching/retaining walls depending on the site location & condition, excavation and compaction of
backfill for foundation, road construction, drainage, trenches and final topping by brick soling/stone
filling.
1) The Employer shall develop the site area to meet the requirement of the intended purpose. The
site preparation shall conform to the requirements of relevant sections of this specification or as per
stipulations of standard specifications. Employer shall also carry out necessary protection of slope of
switchyard area and approach road.
2) The fill material if required shall be suitable for the above requirement. The fill shall be such
material and the site so designed as to prevent the erosion by wind and water of material from its
final compacted position or the in-site position of undisturbed soil.
Part -2 : Employer’s Requirements 139
3) Material unsuitable for founding of foundations shall be removed and replaced by suitable fill
material and to be approved by the Project Manager.
4) Backfill material around foundations or other works shall be suitable for the purpose for
which it is used and compacted to the density described under Compaction. Excavated material not
suitable or not required for backfill shall be disposed off in areas as directed by Project Manager
upto a maximum lead of 1 km.
1. Excavation and backfill for foundations shall be in accordance with the relevant code.
2. Whenever water table is met during the excavation, it shall be dewatered and water table shall
be maintained below the bottom of the excavation level during excavation, concreting and
backfilling.
3. When embankments are to be constructed on slopes of 15% or greater, benches or steps with
horizontal and vertical faces shall be cut in the original slope prior to placement of embankment
material. Vertical faces shall measure not more than 1 m in height.
4. Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be
constructed by compacting the material in successive uniform horizontal layers not exceeding 20 cm
in thickness (of loose material before compaction). Each layer shall be compacted as required by
means of mechanical tampers approved by the Project Manager. Rocks larger than 10 cm in any
direction shall not be placed in embankment adjacent to structures.
5. Earth embankments of roadways and site areas adjacent to buildings shall be placed in
successive uniform horizontal layers not exceeding 20 cm in thickness in loose stage measurement
and compacted to the full width specified. The upper surface of the embankment shall be shaped so
as to provide complete drainage of surface water at all times.
6. The land required for borrowing earth shall be arranged & selected by Contractor. The
identified land shall be got approved by Project Manager. The quoted rates shall include cost of
earth, taxes, duties, royalty, compensation for the land identified for borrow earth. The rate shall also
be inclusive of all leads, lifts, ascent, descent and testing required for completion of work in all
respect.
7. The ground levels for all measurements shall be taken at every 5 meter distance in uniformly
sloping ground and at closer distance where pits/undulations are met with. In fairly leveled area,
Part -2 : Employer’s Requirements 140
levels shall be taken at 15 mt. apart at the discretion of Project Manager. The ground levels shall be
recorded and plotted on plans. The same shall be recorded by Project Manager before the earth work
is started. All labor, material, tool, equipment etc required for the above work shall be arranged by
the Employer at his own cost.
b. Compaction
1. The density to which fill materials shall be compacted shall be as per relevant IS and as per
direction of Project Manager. All compacted sand filling shall be confined as far as practicable.
Backfilled earth shall be compacted to minimum 95% of the Standard Proctor’s density at OMC.
The sub-grade for the roads and embankment filling shall be compacted to minimum 95% of the
Standard Proctor’s density at OMC. Cohesion less material sub grade shall be compacted to 70%
relative density (minimum).
2. At all times unfinished construction shall have adequate drainage. Upon completion of the road’s
surface course, adjacent shoulders shall be given a final shaping, true alignment and grade.
3. Each layer of earth embankment when compacted shall be as close to optimum moisture content
as practicable. Embankment material, which does not contain sufficient moisture to obtain proper
compaction, shall be wetted. If the material contains any excess moisture, then it shall be allowed to
dry before rolling. The rolling shall begin at the edges overlapping half the width of the roller each
time and progress to the center of the road or towards the building as applicable. Rolling will also be
required on rock fills. No compaction shall be carried out in rainy weather.
All foundations shall rest below virgin ground level and the minimum depth of foundation below
the virgin ground level shall be at least 500 mm. For small equipment and minor foundations like
marshalling kiosk, Switch board stand, earth switch and main box support etc. may be reduced to
300 mm with specific approval of the Project Manager.
The Contractor shall furnish all labour, equipment and materials required for complete performance
of the work in accordance with the drawings, specification and direction of the Project Manager.
Stone filling shall be done in the areas of the switchyard wherever equipment and or structures are
to be provided under present scope of work covering entire fencing area.
Part -2 : Employer’s Requirements 141
Prevailing practice of stone filling is to be adopted for the bay extension works of existing
substations. Contractor shall verify the existing practice prevailing at site before quoting.
Before taking up stone rolling, antiweed treatment shall be applied in the switchyard area where
stone filling is to be done and the area shall be thoroughly de-weeded including removal of the roots.
The recommendation of local agriculture/horticulture department shall be sought where ever feasible
while choosing the type of chemical to be used. Nevertheless the effectiveness of chemical shall be
demonstrated by the Contractor in a test area of size 10 meterx 10 meter (approx..). The final
approval based on the result shall be given by Project Manager. Antiweed treatment shall be
procured from reputed manufacturer. The dosage and application of chemical shall be strictly as per
the manufacturer’s recommendation. The Contractor shall be requested to maintain the area free of
weed for a period of one year from the date of application of the first dose of the chemical.
a. The material required for site surfacing shall be free from all types of organic materials and
shall be of standard quality, and as approved by the Project Manager.
The material to be used for stone filling/ site surfacing shall be uncrushed/ crushed/ broken stone of
20 mm nominal size (single sized) conforming to table 2 of IS: 383- 1970. Hardness, flakiness shall
be as required for wearing courses are given below.
40mm 100
20mm 85-100
10mm 0-20
4.75mm 0-5
(b) Hardness
Abrasion value (IS: 2386 part-IV) not more than 40%
Impact value (IS: 2386 part-IV) not more than 30%
b. After all the structures/equipment are erected, the surface of the switchyard area shall be
maintained, rolled/compacted to the lines and grades as decided by Project Manager. De-weeding
including removal of roots shall be done before rolling is commenced. Project Manager shall decide
Part -2 : Employer’s Requirements 142
final formation level so as to ensure that the site appears uniform. The final formation level shall
however be very close to the formation level indicated in the drawing using half-ton roller with
suitable water sprinkling arrangement to form a smooth and compact surface.
d. Over the base layer of site surfacing material, a final surface course of minimum 50 mm
thickness of 20 mm nominal size (single sized) broken stone as specified above shall be spread and
compacted by light roller using half tones steel roller (width 30" and 24" dia meter) with water
sprinkling as directed by the Project Manager. The water shall be sprinkled in such a way that
bulking does not take place.
e. In areas that are considered by the Project Manager to be too congested with foundations and
structures for proper rolling of the site surfacing material by normal rolling equipment, the material
shall be compacted by hand, if necessary. Due care shall be exercised so as not to damage any
foundation structures or equipment during rolling compaction.
a. Adequate site drainage system shall be provided by the Contractor in new and existing
substation. In case of bay extension of existing substation, drainage layout shall be prepared by the
Contractor in such away that it should satisfy the technical parameters stated below while designing
the drainage system so that flow of water of the existing part of substation remain uninterrupted and
the same should be approved by the Project Manager. The technical parameters stated below also to
be taken into account while designing the drainage system for new substation as well.
The Contractor shall obtain rainfall data and design the storm water drainage system, (culverts,
ditches, drains etc.) to accommodate run off due to the most intense rainfall that is likely to occur
over the catchments area in one hour period on an average of once in ten years. The surface of the
site shall be sloped to prevent the ponding of water.
b. The maximum velocity for pipe drains and open drains shall be limited to 2.4m/sec and
1.8m/sec respectively. However, minimum non-silting velocity of 0.6m/sec shall be ensured.
Longitudinal bed slope shall not be milder than 1 in 1000.
c. The drains shall be constructed using Brick masonry except at road crossings etc. where RCC
pipe shall be used. The RCC pipe for drains and culverts shall be as per IS:456 and IS:783.
Part -2 : Employer’s Requirements 143
d. The Contractor shall ensure that water drains are away from the site area and shall prevent
damage to adjacent property by this water. Adequate protection shall be given to site surfaces, roads,
ditches, culverts, etc. to prevent erosion of material by water.
e. The drainage system shall be adequate without the use of cable/pipe trenches. (Pipe drains shall
be provided in areas of switchyard where movement of crane will be necessary in operating phase of
the substation).
f. For pipe drains, concrete pipe of class NP2 shall be used. However, for road crossings etc.
higher strength pipe of class NP3 shall be provided. For rail crossings, pipes conforming to railway
loading standards or at least NP4 class shall be provided. Manholes shall be provided at every 30m
interval, at connection points and at every change of alignment.
g. Open surface drains for new s/s shall be provided with brick masonry in 1:6 (1 cement: 6
coarse sand) cement mortar with 12 mm thick, 1:4 (1 cement: 4 sand) cement plaster inside and
exposed surface of drains as per approved drawing. For bay extension at existing substations,
prevailing practice of the respective substation shall be adopted.
h. Pipe drains shall be connected through manholes at an interval of max. 30m. Effluents shall be
suitably treated by the Contractor to meet all the prevalent statutory requirements and local pollution
control norms and treated effluents shall be conveyed to the storm water drainage system at a
suitable location for its final disposal.
i. Invert of the drainage system shall be decided in such a way that the water can easily be
discharged above the High Flood Level (HFL) outside substation boundary at suitable location upto
a maximum 50M beyond boundary wall of substation or actual whichever occurs earlier and
approved by Project Manager.
j. All internal site drainage system, including the final connection/disposal to Project Manager
acceptance points shall be part of Supplier’s scope including all required civil works. The Contractor
shall connect his drain(s) at one or more points to outfall points as feasible at site.
k. The drainage scheme and associated drawings shall be got approved and constructed as per
enclosed tender drawing.
a. The main approach road including modification of existing road to meet the site conditions,
roads for access to equipment and buildings with in substations (including bay extension in existing
substations) are in the scope of the Contractor. Layout of the roads shall be based on General detail
Part -2 : Employer’s Requirements 144
& Arrangement drawing for the substation. If extra road is required for functional point of view,
which has not been mentioned in the layout drawing, Contractor should provide the same without
extra cost to the Project Manager.
b. All substation roads shall be constructed so as to permit transportation of all heavy equipment.
The roads shall have min. 3.0 m wide RCC road as per enclosed tender drawing.
d. Adequate provision shall be made for road drainage. Protection of cut and embankment slopes
of roads as per slope stability requirement shall be made.
e. All the culverts and its allied structure (required for road/rail, drain trench crossings etc.) shall
be designed for class A loading as per IRC standard / IS code and should be checked for loading.
f. All roads shall be designed for class ‘D’ of traffic as per IRC-37 Guide-lines for the design of
rigid pavements.
The Contractor shall provide a road system integrated with the transformer foundation to enable
installation and the replacement of any failed unit by the spare unit located at the site. This system
shall enable the removal of any failed unit from its foundation to the nearest road.
Similarly all types of equipment foundations with /without supporting structures shall be treated in
similar manner as stated for transformer foundations.
Contractor must access the amount of work involve for augmentation/bay extension of existing
substations while quoting.
a. The cable trenches and precast removable RCC cover (with lifting arrangement) shall be
constructed using RCC of M20 grade for new substation whereas for bay extension of existing
Part -2 : Employer’s Requirements 145
substation size and material of cable trenches shall be same as the existing one and pre-cast
removable RCC cover (with lifting arrangement) shall be constructed using RCC of M20 grade.
Cable trenches must be designed for the design criteria stated below, whether it is of concrete or
brick for both new substations and bay extension works in existing substations.
b. The cable trench walls shall be designed for the following loads.
(i) Dead load of 100 kg/m length of cable support + 75 Kg on one tier at the end.
(ii) Triangular earth pressure + uniform surcharge pressure of 1T/m2.
c. Cable trench covers shall be designed for self-weight of top slab + concentrated load of 200 kg
at center of span on each panel.
d. Cable trench crossing the road/rails shall be designed for class A. Loading of IRC/relevant IS
Code and should be checked for transformer loading.
e. Trenches shall be drained. Necessary sumps be constructed and sump pumps if necessary shall
be supplied. Cable trenches shall not be used as storm water drains.
f. The top of trenches shall be kept at least 100 mm above the finished ground level for the new
substation. The top of cable trench shall be such that the surface rainwater does not enter the trench.
g. The top of trench shall be kept same as existing one to maintain uniformity of the cable
trenches structure in case of bay extension works of existing substations.
h. All metal parts inside the trench shall be connected to the earthing system.
j. Trench wall shall not foul with the foundation. Suitable clear gap shall be provided.
k. The trench bed shall have a slope of 1/500 along the run & 1/250 perpendicular to the run.
l. Cable trenches shall be blocked at the ends if required with brick masonry in cement sand
mortar 1:6 and plaster with 12mm thick 1:6 cement sand mortar.
m. Cable trench contains cable trey that shall be supported on ISA. The size and spacing of angle
section shall be as per design criteria mentioned above.
1. Work covered under this Clause of the Specification comprises the design and
construction of foundations and other RCC constructions for switchyard structures, equipment
supports, trenches, drains, control cubicles, bus supports, transformer, marshalling kiosks, auxiliary
equipment & systems, buildings, tanks, boundary wall or for any other equipment or service and any
other foundation required to complete the work. This clause is as well applicable to the other RCC
constructions.
However, for the augmentation/bay extension works of existing substation, type of RCC structures
and foundations etc. shall be similar to one already existing at the existing substation and for which
design shall be furnished in support of safety of those RCC structures and foundations etc.
Contractor must access the amount of work involved for the construction of switchyard structures,
equipment supports, trenches, drains, control cubicles, bus supports, transformer, marshalling kiosks,
auxiliary equipment & systems, buildings, tanks, boundary wall or for any other equipment or
service and any other foundation required to complete the work for the existing substations.
2. Concrete shall conform to the requirements mentioned in IS: 456 and all the tests shall be
conducted as per relevant Indian Standard Codes as mentioned in Standard field quality plan
appended with the specification
A minimum grade for PCC and RCC shall be used for all structural/load-bearing members as per
latest IS 456.
3. If the site is sloppy, the foundation height will be adjusted to maintain the exact level of
the top of structures to compensate such slopes.
4. The switchyard foundation’s plinths and building plinths shall be minimum 300mm and
500 mm above finished ground level respectively.
5. Minimum 75mm thick lean concrete shall be provided below all underground structures,
foundations, trenches etc. to provide a base for construction.
6. Concrete made with Portland slag cement shall be carefully cured and special importance
shall be given during the placing of concrete and removal of shuttering.
7. The design and detailing of foundations shall be done based on the approved soil data and
sub-soil conditions as well as for all possible critical loads and the combinations thereof. The Spread
footings foundation or pile foundation as may be required based on soil/sub-soil conditions and
superimposed loads shall be provided.
Part -2 : Employer’s Requirements 147
8. If pile foundations are adopted, the same shall be cast-in-situ driven/bored or precast or
under reamed type as per relevant parts of IS Code 2911. Only RCC piles shall be provided.
Suitability of the adopted pile foundations shall be justified by way of full design calculations.
Detailed design calculations shall be submitted by the bidder showing complete details of piles/pile
groups proposed to be used. Necessary initial load test shall also be carried out by the bidder at their
cost to establish the piles design capacity. Only after the design capacity of piles has been
established, the Contractor shall take up the job of piling. Routine tests for the piles shall also be
conducted. All the work (design & testing) shall be planned in such a way that these shall not cause
any delay in project completion.
a. Design
1. Foundations shall be of reinforced cement concrete for new substation but for the augmentation
/ bay extension works of existing substation it could be of RCC/ PCC depending on type of
structures and materials used for the similar type of structures in those bay extension works of
existing substation. Design requirement shall be fulfilled by the Contractor and furnished for
approval for both new substation and existing substation (for bay extension works) as specified in
the scope of work. The design and construction of RCC/ PCC / Masonry structures shall be carried
out as per IS: 456 and relevant IS code/CBIP manual/NBC etc and minimum grade of concrete shall
be as per relevant IS code. Higher grade of concrete than specified above may be used at the
discretion of Contractor without any additional financial implication to the Project Manager.
2. Limit state method of design shall be adopted unless specified otherwise in the specification.
3. For detailing of reinforcement IS: 2502 and SP: 34 shall be followed. Cold twisted deformed
bars (Fe=415 N/mm2) conforming to IS: 1786 shall be used as reinforcement. However, in specific
areas, mild steel (Grade I) conforming to IS: 432 can also be used. Two layers of reinforcement (on
inner and outer face) shall be provided for wall & slab sections having thickness more than 150 mm.
Clear cover to reinforcement towards the earth face shall be minimum 40 mm.
4. RCC water retaining structures like storage tanks, etc. shall be designed as un-cracked section
in accordance with IS: 3370 (Part I to IV) by working stress method. However, water channels shall
be designed as cracked section with limited steel stresses as per IS: 3370 (Part I to IV) by working
stress method.
5. The procedure used for the design of the foundations shall be the most critical loading
combination of the steel structure and or equipment and/or superstructure and other conditions,
which produces the maximum stresses in the foundation or the foundation component and as per the
Part -2 : Employer’s Requirements 148
relevant IS Codes of foundation design. Detailed design calculations shall be submitted by the bidder
showing complete details of piles/pile groups or isolated /combined footings proposed to be used.
6. Design shall consider any sub-soil water pressure that may be encountered following relevant
standard strictly.
