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VOLUME-V

The document outlines the specifications and requirements for the supply and erection of transmission line materials for Madhya Pradesh Power Transmission Co. Ltd. It includes detailed technical specifications for various components such as towers, conductors, insulators, and accessories for 132kV, 220kV, and 400kV transmission lines, as well as guidelines for compliance with standards and climatic conditions. Additionally, it emphasizes the need for proper documentation, testing, and performance guarantees from bidders.

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0% found this document useful (0 votes)
11 views376 pages

VOLUME-V

The document outlines the specifications and requirements for the supply and erection of transmission line materials for Madhya Pradesh Power Transmission Co. Ltd. It includes detailed technical specifications for various components such as towers, conductors, insulators, and accessories for 132kV, 220kV, and 400kV transmission lines, as well as guidelines for compliance with standards and climatic conditions. Additionally, it emphasizes the need for proper documentation, testing, and performance guarantees from bidders.

Uploaded by

somen sharda
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 376

MADHYA PRADESH POWER TRANSMISSION CO. LTD.

SHAKTI BHAWAN RAMPUR: JABALPUR

VOLUME –V

Technical Book Serial No.


MPPTCL/TECH-LINE/PROC/SEP23

SPECIFICATIONS & REQUIREMENTS FOR


SUPPLY AND ERECTION OF TRANSMISSION
LINE MATERIALS

O/o CHIEF ENGINEER (PROCUREMENT)


MPPTCL, JABALPUR.
INDEX
VOLUME-V
Specifications & requirements for supply of Transmission Line
Materials
Page No.
S.No. Description of Items
From To
A Common Technical Requirement 1 9
Specifications & requirements for Supply & Erection of 220kV
B and 132kV Transmission Line Materials

1.0 Technical Specification for supply of 132 kV and 220 kV Towers 10 22


2.0 Technical Specification of ACSR Panther and Zebra Conductor 23 31

3.0 Technical Specification of OPGW and associated hardware & fittings 32 63

4.0 Technical Specification of HTGS Earth wire 64 70


5.0 Technical Specification of Disc Insulators 71 84
Technical Specification of Hardware fittings for 132 kV & 220 kV
6.0 Transmission Lines 85 100
Technical Specification of Accessories for 132 kV & 220 kV
7.0 Transmission Lines 101 114
Technical Specification for Erection of 132 kV & 220 kV
8.0 transmission lines 115 131

9.0 Technical Specification of Steel Monopoles 132 143


Technical Specification of 132 kV Power Cable, Termination Kit and
10.0 Installation of Cable 144 215

C Annexures (Technical Particulars and Sample Drawings)


1 ACSR Panther and Zebra Conductor & Earth wire 216 218
2 Disc Insulators 219 220
3 Hardware for Conductor & Earth wire 221 224
4 Accessories for Conductor & Earth wire 225 227
5 List of Drawings 228 256

D Specifications & requirements for Supply & Erection of 400kV


Transmission Line Materials
1.0 Technical Specification of 400 kV Towers 257 270
2.0 Technical Specification of ACSR Moose Conductor 271 283

3.0 Technical Specification of OPGW and associated hardware & fittings 284 284

4.0 Technical Specification of HTGS Earth wire 285 285


5.0 Technical Specification of Disc Insulators 286 301
6.0 Technical Specification of Hardware fittings and Accessories for
400 KV lines 302 329

7.0 Technical Specification of Erection of 400 kV transmission lines 330 345


E Annexure (Technical Particulars and Sample Drawings)
1 ACSR Moose Conductors 346 347
2 Disc Insulators 348 350
3 List of Drawings 351 373
Volume-V

(A) COMMON TECHNICAL REQUIREMENT

1.01 SCOPE:

1.01.01 The provisions under this section are to supplement common requirements
for supply of Transmission Line Materials and Installation work. (Part-B Section-1 to
Section-10) and (Part-D section-1 to section-7) contains technical specification for all
the Materials to be used for Construction of Transmission Lines. The bidders shall
furnish catalogues, engineering data / technical information, drawing etc. in
conformity with the technical specification.

1.01.02 The scope of work involves fabrication, galvanizing and delivery of 400kV, 220kV
& 132kV Double Circuit/ Multi circuit towers, their body extensions, river/ line crossing
structures (Gantries), Hangers, U bolts, D Shackles, Bolts and Nuts, Spring washers, pack
washers, step bolts, tower accessories (earthing rod with clamps, Danger Boards, Number
plates, Phase plates and Anti-climbing Devices (including fixing arrangements and barbed
wire), ACSR Conductor, OPGW/Earth wire, Disc insulators, hardware and accessories for
conductor and OPGW/Earth wire and complete erection of transmission lines including,
detailed survey/check survey, casting of foundations, tower erection, stringing etc. and
testing & commissioning of the transmission lines. Cement and reinforcement steel for
foundation of towers, extensions, river/ line crossing structures and any such materials
required for erection work shall also be provided by the successful Bidder. The Bidder is
also required to provide required number of stub setting templates for each
installation work at his own cost.

1.01.03 This section also provides for the Design, manufacturing, stage testing, inspection
and testing before despatch, packing and delivery of materials for use on
400kV/220kV/132kV transmission lines in the State of Madhya Pradesh.

1.01.04 It is not the intent to specify completely herein all details of the design and
construction of Material. However, the Material shall conform in all respects to high
standards of engineering, design and workmanship and shall be capable of performing the
duties specified herein. The Material offered shall be complete with all components
necessary for its effective and trouble free operation. Such components shall be deemed to
be within the scope of Bidder’s supply, irrespective of whether these are specifically brought
out in this specification or not.

1.01.05 If due to site condition any other type of tower (which is not envisaged at present)
is required to be provided, the same will also be supplied by the bidder at the same rates
terms and conditions.

1.02 CLIMATIC CONDITION


The equipments and materials shall be suitable for satisfactory continuous operation under
the following climatic conditions:

1 Location in the state of MADHYA PRADESH


2 Maximum ambient air temperature (0C) 50
3 Minimum temperature in shade (0C ) 1
4 Maximum relative humidity (%) 95(sometimes
approaches
saturation)
5 Average daily ambient air temperature (0C ) 32° Centigrade
6 ISOCERANIC Level (days/year) 50

MPPTCL/TECH-LINE/PROC/SEP23 Page 1
Volume-V

(Average number of thunder storm days)


7 Average rainfall(mm) 1250
8 Wind Zone as per IS 802(Part-I)- 1995 4
9 Max. Altitudes above mean sea level (meters) 1000
10 Seismic level (Horizontal acceleration) (g) 0.3

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

1.03 STANDARDS:

1.03.01 Bidders may please note that all offered materials shall be manufactured, tested
and supplied with all guaranteed technical particulars generally conforming to meet the
requirement of technical specification as brought out in various Sections and latest
revisions of relevant standards of international electro technical commission or equivalent
national standards of India with latest amendments of relevant standards rules and codes.
The lists of standards are specified in relevant Sections of bid document.

1.03.02 The works covered by the specification shall be designed, engineered,


manufactured, built, tested and commissioned in accordance with the Acts, Rules Laws and
Regulations of India.

1.03.03 The Contractor shall also note that list of standards presented in this specification
is not complete. Wherever necessary the list of standards shall be considered in
conjunction with specific IS/IEC.

1.03.04 When the specific requirements stipulated in the specifications exceed or differ
than those required by the applicable standards, the stipulation of the specification shall
take precedence.
1.04 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS :

1.04.01 The lists of Indian standards are specified in individual sections for various
materials and Installation work of bid document. However, the Material and Installation work
meeting any other authoritative International Standard, which ensures equal or better
quality than the Standards mentioned in bid document, shall also be acceptable. Material
for which Indian Standards are not available, any equivalent International Standards will be
applicable. Please attach photocopy of all such Standards according to which the material
and Installation work have been offered.

1.04.02 If the material offered by the Bidder conform to any other standards, salient points
of comparison between the standards adopted and the specific standards shall be clearly
brought out in relevant schedule of deviation. It will be sole responsibility of Bidder to prove
that the salient features of offered materials are equivalent or better than Indian standards
as indicated in Section-2 to Section- 8 of Volume-V(Part-1) of bid document.

1.04.03 The Material and Installation work conforming to standards other than specified in
individual sections for various Material and Installation work shall be subject to Employer’s
approval.

1.05 TYPE TESTS:

1.05.01 Type tests shall mean those tests, which are to be carried out to prove the process
of manufacture and general conformity of the Material.
MPPTCL/TECH-LINE/PROC/SEP23 Page 2
Volume-V

1.05.02 The offered Material (except Towers & Tower Accessories) should be fully type
tested as per the relevant standards. Bidder shall invariably furnish type test reports from
the reputed and approved national/international laboratory/Government approved test
houses to prove that specifications of Material to be supplied conform to the relevant
standard. Test certificates shall clearly indicate the type and other details etc., so that
relevant details of offered Material could be verified. While submitting the bid the details and
type etc., shall be clearly indicated. Type test reports so furnished should not pertain to
the period earlier than as specified in latest CEA guidelines for the validity period of
type tests for various materials. The manufacturer will have to conduct these tests
without any extra cost to the Employer. In both the above cases type test certificate must
be submitted with the offer. The Bidders have to submit one complete set of Test reports for
the offered Material. Further, for any change in the design/type already type tested and the
design/type offered against this specification, the Employer reserves the right to demand
repetition of tests without any extra cost.

1.06 DISCREPANCY IN TECHNICAL PARTICULARS:

The bidders will have to furnish confirmation in regard to compliance of our entire technical
requirement. The bid should clearly describe various technical particulars of the material as
per this specification.

1.07 MANUFACTURER'S AUTHORISATION:


The bidders shall have to submit the documentation from the manufacturer of the Material
on the format specified in this volume that they are authorised to supply the material
indicated in their bids in the employer's country

1.08 SCHEDULE OF QUANTITIES:

1.08.01 The requirements of various Materials and Installation work are indicated in Price
Schedules. In these schedules short description of material has been given. The details of
all such description are given in relevant sections of Volume-V of bid document. The bidder
shall refer these detailed descriptions for clarity.

1.08.02 Although all the quantity of Material and Installation work have been included in the
bid as mentioned in Price Schedules. However there may be requirement of some minor
nature items required for successful erection / commissioning of transmission line work
covered under this Bid. Bidder should include all such items in the bid proposal sheets
which are not specifically mentioned but are essential for the execution of the contract. The
cost of supply of such item which explicitly may not appear in various schedules and are
required for successful commissioning of transmission line shall deemed to be inclusive in
the bid price and shall be provided at no extra cost to Employer.

1.09 PERFORMANCE GUARANTEE PERIOD:

All the Material & its accessories and Installation work covered under the Bid shall be
guaranteed for performance and quality for a period as specified in Volume-I from the date
of completion of facilities (or any part thereof).

1.10 WORKMANSHIP:

All Material shall be of the best class and quality most suitable for the conditions of
operation under the climate conditions as per clause no. 1.02 above for supply of Material.
The workmanship shall be of the best grade and the entire construction in accordance with
the best modern practice.

MPPTCL/TECH-LINE/PROC/SEP23 Page 3
Volume-V

1.11 DRAWINGS AND DOCUMENTS:

1.11.01 In addition to those stipulated in Vol. I of bidding document, the following also shall
apply in respect of Contractor drawings.

1.11.02 With in one month from the award of contract, the contractor shall submit the
drawing of all Material for approval. Each drawing submitted by the Contractor shall be
clearly marked with the name of the EMPLOYER, the specification title, the specification
number and the name of the Project. All titles, noting, markings and writings on the drawing
shall be in English. All the dimensions should be to the scale and in S.I. units.

1.11.03 The comments/ approval to drawings submitted by the Contractor shall be


conveyed by the EMPLOYER as far as practicable within 15 days and shall be modified by
the Contractor if any modifications and/or corrections are required by the EMPLOYER. The
Contractor shall incorporate such modifications and/or corrections and submit the final
drawings for approval with 15 days from date of EMPLOYERs comments. Any delays
arising out of failure by the Contractor to rectify the drawings in good time shall not alter the
Contractual Time Schedule.

1.11.04 The drawings submitted for approval to the EMPLOYER shall be in quadruplicate.
One print of such drawings shall be returned to the Contractor by the EMPLOYER marked
“approved/approved with corrections”. The contractor shall there upon furnish the
EMPLOYER additional prints as may be required along with one reproducible in original of
the drawings after incorporating all corrections.

1.11.05 The work shall be performed by the Contractor strictly in accordance with these
drawings and no deviation shall be permitted without the written approval of the
EMPLOYER, if so required.

1.11.06 All manufacturing, fabrication and Installation work under the scope of Contractor,
prior to the approval of the drawings shall be at the Contractor’s risk. The contractor may
incorporate any changes in the design, which are necessary to confirm to the provisions
and intent of the contract and such changes will again be subject to approval by the
EMPLOYER.

1.11.07 The approval of the documents and drawings by the EMPLOYER shall mean that
the EMPLOYER is satisfied that:
a. The Contractor has completed the part of the Works covered by the subject
documents (i.e. confirmation of progress of work).
b. The Works appear to comply with requirements of Specifications.
In no case the approval by the EMPLOYER of any document does imply compliance with
all technical requirements or the absence of errors in such documents.
If errors are discovered any time during the validity of the contract, then the Contractor shall
be responsible for consequences.

1.11.08 All drawings shall be prepared using AutoCAD software. After final approval all the
drawings and documents (structural drawings, BOMs, shop sketches, tower accessories
drawings and drawings of other materials) shall be submitted to the EMPLOYER in a
portable Hard Disk Drive having storage capacity of 1 TB or higher.
A copy of each drawing reviewed will be returned to the Contractor as stipulated herein.

1.11.09 Copies of drawings returned to the Contractor will be in the form of a print with the
EMPLOYER’s marking.
MPPTCL/TECH-LINE/PROC/SEP23 Page 4
Volume-V

1.11.10 All rights of the design/drawing for all Material and Installation work drawings shall
be strictly reserved with the EMPLOYER only and any designs/drawings/data sheets
submitted by the contractor from time to time shall become the property of the EMPLOYER.
Under no circumstances, the contractor shall be allowed to user/offer above
designs/drawings/data sheets to any other authority without prior written permission of the
EMPLOYER. Any deviation to above is not acceptable and may be a cause for rejection of
the bid.

1.11.11 The manufacturing of the material shall be strictly in accordance with the approved
drawings and no deviation shall be permitted without the written approval of the
EMPLOYER. All manufacturing and fabrication work in connection with the material prior to
the approval of the drawing shall be at Contractor’s risk.

1.11.12 Approval of drawing/works by EMPLOYER shall not relieve the Contractor of his
responsibility and liability for ensuring correctness and correct interpretation of the latest
revision of applicable standards, rules and codes of practices. The plant shall conform in all
respect to high standards of engineering, design, workmanship and latest revisions of
relevant standards. EMPLOYER shall have the power to reject any work or material, which
in his judgment is not in full accordance therewith.

1.12 QUALITY ASSURANCE PROGRAM:

1.12.01 Quality Assurance Program: To ensure that the Material and Services under the
scope of this contract whether manufactured or performed within the Contractor's works
or at his Sub-Contractor's premises or at the EMPLOYER's site or at any other place
of work are in accordance with the Specifications, the Contractor shall adopt suitable
Quality Assurance Program (QAP) with hold points for EMPLOYER’s inspection to control
such activities at all necessary points. Such program shall be outlined by the Contractor
and shall be finally accepted by the EMPLOYER after discussions.

1.12.02 Immediately after award of contract, the contractor shall submit to the EMPLOYER,
the quality assurance plan for all major items of Material covering the manufacture and
Installation activities of the transmission line. The list of selected sub vendors for supply of
minor items like Bolts & Nuts, tower accessories etc. shall also be submitted.

1.12.03 The contractor shall ensure that manufacturer must establish that they are
following the accepted quality assurance programme for manufacture of offered
equipments.

1.12.04 The contractor shall ensure that manufacturers of major items of Material
invariably furnish following information:-
(i) Statement giving list of important raw materials, names of sub supplier for
the raw material, list of standards according to which the raw material are
tested, list of tests normally carried out on raw material in presence of
manufacturers representative, copies of test certificates.
(ii) Information and copies of test certificates as in (i) above in respect of bought
out items.
(iii) List of manufacturing facilities available.
(iv) Levels of automation achieved 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 tests and inspection.
(vi) Special features provided in the equipment to make it maintenance free.
MPPTCL/TECH-LINE/PROC/SEP23 Page 5
Volume-V

(vii) List of testing equipment available with the manufacturer for final testing of
equipment specified and test plant limitations, if any vis-à-vis type, special,
acceptance and routine tests specified in the relevant Indian Standards or
equivalent international standard. These limitations shall be very clearly
brought out in schedule of deviations from specified test equipments.

1.12.05 The Contractor shall follow the accepted Quality Assurance Plan in true spirit. If
desired by the EMPLOYER, he shall give access to all the Specifications, equipments and
records so as to satisfy the EMPLOYER that Quality Assurance Plan (QAP) is being
followed properly.

1.12.06 All Material shall be subjected to the routine and acceptance tests before dispatch,
as specified in this Specification.

1.13 INSPECTION AND TEST CERTIFICATES:

1.13.01 All Material to be supplied will be subject to inspection and approval by the
EMPLOYER's representative before despatch. Inspection before despatch will not however
relieve the contractor of his responsibility to supply the Material strictly in accordance with
the specifications.

1.13.02 For Inspection / testing, the contractor shall intimate the EMPLOYER at least 15
days in advance about readiness of Material as per the scheduled delivery so that action
may be taken for getting the Material inspected. While notifying the readiness of the
Material, the factory test certificate in respect of offered Material shall invariably be sent.
The EMPLOYER will depute authorized representative for inspection of Material or
alternatively may issue waiver of inspection.

1.13.03 The contractor will submit a test certificate to the EMPLOYER after inspection of
offered Material by EMPLOYER’s authorized representative. These test certificates should
be in accordance with latest issue of the relevant Indian Standards or as approved by the
order placing authority.

1.13.04 The Material shall not be dispatched unless the test certificates approval and
despatch instructions have been issued by the EMPLOYER.

1.13.05 All Material shall conform to provisions of any statutory acts such as the Indian
Electricity Act, Indian Factory Act, the Indian Boiler Act, etc. and corresponding rules and
regulations as may be applicable.

1.13.06 The EMPLOYER's representatives shall be entitled at all reasonable time during
manufacture to inspect, examine and test at the contractor's premises the material and
workmanship of the plant to be supplied under this contract.

1.13.07 A copy of the accepted Quality Assurance Plan must be available at the
manufacturer’s works of the Material for reviewing by inspecting officer of the EMPLOYER.

1.13.08 The acceptance of any quantity of plant shall in no way relieve the Contractor of
any of his responsibilities for meeting all requirements of the specification, and shall not
prevent subsequent rejection if such plant is later found to be defective. The Contractor will
have to assume the responsibility for free replacement/rectification of such defects

1.13.09 Testing Expenses:


The entire cost of testing for the acceptance and routine tests and tests during manufacture
specified in the bid document shall be treated as included in the quoted unit price of plant.

MPPTCL/TECH-LINE/PROC/SEP23 Page 6
Volume-V

1.14 SPECIAL REQUIREMENTS:

1.14.01 EMPLOYER expects that participating bidder will take all necessary precautions to
supply best quality Material, which may provide trouble free performance and also it is
expected that the modern practices for erection and commissioning shall be adopted to
ensure timely and trouble free commissioning of installation and also to ensure aesthetic
overall view of finished transmission line installation.

Some of the conditions which will have to be essentially accepted and followed by the
Bidders for the purpose of participating against the Bid and also for undertaking
construction activities are enumerated below for specific confirmation by the Bidders.

1.15 STORE FOR SUPPLY OF MATERIAL:


The Contractor shall supply the Material at selected destination set up by him along the
route of the transmission line. The Contractor will set up above site store within one month
from the date of contract and inform the EMPLOYER. The Contractor will have to supply
above materials and receive them at these places only and the rates quoted by the
Bidder should include charges for delivery of such materials at the store set up by him,
receipt and proper stacking/ stocking at the store.

1.16 COMMENCEMENT OF ACTIVITIES:

Commencement of following activities is subject to prior and specific approval of the items
mentioned against each: -

S. Activity Items for which prior approval is


No. necessary from Employer
1. Manufacturing of tower parts. Inspection of Proto Assembly of
each type of tower. Submission
of quality assurance plan.
2. Manufacturing of Conductors, Submission of Quality Assurance
OPGW/Ground wire, Plan, approval of drawings.
Insulators, Hardware fittings &
Accessories for Conductor
and OPGW/Earth wire.
3. Dispatch of towers, Acceptance test and issue of test
Conductors, OPGW/Earth certificate approval
wire, Insulators, Hardware
fittings & Accessories for
Conductor and OPGW/Earth
wire.
4. Foundation work. Classification of foundation.
5. Erection of tower Quality Assurance Plan for
erection.
6. Stringing of Conductor and Stringing chart and stringing
Earth wire. method.

MPPTCL/TECH-LINE/PROC/SEP23 Page 7
Volume-V

1.17 RESPONSIBILITY FOR OBTAINING INFORMATION AND TAKING ACTION IN


TIME:
Whenever any information or clarifications in respect of construction of line has to be
obtained from various authorities, the Contractor shall be responsible for taking action well
in time so that there are no delays on this account. The completion period specified in the
bidding document is deemed to include the time taken for such incidental works. Request
for extension of the completion date on such ground will not be entertained.

1.18 PERMITS AND PRIORITIES:

1.18.01 Necessary permits, if any, required for the execution of the contract shall be
arranged by the Contractor himself. The Contractor shall obtain the necessary
license/permission as per Central/State/local statutory bodies at his cost.

1.18.02 The Purchaser may, however, furnish to the Contractor such certificates (on
receipt of such written request from the Contractor) as may be required for the necessary
permits/priorities for the execution of works, if it considers the demand as justified.

1.18.03 The Purchaser however, shall not be responsible for the delay in execution of
contract, if permits/priorities are not granted in time in spite of issuance of such certificate.

1.19 USE OF PRIVATE ROADS/APPROACH ROAD TO SITE:

1.19.01 The purchaser will help in getting necessary permission for use of
private/forest/canal, roads for transportation of materials and construction personnels,
wherever possible under the rules. Any charges/tole tax etc. levied by the concerned
authorities for use of such roads etc. shall be borne by the Contractor.

1.19.02 During the erection work, if approach roads are required to be constructed in hilly
terrain or river bed areas for reaching the construction sites for transportation of
men/materials, the cost of construction of such approach roads shall be borne by the
Employer

1.20 MATERIALS TO BE ARRANGED BY THE CONTRACTOR FOR ERECTION


WORK:

1.20.01 The supply of cement for foundation work would be arranged by the Contractor of
the quality as per IS - 269 :1989 (Ordinary Portland Cement 33 Grade) or IS – 8112 : 1987
(Ordinary Portland Cement 43 Grade) or IS – 12269 : 1987 (Ordinary Portland Cement 53
Grade) or IS:1489 (Portland-Pozzolana Cement (PPC)). The cost of cement shall be
deemed to be included in the quoted unit rates of concreting.

1.20.02 The cement used shall be procured from reputed manufacturer like JP Cement,
L&T, Birla Cement, ACC, Ambuja, Wonder Cement etc. The Contractor shall submit the
manufacturer’s certificate, for each consignment of cement procured, to the Purchaser. The
cement shall be arranged in conventional Jute/HD bags each weighing 50 Kgs net with
necessary IS certification mark on it. In case of any dispute regarding quality of cement,
sample for testing may be taken jointly by contractor’s representative and Engineer in-
charge of work or any authorized representative of the Company. The sample taken shall
be tested for standard test as per IS code in Govt. Engineering/Polytechnic College and
testing charge shall be borne by the contractor. In case the material is found defective i.e.
not as per relevant ISS, the same shall be replaced by the contractor at his cost. The
Contractor shall also have no claim towards suspension of work due to time taken in

MPPTCL/TECH-LINE/PROC/SEP23 Page 8
Volume-V

conducting tests in the laboratory. Changing of brand or type of cement within the same
structure shall not be permitted without the prior approval of the Purchaser.

1.20.03 The Quantity of cement to be used per unit quantity of consumption for different
mix (nominal mix) of concrete should be as follows:
S. Description Unit Quantity of minimum
No. Cement to be used
per Unit quantity of
work (in kgs)
1 1:1.5:3 nominal mix concrete Cu.m. 400
2 1:2:4 nominal mix concrete Cu.m. 330
3 1:3:6 nominal mix concrete Cu.m. 220
4 Random Rubble Masonry Cu.m 83
with 1:6 cement mortar

1.20.04 The Contractor shall arrange metal, sand, stone and water required for
foundation/revetment work. The transport, octroi, levy or duty on these materials shall be
borne by the Contractor himself and the purchaser will not accept any liability on this
account.

1.20.05 The Contractor will also arrange steel rods and binding wires etc. for foundation,
reinforcement and the cast incurred will be borne by him. Materials for proper
earthing of towers i.e. earthing rod, connecting clamps and connecting wires etc. would also
be arranged by the Contractor as already specified.

1.21 ACCOUNTING PROCEDURE FOR DISMANTLING MATERIALS: -

1.21.01 The contractor will also have to carry out dismantling of existing transmission line
and transport the dismantled tower parts to MPPTCL’s Workshop at Sehore. The
conductor, ground wire, hardware and accessories, insulators shall be transported and
delivered to nearest Transmission store. Unloading of dismantled material at Sehore
workshop and Transmission store at proper place as intimated by MPPTCL’s Authorities
will be carried out by the Successful bidder at his own cost.

1.21.02 The conductor shall be accounted on tonnage basis. The conductor weight to be
accounted by the contractor shall be calculated as per Indian standard specification No.
IS:398/1962 i.e. 2004 Kg per KM for Moose, 1621 Kg per Km for Zebra, 973 Kg per Km for
Panther and 583 Kg per Km for ground wire. The length of conductor/ ground wire will be
calculated based on the line dismantled + 0.5 % towards sag. No wastage will be
allowed in this case.

1.21.03 The hardware & the accessories shall be accounted on actual basis without any
wastage.

1.21.04 In case of disc insulators 2 % wastage/ breakage will be allowed.

***

MPPTCL/TECH-LINE/PROC/SEP23 Page 9
Volume-V

(B) SPECIFICATION & REQUIREMENT FOR SUPPLY & ERECTION OF 220


KV AND 132KV TRANSMISSION LINE MATERIALS

1.0 TECHNICAL SPECIFICATION FOR SUPPLY OF 132 KV and 220 KV


TOWERS

1.01 INDIAN STANDARDS:


The 220kV & 132kV Double Circuit/ Multi circuit towers, their body extensions, river/ line
crossing structures (Gantries) under this specification shall conform to the requirements of
the latest revisions and amendments available at the time of placement of order of all the
relevant Indian standards/codes listed here under or equivalent International Standards,
except as modified in this document.
S. Indian standards or equivalent Title
No. International Standards with
latest Amendments
1 IS:209-1992 Zinc ingot- Specification.

2 IS:278-1991 Galvanized Steel Barbed Wire.

3 IS:800-1991 Code of Practice for General Building


Construction in Steel.
4 IS:802-Part-II-1990 Code of practice for use of structural steel in
overhead transmission line. Part-II Fabrication,
Galvanising, Inspection & packing.
5 IS 808 – 1991 Dimensions for Hot Rolled Steel beam, Column,
Channel and Angle Sections.
6 IS:1363(Part-III)-1992 Specification for Hexagon head bolts, screws and
nut for product grade – “C” Hexagon nuts of
property class 5.
7 IS:1367-1992 Technical supply conditions for threaded
fasteners (1st Revision).
8 IS:1367(Part-III)-1991 Mechanical properties and test method for bolts,
screws & studs with full loadability.
9 IS:1367(Part-VI)-1994 Mechanical properties and test method for nuts
with specified proof loads.
10 IS-1367(Part-XIII)-1983 The hot dip galvanized coating of fasteners.

11 IS:1573-1991 Specification for electroplated coating of zinc on


Iron & steel.
12 IS:1586-1968 Methods of Rock well hardness test (`B’ & `C’
scales) for steel (first revision).
13 IS:1852-1991 Rolling and Cutting Tolerances of Hot Rolled
Steel Products.
14 IS:2016-1992 Plain Washers.

15 IS:2062-2006 Steel for general Structural purposes –


Specification.
16 IS:2614-1969 Method for sampling of fasteners.

17 IS:2629-1990 Recommended practice for hot dip galvanizing of


iron and steel.
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S. Indian standards or equivalent Title


No. International Standards with
latest Amendments
18 IS:2633-1992 Method of testing uniformity of coating of zinc
coated articles.
19 IS:3063-1994 Single Coil Rectangular Section spring washers
for bolts, nuts, and screws.
20 IS:3202-1972 Methods for testing local thickness of electro
plated coatings.
21 IS:3218(Part-V)-1979 Isometric screw threads “Tolerance”.
22 IS:3757-1992 High Strength Structural Bolts.

23 IS:4072-1975 Specification for steel for spring washers (first


revision).
24 IS:4218(Part-VI)-1978 Isometric screw threads limits of sizes for
commercial bolts & nuts.
25 IS:4759-1990 Specification for Hot dip Zinc coatings on
Structural Steel and other Allied products.
26 IS:5358-1969 Hot dip galvanized coatings on fasteners.

27 IS:5369-1991 General Requirements for Plain Washers.

28 IS:6610-1991 Specification for Heavy Washers for Steel


Structures.
29 IS:6623-1992 High Strength Structural Nuts.

30 IS:6745-1972 Method for determination of weight of zinc


coating of zinc coated iron and steel article.
31 IS:6821-1973 Methods for sampling of non threaded fasteners.
32 IS:8500-1992 Specification for weldable structural steel
(Medium & High Strength Qualities).
33 IS:10238-1989 Step Bolts for Steel Structures.

34 IS:12427-1992 Specification for Transmission Tower Bolts of


property class 5.6

1.02 TYPE OF TOWERS :


1.02.1 The towers will be double circuit, self-supporting lattice type, designed for
the specified loading conditions. The following type of towers are required: -
(A) For 220kV Lines :-
i) Tower type B-0: Tangent type tower with maximum line deviation up to 2°
to be used with Single/Double suspension insulator
strings.
ii) Tower type B-30: Medium angle tower to be used for line deviation from 0°
to 30° with Single/Double tension insulator strings.
iii) Tower type B-60: Heavy angle tower to be used for line deviation from 0°
to 60° and also as dead end tower with Single/Double
tension insulator strings.
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iv) Gantry (type-AGT) Wherever necessary will also be required for crossing
220/400kV transmission lines.

(B) For 132kV Lines:-


i) Tower type E/ND-0: Tangent type tower with maximum line deviation up to 2°
to be used with Single/Double suspension insulator
strings.
ii) Tower type E/ND-30: Medium angle tower to be used for line deviation from 0°
to 30° with Single/Double tension insulator strings.
iii) Tower type E/ND-60: Heavy angle tower to be used for line deviation from 0°
to 60° and also as dead end tower with Single/Double
tension insulator strings.
iv) Gantry: Wherever necessary will also be required for crossing
132/220kV transmission lines.

1.03 EXTENSIONS:
Suitable extension of 3M, 6M and 10M height will be supplied for use with 220 kV towers.
Similarly suitable extension of 3M, 5M and 7.5M and 10M height will be supplied for use
with 132 kV towers.

1.04 TOWER TYPE JC/JCT:


River crossing tower to be used across major river crossings with Double suspension
insulator strings.

1.05 220 kV MULTI CIRCUIT TOWERS:


Wherever necessary, MC-0/MC-30/MC-60 type multi circuit towers with 3/6/10 Meter
extension may be required for transmission lines. Further for 220kV and 132kV line
overhead crossings, MC-X type tower may be used.

1.06 132 kV MULTI CIRCUIT TOWERS:


Wherever necessary, MD-0/MD-15/MD-30/ MD60 132kV Multi circuit Towers with 5M &
10M extension may be required for transmission lines.

1.07 132 kV AND 220 kV NARROW BASE TOWERS:


Wherever necessary, NBE Series 132kV narrow base Towers and NBB Series 220kV
narrow base Towers with suitable extensions may be required for transmission lines.

1.08 STUB SETTING TEMPLATES:


The Contractor will fabricate required number of adjustable stub-setting templates for each
type of tower for carrying out the foundation work. The templates will remain property of the
contractor.

1.09 PROCUREMENT OF STEEL AND ZINC:


The following provisions shall apply in connection with the procurement of steel and zinc by
the bidder:
1.09.1 The steel used for fabrication of tower parts, extensions, templates etc. shall be
mild steel of tested quality as per Indian Standard 2062-1992 or equivalent International
Standard.

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1.09.2 The bidder should take into account the fabrication wastage while quoting the
rates. The Employer shall not accept any liability in connection with the actual wastage of
steel during fabrication or otherwise and no additional cost will be allowed on this account.
1.09.3 Substitutions, if any, of steel sections of the tower parts by higher size, due to their
non-availability or otherwise shall be to the Bidder’s account. The Employer shall not accept
any liability on this account.
1.09.4 The steel shall generally be procured from the Main Steel Producers. However,
sections not rolled/available from the main producers, could be procured from re-rollers as
per quality conforming to Indian Standard, provided;
1.09.4.1 Re-rolling of structural steel sections is done from billets/ingots of tested quality
only.
1.09.4.2 Re-rolled sections are duly tested as per relevant Indian Standard. It may
however be noted that no additional cost shall be payable towards procurement of steel
section from re-rollers.
1.09.5 The zinc used for galvanising of fabricated material shall be Electrolytic High
Grade Zinc (99.95% purity).

1.10 MATERIAL:
1.10.1 IS Steel Sections of tested quality in conformity with IS: 2062: 2006 grade E250
(Designated Yield Strength. 250 MPa) and/ or grade E350 (Designated Yield Strength 350
MPa) are to be used in towers, extensions, stubs and stub setting templates. The
Contractor can use other equivalent grade of structural steel angle sections and plates
conforming to latest International Standards. However, use of steel grade having
designated yield strength more than that of EN 10025 grade S355 JR/JO (designated yield
strength 355 MPa) is not permitted, unless otherwise indicated in this specification.
1.10.2 Steel plates below 6mm size exclusively used for packing plates/packing washers
produced as per IS: 1079 -1994 (Grade -0) are also acceptable. However, if below 6mm
size plate are used as load bearing plates viz gusset plates , joint splices etc. the same
shall conform to IS : 2062 or equivalent standard meeting mechanical strength/metallurgical
properties corresponding to grade E250 or E350 (designated yield strength not more than
355MPa), depending upon the type of grade incorporated into design. Flats of equivalent
grade meeting mechanical strength/ metallurgical properties may also be used in place of
plates for packing plates/ packing washers. The chequered plates shall conform to IS:
3502. SAILMA 350HI grade plate can also be accepted in place of HT plates (EN 10025
grade S355 JR/JO / IS 2062:2006 – grade 350, as applicable) provide SAILMA 350HI
grade plate meet all the mechanical properties of plate as per EN 10025 grade S355 JR/JO
(designated yield strength 355 MPa) / IS 2062:2006 – grade 350.
For designing of towers, preferably rationalised steel section has been used. During
execution of the project, if any particular section is not available, the same shall be
substituted by higher section. Any cost on account of the same shall be borne by the
Contractor. However, design approval for such substitution shall be obtained from the
employere before any substitution and records of such substitutions shall be maintained by
the Contractor.
1.10.3

1.11 WEIGHTS:
The unit weight of each type of tower and extension including bolts and nuts, accessories,
attachments and step bolts is indicated in the Bill of Materials which shall be supplied by the
Employer to the successful bidder. The weight of structure means the weight calculated
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using black sectional (i.e. ungalvanised) weights of all steel members of the sizes indicated
in the fabrication drawings without taking into consideration the reduction in weight due to
drilling of bolts, holes, skew cuts, chamfering etc. or increase in weight due to galvanising.

1.12 GALVANISING:
1.12.1 The tower parts, stubs and pack washers shall be hot dip galvanized. The
galvanization shall be done as per requirements of IS 4759 after all fabrication work is
completed. The contractor shall also take guidelines from the recommended practices for
hot dip galvanizing laid down in IS 2629 while deciding and implementing galvanizing
procedure. The mandatory requirements however, are specified herein.
1.12.2 Unless otherwise specified the fabricated tower parts and stubs shall have a
minimum overall zinc coating of 610 gms per sq.m. of surface except for plates below 5mm
which shall have Zinc coating of 460 gms per sq.m of surface. The average zinc coating for
sections 5mm & above shall be maintained as 87 microns and that for sections below 5mm
shall be maintained as 65 microns.
1.12.3 The zinc coating shall be adherent, reasonably uniform, smooth, continuous and
free from imperfections such as black/bare spots, ash rust strains, bulky white
deposits/wet storage strains and blisters.
1.12.4 The surface preparation for fabricated tower parts and stubs for hot dip galvanizing
shall be carried out a indicated herein below:
(i) Degreasing & Cleaning of Surface: Degreasing and cleaning of surface, wherever
required, shall be carried out in accordance with clause 4.1 of IS 2629-1990. After
degreasing the article shall be thoroughly rinsed. However, if acidic degreasers are
used rinsing is not required.
(ii) Pickling: pickling shall be done using either hydrochloric or sulphuric acid as
recommended at clause 4.3 of IS 2629-1990. The actual concentration of the acids
and the time duration of immersion shall be determined by the Contractor depending
on the nature of material to be pickled. Suitable inhibitors also shall be used with
the acids to avoid over pickling. The acid concentration, inhibitors used, and
maximum allowable iron content shall form part of plant standard to be formulated
and submitted to Employer along with Quality Assurance Program.
(iii) Rinsing: After pickling, the material shall be rinsed, preferably in running water to
remove acid traces, iron particles or any other impurities from the surface. Two
rinse tanks are preferable, with water cascading from the second tank to the first to
ensure thorough cleaning. Wherever single tank is employed, the water shall be
periodically changed to avoid acid contamination, and removal of other residue from
the tank.
(iv) Fluxing: The rinsed article shall be dipped in a solution of zinc ammonium chloride.
The concentration and temperature of the flux solution shall be standardized by the
contractor depending on the article to be galvanized and individual circumstances.
These shall form part of plant standard to be formulated and submitted to Employer
along with Quality Assurance Program. The specific gravity of the flux solution shall
be periodically monitored and controlled by adding required quantity of flux crystals
to compensate for drag-out losses. Free acid content of the flux solution also shall
be periodically checked and when it is more than two (2) grams of free acid per litre
of the solution, it shall be neutralized. Alternatively, Ph value should be monitored
periodically and maintained between 5.0 to 5.5.
(v) Drying: When dry galvanizing is adopted the article shall be thoroughly dried after
fluxing. For the purpose of drying, the contractor may use hot plate, air oven or any
other proven method ensuring complete drying of the article after fluxing and prior to
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dipping in the molten zinc bath. The drying process shall be such that the article
shall not attain a temperature at which the flux shall get decomposed. The article
thus dried shall be galvanized before the flux coating picks up moisture from the
atmosphere or the flux layer gets damaged or removed from the surface. The
drying procedure, time duration, temperature limits, time lag between fluxing, drying,
galvanizing etc shall form part of plant standard to be formulated and submitted to
Employer along with Quality Assurance Program.
(vi) Quality of Zinc: Any one or combination of the grades of zinc specified in IS 209 or
IS 13229 or other comparable international standard shall be used for galvanizing.
The contractor shall declare the grade(s) of zinc proposed to be used by them for
galvanizing. The molten metal in the zinc bath shall contain minimum 98.5 % zinc
by mass. It shall be periodically measured and recorded. Zinc aluminium alloy shall
be added as per IS 2629.
(vii) Dipping Process: The temperature of the galvanizing bath shall be continuously
monitored and controlled. The working temperature of the galvanizing bath shall be
maintained at 450 ± 10°C. The article should be immersed in the bath as rapidly as
possible without compromising on safety aspects. The galvanizing bath
temperature, immersion angle & time, time duration of immersion, rate of withdrawal
etc. shall be monitored and controlled depending upon the size, shape, thickness
and chemical composition of the article such that the mass of zinc coating and its
uniformity meets the specified requirements and the galvanized surface is free from
imperfections and galvanizing defects.
(viii) Post Treatment: The article shall be quenched in water. The quench water is to be
changed / drained periodically to prevent corrosive salts from accumulating in it. If
water quenching is not done then necessary cooling arrangements should be made.
The galvanized articles shall be dipped in chromating solution containing sodium
dichromate and sulphuric acid or chromic acid base additive at a predetermined
concentration and kept at room temperature to retard while rust attack. The
temperature of the chromate solution shall not exceed 65°C. The articles shall not
be stacked immediately after quenching and dichromating. It shall be ensured that
the articles are dry before any further handling operation.
(ix) Storing, Picking and Handling: In order to prevent while rust formation sufficient
care should be exercised while storing handling and transporting galvanized
products. The articles shall be stored in an adequately ventilated area. The articles
shall be stored with spacers in between them and kept at an inclination to facilitate
easy drainage of any water collected on the articles. Similar care is to be taken
while transporting and storing the articles at site.
(x) The Contractor shall prepare a detailed galvanizing procedure including Flow Chart
with control parameters and all plant standards as required above and submit to
Employer for acceptance as part of Quality Assurance Plan.
Minor defects in hot-dip galvanised members supplied at site shall be repaired by
applying zinc rich primer and two coats of enamel paint to the satisfaction of the
employer before erection, after obtaining specific permission from Employer.

1.13 GALVANISED BOLTS, NUTS AND WASHERS:


1.13.1 The bolts and nuts to be supplied shall be mild steel hot dip galvanized bolts (5.6
quality) and nuts (5.0 quality). The spring washers are to be supplied for insertion under all
nuts. These washers shall be of steel, electro galvanized, and positive lock type and of
3.5mm thickness. Bolt heads and nuts shall be of hexagonal shape.

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1.13.2 The nuts shall be forged and tapped after galvanizing and then lubricated. The
nuts shall be chamfered on one face only; the other face shall be machined.
1.13.3 The bolts of 16mm size shall be manufactured by cold/hot forging process and the
threads shall be rolled.
1.13.4 The bolts and nuts shall be free from forging and threading defects such as cuts,
splits, burrs, bulging, taper, eccentricity, loose fit etc.
1.13.5 The bolts shall be threaded up to standard length only as per relevant Indian
Standard and not to full length.
1.13.6 The bolts and nuts shall conform to Indian Standard1367: 1991 Part-III and Part-
IV, Indian Standard12427:1992, Indian Standard1363-1992, Indian Standard 1367 (Part-
XIII)-1983 with latest amendment or equivalent International Standards.
1.13.7 The spring washers designated as M 16-B suitable for 16mm dia galvanized bolt
shall be manufactured out of rectangular section with tolerances as per Indian Standard
3063-1994 with latest amendments or equivalent International Standard. The spring steel
shall conform to Indian Standard:4072-1975 with latest amendments "Specification for steel
for spring washers" or equivalent International Standard.
1.13.8 The spring washers after coiling shall be suitably heat-treated to obtain
finished washer having hardness 43 to 50 HRC when tested in accordance with Indian
Standard 1586- 1968 or equivalent International Standard.
1.13.9 The surface of the washers shall be free of scales and burrs. The washers shall be
coiled without any kinks (except for the shape with turned-up ends). The ends of the
washer shall not abut when the washers are compressed. The ends shall be so served as
to prevent tangling.
1.13.10 The approximate weight of 1000 pieces of spring washers suitable for 16mm dia
bolt shall be 8.91 kg. in natural black finish as shown in Indian Standard 3063-1994 with
latest amendments or equivalent International Standard.
1.13.11 The spring washer shall be electro galvanized with chromate passivation. The
electro galvanizing of washers should conform to ’severe’ grading service conditions
incorporated in Indian Standard 1573: 1991 or equivalent International Standard as
"Service Grade No.4", classification Fe Zn 25. The thickness of zinc coating should be
minimum 25 microns and average thickness 38 microns. It should be further suitably heat-
treated to avoid any danger of hydrogen embrittlement.

1.14 STEP BOLTS :


Each tower will be provided, on one of the legs, with step-bolts of 16mm dia and 175mm
long, spaced not more than 450mm and extending from 3 meters above ground level up to
the top portion of the tower. The step bolts shall conform to Indian Standard1363-1992,
Indian Standard10238:1989 and Indian Standard 1367(Part-XIII):1983 or equivalent
International Standards.

1.15 DANGER BOARD, NUMBER PLATE AND PHASE PLATES :


Each tower will be fitted with danger board, number plate and phase plates. The tower to
be supplied shall have provision to fix these plates at a height of about 3 meters above
ground level. Necessary provision in tower & extensions for fixing of these items shall be
made. The Danger board, number plate and phase plates shall be supplied conforming to
following technical details:-
1.15.1 The danger boards shall conform to IS-2551-1982 and their revision, if any except
where modified in this specification.
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1.15.2 The danger boards, number plates and phase plates shall conform to the drawings
enclosed in this specification.
1.15.3 The colour scheme of the enamel and size of figures and dimensions of lettering
shall be as shown in the drawing as also the overall size. The holes as indicated in the
drawing shall be provided before enamellings.
1.15.4 The thickness of the plate out of which the danger board, number plate and phase
plate will be manufactured, shall not be less than 1.6mm.
1.15.5 The enamellings shall be done by vitreous enameling process only.
1.15.6 All letterings shall be centrally spaced. The dimensions of the letters, figures and
their respective positions shall be as given in drawings. The size of each letter in the word
in each language and the spacing between them for the purpose of scribing shall be so
chosen that they are uniformly written in the space earmarked for them.
1.15.7 The corners of the plate shall be rounded off. The location of the fixing holes shall
be according to drawing annexed with this specification.
1.15.8 The plate shall be made from mild steel at least 1.6mm thick and vitreous
enameled white, with letters, figures and the conventional skull and cross-bones in signal
red colour on the front side. The rear side of the plate shall also be enameled.

1.16 ANTICLIMBING DEVICE WITH BARBED WIRE :


The barbed wire type anti-climbing device shall be supplied for use at a height of
approximately 3 meters as an anti-climbing deterrent measure, as per the details given in
Indian Standard: 5613(Part- 2/Sec-I) 1985 or equivalent International Standard. The angle
pieces with notches for accommodating barbed wire shall be used for this purpose. The
towers to be supplied by the Bidder shall have provision of suitable bolt holes on leg
members for fitting the angles to fix the barbed wire as indicated above. The details of anti-
climbing device are indicated in drawing enclosed in Annexure-8. The requirement of angle
pieces with notches and barbed wire (per set) will be as under:-
(A) For 220kV Towers:-
Angle pieces - 23.57 Kgs.
Bolts & nuts - 3.41 Kgs.
Barbed wire - 25.00 Kgs.

(B) For 132kV Towers:-


Angle pieces - 24.34 Kgs.
Bolts & nuts - 2.00 Kgs.
Barbed wire - 20.00 Kgs.

1.17 EARTHING :
1.17.1 A provision shall be made in all stubs for fixing earthing material. The stub will be
provided with a hole at a distance of 250 mm from bottom end and at a distance of 500 mm
below ground level for connection with earthing materials. The hole will be of 17.5 mm dia.
1.17.2 The Bidder shall also supply and erect the following materials per earthing set for
earthing of towers (four sets per tower): -
(i) One no. Hot dip galvanized earthing Mild Steel Rod (2 Meter long, 25 mm
diameter):
(ii) Hot dip galvanized connecting clamps (`F’ type and `U’ type- 2 No. per set);
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(iii) Hot dip galvanized stranded steel wire of size 7/4mm, Grade 5 to be used as
connecting wire conforming to Indian Standard: 2141:1992 and Indian Standard
4826: 1979 or equivalent International Standard (5 Meter per earthing set).
1.17.3 The details of earthing rod and clamps and earthing arrangement for towers are
shown in the drawing enclosed.
1.17.4 The earthing rod shall be of mild steel solid rod of 2 meters in length and 25mm in
diameter with one end pointed. The rods shall be galvanized as per relevant Indian
Standard or equivalent International Standard. The zinc coating on the rod shall not be less
than 610 gm/m² of surface area.
1.17.5 The tower end-connecting clamp shall be of flat type and rod end connecting
clamp shall be of `U’ type. The clamps shall be of forged steel cast iron / malleable iron.
The clamps should be hot dip galvanized as per Indian Standard: 2629:1990 or equivalent
International Standard. The zinc coating on the clamps shall not be less than 610 gm/m² of
surface area.
1.17.6 The hot dip galvanized stranded steel wire of size 7/4.00mm shall be supplied for
connection between the earthing rod and the stub. The steel wire shall conform to Indian
Standard 2141: 1992 or equivalent International Standard and Indian Standard:4826: 1979
and latest revision thereof or equivalent International Standard and shall consist of seven
strands, each strand having a diameter of 4 mm and Grade-5. The galvanizing shall be
done as per Indian Standard specification2141: 1992 or equivalent International
Standard and 4826: 1979 and latest revision thereof or equivalent International Standard for
heavy zinc coating. The coating of zinc shall not be less than 260 gm/m².

1.18 ATTACHMENT FOR INSULATOR STRING & EARTH WIRE CLAMPS:


1.18.1 The towers shall be provided with suitable attachment for supporting insulator
strings and Earth wire suspension and tension assembly.
1.18.2 The towers shall be provided with the cleats to support the hanger.
1.18.3 The Earth wire suspension assembly has got a ‘D’ shackle. There shall be a
suitable arrangement to support the same.
On angle towers, strain plates shall be provided for the purpose of attaching the tension
insulator string. For fixing Earth wire tension assembly a hole 17.5mm dia shall be provided
in the strain plate.

1.19 FABRICATION WORKMANSHIP :


1.19.1 Except where hereinafter modified, details of fabrication shall conform to Indian
Standard-802 (Part-II)-1990 or equivalent International Standard.
1.19.2 The fabrication of towers shall be done strictly in accordance with the drawings
supplied by the Employer.
1.19.3 The tower shall be of bolted construction.
1.19.4 Normally lap splice shall be used for connecting members of un-equal size and
the inside angles of lap splice shall be rounded at the heel to fit the fillet of the outside
angle. All splices shall develop full stress in the members connected through bolts. Butt
joint as well as lap joint splices shall be made as above and as close to the main panel as
possible.
1.19.5 Joints shall be designed and detailed to avoid eccentricity as far as possible. The
use of gusset plates for joining tower members shall be avoided as far as possible.
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However, where the connections are such that the eliminations of the gusset plates would
result in eccentric joints, gusset plates and spacer plates may be used in conformity with
modern practice.
1.19.6 The tower structures shall be accurately fabricated to bolt together easily at site
without any undue strain on the bolts.
1.19.7 No angle member shall have two leg flanges brought together by closing the angle.
1.19.8 The diameter of the hole shall be equal to the diameter of the bolt plus 1.5 mm.
1.19.9 All similar parts shall be made strictly interchangeable. All steel section before
any work is done on them shall be carefully leveled, straightened and made true to
detailed drawings by methods which will not damage the materials so that when assembled
the adjacent matching surfaces are in close contact throughout. No rough edges shall be
permitted in the entire structures. Hammering is not permitted for straightening.
1.19.10 Cutting may be done by shearing, cropping, flame cutting or sawing. The surface
so cut shall be cleaned smooth, reasonably square and free from deformation and
distortion.

1.20 BENDING :
1.20.1 Mild steel angle sections up to 75x75 mm (up to 6mm thick) shall bent cold up to
and including bend angle of 10° Angles. Above 75x75mm (thickness up to 6mm) and up to
and including 100x100 mm (thickness up to 8 mm) may also be bent cold up to the bend
angle of 5 Deg. All other angle sections and bend angles not covered above shall be bent
hot.
1.20.2 All plates up to 12mm thickness shall be bent cold up to a maximum bend angle of
15 Deg. Plates of thickness more than 12mm with bends greater than 15 Degree shall be
bent hot.
1.20.3 All hot bend material shall be air-cooled. The bends shall be of even profile and
free from any surface damages.

1.21 DRILLING AND PUNCHING :


1.21.1 The holes in the member shall either be drilled or punched with a jig; the former
process will be preferred.
1.21.2 Punching may be adopted for sections upto 12 mm thickness. For thicker sections
drilling shall be done.
1.21.3 The holes shall be punched/drilled after bending and related position of
these holes shall be maintained with the use of proper templates/jigs and fixtures.
1.21.4 The holes shall be perfectly circular and no tolerance in this respect is permissible.
The holes shall be perpendicular to the plate and angle flanges.
1.21.5 Holes must be square with the plates or angles and have their walls parallel.
1.21.6 All burrs left by drills or punch shall be removed completely. When the tower
members are in positions, the holes shall be truly opposite to each other. Drilling or
ramming to enlarge defective holes shall not be permitted.
1.21.7 The minimum spacing of bolt and edge distance shall be as under: -

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(a) For 16 mm dia bolt edge distance of 20 mm from hole center to rolled or
swaned edge and 23mm from hole center to sheared or flame cut edge, hole
center to hole center distance minimum 40mm (the hole size being 17.5mm).

(b) The gap between the edges of the connected members in butt joint shall not
be more than 6mm and less than 4mm.

(c) The bolt gauge distance in flanges of angle sections shall generally be in
accordance with Table XXXI of SF6 (1)-1961-ISI “Hand Book for structural
Engineers-Structural Steel Sections (Revised).”

1.22 TOLERANCES :
1.22.1 The maximum allowable difference in the diameter of the hole on the two sides of
the plate or angle shall not exceed 0.8 mm on diameter. The allowable taper in
drilled/punched hole shall not exceed 0.8 mm on diameter.
1.22.2 The tolerance cumulative or between consecutive holes shall be within +/-0.5mm.
1.22.3 The tolerance on the overall length of member shall be within +/- 1.6 mm.
1.22.4 The tolerance on gauge distance shall be within +/- 0.5mm.
1.22.5 Rolling and weight tolerance of steel sections shall be as per Indian Standard:
1852 or equivalent International Standard and Indian Standard: 808 or equivalent
International Standard.

1.23 MARKING :
Every member shall be distinctly given punch mark similar to those given in structural
drawings. The mark shall be given with marking dies of minimum 18 mm size and this
mark shall be legible. Letter XMPTBA, XMPTBB and XMPTBC for 220kV and XMPTEA,
XMPTEB and XMPTEC for 132kV shall precede erection mark where ‘X’ stands for
manufacturer’s name, ‘MPT’ stands for Madhya Pradesh Power Transmission Company
and BA, BB & BC stands for B0, B30 & B60 type towers and EA, EB & EC stands for E0,
E30 & E60 type towers respectively. Similar marking arrangement may be followed for
narrow base towers.

1.24 QUALITY ASSURANCE PROGRAM :


The contractor shall submit the Quality Assurance Programme as specified in clause 1.12
Section-1 of the biding document. A copy of the accepted Quality Assurance Plan must be
available at the manufacturer’s works of the Plant for reviewing by inspecting officer of the
employer.

1.25 INSPECTION OF PROTO TYPES :


1.25.1 Proto type of each type of structure/extensions shall be offered by the successful
bidder for inspection within three month’s time from the date of contract.
1.25.2 Notwithstanding any thing covered in the drawings and other details furnished by
the Employer, the successful bidder shall make minor modifications, if any, in length, size,
notching etc. according to the proto assembly which are necessary for easy assembly of
the structure.

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1.26 INSPECTION :
1.26.1 As specified in clause 1.13 Section-1 of the biding document, Plant to be supplied
will be subject to inspection and approval by the Employer's representative before
despatch.
1.26.2 Each consignment ready for transportation shall be offered to the Employer for
inspection before dispatch giving a minimum time of not less than fifteen days. Only
complete sets of towers/extensions shall be offered for inspection. All materials constituting
towers (Steel parts, Bolts & nuts, spring and pack washers, earthing sets) shall be offered
simultaneously. Samples of fabricated tower materials and accessories shall be subjected
to tests as per relevant Indian Standard or equivalent International Standard. The
Employer shall be kept informed about the source of procurement of raw-steel, particularly
through re-rollers. The Employer reserves right to inspect and get the samples of raw-steel
tested as per Indian Standard-2062 and relevant standards or equivalent International
Standard. The cost of testing shall be borne by the bidder.
1.26.3 The Contractor shall keep the Employer informed in advance of the time of starting
and of the progress of manufacture and fabrication of structures at various stages.
1.26.4 In case, any member of the structure is not found to comply with the relevant
drawing, it shall be liable for rejection even after receipt.
1.26.5 Defects, which may appear during fabrication, shall be made good. Any member
once rejected shall be cut into pieces in front of the Employer’s representative so that it is
not offered again by mistake.

1.27 GENERAL GUIDE-LINE FOR INSPECTION :


1.27.1 Fabricated Structure Members :
(i) Visual examination and quantity verification of offered lot.
(ii) Sample selection from the offered lot at a ratio of 40 MT (or part thereof) 1
no. each for all tests.
(iii) Dimension, fabrication and trueness verification of structure member from
fabrication sketch.
(iv) Galvanising test of each sample i.e. dip test, hammer test and mass of zinc
test.
(v) Random verification of Zinc coating of galvanized surface by Alko-meter.
(vi) Tensile test and bend test of each sample.
(vii) Chemical composition test of at least two samples per offered lot of 50 MT
for inspection.
(viii) Verification of manufacturer’s test certificate for mild steel used in structure
members.
1.27.2 Bolts-Nuts, Washer, Accessories, Attachments etc.: (To be carried out at
manufacturers works of these items)
(i) Visual examination and quantity verification of offered lot.
(ii) Sample selection from the offered lot as per relevant Indian Standard for
each item.
(iii) Dimension, fabrication and trueness verification from fabrication sketch.
(iv) Galvanising test of each sample.
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(v) Other acceptance tests for respective items as per relevant Indian standard.
1.27.3 The supplier shall submit the factory test certificates of bought out accessories at
the time of acceptance tests of towers.
Since at the time of inspection only fabricated tower members and accessories will
1.27.4

be verified, acceptance of any lot shall in no way relieve the bidder of his responsibility to
meet all technical requirements of this specification for fabricated towers. In case any
shortcoming is noticed at the time of actual assembly and erection, the Employer may reject
any part or item or accessory and the contractor will have to assume the responsibility for
free replacement/rectification of such defects.

1.28 PACKING AND MARKING ON PACKING :


1.28.1 The material shall be boxed or bundled for transport in the following manner:
(i) Angle shall be packed in bundles securely wrapped four times around at each end
and over 900 mm with No.9 SWG steel wire with ends twisted tightly. Gross
weight of any bundle shall not be less than 450 Kg and more than 2000 Kg. The
bundle shall be in complete Tower form only.
(ii) Cleat angles, brackets, filler plates and similar small loose pieces shall be nested
and bolted together through holes and wrapped around at least four times with
No.9 SWG wire with ends twisted tightly or packed in wooden crates. Gross
weight of each bundle shall not exceed 200 Kg.
(iii) Correct number of bolts, nuts and washers required for structures shall be packed
in heavy gunny bags accurately tagged in accordance with the contents and a
number of bags packed in a solid box of 22mm thick lumber with paneled ends to
be accurately nailed and further reinforced with 22 mm x 75 mm Batons round the
sides and at the ends with 25 mm x No.18 SWG iron band stretched entirely
around the batons with ends overlapping at least 150mm. Gross weight of each
box shall not exceed 200 Kg.
(iv) Packing list incorporating all relevant details e.g. quantity of structures (complete
sets), number and size of steel sections, quantity of nuts, bolts, washers etc. shall
be forwarded along with each consignment.
(v) In the nutshell the packing arrangement should be such that all lots of one
particular type of structure are identifiable at site for the purpose of allocation for a
particular work. In case more than one structure of a particular type is delivered in
area store/work site, combined packing arrangement by way of clubbing members
of similar type (for more than one structure) in a combined package should not be
done. Uniform packing procedure for each structure should be adopted.
1.28.2 All above packing are subject to the approval of the Employer or his appointed
representatives.
1.28.3 Each bundle or packing shall have the following marks:
(i) The name of the consignee (as per dispatch instructions given by the Employer).
(ii) Ultimate destination as required by the Employer.
(iii) The relevant marks and number of structure members or reference or bolts, nuts
and small components like gusset plats, various attachment, etc. for easy
identification.
The marking shall be stenciled and indelibly inked on the top members in the bundles, on
wooden boxes and also on gunny bas containing smaller components.

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2.0 TECHNICAL SPECIFICATIONS OF ACSR PANTHER AND ZEBRA


CONDUCTOR

2.01 STANDARDS:

This section provides for standard design, manufacture, stage testing, inspection and
testing before despatch, packing and delivery of Steel Cored Aluminium Conductors
specified hereunder for their satisfactory operation. The power conductors shall conform to
the following Indian Standards, which shall mean latest revisions, amendments/changes
adopted and published, unless otherwise specified hereinbefore:

Sr. Indian Standards or any Title


No. Equivalent International
Standard

1 IS:209 -1990 Specification for Zinc


2 IS:398 Part I to Part V Specification for Aluminium Conductors for
(as relevant) overhead Transmission purpose
3 IS:1778 Reels and drums for Bare wires

4 IS:1521 Method of Tensile Testing of Steel wire

5 IS:2629 -1990 Recommended practice for Hot Dip


Galvanising Iron and Steel
6 IS:2633 -1990 Method of Testing Uniformity of Zinc
coating of Zinc coated Articles.
7 IS:4826 Galvanised coating on Round Steel wire

8 IS:6745 -1990 Method of Determination of weight of Zinc


coating of zinc coated Iron and Steel
Articles
9 IS:8263 Method of Radio Interference Tests
10 IS:1841 EC Grade Aluminium Rod produced by
rolling
11 IS:5484 EC grade Aluminium Rod produced by
continuous casting and rolling
12 IS: 2141 -1990 Method of Elongation test of steel wire

2.02 PARAMETERS :

Sr. No. Details of Stranded Conductor ACSR Zebra ACSR Panther

3.01.01 Principal Parameters of Stranded Conductor:

a) No. of Strands Aluminium-54 Aluminium-30


Steel –7 Steel-7
i. Steel Centre 1 1
ii. 1st Steel Layer 6 6

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iii. 1st Aluminium Layer 12 12


iv. 2nd Aluminium Layer 18 18
v. 3rd Aluminium Layer 24 -
b) Sectional Area of Aluminium (Sq.mm) 428.9 212.10
c) Total Sectional Area (Sq.mm) 484.50 261.60
d) Overall diameter(mm) 28.62 21.00
e) Approximate weight (Kg/Km ) 1621 976
f) Calculated D.C. Resistance at 20 0.06915 0.139
Deg.C (Ohm/Km)
g) Minimum UTS (kN) 130.32 89.67
h) Modulus of Elasticity GN/SqMtr 69 80

3.01.02 The details of Aluminium Strand are as follows :

a) Minimum breaking load of strand 1.29 1.17


Before stranding (kN)
b) Minimum breaking load of strand 1.23 1.11
after stranding (kN)
c) Maximum D.C. resistance of strand 3.651 4.107
at 20 deg.C (Ohm/Km)
d) Nominal Strand Dia 3.18 3.00
e) Max. Strand Dia 3.21 3.03
f) Min. Strand Dia 3.18 3.00
g) Mass (Kg/Km) of Strand at Nominal 21.47 19.11
dia

3.01.03 The details of Steel Strand are as follows:

a) Minimum breaking load of strand 10.43 9.29


Before stranding (kN)
b) Minimum breaking load of strand 9.91 8.83
after stranding (kN)
c) Nominal Strand Dia 3.18 3.00
d) Maximum Strand Dia 3.24 3.06
e) Minimum Strand Dia 3.18 3.00
f) Mass (Kg/Km) of Strand at Nom. 61.95 55.18
dia
g) Zinc coating testing 3 dips of 1 min. 3 dips of 1
each min.each
h) Wt. Of Zinc Coating 260gms/sq. 260gms/sq.
metre Metre

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2.03 GENERAL TECHNICAL REQUIREMENTS:


MATERIAL AND WORKMANSHIP (FOR ACSR ZEBRA & ACSR PANTHER):
2.03.1 Materials:
The conductors shall be manufactured from EC grade aluminium rods suitably hard-drawn
on wire drawing machines. The aluminium rods used shall comply with IS: 1841 and IS:
5484 or any equivalent International Standard. The mechanical and electrical properties of
aluminium wire shall comply with the requirements given in relevant standard.
2.03.2 Physical constants for Hard-drawn Aluminium:
2.03.2.1 Resistivity:
The resistivity of aluminium depends upon its purity and its physical condition. For the
purpose of this specification the maximum value permitted is 0.28264 Ohm sq.mm/mt. at
20° C and this value has been used for calculation of the maximum permissible value of
resistance.
NOTE: It is not intended to check the resistivity from the measured values of resistance.
2.03.2.2 Density:
At a temperature of 20° C the density of hard drawn aluminium has been taken as 2.703
g/cm.3
2.03.2.3 Constant-Mass Temperature Co-efficient of Resistance:
At a temperature of 20°C, the constant-mass temperature co-efficient of resistance of hard
drawn aluminium measured between two potential points rigidly fixed to the wire, the metal
being allowed to expand freely, has been taken as 0.004 per degree Celsius.
2.03.2.4 Co-efficient of Linear Expansion:
The co-efficient of linear expansion of hard-drawn aluminium at 0° C has been taken as
23.0 x 10 -6 per ° C. This value holds good for all practical purposes over the range of
temperature from 0 ° C to highest safe operating temperature.
2.03.3 Galvanised steel wire shall be drawn from high carbon steel rods produced by
either acidic or basic open hearth process, electric furnace process or basic oxygen
process. The mechanical and electrical properties of wire shall comply with the
requirements given in relevant standard. The chemical composition of high carbon steel
wires is given below for guidance only.
Element Percentage Composition
Carbon 0.5 to 0.85
Manganese 0.50 to 1.10
Phosphorous Not more than 0.035
Sulphur Not more than 0.045
Silicon 0.10 to 0.35

2.03.3.1 Physical constants for Galvanised steel wires:


2.03.3.1.1 Density :
At a temperature of 20° C, the density of galvanized steel wire is to be taken as 7.80 g/Cm3.

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2.03.3.1.2 Coefficient of Linear Expansion :


In order to obtain uniformity in calculation a value of 11.5 x 10 -6 per ° C may be taken as
the value for the co-efficient of Linear Expansion of galvanized steel wires used for the
cores of steel-reinforced aluminium conductors.
2.03.3.1.3 The zinc used for galvanizing shall be electrolytic high-grade Zinc not less
than 99.95 percent purity. It shall conform to and satisfy all the requirements of IS: 209.
Galvanising may be done either by hot process or electrolytic process. Minimum weight of
Zinc coating shall be 260 g/sq. metre. Neutral grease may be applied between the layers of
wire.

2.03.3.1.4 Freedom From Defects:


The wires shall be smooth and free from all imperfections such as spills, slag inclusion, die
marks, scratches, fittings, blow-holes, projections, looseness, overlapping of strands,
chipping of aluminium layers etc. and all such other defects which may hamper the
mechanical and electrical properties of the conductor. Special care should be taken to keep
away dirt, grit etc. during stranding.
2.04 Wire Sizes
2.04.1 Nominal Size:
The aluminium and galvanized steel wires for the stranded conductor covered by this
standard shall have diameters specified in clause 3.02.02 & 3.02.03. The diameter of the
steel wires shall be measured over the zinc coating.
2.04.2 Tolerances on Nominal Size :
Tolerance of + 1% is permitted on the nominal diameter of Aluminium Wires of Panther
and Zebra Conductor and a tolerance of + 2 % is permitted on the nominal diameter of
Galvanised Steel Core Wire.
2.05 JOINTS IN WIRES:
2.05.1 Aluminium Wires:
No joints shall be permitted in the aluminium wires in the outermost layer of the ACSR
Conductor. Joints in the inner layers are permitted, in addition to those made in the base
rod or wire before final drawing, but no two such joints shall be less than 15 mtr. apart in the
complete stranded conductor. Such joints shall be made only by cold pressure butt-welding.
It may please be noted that Joints are not permitted in the outermost layer of the conductor
in order to ensure a smooth conductor finish and reduce radio interference levels and
corona losses on extra high voltage lines.
2.05.2 Galvanised Steel Wires:
There shall be no joints except those made in the base rods or wires before final drawing, in
steel wires forming the core of the steel-reinforced aluminium conductor. Joints are not
permitted in the steel wires after final drawing also in order to avoid reduction in the
breaking strength of the conductor that may occur as a result of failure of the joints.

2.06 STRANDING :
2.06.1 The wires used in the construction of galvanized steel reinforced aluminium
conductor, before stranding, shall satisfy all the relevant requirements of this specification.

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2.06.2 The lay ratio of the different layers shall be within the limits given in the Table
below:-

Type of Ratio Lay Ratios Lay Ratios for Aluminium wires


conductor of Alu. of Steel (3 Alu. Wire Layer Conductors)
wire core 6 wire
diame layer Layer
Outermost immediately Innermost
ter to layer Layer
steel beneath outer
wire most layer
diame Min. Max. Min. Max Min. Max. Min. Max.
ter .
Panther AL -30
Wire ST. - 7 Wire 1 13 28 10 14 10 16 - -
Zebra AL -54 Wire
ST. - 7 Wire 1 13 28 10 14 10 16 10 17

NOTE : For the purpose of calculation, the mean lay ratio shall be taken as the
arithmetic mean of the relevant minimum and maximum values given in
this table.
2.06.3 In all constructions, the successive layers shall have opposite directions of lay,
the outermost layer being right-handed. The wires in each layer shall be evenly and closely
stranded.
2.06.4 In conductors having multiple layers of aluminium wires, the lay ratio of any
aluminium layer shall not be greater than the lay ratio of the aluminium layer immediately
beneath it.
2.06.5 The finished Conductor shall have a smooth surface without any surface cut,
abrasion, scuff marks and shall be free from dirt, grit, etc. even if the damage to conductor
is acceptable from mechanical considerations. It will not be acceptable from electrical
considerations, and full care should be taken not to supply damaged conductor. Projections
of more than 2 mils shall not be acceptable. Any such damage shall be properly rectified or
new conductor supplied.
2.06.6 Failure of any sample to meet the above requirements shall be sufficient cause
for rejection of the lengths of conductor represented by the sample. Particular care shall,
therefore, be taken during manufacture, handling, packing and transportation of the
conductor, to see that the surface is not dented, cut or damaged in any way.

2.07 STANDARD LENGTH :


2.07.1 The standard length of conductor shall be 1500 metres. A tolerance of +/-5% on
the standard length offered by the Contractor shall be permitted. All lengths outside this
limit of tolerance shall be treated as random lengths.
2.07.2 Contractor shall also indicate the maximum single length, above the standard
length, they can manufacture. This is required for special stretches like river crossing etc.
2.08 GALVANISING:
All the wires of Iron & steel strand shall be galvanized in accordance with IS-
2.08.1

2629-1990. ‘Recommended practice for hot dip galvanizing of Iron and Steel’ or some other
authoritative equivalent standard.

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2.09 TESTS :
2.09.1 The conductor offered shall be type tested as per the relevant standards.
Further the acceptance, routine tests and tests during manufacture shall be carried out on
the conductor.
2.09.2 Acceptance tests shall mean those tests, which are to be carried out on samples
taken from each lot offered for pre-despatch inspection, for the purpose of acceptance of
that lot.
2.09.3 Routine tests shall mean those tests which are to be carried out on each
strand/spool/length of the conductor to check requirements which are likely to vary during
production.
2.09.4 Tests during manufacture shall mean those tests, which are to be carried out
during the process of manufacture and end inspection by the Contractor to ensure the
desired quality of the end product to be supplied by him.
2.09.5 The norms and procedure of sampling for these tests will be as per the Quality
Assurance Programme to be mutually agreed to by the Contractor and the Employer.
2.09.6 The standards to which these tests will be carried out are listed in para 3.01.
Where a particular test is a specific requirement of this specification, the norms and
procedures of the test shall be as mutually agreed to between the Contractor and the
Employer in the Quality Assurance Programme.
2.09.7 For all type and acceptance tests, the acceptance values shall be the values
guaranteed by the Contractor in the “Technical Questionnaire” or the acceptance value
specified in this specification, whichever is more stringent for that particular test.
2.09.8 Type Tests :
The Conductor offered shall be fully type tested for the following tests as per the relevant
International/Indian Standard and the bidder shall furnish the report along with the offer.

a) UTS test on stranded conductor


b) DC resistance test on stranded conductor
c) Stress-strain test on composite conductor

2.09.9 Acceptance Tests :


a) Visual and dimensional check
b) Visual check for joints, scratches etc. and lengths of conductor
c) Dimensional check on steel and aluminium strands
d) Check for lay ratios of various layers
e) Galvanising test on steel strands
f) Torsion and Elongation test on steel wire
g) Breaking load test on steel and aluminium strands
h) Wrap test on steel and aluminium strands
i) DC resistance test on aluminium strands
j) UTS test on welded joint of aluminium strand
NOTE: All the above tests except test mentioned at (j) shall be carried out on aluminium
and steel strands after stranding only.