7. Necessary protection to the foundation work, if required shall be provided to take care of any
special requirements for aggressive alkaline soil, black cotton soil or any other type of soil which is
detrimental/harmful to the concrete/masonry foundations.
8. RCC columns /pedestals shall be provided with rigid connection at the base.
9. All sub-structures shall be checked for sliding and overturning stability during both
construction and operating conditions for various combinations of loads. Factors of safety for these
cases shall be taken as mentioned in relevant IS Codes or as stipulated elsewhere in the
Specifications. For checking against overturning, weight of soil vertically above footing shall be
taken and inverted frustum of pyramid of earth on the foundation should not be considered.
10. Earth pressure for all underground structures shall be calculated using co-efficient of earth
pressure at rest, co-efficient of active or passive earth pressure (whichever is applicable).
11. In addition to earth pressure and ground water pressure etc., a surcharge load of 1T/Sq.m shall
also be considered for the design of all underground structures including channels, sumps, tanks,
trenches, substructure of any underground hollow enclosure etc., for the vehicular traffic in the
vicinity of the structure.
12. Following conditions shall be considered for the design of water tank in pumps house,
channels, sumps, trenches and other underground structures:
i. Full water pressure from inside and no earth pressure & ground water pressure & surcharge pressure
from outside (application only to structures, which are liable to be filled up with water or any other
liquid).
ii. Full earth pressure, surcharge pressure and ground water pressure from outside and no water
pressure from inside.
iii. Design shall also be checked against buoyancy due to the ground water during construction and
maintenance stages. Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the
superimposed loadings.
Part -2 : Employer’s Requirements 149
13. The foundations shall be proportioned so that the estimated total and differential movements of
the foundations are not greater than the movements that the structure or equipment is designed to
accommodate.
14. The foundations of transformer and circuit breaker shall be of block type foundation. Minimum
reinforcement shall be governed by IS: 2974 and IS: 456.
15. The tower and equipment foundations shall be checked for a factor of safety of 2.0 for normal
condition and 1.5 for short circuit condition against sliding, overturning and pullout.
1. Only approved admixtures shall be used in the concrete for the Works. When more than one
admixture is to be used, each admixture shall be batched in its own batch and added to the mixing
water separately before discharging into the mixer. Admixtures shall be delivered in suitably labeled
containers to enable identification.
2. Admixtures in concrete shall conform to IS: 9103. The water proofing cement additives shall
conform to IS: 2645. Project Manager shall approve concrete Admixtures/ Additives.
3. The Contractor may propose and the Project Manager may approve the use of a water-reducing
set-retarding admixture in some of the concrete. The use of such an admixture will not be approved
to overcome problems associated with inadequate concrete plant capacity or improperly planned
placing operations and shall only be approved as an aid to overcoming unusual circumstances and
placing conditions.
5. The waterproofing cement additives shall be used as required / advised by the Project Manager.
1. The Gate frame shall be made of medium duty MS pipe conforming to relevant IS with welded
joints.
2. The gates shall be fabricated with welded joints to achieve rigid connections. The gate frames
shall be painted with one coat of approved steel primmer and two coats of synthetic enamel paint.
Part -2 : Employer’s Requirements 150
3. Gates shall be fitted with approved quality iron hinges, latch and latch catch. Latch and latch
catch shall be suitable for attachment and operation of pad lock from either side of gates. Hinges
shall permit gates to swing through 180 degree back against fence. Gates shall be earthed by G I
wire.
4. Gates shall be fitted with galvanized chain hook or gate hold back to hold gates open. Double
gates shall be fitted with centre rest and drop bolt to secure gates in closed position.
5. Gates shall be installed in locations shown on drawings. Next to the main gate, a men gate
(1.25 m wide, single leaf) shall also be provided.
6. Bottom of gates shall be set approximately 40mm above ground surface and necessary guiding
mechanism shall be fitted.
7. The Contractor shall design and construct boundary wall around substation area as per
requirements. The boundary wall shall be of height 2.0M and shall be made of RCC frame
construction with RCC column and plinth beam arrangement and panels filled with one brick thick
wall in cement sand mortar 1:6. The boundary wall shall be plastered on both external and internal
faces with cement and sand plaster 1:6 of thickness 18 mm and 12 mm respectively. An additional
barbed Y-shaped arm of MS angle 50x50x6 with 3-rows (6 nos) barbed wire A-4 IS: 278. Expansion
joints shall be provided as per codal requirements. MS grating shall be provided at required
locations for drainage purposes. The boundary wall shall be painted with minimum two coats of
color wash over a base coat of white wash with lime. The front portion of boundary wall shall
however be with a RC jail and 12 mm square MS bar top above brick work and pebble dash plaster
finish with colour pigment. The steel work shall be given two coats of synthetic enamel paint of
approved make over one coat of primer. Boundry wall and gate shall be constructed as per enclosed
tender drawing.
The scope for new control room building includes the design, engineering and construction including
anti-termite treatment, plinth protection, DPC of Building including sanitary, water supply,
electrification, false ceiling etc. of control room building. The buildings shall be of RCC framed
structure of concrete of M20 grade (Min.). Following design criteria shall be adopted for design
purposes for new substation.
If any extension of the Control Room building is required in augmentation / bay extension works of
existing substation then extension part shall be compatible to existing one structurally and
architecturally but following design criteria shall be adopted for design purposes for R&M of
existing substation.
Part -2 : Employer’s Requirements 151
Minimum floor area requirements shall be 10000×12000 mm excluding space for wash room which
may be increased at the time of detailed engineering to suit project requirements. The layout of the
control room shall be finalised as per detailed engineering to suit project requirements .The
minimum dimension of different rooms required for C.R.building shall be as per drawing. The CR
building shall consist of the following:
a. Control room
b. S/s In-charge room
c. Battery room
d. Store room
e. Toilet
An open space of 1 m minimum shall be provided on the periphery of the rows of panel and
equipment generally in order to allow easy operator movement and access as well as maintenance.
Any future possibility of annexe building shall be taken care of while finalizing the layout of the
control room building.
Minimum headroom of 3 M below soffit of beams/false ceiling shall be considered for rooms. The
roof shall have four side sloping roof or flat roof as finalised during detailed engineering.
i. Design
1. To the requirements of the National Building Code of India, and the standards quoted therein.
3. To adequately suit the requirements of the equipment and apparatus contained in the buildings and
in all respects to be compatible with the intended use and occupancy.
5. For a life expectancy of structure, systems and components not less than that of the equipment,
which is contained in the building, provided regular maintenance is carried out.
Part -2 : Employer’s Requirements 152
8. With, wherever required, fire retarding materials for walls, ceilings and doors, which would
prevent supporting or spreading of fire.
9. Suitable expansion joints shall be provided in the longitudinal direction wherever necessary with
provision of twin columns.
10. Individual members of the buildings frame shall be designed for the worst combination of forces
such as bending moment, axial force, shear force, torsion etc.
11. Permissible stresses for different load combinations shall be taken as per relevant IS Codes.
12. The building lighting shall be designed in accordance with the requirements of relevant section.
ii.Design loads
Building structures shall be designed for the most critical combinations of dead loads, super-
imposed loads, equipment loads, wind loads, seismic loads, and temperature loads.
Dead loads shall include the weight of structures complete with finishes, fixtures and partitions and
should be taken as per IS: 1911.
Super-imposed loads in different areas shall include live loads, minor equipment loads, cable trays,
small pipe racks/hangers and erection, operation and maintenance loads. Equipment loads shall
constitute, if applicable, all load of equipments to be supported on the building frame.
The wind loads shall be computed as per IS 875, Seismic Coefficient method shall be used for the
seismic analysis as per IS 1893 with importance factor 1.5.
Floors/slabs shall be designed to carry loads imposed by equipment, cables piping, equipment and
other loads associated with building. Floors shall be designed for live loads as per relevant IS. Cable
and piping loads shall also be considered additionally for floors where these loads are expected.
Part -2 : Employer’s Requirements 153
For consideration of loads on structures, IS: 875 shall strictly adhere to. Any other load coming in
the structure, not mentioned in IS 875 shall be calculated as per relevant IS code and NBC.
iii. Submission
The following information shall be submitted for review and approval to the Project Manager:
1. Design criteria shall comprise the codes and standards used, applicable climatic data including
wind loads, earthquake factors maximum and minimum temperatures applicable to the building
locations, assumptions of dead and live loads, including equipment loads, impact factors, safety
factors and other relevant information.
3. Fully, dimensioned concept plan including floor plans, cross sections, longitudinal sections,
elevations and perspective view of each building. These drawings shall be drawn at a scale not
smaller than 1:75 and shall identify the major building components.
4. Fully dimensioned drawings showing details and sections drawn to scales of sufficient size to
clearly show sizes and configuration of the building components and the relationship between them.
5. Product information of building components and materials, including walls partitions flooring
ceiling, roofing, door and windows and building finishes.
7. A door & window schedule showing door types and locations, door lock sets and latch sets and
other door hardware.
Approval of the above information shall be obtained before ordering materials or starting fabrication
or construction as applicable.
2. M.S. Ladder should be provided to access the control room roof from outside. Ladder shall be
made up of ISMC 75x40 which will run as beam one meter apart and intermediate steps will be
Part -2 : Employer’s Requirements 154
made up of 45x45x5 angle with rise of 300 mm. Red oxide premier shall be applied initially, then
two coats of rich zinc paint shall be applied to avoid corrosion.
v.Flooring
Flooring in various rooms of control room building shall be as for detailed schedules given in Table
-1
vi.Walls
Control room buildings shall be of framed superstructure. All walls shall be non-load bearing walls.
Min. thickness of external walls shall be 230 mm (one brick) with 1:6 cement sand mortar.
vii.Plastering
All internal walls shall have minimum 12mm and 15 mm thick 1:6 cement sand plaster on either side
of wall. The ceiling shall have 6mm thick 1:4 cement sand plaster.
viii.Finishing
All external surfaces shall have 18 mm cement plaster in two coats, under layer 12 mm thick cement
plaster 1:5 and finished with a top layer 6 mm thick cement plaster 1:6 (DSR 13.19) with water
proofing compound. The paint shall be antifungal quality of reputed brand suitable for masonry
surfaces for high rainfall zone. White cement primer shall be used as per manufacturer’s
recommendation.
TABLE-1
Note: DSR item references (DSR-2002) to be read with CPWD specifications are only for material and
workmanship guidance of the Contractors.
ix.Roof
Part -2 : Employer’s Requirements 156
Roof of the C.R. Building shall consist of Cast-in-situ RCC slab treated with a water proofing
system which shall be an integral cement based treatment conforming to CPWD specification (item
no. 25.8 of DSR 2002). The water proofing treatment shall be of following operations:
i.Applying and grouting a slurry coat of neat cement using 2.75 kg/m2 of cement admixed with
proprietary water proofing compounds conforming to IS: 2645 over the RCC slab including cleaning
the surface before treatment.
ii.Laying cement concrete using broken bricks/brick bats 25mm to 100mm size with 50% of cement
mortar 1:5 (1 cement: 5 coarse sand) admixed with proprietary water proofing compound
conforming to IS: 2645 over 20mm thick layer of cement mortar of min 1:5 (Cement: 5 coarse sand)
admixed with proprietary water proofing compound conforming to IS: 2645 to required slope and
treating similarly the adjoining walls upto 300mm height including rounding of junctions of walls
and slabs.
iii.After two days of proper curing applying a second coat of cement slurry admixed with proprietary
water proofing compound conforming to IS: 2645.
iv.Finishing the surface with 20mm thick joint less cement mortar of mix 1:4 (1 cement: 4 course sand)
admixed with proprietary water proofing compound conforming to IS: 2645 and finally finishing the
surface with trowel with neat cement slurry and making of 300 x 300 mm square.
v.The whole terrace so finished shall be flooded with water for a minimum period of two weeks for
curing and for final test. All above operations to be done in order and as directed and specified by
the Project Manager.
x.Glazing
The details of doors and windows of the control room building shall be as per finish schedule Table-
1 and tender drawing with the relevant IS code. Rolling steel shutters and rolling steel grills shall be
provided as per layout and requirement of buildings. Paints used in the work shall be of best quality
specified in CPWD specification.
Part -2 : Employer’s Requirements 157
1. All plumbing and sanitation shall be executed to comply with the requirements of the
appropriate byelaws, rules and regulations of the Local Authority having jurisdiction over such
matters. The Contractor shall arrange for all necessary formalities to be met in regard to inspection,
testing, obtaining approval and giving notices etc.
2. PVC syntax or equivalent make Roof water tank of adequate capacity depending on the number
of users for 24 hours storage shall be provided. Minimum 1 Nos. 500 liters capacity shall be
provided.
3. Galvanized MS pipe of medium class conforming to IS: 1239 shall be used for internal &
external piping work for potable water supply.
4. Sand CI pipes with lead joints conforming to IS: 1729 shall be used for sanitary works above
ground level.
(a) WC (Western type) 390 mm high with toilet paper roll holder and all fittings
Or
WC (Indian Type) Orissa Pattern (580 x 440 mm) with all fittings (both types of WCs shall be
provided at alternate locations).
(e) CP brass towel rail (600 x 20 mm) with C.P. brass brackets
7. All sanitary fixtures and fittings shall be of approved quality and type manufactured by well
known manufacturers. All items brought to site must bear identification marks of the type of the
Manufacturer.
Part -2 : Employer’s Requirements 158
8. Soil, waste and drain pipes, for underground works shall be stoneware for areas not subject to
traffic load. Heavy-duty cast iron pipes shall be used otherwise.
1. Dense concrete with controlled water cement ratio as per IS-code shall be used for all
underground concrete structures such as pump-house, tanks, water retaining structures, cable and
pipe trenches etc. for achieving water-tightness.
2. All joints including construction and expansion joints for the water retaining structures shall be
made water tight by using PVC ribbed water stops with central bulb. However, kicker type
(externally placed) PVC water stops shall be used for the base slab and in other areas where it is
required to facilitate concreting. The minimum thickness of PVC water stops shall be 5 mm and
minimum width shall be 230 mm.
3. All steel sections and fabricated structures that are required to be transported on sea shall be
provided with anti corrosive paint to take care of sea worthiness.
4. All mild steel parts used in the water retaining structures shall be hot-double dip galvanised. The
minimum coating of the zinc shall be 750 gm/sq. m. for galvanised structures and shall comply with
IS: 2629 and IS: 2633. Galvanizing shall be checked and tested in accordance with IS: 2633.The
galvanizing shall be followed by the application of an etching primer and dipping in black bitumen
in accordance with BS: 3416.
5. A screed concrete layer not less than 100 mm thick and of grade not weaker than M10
conforming to IS: 456-1978 shall be provided below all water retaining structures. A sliding layer of
bitumen paper or craft paper shall be provided over the screed layer to destroy the bond between the
screed and the base slab concrete of the water retaining structures.
6. Bricks having minimum 75kg/cm2 compressive strength can only be used for masonry work.
Contractor shall ascertain himself at site regarding the availability of bricks of minimum 75kg/cm2
compressive strength before submitting his offer.
7. Doors and windows on external walls of the buildings (other than areas provided, with insulated
metal claddings) shall be provided with RCC sunshade over the openings with 300 mm projection on
Part -2 : Employer’s Requirements 159
either side of the openings. Projection of sunshade from the wall shall be minimum 450 mm over
window openings and 750 mm over door openings.
9. Angles 45x45x5 mm (minimum) with lugs shall be provided for edge protection all round cut
outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe
trenches supporting covers, edges of manholes supporting covers, supporting edges of manhole
precast cover and any other place where breakage of corners of concrete is expected.
10. Anti termite chemical treatment shall be given to column pits, wall trenches, foundations of
buildings, filling below the floors etc. as per IS: 6313 and other relevant Indian Standards.
11. All rungs for ladder shall also be galvanised as per IS: 277 medium classes.
12. For all civil works covered under this specification, nominal mix by volume batching as per
CPWD specification is intended. The relationship of grade of concrete and ratio of ingredients shall
be as below:
------------------------------------------------------------------------------------------
2. M 15 1 2 4
3. M 20 1 1.5 3
------------------------------------------------------------------------------------------
The material specification, workmanship and acceptance criteria shall be as per relevant clauses of
CPWD specification and approved standard Field Quality Plan.
Part -2 : Employer’s Requirements 160
13. The details given in tender drawings shall be considered along with details available in this
section of the specification while deciding various components of the building.
14. Items/components of buildings not explicitly covered in the specification but required for
completion of the project shall be deemed to be included in the scope.
13.00 Interfacing
The proper coordination & execution of all interfacing civil works activities like fixing of conduits
in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of
supports/embedment, provision of cutouts etc. shall be the sole responsibility of the Contractor. He
shall plan all such activities in advance and execute in such a manner that interfacing activities do
not become bottlenecks and dismantling, breakage etc. is reduced to minimum.
(i) Contractor shall make its own arrangement for construction water.
(ii) The Contractor shall carry out all the plumbing/erection works required for supply of
water in control room building.
(iii) The details of tanks, pipes, fittings, fixtures etc for water supply are given elsewhere in the
specification under respective sections.
(iv) A scheme shall be prepared by the Contractor indicating the layout and details of water supply
which shall be got approved by the Project Manager before actual start of work including all other
incidental items not shown or specified but as may be required for complete performance of the
works.
(v) Bore wells and pumps for water supply are in the scope of Contractor meeting the day-
to-day requirement of the water supply.