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2.09.10 Routine Test :


a) Check to ensure that the joints are as per specification.
b) Check that there are no cuts, fins etc. on the strands.
c) Check that drums are as per specifications.
d) All acceptance tests as mentioned in Clause 3.09.09 above shall be carried
out on each coil.
2.09.11 Tests During Manufacture :
a) Chemical analysis of zinc used for galvanizing
b) Chemical analysis of aluminium for making aluminium strands
c) Chemical analysis of steel used for making steel strands
2.09.12 Additional Tests:
The Employer reserves the right of having at his own expenses any other test(s) of
reasonable nature carried out at Contractor’s premises, at site, or in any other place in
addition to the aforesaid type, acceptance and routine tests to satisfy himself that the
material comply with the specification.
2.09.13 Test Reports
(a) Record of routine test reports shall be maintained by the Contractor at his
works for periodic inspection by the Employer’s representative.
(b) Test Certificates of test during manufacture shall be maintained by the
Contractor. These shall be produced for verification as and when desired by
the Employer.
2.09.14 Test Facilities
The following additional test facilities shall be available at Contractor’s Works.
(a) Calibration of various testing and measuring equipment including tensile
testing machine, resistance measurement facilities, burette, thermometer,
barometer etc.
(b) Standard resistance for calibration of resistance bridges.
(c) Finished conductor shall be checked for length verification and surface finish
on separate rewinding machine at reduced speed (variable from 8 to 16
metres per minute). The rewinding facilities shall have appropriate clutch
system and free of vibrations, jerks etc. with transverse layering facilities.
2.10 QUALITY ASSURANCE PROGRAM
The contractor shall submit the Quality Assurance Programme as specified in clause 1.12
Section-1 of the biding document. A copy of the accepted Quality Assurance Plan must be
available at the manufacturer’s works of the Plant for reviewing by inspecting officer of the
employer.

2.11 INSPECTION :
2.11.1 As specified in clause 1.13 Section-1 of the biding document, Plant to be
supplied will be subject to inspection and approval by the Employer's representative before
despatch.

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2.11.2 At least 5% of the total number of drums subject to minimum of two in any lot put
up for inspection, shall be selected at random to ascertain the length of conductor by
following method:
“At the works of the manufacturer the conductor shall be transferred from one
drum to another at the same time measuring its length with the help of graduated pulley and
Cyclometer. The difference in the average length thus obtained and as declared by the
Contractor in the packing list shall be applied to all the drums if the conductor is found short
during checking”
2.11.3 The supplier shall submit the factory test certificates of raw materials & bought
out accessories at the time of acceptance tests of the Conductor.
2.12 PACKING AND FORWARDING :
2.12.1 The conductor shall be supplied in non-returnable strong wooden drums
provided with lagging of adequate strength, to protect the conductor against all damage and
displacement during transit, storage and subsequent handling and stringing operations in
the field. The drums shall generally conform to IS: 1778 except otherwise specified
hereinafter.
2.12.2 The drums shall be suitable for wheel mounting and for jetting off the
conductor under a minimum controlled tension of the order of 5kN.
2.12.3 The standard drum drawings are enclosed. However, Contractor should submit
the proposed drum drawings along with the bid. The same shall be in line with the
requirements of standard drawings and as stated herein. The Contractor shall submit four
copies of fully dimensioned drawing of the drum he wishes to supply, for Employer’s
approval, before taking up manufacturing of conductor.
2.12.4 All wooden components shall be manufactured out of seasoned soft wood free
from such defects that may materially weaken the component part of the drums.
Preservative treatment for anti-termite /anti-fungus (Aldrine/Aldruse) shall be applied to the
entire drum with preservatives of a quality which is not chemically harmful to the conductor.
2.12.5 The flanges shall be of two/three ply construction with each ply at right angles to
the other and nailed together. Further the outer face of the flange shall be reinforced with
the circumferential battens, fixing in octagonal shape. The nails shall be driven from the
inside face of flange, punched and then clenched on the outer face. The tolerance in
thickness of each ply shall be +/- 3 mm only. There shall be at least 3 nails per plank of ply
with maximum nail spacing of 75 mm. Where a slot is cut in the flange to receive the inner
end of the conductor, the entrance shall be in line with the periphery of the barrel. Spindle
hole shall be provided at the centers of the planks of the plies and spindle plates with 102
mm dia. Holes shall be fitted on either side of both the flanges.
2.12.6 The wooden battens used for making the barrel of the conductor shall be of
segmental type. These shall be nailed to the barrel supports with at least two nails. The
battens shall be closely butted and shall provide a round barrel with smooth external
surface. The edges of the battens shall be rounded or chamfered to avoid damage to the
conductor.
2.12.7 Barrel studs shall be used for construction of drums. The flanges shall be holed
and the barrel supports slotted to receive them. The barrel studs shall be threaded over a
length on either end, sufficient to accommodate washers, spindle plates and nuts for fixing
flanges at the required spacing. Barrel studs should be tack welded with the nuts after
tightening.
2.12.8 Normally, the nuts on the studs shall stand protrude of the flanges. All the nails
used on the inner surface of the flanges and the drum barrel shall be counter sunk. The
ends of barrel shall generally be flushed with the top of the nuts.

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2.12.9 The inner cheek of the flanges and drum barrel surface shall be painted with
bitumen based paint.
2.12.10 Before reeling, cardboard or double corrugated or thick bituminised waterproof
bamboo paper shall be secured to the drum barrel and inside of flanges or the drum by
means of a suitable commercial adhesive material. The paper should be dried before use.
Medium grade craft paper shall be used in between the layer of the conductor/earth wire.
After reeling the conductor the exposed surface of the outer layer of conductor shall be
wrapped with thin polythene sheet across the flanges to preserve the conductor from dirt,
grit and damage during transportation and handling and also to prevent ingress of rain
water during storage/transport.
2.12.11 Minimum space of 125 mm shall be provided between the inner surface of the
external protective layer and outer layer of the conductor.
2.12.12 Each batten shall be securely nailed across grains as far as possible to the
flange edges with at least 2 nails per end. The length of the nails shall not be less than
twice the thickness of the battens. The nail shall not protrude above the general surface
and shall not have exposed sharp edges or allow the battens to be released due to
corrosion.
2.12.13 Outside the protective layer, there shall be minimum of two binder consisting of
hoop iron/galvanized steel wire. Each protective layer shall have two recess to
accommodate the binders.
2.12.14 The conductor ends shall be properly sealed and secured with the help of U-
nails on one side of the flanges. The end securing shall be done by taking out at least 500
mm of steel core on either ends by U-nails. The composite conductor shall be binded by
use of galvanized steel wire/aluminum wire at three locations at least 75 mm apart or more
covered with PVC adhesive tape so as to avoid loosening of conductor layers in transit and
handling.
2.12.15 Only one length of conductor shall be wound on each drum.

2.13 MARKING :
Each drum shall have the following information stenciled on it in indelible ink along with
other essential data:
i. Contract
ii. Name and address of consignee
iii. Manufacturer’s name and address
iv. Drum number
v. Size of conductor
vi. Length of conductor in metres
vii. Gross weight of drum with conductor
viii. Weight of empty drum with protective lagging
ix. Arrow marking for unwinding

2.14 END SEALING:


Both the ends of each length of conductor should be provided with non-destructive type
metal crimped or epoxy capped seals with punching embossing/ engraving of
manufacturer’s monogram and drum number.
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3.0 TECHNICAL SPECIFICATION OF OPTICAL FIBER GROUND WIRE


(OPGW) AND ASSOCIATED HARDWARE & FITTINGS

3.01 STANDARDS:

Unless otherwise mentioned in the specification the offered Optical Ground wire
(OPGW) and associated Hardware shall be manufactured, tested and supplied with
all guaranteed technical particulars generally confirming to meet the requirement of
the latest revisions of relevant standard of International Electro- Technical
Commission or equivalent National Standards of India.

S.
STANDARD TITLE
NO.
1 IEEE 1138 Standard Construction of Composite Fiber Optic Ground
wire (OPGW) for use on Electric Utility Power Lines
2 ITUT G.652 For Optical Fibers
3 IEC 1396 Requirements and test methods for Optical
Ground wires (OPGW)
4 IEC 1089 Overhead electrical standard conductors

5 IS 2486 Metal fittings of Insulator for overhead power lines with a


nominal voltage greater than 1000V

6 IS 802 Code of practice for use of structural steel in overhead


transmission line

7 IS 875 Code of practice for design load for building & structural

8 IEC794-1-C10 Test Procedure

9 IS 1804 Fibre cores for steel wire ropes

3.02 Tenderer shall clearly state the standards to which the equipment offered by them
conforms. In the event of offering of equipment conforming to standards other than
IS, the salient points of comparison between standards adopted and the relevant
IS shall be indicated in the proposal alongwith copies of adopted standards. It will
be sole responsibility of the Tenderer to prove that the salient features of offered
equipment are equivalent or better than standards specified above.

3.02 GENERAL REQUIREMENT FOR OPGW:


3.02.1 Fiber and Cladding
Each optical fiber shall consist of a core made of fused silica and the cladding
intimately surrounding the core shall be also fused silica. The properties of optical
fiber are shown in Annexure ‘D’.

3.02.2 Fiber Coating


The clad fiber core shall be coated with UV cured urethane acrylate resin.

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3.02.3 Optical Fiber Unit

OPGW cable construction shall comply with IEEE-1138, 2009. The cable provided shall
meet both the construction and performance requirements such that the ground wire
function, the optical fibre integrity and optical transmission characteristics are suitable
for the intended purpose. The cable shall consist of optical fibre units as defined in this
specification. There shall be no factory splices within the cable structure of a continuous
cable length.
The composite fibre optic overhead ground wire shall be made up of multiple buffer
tubes embedded in a water tight aluminium/aluminium alloy/stainless steel with
aluminium coating protective central fibre optic unit surrounded by concentric-lay
stranded metallic wires in single or multiple layers. Each buffer tube shall have
maximum 12 no. of fibres. The dual purpose of the composite cable is to provide the
electrical and physical characteristics of conventional overhead ground wire while
providing the optical transmission properties of optical fibre.
All optical fibre cabling including fibre itself and all associated installation hardware shall
have a minimum guaranteed design life span of 25 years. Documentary evidence in
support of guaranteed life span of cable and fibre shall be submitted by the Contractor
during detailed engineering.

3.02.4 Physical Characteristics

Dual-Window Single mode (DWSM), G.652D optical fibres shall be provided in the fibre
optic cables. DWSM optical fibres shall meet the requirements defined in Table below.

3.02.5 Attenuation
The attenuation coefficient for wavelengths between 1525 nm and 1575 nm shall not
exceed the attenuation coefficient at 1550 nm by more than 0.05 dB/km. The attenuation
coefficient for wavelengths between 1285 nm and 1330 nm shall not exceed the
attenuation coefficient at 1310 nm by more than 0.05 dB/km. The attenuation of the fibre
shall be distributed uniformly throughout its length such that there are no point
discontinuities in excess of 0.10 dB. The fibre attenuation characteristics specified in
table below shall be "guaranteed" fibre attenuation of any and every fibre reel.

The overall optical fibre path attenuation shall not be more than calculated below:

Maximum attenuation 0.21 dB/km x total km + 0.05 dB/splice x no. of


@ 1550nm: splices + 0.5 dB/connector x no. of connectors
Maximum attenuation 0.35 dB/km x total km + 0.05 dB/splice x no. of
@1310nm: splices + 0.5 dB/connector x no. of connectors

Table 3-1(a)
DWSM Optical Fibre Characteristics

Fibre Description: Dual-Window Single-Mode

Mode Field Diameter: 8.6 to 9.5 µm (± 0.6µm )


Cladding Diameter: 125.0 µm ± 1 µm
Mode field ≤ 0.6µm
concentricity error
Cladding non- ≤ 1%
circularity
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Cable Cut-off ≤ 1260 nm


Wavelength A,cc
1550 nm loss As per G.652 D
performance
Proof Test Level ≥ 0.69 Gpa

Attenuation Coefficient: @ 1310 nm ≤ 0.35dB/km


@ 1550 nm ≤ 0.21dB/km
Chromatic Dispersion; 18 ps/(nm x km) @ 1550 nm
Maximum: 3.5 ps/(nm x km) @ 1288-
1339nm 5.3 ps/(nm x km) @
1271-1360nm
Zero Dispersion 1300 to 1324nm
Wavelength:Zero 0.092 ps/(nm2xkm) maximum
DispersionSlope:
Polarization mode < 0.2 ps/km^ ½
dispersion coefficient
Temperature Induced attenuation < 0.05 dB
Dependence: (-60°C to
+85°C )
Bend Performance: @ 1310 nm (75±2 mm dia
Mandrel), 100 turns;
Attenuation Rise ≤ 0.05 dB
@ 1550 nm (30±1 mm radius
Mandrel), 100 turns;
Attenuation Rise ≤ 0.05 dB @
1550 nm (32±0.5 mm dia
Mandrel, 1 turn; Attenuation
Rise ≤ 0.50 dB

3.02.6 Fibre Optic Cable Construction


Overhead Fibre Optic Cables shall be OPGW (Optical Ground Wire). The OPGW cable is
proposed to be installed on the 132kV, 220kV and 400kV EHV transmission lines spread
across the State of Madhya Pradesh in India. The design of cable shall account for the
varying operating and environmental conditions that the cable shall experience while in
service. The OPGW cable to be supplied shall be designed to meet the overall
requirements of all the transmission lines. Normally the tower span of the lines shall not
exceed 525 m; however, some of the spans may be up to around 1000 m or more. To
meet the overall requirement of all the transmission lines, the contractor may offer more
than one design without any additional cost, in case one type of offered OPGW does not
meet the requirements for using on spans more than 525m.

3.02.7 Optical Fibre Cable Link Lengths


The estimated optical fibre link lengths shall be as per transmission line route length.
However, the Contractor shall supply and install the optical fibre cable as required based
on detailed site survey to be carried out by the Contractor during the project execution.
The Contractor shall verify the transmission line route length during the survey and the
Contract price shall be adjusted accordingly.
For the purpose of payment, the optical fibre link lengths are defined as transmission line
route lengths from Gantry at one terminating station to the Gantry in the other terminating
station. The actual cable lengths to be delivered shall take into account various factors

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such as sag, service loops, splicing, working lengths and wastage etc. and no additional
payment shall be payable in this regard. The unit rate for FO cable quoted in the Bid price
Schedules shall take into account all such factors.

3.02.8 Optical Fibre Identification


Individual optical fibres within a fibre unit and fibre units shall be identifiable in accordance
with EIA/TIA 598 or IEC 60304 or Bellcore GR-20 colour-coding scheme.
Colouring utilized for colour coding optical fibres shall be integrated into the fibre coating
and shall be homogenous. The colour shall not bleed from one fibre to another and shall
not fade during fibre preparation for termination or splicing.
Each cable shall have traceability of each fibre back to the original fibre manufacturer's
fibre number and parameters of the fibre. If more than the specified number of fibers is
included in any cable, the spare fibers shall be tested by the cable manufacturer and any
defective fibres shall be suitably bundled, tagged and identified at the factory by the
vendor.

3.02.9 Buffer Tube


Loose tube construction shall be implemented. The individually coated optical fibre(s)
shall be surrounded by a buffer for protection from physical damage during fabrication,
installation and operation of the cable. The fibre coating and buffer shall be strippable for
splicing and termination. Buffer tubes shall be filled with a water-blocking gel.

3.02.10 Optical Fibre Strain

3.02.10.1 The fibre optic cable shall be designed such that the optical fibres experience
no strain under all loading conditions defined in IS 802. No fibre strain condition shall
apply even after a 25 year cable creep.
3.02.10.2 For the purpose of these specifications, the following definitions shall apply

3.02.10.2.1 Maximum Working Tension (MWT) is defined as the maximum cable


tension at which there is no fibrestrain.
3.02.10.2.2 The no fibre strain condition is defined as fibre strain of less than or equal to
0.05%, as determined by direct measurements through IEC/ ETSI (FOTP) specified
optical reflectometry techniques.
3.02.10.2.3 The Cable strain margin is defined as the maximum cable strain at which
there is no fibrestrain.
3.02.10.2.4 The cable Maximum Allowable Tension (MAT) is defined as the maximum
tension experienced by the Cable under the worst case loading condition as defined in
IS802.
3.02.10.2.5 The cable max strain is defined as the maximum strain experienced by the
Cable under the worst case loading condition as defined in IS802.

3.02.10.2.6 The cable Every Day Tension (EDT) is defined as the maximum cable tension
on any span under normal conditions viz at 32 C and nowind.
3.02.10.2.7 The Ultimate /Rated Tensile Strength (UTS/ RTS/ breaking strength) is
defined as the maximum tensile load applied and held constant for one minute at which
the specimen shall not break.

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3.02.10.3 While preparing the Sag-tension charts for the OPGW cable the following
conditions shall be met:
a) The Max Allowable Tension (MAT) / max strain shall be less than or
equal to the MWT/ Strain margin of the cable.
b) The sag shall not exceed the earth wire sag in all conditions.
c) The Max. Allowable Tension shall also be less than or equal to 0.4
times the UTS of OPGW. However, Max Allowable Tension up to 0.5
times the UTS of OPGW may be accepted, subject to no fibre strain.
d) The 25 year creep at 25% of UTS (creep test as per IEEE 1138) shall
be such that the 25 year creep plus the cable strain at Max Allowable
Tension (MAT) is less than or equal to the cable strain margin.
e) The everyday tension (EDT) shall not exceed 20% of the UTS for the
OPGW cable.

03.02.10.4 The Sag-tension chart indicating the maximum tension, cable strain and sag
shall be submitted for the following conditions as specified in IS 802:1977/1995:-
a. 53 oC, no wind, no ice
b. 32 oC, no wind, no ice
c. 0 oC, no wind, no ice
d. 32 oC, full wind, no ice
e. 0 oC, 2/3rd / 36% of full wind (IS802:1977/1995)
f. MPPTCL standard 400kV, 220kV and 132kV tower type technical
details defined in Table 2.1(b).
Table 3-1(b)
400/220/132kV Tower Type Technical Details

Max Max
Sag
Sag at Tension at
at
S. Tower KV Wind Design 53°C 32°C with
0°C
No. Type Level Load Span With Full Wind
with Nil
Nil
Wind
Wind
45 400 8.69 10.19
1 FD Series 400kV 1686 Kg
Kg/meter2 Meter Meter meter
NFD 189 400 8.69 10.19
2 400kV 3327 Kg
Series Kg/meter2 meter meter meter
194 350 5.508 6.91
3 B Series 220kV 3300 Kg
Kg/meter2 meter Meter meter
189 350 4.835 6.19
4 E Series 132kV 3400 Kg
Kg/meter2 meter Meter meter
ND 45 350 4.835 6.19
5 132kV 1942 Kg
Series Kg/meter2 meter Meter meter
MD 254 250 2.30 3.21
6 Series 132kV meter meter meter 3536 Kg
Kg/meter2
MC 257 350 5.50 6.90
7 220kV 3976 Kg
Series Kg/meter2 meter meter meter

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Table 3-1(C)
Ground Wire Technical Details

S. No. Particulars Ground Wire


1. Material Steel
2. Size --
3. Nominal Aluminium area --
4. Stranding and wire diameter (no./mm) 7/3.66mm.
5. Number of strands in each layer.
Central core 1 of steel
1st layer 6 of steel
6. Sectional area of Alu. --
7. Total sectional area --
8. Approximate overall diameter 10.98 mm
9. Overall diameter when wrapped with 18.30 mm
preformed Armour Rod
10 Approximate weight 583Kg per Km
11 Calculated D.C. resistance at 20º C 2.5 Ohm/km
12 Approximate Breaking Load 6972 kgs
13 Co-efficient of Linear Expansion 11.5 x 10-6 per ºC
14 Final Modulus of Elasticity 1.931X106 kg/cm²

The above cases shall be considered for the spans from 100 m to 525 m or higher span
length in the steps of 20 m increase in spans. Max. Vertical sag, max. Tension and max
sag at 0° C & no wind shall be considered in line with the design parameter of
transmission line. In order to maintain the minimum Mid Span vertical clearance between
OPGW and top conductor, the OPGW Sag at 0° C no wind condition must be equal to or
less then the corresponding sag of ground wire as considered in the design of tower and
also indicated in the above table. The full wind load shall be considered as the design
wind load for all the specified transmission lines as per relevant IS 802 version and the
sag-tension chart shall be submitted considering the transmission lines for approval of
MPPTCL and the same shall be followed during installation of OPGW Cable.

3.02.11 Cable Materials


The materials used for optical fibre cable construction, shall meet the following
requirements:

3.02.12 Filling Materials

The interstices of the fibre optic unit and cable shall be filled with a suitable compound to
prohibit any moisture ingress or any water longitudinal migration within the fibre optic unit
or along the fibre optic cable. The water tightness of the cable shall meet or exceed the
test performance criteria as per IEC-60794-1-F-5.

The filling compound used shall be a non-toxic homogenous waterproofing compound that
is free of dirt and foreign matter, non- hygroscopic, electrically nonconductive and non-
nutritive to fungus. The compound shall also be fully compatible with all cable components
it may come in contact with and shall inhibit the generation of hydrogen within the cable.

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The filling compound shall remain stable for ambient temparature between - 20°C and
+65°C and shall not drip, flow or leak with age or at high temperatures during short duration
lightning strikes and short circuit currents The filling compound shall meet the requirements
of “Seepage of Filling Compound test” as per EIA/TIA 455-81.

The waterproofing filling materials shall not affect fibre coating, colour coding, or
encapsulant commonly used in splice enclosures, shall be dermatologically safe, non-
staining and easily removable with a non- toxic cleaning solvent.

3.02.13 Metallic Members

When the fibre optic cable design incorporates metallic elements in its construction, all
metallic elements shall be electrically continuous.

3.03 COMPLETED OPGW

The optical fiber unit shall be surrounded with a number of strands of aluminium-clad steel
wires. The direction of outermost layer shall be left-handed (S direction).

3.03.1 Optical Ground Wire(OPGW)

OPGW cable construction shall comply with IEEE-1138-2009 and IEC publication 1396.
The cable provided shall meet both the construction and performance requirements such
that the ground wire function, the optical fibre integrity and optical transmission
characteristics are suitable for the intended purpose.
The composite fibre optic overhead ground wire shall be made up of buffered optical fibre
units embedded in a water tight aluminium/aluminium alloy/stainless steel protective central
fibre optic unit surrounded by concentric-lay stranded metallic wires in single or multiple
layers. However, other material may be accepted subject to meeting the cable type-testing
requirements as specified in the technical specifications. The dual purpose of the composite
cable is to provide the electrical and physical characteristics of conventional overhead
ground wire while providing the optical transmission properties of optical fibre.

3.03.2 Central Fibre Optic Unit

The central fibre optic unit shall be designed to house and protect multiple buffered optical
fibre units from damage due to forces such as crushing, bending, twisting, tensile stress
and moisture. The central fibre optic unit and the outer stranded metallic conductors shall
serve together as an integral unit to protect the optical fibres from degradation due to
vibration and galloping, wind and ice loadings, wide temperature variations, lightning and
fault current, as well as environmental effects which may produce hydrogen. The OPGW
design of dissimlar materials for stranded wires and tubes are not allowed. Central fibre
optic unit may be of aluminium/ aluminium alloy / stainless steel tube. There shall be no
exposed areas of tubing that can make electrical contact either directly or indirectlly through
moisture, contamination, protrusions, etc with the surroundings stranded wires. The tube
may be fabricated as a seamless tube, seam welded, or a tube without a welded seam.

3.03.03 Basic Construction

The cable construction shall conform to the applicable requirements of Technical


Specification, applicable clauses of IEC 61089 related to stranded conductors and Table 4-
1(d) OPGW Mechanical and Electrical Characteristics. In addition, the basic construction
shall include bare concentric-lay-stranded metallic wires with the outer layer having left
hand lay. The wires may be of multiple layers with a combination of various metallic wires
within each layer. The direction of lay for each successive layer shall be reversed.

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The Wires shall be so stranded that when the complete OPGW is cut, the indivisual wires
can be readily regrouped and then held in place by one hand.

03.03.4 Breaking Strength

The rated breaking strength of the completed OPGW shall be taken as no more than 90
percent of the sum of the rated breaking strengths of the individual wires, calculated from
their nominal diameter and the specified minimum tensile strength.
The rated breaking strength shall not include the strength of the optical unit. The fibre optic
unit shall not be considered a load bearing tension member when determining the total
rated breaking strength of the composite conductor.

03.03.5 Electrical and Mechanical Requirements

Table below provides OPGW Electrical and Mechanical Requirements for the minimum
performance characteristics. Additionally, the OPGW mechanical & electrical characteristics
shall be similar to the electrical & mechanical characteristics of the earthwire being replaced
such that there is no or minimal consequential increase in stresses on towers. The existing
earthwire parameters are listed in appendices. For the purposes of determining the
appropriate Max Working Tension limit for the OPGW cable, IS 802:1995 and IS 875: 1987
shall be applied. However the OPGW sag & tension charts shall be based on IS 802. For
the OPGW cable design selection and preparation of sag tension charts, the limits specified
in this section shall also be satisfied. The Bidder shall submit sag-tension charts for the
above cases with their bids.

Table 3-1(d)
OPGW Electrical and Mechanical Requirements

1 Everyday Tension at ≤ 20% of UTS of OPGW


32ºC, no wind:
2 D.C. Resistance at 20ºC: < 1.0 ohm/Km
3 Short Circuit Current: ≥6.32 kA for 1.0 second(for 220
kV & above lines)
≥5.6 kA for 1.0 second (for 132 kV)

03.03.6 Operating conditions


Since OPGW shall be located at the top of the EHV transmission line support structure, it
will be subjected to Aeolian vibration, Galloping and Lightning strikes. It will also carry
ground fault currents. Therefore, its electrical and mechanical properties shall be the same
or similar as those required of conventional ground conductors.

03.03.7 Live Line Installation Suitability

OPGW shall be suitable for installation under live line condition, i.e. with all circuits charged
to the rated line voltage as specified in this section.

03.04 SPECIFIC REQUIREMENTS FOR OPGW ACCESSORIES:

03.04.1 Assemblies and Line Accessories

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a. General
The OPGW assemblies and line accessories shall consist of the hardware indicated
herein. All hardware and accessories shall be made of aluminium, aluminium alloy,
malleable iron, steel (metal mould of drop forging process), stainless steel, or non-
ferrous metal, unless otherwise specified. In addition, all hardware and accessories
shall have an ultimate tensile strength equal to or exceeding the rated ultimate
tensile strength of the overhead ground wire. All metal shall be free from burrs,
sharp edges, lumps and dross, and shall be smooth, so that interconnecting parts
will fit properly, and so that the parts may be assembled and readily.

Unless otherwise specified, all ferrous metal shall be galvanized in accordance with
ASTM A153. Bolts and nuts shall be galvanized after being threaded, and
excessive zinc shall be removed; they shall run freely (hand fit) for the entire length
of the thread. Re-tapping of nuts after galvanizing is permitted. Each piece of
hardware shall be permanently marked by casting or die-forging.
All bolts and other fasteners shall be installed according to manufacturer’s
recommendations. Materials not specifically covered herein by detailed
specifications shall be of standard commercial quality suitable for the intended use.
The Contractor shall determine the most suitable type of clamp to be used at each
and every transmission tower location.

b. Suspension Assembly Clamps

Preformed armour grip suspension clamps and aluminum alloy armour


rods/reinforcing rods shall be used. The suspension clamps shall be designed to
carry a vertical load of not less than 25KN. The suspension clamps slippage shall
occur between 12kN and 17kN as measured.
The Contractor shall supply all the components of the suspension assembly
including shackles, bolts, nuts, washers, split pins, etc. the total drop of the
suspension assembly shall not exceed 150mm (measured from the centre point of
attachment to the centre point of the OPGW). The design of the assembly shall be
such that the direction of run of the OPGW shall be the same as that of the
conductor.

c. Tension Clamps

All dead end clamp assemblies shall preferably be of performed armoured grip type
and shall include all necessary hardware for attaching the assembly to the tower
strain plates. Dead end clamps shall allow the OPGW to pass through continuously
without cable cutting. The slip strength shall be rated not less than 95% of the rated
tensile strength of the OPGW.

d. Vibration dampers

Stockbridge type vibration dampers, suitable for use on the OPGW shall be
supplied. The dampers shall have an aluminum clamping bolt, or other suitable
device, on the galvanized wire between the weights, and be suitable for attachment
to the OPGW. The damper clamp shall be designed to permit installation and
removal using hot line tools. Each damper weight, subject to the accumulation of
moisture, shall be provided with one drain hole positioned at the bottom of the
weight when the damper is installed in the vertical plane. Damper weights shall be
made of hot dip galvanized cast iron or steel.

The Vibration analysis of the system, with and without damper and dynamic
characterstics of the damper as detailed in Technical specification, shall have to be
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submitted. The Technical paticulars for vibration analysis and damping design of
the system are as follows:-

S.No. Description Technical Particulars

1 Span Lengths in meters


(i) Ruling design span: 350 meters
(ii) Maximum span: 1100 meters
(iii) Minimum Span: 100 meters
2 Cofiguration: As per Specifications
3 Tensile load in each: As per sag tension
calculations
4 Armour rods used: Standard performed
armour rods / AGS
5 Maximum Permissible Dynamic +/- 150 micro strains
strain:

e. Armour Rods
The armor rods for the OPGW shall be of the preformed type. They shall be
smooth and free from corrosion, splitting, cracking, or any other defects. They shall
be designed to effectively protect the OPGW from fatigue caused by vibration.

f. Down Lead Clamp


The tenderer should offer Down Lead Clamp suitable for OPGW & the offered
clamps should meet requirement stipulated in the relevant standard. Details of
Down Lead Clamp including drawing shall be submitted with the offer.

g. Box Fibre Optic Splice Enclosures (Joint Box)


The joint box shall be air-tight, water-proof. The cover shall be securely fastened to
the case by non-loosening fasteners. Both the case and the cover shall be made of
non-corrosive aluminum alloy or hot dip galvanized steel or approved materials. The
joint box shall be sufficiently rugged and sturdy to withstand outdoor climatic and
environmental conditions. The joint box shall accommodate sheath protected arc-
fusion splices and up to 1.5 m of additional fiber on each side of the splice; guides
shall be provided to keep the extra fiber well above the allowable bending radius of
the fiber. The spliced parts of the optical fiber within the joint box shall be reinforced
and free from tension after completion of the splicing.
The Supplier shall provide one set of terminating materials with every joint box for
optical fiber connection.

1. Way Joint Box for OPGW


This type of joint box shall be used to straight joint OPGW to OPGW,
or OPGW to approach cable. It shall be used at all locations requiring
such a device except those specified otherwise in the text or drawings
elsewhere in this specification.
2. Way Joint Box for OPGW and approach cable
This type of joint box shall be used to spur joint all fibers contained in
two OPGW cables to OPGW or one multi-core optical fiber cable at

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each terminal station, repeater station, or other location, as detailed in


the text or drawings elsewhere in this Specification.

h. Earth Bond
The Tenderer should offer Earth Bonds suitable for OPGW & the offered Earth Bonds
should meet requirement stipulated in the relevant standard. Details of Earth Bonds
including drawing shall be submitted with the offer.

i. In-Line Fibre Optic Splice Enclosures


All in-line splices shall be encased in In-Line Fibre Optic Splice Enclosures. Suitable
splice enclosures shall be provided to encase the optical cable splices in protective,
moisture and dust free environment. In line splice enclosures shall comply to ingress
protection class IP 66 or better. The splice enclosures shall be designed for the
storage and protection of 48 optical fibre splices and equipped with sufficient
number of splice trays for splicing all fibres in the cable. No more than 12 fibres shall
be terminated in a single splice tray. They shall be filled with suitable encapsulate
that is easily removable should re-entry be required into the enclosures.
In-line splice enclosures shall be suitable for outdoor use with each of the cable
types provided under this contract. Splice enclosures shall be appropriate for
mounting on EHV transmission towers above anti-climb guard levels at about 10
metres from the ground level and shall accommodate pass-through splicing. The
properties of required for Splice Enclosures are shown in Annexure ‘F’.

03.04.2 Fibre Optic Approach Cables


For purposes of this specification, a fibre optic approach cable is defined as the Armoured
underground fibre optic cable required to connect Overhead Fibre Optic Cable (OPGW)
between the final in line splice enclosure on the gantry / tower forming the termination of the
fibre cable on the power line and the Fibre Optic Distribution Panel (FODP) installed within
the building. The estimated fibre optic approach cabling length requirements are indicated
in the BoQ. Actual supply to be done as per directives of MPPTCL. However, actual supply
shall be done based on the actual site survey.

3.04.02.1 Basic Construction


The cable shall be suitable for direct burial, laying in trenches & PVC/Hume ducts, laying
under false flooring and on indoor or outdoor cable raceways.

3.04.02.2 Jacket Construction & Material


The Approach Cable shall be a UV resistant, rodent proof, armoured cable with metallic
type of armouring. The outer cable jacket for approach cable shall consist of carbon black
polyethylene resin to prevent damage from exposure to ultra- violet light, weathering and
high levels of pollution. The jacket shall conform to ASTM D1248 for density.
3.04.02.3 Optical, Electrical and Mechanical Requirements
Approach cable shall contain fibres with identical optical/ physical characteristics as those
in the OPGW cables. The cable core shall comprise of tensile strength member(s), fibre
support/bedding structure, core wrap/bedding, and an overall impervious jacket.
3.04.02.4 Installation of Approach Cable
The existing cable trenches/cable raceways proposed to be used shall be identified in the
survey report. The contractor shall make its best effort to route the cable through the
existing available cable trenches. Where suitable existing cable trenches are not available,

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suitable alternative shall be provided after MPPTCL/site engineer approval. However, the
approach cable shall be laid in HDPE pipe in all condition.
Suitable Provision shall be made by the contractor to ensure adequate safety earthing and
insulated protection for the approach cable
All required fitting, support, accessories, ducts, inner ducts, conduits, risers and any item
not specially mentioned but required for laying an installation of approach cable shall be
supplied and installed by the contractor.

3.04.03 Fibre Optic Distribution Panel


At each location requiring the termination of at least one fibre within a cable, all fibres
within that cable shall be connectorized and terminated in Fibre Optic Distribution
Panels in a manner consistent with the following:
(a) All fibre optic terminations shall be housed using FODPs provisioned
with splice organizers and splice trays. All fibres within a cable shall be
fusion spliced to pre connectorized pigtails and fitted to the "Back-side"
of the provided fibre optic couplings.
(b) FODPs shall be suitable for use with each of the cable types provided
as part of this contract. FODPs shall accommodate pass-through
splicing and fibre terminations.
(c) FODPs shall be supplied in suitable cabinets/racks with locking
arrangement.
(d) The dimension of FODP cabinet shall be minimum 2200mm x 600mm
x 600mm (HxWxD) and shall meet or exceed ingress protection class
IP55 specifications.
(e) All FODPs shall be of corrosion resistant, robust construction and shall
allow both top or bottom entry for access to the splice trays. Ground
lugs shall be provided on all FODPs and the Contractor shall ensure
that all FODPs are properly grounded.
(f) Flexible protection shall be provided to the patch cord bunches going
out from FODP to other equipment.

03.05 TEST FOR OPGW

TYPE TESTING/ FACTORY ACCEPTANCE TESTS REQUIREMENTS


Wherever the referenced test procedures or the technical specifications call
for visual inspection for damage, the test report shall include a full description of observed
status of the sample. (Visually inspected samples shall also be colour photographed and
copies of colour photographs shall be included in type test report)

3.05.1 Type Tests for Optical Fibres

The type tests listed below in Table 4-1(d) shall be conducted on DWSM fibres. The tests
specific to the cable type are listed in subsequent sections.

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Table 3-1(d)
Type Tests for Optical Fibres

S. Test Name Acceptance Test


Criteria procedure
No.
1 Attenuation
2 Attenuation Variation with Wavelength
3 Attenuation at Water Peak
4 Temp. Cycling (Temp dependence of
Attenuation)
5 Attenuation With Bending (Bend
Performance)
AS per Tender AS per Tender
6 Mode Field dia. Specification Specification
7 Chromatic Dispersion
8 Cladding Diameter
9 Point Discontinuities of attenuation
10 Core -Clad concentricity error
11 Fibre Tensile Proof Testing

03.05.4 Type Tests For OPGW Cables

The type tests to be conducted on the OPGW cable are listed in Table 4-1(e): Type Tests
for OPGW Cables. Unless specified otherwise in the technical specifications or the
referenced standards, the optical attenuation of the specimen, measured during or after the
test as applicable, shall not increase by more than 0.05 dB/Km.

Table 3-1(e)
Type tests for OPGW Cable
S. Test Name Test Test Procedure
No. Description
1 Water IEEE 1138 IEEE 1138, Section 5.1.1.1
Ingress Section 4.1.1.1 (IEC 794-1-F5 /EIA/TIA 455-82B)
Test IEEE 1138, Section 5.1.1.1
(IEC 794-1-F5 /EIA/TIA 455-82B),
Test duration : 24 hours
2 Seepage IEEE 1138 IEEE 1138 Preconditioning period: 72 hours.
of filling Section 4.1.1.2 Section 5.1.1.2 Test duration: 24 hours.
compound (EIA/TIA 455-
81B)

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S. Test Name Test Test Procedure


No. Description
3 Short Circuit IEEE 1138 IEEE 1138 Fibre attenuation shall be
Test Section 4.1.1.3 Section 5.1.1.3 continuously monitored and
recorded through a digital data
OR logging system or equivalent
means.
A suitable temperature sensor
such as thermocouple shall be
used to monitor and record the
temperature inside the OPGW tube
in addition to monitoring &
recording the temperatures
between the strands and between
optical tube and the strand as
required by IEEE 1138.
Test shall be conducted with
the tension clamps proposed to be
supplied. The cable and the
clamps shall be visually inspected
for mechanical damage and
photographed after the test.
IEC 60794-1-2 Initial temperature during the test
(2003) shall be greater than or equal to
Method H1 ambient field temperature.
However, maximum temperature
recorded on any component of
OPGW cable shall not exceed the
Short Circuit transient peak
temperature guaranteed by the
Contractor during design.
4 Aeolian IEEE 1138 IEEE 1138 Fibre attenuation shall be
Vibration Test Section 4.1.1.4 Section 5.1.1.4 continuously monitored and
recorded through a digital data
logging system or equivalent
means.
The vibration frequency and
amplitude shall be monitored and
recorded continuously. All fibres of
the test cable sample shall be
spliced together in serial for
attenuation monitoring.
Test shall be conducted with the
tension/suspension clamps
proposed to be supplied. The cable
and the clamps shall be visually
inspected for mechanical damage
and photographed after the test.
5 Galloping IEEE 1138 IEEE 1138 Test shall be conducted with the
test Section 4.1.1.5 Section 5.1.1.5 tension/suspension clamps
proposed to be supplied. The cable
and clamps shall be visually
inspected for mechanical damage
and photographed after the test. All
fibres of the test cable sample shall
be spliced together in serial for
attenuation monitoring.
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S. Test Name Test Test Procedure


No. Description
6 Cable Bend Procedure 2 in IEC:794-1-E11 The short-term and long- term
Test bend tests shall be conducted in
accordance with Procedure 2 in
IEC:794-1- E11 to determine the
minimum acceptable radius of
bending without any increase in
attenuation or any other damage to
the fibre optic cable core such as
bird caging, deformation, kinking
and crimping.
7 Sheave IEEE 1138 IEEE 1138 Fibre attenuation shall be
Test Section 4.1.1.6 Section 5.1.1.6 continuously monitored & recorded
Or through a digital data logging
IEC 60794-1-2 system or equivalent means. The
(2003) Sheave dia. Shall be based on the
Method E18B pulling angle and the minimum
pulley dia employed during
installation. All fibres of the test
cable sample shall be spliced
together in serial for attenuation
monitoring.
8 Crush IEEE 1138 IEEE 1138 The crush test shall be carried out
Test Section 4.1.1.7 Section 5.1.1.7 on a sample of approximately one
(1) metre long in accordance with
(IEC 794-1-E3/ IEC:794-1-E3. A load equal to 1.3
EIA/TIA 455- times the weight of a 400-metre
41B) length of fibre optic cable shall be
applied for a period of 10 minutes.
A permanent or temporarily
increase in optical attenuation
value greater than 0.1dB change in
sample shall constitute failure. The
load shall be further increased in
small increments until the
measured attenuation of the optical
waveguide fibres increases and
the failure load recorded along with
results.
9 Impact IEEE 1138 IEEE 1138, The impact test shall be carried out
Test Section 4.1.1.7 Section 5.1.1.7 in accordance with IEC:794-1-E4.
(IEC 794-1-E4/ Five separate impacts of 0.1-
EIA/TIA 455- 0.3kgm shall be applied. The
25B) radius of the intermediate piece
shall be the reel drum radius ±
10%. A permanent or temporary
increase in optical attenuation
value greater than 0.1 dB/km
change in sample shall constitute
failure.

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S. Test Name Test Test Procedure


No. Description
10 Creep IEEE 1138 IEEE 1138 As per Aluminium Association
Test Section 4.1.1.8 Section 5.1.1.8 Method, the best-fit straight line
shall be fitted to the recorded
creep data and shall be
extrapolated to 25 years. The
strain margin of the cable at the
end of 25 years shall be
calculated. The time when the
creep shall achieve the strain
margin limits shall also be
calculated.
11 Fibre Strain IEEE 1138 IEEE 1138
Test Section 4.1.1.9 Section 5.1.1.9
12 Strain Margin IEEE 1138 IEEE 1138
Test Section 4.1.1.10 Section 5.1.1.10
13 Stress strain IEEE 1138 IEEE 1138
Test Section 4.1.1.11 Section 5.1.1.11
14 Cable Cut-off IEEE 1138 IEEE 1138
wavelength Section 4.1.1.12 Section 5.1.1.12
Test
15 Temperature IEEE 1138 IEEE 1138
Cycling Test Section 4.1.1.13 Section 5.1.1.13
16 Corrosion EIA/TIA 455-16A
(Salt Spray)
Test
17 Tensile IEC 794-1-E1 / The test shall be conducted on a sample of sufficient
Performance EIA/TIA 455- 33A length in accordance with IEC:794-1- E1. The
Test attenuation variation shallnot exceed 0.05 dB/kM up
to 90% of RTS of fibre optic cable.
The load shall be increased at a steady rate up to
rated tensile strength and held for one (1) minute. The
fibre optic cable sample shall not fail during the
period. The applied load shall then be increased until
the failing load is reached and the value recorded.
18 Fault IEEE Std. 4- Tension equal to 20% of the OPGW RTS shall be
Current/ 1978 applied to a sample with minimum length of 15 m of
lightningTest cabled fibres and two separate 4/10 micro second
current impulses each having a peak value of 150 KA
and a negative polarity shall be applied through a 1
cm gap. The attenuation during the tests shall be
continuously measured. After the tests the same shall
be visually inspected. Any increase in optical
waveguide fibres attenuation measured at 1550 nm
shall constitute failure.
Fibre attenuation shall be continuously monitored
and recorded through a digital data logging system
or equivalent means.
The tensile performance test shall be repeated on the
sample subjected to the lightning arc test.
IEC 60794-1- The cable construction shall be tested in
2(2003) accordance with Method H2

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S. Test Name Test Test Procedure


No. Description
19 DC On a fibre optic cable sample of minimum 1 metre length, two contact
Resistance clamps shall be fixed with a predetermined bolt torque. The resistance
Test shall be measured by a Kelvin double bridge by placing the clamps
initially zero metre and subsequently one metre apart. The tests shall be
repeated at least five times and the average value recorded after
correcting at 20°C.

03.06 Type Test on OPGW Cable Fittings


The type tests to be conducted on the OPGW Cable fittings and accessories are listed
below:

03.06.4 Mechanical Strength Test for Suspension/Tension Assembly


Applicable Standards: IS:2486 / IEC:61284-1997.

03.06.4.1 Suspension Assembly


The armour rods /reinforcement rods are assembled on to the approved OPGW using the
Installation Instructions to check that the assembly is correctly fitted and is the same that
will be carried out during installations.

Part 1:
The suspension assembly shall be increased at a constant rate up to a load
equal to 50% of the specified minimum Failure Load increased and held for one
minute for the test rig to stabilise. The load shall then be increased at a steady rate
to 67% of the minimum Failure Load and held for five minutes. The angle between
the cable, the Suspension Assembly and the horizontal shall not exceed 16o. This
load shall then be removed in a controlled manner and the Protection Splice
disassembled. Examination of all the components shall be made and any evidence
of visual deformation shall be documented.

Part 2:
The Suspension clamp shall then be placed in the testing machine. The
tensile load shall gradually be increased up shall gradually be increased up to 50%
of the specified Minimum Failure Load of the Suspension Assembly and held for one
minute for the Test Rig to stabilise and the load shall be further increased at a
steady rate until the specified minimum Failure Load is reached and held for one
minute. No fracture should occur during this period. The applied load shall then be
increased until the failing load is reached and the value shall be documented.

03.06.4.2 Tension Assembly


The Tension Assembly is correctly fitted and is the same that will be carried out during
installations.

Part 1:
The tension assembly (excluding tension clamp) shall be increased at a
constant rate up to a load equal to 50% of the specified minimum Failure Load
increased at a constant rate and held for one minute for the test rig to stabilise.
The load shall then be increased at a steady rate to 67% of the minimum Failure
Load and held for five minutes. This load shall then removed in a controlled
manner and the Tension Assembly disassembled. Examination of the Tension
Dead-End and associated components shall be made and any evidence of
visual deformation shall be documented.
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Part 2:
The Tension Dead-End and associated components shall then be reassembled
and bolts tightened as before. The tensile load shall gradually be increased up
shall gradually be increased up to 50% of the specified Minimum Failure Load of
the Tension Assembly and held for one minute for the Test Rig to stabilise and
the load shall be further increased at a steady rate until the specified minimum
Failure Load is reached and held for one minute. No fracture should occur
during this period. The applied load shall then be increased until the failing load
is reached and the value shall be documented.

Acceptance Criteria:

- No evidence of binding of the Nuts or Deformation of components at end of part 1


ofTest.

- No evidence of Fracture at the end of one minute at the minimum failure load during Part
2 of theTest.

Any result outside these parameters shall constitute a failure.

03.06.4.3 Clamp Slip Strength Test for Suspension Assembly

The suspension assembly shall be vertically suspended by means of a flexible


attachment. A suitable length fibre optical cable shall be fixed in the clamps. Once the
Suspension Clamp has been assembled, the test rig is tensioned to 1 kN and the position
scale on the recorder ‘zeroed’. The test rig is then tensioned to 2.5 kN and the relative
positions of the Reinforcing Rods, Armour Rods and Suspension Clamp shall be marked
by a suitable means to confirm any slippage after the test has been completed. The
relative positions of the helical Armour Rods and associated Reinforcing Rods at each
end shall be marked and also 2 mm relative position between clamp body and Armour
Rods shall be marked on one side. The load shall be increased to 12 kN at a loading rate
of 3 kN/min and held for one minute. At the end of this one minute period, the relative
displacement between clamp body and the armour rods shall be observed. If the slippage
is 2 mm or above, the test shall be terminated. Otherwise, at the end of one minute the
position of the clamp body and 2 mm. relative positions between clamp body and armour
rods shall be marked on the other side. After the one minute pause, the load shall be
further increased at a loading rate of 3 kN/min, and recording of load and displacement
shall continue until either the relative Position displacement between clamp body and
armour rods reaches more than 2 mm.or the load reaches the maximum slip load of 17
kN. On reaching either of the above values the test is terminated. Visual examination of all
paint marks shall be recorded, and a measurement of any displacement recorded in the
Table of Results.

Acceptance Criteria :

The Suspension Clamp has passed the Slip Test if the following conditions are met:
a) No slippage* shall occur at or below the specified minimum slip load.
* Definition of no slippage in accordance with IEC 61284:1997:- Any
relative movement less than 2 mm is accepted. The possible couplings or
elongations produced by the cable as a result of the test itself are not
regarded as slippage.

b) Slippage shall occur between the specified maximum and minimum slip
load of 12 - 17 kN.

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c) There shall be no slippage of the Reinforcing Rods over the cable, and no
slippage of the Armour Rods over the ReinforcingRods.

d) The relative movement (i.e. more than 2 mm between Armour Rods &
Clamp body) between minimum 12 kN and maximum slip 17 kN, shall be
considered asslip.

e) The Armour Rods shall not be displaced from their original lay or
damaged**.
** Definition of no damage in accordance with convention expressed in
IEC 61284 : 1997 no damage, other than surface flattening of the
strands shall occur.

Any result outside these parameters is a failure.

03.06.5 Slip Strength Test of Tension Clamp


Tension clamps shall be fitted on a 8 m length of fibre optic cable on both ends. The
assembly shall be mounted on a tensile testing machine and anchored in a manner similar
to the arrangement to be used in service. A tensile load shall gradually be applied up to 20
% of the RTS of OPGW. Displacement transducers shall be installed to measure the
relative movement between the OPGW relative to the Reinforcing Rods and Tension
Dead -End relative to Reinforcing Rods. In addition, suitable marking shall be made on the
OPGW and Dead-End to confirm grip. The load shall be gradually increase data constant
rate upto 50% of the UTS and the position scale of the recorder is zeroed. The load shall
then gradually increased up to 95% of the UTS and maintained for one minute. After one
minute pause, the load shall be slowly released to zero and the marking examined and
measured for any relative movement.

Acceptance Criteria :
03.06.5.1 No movement* shall occur between the OPGW and the Reinforcing Rods, or
between the Reinforcing Rods and the Dead-End assembly.
03.06.5.2 No failure or damage or disturbance to the lay of the Tension Dead- End,
Reinforcing Rods orOPGW.
* Definition of no movement as defined in IEC 61284: Any relative movement
less than 2 mm is accepted. The possible couplings or elongations produced
by the conductor as a result of the test itself are not regarded as slippage.
Any result outside these parameters shall constitute a failure.

03.06.6 Grounding Clamp and Structure Mounting Clamp Fit Test


For structure mounting clamp, one series of tests shall be conducted with two fibre optic
cables installed, one series of tests with one fibre optic cable installed in one groove, and
one series of tests with one fibre optic cable in the other groove. Each clamp shall be
installed including clamping compound as required on the fibre optic cable. The nut shall
be tightened on to the bolt by using torque wrench with a torque of 5.5 kgm or supplier's
recommended torque and the tightened clamp shall be held for 10 minutes. After the test
remove the fibre optic cable and examine all its components for distortion, crushing or
breaking. Also the fibre optic cable shall be checked to ensure free movement within the
core using dial callipers to measure the diameter of the core tube. The material shall be
defined as failed if any visible distortion, crushing, cracking or breaking of the core tube is
observed or the fibre optic cable within the core tube is not free to move, or when the
diameter of the core tube as measured at any location in the clamped area is more than
0.5 mm larger or smaller of the core diameter as measured outside the clamped area.

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03.06.7 Structure Mounting Clamp Strength Test


The clamp and mounting assembly shall be assembled on a vertical 200 mm x 200 mm
angle and a short length of fibre optic cable installed. A vertical load of 200 kg shall be
applied at the end of the mounting clamp and held for 5 minutes. Subsequently, the load
shall be increased to 400 kg and held for 30 seconds. Any visible distortion, slipping or
breaking of any component of the mounting clamp or assembly shall constitute failure.

03.06.7.1 Type Test on Vibration Damper

03.06.7.2 Dynamic Characteristic Test


The damper shall be mounted with its clamp tightened with torque recommended by the
manufacturer on shaker table capable of simulating sinusoidal vibrations for Critical
Aeolian Vibration frequency band as determined through vibration analysis of undamped
OPGW. The damper assembly shall be vibrated vertically with a ±1 mm amplitude from 5
to 15 Hz frequency and beyond 15 Hz at 0.5 mm to determine following characteristics
with the help of suitable recording instruments.
03.06.7.2.1 Force Vs frequency
03.06.7.2.2 Phase angle Vs frequency
03.06.7.2.3 Power dissipation Vs frequency
The Force Vs frequency curve shall not show steep peaks at resonance frequencies and
deep troughs between the resonance frequencies. The resonance frequencies shall be
suitably spread within the Aeolian vibration frequency-band between the lower and upper
dangerous frequency limits determined by the vibration analysis of fibre optic cable
without dampers.
The above dynamic characteristics test shall be conducted on five dampers. The
variations between the samples tested shall conform to the sample test limits.

03.06.7.3 Vibration Analysis


The vibration analysis of the fibre optic cable shall be done with and without damper
installed on the span. The vibration analysis shall be done on a digital computer using
energy balance approach. The following parameters shall be taken into account for the
purpose of analysis.
03.06.7.3.1 The analysis shall be done for single fibre optic cable without armour rods.
The tension shall be taken as max Permissible Every Day Tension (20% of UTS), for a
span ranging from 100 m to 1100m.
03.06.7.3.2 The self damping factor and flexural stiffness (EI) for fibre optic cable shall
be calculated on the basis of experimental results. The details to experimental analysis
with these data shall be furnished.
03.06.7.3.3 Examine the Aeolian Vibration level of the fibre optic cable with and without
vibration damper installed at the recommended location or wind velocity ranging from 0 to
30 Km per hour, predicting amplitude, frequency and vibration energy input.
03.06.7.3.4 From vibration analysis of fibre optic cable without damper, antinode
vibration amplitude and dynamic strain levels at clamped span extremities as well as
antinodes shall be examined and thus lower and upper dangerous frequency limits
between which the Aeolian vibration levels exceed the specified limits shall bedetermined.
03.06.7.3.5 From vibration analysis of fibre optic cable with damper(s) installed at the
recommended location, the dynamic strain level at the clamped span extremities, damper
attachment point and the antinodes on the fibre optic cable shall be determined. In addition
to above damper clamp vibration amplitude and antinodes vibration amplitudes shall also
be examined.
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03.06.7.3.6 The dynamic strain levels at damper attachment point, clamped span
extremities and antinodes shall not exceed the specified limits. The damper clamp vibration
amplitude shall not be more than that of the specified fatigue limits.

03.07.4.4 Vibration Damper Clamp Slip and Fatigue Tests

3.07.4.01 Test Set Up

The clamp slip and fatigue tests shall be conducted on a laboratory set up with a minimum
effective span length of 30m. The fibre optic cable shall be tensioned at 15kN & shall not be
equipped with protective armour rods at any point.
Constant tension shall be maintained within the span by means of lever arm arrangement.
After the fibre optic cable has been tensioned, clamps shall be installed to support the fibre
optic cable at both ends and thus influence of connecting hardware fittings are eliminated
from the free span. The clamps shall not be used for holding the tension on the fibre optic
cable. There shall be no loose parts, such as suspension clamps, U bolts, on the test span
supported between clamps mentioned above. The span shall be equipped with vibration
inducing equipment suitable for producing steady standing vibration. The inducing
equipment shall have facilities for step less speed control as well as step less amplitude
arrangement. Equipment shall be available for measuring the frequency, cumulative
number of cycles and amplitude of vibration at any point along the span.

3.07.4.2 Clamp SlipTest


The vibration damper shall be installed on the test span. The damper clamp, after tightening
with the manufacturer's specified tightening torque, when subjected to a longitudinal pull of
2.5kN parallel to the axis of fibre optic cable for a minimum duration of one minute shall not
slip, i.e., the permanent displacement between fibre optic cable and clamp measured after
removal of the load shall not exceed 1.0 mm. The load shall be further increased until the
clamp starts slipping. The load at which the clamp slips shall not be more than 5kN.

3.07.4.3 Fatigue Test

The vibration damper shall be installed on the test span with the manufacturer's specified
tightening torque. It shall be ensured that the damper shall be kept minimum three loops
away from the shaker to eliminate stray signals influencing damper movement.

The damper shall then be vibrated at the highest resonant frequency of each damper mass.
For dampers involving torsional resonant frequencies, tests shall be done at torsional
modes also in addition to the highest resonant frequencies at vertical modes. The
resonance frequency shall be identified as the frequency at which each damper mass
vibrates with the maximum amplitude on itself. The amplitude of vibration of the damper
clamp shall be maintained not less than ±25/f mm where f is the frequency in Hz.

The test shall be conducted for minimum ten million cycles at each resonant frequency
mentioned above. During the test, if resonance shift is observed, the test frequency shall be
tuned to the new resonant frequency.

The clamp slip test as mentioned herein above shall be repeated after fatigue tests without
retorquing or adjusting the damper clamp, and the clamp shall withstand a minimum load
equal to 80% of the slip strength for a minimum duration of one minute.

After the above tests, the damper shall be removed from fibre optic cable and subjected to
dynamic characteristics test. There shall not be any major deterioration in the
characteristics of the damper. The damper then shall be cut open and inspected. There
shall not be any broken, loose, or damaged part. There shall not be significant deterioration
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or wear of the damper. The fibre optic cable under clamp shall also be free from any
damage.

For purposes of acceptance, the following criteria shall be applied:


3.07.4.3.1 There shall not be any frequency shift by more than ±2Hz for frequencies
lower than 15Hz & ±3Hz for frequencies higher than 15Hz.

3.07.4.3.2 The force response curve shall generally lie within guaranteed % variation
in reactance after fatigue test in comparison with that before fatigue test by the Supplier.

3.07.4.3.3 The power dissipation of the damper shall not be less than guaranteed %
variation in power dissipation before fatigue test by the Supplier. However, it shall not be
less than minimum power dissipation which shall be governed by lower limits of reactance
and phase angle indicated in the envelope.

3.07.4.4 Type Tests for In Line Splice Enclosures


Following Type tests shall be demonstrated on the In Line Splice Enclosure(s) (Splice
Enclosure/Box). For certain tests, lengths of the fibre optic cable shall be installed in the
splice box, and the fibres must be spliced and looped in order to simulate conditions of
use. The attenuation of the fibres shall be measured, during certain tests, by relevant
Fibre Optic Test Procedures (IEC 794-1 procedures).

03.06.7.4 Temperature Cycling Test


FO cable is installed in the splice enclosure and optical fibres spliced and looped. The box
must be subjected to 5 cycles of temperature variations of -40 C to +65 C with a dwell
time of at least 2 hours on each extreme.
Fibre loop attenuation shall be measured in accordance with IEC 794-1- C10. The
variation in attenuation shall be less than ±0.05dB. The final humidity level, inside the box,
shall not exceed the initial level, at the closing of the box.

03.06.7.5 Humid Heat Test


The sealed splice enclosure, with fibres spliced and looped inside, must be subjected to a
temperature of +55 C ±2 C with a relative humidity rate of between 90% and 95% for 5
days. The attenuation variation of the fibres during the duration of the test shall be less
than ±0.05dB, and the internal humidity rate measured, less than 2%.

03.06.7.6 Rain Withstand Test


The splice enclosure with optical fibres cable installed and fibres spliced fixed, shall be
subjected to 24 hours of simulated rain in accordance with IEC 60 testing requirements.
No water seepage or moisture shall be detected in the splice enclosure. The attenuation
variation of the fibres after the test shall be less than±0.05dB.

03.06.7.7 Vibration Test


The splice enclosure, with fibres united inside, shall be subjected to vibrations on two
axes with a frequency scanning of 5 to 50 Hz. The amplitude of the vibrations shall be
constant at 0.450mm, peak to peak, for 2 hours, for each of the vibrations' axes. The
variation in attenuation, of the fibres, shall be less than ±0.05dB. The splice enclosure
shall be examined for any defects or deformation. There shall be no loosening or visible
damage of the FO cable at the entry point.

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03.06.7.8 Bending and Torsion Test


The splice enclosure, with fibres spliced inside, shall be firmly held in place and be
subjected to the following sequence of mechanical stresses on the cable:
a) 3 torsion cycles of ±180 shall be exercised on the cable. Each cycle shall
be less than one minute.
b) 3 flexure cycles of the cable, of ±180 with one cycle less than one
minute.
The variation in the attenuation, of the fibres, shall be less than ±0.05dB. The cables
connection ring shall remain securely fixed to the box with the connection maintained
firmly. No defects/fissures shall be noted on the joint ring or on the splice enclosure

03.06.7.9 Tensile test


The splice enclosure with cable fixed to the boxes shall be subjected to a minimum
tension of 448 N for a period of two minutes. No fissure shall be noted in the connections
or on thebox.

03.06.7.10 Drop Test

With 2 lengths of 10 metres of cable fixed to the box, it shall be dropped five times from a
height of 11 metres. There shall be no fissure, at all, of the box, and the connections shall
remain tight. The test shall be carried out in accordance with procedure described in IEC-
68-2-32.

03.06.8 Factory Acceptance Tests on Fibre Optic Cables

As specified in technical specifications, the Factory acceptance tests shall be conducted


on random sampling of fibre optic cable tobe supplied for the present procurement, prior
to any shipment.

03.06.8.1 FAT on Fibre: Optical Acceptance Tests

The Optical acceptance tests listed in Table 4-1(f) below are applicable for the fibres of all
types of Fibre Optic Cables i.e. OPGW and approach cable to be supplied. The listed
tests follow testing requirements set forth in IEEE standard 1138 section 4.2.2.1 and
section 5.2.2.1. The referenced sections specify the detailed test description. The
acceptance norm shall be as specified in the above mentioned IEEE standards unless
specified otherwise in the technical specifications.

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Table 3-1(f)
Factory Acceptance Tests for Fibres of all FO cables: Optical Tests
S. Test Name Acceptance Test
No. Criteria procedure
1 Attenuation Coefficient
2 Point Discontinuities of
attenuation
3 Attenuation at Water
Peak AS per
AS per
Techni
Technical
4 Chromatic Dispersion cal
Specificatio
Specifi
5 Core – Clad n
cation
Concentricity Error
6 Cladding diameter
7 Fibre Tensile Proof
Testing

The test reports for the above tests for all types of the fibres carried out by the Fibre
Manufacturer and used in the OPGW cables and approach cable shall be shown to the
inspector during OPGW cable FAT and shall be submitted along with the OPGW cable
FAT report.

03.06.9 Factory Acceptance Test On OPGW Cable

The factory acceptance tests for OPGW cable specified below in Table 4.6 follow the
requirements set forth in section 4.1.2 and section 5.1.2 of IEEE standard 1138. The FAT
shall be carried out on 10% of offered drums in each lot as specified in technical
specifications and the optical tests shall be carried out in all fibers of the selected sample
drums. The Rated Tensile Strength test shall be carried out on one sample in each lot.
Table 3-1(g)
Factory Acceptance Tests On OPGW Applicable standard: IEEE 1138

S. No. Factory Acceptance Test on Manufactured OPGW


1 Attenuation Co-efficient at 1310 nm and 1550 nm
2 Point discontinuities of attenuation
Visual Material verification and dimensional checks as per
3 approved DRS/Drawings

4 Rated Tensile Strength


5 Lay Length Measurements

03.06.10 Factory Acceptance Test On OPGW Fittings

The factory acceptance tests for OPGW Fittings as specified below in Table 4-1(h). The
sampling plan shall be as per IS 2486:
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Table 3-1(h)
Factory Acceptance Tests On OPGW Fittings

S. No. Factory
Acceptance
Test
Suspension Assembly
1 UTS/Mechanical Strength of the assembly
2 Clamp Slip Test
Visual Material verification and dimensional checks as
3
per approved DRS/Drawings
4 Mechanical strength of each component
Tension Assembly
5 Clamp Slip Strength test
Visual Material verification and dimensional checks as
6
per approved DRS/Drawings
7 Mechanical strength of each component
Vibration Damper
8 Galvanising test on damper, masses and messenger wires
9 Damper response (resonant frequencies)
10 Clamp Slip test
11 Strength of messenger wires
12 Mass pull off test
13 Visual Material verification and dimensional checks as per
approved DRS/Drawings
Structure Mounting Clamp
14 Clamp fit test
15 Clamp Strength test
16 Visual Material verification and dimensional checks as per
approved DRS/Drawings

3.06.11 Factory Acceptance Test on In Line Splice Enclosures


The factory acceptance tests for In Line Splice Enclosures as specified below in Table 4-
1(i):
Table 3-1(i)
Factory Acceptance Tests on In Line Splice Enclosures

S. No. Factory Acceptance


Test
Visual check Kit Quantities and Specific Component Number for
1
each component of In Line Splice Enclosure and dimensional
checks against the approved drawings.

03.07 PACKING AND MARKING-

All conductors for export shipment are generally shipped on best commercial practice non-
returnable steel reels having suitable dimension for winding a specified length.

MPPTCL/TECH-LINE/PROC/SEP23 Page 56
Volume-V

Each length of cable shall be wound on a separate cable reel and the cable ends shall be
securely fastened to the reel to prevent the cable from becoming loose in transit or during
placing operations. Both ends of the cable shall be sealed with a suitable plastic cap to
prevent the entry of moisture during shipping, handling and storage. Spare plastic cap shall
be provided with each drum.
The cable shall be shipped on reels designed to prevent damage to the cable during
shipment and installation. The wooden lagging will be given a preventive treatment from
termite and wood preservative treatment. The construction of reels and markings shall be
as per approved documents.
The wire shall be furnished on reels of sufficiently sturdy construction to withstand normal
shipping, hauling and field erection. The size, length, weight, manufacturer’s name or trade
mark, date of manufacturer direction of rolling for each drum, and contract number shall be
clearly marked on the outside of each drum. The wire shall be packed to protect it from
moisture, salt, or any other impurities which may cause rust or other harmful effects.
The packing and shipping requirements for overhead galvanized steel wire hardware shall
be applied for assemblies and line accessories for OPGW.
Each package shall be clearly, legibly and durably marked on both sides as follows:-
a. Name & designation of the consignee (to be
furnished by the purchaser.)
b. Ultimate destination (as required by the purchaser).
c. Items and respective quantities contained in the
package to be furnished by the purchaser.)
d. Net and gross weight of the material.
e. Gross weight of each package.

03.08 DESIGN AND DRAWING DETAILS

The design, manufacture and performance of OPGW and accessories shall comply with all
the requirements of the latest editions of International codes and standards applicable.
Nothing in this specification shall be construed to relieve the vendor of this responsibility.
The design and workmanship shall be in accordance with best engineering practices to
ensure satisfactory performance and long service life and shall be such as has been proved
to be suitable for the intended purpose.
The equipment offered shall be robust and durable. It shall be generally possible to set up
and assemble the equipment without the use of special tools but in case special tools are
required for installation the same shall be provided free cost basis with the supply of
OPGW.
The equipment offered shall require minimum maintenance. All relevant requirements of
data and drawings for galvanized steel wire and its hardware shall be applicable for OPGW
and joint boxes.

03.09 INSTALLATION OF OPGW

The Supplier shall provide a complete description of all procedures and methods to be used
during installation of the OPGW.
The installation methods and tools required for OPGW shall be similar to those of
conventional overhead ground wire. The OPGW shall be strung, sagged and clipped before
phase conductors are strung. The OPGW shall be connected to the transmission tower for
grounding at every location.
MPPTCL/TECH-LINE/PROC/SEP23 Page 57
Volume-V

03.10 OVERHEAD GROUNDWIRE WITH OPTICAL FIBER


CONNECTIONS
The jointing of overhead ground wires shall be performed using joint boxes located on
tension towers. All overhead ground wire connections shall be of the underpass variety.

03.10.1 OPTICAL FIBER CONNECTIONS

The jointing of optical fiber shall be performed using arc-fusion splicing. All cores shall be
spliced at every locations, fiber identification shall be matched and maintained for the entire
length of the installation.
The optical fiber splicing loss shall not be more than 0.10 dB for any one joint, and shall
average no more than 0.05 dB per joint on any given repeater span. Splicing loss shall be
measured immediately after the splice has been made, and if the splice does not meet
minimum standards above, it shall bereplaced.
All successful splices shall be protected using a heat shrink protection sleeve with
integrated reinforcement, or some other material/process providing equivalent protection.
An additional slack of 1 to 1.5 m shall be provided on each side of each splice, and stored
securely in the joint box.

03.10.2 COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS

3.10.02.1 Offered material shall be complete in all respects and shall include all minor
component, accessories, small wiring etc., not specifically mentioned in this order,
specifications etc; but essential for the completeness of the system. Supplier shall not be
eligible for extra charges in respect of such minor components, accessories, small wiring
etc., though not included specifically in this Tender but requires for satisfactory operation of
equipment offered.

3.10.02.2 It is obligatory on the part of supplier to ensure that supply of all accessories
along with Main equipment are simultaneously delivered to avoid any holdups.
Responsibility for obtaining timely supplies of bought out items will rest on the supplier.

3.10.02.3 It may be noted that in case of damages/shortages due to improper packing


or any other negligence, replenishment shall be arranged within one months time.
For bought out items, responsibility for guarantee and obtaining immediate
replacement in case any defects are noticed and also in case defective supply of any
item is reported, will rest on the suppliers.

MPPTCL/TECH-LINE/PROC/SEP23 Page 58
Volume-V

ANNEXURE -A
OPGW TECHNICAL SPECIFICATION
(To be submitted by manufacturer)

Configuration : To be filled by bidder.

Description Unit Guaranteed value 48


fibers
Applicable standard - IEEE std. 1138:2009
Number of fiber
No. 48
Aluminium-cladsteel wire To be filled by
Structure Aluminium alloy wire No/dia Bidder
Stainless steel tube -do-
Lay direction of outer layer - (Left-hand (S)
Ratio of length of lay or a layer to nominal
Times To be filled by
outside diameter of that layer Bidder
Outer diameter mm -do-
Aluminium-clad steel wire -do-
2
(*) Cross Aluminium alloy wire mm -do-
Steel tube -do-
section

(*)Approximate weight Kg/km -do-


Rated tensile strength (RTS) (min) -do-
Ultimate tensile strength (UTS) Kg
(min)
2
(*) Modules of elasticity Kg/mm -do-
(*) Co-efficient of linear expansion /deg C -do-
D.C. resistance at 20 deg C (max) ohm/km -do-

Short circuit current capacity for 1 second


(Initial temperature : 40 ° C) KA 6.32

Assumed maximum temperature under short


circuit current deg C To be filled by
Bidder

Remark – (*) means data for information only.

MPPTCL/TECH-LINE/PROC/SEP23 Page 59
Volume-V

ANNEXURE-B
PROPERTIES OF INDIVIDUAL WIRE
(To be submitted by manufacturer)

Guaranteed value 48
Description Unit
fibers
Type of individual wire - ACS Wires Al-alloy
Applicable standard -
To be filled To be
by filled
bidder by
bidder
Standard diameter mm -do- -do-
Tolerance of diameter mm -do- -do-
2
Minimum tensile strength Kg/mm -do- -do-
Minimum elongation in 250 mm % -do- -do-
Minimum conductivity %ACS -do- -do-
Minimum number of twisting
No. -do- -do-
(100 x dia)

Minimum thickness of Aluminium mm -do- -do-


Properties of wrapping % -do-
-do-

ANNEXURE – C
PROPERTIES OF OPTICAL FIBER UNIT
(To be submitted by manufacturer)

Guaranteed value 48
Description Unit Fibers

Loose type (Stainless


Buffer type - SteelTube
typepreffered)
Number of Loose tube No. To be filled by bidder
Total No.of Fibers No 48
(*) Diameter Mm To be filled by bidder
Loose tube Number of empty tube Nos. To be filled by bidder
To be filled by bidder
(*) Material -

Remark : (*) means data for information only.

MPPTCL/TECH-LINE/PROC/SEP23 Page 60
Volume-V

ANNEXURE - D

PROPERTIES OF OPTICAL FIBER

Description Unit Guaranteed value


Applicable standard - ITU-TG 652 D
Cladding diameter µm 125±1
Core concentricity error µm ≤ 0.6
Cladding non-circularity % ≤ 1.0
Mode field diameter at 1310 mm (8.6-9.5)+0.6
µm

Attenuation coefficient at 1310 mm dB/km ≤0.4

at 1550 mm dB/km ≤0.3


Attenuation at water peak at 1383±3nm dB/km ≤ 0.4
Bend performance
dB/km ≤ 0.05 at 1310nm
@1310 nm (75±2mm diameter mandrel),
100 turns, AttenuationRise
@1550 nm (75±2mm diameter mandrel),
100 turns, AttenuationRise dB/km dB/km ≤ 0.10 at 1550nm
@1550 nm (32±0.5mm diameter
mandrel), 1turn ≤ 0.50 at 1550nm

Temperature dependence (-60°C +̃


dB/km ≤ 0.05 dB
85°C)
Cutoff wavelength for cabled fiber (λ) nm ≤ 1260 nm

Chromaticdispersion
@ 1288 nm 1339nm
̃ ps/(nm.km) ≤3.5
@ 1271 nm 1360nm
̃ ps/(nm.km) ≤5.3
@ 1550 nm ps/(nm.km) ≤18
Zero dispersion wavelength Nm 1300 to1324
2
Zero dispersion Slope Ps/Nm .km ≤0.093
½
Polarization mode dispersion (PMD) ps/km ≤0.2
Point discontinuities of attenuation dB ≤0.1@1310&1550 nm
Proof-test level Gpa ≥ 0.69

ANNEXURE-E

COLOR CODE OF OPTICAL FIBER UNIT


Loose Tube : To be filled by bidder.
Fiber Colors(12 No;s)
Blue,Orange,Green,Brown,Slate,white,Red,Black,Yellow,Violet,Pink and Aqua

MPPTCL/TECH-LINE/PROC/SEP23 Page 61
ANNEXURE-F

DATA REQUREMENT SHEETS FOR INLINE SPLICE ENCLOSURE

S. Parameter Unit Particulars


No.
1. Dimensions HWD mm To be filled by bidder
2. Weight Kg To be filled by bidder
3. Color and Finish Stainless Steel AISI 304
4. Cable Glanding& Fixing Mechanical clamp
5. Construction materials & Gauge Stainless Steel AISI 304
(1.0 - 3.0 )mm
6. Locking arrangements Bolts and nuts
Installation Clearances:
7. Front access: N/A N/A
Rear access: Cm 2 To be filled by bidder
Top*Bottom*Sli
des
8. IP Protection Code IP 68
9. Total number of optical couplings n* To be filled by bidder
10. Provision of pass through splicing Yes/No Yes
11. Whether filled with suitable Yes/No To be filled by bidder
encapsulant
12. Method(s) for mounting with the Mechanical
tower

Optical Fiber Cable Accommodations

MPPTCL/TECH-LINE/PROC/SEP23 Page 62
13. Cable Glanding Cable Blocking
14. Maximum number of cables that can be n* To be filled by bidder
accommodated
15. Diameter(s) of cables that can be mm To be filled by bidder
accommodated :
Details of Splice Trays :
Dimension: Mm To be filled by bidder
17. Material/Gauge: ABS/1 mm
Weight: kg To be filled by bidder
Color & Finish: RAL 7035
Method of mounting: Release
18. Maximum number of splices per tray n* To be filled by bidder
19. Number of splices per tray n* To be filled by bidder
20. Provision of maximum splice organizers n* To be filled by bidder
21. Do splice trays require a separate enclosure? Yes/No To be filled by bidder

If so:
Manufacturer:
Dimensions: H*W*D Cm
Weight: kg
Color and Finish:
Method(s) of Mounting:
Construction Materials & Gauge:
Locking arrangements
Installation Clearances: Front
Access:
Rear Access:
Top*Bottom*Slides:
22. Excess length of Fiber service m 1.5 + 1.5
loops

MPPTCL/TECH-LINE/PROC/SEP23 Page 63
4.0 TECHNICAL SPECIFICATIONS FOR HIGH TENSILE GALVANISED STEEL
EARTH WIRE

4.01 STANDARDS:
The High Tensile Galvanised Steel Earth Wire shall conform to the following Indian
Standards, which shall mean latest revisions, amendments/changes adopted and
published, unless otherwise specified hereinbefore.
Indian Standards or any
S. No. Equivalent International Title
Standard
1 IS:209 -1992 Specification for Zinc
2 IS:2141 -1992 Specification for Earth wire for overhead
Transmission purpose
3 IS:1778 Reels and drums for Bare wires
4 IS:1521 Method of Tensile Testing of Steel wire
5 IS:2629 -1992 Recommended practice for Hot Dip
Galvanising Iron and Steel
6 IS:2633 -1992 Method of Testing Uniformity of Zinc coating
of Zinc coated Articles.
7 IS:4826 Galvanised coating on Round Steel wire
8 IS:6745 -1992 Method of Determination of weight of Zinc
coating of zinc coated Iron and Steel Articles
9 IS: 12776 Method of Testing of Earth wire

4.02. 4 PARAMETERS:
PRINCIPAL PARAMETERS OF EARTH WIRE:
The standard technical particulars of 7/3.66mm galvanized steel earth wire shall be as
follows:-
a. The details of Steel strand:
i. Material Steel
ii. Stranding 7
iii. Weight per Km 583 Kgs
iv. Dia. of wire 3.66 mm
v Tolerance 2%
vi Minimum elongation in 100 mm length 5 mm
vii Minimum breaking strength per strand 1000 Kg
viii Minimum tensile strength 95 Kg./mm2
ix D.C. resistance at 20 Deg. C 17.15 hms/Km
MPPTCL/TECH-LINE/PROC/SEP23 Page 64
b. The details of Stranded Earth Wire :

i. Maximum Length of Lay 198


ii. Minimum Length of Lay 165
iii. Minimum breaking load 6972 Kgs
iv. Overall diameter 10.98mm
v Modulus of elasticity 1.933 x 106 Kg./cm2
vi Co-efficient of linear expansion 11.50 x 10- 6 per
Deg.C
vii Weight of zinc coating on wire 260 gms./ m 2 (Min.)
viii No. of one minute dip and half 3 one minute and 1 half
minute dip respectively minute
ix Calculated d.c. Resistance at 20 2.5 Ohms per Km
Deg.C

4.03 GENERAL TECHNICAL REQUIREMENT :

MATERIAL AND WORKMANSHIP FOR EARTH WIRE: 4.03.01 The steel wire
(strands) used in manufacture of galvanized steel earth wire shall be drawn from steel
wire rod produced by either acid or basic open hearth process or by the electric furnace
process or basic oxygen process. The steel wire shall not have sulphur and
phosphorous contents exceeding 0.045% each. The carbon content shall not exceed
0.55%. The steel produced by bassemer process shall not be used for drawing of steel
wire strands. The finished earth wire shall have minimum brittleness as it will be
subjected to continuous vibration while in use on line.
4.03.02 The steel wire shall be hot dip galvanized and shall have zinc coating of
minimum 260 gram per sq. meter of the uncoated wire surface. The zinc coating shall
be smooth and continuous of uniform thickness, free from imperfections not consistent
with good commercial practice and shall meet the test requirement. The zinc used in
galvanizing of earth wire shall be as per IS: 209-1992.
4.03.03 All the steel wires shall be circular, smooth, uniform and free from
imperfections, such as spills and splits, die marks scratches, abrasions, cuts and kinks
etc. drawing and after stranding.
4.03.04 The steel wires, after galvanizing shall be bright in appearance, smooth and
free from all defects like flux, ash, cross inclusions, bare and black spots, pimples,
lumpiness in runs, rust, stains, bulky white deposits and blisters.
4.03.05 To avoid susceptibility towards wet storage stains (white rust) the stranded
earth wire shall be provided with a protective coating of boiled linseed oil.
4.03.06 The finished earth wire shall have a smooth surface without any surface cuts,
abrasions, scuff marks and shall be free from dirt, grit etc.
4.03.07 Failure of any sample to meet the above requirements shall be sufficient cause
for rejection of the lot of earth wire represented by the sample, particular care shall
MPPTCL/TECH-LINE/PROC/SEP23 Page 65
therefore be taken during manufacture, handling, packing and transportation of the earth
wire so that it is not dented, cut or damaged in any way.
4.04 SIZE AND PROPERTIES:
4.04.01 The earth wire size, physical properties, tolerance in diameter of individual
strands and length of lay of the strand shall be as given above.
4.04.02 The wires shall be so stranded together that when an evenly distributed pulls is
applied at the end of completed strands, each wire will take an equal share of the pull.
4.04.03 The earth wire shall be supplied in the standard lengths which shall not be less
than 3 Km. Not less than 95% of the total quantity of the earth wire shall be supplied in
standard lengths. The quantity of earth wire in length shorter than standard one shall not
exceeds 5% of the total quantity to be supplied. Further, no single earth wire length in
respect of such 5% (maximum) supply in random lengths shall be shorter than 50% of the
standard length.
4.04.04 The length of the stranded wire shall be supplied without joints in the individual
wires comprising it, excluding welds made in base rod before it is drawn.
4.04.05 Each coil be warranted to contain no welds, joints or splice other than in the base
rod before it is drawn.
4.05 GALVANISING AND OILING:
4.05.01 All the wires of the strand shall be galvanized in accordance with IS-2629-1990.
Recommended practice for Hot dip galvanizing of Iron and Steel of some other
authoritative equivalent standard.
4.05.01 The galvanized earth wire after stranding operation shall have dipped in boiled
linseed oil before winding it on drums.

4.06 TEST FOR EARTH WIRE :


4.06.01 Earth wire shall be subjected, before despatch from the works to tests as
specified in the IS-2141, IS 1521, IS 1755 & IS 4826 or any other authoritative equivalent
standard.
4.06.02 All the drums of galvanized steel stranded earth wire of the same grade,
diameter and construction, manufactured under similar condition shall be grouped to
constitute one lot.
4.06.03 Samples from each lot shall be tested for ascertaining the conformity to the
requirements of the earth wire specified herein. The drums selected shall be tested for
length of the lay and diameter of individual strands etc. The lot shall be declared
conforming to the requirement of these characteristics if all the samples are found
satisfactory. One test specimen from each wire of the strand shall now be drawn from
every selected drum and subjected to chemical analysis, tensile tests, ductility test,
elongation test and coating test. One test specimen, of the completed strand from each
drum shall be subjected to tensile strength. The lot shall be declared conforming to the
requirements of these characteristics, if the entire test specimen satisfies the relevant
requirement.

4.07 QUALITY ASSURANCE PROGRAM


MPPTCL/TECH-LINE/PROC/SEP23 Page 66
The contractor shall submit the Quality Assurance Programme as specified in clause 1.12
Section-1 of the biding document. A copy of the accepted Quality Assurance Plan must
be available at the manufacturer’s works of the Plant for reviewing by inspecting officer of
the employer.
4.08 INSPECTION :
4.08.01 The purchaser’s representative shall at all times be entitled to have access to the
works and all places of manufacture where earth wire shall be manufactured and the
representative shall have full facilities for unrestricted inspection of the Supplier’s works,
raw materials and process of manufacture for conducting necessary tests as detailed
herein.
4.08.02 The Supplier shall keep the Purchaser informed in advance of the time of starting
and of the progress of manufacture of earth wire in its various stages so that
arrangements can be made for inspection.
4.08.02 No material shall be despatched from its point of manufacture before it has
been satisfactorily inspected and tested, unless the purchaser in writing waives off the
inspection. In the later case also, the earth wire shall be despatched only after
satisfactory testing for all tests specified herein has been completed.
4.08.03 The acceptance of any quantity of material shall in no way relieve the
Supplier of any of his responsibilities for meeting all requirements of the specification,
and shall not prevent subsequent rejection if such material is later found to be defective.
4.08.04 At least 5% of the total number of drums subject to minimum of two in any
lot put up for inspection, shall be selected at random to ascertain the length of earth wire
by following method:
“At the works of the manufacturer of the earth wire, the earth wire shall be
transferred from one drum to another at the same time measuring its length with the help
of graduated pulley and Cyclometer. The difference in the average length thus obtained
and as declared by the supplier in the packing list shall be applied to all the drums if the
conductor/earth wire is found short during checking”

4.09 DOCUMENTATION:
4.09.01 Six sets of type test reports, duly approved by the Purchaser shall be submitted
by the supplier for distribution, before commencement of supply. Adequate copies of
acceptance and routine test certificates, duly approved by the Purchaser shall
accompany with despatched consignments.
4.09.02 The manufacturing of the material shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written approval of
the Purchaser. All manufacturing and fabrication work in connection with the material
prior to the approval of the drawing shall be at Supplier’s risk.
4.09.03 Approval of drawing/work by Purchaser shall not relieve the Supplier of his
responsibility and liability for ensuring correctness and correct interpretation of the latest
revision of applicable standards, rules and codes of practices. The equipment shall
conform in all respect to high standards of engineering, design, workmanship and latest
revisions of relevant standards at the time of ordering. Purchaser shall have the power to
reject any work or material, which in his judgment is not in full accordance therewith.
MPPTCL/TECH-LINE/PROC/SEP23 Page 67
4.10 PACKING AND FORWARDING:
4.10.01 The earth wire shall be supplied in strong wooden drums provided with lagging of
adequate strength, to protect the conductor/earth wire against all damage and
displacement during transit, storage and subsequent handling and stringing operations in
the field. The drums shall generally conform to IS: 1778 except otherwise specified
hereinafter.

4.10.02 The drums shall be suitable for wheel mounting and for jetting off the
conductor/earth wire under a minimum controlled tension of the order of 5kN.

4.10.03 The standard drum drawings are enclosed. However, Contractor should submit
the proposed drum drawings along with the bid. The same shall be in line with the
requirements of standard drawings and as stated herein. The Contractor shall submit four
copies of fully dimensioned drawing of the drum he wishes to supply, for Employer’s
approval, before taking up manufacturing of earth wire.

4.10.04 All wooden components shall be manufactured out of seasoned soft wood free
from such defects that may materially weaken the component part of the drums.
Preservative treatment for anti-termite /anti-fungus (Aldrine/Aldruse) shall be applied to
the entire drum with preservatives of a quality which is not harmful to the earth wire.

4.10.05 The flanges shall be of two/three ply construction with each ply at right angles to
the other and nailed together. Further the outer face of the flange shall be reinforced with
the circumferential battens, fixing in octagonal shape. The nails shall be driven from the
inside face of flange, punched and then clenched on the outer face. The tolerance in
thickness of each ply shall be +/- 3 mm only. There shall be at least 3 nails per plank of
ply with maximum nail spacing of 75 mm. Where a slot is cut in the flange to receive the
inner end of the conductor/earth wire, the entrance shall be in line with the periphery of
the barrel. Spindle hole shall be provided at the centers of the planks of the plies and
spindle plates with 102 mm dia. Holes shall be fitted on either side of both the flanges.

4.10.06 The wooden battens used for making the barrel of the earth wire shall be of
segmental type. These shall be nailed to the barrel supports with at least two nails. The
battens shall be closely butted and shall provide a round barrel with smooth external
surface. The edges of the battens shall be rounded or chamfered to avoid damage to the
earth wire.

4.10.07 Barrel studs shall be used for construction of drums. The flanges shall be holed
and the barrel supports slotted to receive them. The barrel studs shall be threaded over a
length on either end, sufficient to accommodate washers, spindle plates and nuts for
fixing flanges at the required spacing. Barrel studs should be tack welded with the nuts
after tightening.

4.10.08 Normally, the nuts on the studs shall stand protrude of the flanges. All the nails
used on the inner surface of the flanges and the drum barrel shall be counter sunk. The
ends of barrel shall generally be flushed with the top of the nuts.

MPPTCL/TECH-LINE/PROC/SEP23 Page 68
4.10.09 The inner cheek of the flanges and drum barrel surface shall be painted with
bitumen-based paint.
4.10.10 Before reeling, cardboard or double corrugated or thick bituminised waterproof
bamboo paper shall be secured to the drum barrel and inside of flanges or the drum by
means of a suitable commercial adhesive material. The paper should be dried before use.
Medium grade craft paper shall be used in between the layer of the conductor/earth wire.
After reeling the earth wire the exposed surface of the outer layer of earth wire shall be
wrapped with thin polythene sheet across the flanges to preserve the conductor/earth
wire from dirt, grit and damage during transportation and handling and also to prevent
ingress of rain water during storage/transport.
4.10.11 Minimum space of 125 mm shall be provided between the inner surface of the
external protective layer and outer layer of the earth wire.
4.10.12 Each batten shall be securely nailed across grains as far as possible to the
flange edges with at least 2 nails per end. The length of the nails shall not be less than
twice the thickness of the battens. The nail shall not protrude above the general surface
and shall not have exposed sharp edges or allow the battens to be released due to
corrosion.
4.10.13 Outside the protective layer, there shall be minimum of two binders consisting of
hoop iron/galvanized steel wire. Each protective layer shall have two recesses to
accommodate the binders.
4.10.14 The earth wire ends shall be properly sealed and secured with the help of U-nails
on one side of the flanges. The end securing shall be done by taking out at least 500 mm
of steel wire on either end by U-nails. The earth wire shall be binded by use of galvanized
steel wire/aluminum wire at three locations at least 75 mm apart or more covered with
PVC adhesive tape so as to avoid loosening of earth wire layers in transit and handling.
4.10.15 Only one length of earth wire shall be wound on each drum.
4.11 MARKING :
Each drum shall have the following information stenciled on it in indelible ink
along with other essential data:
(i) Order Number and date.
(ii) Name and address of consignee
(iii) Manufacturer’s name and address
(iv) Drum number
(v) Size of earth wire (7/3.66mm)
(vi) Length of earth wire in meters
(vii) Gross weight of drum with earth wire
(viii) Weight of empty drum with protective lagging
(ix) Arrow marking for unwinding
4.12 END SEALING :

MPPTCL/TECH-LINE/PROC/SEP23 Page 69
Both the ends of each length of earth wire should be provided with non-destructive type
metal crimped or epoxy capped seals with punching embossing/ engraving of
manufacturer’s monogram and drum number.
***

5.0 TECHNICAL SPECIFICATION OF DISC INSULATORS

MPPTCL/TECH-LINE/PROC/SEP23 Page 70
5.01 STANDARDS

This section provides for the design, manufacture, stage testing and inspection and
testing before dispatch packing and delivery of disc insulators as per technical
requirements furnished in this section. Unless otherwise specified elsewhere in this
specification, the rating as well as performance & testing of the disc insulators shall
conform but not limited to the latest revision & amendments available at the time of
placement of order of all the relevant standards as listed hereunder, except as modified in
this document.

S. No Indian Standard Title


1 IS:209-1992 Specification for Zinc
2 IS:206-1991 Method for Chemical Analysis of Slab Zinc
3 IS:731-1991 Porcelain insulators for overhead power lines with
a nominal voltage greater than 1000V

4 IS:2071 Method of High Voltage Testing


Part(I)-1993
Part(II)-1991
Part(III)-1991

5 IS:2121 Specification of Conductors and Earth wire


Accessories for Overhead Power Lines.
Part(I) Armour Rods, Binding Wires & Tapes for
Conductors
6 IS:2486 Specification for insulator fittings for overhead
power lines with a nominal voltage greater than
1000V
Part I-1993 General Requirements & Tests
Part II-1989
Dimensional Requirements
Part III -1991
Locking Devices
7 IS:2629-1990 Recommended practice for Hot Dip Galvanization
for iron & steel
8 IS:2633-1992 Testing for Uniformity of Coating of Zinc coated
articles
9 IS:3188-1988 Dimensions for Disc Insulators
10 IS:6745-1990 Determination of Weight of Zinc coating on Zinc
coated iron and steel articles
11 IS : 8263-1990 Methods of RIV Test of HV Insulators
12 IS:8269-1990 Methods for Switching impulse test on HV
insulators

5.02 PRINCIPAL PARAMETERS

MPPTCL/TECH-LINE/PROC/SEP23 Page 71
5.02.01 DETAILS OF DISC INSULATORS

i) The insulator strings shall consist of standard discs for a three phase 50 Hz,
effectively earthed 220KV/132KV transmission system in a moderately polluted
atmosphere. The discs shall be cap and pin, ball and socket type.

ii) The specified values and disc dimensions, impulse and power frequency
voltages, electromechanical strength [EMS] of individual insulator units are as
under. The values given are minimum which apply to all cases. Specified
withstand and flashover voltages are referred to standard atmospheric
condition.

5.02.02 CHARACTERISTICS OF DISC INSULATORS

The disc insulators should have the following particulars and characteristics:

S.No Particulars Disc Insulators


70KN EMS 90kN EMS 160kN EMS
i Diameter of the disc (mm) 255 255 280
ii Spacing of the disc (mm) 145 145 170
iii Size and designation of pin-ball 16 mm 16 mm 20 mm
shank
iv Creepage distance (mm) 320 320 330
(minimum)
v Power frequency one minute dry 70 75 75
withstand voltage kV (rms)
vi Power frequency one minute wet 40 45 45
withstand voltage kV (rms)
vii Power frequency puncture 120 125 125
withstand voltage kV (rms)
viii Minimum dry impulse withstand 110 110 120
voltage 1.2x50 micro second wave,
positive and negative Kv Peak)
ix Maximum Radio interference 50 50 50
voltage with 10 kV RMS to ground.
(microvolts)
x Minimum corona extinction voltage 9 9 18
kV(rms)

5.03 SPECIFICATION DRAWINGS

The specification drawing in respect of the disc insulators indicated above is attached
with this specification. The specification drawing is attached herewith for information and
guidance of the Contractor only. The drawings to be furnished by the Contractor shall be
as per his own design and manufacture and shall be distinct and separate from these
specification drawings.

The drawing shall include but not limited to the following information:-

MPPTCL/TECH-LINE/PROC/SEP23 Page 72
a) Shell diameter and ball to ball spacing with manufacturing tolerances.
b) Minimum creepage distance with positive tolerance.
c) Protected creepage distance
d) Eccentricity of the disc
i) Axial run out
ii) Radial run out
e) Unit mechanical and electrical characteristics
f) Size and weight of ball & socket parts
g) Weight of unit insulator disc
h) Materials
i) Identification mark
j) Manufacturer’s catalogue number.

After placement of order, the Contractor shall submit full dimensioned manufacturing
drawing of insulator cap, pin & insulator shell in six copies to the Employer for reference &
record.

5.04 GENERAL TECHNICAL REQUIREMENTS

5.04.01 Porcelain
The porcelain used in the manufacture of the shells shall be ivory white, nonporous of
high dielectric, mechanical and thermal strength, free from internal stresses, blisters,
laminations, voids, foreign matter, imperfections or other defects which might render it in
any way unsuitable for insulator shells. Porcelain shall remain unaffected by climatic
conditions, ozone, acid, alkalizes, zinc or dust. The manufacturing shall be by the wet
process and impervious character obtained by thorough verification.
5.04.02 Porcelain Glaze
Surfaces to come in contact with cement shall be made rough by sand glazing. All other
exposed surfaces shall be glazed with ceramic materials having the same temperature
coefficient of expansion as that of the insulator shell. The thickness of the glaze shall be
uniform throughout and the colour of the glaze shall be brown. The glaze shall have a
visible luster, smooth on surface and be subject to satisfactory performance under
extreme tropical climatic weather conditions and prevent ageing of the porcelain. The
glaze shall remain under compression on the porcelain body throughout the working
temperature range.
5.04.03 METAL PARTS

5.04.03.1 Cap and Ball Pins


Ball pins shall be made with drop forged steel and caps with malleable cast iron. They
shall be in one single piece and duly hot dip galvanized. They shall not contain parts or
pieces joined together, welded, shrink fitted or by any other process from more than one
piece of material. The pins shall be of high tensile steel, drop forged and heat-treated.
The caps shall be cast with good quality black hearth malleable cast iron and annealed.
Galvanising shall be by the hot dip process with a heavy coating of zinc of very high

MPPTCL/TECH-LINE/PROC/SEP23 Page 73
purity. The Contractor shall specify the grade, composition and mechanical properties of
steel used for caps and pins.
5.04.03.2 Security Clips
The security clips shall be made of phosphor bronze or of stainless steel.2.5% extra
security clip shall be provided.

5.05 FILLER MATERIAL


Cement to be used as a filler material shall be quick setting, fast curing Portland cement.
It shall not cause fracture by expansion or loosening by contraction. Cement shall not
react chemically with metal parts in contact with it and its thickness shall be as small and
as uniform as possible.
The insulator design shall be such that the insulating medium shall not directly engage
with hard metal. The surfaces of porcelain and hard metal should be coated with resilient
paint to offset the effect of difference in thermal expansions of these materials.

5.06 MATERIAL DESIGN AND WORKMANSHIP

5.06.01 GENERAL

(i) All raw materials to be used in the manufacture of these insulators shall be
subject to strict raw material quality control and to stage testing/quality
control during manufacturing stage to ensure the quality of the final end
product. Manufacturing shall conform to the best engineering practices
adopted in the field of extra high voltage transmission. Bidders shall
therefore offer insulators as are guaranteed by them for satisfactory
performance on 220KV/132KV Transmission lines.

(ii) The design, manufacturing, process and material control at various stages
be such as to give maximum working load, highest mobility, best
resistance to corrosion, good finish, elimination of sharp edges and
corners to limit corona and radio interference voltages.

5.06.02 INSULATOR SHELL


The design of the insulator shells shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration. Shells with cracks
shall be eliminated by temperature cycle test followed by mallet test. Shells shall be dried
under controlled conditions of humidity and temperature.

5.06.03 METAL PARTS

(i) The pin and cap shall be designed such that it will not transmit the
mechanical stresses to the shell by compression and develop uniform
mechanical strength in the insulator. The cap shall be circular with the
inner and outer surfaces concentric and of such design that it will not yield
or distort under loaded conditions. The head portion of the pin ball shall be
suitably designed so that when the insulator is under tension the stresses
MPPTCL/TECH-LINE/PROC/SEP23 Page 74
are uniformly distributed over the pinhole portion of the shell. The pin ball
shall move freely in the cap socket either during assembly of a string or
during erection of a string or when a string is placed in position.

(ii) Metal caps shall be free from cracks, seams, shrinks, air holes, blow holes
and rough edges. All metal surfaces shall be perfectly smooth with no
projecting parts or irregularities, which may cause corona. All load bearing
surfaces shall be smooth and uniform so as to distribute the loading
stresses uniformly. Pins shall not show any microscopically visible cracks,
inclusions and voids.

5.06.04 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the latest edition of IS:
2629. The zinc to be used for galvanizing shall conform to grade Zn 99.95 as per IS: 209.
The Zinc coating shall be uniform, smoothly adherent, reasonably bright, continuous and
free from impurities such as flux, ash, rust stains, bulky white deposits and blisters.
Before ball fittings are galvanized, all die flashing on the shank and on the bearing
surface of the ball shall be carefully removed without reducing the designed dimensional
requirements.
5.06.05 SECURITY CLIPS (LOCKING DEVICES)
The security clips to be used as a locking device for ball and socket coupling shall be ‘R’
shaped hump type to provide for positive locking of the coupling as per IS:2486 (Part IV).
The legs of the security clips shall allow for spreading after installation to prevent
complete withdrawal from the socket. The locking device shall be resilient, corrosion
resistant and of sufficient mechanical strength. There shall be no possibility of the locking
device to be displaced or be capable of rotation when placed in position and under no
circumstances shall it allow separation of insulator units and fittings. ‘W’ type security
clips are also acceptable. The hole for the security clip could be countersunk and the clip
shall be of such design that the eye of the clip may be engaged by a hot line clip puller to
provide for disengagement under energized conditions. The force required for pulling the
clip into its unlocked position shall not be less than 50 N (5 kgs) or more than, 500 N (50
kgs).
5.06.06 BALL AND SOCKET DESIGNATION
The dimensions of the balls and sockets for 70 KN & 90 KN discs shall be of 16 mm and
for 160KN discs shall be of 20 mm designation in accordance with the standard
dimensions stated in IS:2486 (Part II).

5.07 DIMENSIONAL TOLERANCE OF DISC INSULATOR


It shall be ensured that the dimensions of the disc insulators are within the limits specified
below:
a. Diameter of Disc (mm)
Rating Standard Maximum Minimum
160 KN Disc 280 293 267
90 KN Disc 255 266 244
MPPTCL/TECH-LINE/PROC/SEP23 Page 75
Rating Standard Maximum Minimum
70 KN Disc 255 266 244

b. Ball to Ball Spacing between Discs (mm)

Rating Standard Maximum Maximum

160 KN Disc 170 175 165


90 KN Disc 145 149 141
70 KN Disc 145 149 141

5.08 INTERCHANGEABILITY
The insulators inclusive of the ball and socket fittings shall be of standard design suitable
for use with hardware fittings of any make conforming to relevant Indian Standards.
5.09 SUITABILITY FOR LIVE LINE MAINTENANCE
The insulators shall be compatible for use with hot line or live line maintenance
techniques so that usual hot line operations can be carried out with ease, speed and
safety.

Contractors shall indicate the methods generally adopted in routine hot and cold line
maintenance of EHV lines for similar insulators supplied by them. Contractors shall also
indicate the recommended periodicity of such maintenance.
5.10 FREEDOM FROM DEFECTS
Insulators shall have none of the following defects:
i) Ball pin shake
ii) Cementing defects near the pin like small blow holes, small hair cracks,
lumps, etc.
iii) Sand fall ferro particle defects on the surface of the insulator.
iv) Shell eccentricity

5.11 INSULATOR STRINGS:

5.11.01 TYPE AND RATING


The insulator strings shall be formed with standard discs described in this specification for
use on 3 phase, 220kV/132kV, 50Hz effectively earthed systems in a moderately polluted
atmosphere. Suspension insulator strings for use with suspension towers are to be fitted
with discs of 70 kN EMS rating while tension insulator strings for use with Anchor/Tension
towers are to be fitted with discs of 90 kN & 160 kN EMS rating.
5.11.02 STRING SIZE
The size of the disc insulator, the number to be used in different types of strings and their
electro-mechanical strength shall be as follows:

MPPTCL/TECH-LINE/PROC/SEP23 Page 76
S. Size of disc No. of Electro
Type of String
No. insulator standard mechanical
(mm) discs strength of
insulator
string (kN)
a) Single Suspension for 220/132KV 255x145 13/9 70

b) Double Suspension for 255x145 2x13/2x9 2x70


220KV/132KV
c) Single Tension for 220KV 280x170 14 160
d) Double Tension for 220KV 280x170 2x14 2x160
e) Single Tension for 132KV 255x145 10 90
f) Double Tension for 132KV 255x145 2x10 2x90

5.11.03 STRING CHARACTERISTICS :

5.11.03.1 The characteristics of the complete string shall be as


follows :
S. Characteristics Single/Double Single/Double
NO. Suspension Suspension
220kV 132kV 220kV 132kV
1 No. of Standard Discs 1x13 1x9 1x14 1x10
2x13 2x9 2x14 2x10
2 Nominal diameter of discs 255 255 280 255
3 Power frequency Withstand 460 280 490 300
voltage (wet) kV (rms)
4 Lighting impulse withstand 1200 800 1200 800
voltage (dry)(kVp)
5 Switching surge Withstand 900 350 900 350
voltage (Dry & wet) (kVp)
6 Mechanical failing Load 7000/ 7000/ 16500/ 9000/
(kgf) 14000 14000 33000 18000

7 Pollution Moderately polluted Moderately polluted


8 No deformation load (kgf) 4690/ 4690/ 11055/ 6030/
9380 9380 22110 12060
9 Corona Extinction voltage 176 - 176 -
(KV rms)

5.11.03.2 Insulator units after assembly shall be concentric and coaxial within limits
as permitted by Indian standards.

MPPTCL/TECH-LINE/PROC/SEP23 Page 77
5.11.03.3 The string design shall be such that when units are coupled together there
shall be contact between the shell of one unit and metal of the next adjacent unit.
5.12 TESTS :
5.12.01 The Disc insulators offered should be fully type tested as per the relevant
standards. The following tests shall be carried out on the insulator string and also on unit
disc insulators.
5.12.02 Acceptance Tests shall mean those tests which are to be carried out on
samples taken from each lot offered for pre-despatch inspection for the purpose of
acceptance of the lot.
5.12.03 Routine Tests shall mean those tests, which are to be carried out on each
insulator to check the requirements which are likely to vary during production.
5.12.04 Stage tests during manufacture shall mean those tests which are to be carried
out during the process of manufacture to ensure quality control such that the end product
is of the designed quality conforming to the intent of this specification.
5.12.05 The norms and procedure of sampling for the above tests shall be as per the
relevant Indian Standard or other internationally accepted standards.
5.12.06 The standards according to which these tests are to be carried out are listed
against each test. Where a particular test is a specific requirement of this specification,
the norms and procedure for the same shall be as specified in Appendix-I attached hereto
or as mutually agreed to between the Contractor and the Employer in the Quality
Assurance Programme.
5.12.07 For all type and acceptance tests, the acceptance values shall be the value
guaranteed by the Contractor in the “Technical Questionnaire” or the acceptance value
specified in this specification or the relevant standard whichever is more stringent for that
particular test.

5.13 DETAILS OF TYPE TESTS :


5.13.01 The Disc insulators offered shall be fully type tested for the following tests as
per relevant International/Indian Standard and the bidder shall furnish type test reports
along with the offer.

a) Visible discharge test IS:731


b) Impulse voltage withstand test IS:731
c) Wet power frequency voltage withstand test IS:731
d) Verification of dimension test IS:731
e) Temperature cycle test IS:731
f) Electro-Mechanical failing load test IS:731
g) Puncture test IS:731
h) Porosity test IS:731
i) Galvanising test IS:731
j) 24 hours mechanical failing load test IS:731
k) Metallurgical test IS:2108 & IS:2004

MPPTCL/TECH-LINE/PROC/SEP23 Page 78
5.14 DETAILS OF ACCEPTANCE AND ROUTINE TESTS :

5.14.01 All Acceptance and Routine tests as stipulated herein shall be carried out by the
Contractor in the presence of Employer’s representative. Immediately after finalisation of
the programme of acceptance/routine testing, the Contractor shall give sufficient advance
intimation to the Employer, to enable him to depute his representative for witnessing the
test.
5.14.02 For String Insulator Units following Acceptance & Routine tests shall be
conducted:
(A) Acceptance tests:

a) Verification of dimensions IS:731


b) Temperature cycle test IS:731
c) Galvanising test IS:731
d) Mechanical performance test IEC:575
e) Test on locking device for ball and IEC:372/IS-2486(part-IV)
socket coupling
f) Eccentricity test As per Specification
g) Electro-mechanical strength test
h) Puncture test IS-731
i) Porosity test
(B) Routine tests:

a) Visual Inspection IS-731


b) Mechanical routine test
c) Electrical routine test IEC:383

5.15 Tests during Manufacture (STAGE TESTS)


On all components as applicable
a) Chemical analysis of Zinc used for
galvanizing
b) Chemical analysis, mechanical and
metallographic test and magnetic
particle inspection for malleable
castings As per this Specification
c) Chemical analysis, hardness test
and magnetic particle inspection for
forgings
d) Crack detection test for metal parts

MPPTCL/TECH-LINE/PROC/SEP23 Page 79
5.16 ADDITIONAL TESTS :

The Employer reserves the right for carrying out any other tests of a reasonable nature at
the works of the Contractor/laboratory or at any other recognized laboratory / research
institute in addition to the above mentioned type, acceptance and routine tests at the cost
of the Employer to satisfy that the material complies with the intent of this specification.

5.17 COORDINATION FOR TESTING:

For 220KV/132KV insulator strings, the Contractor is required to produce type test reports
to the satisfaction of the Employer. However, in case the Employer desires, the
Contractor shall conduct all the type tests on the complete string with relevant hardware
fittings. Responsibility of arranging required hardwares for the purpose of type testing will
remain with the Contractor.

5.18 QUALITY ASSURANCE PROGRAM :


The contractor shall submit the Quality Assurance Programme as specified in clause 1.12
Section-1 of the biding document. A copy of the accepted Quality Assurance Plan must
be available at the manufacturer’s works of the Plant for reviewing by inspecting officer of
the employer.
5.19 INSPECTION :

5.19.01 As specified in clause 1.13 Section-1 of the biding document, Plant to be


supplied will be subject to inspection and approval by the Employer's representative
before despatch.
5.19.02 The acceptance of any quantity of insulators shall in no way relieve the
successful Contractor of his responsibility for meeting all the requirement of this
specification and shall not prevent subsequent rejection, if such disc insulators are later
found to be defective.
5.19.03 The Contractor shall submit the routine test certificates of bought out items and
raw material at the time of routine testing of the insulator.

5.20 IDENTIFICATION MARKING :

i) Each disc insulator shall be legibly and indelibly marked with the trade
mark of the manufacturer, the month and year of manufacture, the
guaranteed combined mechanical and electrical strength in kilo-newtons
abbreviated by ‘KN’ to facilitate easy identification and proper use.

ii) The marking shall be on porcelain shell of insulators. The marking shall be
printed and not impressed/embossed and same shall be applied before
firing.

iii) One 10mm thick ring of good quality paint shall be marked on the cap of
each insulator of particular strength for easy identification of the type of
insulator. The paint shall not have any deteriorating effect on the insulator
performance. Following codes shall be used as identification mark:-
MPPTCL/TECH-LINE/PROC/SEP23 Page 80
For 70kN disc insulator – Green
For 90kN disc insulator – Blue
For 160kN disc insulator – Red

5.21 DOCUMENTATION

The Contractor shall furnish full description and illustrated catalogues of insulators
offered, alongwith the bid. The supplier shall also furnish alongwith the bid the
outline drawing of each insulator unit including cross-sectional view of the shell.
The drawing shall include the following information :

i) Shell diameter and unit spacing with manufacturing tolerance.

ii) Creepage distance.

iii) Unit mechanical and electrical characteristics as also for the complete
string-suspension and tension.

iv) Size and weight of ball and socket part.

v) Weight of unit insulator disc.

vi) Materials for the disc, cap and pin.

vii) Identification mark.

viii) Manufacturer’s catalogue number.

ix) Brief installation instructions.

x) Relevant technical details of significance.

5.22 PACKING & FORWARDING :


i) All disc insulators shall be packed in strong seasoned wooden crates. The
gross weight of the crates alongwith disc insulators shall not normally
exceed 100 kg. to avoid handling problem.
ii) The packing shall be of sufficient strength to withstand rough handling
during transit, storage at site and subsequent handling in the field.
iii) Suitable cushioning, protective padding, or dunnage or spacers shall be
provided to prevent damage or deformation during transit and handling.
iv) All packing cases shall be marked legibly and correctly so as to ensure
safe arrival at their destination and avoid the possibility of goods being lost
or wrongly dispatched on account of faulty packing and faulty or illegible
markings. Each wooden case/crate shall have all the markings stenciled
on it in indelible ink.

MPPTCL/TECH-LINE/PROC/SEP23 Page 81
Appendix-I
TEST DETAILS

1. Voltage Distribution Test:


The voltage across each insulator unit shall be measured by sphere gap method. The
result obtained shall be converted into percentage and proportionate correction be
applied so as to give a total of 100% distribution. The voltage across any disc shall not
exceed 9% for suspension insulator strings and for double tension insulator strings. The
total of the voltage distribution of all discs so computed shall be within 95% and 105%. If
not, the test shall be repeated. The proportions correction shall be made on the values so
as to give a total of 100% distribution.
2. Mechanical Strength Test:
The complete insulator string alongwith its hardware fittings excluding arcing horn, corona
control ring/grading ring and suspension assembly/dead end assembly shall be subjected
to a load equal to 50% of the specified minimum ultimate tensile strength (UTS) which
shall be increased at steady rate to 67% of the minimum UTS specified. The load shall
be held for five minutes and then removed. After removal of the load, the string
components shall not show any visual deformation and it shall be possible to disassemble
them by hand. Hand tools may be used to remove cotter pins and loosen the nuts
initially. The string shall then be reassembled and loaded to 50% of UTS and the load
shall be further increased at a steady rate till the specified minimum UTS and held for one
minute. No fracture should occur during this period. The applied load shall then be
increased until the failing load is reached and the value recorded.
3. Vibration Test:
The suspension string shall be tested in suspension mode, and tension string in tension
mode itself in laboratory span of minimum 30 metres. In the case of suspension string a
load equal to 600 kg shall be applied along the axis of the suspension string by means of
turn buckle. The insulator string alongwith hardware fittings and two sub-conductors
(each tensioned at 4500 kg) shall be secured with clamps. The system shall be suitable
to maintain constant tension on each sub-conductors throughout the duration of test.
Vibration Dampers shall not be used on the test span. Both the sub-conductors shall be
vertically vibrated simultaneously at one of the resonance frequencies of the insulator
string (more than 10 Hz) by means of vibration inducing equipment. The amplitude of
vibration at the antinode point nearest to the string shall be measured and the same shall
not be less than + 120/f , f being the frequency of vibration. The insulator string shall be
vibrated for five million cycles then rotated by 90 deg. and again vibrated for 5 million
cycles without any failure. After the test, the disc insulators shall be examined for
looseness of pins and cap or any crack in the cement. The hardware fittings shall be
examined for fatigue failure and mechanical strength test. There shall be no deterioration
of properties of hardware components and disc insulators after the vibration test. The
disc insulators shall be subjected to the following tests as per relevant standards:

MPPTCL/TECH-LINE/PROC/SEP23 Page 82
S. Test Percentage of
No. discs to be tested

a) Temperature cycle test followed 60


by mechanical performance test

b) Puncture test (for porcelain 40


insulator only)

If the results of the second test show a porcelain shell rupture, the production does not
comply with this specification.

4. Chemical Analysis of Zinc used for Galvanising:


Samples taken from the zinc ingot shall be chemically analysed as per IS:209. The purity
of zinc shall not less than 99.95%.
5. Tests for Forgings:
The chemical analysis, hardness tests and magnetic particle inspection for forgings, will
be as per the internationally recognized procedures for these tests. The sampling will be
based on heat number and heat treatment batch. The details regarding test will be as
discussed and mutually agreed to by the Contractor and Employer in Quality Assurance
Programme.
6. Test on Castings:
The chemical analysis, mechanical and metallographic tests and magnetic particle
inspection for castings will be as per the internationally recognized procedures for these
tests. The samplings will be based on heat number and heat treatment batch. The
details regarding test will be as discussed and mutually agreed to by the Contractor and
Employer in Quality Assurance Programme.
7. Eccentricity Test:
The insulator shall be vertically mounted on a fixture using dummy pin and socket. A
vertical scale with horizontal slider shall be used for the axial run out. The pointer shall
be positioned in contact with the bottom of the outermost petticot of the disc. The disc
insulators shall be rotated with reference to the fixture and the slider shall be allowed to
move up and down on the scale but always maintaining contact with the bottom of the
outer most petticot. After one full rotation of the disc, the maximum and minimum position
the slider has reached on the scale can be found out. Difference between the above two
readings shall satisfy the guaranteed value for axial run out. Similarly using a horizontal
scale with vertical slider the radial run out shall be measured. The slider shall be
positioned on the scale to establish contact with the circumference of the disc insulator
and disc insulator rotated on its fixture always maintaining the contact. After one full
rotation the maximum and minimum position of the slider reached on the scale are found
out. The difference between the above readings shall satisfy the guaranteed value for
radial run out.

MPPTCL/TECH-LINE/PROC/SEP23 Page 83
8. Crack Detection Test:
Crack detection test shall be carried out on each ball and pin before assembly of disc
unit. The manufacturer shall maintain complete record of having conducted such tests on
each and every piece of ball pin. The Contractor shall furnish full details of the equipment
available with him for crack test and also indicate the test procedure in detail.
SYSTEM PARTICUALRS

S.No PARTICULARS Electrical System Data


.
1 System A.C. A.C. A.C.
3phase 3phase 3phase
2 Line voltage (kV rms) 220 132 400
3 Max.voltage (kV rms) 245 145 420
4 Frequency 50Hz. 50Hz. 50 Hz
5 Neutral grounding system effectively effectively effectively
earthed earthed earthed
6 Lightning impulse with-stand 1050 550 1425
voltage(dry & wet)(kVp)
7 Power frequency withstand 395 230 630
voltage (wet) (kVp)
8 Switching surge withstand 650 325 1050
voltage (wet) (kVp)
9 Short circuit level (kA) 40 40 40
10. Minimum corona extinction - - 320
voltage at 50 Hz AC system
dry condition (Kv rms)
11. Radio interference voltage at - - 500
one MHz for phase to earth
voltage of 266KV dry
conditions(Microvolt)

MPPTCL/TECH-LINE/PROC/SEP23 Page 84
6.0 TECHNICAL SPECIFICATION OF HARDWARE FITTINGS FOR 132KV AND
220 KV TRANSMISSION LINES
6.01 STANDARDS:

This section provides for the Design, manufacturing, stage testing, inspection and testing
before despatch, packing and delivery of Hardware fittings for Insulator string suitable for
Conductor and Earth wire for use on 132 KV/220KV transmission lines. The material and
services under this specification shall be performed as per the requirements of the latest
revisions and amendments available at the time of placement of order of all the relevant
Indian Standards/Codes listed here under or equivalent International Standards, except
as modified in this document:

S. Indian Standard Title


No

1 IS:209-1992 Specification for Zinc Ingot


2 IS:206 –1992 Tee and Strap Hinges
3 IS:7814-1985 Phosphor Bronze Sheet and Strip
4 IS:2071 Method of high voltage testing (P
5 IS:731 Porcelain Insulator for Overhead Power Lines with a
Nominal Voltage Greater than 1000 V.
6 IS:961 Structural Steel
7 IS:1385 Phosphor Bronze Rods & Bar Sheet and Strips and Wire
8 IS:2004 Carbon Steel Forgings for General Engineering Purpose
9 IS:2107 White Hearth Malleable Iron Castings
10 IS:2108 Black Hearth Malleable Iron Castings
11 IS:2121(Part-I & Specification for Conductors and Earth wire Accessories for
II) Overhead Power Line, Armour Rods Binding Wires and
Tapes for Conductor
12 IS:2486 Specification for Insulator Fittings for Overhead Power
Lines with a Nominal Voltage Greater than 1000 V.
13 IS:2629 Recommended Practice for Hot Dip Galvanization of Iron
and Steel.
14 IS:2633 Testing of Uniformity of Coating of Zinc coated Articles
15 IS:3138 Hexagon Bolts and Nuts
16 IS:6639 Hexagon Bolts for Steel Structures
17 IS:6745 Determination of Weight of Zinc Coating on Zinc Coated
Iron and Steel Articles
18 IS:3188 Characteristic of String Insulators Units
19 IS:4218 ISO Metric screw Threads
20 IS:4172 Dimensions for Radii under the Heads of Bolts & Screws
MPPTCL/TECH-LINE/PROC/SEP23 Page 85
S. Indian Standard Title
No

21 IS:4206 Dimensions for nominal lengths and Thread length for


Screws and Studs (with amendment)
22 IS:4759 Hot Dip Zinc Coatings on Structural Steel and other Allied
Products
23 IS:1573 Electroplated Coatings of Zinc on Iron and Steel
24 IS: 398 Specification for Aluminium Conductor Steel Reinforced for
overhead transmission purpose.
25 IS: 1327-1966 Methods for determination of weight of tin Coating on Tin
Plates
26 IS: 4826-1979 Hot Dip Galvanised Coating on Round Steel Wires
27 IS: 1363 Hexagon Head Bolts, Screws & Nuts.
28 IS: 1367 Technical supply conditions for threaded Steel Fasteners
29 IS: 9708 Stockbridge Vibration Dampers for Overhead Power lines.
30 IS: 8263 Method of Radio Interference Tests on High Voltage
Insulators.
31 IS:10162 Spacers and Spacer Dampers for twin horizontal bundle
Conductors.
32 IS: 2004 Carbon Steel Forgings for general engineering purposes.
33 BS:970 General Instructions and Testing Procedures Specific
(Part-I) Requirements for Carbon and Carbon Manganese Alloy
and Stainless Steels.

6.02 PRINCIPAL PARAMETERS:

6.02.01 Details of Hardware Fittings:


The Hardware fittings shall meet the technical requirement as per clause 6.3 and also
general arrangement drawings of Hardware fittings attached herewith. Hardware fittings
shall be suitable for single/double suspension Insulator strings and single/double tension
Insulator strings. Each Hardware fitting shall be supplied complete in all respect and shall
include all components, which are required for making complete set.

The hardware fittings for lines shall be suitable for ACSR Conductor and Earth wire as per
technical parameters indicated in Annexure-3

6.03 INSULATOR STRING CHARACTERISTICS:

6.03.01 The complete insulator string including Hardware fittings shall have the
following characteristics:

MPPTCL/TECH-LINE/PROC/SEP23 Page 86
S. Characteristics Single/Double Single/Double
NO. Suspension Suspension
220kV 132kV 220kV 132kV

1 No. of Standard Discs 1x13 1x9 1x14 1x10


2x13 2x9 2x14 2x10
2 Nominal diameter of discs 255 255 280 255
3 Power frequency Withstand 460 280 490 300
voltage (wet) kV (rms)
4 Lighting impulse withstand 1200 800 1200 800
voltage (dry)(kVp)
5 Switching surge Withstand 900 350 900 350
voltage (Dry & wet) (kVp)
6 Mechanical failing Load 7000/ 7000/ 16500/ 9000/
(kgf) 14000 14000 33000 18000
7 Pollution Moderately polluted Moderately polluted
8 No deformation load (kgf) 4690/ 4690/ 11055/ 6030/
9380 9380 22110 12060
9 Corona Extinction voltage 176 - 176 -
(KV rms)

6.03.02 The Insulator string Hardware fittings and Earth wire assemblies shall comply
and conform to the above requirement.

6.04 BALL AND SOCKET DIMENSIONS:


The Ball and Socket for Hardware fittings shall necessarily conform to the dimensions as
stipulated in the Indian Standards. The Ball and Socket dimensions of the Hardware sets
to be used with 7000 kg and 9100 kg Electro Mechanical strength Disc Insulators shall
conform to designation 16mm/16mm-B in accordance with IS:2486(Part-II) or equivalent
International Standard. The Ball and Socket dimension of Hardware to be used with 11500
Kg & 16,500 kg Electro Mechanical strength disc insulator shall conform to designation
20mm in accordance with IS-2486:(Part-II) or equivalent International Standard. The
Bidder shall offer full detail of locking device in accordance with IS 2486:(Part-III) or
equivalent International Standard along with test reports, gauges and adherence to
Standards for Tests on Locking Devices in line with IS:2486 (Part-IV) or equivalent
International Standar

6.05 REQUIRED GUARANTEED STRENGTH OF HARDWARE OF INSULATOR


STRINGS:

MPPTCL/TECH-LINE/PROC/SEP23 Page 87
6.05.01 The Hardwares and Clamps of 132kV/220kV single suspension and double
suspension strings suitable for Panther ACSR and Zebra ACSR for transmission line and
shall have the ultimate breaking strength of not less than 7,000 kgs.

6.05.02 The slipping strength of the suspension clamp shall not be less than 15% and
more than 20% of the Conductor strength with which it is to be used.

6.05.03 The Hardware and Compression Clamp of single and double tension strings
suitable for Panther ACSR shall have ultimate breaking strength of not less than 9,100
kgs. The slipping strength of Compression Clamp shall not be less than 95% of the
ultimate breaking strength of Panther ACSR.

6.05.04 The Hardware and Compression Clamp of single & double tension strings
suitable for Zebra ACSR for 220kV transmission line shall have ultimate breaking strength
of not less than 16500 kgs. The Compression Clamp shall have slipping strength not less
than 95% of breaking strength of Zebra ACSR.

6.05.05 Each individual Hardware component of double suspension and double tension
strings such as ball-clevis, socket clevis etc. shall have minimum breaking strength as
specified for respective single suspension and tension string respectively.

6.06 PARTICULARS OF HARDWARE FITTINGS:

Each Hardware fitting for the transmission line shall be complete in all respect and Bidder
should furnish complete drawings and technical particulars of the items of hardware
fittings. The Hardware fittings should normally comprise items conforming to enclosed
drawing as under: -

6.06.01 Single Suspension Hardware Fitting With AGS Type Clamp:

Single suspension Hardware string shall comprise of one Ball Hook, one Socket Eye
Horn holder, one line side Arcing Horn and one Suspension Clamp of AGS type with
armour rod suitable for respective sizes of Conductors.

6.06.02 Double Suspension String Hardware Fittings With AGS Type Clamp:
The double suspension string Hardware fittings shall comprise of one Ball Hook, one
Socket Clevis, one Top Yoke Plate, two Ball Clevis, two Socket Clevis, one bottom Yoke
Plate, two line side Arcing Horns, one Clevis Eye and one AGS type Suspension Clamp
suitable for respective sizes of Conductors.

6.06.03 Single Tension String Hardware Fittings:


Single tension string Hardware shall comprise of one `D’ Shackle, one Ball Link, one
Forged Steel Socket, Socket Clevis Horn holder, one line side Arcing Horn and one
Tension Clamp of compression type having before and after compression dimensions
strictly as shown in enclosed Appendix-2.

6.06.04 Double Tension String Hardware Fittings:

MPPTCL/TECH-LINE/PROC/SEP23 Page 88
The double tension string Hardware shall comprise of two `D’ shackle, one chain link one
top yoke plate, two ball clevis, two socket clevis, one bottom yoke plate, one line side
arcing horn, one clevis and a compression type dead-end Clamp having `before and after
compression’ dimensions strictly as shown in enclosed Appendix-2.

6.07 EARTH WIRE ASSEMBLIES:

6.07.01 Earth Wire Suspension Assembly With Preformed Armour Rods:

This shall comprise of envelope type Suspension Clamp of heat-treated malleable iron,
one Chain Link and one ‘D’ Shackle. The entire assembly shall be hot dip galvanized
complete with minor accessories. The breaking strength of all the Hardware items of the
assembly shall not be less than 7000 kgs. The complete assembly of suspension clamp
shall be guaranteed for slip strength of not less han 15 KN & not more than 19 KN. The
strength of the Earth wire has been specified in Annexure-3. The suspension assembly
shall be supplied with armour rod for Earth wire.

6.07.02 Earth Wire Tension Assembly:


The Earth wire tension assembly shall have minimum breaking strength equal to that of
the Earth Wire. The slipping strength of the Compression Clamp shall not be less than
95% of the breaking strength of Earth Wire. The strain assembly of the Earth wire for
transmission line shall comprise of compression type dead end Clamp and two `D’
Shackles complete with minor accessories such as pins, bolts & nuts etc. Strain
assembly shall be hot dip galvanized and made inherently resistant to the atmosphere
corrosion. The dead end Clamp of the assembly shall be of compression type. The
tension clamp shall be attached to the horizontal strain plate of the tower body by means
of a “D” shackle. “D” shackle shall be suitable for attaching the tension clamp to strain
plate of towers having 8mm thickness with a hole of 21.5 mm diameter. The tension
clamp body shall be made out of steel of 304 L grade or equivalent with Brinnel
Hardness not exceeding 200. The complete assembly shall also include one 12.5mm dia,
45 mm long HRH MS Bolt hot dip galvanized with nuts and lock washers for attaching
G.I. earth bond. A detailed drawing giving dimensional details of the complete assembly
shall accompany the tender. After compression, dimensions of the joint shall be as
indicated in enclosed Appendix-2.

6.08 DETAILS OF COMPONENTS OF HARDWARE FITTINGS:


6.08.01 Armour Grip Suspension Clamp (AGS):

AGS fitting shall consist of 2 Neoprene Halves, a set of Helical rods made of Aluminium
alloy, two Aluminium halves casting having inner profile matching with the profile of the
Armour rod cage and jointed by supporting strap made of Aluminium alloy.
The Contractor should give complete data on the reduction of the dynamic stresses of
the Conductor at the point of AGS support compared to that of bare clamp used with
preformed types of Armour rods.

The Contractor will be required to prove the comparative performance in regard to the
dynamic flexural stress pattern on the vibrating Conductor on the tensioned span with
actual tests on the AGS unit compared to the normal bare clamp with Armour rods.
Suitable curves should be furnished for the same and also actual reports on the stress/
MPPTCL/TECH-LINE/PROC/SEP23 Page 89
strain determinations. The Contractor should give the guaranteed value of the power
loss of the AGS units to be supplied by them supported by a test certificate of any
reputed laboratory of the country. Suitable curves should be furnished for the power loss
due to AGS unit as well as with the conventional envelope type of Suspension Clamps.

The housing supports and housing straps should provide positive stop closure. AGS unit
should have low rotational inertia, strut action of the Armour Cage, resilient cushioning of
the neoprene insert, immunity from high compressive and flexural stress and wide area
support. Manufacturer is required to guarantee minimum fatigue life of the AGS units
and this would be established under actual tests on tensioned Conductor span. The
manufacturer is required to guarantee minimum 40 years life of the complete AGS units
including Neoprene cushioning and this should be established under actual test on a
tensioned Conductor span.

The rubber used with AGS unit must be capable of withstanding desired long out-door
performance including the variation of temperature from 00C to 750C. The Contractor will
have to provide certificate from reputed manufacturers that the rubber being supplied by
them is suitable for AGS fitting and must have tensile strength of 2000 PSI and minimum
ultimate elongation 300%.

The helical retaining rods required for AGS assembly shall be made of Aluminium alloy of
HE 20 grade as per IS-6051/1970 or equivalent International Standard duly heat treated
and shall be suitable to wrap a desired size of Conductor. The tensile strength of the
retaining rod material should not be less than 50,000 PSI and the electrical conductivity
should not be less than 40% (IACS). The minimum slipping strength of the complete
fitting shall not be less than 15% and more than 20% of the UTS of the cable on which it
is to be used. The Clamp shall be in 2 parts made of Aluminium and will have inner
profile matching with the profile of Armour rod. This Clamp should be made by drop
forging process. AGS assembly should be provided with the forged steel socket eye to
match with the suspension string and should have UTS not less than 7,000 kgs.

IT IS ESSENTIAL FOR THE CONTRACTOR TO HAVE SUITABLE HEAT TREATMENT


FACILITIES FOR ALUMINIUM ALLOY WIRES IN THE ARMOUR GRIP SUSPENSION
UNITS. FORMED ROD BASED ITEMS WILL NOT BE ACCEPTABLE FROM
MANUFACTURERS WHO DO NOT HAVE NECESSARY TECHNOLOGY FOR
DEVELOPMENT OF ADEQUATE RESILIENCE, ELONGATION UTS AND TWIST
TEST FACILITIES BACKED WITH PROPER HEAT TREATMENT SYSTEMS.

6.08.02 AGS Preformed Armour Rods:

The AGS Preformed Armour rods set suitable for ACSR Zebra/ Panther conductor (as
the case may be) shall be used to minimize the stress developed in a conductor due to
different static and dynamic loads because of vibration due to wind, slipping of conductor
from suspension clamp as a result of unbalance conductor tension in adjacent span and
broken wire condition. It shall be made of Aluminium alloy of HE 20 grade as per IS-
6051/1970 duly heat-treated. The aluminium alloy wires (pre heat treated) for
manufacturing of Armour rods can also be used, however Contractor shall submit the test
certificates in support of their claim for using pre heat-treated wires. It shall also

MPPTCL/TECH-LINE/PROC/SEP23 Page 90
withstand power arcs, chafing and abrasion from suspension clamp and localized heating
effects due to resistance losses of the conductor.
The pitch length of the rods shall be determined by the Contractor but shall be less than
that of the outer layer of ACSR conductor and the same shall be accurately controlled to
maintain uniformity and consistently reproducible characteristics wholly independent of
the skill of lineman.
The preformed armour rod sets shall have right hand lay and the inside diameter of the
helices shall be less than the outside diameter of the conductor to grip the same tightly.
The surface of the armour rod when fitted on the conductor shall be smooth and free
from projections, cuts and abrasions etc.
The length of each rod shall be as per drawing enclosed. The tolerance in length of each
rod shall be +/-25mm. The tolerance in length of the rods in completed sets should be
within 13 mm between the longest and shortest rod. The ends of the armour rod shall be
parrot billed.
The number of armour rods in each set shall be 11/12. The each rod shall be marked in
the middle with paint for easy applications on the line.
The armour rod shall not loose their resilience even after five applications. The
conductivity of each rod of the set shall not be less than 40% of the conductivity of
International Annealed Copper Standard (IACS). The minimum tensile strength of
armour rod should be 35 kg per sq.mm.

6.08.03 Strain Clamp:


The Strain Clamp shall be of the compression type for the specified size of Conductor for
220/132KV lines. The outer sleeve of the Compression Clamp and Jumper Terminal shall
be of EC grade Aluminium 99.5% pure tube formed by extrusion process and the inner
sleeves shall be of galvanized steel. The angle of jumper terminal to be mounted should
be 30 deg. with respect to the vertical line. The Compression Clamp shall have slipping
strength not less than 95% of the ultimate breaking strength of Conductor with which it is
to be used. The compression dead end clamp for transmission line shall be
manufactured out of extruded Aluminium.

The resistance of the clamp when compressed on the conductor shall not be more than
75% of the resistance of equivalent length of conductor. Die compression line shall be
clearly marked on each dead-end assembly designed for continuous die compression
and shall bear the words “COMPRESS FIRST” suitably inscribed near the point on each
assembly where the compression begins. It shall bear identification marks
“COMPRESSION ZONE” and “NON COMPRESSION ZONE” distinctly with arrow marks
showing the direction of compressions and knurling marks showing the ends of the
Zones. Tapered aluminium filler plugs shall also be provided at the line of demarcation
between Compression and Non-compression zone. The letters, numbers and other
marking on the finished clamp shall be distinct and legible.

6.08.04 Arcing Horn:


132/220kV Insulator strings for transmission line shall be provided with Arcing Horns of
different type as indicated in the enclosed drawings. In case of 132 kV line, the Arcing
Horn shall be made out of 25mm x 6mm size flat. At the ends of flat, spherical ball of 38
MPPTCL/TECH-LINE/PROC/SEP23 Page 91
mm dia. shall be provided as shown in enclosed drawing. In case of 220kV Hardware
strings, the Arcing Horn shall be made out of 25mm dia steel pipe. The dimension of the
Arcing Horn shall be as indicated in the drawing. However, the height of the Arcing Horn
may be changed depending upon the length of Socket Eye, Yoke Plate etc. Please note
that Arcing Horn shall be strictly according to above. Any other type of Arcing Horn
including graded type, may not be acceptable.

The designed fixture of the Arcing Horn with that of the string Hardware of Yoke Plate
shall be such that the possibility of relative movement between the two, due to vibration
of assembly in service is altogether avoided. Making two bolt connections and providing
a collar to the Hardware item can achieve this. An additional nut should be provided
along with bolts and nuts to fix the Arcing Horn with Hardware items. The provision of an
additional nut will avoid the possibility of relative movement between the Arcing Horn and
the Hardware item, due to vibration of string. The arrangement for fixing of Arcing Horn
shall be such that they do not get loose while in service. To achieve this, they should
have proper seat for the Arcing Horn and heat-treated Belleville washers should be
provided with the bolts.

6.08.05 Socket Eye & Ball Clevis:


The Socket Eye and Ball Clevis be made of forged steel as per the drawing enclosed.
6.08.06 U Clevis:
These shall be made of forged steel complete with galvanised steel rivets washer and
Phosphorus Bronze/Stainless Steel pins.
6.08.07 Ball Fittings:
These shall be made of forged steel in one piece. They shall be normalized to achieve
the minimum breaking strength specified in the respective drawings. Before galvanising
of ball fittings, all die fleshing on the shank and on the bearing surface of the ball shall be
carefully removed without reducing the dimension below the requirements. The
dimension of the ball & socket shall be 16mm/20mm designation in accordance with
standard dimensions stated in IS:2486 (Part-II).

6.08.08 Dimensions & Tolerances:


6.08.08.1 The dimensions and tolerances of pin balls and socket ends shall conform to IS
2486 Part-II/IEC-120 and shall be checked by the gauge therein after galvanizing.
6.08.08.2 The pin balls shall be checked with the applicable “GO” gauges in at least two
directions, one of which shall be across the line of die flashing and the other 90 deg. to
this line. “NO GO” gauges shall not pass in any direction.

6.08.08.3 The bearing surfaces of balls and machined sockets, before galvanizing shall
not have surface roughness more than 250 micro inches.

6.08.08.4 The bearing surface of socket ends shall be uniform about the entire
circumference without depressions or high spots. The internal contour of the socket ends
shall be concentric with the axis of fittings. The axis of the bearing surface of socket ends
shall be coaxial with the axis of fittings with no appreciable tilting.

MPPTCL/TECH-LINE/PROC/SEP23 Page 92
6.08.09 Socket Fittings:

Socket fittings shall be made of class IV steel as per IS:2004 or steel of equivalent grade
and shall be forged in one piece. They shall be normalized to achieve the minimum
breaking strength specified on the respective drawings.

6.08.10 Security clip for Socket fittings:


6.08.10.1 Socket fittings shall be provided with R-shaped security clip in accordance with
IS:2486 (Part-III) to provide positive locking against unintentional disengagement of
socket from the ball of the insulator. The security clip shall be humped to maintain the
clip in the locked position and shall have both prongs spread to prevent complete
withdrawal from the socket. The clip end shall not project outside the recess of socket
when the clip is in locked position.
6.08.10.2 The hole for the security clip shall be on the side of the socket opposite to the
socket opening . The hole for the clip shall be counter sunk. The clip eye shall be of such
design that the same may be engaged by a hotline clip puller to provide for
disengagement under energized conditions.

6.08.10.3 The force required to pull the clip to its unlocked position shall not be less than
50 N or more than 500N.
6.08.10.4 The security clip shall be made of stainless steel of type AISI 302 or 304 or
phosphor bronze as per IS:7814.
6.08.11 Clevis-Eye:
These shall be forged steel of malleable cast iron and shall be complete with galvanised
pin with flat washer and split pin of Phosphorus Bronze/Stainless Steel.
6.08.12 Yoke Plate:
6.08.12.1 The yoke plates/link plate shall be made of mild steel plate as per IS: 2062 or
equivalent standards. Shearing/cutting of the plates shall be clean without drawn or
ragged edges. If the plates are flame cut, mechanical guides shall be used. It shall be
ensured that the grain flow of the yoke plate shall be in the direction of the tensile load.
6.08.12.2 Holes shall be cylindrical clean cut and perpendicular to the plane of the
material. The periphery of the holes shall be free from burrs.

6.08.12.3 All the corners and edges should be rounded off with a radius of at least 3mm.

6.08.12.4 Design calculation is for bearing and tensile strength for deciding the
dimensions of yoke plate shall be furnished by the Contractor. The holes provided for
bolts in the yoke plate should satisfy shear edge condition as per IS:800.

6.09 IMPORTANT CONDITIONS:

6.09.01 All Hardware items shall be complete with minor items such as security clip,
bolts, nuts, washer, split pins and inners etc.

MPPTCL/TECH-LINE/PROC/SEP23 Page 93
6.09.02 Enclosed drawings show the attachment proposed to be fitted on the towers.
The Contractor shall be responsible for satisfying him that the Insulator fittings offered are
entirely suitable for the proposed attachments and for the sizes of the Conductor
specified.
6.09.03 All ferrous fittings (except those specified otherwise) shall be hot dip
galvanized, after all machining and fitting has been completed, in accordance with
relevant Indian Standard. All Hardware items (other than clamps) and those specified
otherwise should be made of Drop Forged Steel. Socket items in forged steel must be
forged. All forgings supplied should be stress relieved and this treatment should be done
at the Contractor works. Forgings, which are not stress relieved, will not be acceptable.
The items like Yoke Plate, Arcing Horn, Bolts and Nuts shall be of mild steel and rest of
the items shall be of forged steel.
6.09.04 All Bolts, Nuts and Screw heads shall have only wide worth standard thread
and of sizes indicated in the enclosed drawing. Bolts head and Nuts shall be hexagonal.
Where required, nuts shall be locked in approved manner. The thread in Nuts shall be
over tapped after galvanizing and shall be cut before galvanizing. The threads shall not
be under cut. The Nuts should be tapped such that they are fit on the bolt threads i.e.
these should not have loose fitting.
6.10 LENGTH OF STRINGS:

6.10.01 The clearance to the tower steel parts under service conditions of Insulator
have been decided on the basis that the overall length of 9 Disc for 132kV line and 13
Disc for 220kV line (both of 7000 kgs EMS for single suspension string) will not exceed
the length as indicated in the attached drawings. The dimension of the Disc for Ball and
Socket type will be 255mm (dia) x145mm (height) for 7000 kgs EMS to be used with
suspension strings on 132kV and 220kV lines.
6.10.02 In case of 132kV tension strings, 10 Disc insulators of 9100 kg EMS of size
255mm (dia) x 145mm (height) will be used. In case of 220kV tension strings, 14 Disc
insulators of 16,500 kgs EMS of size 280mm (dia) x 170mm (height) will be used.
6.11 GALVANISING:

6.11.01 Hot dip galvanizing shall conform to Indian Standard specification IS-2633 or
equivalent International Standard. Galvanising shall be uniform, free from blisters, and
shall not peel off due to abrasion, Zinc coating shall be thick enough to withstand 6 one
minute dips in Copper Sulphate solution (precee test) for all ferrous parts except for
threaded portions which shall withstand at least 4 one minute dips.
6.11.02 The Contractor must emboss/engrave their name in each forged steel item and
Aluminium castings such as Ball Hook, Yoke Plate, Socket Clevis, Clevis Eye, Clevis-
Clevis, Anchor Shackle/D-Shackle, Chain Link, Suspension Clamps of AGS type, Tension
Clamps and Arcing Horns.
6.12 TESTS :

6.12.01 The hardware fittings offered shall be type tested as per the relevant standards.
Further the acceptance, routine tests and tests during manufacture shall be carried out on
the conductor.

MPPTCL/TECH-LINE/PROC/SEP23 Page 94
6.12.02 Acceptance tests shall mean those tests, which are to be carried out on
samples taken from each lot offered for pre-despatch inspection, for the purpose of
acceptance of that lot.
6.12.03 Routine tests shall mean those tests which are to be carried out on each and
every product so as to check with requirements which are likely to vary during production.
6.12.04 Tests during manufacture shall mean those tests, which are to be carried out
during the process of manufacture and end inspection by the Contractor to ensure the
desired quality of the end product to be supplied by him.
6.12.05 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.
6.12.06 The standards to which these tests will be carried out are listed in para 6.01.
Where a particular test is a specific requirement of this specification, the norms and
procedures of the test shall be as mutually agreed to between the Contractor and the
Employer in the Quality Assurance Programme.
6.12.07 For all type and acceptance tests, the acceptance values shall be the values
guaranteed by the Contractor in the “Technical Questionnaire” or the acceptance value
specified in this specification, whichever is more stringent for that particular test.
6.13 ACCEPTANCE TEST/SAMPLE TESTS:

6.13.01 On both suspension and tension hardware fittings:

a. Visual Examination IS:2486 (Part-I)


b. Verification of dimensions IS:2486 (Part-I)
c. Galvanising test/Electroplating As per this
specification.
d. Mechanical strength test of welded As per this
joint specification.
e. Mechanical strength test for corona BS:3288(Part-I)
control rings.
f. Test on locking devices for ball & IEC:372(2)
socket coupling.
g. Mechanical strength test of each As per this
components excluding corona control specification.
ring and arcing horn.

6.13.02 On suspension Hardware fittings only

a. Clamp slip strength vs torque test As per this specification.


for suspension clamp.

b. Shore hardness test of elastomer


cushion for AG suspension clamp.

c. Bend test for armour rod set.

MPPTCL/TECH-LINE/PROC/SEP23 Page 95
d. Re silence test for armour rods set. IS:2121 (Part-I)

e. Conductivity test for armour rods


set

6.13.03 On tension hardware fittings only:-

a. Slip strength test for dead end IS:2486 (Part-I)


assembly

6.13.04 Suspension hardware for Earthwire:-

a. Visual examination

b. Dimensional verification.

c. Slip strength test.

d. Mechanical strength test on each component

e. Galvanising test

f. Mechanical strength test of welded joint

6.13.05 Tension hardware for Earth wire:-

a. Visual examination

b. Dimensional verification.

c. Slip strength test.

d. Electrical resistance test .