(vi) If the water is supplied by Municipal Corporation then bore well for water supply
purposes is not required to be carried out by Contractor. Contractor shall also make necessary
arrangement /formalities to receive water connection from corporation.
(ii) The Contractor shall construct septic tank and soak pit suitable for 5 users if outside of
Municipal Corporation zone. Otherwise, all necessary arrangement for the disposal of sewerage to
the Municipal Corporation’s end shall be arranged by the Contractor at his own cost for regularizing
the disposal activity.
(iii) The septic tank and soak pit shall be constructed as per enclosed tender drawing.
a. Contractor shall comply with all the applicable statutory rules pertaining to factories act
(as applicable for the State). Fire Safety Rules of Tariff Advisory Committee, Water Act for
pollution control etc.
b. Provisions for fire proof doors, no. of staircases, fire separation wall, plastering on
structural members (in fire prone areas) etc. shall be made according to the recommendations of
Tariff Advisory Committee.
c. Statutory clearance and norms of State Pollution Control Board shall be followed as per
Water Act for effluent quality from plant.
d. Requirement of sulphate resistant cement (SRC) for sub structural works shall be
decided in accordance with the Indian Standards based on the findings of the detailed soil
investigation to be carried out by the Bidder.
e. Foundation system adopted by Bidder shall ensure that relative settlement and other
criteria shall be as per provision in IS: 1904 and other Indian Standards
f. All water retaining structures designed as un-cracked section shall also be tested for
water tightness at full water level in accordance with clause no. 10 of IS: 3370 (Part-I).
h. All underground concrete structures like water retaining structures etc. shall have
plasticizer cum water proofing cement additive conforming to IS: 9103. In addition, limit on
permeability as given in IS: 2645 shall also be met with. The concrete surface of these structures in
contact with earth shall also be provided with two coat of bituminous painting for water/damp
proofing. In case of water leakage in the above structures, Injection Method shall be applied for
repairing the leakage.
Part -2 : Employer’s Requirements 162
i. All building/construction materials shall conform to the best quality specified in CPWD
specifications if not otherwise mentioned in this specification.
j. All tests as required in the standard field quality plans have to be carried out.
17.00 Fencing
1. Size of mesh : 75 mm
ii.Posts
Angle Section
Intermediate : L 65 x 65 x 6
Straining posts : L 65 x 65 x 6
Stay post : L 65 x 65 x 6
1. All structural steel shall conform to IS: 2062 and shall be painted with a coat of approved steel
primer and two coats of synthetic enamel paint.
2. The Chain Link fabric shall be fixed to the post at the top and bottom of the fence by
welding/fixing 50 mm MS flat all through its length.
Part -2 : Employer’s Requirements 163
3. Fencing top shall be either of galvanised barbed wire or tape. Barbed wire shall conform to IS:
278.
4. The barbed wire may consist of not more than two splices per reel. The barbed wire shall be
formed by twisting two line wires, one containing the barbs. The barbed wire shall be designated as
A-4 IS: 278 and shall be galvanized.
5. Above chain link, 3-rows (6 nos) of barbed tape/wire shall be provided in each arm of the Y
shaped barbed arm at top.
6. With barbed tape/wire above the chain link fence, the total fence height shall be minimum 2500
mm above finished gravel level.
8. Tension wire: single strand, high tensile, galvanised steel wire, 4 mm diameter.
9. Fittings and hardware: cast aluminum alloy or galvanized steel, malleable or ductile cast iron
turnbuckles to be drop forged.
10. GI chain link mesh shall be as per IS: 2721. Mesh size 75 mm and nominal wire size shall be
4.0 mm diameter.
On the results of these additional tests, the whole or portion of the barbed wire/tape shall be
accepted or discarded by the Purchaser, as the case may be.
b. Installation
1. Contractor shall submit the fencing drawing Fence shall be installed along lines shown on
approved drawings.
3. Intermediate posts shall be spaced 2.5 m apart measured parallel to ground surface.
5. Straining posts shall be installed at sharp changes in grade, at corners, at change of direction
and where directed.
Part -2 : Employer’s Requirements 164
6. All corner post will have two-stay post and every tenth post will have a transverse stay post.
7. Posts shall be set in 1:2:4 plain cement concrete Blocks of minimum dimension 400 mm x 400
mm x 1000 mm deep Concrete work shall conform to relevant clause. Post shall be braced and held
in plumb position and true alignment and elevation until concrete has set.
8. Fence fabric shall not be installed until concrete has cured a minimum of 7 days.
9. Bottom and top of the fence fabric shall be fixed with MS flats of 50 mm x 6mm (min).
10. Fence fabric shall be laid out with barbed edge on top, stretched tightly and shall be fastened to
intermediate, post gate and straining post with 50 x 6 flats.
11. Fabric shall be secured to tension wires with tie wires at 400 mm intervals. Tie wires shall be
given not less than two twists.
14. Barbed tape shall be attached to barbed wire arms with approved metal clips.
15. Toe wall of one Brick/Random Rubble masonry, with notches over 75 mm thick PCC
(1:4:8) shall be provided below all fencing and shall be minimum 200 mm above and 200 mm below
finished ground level. All exposed surfaces of brick toe wall shall be provided with 1:6 cement sand
plaster and coated with two coats of colour wash with a base coat of white wash with lime. Rubble
masonry toe wall shall be with raised & cut pointing and 50 mm PCC (1:2:4) band coping.
1. Survey
1.1. Survey
The Contractor shall carry out a GPS based survey of existing bare conductor LT distribution
lines in the habitation. The Survey should cover Pole by pole survey of all the bare conductor
lines to identify the location of poles and phase configuration, pole condition, Existing stays /
struts, Existing street lamp connections, Location and capacity of the connected distribution
transformer (DTR) to each LT line, Connection points of any existing ABC lines connected to
the bare conductor lines should be identified. The length of such ABC lines and total service
connections provided through this line should be indicated on the map at this point, Load
readings for each LT feeder. Upon completion of the survey the Contractor is required to
develop the Single Line Diagram (SLD-A) indicating the survey Information and Schedule of
network survey information (Schedule – A).
1,1 kV voltage grade XLPE insulated aluminum conductor and aluminum alloy bare neutral
messenger type cables shall be used for proposed ABC conversions. The AB cables provided
shall fully comply with technical specifications provided in this tender document.
The following standard sizes of AB cables shall be used:
• ABC16-SP : 1X16 mm2 (ph)+1X25 mm2 (bare messenger cum neutral) +1x16 mm2 (insulated
street lighting cable)
• ABC50 : 3X50 mm2 (ph)+1x35 mm2 (bare messenger cum neutral) +1x16 mm2 (insulated
street lighting)
• ABC95 : 3X95 mm2 (ph)+1x70 mm2 (bare messenger cum neutral) +1x16 mm2 (insulated
street lighting)
As per ISS 162-1961 minimum electrical clearance from live part to earth and safety clearance in case of
different voltage must be kept as follows:
Voltage Electrical Clearance (mm) Safety Clearance in SIS (mm)
Phase - Earth Phase - Phase
33kV 381 432 2740
66kV 658 786 3050
AB cable should be installed on poles using anchoring and suspension clamps according to the
approved drawings by the Project Manager. Samples of complete clamp assemblies shall be
approved by the Project Manger prior to use.
Anchoring clamps shall be used at the beginning and end of each cable run, at a major change in
direction, terminal poles and at T-off points. Suspension clams shall be used at other
intermediate points.
It should be noted that different clamps are specified for cable ranges 25-50 sqmm and 70-95
sqmm. These have different dimensional and maximum load specifications. If ABC
manufacturer recommends any alternate clamps it should be approved by the Project Manger
prior to use.
Stainless steel straps and buckles shall be used for fixing pole brackets to the pole as shown in
drawings. Strap binding tool shall be used for tensioning and cutting the straps.
Separation of neutral messenger for tensioning and fixing to the clamp should be done using
plastic phase separators. Weather resistant black nylon ties should be used for typing insulated
conductors to the neutral messenger at either side of suspension clamps, to prevent the phase
conductors from chatting against suspension clamp.
Minimum clearance above ground to line shall be maintained. Sag tension charts for installing
AB cables shall be developed by the Contractor taking into consideration of cable
characteristics, maximum / minimum temperatures and maximum wind pressure as per service
conditions provided by Employer. Based on this clear guidelines shall be provided to linesmen
to ensure bare neutral messenger is pulled at appropriate tension so that;
(a) Required ground clearances are maintained, and
(b) Messenger conductor tension is maintained well below its breaking load at all temperatures.
Dynamometer method or sag method may be used to ensure appropriate tension of neutral
messenger during installation. Over tensioning of neutral messenger should be avoided to
ensure its tension does not exceed permissible loading limits at low temperatures. Loose spans
of AB cable should be avoided to maintain permissible maximum sag at high temperatures.
Loose spans may only be allowed for short spans in special cases. This applies when there are
practical difficulties to install necessary stays or struts as required at a t-off point. A short loose
span of AB cable may be used in this case to transfer the stay / strut support point upstream or
downstream of the line.
Part -2 : Employer’s Requirements 168
Stringing of AB cable shall be done using proper equipment such as stringing blocks with
plastic coated pulleys, pulling (come along) clamp, cable hoist and pulling tool, dynamometer
etc. Proper equipment recommended by the ABC manufacturer shall be used to avoid any
damage to the cable during installation. Temporary stays or strut poles shall be employed as
necessary during stringing operation to ensure safety of personnel and equipment.
Phasing of insulated conductors shall be identified by one, two and three ridges on the XLPE
insulation. Same phasing shall be maintained accordingly through the line. Interchanging of
phasing at any connection point is not permitted.
In order to ensure durability of AB cables and to prevent possibility of failures due to effects of
water treeing, any exposed parts of phase conductors or open cuts of insulation are strictly not
permitted. Hence all connectors to be used in ABC line shall be pre-insulated type or bare
connectors covered by heat shrinkable tubing or GelWrap sleeves. For installing connectors
proper equipment such as insulation stripping tool, ratchet cable cutter, hydraulic compression
tool with compression dies shall be used.
All cable ends shall be properly sealed by pre-moulded or heat-shrinkable type end caps.
Samples of all ABC accessories including connectors shall be approved by the Project Manager
prior to use.
Mid-span joints shall be generally avoided by properly planning stringing work. In exceptional
cases where mid span joint is required, pre-insulated compression connectors shall be used. The
joints for each phase shall be staggered along the cable. No mid-span joints are allowed for AB
cable sections running across a street.
Insulated piercing connectors or non-tension mechanical connectors with heat shrinkable tubing
shall be used for non-tension inline connections at anchoring points where necessary.
Earthing shall generally be carried out in accordance with the requirements of latest CEA
regulations (as amended from time to time) and the relevant regulations of the Electricity
Supply Authority
The Contractor shall ensure every 6th pole of ABC line including neutral messenger and any
metallic hardware is earthed with spike earth (20x2500 mm) as per existing practice of
Employer. (for normal soil).
Poles shall be earthed using 8 SWG (7/4.0 mm) GI wire with 1 No. Coil/Spike/Pipe earth.
Existing service cables shall be replaced with armored service cables only in certain specified
areas which are high theft prone areas. This will be specified by the Project Manger during
execution. No service cable replacements shall be carried out without the approval of Project
Manager.
In this case existing service cables shall be replaced with new armoured cables. Existing un-
armoured service cables shall be removed and returned to Employer warehouse. Any non-
standard supports used as supports for existing service cables shall also be removed.
New armoured service cables shall be drawn from the LT Distribution Box/SMC Distribution
Box upto the meter board as shown in drawings. The service wire is to be hanged on supportive
GI wire between pole support and the house. 7/3.15 mm (10 SWG) & 7/4.00 mm (8 SWG) GI
wires shall be used for single phase and three phase services respectively.
Before installing service wires and GI wire, GI pipe / MS Angle on the consumer premises is to
be erected using clamps/ nails/proper binding etc. In case of hut or poor structure at consumer
premises, GI pipe is to clamp on wooden planks/wooden structure existing in the house. The GI
pipe should be supported for neutralizing tension by means of GI tie wire support. In
pukka/brickwork/cement concrete foundations, house, GI support pipe is to be clamped by
means of MS clips.
New service cable shall be connected to existing consumer meter terminals or incoming fuse /
MCB / MCCB terminals. Care should be taken not to damage the existing meters in the process.
20mm dia PVC conduit pipes shall be used to take down service cable from the roof to the
meter box along the walls. The service cable shall be drawn inside PVC pipes from roof upto
the meter board.
Terminal cover of the meter or fuses shall be sealed upon connection of new service cable as
arranged with the Employer.
Earth terminal point shall be provided at meter board via bearer GI wire. This point shall be
connected with the proper earthing system through GI wire. 10mm diameter earth knob in form
of bolt and nut is to be installed on energy meter board.
All work required to install service cable from LT Distribution Box/SMC Distribution Box upto
the meter board shall be carried out as per drawings. This includes GI wire for supporting
service cables from LT Distribution Box/SMC Distribution Box upto the consumer premises,
MS angle fixed at roof, clamp with bolts nuts and flat iron for fixing GI wire on pole, clamps
Part -2 : Employer’s Requirements 172
for fixing cable to GI wire, PVC conduit pipes and accessories to draw the service cable from
roof upto the meter board.
Contractor
6. Installation of Poles
6.1. Types of pole installation works for ABC conversions
The following types of pole installation works applicable for ABC conversions as per site
requirements specified in the table below;
7. Erection of Poles
7.1. Removal of existing poles for re-use or disposal
Part -2 : Employer’s Requirements 173
All unusable poles or non-standard line supports in the existing LT lines shall be removed and
disposed. If the existing pole is removed for re-use adequate measures should be taken not to
damage the pole during removal.
Existing poles shall be removed by pulling the complete pole from the ground; poles shall not
be cut off at the ground line. Pole shall be cleaned and any material attached with the pole
(including concrete) shall be removed. The RCC base plate may be removed and re-used if it is
in re-usable condition.
Pits shall be backfilled and compacted completely with sufficient added backfill piled above
grade to prevent depressions being created by natural compaction.
Contractor shall be responsible for disposal of unusable poles or non-standard line support
structures after taking approval of the Project Manager/ Engineer In- Charge of the Employer.
If there are no existing stays installed at such locations in the existing line, such poles shall be
identified and included in Schedule-B for installation of new stays. In addition required stays
for proposed new and relocated poles shall also be included.
10 SWG stay wire (7/ 3.15 mm) with 16 mm stay rod shall be used for 11 kV / LT lines. Stay
shall be installed in the opposite direction of resultant force due to AB cable tension in order to
nullify the same.
If the stay wire proves to be hazardous, it should be protected with suitable asbestos pipe filled
with concrete of about 2 m length above the ground level, painted with white and black strips so
that, it may be visible at night.
In general, the stay should be applied on the pole as close as possible to the load center. The
angle between stay wire and pole shall be between 45o – 60o. Where there are issues obtaining
specified angle due to physical obstacles, bow (outrigger) stay arrangement may be considered
with the approval of the Project Manager. In case of critical space issues, fly stays may also be
considered subject to approval of the Project Manager. (Reference : REC Drawing # G4).
Concreting of stay pit shall be done as shown in drawings except for firm soil where
compacting with necessary aggregates shall be done.
Stay wire shall be properly tightened after installation and allowing sufficient time for setting
concrete. Contractor shall ensure all stays in the existing line are properly tightened including
new and existing stays.
Part -2 : Employer’s Requirements 175
Shut down shall be planned with concerned substation incharge well in advance. This may
subject to exigencies leading to cancellation of requisition if situation so desire. Contractor shall
be responsible to take advance action on resource mobilization (men, materials and machine)
well in advance to perform shut down works. Adequate manpower shall be mobilise so as to
take-up the works in parallel at ll supports on given shut-down area. Contractor shall deply well
educated and experience engineer to take care of shut down, eand earthing of lines, check
clearances on completion of works, return shut down and ensure re-energisation of section/part
of line. He shall be available at site for taking shut-down, during execution of works, return of
shut down and re-energisation of line. Safety of working crew shall be looked after by him. He
must be a trained person having requisite experience of shut-down works. He must be well
aware of LT/HT networks and their supply sources.
Upon completion of the survey the Contractor shall provide a survey report with the
following information;
• Single line diagram of the route survey and proposed line alignment details mapped and
provided in a standard mapping software. This should also include information such as
existing electrical infrastructure and PTW information.
• Road and railway crossing points of the proposed 11 kV line shall be marked on the
single line diagram.
• Line sections proposed for 11 kV AB (Ariel Bunched) cables due to vegetation, safety
and forest clearance issues (if applicable) shall be marked on the single line diagram.
Lengths of proposed AB cable line sections shall be indicated.
• Schedule of location wise pumps to be fed through new feeder or alternatively general
consumer distribution transformers to be transferred to new feeder for making dedicated
feeder for agricultural consumers. This schedule should include location / capacity of the
existing distribution transformers to be transferred and location /capacity and load of
agriculture PTWs with reference to the locations of the single line diagram.
• Estimated peak demand on each feeder/s upon implementation and percentage voltage
regulation at farthest point on various spur sections.
• Single line diagram of the 33/11 kV substation indicating of 11 kV outgoing feeder to
connect the new feeder. If existing spare feeder is unavailable list of works to be
performed at the substation to install additional new feeder.
The survey report shall be submitted in a suitable format for uploading to the web portal
and for printing.
The survey report will be used as the basic document for execution of work upon
approval by the Project Manager. Upon completion of work, as built single line diagram
shall be provided with relevant information of the works carried out.
• On the survey drawings Line to line crossing (HT/LT, LT/LT, HT/HT/Railways Crossing
) details to be marked with available clearances.
• Efforts shall be taken to avoid long zig-zag lines and too many line-to-line crossing while
surveying and finalizing route maps/SLD.
For execution of new 11 KV line construction work, all statutory clearances shall be obtained
by the Contractor coordinating through the Project Manager. These include road crossing
clearances, railway crossing approvals, way leave clearance and any approvals needed from
local authorities, road authorities and other regulatory authorities. All statutory clearances
shall be ensured for ground clearance, line-to-line clearance, road crossing clearance,
horizontal and vertical clearances from buildings/objects etc. All road crossings and line
crossings shall be guarded as per specifications. Conductor joint should not be provided in
mid span length. Instead, it should be nearer to the support.
Based on this, clear guidelines shall be provided to linesmen to ensure ACSR conductors or
bare neutral messenger (for AB cables) are pulled at appropriate tension so that;
(a) Required ground clearances are maintained and
(b) Conductor tension is maintained well below its breaking load at all temperatures.
2 Nos. separate cables shall be laid in separate HDPE pipe enclosures per crossing. One cable
to be kept as a spare. Horizontal Direct Drilling (HDD) shall be used for installation of cables
below the railway tracks.
The detailed survey shall be carried out for the approved feeders/spur lines by the Contractor and
submitted for Employer’s approval. The Successful Tenderer shall carry out radar survey of the
route using Ground penetrating Radar and determine route profile of any other utility cables,
pipes etc along the route. The route survey and drilling profile shall be got approved and
finalized by the Engineer-in-Charge prior to commencement of the drilling, HDPE pipe insertion
and cable insertion.
3.2. The Horizontal drilling shall be for a distance of not less than 90 mts at each stretch and
subsequently thereafter. The reinstatement of road dug up for drilling at every 90 mts shall be
incorporated in the price for Horizontal Directional Drilling.
3.3. Disposal of extra excavated material such as mud, slurry, stones etc shall be also included in the
rate per meter of horizontal drilling and shall not be charged extra.
3.4. The trenchless technology shall be used with HDPE casing for the portion of the cable route such
as road, railway, nullah crossing and without HDPE casing for major portion of the cable route.
The outer diameter of the HDPE pipe shall be suitable for insertion in an 8” diameter
horizontally drilled bore. The HDPE pipe shall be of PE 80 grade with pressure rating PN4
conforming to IS 4984/1995 and shall have wall thickness of 6.20 to 7.10 mm. The HDPE pipes
shall be joined by using Butt welding and a 7/20 G.I wire shall be provided along the entire
length of each pipe duct.
3.5. The directional drilling equipment shall consist of a directional drilling rig of sufficient capacity
to perform the bore and pull back the pipe/cable, a drilling fluid mixing, delivery, and recovery
system of sufficient capacity to successfully complete the installation, a drilling fluid recycling
system to remove solids from the drilling fluid so that the fluid can be reused (if required), a
magnetic guidance system or walk over system to accurately guide boring operations, a vacuum
truck of sufficient capacity to handle the drilling fluid volume, and trained and competent
personnel to operate the system. All equipment shall be in good, safe condition with sufficient
supplies, materials and spare parts on hand to maintain the system in good working order for the
duration of this project.
3.6. The directional drilling machine shall consist of a hydraulically powered system to rotate and
push hollow drilling pipe into the ground at a variable angle while delivering a pressurized fluid
mixture to a guidable drill (bore) head. The machine shall be anchored to the ground to withstand
the bulling, pushing and rotating pressure required to complete the installation. The hydraulic
power system shall be self-contained with sufficient pressure and volume to power drilling
operations. Hydraulic system shall be free of leaks. Rig shall have a system to monitor and
record maximum pullback pressure during pullback operations.
3.7. There shall be a system to detect electrical current from the drill string and an audible alarm
which automatically sounds when an electrical current is detected.
3.8. The drill head shall be steerable by changing its rotation and shall provide necessary cutting
surfaces and drilling fluid jets.
3.9. Mud motors shall be of adequate power to turn the required drilling tools.
3.10. Drill Pipe shall be constructed of high quality 4130 seamless tubing, grade D or better, with
threaded box and pins. Tool joints should be hardened to 32-36 RC.
4. Accessories
4.1. This being a Turnkey contract, successful installation, commissioning & integration with
existing system, of those equipment/accessories/material not specifically mentioned in the
Part -2 : Employer’s Requirements 181
specifications, shall be the responsibility of Contractor. No extra payment shall be made for these
inherent works.
4.2. He shall also supply all other associated equipment/ material/accessories not specifically
mentioned in this tender specification but are required for successful and trouble free operation
of the executed work as a whole. For that no extra payment shall be made to the Contractor.
5. Technical Standards
5.1. The electrical equipments and materials required during erection should be of high standard.
Technical features of these equipments and materials must conform to the technical specification
given in this bidding document. Wherever the same is not specified, it must conform to the
relevant I.S for that material.
5.2. Materials conforming to other international standards, which ensure equal or higher quality than
the standards mentioned above, shall also be acceptable. In case the bidders who wish to offer
materials conforming to other standards, salient points of difference between standards adopted
and specific standards shall be clearly brought out in the respective schedule. Four copies of such
standards with authentic English version shall be furnished along with the offer.
5.3. Whenever a material or an article is specified or described by the name of a particular brand,
manufacturer or trade mark, the specific item shall be understood as establishing type, function
and quality desired. Products of other manufacturers may also be considered, provided sufficient
information is furnished, so as to enable the Employer to determine that the products are
equivalent to those mentioned.
5.4. Materials supplied/used shall conform in all respects to the relevant Indian Standard
Specification with latest amendments there to.
Title IS No.
1. Cement IS 269
2. Steel IS 6003/1970
3. Fasteners IS 6639/1972
4. Concrete mix IS 1343
5. RCC IS 456
6. Cable laying and jointing IS 1255
Installation work pertaining to equipment, cable laying etc should be in accordance with the
applicable standards, safety codes etc.
7.13. Precaution: The Contractor shall exercise all possible care to avoid damage to public utilities
e.g. water/ sewage pipes telephone and power lines/cable already existing. In case of any
accidental damage during the work, the Contractor shall be responsible to repair/replace the same
at his own cost, and shall ensure that the purchaser is not put to any loss.
7.14. The Contractor shall have to provide proper lighting, barricading, signboards etc. at the work
site as a necessary precautionary arrangement to avoid accident/ damage/ losses to the public
/utilities/properties.
7.15. Site Solution: It may be possible due to some reasons or others that it would not be possible to
work as per the procedure. In such case/cases, the solution to the problem shall be achieved by
the purchaser with the consultation of Contractor, and the Contractor shall work as per procedure
proposed by the purchaser. Such cases shall in variably be informed to the engineer of the
contract for which no extra payments shall be made.
7.16. Space Constraints: While executing the job it is quite possible that some of the specified work
may not be carried out due to space/land/ other technical constraints etc. In such case the
concerned Employer, if required, may divert this work at some other site or cancel the left over
portions of work.
7.17. The Contractor shall ensure that the equipment under erection as well as the work area and the
site are kept clean to the satisfaction of the Engineer. In case, the Engineer is not satisfied about
the cleanliness he will have the right to carry out the cleaning operations and expenditure
incurred in this regard will be to Contractor’s account. Packing cases and packing materials shall
be promptly cleared from sites.
Part -2 : Employer’s Requirements 184
1.1.2. The Contractor shall be fully responsible for completing all the above works and till them
are taken over by the Employer.
1.1.3. The methods of erection are dealt within details, but are left to the Contractor who shall
exercise his own judgment with regards to actual handling of materials and in deciding upon the best
methods to be adopted in the erection of the towers, conductors and other materials.
be got insured for storages and erection risk by the Contractor at his own cost. An indemnity
Bond/Bonds have to be issued by the Contractor for the materials take over by him for erection.
1.4.2. On completion of the work all surplus tower and line materials including the excess Bolts
& Nuts and stub materials shall be returned by the Contractor to the nearest respective stores of the
Employer as per the instructions of the Engineer-in-charge of the works at no extra cost to the
Employer.
1.4.3. The Contractor shall submit the complete material account immediately after the works is
completed and in case not late than one month of completion and Handing over of the line.
1.5.5. CONCRETE :
1.5.5.1. The cement required shall be supplied by the Contractor approved by the Employer
1.5.5.2. All cement is used shall be accountable. If the quantity of cement utilized in the work is
observed to be more than the permissible quantities worked out bases on the finally approved
foundation drawings and subject to the maximum as per the guaranteed volumes, irrespective of the
fact that the cost of cement is recovered from the Contractor’s Bills.
Part -2 : Employer’s Requirements 186
The cement consumption for difference types of concrete shall be considered as follows:-
1. M-20 Mix (1:1.5:3) 8.2 bags.
2. M-15 Mix (1:2:4) 6.5 bags.
1.5.5.3. The sand shall be of best quality containing hard siliceous materials, clean and of snap
angular grit type and free from earth or organics matter of salts and to the satisfaction of the
Engineer-in-charge. The sand shall be washed before use. No. salty or Darkish water shall be used
for concreting.
1.5.5.4. The aggregate shall be of the best quality to the satisfaction of the Engineer-in-charge and
brakes to maximum size of 40mm for thick concrete and 20mm thin concrete section. It should also
be free from grit and dirt.
1.5.5.5. The mixture of concrete to be used shall be such as to produce a sound : compact and water
proof concrete and shall not be weaker than 1:2:4 ratio with 20mm stone metal for chimney portion
and 40mm stone metal for mass concreting pyramid portion or slab portion, unit rates may be quoted
for concrete of M-15 Mix ratio. The concrete shall be mixed as stiff as the requirements of placing
the concrete in the form of moulds with case and degree to which concrete resists segregations will
permit. Hence the quantity of water used should not be too much.
1.5.5.6. Proper forms or moulds adequately braced to retain proper shape while concreting should
be used for chimney or pyramid and slab portions. Form boxes should be water tight so as not to
allow cement cream to come out leaving only sand and jelly to form money coml. in concrete. Form
excess boxes should be cleaned and oiled before using for concreting.
1.5.5.7. All wet locations must be kept completely dewatered both during the placing of concrete
and for 24 hours after completion. There should be no disturbance of concrete by water during this
period.
1.5.5.8. Form boxes should not be removed before 24 hours after concreting. Concrete surface
where required should be set right with tick cement and mortar immediately after removal of the
forms.
1.5.5.9. After 24 hours of pouring, the concrete should be cured by keeping it continuously wet for
14 days. The pit may be back filled with selected earth sprinkled with necessary amount of water and
well consolidated layers not exceeding 150mm after 48 hours and thereafter both the exposed top
and the fill shall be kept wet for the remainder of the prescribed time.
1.5.5.10. Payment for the quantity of excavation and concreting for each type of tower shall be made
on prorate basis of actual work done subject to the maximum of guaranteed volumes as per the
approved drawings to be furnished by the purchaser.
1.5.5.11. The supply of steel for reinforcement, if required is to be supplied by the Contractor
1.5.6. EXCAVATION IN ROCK :
1.5.6.1. Where towers are to be planted in rock, suitable holes should be drilled, but if drilling is
difficult, blasting may be resorted to, but sufficient care should be taken to eliminate the possibility
of serious cracking of the rock.
1.5.6.2. Care should also be taken to minimize the concreting for filling blasted areas. Stubs may
be shortened suitably in case of drilled holes as per design drawings.
Part -2 : Employer’s Requirements 187
1.7. GROUNDING :
1.7.1. It is necessary that in no case tower footing resistance should be more than 10 ohms.
During dry weather.
1.7.2. PIPE TYPE EARTHING :
1.7.2.1. At location where footing resistance does not exceeds 10 ohms the pipe type earthing as
per method specified by Employer would be followed. The Contractor will have to supply all
materials required for grounding including salt, finely broken coke/charcoal, G.I. Pipe G.I. Wire
clamp & Nuts-Bolts etc.
1.7.3. COUNTERPOISE EARTHING :
1.7.3.1. In place of high receptivity soil conditions, counterpoise earthing shall be adopted as per
Employer specifications to bring down the tower footing resistance below 10 ohms. The
counterpoise earthing shall be buried 600mm below ground level and for this purpose some space
should be left out in chimney coping portion at the time of stub setting. Coping should be complete
after installation of counterpoise earthing. All materials are to be supplied by the Contractor.
with each clamping bolt and in correct vertical position in relation to conductor. Compression type
joints are to be used for jointing of conductors. Each part connected with joints shall be perfectly
cleaned by wire brush and properly greased before final compression. All the joints of conductors
and earth wire shall be made in the best workmanship manner and shall be perfectly straight and
having maximum possible strength.
1.9.10. Stringing work includes the hoisting insulators, fixing hardware, lifting amour rods, and
vibration dampers, making joints, repair sleeve etc. All stringing tools and hydraulic compressor
machine should be arranged by the Contractor.
1.0 SCOPE
The specification covers the design, engineering, manufacture, stage inspection, testing, pre-
delivery inspection, supply, delivery, loading, unloading and performance requirements of 11/0.433
KV non-sealed type aluminum and copper wound distribution transformers for outdoor use. The
transformers shall be double wound, three phase, oil immersed with ONAN cooling. The rating
required under this specification is 500 KVA with copper windings.
The equipment offered should have been successfully type tested within five years from date of
tender and the designs should have been in satisfactory operation for a period not less than three
years as on the date of bid opening. Compliance shall be demonstrated by submitting with the bid,
(i) authenticated copies of the type test reports and (ii) performance certificates from the users,
specifically from Central Govt./ State Govt. or their undertakings.
The scope of supply should also include the provision of type tests on random samples if desired by
the purchaser. In this case the bidder has to bear the charges for conducting such type tests at CPRI
or National Govt. approved Laboratory.
The transformer shall conform in all respects to highest standards of engineering, design,
workmanship, this specification and the latest revisions of relevant standards at the time of offer
and the Purchaser shall have the power to reject any work or material, which, in his judgment, is not
in full accordance therewith.
Environmentally, the region where the equipment will be installed includes coastal areas, subject to
high relative humidity, which can give rise to condensation. Onshore winds will frequently be salt
laden. On occasions, the combination of salt and condensation may create pollution conditions for
outdoor insulators.
Therefore, outdoor material and equipment shall be designed and protected for use in exposed,
heavily polluted, salty, corrosive, tropical and humid coastal atmosphere.
PART 2: TECHNICAL
SPECIFIC TECHNICAL REQUIREMENTS
9
2 Over Voltage operating capability and 112.5 % of rated
0 duration voltage
(continuous)
2 Maximum Flux Density in any part of the core and yoke at rated KVA, 1.5 Tesla
1 rated voltage i.e. 11 KV / 0.433 KV and system frequency of 50 HZ
bushings
(Antifog type)
2 Insulation level of bushing HV LV
9
a) Lightning Impulse withstand (KVP) 75 Not applicable
b) 1 Minute Power Frequency withstand 28 3
voltage (KV –rms )
c) Creepage distance (mm) (minimum) 25 mm/ KV
3 Material of HV & LV Conductor Electrolytic
0 Copper for 500
KVA
3 Maximum current density for HV and LV 1.4 Amp/ mm2 for
1 winding for rated current Aluminum
windings and 2.4
Amp/ mm2 for
Copper windings.
3 Polarisation index i.e ratio of megger values at 600 sec. to 60 sec for HV Shall be greater
2 to earth, L.V to earth and HV to LV. than or equal to 1.5,
but less than or
equal to ‘5’.
3 Core Assembly Boltless type
3
3 Maximum permissible No Load and Load 500 KVA
4 Losses (Watts)
a) No Load Losses at rated voltage and rated - 950
frequency
b) Load Losses at rated current and at 750 C - 6500
The transformer shall be capable of supplying a continuous load equal to its KVA rating, under the
following conditions:
• continuous steady load;
• design at maximum ambient air temperature of 500C;
• 400 C average winding temperature rise and 350C top oil temperature rise for conventional
breathing transformers.
The transformer may be overloaded during emergency up to 150% of its continuous rating in
accordance with IEC Publication 354 or IS: 6600. Bushings and other current-carrying parts shall
also be designed for this condition.
The transformer shall be capable of withstanding for two seconds without damage to any external
short circuit, with the short circuit MVA available at the terminals of either winding with rated
voltage on the other winding. If short circuit tests have been carried out on the particular design of
transformer offered, the test results shall be supplied with the bid.
The transformer shall be capable of withstanding the thermal and dynamic effects of short circuits,
as specified in IEC 76-5 or IS: 2026: Ability to withstand short circuits.
The maximum flux density in any part of the core and yoke at rated KVA, Voltage and frequency
shall not exceed 1.5 Tesla.
The bidder shall state in the technical schedule, the percentage regulation at full load, power factor
1.0 and at full load, power factor 0.8 lagging.
Transformers shall be suitable for parallel operation with each other.
8.0 PERCENTAGE IMPEDANCE
The Percentage of Impedance at 75ºC shall be 5% for 500 KVA transformer with positive tolerance
of 10%. No negative tolerance on percentage Impedance is allowed.
9.0 LOSSES
The No Load and Load Losses shall not exceed the values given below:-
The above losses are maximum allowable and there should not be any positive tolerance.
The offered transformer(s) should have been type-tested at CPRI/ National Govt. approved
laboratory. The bid shall be accompanied with type-test reports (short circuit test and Impulse test)
conducted at Central Power Research Institute / National Govt. approved laboratory for the offered
transformers within five years from date of tender. The short circuit test report(s) must contain the
measured no load loss and load loss, determined by CPRI/ National Govt. approved laboratory.