6.13.06 Test during manufacture.


a. On all components as applicable.

b. Chemical analysis of zinc used for galvanizing

c. Chemical analysis, hardness test grain size inclusion rating


and magnetic particle inspection for forgoing/castings.

d. Chemical analysis and proof load test fabricated hardware.

e. Tests on malleable castings forgings and fabricated


hardware’s.

MPPTCL/TECH-LINE/PROC/SEP23 Page 96
6.14 MATERIALS AND WORKMANSHIP:

6.14.01 All the materials shall be of the latest design and conform to the best modern
practice adopted in the extra high voltage field. The manufacturer shall supply only such
material as guaranteed by him to be satisfactory and suitable for 220/132kV Transmission
lines.
6.14.02 The design, manufacturing process and quality control of all the materials shall
be such as to give maximum factor of safety, maximum possible working load, highest
mobility, elimination of sharp edges and corners, best resistance to corrosion and a good
finish.
6.14.03 All ferrous parts shall be hot dip galvanised, after all machining has been
completed. Nuts may, however, be tapped (threaded) after galvanising and the threads
oiled. Spring washers shall be electro galvanised. The bolts threads shall be under cut
to take care of increase in diameter due to galvanising. Galvanising shall be done in
accordance with IS:2629-1990 or equivalent International Standard and satisfy the tests
mentioned in IS:2633-1992 or equivalent International Standard. Fasteners shall
withstand four dips while spring washers shall be guaranteed to withstand at least six dips
each lasting one minute under the standard precee test for galvanising.
6.14.04 The Zinc coating shall be perfectly adhere, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash, rust stains,
bulky while deposits and blisters. The Zinc used for galvanising shall be grade Zn. 99.95
as per IS: 209-1992 or equivalent International Standard.
6.14.05 In case of castings, the same shall be free from all internal defects like
shrinkage, inclusion, blowholes, cracks etc.
6.14.06 All current carrying parts shall be so designed and manufactured that contact
resistance is reduced to minimum.
6.14.07 No item which would produce high electrical and mechanical stresses in normal
working shall have sharp ends or edges, abrasions or projections and shall not cause any
damage to the Conductor in any way during erection or during continuous operation. The
design of adjacent metal parts and mating surfaces shall be such as to prevent corrosion
of the contact surface and no maintain good electrical contact under service conditions.
6.14.08 Particular care shall be taken during manufacturing and subsequent handling to
ensure smooth surface free from abrasion or dents.
6.14.09 The fasteners shall conform to the requirement of IS: 6639-1972 or equivalent
International Standard. All fasteners and clamps shall have locking arrangements to
guard against vibration loosening.

6.15 IDENTIFICATION MARKING:

The main component of the material covered in the specification shall be legibly and
indelibly marked with the trademark of the manufacturer, the month and year of
manufacture, the guaranteed combined mechanical and electrical strength in kilo-Newton
abbreviated by ‘kN’ to facilitate easy identification and proper use. Marks shall be forged
or stamped with a steel die before Galvanizing. The marks shall be distinct, durable and
MPPTCL/TECH-LINE/PROC/SEP23 Page 97
conspicuous. Embossing/Engraving should be done at the time of manufacturing process
itself, but before Galvanizing. Smaller component like bolts & nuts, split pin and washers
etc. may be excluded from this requirement.

6.16 QUALITY ASSURANCE PROGRAM :

The contractor shall submit the Quality Assurance Programme as specified in clause 1.12
Section-1 of the biding document. A copy of the accepted Quality Assurance Plan must
be available at the manufacturer’s works of the Plant for reviewing by inspecting officer of
the employer.
6.17 INSPECTION :
6.17.01 As specified in clause 1.13 Section-1 of the biding document, Plant to be
supplied will be subject to inspection and approval by the Employer's representative
before despatch.
6.17.02 The acceptance of any quantity of material shall in no way relieve the
Contractor of his responsibility for meeting all the requirement of this specification and
shall not prevent subsequent rejection, if such materials are later found to be defective.
6.17.03 The supplier shall submit the factory test certificates of raw materials & bought
out accessories at the time of acceptance tests of the material covered in the
specification.

6.18 DOCUMENTATION & LIST OF DRAWINGS:


6.18.01 The detailed drawings of each component assembly drawings and descriptive
literature of the Hardware assembly shall be submitted for approval of EMPLOYER. The
detailed dimension drawings for each and all-individual Hardware items such as clamps,
U Clevis, Socket Eye, Yoke Plate and Socket Clevis etc. shall also be submitted
separately. Test certificates for different tests conducted as per relevant ISS, for all the
offered items must also be submitted essentially.
6.18.02 The bidder shall furnish full description, illustrated catalogues and dimensional
drawings, along with the bid. The drawing shall include the following information:
(i) General outline & assembly drawings of all the items /material covered in
the specification.
(ii) Dimensions, unit spacing.
(iii) Unit mechanical and electrical characteristics as also for the complete
assembly/set.
(iv) Weight of each component.
(v) Identification mark.
(vi) Material designation used for different components with reference to
Standards.
(vii) Fabrication details such as welds, finishes and coatings
(viii) Manufacturer’s catalogue number.
(ix) Brief installation instructions.
MPPTCL/TECH-LINE/PROC/SEP23 Page 98
(x) Reference of type testing.
(xi) Relevant technical details of significance.
6.19 PACKING:
6.19.01 The material shall be packed in strong wooden boxes with steel straps. The
gross weight of packing shall be in range of 50 kgs to 200 kgs to avoid handling problem.
The packing shall be strong enough to withstand rough handling during transit or storage
in the field. All the packing cases shall be legibly marked to avoid possibility of loss in
transit. The Contractor shall be responsible for any damage during transit due to improper
and inadequate packing and handling.
6.19.02 Each consignment shall be accompanied by a detailed packing list showing
following details:-
(i) The name of the consignees
(ii) Details of consignment.
(iii) Destination.
(iv) Total weight of consignment.
(v) Handling and unpacking instrumentation.
(vi) Bill of material indicating content of each package.

MPPTCL/TECH-LINE/PROC/SEP23 Page 99
APPENDIX-2
BEFORE AND AFTER COMPRESSION DIMENSIONS OF COMPRESSION TYPE DEAD-END
CLAMPS AND REPAIR SLEEVE FOR CONDUCTOR AND EARTH WIRE

Dimension before Dimension after Length of sleeve Length of sleeve


compression (Rod compression (Flat before after
Sl. cross section) to flat distance of compression compression
Particular
No. hexagon)
Panth Zebr G/ W Panth Zebra G/ W Panth Zebr G/ W Panth Zebr G/ W
er a er er a er a
A Aluminium sleeve
a Inner 23 31 - - - -
dimension
(mm)
b Outer 38 48 - 32 40 - 610 711 - 660 763 -
dimension
(mm)
B Steel sleeve
a Inner 9.35 9.95 11.5 - - -
dimension
(mm)
b Outer 18 19.2 21 15 16.1 17.5 203 241 230 233 270 262
dimension
(mm)
C Repair sleeve
Outer 38 48 20.8 32 46 17.5 241 279 150 270 310 175
dimension
(mm)

MPPTCL/TECH-LINE/PROC/SEP23 Page 100


7.0 TECHNICAL SPECIFICATION OF ACCESSORIES FOR 220/132KV
TRANSMISSION LINES

7.01 INDIAN STANDARDS/EQUIVALENT INTERNATIONAL STANDARD:This section


provides for the Design, manufacturing, stage testing, inspection and testing before
despatch, packing and delivery of Accessories suitable for Conductor and Earth wire for
use on 132/220kV transmission lines. The material and services under this specification
shall be performed as per the requirements of the latest revisions and amendments
available at the time of placement of order of all the relevant Indian Standards/Codes
listed here under or equivalent International Standards, except as modified in this
document:

S.No Indian Standard/equivalent Title


International Standards
1 IS:209-1992 Specification for Zinc Ingot
2 IS:206 –1992 Tee and Strap Hinges
3 IS:7814-1985 Phosphor Bronze Sheet and Strip
4 IS:2071 Part-I, II & III Method of high voltage testing (Par
5 IS:731 Porcelain Insulator for Overhead Power Lines
with a Nominal Voltage Greater than 1000 V.
6 IS:961 Structural Steel
7 IS:1385 Phosphor Bronze Rods & Bar Sheet and
Strips and Wire
8 IS:2004 Carbon Steel Forgings for General Engineering
Purpose
9 IS:2107 White Hearth Malleable Iron Castings
10 IS:2108 Black Hearth Malleable Iron Castings
11 IS:2121(Part-I & II) Specification for Conductors and Earth wire
Accessories for Overhead Power Line, Armour
Rods Binding Wires and Tapes for Conductor
12 IS:2486 Specification for Insulator Fittings for Overhead
Power Lines with a Nominal Voltage Greater
than 1000 V.
Part-I General Requirements and Tests
Part-II Dimensional Requirements
Part-III Locking Devices
Part-IV Tests for Locking Devices
13 IS:2629 Recommended Practice for Hot Dip
Galvanization of Iron and Steel.
14 IS:2633 Testing of Uniformity of Coating of Zinc coated
Articles
15 IS:3138 Hexagon Bolts and Nuts
16 IS:6639 Hexagon Bolts for Steel Structures
17 IS:6745 Determination of Weight of Zinc Coating on
Zinc Coated Iron and Steel Articles
MPPTCL/TECH-LINE/PROC/SEP23 Page 101
S.No Indian Standard/equivalent Title
International Standards
18 IS:3188 Characteristic of String Insulators Units
19 IS:4218 Part-I to VI Isometric screw Threads
20 IS:4172 Dimensions for Radii under the Heads of Bolts
& Screws
21 IS:4206 Dimensions for nominal lengths and Thread
length for Screws and Studs (with amendment)
22 IS:4759 Hot Dip Zinc Coatings on Structural Steel and
other Allied Products
23 IS:1573-1986 Electroplated Coatings of Zinc on Iron and Steel
24 IS: 398 (Part-II & III) Specification for Aluminium Conductor Steel
Reinforced for overhead transmission purpose.
25 IS: 1327-1966 Methods for determination of weight of tin
Coating on Tin Plates
26 IS: 4826-1979 Hot Dip Galvanised Coating on Round Steel
Wires
27 IS: 1363 Part-I to III Hexagon Head Bolts, Screws & Nuts.
28 IS: 1367 Technical supply conditions for threaded Steel
Fasteners.
IS: 1367 (Part-I) Introduction and General Information.
IS: 1367 (Part-II) Product Grades and Tolerances.
IS: 1367 (Part-III) Mechanical Properties and Test Methods for
Bolts, Screws and Studs with full Load ability.
29 IS: 9708 Stockbridge Vibration Dampers for Overhead
Power lines.
30 IS: 8263 Method of Radio Interference Tests on High
Voltage Insulators.
31 IS:10162 Spacers and Spacer Dampers for twin
horizontal bundle Conductors.
32 IS: 2004 Carbon Steel Forgings for general engineering
purposes.
33 BS:970 (Part-I) General Instructions and Testing Procedures
Specific Requirements for Carbon and Carbon
Manganese Alloy and Stainless Steels.

7.02 PRINCIPAL PARAMETERS:


7.02.01 Bidders will have to furnish confirmation in regard to compliance of our entire
technical requirement. The bid should clearly describe various technical particulars of the
material as per details given in this section. Based on above information all details
required should be furnished so that we may be able to examine whether the bid
submitted is technically acceptable or not.

MPPTCL/TECH-LINE/PROC/SEP23 Page 102


7.02.02 Details of Accessories:
i. The Conductor Accessories shall be suitable for ACSR Conductor as per
technical parameters furnished in Annexure-6.
ii. The Earth wire accessories shall be suitable for Earth wire as per
technical parameters furnished in Annexure-6.

7.03 GENERAL TECHNICAL REQUIREMENTS FOR ACCESSORIES:


The technical requirements of the individual Accessories are as under:

7.03.01 Mid Span Joints and Repair Sleeves:


i. The Mid Span Joints for Conductor & Earth wire shall be compression type.
ii. The Conductor Mid Span Joints shall comprise of Aluminium and Steel
Sleeves. The Earth wire Mid Span Joints and Steel Sleeves of Conductor Mid
Span Joints shall be Hot dip Galvanized. Sleeves shall be of circular shape
suitable for compression into hexagonal shape. The detailed drawing showing
the length of Sleeves, inner and outer cross sectional dimension, before
compression for Aluminium corresponding dimensions of hexagon after
compression for Aluminium and Steel Sleeve shall be indicated. The
Aluminium Sleeve shall be of extruded Aluminium. The material of the Steel
Sleeve shall be specified.
iii. The Repair Sleeve of Conductor shall be in two halves preferably of same
shape, and this should be of extruded Aluminium. The Repair Sleeve for Earth
wire shall be single piece and Hot dip Galvanized. Its material shall be
specified. The Repair Sleeves shall be of circular shape suitable for
compression into hexagonal shape.
iv. The steel and Aluminium Sleeves for Mid Span Joints as well as Aluminium
Repair Sleeves and Steel Repair Sleeves shall have their outer dia tapered
towards the two ends. Also the inside of the Sleeves shall be well rounded off,
so that there is no sharp edge, which can cut the strands.
v. The compression type of Joints and Repair Sleeves shall be circular shape
suitable for compression into hexagonal shape. The length of Sleeves before
compression & cross-sectional dimensions after compression and the cross
sectional dimensions between the flats of the opposite sides of the hexagon &
other dimensions are indicated in Appendix-2, Section-6 in Volume-II of bid
document.
vi. Other dimensions are indicated in the enclosed drawing.
vii. The Joints and Repair Sleeves shall conform to IS:2121/1981 or equivalent
International Standard.
viii. The conductor compressed with mid span joint or with repair sleeve shall not
permit slipping of, damage to or failure of complete conductor or any part

MPPTCL/TECH-LINE/PROC/SEP23 Page 103


thereof at a load of not less than 95% of the ultimate tensile strength of the
conductor.
ix. The electrical resistance of the joint/repaired portion of the conductor shall not
exceed 75% of the measured resistance of equivalent length of conductor.
7.03.02 4R-VIBRATION DAMPERS FOR PANTHER & ZEBRA ACSR:
7.03.02.1 Only Vibration Dampers having 4-resonance frequency characteristic
commonly called 4R Dampers shall be offered. The Damper shall eliminate fatigue on
the Conductor due to vibration and damp-out the vibrations effectively, so that no damage
due to vibration is caused to Conductor and string.

7.03.02.2 The Dampers are to be used at all tension locations and suspension
locations. One or more Dampers are proposed to be used on tension/suspension
locations depending upon the span. The Damper shall be such as to effectively damp out
the vibration on the conductor, so that the dynamic strain at the suspension point with
conventional type of Suspension Clamp ‘U’ bolt and keeper pieces, shall not exceed 150
micro strains. Contractor shall recommend the number of Dampers required to effectively
damp out the vibration of the Conductor, so that the dynamic strain at the suspension
point with conventional Suspension type Clamp shall not exceed 150 micro strains.
7.03.02.3 The requirement indicated in Schedule-I Ais based on use of two Vibration
Dampers per Conductor per span. However, final requirement will depend upon Bidder’s
recommendations duly supported by literature. Contractor shall also recommend the
number of Dampers required to effectively damp out Conductor vibration for different
values of span lengths and the distance for fixation. While working out Damper
Characteristics, it may be kept in view that on suspension locations, preformed Armour
rods are also to be fitted on the conductor. Contractor shall given full details of the
damper characteristics and energy dissipation curves of the Damper and shall also
guarantee their effectiveness for damping design.
7.03.02.4 The messenger cable shall be made of high strength steel strands of spring
steel with a minimum strength of 136 Kg/sq. mm and preformed in order to prevent
subsequent dropping of weights in service. The Contractor shall indicate full technical
particulars of the messenger cable. The keeper pieces shall have proper curvature and
edges be rounded off so that it shall have proper grip over the conductor without any
damage to conductor strands. Clamping bolts shall be provided with self-locking nuts
designed to prevent corroding of the threads or loosening during service ensuring that no
slippage occurs up to specified longitudinal force on clamp along the conductor. All
ferrous parts including the messenger cable shall be effectively sealed to prevent
corrosion.
7.03.02.5 The collar for fixing the bolt shall be designed in such a way that sufficient
space is available for tightening the bolt through spanner. Further bolt length be
maintained in such a way that it should not come out completely while affixing the clamp
on Conductor.
7.03.02.6 The Contractor shall specify the material used for the Damper weight and
shall confirm and explain, how constant design characteristics will be maintained during
production. Fixing of the masses to the messenger cable shall be done by pressing
Aluminium Sleeves at each end of the messenger cable under pressure. Each end

MPPTCL/TECH-LINE/PROC/SEP23 Page 104


should be sealed properly so as to achieve prefect joint. The molten metal filling method
for attachment of messenger cable to counter weight is not acceptable.
7.03.02.7 The Dampers shall meet the test requirements specified hereunder:
The effectiveness of the Vibration Dampers shall be to reduce the amplitude of vibration,
when tested for span of 320 meters for Panther and 335 meters for Zebra ACSR, tension
taken as 25% of ultimate tensile strength in such a order that it limits the dynamic strain in
the Conductor below 150 micro strains for 0 to 15 miles per hour wind condition in
general and 2 to 10 miles per hour wind condition in particular condition, conforming to as
close as possible to the optimum damping force requirement which the Contractor can
predict and furnish for the ranges of wind velocity and the conductor tension.

7.03.02.8 The Contractor shall furnish the recommended spacing and the basis including
wind velocity range for selecting the spacing. The results of the analysis shall account for
the following:
i. Prediction of (a) Amplitude (b) Frequency and (c) Vibration energy levels of
Aeolian vibration on Panther and Zebra ACSR for spans of 50, 100, 150, 200,
250, 300, 350, 400, 450 and 500 meters.
ii. Test results for various frequency response characteristics of Vibration
Dampers such as vibration amplitude and phase angle including power
dissipation measured from its hysteretic loops.

7.03.02.9 Maximum residual vibration must be of such an order that the strain level does
not exceed 150 micro strains.

7.03.02.10 The Vibration Dampers and their attachments shall have smooth surface so
that corona and radio interference voltage levels are within specified limits.

7.03.02.11 All Ferrous parts shall be fully galvanized..


7.03.02.12 The Vibration Damper shall be capable of being installed and removed from
energized line by means of hot line tools without completely separating components. The
Damper Assembly shall be electrically conductive. The transmission line details are as
under:-
S. Description Technical Particulars
No. 220kV 132 kV
1 Configuration Single ACSR Single ACSR
Zebra Panther
2 Span length in meters:
i. Ruling design span 350 350
ii. Maximum span 500 M 500 M
iii. Minimum span 100 100
3 Tensile load in Kg:
i. At minimum temp. of 0o C and still 4064 2794

MPPTCL/TECH-LINE/PROC/SEP23 Page 105


S. Description Technical Particulars
No. 220kV 132 kV
air

ii. At every day temp. of 32o C 3329 2282


iii. At 0o C and 2/3rd full wind 4360 3050
4 Nature of terrain Partly hilly, partly flat with cultivated
fields
5 Armour rods/AGS clamp AGS clamps
6 Maximum wind load 45 Kg/m2 Acting on full projected
area.
7 Max permissible dynamic strains 150 micro strains

The Contractor shall recommend the number of vibration dampers of the type offered and
their points of fixation for spans of 100M to 1000M in steps of 50M.

7.03.02.13 The other important features of vibration dampers as regards to


materials test, etc., are as under:

Material:
i. Dampers - As per IS-9708/1993 or equivalent International
Standard.
ii. Clamp - Aluminium alloy
iii. Messenger cable - High strength steel wire with a strength (kg/sq. mm)
not less than the strength of steel core of power
Conductor/Earth Wire.
iv. Weight - Cast Iron (Hot dip Galvanized)

Galvanising:

i. Spring washers - Electro Galvanized.

ii. Other Ferrous parts - Hot Dip Galvanized.


iii. Casting - As per IS:729-1961 or equivalent International
Standard.
iv. Wires - As per IS:326-1968 or equivalent International
Standard.
v. Bolts & Nuts - As per IS:5358-1969 or equivalent International
Standard.
Slip strength of Clamp:
i. Not less than 250 kg. When an untested Vibration Damper is installed on
Panther and Zebra ACSR Conductor.

MPPTCL/TECH-LINE/PROC/SEP23 Page 106


ii. Not less than 200 kg. After conducting the fatigue test.
Maximum permissible dynamic strain - 150 micro strains.
on the Conductor with the Damper
Minimum number of cycles for fatigue - 10 millions Performances.
Amplitude for fatigue test - ±1 mm at the highest
Resonant frequency.
Radio interference voltage at - Less than 500 microvolts.
266 kV (rms) phase to ground.

7.04 4R VIBRATION DAMPERS FOR 7/3.66MM 95 Kg PER MM2 QUALITY EARTH


WIRE:
7.04.01 The design and general particulars of Vibration Damper for Earth wire shall be
the same as described for Dampers for Conductor, Preformed Armour Rods will be used
at Earth wire suspension locations. The dynamic strain at suspension point shall not
exceed 150 micro strains.
7.04.02 The entire test as described for Vibration Dampers for Conductor shall be
carried out except for Magnetic Power Loss Test.
7.05 FLEXIBLE G.I. EARTH BONDS:
The flexible G.I. MS earth bond shall be made of flexible MS wire of size 37/7/0.417 with
9.81mm dia and area equivalent to 34 sq.mm. The length of MS wire shall not be less
than 500mm. Two steel connecting lugs shall be press jointed to the either ends of the
flexible MS cable. One end of the lug shall have hole of 17.5mm size and another of
14.5mm. The complete assembly shall also include one 16mm dia 40mm long HRH
M.S.Bolt hot dip galvanized with nut and lock washer.
7.06 TECHNICAL PARTICULARS FOR “ CLAMPS ”
7.06.01 All the current carrying parts shall be designed and manufactured to have
minimum contact resistance. There shall not be any sharp edges which may lead to
accumulation of charge & electrical breakdown. All corners/ edges shall be rounded.
7.06.02 The clamps shall be liberally designed and certain minimum contact surface
shall be provided.
7.06.03 The clamps and fittings shall be designed so that insulators shall not be subject
to any abnormal stresses due to thermal changes in conductor.
7.06.04 All the clamps & fittings shall enable the connection to be as short as possible.
Wherever possible the clamps shall be two separate halves. No “U” bolts shall be used.
All components of like design shall be inter-changeable
7.06.05 All nuts, bolts & washers shall be made of Hot dip galvanized Mild Steel
conforming to relevant ISS only.
7.06.06 The clamp in all respect shall incorporate highest quality of modern
engineering design and workmanship. The specification is merely for the guidance of the
Contractor as has been clearly stated earlier and it is not the intention to specify the
details of design and workmanship. The clamps shall be designed and manufactured in

MPPTCL/TECH-LINE/PROC/SEP23 Page 107


accordance with the Contractor’s standard practices, when such practices do not conflict
with this specification.
7.06.07 The materials offered shall be complete with all components and accessories
which are necessary or useful for their satisfactory performance and efficient
maintenance. Such parts shall be deemed to be within the scope of this specification
whether specifically included or not.
7.06.08 The design should be such that adequate clamping pressure is obtained with
the tightening of the nuts and the pressure should be maintained throughout the service
of the connector. In order to provide for creep of Aluminium under pressure, it is essential
that only Belleville washers are used. This should be specifically confirmed and should
also indicate tightening torque required.
7.06.09 All clamps shall be suitable to carry safely the maximum allowable current in the
associated conductor and to withstand the maximum loads occurring under adverse
circumstances and operating conditions. The maximum fault current is 40 KA rms for a
period of 3 seconds. The temperature of the clamps and fittings shall never exceed that of
the associated conductor.
7.06.10 Fittings intended to connect two dissimilar metals shall be designed to avoid
harmful bimetallic corrosion under service condition, by way of provision of best quality
bimetallic strips.
7.06.11 The short circuit current shall be of the order of 40 KA for 3 seconds. The
clamps should be suitable to withstand the short circuit forces corresponding to this
current.
7.06.12 The design of clamps should be such that proper space for movement of
normal quality single head spanner during tightening is available. This is an important
requirement and should be confirmed by the Contractor.
7.07 Materials:
7.07.01 The Clamps & Connectors/Spacers shall be made of materials listed below: -
i. For connecting ACSR conductor Aluminium alloy casting conforming to
designation A6 of IS:617.(Redesignation 4600)

ii. Bolts, Nuts, plain washers and spring washers for above items shall be made
of hot dip galvanized Mild Steel conforming to relevant IS only.

The Contractor shall ensure that the Alloy used assures good stability and sound casting
by proper fluidity. Proper mechanical and physical strength characteristics should be
obtained corresponding to the standard requirements of the Alloy specified.

7.07.02 The Contractor shall ensure that the Alloy used assures good stability and
sound casting by proper fluidity. Proper mechanical and physical strength characteristics
should be obtained corresponding to the standard requirements of the Alloy specified.
7.07.03 The clamps bodies shall be made by gravity die-casting only and thereafter
given the appropriate heat treatment and precipitation treatment. Clamps bodies made by
sand casting shall not be accepted in any case.

MPPTCL/TECH-LINE/PROC/SEP23 Page 108


7.08 CASTINGS:
All casting shall be free from blow holes, surface, Blisters and shall be rounded off.

7.09 CONSTRUCTIONAL DETAILS:


7.09.01 All sharp edges and corners shall be blurred and rounded off.
7.09.02 Thickness of the clamps shall not be less than 12mm
7.09.03 Bolts and nuts shall have hexagonal heads and threads as per Indian Standard.
7.09.04 Flexible connectors, braids or laminated straps shall be made from tinned
copper strips or aluminium laminates depending upon the clamp.
7.09.05 Size of terminal / conductor for which the clamps is suitable shall be embossed
on each component of the clamp.
7.09.06 Casting should be such that adequate free space for placement and movement
of spanners for tightening of nuts is available.

7.10 BOLTS, NUTS & WASHERS:


These shall be as per Indian Standard and shall have tensile strength and elongation as
per grade 5.6. The Contractor should ensure proper tightening either by use of Belleville
or by the use of torque wrenches.
7.11 GALVANISING:
Hot dip galvanizing shall conform to Indian Standard specification IS-2633 or equivalent
International Standard. Galvanising shall be uniform, free from blisters, and shall not peel
off due to abrasion, Zinc coating shall be thick enough to withstand 6 one minute dips in
Copper Sulphate solution (precee test) for all ferrous parts except for threaded portions
which shall withstand at least 4 one minute dips.

7.12 TESTS:
7.12.01 The hardware fittings offered shall be type tested as per the relevant
standards. Further the acceptance, routine tests and tests during manufacture shall be
carried out on the conductor.
7.12.02 Acceptance tests shall mean those tests, which are to be carried out on
samples taken from each lot offered for pre-despatch inspection, for the purpose of
acceptance of that lot.
7.12.03 Routine tests shall mean those tests which are to be carried out on each and
every product so as to check with requirements which are likely to vary during production.
7.12.04 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.
7.12.05 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.
7.12.06 The standards to which these tests will be carried out are listed in para 6.01.
Where a particular test is a specific requirement of this specification, the norms and

MPPTCL/TECH-LINE/PROC/SEP23 Page 109


procedures of the test shall be as mutually agreed to between the Contractor and the
Employer in the Quality Assurance Programme.
7.12.07 For all type and acceptance tests, the acceptance values shall be the values
guaranteed by the Contractor in the “Technical Questionnaire” or the acceptance value
specified in this specification, whichever is more stringent for that particular test.

7.13 TYPE TESTS:

7.13.01 Flexible G.I. Bond for Earth wire:


Slip strength test
7.13.02 Mid span compression joint for conductor & Earth wire.

i. Slip strength test


ii. Electrical Resistance test
Iii Healing cycle test As per IS
iv. Corona Extinction voltage test dry. 2121,2633 6745
v. Radio interference voltage test Dry.
vi. Galvanising test
7.13.03 Repair Sleeve for conductor:

i Electrical Resistance test


As per IS 2121
ii Corona Extinction Voltage test

iii Radia interference voltage test dry

7.13.04 Vibration Damper for conductor & Earth wire


a. Chemical analysis of material
b. Dynamic Characteristic Test.
c. Vibration Analysis.
d. Clamp Slip test.
e. Fatigue Test.
f. Magnetic power loss test.
g. Corona extinction voltage test (Dry).
h. Radio interference voltage test (Dry).
i. Damper efficiency test.
NOTE: Tests mentioned at (f) (g)& (h) are not applicable to dampers for Earth wire.
7.13.05 Clamps

i Tensile Test

ii Resistance Test

iii Temperature rise Test

MPPTCL/TECH-LINE/PROC/SEP23 Page 110


As per IS:5561
iv Short time current Test
Dimensional Check
v
Galvanising Test
vi

7.14 ACCEPTANCE TEST:


7.14.01 FLEXIBLE G.I. BOND :-

a. Visual examination IS:2121

b. Dimensional verification

c. Slip strength test.

7.14.02 Midspan Compression Joint for Power Conductor & Earth wire

i. Visual examination

ii. Dimensional verification.

iii. Galvanising Test

iv. Hardness test.

v. Failing load test (test to be conducted after 24 hours of


compression).

7.14.03 Repair Sleeves for Conductor.

i. Visual examination

ii. Dimensional verification.

7.14.04 Vibration Damper for power conductor/ Earth wire.

i. Visual examination

ii. Dimensional verification.

iii. Galvanising Test

iv. Verification of resonance frequencies

v. Clamp slip test

vi. Clamp bolt torque test

MPPTCL/TECH-LINE/PROC/SEP23 Page 111


vii. Strength of messenger cable.

viii. Mass pull off test.

7.14.05 Clamps

i. Tensile Test

ii. Resistance Test

iii. Dimensional Check

iv. Galvanising Test

7.14.06 Test during manufacture.

i. On all components as applicable.

ii. Chemical analysis of zinc used for galvanizing

iii. Chemical analysis, hardness test grain size inclusion rating and
magnetic particle inspection for forgoing/castings.

iv. Chemical analysis and proof load test.

v. Tests on malleable castings forgings and fabricated hardware’s.

7.15 MATERIAL AND WORKMANSHIP:


7.15.01 All the materials shall be of the latest design and conform to the best
modern practice adopted in the extra high voltage field. The Contractor shall offer only
such equipment as guaranteed by him to be satisfactory and suitable for 220/132kV
Transmission lines.
7.15.02 The design, manufacturing process and quality control of all the materials shall
be such as to give maximum factor of safety, maximum possible working load, highest
mobility, elimination of sharp edges and corners, best resistance to corrosion and a good
finish.
7.15.03 All ferrous parts shall be hot dip galvanised, after all machining has been
completed. Nuts may, however, be tapped (threaded) after galvanising and the threads
oiled. Spring washers shall be electro galvanised. The bolts threads shall be under cut
to take care of increase in diameter due to galvanising. Galvanising shall be done in
accordance with IS:2629-1966 or equivalent International Standard and satisfy the tests
mentioned in IS:2633-1972 or equivalent International Standard. Fasteners shall
withstand four dips while spring washers shall be guaranteed to withstand at least six dips
each lasting one minute under the standard precee test for galvanising.

MPPTCL/TECH-LINE/PROC/SEP23 Page 112


7.15.04 The Zinc coating shall be perfectly adhere, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash, rust stains,
bulky while deposits and blisters. The Zinc used for galvanising shall be grade Zn. 99.95
as per IS: 209-1966 or equivalent International Standard.
7.15.05 In case of castings, the same shall be free from all internal defects like
shrinkage, inclusion, blowholes, cracks etc.
7.15.06 All current carrying parts shall be so designed and manufactured that
contact resistance is reduced to minimum.
7.15.07 No item which would produce high electrical and mechanical stresses in
normal working shall have sharp ends or edges, abrasions or projections and shall not
cause any damage to the Conductor in any way during erection or during continuous
operation. The design of adjacent metal parts and mating surfaces shall be such as to
prevent corrosion of the contact surface and no maintain good electrical contact under
service conditions.
7.15.08 Particular care shall be taken during manufacturing and subsequent handling to
ensure smooth surface free from abrasion or dents.
7.15.09 The fasteners shall conform to the requirement of IS: 6639-1972 or equivalent
International Standard. All fasteners and clamps shall have locking arrangements to
guard against vibration loosening.
7.16 IDENTIFICATION MARKING:
The main component of the material covered in the specification shall be legibly and
indelibly marked with the trademark of the manufacturer, the month and year of
manufacture, the guaranteed combined mechanical and electrical strength in kilo-Newton
abbreviated by ‘kN’ to facilitate easy identification and proper use. Marks shall be forged
or stamped with a steel die before Galvanizing. The marks shall be distinct, durable and
conspicuous. Embossing/Engraving should be done at the time of manufacturing
process itself, but before Galvanizing. Smaller component like bolts & nuts, split pin and
washers etc. may be excluded from this requirement.

7.17 QUALITY ASSURANCE PROGRAM


The contractor shall submit the Quality Assurance Programme as specified in clause 1.12
Section-1 of the biding document. A copy of the accepted Quality Assurance Plan must
be available at the manufacturer’s works of the Plant for reviewing by inspecting officer of
the employer.
7.18 INSPECTION :
7.18.01 As specified in clause 1.13 Section-1 of the biding document, Plant to be
supplied will be subject to inspection and approval by the Employer's representative
before despatch.
7.18.02 At least 5% of the total number of drums subject to minimum of two in any lot
put up for inspection, shall be selected at random to ascertain the length of conductor by
following method:
“At the works of the manufacturer the conductor shall be transferred from one
drum to another at the same time measuring its length with the help of graduated pulley
and Cyclometer. The difference in the average length thus obtained and as declared by
MPPTCL/TECH-LINE/PROC/SEP23 Page 113
the Contractor in the packing list shall be applied to all the drums if the conductor is found
short during checking”
7.18.03 The supplier shall submit the factory test certificates of raw materials & bought
out accessories at the time of acceptance tests of the Conductor.

7.19 DOCUMENTATION & LIST OF DRAWINGS


7.19.01 The Contractor shall submit the detailed drawings of the Accessories offered
and descriptive literature. The dimensional drawings for compression type Mid Span Joint
(Aluminium & Steel Sleeve), compression type Repair Sleeve Preformed Armour rods for
Conductor & Earth wire and 4R Vibration Dampers etc. must be submitted. Test
certificates for different tests conducted as per relevant ISS, for all the offered items must
also be submitted essentially.
7.19.02 The bidder shall furnish full description, illustrated catalogues and dimensional
drawings of offered items ,along with the bid.. The drawing shall include the following
information:
(i) General outline & assembly drawings of all the items /material covered in
the specification.
(ii) Dimensions, unit spacing
(iii) Unit mechanical and electrical characteristics as also for the complete
assembly/set .
(iv) Weight of each component.
(v) Identification mark.
(vi) Material designation used for different components with reference to
Standards.
(vii) Fabrication details such as welds, finishes and coatings
(viii) Manufacturer’s catalogue number.
(ix) Brief installation instructions.
(x) Reference of type testing
(xi) Relevant technical details of significance.

7.20 PACKING:
7.20.01 The material shall be packed in strong wooden boxes with steel straps. The
gross weight of packing shall be in range of 50 kgs to 200 kgs to avoid handling problem.
The packing shall be strong enough to withstand rough handling during transit or storage
in the field. All the packing cases shall be legibly marked to avoid possibility of loss in
transit. The bidder shall be responsible for any damage during transit due to improper and
inadequate packing and handling.

7.20.02 Each consignment shall be accompanied by a detailed packing list showing


following details:-
(ii) The name of the consignees
(iii) Details of consignment.
(iv) Destination.
(v) Total weight of consignment.
(vi) Handling and unpacking instrumentation.
(vii) Bill of material indicating content of each package.
MPPTCL/TECH-LINE/PROC/SEP23 Page 114
8.0 TECHNICAL SPECIFICATION FOR ERECTION OF 132KV AND 220KV
TRANSMISSION LINES
8.01 INDIAN STANDARDS/ CODE :
The material and services under this section shall conform to the requirements of the
latest revisions and amendments available at the time of placement of order of all the
relevant Indian standards/codes listed here under or equivalent International Standards,
except as modified in this document.

S.No Indian standards Title


.
1. IS:5613-1995 (part-II) Code of practice for design, installation and
maintenance of overhead power lines.
Sec.-1 - Designs.
Sec.-2 - Installation & Maintenance
2. IS:269-1967 Ordinary rapid hardening and low heat Portland
cement.
3. IS:456-2000 Code of practice for plain and reinforced
concrete
4. IS:1786-1966 Cold twisted steel bars for concrete
reinforcements
5. IS:4091-1967 Code of practice for design & construction of
foundation for transmission line towers & poles

8.02 LINE MATERIALS:


8.03 Conductor:
The conductor used in the132kV line will be single ACSR Panther Conductor and the
conductor size is 30/3.00mm A1. + 7/3.00 mm steel and the conductor used in the 220kV
line will be single ACSR Zebra Conductor and the conductor size is 54/3.18mm A1. +
7/3.18 mm steel.
8.03.01 Earth wire :
The Earth wire to be used on the line shall be 7/3.66 mm; 95 kg/mm2 quality galvanized
steel stranded wire.
8.03.02 Insulator Strings with Hardware Fittings:
(A) For 220kV lines
(i) Single suspension and single tension strings will be used on the line as under:
a. At suspension locations:
13 disc single suspension strings having 70KN E&MS of 255x145 mm
size disc insulators with AGS type clamps will be used.

MPPTCL/TECH-LINE/PROC/SEP23 Page 115


b. At tension locations :
14-disc single tension strings with 160 KN E&MS disc insulators of
280x170 mm size disc insulators will be used with compression type
dead end clamp.
(ii) In the cases of Railway/Road/River/Other transmission line crossing, double
suspension/double tension insulator strings will be used.
(B) For 132kV lines
(i) Single suspension and single tension strings will be used on the line as under:
a. At suspension locations:
9 disc single suspension strings having 70KN E&MS of 255x145 mm size disc
insulators with AGS type clamps will be used.
b. At tension locations :
(ii) 10-disc single tension strings with 90 KN E&MS disc insulators of 255x145 mm size
disc insulators will be used with compression type dead end clamp.
(iii) In the cases of Railway/Road/River/Other transmission line crossing, double
suspension/double tension insulator strings will be used.
8.03.03 Conductor Accessories:
(i) AGS type suspension clamps shall be used with suspension strings.
(ii) Vibration Dampers (4-R type) shall be used for Conductors.
8.03.04 Miscellaneous Items:
Enameled Number Plates, Phase Plates and Danger Board, Bolts and Nuts, Spring
washers, Pack washers and other tower accessories like ‘D’ Shackle, Hanger, U-Bolts
and fasteners etc., shall be provided with the tower.

8.04 DETAILED SURVEY/CHECK SURVEY:


The contractor will have to carry out detailed survey of the line for which route map
indicating the proposed alignment of the transmission line will be handed over by the
Employer. If the detailed survey is already conducted by the Employer for some portion of
the line, the profiles for such portion will be handed over to the Contractor for check
survey. It may please be noted that no check survey is required to be conducted for the
portion of line for which detail survey is conducted by the contractor himself.
8.04.01 Detailed Survey:-
(a) At the starting point of the commencement of route survey, an angle iron spike 65
x 65 x 1000mm shall be driven firmly into the ground to show only 150mm above the
ground level. A punch mark on the top section of the angle iron shall be made to indicate
location of the surveying instrument. Teak wood pegs 50 x 50 x 650 mm shall be driven
at prominent positions at intervals of not more than 750 meter along the transmission line

MPPTCL/TECH-LINE/PROC/SEP23 Page 116


to be surveyed up to the next angle point. 125 mm wire nails should be fixed on the top
of these pegs to show the location of instrument. The pegs shall be driven firmly into the
ground to show only 100 mm above ground level. At angle positions, stones shall be put
up for easy identification. Paint mark in white lead paint shall be put in, about 300 mm
squares with a direction indication, on nearby boulders, rocks, or trees, along the
complete line alignment. At peg position, identification marks giving the peg position, with
reference to painting marks, shall be given. The white lead paint mark shall indicate to
the individual the direction of alignment from either direction.
(b) Routing/Re-routing of transmission line through protected/reserved forest area
should be avoided. In case it is not possible to avoid the forests or areas having large
trees completely, then keeping in view of the overall economy, the route should be
aligned in such a way that cutting of trees is minimum.
(c) The route should have minimum crossings of Major river, Railway lines,
National/State highways, overhead EHV power line and communication lines.
(d) The number of angle points shall be kept to minimum.
(e) The distances between the terminal points specified shall be kept shortest
possible, consistent with the terrain that is encountered.
(f) Marshy and low lying areas, river beds and earth slip zones shall be avoided to
minimize risk to the foundations.
(g) It would be preferable to utilize level ground for the alignment.
(h) Crossing of power lines shall be minimum. Alignment will be kept at a minimum
distance of 300 m from power lines to avoid induction problems on the lower voltage
lines.
(i) Crossing of communication line shall be minimized and it shall be preferably at
right angle. Proximity and parallelism with telecom lines shall be eliminated to avoid
danger of induction to them
(j) Areas subjected to flooding such as nalah shall be avoided.
(k) Restricted areas such as civil and military airfield shall be avoided. Care shall
also be taken to avoid aircraft landing approaches.
(l) All alignment should be easily accessible both in dry and rainy seasons to enable
maintenance throughout the year.
(m) Certain areas such as quarry sites, tea, tobacco and saffron fields and rich
plantations, gardens and nurseries which will present the Employer problems in
acquisition of right of way and way leave clearance during construction and maintenance
should be avoided.
(n) Angle points should be selected such that shifting of the point within 100 m radius
is possible at the time of construction of the line.
(o) The line routing should avoid large habitations, densely populated areas, Forests,
Animal/Bird sanctuary, reserve coal belt areas, oil pipe line/underground inflammable
pipe lines etc to the extent possible.

MPPTCL/TECH-LINE/PROC/SEP23 Page 117


(p) The areas requiring special foundations and those prone to flooding should be
avoided.
(q) From the field book entries, the route plan and level profile shall be plotted and
prepared to the scales of 1=2000 horizontal and 1=200 vertical on 1 mm/5 mm/1 cm
square paper.
(r) If the difference in levels be too high, the chart may be broken up according to
requirement. A 400 meter overlap shall be shown on each following sheet. The chart
shall progress from left to right. For convenience in handling, the sheet size may be
limited to 594x841 mm (Al) size.
(s) After completing the detail survey, profiles shall be submitted to the Employer duly
spotted with tower for approval. While submitting the profiles after conducting the detail
survey, the contractor will also submit a copy of route alignment on the route map
indicating the surveyed route.
8.04.02 Check Survey:-
The Contractor shall conduct the check survey only for such portion of line for
which detailed survey has been done by the Employer after the profiles are handed over
to the Contractor. The check survey shall include checking of deviation angles, checking
of levels at critical points. After completing the check survey, profiles shall be re-submitted
to the Employer duly spotted with tower for approval.
8.04.03 The requirement of tower site leveling and revetment work, if required, shall also
be marked by the Contractor on the profiles while carrying out the detail or check survey
work.
8.04.04 If due to site conditions any change in the tower location/provision of extension
is considered necessary compared to approve profiles, the contractor shall bring the
same to the knowledge of the Employer well in time and get revised approval of the
profile before setting the stubs. The revised approval shall be conveyed to the
Contractor by the Employer.
8.05 APPROVED PROFILE:
(Applicable for check survey only)
8.05.01 The detailed survey may be conducted by the Employer for some portion of
the transmission line and in such case, the profiles will be handed over to contractor
for carrying out check survey and marking of towers on the profiles. The profile will be
prepared on cm. graph paper on scale 1:2000 horizontal and 1:200 vertical. The profile
will be submitted along with the route map showing the route followed by the contractor
during check survey.
8.05.02 The route alignment surveyed by the Employer shall be marked at angle
points. At angle points concrete blocks shall be provided and in the straight alignment
marking will be done by pegs.
The Contractor will be responsible for the correct setting of towers as shown in
8.05.03

approved profiles. If towers after erection are found to be out of the approved
alignment/position in the profile, the Contractor will dismantle and re-erect them
correctly fully at his own cost and without extension of time.
MPPTCL/TECH-LINE/PROC/SEP23 Page 118
8.05.04 Soil Resistivity:-
While carrying out detailed/ check survey work, the Soil Resistivity values will have to be
measured at convenient points along the route, not exceeding 2.50 Km between adjacent
points. The Soil Resistivity wiil be measured using 4 electrod method with an inter
electrod spacing of 50 M . The following formula shall be used :
P=2πaR
Where a = Interelectrod spacing = 50M
R = Earth resistance measured in Ohms
P = Soil Resistivity in Ohm- m
The soil resistivity values shall be submitted duly marked on the route map and
also in the form of statement. The quoted rates for detailed survey/ check survey work
shall be inclusive of cost of measuring soil resistivity values along the proposed route
and the contractor will not be paid separately for this work.
8.06 EXCAVATION:
8.06.01 Except as specifically otherwise provided, all excavation for footing shall be
made to the lines and grades of the foundation. The excavation walls shall be vertical
and the pit dimensions shall be such as to allow a clearance of 150mm on all sides from
the foundation pit, where form boxes are used. In undercut/stepped (slab type)
foundations where form box is not required to be used at the base, the pit dimensions
should be as per the standard drawings. All excavation shall be protected so as to
maintain a clean sub-grade, until the footing is placed, by using timbering, shoring or
casing, if necessary. Any sand, mud, silt or other undesirable materials which may have
accumulated in the excavation shall be removed by the Contractor before placing
concrete.
8.06.02 The Soil to be excavated for tower foundations shall be classified as under
for the purpose of payment of excavation for tower site leveling and building stone
revetment:
(a) Normal Dry Soil : Soil removable by means of ordinary pick axes and shovels
(Normal Soil, intermediate Soil fall under this category).
(b) Wet Soil : Soil as per (a) above, where the sub Soil water table is
encountered within the range of foundation depth, the Soil below the
water table and that at locations where pumping or bailing out of
water is required due to presence of surface water, will be treated
as wet Soil.
(c) Black cotton (Dry/Wet) :To be used at locations where soil is clayey type, not
necessarily black in colour, which shrinks when dry and
swells when wet, resulting in differential movement extending to a
maximum depth of about 3.5 meter below ground level.
(d) Soft Rock: This will mean fissured rock i.e. decomposed rock, hard gravel, kankar,
limestone, laterite or any other Soil of similar nature which can be
excavated with pick axe, crow bar etc. However, if required, light

MPPTCL/TECH-LINE/PROC/SEP23 Page 119


blasting may be resorted to for loosening the material but this will not
in any way entitle the excavation to be classified as hard rock.
(e) Hard Rock: Hard rock will be that which requires chiseling or drilling and blasting.
8.06.03 No extra charges shall be admissible for the removal the fallen earth in the
pits when once excavated.
8.06.04 If water is encountered in the foundation pit, de-watering will have to be
done. The cost of dewatering shall be deemed to be included in the unit rates of
excavation for foundation work.
8.06.05 For excavation of foundation in rock, where blasting is unavoidable, care
should be taken to minimize the volume of concrete necessary for filling up the blasted
area. The blasted area shall be reduced to the minimum possible so that the specified
form for the foundation could be obtained. No extra payment for excavation in hard rock
shall be allowed if the excavated area exceeds the designed excavation volumes.
Similarly, no extra payment shall be made if concrete volume exceeds the designed
volume due to excessive blasting.
8.06.06 The payment for excavation shall be made as per actual type of soil
encountered at the time of excavation, but the total payment for excavation portion shall
not exceed the amount as payable for excavation considering the foundation as
classified for that location.
8.06.07 The Contractor shall arrange requisite blasting material, excavation and drilling
equipment, necessary license etc., at his own cost and the quoted rates shall be
deemed to be inclusive of all such costs.
8.06.08 The decision of the owner shall be final and binding with respect to classification
of soil and foundation.
8.07 CLASSIFICATION OF FOUNDATIONS :

8.07.01 The foundation designs shall depend upon the type of Soil, sub-Soil water
level and the presence of surface water which have been classified as follows:
(i) Normal dry : To be used for locations where normal dry cohesive or non-
cohesive soils are met.
(ii) Wet : To be used for locations :
(a) Where sub-soil water is met at 1.5meter or more below the ground
level.
(b) Which are in surface water for long periods with water
penetration not exceeding one meter below the ground level
e.g. the paddy fields.
(iii) Partially Submerged: To be used at locations where sub-soil water level is met
between 0.75 meter to 1.5 meter below the ground level.
(iv) Fully Submerged : To be used at locations where sub-soil water level is met less
than 0.75 meter below ground level.

MPPTCL/TECH-LINE/PROC/SEP23 Page 120


(v) Black cotton(Dry/Wet): To be used at locations where soil is clayey type, not
necessarily black in colour, which shrinks when dry and
swells when wet, resulting in differential movement extending to a
maximum depth of about 3.5meter below ground level.
(vi) Dry Fissured rock: To be used at locations where decomposed or fissured rock,
hard gravel, kanker, limestone, laterite or any other soil of similar
nature is met. Under cut type foundation is to be used for fissured
rock locations.
(vii) Submerged Fissured rock: In case of fissured rock locations where water level
is met at 1.5meter or more below ground level, submerged
fissured rock foundations shall be adopted. If after soil
investigation, water level is encountered at less than 1.5meter below
ground level, a separate foundation shall be developed.

(viii) Hard rock : The locations where chiseling, drilling and blasting is required for
excavation, hard rock type foundations are to be used.

8.08 SHORING OF PITS:


Shoring of pits with shuttering on the internal walls surrounding the vertical facing of
approved dimensions of the pit shall be done when the Soil condition is so bad that there
is likelihood of accident due to falling of surrounding earth in foundation pit. The cost of
carrying out shoring & shuttering shall be deemed to be included in the unit rate of
excavation for foundation work and no extra payment shall be made on this account.
8.09 TOWER SITE LEVELLING:
In case of foundations located on sloping ground, it may be necessary to level the ground
for locating the tower. In leveling the tower site, only excavation will be allowed. The
Contractor shall quote separate rates for excavation for purpose of site leveling for dry
Soil, wet Soil, soft and hard rock in respective Schedule. The requirement of tower site
leveling will be decided by the Employer’s site Engineer and will be marked by the
Contractor in the profiles while carrying out the check survey work.

8.10 SETTING OF STUBS:


8.10.01 The Contractor shall be responsible for correct setting of stubs. Discrepancies, if
any, shall be brought to the notice of Employer and final approval shall be taken before
execution of work. The stub shall be set correctly in accordance with approved method at
the exact locations and alignment and imprecisely correct levels. The stub setting
Templates shall be used for proper setting of stubs. Stubs shall be set in the presence of
Employer’s representative available at site whenever required and for which the
contractor shall give adequate advance intimation to the site Engineer.
8.10.02 The foundations are to be made as per designs and drawings approved by the
Employer. Extent of the work as defined by such drawings shall not be exceeded except
in very exceptional cases where the prior approval of Employer has been obtained.

MPPTCL/TECH-LINE/PROC/SEP23 Page 121


8.10.03 The setting of stubs in hard rock foundation may require cutting of stubs
depending on depth at which hard rock is encountered. The cutting of stubs and drilling
of new holes for fixing cleats etc. shall be considered inclusive in the rate of foundation of
towers in hard rock. However, the cut pieces of stubs shall be returned to EMPLOYER.
8.10.04 Setting of stub at each location shall be approved by the Employer’s site
Engineer. This approval shall not however, absolve the Contractor of his responsibility of
correct setting of stubs and casting of foundations, who will be required to rectify the
faulty work at his own expense.
8.11 PLACEMENT OF REINFORCEMENT:
8.11.01 Some of the tower foundations may be designed with steel reinforcement so as
to achieve better foundation strength with lesser space. The cost of placing of
reinforcement steel, binding etc. in the foundation pit shall be paid as per rate to be
quoted in the price schedule.
8.11.02 The Contractor shall arrange foundation reinforcement steel etc. at their cost
which shall be deemed to be included in the quoted rate of placement of reinforcement
steel. The reinforcement bars will have to be properly cut, bent in required shape and
placed in the foundation in approved manner after due cleaning of oil, grease or organic
matter. The reinforcement shall be properly tied by binding wire.
8.12 CONCRETE:
8.12.01 The cement concrete used for the foundation shall be of 1:2:4 mix ratio (M150)
with 20mm nominal size stone metal for chimney portion and 40mm nominal size stone
metal for pyramid or slab portions 1:3:6 mix ratios (M 100) shall be used for base
padding (lean pad). For RCC, the aggregates shall preferably be of 20mm nominal size.
8.12.02 The cement required for the purpose of foundations, building revetment walls
etc. shall be arranged by the Contractor at his own cost, which shall be deemed to be
included in the cost of foundations.
8.12.03 The sand used for the concrete shall be arranged by the Contractor at his own
cost including necessary license etc., which shall be deemed to be included in the cost of
foundations. The sand shall be composed of hard silicate materials. It shall be clean
and of a sharp angular grit type and free from earthy or organic matter and deleterious
salts.
8.12.04 The aggregate shall be arranged by the contractor at his own cost including
necessary license etc, which shall be deemed to be included in the cost of foundations.
The aggregate shall be of clean broken hard granite or other stone specified or
approved by the Employer. It shall be of hard and coarse-grained quality. It shall also
be as far as possible cube like, preferably angular, but not flaky, perfectly clean and free
from earth, organic or other deleterious matter. 40mm aggregate shall be of size as will
pass through a mesh of 40 mm measured in the clear and 20 mm aggregate through
20mm square mesh measured in clear.
8.12.05 The water used for mixing concrete shall be arranged by the contractor at his
own cost including necessary license etc, which shall be deemed to be included in the
cost of foundations. The water used shall be fresh, clean and free from oil, acid and

MPPTCL/TECH-LINE/PROC/SEP23 Page 122


alkali, organic materials or other deleterious substances. Salty/Saline or brackish water
should not be used. Potable water is generally satisfactory.
8.12.06 The concrete shall be mixed in a mechanical mixer. However in case of
locations not accessible for concrete mixers, hand mixing may be permitted at the
discretion of our site Engineer.
8.12.07 Mixing shall be continued until there is uniform distribution of materials and the
mixing is uniform in colour and consistency but in no case the mixing is done for less
than two minutes. Normally mixing shall be done close to the foundation, but in case it
is not possible, the concrete may be mixed at the nearest convenient place. The
concrete shall be transported from the place of mixing to the place of final deposit as
rapidly as practicable by methods, which shall prevent the segregation or loss of any
ingredient. The concrete shall be placed and compacted before setting commences. The
transportation cost of these materials shall be deemed to be included in the cost of
foundations.
8.12.08 The concrete should be mixed as stiff as per the requirements of placing the
concrete in the form boxes, with ease and the degree to which the concrete resists
segregation. Hence the quantity of water used should not be too much.
8.12.09 Proper form boxes adequately braced to retain proper shape while concreting
should be used for chimney or pyramid and slab portions. The form boxes should be
made water tight so that cement cream may not come out leaving only sand and jelly
consequently forming of honeycombing in the concrete. The form boxes shall be
cleaned and oiled before these are used for concreting.
8.12.10 The concrete shall be laid in 150mm layers and consolidated well so that the
cement cream works up to the top and no honeycombing is left in the concrete.
Concreting is to be done continuously so that the subsequent layers are laid before the
initial setting of the bottom layer begins. The consolidation of concrete shall normally be
done by using vibrators.
8.12.11 After concreting the chimney portion up to the required height, the top
surface should be finished smooth, with slight slope towards the outer edge, to drain off
the rainwater falling on the coping.
8.12.12 In wet locations, the site must be kept completely de-watered both during the
placing of the concrete and up to 24 hours after completion. There should be no spilling
to concrete by water during this period.
8.12.13 The form boxes shall be removed only after at least 24 hours after the
completion of concreting. After removal of the forms and boxes the concreted surface
wherever required shall be repaired with a mixture of rich cement and sand mortar in the
shortest possible time.
The cost of carrying out concreting of shall be payable as per unit rates quoted by the
Bidder.

8.13 BACKFILLING AND REMOVAL OF STUB TEMPLATE:


8.13.01 Following opening of form work and removal of shoring and shuttering, if
required, backfilling shall be started after 24 hours of casting repairs, if any, to the
MPPTCL/TECH-LINE/PROC/SEP23 Page 123
foundation concrete. Backfilling shall normally be done with the excavated Soil, unless it
consists of large boulders, which shall be broken to a maximum size of 80mm.
8.13.02 The backfill materials should be clean and free from organic or other foreign
materials The earth shall be deposited in maximum 200mm layers, leveled, and
wetted and rammed properly before another layer of earth is deposited. Care shall be
taken that the back filling is started from the foundation end only in the pits towards the
outer end.
8.13.03 The backfilling and grading shall be carried to an elevation of about 150mm
above the finished ground level to drain out water. After backfilling, 50mm high earthen
embankment (bandh) will be made along the sides of excavated pits and sufficient water
will be poured in the backfilled earth for at least next 24 hours.
8.13.04 The stub setting Templates shall be opened only after the completion of back-
filling.
8.13.05 After completing stringing work, if level of backfilling of some of the locations
gets settled and it is required to backfill the locations again, the same would be done by
the contractor at no extra cost.
8.13.06 No extra charge is admissible for carrying out backfilling of foundation pit
(including backfilling from borrowed earth if required) and the cost of backfilling shall
be deemed to be included in the cost of excavation quoted by the bidder in the price
schedule.
8.14 CURING:
The concrete, after it is 24 hours old, shall be cured by keeping the concrete wet
continuously for a period of 14 days after laying. The pit may be backfilled with
selected earth sprinkled with necessary amount of water and well consolidated in
layers not exceeding 200mm of consolidated thickness after a minimum period of 24
hours and thereafter both the backfilled earth and exposed chimney top shall be kept wet
for the remainder of the prescribed time of 14 days. The uncovered concrete chimney
above the backfilled earth shall be kept wet by providing empty cement bags dipped in
water fully wrapped around the concrete chimney for curing duly ensuring that the bags
are kept wet by frequent pouring of water on them. The Contractor may use anti curing
paint. However no extra payment shall be made on this account.
8.15 BUILDING STONE REVETMENT:
Stone revetment in 1:5 cement mortars shall be constructed by the Contractor at
specified locations. The detailed proposal in consultation with the site Engineer, for
carrying out revetment work shall be submitted to the O/o. Chief Engineer (Trans),
Jabalpur through concerned Superintending Engineer, EHT Construction and
approval shall be obtained before carrying out revetment work. The top seal cover of
revetment work shall be done with 1:2:4 normal mixes. All materials including cement
shall be provided by the contractor and cost of building revetment shall be deemed to
include cost of such materials also i.e. Cement, sand, metal and stone. Curing
of revetment shall be done as specified for tower foundation. The back filling of the inside
of the revetment wall with Soil/borrowed earth will be paid for extra on per m³ basis and
shall include its compacting and watering. The excavation for revetment foundation
shall be paid at the rates as indicated by the bidder in Price Schedule. The revetment
MPPTCL/TECH-LINE/PROC/SEP23 Page 124
work, wherever necessary, shall have to be completed before taking up final tensioning
work in the Section.
8.16 TOWER EARTHING:
8.16.01 For the purpose of earthing, necessary earthing rods (25mm dia, 2 meter
long) connecting clamps, and connecting wire will be provided by the contractor.
The earthing rods are to be hammered preferably in the side wall of foundation pits and
connected to stub by 7/4.00mm Earth wire and with necessary connecting clamps before
concreting the foundation. If it is not possible to tie the rods in the foundation pit i.e. in
rocky location, they shall be buried near the foundation pit and connected to the
stubs. The earthing rods are to be provided in every leg of the tower. Each tower shall
be earthed before the foundation is casted.
8.16.02 The tower footing resistance of all towers shall be measured in dry whether after
the erection and before the stringing of Earth wire. The counterpoise earthing shall be
resorted to, in accordance with the instructions of the site Engineer, in case the tower
footing resistance (TFR) exceeds the specified value. It shall be ensured that the tower
footing resistance is less than 10 ohms. Each tower footing resistance shall be intimated
(along with the tower location number) while submitting the progress report of tower
erection.
8.16.03 Counterpoise Earthing :
In case of high resistivity, counterpoise earthing shall be provided which consists of
four lengths of galvanized steel stranded wires, 7/4.00mm fitted with each leg of the
tower with proper clamps for connection to the tower leg at one end. The
counterpoise will be laid radially away from the tower and will normally be 15 meters in
length, buried to the depth of 600mm below the ground level. The length of
counterpoise wire may be increased if the resistance requirements are not met.
Connecting clamps shall be buried in the chimney portion of the foundation. Contractor
shall quote for the laying of counterpoise earthing on per running meter basis, excluding
cost of all materials. The scope of work of connecting the counterpoise to the tower legs
shall be deemed to be included in the cost of laying of counterpoise. The counterpoise
shall preferably be laid through soft soil areas if available. The planning of laying
counterpoise shall be done as per approval of site Engineer. The cost of laying of
counterpoise shall be inclusive of excavation and backfilling work also.
The Contractor shall have to provide rod earthing at the end of each counterpoise wire
and this may lead to T.F.R. values within specified limits. This work of additional rod
earthing shall be paid extra on per location basis as per the rates indicated in Price
Schedule.
8.17 TOWER ERECTION/ ASSEMBLY:
Towers shall be erected after the foundation concrete is at least 14 days old, but a gap
of 24 days shall be preferred. The method followed for the erection of towers, shall
ensure the points mentioned below:

(i) Straining of the members shall not be permitted for bringing them into position. It
may, however, be necessary to match hole positions at joints and to facilitate
this, Tommy bars not more than 450mm long may be used.

MPPTCL/TECH-LINE/PROC/SEP23 Page 125


(ii) Before starting erection of an upper section, the lower section of tower shall be
completely braced and all bolts provided in accordance with approved
drawings.
(iii) All plan diagonals relevant to a section of tower shall be placed in position before
assembly of upper section is taken up.
(iv) The bolt positions in assembled towers shall be as per IS: 5613 (Part-II/Sec.2),
1995 with latest amendments.
(v) Tower shall be fitted with Number, Phase and Danger Plates which shall be
arranged by the Contractor.
(vi) Anti-climbing Devices:
Barbed wire will be used at a height of approx. 3 meters and above as an anti-
climbing measure, which shall be arranged by the Contractor. At every location
three layers of Barbed wires will be provided each inside and outside the tower in
horizontal plane. Spacing between the layers with fixing arrangements shall be
provided as per the provisions of IS:5613 (Part-II/Sec.1)-1976 with latest
amendments. The galvanized angle pieces with notches for accommodating
Barbed wire with Bolts Nuts etc. shall be supplied by the Contractor. After the
Barbed wire is placed in position in the notches, the notch opening shall be
welded to avoid the theft of Barbed wire and anti-corrosive treatment with
cold galvanizing paint shall be given, as also in the case of bolts to be welded
below bottom cross arm level. Suitable locking arrangement (pad-lock) shall also
be provided.
(vii) All blank holes, if any left, after complete erection of the tower, are to be filled up
by bolts and nuts of proper size.
8.17.01 TIGHTENING PUNCHING AND WELDING OF BOLTS ANDNUTS:

8.17.02 All nuts shall be tightened properly using correct size of spanners. Before
tightening, it will be seen that packing washers and plates are placed in relevant
gaps between members, bolts of proper size and length are provided and one spring
washer is used under each nut and in case of step bolts, spring washers shall be placed
under the outer nut.
8.17.03 The tightening shall progressively be carried out from the top to downwards,
care being taken that all bolts at every level are tightened simultaneously. The threads
of bolts projecting outside the nuts shall be punched at three positions on the
periphery to ensure that the nuts are not loosened in course of time. If during tightening
a nut is found to be slipping or running over the bolt threads, the bolt together with the
nut shall have to be replaced.
8.17.04 The threads of all the bolts projected outside the nuts shall be welded around
the periphery of nut & bolts. The welding of bolt projections as above shall be
provided from ground level to bottom cross arm level in all towers and also on extensions
up to 10M except in case of special river crossing tower in which case welding shall be
done up to 20 meter height from ground level.

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8.17.05 After welding, cold galvanized paint having at least 90% zinc content shall be
applied on the welded portion. At least two coats of the paint shall be applied. The cost
of such paint and welding etc., including application of paint etc., shall be deemed to be
included in the quoted erection rates.
8.18 INSULATOR HOISTING:
Suspension insulator strings shall be used on suspension towers and tension insulator
strings on angle and dead end towers. They shall be fixed on all the towers just prior
to the stringing. Damaged Insulators and fittings, if any, shall not be used in the
assemblies. Before hoisting, all Insulators shall be cleaned in a manner that will not
spoil, injure or scratch the surface of the Insulator, but in no case shall any oil be used
for the purpose. Security clips shall be fitted in position for the Insulators before
hoisting. Arcing Horns shall be fitted in an approved manner. Torque wrench shall be
used for fixing different line materials and their components, like suspension clamps etc.
for Conductor and Earth wire etc.
8.19 HANDLING OF CONDUCTOR AND EARTH WIRE:
8.19.01 The Contractor shall be entirely responsible for any damage caused to the
towers or Conductors during stringing. While running out the Conductors, proper care
shall be taken ensuring that the Conductors do not touch and rub against the ground or
objects which could cause scratches or damage to the Conductor strands. The
Conductors shall be run out of the drums from the top in order to avoid damage due to
chafing. The drum stand shall be provided with a suitable braking device to avoid
damage, loose running out and kinking of Conductor. The Conductor will be pulled by
pull cable and consequently pass over the running out blocks. The groove of the running
out blocks will be of such a design that the seat is semi-circular and larger than the
diameter of the Conductor and it does not slip over or rub against the sides. The
grooves shall be lined with hard rubber or neoprene to avoid damage to Conductor and
shall be mounted on properly lubricated bearings.
8.19.02 The running blocks shall be suspended in a manner to suit the design of the
cross arm. All running out blocks especially those at the tensioning end, will be fitted
on the cross arm with jute cloth wrapped over the steel work and under the slings to
avoid damage to the slings as well as to the protective surface finish of the steel
work. The Conductor shall be continuously observed for loose or broken strands or any
other kind of damage. When approaching towards end of a drum length, at least three
coils shall be left when the stringing operations are to be stopped. These coils are to
be removed carefully if another length is required to be run out, new length may be
joined to the length already run out by the compression joint in approved manner.
8.19.03 The Conductor joints and clamps shall be erected in such a manner that no bird
caging, over tensioning of individual wires or layers or other deformities or damage to the
conductor shall occur. Clamps or bracing devices shall under erection conditions allow
no relative movement of strands or layers of the conductors.
8.19.04 Repairs of Conductors, in the event of damage being caused to isolated
strands of a conductor during the course of erection, if necessary, shall be carried out
during the running out operations, with repair sleeves. Repairing of Conductor
surface with repair sleeve shall be done only in case of minor damage, scuff marks etc.,
keeping in view both electrical and mechanical safety requirements. The final
MPPTCL/TECH-LINE/PROC/SEP23 Page 127
Conductor surface shall be clean, smooth and shall be without any projections, sharp
points, cuts, abrasions etc. Repair sleeves may be used when the damage is limited
to the outermost layer of the Conductor and is equivalent to the severance of not more
than one third of the strands of the outermost layer. No repair sleeve shall be fitted
within 30 m of tension or suspension clamp or fittings. Further, more than one repair
sleeve per Conductor shall not be normally used in any single span.
8.19.05 Conductor splices shall be so made that they do not crack or get damaged in
the stringing operation. The Contractor shall use only such equipment/methods
during Conductor stringing which ensures complete compliance in this regard.
8.19.06 Derricks shall be used where roads, rivers, canals, telecommunication or
overhead power lines, railway lines, fences or walls have to be crossed during
stringing operations. It shall be seen that normal services are not interrupted and no
damage is caused to property. Shut down shall be obtained when working at crossing of
overhead power lines.
8.19.07 The sequence of running out shall be from top to downwards, i.e. the Earth
wire shall be run out first followed by the Conductors in succession. Imbalances of
loads on towers shall be avoided as far as possible i.e. both Earth wires, then both
bundles of top Conductor and then both bundles of middle Conductor followed by both
bundle Conductors of bottom Cross-arm should be strung.
8.19.08 The proposed transmission line may run parallel for certain distance with the
existing 400/220/132KV lines which will remain energized during the stringing period. As
a result there is a possibility of dangerous voltage build up due to electromagnetic and
electrostatic coupling in the pulling cables, Conductors and Earth wires, which
although comparatively small in magnitude during normal operations, can be severe
during switching and ground fault conditions on the energised lines. It shall be the
Contractor's responsibility to take adequate safety precautions to protect his employees
and others from this potential danger.
8.20 STRINGING OF CONDUCTOR AND EARTH WIRE:
The contractor shall give complete details of the stringing methods, which he proposes to
follow. At least one month in advance of the commencement of stringing, the
contractor will submit the stringing charts for the conductors and earth wire
showing the initial and final sags and tension for various temperatures and spans,
alongwith equivalent spans in the lines, for the approval of the Employer. The
stringing shall be carried out as per the stringing charts approved by the Employer
and in accordance with relevant IS. All the tolerances for the line shall conform to IS
5613 (Part-2/Sec-2) 1995
8.21 JOINTING:

8.21.01 The number of joints in Conductor/Earth wire shall be kept to minimum


possible by properly selecting the drums from available lot of respective drums. All the
joints on the Conductor and Earth wire shall be of compression type. Each part of the
joint shall be cleaned by wire brush to make it free of rust or dirt etc. and properly
greased with anti-corrosive compound, as approved by our Engineer before the final
compression is done with the compressors. The cost of such grease etc. used for joints
shall not be paid extra and shall be deemed to be included in the stringing rates.
MPPTCL/TECH-LINE/PROC/SEP23 Page 128
8.21.02 All joints shall be made at least 30 meter away from the structures. No joints
shall be made in the spans crossing over the main roads, railways, rivers etc. Not more
than one joint per Conductor shall be allowed in one span. Care shall be taken to mark
the conductor for properly centering the compression clamp before compressing. During
compression operation, the conductor shall be handled in such a manner as to prevent
lateral or vertical bearing against the dies. After pressing the joint the aluminum
sleeve shall have all corners rounded, burrs and sharp edges removed and
smoothened.
8.21.03 Suitable protector shall be used during stringing of Conductor to avoid any
damage to the joint while it passes over the traveler.
8.22 SAGGING IN OPERATION:
8.22.01 The Conductors shall be pulled up to the desired sag and left in running block
for at least one hour after which the sag shall be rechecked and adjusted, if necessary,
before transferring the conductor from the running out blocks to the suspension clamps.
The Conductors shall be clamped within 36 hours of sagging in.
8.22.02 The sag will be checked in the first and the last span of the section in case of
sections up to eight spans and in one intermediate span also for sections with more
than eight spans. The sag shall also be rechecked when the Conductor have been
drawn up and transferred from running blocks to the insulator clamps.
8.22.03 The running out blocks, when suspended from the transmission structure
for sagging shall be so adjusted that the Conductors on running out blocks will be at the
same height as that of the suspension clamps to which it is to be secured.
8.22.04 At sharp vertical angles, the sags and tensions shall be checked on both sides
of the angle. The Conductor and Earth wire shall be checked on the running out blocks
for equality of tension on both sides. The suspension insulator assemblies will normally
assume vertical positions when the Conductor is clamped.

Tensioning and sagging operations shall be carried out in calm weather, when
8.22.05

rapid changes in temperature are not likely to occur.