In case of any doubts, <EMPLOYER> reserves the right to verify the original type test reports of
CPRI/ National Govt. approved Laboratory or ask the supplier to conduct the type tests at CPRI/
National Govt. approved Laboratory at his (supplier’s) cost for re-confirmation of the test results
particularly no load losses, load losses and percentage impedance. Bids without type test reports
shall not be considered for evaluation.
If the bidder quotes lower values of losses than the CPRI’s measured losses, he has to prove the
same by conducting the Impulse & short Circuit tests at CPRI/ National Govt. approved laboratory
along with measurement of no load losses and load losses at his own cost in presence of
EMPLOYER’ s authorized representative without any financial liability to EMPLOYER.
However, if the loss figures will exceed the stipulated values as per specification, the transformer(s)
shall be out rightly rejected.
Part -2 : Employer’s Requirements 198
The LV neutral shall be brought out to a terminal bushing, which shall be identical to the phase
bushings in all respects.
• Stage level inspection for core construction shall be carried out by the Employer.
• Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure
and the action of hot transformer oil.
• The core shall be constructed from high grade, non-ageing, Cold Rolled Grain Oriented silicon
steel laminations (CRGO or M3 or better) only. No other core materials shall be entertained.
Bidders are requested to note that only PRIME CORE materials are to be used. In no case, second
grade core material is to be used. The bids should contain copies of invoices towards purchase of
core laminations along with test certificates and curves of specific core loss of the laminations
proposed to be used.
The purchaser at his discretion, may select samples from the core laminations and get the same
tested in CPRI/ Approved National Govt. Laboratory to prove the quality of the core material.
• For the above purpose, the supplier shall have to offer every batch of core laminations received
from his Sub-Vendor along with Invoice of the sub-vendor, Mills test certificate, packing list, Bill
of lading, Bill of entry certificate to customs etc. towards proof of prime core materials for
verification by the Purchaser’s representative without any cost to the Purchaser. Besides, the
Contractor must mention in his bid about the type of CRGO lamination to be utilized for the offered
transformers along with a copy of the specific core loss curve at different flux densities.
• Core materials should be directly procured either from the manufacturer or through their
accredited marketing organization of repute, but not through any agent. The core and winding shall
be capable of withstanding shocks during transport, installation and service. Provision shall be
made to prevent movement of the core and windings relative to the tank during these conditions and
also during short circuits.
• The design shall avoid the presence of pockets which would prevent the complete emptying of
the tank through the drain valve. The core material offered in the tender to be checked for its
correctness before core coil assembly. For this, the tenderer must ask for core and coil inspection
before its tanking.
• The laminations shall be free of all burrs and sharp projections. Each sheet shall have an
insulting coating resistant to the action of hot oil.
• The insulation structure for the core to bolts and core to clamp plates, shall be such as to
withstand 2000 V DC voltage for one minute.
• The completed core and coil shall be so assembled that the axis and the plane of the outer
surface of the core assemble shall not deviate from the vertical plane by more than 25mm.
• All steel sections used for supporting the core shall be thoroughly shot or sand blasted, after
cutting, drilling and welding.
• The finally assembled core with all the clamping structures shall be free from deformation and
shall not vibrate during operation.
• The core clamping structure shall be designed to minimize eddy current loss.
• The framework and clamping arrangements shall be securely earthed.
Part -2 : Employer’s Requirements 200
• The core shall be carefully assembled and rigidly clamped to ensure adequate mechanical
strength.
• Oil ducts shall be provided, where necessary, to ensure adequate cooling inside the core. The
welding structure and major insulation shall not obstruct the free flow of oil through such ducts.
• The design of magnetic circuit shall be such as to avoid static discharges, development of short
circuit paths within itself or to the earth clamping structure and production of flux component at
right angle to the plane of the lamination, which may cause local heating. The supporting
framework of the cores shall be so designed as to avoid the presence of pockets, which would
prevent complete emptying of the tank through the drain valve or cause trapping of air during
filling.
• The construction is to be of boltless core type. The core shall be provided with lugs suitable for
lifting the complete core and coil assembly. The core and coil assembly shall be so fixed in the tank
that shifting will not occur during transport or short circuits.
INTERNAL EARTHING
• All internal metal parts of the transformer, with the exception of individual laminations and
their individual clamping plates shall be earthed.
• The top clamping structure shall be connected to the tank by a copper strap. The bottom
clamping structure shall be earthed by one or more the following methods:
Windings
• Winding shall be subjected to a shrinking and seasoning process, so that no further shrinkage
occurs during service. Adjustable devices shall be provided for taking up possible shrinkage in
service.
• All low voltage windings for use in the circular coil concentric winding shall be wound on a
performed insulating cylinder for mechanical protection of the winding in handling and placing
around the core.
Part -2 : Employer’s Requirements 201
• Winding shall not contain sharp bends which might damage the insulation or produce high
dielectric stresses. No strip conductor wound on edge shall have width exceeding six times the
thickness.
• The winding insulation shall be free from insulating compounds which are liable to soften,
ooze out, shrink or collapse. It shall be non catalytic and chemically inert in hot transformer oil
during normal service.
• The stacks of windings are to receive adequate shrinkage treatment.
• The windings and connections are to be braced to withstand shocks during transport, switching,
short circuit or other transient conditions.
• Permanent current carrying joints in the windings and leads shall be welded or brazed.
Clamping bolts for current carrying parts inside oil shall be made of oil resistant material which
shall not be affected by acidity in the oil steel bolts, if used, shall be suitably treated.
• Terminals of all windings shall be brought out of the tank through bushings for external
connections.
• The windings shall be uniformly insulated and the L.V neutral points shall be insulated for full
voltage.
• The completed core and coil assemble shall be dried in vacuum at not more than 0.5mm of
mercury absolute pressure and shall be immediately impregnated with oil after the drying process to
ensure the elimination of air and moisture within the insulation. Vacuum may be applied in either
vacuum over or in the transformer tank.
• The winding shall be so designed that all coil assembles of identical voltage ratings shall be
interchangeable and field repairs to the winding can be made readily without special equipment.
The coils shall have high dielectric strength.
• Coils shall be made of continuous smooth high grade electrolytic copper or aluminium
conductor shaped and braced to provide for expansion and contraction due to temperature changes.
• Adequate barriers shall be provided between coils and core and between high and low voltage
coil. End turn shall have additional protection against abnormal line disturbances
• The insulation of winding shall be designed to withstand voltage stress arising from surge in
transmission lines due to atmospheric or transient conditions caused by switching etc
• Tapping shall not be brought out from inside the coil or from intermediate turns and shall be so
arranged as to preserve as far as possible magnetic balance of transformer at all voltage ratios.
• Magnitude of impulse surges transferred from HV to LV windings by electromagnetic
induction and capacitance coupling shall be limited to BIL of LV winding.
• The winding conductor shall be of Al. up to 250 KVA transformers and copper for 500 KVA
Transformers. The current density shall not exceed 1.4 Amp/ mm2 for aluminium and 2.4 Amp/
mm2 for copper at normal full load current.
Bushings
• Bushings shall be of the outdoor type and easily replaceable. Cemented in types will not be
accepted. They shall be sufficiently robust to withstand normal transport and erection hazards and
shall confirm to IEC 137 /IS 3347 and 2099.
• All bushings shall have a minimum creepage distance of 25 mm /KV and shall have a
continuous rating of 200% of the transformer rating. The protected creepage distance shall not be
less than 50% of the total.
Bushing Labels
• The HV bushings shall be labeled U, V and W and the LV bushing u, v, w and n. Marking
letters shall be at least 12 mm high. The means of marking shall be either,
❖ engraved metal plate; or
❖ etched anodized aluminum.
Phase identification by adhesive stickers shall not be acceptable.
• If labeling is to be carried out on the tank, it is preferred that one plate be used rather than
individual markings for each phase, in order to prevent incorrect phase markings. Labels shall
conform to the requirements of the section on labels in this specification.
Earthing Terminals
Part -2 : Employer’s Requirements 203
All transformers shall be provided with two earthing terminals conforming to relevant Standards
and M12 ISO metric bolt and nut which shall be non ferrous. It shall include a spring washer and
lock washer.
18.0 LIGHTNING ARRESTORS
9 KV, 5KA metal oxide lightning arresters of reputed make conforming to IS-3070 Part- III, one
number per phase shall be provided.(Under the HV bushing with GI earth strip 25x4 mm connected
to the body of the transformer with robust clamping arrangement). Lightening arrestors with
polymer insulators in conformance with relevant IEC can also be used.
19.0 TANK FABRICATION
All transformer sizes, the tank shall be of bolted type construction in accordance with IS 1180 (Part
2).
• The tank shall be at atmospheric pressure at an internal temperature of 100 C;
• The tank shall be designed for an internal pressure of 100 Kg/ m2 at 500 C ambient conditions.
It shall be capable of withstanding an unlimited number of 24 hours cyclic variations of internal
pressure from atmospheric to this value.
• The tenderer shall state the top oil temperature at which the tank internal pressure shall reach
the value of 100 kN/ m2 and the value of steady load which will result in this top oil temperature
with an ambient temperature of 450 C.
• Adequate space shall be provided at the bottom of the tank for collection of sediments.
Transformer tanks of all types shall be designed so that the completed transformer can be lifted and
transported without permanent deformation or oil leakage. Stiffeners provided on all the four side
walls for rigidity should be so designed that there is no accumulation of water.
The Tank shall be of rectangular shape with round edges fabricated from tested quality mild steel
plates with minimum thickness of 3.15 mm. for the side walls while top cover and the bottom plate
of the tank shall have a minimum thickness of 5 mm. The transformer tank and the top cover shall
be designed in such a manner as to leave no external pockets in which water can log, or any internal
pocket where air/ gas can accumulate.
All sealing washers / gaskets shall be made of oil and heat resistant neoprene rubber or neoprene
bonded cork seals suitable for temperature as stipulated in this specification. Surfaces at gasketted
joints shall be such that an even face is presented to gasket, thereby eliminating the necessity for the
gasket to take up surface irregularities.
All pipes, radiators, stiffeners or corrugations which are welded to the tank wall shall be welded
externally and shall be double welded wherever possible. All welds shall be stress relieved.
Part -2 : Employer’s Requirements 204
The transformer tank shall be complete with all accessories, lifting lugs etc. and shall be designed to
allow the complete transformer filled with oil to be lifted by crane or jacks without risk of any
damage and can be transported by Rail/ Road without straining any joints and without causing any
leakage of oil.
All transformers shall be fitted with a silica gel breather of weatherproof design at a convenient
height with oil seal at the bottom, draw in plug and filling holes with covers to isolate the silica gel
from the atmosphere. The breather pipe should be connected at top of the conservator tank with two
bends at right angles. The cover of the main tank and bushings turrets shall be provided with air
release plug to enable the trapped air to be released.
23.0 FITTINGS AND ACCESSORIES
The following standard fittings and accessories shall be provided:
• rating, diagram and terminal marking plate.
• two earthing terminals .
• lifting lugs/ platform lugs.
• pressure relief device in form of explosion vent.
• silica gel breather. (1 Kg for 500KVA)
Part -2 : Employer’s Requirements 205
• filling and drain / sampling plugs ( A single drain / filling plug shall consist of a 20 mm pipe
inside the transformer tank, starting from the bottom and projecting to the top cover with a
hermetically sealed / welded plug).
• a magnetic or prismatic oil level gauge for all transformers indicating three position of oil i.e.
minimum. 5 0C, 30 0C and 98 0C.
• A thermometer pocket with thermometer with screwed top to prevent ingress of water or
leakage oil.
• Inlet valve having p-30 mm thread (with cover) on the transformers body/ conservator.
• Drain valve 12 mm size for draining the conservator oil with locking arrangement.
• Top filter valve (25 mm with adopter for 16 mm hole) with plug.
• Bottom filter valve with drain Plug.
• Air release plugs at transformer top cover, bushing turrets etc.
• Lightning Arresters (LA) for HT bushing.
• Set of Radiators.
• Conservator Tank.
Bi-metallic terminals on the bushings for connection with over head ACSR/ AAAC conductor (For
HV & LV).
The Specification and brief details of the salient features of these terminals should be stated.
The fittings, tap-changer for 250 KVA and 500 KVA Transformers, accessories and sizes listed are
indicative only and any other fittings and accessories which are generally required for satisfactory
operation of the transformer are to be provided without any extra cost.
24.0 TAP CHANGING ARRANGEMENTS
Off - load tap changing mechanism for 250 KVA & 500 KVA, 11/0.433 KV Transformers shall
have the following characteristics:-
• Tap changing shall be carried out with the transformers in off circuit.
• Tap positions shall be numbered as follows:
Tap No. - 1 Tap No. - 2 Tap No. - 3 Tap No. - 4 Tap No. - 5
+ 2.5 % Principal/ Normal - 2.5 % -5% - 7.5 %
tap
• Provision shall be made for locking of the tap switch handled by using a pad-lock with 6 mm
diameter hasp.
• Tap-changing handles shall be fitted with gasketed covers, so that sealing of the transformers
under normal condition is independent of the switch shaft gland.
25.0 TRANSFORMER OIL
The transformers shall be supplied complete with first filling of transformer oil and 10% extra. The
quantity of oil required for the first filling of the transformer and its full specification shall be stated
Part -2 : Employer’s Requirements 206
in the bid. The complete first filling shall be of new oil free from inhibitors and additives. The
bidder shall quote the price of transformer complete with first filling of oil plus 10% extra.
However, the rate of transformer oil in Rupees per litre shall be quoted separately also. The
transformer oil shall be supplied in non-returnable drums.
The insulating oil for the transformer shall be of EHV grade, generally conforming to IEC: 296/
BS: 148/ REC: 39/ 1993 or latest version of IS: 335/ 1983 whichever is more stringent. No
inhibitors shall be used in the oil. The dielectric strength of the oil shall not be less than 60 KV at
2.5 mm. gap when tested in accordance with IS: 6792/ 1972. If an anti-oxidant inhibitor is
recommended, its use shall be subject to the purchaser’s approval.
The design and materials used in the construction of the transformer shall be such as to reduce the
risk of the development of acidity in the oil.
The Contractor shall warrant that oil furnished is in accordance with the following specifications.
• type of transformer
• standard to which it is manufactured (preferably IEC 76)
• manufacturer’s name
• transformer serial number
• year of manufacture
• rated frequency in Hz (50)
• rated voltages in KV (11/0.433)
• number of phases (3)
• rated power in KVA
• type of cooling (ONAN)
• rated currents in A
• vector group symbol (Dyn11)
• 1.2/50μs wave impulse voltage withstand level in KVp
• power frequency withstand voltage in KV
• impedance voltage at rated current and frequency in percentage at 75ºC at normal tap
• Measured load loss in KW at rated current and at 75ºC at normal tap
• Measured no-load loss in KW at rated voltage and rated frequency
• continuous ambient temperature at which ratings apply in 0C
• top oil and winding temperature rise at rated load in 0C
• winding connection diagram
• total weight in kg with complete oil filled.
• total weight of the transformer without oil
• volume of oil in litres.
• weight of core and windings in kg; and
• name of the purchaser (<EMPLOYER>)
The rating plate shall conform to the requirements of the section of Labels in this specification.
The under base of all transformers of 460 mm long with holes of 14 mm dia at a centre to centre
distance of 415 mm to make them suitable for fixing on a platform or plinth. 500 KVA transformers
shall be provided with bi-directional flat rollers, suitable for use on a 1000 mm gauge track.
28.0 PAINTING
All paints shall be applied in accordance with the paint manufacturer’s recommendations.
Particular attention shall be paid to the following:
a) Proper storage to avoid exposure as well as extremes of temperature.
b) Surface preparation prior to painting.
c) Mixing and thinning
d) Application of paints and the recommended limit on time intervals between coats.
e) Shelf life for storage.
All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness,
brush marks or other defects.
All primers shall be well marked into the surface, particularly in areas where painting is evident,
and the first priming coat shall be applied as soon as possible after cleaning. The paint shall be
applied by airless spray according to the manufacturer’s recommendations. However, wherever
airless spray is not possible, conventional spray be used with prior approval of purchaser.
The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings
and similar such items.
Protective Coating
• As soon as all items have been cleaned and within four hours of the subsequent drying, they
shall be given suitable anticorrosion protection.
Paint Material
Part -2 : Employer’s Requirements 209
Followings are the type of paints that may be suitably used for the items to be painted at shop and
supply of matching paint to site:
i) Heat resistant paint (Hot oil proof) for inside surface.
ii) For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2
coats of Synthetic Enamel paint. The color of the finishing coats shall be dark admiral grey
conforming to No.632 or IS 5:1961.
Painting Procedure
• Al painting shall be carried out in conformity with both specifications and with the paint
manufacture’s recommendations. All paints in any one particular system. Whether shop or site
applied, shall originate from one paint manufacturer.
• Particular attention shall be paid to the manufacturer’s instructions on storage, mixing, thinning
and pot life. The paint shall only be applied in the manner detailed by the manufacturer e.g. brush,
roller, conventional or airless spray and shall be applied under the manufacturer’s recommended
conditions. Minimum and maximum time intervals between coats shall be closely followed.
• All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours
whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the surface is dry
and while the surface is warm.
• Where the quality of film is impaired by excess film thickness,(wrinkling, mud cracking or
general softness) the supplier shall remove the unsatisfactory paint coatings and apply another. As a
general rule, dry film thickness should not exceed the specified minimum dry film thickness by
more than 25%. In all instances, where two or more coats of the same paints are specifies, such
coatings may or may not be of contrasting colors.
• Paint applied to items that are not be painted, shall be removed at supplier’s expense, leaving
the surface clean, un-stained and undamaged.
To the maximum extent practicable, the coats shall be applied as a continuous film of uniform
thickness and free of pores. Over-spray, skips, runs, sags and drips should be avoided. The different
coats may or may not be same color.
Each coat of paint shall be allowed to harden before the next is applied as per manufacture’s
recommendations. Particular attention must be paid to full film thickness at edges.
The requirement for the dry film thickness (DFT) of paint and the material to be used shall be as
given below:
The manufacturers of the transformer shall provide a guarantee of 60 months from the date of date
of commissioning. In case the Distribution transformer fails within the guarantee period the
purchaser will immediately inform the supplier who shall take back the failed DT within 15 days
from the date of the intimation at his own cost and replace/repair the transformer within forty five
days of date of intimation with a roll over guarantee.
The outage period i.e. period from the date of failure till unit is repaired/ replaced shall not be
counted for arriving at the guarantee period.
Part -2 : Employer’s Requirements 211
In the event of the supplier's inability to adhere to the aforesaid provisions, suitable penal action
will be taken against the supplier which may inter alia include blacklisting of the firm for future
business with the purchaser for a certain period.
32.0 TESTS
Routine Tests
Routine tests shall be carried out on all transformers and the tests shall be conducted in accordance
with relevant National/ International Standards. No sampling is allowed. In addition, tank tests in
accordance with IS:1180 shall be carried out.
The following routine measurements and tests shall be carried out in presence of Purchaser’s
authorized representative(s):
a) Measurement of winding resistance. (For 500 KVA at all tap positions)
b) Voltage ratio measurement and check of polarity and vector group. Bushing positions shall have
permanent markings at this stage of production;
c) Measurement of impedance voltages/ short circuit impedance at rated current and frequency (for
500 KVA transformers at normal, highest and lowest tap positions)
d) Measurement of load loss at half load & full load at 750C; (for 500 KVA transformers at normal,
highest and lowest tap positions)
e) Measurement of neutral unbalance current;
f) Temperature rise test on one transformer of each rating and measurement of hot resistance.
g) Measurement of no-load loss and no-load currents at 50%, 75%, 90%, 100%, 110%, 115%, and
120% of rated voltages on one transformer of each rating; (For unit transformer of each Lot)
h) Induced over voltage withstand test at 22KV for 60 sec on the HV windings;
i) Power frequency voltage withstand tests on HV and LV windings;
j) Magnetic balance test
k) Polarization Index test P.I. value shall be not less than 1.5. P.I. = IR at 600 sec / IR at 60 sec.
l) Oil leakage test : The criterion of leakage shall be discoloration by oil of whitewash applied
externally to suspected parts at an oil temperature of 900C or other method, as approved by the
Purchaser;
m) Pressure test on transformer tank on one unit for each rating. Bushings and oil shall be subject to
the following routine tests.
n) Bushing routine test: in accordance with IEC 137/IS 3347;
o) Oil dielectric and moisture content test: conforming to IEC 156 or IS 335. Routine test
certificates shall include in addition to the test results, the purchaser’s order number, the
transformer serial number, outline drawing number and transformer KVA rating.
Any other applicable tests shall be conducted at the discretion of the Purchaser without any extra
cost to purchaser.
Type Tests
Part -2 : Employer’s Requirements 212
• The measurements and tests should be carried out in accordance with the standard specified in
each case as indicated in the following table if the same tests were not conducted earlier at CPRI or
any Govt. approved Laboratory on the transformers of the offered design.
In accordance with IEC 76-3 the following sequence of impulses should have been/ should be
applied;
o one full wave at 50% BIL;
o one full wave at 100% BIL;
o one chopped wave at 50% BIL;
o two chopped waves at 100% BIL and
o two full waves at 100% BIL.
• If the type test report(s) submitted by the bidder do not fulfil the criteria, as stipulated in this
technical specification/ Bidder’s offer, the relevant type test(s) has/ have to be conducted by the
Bidder at his own cost in CPRI/ National Govt. approved laboratory in the presence of
EMPLOYER’s representative(s) without any financial liability to EMPLOYER, in the event of
order placed on him.
• Even if the Type test report(s) confirm(s) the Purchaser’s specification, the Purchaser at his
discretion may ask the Supplier to repeat any or all specified type tests at CPRI/ National Govt.
approved laboratory on sample(s), selected at random by the purchaser’s representative(s) out of the
offered quantity (first lot i.e. minimum one third of the total ordered quantity). The type test(s) are
to be test-witnessed by the Purchaser’s representative(s). For such type of repetition of type tests,
the Bidder may quote Type Test Charges in the enclosed Price Schedule or conduct the tests free of
cost.
• The supplier shall furnish calculations in accordance with IS: 2026 to demonstrate the Thermal
ability of the transformers to withstand Short Circuit forces.
TEST VOLTAGE
Transformers shall be capable of withstanding the Power frequency and Impulse test voltage as described
below:
Nominal Highest System Impulse Test Power frequency
system voltage voltage test voltage
Part -2 : Employer’s Requirements 213
voltage
1.2 The equipments to be supplied against this specification are required for vital installations where
continuity of service is very important. The design, materials and manufacture of the equipment shall,
therefore, be of the highest order to ensure continuous and trouble-free service over the years
1.3 The equipment offered shall be complete with all parts necessary for their effective and trouble-free
operation. Such parts will be deemed to be within the scope of the supply irrespective of whether
they are specifically indicated in the commercial order or not.
1.4 Configuration: The major equipments involved for each mechanically switched shunt capacitor bank
are as follows:
1. 12.65 kV, 1980 kVAr( or any other rating as defined by Employer), 3-Phase, 50 C/s housed in
Outdoor Type CRCA Panel, Capacitor bank having two variable step of 792 Kvar& one Variable steps
of 396 kVAr. Bank shall be complete with Capacitor units of 264/132 kVAr, Aluminium busbars, Pin &
Post insulators, HRC fuses, Surge arrestor etc. with details as follows-(1) 11 kV, Aluminium Wound,
Dry type Series reactors a) 0.52 kVAr for 792 kVAr step - 6 Nos. , b) 0.25 kVAr for 396 kVAr step - 3
Nos. (2) 11 kV, 3-Phase Dry Type RVT - 1 No. (3) 12 kV 3 Phase Indoor type metal enclosed Vacuum
Capacitor switches. - 3 Nos. (4) Indoor Type Automatic Control Unit - 1 No.(5) IP 55 , Outdoor CRCA
cubicle Panel for accommodating capacitors, Series Reactor, Vacuum contactor, Surge arrestor & Fuses
2. 12.65 kV, 3960 kVAr, 3-Phase, 50 C/s housed in Outdoor Type CRCA Panel, Capacitor bank having
two variable step of 792 Kvar& two Variable steps of 1188 kVAr. Bank shall be complete with
Capacitor units of 396/264 kVAr, Aluminium busbars, Pin & Post insulators, HRC fuses, Surge arrestor
etc.with details as follows-
(1) 11 kV, Aluminium Wound, Dry type Series reactors
a) 0.52 kVAr for 792 kVAr step - 6 Nos. ,
b) 0.8 kVAr for 1188 kVAr step - 6 Nos.
(2) 11 kV, 3-Phase Dry Type RVT - 1 No.
(3) 12 kV 3 Phase Indoor type metal enclosed Vacuum Capacitor switches. - 4 Nos.
(4) Indoor Type Automatic Control Unit - 1 No.(5) IP 55 , Outdoor CRCA cubicle Panel for
accommodating capacitors, Series Reactor, Vacuum contactor, Surge arrestor & Fuses etc
Part -2 : Employer’s Requirements 214
3. 11 kV Circuit Breaker
4. 11 kV Isolator with earth blade
5 11 kV lightning Arrestors
6. 11 kV Current Transformer
7. 11 kV Neutral current transformer
8. 11 kV Single phase Current Limiting Reactors
9. Control & Protection Equipment.
1.5. It is not the intent to specify herein complete details of design and construction. The equipment
offered shall conform to the relevant standards and be of high quality, sturdy, robust and of good design
and workmanship complete in all respects and capable to perform continuous and satisfactory operations
in the actual service conditions at site and shall have sufficiently long life in service as per statutory
requirements. The dimensional drawings attached with this specification and the notes thereto are
generally of illustrative nature. In actual practice, not withstanding any anomalies, discrepancies,
omissions, in-completeness, etc. in these specifications and attached drawings, the design and
constructional aspects, including materials and dimensions, will be subject to good engineering practice
in conformity with the required quality of the product, and to such tolerances, allowances and
requirements for clearances etc. as are necessary by virtue of various stipulations in that respect in the
relevant Indian Standards, IEC standards, I.E. Rules, I.E. Act and other statutory provisions.
1.6 The Tenderer/supplier shall bind himself to abide by these considerations to the entire satisfaction of
the purchaser and will be required to adjust such details at no extra cost to the purchaser over and above
the tendered rates and prices.
1.7 The tenderer shall furnish in his offer a list of recommended spares with unit rates for each set of
equipment that may be necessary for satisfactory operation and maintenance of circuit breaker and
Isolators for a period of 10 years. The purchaser reserves right of selection of items and quantities of
these spares to be ordered. The cost of such spares shall not be considered for tender evaluation.
1.8 The tenderer shall submit a list and unit rates of all the special tools, equipment and instruments
required for erection, testing, commissioning and maintenance of the equipment. The purchaser shall
decide the quantity of tools to be ordered. Prices of these tools shall not be considered for tender
evaluation. However, the list of necessary tools/equipment which will be supplied free of cost with each
CB may be furnished separately.
2.0 STANDARDS
The equipment shall conform (for performance and testing thereof) in all respects to the
relevant Indian/International Standards specifications with latest amendments thereto.
The other components such as VCB panel & other auxiliary equipments shall comply with
the latest version of latest Indian/International standards.
2.3 Equipment conforming to other internationally accepted standards which ensure equal or
higher quality than the above mentioned standards would also be acceptable. In such
case bidders, who wish to offer material conforming to standards other than listed above,
shall clearly bring the salient points of difference between the standards forward/adopted and
specified hereinabove. Four copies of such standards with authentic English Translation shall
be furnished along with the offer. In case of conflict order of preference shall be (1) ISS (2)
IEC (3) other standards. In case of any difference between provisions of these standards and
provision of this specification the provision contained in this specification shall prevail.
30 SERVICE CONDITIONS
The capacitor Bank to be supplied against this specification shall be required to operate
satisfactorily and continually under the following moderately hot and humid tropical climate
conducive to rust and fungus growth
• Location: - To be defined by the Employer
• Maximum ambient air temperature (deg. C) To be defined by the Employer
• Minimum ambient temperature (deg. C) To be defined by the Employer
• Average daily ambient air temperature (deg/C) To be defined by the Employer
• Maximum relative Humidity (%) To be defined by the Employer
• Maximum altitude above sea level (M) To be defined by the Employer
• Average annual rainfall (MM) To be defined by the Employer
• Isoceraunic level (days per year) To be defined by the Employer
• Sciemic level (Horigentalaccn.) To be defined by the Employer
• Maximum wind pressure 0kg/sqm) To be defined by the Employer
40 PRINCIPAL PARAMETER
The equipment covered under this specification shall conform to specific parameters given
below:
Note: The stages may be changed during detailed engineering Residual Voltage Transformer
The capacitor shall be of unit type construction suitable for indoor installation having high
dielectric strength. No sun protection will be provided. The capacitor bank shall be complete
with mounting frames, insulators and all other components for formation of capacitor bank.
The bank shall be open type complete with inter connecting aluminum bus bars and
adequate clearance shall be provided between phases and phase to earth..
The capacitor should be able to withstand 10% overvoltage and 30% over current (r.m.s.
value) arising due to over voltage and harmonics
Part -2 : Employer’s Requirements 217
5.2 ASSEMBLY
Capacitor units of 132, 264 & 396 KVAR, 7.3 single phase shall be connected in parallel
in each phase to form a three phase star connected capacitor bank. The bank shall be
mounted on a steel frame work in suitable one/two tier formation and shall be so arranged that
an individual unit of 132, 264 & 396 KVAR can be removed easily without disturbing the
complete assembly/ other units.
A. CONTAINER
The container shall be built from CRCA of sufficient thickness (not less than 1.6 mm) to
avoid damages to the tank in case of internal fault. It shall be of fabricated construction
with all joints properly welded and designed to withstand rough handing and should be
hydraulically tested before assembling the internal elements. It shall be adequately epoxy
pointed. The lid of container shall be properly welded to the container.
The capacitor unit shall be hermetically sealed after the entire assembly has been dried and
impregnated with suitable liquid (Dielectric.) The capacitor elements shall be thoroughly
dried and impregnated with an impregnate which has been completely refined and degasified
so as not to have any impurities or gas which may cause deterioration of the dielectric. The
impregnate used shall have low viscosity and high chemical stability and should be non-
PCB. The container shall be adequately insulated from capacitor elements. Sufficient 'Wall'
insulation shall be provided so that the capacitor units meant for use of 11 KV nominal
system can be place directly on grounded steel structures. The metallic surface of capacitor
units shall be epoxy painted making capacitor units suitable for installing outdoor under
moist tropical climatic conditions.Capacitorpanel shall be bolted type design. Capacitor
Panel shall have IP-55 Degree ofprotection. Capacitor Panel shall be Powder coated
B. CAPACITOR UNIT
The capacitor unit shall have aluminium foil as conducting layer. The dielectric used shall be
polypropylene film by using layers of polypropylene film shall have the following
compatibility criterion: -
(i) Polypropylene film shall conform to standard specification with latest amendments, for
plastic film for new generation.
(ii) Compatibility between oil film (after thermal aging at 115 C for 96 Hrs.)
The impregnate used shall be non PCB liquid with low be accumulating, rapid bio
degradation and low toxicity. Adequate number of such elements shall be assembled and
enclosed in the enclosure to form a single phase unit with terminal bushings. The air in the
enclosure and moisture absorbed by the paper shall be removed under high vacuum at
elevated temperature and replaced by suitable impregnating medium having high
permeability, high dielectric strength and non-inflammable properties.
C. DISCHARGE DEVICE:
Suitable discharge device shall be connected across the capacitor unit in accordance with IS:
13925. The discharge device shall reduce the residual voltage from the crest value of the
Part -2 : Employer’s Requirements 218
rated voltage to 50 V the or less within 10 Minutes after the capacitor is disconnected
from the source supply.
D. EARTHING CONNECTIONS:
The container of each capacitor unit shall be provided with suitable earthing terminal
clearly marked with Earth symbol.
E. MARKING:
The capacitor unit shall be provided with a rating plate and terminal markings as
stipulated in IS: 13925. The bidder shall submit the type test report along with the bid.
F. FUSES
Each capacitor element shall be protected by External HRC fuse of suitable rating
and interruption capacity so that a faulty capacitor element shall be disconnected by fuse.
The fuse shall satisfactorily operate under ambient conditions. The following requirements
shall be considered while selecting the right size of fuse.
a. Ability to withstand the maximum discharge current from healthy capacitor
element.
b. Capability of handing fault current so as to Blow off before the in case rupture
takes place thereby avoiding damage to adjoining capacitor elements/capacitor
units.
G. BUSHINGS
Bushing shall be of porcelain or polycrete and shall be jointed to the case by welding
method (Weldable type bushing) to ensure adequate and permanent seal. Leads shall be
brought out through one-piece bushing and welded to the terminal stud to make a strong and
positive electrical contract. Bushing terminal shall be of stainless steel.
Capacitors to be tested for cyclic Over voltage and 3 G test for mechanical shock &
vibration, bidder has to clarify / confirm these points in GTP
The switching ON operation will take place after period of 10 minutes. The
switching OFF operation of relevant steps will be instantaneous.
(c) Controls:
The Automatic control unit shall instantly switch OFF the capacitor bank in the following
contingencies occurring in any of the phases.
i) Voltage increased by 10% above the rated voltage of 11 KV.
ii) Power transformer current impedance (due to single phasing and for any other
reasons) between any of the two phases exceeding 20% of the lowest, iii) Current increases
in any capacitor unit by 30% above the rated current (only the relevant capacitor switch
will open).Current between any of the two phases of the capacitor bank differs more than 15%
of the lowest current of the 3 phases (only the relevant capacitor switch will open).
• Quad-band 850/900/1800/1900MHz
• GPRS multi-slot class 12/10
• GPRS mobile station class B
• Compliant to GSM phase 2/2+
– Class 4 (2 W @ 850/900MHz)
– Class 1 (1 W @ 1800/1900MHz)
• Control via AT Commands (3GPP TS 27.007, 27.005 and enhanced AT Commands)
(f) Rated Short Circuit Making Current: The rated making current shall be 25 KA Peak .
(l) Marking:
The Vacuum Contactor Switch shall be provided with a legible and indelibly marked
name plate with the following:
a) Name of the manufacturer.
b) Type, designation and serial number.
c) Rated voltage and current.
d) Rated frequency.
e) Number of poles.
f) Rated short time current (symmetrical).
g) Rated making current.
h) Rated capacitive switching current.
i) Date of manufacturing.
j) Property of respective Employer
(m) Testes: The Vacuum Contactor Switch shall be subjected to the following tests in accordance
with the IS:9920 (Part-IV), &Should also be tested by international labs as per IEC 60265-
1(1998)
values.
c) Making and breaking tests including tests for the rated capacitive current.
d) Tests to prove the capability of the switch to carry the rated short time current.
e) Tests to prove satisfactory operation and mechanical/electrical endurance.