8.23 TENSIONING & SAGGING OF CONDUCTOR AND EARTH WIRE:
The tensioning and sagging shall be done in accordance with the approved stringing
charts before the Conductor and Earth wire is finally attached to the towers through the
insulator strings for the Conductor and Earth wire clamps for the Earth wire
Dynamometers shall be used for measuring tension in the Conductor and Earth wire.
8.24 CLIPPING IN:

8.24.01 Clipping of the Conductors in position shall be done in accordance with the
method approved by our Engineer. At suspension location free center type suspension
clamp with Armour rod set or AGS type suspension clamp shall be used.
8.24.02 The jumpers at the section and angle towers shall be formed to parabolic shape
to ensure maximum clearance requirements. Pilot suspension insulator string shall
be used, if necessary, to restrict the jumper swings to the design values. Jumper

MPPTCL/TECH-LINE/PROC/SEP23 Page 129


connections of transposition towers shall be so made that adequate clearances are
available from tower body as well as phase conductors.
8.24.03 Fasteners in all fittings and accessories shall be secured in position. The
security clip shall be properly opened and sprung into position.
8.25 FIXING OF CONDUCTORS AND EARTH WIRE ACCESSORIES :
Vibration dampers (4-R type) and other Conductor and Earth wire Accessories supplied
by the Employer shall be installed by the Contractor as per the design/drawing
requirement and as per instructions of the Engineer. While installing the Conductor and
Earth wire Accessories, proper care shall be taken to ensure that the surfaces are clean
and smooth and no damage shall occur to any part of the Accessories.
8.26 MAINTENANCE:
8.26.01 For a period of 12 (twelve) calendar months commencing immediately
upon the satisfactory completion of the final tests at site and taking over of the line,
the Contractor's liability shall be limited to the replacement (supply and re-erection) of
any defective parts that may develop on line of his own manufacture or those of his
Sub-Contractors approved by the Employer under the conditions provided for by the
contract under proper use and arising solely from faulty materials, or workmanship.
8.26.02 If it becomes necessary for the Contractor to replace or renew any defective
portions of the line under this clause, the provisions of this clause shall apply to the
portions of the line so replaced or renewed until the expiration of six months from the
date of such replacement or renewal or until the end of the above mentioned period of
twelve months whichever may be the later.
8.26.03 If any defects be not remedied within a reasonable time, the Employer may
proceed to do the work at the Contractor's risk and expense, but without prejudice to any
other rights which the Employer may have against the Contractor in respect of such
defects. The Contractor shall bear reasonable cost of minor repairs carried out on his
behalf at site. At the end of the maintenance period the Contractor’s liability ceases.
In respect of plant not covered by the first paragraph of this clause, the Employer shall be
entitled to the benefit of any guarantee given to the Contractor by the original Contractor
or manufactures of such plant.
8.27 REPLACEMENT:
If any replacements are to be effected after stringing and tensioning or during
maintenance, members and bracing shall not be removed without reducing the
tension on the tower with proper guying or releasing the Conductor. If the replacement
of cross arms becomes necessary after stringing, the Conductor shall be suitably tied to
the tower at tension points or transferred to suitable roller pulleys at suspension points.
8.28 PRE-COMMISSIONING:
After completion of the works, final checking of the line shall be done by the Contractor
to ensure that all the foundation works, tower erection, and stringing have been done
strictly in accordance with the specification and as approved by the Employer. All
the works shall be thoroughly inspected keeping in view the following main points:

MPPTCL/TECH-LINE/PROC/SEP23 Page 130


8.28.01 Sufficient back-filled earth is lying over each foundation pit and it is adequately
compacted.
8.28.02 Concrete chimneys and their copings are in good finely shaped conditions.
8.28.03 All the tower members are correctly used, strictly according to approved drawing
and are free from defects or damages, whatsoever.
8.28.04 All bolts are properly tightened and punched/tack welded as per this
specification.
8.28.05 The stringing of the Conductors and Earth wire has been done as per the
approved sag and tension charts and desired clearances are clearly available.
8.28.06 All Conductor and Earth wire Accessories are properly installed.
8.28.07 All other requirements to complete the work like fixing of Danger Plate, Phase
Plate, Number Plate, Anti-climbing devices, Aviation Signal (wherever required) etc. are
properly installed and the painting has been done wherever required as per Aviation
Rules.
8.28.08 It should be ensured that revetment is provided, wherever required.
8.29 COMMISSIONING:-
8.29.01 The line insulation is tested by the Contractor by providing his own equipment
labour etc. to the satisfaction of the Employer to ascertain the insulation condition of the
line.
8.29.02 Conductor continuity test is carried out to verify that each Conductor of the
overhead line is properly connected electrically also.
The line may be charged at a low value of Power Frequency Voltage for the purpose of
testing and commissioning.
8.30 TAKING OVER:
When all performance tests called for by the Specification have been successfully
carried out, the transmission line shall be accepted and taken over when it has been
satisfactorily put into operation on site, or within one month of its being ready to be put
into operation, whichever shall be the earlier and the Engineer shall forthwith issue
a taking over certificate. The Engineer shall not delay the issue of any taking over
certificate contemplated by this clause on account of minor defects in the plant which
do not materially effect the commercial use thereof, provided that the Contractor
shall undertake to make good the same in due course.

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9.0 TECHNICAL SPECIFICATION OF STEEL MONOPOLES

9.01 SCOPE:

9.01.1 The designs of multi circuit and double circuit steel monopoles for EHV
transmission lines and their extensions should be conforming to the IS 802:2015. The
scope also includes supply of design calculations of Monopoles and their foundations with
test reports and foundation design vetting by CPRI/ IITs, the detailed structural/shop
drawings of monopoles, drawings of foundations in various types of soil, sag
templates, sag tension chart for conductor, for ground wire/OPGW etc. The foundation
design shall be vetted by CPRI/IITs.

9.01.2 The fabricated steel poles shall include base plate with its required accessories,
monopole body (including extensions, as per site requirement), Cross Arms and
arrangement for maintenance like attachments for ladders etc. Monopole shall be joined
with friction clip or Flanged joint. Cross Arms shall be Polygonal with structural jointing
arrangement. The accessories shall include strain plates, D-shackles with nuts, bolts and
washers, U-Bolts with nuts and washers, space washers, links for providing attachment to
the E.W./OPGW and Conductor, anti-climbing devices and any other equipment/ material
/ article to complete the works as per the scope given in this specification.

9.01.3 The monopoles shall be fully galvanized. Provision will be made for fixing phase
plates and Bird guards. Arrangement for fixing the Earthing bonds at the peak and for
grounding the monopoles at bottom or any other holes, which the purchaser may require,
shall be provided at the convenient locations on the monopoles.

9.02 TYPE OF MULTI CIRCUIT AND DOUBLE CIRCUIT STEEL MONOPOLE

9.02.1 The multi circuit Poles will have four circuits of 132kV, self supporting, designed
for the specified loading conditions. There will generally be following type of Poles:
-

i)Pole type MEP0: Tangent type Pole with maximum line deviation up
to 2° to be used with Single/Double suspension
insulator strings.

ii)Pole type MEP15: Medium angle Pole to be used for line deviation
from up to 15° with Single/Double tension insulator
strings.

iii)Pole type MEP30: Medium angle Pole to be used for line deviation
upto 30° with Single/Double tension insulator
strings.

iv)Pole type MEP60: Medium angle Pole to be used for line deviation
upto 60° and also as dead end Pole upto 15° with
Single/Double tension insulator strings.

MPPTCL/TECH-LINE/PROC/SEP23 Page 132


9.02.2 The 132kV double circuit steel monopoles will have two circuits (six cross arms),
self supporting, designed for the specified loading conditions. There will generally be
following type of Poles: -

i)Pole type EP0: Tangent type Pole with maximum line deviation up
to 2° to be used with Single/Double suspension
insulator strings.

ii)Pole type EP15: Medium angle Pole to be used for line deviation
from up to 15° with Single/Double tension insulator
strings.

iii)Pole type EP30: Medium angle Pole to be used for line deviation
upto 30° with Single/Double tension insulator
strings.

iv)Pole type EP60: Medium angle Pole to be used for line deviation
upto 60° and also as dead end Pole upto 15° with
Single/Double tension insulator strings.

v)Pole type EP90: Heavy angle Pole to be used for line deviation
from up to 90° and also as dead end Pole with
Single/Double tension insulator strings.

9.02.3 The 220kV double circuit steel monopoles will have two circuits (six cross arms),
self supporting, designed for the specified loading conditions. There will generally be
following type of Poles: -

i)Pole type BP0: Tangent type Pole with maximum line deviation up
to 2° to be used with Single/Double suspension
insulator strings.

ii)Pole type BP15: Medium angle Pole to be used for line deviation
from up to 15° with Single/Double tension insulator
strings.

iii)Pole type BP30: Medium angle Pole to be used for line deviation
upto 30° with Single/Double tension insulator
strings.

iv)Pole type BP60: Medium angle Pole to be used for line deviation
upto 60° and also as dead end Pole upto 15° with
Single/Double tension insulator strings.

v)Pole type BP90: Heavy angle Pole to be used for line deviation
from up to 90° and also as dead end Pole with
Single/Double tension insulator strings.

MPPTCL/TECH-LINE/PROC/SEP23 Page 133


9.02.04 Cable Termination Pole: Further, a 132kV double circuit steel monopole with
provision for 132kV Cable termination arrangement shall be designed. The pole shall
have two circuits (six cross arms), self supporting, designed for the specified loading
conditions and shall have mounting arrangement of 145kV Lightening Arrestors and EHV
cable termination on the pole: -
Pole type CTEP60: Pole for EHV Cable termination with mounting
arrangement for Lightening Arrestors. Pole to be
used for line deviation upto 60° and also as dead
end Pole with Single/Double tension insulator
strings. There shall be four single phase cable (R,
Y, B phase and one spare) in each circuit.
The above pole types / tower types are indicative and the bidder is required to offer
bids as per BoQ and has to carry out work as per site requirement.
9.03 DESIGN:

9.03.1 The bidder will furnish a design as per ASCE/SEI 48-11, "Design of Steel
Transmission Pole Structures", ASTM A6 and loading conditions as per IS 802(Part-I)-
2015 for each of the offered monopoles with extensions based on the loading conditions
indicated herein. The suspension monopoles shall be designed with using `I’ suspension
string.

9.03.2 In case of overlapping of pole sections, minimum overlap shall be 1.5 times the
maximum inside diameter of the outer section at the telescopic joint or as per design
calculations, whichever is higher. Further, the pole shall be continuously tapered from
top to bottom with a uniform slope

9.03.3 The 132kV multicircuit monopole will have one conductor per phase (Panther
ACSR) in vertical formation for top and bottom circuits and one OPGW equivalent to
ground-wire of 7/3.66 mm galvanized stranded steel wire of 95kg/sq.mm grade placed on
the top of the monopole.

9.03.4 The 132kV double circuit monopole will have one conductor per phase (Panther
ACSR) in vertical formation and one OPGW equivalent to ground-wire of 7/3.66 mm
galvanized stranded steel wire of 95kg/sq.mm grade placed on the top of the monopole.

9.03.5 The OPGW/ground-wire at its suspension point shall provide a shielding angle of
30° with respect to the top most conductors. The drop of OPGW/ground-wire suspension
assembly should be taken into account so as to determine the shielding angle.

9.03.6 The minimum mid-span vertical clearance between OPGW/ground-wire and


Conductor in still air shall be 6.1 M.

9.03.7 The minimum electrical clearance between conductors shall be 3.9M (Vertical)
and 6.8M (Horizontal) for 132kV poles.

9.03.8 Workability: The design of multi circuit poles be such that maintenance personnel
may work on lower circuit while upper circuit is live (charged) and vice versa

MPPTCL/TECH-LINE/PROC/SEP23 Page 134


9.03.9 The conductor and OPGW/ground-wire parameters to be considered in the design
of 132kV poles (ACSR Panther) are as under: -

ACSR Panther Conductor:


a. Stranding and wire diameter 30/3.00mm Al., 07/3.00mm Steel
b. Total sectional area 261.5 mm²
c. Approximate overall diameter 21.00 mm
d. Approximate weight 973 kg/km
e. Approximate calculated breaking load 9127 Kg
f. Co-efficient of linear expansion 17.73 x10-6 per degree C
g. Final modules of elasticity 0.7034x 106 kg/cm²

95 Kg/mm² Groundwire:
a. Stranding and wire diameter 7/3.66mm
b. Total sectional area 73.65 mm²
c. Approximate overall diameter 10.98 mm
d. Approximate weight 583 kg/km
e. Approximate calculated breaking load 6972 kg
f. Co-efficient of linear expansion 11.5x10-6 per degree C
g. Final modules of elasticity 1.9329 x 106 kg/cm²

OPGW:
a. Diameter of OPGW 12.6 mm
b. Effective area of OPGW 79.64 mm²
c. Approximate weight of OPGW 487 kg/km
d. Ultimate Tensile Strength (UTS) 8954 kg
e. Co-efficient of linear expansion 13.1x10-6 per degree C
f. Final modules of elasticity 14308 kg/mm²
g. Max. tension at everyday temp. & No ≤ 20% of UTS
wind condition
h. Max. tension at everyday temp. & Full ≤ 40% of UTS
wind condition

9.04 CLEARANCES:
The following minimum clearances may be made available between the live parts and
the nearest monopole body.

a. The clearances for 132kV level are given hereunder:

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Double
Single Jumper in case of Single/Double
Suspension
Suspension string tension poles Tension string
string
Clearance Clearance Clearance Clearance
1530 mm 1530 mm 1530 mm 1530 mm
(at 0° & 15° swing) (at 0° swing) (at 0° & 10° swing)
1370 mm 1070 mm
(at 30° swing ) (at 20° & 30° swing)
1220 mm
(at 45° swing )
1070 mm
(at 60° swing )

The above clearances are based on maximum and minimum insulator string lengths. If
Pilot string is used in case of 60°/90° monopole; swing of the pilot string shall be 15o. Only
disc Insulator string shall be used as pilot string. The clearance shall be available from
grading ring if the same happens to be the nearest to the monopole body at any point of
time.

9.05 DESIGN SPANS:

9.05.1 The wind span for the purpose of computing the wind load on conductors and
OPGW/ground-wire shall be 350M. The weight span shall be 1.5 times wind span.

9.05.2 Negative weight span: Based on site requirement, negative weight span for
suspension poles shall be considered. For angle poles MEP60 and EP 60, negative
weight span of (-) 150M shall be considered.

9.06 WIND LOAD:


The wind load on conductors, OPGW / ground-wire, monopoles and insulator strings
shall be taken as per recommendations of IS:802 (Part-I) -2015 with latest revision
thereof, for following conditions: -

(a) Wind zone 4 (Four)


(b) Reliability level 1(one) for 132 kV double circuit monopoles and
2 (Two) for multicircuit monopoles.
(c) Terrain category 2 (Two)

9.07 TEMPERATURE VARIATION:


The maximum working tension of conductor, OPGW/ground-wire and the uplift conditions
shall correspond to the minimum temperature of 0° C.
The maximum conductor sag and ground clearance beneath should correspond to the
maximum working temperature of 85° C. The maximum OPGW/ground-wire temperature
shall be taken as 53° C.

MPPTCL/TECH-LINE/PROC/SEP23 Page 136


9.08 STRUCTURAL STEEL:
The following materials will be used:

Pole shaft: A572-65 or Equivalent


Base plate: A572-50 or Equivalent
Ladder & Other: A572-36 or Equivalent
Anchor bolts: 6.8 Grade (132kV poles) and 8.8 Grade (220/132kV MC poles
Connection bolts: 8.8 Grade
Galvanizing: ASTM A123 (Structure: Avg. coating 85 micron) / A153 (Hardware)

9.09 LOADS ON MONOPOLES:

Transmission lines are subjected to various loads during their life time. These loads
areclassified into three distinct categories, namely
a) Climatic Loads: related to the reliability requirements.
b) Failure containment Loads: related to security requirements.
c) Construction & Maintenance Loads: related to safety requirements.
a) Climatic Loads:
These are random loads imposed on monopole, insulator string, conductor & ground wire
due to action of wind on transmission line & do not act continuously. Climatic loads shall
be determined under either of the following climatic conditions whichever is more
stringent:
• 100 percent design wind pressure at every day temperature (32°C) or
• 36 percent design wind pressure at minimum temperature (0°C)
b) Failure Containment Loads:
• Anti cascading Loads &
• Torsional & Longitudinal Loads
Anti Cascading Loads:
Cascade failure may be caused by failure of items such as insulators, hardware, joints
failures of major components such as monopoles, foundations, conductor due to
defective material or workmanship or from.
climatic overloads sometimes from casual events such as misdirected aircraft,
avalanches, sabotage etc. The security measures adopted for containing cascade failures
in the line is to provide angle monopoles at specific intervals which shall be checked for
anti cascading loads.
Anti cascading checks:
i) Suspension monopoles shall be checked for narrow front wind as per IS 802:2015.
ii) Angle monopoles shall be checked for the following anti cascading conditions with all
the conductors & ground wire intact only on one side of the monopole.
• Transverse load: These loads shall be taken under no wind condition.

MPPTCL/TECH-LINE/PROC/SEP23 Page 137


• Vertical Load: These loads shall be the sum of weight of conductor/ground wire as
per weight span of intact conductor/ground wire, weight of insulator strings and
accessories.

• Longitudinal Loads: These loads shall be the pull of conductor/ground wire at


every day temperature & no wind applied simultaneously at all points on one side
with zero-degree line deviation.
Torsional & Longitudinal Loads:
These loads are caused by breakage of conductors and/or ground wire. All the
monopoles shall be designed for these loads for the number of conductor(s) and or
ground wire considered broken as per provisions of this specification.
c) Construction & Maintenance Loads:
These are loads that are imposed on monopoles during constructions & maintenance of
transmission lines.

Computation of Loads & loading combinations: The computation of loads is to be done in


line with relevant provisions/ sections of IS 802- 1992 (latest amendment)

Tension Limits:
Conductor/OPGW/ground-wire tension at everyday temperature & without external load,
should not exceed the following percentage of the ultimate tensile strength of the
conductor:
Initial unloaded tension 35 percent
Final unloaded tension 25 percent.
provided that the ultimate tension under everyday temperature & 100 percent design wind
pressure or minimum temperature & 36 percent design wind pressure does not exceed
70 percent of the ultimate tensile strength of the conductor/ground wire.

9.10 TRANSVERSE LOADS


The transverse loads due to wind on conductors and OPGW/ground-wire shall be
calculated for wind span under normal condition as per IS 802:2015. Under broken wire
conditions 50% of the intact span and 10% of the broken span shall be assumed as wind
span. In addition to this, transverse loads due to line deviation, wind on poles, and wind
on insulator strings should also have to be taken into consideration in the design of the
Poles.

9.11 CONDUCTOR SAG:


The maximum sag for the conductor should be calculated for 85° C and no wind with an
allowance of 4% of maximum sag to allow for plotting and sagging errors.

9.12 GROUND CLEARANCE:


The minimum ground clearance of 6.100 Meters shall be available corresponding to the
maximum working temperature and normal span.

MPPTCL/TECH-LINE/PROC/SEP23 Page 138


9.13 BROKEN WIRE CONDITIONS:

9.13.1 Following broken wire conditions should be assumed in the design of Poles: -
a. Suspension monopole- Any one of power conductor broken or OPGW/ground-
wire broken which ever condition is more stringent for
design.

b. Angle monopole (0° to 15°/30°) - Any two of power conductors broken on the same
side and on the same span or any one of the power
conductor broken and OPGW/ground-wire broken on
the same span whichever combination constitutes the
most stringent condition for design of a particular
member.

c. Angle monopole (0° to 60°/90°) - Any Three power conductors broken on the same
side and on the same span or any two of the power
conductor broken and OPGW/ground-wire broken on
the same side and same span whichever combination
constitutes the most stringent condition for design.
Further, this monopole shall also be designed for dead
end condition i.e. all conductors and
OPGW/Groundwire broken on the same side and
same span.

d. Angle monopole (0° to 90°) - Any Three power conductors broken on the same side
and on the same span or any two of the power
conductor broken and OPGW/ground-wire broken on
the same side and same span whichever combination
constitutes the most stringent condition for design.

9.13.2 In all type of monopoles, the power conductor’s supports and OPGW/ground-wire
supports should be designed for broken wire conditions also.

9.14 FACTORS OF SAFETY FOR MONOPOLES:

The factors of safety for design of monopoles shall be with type testing as under:
Normal condition - 1.1
Broken wire condition - 1.1
The factors of safety for design of monopoles shall be without type testing as under:

Normal condition - 1.5


Broken wire condition - 1.5

9.15 BOLTS AND NUTS AND WASHERS:

9.15.1 The design of the monopoles should be based on use of HRH mild steel hot dip
galvanized bolts grade 6.8 for 132kV and 8.8 for multicircuit monopoles. The spring
MPPTCL/TECH-LINE/PROC/SEP23 Page 139
washers shall be provided for insertion under all nuts. These washers shall be of steel,
electro galvanized, positive lock type and of 3.5mm thickness.

9.15.2 The nuts shall be forged and tapped after galvanizing and then lubricated. The
nuts shall be chamfered on one face only, the other face shall be machined.

9.15.3 The bolts and nuts shall be free from forging and threading defects such as cuts,
splits, burrs, bulging, taper, eccentricity, loose fit etc.

9.15.4 The bolts shall be threaded up to standard length only as per relevant Indian
Standard and not to full length.

9.15.5 The bolts and nuts shall confirm to IS 1367-1971 Part-III and Part-IV, IS 12427,
IS 1363-92, IS 1367 Part-XIII with latest amendment.

9.15.6 The spring washers after coiling shall be suitably heat treated so as to result in
the finished washer having hardness 43 to 50 HRC when tested in accordance with IS
1586- 1968.

9.15.7 The surface of the washers shall be free of scales and burrs. The washers shall
be coiled without any kinks (except for the shape with turned-up ends). The ends of the
washer shall not abut when the washers are compressed. The ends shall be so served as
to prevent tangling.

9.16 STEP BOLTS/LADDER:


Each Pole will be provided, with step-bolts of 16mm dia and 175mm long, spaced not
more than 450mm extending from 2.5 meters above the ground level for 3 meters and
then ladder shall be provided for convenience in maintenance upto the top of the pole.
The step bolts shall conform to Indian Standard1363-1992, Indian Standard10238:1989
and Indian Standard 1367(Part-XIII):1983 or equivalent International Standards.

9.17 DANGER BOARD, NUMBER PLATE AND PHASE PLATES:


Each Pole will be fitted with danger board, number plate and phase plates. The Pole to
be supplied shall have provision to fix these plates at a height of about 4 meters above
ground level. Necessary provision in Pole for fixing of these items shall be made. The
Danger board, number plate and phase plates shall be supplied conforming to following
technical details: -

9.17.1 The danger boards shall conform to IS-2551-1982 and their revision, if any
except where modified in this specification.

9.17.2 The danger boards, number plates and phase plates shall conform to the
drawings provided by MPPTCL.

9.17.3 The colour scheme of the enamel and size of figures and dimensions of lettering
shall be as shown in the drawing as also the overall size. The holes as indicated in the
drawing shall be provided before enamelling.

MPPTCL/TECH-LINE/PROC/SEP23 Page 140


9.17.4 The thickness of the plate out of which the danger board, number plate and
phase plate will be manufactured, shall not be less than 1.6mm.

9.17.5 The enamellings shall be done by vitreous enameling process only.

9.17.6 All letterings shall be centrally spaced. The dimensions of the letters, figures and
their respective positions shall be as given in drawings. The size of each letter in the
word in each language and the spacing between them for the purpose of scribing shall be
so chosen that they are uniformly written in the space earmarked for them.

9.17.7 The corners of the plate shall be rounded off. The location of the fixing holes shall
be according to drawing annexed with this specification.

9.17.8 The plate shall be made from mild steel at least 1.6mm thick and vitreous
enameled white, with letters, figures and the conventional skull and cross-bones in signal
red colour on the front side. The rear side of the plate shall also be enameled.

9.18 ANTICLIMBING DEVICE WITH BARBED WIRE:


The barbed wire type anti-climbing device shall be supplied for use at a height of
approximately 3 meters as an anti-climbing deterrent measure.

9.19 LOAD ON FOUNDATIONS:

9.19.1 The foundations shall withstand the ultimate loads on the superstructure as
specified in this specification, for the full footing reactions along the stub angle
slopes obtained from the structural stress analysis.

9.19.2 The reactions on the footing shall be composed of the following types of loads for
which they shall be required to be checked.

(a) Maximum tension or uplift.


(b) Maximum compression or down-thrust.
(c) Maximum horizontal shear or side thrust.
9.19.3 The additional weight of concrete in the footing below ground level over the earth
weight and full weight of concrete above the ground level in the footing and embedded
steel parts will also be taken into account adding to the down-thrust.

9.20 STABILITY ANALYSIS:

9.20.1 The following primary types of soil resistances shall be assumed to act in resisting
the loads imposed on the footings in earth:
(a) Resistance against uplift:
The uplift loads will be assumed to be resisted by weight of earth in an inverted frustum of
a conical pyramid of earth on the footings pad whose sides make an angle equal to the
angle of repose of the earth with the vertical in average soil. The weight of concrete
embedded in earth and that above the ground will also be considered for resisting the
uplift. In case where the frustum of earth pyramids of two adjoining legs super-impose

MPPTCL/TECH-LINE/PROC/SEP23 Page 141


each other, the earth frustum will be assumed truncated by a vertical plane passing
through the center line of the pole base.
(b) Resistance against down-thrust:
The down -thrust loads combined with the additional weight of concrete above earth will
be resisted by bearing strength of the soil assumed to be acting on the total area of the
bottom of the footings.
(c) Resistance against side thrust:

The bidder shall describe in detail the methods followed by them to check the stability of
foundations for horizontal shears or side-thrust alongwith the relevant reference (IS or
other standard) in support of their contentions.

9.20.2 In addition to the strength design, stability analysis of the foundation shall be done
to check the possibility of failure by over-turning, uprooting, sliding and tilting of the
foundation.

9.21 DESIGN OF FOUNDATIONS:

The bidder is requested to submit the design of foundations. It is recommended to give


Single Pile Foundation. The foundation shall be designed on ultimate load. The
foundation shall be designed as per site requirement and shall be submitted after design
vetting from the reputed IITs (like IIT Bombay/Delhi/ Madras/ Kanpur /Kharagpur
/Roorkee) to ascertain that the same can be used for safe and reliable installation of the
monopole.

9.22 TYPE TESTS: -

9.22.1 The poles shall be type tested from CPRI /Govt. NABL accredited Laboratory in
India. A Black/Galvanised Double circuit/multicircuit steel monopole of each type with
maximum designed extension shall be subjected to design test by first applying test loads
equivalent to the specified maximum loads multiplied by specified factor of safety and
applied in a manner approved by the purchaser. The monopole should withstand these
tests without showing any sign of failure or permanent distortion in any part. The
monopole shall be successfully tested for all the conditions considered in the design of
monopole as per the procedure specified in IS- 802(part-III)-1977/ IEC 60652. Additional
condition for type test of the pole as per IEC 60652 are given hereunder:

a. Clause 9.5 “Loading rate and holding period”: For the design 100% load, the
loads shall be maintained for a period of 5 minutes.
b. Clause 13 “Acceptance Criteria”: The performance of the pole shall be acceptable
if it resists the 100% designed load for a period of 5 minutes without failure of any
components or assemblies.
c. Clause 14 “Premature failure”: The pole shall be modified and retested till it
achieves the performance as per acceptance criteria of 100% designed load for a
period of 5 minutes without failure of any components or assemblies.

9.22.2 The successful bidder shall submit the detailed programme and proposal for
testing the monopoles, to the purchaser for approval, showing the methods of carrying
MPPTCL/TECH-LINE/PROC/SEP23 Page 142
out the tests and manner of applying the loads. After the approval of the test procedure
and programme by the purchaser, the bidder shall intimate the purchaser about carrying
out the tests at least 15 days in advance of the scheduled date of tests during which the
purchaser shall arrange to depute his representatives to be present at the time of carrying
out the tests. Four copies of the test reports shall be submitted.

9.22.3 The poles with maximum extensions shall be tested for minimum 6 cases or as
decided by MPPTCL up to 100% designed loading condition. The test pole may be used
in the line after galvanizing if the pole has passed the tests, has return to its original
position within reasonable tolerance, and no failure (i.e. bending, yielding, breaking etc.)
of the material or welds is detected.

9.22.4 In case if it is specified in the tender that testing of poles shall not be carried out,
then in order to ensure proper design of monopoles the factor of safety for the purpose of
design of monopole will be considered as 1.5 and the bidder will be asked to submit
validation of design from the reputed government test beds (like CPRI) or IITs (like IIT
Bombay/Delhi/ Madras/ Kanpur/Kharagpur/Roorkee) to ascertain that the monopoles
meet the requirement of IS 802:2015 read with tender specification and the same can be
used for transmission line work as per the site requirement.

9.22.5 DEFLECTION CRITERIA (As per CBIP Manual) 5.0% of the height of pole @
Ultimate Load Condition, 2.0% of the height of pole @ Safety Normal Load Condition.

9.22.6 Aviation Requirement: Span Marker and Night Marker (Obstruction Light)
confirming to IS: 5613 wherever required shall be provided by the contractor.

9.22.7 Sealing of Poles: The top end of the pole, OPGW peaks, end of cross arms etc.
shall be suitably sealed with cover plate welded to the structure to avoid entry of outside
material/water.

9.22.8 Provision for Line maintenance: Arrangements shall be made to facilitate Hot
Line Maintenance gang to stand upon and carry out maintenance in live line condition.

9.22.9 Footing Resistance: The footing resistance shall be maintained below 10 Ohm.
Arrangement for Earthing at four numbers diagonally opposite points shall be made.

9.22.10 Other Design of poles: Other design of steel monopoles meeting the
loading and testing conditions as stipulated in the technical specification above will also
be acceptable.

9.22.11 Use of Ready Mix Concrete: It is hereby clarified that use of ready mix
concrete of designated strength is permitted.

MPPTCL/TECH-LINE/PROC/SEP23 Page 143


10.0 TECHNICAL SPECIFICATION OF 132 KV POWER CABLE, TERMINATION KIT
AND INSTALLATION OF CABLE

INDEX
S. No. PARTICULARS
(A) SECTION-I
1 TECHNICAL SPECIFICATION FOR 132 KV CROSS LINKED
POLYETHYLENE INSULATED POWER CABLE
2
ANNEXURE – I (OF SECTION-I)
(B) SECTION- II
1 TECHNICAL SPECIFICATION FOR 132 KV CABLE TERMINATION &
JOINTING KITS FOR 1 X 800 SQ.MM XLPE CABLE

2 ANNEXURE- I (OF SECTION-II)


(C) SECTION – III TECHNICAL SPECIFICATION FOR INSTALLATION
OF CABLE
1 SECTION-III (A): SCOPE, ROUTE SURVEY, WORKS REQUIREMENT
AND STATUTORY CLEARANCES
2 SECTION-III (B): LAYING AND INSTALLATION OF CABLE
3 SECTION-III (C): DETAILS OF JOINTING AND TERMINATION
WORKS OF CABLE
4 SECTION-III (D): CIVIL AND STRUCTURAL WORKS
5 SECTION-III (E): EARTHING, SITE TESTING, COMMISSIONING OF
COMPLETE CABLE SYSTEM
(D) GENERAL DRAWINGS
1 132KV CABLE ROUTE MARKER (RCC)/JOINT MARKER
2 CABLE LAYING AT NORMAL EXCAVATION FOR 2 X S/C
3 JOINT PIT FOR 132KV LUG
4 TYPICAL ARRANGEMENT FOR MAINTENANCE FREE TREATED
EARTH PIT FOR NORMAL SOIL
5 TYPICAL ARRANGEMENT FOR MAINTENANCE FREE TREATED
EARTH PIT FOR ROCKY SOIL
6 132KV CABLE RCC SLAB
7 132KV CABLE PRE WARNING TAPE
8 TREFOIL CLAMP & CLEAT FOR EHV CABLE
9 CABLE LAYING AT ROAD / NALA CROSSING
10 CABLE LAYING FOR ROAD CROSSING BY TRENCH
LESS BY HDD METHOD
11 WARNING BOARD FOR 132KV U/G CABLE
12 CABLE LAYING AT NORMAL EXCAVATION FOR S/C
13 CABLE LAYING AT NORMAL EXCAVATION FOR 3 X S/C
MPPTCL/TECH-LINE/PROC/SEP23 Page 144
SECTION-I

132 kV CROSS LINKED POLYETHYLENE


INSULATED POWER CABLE

MPPTCL/TECH-LINE/PROC/SEP23 Page 145


SECTION-I

TECHNICAL SPECIFICATION FOR


132 kV CROSS LINKED POLYETHYLENE
INSULATED POWER CABLE

1.0 SCOPE:

1.1 The scope under this section covers design, engineering, manufacture, testing,
packing and supply of 132 kV, 800 sq. mm, XLPE insulated power cable and its
accessories. The XLPE cable and its accessories shall be complete with all
fittings and components necessary for the satisfactory performance and ease of
maintenance.

2.0 STANDARDS: The cable covered by the specification shall be designed,


engineered, manufactured, tested and commissioned in accordance with the
Standards as specified in the table below.

Other internationally accepted standards which ensure equivalent or


better performance than that specified in the standards referred shall also be
accepted. Copies of such standards shall be submitted by the bidder along with
the bid.

IS 7098 : Part 3 : Cross-linked polyethylene insulated thermoplastic sheathed


1993 cables:
IS 8130 : 1984 For working for
Conductors voltage from electric
insulated 66KV up to andand
cables including
flexible220KV.
cords
IS 5831 : 1984 PVC insulation and sheath of electric cables.
IS 1255 : 1983 Code of practice for installation and maintenance of power
cables
IS 3975 : 1999 upto and including
Mild steel 33KVwires
wires, formed rating.and tapes for armouring of
cables.
IS 6380 : 1984 Elastomeric insulation and sheath of electric cables.
IS10418 : 1982 Drums for electric cables
IS 5 : 1994 Colours for ready mixed paints and enamels.
IS 617 : 1994 Aluminium a n d A l u m i n i u m a l l o y i n g o t s a n d c a s t i n g s
for general
IS 3043 : 1987 engineering purposes
Code of practice (Superseded IS 20 : 1977)
for earthing.
IS 5578 : 1984 Guide for marking of insulated conductors.
IS 11353 : 1985 Guide for Uniform System of Marking and
Identification of Conductors and Apparatus Terminals.
IS 5216 : Part I : Recommendations on Safety Procedures and Practices in
1982 Electrical Work.
IS 2071 : 1993 High voltage test techniques.
IEC-60540 Power cables with extruded insulation and their accessories
and cords

MPPTCL/TECH-LINE/PROC/SEP23 Page 146


IEC 60060 : 1989 High Voltage Test Techniques
IEC-60502 Extruded solid dielectric insulated power cables for rated
voltages
IEC-60754 : 1991 from
Tests1KV up to 30KV
on gases evolved during combustion of electric cables
IEC-60183 : 1990 Guide to the Selection of High Voltage Cables.
IEC-60230 : 1996 Impulse tests on cables and their accessories.
IEC-60840 Tests for power cables with extruded insulation for rated voltage
up to 132 kV
IEC-60287 : 1995 Calculation of the continuous current rating of cables (100%
load factor).
IEC-60304 : 1982 Standard colours for insulation for low-frequency cable and
wires.
IEC-60331 : 1970 Fire resisting characteristics of Electric cables.
IEC-60332 : 1992 Tests on electric cables under fire conditions.
BS-5468 Cross-linked polyethylene insulation of electric cables
IEC-60228 : 1978 Conductors of insulated cables
IEC-60066 Environmental Test
IEC-60117 Graphical Symbols
IEC-60270 : 2000 Partial Discharge Measurements

3.0 CLIMATIC CONDITIONS:

3 . 1 The climatic conditions under which the cable shall operate satisfactorily are as
follows: -

1. Location in the state of MADHYA PRADESH


2. Max. ambient air temp. (deg.C) 50
3. Min ambient air temp (deg.C) 1
4. Average daily ambient air temperature(deg.C) 40
5. Maximum Relative humidity (%) 95, sometimes reaches
saturation.
6. Average annual rainfall (mm) 1250
7. Max. Wind pressure (Kg/sq.m.) 150
8. Max. Altitude above mean (Meters) sea level 1000
9. Isoceraunic level (days/year) 50
(Average number of thunderstorm days)
10. Seismic level (horizontal acceleration) 0.3 g

4.0 SYSTEM PARAMETERS:

Sl. NO TECHNICAL PARAMETERS 132 KV SYSTEM


1 Rated Max. Voltage 145 kV (rms)
2 Rated Frequency 50 Hz
3 Grounding Effectively Earthed
4 Rated Power Frequency Withstand Voltage (1 min) 275 KV (rms)
5 Impulse withstand BIL (1.2/50/micro Sec) Line to ±650 kVp
earth
MPPTCL/TECH-LINE/PROC/SEP23 Page 147
6 Rated short time withstand current (1 sec) 40 kA (rms)for 1 sec
7 Rated peak withstand current (1 sec) 100 kA (peak)
Rated normal current 567 Amp. for single
8 (at 35 degree C design ambient temperature) circuit and 484 Amp for
Double circuit
9 Seismic level Zone- II

5.0 PRINCIPAL PARAMETERS:


5.1 The detailed specification of 132 kV (E) grade 800 sq.mm XLPE single core power
cable is given in Clause 6.0. The cable shall conform to IEC-60502 for
construction, IEC-60840 for testing and in line with IS: 7098 (Part-III) /1993 or
any latest amendments thereof. Outer sheathing should be designed to afford high
degree of mechanical protection and should also be heat, oil, chemicals and
weather resistant. Common acids, alkalis and saline solution should not have
adverse effect on the Thermoplastic HDPE sheathing material used. The
construction of cable shall generally conform to the description mentioned in Clause
6.0 and desired technical particulars in Annexure-I enclosed. Bidder may offer
necessary layers such as separation tape, binder tapes etc. additionally as per
their manufacturing practices for meeting required performance of the offered
cable. The bidder shall enclose the drawing showing cross section of the cable with
the bid.

5.2 The cable shall be suitable for laying underground considering uncontrolled back fill
and chances of flooding by water and suitably designed by the addition of
chemicals in the outer sheath for protection against rodent and termite attack.

5.3 The cables shall be designed to withstand all mechanical, electrical and
thermal stresses under steady state and transient operating conditions.

5.4 Progressive sequential marking of the length of cable in meters at every one meter
shall be provided on the outer sheath of the cable.

5.5 Allowable tolerance on the overall diameter of the cables shall be plus or minus 2
mm.

6.0 GENERAL TECHNICAL REQUIREMENTS:

6.1 CONDUCTOR: The cable conductor shall be made from stranded H.D. aluminium
to form compacted circular shaped conductor having resistance within limits
specified in IS: 8130 / 1984 and any amendment thereof. The conductor shall
conform to IEC: 228.

6.2 CONDUCTOR SCREEN: The conductor having a semi-conducting screen shall


ensure perfectly smooth profile and avoid stress concentration. The conductor
screen shall be extruded in the same operation as the insulation. The semi-
conducting polymer shall be cross-linked. The screen shall be firmly bonded to
XLPE insulation. The minimum thickness of extruded conductor screen shall be
1.0 mm. The outer surface of the conductor screen shall be circular and free from
irregularities. A non- hygroscopic semi-conducting tape, if required, shall be applied
MPPTCL/TECH-LINE/PROC/SEP23 Page 148
to the conductor under extruded layer to prevent penetration of compound into the
conductor interstices.

6.3 INSULATION: The insulation material shall be extruded cross-linked polyethylene


(XLPE). In order to ensure that the screen and insulation are intimately bonded
together and free from all possibilities of voids between layers, the conductor
screen, the insulation and the insulation screen should be extruded
simultaneously in one process. The extrusion process should be carried out
under strictly controlled atmospheric conditions. The thickness of the insulation
layer should be maintained as the maximum value figured out from the design of
the impulse voltage and A.C. voltage. The cross-linking process by N2 gas shall be
preferred instead of conventional cross-linking process by saturated steam. The
insulation of the cable shall be of standard quality, generally confirming to IEC-
60840 and I.S. 7098 Part-III / 1993 (latest edition). The eccentricity of insulation
should not be more than 10%.

6.4 INSULATION SCREEN: The insulation screening shall consist of non-metallic part
(extruded & taped) and metallic part.

i. Non-Metallic Part (extrusion): -


A non-metallic insulation screen of semi-conducting compound similar to
conductor screen (clause 6.2) for similar purpose shall be applied directly
over the insulation core by extrusion and shall be continuous and cover
whole surface area of insulation. It shall be firmly bonded to the insulation.
The minimum thickness of extruded insulation screen layer shall be 0.8 mm.
The ovality of the core shall be not more than 5%.

ii. Non-metallic part (taped)-Longitudinal water barrier: -


Under-sheath water barrier shall consist of a synthetic semi-conducting
moisture swellable layer (non-woven synthetic tape with suitable water
swellable absorbent with suitable overlap) covering the whole surface area of
the insulation screen. The barrier shall restrict longitudinal water penetration
under the metallic sheath. The nominal thickness of water swellable tape shall
be 0.3 mm. The semi conducting compound and the semi conducting tape
shall be compatible with the insulating material and suitable for the operating
temperature of the cable.

iii. Metallic Part - Radial Water Barrier: -


The metallic screen of Lead Alloy E sheath/ Corrugated Aluminium sheath
OR Poly Aluminium Laminate sheath (as specified in BoQ) shall be provided
over the non-metallic part of the insulation screening. The details of various
types of metallic screen (sheath) are as under: -

A. Lead Alloy E Sheath: The lead alloy sheath shall have composition as per
IS: 692. The lead alloy 'E' Sheath shall be extruded using a continuous
screw press and shall be free from all extrusion defects. The nominal
thickness of lead alloy E sheath shall be as per IEC-60502-2/ IS: 7098 (Part-
3). The bedding over the metallic sheath shall be of semiconducting tape(s).
Copper wire screen of annealed plain copper wires with gap shall be helically
MPPTCL/TECH-LINE/PROC/SEP23 Page 149
applied over/below the Radial Water Barrier lead alloy metallic sheath. The
diameter of copper wire in the screen shall not be less than 0.8 mm. The
perpendicular gap between two adjacent wires shall not be more than 4.0
mm. An open helix copper tape binder shall be applied over the copper
wire screen. The nominal thickness of the tape shall not be less than 0.1 mm.
The minimum thickness shall not fall below the nominal value by more than
10%. Suitable non-metallic binder tape may also be applied over the copper
screen to prevent the penetration of the outer sheath into the screen. Metallic
screen, together with copper screen shall be able to withstand short
circuit current of 40 kA for duration of one second.
B. Corrugated Aluminium Sheath: (Not Applicable) The metallic screen
shall comprise of a corrugated seam welded/ seamless (extruded) aluminium
sheath of suitable radial thickness for 800 sq.mm. cable. A suitable anti-
corrosive treatment should be given to outer surface of Aluminium sheath. It
should be of adequate thickness, consistent quality and free from all defects.
Aluminium sheath shall be suitable to carry 40 kA earth fault current for
one second. Detailed calculation with support documents shall be submitted
with technical bid. For seam welded sheath, the welding shall be of high
quality and shall have strength not less than that of Aluminium with no
porosity.
C. Poly Aluminium Laminate Sheath (Tape): (Not Applicable)
The metallic screen shall comprise of annealed plain concentric copper wires
helically applied with gap followed by open helix of copper tape binder. The
copper screen along with aluminium armour shall be able to withstand
short circuit current of 40 kA for duration of one second. To prevent entry /
propagation of longitudinal ingress of moisture, semiconducting non-woven
water swellable tapes shall be provided above and below the metallic screen.
The nominal thickness of water swellable tape shall be 0.3 mm. The semi
conducting tape shall be compatible with the insulating material and suitable
for the operating temperature of the cable. Poly aluminium laminate tape
shall be applied longitudinally over water swellable tape (provided over the
metallic screen), with suitable overlap for water tightness. Inner sheath and
Armouring shall also be provided as under: -

(a) Inner Sheath: The sheath shall be suitable to withstand the site conditions
and the desired temperature. It should be of adequate thickness, having
consistent quality and free from all defects. The sheath shall be extruded and
of black Thermoplastic H.D.P.E. (Poly-ethylene).

(b) Armour: Single H.D. Aluminium wire armouring shall be provided. The
dimension of H.D. Aluminium wire armouring shall be as per latest
IS:3975/1988. The armour together with copper screen shall have fault
current capacity of 40 kA for 1 sec.

6.5 OUTER SHEATH: Extruded HDPE type ST7 outer sheath conforming to IEC:
502/1983, with suitable additives to prevent attack by rodents and termites, shall be
provided. The outer sheath shall be coated with graphite throughout the length of
cable.
MPPTCL/TECH-LINE/PROC/SEP23 Page 150
6.6 Each cable length shall be provided with a pulling socket/eye which shall be
fitted to pulling end on conductor. The pulling socket/eye shall be able to take
pulling tension as per recommended for cable conductor size along with
reasonable factor of safety. The pulling socket/eye shall be fitted in such a fashion
to avoid moisture/water ingress during storage/transit.

7.0 MANUFACTURING PROCESS:

7.1 XLPE cable should be processed in modern triple head extrusion manufacturing
line. The extrusion and curing shall be done to ensure circularity and concentricity
of the extruded layers around the conductor meeting the relevant IEC standards
and successful valid type tests.

7.2 The conductor screen, insulation and insulation screen shall be extruded in
one simultaneous triple extrusion process (Clause 14.2.1 of IS: 7098-3) through
common triple crosshead. The extruders and triple crosshead shall be designed to
prevent stagnation of materials to eliminate hot spots and ensure smoothness of
the conductor screen and screen surfaces. Insulation thickness should be
controlled on-line using X- ray monitoring system.

7.3 The cross linking, curing and cooling shall be carried out in one operation and shall
be a dry curing process under high pressure to eliminate the formation of voids in
the insulation and contaminations in the dielectric.

7.4 Process conditions such as curing and cooling temperature, production speed
etc. shall be closely monitored during manufacture to ensure a good degree of
cross- linking through the whole insulation.

7.5 The manufacturing process shall eliminate irregularities like protrusions, voids and
contamination etc. to ensure the long-term reliability of the cable.

7.6 Loading of the extruder in the manufacturing plant shall be performed in an entirely
closed and dust proof enclosure. The entire line of processing should be controlled
from a computerized central control console. Contamination shall be avoided by
use of a fully enclosed material handling system. To avoid contamination XLPE
Granules must be transported using gravitational material feeding system.

8.0 CURRENT RATING: The cable will have current ratings and derating factors as per
relevant IEC.

8.1 The one-second short circuit current rating values each for conductor & metallic
screen shall be furnished with detailed calculations along with support documents
and shall be subject to the purchaser's approval.

8.2 The current ratings shall be based on maximum conductor temperature of 90


deg. C with ambient site condition specified for continuous operation at the
rated current.

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9.0 OPERATION:

9.1 Cables shall be capable of satisfactory operation under a power supply system
frequency variation of ±5% voltage variation of ±10 % and combined frequency
voltage variation shall be +10 % & - 15%.

9.2 Cable shall be suitable for


a. Laying directly on ground /metalled road.
b. Installing outdoor in free air in vertical position.
c. Drawing into underground ducts/trenches below metalled road/nalas.
d. Laying directly in open trench.

9.3 Cable shall have heat and moisture resistant properties. These shall be of type
and design with proven record on transmission network service.

10.0 LENGTHS: The cable shall be supplied in standard drum lengths as below:

Size of cable Standard Drum length


132 kV single core , 800 sq.mm. 500 meters ±5% tolerance and ±2 % overall
tolerance in total quantity of cable.

11.0 INDENTIFICATION MARKING: The following particulars shall be marked on cable


outer sheath:

i. Manufacturer's name/ trade name


ii. Voltage grade (132 kV)
iii. Cable size (no. of core x conductor cross section)
iv. Month and Year of manufacture.
v. Purchaser's name i.e. MPPTCL

11.1 The spacing between one set of marking and the beginning of the next on the
legend shall not exceed 150 mm.

11.2 Besides above, progressive sequential marking of length shall also be provided at
every one meter, which shall be clear and legible. Sequential length marking by
embossing in same colour as that of outer sheath is permitted.

12.0 TESTS:

12.1 GENERAL

12.1.1 This schedule gives tests to be carried out on 132 kV, single core XLPE type
cables and associated accessories being supplied under these specifications.
The schedule of tests to be followed shall be generally as per IS-7098 (Part-3) /
IEC 60840.

12.1.2 The facilities available f o r site tests shall be clearly and implicitly brought out
in the tender. The site tests shall be carried out during and after
laying/installation b y the supplier.

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12.2 TYPE TESTS:
12.2.1 The cable & accessories offered shall be fully type tested as per the relevant
standards i.e. IS-7098 (Part-3)/ IEC-60840. In case the cable & accessories of
the type and design offered has already been type tested in a Govt.
approved/ NABL laboratory, the Bidder shall furnish one set of type test reports
along with the offer. Type test reports shall not be older than TEN years and
shall be valid up to the expiry of the validity of the offer. The purchaser reserves
the right to demand repetition of some or all the type tests in the presence of
purchaser's representative. In case of non-submission of some of the type test
reports, the bidder shall have to undertake to submit the same without
affecting delivery schedule at no extra cost to MPPTCL.
Type test reports for cable of construction other than specified in tender will be
considered for evaluation purpose, but in the event of order, the bidder shall
have to carry out all type tests on cable of construction as per specification at
Govt. approved / NABL laboratory without affecting delivery schedule and at no
extra cost to MPPTCL, for which necessary confirmation shall be submitted with
technical bid.

12.2.2 The electrical tests shall be carried out on cable system (cable & accessories)
in accordance with clause 12 of IEC 60840 and in accordance with the
sequence prescribed in clause 12.3 of IEC 60840/IS-7098 (Part-3) with relevant
clauses before the dispatch of cable from contractor’s works in any Govt.
approved/ NABL laboratory.

12.3 ROUTINE TESTS:


The manufactured cable shall be subjected to tests as prescribed in the
different IS/ IECs for routine, acceptance and type test and any other test
mandatory under relevant IS/IEC.

The following routine tests shall be carried out on each manufactured length: -
a) Conductor resistance test
b) Voltage test
c) DC voltage test on outer sheath
d) Partial discharge test

12.4 ACCEPTANCE TESTS:

The following tests shall be carried out on samples taken to represent a batch: -

a) Measurement of electrical resistance of conductor and metal screen


b) Measurement of thickness of insulation and oversheath
c) Measurement of thickness of metal sheath
d) Hot set test for insulation
e) Void and contaminants test
f) Measurement of diameters
g) Partial discharge test
h) High voltage test
i) Measurement of capacitance & tan delta
MPPTCL/TECH-LINE/PROC/SEP23 Page 153
Note: High voltage test shall be conducted as per IEC 60840 on a fresh
sample, with magnitude of test voltage 190kV. Time duration shall be 30
minutes.
12.5 FREQUENCY OF TESTS:
The above acceptance tests shall be made on one length from each
manufacturing series of the same type and size of cable, but shall be limited to
not more than 10% of the number of lengths in any contract, rounded to upper
unity.
12.6 NON-ELECTRICAL TYPE TESTS
a) All non-electrical type tests shall be performed in accordance with the
provisions laid in clause 12.5 of IEC 60840, IS-7098 (Part-3) with relevant
clauses.
b) Insulation resistance after laying each cable length shall withstand a
voltage of 10kV DC between each reinforcement and external
conducting surface and for one minute as per clause no. 16 of IEC -
60840. In addition, the serving insulation resistance shall be measured
and checked with the values obtained in the routine factory test.
c) On completion of the cable laying and jointing work the complete
installation shall be tested as per clause 16 of IEC 60840. The testing kit
required for the tests shall be arranged by the tenderer.
12.7 TESTS AT SITE AFTER INSTALLATION:
Pre-commissioning tests on site, which shall be performed by the successful
bidder, shall include the following: -

a) DC voltage test on outer sheath at 10 kV for one minute between metallic


sheath/screen and external conducting surface.
b) Conductor resistance of each complete circuit.
c) AC system voltage (U0) for 24 Hrs. to keep the cable on idle charge with
minimum protection setting to protect the cable in 24 Hrs.
13.0 INSPECTION:
The inspection may be carried out by the purchaser at any stage of manufacture.
The successful Bidder shall grant free access to the purchaser's representative at
any reasonable time when the work is in progress. Inspection and acceptance of
any equipment/items under this specification by the Purchaser shall not relieve the
supplier, of his obligation of furnishing equipment in accordance with the
specification and shall not prevent subsequent rejection, if the equipment/items is
found to be defective. The supplier shall keep the purchaser informed in advance,
about the manufacturing progamme, so that arrangement can be made for
inspection, without delay. The purchaser reserves the right to insist for witnessing
the acceptance/routine testing of the bought out items.

14.0 DOCUMENTATION:

14.1 LIST OF DRAWINGS AND DOCUMENTS:

The Bidder shall furnish two sets of following documents along with the offer. The
offer without documents shall be considered incomplete.
MPPTCL/TECH-LINE/PROC/SEP23 Page 154
a) The sectional view drawing showing general constructional features of power
cable with details of materials / conductor / conductor screen / XLPE insulation
/ water swellable tape/ insulation screen/ outer HDPE sheath etc. with offered
dimensions.
b) Literature for offered items.
c) Type test reports for the offered items in case the items have already been
type tested for specified type of cable.

15.0 PACKING AND FORWARDING:

15.1 The cable shall be packed returnable steel drums suitable for vertical/horizontal
transport as the case may be, and suitable to withstand handling during transport
and outdoor storage during transit. The supplier shall be responsible for any
damage to the items during transit, due to improper and inadequate packing.
Wherever necessary, proper arrangement for lifting shall be provided. Any item
found short shall be replenished by supplier without any extra cost.

15.2 Each consignment shall be accompanied by a detailed packing list containing


the following information:

a) Name of the consignee


b) Details of consignment
c) Destination
d) Total weight of consignment
e) Handling and unpacking instructions
f) Bill of material indicating contents of package

16.0 SEALING AND DRUMMING

16.1 Immediately after the works tests, both ends of every length of cable shall be
sealed by means of heat shrinkable end caps.

16.2 Cables shall be wound on returnable metallic drums. All the drums shall be
arranged to take a round spindle and be legged with strong closely fitting wooden
battens so as to prevent damage to the cable. Each drum shall bear an
identification number permanently stenciled or branded on the outside of the
flange.

16.3 Cable reels shall be of rugged construction, with a drum diameter of ample
dimensions to accommodate the single conductor. Manufacturer shall be
responsible for any damage to the cables during transit. Changes in the shape of
the cable during transit shall not result in deformation in metallic drum. A detail of
Steel Drum/reel is to be furnished by bidder in their bid.

16.4 The cable drum/ reel shall carry the following information clearly marked on one
flange of the drum: -

a) Manufacturer's name, Brand or trade mark.


b) Conductor of cable.
MPPTCL/TECH-LINE/PROC/SEP23 Page 155
c) Type of cable and voltage grade.
d) Size of cable.
e) Length of cable on the drum.
f) Direction of rotation of drum (by means of an arrow).
g) Net weight
h) Gross weight.
i) Year of manufacture.
j) Confirming to IEC/ IS No.
k) Purchase order details.
1) Name of owner.
m) Name of consignee.

MPPTCL/TECH-LINE/PROC/SEP23 Page 156


Annexure – I (of Section-I)

Principal Parameters of XLPE Cable

S.
Particulars Technical Details
No.
Single core, aluminium conductor
1 Type of Cable
XLPE cable
IEC 60840/ IS 7098 (part-3) amended
2 Applicable Standard
up to date
3 System voltage & frequency 132 ± 10% kV, 50 Hz ± 3%
4 Highest System Voltage 145 kV
5 Suitable for earthed system Yes
6 CONDUCTOR
i) Material as per IEC 60228/IS:8130 Stranded hard drawn aluminium
ii) Nominal cross sectional area 800 sq.mm
Construction of conductor/ flexibility
iii) Class-2 IEC 228/ IS:8130
class
iv) Shape and formation of conductor Stranded very well compacted circular
7 CONDUCTOR SCREENING
Extruded, semi conducting compound
i) Material & type
layer
ii) Grade As per IEC/IS
iii) Thickness 1.0 mm
8 INSULATION
Special super clean grade cross linked
i) Material
polyethylene (XLPE)
ii) Nominal thickness of insulation As per IEC-60840/7098 (Part-3)
9 INSULATION SCREENING
A Non-metallic part (extruded)
Extruded semi conducting compound
i) Material
layer
ii) Grade As per IEC/IS:7098 (Part-3)
iii) Min. Thickness 0.8 mm
Non-metallic part (taped) longitudinal
B
water barrier over insulation screen
Synthetic, non-woven, semi-
i) Material
conducting water swellable tape
ii) Min. thickness(mm) As per standard
C METALLIC SCREEN
a) Lead Alloy Sheathed Cable
Lead Alloy E Sheath conforming to IS
i) Material
692/IEC 60502/ IS 7098 (part-3)
Annealed plain copper wires applied
ii) Metallic Screen helically with gap followed by open
helix of copper tape binder

MPPTCL/TECH-LINE/PROC/SEP23 Page 157


S.
Particulars Technical Details
No.
Short Circuit Current Withstand of
iii) 40 kA for one second
metallic sheath and metallic screen
b) Corrugated Aluminium Sheathed
Cable
Corrugated seam welded/ seamless
i)
Material (extruded) aluminium sheath
Short Circuit Current Withstand of
ii) 40 kA for one second
metallic sheath
Cable with Poly Aluminium
c)
Laminate tape
Poly Aluminium Laminate Tape of
i) Material minimum thickness conforming to IS-
60502-2/ IS: 7098 (Part 3)
Annealed plain copper wires applied
helically with gap followed by open
ii) Metallic Screen
helix of copper tape binder & poly
aluminium laminate tape
Short Circuit Current Withstand of
iii) 40 kA for one second
metallic screen and Armour
iv) Inner Sheath
(a) Material Extruded black thermoplastic HDPE
Conforming to IS-60502-2/ IS: 7098
(b) Min. thickness of inner sheath
(Part 3)
v) Armouring
Single hard drawn aluminium wire
(a) Material
conforming to IS-3975/1988
Fault Current Capacity together with
(b) 40 kA for 1 sec.
metallic screen
10 OUTER SHEATH
Extruded Layer of Black PE type ST-7
i) Material
as per IS:7098 (Part-3)
ii) Min. thickness of outer sheath As per standard
11 Conducting layer over outer sheath Graphite coating
Maximum D.C. Resistance of
12 As per standard
conductor at 90 deg C in ohm/km
Maximum allowable temperature for
13
cable and accessories
At rated full load and at site
i) 90°C
conditions
The conductor temperature after a
short circuit for one second shall not
ii) 250°C
exceed (with conductor temperature
at start of short circuit as 90°C)
Symmetrical Short circuit rating for 40 kA for one second (for lead Alloy
14
one second duration for copper Sheath and Copper Screen combined)
MPPTCL/TECH-LINE/PROC/SEP23 Page 158
S.
Particulars Technical Details
No.
screen and tape.
15 Standard Drum Length 500 mtr
16 Expected cable life 35 years

MPPTCL/TECH-LINE/PROC/SEP23 Page 159


SECTION- II

132 kV CABLE TERMINATION

&

JOINTING KITS FOR


1 x 800 SQ.MM XLPE CABLE

MPPTCL/TECH-LINE/PROC/SEP23 Page 160


SECTION- II

TECHNICAL SPECIFICATION FOR


132 kV CABLE TERMINATION & JOINTING KITS
FOR 1 x 800 sq.mm XLPE CABLE

1.0 SCOPE

1.1 The scope includes supply, testing at manufacturer’s works before dispatch
and delivery of internationally reputed make of following types of cable sealing
ends, (end terminals), and straight through joints conforming to relevant IEC,
unless otherwise stipulated in the Section-II and all other accessories as well as
consumables etc. suitable for XLPE cable (Section-I). These kits and accessories
shall be an integral part of 132 kV cable system.

i. 132 kV rated outdoor cable sealing ends conforming to IEC 60840 for terminating
the single circuit highest voltage 145 kV XLPE cables along with all the
necessary supporting structure, fittings & mountings.

ii. 132 kV rated outdoor straight through joints conforming to IEC 60840 for jointing
of highest voltage 145 kV XLPE buried underground cables.

1.2 Single/ Three ph as e Ea rth L i n k bo x es w i t h a l l associated ac c es s orie s


(for the connection of the cable sheath of 132 kV rated XLPE cable) suitable for
cross bonding arrangement of the complete cabling system.

1.3 All the testing devices and instruments etc. including HV Generator required for
final acceptance testing and commissioning shall be the responsibility of the
contractor and no separate cost/ rental is payable. The testing devices etc. shall be
taken back by the contractor after successful testing & commissioning. List of
special tools and equipment required for installation, commissioning and testing of
the cable system by contractor (on returnable basis) shall be enclosed with the bid.

1.4 It is not the intent to specify completely herein all details of design and
construction of the equipment/ system and accessories required. However, the
cable system and its installation shall be complete with all accessories, conform in
all respects to high standards of engineering, design and workmanship and be
capable of performing the continuous commercial operation up to guarantee in a
manner acceptable to MPPTCL.

2.0 STANDARDS
Unless otherwise stated hereafter, rating, characteristics, test and procedures etc.
concerning the 132 kV XLPE cable accessories shall preferably be as per IEC
standards wherever existing and shall be in compliance with the latest editions or
revisions thereof. Although a few preferred IEC standards are mentioned below
but the list is not exhaustive and may be improved.

IEC-60840 Tests for power cables with extruded insulation for rated
voltage up to 132 kV.

MPPTCL/TECH-LINE/PROC/SEP23 Page 161


IEC : IS 60859 Cable connection for Gas insulated metal enclosed
switchgear for rated voltages of 72.5 kV and above.
IEC: 62271-203 Gas-insulated metal- enclosed switchgear for rated
voltages of 72.5 kV and above.
IEC: 60228 Conductor for insulated cable
IEC: 60229 Tests on cable over sheaths
IEC: 60230 Impulse tests on cables and their accessories
IEC: 60270 Partial discharge measurements
IEC: 60287 Calculation of continuous current carrying capacity
IEC: 60502 Power Cables with extruded insulation and their
accessories.
BIS: 7098 (Part- XLPE cable specification-for working voltages from 66
3) kV up to and including 220 kV.
IEEE 48-1990 IEEE Standard Test, Procedure & requirement for high
voltage alternating current cable terminations

3.0 SYSTEM CONFIGURATION

3.1 The 132 kV systems will be solidly grounded. Cables will be protected from
over-voltages caused by lightning strikes or switching surges by means of 120 kV
Class 3 station type lightning arresters located at terminal points.

4.0 GENERAL DETAILS OF CABLE KITS

4.1 All the cable sealing ends/ termination kits and straight through joints rated for
132 kV shall be of pre-molded type from one of internationally reputed
manufacturers of proven design which has already been extensively used and fully
type tested.

4.2 The offered kits shall be easy in handling, simple to install without much skill with
minimum tools at site.

4.3 All cable sealing ends and straight through joints shall be suitable for
connecting single core, Aluminium Conductor XLPE cables for a maximum
continuous voltage of 145 kV and core cross section of 800 sq. mm. as per details
in Section-I.

4.4 The kits shall be suitable for storage without deterioration at a temperature up to 55°
C.

4.5 The offered XLPE cable termination and straight through jointing kits for 132 kV
earthed system shall meet the technical particulars indicated in Annexure–I of
Section-II.

4.6 Field tests of sealing end terminals shall be made in conjunction with the 132 kV
cables after installation of the cables and terminals.

5.0 TYPE OF CABLE KITS

MPPTCL/TECH-LINE/PROC/SEP23 Page 162


5.1 OUTDOOR TYPE SEALING END

5.1.1 The cable sealing end conforming to IEC-60840 of termination for maximum
continuous voltage of 145 kV cables shall be supplied by the cable manufacturer.
The contractor shall be responsible for correct termination of each cable to sealing
ends, installation of the cable sealing end and providing of terminal connectors for
connecting to terminal conductor. The requisite interconnection between line end &
sealing end is required to be designed (as per safety and statutory provision
aspects) and executed (after approval of MPPTCL) by the successful bidder.

5.1.2 The silicone rubber /composite bushing termination of rated capacity, suitable for
outdoor installation in moderately polluted atmosphere shall be used. It should be
resistant to UV exposure. The termination stress control shall be means of stress
cone.

5.1.3 The stress cone made of silicone rubber shall inhibit possible mechanical stress and
deformation of the cable insulation surface during operation and also shall be
capable of accommodating minor radial and longitudinal movement without
determent to the dielectric stress in the insulation shield.

5.2 STRAIGHT THROUGH JOINTS


The straight through joints for XLPE cable (Section I), conforming to IEC-60840
shall be suitable for underground buried installation with incorporated back fill
and chances of flooding by water. The straight through joints should be absolutely
impervious to the entry of water. The manufacturer shall use the proven technology
and design to prevent entry of water or any other liquid inside the straight through
joints and cables.

5.3 MAKE OF CABLE KITS


All cable sealing ends and straight through joints shall be of reputed make. New
technology is to be used/ adopted while manufacturing and latest technology kits
are essential requirement. The successful valid type test reports (not older than 10
years from the bid opening date) for cable sealing ends and straight through joints
are to be submitted by the bidder at the time of bid submission.

6.0 ELECTRICAL CHARACTERISTICS OF CABLE KITS

6.1 The cable termination and straight through jointing kits and accessories shall be
capable of carrying the specified rated current continuously without exceeding the
specified temperature limits.

6.2 The cable termination and straight through jointing kits and accessories to be
supplied against this specification shall be rated for 40 kA for 1 second.

6.3 The sheath voltage under full load conditions shall not exceed 65 volts
specified in relevant standards for safety of personnel as well as satisfactory
working of cable. The sheath shall be solidly grounded at the terminations.

6.4 The fault level withstand capacity of end termination and straight through
jointing kits should strictly match with the parameters of cables for which the kits
MPPTCL/TECH-LINE/PROC/SEP23 Page 163
are intended to be used.

6.5 After jointing by straight through joints and connecting the cable with terminal
ends, the cable sheath/ screen bonding system shall provide a continuous current
path through the cable sheath/ screen and shall be bonded and earthed at both
ends.

6.6 The XLPE cable termination and straight through jointing kits shall be suitable for
use where combined ambient temperature and temperature rise due to load result
in conductor temperature not exceeding 90 deg C under normal operation and 250
deg C under short circuit conditions.

6.7 132 kV XLPE cable termination and straight through jointing kits shall be designed
to withstand the mechanical, electrical and thermal stresses under the steady state
and transient/ fault conditions and shall be suitable for proposed method of
installation.

7.0 DESIGN & COMPONENT FEATURES OF CABLE KITS

The following considerations shall be taken into account in the design of the
product, material properties & components of cable kits.

7.1. The most important part of cable accessories is the stress grading device, the
stress cone. The pre-molded cone shall be made of insulating and conducting
silicone rubber molded together in the shape of geometric stress control unit. The
synthetic insulating compound shall be used together with stress cone to improve
the electrical properties inside the termination. The compound should swell the
insulation of the cone and the cable to some extent so as to improve the electrical
strength along with interface.

7.2 For XLPE cable, the critical part of the operation is making an electrical
connection between the stress relief device and insulation screen. If any air pocket
is created, discharge and breakdown can occur. As such, connection method and
material should be such that no risk of cable damage arises and that the jointer can
check the result of his work at every stage. The installation instructions should be
easy to follow and should be well illustrated.

7.3 The design shall be such that when the cone is supplied, the diameter of hole in the
cone shall be smaller than the diameter over cable insulation. After the cone is
pushed on, the elasticity of silicone rubber should guarantee an active pressure on
the cable insulation to ensure that no voids appear between the cone and the cable
even after years of load cycling.

7.4 The straight through joints shall be of pre-molded construction. This design shall
comprise a factory tested synthetic rubber joint, with all stress management
elements provided during the molding process in the factory. The dielectric design
of the straight through joints shall be optimized. The electric stress distribution
along the interface between the insulator and the cable shall take into account the
dimensions of the joint and the dielectric permittivity of the cable insulation. The
material of insulator shall have good thermo-mechanical behavior.
MPPTCL/TECH-LINE/PROC/SEP23 Page 164
7.5 The materials used in the assembly of the straight through joints shall be
compatible with the material of the insulator and the cable insulation. The conductor
shall be connected by means of an approved arrangement. The tensile strength of
the connector shall meet the requirements of the aluminium conductor.

7.6 Every single stress cone & stress grading device shall be tested electrically prior to
delivery in presence of Purchaser’s representative. Each stress cone shall be
marked with an individual number and a certificate containing detailed specification
of tests shall be included with every delivery.

7.7 The different accessories shall be type tested according to IEC- 60840 and
IEEE standards which include tests for impulse, AC, load cycling and partial
discharge. Before delivery, every stress cone shall be installed on cable and
carefully checked to establish that it is PF free in presence of owner's
representative(s).

7.8 Details of proper stress control, stress grading and non-tracking arrangement in
the terminations & joints shall be elaborated in the offer. Detailed sectional view of
assemblies shall be submitted along with the offer. The application of stress control
system shall be safe, fool-proof & independent of cable jointers’ skills. The
stress control method should withstand expansion & contraction of cable during
load cycling.

7.9 The jointing kits offered shall be so designed so as to prevent discharge/ leakage at
the cut back, nicks and scratches on XLPE insulations. Full details of method of
discharge prevention shall be indicated by the bidder.

7.10 The cable end termination and straight through joints shall be designed in such a
way so as to give track resistant, erosion & weather resistant protection to the cable
insulation. The outdoor end termination & straight through joints shall be
totally sealed against ingress of moisture of environment.

7.11 All end outdoor terminations shall be provided with rain sheds/ creepage
petticoats. The weather sheds shall be non-tracking, weather resistant, hydrophobic
and have smooth surface to collect any water/ dirt etc. The design of rain skirts shall
avoid any skirt to skirt conducting path under heavy rain conditions.

7.12 For XLPE cables, the lugs should withstand thermal short circuit of 250 degrees
centigrade. For XLPE cables, the ferrule should be suitable for compacted
conductor and should withstand thermal short circuit of 250 degrees centigrade.

7.13 Design features may be highlighted in the bid and the moldings of rubber
components should be aimed to achieve a smooth finish on interior and exterior of
the components.

7.14 The kits shall be provided with protection against rodent & termite attack.

7.15 The kits offered shall provide for total environment sealing of the cable crutch and
at the lugs end, details of which shall be offered along with the offer. Provision for
MPPTCL/TECH-LINE/PROC/SEP23 Page 165
effective screening over each core shall be made and bidder shall categorically
confirm this aspect in their offer.

7.16 The materials & components of kits not specifically stated in the specification, but
which are essential for satisfactory operation of cable shall be deemed to be
included in scope of supply without any extra cost.

7.17 The earthing arrangement shall form part of the termination joints and shall be
protected from erosion either by suitable tape or tube.

7.18 The word “ MPPTCL” along with t r a d e nam e o f the m a n u f a c t u r e r , m o n t h /


y e a r o f manufacture, size etc. shall be embossed/ engraved for the purpose of
identification.

7.19 Adequate provision for eliminating the chances of entrapment of air at steps formed
by semiconductor screen shall be made.

7.20 The terminations/ joints shall be supplied in kit form. All insulation and sealing
materials, consumable items, conductor fittings, earthing arrangements & lugs etc.
should be provided. Requisite No. and size of lugs & ferrules depending upon the
type of the cable shall be provided in the kit. Lugs & Ferrules shall be of crimping
type and shall conform to the relevant standards applicable to XLPE cables.

8.0 LINK BOX FOR EARTHING & EARTHING CABLE WITH PVC INSULATION

8.1 Bidder shall carry out the earthing of sheath/ screen in the cross bonding
configuration. The successful bidder shall submit the complete sheath voltage
calculation along with identification of major/ minor sections for cross bonding. The
3 Phase link boxes with SVLs shall be installed at cross bonding points and three/
single Phase link boxes with direct grounding at cable termination ends. The
bonding lead/ grounding cable of suitable sizes (as per sufficiency/ adequacy
calculation submitted by successful bidder) shall be used for connecting cable
sheath to earth.

9.0 SUPPORTING STRUCTURE & ANGLE BRACKET SUPPORTS FOR CABLE

9.1 Any support structures and cable clamps required to support the cables between
the trays and the sealing end supports will be supplied and installed by the bidder.

9.2 Fabricated structure of suitable height, to be approved by Purchaser, shall be


provided and installed by manufacturer of cable for supporting the outdoor cable
sealing ends. The height of the structure shall be suitable for the terminal
connection to receive the Purchaser's ACSR Zebra conductor maintaining phase
to phase and phase to earth and ground clearances. Exact height shall be
intimated/ confirmed to the successful bidder at the time of approval of drawings.
The structures shall be of galvanized steel structural sections. Anchor bolts,
washers etc. will be supplied and installed by successful bidder.