5.8 B) Suitable one number RC surge suppressor shall be provide per bank inside of cubicle panel.
LA and Isolator shall be mounted on same structure and outgoing of Isolator shall be connected
with CRCA capacitor panel through suitable power cable .
Suitable indoor type 11 KV HRC fuses along with the mounting insulators etc. to
provide proper protection for the capacitor unit shall form part of the equipment to be
supplied.
0.2 % Series reactor per phase per step of capacitor rating for inrush current restriction to
be connected on neutral end as per IS: 5553. The rated voltage shall be 12 KV.
Thereactor shall be dry type single phase reactors mounted on post insulators and
designedto carry 130 % of rated current continuously without exceeding the
temperature rise& shall be applicable for thermal class of insulation used. The reactor shall
be mountedon structure.
i. Tests: The series reactor shall be type tested and shall be subjected to routine
andacceptance test in accordance with IS: 5553.
ii. The bidder shall submit guaranteed technical particulars along with their bid.
Suitable bus bar arrangement shall be provided by the supplier and requisite quantity of bus
bar material shall be provided for the Bank. All bus bars shall be aluminum flats with
suitable cross section . Bus bar connections between Bank and RVT. Shall also be provided.
5.14 ACCESSIORIES
Each capacitor bank cubicle panel shall be provided with the following accessories:-
Part -2 : Employer’s Requirements 224
All other accessories required for erection, assembly and commissioning of the capacitor bank
ACU shall be floor mounted and kept inside of substation building near to VCB panel.
LA and Isolator shall be mounted on external structure and to be kept outside.
6.0 TESTS
All the offered equipment shall be fully type tested by the bidder as per relevant standards
including the type tests mentioned below. Type test should have been conducted on the
similar or higher capacity of equipments for 11 KV or 33 KV class of capacitor bank from
recognized test laboratory preferably CPRI or other Govt. test labs within 5 years prior to
date of opening of bid. The bidder shall furnish four sets of test reports as per relevant
standards for each type of equipment offered. along with the bid. The offers received without
type tests shall be tested as non responsive and rejected.
a. Thermal stability
b. Capacitor less tangent measurement at elevated temperature.
c. A.C. voltage test between terminal & container.
d. Lightening impulse voltage test between terminal and container.
e. Short circuit discharge test.
The method shall be subject to agreement between the Supplier and Purchaser where it is
not specified in the relevant standards. The Purchaser reserves the right to carry out any
other test (s) of reasonable nature, in addition to above mentioned tests, at works/test house
of the Supplier or any other recognized laboratory/Research Institute to satisfy that the
material compiles with the intent of this specification
7.0 INSPECTION
The inspection shall be carried out by the Purchaser at two stages of manufacture i.e.
inspection during manufacturing and final inspection and testing. The Supplier shall keep the
Purchaser informed in advance of the manufacturing programmer so that the arrangement
can be made for inspection. The Manufacturer shall grant free access to works, for
Purchaser's representative at a reasonable time. Inspection and acceptance of any equipment
under this specification by the Purchaser shall not relieve the Supplier of his obligation of
furnishing the equipment in accordance with this specification and shall not prevent
subsequent rejection if the equipment is found to be defeat/not as per this specification.
All acceptance tests and inspection shall be carried out at the place of manufacture
unless otherwise specifically agreed upon by the contractor and Purchase. The contractor
shall offer to the inspecting official (s) representing the Purchase, all reasonable facilities
without charge, to satisfy that the material is being furnished in accordance with this
specification. The Purchase has the rights to have the tests carried out at his own cost by an
independent agency wherever there is a dispute regarding the quality of the supply.
The contractor shall give not less than 15 days advance intimation to enable the purchase to
depute his representative for witnessing the state/acceptance tests.
Part -2 : Employer’s Requirements 226
8.1 The bidder shall have ISO-9001/9002 or any latest, certification'. The bidder shall
invariably furnish the following information along with his bid part-I falling which his bid
shall be liable for rejection. Separate information should be given be individual type of
material offered.
(I) Statement giving list of important raw materials, name of Suppliers for raw
material, list of standards according to which the raw materials are tested and list
of tests normally carried out on raw materials in presence of bidder's
representative, copies of tests certificates
(II) Information and copies of test certificates as in (1) above in respect of bought out
items,
(IV) Level of automation and list of areas where manual processing exists.
(V) List of areas in manufacturing process where stage inspections are normally
carried out for quality control and details of such test.
(VI) List of testing equipment available with the bidder for stage and final testing of
equipment offered and test plant limitations if ay, vis-a vis the type test, special
acceptance and routine test specified in the relevant standards. These limitations
shall be very clearly brought out in the relevant schedule of deviations as
deviations from specified tests requirements.
8.2 The successful bidder(s) shall within 30 days of placement of order submit the following
Information: -
i. List of raw material and bought out items and names of the Suppliers selected
from those furnished along with the bid.
ii. Type test certificates or the raw material and bought out items.
iii. Quality assurance plan (QAP) with hold points for purchase's inspection (to be
finalized after mutual discussions between the bidder and the purchaser, at
latter's office.)
HOLD POINT
A stage in the material procurement of manufacturing process beyond which work shall
not proceed without the documental approval of the purchase.
NOTIFICATION POINT:
A stage in the material procurements, or manufacturing process for which advance
notice of the activity is required to facilitate witness by the
purchasersrepresentatives.
Part -2 : Employer’s Requirements 227
8.4 The QAP of the contractor shall consist of the following details.
➢ An outline of the proposed work and program sequence.
➢ The structure of contractor organisation for the contract.
➢ The duties and responsibilities assigned to the staff ensuring quality of work
➢ Hold and Notifications points.
➢ Submission of engineering documents required by this specification.
➢ The inspection of material and components on receipt
➢ Stage Inspection.
➢ Final Inspection.
90 DOCUMENTATION
All drawing shall conform to International standards organisation (ISO), 'A' series of
drawing sheets/Indian standards specification IS: 656. All dimensions shall be in SI
units.
9.4 Interpretation of the drawing for meeting the requirements of latest revisions of
applicable standards, rules and code 6f practices. The purchase shall have power to reject any
work or material which in his judgment is no in all accordance therewith.
9.5 Three sets of drawings for purchaser's approval shall be furnished within two weeks of
placement of order. The purchaser shall communicate his comments/ approval within
reasonable. The supplier, shall, if necessary modify the drawings and resubmit three
copies of modified drawings for a approval.
9.6 Three sets of separating manual, drawing, technical leaflets, inspection manual etc shall be
supplied to each consignee in the first instance.
9.7 One set of routine test certificate shall accompany such dispatch consignment.
to improper and to the equipment during transit, due to improper and inadequate packing.
The easily damageable material shall be carefully-packed and marked with the appropriate
caution symbol. Wherever necessary proper arrangement for lifting such as fitting hooks
shall be provided. Any material found short within the packing case(s) shall be supplied
immediately by the supplier without any extra cost to purchaser.
Each consignment shall be accompanied with a detailed packing list containing the
following information and shall be marked "PROPERTY OF respective <DISCOM>".
a) Name of the consignee
b) Details of consignment
c) Destination
d) Total weight
e) Handling and packing instructions
f) Bill of material indicating contents of each package.
In addition to the above the marking on each package shall per relevant standards.
10.1 The packing shall be done an per manufacture's standards practice ensuring that no
material is damaged during transit by Rail/Road.
13. TRAINING:-
13.1. Bidder has to organise at least two training sessions every Division for substation operator
and field staff at substation only after commissioning.
13.2. Bidder shall provide posters in Hindi regarding DOs and DON’Ts regarding operation of
Capacitor Banks properly displayed in Control room at minimum two locations along
with contact details of person to approach in case of problem/ fault.
Bidder shall provide service for monitoring of working of capacitor bank by visiting every
installed capacitor bank location once in three months and submit report asper attached
sheet.
Part -2 : Employer’s Requirements 229
Indicative Scope of Work for Facility Management Services to be carried out for Keeping 12.65
kV, HT Capacitor bank System at 33/11kV Sub-Stations Healthy and Operational
1 Visiting each substation on quarterly basis , and log the measurement of 11 KV Incomer breaker data in following format.
Sl Name Rating Incomers Date of KHW KVAH Date of KWH KVAH Total Hrs Total
No of S/s of Energy Current PF1 Last PF2 between operational
bank meter Recording Recording two R/Hrs of
serial no recordings Capacitor
Banks between
two recordings
1
2
3
.
.
n
These readings shall be MRI based and submitted to concerned Executive Engineer office for applying payment of FMS charges ,
2
which shall be paid on quarterly basis .
During quarterly visit , bidder shall check the complete capacitor bank for any deficiency , if any deficiency is noticed same shall be rectified
3 within fortnight .In addition to this the healthiness of relay/trip circuit and proper operation inundervoltage/overvoltage conditions
shouldbe ensured by the bidder.
At the event of any fault occurred ,shall be duly communicated to bidder by substation in charge or concerned SDO offices -which has to
4 beattended within 7 working days time , and resolution of such complaints specific to capacitor bank shall be done within fortnight of
complaint attend date.
To establish one office in each zone - with provision of e-mail and mobile communication connectivity and shall have minimum 4 well
5
qualified technicians to attend faults / provide services .
6 All required spares shall be kept at FMS Zonal Centres for prompt service .
7 Any other activity required to ensure the contracted Capacitor bank System is operational for maximum time.
Part -2 : Employer’s Requirements 230
Annexure-B
General Technical Instructions
(This document is meant for the exclusive purpose of bidding against this Package and shall not be
transferred, reproduced or otherwise used for purposes other than that for which it is specifically
issued.)
Part -2 : Employer’s Requirements 231
b. Safety Regulation for construction and O&M - Central Electricity Authority (Safety requirements
for construction, Operation and Maintenance of electrical plants and electric lines) Regulation,
2011 (as amended time to time)
e. Central Electricity Authority (Measures relating to safety and Electric supply regulations), 2010
and amendment regulation 2015 (as amended time to time)
9.1m meter long PCC Pole (or PCC Pole as per state practice shall be used for 33 KV line support).
152x152mm H-Beam (37.1kg/m) / Wide parallel Beams 160x30.44 kg/m can also be used as
support in urban/forest area and or Steel Tubular Poles/ Wide parallel Beams 160x30.44 kg/m
(Expandable through jointing plates) may be used in hilly area where head load shifting is the
only option. Cement concreting shall be used for 33 KV support foundations in mixture 1:3:6 (1:
cement, 3: coarse sand and 6 Stone ballast 40mm sizes). Each support shall be concrete
(0.5mx0.5mx2m) = 0.5 cmt. 0.014 cmt shall also be used in muffing of the support. PCC pole
shall not be provided with muffing.
1.1.1. Pole base plates as per specifications shall be used.
1.1.2. Pole earthing shall be performed through earthing coil duly connected with 8 SWG wire. The GI
wires between pole structure and the earthing coil should not be used in cut length. Wherever, cut
is evitable, proper nut bolt, washer and binding should be made as per REC specifications. The GI
wire between support and earth coil should be placed 1 meter below the ground level.
1.2.1. 8.0 meters or equivalent PCC Poles as per prevailing practices of the state shall be used for 11
KV line and substation support. 152x152mm H-Beam (37.1kg/m) or Wide Parralel Beam
160x30.44 kg/m can also be used as support in urban/forest area and or Steel Tubular Poles/Wide
parallel Beam (with expandable lengths through jointing plates) may be used in hilly area where
head load shifting is the only option.
The single PCC pole supports shall be erected with Stone bolder/stone ballast mixed with
excavated earth in normal soil. PCC poles in Double Pole structures, turning point structure,
Distribution Transformer Substation structure shall be grouted in cement concrete mixture of
1:3:6 (1: cement, 3: coarse sand and 6 Stone ballast 40mm sizes). Single pole supports in water
logging area shall also be grouted in cement concrete mixture of 1:3:6 (1: cement, 3: coarse sand
and 6 Stone ballast 40mm sizes). PCC pole shall be grouted with concrete (0.6mx0.6mx1.35m) =
0.486 cmt.. In special location, wherever, Project Manager specifically decides, to enhance
additional strength, concreting may be used as support foundation.
In forest, wherever special care is to be made for elephant corridors, 13m long, 152x152mm RS
Joist (37.1kg/m) / Wide Parallel Beams 160x 30.44 kg/m may be used for 11 KV line support.
152x152mm H-Beam (37.1kg/m)/ Steel Tubular Poles/ Wide Parallel Beams 160 x 30.44 kg/m shall be
grouted in cement concrete mixture of 1:3:6 (1: cement, 3: coarse sand and 6 Stone ballast 40mm
sizes) in all the formation.
1.2.2. Pole base plates as per specifications shall be used.
1.2.3. Pole earthing shall be performed through earthing coil duly connected with 8 SWG wire. The GI
wires between pole structure and the earthing coil should not be used in cut length. Wherever, cut
is evitable, proper nut bolt, washer and binding should be made as per REC specifications. The GI
wire between support and earth coil should be placed 1 meter below the ground level.
1.3.1. The scope of HT/LT length of feeder are enclosed with the tender documents. On award of the
contract, Contractor shall perform foot survey to access the route, pole location and thus Single
Line Diagram of the line works. The survey shall be approved by Project Manager. Accordingly
requirements of materials shall be finalized by the turnkey contactor in association with Project
Manager.
Part -2 : Employer’s Requirements 234
1.4.1. The detailed survey shall be carried out for the approved feeders/spur lines by the Contractor and
submitted for Employer approval.
1.5.1. Span: The number of consecutive spans between the section points shall not exceed design length
considering wind pressure, type of poles and size of conductor.
1.5.2. 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 undulation in ground
profile, one or both the supports of the span may be extended by inserting standard body
extension designed for the purpose according to technical specification.
1.5.3. Loading: There shall not be any upward force on poles under normal working conditions and the
suspension poles shall support at least the minimum weight span as provided in the design. In
case uplift is unavoidable, it shall be examined if the same can be overcome by adding standard
body extensions to the poles failing which tension poles designed for the purpose shall be
employed at such positions.
1.5.4. Horizontal Tensions on pin insulators are to be avoided by proper alignment of the line. In case
where installation of DP structure is not possible to erect for turning the line, “two pins”
arrangement with suitable jumpering shall be provided at all those locations where pins are
subjected to horizontal tension. Bridling type V Cross arms for such installations shall be used by
the agency accordingly.
At all road crossings, the poles shall be fitted with horizontally aligned disc type tension insulator
string(s) or bridling V-cross arm supports using double pin insulator per phase depending on the
type of poles and line but the ground clearance at the roads under maximum temperature and in
still air shall be such that it should not fall below 6.1m in case of 33 KV and 11 KV lines. Also,
cradle guarding is to be used at all the road crossing locations as per drawings / specifications
enclosed.
Railway Crossings at pre-planned locality shall be selected in such a way that minimum feeder
length shall be re-routed. The line crossing should be executed as per prevailing practices and
approved drawings of railways. Railways crossing shall preferably be executed through
underground cabling. Horizontal drill machine shall be used for this purpose. Required
permission to block the Railways traffic and approval for railway crossing shall be arranged by
the Employer at his own cost. All liaison works shall be performed by turnkey Contractor.
The angle of crossing shall be as near 90 degrees as possible. However, deviation to the extent of
30 degree may be permitted under exceptionally difficult situations. Cradle guarding is to be used
at all such crossing locations as per drawings / specifications enclosed.
All topographical details, permanent features, such as well, trees, building etc. 75 m on either side
of the alignment shall be detailed on the profile plan.
For the purpose of computing the vertical clearance of an over-head line, the maximum sag of any
conductor shall be calculated on the basis of the maximum sag in still air and the maximum
design temperature. Similarly, for the purpose of computing any horizontal clearance of an over-
head line, the maximum deflection of any conductor shall be calculated on the basis of the wind
pressure specified by the State Government under rule 76 (2) (a) [or may be taken as 35º,
whichever is greater]. Following clearances shall be maintained by the Contractor while executing
the work:
1.6.2. No conductor of an over-head line, including service, lines, erected along any street shall at any
part thereof be at a height less than
Part -2 : Employer’s Requirements 236
a. For low, medium and high voltage lines upto and including
11,000 volts, if bare - 4.6 metres
b. For low, medium and high voltage lines Upto and including
11,000 volts, if insulated - 4.0 metres
c. For high voltage lines above 11,000 volts - 5.2 metres
For extra-high voltage lines the clearance above ground shall not be less than 5.2 meters plus 0.3 meter
for every 33,000 volts or part thereof by which the voltage of the line exceeds 33,000 volts:
Provided that the minimum clearance along or across any street shall not be less than 6.1 meters.
1.6.3. CLEARANCE FROM BUILDINGS OF LOW AND MEDIUM VOLTAGE LINES AND
SERVICE LINES:
Where line is to cross over another line of the same voltage or lower voltage, pole with suitable
extensions shall be used. Provisions to prevent the possibility of its coming into contact with other
overhead lines shall be made in accordance with the latest CEA regulations (as amended from
time to time). The Contractor will required to under cross higher voltage lines by erecting
gantries/suitable Rail Pole structures.