9.3 The supporting structure shall be suitable to withstand the wind pressure,
seismic forces and the short circuit forces; etc., and the design shall have an
MPPTCL/TECH-LINE/PROC/SEP23 Page 166
adequate factor of safety as specified in I.E. rules 1956.

9.4 The bidder shall furnish the design and fabrication drawings of these structures
& foundation anchor bolts and design calculations etc.

9.5 The bidder shall quote for unit prices for support structures for each single core
cable to suit the end terminations supplied by them.

10.0 CABLE END TERMINALS (OUT DOOR TYPE) CONNECTORS

10.1 Clamps shall be pressure die cast aluminium (LM-6) or Nylon-6 or fibre glass and
shall include neoprene rubber lining wherever the cable touches the clamps and
below the clamp base and necessary fixing nonmagnetic nuts, bolts, washer etc. The
thickness of neoprene rubber shall not be less than 10 mm inside the inner surface of
the trefoil clamp and minimum 20 mm thick below the base of trefoil clamp. The
neoprene shall be tested as per IS 11149 – 1984. Trefoil clamps shall be provided at
every five meter of cable run for maintaining perfect trefoil. The contractor shall
submit drawings of trefoil clamps and arrangements for employer’s approval.
10.2 The terminal connector/clamps shall be suitable for connection to Zebra ACSR
conductor.
10.3 The type and size of the conductor will be confirmed to the successful bidder.
10.4 The connector/clamp shall be designed to overcome:
i) Galvanic Corrosion.
ii) Thermal Cycling.
10.5 The current carrying capacity of the connector/ clamps shall be greater than the
maximum capacity of the power cable. The terminal clamp shall be free from burrs,
voids, and blow holes.

10.5 The terminals clamps shall have passed the tests for short circuit current capability
and temperature rise.

11.0 TESTING INSTRUMENTS & DEVICES


11.1 The contractor shall arrange for all testing devices, instruments etc. required during
assembly, erection, testing and commissioning of 132 kV XLPE cable.

11.2 Arrangement of all the testing devices and instruments etc. including HV Generator
required for final acceptance testing and commissioning shall be the responsibility
of the contractor and no separate cost/ rental is payable. The testing devices etc.
shall be taken back by the contractor after successful testing & commissioning.

12.0 EARTHING

12.1 Bidder shall carry out the earthing of sheath/screen at cross bonding points as well
as at both termination ends of 132 kV cable using insulation sheath bonding
(earthing) cable of required size through Link box with/ without surge voltage limiter
at cross bonding points. The Link box should preferably be of stainless steel. It
should be provided with IP 65 or better weather protection.

12.2 Earthing shall be as per relevant standards and the details of the earthing
arrangement offered for the cable accessories shall be submitted along with the
MPPTCL/TECH-LINE/PROC/SEP23 Page 167
offer.

12.3 The sheath/screen shall bound in the earth station through disconnecting type link
boxes.

12.4 Screen continuity by using tinned copper mesh and earth continuity by tinned
copper braids of appropriate size shall be provided for transfer of screen earth in
straight through joints.
12.5 The earth conductor shall be of GI flat and shall be protected against mechanical
damage and corrosion. The connection of the earth continuity conductors to earth
bus and earth electrodes shall be strong, secure and sound and shall be easily
accessible.

13.0 TESTS
13.1 The testing of cable termination for outdoor type sealing end and straight
through jointing kits for XLPE Cable shall be as per IEC: 60840. All the
acceptance tests and routine tests shall be carried out on the cable kits (referred as
accessories in IEC) as per Clause 12 (Tests), Section-I.

13.2 The acceptance tests shall be carried out in presence of Purchaser's


representative as per relevant standard IEC: 60840 at bidder's cost and the
sampling plan shall be 1 percent subject to minimum of one number.

13.3 The contractor shall make available to the MPPTCL Engineer a complete set of
detailed data required for inspection and tests.

13.4 Details of Tests: The bidder must specify the details of the type, acceptance and
routine tests to be conducted on offered cable kits at their works along with the
standards applicable in their offer.

14.0 QUALITY ASSURANCE

14.1 Raw materials used for manufacture of cable shall be of highest quality and
material received by manufacturer should be checked/ tested to ensure that it
meets manufacturer's material specification. The materials shall be clean and
packed in moisture and dust proof packing.

14.2 As t h e q u a l i t y control o f EHV X L P E c a b l e s t e r m i n a t i o n & jointing kits


a n d accessories while manufacturing is very critical, expert supervision is required
for raw material testing, in process checks and also for final testing. A specially
trained quality assurance team should be in place for maintenance of the quality at
an optimum level at the plant. Complete details of manufacturing process along
with details of automatic manufacturing plant, list of officers /staff to supervise the
manufacturing and other details desired shall be furnished by bidder in the bid.

14.3 Quality assurance plan indicating test /checks of raw material, process
of manufacturer and final inspection with customer hold points shall be submitted to
the Purchaser for approval.

MPPTCL/TECH-LINE/PROC/SEP23 Page 168


15.0 TEST CERTIFICATES

The latest complete type test certificates' (conducted during last 10 years from date
of tender along with attested drawing) in duplicate for all types of terminations
&joints of offered design/material conducted at International repute test house
confirming to IEC: 60840 must be enclosed with the offer. The offer without type
tests results shall be ignored.

16.0 INSPECTION & TRAINING AT MANUFACTURER'S WORKS

16.1 The 132 kV XLPE cable termination for outdoor type sealing end and straight
through jointing kits and other accessories should be manufactured and tested
while manufacturing as per approved Quality Assurance plan and foregoing
specification. Supplier shall intimate the programme of manufacturing of the cable
termination & jointing kits and accessories in advance. The inspection during
manufacturing shall be carried out by the MPPTCL engineers at various stages of
manufacture. The successful bidder shall grant free access to the purchaser's
representative at a reasonable time when the work is in progress.

16.2 Inspection and acceptance of any equipment/material under this specification by


the purchaser shall not relieve the supplier of his obligation of furnishing equipment
in accordance with the specification and shall not prevent subsequent rejection if
the equipment/material is found to be defective.

16.3 The supplier shall present the latest Calibration Certificate(s) of testing
instruments / equipment to be used for the testing of the material covered in the
Purchase Order to the authorized inspecting officer/ inspecting agency of the
purchaser. The testing instruments /meters/apparatus etc. should be got calibrated
by the supplier from time to time from independent test laboratory/house having
valid accreditation from NABL for the testing equipment/ original manufacturer
having credibility to NABL/ NPL or equivalent.

16.4 The calibration certificate(s) should not in any case be older than one year at the
time of presenting the same to the inspecting officer/ inspecting agency of the
purchaser. The testing instruments/ equipment should be duly sealed by the
Calibrating Agency and mention thereof shall be indicated in the calibration
certificate(s).

16.5 The Purchaser reserves the right to insist for witnessing the sample/routine tests of
the bought out raw material/items used in manufacturing of cable end terminations/
joints.

17.0 FIRE RESISTANCE

The cable terminations shall be fire resistant. The components of kits shall have
flame retardant property.

18.0 INTERCHANGEABILITY

The components of different number of the kits shall be inter-changeable in case


MPPTCL/TECH-LINE/PROC/SEP23 Page 169
the need arises.

19.0 COMPLETENESS OF CABLE KIT FOR EASY INSTALLATION

19.1 The bidder shall offer complete material and components for each kit so as to
meet one termination complete in all respects. The bidder shall indicate the list of
the material/ components with quantities of each or cable end termination.

19.2 An instruction manual in English, indicating the complete method/ proceedings


adopted for installations of kits, preferably with more diagrams/ pictorial
presentation shall be supplied with each kit. Various items, quantity thereof
against each kit must be indicated in the instruction manual.

19.3 The detailed bill of material and installation instructions shall be provided with
each kit for verification by purchaser's inspecting officer & at MPPTCL's stores/ site.

19.4 All components shall be sealed separately and marked clearly for the purpose
of identification of each component. All components shall be supplied in single
package as a complete kit for one termination joints and shall bear
manufacturer's name & cable size of kit size for which it can be used.

19.5 The Bidder shall also indicate shelf life & ideal life of kit contents.

20.0 GUARANTEE

The cable termination & straight through joints shall be guaranteed for satisfactory
performance as stipulated in Volume –I of Bidding Document. Any defect noticed in
the kit shall be attended by the successful bidder at the earliest on getting the
complaint and if required shall be replaced and installed free of cost, otherwise the
same will be arranged at the successful bidder's risk and cost.

21.0 SPECIAL TOOLS & TACKLES

Complete outfit of tools, special tools, spanners and other lifting devices, instrument
and appliance necessary for the complete assembly, erection at site, dismantling
and maintenance of Power Cable including all accessories (kits) covered by the
contract together with suitable racks for holding them shall be supplied by the
contractor.

22.0 MANUALS AND LITERATURE ON CABLE & CABLE KITS

The following documents should be furnished along with the bid: -

i) Dimensioned cross sectional details of the cable.


ii) Current carrying capacities "with supporting calculated data" of the cable and
de-rated factors.
iii) Instructions Manual on cable laying installation, storage, handling,
maintenance, fault finding, repairs, preventive maintenance, etc.,
iv) Type, acceptance and routine test certificates on the cable as per relevant IS,
IEC or other International standards.
MPPTCL/TECH-LINE/PROC/SEP23 Page 170
v) Dimensioned cross sectional details of the straight through Joint kit along with
bill of materials.
vi) Instruction Manual on the method and formation on cable joining techniques
of the straight through joint.
vii) Type, acceptance and routine test certificate on the straight through joints.
viii) OGA drawing of the cable end termination.
ix) Dimensioned cross sectional details of cable end terminations with bill of
materials.
x) Instructions Manual on the method and formation on cable joining techniques
of the cable end terminations.
xi) Type, acceptance and routine test certificate on the cable end terminations.
xii) OGA drawing of the cable termination structure along with the bill of
materials.
xiii) Literature on special Tools & Plant.
xiv) Literature on sheath bonding, maintenance of link boxes.
xv) Any other relevant literature/ manual.
xvi) Drawing showing additional details if any.

23.0 TRAINING DURING ERECTION

At the time of erection, the successful bidder shall arrange demonstration of use of
kits (ordered by purchaser) for giving the training to three or more personnel of
MPPTCL for getting acquainted with the cable jointing method/ procedure.

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Annexure- I (of Section-II)

PRINCIPAL PARAMETERS OF
XLPE CABLE KITS & ACCESSORIES

A. OUTDOOR CABLE END TERMINATION


1 Nominal System Voltage U 132 kV( rms)
2 Rated/Highest System Voltage Urn 145 kV (rms)
3 Rated frequency & No. of phase 50 Hz±3%, Three (3)
4 Installation Outdoor
5 Type of Kit Pre-molded
6 Suitable for Single Core Copper Conductor XLPE Yes
cable Conforming to IEC 60840 /IS 7098(part-3)
amended upto date and as per Section -1 of the
specification.
7 Rated continuous current Maximum current of the
cable
8 Applicable standard for testing IEC 60840
9 Maximum allowable Pd-level As per IEC
10 Type of Insulator. Silicone/ Composite.
11 Creepage distance 25 mm/kV
12 Colour Brown
13 Maximum allowable temperature for cable and
accessories
i) At rated full load and at site condition 90°C

ii) The conductor temperature after a short circuit for 250°C


one second shall not exceed (with conductor
temperature at start of short circuits as 90°C).
14 Basic impulse insulation level 650 kV
(1.2/50 micro second wave)
15 Power frequency withstand voltage As per Standard
16 Stress relief cone made of Silicone rubber
17 Whether provision made for: Yes
a. Stress relief
b. Track Resistance
c. Sealing
18 Sectional Drawing Showing constructional details To be f urnis hed
along with material and description of each item
19 Expected life of Cable joint and cable: 35 years
20 Guarantee of kit. Five (5) years from date of
commissioning

MPPTCL/TECH-LINE/PROC/SEP23 Page 172


B STRAIGHT THROUGH JOINTS
1 Nominal System Voltage U 132 kV( rms)
2 Rated/Highest System Voltage Urn 145 kV (rms)
3 Rated frequency & No. of phase 50 Hz±3%, Three ( 3)
4 Installation Underground buried
installation
5 Name and address of manufacturer of end Refer clause no 5, Section-2
termination
6 Type of Kit Pre-molded
7 Suitable for Single Core Copper Conductor XLPE Yes
cable Conforming to IEC 60840 /IS 7098 (Part-3)
amended upto date and as per Section – I of the
specification
8 Rated continuous current Maximum current of the
cable
9 Applicable standard for testing IEC 60840
10 Maximum allowable Pd-level As per IEC
11 Guarantee of kit. Five (5) years from date of
commissioning
12 Proven technology and design to prevent entry of Yes
water
13 Sectional Drawing Showing constructional details Yes.
along with each item material, description enclosed.
14 Maximum allowable temperature for cable and
accessories
i) At rated full load and at site condition
ii) The conductor temperature after a short circuit for 90° C
one second shall not exceed (with conductor 250°C
temperature at start of short circuits as 90° C).
15 Basic impulse insulation level (1.2/50 micro second 650 kV
wave)
16 Power frequency withstand voltage As per Standard.
17 Power frequency withstand voltage As per IEC
(a) Dry (KV rms.)
(b) Wet (KV rms.)
18 Stress relief cone made of Silicone rubber
19 Whether provision made for: Yes
a) Stress relief.
b) Track resistance.
c) Sealing.

MPPTCL/TECH-LINE/PROC/SEP23 Page 173


SECTION – III

TECHNICAL SPECIFICATION FOR INSTALLATION OF CABLE CONSISTING OF

Section-III (A): Scope, Route Survey, Works requirement and statutory


clearances

Section-III (B): Laying and Installation of cable

Section-III (C): Details of Jointing and Termination works of Cable

Section-III (D): Civil and Structural Works

Section-III (E): Earthing, Site Testing, commissioning of complete cable


system

MPPTCL/TECH-LINE/PROC/SEP23 Page 174


SECTION-III (A)

SCOPE, ROUTE SURVEY, WORKS REQUIREMENT AND


STATUTORY CLEARANCES

1.0 SCOPE

1.1 The 132 kV XLPE cable (Section-I) is to be laid underground along with jointing
with straight through joints in route run and termination kits (Section II) detailed
hereunder in the Section-III. Earthing of the cable screens/ sheath bonding at
cross bonding points and terminal ends of cable is to be done. After erection of
complete cable system, site testing is to be conducted in presence of owner
and after successful commissioning, complete cable system is to be handed over
along with completion report.

1.2 The scope includes detailed route survey, evaluation of soil thermal resistivity along
the cable route, laying and erection of the XLPE cable in ground, under bitumen
road, under roadside lane, under road crossing under open drains/ closed
drains, sewer line and water pipe line and other crossings etc., in cable trench &
jointing of straight through joints in between cable lengths as well as jointing of end
terminals at ends of cable by expert cable jointer, as per respective approved
drawings etc.

1.3 The scope also includes the inspection of cable on receipt, handling of
cables, providing of cable end sealing caps whenever required, paying out, flaking
and providing/ fixing of joint markers, route indicators, precaution indicators for joint
hole & sump holes & all necessary precautions required in conformation with IS
1255-1983 or its equivalent. Supply & providing of warning tape, cable laying i n
cable trenches with covers up to cable termination.

1.4 The scope of civil works includes digging of road, earth excavation, removal of
excavated earth, design, supply and providing plain and reinforced cement
concrete slabs etc. paying out, flaking, cushioning of cable with sand or sieved
compacted soil, back-filling, removal of excavated earth, dewatering of trenches,
dressing of road surfaces as per requirement of the field conditions, design, supply
and construction of cable jointing bays, design of cable duct/ pipe ducts for
crossing drains, roads, bridges and other obstacles as per site condition and their
construction as per approved drawings.

1.5 The scope of civil works also includes foundations of end terminations support
structures etc., back filling, erection of galvanized steel structure for cable end
terminations, mounting of earthing link boxes, providing of earth continuity cable
and OFC clamping/ fixing in cable trench.

1.6 The scope also includes supply of all requisite materials, labour, tools and plant like
sand, brick, stones, steel, cement/ aggregate for all civil works for works detailed in
above paras including reinforcement, trenches, pipes, fabrication of joint and route
markers, materials like wall brackets, anchor bolts etc. and all other consumables
required for the completion of the work.

MPPTCL/TECH-LINE/PROC/SEP23 Page 175


1.7 Supply of all consumable and sundry materials not included in the specification in
detail but which are necessary to meet the intent of the project.

1.8 The successful bidder shall carry out all activities connected with the laying and
installation of power cables & arrange for security till commissioning and handing
over to MPPTCL and completion of the work, for which the project is intended, to
the full satisfaction of the owner.

1.9 However, alternate installation arrangements offered by the bidders with clear
justification for these alternatives will be considered by the owner, if they prove to
be of a better and economical design.

2.0 CABLE LENGTHS AND ROUTE SURVEY

2.1 Bidder shall conduct detailed survey of cable route and accordingly finalize the
route plan. The final total quantity, the number of drums, the length of cable on
each drum etc. shall be ascertained by the successful bidder after detailed survey
and identifying locations of jointing bays preferably within two months from the date
of letter of award. The route plan and actual lengths of 132 kV XLPE cables
required shall be submitted to Purchaser for approval.

2.2 The route plan of the cable is enclosed with bid documents for reference only to
enable the bidder to assess the work involved in a broad way. The bidder is
advised to visit the site and acquaint themselves with the topography,
infrastructure and requirements etc. The contractor shall be fully responsible for
providing all equipment, materials, T&P and services specified or otherwise which
are required to complete the erection and successful commissioning of 132
kV cable system in all respects.

2.3 The arrangement of laying the cable under road, road side lane, under the road
crossing etc. are indicated in enclosed drawing section of bid documents for
reference of bidders The bidder should furnish the drawings of arrangement of
laying in above cases along with others to meet site condition.

2.4 RIGHT OF WAY:

2.4.1 Any right of way, which may be required by the contractor for execution of cable
line, shall be arranged by him. The approval from civil authorities, P&T authorities
and other agencies / Government as required shall be arranged by the contractor.
Statutory signature of MPPTCL officers for PTCC and other clearance shall have to
be obtained by the contractor at appropriate time. Obtaining approval of the above
proposal is the contractor’s responsibility.

2.4.2 For PTCC clearance, the contractor shall prepare all drawings including route map,
obtain soil resistivity data as per requirement of PTCC and submit PTCC proposal
to PTCC authority at appropriate time. The cost of compensation, if required for
strengthening, protection of telecom lines from inductive interference from power
lines will however be paid by MPPTCL to appropriate authorities at actual.

MPPTCL/TECH-LINE/PROC/SEP23 Page 176


2.5 SOIL DATA:

2.5.1 The bidder shall be responsible for carrying out the required survey and should fully
satisfy himself about the nature of soil expected to be encountered prior to the
submission of bid. The unit rate quoted by the Bidder shall be irrespective of soil
type such as normal soil, soft rock, hard rock and crossings such as pavements, all
types of roads, rivers, canals, drains, culverts, rail track etc. encountered during
the actual installation. The bidders are required to make their own estimates and
offer a single uniform rate applicable for all kinds of soil strata and crossings. The
Employer shall not entertain any additional claims for payment for any type of
soil/crossings encountered during installation. Employer strongly recommends site
visits/investigation by the Bidders (at their own cost) before submission of the bid
for proper estimation. The contractor shall be required to carry out excavation and
back filling in accordance with this specification and provide all additional items
required at its own cost for proper installation not limited to those described in this
specification. Unit rate for construction of buried cable trench and Back filling shall
interalia include all related work/activities such as excavation, blasting of rocks and
backfilling of trenches, fixing of gradient of trench, excavation of trial pits if required,
clearing of bushes, roots of trees along the trenches, cutting of bushes, trees,
shoring, dewatering, excavation and backfilling of any temporary manhole, support
of the existing facilities/plant, removal of let out materials, breaking of pavement,
clearing of obstacles, temporary reinstatement of footpath wherever required,
providing all types of markers, cover slab and tapes etc., suitable
structure/techniques, material for crossings (road, rail, culvert, river, canal etc.)
for installation of HDPE pipe and other installation materials etc. A unit rate of laying
of cable will be considered in all type of trenches, trench less laying, through air,
through hangers while negotiating existing overhead road bridges etc. No separate
rate for specified type of laying of cable will be considered. The BOQ in the bid
proposal sheets indicates the total route length to be implemented under subject
package.

2.5.2 Map Study: The Contractor shall arrange topographical maps and other maps of
the concerned area in proper scale. All links shall then carefully be studied using
maps. Various feasible alternative routes shall be identified on the maps and the
Contractor shall shortlist most suitable route.

2.5.3 Collection of details of other utilities: Contractor shall arrange information about
existing underground facilities for the proposed routes. To do so as built drawing or
route index diagram for various services viz. water works, electric supply utilities,
telecom services providers, public health, gas/oil authorities etc. may be collected
from the concerned authorities. In case details are not available, the Contractor
shall assess suitably by conducting enquiries and surveys with help of cable locator
or similar type of instrument.

2.5.4 Identification of underground cable route: The Contractor shall propose most
suitable route for cable laying keeping in view the following broad criteria:

1) The route shall be as straight and as short as possible.


2) The route shall have minimum obstacles in order to minimize reinstatement
MPPTCL/TECH-LINE/PROC/SEP23 Page 177
cost.
3) Minimum clearances shall be required from other authorities/ bodies and
that the clearances can be obtained expeditiously.
4) Wet or unstable ground shall be avoided to the extent possible.
5) The route for the cables shall be away from the carriage way of the road to
the extent possible.
6) The route shall be suitable for placing manholes wherever required.
7) Future expansion of roads shall be taken into consideration.

8) Road/ rail/ canal/ drain/ culvert crossing and trenchless digging shall be
minimum.
9) As far as possible underground cable route shall be on the opposite side of
the existing cables laid by DOT/BSNL or other utilities. Wherever both
routes fall on the same side of the road, a spacing of about 2.0 mtr.
horizontal and 1 mtr vertical spacing is to be maintained to the extent
possible.
10) Care must be taken to avoid choosing routes, roads and areas that are
prone to floods etc.
11) Cable crossing of HV, LT, communication cable or Gas, water, sewage line
etc. shall be at a suitable distance according to guidelines available
(Indian/International or guide line of the concerned utilities).

2.5.5 After finalizing the best alternative route, some trial pits shall be dug at suitably
selected locations to assess the obstacles. It is necessary to locate the trial pits at
proposed manhole locations. They shall be dug carefully keeping watch over the
existing underground facilities. The presence of each type of facilities shall be
recorded in the inspection note of the trial pit along with their sites sketch are kept
in record for future reference. These details shall be enclosed along with the
survey report. The Contractor shall submit the survey report with the most
suitable route for cable link along with details above. Contractor shall submit the
final survey report for approval before implementation. The final survey report shall
include at least the following: -

1) A drawing of the proposed route indicating all details of the route including
relevant details of soil strata, bridges, culverts, causeways, rail over under
bridges, canal, defense area, underground gas/oil/water pipe line, power
and communication cable routes, other important landmarks etc.
2) The distance of the cable route from the centre of the road/ rail/ canal/ river/
bridge/ culvert etc. shall be indicated on the route maps as well as
documented in table.
3) Coverage Area of city/ town/ village/ forest/ defence etc.
4) Sections of the links where trenchless digging may be required.
5) Location and number of permanent and temporary manholes.
6) Location of all turns, bends and major landmarks.
7) List of authorities from which clearance shall be required to be obtained
from each relevant section. The final survey report shall have to be
approved by the Employer and requisite clearances need to be obtained
before the cable installation work is commenced. The contractor shall
MPPTCL/TECH-LINE/PROC/SEP23 Page 178
prepare and submit for approval by the Employer, specific construction
drawings for all types of soil strata/ crossings taking into consideration the
guidelines given in this specification. The construction/implementation shall
be carried out as per the approved drawings. The construction drawings
shall inter-alia include the longitudinal sectional diagram of the trench for
different soil strata and detail arrangement of crossings, number of pipes,
size of pipes, location and position of manholes, other details as per the
technical specification. Any other items not specifically mentioned in the
specification but which are required for installation, testing, commissioning
and satisfactory operation of the cable as per Indian Standards/IE Rules/IE
Act and concerned authority regulations are deemed to be included in the
scope of the specification and no deviation in this regard shall be accepted.
The contractor shall also be responsible for the overall co-ordination with
internal/external agencies, project management, manpower, loading,
unloading, handling, moving to final destination for successful erection,
testing and commissioning of the 132 kV cable.

3.0 CODES AND STANDARDS


3.1 Cable installation shall be carried out generally as per following applicable
standards and other relevant applicable standards unless otherwise stated: -

IS 1255 Installation and maintenance of power Cable Specification for pre-


IS: 5820 cast concrete cable covers
IS: 209 Quality of zinc for galvanizing.
IS: 226 Structural steel
IS : 456 Plain and reinforced cement concrete
IS: 800 Use of structural steel in general building construction. Plain
IS: 2016 Washers
IS: 2633 Zinc coating on galvanized steel. Spring washers
IS: 3063 & 5358 Hot Dip Galvanized coating on fasteners.
IS: 6639 Hexagonal bolts for steel structures.
IEC-62067 Tests for power cables with extruded insulation for rated voltage
above 150 kV upto 500 kV.
BIS: 7098 (Part-3) XLPE cable specification for working voltage from 66 kV up to and
IEC: 60229 including 220 kV.
Tests on cable over sheaths
Any other equivalent International/National standard referred in the sections-I, II& III or
otherwise.

4.0 INSPECTION, STORAGE AND HANDLING

4.1 The cable drums shall be mounted and transported only on approved type cable
drum conveyors.

4.2 The contractor should take all necessary precautions for inspection of cables
on receipt and for the proper handling and storage. The contractor shall have
his own arrangement for transporting the cables, materials and equipment to site
and back to store.
MPPTCL/TECH-LINE/PROC/SEP23 Page 179
4.3 While laying cable, cable drum shall be unloaded, handled and stored in an
approved manner. In no case the drum shall be stored flat i.e. with flank age
horizontal. Rolling of drums shall be avoided as far as possible.

4.4 The cables shall be stored on hard packed surfaces and protected from harmful
weather conditions.

4.5 For unreeling of cables, the drum shall be mounted on suitable jacks or wheels. All
possible care shall be taken during unreeling and laying to avoid damage due to
twist, kink or sharp bends.

4.6 Bending radii for cables shall be as per manufacturer's recommendations. The
cable should not be bent beyond permissible limits of the bending radius while
laying and jointing.

4.7 Manufacturer's instructions shall be strictly adhered to.

5.0 EXECUTION OF WORK

5.1 This specification is intended for general description of quality of materials and
workmanship of finished work. They are not intended to cover the minute details.
The work shall be executed in accordance with the best modem practices, Indian
standards (I.S.) and other relevant codes.

5.2 The specification shall be read in conjunction with the other parts of the bid
documents.

5.3 The Purchaser's decision shall be final on any issue in respect of installation.

5.4 The bidder shall prepare the drawings for applicable field conditions of cable
installation like cables directly buried, below metalled road, in ducts, in road
crossing, on drainage crossings, cable jointing bays, man holes and other drawings
referred in foregoing paras etc. and furnish 3 copies of each to the owner for
approval and 6 sets of final approved drawings for execution of work.

5.5 All works are to be executed by bidder only after due approval of the MPPTCL
engineer and under his supervision.

6.0 STATUTORY CLEARANCES

6.1 The installation of cables shall be as per established code or practice and fulfill
the requirements of status. All clearances as per statute shall be maintained from
other utility services, like telephones, water supply, power supply etc.

6.2 The civic highways/traffic authorities etc. charge as per their standard schedules
for grant of permission for trenching. These charges are towards restoration of the
surface to its original condition. These charges shall be paid by the owner as

MPPTCL/TECH-LINE/PROC/SEP23 Page 180


per actual, on production of bills/demand notices.

7.0 EXPERTISE OF UNIT TO HANDLE WORK

7.1 Cable laying/erection unit shall be having good experience (at least 5-7 years) of
similar work of 66 kV and above class cables and have at least completed 5 such
jobs of 66 kV and above class cables but at least conducted 2 jobs of 132 kV and
above cables. Unit in-charge should have at least 15 years of experience of EHV
class cable laying /erection.

7.2 The cables jointing and termination work shall be carried out by experienced cable
jointer who shall have more than 15 years’ experience in jointing and termination of
33 kV or higher voltage grade XLPE cables and have at least completed 2 such
Job of 132 kV and above class cables.

7.3 The bidder should give the bio data of team in-charge and other
engineers/ supervision/experts along with the bid to assess the capability of
bidder in this respect. Bidder should also enclose the list of such work conducted
along with bid.

8.0 PREVENTION FROM TRAFFIC ACCIDENTS WHILE WORK IS IN PROGRESS.

8.1 Suitable barrie rs s houl d be erec te d be twe en th e c able trench a n d


pedes t ria n / motorway to prevent accidents. The barriers shall be painted with
yellow and black or red and white coloured cross stripes. Warning and caution
boards should be consciously displayed. Red lights as warning signal should be
placed along the trench during the nights.

8.2 The excavated material shall be properly stored to avoid obstruction to public and
traffic movement.

9.0 DAMAGE TO PUBLIC PROPERTY WHILE WORK IS IN PROGRESS.

9.1 The contractor shall take all precautions during excavation of trench, trial pits etc.,
to protect the public and private properties and to avoid accidental damage. Any
damage so caused shall be immediately repaired and brought to the notice of the
concerned and MPPTCL Engineer/ Purchaser

9.2 The contractor shall bear all responsibilities and liabilities and shall bear all costs of
the damages so caused by him or by his workman or agents.

9.3 At places where the cables cross private roads, gates of residential houses or
buildings, the cables shall be laid in PVC pipes of adequate strength.

10.0 DOCUMENTATION

10.1 Bidder should enclose complete literature of following with bid: -

i) Laying method and precautions to be taken.

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ii) Method and detailed description of joints through straight through
terminals.
iii) Method and detailed description of cable end terminations

10.2 The contractor shall prepare the route layout plan indicating the road crossing,
crossing across drains, nallahs, etc., and location of the straight through joints and
relevant and associated drawings.

11.0 INSPECTION AND SITE TESTING WHILE WORK IS IN PROGRESS

11.1 The material and equipment covered under this contract are subject to strict codes
of owner approved Q.A.P. inspection and tests.

11.2 Approval or passing of any such testing/inspection by the owner shall not however
prejudice the right of the owner to reject the material/ equipment if it does not
comply with the specification when installed and or fails to give the intended
service.
11.3 A complete test schedule/ program shall be furnished by the contractor.

11.4 The bidder shall provide test pieces in required quantity, to determine the quality of
material supplied under this contract. If any test piece fails to comply with the
requirement the Engineer may reject the whole material represented by the test
pieces.

11.5 In the case of stage inspection during erection work, the bidder shall proceed
from one stage to another only after the component is inspected by the Engineer
and permission given to proceed further. The same procedure shall apply for any
rectification or repairs suggested by the Engineer.

11.6 The contractor shall give the owner 3/5 days’ written notice for inspection/site
tests. The Engineer shall within 3 days of the inspection give notice in writing to the
bidder of any defects noticed during inspection site tests. The bidder shall take
corrective measures and shall confirm in writing, of the compliance or otherwise
with due reason.

11.7 The purchaser or the Engineer shall have the right to inspect any machinery,
material, structure, equipment, plant or workmanship furnished or used by the
contractor and may reject any or all which is defective or unsuitable for the use and
purpose intended or which is not in accordance with the specification.

11.8 The contractor on demand by the owner shall remedy or replace at his expense
such defective material/plant equipment. In the event of the failure of the contractor
to correct the defect or replace the material/equipment/plant, the owner may take
such remedial measures necessary at the expense of the contractor.
11.9 In the event of inspection by t h e engineer a n d the i n s p e c t i o n
revealing that the Goods/ materials are not in conformity with the
standard/specification, the owner shall specify additional tests/inspection
procedures, if required to ascertain compliance with specifications.
11.10 A set of latest relevant approved drawings/data shall be made available to the
Engineer during inspection.
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11.11 The Engineer shall issue a certificate for having inspected the material/equipment
within seven days of inspection. The issue of the certificate does not bind the
purchaser to accept the material should further tests on installation be found not to
comply with the contract specification.

11.12 The bidder shall conduct all tests or repeat the tests already conducted, for the
satisfaction of the purchaser.

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SECTION-III (B)

LAYING AND INSTALLATION OF CABLE

1.0 LAYING OF CABLE:

132 kV XLPE Power Cable (as per specification in Section-I) shall be laid throughout
the route as under:

Four No. cable lengths (@3 No. per Ckt. + 1 No. spare) in trefoil formation.

However, the cables shall also have to be laid as per approved drawings, as per
requirement of the field conditions:

1. In ducts
2. In HDPE Pipes at road crossings (pipes to be filled with sand / suitable
material after cabling)
3. In HDPE pipes at crossings of private roads and gates of residential houses /
buildings.
4. In open air / over steel rack (for end termination).
5. At varying depths due to obstructions.

2.0 LAYING OF POWER AND OPTICAL FIBRE CABLES


2.1 One / Two circuits of the 132 kV XLPE cable shall be laid in the same trench/duct
along with 1 No. earth continuity cable (@1 No. per Ckt) and 1 No. optical fibre
cable in HDPE pipe (@1 No. per Ckt.) as indicated in drawing enclosed for
reference. The contractor shall furnish detailed drawing complying with all
applicable standards for approval by the owner.

2.2 The 132 kV XLPE power cable shall be laid wherever required in 0.6 Mpa class
HDPE pipes of ISI approved quality as indicated in drawing enclosed for reference.

3.0 TRENCHING & TRENCHLESS DIGGING

3.1 TRENCHING:
3.1.1 The cable trench work involves earth excavation for cable trench, back filling and
removal of excess earth from site. The work site shall be left as clean as possible.

3.1.2 The trench shall be excavated using manual/mechanical modes as per field
conditions. Most main roads are of asphalt surface and some of the roads with
cement concrete surface. At road / nallah crossing with open excavated trench, the
cable shall be laid in 0.6 Mpa HDPE pipe of min. 200 mm dia @ 1 No. per phase
and all phases per circuit simultaneously in trefoil formation in NP4 RCC hume pipe
of min 600 mm dia, 0.6 Mpa class, @ 1 No. per ckt.

3.1.3 Where paved footpaths are encountered, the pavement slabs shall be properly
stored and reinstated. Identification markers of other services shall be properly
stored and restored. The excavated material shall be properly stored to avoid

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obstruction to public and traffic movement.

3.1.4 The sides of the excavated trenches shall be well shored up wherever required.

3.1.5 The bottom of the excavated trench should be levelled flat and free from any
object which would damage the cables. Any gradient encountered shall be gradual.

3.1.6 Suitable barriers should be erected between the cable trench and pedestrian/
motorway to prevent accidents. The barriers shall be painted with yellow and black
or red and white coloured cross stripes. Warning and caution boards should be
consciously displayed. Red lights as warning signal should be placed along the
trench during the nights.
3.1.7 The bottom of the excavated trench should be levelled flat and free from any object
which would damage the cables. Any gradient encountered shall be gradual.
3.2 TRENCHLESS DIGGING:
3.2.1 It is envisaged that trench less digging shall be used for crossing national
highways, rail line and canal / nallah and this shall be in the scope of bidder. The
cable shall be laid in 0.6 Mpa HDPE pipe of min. 200 mm dia @ 1 No. per phase
and all phases per circuit simultaneously in trefoil formation in one HDPE pipe of
min 600 mm dia, 0.6 Mpa class. Trenchless digging shall also be used where the
concerned authorities do not permit open cut method and it is essentially required
to be carried out for installation of underground cables. The trenchless digging
methods shall generally conform to ITU-T 1.38. The various methods of trenchless
digging such as hand/manual auguring (up to 15m.) impact moulding (from 16m
to about 40-50m.) and HDD (above 40-50m) shall be adopted based on the
soil/site conditions and the requirement and exact method for trenchless digging
shall be finalized during detail engineering as per actual site/soil condition. The
equipment used for HDD shall be capable of drilling at least 100m at one go. The
contractor shall propose the exact methods and procedures for implementation of
trench less digging at various crossings taking into consideration the following
guidelines, for approval by the Employer.
a) Excavation and backfilling of trial pits and verification of soil condition.
b) Excavation of entry and exit pits.
c) Erection of drill machine. Drilling of pilot hole.
d) Placement and driving hand augur.
e) Placement and carrying out impact moulding.
f) Reaming and widening of bore holes in steps (if required).
g) Pulling of product pipe.

4.0 DEPTH OF LAYING OF CABLES


Depth of laying shall be 1.5 m. During detailed engineering, depth proposed for
more than 1.5 m at typical location (s) shall be accepted subject to approval of
MPPTCL.
5.0 PAYING OUT THE CABLE
The excavated cable trench shall be drained of all water and the bed surface shall
be smooth, uniform and fairly hard before paying out the cable. The cable shall be
rolled in the trench on cable rollers, spaced out at uniform intervals. The paying out
MPPTCL/TECH-LINE/PROC/SEP23 Page 185
process must be smooth and steady without subjecting the cable to abnormal
tension. The cable on being paid out shall be smoothly and evenly transferred to
the ground after providing the cushion. The cables shall never be dropped. All
snake bends shall be straightened. Suitable size cable stocking pulling eye shall
be used for pulling the cable. While pulling the cable by winches or machines, the
tension loading shall be by tension indicator and shall not exceed the permissible
value for the cable. The cable laying shall be performed continuously at a speed
not exceeding 200 to 300 meters per hour.

6.0 CABLE END SEALS


The cable end seals shall be checked after laying and if found damaged shall
immediately be resealed. Sufficient number of heat shrinkable cable end
sealing caps shall be stocked at site stores for testing and jointing work. The
integrity of the outer sheath shall be checked after the cable is laid in position.

7.0 FLAKING
The cables shall be flaked and left with slight extra lengths at jointing bays for
expansion and flexibility. This shall have prior approval of Engineer.

8.0 SAND CUSHION


The sand cushion for the cables shall be provided as per the drawings. Sand
covering shall be done by hand and in such a manner as to provide complete
envelope for the cables.

9.0 SAND BEDDING


The cable shall be completely surrounded by well compacted cable sand having
low thermal resistivity (selected sand) about 250 mm above and below the cable
surface so that the cable is protected against damage.

10.0 THERMAL BACKFILL


Based on the evaluation of soil thermal resistivity along the cable route and after
approval from the MPPTCL the contractor shall design, specify, supply, lay and
monitor the installation of thermal backfill surrounding the cables.

11.1 IMMEDIATE ENVELOPE TO CABLE


The option on the use of the material that immediately envelopes the cable viz.,
thermal backfill or sand or sieved native soil rests with the MPPTCL. The contractor
shall seek prior approval on the use of the envelop material from the MPPTCL
before execution of the works.

12.0 BACK FILLING


Normally back filling shall consist of the material earlier excavated. However, bigger
stones or pieces of rock should be removed.

13.0 PREVENTION OF DAMAGE DUE TO SHARP EDGES


13.1 After the cables have been laid in the trench and until the cables are covered
with protective covering, no sharp metal tool shall be used in the trench or placed in
such a position that may fall into the trench.
13.2 Straight and curved rollers used shall have no sharp projecting parts liable to
MPPTCL/TECH-LINE/PROC/SEP23 Page 186
damage the cable.
13.3 While pulling through pipes and ducts, the cable shall be protected to avoid damage
due to sharp edges.
13 4 The cables shall never be bent, beyond the specified bending radius.
14.0 WARNING TAPE
A pre-warning, yellow colour plastic/ PVC tape, 250 mm wide 100 microns
thick, shall be laid at approx. 0.4 m above the cable specified depth, throughout the
cable route. The tape shall carry the legend printed in red continuously as under;
CAUTION:132000 V CABLE MPPTCL.
15.0 IDENTIFICATION
An identification marker/ tag of lead of size 50 mm x 25 mm x 2 mm shall be
provided at 2.5 meters’ interval throughout the route length of the cable and
fastened with a suitable nylon string. The marker shall be embossed/ bunched on
both sides with the letters MPPTCL 132 kV Cable Ckt-I; MPPTCL OFC;
MPPTCL 132 kV Cable Ckt-II respectively. In case of double circuit, phase
identification by coloured PVC tape shall be at 1 M interval. Alternatively, plastic
tags may be used. These tags should also be fixed at the cable inlet and outlets
of a duct, tunnel, manhole and joint bays.

16.0 CABLE OVER BRIDGES


16.1 Wherever the cable route crosses the bridges, the cables shall be laid in ducts
by removing and replacing the R.C.C. covers and properly back filled.

16.2 Cable Crossing Open Drains with Long Span


a) Wherever the cable route has to cross an open drain, with a long span, the
cable shall be laid in suitable size ducts or pipes, suitably jointed with collars.
The entire duct system shall be designed as per civil engineering practice and
shall be got approved by the concerned authorities and owner.

b) At places where the cables cross private roads, gates of residential houses or
buildings, the cables shall be laid in HDPE pipes.

17.0 ROAD CUTTING


The road cutting, whether of cement concrete/ asphalt or macadam road
surface shall be taken after obtaining approval for cutting from the civic authorities,
traffic police, telephone authorities and work should be planned to be completed in
the shortest possible time. Where necessary the work shall be planned during night
or light traffic periods.

18.0 ROAD CROSSING


Cables shall be laid in 0.6 MPa HDPE pipes of min. 200 mm outer diameter at road
/nallah crossings.

19.0 FOOTPATH CUTTING


The slabs/ kerb-stones on the roads shall be removed and reinstated without
damage.

MPPTCL/TECH-LINE/PROC/SEP23 Page 187


20.0 REINSTATEMENT

20.1 After the cables and pipes have been laid and before the trench is backfilled
all joints and cable positions should be carefully plotted and preserved till such
time the cable is energized and taken over by the Engineer. The protective covers
shall then be provided, the excavated soil riddled, sieved and replaced. It is
advisable to leave a crown of earth not less than 50 mm and not more than 100
mm in the centre and tapering towards the sides of the trench.

20.2 The temporary reinstatement of roadways should be inspected at regular


intervals, more frequently in rainy season and immediately after overnight rain for
checking settlement and if required the temporary reinstatement should be done.

20.3 After the subsidence has ceased the trench may be permanently reinstated and the
surface restored to the best possible condition.

20.4 The road surface being cement concrete, asphalt or tarred macadam,
resurfacing will be done by the civic authorities at owner's cost. The fixing of
markers etc. shall be co-ordinated by bidder.

20.5 All works shall be carried out under supervision of the engineer in charge or his
representative.

21.0 CABLE ROUTE MARKERS/ CABLE JOINT MARKERS

21.1 Permanent means of indicating the position of joints and cable route shall be
fabricated, supplied and erected by successful bidder as per approved drawings.
Pre-cast RCC markers shall be placed as per the field requirement, if the route
passes through open fields, markers should be conspicuously visible and above
ground surface.
21.2 The marker should incorporate the relevant information viz. the name of purchaser
(MPPTCL), voltage, circuit and distance of cable from the marker. The minimum
size shall be 600 (L) x 30 (Thk) x 100 (W) mm and it shall be embedded in ground
up to at least 500 mm.
21.3 The exposed portions shall be painted with non-washable paints (preferably yellow
paint). Letters shall be painted in red colour.
21.4 The interval should be maximum 50 meters between two markers. It should be put
a bends, curves, road crossing, etc. of cable route.

22.0 TOOLS AND PLANTS

22.1 The successful bidder shall have all necessary tools, plant and equipment to carry
out the survey and cable installation work.

22.2 The bidders are instructed to give all the details of equipment at their disposal to
carry out the work successfully and speedily.

23.0 MAINTENANCE OF SITE CONDITIONS


The contractor shall clean the completed cable route and shall remove all surplus
and waste materials, empty cable reels etc. preferably the same day but not later
MPPTCL/TECH-LINE/PROC/SEP23 Page 188
than the next day after the particular work is completed.

24.0 B E N D I N G RADIUS
The minimum bending radius of XLPE insulated cables are as follows:

Cable Bending radius

Single Core 25 x Overall diameter of cable

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SECTION-III(C)

DETAILS OF JOINTING AND


TERMINATION WORKS OF CABLES

1.0 GENERAL

1.1 The cable jointing personnel and his crew shall have good experience in the type
of joints and terminations that are used. The jointing work shall commence as soon
as two or three lengths of cables have been laid. All care should be taken to protect
the factory-plumbed caps/ seals on the cable ends, and the cable end shall be
sealed whenever the end is exposed for tests.

1.2 Jointing of cables in carriage ways, drive ways under costly paving, under
concrete or asphalt surfaces and in proximity to telephone cables and water mains
should be avoided whenever possible.

1.3 Sufficient overlap of cables shall be allowed for making the joints.

1.4 The joint bay should be of sufficient dimensions to allow the jointers to work with
as much freedom of movement and comfort as possible. Sufficient space should be
kept below the cable to be jointed.

1.5 The joints of different phases shall be staggered in the jointing bay.

1.6 During the cable jointing works, the overlapping cable portions are cut for suitable
positioning of cable joints. In this process, lot of cable pieces gets accumulated as
wastage/ scrap. Such wastage of cable for jointing shall be kept to a minimum by
the contractor.

1.7 All accessories and consumables used in the termination should be of good quality
and compatible with the cable.

2.0 JOINTING BAYS / MANHOLES:


2.1 The bidder shall identify the location of the joint bays after carrying out detailed
survey of the cable route and excavation of the trial pits. The delivery lengths of the
cables shall match the location.

2.2 In case of underground portion, 'the joint bay should have a flat and level
surface lined with bricks and properly plastered. The retaining walls on all sides, to
the required height shall be of brick/stone masonry. The top of the wall shall have a
cement concrete bed 1:2:4 with 20 mm size aggregate all-round. The top shall be
covered with pre-fabricated RCC slabs of adequate strength and shall be provided
with an inspection cover. At the bottom in a corner, a sump pit shall be made for
bailing out water.

2.3 The contractor shall submit design and drawing of joint bay for both underground
and bridge portion for approval of the MPPTCL.

2.4 Manholes shall be provided at every proposed joint location for jointing bays.
MPPTCL/TECH-LINE/PROC/SEP23 Page 190
The Contractor shall get inspected all manholes by a representative of the
Employer, before carrying out the backfilling. Pipe and cable sealing, installation of
joint bus and cable service loops as per approved drawings shall be visually
inspected and checked for tightness. The contractor shall submit design and
drawing of Jointing bay including manholes in the buried cable trench portion for
withstanding a live load of 20 tons’ vehicle plus 30% for impact from moving
vehicle. The Contractor shall propose a suitable procedure for testing the
manhole for approval by the Employer. Manholes of the type approved by the
Employer only shall be acceptable. The manhole shall include sufficient number
of suitable entries. All works shall be carried out under supervision of
the engineer in charge or his representative .

3.0 SUMP HOLES


When jointing cables in water logged ground or under unforeseen rainy conditions,
a sump hole should be made at one end of the joint bay, in such a position so
that the accumulated water can be pumped or bailed out by buckets, without
causing interference to the jointing operation.

4.0 TENTS/COVERS
An enclosure or suitable protection cover shall be used in all circumstances
wherever jointing work is carried out in the open irrespective of the weather
conditions. The joint shall be made in dust free, moisture free and clean
atmosphere. The full details of the cover and how it will be provided at site so as to
ensure full compliance to the requirements of this clause should be furnished by the
bidder along with the offer.

5.0 PRECAUTIONS BEFORE MAKING A JOINT


The cable end seals should not be opened until all necessary precautions have
been taken to prevent circumstances arising out of rainy/ inclement weather
conditions which might become uncontrollable. If the cable end seals or cable ends
are found to have suffered damage, the cables should not be jointed without tests
and rectification.

6.0 MEASUREMENT OF INSULATION RESISTANCE


Before jointing, the insulation resistance of both sections of cables shall be
checked.

7.0 IDENTIFICATION OF PHASES AT JOINT BAYS


The identification of each phase shall be clearly and properly marked. The
cables shall be jointed as per the approved design. Each cable shall have
identification for phase at joint bays.

8.0 MAKING A STRAIGHT THROUGH JOINT

8.1 Comprehensive jointing instructions of the straight through joints detailed in


Section- II of this specification shall be supplied by the manufacturer of jointing kits
and same shall be meticulously followed by bidders' jointers.
8.2 The materials used in the joints like ferrules, screen/ sheath continuity bonds, lugs
etc., shall be of good quality and conform to standards.

MPPTCL/TECH-LINE/PROC/SEP23 Page 191


8.3 The jointing tools shall be appropriate and as per the requirement of jointing HV
XLPE cables.

9.0 MAKING A CABLE END TERMINATION

9.1 The cable end terminations and its supporting structures shall be as per Section-II
of this specification. The preparation of the cable end for installing the
terminations and the precautions to be taken before fixing the terminations shall
be followed as in the case of the cable jointing procedures.

9.2 The instructions furnished by the manufacturer of cable terminals ends shall be
strictly followed.
9.3 At cable terminating end, the following provisions for supply and erection are to be
included: -

(i) A sufficient length of spare cable shall be left in the ground for future needs.
(ii) The rise of the cable immediately from the ground shall be enclosed in
PVC/ PE pipe of suitable diameter to protect against direct exposure to
the sun.
(iii) The cable shall be properly fastened using non-metallic clamps.
(iv) Appropriate labels shall be fixed identifying the phase circuit, voltage and date
of commissioning etc. on the cable supporting structure.
(v) The sealing end shall be mounted on pedestal insulators to isolate them from
their supporting steel work.
(vi) Protection from contact with the exposed metal work at the termination shall
be provided by resin bonded glass fiber shroud.
(vii) Providing earth stations with all required materials, like leads, connectors etc.

10.0 BONDING OF SCREEN/ SHEATH


The screens at both ends/ cross bonded points end-route, shall be brought out and
bonded to the earth station through disconnecting type link boxes and through SVL
wherever applicable.

The sheath bonding as per relevant standards shall be done to effectively reduce
sheath voltage below the acceptable level of 65 Volts. Bidders shall give complete
details of the type of the bonding offered and its effect with the designed current

11.0 CONNECTION OF RADIAL WATER BARRIER AND CABLE SCREEN


If the metallic radial water barrier is insulated from the metallic wire screen a
connection suitable to carry the currents occurring during operation must be
installed between metallic radial water barrier of the cable and metallic wire screen
in joints and sealing ends.

12.0 CABLE TERMINATING STRUCTURES.

12.1 The cable terminating structure (Section-II) shall be fixed on the cement
concrete foundation, the design and drawings of which shall be submitted to
MPPTCL for their approval during the course of detailed engineering

12.2 After fixing the end termination, the cable shall be fixed to the support, with non-
MPPTCL/TECH-LINE/PROC/SEP23 Page 192
magnetic material clamps to the required height securely

12.3 The mounting structure includes the supports for cable end boxes, link boxes and
any other structure required for the intent of the contract.

12.4 All steel sections used shall be free from all imperfections, mill scales, slag
intrusions, laminations, fillings, rust etc., which may impair their strength, durability
and appearance. All materials shall be of tested quality only unless otherwise
permitted by the MPPTCL.

MPPTCL/TECH-LINE/PROC/SEP23 Page 193


SECTION -III (D)
SPECIFICATION FOR CIVIL AND
STRUCTURAL WORKS

1.0 EXCAVATION
1.1 The specification covers excavation for cable trenches, ducts, structural foundation
and jointing bays.

1.2 The contractor shall control the grading in the vicinity of all excavations so that the
surface of the ground will be properly sloped or diked to prevent surface water from
running into the excavated area during construction.

1.3 The excavation shall include the removal of all materials required to execute the
work properly and shall be made with sufficient clearance to permit the placing,
inspection and setting of forms and completion of all works for which the
excavation was done.

1.4 The sides and bottoms of excavation shall be cut sharp and true. Undercutting
shall not be permitted. Earth sides of excavation shall not be used in lieu of form
work for replacement of concrete unless authorized by the Engineer where the
limitations of space for large excavation necessitate such decision.

1.5 When machines are used for excavation, the last 300 mm before reaching the
required level shall be excavated by hand or by such equipment that will leave the
soil at required final level in its natural condition.

1.6 The bottom of the excavation shall be trimmed to the required level and when
carried below such level by error, shall be brought to level by filling with lean
concrete of 1:4:8 mix at contractor’s cost.

1.7 All excavation for installation of underground facilities shall be open cuts.

1.8 The excavation for foundation where specified shall be carried out at least 75 mm
or as specified in relevant drawing below the bottom of the structure concrete and
then be brought to the required level by placing lean concrete of 1:4:8 mix or as
specified with aggregate of 40 mm nominal size.

1.9 When the excavation requires tracing, sheeting, shoring, strutting etc. the
contractor shall submit to the Engineer in charge drawings showing arrangement
and details of proposed installation and shall obtain the approval from the Engineer
in charge before proceeding with the work.

1.10 The contractor shall have to constantly pump out the water collected in the pits
and trenches due to rain, sub-soil springs etc. and maintain dry working
conditions at no extra cost to the owner.
2.0 DISPOSAL OF EXCAVATED EARTH
2.1 The contractor shall arrange to transport the surplus excavated earth by
mechanical transport. It shall however be ensured that stacking /disposal shall be
as directed by the Engineer-in-charge.

MPPTCL/TECH-LINE/PROC/SEP23 Page 194


2.2 However the contractor shall take all precautions at the site of excavation for
keeping the free flow of vehicular and human traffic and to avoid inconvenience in
general. The soil transported for disposal shall be stacked, levelled and dressed
neatly.

3.0 BACK FILLING MATERIALS


3.1 The backfilling of excavated trenches around foundation shall consist of one of the
following materials, as the Engineer-in-charge may direct, in each location.

i) Selected sieved earth from excavated soil.


ii) Selected sieved earth brought from borough area.
iii) Sand filling (sieved).

3.2 Filling shall be done after the concrete or masonry work has fully set and its curing
completed.

3.3 The contractor shall not fill in and around any work until it has been properly
reinstated and approved by the Engineer-in-charge.

4.0 BACK FILLING FOR CABLE TRENCH

4.1 Back filling shall be done in horizontal layers of thickness not exceeding 300
mm, free from pockets with careful watering where necessary for compaction. The
backfill shall be riddled earth free from materials likely to cause damage to the
cables.

4.2 The thermal backfill surrounding the cable shall be as per the design approved by
the owner.

5.0 SPECIFICATION FOR CEMENT CONCRETE

5.1 For the cement concrete, plain or reinforced for general use, requirement of
concrete for nominal mix, strength and quality of pouring at all levels, from works,
protective covering, finishing, add mixtures, inserts, curing etc., the provision of
the latest revision of IS: 456 shall be complied with, unless permitted otherwise
by any other Indian Standard codes and shall form the part of the specification to
the extent applicable. The cement used shall comply with IS: 12269 (OPC). The
metal (Jelly) used in PCC/RCC shall be properly graded and machine mixed.

6.0 CURING AND PROTECTION OF CONCRETE

6.1 All fresh concrete shall be covered with the layer of an absorbent material and
kept constantly wet for a period of seven days or more from the date of placing
concrete. The immature concrete shall be protected from damage and
contamination that would impair the strength of the concrete.

7.0 PRECAST RCC ITEMS

7.1 The concrete mix for the various types of pre-cast units shall conform to IS:
456. The aggregate shall be mixed by weight and water cement ratio shall be
MPPTCL/TECH-LINE/PROC/SEP23 Page 195
controlled to obtain the dense concrete and the strength required. The
reinforcement shall be as per the design approved. The curing shall be carried out
for the period of minimum seven days from the date of casting and the pre-cast
element shall be cured by flooding with water of minimum 25 mm depth over the
element for the period mentioned above.

7.2 All the pre-cast element shall be marked appropriately as specified.

8.0 FOUNDATION

Foundations for mounting structures in cement concrete shall be cast by bidder as


per approved drawings.

9.0 BOLTS, NUTS AND WASHERS

Standard bolts, nuts and washers shall be used in all works. These should be
galvanized in accordance with IS: 5358.

10.0 PAINTING

Outdoor kiosk for link boxes etc. shall be painted with anticorrosive paint and red
oxide as primer and two coats of enamel paint. The boxes should be
appropriately labelled as per installation at site regarding S.No., location, type etc.
and provided with caution/ danger board.

11.0 MATERIALS USED IN CABLE LAYING

Specification in brief on the materials used in installation of the 132 kV


underground cables, like RCC precast cable protection covers, precluded cement
concrete blocks for cable route/joint indication, cable and mounting structures,
joint bays, earthing and other miscellaneous materials are given below. All
materials shall conform to relevant standards and shall be approved by the
Engineer.

12.0 RCC PRE CAST CABLE PROTECTION COVERS

These should be fabricated as per the design supplied by the purchaser. The
reinforced cement concrete should be in the proportion not less than 1:2:4 of 20
mm and down size aggregate and steel reinforcement of 6 / 8 mm diameter
mild steel rods should be used (4 No. on 300 mm side and 5 No. on 600 mm
side) and cured as per Civil Engineering standards. The covers should carry the
legends MPPTCL 132 kV CABLES, Ckt-I OR Ckt-II as the case may be The
covers should be free from burrs and projecting edges so that they may be easily
laid to butt. The average breaking load shall be 450 kg for the cover slabs.

13.0 CABLE ROUTE MARKERS/JOINT MARKERS

13.1 Permanent and durable type, cable route markers/joint indicating blocks should be
provided as per the design approved by the purchaser.

MPPTCL/TECH-LINE/PROC/SEP23 Page 196


13.2 The cement concrete block should be made by wet process and the concrete
shall consist of one-part cement, two parts sand, four parts aggregate of size 20
mm and below.

13.3 The marking block should be given a smooth cover surface or cement mortar
and shall have the appropriate legends engraved 5 mm deep such as “MPPTCL
132kV CABLE Ckt- I" OR "MPPTCL 132kV CABLE Ckt- II ", "MPPTCL 132kV
CABLE JOINT Ckt- I" OR "MPPTCL 132kV CABLE JOINT. Ckt- II".

14.0 PIPES

14.1 HDPE Pipes of ISI mark, of 200 mm OD (min), of good quality shall be used for
formation of cable ducts. All sundry materials like coupling, collars and caps to
cover the pipe ends before cable is pulled in, shall be provided. Bidder shall
indicate diameter and thickness of these pipes in the bid itself.

14.2 NP4 Reinforced Hume pipes of 600 mm OD and accessories conforming to IS


shall be used, if required, at Road crossing / Nallah/ bridges.

14.3 Hume pipes without steel reinforcement, stoneware pipes, PVC pipes can also
be used where the cable passes through the passage or drive ways of public and
private buildings.

15.0 SAND
15.1 Sand supplied for backfill shall be river sand, free from flakes, dust, earth,
organic matter and large pebbles and stones and should be free from any
chemical contaminants, likely to have corrosive action on the cable coverings.
The sand should be sieved through a mesh to remove all large stones and
pebbles. The sand shall be properly graded and shall conform to IS: 383 for
concreting work.

15.2 The owner will decide on the requirement of the use of sand depending on
the availability of the excavated earth to be used for backfill. The sand should be
used with the approval of the owner as a backfill.

16.0 QUANTITIES

16.1 The bidder shall indicate the ceiling volumes/quantities for excavation and RCC
works and steel structure works, wherever specifically indicated.

16.2 The bidder shall quote unit rates also for the items of works. He shall have to
quote the total price for each of the works. The quoted price shall also include
supply of all material transportation charges, taxes, duties, octroi and toll tax,
labour, construction, plant and equipment and fixtures, fittings and all temporary
and permanent works necessary for satisfactory completion in all respects.

16.3 The measurement for the payment of earth excavation will be based on
volume calculations of pit/trench. The unit of measurement shall be cubic meters.
Nothing extra would be payable for slopes, shoring, strutting, etc., irrespective of
whatever is provided. If directed by the Engineer in charge, the excavation shall
MPPTCL/TECH-LINE/PROC/SEP23 Page 197
be done on the slopes from slope stability point of view at no extra cost to the
owner.

16.4 If the contractor is directed by the Engineer in charge to excavate to a lower


level than that indicated in the drawing, such additional excavation shall be paid
for at the applicable unit rates.

16.5 LEAD AND LIFT

16.6 The rates quoted for all items of works shall include all lifts and leads wherever
applicable unless otherwise specified.

16.7 Payments for back filling shall be based on the volume of consolidated fill. This
volume shall be derived from the difference between the volume of excavation
and that of the structure (concrete work, sand filling), or trench as the case may
be.

16.8 CARRIAGE OF EXCAVATED SOIL BEYOND A LEAD OF 50 MTRS PER LIFT


OF 1.5 MTRS.

16.8.1 BY MANUAL LABOUR:


The excavated earth for disposal purpose up to 300 mtrs. shall be carried by
manual labour. If directed by the Engineer-in-charge this earth shall be used for
back filling purpose/ filling of low laying areas with prior approval of the concerned
local bodies. The rate for disposal of earth by manual labor up to a lead of 300Mtrs
shall be included in the rate for excavation items and no extra rate for the same is
admissible.

16.8.2 BY MECHANICAL TRANSPORT:


The contractor shall arrange to transport the surplus earth including hard rock and
soft rock left over after back filling the trench/ raising low laying areas by manual
labor up to a lead of 300 mtrs, by mechanical means to the disposal point of the
local bodies with all leads and lifts and as directed by the Engineer in charge. It
shall however be ensured that no soil is stacked in excavated area. Location where
the soil is to be stacked/disposed shall be as directed by the Engineer-in-charge.
However, the successful bidder shall take all precautions at the site of excavation,
for keeping the free flow of vehicular and human traffic and to avoid inconvenience
in general. The soil transported for disposal, shall be stacked and leveled neatly
and dressed. The rate for this item shall include loading, carriage, unloading,
stacking and dressing etc., complete. In no case the excavated soil shall be
stacked upto the distance of 1.5 Mtrs. from the edge of excavation or one third the
depth of excavation whichever is more.

16.9 The measurements of various civil works shall be jointly recorded by the
contractor and the Engineer in charge and duly certified.

16.10 The contractor shall be responsible for estimates, assumptions and


conclusions regarding the nature of the materials to be excavated and difficulty of
making and maintaining of required excavations and performing the work required

MPPTCL/TECH-LINE/PROC/SEP23 Page 198


as shown on the drawing and in accordance with these specifications.
Cofferdams, sheeting, shoring, draining, dewatering etc. shall be furnished and
installed as required and the cost thereof shall be included in the rate quoted.
The contractor shall be held responsible for any damage to any part of the work
and property caused by collapse of sides of excavation. The materials can be
salvaged if it can be done with safety for the work and structure and as approved
by the Engineer in charge.

16.11 However, no extra claim shall be entertained for material not salvaged or any other
damage to contractor’s property as a result of the collapse. He shall not be entitled
to any claim for redoing the excavation as a result of the same.

MPPTCL/TECH-LINE/PROC/SEP23 Page 199


SECTION-III (E)

EARTHING, SITE TESTING AND COMMISSIONING


OF COMPLETE CABLE SYSTEM

1.0 EARTHING OF SYSTEM

1.1 The earthing system required is for:

a) Earthing of all non-current carrying metal parts and


b) Earthing system for cable screens/sheath bonding at terminations.

1.2 The latest edition of following standards and codes are applicable: -
i) IS: 3043: Code or practice for earthing.
ii) IS: 2309: Code of practice for the protection of buildings and allied structures
against lightning.
iii) Indian Electricity Rules 1956: Provision of Rules on EHV systems
iv) IEEE- 80: Guide for safety in substation grounding.

1.3 All equipment, supporting and mounting structures of the installation shall be
bonded together and connected by separate and distinct conductor to earth
electrode.

2.0 EARTH CONDUCTOR


The earth conductor shall be of G.I flat, of approved size and shall be protected
against mechanical damage and corrosion. The connection of the earth continuity
conductors to earth bus and earth electrodes shall be strong, secure and sound
and shall be easily accessible.

3.0 PIPE EARTH STATION

3.1 The pipe earth electrodes shall be in conformity with IS: 3043, buried vertically and
the pit filled with alternate layers of charcoal, salt and earth. The earth lead shall be
properly fastened with brass bolts, nuts and connections shall be enclosed in a
masonry chamber. The chamber shall be provided with RCC inspection cover.

3.2 The connection between the earthing terminal of equipment and earth electrode
shall be made by short and direct earthing lead, free from kinks and splices.

3.3 The distance between any two electrodes shall not be less than twice the length of
the electrode.

3.4 All joints shall be covered with suitable compound to protect against corrosion.
Earthing connections with equipment earthing terminals shall be of bolted type.
The contact surfaces shall be free from scale, paint, enamels, grease, rust or dirt.
Two bolts shall be provided for making earth connection. The bolted connections
after being checked and tested shall be painted with anticorrosive paint or
compound.

MPPTCL/TECH-LINE/PROC/SEP23 Page 200


3.5 Welds and brazed joints shall be treated with red lead and afterwards coated with
bitumen compound to prevent corrosion.

3.6 Steel to copper connection shall be brazed type and shall be treated to prevent
moisture ingress.

3.7 The resistance of the welded joint shall not be more than the resistance of
equivalent length of the conductor.

3.8 All welded joints shall be made by electric arc welding. All welded joints shall be
allowed to cool down gradually to atmospheric temperature.

3.9 Arc welding with large diameter conductor shall be done with low hydrogen content
electrodes.

4.0 BONDING OF CABLE SCREENS/ SHEATH

4.1 Each single phase cable shall have a separate earth for the screen earthing.
The system short circuit level is 40 kA for 1 sec. The earthing lead at solid
earth position shall be single core, 300 sq.mm copper conductor PVC insulated
6.6 kV voltage grade (or appropriate size/type supported by calculation and
approved by MPPTCL) cable.

5.0 EARTH TESTS

5.1 Tests on earths shall be carried out by the contractor in presence of MPPTCL
Engineer for testing the effectiveness of earth resistance of electrodes and the
results furnished to the owner.

6.0 ELECTRICAL TESTS AFTER INSTALLATION

6.1 The contractor shall conduct the following tests during and after installation of
complete cable system (Section-I, II and III) as per IEC 62067.

6.2 In the event of the installation failing the tests, the contractor shall at his expense
identify the cause and rectify the defects and render the installation serviceable.

6.3 D.C. TESTING


a) The insulation resistance of each cable length shall be checked after laying
and before jointing and terminating.
b) Polarization Index test.
c) After laying, jointing and terminating, the cables shall be tested with all
accessories.

6.4 AC TESTING

8.1 The installation shall be tested with AC voltage at power frequency.

8.2 The installation shall withstand for 5 minutes, the phase to phase voltage applied
between the conductor and metallic screen/ sheath.
MPPTCL/TECH-LINE/PROC/SEP23 Page 201
OR
8.3 Test for 24 hours with normal operative voltage of the system.

7.0 TESTS ON NON METALLIC SHEATH

The non-metallic sheath shall be subjected to test as per IEC publication


60229. The bidder can recommend any other test for satisfactory performance of
the installed system.

8.0 Any other site installation / commissioning tests as specified in Section I & II shall
be conducted by the bidder in presence of MPPTCL Engineer.

MPPTCL/TECH-LINE/PROC/SEP23 Page 202


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(C) ANNEXURES (TECHNICAL PARTICULARS AND SAMPLE DRAWINGS)

ANNEXURE- 1

GUARANTEED TECHNICAL PARTICULARS OF CONDUCTOR & EARTH WIRE

[A] ACSR CONDUCTOR

S. Description ZEBRA PANTHER


No.
1. Particulars of ACSR Conductor

i. Standard nominal Copper area (sq. mm) 260 130

ii. Stranding, lay and wire dia (mm) 54/7/3.18 30/7/3.00

iii. Diameter of complete conductor (mm) 28.62 21.00

iv. Overall diameter when wrapped with preformed 44.36 33.78


Armour Rod (mm)
v. Weight (kg/km)

a. Steel Section (kg) 436 586

b. Aluminium Section (kg) 1185 390

c. Conductor (kg) 1621 976

2. Guaranteed ultimate tensile strength of conductor 130.32 89.67


in KN
3. Calculated D.C. resistance/km of conductor when 0.06915 0.139
corrected to standard weight at 20oC
4. i. Standard Cross Sectional Area of Aluminium 7.942 7.069
strand in sq. mm
ii. Standard Cross Sectional Area of Steel strand in 7.942 7.069
sq. mm
iii. Standard Cross Sectional Area of conductor in 484.5 261.60
sq. mm.
5. Modulus of elasticity of Conductor (GN/M2 ) 69 80

6. Co-efficient of liner expansion per oC of

a. Aluminium strand Kg/sq.cm 23X10-6 23X10-6

b. Steel strand Kg/sq.cm 11.5X10-6 11.5X10-6

c. ACSR Conductor Kg/sq.cm 19.3X10-6 17.8X10-6

MPPTCL/TECH-LINE/PROC/SEP23 Page 216


S. Description ZEBRA PANTHER
No.
7. Mean Lay-ratio

i. First layer 13-28 13-28

ii. Second layer 10-17 10-16

iii. Third layer 10-16 10-14

iv. Fourth layer 10-14

8. i. Continuous maximum current rating of conductor 750 427


in still air at 40 oC ambient temperature (amp)
ii. Temperature rise for the above current (oC) 35 oC 30 oC
9. i. Standard length of conductor (km.) 1.5 1.5

ii. Tolerance in length (in percent) +/- 5% +/- 5%

10. Particulars of strands


i. Aluminium/ Aluminium/
Minimum ultimate tensile strength in kg/sq.mm. St eel St eel

a. Aluminimum strand 16.56 16.02


b. Steel strand 134 127.41
ii. Nominal strand Dia 3.18/3.18 3.0/3.0
a. Maximum (mm) 3.21/3.24 3.03/3.06
b. Minimum (mm0 3.18/3.18 3.0/3.0
iii Mass (kg/Km) of strand at Nominal Dia of 21.47 19.11
Aluminium
iv. Mass (kg/Km) of strand at Nominal Dia of Steel 61.95 55.18
v. Minimum breaking load in KN for
a. Aluminium strand
i) Before stranding 1.29 1.17
ii) After stranding 1.23 1.11
b. Steel strand
i) Before stranding 10.43 9.29
ii) After stranding 9.91 8.83
c. Approximate breaking load of conductor in kgs 13316 9127

vi. Zinc coating


a. Uniformity of coating, number and duration of 3 dips 1 3 dips 1 min.
dips(according to Preece test) min.
b. Minimum weight of coating (gms/sq.meter) 260 260
c. Purity of zinc and the standard to which it will 99.95% 99.95%
conform IS:209 IS:209
MPPTCL/TECH-LINE/PROC/SEP23 Page 217
[B] HTGS EARTH WIRE

S.N. Particulars HTGS EARTH WIRE


1 Particulars of single steel wire before stranding
a) No. of wires 7
b) Diameter (mm) 3.66 mm
c) Tolerance 2%
Plus 3.74
Minus 3.58
d) Minimum elongation in 100 mm length 5 mm
e) Breaking load (Kg.)
Standard/Minimum 1179/1000
f) Minimum ultimate tensile stress (Kg/mm2) 95
g) D.C. resistance at 20 deg. C (Ohm/Km) 17.57(Max.)
2 Stranded Wire
a) Length of lay (mm)
Maximum 198
Minimum 165
b) Overall diameter of Earth wire(mm) 10.98
c) Area of cross section of Earth wire (sq. mm.) 73.64
d) Breaking load (Kg.)
Standard/Minimum 7431/6972
e) Resistance in Ohms per Km. at 20 deg. C. 2.5
f) Modulus of elasticity of Earth Wire (Kg/cm2) 19 x10 5Kg/cm2
g) Weight of Earth wire (Kg/Km) 583
h) Co-efficient of linear expansion (per deg. C) 11.5x10-6 /deg. C
3 Quality of zinc used (Specify the grading and
Zn - 99.95 %
percentage)
4 Coating of zinc on wires In Gms. per sq. mtrs. 260
5 Nos. of Dip 3,one minute&1, half
minute
6 Oiling/greasing on Earth wire Boiled Linseed Oil
7 Tolerance in standard length Plus/Minus 5%

MPPTCL/TECH-LINE/PROC/SEP23 Page 218


ANNEXURE-2

GUARANTEED TECHNICAL PARTICULARS OF DISC INSULATORS

S. Description 70 kN EMS 90kN EMS 160kN EMS


No. Single Double Single Double Single Double
Suspensi Suspensi Tension Tension Tension Tensio
on on n
1. Size and designation of 16 mm 16 mm 20 mm
Ball & Socket and
standard to which it will
conform (mm)
2. No. of insulator discs per 9/132KV 2x9/132K 10 2X10 14 2X14
string 13/220K V
V 2x13/220
KV
3. Outside dia. of the disc – 255 255 280
mm
4. Spacing - mm 145 145 170
5. Creepage distance of the 320 320 340
single disc-mm
6. Electro-mechanical 7000 9178 16500
strength of single disc –
kg.
7. Withstand voltage of
single disc-kVp
7.1 Power frequency
a) Dry – kV (rms) 70 75 75
b) Wet – kV (rms) 40 45 45
7.2 Impulse voltage 1.2/50
microsecond
a) Positive – kV 110 110
b) Negative - kV 110 115 120
120
8. Withstand voltage for
the complete string
8.1 Power frequency (with
and without Corona ring)
a) Dry – kV (rms) 280 400/405 490/690
b) Wet – kV (rms) 280 300/305 490/690
8.2 Lightning Impulse voltage
1.2/50 microsecond (With
and without Corona ring) .
a) Positive – kVp 550 800/805 1050/1425
b) Negative – kVp 550 805/810 1050/1425
9. Flashover voltage for the
disc

MPPTCL/TECH-LINE/PROC/SEP23 Page 219


S. Description 70 kN EMS 90kN EMS 160kN EMS
No. Single Double Single Double Single Double
Suspensi Suspensi Tension Tension Tension Tensio
on on n
9.1 Power frequency
a) Dry – kV (rms)
b) Wet – kV (rms) 75 80 85
45 50 55
9.2 Lightning impulse voltage
1.2/50 microsecond
a) Positive – kVp 115 115 130
b) Negative – kVp 115 120 130
10. Flashover voltage for the
complete string
10.1 Power frequency (with
Corona ring)
a) Dry – kV (rms) 290 470 415/420 500
b) Wet – kV (rms) 290 470 310/315 500
10.2 Lightning Impulse voltage
1.2/50
microseconds (with and
without Corona ring)
a) Positive – kVp 560 1060 825/830 1050
b) Negative – kVp 560 1060 830/835 1050
11. Max. voltage (%) across
any disc in the string
9% 13% 14%
(with and without Corona
ring)
12. P.F. Puncture Voltage of
each disc insulator 110 125 125
KV(rms)
13. Maximum RIV with 10
KV(RMS) of each disc
50 50 50
insulator (microvolts)

14. Weight of each disc (kgs) 5.2 5.2 9.5


15. Electromechanical
strength of complete 7000 14000 9178 18356 16500 33000
string (kgs.)

MPPTCL/TECH-LINE/PROC/SEP23 Page 220


ANNEXURE-3

GUARANTEED TECHNICAL PARTICULARS OF HARDWARE FITTINGS FOR ACSR


ZEBRA/PANTHER AND EARTH WIRE FOR LINE

S. Particulars Panther ACSR Zebra ACSR Earth Wire


No. (7/3.66) mm
A) Conventional Type Hardware Sets:

1 Length of single suspension strings


with 9 Disc Insulators and 13 Disc
Insulators of size 255 mm (Dia.) x 1551 2171 185
145 mm (Height) respectively for
Panther & Zebra ACSR. In mm
2 Length of double suspension strings
9x2 Disc Insulators & 13x2 Disc
Insulators of 255mm (Dia) x 145 1873 2429 NA
mm (height) size respectively for
Panther and Zebra ACSR.
3 Length of single tension strings with
10 Disc Insulator of 255
mm(Dia)x145 mm (Height) size for
1728 2679 375
Panther and 14 Disc Insulator of 280
mm (Dia) x170 mm (Height) size for
Zebra Conductor.
4 Length of double tension strings with
10x2 Disc insulator of 255 mm x 145
mm size for Panther and 14x2 disc 2069 3202 NA
insulators of size 280 mm x 170 mm
for Zebra ACSR.
5 Minimum breaking strength of
suspension strings Hardware.
(i) Single 7000kgf 7000kgf 7000kgf
(ii) Double 2x7000kgf 2x7000kgf
6 Minimum slipping strength of 25% of UTS of
15to20% of UTS of Conductor
suspension clamp. Wire
7 Minimum breaking strength of
tension strings Hardware.
(i) Single 9000kgf 16500kgf 7000kgf
(ii) Double 2x9000kgf 2x16500kgf
8 Minimum slipping strength of tension 95% of UTS of 95% of UTS of 95% of UTS of
clamp. Conductor Conductor wire
9 Ball & Socket designation of
Hardware items for Tension Type of 16mm 16mm NA
strings.
10 Ball & Socket designation of
Hardware items for suspension 16mm 16mm NA
strings.
MPPTCL/TECH-LINE/PROC/SEP23 Page 221
S. Particulars Panther ACSR Zebra ACSR Earth Wire
No. (7/3.66) mm
11 Unit weight of Single Suspensions
String Hardware sets(without Disc 6.4kg appox. 11kg appox. 2.9kg appox.
Insulators)
12 Unit weight of double suspension
string Hardware sets(without Disc 24.5kg appox. 29.32kg appox. NA
Insulators)
13 Unit weight of single tension string
Hardware sets (without Disc 6.6kg appox. 9.8kg appox. 2.3kg appox.
Insulators).
14 Unit weight of double tension
Hardware sets (without Disc 21kg appox. 31.7kg appox. NA
Insulators).
15 Type of suspension clamp. Envelope
AGS Type AGS Type
Type
16 Material used for suspension Clamp
Al. Alloy Al. Alloy MCI
giving reference of ISS
17 Type of tension clamp. Compression
Type
18 Material used for tension Clamp Extruded Al. Extruded Al.
Mild Steel
giving reference of ISS Alloy Alloy
19 Unit weight and material used for
each of the following Hardware items
in Kg.
a. Ball hook 0.775kg
0.775kg appox. NA
appox.
b. Socket type horn holder 0.920kg
0.920kg appox. NA
appox.
c. `D’ Shackle 0.450/
0.950/ 0.450kg
0.950kg
2.000kg appox. appox.
appox.
d. Ball link 0.375kg
0.750kg appox. NA
appox.
e. Socket clevis 0.650kg 0.650/1.275kg
NA
appox. appox.
f. Ball clevis 0.300kg 0.300/0.600kg
NA
appox. appox.
g. Clevis Eye 0.650kg
0.650kg appox. NA
appox.
h. Chain Link 0.600kg 0.350kg
1.500kg appox.
appox. appox.
i. Suspension Clamp 3.0kg appox. 6.0kg appox. 2.0kg appox.
j. Tension Clamp with Jumper
2.4kg appox. 4.5kg appox. 1.0kg appox.
Sleeves.
20 Power loss in Aluminium alloy
100 Milli Watt 143 Milli Watt NA
Suspension Clamp at 400 amps.

MPPTCL/TECH-LINE/PROC/SEP23 Page 222


S. Particulars Panther ACSR Zebra ACSR Earth Wire
No. (7/3.66) mm
21 Power loss in extruded Aluminum NA
Insignificant
Tension Clamp at 400 amps.
22 Type of arcing horn
(i) 132 kV Flat type NA NA
(ii) 220 kV Pipe type Pipe type NA
B) AGS Type Suspension Assembly:

1 Type of material used for retaining


Al.Alloy of HE 20 Grade as per
rod for AGS assembly giving NA
IS:6051
reference of ISS
2 Minimum tensile strength of retaining
35kg/sq. mm NA
rod material.
3 Chemical composition of retaining
As per IS:733 NA
rod material.
4 Electrical conductivity of Armour Rod
material (in percentage of the
conductivity of IACS i.e. International Not less than 40% of the IACS NA
Annealed Copper Standard)

5 Slipping strength of cushioned


15to20% of UTS of Conductor NA
suspension assembly
6 Breaking strength of cushioned
7000 kgf NA
suspension assembly
7 Physical properties of synthetic
rubber:
a. Minimum tensile strength 2000PSI NA

b. Minimum ultimate elongation 300% NA


8 Details of the retaining rods of
AGS assembly:
a. Length of Armour Rod (mm) 1550 2080 NA

b. Diameter of Armour Rod(mm) 6.35 7.87 NA

c. Number of Armour Rod/set 11 12 NA

d. Wt. of each Armour Rod(gm) 150 292 NA

e. Tolerance in diameter of each


Armour Rod
i. Maximum (mm) NA
+/- 1% +/- 1%
ii. Minimum (mm) +/- 1% +/- 1% NA

MPPTCL/TECH-LINE/PROC/SEP23 Page 223


S. Particulars Panther ACSR Zebra ACSR Earth Wire
No. (7/3.66) mm
f. Tolerance in flattening Max. (mm) +/- 0.08 +/- 0.08 NA

g. Pitch length of the helix (mm) 190.5 260.4 NA

h. Tolerance in pitch length

i. Maximum (mm) NA
+/- 6 +/- 6
ii. Minimum (mm) +/- 6 +/- 6 NA
i. Tolerance in internal diameter of
helix.
i. Maximum (mm) NA
+/- 0.2 +/- 0.2
ii. Minimum (mm) +/- 0.2 +/- 0.2 NA
j. Tolerance in outer diameter of
helix
i. Maximum (mm) NA
+/- 0.2
ii. Minimum (mm) NA
9 Power loss at 400 Amp. Current
200 Milli Watt 501.50 Milli Watt NA
AGS suspension assembly

MPPTCL/TECH-LINE/PROC/SEP23 Page 224


ANNEXURE-4

GUARANTEED TECHNICAL PARTICULARS FOR ACCESSORIES FOR


ZEBRA/PANTHER ACSR & EARTH WIRE FOR LINES

S. Particulars Panther ACSR Zebra ACSR Earth Wire (7/3.66)


No. mm
A MIDSPAN JOINTS (Compression Type)
1 Breaking strength. 95% of UTS of 95% of UTS of 95% of UTS of
Conductor Conductor Earth wire
2 Slipping strength. 95% of UTS of 95% of UTS of 95% of UTS of
Conductor Conductor Earth wire
3 Conductivity. 100% of eqvt.
100% of eqvt. 100% of eqvt.
Length of Earth
Length of conductor Length of conductor
wire
4 Before and after compression
dimensions in mm
OD Al. Steel Al. Steel Al. Steel
38.0 18.0 48.0 19.20 NA 21.0
ID
23.0 9.35 31.0 9.95 NA 11.5
Across Corner 37.0 17.40 46.0 18.80 NA 20.20
Across Flat 32.0 15.10 40.0 16.10 NA 17.50
5 Material from which following is
made. Also give reference to
ISS for the same.
a. Aluminium sleeve. Extruded
Extruded Aluminium. NA
Aluminium.
b. Steel sleeve. Mild Steel Mild Steel Mild Steel
Galvanised Galvanised Galvanised
6 Unit weight of:
a. Aluminium sleeve. 1.15 1.91 Appox. NA
b. Steel sleeve. 0.28 Appox. 0.41 Appox. 0.470 Appox.
7 Length of steel and Aluminium
sleeve in mm
Before compression Al. Steel Al. Steel Al. Steel
610 203 711 241 NA 230
Tolerance
+/-5 +/-5 +/-5 +/-5 NA +/-5
After compression 660 233 763 273 NA 252
Tolerance +/-5 +/-5 +/-5 +/-5 NA +/-5
B REPAIR SLEEVE (Compression Type)
1 Breaking strength of cable with 95% of UTS of 95% of UTS of 95% of UTS of
sleeve compressed. Conductor Conductor Earth wire
2 Conductivity of cable with 100% of eqvt.
100% of eqvt. 100% of eqvt.
sleeve compressed. Length of Earth
Length of conductor Length of conductor
wire conductor
MPPTCL/TECH-LINE/PROC/SEP23 Page 225
S. Particulars Panther ACSR Zebra ACSR Earth Wire (7/3.66)
No. mm
3 Before and after compression
dimensions in mm
OD 38.0 48.0 20.8
ID 23.0 31.0 41.3
4 Material from which sleeve is Mild Steel
made with IS for the same. Extruded
Extruded Aluminium. Galvanised
Aluminium.
5 Unit weight of repair sleeve. 0.40 appx. 0.740 appx. 0.400 kg appx.
6 Length of repair sleeve in mm
Before compression 241 +/- 0.5 279 +/- 5 254 +/- 5
After compression. 270 +/- 5.0 310 +/- 5 280 +/- 5
C 4R VIBRATION DAMPER
1 Type 4R Type
2 Suitable for conductor size. 21 28.62 10.98
3 Material used for :
a. Clamp Al. Alloy GDC
b. Messenger cable. H T G S IS:4826
4 Number of strands and dia. of 19/2.11 19/2.59 19/2.11
each wire used in messenger
cable.
5 Over all dia. of messenger 10.55 mm appox. 12.95mm appox. 10.55mm appox.
cable.
6 Weight per Km of messenger - - -
cable.
7 Slipping strength of messenger 2.5 KN 2.5 KN 2.5 KN
cable.
8 Total weight of each damper 3.4 kg +/- 5% 6.5 kg +/- 5% 2.3 kg +/- 5%
with tolerance.
9 Weight of each counter weight
with tolerance.
a. Heavier mass. 2.4 kg +/- 5% 3.3 kg +/- 5% 1.150 kg +/- 5%
b. Lighter mass. 1.750 kg +/- 5% 2.4 kg +/- 5% 0.950 kg +/- 5%
10 Natural frequencies of damper. 12+/-1 18.5+/-1 8+/-1 12+/-1 12+/-1 18.5+/-1
30+/-2 46+/-2 17.5+/-2 30+/-2 30+/-2 46+/-2
11 Clamping torque (Kg meter). 6.5 7.5 6
12 a. Minimum fatigue test at the 10 Million cycles 10 Million cycles 10 Million cycles
highest resonant frequency.
b. Amplitude of fatigue test of +/- 1 +/- 1 +/- 1
the resonant frequency.
13 Slip strength of clamp. 2.5 KN 2.5 KN 2.5 KN

14 Maximum magnetic power loss Less than 1Watt Less than 1Watt Less than 1Watt
MPPTCL/TECH-LINE/PROC/SEP23 Page 226
S. Particulars Panther ACSR Zebra ACSR Earth Wire (7/3.66)
No. mm
of damper at 500 Amps, 50 Hz,
AC current.
15 Wind velocity range for which Max. Wind load Max. Wind load Max. Wind load
damper will be effective. 45 kg/sq. m 45 kg/sq. m 45 kg/sq. m

16 Maximum dynamic strain on the


conductor with the damper at 150 Micro strain 150 Micro strain 150 Micro strain
clamping points.
17 Standard to which material will
IS:9708 IS:9708 IS:9708
be manufactured and tested.

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ANNEXURE-5
LIST OF DRAWINGS

S.No Particulars
1. Details of earthing arrangement.
2. Number plate for 220 kV Transmission line.
3. Phase plate for 220 kV Transmission line.
4. Anticlimbing device for 220kV towers
5. Danger Board for 220 kV Transmission line.
6. Number plate for 132 kV Transmission line.

7. Phase plate for 132 kV Transmission line.


8. Danger plate for 132 kV Transmission line
9. Anticlimbing device for 132kV towers.
10. Flexible GI Bond for earth wire.
11. Drum for Panther conductor
12. Drum for Zebra conductor
13. Drum for earth wire
14. 220kV Single & Double suspension insulator string hardware for
Zebra ACSR conductor
15. 220kV Single & Double tension insulator string hardware for Zebra
ACSR conductor
16. 132kV Single & Double suspension insulator string hardware for
Panther ACSR conductor
17. 132kV Single & Double tension insulator string hardware for Panther
ACSR conductor
18. Hardware fittings for Earth wire

19. Mid span compression joint for Zebra ACSR Conductor


20. Vibration damper for Zebra ACSR Conductor
21. Repair sleeve for Zebra ACSR
22. Mid span compression joint for panther ACSR
23. Vibration damper for Panther ACSR Conductor

24. Repair sleeve for panther ACSR

25. Mid span compression joint for earth wire

26. Vibration damper for earth wire


27. Repair sleeve for earth wire

28. Disc Insulators of Ball & Socket type

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(D) SPECIFICATIONS & REQUIREMENTS FOR SUPPLY & ERECTION OF


400KV TRANSMISSION LINE MATERIALS

1.0 TECHNICAL SPECIFICATIONS OF 400KV TOWERS


1.01 INDIAN STANDARDS/CODE :
The material and services under this specification shall be performed as per the
requirements of the latest revisions and amendments available at the time of placement of
order of all the relevant Indian standards/codes listed here under or equivalent International
Standards , except as modified in this document.

S.No. Indian standards Title


1. IS:209-1992 Zinc ingot- Specification.
2. IS:278-1991 Galvanized Steel Barbed Wire.
3. IS:800-1991 Code of Practice for General Building
Construction in Steel.
4. IS:802 -1990 ( Part-II) Code of practice for use of structural
steel in over-head Transmission Line :
Fabrication, Galvanising, Inspection &
packing.
5. IS:802 -1990 ( Part-III) Code of practice for use of structural
steel in over-head Transmission Line
Towers: Testing
6. IS:808-1991 Dimensions for Hot Rolled
Steel Beam, Column, Channel
and Angle Sections.
7. IS:1363(Part-III)-1992 Specification for Hexagon head bolts,
screws and nut for product grade – “C”
Hexagon nuts of property class 5.
8. IS:1367-1979 Technical supply conditions for
threaded fasteners (1st Revision).
9. IS:1367(Part-III)-1991 Mechanical properties and test method
for bolts, screws & studs with full
loadability.
10. IS:1367(Part-VI)-1994 Mechanical properties and test method
for nuts with specified proof loads.
11. IS-1367(Part-XIII)-1983 The hot dip galvanized coating of
fasteners.
12. IS:1573-1991 Specification for electroplated coating
of zinc on Iron & steel.
13. IS:1586-1968 Methods of Rock well hardness test (`B’
& `C’ scales) for steel (first revision).
14. IS:1852-1991 Rolling and Cutting Tolerances of Hot
Rolled Steel Products.
15. IS:2016-1992 Plain Washers.

16. IS:2062-1992 Steel for general Structural purposes –


Specification.
17. IS:2614-1969 Method for sampling of fasteners.
18. IS:2629-1990 Recommended practice for hot dip
MPPTCL/TECH-LINE/PROC/SEP23 Page 257
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S.No. Indian standards Title


galvanizing of iron and steel.
19. IS:2633-1992 Method of testing uniformity of coating
of zinc coated articles.
20. IS:3063-1994 Single Coil Rectangular Section spring
washers for bolts, nuts, and screws.
21. IS:3202-1972 Methods for testing local thickness of
electro plated coatings.
22. IS:3218(Part-V)-1979 Isometric screw threads “Tolerance”.
23. IS:3757-1992 High Strength Structural Bolts.
24. IS:4072-1975 Specification for steel for spring
washers (first revision).
25. IS:4218(Part-VI)-1978 Isometric screw threads limits of sizes
for commercial bolts & nuts.
26. IS:4759-1990 Specification, for Hot dip Zinc coatings
on Structural Steel and other Allied
products.
27. IS:5358-1969 Hot dip galvanized coatings on
fasteners.
28. IS:5369-1991 General Requirements for Plain
Washers.
29. IS:5613-1995 (part-II) Code of practice for design, installation
and maintenance of overhead power
lines.
Sec.-1 - Designs.
Sec.-2 - Installation &
Maintenance
30. IS:6610-1991 Specification for Heavy Washers for
Steel Structures.
31. IS:6623-1992 High Strength Structural Nuts.
32. IS:6745-1972 Methods for determination of weight of
zinc coating of zinc coated iron and
steel articles.
33. IS:6821-1973 Methods for sampling of non threaded
fasteners.
34. IS:8500-1992 Specification for weldable structural
steel (Medium & High Strength
Qualities).
35. IS:10238-1989 Step Bolts for Steel Structures.
36. IS:12427-1992 Specification for Transmission Tower
Bolts of property class 5.6
37. IS:269-1967 Ordinary rapid hardening and low heat
Portland cement.
38. IS:456-2000 Code of practice for plain and
reinforced concrete
39. IS:1786-1966 Cold twisted steel bars for concrete
reinforcements

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S.No. Indian standards Title


40. IS:4091-1967 Code of practice for design &
construction of foundation for
transmission line towers & poles

1.02 TYPE OF TOWERS:

The towers are self supporting lattice type, designed for the specified loading conditions.
There will generally be following type of towers:-

a. Tower type NFD-0: Tangent type tower with maximum line


deviation up to 2° to be used with
Single/Double suspension insulator strings.

b. Tower type NFD-30/FDT: Medium angle tower to be used for line


deviation from 0° to 30° with Single/Double
tension insulator strings. NFD-30 type tower
is also used as Transposition tower with
modified cross arms.

c. Tower type NFD-60: Heavy angle tower to be used for line


deviation from 0° to 60° and also as dead end
tower with Single/Double tension insulator
strings.

d. River Crossing Towers:- The Bidder will have to supply River Crossing
Towers for crossing major river. Similarly for
crossing 400kV line if NFD60+ 30/35M
extension tower is required, the same will
have to be supplied by the contractor after
approval of the Purchaser.
1.03 EXTENSIONS:

Suitable extension of 3M, 6M, 10M height shall be supplied for use with the NFD-0, NFD-
30 and NFD-60 type towers. 18/25M extension shall be supplied for NFD-0 type tower
depending upon the requirement intimated by the Purchaser.

1.04 STUB SETTING TEMPLATES:

The stub setting template shall be required for each type of tower and its respective
extensions and shall be supplied by the Bidder for each type of tower and its respective
extensions. The template shall be of adjustable type i.e. for use with normal towers as well
as extensions.
1.05 DESIGN:

1.05.1 400kV Towers/extensions to be supplied are designed as per IS 802-1995.

1.05.2 The towers have square base with twin MOOSE ACSR conductor per phase in
vertical formation and two ground-wires of 7/3.66 mm galvanized stranded steel wire of
95kg/sq.mm grade placed on the top of the towers. .

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1.06 GALVANIZING PASSIVATION AND PAINTING:


The tower parts, stubs and pack washers shall be hot dip galvanized.The galvanization
shall be done as per requirements of IS 4759 after all fabrication work is completed. The
contractor shall also take guidelines from the recommended practices for hot dip
galvanizing laid down in IS 2629 while deciding and implementing galvanizing procedure.
The mandatory requirements however, are specified herein.

Unless otherwise specified the fabricated tower parts and stubs shall have a minimum
overall Zinc coating of 610 gms per sq. m of surface except for plates & sections below
5mm which shall have Zinc coating of 460 gms per sq. m of surface. The average zinc
coating for all sections and plates 5mm & above shall be maintained as 87 microns and
that for plates and sections below 5mm shall be maintained as 65 microns.

The zinc coating shall be adherent, reasonably uniform, smooth, continuous and free from
imperfections such as black/bare spots, ash rust strains, bulky white deposits/wet storage
strains and blisters.

The surface preparation for fabricated tower parts and stubs for hot dip galvanizing shall
be carried out a indicated herein below:

(i) Degreasing & Cleaning of Surface: Degreasing and cleaning of surface,


wherever required, shall be carried out in accordance with clause 4.1 of IS
2629-1985. After degreasing the article shall be thoroughly rinsed.
However, if acidic degreasers are used rinsing is not required.

(ii) Pickling: pickling shall be done using either hydrochloric or sulphuric acid
as recommended at clause 4.3 of IS 2629-1985. The actual concentration
of the acids and the time duration of immersion shall be determined by the
Contractor depending on the nature of material to be pickled. Suitable
inhibitors also shall be used with the acids to avoid over pickling. The acid
concentration, inhibitors used, and maximum allowable iron content shall
form part of plant standard to be formulated and submitted to MPPTCL
along with Quality Assurance Program.

(iii) Rinsing: After pickling, the material shall be rinsed, preferably in running
water to remove acid traces, iron particles or any other impurities from the
surface. Two rinse tanks are preferable, with water cascading from the
second tank to the first to ensure thorough cleaning. Wherever single tank
is employed, the water shall be periodically changed to avoid acid
contamination, and removal of other residue from the tank.

(iv) Fluxing: The rinsed article shall be dipped in a solution of zinc ammonium
chloride, The concentration and temperature of the flux solution shall be
standardized by the contractor depending on the article to be galvanized
and individual circumstances. These shall form part of plant standard to be
formulated and submitted to MPPTCL along with Quality Assurance
Program. The specific gravity of the flux solution shall be periodically
monitored and controlled by adding required quantity of flux crystals to
compensate for drag-out losses. Free acid content of the flux solution also
shall be periodically checked and when it is more than two (2) grams of
free acid per litre of the solution, it shall be neutralized. Alternatively, Ph
value should be monitored periodically and maintained between 5.0 to 5.5.

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(v) Drying: When dry galvanizing is adopted the article shall be thoroughly
dried after fluxing. For the purpose of drying, the contractor may use hot
plate, air oven or any other proven method ensuring complete drying of the
article after fluxing and prior to dipping in the molten zinc bath. The drying
process shall be such that the article shall not attain a temperature at which
the flux shall get decomposed. The article thus dried shall be galvanized
before the flux coating picks up moisture from the atmosphere or the flux
layer gets damaged or removed from the surface. The drying procedure,
time duration, temperature limits, time lag between fluxing, drying,
galvanizing etc shall form part of plant standard to be formulated and
submitted to MPPTCL along with Quality Assurance Program.

(vi) Quality of Zinc: Any one or combination of the grades of zinc specified in
IS 209 or IS 13229 or other comparable international standard shall be
used for galvanizing. The contractor shall declare the grade(s) of zinc
proposed to be used by them for galvanizing. The molten metal in the zinc
bath shall contain minimum 98.5 % zinc by mass. It shall be periodically
measured and recorded. Zinc aluminium alloy shall be added as per IS
2629.

(vii) Dipping Process: The temperature of the galvanizing bath shall be


continuously monitored and controlled. The working temperature of the
galvanizing bath shall be maintained at 450 ± 10°C. The article should be
immersed in the bath as rapidly as possible without compromising on
safety aspects. The galvanizing bath temperature, immersion angle &
time, time duration of immersion, rate of withdrawal etc. shall be monitored
and controlled depending upon the size, shape, thickness and chemical
composition of the article such that the mass of zinc coating and its
uniformity meets the specified requirements and the galvanized surface is
free from imperfections and galvanizing defects.

(viii) Post Treatment: The article shall be quenched in water. The quench
water is to be changed / drained periodically to prevent corrosive salts from
accumulating in it. If water quenching is not done then necessary cooling
arrangements should be made. The galvanized articles shall be dipped in
chromating solution containing sodium dichromate and sulphuric acid or
chromic acid base additive at a predetermined concentration and kept at
room temperature to retard while rust attack. The temperature of the
chromate solution shall not exceed 65°C. The articles shall not be stacked
immediately after quenching and dichromating. It shall be ensured that the
articles are dry before any further handling operation.

(ix) Storing, Picking and Handling: In order to prevent while rust formation
sufficient care should be exercised while storing handling and transporting
galvanized products. The articles shall be stored in an adequately
ventilated area. The articles shall be stored with spacers in between them
and kept at an inclination to facilitate easy drainage of any water collected
on the articles. Similar care is to be taken while transporting and storing
the articles at site.

(x) The Contractor shall prepare a detailed galvanizing procedure including


Flow Chart with control parameters and all plant standards as required
above and submit to Purchaser for approvals as part of Quality Assurance
Plan.

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(xi) Minor defects in hot-dip galvanised members shall be repaired by applying


zinc rich primer and two coats of enamel paint to the satisfaction of the
Owner before erection.

1.07 MATERIAL :

1.07.1 IS Steel Sections of tested quality in conformity with IS:2062 : 2006 grade E250
(Designated Yield Strength. 250 MPa) and/ or grade E350 (Designated Yield Strength 350
MPa) are to be used in towers, extensions, stubs and stub setting templates. The
Contractor can use other equivalent grade of structural steel angle sections and plates
conforming to latest International Standards. However, use of steel grade having
designated yield strength more than that of EN 10025 grade S355 JR/JO(designated
yield strength 355 MPa) is not permitted, unless otherwise indicated in this specification.

1.07.2 Steel plates below 6mm size exclusively used for packing plates/packing washers
produced as per IS : 1079 -1994 (Grade -0) are also acceptable. However, if below 6mm
size plate are used as load bearing plates viz gusset plates , joint splices etc. the same
shall conform to IS : 2062 or equivalent standard meeting mechanical
strength/metallurgical properties corresponding to grade E250 or E350 (designated yield
strength not more than 355MPa), depending upon the type of grade incorporated into
design. Flats of equivalent grade meeting mechanical strength/ metallurgical properties
may also be used in place of plates for packing plates/ packing washers. The chequered
plates shall conform to IS : 3502. SAILMA 350HI grade plate can also be accepted in
place of HT plates (EN 10025 grade S355 JR/JO / IS 2062:2006 – grade 350, as
applicable) provide SAILMA 350HI grade plate meet all the mechanical properties of plate
as per EN 10025 grade S355 JR/JO (designated yield strength 355 MPa) / IS 2062:2006
– grade 350.

1.07.3 F
or designing of towers, preferably rationalised steel sections has been used. During
execution of the project, if any particular section is not available, the same shall be
substituted by higher section. Any cost on account of the same shall be borne by the
Contractor. However, design approval for such substitution shall be obtained from the
Owner before any substitution and records of such substitutions shall be maintained by
the Contractor.

1.08 WEIGHTS :
The unit weight of each type of tower and extension including bolts and nuts, accessories,
attachments and step bolts is indicated in the Bill of Materials which shall be supplied by
the Employer to the successful Bidder. The weight of structure means the weight
calculated using black sectional (i.e. ungalvanised) weights of all steel members of the
sizes indicated in the fabrication drawings without taking into consideration the reduction
in weight due to drilling of bolts, holes, skew cuts, chamfering etc. or increase in weight
due to galvanising. The weight of gusset plates shall mean the weight of its circumscribing
rectangle, without taking into considerations the reductions in weight due to holes,
notches etc.

1.09 GALVANISED BOLTS AND NUTS AND WASHERS :

1.09.1 The design of the towers and extensions are based on use of HRH mild steel hot
dip galvanized bolts (5.6 quality) and nuts (5.0 quality). The connections are designed on
the basis of use of 16mm dia bolts. The spring washers shall be provided for insertion
under all nuts.

1.09.2 The nuts shall be forged and tapped after galvanizing and then lubricated. The
nuts shall be chamfered on one face only, the other face shall be machined.
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1.09.3 The Bolts up to M16 and having length up to 10 times the diameter of the bolt
should be manufactured by cold forging and thread rolling process to obtain good and
reliable mechanical properties and effective dimensional control. The shear strength of
bolts for 5.6 grade should be 310 MPa minimum as per IS:12427. Bolts should be
provided with washer face in accordance with IS:1363 (Part-I) to ensure proper bearing.

1.09.4 Nuts for hexagonal bolts should be double chamfered as per the requirement of
IS:1363 Part-III. It should be ensured by the manufacturer that nuts should not be over
tapped beyond 0.4mm oversize on effective diameter for size up to M16.

1.09.5 Fully threaded bolts shall not be used. The length of bolts shall be such that the
threaded portion will not extend into the place of contact of the members

1.09.6 All bolts shall be threaded to take the full depth of the nuts and threaded for
enough to permit firm gripping of the members, but not further. It shall be ensured that the
threaded portion of each bolt protrudes not less than 3mm and not more than 8mm when
fully tightened. All nuts shall fit tight to the point where the shank of the bolt connects to
the head.

1.09.7 Flat and tapered washers shall be provided wherever necessary. Spring washers
shall be provided for insertion under all nuts. These washers shall be steel
electrogalvanised, positive lock type and 3.5mm in thickness for 16mm dia bolt and
4.5mm for 24mm bolt.

1.09.8 To avoid bending stress in bolts or to reduce it to minimum, no bolt shall connect
aggregate thickness of members more than three (3) times its diameter.

1.09.9 The bolt positions in assembled towers shall be as per structural drawing.

1.09.10 Bolts at the joints shall be so staggered that nuts shall be tightened with
spanners without fouling.

1.09.11 To ensure effective in-process Quality control it is desirable that the


manufacturer should have in house testing facility for all tests like weight of zinc coating,
shear strength and other tests etc. The manufacturer should also have proper Quality
Assurance System which should be in line with the requirement of this specification and
IS:14000 series Quality System Standard

1.09.12 The bolts and nuts shall be free from forging and threading defects such as
cuts, splits, burrs, bulging, taper, eccentricity, loose fit etc.

1.09.13 The bolts shall be threaded up to standard length only as per relevant Indian
Standard and not to full length.

1.09.14 The bolts and nuts shall confirm to IS 1967-1971 Part-III and Part-IV, IS
12427, IS 1363-92, IS 1367 Part-XIII with latest amendment.

1.09.15 The spring washers designated as M 16-B suitable for 16mm dia galvanized
bolt shall be manufactured out of rectangular section with tolerances as per IS 3063-
1994 with latest amendments. The spring steel shall conform to IS- 4072-1975 with
latest amendments "Specification for steel for spring washers".

1.09.16 The spring washers after coiling shall be suitably heat treated so as to result in
the finished washer having hardness 43 to 50 HRC when tested in accordance with IS
1586- 1968.

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1.09.17 The surface of the washers shall be free of scales and burrs. The washers
shall be coiled without any kinks (except for the shape with turned-up ends). The ends
of the washer shall not abut when the washers are compressed. The ends shall be so
served as to prevent tangling.

1.09.18 The approximate weight of 1000 pieces of spring washers suitable for
16mm dia bolt shall be 8.91 kg. in natural black finish as shown in IS 3063-1972 with
latest amendments.

1.09.19 The spring washer shall be electro galvanized with chromate passivation. The
electro galvanizing of washers should conform to 'severe’ grading service conditions
incorporated in IS 1573-1986 as "Service Grade No.4", classification Fe Zn 25. The
local thickness of zinc coating should be minimum 25 microns and average thickness
38 microns. It should be further suitably heat treated to avoid any danger of hydrogen
embrittlement.

1.10 STEP BOLTS :


Each tower will be provided, on one of the legs, with step-bolts of 16mm dia and
175mm long, spaced not more than 450mm and extending from 3 meters. approx.
above ground level up to the top portion of the tower. The step bolts shall be confirm
to IS 1363-1992, IS 10238:1989 and IS 1367(Part-XIII): 1983.
1.11 DANGER BOARD, NUMBER PLATE AND PHASE PLATES :
Each tower will be fitted with danger board, number plate and phase plates. The tower to
be supplied shall have provision to fix these plates at a height of about 3 meters above
ground level. Necessary provision in tower & extensions for fixing of these items shall be
made. The Danger board, number plate and phase plates shall be supplied conforming to
following technical details:-

1.11.1 The danger boards shall conform to IS-2551-1982 and their revision, if any except
where modified in this specification.

1.11.2 The danger boards, number plates and phase plates shall conform to the drawings
enclosed in this specification.

1.11.3 The colour scheme of the enamel and size of figures and dimensions of lettering
shall be as shown in the drawing as also the overall size. The holes as indicated in the
drawing shall be provided before enamellings.

1.11.4 The thickness of the plate out of which the danger board, number plate and phase
plate will be manufactured, shall not be less than 1.6mm.

1.11.5 The enamellings shall be done by vitreous enameling process only.

1.11.6 All letterings shall be centrally spaced. The dimensions of the letters, figures and
their respective positions shall be as given in drawings. The size of each letter in the word
in each language and the spacing between them for the purpose of scribing shall be so
chosen that they are uniformly written in the space earmarked for them.

1.11.7 The corners of the plate shall be rounded off. The location of the fixing holes shall
be according to drawing annexed with this specification.

1.11.8 The plate shall be made from mild steel at least 1.6mm thick and vitreous
enameled white, with letters, figures and the conventional skull and cross-bones in signal
red colour on the front side. The rear side of the plate shall also be enameled.

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1.11.9 The corners of the danger, number and circuit plates shall be rounded off to
remove sharp edges.

1.11.10 The letters of number and phase plates shall be red enameled with white
enameled background.

1.12 ANTICLIMBING DEVICE WITH BARBED WIRE :

The barbed wire type anticlimbing device shall be used at a height of approximately 3
meters as an anticlimbing deterrent measure, as per the details given in IS:5613(Part-
2/Sec-I)1985. The towers to be supplied by the Bidder shall have provision to fix the
barbed wire as indicated above.

Thus the angle pieces with notches for accommodating barbed wire shall be supplied
with the towers alongwith with provision for suitable bolt holes on leg members for fitting
the angles. It should have the facility of the locking arrangement. The Barbed wire shall
confirm to IS:278/1978 with latest amendment and shall be type 'A-3'.

The Barbed wire shall be made of Hot dip Galvanised MS solid wire of size 2.5mm dia (for
line wire) and 2.0 mm dia (for point wire). The barbs shall have four points and shall be
formed by twisting 2 point wires, each two turns, tightly around both line wires making
altogether four complete turns. The wire shall be galvanised by Hot dip process as per
IS:2629/1966 (with latest amendment). The galvanised wire shall confirm to the
requirement as per IS:4826/1971 with latest amendment in all respect. IS:2633/1972 and
IS 6745/1972 for testing of uniformity & mass of zinc coating. The zinc coating shall be
medium type on line wire and light type on point wire i.e. having zinc coating minimum 110
gm/m² on line wire and 70 gm/m² on point wire.

1.13 EARTHING :

1.13.1 A provision shall be made in the stub for fixing earthing material. The stub will be
provided with a hole at a distance of 250 mm from bottom end and at a distance of 500
mm below ground level for connection with earthing materials. The hole will be of 17.5 mm
dia.

1.13.2 The Bidder shall also supply the following materials per earthing set for earthing of
towers (four sets per tower): -

(i) One no. Hot dip galvanized earthing Mild Steel Rod (2 Meter long, 25 mm
diameter):

(ii) Hot dip galvanized connecting clamps (`F’ type and `U’ type- 2 Nos. per
set);

(iii) Hot dip galvanized stranded steel wire of size 7/4.00mm, Grade 5 to be
used as connecting wire conforming to Indian Standard:2141:1992 and
Indian Standard 4826: (5 Meter per earthing set).

1.13.3 The details of earthing rod and clamps and earthing arrangement for towers are
shown in the drawing enclosed.

1.13.4 The earthing rod shall be of mild steel solid rod of 2 meters in length and 25mm in
diameter with one end pointed. The rods shall be galvanized as per relevant Indian
Standard . The zinc coating on the rod shall not be less than 610 gm/m² of surface area.

1.13.5 The tower end-connecting clamp shall be of flat type and rod end connecting
clamp shall be of `U’ type. The clamps shall be of forged steel cast iron / malleable iron.
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The clamps should be hot dip galvanized as per Indian Standard:2629:1990. The
zinc coating on the clamps shall not be less than 610 gm/m² of surface area.

1.13.6 The hot dip galvanized stranded steel wire of size 7/4.00mm shall be supplied for
connection between the earthing rod and the stub. The steel wire shall conform to Indian
Standard 2141: 1992 and Indian Standard:4826: 1979 and latest revision thereof and
shall consist of seven strands, each strand having a diameter of 4 mm and Grade-5. The
galvanizing shall be done as per Indian Standard specification2141: 1992 and 4826: 1979
and latest revision thereof for heavy zinc coating. The coating of zinc shall not be less
than 260 gm/m².

1.14 ATTACHMENT FOR INSULATOR STRING & GROUNDWIRE CLAMPS:

1.14.1 The towers shall be provided with suitable attachment for supporting insulator
strings and ground-wire suspension and tension assembly.

1.14.2 The towers shall be provided with the cleats to support the hanger. The details
of hanger are shown in the drawing enclosed.

1.14.3 The ground-wire suspension assembly has got a 'D’ shackle. There shall be a
suitable arrangement to support the same.

1.14.4 On angle towers, strain plates shall be provided for purpose of attaching the
tension insulator string. For fixing ground-wire tension assembly a hole 17.5mm dia
shall be provided in the strain plate.

1.14.5 FABRICATION WORKMANSHIP :

1.14.6 Except where hereinafter modified, details of fabrication shall conform to IS-
802(Part-II)-1990.

1.14.7 The fabrication of towers shall be done strictly in accordance with the drawing
supplied by the Employer.

1.14.8 The towers shall be of bolted construction.

1.14.9 Normally lap splice shall be used for connecting members of un-equal size and
the inside angles of lap splice shall be rounded at the heel to fit the fillet of the outside
angle. All splices shall develop full stress in the members connected through bolts.
Butt-joint as well as lap joint splices shall be made as above and as close to the main
panel as possible.

1.14.10 Joints are designed and detailed to avoid eccentricity as far as possible. The
use of gusset plates for joining tower members shall be avoided as far as possible.
However, where the connections are such that the eliminations of the gusset plates
would result in eccentric joints, gusset plates and spacer plates may be used in
conformity with modern practice.

1.14.11 The tower structures shall be accurately fabricated to bolt together easily at site
without any undue strain on the bolts.

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

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

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1.14.14 All similar parts shall be made strictly interchangeable. All steel section
before any work is done on them shall be carefully leveled, straightened and made
true to detailed drawings by methods which will not injure the materials so that when
assembled the adjacent matching surfaces are in close contact throughout .No rough
edges shall be permitted in the entire structures. Hammering is not permitted for
straightening.

1.14.15 Cutting may done by shearing, cropping, flame cutting or sawing . The
surface so cut shall be cleaned smooth , reasonably square and free from deformation
and distortion.

1.15 BENDING :

1.15.1 Mild steel angle sections up to 75x75 mm (up to 6mm thick) shall bent cold up to
and including bend angle of 10° Angles. Above 75x75mm (thickness up to 6mm) and up
to and including 100x100 mm (thickness up to 8 mm) may also be bent cold up to the
bend angle of 5 Deg. All other angle sections and bend angles not covered above shall
be bent hot.

1.15.2 All plates up to 12mm thickness shall be bent cold up to a maximum bend angle
of 15 Deg. Plates of thickness more than 12mm with bends greater than 15 Degree shall
be bent hot.

1.15.3 All hot bend material shall be air-cooled. The bends shall be of even profile and
free from any surface damages.

1.15.4 DRILLING AND PUNCHING :

1.15.5 The holes in the member shall either be drilled or punched with a jig , the
former process will be preferred.

1.15.6 Punching may be adopted for sections upto 12 mm thickness. For thicker
sections drilling shall be done.

1.15.7 The holes shall be punched/drilled after bending and related position of these
holes shall be maintained with the use of proper templates/jigs and fixtures .

1.15.8 The holes shall be perfectly circular and no tolerance in this respect is
permissible. The holes shall be perpendicular to the plate and angle flanges.

1.15.9 Holes must be square with the plates or angles and have their walls parallel.

1.15.10 All burrs left by drills or punch shall be removed completely. When the tower
members are in positions, the holes shall be truly opposite to each other. Drilling or
ramming to enlarge defective holes shall not be permitted.

1.15.11 The minimum spacings of bolt and edge distance shall be as under :-

a. For 16 mm dia bolt edge distance of 20 mm from hole center to rolled


or swaged edge and 23mm from hole center to sheared or flame cut
edge, hole center to hole center distance minimum 40mm (the hole
size being 17.5mm).
b. The gap between the edges of the connected members in butt joint
shall not be more than 6mm and less than 4mm.

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c. The bolt gauge distance in flanges of angle sections shall generally


be in accordance with Table XXXI of SF6(1)-1961-ISI “Hand Book for
structural Engineers-Structural Steel Sections (Revised).”
d. The bolt gauge distance in flanges of angle sections shall
generally be in accordance with Table XXXI of SF6(1)-1961-ISI “
Hand Book for structural Engineers-Structural Steel Sections
(Revised).”

1.16 TOLERANCES :

1.16.1 The maximum allowable difference in the diameter of the hole on the two sides of
the plate or angle shall not exceed 0.8 mm on diameter.The allowable taper in
drilled/punched hole shall not exceed 0.8 mm on diameter.

1.16.2 The tolerance cumulative or between consecutive holes shall be within


+/- 0.5mm.

1.16.3 The tolerance on the overall length of member shall be within +/- 1.6 mm.

1.16.4 The tolerance on gauge distance shall be within +/- 0.5mm.

1.16.5 Rolling and weight tolerance of steel sections shall be as per Indian Standard:
1852 and Indian Standard: 808.

1.17 MARKING :

All members shall be distinctly given punch mark similar to those given in structural
drawings. The mark shall be given with marking dies of minimum 18 mm size and this
mark shall be legible. Letter XMPTNFD0, XMPTNFD30 and XMPTNFD60 shall precede
erection mark where ‘X’ stands for manufacturer’s name, ‘MPT’ stands for Madhya
Pradesh Power Transmission Company and NFD0, NFD30 & NFD60 stands for type
towers.

1.18 QUALITY ASSURANCE PROGRAM :

The contractor shall submit the Quality Assurance Programme as specified in clause 1.12
Section-1 of the biding document. A copy of the accepted Quality Assurance Plan must be
available at the manufacturer’s works of the Plant for reviewing by inspecting officer of the
employer.

1.19 INSPECTION OF PROTOTYPES :

1.19.1 Proto type of each type of structure/extensions shall be offered by the successful
bidder for inspection within three month’s time from the date of contract.

1.19.2 Notwithstanding any thing covered in the drawings and other details furnished by
the Employer, the successful bidder shall make minor modifications, if any, in length, size,
notching etc. according to the proto assembly which are necessary for easy assembly of
the structure.

1.20 INSPECTION :

1.20.1 As specified in clause 1.13 Section-1 of the biding document, Plant to be supplied
will be subject to inspection and approval by the Employer's representative before
despatch.

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1.20.2 Each consignment ready for transportation shall be offered to the Employer for
inspection before dispatch giving a minimum time of not less than fifteen days. Only
complete sets of towers/extensions shall be offered for inspection. All materials
constituting towers (Steel parts, Bolts & nuts, spring and pack washers, earthing sets)
shall be offered simultaneously. Samples of fabricated tower materials and accessories
shall be subjected to tests as per relevant Indian Standard or equivalent International
Standard. The Employer shall be kept informed about the source of procurement of raw-
steel, particularly through re-rollers. The Employer reserves right to inspect and get the
samples of raw-steel tested as per Indian Standard-2062 and relevant standards or
equivalent International Standard. The cost of testing shall be borne by the bidder.

1.20.3 The Contractor shall keep the Employer informed in advance of the time of starting
and of the progress of manufacture and fabrication of structures at various stages.

1.20.4 In case, any member of the structure is not found to comply with the relevant
drawing, it shall be liable for rejection even after receipt.

1.20.5 Defects, which may appear during fabrication, shall be made good. Any member
once rejected shall be cut into pieces in front of the Employer’s representative so that it is
not offered again by mistake.

1.21 GENERAL GUIDE-LINE FOR INSPECTION :

1.21.1 Fabricated Structure Members :

(i) Visual examination and quantity verification of offered lot.

(ii) Sample selection from the offered lot at a ratio of 40 MT (or part thereof)
1 no. each for all tests.

(iii) Dimension, fabrication and trueness verification of structure member from


fabrication sketch.

(iv) Galvanising test of each sample i.e. dip test, hammer test and mass of
zinc test.

(v) Random verification of Zinc coating of galvanized surface by Alko-meter.

(vi) Tensile test and bend test of each sample.

(vii) Chemical composition test of at least two samples per offered lot of 50
MT for inspection.

(viii) Verification of manufacturer’s test certificate for mild steel used in


structure members.

(ix) Bolts-Nuts, Washer, Accessories, Attachments etc.: (To be carried out at


manufacturers works of these items)

(x) Other acceptance tests for respective items as per relevant Indian
standard.

1.21.2 The supplier shall submit the factory test certificates of bought out accessories at
the time of acceptance tests of towers.

1.21.3 Since at the time of inspection only fabricated tower members and accessories will
be verified, acceptance of any lot shall in no way relieve the bidder of his responsibility to
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meet all technical requirements of this specification for fabricated towers. In case any
shortcoming is noticed at the time of actual assembly and erection, the Employer may
reject any part or item or accessory and the contractor will have to assume the
responsibility for free replacement/rectification of such defects.

1.22 PACKING AND MARKING ON PACKING :

1.22.1 The material shall be boxed or bundled for transport in the following manner:

(i) Angle shall be packed in bundles securely wrapped four times around at
each end and over 900 mm with No.9 SWG steel wire with ends twisted
tightly. Gross weight of any bundle shall not be less than 450 Kg and more
than 2000 Kg. The bundle shall be in complete Tower form only.

(ii) Cleat angles, brackets, filler plates and similar small loose pieces shall be
nested and bolted together through holes and wrapped around at least four
times with No.9 SWG wire with ends twisted tightly or packed in wooden
crates. Gross weight of each bundle shall not exceed 200 Kg.

(iii) Correct number of bolts, nuts and washers required for structures shall be
packed in heavy gunny bags accurately tagged in accordance with the
contents and a number of bags packed in a solid box of 22mm thick lumber
with paneled ends to be accurately nailed and further reinforced with 22
mm x 75 mm Batons round the sides and at the ends with 25 mm x No.18
SWG iron band stretched entirely around the batons with ends overlapping
at least 150mm. Gross weight of each box shall not exceed 200 Kg.

(iv) Packing list incorporating all relevant details e.g. quantity of structures
(complete sets), number and size of steel sections, quantity of nuts, bolts,
washers etc. shall be forwarded along with each consignment.

(v) In the nutshell the packing arrangement should be such that all lots of one
particular type of structure are identifiable at site for the purpose of
allocation for a particular work. In case more than one structure of a
particular type is delivered in area store/work site, combined packing
arrangement by way of clubbing members of similar type (for more than
one structure) in a combined package should not be done. Uniform packing
procedure for each structure should be adopted.

1.22.2 All above packing are subject to the approval of the Employer or his appointed
representatives.

1.22.3 Each bundle or packing shall have the following marks:

(i) The name of the consignee (as per dispatch instructions given by the
Employer).
(ii) Ultimate destination as required by the Employer.
(iii) The relevant marks and number of structure members or reference or bolts,
nuts and small components like gusset plats, various attachment, etc. for
easy identification.
1.22.4 The marking shall be stenciled and indelibly inked on the top members in the
bundles, on wooden boxes and also on gunny bag containing smaller components.

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2.0 TECHNICAL SPECIFICATIONS OF ACSR MOOSE CONDUCTOR

2.1 SCOPE :

2.1.1 This specification provides for standard design, manufacture, stage testing,
inspection and testing before despatch, packing and delivery of Steel Cored
Aluminium Conductor specified hereunder for their satisfactory operation in
various lines and sub-stations of the State. The Conductor is to be used as power
conductor on double circuit transmission lines.

2.1.2 Bidders are required to quote for supply of all materials as detailed in the
specification.The bidder shall furnish full particulars as called for in various clauses, in
addition to filling and completing the schedules annexed to this specification.

2.1.3 The unit rate quoted shall be inclusive of deployment of all plant, equipment, men,
material, skilled & unskilled labors etc. essential for satisfactory supply of ACSR Moose.

2.1.4 All the raw materials for supply of ACSR Moose shall be included in the Bidder’s
scope of supply. Bidder shall inform the sources from where he proposes to procure the
raw materials.

2.2 STANDARDS:

2.2.1 The power conductor shall conform to the following Indian Standards, which shall
mean latest revisions, amendments/changes adopted and published, unless otherwise
specified hereinbefore.

Sl. Indian Standards or any Title


Equivalent International
No.
Standard
1 IS:209 Specification for Zinc
2 IS:398 Part I to Part V (as Specification for Aluminium Conductors for
relevant) overhead Transmission purpose.
3 IS:1778 Reels and drums for Bare wires
4 IS:1521 Method of Tensile Testing of Steel wire
5 IS:2629 Recommended practice for Hot Dip
Galvanising Iron and Steel
6 IS:2633 Method of Testing Uniformity of Zinc
coating of Zinc coated Articles.
7 IS:4826 Galvanised coating on Round Steel wire
8 IS:6745 Method of Determination of weight of Zinc
coating of zinc coated Iron and Steel
Articles
9 IS:8263 Method of Radio Interference Tests
10 IS:1841 EC Grade Aluminium Rod produced by
rolling
11 IS:5484 EC grade Aluminium Rod produced by
continuous casting and rolling
12 IS: 2141 Method of Elongation test of steel wire
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2.2.2 Acceptance of Other Authoritative Standards :


In the paragraph above, relevant Indian standards have been mentioned. However, the
ACSR Moose meeting any other authoritative international standard, which ensures equal
or better quality than the standards, mentioned above shall also be acceptable. Please
attach photocopy of all such standards according to which the, ACSR Moose have been
offered.

In this bid, the Bidders will have to furnish confirmation in regard to compliance of our
entire technical requirement. The bid should clearly describe various technical particulars
of the, ACSR Moose as per details given in this specification.

2.3 CLIMATIC CONDITIONS :

2.3.1 The ACSR conductor shall be suitable for being installed directly in air supported
with suspension insulator strings or anchored through tension insulator strings supported
with hanger/suspension clamp or tension clamp at the cross arms of single circuit and
double circuit transmission line towers. The conductor shall be therefore suitable for
satisfactory continuous operation under the following climatic conditions:

1 Location in the state of MADHYA PRADESH


2 Maximum ambient air temperature (0C) 50.
3 Minimum temperature in shade (0C ) 1.
4 Maximum relative humidity (%) 95(sometimes approaches
saturation)
5 Average daily ambient air temperature (0C ) 40° Centigrade
6 ISOCERANIC Level (days/year) 50
(Average number of thunder storm days)
7 Average rainfall(mm) 1250
8 Maximum wind pressure (kg/ square metre) 150
9 Max. Altitudes above mean sea level (metres) 1000
10 Seismic level (Horizontal acceleration) (g) 0.3

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

2.4 PARAMETERS :
2.4.1 Principal Parameters of Stranded Conductor:

Sr. No. Details of Stranded Conductor ACSR


Moose
a) No. of Strands Aluminium-54
Steel –7
i. Steel Centre 1
ii. 1st Steel Layer 6
iii. 1st Aluminium Layer 12
iv. 2nd Aluminium Layer 18
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Sr. No. Details of Stranded Conductor ACSR


Moose
v. 3rd Aluminium Layer 24
b) Sectional Area of Aluminium (Sq.mm) 528.5
c) Total Sectional Area (Sq.mm) 597.0
d) Overall diameter(mm) 31.77 mm
e) Approximate weight (Kg/Km ) 2004
f) Calculated D.C. Resistance at 20 Deg.C 0.05552
(Ohm/Km)
g) Minimum UTS (kN) 161.2
h) Modulus of Elasticity kg/cm2 0.703x106

2.4.1.1 The details of aluminium strand are as follows :

Sr. Details of Aluminium Strands ACSR


No. Moose
a) Minimum breaking load of strand Before stranding 1.57
(kN)
b) Minimum breaking load of strand after stranding 1.49
(kN)
c) Maximum D.C. resistance of strand at 20 deg.C 2.921
(Ohm/Km)
d) Nominal Strand Dia 3.53
e) Max. Strand Dia 3.55
f) Min. Strand Dia 3.53
g) Mass (Kg/Km) of Strand at Nominal dia 21.47

2.4.1.2 The details of steel strand are as follows:

Sr. Details of Steel Strands ACSR Moose


No
a) Minimum breaking load of strand Before stranding 12.86
(kN)
b) Minimum breaking load of strand after stranding 12.22
(kN)
c) Nominal Strand Dia 3.53
d) Maximum Strand Dia 3.60
e) Minimum Strand Dia 3.53
f) Mass (Kg/Km) of Strand at Nom. dia 76.34
g) Zinc coating testing 3 dips of 1
min. each
h) Wt. of Zinc Coating (gms/sq. metre) 260

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2.5 GENERAL TECHNICAL REQUIREMENTS : MATERIAL AND WORKMANSHIP


(FOR ACSR MOOSE):

2.5.1 Materials:

2.5.1.1 The conductors shall be manufactured from EC grade aluminium rods suitably
hard-drawn on wire drawing machines. The aluminium rods used shall comply with IS:
1841 and IS: 5484 or any equivalent International Standard. The mechanical and
electrical properties of aluminium wire shall comply with the requirements given in relevant
standard.
2.5.1.2 Physical constants for Hard-drawn Aluminium:

i. Resistivity:

The resistivity of aluminium depends upon its purity and its physical condition. For the
purpose of this specification the maximum value permitted is 0.28264 Ohm sq.mm/mt. at
20° C and this value has been used for calculation of the maximum permissible value of
resistance.
NOTE : It is not intended to check the resistivity from the measured values of resistance.
ii. Density:
At a temperature of 20° C the density of hard drawn aluminium has been taken as 2.703
g/cm.3
iii. Constant-Mass Temperature Co-efficient of Resistance:

At a temperature of 20°C, the constant-mass temperature co-efficient of resistance


of hard drawn aluminium measured between two potential points rigidly fixed to the wire,
the metal being allowed to expand freely, has been taken as 0.004 per degree Celsius.
iv. Co-efficient of Linear Expansion:

The co-efficient of linear expansion of hard-drawn aluminium at 0° C has been taken as


23.0 x 10 -6 per ° C. This value holds good for all practical purposes over the range of
temperature from 0 ° C to highest safe operating temperature.
Galvanised steel wire shall be drawn from high carbon steel rods produced by either
acidic or basic open hearth process, electric furnace process or basic oxygen process.
The mechanical and electrical properties of wire shall comply with the requirements given
in relevant standard. The chemical composition of high carbon steel wires is given below
for guidance only.
Element Percentage Composition
Carbon 0.5 to 0.85
Maganese 0.50 to 1.10
Phosphorous Not more than 0.035
Sulphur Not more than 0.045
Silicon 0.10 to 0.35
2.5.1.3 Physical constants for Galvanised steel wires:
i. Density :
At a temperature of 20° C, the density of galvanized steel wire is to be taken as 7.80
g/Cm3.

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ii. Coefficient of Linear Expansion :


In order to obtain uniformity in calculation a value of 11.5 x 10 –6 ° C may be
taken as the value for the co-efficient of Linear Expansion of galvanized steel wires
used for the cores of steel-reinforced aluminium conductors.

iii. The zinc used for galvanizing shall be electrolytic high-grade Zinc not less than
99.95 percent purity. It shall conform to and satisfy all the requirements of IS: 209.
Galvanising may be done either by hot process or electrolytic process. Minimum
weight of Zinc coating shall be 260 g/sq. metre. Neutral grease may be applied
between the layers of wire.
iv. Freedom From Defects:
The wires shall be smooth and free from all imperfections such as spills, slag
inclusion, die marks, scratches, fittings, blow-holes, projections, looseness,
overlapping of strands, chipping of aluminium layers etc. and all such other defects
which may hamper the mechanical and electrical properties of the conductor.
Special care should be taken to keep away dirt, grit etc. during stranding.

2.5.2 Wire Sizes

2.5.2.1 Nominal Size:

The aluminium and galvanized steel wires for the stranded conductor covered by this
standard shall have diameters specified in clause 3.4.1.1 & 3.4.1.2. The diameter of the
steel wires shall be measured over the zinc coating.

2.5.2.2 Tolerances on Nominal Size :

Tolerance of + 1% is permitted on the nominal diameter of Aluminium Wires of Moose


Conductor and a tolerance of + 2 % is permitted on the nominal diameter of Galvanised
Steel Core Wire.

2.5.2.3 Joints in Wires:

2.5.2.4 Aluminium Wires:

No joints shall be permitted in the aluminium wires in the outermost layer of the ACSR
Conductor. Joints in the inner layers are permitted, in addition to those made in the base
rod or wire before final drawing, but no two such joints shall be less than 15 mtr. apart in
the complete stranded conductor such joints shall be made only by cold pressure butt-
welding. It may please be noted that Joints are not permitted in the outermost layer of the
conductor in order to ensure a smooth conductor finish and reduce radio interference
levels and corona losses on extra high voltage lines.
2.5.2.5 Galvanised Steel Wires:
There shall be no joints except those the base rods or wires before final drawing, in steel
wires forming the core of the steel-reinforced aluminium conductor. Joints are not
permitted in the steel wires after final drawing also in order to avoid reduction in the
breaking strength of the conductor that may occur as a result of failure of the joints.

2.5.3 Stranding:
2.5.3.1 The wires used in the construction of galvanized steel reinforced aluminium
conductor, before stranding, shall satisfy all the relevant requirements of this
specification.

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2.5.3.2 The lay ratio of the different layers shall be within the limits given in the Table
below:-

LAY RATIO OF ALUMINIUM CONDUCTORS GALVANISED STEEL-


REINFORCED (Moose Aluminium-54 Wire Steel - 7 Wire)

Ratio of Lay Ratios Lay Ratios for Aluminium wires (3 Alu. Wire
Alu. of Steel core Layer Conductors)
wire 6 wire layer
diamet
er to Outermost Layer Innermost
steel layer immediately Layer
wire beneath
diamet outer most
er layer
Min. Max. Min. Max. Min. Max. Min Max.
.
1 16 18 10 12 11 13 12 14

NOTE :For the purpose of calculation, the mean lay ratio shall be taken as the arithmetic
mean of the relevant minimum and maximum values given in this table.

2.5.3.3 In all constructions, the successive layers shall have opposite directions of lay, the
outermost layer being right-handed. The wires in each layer shall be evenly and closely
stranded.

2.5.3.4 In conductors having multiple layers of aluminium wires, the lay ratio of any
aluminium layer shall not be greater than the lay ratio of the aluminium layer immediately
beneath it.

2.5.3.5 The finished Conductor shall have a smooth surface without any surface cut,
abrasion, scuff marks and shall be free from dirt, grit, etc. even if the damage to conductor
is acceptable from mechanical considerations. It will not be acceptable from electrical
considerations, and full care should be taken not to supply damaged conductor.
Projections of more than 2 mils shall not be acceptable. Any such damage shall be
properly rectified or new conductor supplied.

2.5.3.6 Failure of any sample to meet the above requirements shall be sufficient cause for
rejection of the lengths of conductor represented by the sample. Particular care shall,
therefore, be taken during manufacture, handling, packing and transportation of the
conductor, to see that the surface is not dented, cut or damaged in any way.

2.5.4 Standard Length :


2.5.4.1 The standard length of conductor shall be 1500 metres. A tolerance of +/-5% on
the standard length offered by the supplier shall be permitted. All lengths outside this limit
of tolerance shall be treated as random lengths.

2.5.2.1 Random lengths will be accepted provided no length is less than 70% of the
standard length specified and the total quantity of such random lengths shall not be more
than 5% of the total quantity ordered.

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2.5.2.2 Supplier shall also indicate the maximum single length, above the standard
length, they can manufacture in the guaranteed technical particulars. This is required for
special stretches like river crossing etc. The purchaser reserves the right to place orders
for the above length to the 5% of the total ordered quantity on the same terms and
conditions applicable for the standard lengths during the pendency of the contract.

2.5.3 Galvanising:

2.5.3.1 All the wires of Iron & steel strand shall be galvanized in accordance with IS-2629-
1966. ‘Recommended practice for hot dip galvanizing of Iron and Steel’ or some other
authoritative equivalent standard.

2.5.3.2 Specific technical requirements for galvanizing and relevant tests quoted in clause-
6 of this specification for guidance shall be complied.

2.6 TESTS :

2.6.1 The conductor offered shall be type tested as per the relevant standards. Further the
acceptance, routine tests and tests during manufacture shall be carried out on the
conductor.

2.6.2 Type tests shall mean those tests, which are to be carried out to prove the process
of manufacture and general conformity of the material to this specification.

2.6.2 All the materials offered shall be fully type tested as per the relevant standards and
the supplier shall furnish four sets of type test reports along with the offer. These tests
must not have been conducted earlier than five years, prior to the date of opening of bid.
For any change in the design/type already type tested and the design/type offered against
this specification, the purchaser reserves the right to demand repetition of tests without
any extra cost.

2.6.3 Acceptance tests shall mean those tests, which are to be carried out on samples
taken from each lot offered for pre-despatch inspection, for the purpose of acceptance of
that lot.

2.6.4 Routine tests shall mean those tests which are to be carried out on each
strand/spool/length of the conductor to check requirements which are likely to vary during
production.

2.6.5 Tests during manufacture shall mean those tests, which are to be carried out
during the process of manufacture and end inspection by the supplier to ensure the
desired quality of the end product to be supplied by him.

2.6.6 The norms and procedure of sampling for these tests will be as per the Quality
Assurance Programme to be mutually agreed to by the Supplier and the Purchaser as per
relevant clause of General Conditions of Contract.

2.6.7 The standards and norms to which these tests will be carried out are listed in para
2.0. Where a particular test is a specific requirement of this specification, the norms and
procedures of the test shall be as mutually agreed to between the Supplier and the
Purchaser in the Quality Assurance Programme.

2.6.8 For all type and acceptance tests, the acceptance values shall be the values
guaranteed by the Supplier in the ‘Guaranteed Technical Particulars’ of his proposal or
the acceptance value specified in this specification, whichever is more stringent for that
particular test.

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2.6.9 Type Tests :


The Conductor offered shall be fully type tested as per the relevant International/Indian
Standard and the bidder shall furnish the report along with the offer. These tests must not
have been conducted earlier than 5 years prior to the date of opening of bid. For any
change in the design/type, already type tested and the design/type offered against this
bid, the purchaser reserves the right to demand repetition of some or all type tests without
any extra cost.

The above said test reports submitted with the offer shall not be older than five years,
prior to the date of opening of bid.

a) UTS test on stranded conductor


b) DC resistance test on stranded conductor
c) Stress-strain test on composite conductor

2.6.10 Acceptance Tests :

a) Visual and dimensional check

b) Visual check for joints, scratches etc. and lengths of conductor

d) Dimensional check on steel and aluminium strands

d) Check for lay ratios of various layers

e) Galvanising test on steel strands

f) Torsion and Elongation test on steel wire

g) Breaking load test on steel and aluminium strands

h) Wrap test on steel and aluminium strands

i) DC resistance test on aluminium strands

j) UTS test on welded joint of aluminium strand

NOTE: All the above tests except test mentioned at (j) shall be carried out on
aluminium and steel strands after stranding only.

2.6.11 Routine Test :

a) Check to ensure that the joints are as per specification.

b) Check that there are no cuts, fins etc. on the strands.

c) Check that drums are as per specifications.

d) All acceptance tests as mentioned in Clause 6.1.10 above shall


be carried out on each coil.

2.6.12 Tests During Manufacture :

a) Chemical analysis of zinc used for galvanizing

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b) Chemical analysis of aluminium for making aluminium strands

c) Chemical analysis of steel used for making steel strands

2.6.13 Testing Expenses:


The entire cost of testing for the acceptance and routine tests and tests during
manufacture specified herein shall be treated as included in the quoted unit price of
conductor, except for the expenses of the inspection/Purchaser’s representative.
2.6.14 Additional Tests:

The Purchaser reserves the right of having at his own expenses any other test(s) of
reasonable nature carried out at Supplier’s premises, at site, or in any other place in
addition to the aforesaid type, acceptance and routine tests to satisfy himself that the
material comply with the specification.
2.6.15 Sample Batch for Type Testing

(a) The bidder shall offer at least three (3) drums for selection of samples required for
conducting all the type tests, in case of change in design/type already tested and the
design type offered against this specification, for which the purchaser reserves the right to
demand carrying out type test without any extra cost.

(b) The bidder is required to carry out all the acceptance tests successfully in the
presence of Purchaser’s representative before despatch of conductor.

2.6.16 Test Reports

(a) Record of routine test reports shall be maintained by the Supplier at his works for
periodic inspection by the Purchaser’s representative.

(b) Test Certificates of test during manufacture shall be maintained by the Supplier.
These shall be produced for verification as and when desired by the Purchaser.
2.6.17 Test Facilities
The following additional test facilities shall be available at Bidder’s Works.

(a) Calibration of various testing and measuring equipment including tensile testing
machine, resistance measurement facilities, burette, thermometer, barometer etc.

(b) Standard resistance for calibration of resistance bridges.

(c) Finished conductor shall be checked for length verification and surface finish on
separate rewinding machine at reduced speed (variable from 8 to 16 metres per
minute). The rewinding facilities shall have appropriate clutch system and free of
vibrations, jerks etc. with transverse layering facilities.

2.7 INSPECTION :

2.7.1 The purchaser’s representative shall at all times be entitled to have access to the
works and all places of manufacture where conductor shall be manufactured and the
representative shall have full facilities for unrestricted inspection of the Supplier’s works,
raw materials and process of manufacture for conducting necessary tests as detailed
herein.

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2.7.2 The Supplier shall keep the Purchaser informed in advance of the time of starting
and of the progress of manufacture of conductor in its various stages so that
arrangements can be made for inspection.

2.7.3 No material shall be despatched from its point of manufacture before it has been
satisfactorily inspected and tested, unless the inspection is waived off by the purchaser in
writing. In the later case also, the conductor shall be despatched only after satisfactory
testing for all tests specified herein has been completed.

2.7.4 The acceptance of any quantity of material shall in no way relieve the Supplier of
any of his responsibilities for meeting all requirements of the specification, and shall not
prevent subsequent rejection if such material is later found to be defective.

2.7.5 At least 5% of the total number of drums subject to minimum of two in any lot put
up for inspection, shall be selected at random to ascertain the length of conductor by
following method:

“At the works of the manufacturer the conductor shall be transferred from one
drum to another at the same time measuring its length with the help of graduated pulley
and Cyclometer. The difference in the average length thus obtained and as declared by
the supplier in the packing list shall be applied to all the drums if the conductor is found
short during checking”

2.8 QUALITY ASSURANCE PLAN :

2.8.1 The Supplier shall invariably furnish following information along with his offer, failing
which his offer may be liable for rejection. Information shall be separately given for
individual type of equipment offered.
(i) Statement giving list of important raw materials names of sub supplies for
the raw materials, list of standards according to which the raw materials
are tested, list of tests normally carried out on raw materials in presence
of Supplier’s representative, copies of test certificates.
(ii) Information and copies of test certificates as in (i) above in respect of
bought out accessories.
(iii) List of manufacturing facilities available.
(iv)Level of automation achieved and list of areas where manual process
exists.
(v) List of areas in manufacturing process, where stage inspections are
normally carried out for quality control and details of such tests and
inspections.
(vi)Special features provided in the equipment to make it maintenance free.
(vii) List of testing equipments available with the Supplier for final testing of
material specified and test plant limitation. If any, vis-a-vis the type,
special, acceptance and routine tests specified in the relevant
standards. These limitations shall be very clearly brought out in
schedule of deviation from specified test requirements.

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2.8.2 The successful Supplier shall within 30 days of placement of order, submit
following information to the purchaser.
(i) List of raw materials as well as bought out accessories and the
names of sub-suppliers selected from those furnished along with
offer.
(ii) Type test certificates of the raw material and bought out
accessories.
(iii) Quality assurance plan (QAP) with hold points for Purchaser’s
inspection. The quality assurance of plan and Purchaser’s hold
points shall be discussed between the Purchaser and Supplier,
before QAP is finalized.

2.8.3 The successful Supplier shall submit the routine test certificates of bought out
accessories and central excise passes for raw material viz. oil, copper, aluminium,
conductor’s insulating materials, core material at the time of routine testing of the
Conductor.

2.9 DOCUMENTATION :
2.9.1 Six sets of type test reports, duly approved by the Purchaser shall be submitted by
the supplier for distribution, before commencement of supply. Adequate copies of
acceptance and routine test certificates, duly approved by the Purchaser shall accompany
with despatched consignments.

2.9.2 The manufacturing of the material shall be strictly in accordance with the approved
drawings and no deviation shall be permitted without the written approval of the
Purchaser. All manufacturing and fabrication work in connection with the material prior to
the approval of the drawing shall be at Supplier’s risk.

2.9.2 Approval of drawing/work by Purchaser shall not relieve the Supplier of his
responsibility and liability for ensuring correctness and correct interpretation of the latest
revision of applicable standards, rules and codes of practices. The material shall conform
in all respect to high standards of engineering, design, workmanship and latest revisions
of relevant standards at the time of ordering. Purchaser shall have the power to reject any
work or material, which in his judgment is not in full accordance therewith.