Where a low or medium voltage over-head line passes above or adjacent to or terminates on any
building, the following minimum clearances from any accessible point, on the basis of maximum
sag, shall be observed:-
a) For any flat roof, open balcony, verandah roof and lean-to-roof
i. When the line passes above the building a vertical clearance of 2.5 meters from the highest point;
and
ii. When he line passes adjacent to the building a horizontal clearance of 1.2 meters from the nearest
point, and
i. When the line passes above the building a vertical clearance of 2.5 meters immediately under the
lines, and
ii. When the line passes adjacent to the building a horizontal clearance of 1.2 meters.
The horizontal clearance shall be measured when the line is at a maximum deflection from the
vertical due to wind pressure.
Part -2 : Employer’s Requirements 237
Where a high or extra-high voltage over-head line passes above or adjacent to any building or part
of building it shall have on the basis of maximum sag a vertical clearance above the highest part
of a building immediately under such line, of not less than
(a)
For High Voltage Lines up 3.7 m
to and including 33,000
volts
(b) For Extra High Voltage 3.7 m plus 0.3 m for
Lines every additional 33 KV or
part thereof.
1.11. Electrical System Data
33 KV 11KV
Nominal voltage 33 kV 11KV
Maximum system voltage 36 kV 12KV
BIL (Impulse) 170 kVp 75KV
Power frequency withstand voltage (wet) 75 kV (rms) 28KV
Minimum corona extinction voltage for Not less than 27 kV, 50 Hz ac system under Dry condition
(rms) phase to earth
Radio interference voltage at one MHz for Not exceeding 1000 micro-volts
27 kV (dry condition)
In locating poles on lines, the following general principles should be kept in mind:-
3. By locating the poles on high places short poles can be used and will maintain proper ground
clearance at the middle of the span. In extremely hilly or mountainous country, poles are located
on ridges there by greatly increasing the spans without greatly increasing the pull on the
conductor. This is possible because the sag can be made very large and will maintain the required
ground clearance. Special attention should be given to the locations of poles, where the ground
washes badly. Poles should not be placed along the edges of cuts at or embankment or along the
banks of creeks of streams.
Part -2 : Employer’s Requirements 238
1.13. Construction
For angles of deviations more than 10 degree, DP structure may be erected. The pit digging
should be done along the bisection of angle of deviation.
After the poles are erected, the horizontal/cross bracings should be fitted and the supports held in
a vertical position with the help of temporary guys of Manila rope 20/25 mm dia.
Wherever space is not found sufficient to install double Pole structure, single pole cut point may
be installed. The support so erected must be grouted.
1.15. Concreting
The concreting mixture of one cum 1:3:6 ratios would mean 1 part cement, 3 parts coarse sand
and 6 part 40 mm aggregate size stones. It may be noted that while preparing the concrete
mixture, large quantities of water should not be used as this would wash away cement and sand.
Guys are installed at locations where terminal poles are erected at sectional cut points. These cut
points may be in same alignment or at turn points. Guys are installed to nullify tension on
supports resulted due to conductors tension. In spite of careful planning and alignment of line
route, certain situations arise where the conductor tries to tilt the pole from its normal position
Part -2 : Employer’s Requirements 239
due to abnormal wind pressure and deviation of alignment, etc. When these cases of strain arise,
the pole is strengthened and kept in position by guys. One or more guys will have to be provided
for all supports where there is unbalanced strain acting on the support, which may result in
tilting/uprooting or breaking of the support.
Guys are braces fastened to the pole. In this work anchor type guy sets are to be used. These guys
are provided at (i) angle locations (ii) dead end locations (iii) T - off points (iv) Steep gradient
locations and (v) where the wind pressure is more than 50 kg / Sq.m.
The fixing of guys stays will involve (i) pit digging and fixing stay rod (ii) fastening guy wire to
the support (iii) Tightening guy wire and fastening to the anchor. The marking of guy pit, digging
and setting of anchor rod must be carefully carried out. The stay rod should be placed in a
position so that the angle of rod with the vertical face of the pit is 30º/45º as the case may be.
Before start of erection of Stay sets, required concreting materials like Cement, Sand, Stone
Chips and Construction water need to be made available near the pit.
G.I. stay wires of size 7/3.15 mm (10 SWG) & 7/4.00 mm (8 SWG), for 16 mm/20 mm stay rods
respectively, are to be provided. 8.5 Kg. Stay Wire (7/4.00 mm) per Stay with 20 mm Stay rod
for 33 KV line and 5.5 Kg. Stay Wire (7/ 3.15 mm) per Stay with 16 mm Stay rod for 11 KV
lines are to be used. For double pole structure (DP), four stays along the line, two in each
direction and two stays along the bisection of the angle of deviation (or more) as required
depending on the angle of deviation are to be provided. Hot dip galvanized stay sets are to be
used. One stay to counter the angular deformation force shall be used.
After concreting, back filling and ramming must be done well and allowed 7 days to set. The free
end of the guy wire/stay wire is passed through the eye of the anchor rod, bent back parallel to the
main portion of the stay/guy and bound after inserting the G.I. thimble, where it bears on the
anchor rod. If the guy wire proves to be hazardous, it should be protected with suitable asbestos
pipe filled with concrete of about 2 m length above the ground level, painted with white and
black strips so that, it may be visible at night. The turn buckle shall be mounted at the pole end
of the stay and guy wire so fixed that the turn buckle is half way in the working position, thus
giving the maximum movement for tightening or loosening.
Guy insulators are placed to prevent the lower part of the Guy from becoming electrically
energized by a contact of the upper part of the guy when the conductor snaps and falls on them or
due to leakage. No guy insulator shall be located less than 2.6 m from the ground. Guy insulators
Part -2 : Employer’s Requirements 240
are to be used in stay wires only. All stay conductors are to be provided with guy insulators as per
following specifications.
11 KV line stay Type C guy insulator (1 No)
33 KV line stay Type C guy insulators (2Nos)
After the erection of supports and providing guys, the cross-arms are to be mounted on the
support with necessary clamps, bolts and nuts. The practice of fixing the cross arms before the
pole erection is also there. In case, the cross-arm is to be mounted after the pole is erected, the
lineman should climb the pole with necessary tools. The cross-arm is then tied to a hand line and
pulled up by the ground man through a pulley, till the cross-arm reaches the line man. The ground
man should station himself on one side, so that if any material drops from the top of the pole, it
may not strike him. All the materials should be lifted or lowered through the hand line, and
should not be dropped.
Line conductors are electrically insulated from each other as well as from the pole by ‘Insulators’.
Following two type of insulators shall be used for the line insulation:
The pin type insulators will be used for straight stretch of line. The insulator and its pin should be
mechanically strong enough to withstand the resultant force due to combined effect of wind
pressure and weight of the conductor in the span.
The strain insulators are intended for use at terminal locations or dead end locations and where
the angle of deviation of line is more than 10º. Strain insulators are also intending to use at major
road crossing locations.
The pins for insulators are fixed in the holes provided in the cross-arms and the pole top brackets.
The insulators are mounted in their places over the pins and tightened. In the case of strain or
angle supports, where strain fittings are provided for this purpose, one strap of the strain fittings
is placed over the cross-arm before placing the bolt in the hole of cross-arms. The nut of the
straps is so tightened that the strap can move freely in horizontal direction.
Part -2 : Employer’s Requirements 241
All HT/LT insulators shall be tested for insulation tests before installation on line. They shall be
dipped into water for 24 hrs and then tested for insulation resistance tests at the stores. The
insulators found fit in IR testing shall be sent to site for erection. 11KV na d33 KV insulators
shall be tested by at-least 1 KV megger whereas LT insulators shall be tested by 500 Volts
megger.
While transporting conductors drums to site, precautions are to be taken so that the conductor
does not get damaged/injured. The drum could be mounted on cable drum support, which
generally is made from crow-bar and wooden slippers for small size conductor drums. The
direction of rotation of the drum has to be according to the mark in the drum so that the conductor
could be drawn. While drawing the conductor, it should not rub causing damage. The conductor
could be passed over poles on wooden or aluminum snatch block (pulley) mounted on the poles
for this purpose.
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.
The mid span jointing is done through compressions or if helical fittings are used the jointing
could be done manually. After completing the jointing, tensioning operation could be
commenced. The conductor is pulled through come-along clamps to stringing the conductor
between the tension locations.
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 earth-wire 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
Part -2 : Employer’s Requirements 242
by wire brush till it is free of rust 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 or splices shall be made at least 15 meters away from the pole. No joints or splices
shall be made in spans crossing over main roads, railways and small river 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 aluminum 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 / aerail
rollers. The pulley groove size shall be such that the joint along with protection can be passed
over it smoothly.
The tensioning and 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 earth-wire. 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 36 hours of sagging in.
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.
At sharp vertical angles, conductor and earth-wire 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 weather when rapid changes in
temperature are not likely to occur.
1.22. Clipping In
Part -2 : Employer’s Requirements 243
Clipping of the conductors into position shall be done in accordance with the manufacturer’s
recommendations. Jumpers at section and angle towers shall be formed to parabolic shape to
ensure maximum clearance requirements. Fasteners in all fittings and accessories shall be secured
in position. The security clip shall be properly opened and sprung into position.
Conductor and earth-wire accessories supplied by the Contractor shall be installed by the
Contractor as per the design requirements and manufacturer’s instruction within 24hours of the
conductor / earth-wire clamping. While installing the conductor and earth-wire 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.
1.24. Replacement
If any replacements are to be effected after stringing and tensioning or during maintenance e.g.
replacement of cross arms, the conductor shall be suitably tied to the pole at tension points or
transferred to suitable roller pulleys at suspension points.
Sagging of conductor has to be in accordance to the Sag Tension chart. In order to achieve it, it is
preferred to pull the conductor to a tension a little above the theoretical value so that while
transferring it from the snatch blocks to the pit insulators and to take care of temperature
variation. Proper sag could achieve. Sagging for 33/11 KV line is mostly done by “Sighting”. A
horizontal strip of wood is fixed below the cross-arm on the pole at the required sag. The lineman
sees from other end and the sag is adjusted by increasing or decreasing the tension. The tension
clamps could then be finally fixed and conductor be fixed on pin-insulators. All fittings,
accessories like guys, cross-arms, etc., could be checked as they should not have de-formalities.
The maximum permissible spans for all the lines of 33/11/0.4 KV are prescribed according to the
design of the supports. Sag-tension charts for these conductors are to be followed.
Conductors should occupy such a position on the insulator as will produce minimum strain on the
tie wire. The function of the wire is only to hold the conductor, in place on the insulator, leaving
the insulator and pin to take the strain of the conductor.
Part -2 : Employer’s Requirements 244
In straight line, the best practice is to use a top groove insulator. These insulators will carry
grooves on the side as well. When the conductor is placed on the top groove, the tie wire serves
only to keep the conductor from slipping out.
On corners and angles (below 5 degree deviations) the conductors should be placed on the
outside of the insulators. On the far side of the pole, this pulls the conductor against the insulator
instead of away from the insulator.
Helically formed fittings are to be used for tying the insulators, end terminal connectors etc.. The
tie should always be made of soft annealed wire so that it may not be brittle and injure the line
conductor. A tie wire should never be used for second time. Specifications of helically formed
fittings are given in this section.
(a) Provide a secure binding between line wire insulator and tie wire.
(b) Have positive contacts between the line wire and the tie wire so as to avoid any chattering of the
contacts.
(c) Re-enforce line wire in the vicinity of insulator.
In urban area, lines are to be erected with provision for forming lines of two different gradients as
under
Where conductors forming parts of systems at different voltages are erected on the same
supports, the Contractor shall make adequate provision to guard against danger to linesmen and
others from the lower voltage system being charged above its normal working voltage by leakage
from or contact with the higher voltage system; and the methods of construction and the
clearances between the conductors of the two systems shall be as described in the specifications.
The agency shall be intimated by the Project Manager in writing about the locations where such
provisions is intended by him. At all such locations, the Contractor shall make adequate provision
to guard against danger to linesmen and others from the lower voltage system being charged
above its normal working voltage by leakage from or contact with the higher voltage system.
1.29. Earthing
Earthing shall generally be carried out in accordance with the requirements of latest CEA regulations (as
amended from time to time) and the relevant regulations of the Electricity Supply Authority
concerned and as indicated below:
d) The supports on either side of the road, railway or river crossing should be earthed.
e) All supports (Steel & PCC) HT lines passing through inhabited areas, road crossings and along
such other places, where Earthing of all poles is considered desirable from safety considerations
should be earthed.
f) In special locations and special structures, road crossings etc., pipe/rod Earthing should be done
on either side of the construction.
g) At other locations the coil Earthing may be adopted. The coil Earthing consists of 10 m length of
8 SWG. G.I. wire compressed into a coil 450 mm length and 50 mm dia and buried 1500 mm
deep as per REC standard J-1.
In order to prevent unauthorized persons from climbing any of the supports of HT lines without
the aid of a ladder or special appliance, certain anti-climbing devices are provided to the supports.
Barbed wire binding is to be adopted for this purpose at a distance of 30 to 40 cm at a height of
3.5 to 4 m from ground level. The barbed wire shall conform to IS – 278 (Grade A1). The barbed
wired shall be given chromatin dip as per procedure laid down in IS: 1340. At-least 3.5 kgs
barbed wire is to be used per pole for the purpose.
When the line is ready for energisation, it should be thoroughly inspected in respect of the following:-
After the visual inspection is over and satisfied, the conductor is tested for continuity/ground, by
means of megger. At the time of testing through megger person should not climb on the pole or
touch the guarding, conductor, guy wire etc.
a. Before charging any new line, it should be ensured that the required inspection fee for the new
line is paid to the Electrical Inspector and approval obtained from him for charging the line.
b. The line should be energized before the officer who has been authorized by the Project Manager
in this regard.
c. Before energizing any new line, the Contractor of the line shall notify to the workmen that the
line is being energized and that it will no longer be safe to work on line. Acknowledgement of all
the workmen in writing should be taken in token of having intimated them.
d. Wide publicity by Tom-toming should be arranged in all the localities through which the line,
that is to be energized passes, intimating the time and date of energizing and warning public
against the risk in meddling with the line.
e. The Officer-in-charge of the line shall personally satisfy himself that the same is in a fit state to
be energized.
No special structures are to be erected for this work. River crossing more than normal span of
poles are not considered under the package. For small rivers etc., data for the highest flood-level
should be obtained for previous years. The structures should be located at such places that they
should be approached under flood condition. Normal DP structures are to be used for such
crossings on approval of Project Manager.
In case of river crossing with longer span, special designed structures are to be used for the
purpose.
1.33. Guarding
Guarding is to be provided for the lines, so that a live conductor, when accidentally broken, is
prevented to come in contact with other electric lines, telephone or telegraph lines, roads, and
persons or animals and carriages moving along the road, by providing a sort of cradle below the
main electric line.
Part -2 : Employer’s Requirements 248
Guarding is not required for crossings of 66 KV and higher voltage lines where the transmission
line is protected by fast acting relay operated circuit breaker of modern design with a tripping
time of the order of 0.25 sec. from occurrence of fault to its clearance. For all other crossings,
guarding is essential for all telecommunication lines and major road crossing.
The guarding shall consist of GI guard cross arm of length 2.5 mtrs made out of 65x65x6 mm
angle & shall be hot dipped galvanized generally conforming to IS : 2633/72. The clamps shall
also be hot dipped galvanized generally conforming to IS: 2633/72 & suitable for 13 m 52 kgs/m
rail pole & for 8.0 meters longs RCC poles. Guarding shall be erected with ground & line
clearances as per the I.E. rules. Cradle guard wire should be of 8 SWG GI Wire provided with
lashing of 10 SWG GI wire at a distance of 2 m along the length of the guarding. Tension clamps,
threaded eye bolts, turn buckles, thimble, tying wires and hardware are as per specified in the
specifications. A sketch showing arrangement of guarding at road crossing is enclosed with
tender drawing.
The minimum height between any guard wires and live crossing conductor shall not be less than
1.5 m in case of a railway crossing.
The conductor shall be continuously observed for loose or broken strands or any other damage
during the running out operations. Repair to conductors, if necessary, shall be carried out with
repair sleeves. 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, abrasions, etc. The Contractor shall be entirely responsible for any
damage to the poles during stringing.
1.7.1. The LT line shall be erected of single phase or three phase arrangements through AB Cable
depending on site requirements. Every 6th pole of LT line shall be earthed with GI spike/GI Coil
as per specifications.
1.7.2. In all those locations where LT AB cable is to be erected on the same support in which 11KV or
33KV line is also erected, proper isolation is to be maintained.
1.7.3. All single phase service connections released under the RDSS schemes shall be provided with one
earth point near the energy meter. This point is connected with the proper earthing system through
GI wires. 10mm diameter earth knob in form of bolt and nut is to be installed on energy meter
Part -2 : Employer’s Requirements 249
board. This earth point is to be maintained by service providing Distribution Company after
installation and energisation. In up-stream network, this earth point is to be connected with earth
point.
1.7.4. Service connection is to be issued on proper surveying of the location so that excessive erection
of LT line or 11 KV line may be avoided. The service wire is to be hanged on supportive GI wire
between pole support and the house. Before installing service wires and GI wire, GI pipe on the
consumer premises is to be erected using clamps/ nails/proper binding etc. In case of hut or poor
structure at consumer premises, GI pipe is to clamp on wooden planks/wooden structure existing
in the house. The GI pipe should be supported for neutralizing tension by means of GI tie wire
support. In pukka/brickwork/cement concrete foundations, house, GI support pipe is to be
clamped by means of MS clips.