2.10 PACKING AND FORWARDING :

2.10.1 The conductor shall be supplied in non-returnable strong wooden drums provided
with lagging of adequate strength, to protect the conductor against all damage and
displacement during transit, storage and subsequent handling and stringing operations in
the field. The drums shall generally conform to IS: 1778 except otherwise specified
hereinafter.

2.10.2 The drums shall be suitable for wheel mounting and for jetting off the conductor
under a minimum controlled tension of the order of 5kN.

2.10.3 The standard drum drawings are enclosed however, supplier should submit the
proposed drum drawings along with the bid. The same shall be in line with the
requirements of standard drawings and as stated herein. After placement of the letter of
Award, the supplier shall submit four copies of fully dimensioned drawing of the drum he
wishes to supply, for Purchaser’s approval, before taking up manufacturing of conductor.
After getting approval from the Purchaser, Supplier shall submit 30 more copies of the
approved drawing to Purchaser for further distribution and field use at Purchaser’s end.

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2.10.4 All wooden components shall be manufactured out of seasoned soft wood free
from such defects that may materially weaken the component part of the drums.
Preservative treatment for anti-termite /anti-fungus (Aldrine/Aldruse) shall be applied to
the entire drum with preservatives of a quality which is not chemically harmful to the
conductor.

2.10.5 The flanges shall be of two/three ply construction with each ply at right angles to
the other and nailed together. Further the outer face of the flange shall be reinforced with
the circumferential battens, fixing in octagonal shape. The nails shall be driven from the
inside face of flange, punched and then clenched on the outer face. The tolerance in
thickness of each ply shall be +/- 3 mm only. There shall be at least 3 nails per plank of
ply with maximum nail spacing of 75 mm. Where a slot is cut in the flange to receive the
inner end of the conductor, the entrance shall be in line with the periphery of the barrel.
Spindle hole shall be provided at the centers of the planks of the plies and spindle plates
with 102 mm dia. Holes shall be fitted on either side of both the flanges.

2.10.6 The wooden battens used for making the barrel of the conductor shall be of
segmental type. These shall be nailed to the barrel supports with at least two nails. The
battens shall be closely butted and shall provide a round barrel with smooth external
surface. The edges of the battens shall be rounded or chamfered to avoid damage to the
conductor.

2.10.7 Barrel studs shall be used for construction of drums. The flanges shall be holed
and the barrel supports slotted to receive them. The barrel studs shall be threaded over a
length on either end, sufficient to accommodate washers, spindle plates and nuts for fixing
flanges at the required spacing. Barrel studs should be tack welded with the nuts after
tightening.
2.10.8 Normally, the nuts on the studs shall stand protrude of the flanges. All the nails
used on the inner surface of the flanges and the drum barrel shall be counter sunk. The
ends of barrel shall generally be flushed with the top of the nuts.

2.10.9 The inner cheek of the flanges and drum barrel surface shall be painted with a
bitumen based paint.

2.10.10 Before reeling, cardboard or double corrugated or thick bituminised waterproof


bamboo paper shall be secured to the drum barrel and inside of flanges or the drum by
means of a suitable commercial adhesive material. The paper should be dried before use.
Medium grade craft paper shall be used in between the layer of the conductor/earth wire.
After reeling the conductor the exposed surface of the outer layer of conductor shall be
wrapped with thin polythene sheet across the flanges to preserve the conductor from dirt,
grit and damage during transportation and handling and also to prevent ingress of rain
water during storage/transport.

2.10.11 Minimum space of 125 mm shall be provided between the inner surface of the
external protective layer and outer layer of the conductor.

2.10.12 Each batten shall be securely nailed across grains as far as possible to the flange
edges with at least 2 nails per end. The length of the nails shall not be less than twice the
thickness of the battens. The nail shall not protrude above the general surface and shall
not have exposed sharp edges or allow the battens to be released due to corrosion.

2.10.13 Outside the protective layer, there shall be minimum of two binder consisting of
hoop iron/galvanized steel wire. Each protective layer shall have two recess to
accommodate the binders.

2.10.14 The conductor ends shall be properly sealed and secured with the help of U-nails
on one side of the flanges. The end securing shall be done by taking out at least 500 mm
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of steel core on either ends by U-nails. The composite conductor shall be binded by use of
galvanized steel wire/aluminum wire at three locations at least 75 mm apart or more
covered with PVC adhesive tape so as to avoid loosening of conductor layers in transit
and handling.

2.10.15 Only one length of conductor shall be wound on each drum.

2.11 MARKING :

Each drum shall have the following information stenciled on it in indelible ink along with
other essential data:

i. Contract/Award letter number


ii. Name and address of consignee
iii. Manufacturer’s name and address
iv. Drum number
v. Size of conductor
vi. Length of conductor in metres
vii. Gross weight of drum with conductor
viii. Weight of empty drum with protective lagging
ix. Arrow marking for unwinding

2.12 END SEALING :

Both the ends of each length of conductor should be provided with non-destructive type
metal crimped or epoxy capped seals with punching embossing/ engraving of
manufacturer’s monogram and drum number.

2.13 CHECK MEASUREMENT

2.13.1 At least 5% of the total number of drums in any lot put up for inspection shall be
selected at random to ascertain the length of conductor by rewinding method.The %
shortage if any in the length thus obtained and as declared by the supplier in the packing
list, shall be applied to all the drums if the conductor is found short during checking.

2.13.2 The length of conductor shall also be verified at the consignees end. Where
length measurement machines are not available the length will be verified by the
weighment basis. The determining factor will be length weight ratio of the sample drums
verified at the firm’s premises of the Lot of which the drum under measurement at the
consignees end forms a part.

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3.0 TECHNICAL SPECIFICATION FOR OPTICAL FIBER GROUND WIRE (OPGW),


ASSOCIATED HARDWARE & ACCESSORIES

Please refer technical specification for optical fiber ground wire (opgw), associated hardware &
accessories from Section B (S.No. 03) of this document.

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4.0 TECHNICAL SPECIFICATIONS FOR HIGH TENSILE GALVANISED STEEL EARTH


WIRE

Please refer technical specification for High Tensile Galvanised Steel Earth wire from Section B
(S.No. 04) of this document.

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5.0 TECHNICAL SPECIFICATION OF DISC INSULATORS


5.01 SCOPE
5.01.1 This specification provides for the design, manufacture, stage testing and
inspection and testing before despatch, packing and delivery F.O.R. destination of disc
insulators as per technical requirements furnished in this specification for various 400 KV
Transmission lines to be constructed anywhere in the state of Madhya Pradesh.
5.01.2 These insulators are to be used for suspension and Tension strings for the
suspension and Tension of the power conductors on 400 KV Double Circuit transmission
lines.
5.02 STANDARDS
5.02.1 Unless otherwise specified elsewhere in this specification, the rating as well as
performance & testing of the disc insulators shall conform but not limited to the latest
revision & amendments available at the time of placement of order of all the relevant
standards as listed hereunder, except as modified in this document.
S. No Indian Standard Title
1 IS:209-1992 Specification for Zinc
2 IS:206-1991 Method for Chemical Analysis of Slab Zinc
3 IS:731-1991 Porcelain insulators for overhead power
lines with a nominal voltage greater than
1000V
4 IS:2071 Method of High Voltage Testing
Part(I)-1993
Part(II)-1991
Part(III)-1991
5 IS:2121 Specification of Conductors and Earth wire
Accessories for Overhead Power Lines.
Part(I) Armour Rods, Binding Wires & Tapes for
Conductors
6 IS:2486 Specification for insulator fittings for
overhead power lines with a nominal
voltage greater than 1000V

Part I-1993 General Requirements & Tests


Part II-1989 Dimensional Requirements
Part III -1991 Locking Devices
7 IS:2629-1990 Recommended practice for Hot Dip
Galvanization for iron & steel
8 IS:2633-1992 Testing for Uniformity of Coating of Zinc
coated articles
9 IS:3188-1988 Dimensions for Disc Insulators
10 IS:6745-1990 Determination of Weight of Zinc coating on
Zinc coated iron and steel articles
11 IS : 8263-1990 Methods of RIV Test of HV Insulators
12 IS:8269-1990 Methods for Switching impulse test on HV
insulators

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5.02.2 Material meeting with the requirements of other authoritative standards, which
ensure equal or better performance than the standards mentioned above, shall also be
considered. When the material offered by the bidder conforms to other standards, salient
points of difference between standards adopted & the standards specified in this
specification shall be clearly brought out in the relevant schedules. Three copies of such
standards with authentic translation in English shall be furnished along with the bid.

5.03 CLIMATIC CONDITIONS

5.03.1 The insulators shall be suitable for being installed directly in air with power
conductors of Double Circuit Double Strung transmission lines. They shall be therefore
suitable for satisfactory continuous operation under the following climatic conditions: -

1 Location in the state of MADHYA PRADESH


2 Maximum ambient air temperature (0C) 50
3 Minimum temperature in shade (0C ) 1
4 Maximum relative humidity (%) 95(sometimes
approaches saturation)
5 Average daily ambient air temperature (0C 40° Centigrade
)
6 ISOCERANIC Level (days/year) 50
(Average number of thunder storm days)
.
7 Average rainfall(mm) 1250
8 Maximum wind pressure ( kg/ square 150
meter)
9 Maximum Altitudes above mean sea level 1000
(meters)
10 Seismic level(Horizontal acceleration) (g) 0.3

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

5.04 PRINCIPAL PARAMETERS

5.04.1 DETAILS OF DISC INSULATORS

5.04.1.1 The insulator strings shall consist of standard discs for a three phase 50 Hz,
effectively earthed 400KV transmission system in a moderately polluted atmosphere. The
discs shall be cap and pin, ball and socket type.

5.04.1.2 The specified values and disc dimensions, impulse and power frequency
voltages, electromechanical strength [EMS] of individual insulator units are as under.
The values given are minimum which apply to all cases. Specified withstand and
flashover voltages are referred to standard atmospheric condition.

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CHARACTERISTICS OF DISC INSULATORS


The disc insulators should have the following particulars and characteristics:

S.No Particulars Disc Insulators


120kN EMS 160kN
EMS
i Diameter of the disc (mm) 255 280
ii Spacing of the disc (mm) 145 170
iii Size and designation of pin-ball shank 20 mm 20 mm
iv Creepage distance (mm) (minimum) 320 330
v Power frequency one minute dry 75 75
withstand voltage kV (rms)
vi Power frequency one minute wet 45 45
withstand voltage kV (rms)
vii Power frequency puncture withstand 125 125
voltage kV (rms)
viii Minimum dry impulse withstand 110 120
voltage 1.2x50 micro second wave,
positive and negative Kv Peak)
ix Maximum Radio interference 50 50
voltage with 10 kV RMS to ground.
(microvolts)
x Minimum corona extinction voltage 18 18
kV(rms)

5.04.2 SPECIFICATION DRAWINGS

5.04.2.1 The specification drawing in respect of the disc insulators indicated above is
attached with this specification. The specification drawing is attached herewith for
information and guidance of the Supplier only. The drawings to be furnished by the
Supplier shall be as per his own design and manufacture and shall be distinct and
separate from these specification drawings.
The drawing shall include but not limited to the following information :-
a) Shell diameter and ball to ball spacing with manufacturing
tolerances.
b) Minimum creepage distance with positive tolerance.
c) Protected creepage distance
d) Eccentricity of the disc
i) Axial run out
ii) Radial run out
e) Unit mechanical and electrical characteristics
f) Size and weight of ball & socket parts
g) Weight of unit insulator disc
h) Materials
i) Identification mark
j) Manufacturer’s catalogue number.
After placement of award, the supplier shall submit full dimensioned
manufacturing drawing of insulator cap, pin & insulator shell in six copies to the
purchaser for reference & record.

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5.05 GENERAL TECHNICAL REQUIREMENTS

5.05.1 Porcelain
The porcelain used in the manufacture of the shells shall be ivory white, nonporous of
high dielectric, mechanical and thermal strength, free from internal stresses, blisters,
laminations, voids, foreign matter, imperfections or other defects which might render it in
any way unsuitable for insulator shells. Porcelain shall remain unaffected by climatic
conditions, ozone, acid, alkalizes, zinc or dust. The manufacturing shall be by the wet
process and impervious character obtained by thorough verification.
5.05.1.1 Porcelain Glaze
Surfaces to come in contact with cement shall be made rough by sand glazing. All other
exposed surfaces shall be glazed with ceramic materials having the same temperature
coefficient of expansion as that of the insulator shell. The thickness of the glaze shall be
uniform throughout and the colour of the glaze shall be brown. The glaze shall have a
visible luster, smooth on surface and be subject to satisfactory performance under
extreme tropical climatic weather conditions and prevent ageing of the porcelain. The
glaze shall remain under compression on the porcelain body throughout the working
temperature range.
5.05.2 METAL PARTS

5.05.2.1 Cap and Ball Pins


Ball pins shall be made with drop forged steel and caps with malleable cast iron. They
shall be in one single piece and duly hot dip galvanized. They shall not contain parts or
pieces joined together, welded, shrink fitted or by any other process from more than one
piece of material. The pins shall be of high tensile steel, drop forged and heat-treated.
The caps shall be cast with good quality black hearth malleable cast iron and annealed.
Galvanising shall be by the hot dip process with a heavy coating of zinc of very high
purity. The Supplier shall specify the grade, composition and mechanical properties of
steel used for caps and pins.
5.05.2.2 Security Clips
The security clips shall be made of phosphor bronze or of stainless steel. 2.5% extra
security clip shall be provided.
5.05.3 FILLER MATERIAL
Cement to be used as a filler material shall be quick setting, fast curing Portland cement.
It shall not cause fracture by expansion or loosening by contraction. Cement shall not
react chemically with metal parts in contact with it and its thickness shall be as small and
as uniform as possible.

The insulator design shall be such that the insulating medium shall not directly engage
with hard metal. The surfaces of porcelain and hard metal should be coated with resilient
paint to offset the effect of difference in thermal expansions of these materials.
5.05.4 MATERIAL DESIGN AND WORKMANSHIP

5.05.4.1 GENERAL
(i) All raw materials to be used in the manufacture of these insulators shall be
subject to strict raw material quality control and to stage testing/quality control
during manufacturing stage to ensure the quality of the final end product.
Manufacturing shall conform to the best engineering practices adopted in the field
of extra high voltage transmission. Bidders shall therefore offer insulators as are
guaranteed by them for satisfactory performance on 400KV Transmission lines.

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(ii) The design, manufacturing, process and material control at various stages
be such as to give maximum working load, highest mobility, best resistance to
corrosion, good finish, elimination of sharp edges and corners to limit corona and
radio interference voltages.
5.05.4.2 INSULATOR SHELL
The design of the insulator shells shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration. Shells with cracks
shall be eliminated by temperature cycle test followed by mallet test. Shells shall be dried
under controlled conditions of humidity and temperature.
5.05.4.3 METAL PARTS
(i) The pin and cap shall be designed such that it will not transmit the
mechanical stresses to the shell by compression and develop uniform mechanical
strength in the insulator. The cap shall be circular with the inner and outer surfaces
concentric and of such design that it will not yield or distort under loaded
conditions. The head portion of the pin ball shall be suitably designed so that when
the insulator is under tension the stresses are uniformly distributed over the
pinhole portion of the shell. The pin ball shall move freely in the cap socket either
during assembly of a string or during erection of a string or when a string is placed
in position.

(ii) Metal caps shall be free from cracks, seams, shrinks, air holes, blow holes
and rough edges. All metal surfaces shall be perfectly smooth with no projecting
parts or irregularities, which may cause corona. All load bearing surfaces shall be
smooth and uniform so as to distribute the loading stresses uniformly. Pins shall
not show any microscopically visible cracks, inclusions and voids.
5.05.4.4 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the latest edition
of IS:2629. The zinc to be used for galvanizing shall conform to grade Zn 99.5 as per
IS:209. The Zinc coating shall be uniform, smoothly adherent, reasonably bright,
continuous and free from impurities such as flux, ash, rust stains, bulky white deposits and
blisters. Before ball fittings are galvanized, all die flashing on the shank and on the
bearing surface of the ball shall be carefully removed without reducing the designed
dimensional requirements.
5.05.4.5 SECURITY CLIPS (LOCKING DEVICES)
The security clips to be used as a locking device for ball and socket coupling shall be ‘R’
shaped hump type to provide for positive locking of the coupling as per IS:2486 (Part IV).
The legs of the security clips shall allow for spreading after installation to prevent
complete withdrawal from the socket. The locking device shall be resilient, corrosion
resistant and of sufficient mechanical strength. There shall be no possibility of the locking
device to be displaced or be capable of rotation when placed in position and under no
circumstances shall it allow separation of insulator units and fittings. ‘W’ type security clips
are also acceptable. The hole for the security clip could be countersunk and the clip shall
be of such design that the eye of the clip may be engaged by a hot line clip puller to
provide for disengagement under energized conditions. The force required for pulling the
clip into its unlocked position shall not be less than 50 N (5 kgs) or more than, 500 N (50
kgs).

5.05.5 BALL AND SOCKET DESIGNATION

The dimensions of the balls and sockets for 120KN discs shall be of 20 mm designation in
accordance with the standard dimensions stated in IS:2486 (Part II).
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5.05.6 DIMENSIONAL TOLERANCE OF DISC INSULATOR

It shall be ensured that the dimensions of the disc insulators are within the limits specified
below:
a. Diameter of Disc (mm)

Rating Standard Maximum Minimum


120 KN Disc 255 266 244
160 KN Disc 280 293 267

b. Ball to Ball Spacing between Discs (mm)

Rating Standard Maximum Minimum


120 KN Disc 145 149 141
160 KN Disc 170 175 165

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

5.05.8 CORONA AND RADIO INTERFERENCE VOLTAGE (RIV) PERFORMANCE


All surfaces shall be even, smooth, without cuts, abrasions or projections. No part shall
be subjected to excessive localized pressure. The metal parts and porcelain shall not
produce any noise generating corona under all operating conditions.

5.05.9 SUITABILITY FOR LIVE LINE MAINTENANCE

5.05.9.1 The insulators shall be compatible for use with hot line or live line maintenance
techniques so that usual hot line operations can be carried out with ease, speed and
safety.

5.05.9.2 Suppliers shall indicate the methods generally adopted in routine hot and cold
line maintenance of EHV lines for similar insulators supplied by them. Suppliers shall also
indicate the recommended periodicity of such maintenance.

5.05.10 FREEDOM FROM DEFECTS


Insulators shall have none of the following defects:

i) Ball pin shake


ii) Cementing defects near the pin like small blow holes, small hair cracks,
lumps, etc.
iii) Sand fall ferro particle defects on the surface of the insulator.
iv) Shell eccentricity

5.05.11 INSULATOR STRINGS

5.05.11.1 TYPE AND RATING

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The insulator strings shall be formed with standard discs described in this specification for
use on 3 phase, 400kV, 50Hz effectively earthed systems in a moderately polluted
atmosphere. Suspension insulator strings for use with suspension towers are to be fitted
with discs of 120KN EMS rating .Tension insulator strings for use with Anchor/Tension
towers are to be fitted with discs of 160 kN EMS rating.

5.05.11.2 STRING SIZE


The size of the disc insulator, the number to be used in different types of strings and their
electro-mechanical strength shall be as follows:
S.No. Type of String Size of No.of Electro
disc standard mechanical
insulator discs strength of
(mm) insulator
string (kN)
a) Single Suspension for 400KV 255 X145 23 120
b) Double Suspension for 400KV 255 x145 2x23 2x120
c) Single Tension for 400KV 280x170 24 160

d) Double Tension for 400KV 280x170 2x24 2x160

5.05.12 STRING CHARACTERISTICS

5.05.12.1 The characteristics of the complete string shall be as follows :

S.No Particulars Single / Double Single /Double


Suspension Tension
400KV 400KV
i. Switching surge withstand 1050 1050
voltage(dry & wet) KV peak
ii Lightening Impulse withstand 1600 1700
voltage (dry) KV peak
iii Power frequency withstand voltage 680 690
(wet) KV r.m.s
iv Mechanical failing Load-kgf 11500/23000 16500/ 33000
v No deformation load-kgf 7705/ 15410 11055/ 22110
vi. Corona Extinction Voltage KV rms 320 320
vii. Max.RIV for complete string at 500 500
266KV(rms) line to ground voltage
(micro volt)
viii. Max.voltage across any disc 9% 9%

5.05.12.2 Insulator units after assembly shall be concentric and coaxial within limits
as permitted by Indian standards.

5.05.12.3 The string design shall be such that when units are coupled together there
shall be contact between the shell of one unit and metal of the next adjacent unit.

5.06 TESTS
The following tests shall be carried out on the insulator string and also on unit disc
insulators.
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5.06.1 TYPE TESTS


This shall mean those tests which are to be carried out to prove the design, process of
manufacture and general conformity of the material and product with the intents of this
specification. These tests shall be conducted on a representative number of samples prior
to commencement of commercial production. The successful supplier shall indicate his
schedule for carrying out these tests. For any change in the design/type already type tests
and the design/type offered against this specification , the purchaser reserves the right to
demand repetition of test without extra cost

5.06.2 ACCEPTANCE TESTS


This shall mean those tests which are to be carried out on samples taken from each lot
offered for pre-despatch inspection for the purpose of acceptance of the lot.

5.06.3 ROUTINE TESTS


This shall mean those tests, which are to be carried out on each insulator to check the
requirements which are likely to vary during production.

5.06.4 STAGE TESTS DURING MANUFACTURE

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

5.06.5 TEST VALUES

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

5.06.6 TEST PROCEDURES AND SAMPLING NORMS

5.06.6.1 The norms and procedure of sampling for the above tests shall be as
per the relevant Indian Standard or other Internationally accepted standards. This
will be discussed and mutually agreed to between the successful Supplier and
Purchaser before placement of order. The standards and norms according to
which these tests are to be carried out are listed against each test. Where a
particular test is a specific requirement of this specification, the norms and
procedure for the same shall be as specified in Appendix-I attached hereto or as
mutually agreed to between the successful Supplier and the Purchaser in the
Quality Assurance Programme. The supplier shall offer at least three times the
quantity of materials required for conducting all the type tests for sample selection.
Before sample selection, the supplier shall be required to conduct all the
acceptance tests successfully in presence of Purchaser’s representative.

5.06.7 DETAILS OF TYPE TESTS

5.06.7.1 The material offered shall be fully type tested as per this specification and
the Supplier shall furnish four sets of type test reports alongwith the offer. These tests
must not have been conducted earlier than five years.

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5.06.7.2 TYPE TESTS

(A) The following type tests shall be conducted on all types of the complete
insulator string with hardware fittings :

a) Power frequency voltage withstand test with corona control


rings and arcing horn under (dry/wet) conditions
b) Power frequency voltage flash over test with corona control
rings and arcing horn under (dry/wet) conditions
c) Power frequency voltage flash over test without corona control
rings and arcing horn under (dry/wet) conditions
d) Switching surge voltage withstand test under wet condition.
e) Impulse voltage withstand test under dry condition.
f) Voltage Distribution test
g) Impulse voltage flash over test under dry condition
h) Corona and RIV Test under dry condition.
i) Mechanical strength test
j) Vibration test.

(B) Following type tests shall be conducted on string insulators/unit disc


insulators

a) Visible discharge test IS:731


b) Impulse voltage withstand test IS:731
c) Wet power frequency voltage withstand test IS:731
d) Verification of dimension test IS:731
e) Temperature cycle test IS:731
f) Electro-Mechanical failing load test IS:731
g) Puncture test IS:731
h) Porosity test IS:731
i) Galvanising test IS:731
j) 24 hours mechanical failing load test IS:731
k) Metallurgical test IS:2108 & IS:2004

5.06.8 DETAILS OF ACCEPTANCE AND ROUTINE TESTS

i. All Acceptance and Routine tests as stipulated herein shall be carried out by the
Supplier in the presence of Purchaser’s representative.Immediately after
finalisation of the programme of acceptance/routine testing, the Supplier shall give
sufficient advance intimation to the Purchaser, to enable him to depute his
representative for witnessing the test.
ii. For String Insulator Units following Acceptance & Routine tests shall be
conducted:
(A) Acceptance tests:
a) Verification of dimensions IS:731
b) Temperature cycle test IS:731

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c) Galvanising test IS:731


d) Mechanical performance test IEC:575
e) Test on locking device for ball and IEC:372/IS-2486(part-IV)
socket coupling
f) Eccentricity test As per Specification
g) Electro-mechanical strength test
h) Puncture test IS-731
i) Porosity test
(B) Routine tests:

a) Visual Inspection IS-731


b) Mechanical routine test

c) Electrical routine test IEC:383

iii. Tests during Manufacture (STAGE TESTS)


On all components as applicable
a) Chemical analysis of Zinc used for
galvanizing
b) Chemical analysis, mechanical and
metallographic test and magnetic
particle inspection for malleable
castings As per this
Specification
c) Chemical analysis, hardness test and
magnetic particle inspection for
forgings
d) Crack detection test for metal parts

5.06.9 ADDITIONAL TESTS

The purchaser reserves the right for carrying out any other tests of a reasonable nature at
the works of the Supplier/laboratory or at any other recognized laboratory / research
institute in addition to the above mentioned type, acceptance and routine tests at the cost
of the Purchaser to satisfy that the material complies with the intent of this specification.

5.06.10 COORDINATION FOR TESTING:

For 400KV insulator strings, the Supplier is required to produce type test reports to the
satisfaction of the Purchaser. However, in case the Purchaser desires, the Supplier shall
conduct all the type tests on the complete string with relevant hardware fittings.
Responsibility of arranging required hardwares for the purpose of type testing will remain
with the insulator Supplier.

5.07 INSPECTION

i) Purchaser and its representatives shall at all times be entitled to have


access to the works and to all places of manufactures where insulators are
manufactured and the successful Supplier shall afford all facilities to them for
unrestricted inspection of the works, inspection of material, inspection of
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manufacturing process of insulators and for conducting necessary tests as


specified herein.

ii) The successful Supplier shall keep the Purchaser informed in advance of the time
of starting and progress of manufacture of insulators in its various stages so that
arrangements could be made for inspection.

iii) No material shall be dispatched from its point of manufacture unless the material
has been satisfactorily inspected and tested.

iv) The acceptance of any quantity of insulators shall in no way relieve the successful
Supplier of his responsibility for meeting all the requirement of this specification
and shall not prevent subsequent rejection, if such disc insulators are later found to
be defective.

5.08 IDENTIFICATION MARKING

5.08.1 Each disc insulator shall be legibly and indelibly marked with the trade mark of the
manufacturer, the month and year of manufacture, the guaranteed combined mechanical
and electrical strength in kilo-newtons abbreviated by ‘KN’ to facilitate easy identification
and proper use.

5.08.2 The marking shall be on porcelain shell of insulators. The marking shall be printed
and not impressed/embossed and same shall be applied before firing.

5.08.3 One 10mm thick ring of good quality paint shall be marked on the cap of each
insulator of particular strength for easy identification of the type of insulator. The paint
shall not have any deteriorating effect on the insulator performance. Following codes shall
be used as identification mark:-
For 120KN disc insulator- Yellow
For 160kN disc insulator – Red

5.09 QUALITY ASSURANCE PLAN

5.09.1 The Supplier hereunder shall invariably furnish following information alongwith his
offer, failing which the offer shall be liable for rejection. Information shall be separately
given for individual type of material offered.

i) Statement giving list of important raw materials, names of sub-suppliers for the raw
material, list of standards according to which the raw material are tested, list of
tests, normally carried out on raw material in presence of Supplier’s representative,
copies of test certificates.
ii) Information and copies of test certificates as in (i) above in respect of bought out
items.
iii) List of manufacturing facilities available.
iv) Level of automation achieved and list of areas where manual processing exists.
v) List of areas in manufacturing process, where stage inspections are normally
carried out in quality control and details of such test and inspections.
vi) Special features provided in the insulators to make it maintenance free.
vii) List of testing equipment available with the Supplier for final testing of insulators
specified and test plant limitation, if any, vis-a-vis the type, special, acceptance
and routine tests specified in the relevant standards.

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5.09.2 The successful Supplier shall within 30 days of placement of order submit the
following information to the Purchaser.

i) List of raw material as well as bought out accessories and the name of material as
well as bought out accessories and the names of sub-suppliers selected from
those furnished alongwith the offer.
ii) Type test certificates of the raw material and bought out accessories.
iii) Quality assurance plan (QAP) with hold points for Purchaser’s inspection. The
QAP and Purchaser’s hold points shall be discussed between the Purchaser and
the Supplier before the QAP is finalized.

5.09.3 The successful Supplier shall submit the routine test certificates of bought out
items and raw material at the time of routine testing of the insulator.

5.10 DOCUMENTATION

5.10.1 The Supplier shall furnish full description and illustrated catalogues of insulators
offered, alongwith the bid. The supplier shall also furnish alongwith the bid the outline
drawing of each insulator unit including cross-sectional view of the shell. The drawing
shall include the following information :
i) Shell diameter and unit spacing with manufacturing tolerance.
ii) Creepage distance.
iii) Unit mechanical and electrical characteristics as also for the complete
string-suspension and tension.
iv) Size and weight of ball and socket part.
v) Weight of unit insulator disc.
vi) Materials for the disc, cap and pin.
vii) Identification mark.
viii) Manufacturer’s catalogue number.
ix) Brief installation instructions.
x) Relevant technical details of significance.

5.10.2 TEST REPORTS


i) Four copies of type test reports shall be furnished to the Purchaser within
one month of conducting the tests. One copy will be returned duly certified
by the Purchaser to the Supplier within three weeks thereafter and on
receipt of the same Supplier shall commence with the commercial
production of the insulators.

ii) Four copies of acceptance test reports shall be furnished to the Purchaser.
One copy will be returned, duly certified by the Purchaser and only
thereafter shall the materials be despatched.

iii) All records of routine test reports shall be maintained by the Supplier at his
works for periodic inspection by the Purchaser.

iv) All test reports of tests conducted during manufacture shall be maintained
by the Supplier. These shall be produced for verification as and when
requested for by the Purchaser.
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5.11 PACKING & FORWARDING


i) All disc insulators shall be packed in strong seasoned wooden crates. The
gross weight of the crates alongwith disc insulators shall not normally
exceed 100 kg. to avoid handling problem.

ii) The packing shall be of sufficient strength to withstand rough handling


during transit, storage at site and subsequent handling in the field.

iii) Suitable cushioning, protective padding, or dunnage or spacers shall be


provided to prevent damage or deformation during transit and handling.

iv) All packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and avoid the possibility of goods being lost or
wrongly dispatched on account of faulty packing and faulty or illegible
markings. Each wooden case/crate shall have all the markings stenciled on
it in indelible ink.

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Appendix-I
TEST DETAILS

1. Voltage Distribution Test:


The voltage across each insulator unit shall be measured by sphere gap
method. The result obtained shall be converted into percentage and proportionate
correction be applied so as to give a total of 100% distribution. The voltage across
any disc shall not exceed 9% for suspension insulator strings and for double tension
insulator strings. The total of the voltage distribution of all discs so computed shall be
within 95% and 105%. If not, the test shall be repeated. The proportions correction
shall be made on the values so as to give a total of 100% distribution.
2. Mechanical Strength Test:
The complete insulator string alongwith its hardware fittings excluding arcing
horn, corona control ring/grading ring and suspension assembly/dead end assembly
shall be subjected to a load equal to 50% of the specified minimum ultimate tensile
strength (UTS) which shall be increased at steady rate to 67% of the minimum UTS
specified. The load shall be held for five minutes and then removed. After removal of
the load, the string components shall not show any visual deformation and it shall be
possible to disassemble them by hand. Hand tools may be used to remove cotter pins
and loosen the nuts initially. The string shall then be reassembled and loaded to 50%
of UTS and the load shall be further increased at a steady rate till the specified
minimum UTS and held for one minute. No fracture should occur during this period.
The applied load shall then be increased until the failing load is reached and the value
recorded.
3. Vibration Test:
The suspension string shall be tested in suspension mode, and tension string
in tension mode itself in laboratory span of minimum 30 metres. In the case of
suspension string a load equal to 600 kg shall be applied along the axis of the
suspension string by means of turn buckle. The insulator string alongwith hardware
fittings and two sub-conductors (each tensioned at 4500 kg) shall be secured with
clamps. The system shall be suitable to maintain constant tension on each sub-
conductors throughout the duration of test. Vibration Dampers shall not be used on the
test span. Both the sub-conductors shall be vertically vibrated simultaneously at one
of the resonance frequencies of the insulator string (more than 10 Hz) by means of
vibration inducing equipment. The amplitude of vibration at the antinode point nearest
to the string shall be measured and the same shall not be less than + 120/f , f being
the frequency of vibration. The insulator string shall be vibrated for five million cycles
then rotated by 90 deg. and again vibrated for 5 million cycles without any failure.
After the test, the disc insulators shall be examined for looseness of pins and cap or
any crack in the cement. The hardware fittings shall be examined for fatigue failure
and mechanical strength test. There shall be no deterioration of properties of
hardware components and disc insulators after the vibration test. The disc insulators
shall be subjected to the following tests as per relevant standards:
Test Percentage of
discs to be
tested
Temperature cycle test followed by 60
mechanical performance test
Puncture test (for porcelain insulator only) 40

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If the results of the second test show a porcelain shell rupture, the production does
not comply with this specification.

4. Chemical Analysis of Zinc used for Galvanising:

Samples taken from the zinc ingot shall be chemically analysed as per IS:209. The
purity of zinc shall not less than 99.95%.

5. Tests for Forgings:

The chemical analysis, hardness tests and magnetic particle inspection for
forgings, will be as per the internationally recognized procedures for these
tests. The sampling will be based on heat number and heat treatment batch.
The details regarding test will be as discussed and mutually agreed to by the
Supplier and Purchaser in Quality Assurance Programme.

6. Test on Castings:

The chemical analysis, mechanical and metallographic tests and magnetic


particle inspection for castings will be as per the internationally recognized procedures
for these tests. The samplings will be based on heat number and heat treatment
batch. The details regarding test will be as discussed and mutually agreed to by the
Supplier and Purchaser in Quality Assurance Programme.

7. Eccentricity Test:

The insulator shall be vertically mounted on a fixture using dummy pin and socket.
A vertical scale with horizontal slider shall be used for the axial run out. The
pointer shall be positioned in contact with the bottom of the outermost petticot of
the disc. The disc insulators shall be rotated with reference to the fixture and the
slider shall be allowed to move up and down on the scale but always maintaining
contact with the bottom of the outer most petticot. After one full rotation of the
disc, the maximum and minimum position the slider has reached on the scale can
be found out. Difference between the above two readings shall satisfy the
guaranteed value for axial run out. Similarly using a horizontal scale with vertical
slider the radial run out shall be measured. The slider shall be positioned on the
scale to establish contact with the circumference of the disc insulator and disc
insulator rotated on its fixture always maintaining the contact. After one full
rotation the maximum and minimum position of the slider reached on the scale are
found out. The difference between the above readings shall satisfy the
guaranteed value for radial run out.

8. Crack Detection Test:

Crack detection test shall be carried out on each ball and pin before
assembly of disc unit. The manufacturer shall maintain complete record of having
conducted such tests on each and every piece of ball pin. The supplier shall furnish
full details of the equipment available with him for crack test and also indicate the test
procedure in detail.

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SYSTEM PARTICUALRS

S.No PARTICULARS Electrical


. System Data
1 System A.C.
3phase
2 Line voltage (kV rms) 400
3 Max.voltage (kV rms) 420
4 Frequency 50 Hz
5 Neutral grounding system effectively earthed
6 Lightning impulse with-stand voltage(dry & 1425
wet)(kVp)
7 Power frequency withstand 630
voltage (wet) (kVp)
8 Switching surge withstand 1050
voltage (wet) (kVp)
9 Short circuit level (kA) 40
10. Minimum corona extinction voltage at 50 320
Hz AC system dry condition (Kv rms)
11. Radio interference voltage at one MHz for 500
phase to earth voltage of 266KV dry
conditions(Microvolt)

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6.0 TECHNICAL SPECIFICATIONS OF HARDWARE FITTINGS & ACCESSORIES


FOR 400 kV LINES

6.1 SCOPE:

6.1.1 This section provides for manufacturing, stage testing, inspection and testing
before despatch, packing and delivery of Hardware fittings for Insulator string and
accessories suitable for Conductor and Ground wire for use on 400KV transmission line.
6.1.2 It is not the intent to specify completely herein all details of the design and
construction of material. However, the material shall conform in all respects to high
standards of engineering, design and workmanship and shall be capable of performing the
duties specified herein. The material offered shall be complete with all components
necessary for its effective and trouble free operation. Such components shall be deemed
to be within the scope of Bidder’s supply, irrespective of whether these are specifically
brought out in this specification or not.
6.2 STANDARDS:

6.2.1 The material and services under this specification shall be performed as per the
requirements of the latest revisions and amendments available at the time of placement of
order of all the relevant Indian Standards/Codes listed here under except as modified in
this document:
S.No Indian Standard Title
1 IS:209-1992 Specification for Zinc Ingot
2 IS:206 –1992 Tee and Strap Hinges
3 IS:7814-1985 Phosphor Bronze Sheet and Strip
4 IS:2071 Part-I, II & III Method of high voltage testing (P
Porcelain Insulator for Overhead Power Lines
5 IS:731
with a Nominal Voltage Greater than 1000 V.
6 IS:961 Structural Steel
Phosphor Bronze Rods & Bar Sheet and Strips
7 IS:1385
and Wire
Carbon Steel Forgings for General Engineering
8 IS:2004
Purpose
9 IS:2107 White Hearth Malleable Iron Castings
10 IS:2108 Black Hearth Malleable Iron Castings
Specification for Conductors and Ground wire
11 IS:2121(Part-I & II) Accessories for Overhead Power Line, Armour
Rods Binding Wires and Tapes for Conductor
Specification for Insulator Fittings for Overhead
IS:2486 Power Lines with a Nominal Voltage Greater
12 than 1000 V.
Part-I General Requirements and Tests

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S.No Indian Standard Title


Part-II Dimensional Requirements
Part-III Locking Devices
Part-IV Tests for Locking Devices
Recommended Practice for Hot Dip
13 IS:2629
Galvanization of Iron and Steel.
Testing of Uniformity of Coating of Zinc coated
14 IS:2633
Articles
15 IS:3138 Hexagon Bolts and Nuts
16 IS:6639 Hexagon Bolts for Steel Structures
Determination of Weight of Zinc Coating on
17 IS:6745
Zinc Coated Iron and Steel Articles
18 IS:3188 Characteristic of String Insulators Units
19 IS:4218 Part-I to VI ISO Metric screw Threads

20 Dimensions for Radii under the Heads of Bolts


IS:4172
& Screws

21 Dimensions for nominal lengths and Thread


IS:4206
length for Screws and Studs (with amendment)

22 Hot Dip Zinc Coatings on Structural Steel and


IS:4759
other Allied Products
Electroplated Coatings of Zinc on Iron and
23 IS:1573-1986
Steel

24 Specification for Aluminium Conductor Steel


IS: 398 (Part-II & III)
Reinforced for overhead transmission purpose.

25 Methods for determination of weight of tin


IS: 1327-1966
Coating on Tin Plates
Hot Dip Galvanised Coating on Round Steel
26 IS: 4826-1979
Wires
27 IS: 1363 Part-I to III Hexagon Head Bolts, Screws & Nuts.
Technical supply conditions for threaded Steel
IS: 1367
Fasteners.
28 Introduction and General Information.
IS: 1367 (Part-I)
Product Grades and Tolerances.
IS: 1367 (Part-II)
Mechanical Properties and Test Methods for
IS: 1367 (Part-III)
Bolts, Screws and Studs with full Load ability.
29 Stockbridge Vibration Dampers for Overhead
IS: 9708
Power lines.
30 Method of Radio Interference Tests on High
IS: 8263
Voltage Insulators.
31 Spacers and Spacer Dampers for twin
IS:10162
horizontal bundle Conductors.
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S.No Indian Standard Title

32 Carbon Steel Forgings for general engineering


IS: 2004
purposes.
General Instructions and Testing Procedures
33 BS:970 (Part-I) Specific Requirements for Carbon and Carbon
Manganese Alloy and Stainless Steels.

6.2.2 In the paragraph 2.1 above, relevant Indian Standards have been mentioned.
However, the Hardware fittings meeting any other authoritative international standard,
which ensures equal or better quality than the Standards, mentioned above shall also be
acceptable. Please attach photocopy of all such Standards according to which the
Hardware fittings have been offered.

6.3 TOPOGRAPHY AND CLIMATIC CONDITIONS:

The material to be supplied against this specification shall be suitable for satisfactory
operation under the tropical climatic conditions as under:

1 Location in the state of MADHYA PRADESH


2 Maximum ambient air temp. 50 0C
3 Minimum temperature in shade 1 0C.
95%(sometimes approaches
4 Maximum relative humidity
Saturation)
5 Average daily ambient air temp. 40 0C
Isoceraunic Level (Average number of
6 50 days per year
thunder storm days)
7 Average rainfall 1250 mm
8 Max. Altitudes above mean sea level 1000 meter
9 Seismic level (Horizontal acceleration) 0.3 g

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

6.3.1 PRINCIPAL PARAMETERS:

6.3.2 DETAILS OF HARDWARE FITTINGS:

(a) The Hardware fittings shall meet the technical requirement as per
specification and also general arrangement drawings of Hardware fittings attached
herewith. Hardware fittings shall be suitable for single/double suspension Insulator
strings, single/double tension Insulator strings and single suspension-pilot insulator
strings. Each Hardware fitting shall be supplied complete in all respect and shall
include all components, which are required for making complete set.
(b) The hardware fittings for lines shall be suitable for ACSR Moose Conductor
and Groundwire as per technical parameters indicated below:-

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S.No Particulars Moose ACSR Ground


Wire
1. Material ACSR Steel
2. Size 325 mm² Cu. --
eq.
3. Nominal Aluminium area 515.70 mm² --
4. Stranding and wire diameter 54/3.53 Alu.+ 7/3.66mm.
(no./mm) 7/3.53 steel.
5. Number of strands in each layer.
Central core 1 of steel 1 of steel
1st layer 6 of steel 6 of steel
2nd layer 12 of Alu.
3rd layer 18 of Alu.
4th layer 24 of Alu.
6. Sectional area of Alu. 515.70 --
7. Total sectional area 597 mm² --
8. Approximate overall diameter 31.77 mm 10.98 mm
9. Overall diameter when wrapped - 18.30 mm
with preformed Armour Rod
10 Approximate weight 2004 Kg per 583Kg per
Km Km
11 Calculated D.C. resistance at 20º C 0.0551 2.5 Ohm/km
Ohm/km
12 Approximate Breaking Load 16250 Kgs. 6972 kgs
13 Co-efficient of Linear Expansion 19.53 x 10-6 11.5 x 10-6
per ºC per ºC
14 Final Modulus of Elasticity 0.686 X 106 1.931X106
kg/cm² kg/cm²
6.4 INSULATOR STRING CHARACTERISTICS:

(a) The complete insulator string including Hardware fittings shall have the following
characteristics:
S. Single/ Double Single/ Double
Characteristics
No Suspension Tension
1 1x23 1x24
No. of Standard Discs
2x23 2x24
2 Nominal diameter of discs 280 280
3 Power frequency Withstand voltage (wet) kV
680 690
(rms)
4 Lighting impulse withstand voltage
1600 1700
(dry)(kVp)
5 Switching surge Withstand voltage (Dry &
1050 1050
wet) (kVp)
6 Mechanical failing Load (kgf) 11500/23000 16500/33000
7 Pollution Moderately Moderately
polluted polluted
8 Corona Extinction voltage (KV rms) 320 320

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(b) The Insulator string Hardware fittings shall comply and conform to the above
requirement.

6.5 BALL AND SOCKET DIMENSIONS:

The Ball and Socket for Hardware fittings shall necessarily conform to the
dimensions as stipulated in the Indian Standards. The Ball and Socket dimension of
Hardware to be used with 11500 Kg & 16,500 kg Electro Mechanical strength disc
insulator shall conform to designation 20mm in accordance with IS-2486:(Part-II). The
Bidder shall submit full detail of locking device in accordance with IS 2486:(Part-III) or
equivalent International Standard along with test reports, gauges and adherence to
Standards for Tests on Locking Devices in line with IS:2486 (Part-IV) or equivalent
International Standard.
6.6 REQUIRED GUARANTEED STRENGTH OF HARDWARE OF INSULATOR STRINGS:

6.6.1 The slipping strength of the suspension clamp shall not be less than 15% and
more than 20% of the Conductor strength with which it is to be used.
6.6.2 The Hardware and Compression Clamp of single & double tension strings suitable
for Moose ACSR for 400KV transmission line shall have ultimate breaking strength of not
less than 16500 kgs. The Compression Clamp shall have slipping strength not less than
95% of breaking strength of Moose ACSR.
6.6.3 Each individual Hardware component of double suspension and double tension
strings such as ball-clevis, socket clevis etc. shall have minimum breaking strength as
specified for respective single suspension and tension string respectively.

6.7 PARTICULARS OF HARDWARE FITTINGS:

Each Hardware fitting shall be complete in all respect and Bidder should furnish
complete drawings and technical particulars of the items quoted. The Hardware fittings
should normally comprise items conforming to enclosed drawing as under: -
6.7.1 Single Suspension Hardware Fitting with AGS Type Clamp:
Single suspension Hardware string shall comprise of one Anchor Shackle, Horn
holder Ball eye, line side arcing horn, yoke plate, corona control ring and two Suspension
Clamps of AGS type with armour rod as per enclosed drawing.
6.7.2 Double Suspension String Hardware Fittings with AGS Type Clamp:
The double suspension string Hardware fittings shall comprise of one Anchor
Shackle, one Top Yoke Plate, two Ball Clevis, two Socket Clevis, corona control ring, one
bottom Yoke Plate, two line side Arcing Horns, two Clevis Eye and two AGS type
Suspension Clamps with armour rod as per enclosed drawing.
6.7.3 Single suspension Pilot string for Moose ACSR:
The single suspension pilot string for Moose ACSR shall comprise of one Anchor
Shackle, one Horn holder Ball eye, one line side arcing horn, one yoke plate, corona
control ring and two envelope type suspension clamps as per enclosed drawing.
6.7.4 Single Tension String Hardware Fittings:
Single tension string Hardware shall comprise of one `D’ Shackle, one Ball Link,
one Forged Steel Socket, Socket Clevis Horn holder, one line side Arcing Horn and one
Tension Clamp of compression type having before and after compression dimensions
strictly as shown in Clause 7.10 below.
6.7.5 Double Tension String Hardware Fittings:

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The double tension string Hardware shall comprise of two Anchor shackle, one
chain link one top yoke plate, two ball clevis, two socket clevis, one bottom yoke plate,
one arcing horn, two socket clevis, two clevis eye and two compression type dead-end
Clamps having `before and after compression’ dimensions strictly as shown in Clause
7.10 below.
6.8 GROUNDWIRE ASSEMBLIES:

6.8.1 Ground Wire Suspension Assembly With Preformed Armour Rods:


This shall comprise of envelope type Suspension Clamp of heat-treated malleable
iron, one Chain Link and one ‘D’ Shackle. The entire assembly shall be hot dip galvanized
complete with minor accessories. The breaking strength of all the Hardware items of the
assembly shall not be less than 7000 kgs. The complete assembly of suspension clamp
shall be guaranteed for slip strength of not less than 15 KN & not more than 19 KN. The
strength of the Ground wire has been specified in Clause 7.04.01. The suspension
assembly shall be supplied with armour rod for groundwire.
6.8.2 Ground Wire Tension Assembly:
The Ground wire tension assembly shall have minimum breaking strength equal to
that of the Ground Wire. The slipping strength of the Compression Clamp shall not be
less than 95% of the breaking strength of Ground Wire. The Ground wire tension
assemblies shall be of two types as under: -
The strain assembly of the Ground wire shall comprise of compression type dead
end Clamp and two `D’ Shackles complete with minor accessories such as pins, bolts &
nuts etc. Strain assembly shall be hot dip galvanized and made inherently resistant to the
atmosphere corrosion. The dead end Clamp of the assembly shall be of compression
type. The tension clamp shall be attached to the horizontal strain plate of the tower body
by means of a “D” shackle. “D” shackle shall be suitable for attaching the tension clamp to
strain plate of towers with a hole of 21.5 mm diameter. The tension clamp body shall be
made out of steel of 304 L grade or equivalent with Brinnel Hardness not exceeding 200.
The complete assembly shall also include one 12.5mm dia, 45 mm long HRH MS Bolt hot
dip galvanized with nuts and lock washers for attaching copper earth bond. A detailed
drawing giving dimensional details of the complete assembly shall accompany the tender.
After compression, dimensions of the joint shall be as indicated in Clause 4.10 below.
6.9 BEFORE AND AFTER COMPRESSION DIMENSIONS OF COMPRESSION TYPE DEAD-
END CLAMPS FOR CONDUCTOR AND GROUND WIRE

Dimension Dimension Length of Length of


before after sleeve before sleeve after
compression compression compression compression
Sr. (Rod cross (Flat to flat
Particular
No. section) distance of
hexagon)
G/ W Moose G/ W Moose G/ W Moose G/ W Moose

A Aluminium clamp
a Inner dimension (mm) - 34 -
b Outer dimension (mm) - 54 - 46 - 735 - 785
B Steel clamp
a Inner dimension (mm) 11.5 11.1 -
b Outer dimension (mm) 21 21 17.5 17.5 230 250 262 285

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6.10 DETAILS OF COMPONENTS OF HARDWARE FITTINGS:


6.10.1 Suspension Assembly for twin Moose:
a) The suspension assembly suitable for twin ACSR “Moose Conductor for
400KV Lines shall include two armour-grip suspension clamps except for pilot
insulator string for which two suitable Envelope type suspension clamps shall
be used.
b) The suspension clamp alongwith standard preformed armour rods set shall be
designed to have maximum mobility in any direction and minimum moment of
inertia so as to have minimum stress on the conductor in the case of oscillation
of the same.
c) The suspension clamp alongwith standard preformed armour rods shall have
slip strength between 20 to 29KN.
d) The suspension assembly shall be smooth without any cuts, grooves,
abrasions, projections, ridges or excrescence, which might damage the
conductor.
6.10.2 Armour Grip Suspension Clamp (AGS):
(a) AGS fitting shall consist of 2 Neoprene Halves, a set of Helical rods made of
Aluminium alloy, two Aluminium halves casting having inner profile matching
with the profile of the Armour rod cage and jointed by supporting strap made
of Aluminium alloy.
(b) The Bidder should give complete data on the reduction of the dynamic
stresses of the Conductor at the point of AGS support compared to that of
bare clamp used with preformed types of Armour rods.
(c) The Bidder will be required to prove the comparative performance in regard to
the dynamic flexural stress pattern on the vibrating Conductor on the
tensioned span with actual tests on the AGS unit compared to the normal bare
clamp with Armour rods. Suitable curves should be furnished along with the
bid for the same and also actual reports on the stress/ strain determinations.
The Bidder should give the guaranteed value of the power loss of the AGS
units offered by them supported by a test certificate of any reputed laboratory
of the country. Suitable curves should be furnished along with the bid for the
power loss due to AGS unit as well as with the conventional envelope type of
Suspension Clamps.
(d) The housing supports and housing straps should provide positive stop
closure. AGS unit should have low rotational inertia, strut action of the Armour
Cage, resilient cushioning of the neoprene insert, immunity from high
compressive and flexural stress and wide area support. Manufacturer is
required to guarantee minimum fatigue life of the AGS units and this would be
established under actual tests on tensioned Conductor span.The manufacturer
is required to guarantee minimum 40 years life of the complete AGS units
including Neoprene cushioning and this should be established under actual
test on a tensioned Conductor span.
(e) The rubber used with AGS unit must be capable of withstanding desired long
out-door performance including the variation of temperature from 0°C to 75°C.
The Bidder will have to provide certificate from reputed manufacturers that the
rubber being supplied by them is suitable for AGS fitting and must have
tensile strength of 2000 PSI and minimum ultimate elongation 300%.
(f) The helical retaining rods required for AGS assembly shall be made of
Aluminium alloy of HE 20 grade as per IS-6051/1970 or equivalent
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International Standard duly heat treated and shall be suitable to wrap a


desired size of Conductor. The tensile strength of the retaining rod material
should not be less than 50,000 PSI and the electrical conductivity should not
be less than 40% (IACS). The minimum slipping strength of the complete
fitting shall not be less than 15% and more than 20% of the UTS of the cable
on which it is to be used. The Clamp shall be in 2 parts made of Aluminium
and will have inner profile matching with the profile of Armour rod. This Clamp
should be made by drop forging process. AGS assembly should be provided
with the forged steel socket eye to match with the suspension string and
should have UTS not less than 7,000 kgs.

IT IS ESSENTIAL FOR THE MANUFACTURER TO HAVE SUITABLE


HEAT TREATMENT FACILITIES FOR ALUMINIUM ALLOY WIRES IN THE
ARMOUR GRIP SUSPENSION UNITS. FORMED ROD BASED ITEMS WILL NOT
BE ACCEPTABLE FROM MANUFACTURERS WHO DO NOT HAVE
NECESSARY TECHNOLOGY FOR DEVELOPMENT OF ADEQUATE
RESILIENCE, ELONGATION UTS AND TWIST TEST FACILITIES BACKED
WITH PROPER HEAT TREATMENT SYSTEMS.
6.10.3 AGS Preformed Armour Rods:
(a) The AGS Preformed Armour rods set suitable for ACSR Moose conductor shall
be used to minimize the stress developed in a conductor due to different static
and dynamic loads because of vibration due to wind, slipping of conductor from
suspension clamp as a result of unbalance conductor tension in adjacent span
and broken wire condition. It shall be made of Aluminium alloy of HE 20 grade
as per IS-6051/1970 duly heat-treated. The aluminium alloy wires (pre heat
treated) for manufacturing of Armour rods can also be used, however Bidder
should submit the test certificates in support of their claim for using pre heat-
treated wires. It shall also withstand power arcs, chafing and abrasion from
suspension clamp and localized heating effects due to resistance losses of the
conductor.
(b) The pitch length of the rods shall be determined by the supplier but shall be
less than that of the outer layer of ACSR conductor and the same shall be
accurately controlled to maintain uniformity and consistently reproducible
characteristics wholly independent of the skill of lineman.
(c) The preformed armour rod sets shall have right hand lay and the inside
diameter of the helices shall be less than the outside diameter of the conductor
to grip the same tightly. The surface of the armour rod when fitted on the
conductor shall be smooth and free from projections, cuts and abrasions etc.
(d) The length of each rod shall be as per drawing enclosed. The tolerance in
length of each rod shall be +/-25mm. The tolerance in length of the rods in
completed sets should be within 13 mm between the longest and shortest rod.
The ends of the armour rod shall be parrot billed.
(e) The number of armour rods in each set shall be 11/12. The each rod shall be
marked in the middle with paint for easy applications on the line.
(f) The armour rod shall not loose their resilience even after five applications. The
conductivity of each rod of the set shall not be less than 40% of the
conductivity of International Annealed Copper Standard (IACS). The minimum
tensile strength of armour rod should be 35 kg per sq.mm.
6.10.4 Strain Clamp:
(a) The Strain Clamp shall be of the compression type for the specified size of
Conductor for 400KV lines. The outer sleeve of the Compression Clamp and
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Jumper Terminal shall be of EC grade Aluminium 99.5% pure tube formed by


extrusion process and the inner sleeves shall be of galvanized steel. The angle
of jumper terminal to be mounted should be 30 deg. with respect to the vertical
line. The Compression Clamp shall have slipping strength not less than 95% of
the ultimate breaking strength of Conductor with which it is to be used. The
compression dead end clamp for transmission line shall be manufactured out
of extruded Aluminium.
(b) The resistance of the clamp when compressed on the conductor shall not be
more than 75% of the resistance of equivalent length of conductor. Die
compression line shall be clearly marked on each dead-end assembly
designed for continuous die compression and shall bear the words
“COMPRESS FIRST” suitably inscribed near the point on each assembly
where the compression begins. It shall bear identification marks
“COMPRESSION ZONE” and “NON COMPRESSION ZONE” distinctly with
arrow marks showing the direction of compressions and knurling marks
showing the ends of the Zones. Tapered aluminium filler plugs shall also be
provided at the line of demarcation between Compression and Non-
compression zone. The letters, numbers and other marking on the finished
clamp shall be distinct and legible.
6.10.5 Socket Eye & Ball Clevis:
The Socket Eye and Ball Clevis be made of forged steel as per the drawing
enclosed.
6.10.6 U Clevis:
These shall be made of forged steel complete with galvanised steel rivets washer
and Phosphorus Bronze/Stainless Steel pins.
6.10.7 Ball Fittings:
These shall be made of forged steel in one piece. They shall be normalized to
achieve the minimum breaking strength specified in the respective drawings. Before
galvanising of ball fittings, all die fleshing on the shank and on the bearing surface of the
ball shall be carefully removed without reducing the dimension below the requirements.
The dimension of the ball & socket shall be 20mm designation in accordance with
standard dimensions stated in IS:2486 (Part-II).
6.10.8 Dimensions & Tolerances:
(a) The dimensions and tolerances of pin balls and socket ends shall conform to
IS 2486 Part-II/IEC-120 and shall be checked by the gauge therein after
galvanizing.
(b) The pin balls shall be checked with the applicable “GO” gauges in at least two
directions, one of which shall be across the line of die flashing and the other 90
deg. to this line. “NO GO” gauges shall not pass in any direction.
(c) The bearing surfaces of balls and machined sockets, before galvanizing shall
not have surface roughness more than 250 micro inches.
(d) The bearing surface of socket ends shall be uniform about the entire
circumference without depressions or high spots. The internal contour of the
socket ends shall be concentric with the axis of fittings. The axis of the bearing
surface of socket ends shall be coaxial with the axis of fittings with no
appreciable tilting.

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6.10.9 Socket Fittings:


Socket fittings shall be made of clause IV steel as per IS:2004 or steel of
equivalent grade and shall be forged in one piece. They shall be normalized to achieve
the minimum breaking strength specified on the respective drawings.
6.10.10 Security clip for Socket fittings:
(a) Socket fittings shall be provided with R-shaped security clip in accordance with
IS:2486 (Part-III) to provide positive locking against unintentional
disengagement of socket from the ball of the insulator. The security clip shall
be humped to maintain the clip in the locked position and shall have both
prongs spread to prevent complete withdrawal from the socket. The clip end
shall not project outside the recess of socket when the clip is in locked position.
(b) The hole for the security clip shall be on the side of the socket opposite to the
socket opening. The hole for the clip shall be counter sunk. The clip eye shall
be of such design that the same may be engaged by a hotline clip puller to
provide for disengagement under energized conditions.
(c) The force required to pull the clip to its unlocked position shall not be less than
50 N or more than 500N.
(d) The security clip shall be made of stainless steel of type AISI 302 or 304 or
phosphor bronze as per IS:7814.
6.10.11 Clevis-Eye:
These shall be forged steel of malleable cast iron and shall be complete with
galvanised pin with flat washer and split pin of Phosphorus Bronze/Stainless Steel.
6.10.12 Yoke Plate:
(a) The yoke plates/link plate shall be made of mild steel plate as per IS:2062 or
equivalent standards. Shearing/cutting of the plates shall be clean without
drawn or ragged edges. If the plates are flame cut, mechanical guides shall be
used. It shall be ensured that the grain flow of the yoke plate shall be in the
direction of the tensile load.
(b) Holes shall be cylindrical clean cut and perpendicular to the plane of the
material. The periphery of the holes shall be free from burrs.
(c) All the corners and edges should be rounded off with a radius of at least 3mm.
(d) Design calculation is for bearing and tensile strength for deciding the
dimensions of yoke plate shall be furnished by the Bidder. The holes provided
for bolts in the yoke plate should satisfy shear edge condition as per IS:800.
6.10.13 Corona Control Ring :
(a) The corona control ring shall be provided with hardware fittings and shall be of
such design that it should cover at-least one disc insulator in disc insulator
strings so that they will reduce the voltage across the insulator units. It shall
also improve corona and radio interference performance of the complete
insulator string alongwith hardware fittings.
(b) The corona control rings shall conform to the specification drawings. The same
shall be made of aluminium alloy tube of minimum 2.5mm wall thickness of
type 6063 or equivalent. The same shall be heat treated to maintain
consistency in material properties during service.
(c) Welding of corona control ring shall be done with Argon welding. The welded
locations shall be suitably grinded and shall not allow penetration of water
inside the tube during service. The mechanical strength of welded joint shall
not be less than 20kN.
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(d) The corona control ring shall be buffed and have a brushed satin finish. No
blemish shall be seen or felt while rubbing a hand over the surface.
6.10.14 Sag Adjustment Device:
(e) The sag adjustment devices to be provided with double tension hardware
fittings shall be of three plate type. The sag adjustment device shall be
provided with a safety locking arrangement.
(f) Sag adjuster plates shall be made from high qualify mild steel plate as per
IS:2062. The grain flow shall not be in a direction transverse to the tensile load.
Cutting/shearing and drilling of holes shall be similar to those for yoke plate
mentioned under clause 10.13.2 & 10.13.4.
(g) The maximum length of the sag adjustment plate from the connecting part of
the rest of the hardware fittings shall be 520 mm. The details of the minimum
and maximum adjustment possible and the steps of adjustment shall be clearly
indicated in the drawing. An adjustment of 150mm maximum at the interval of
6mm shall be possible with the sag adjustment plate.
6.11 IMPORTANT CONDITIONS:

6.11.1 All Hardware items shall be complete with minor items such as security clip, bolts,
nuts, washer, split pins and inners etc.
6.11.2 Enclosed drawings show the attachment proposed to be fitted on the towers. The
Bidder shall be responsible for satisfying him that the Insulator fittings offered are entirely
suitable for the proposed attachments and for the sizes of the Conductor specified.
6.11.3 All ferrous fittings (except those specified otherwise) shall be hot dip galvanized,
after all machining and fitting has been completed, in accordance with relevant Indian
Standard. All Hardware items (other than clamps) and those specified otherwise should
be made of Drop Forged Steel. Socket items in forged steel must be forged. All forgings
supplied should be stress relieved and this treatment should be done at the Bidder works.
Forgings, which are not stress relieved, will not be acceptable. The items like Yoke Plate,
Arcing Horn, Bolts and Nuts shall be of mild steel and rest of the items shall be of forged
steel.
6.11.4 All Bolts, Nuts and Screw heads shall have only wide worth standard thread and of
sizes indicated in the enclosed drawing. Bolts head and Nuts shall be hexagonal. Where
required, nuts shall be locked in approved manner. The thread in Nuts shall be over
tapped after galvanizing and shall be cut before galvanizing. The threads shall not be
under cut. The Nuts should be tapped such that they are fit on the bolt threads i.e. these
should not have loose fitting.
6.12 LENGTH OF STRINGS:

6.12.1 The clearance to the tower steel parts under service conditions of Insulator have
been decided on the basis of length of string that the overall length of the 23 Disc for
400KV line will not exceed the length as indicated in the attached drawings. The
dimension of the Disc for Ball and Socket type will be 280mm x145mm for 11500 kgs
EMS to be used with suspension strings.
6.12.2 In case of 400kV tension strings, 24 Disc insulators of 16500 kg EMS of size
280mm (dia) x 170mm (height) will be used.
6.13 GENERAL TECHNICAL REQUIREMENT FOR ACCESSORIES

Details of Accessories:

i. The Conductor Accessories shall be suitable for ACSR Moose Conductor


as per technical parameters furnished in Clause 7.04.

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ii. The Ground wire accessories shall be suitable for Ground wire as per
technical parameters furnished in Clause 7.04.
The technical requirements of the individual Accessories are as under:
6.13.1 MID SPAN JOINTS AND REPAIR SLEEVES:
(a) The Mid Span Joints for Conductor & Ground wire shall be compression type.
(b) The Conductor Mid Span Joints shall comprise of Aluminium and Steel Sleeves.
The Ground wire Mid Span Joints and Steel Sleeves of Conductor Mid Span
Joints shall be Hot dip Galvanized. Sleeves shall be of circular shape suitable
for compression into hexagonal shape. The detailed drawing showing the length
of Sleeves, inner and outer cross sectional dimension, before compression for
Aluminium corresponding dimensions of hexagon after compression for
Aluminium and Steel Sleeve shall be indicated. The Aluminium Sleeve shall be
of extruded Aluminium. The material of the Steel Sleeve shall be specified.
(c) The Repair Sleeve of Conductor shall be in two halves preferably of same
shape, and this should be of extruded Aluminium. . The sleeve shall be
manufactured from 99.5% pure aluminium and shall have a smooth surface The
Repair Sleeve for Ground wire shall be single piece and Hot dip Galvanized. Its
material shall be specified. The Repair Sleeves shall be of circular shape
suitable for compression into hexagonal shape.
(d) The steel and Aluminium Sleeves for Mid Span Joints as well as Aluminium
Repair Sleeves and Steel Repair Sleeves shall have their outer dia tapered
towards the two ends. Also the inside of the Sleeves shall be well rounded off,
so that there is no sharp edge, which can cut the strands. A dimensional
drawing must be enclosed with the bid.
(e) The compression type of Joints and Repair Sleeves shall be circular shape
suitable for compression into hexagonal shape. The length of Sleeves before
compression & cross-sectional dimensions after compression and the cross
sectional dimensions between the flats of the opposite sides of the hexagon
shall be as under:-
Dimension Dimension Length of Length of
before after sleeve before sleeve after
compression compression compression compression
Sr. (Rod cross (Flat to flat
Particular
No. section) distance of
hexagon)
G/ W Moose G/ W Moose G/ W Moose G/ W Moose

A Aluminium Sleeves
a Inner dimension (mm) - 34 -
b Outer dimension (mm) - 54 - 46 - 735 - 785
B Steel Sleeves
a Inner dimension (mm) 11.5 11.1 -
b Outer dimension (mm) 21 21 17.5 17.5 230 250 262 285
2 REPAIR SLEEVES
Outer dimension (mm) 20.8 54 17.5 46 254 305 280 330

(f) Other dimensions are indicated in the enclosed drawing. The Bidder shall
indicate the elongation of the above sleeves after compression.
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(g) The Joints and Repair Sleeves shall conform to IS:2121/1981 or equivalent
International Standard.
(h) The conductor compressed with mid span joint or with repair sleeve shall not
permit slipping of, damage to or failure of complete conductor or any part
thereof at a load of not less than 95% of the ultimate tensile strength of the
conductor.
(i) The electrical resistance of the joint/repaired portion of the conductor shall not
exceed 75% of the measured resistance of equivalent length of conductor.
6.13.2 4R-VIBRATION DAMPERS FOR MOOSE ACSR:
(a) Only Vibration Dampers having 4-resonance frequency characteristic commonly
called 4R Dampers shall be offered. The Damper shall eliminate fatigue on the
Conductor due to vibration and damp-out the vibrations effectively, so that no
damage due to vibration is caused to Conductor and string.
(b) The Dampers are to be used at all tension locations and suspension locations.
One or more Dampers are proposed to be used on tension/suspension
locations depending upon the span. The Damper shall be such as to effectively
damp out the vibration on the conductor, so that the dynamic strain at the
suspension point with conventional type of Suspension Clamp ‘U’ bolt and
keeper pieces, shall not exceed 150 micro strains. The manufacturer shall
recommend the number of Dampers required to effectively damp out the
vibration of the Conductor, so that the dynamic strain at the suspension point
with conventional Suspension type Clamp shall not exceed 150 micro strains.
(c) The requirement indicated in Price Schedule is based on use of two Vibration
Dampers per Conductor per span. However, final requirement will depend upon
Manufacturer’s recommendations duly supported by literature. Manufacturer
shall also recommend the number of Dampers required to effectively damp out
Conductor vibration for different values of span lengths and the distance for
fixation. While working out Damper Characteristics, it may be kept in view that
on suspension locations, preformed Armour rods are also to be fitted on the
conductor. Manufacturer shall give full details of the damper characteristics and
energy dissipation curves of the Damper and shall also guarantee their
effectiveness for damping design.
(d) The messenger cable shall be made of high strength steel strands of spring
steel with a minimum strength of 136 Kg/sq. mm and preformed in order to
prevent subsequent dropping of weights in service. The Manufacturer shall
indicate full technical particulars of the messenger cable. The keeper pieces
shall have proper curvature and edges be rounded off so that it shall have
proper grip over the conductor without any damage to conductor strands.
Clamping bolts shall be provided with self-locking nuts designed to prevent
corroding of the threads or loosening during service ensuring that no slippage
occurs up to specified longitudinal force on clamp along the conductor. All
ferrous parts including the messenger cable shall be effectively sealed to
prevent corrosion.
(e) The collar for fixing the bolt shall be designed in such a way that sufficient
space is available for tightening the bolt through spanner. Further bolt length be
maintained in such a way that it should not come out completely while affixing
the clamp on Conductor.
(f) The Bidder shall specify the material used for the Damper weight and shall
confirm and explain, how constant design characteristics will be maintained
during production. Fixing of the masses to the messenger cable shall be done
by pressing Aluminium Sleeves at each end of the messenger cable under
pressure. Each end should be sealed properly so as to achieve prefect joint.
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The molten metal filling method for attachment of messenger cable to counter
weight is not acceptable. The Bidder should specifically bring out the procedure
for attachment in the bid.
(g) The Dampers shall meet the test requirements specified hereunder:
(h) The effectiveness of the Vibration Dampers shall be to reduce the amplitude of
vibration, when tested for span of 400 meters for Moose ACSR, tension taken
as 25% of ultimate tensile strength in such a order that it limits the dynamic
strain in the Conductor below 150 micro strains for 0 to 15 miles per hour wind
condition in general and 2 to 10 miles per hour wind condition in particular
condition, conforming to as close as possible to the optimum damping force
requirement which the Bidder can predict and furnish for the ranges of wind
velocity and the conductor tension.
(i) The Bidder shall furnish the recommended spacing and the basis including wind
velocity range for selecting the spacing. The results of the analysis shall
account for the following:
i. Prediction of (a) Amplitude (b) Frequency and (c) Vibration energy levels of
Aeolian vibration on Moose ACSR for spans of 100m to 1100m.
ii. Test results for various frequency response characteristics of Vibration
Dampers such as vibration amplitude and phase angle including power
dissipation measured from its hysteretic loops.

(j) Maximum residual vibration must be of such an order that the strain level does
not exceed 150 micro strains.
(k) The Vibration Dampers and their attachments shall have smooth surface so that
corona and radio interference voltage levels are within specified limits.
(l) All Ferrous parts shall be fully galvanized.
(m) The Vibration Damper shall be capable of being installed and removed from
energized line by means of hot line tools without completely separating
components. The Damper Assembly shall be electrically conductive. The
transmission line details are as under:-

S.N Description Technical Particulars


1 Configuration Twin ACSR Moose
2 Span length in meters:
i. Ruling design span 400m
ii. Maximum span 1100m
iii. Minimum span 100m
3 Tensile load in Kg:
i. At minimum temp. of 0o C and still air 4145 Kg.
ii. At every day temp. of 32 o C 3614 Kg.
o rd
iii. At 0 C and 2/3 full wind 4477 Kg.
4 Nature of terrain Partly hilly, partly flat with
cultivated fields
5 Armour rods/AGS clamp AGS clamps
6 Maximum wind load 45 Kg/m2 .
7 Max permissible dynamic strains 150 micro strains

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The Bidder shall recommend the number of vibration dampers of the type offered
and their points of fixation for spans ranging from 100M to 1100M in steps of 50M .
(n) The other important features of vibration dampers as regards to materials
test, etc., are as under: -
Material:
i. Dampers - As per IS-9708/1993 or equivalent International Standard.
ii. Clamp - Aluminium alloy
iii. Messenger cable - High strength steel wire with a strength (kg/sq. mm) not less
than the strength of steel core of power Conductor/Ground
Wire.
iv. Weight - Cast Iron (Hot dip Galvanized)
Galvanising:

i. Spring washers - Electro Galvanized.


ii. Other Ferrous parts- Hot Dip Galvanized.
iii. Casting - As per IS:729-1961 or equivalent International Standard.
iv. Wires - As per IS:326-1968 or equivalent International Standard.
v. Bolts & Nuts - As per IS:5358-1969 or equivalent International Standard.
Slip strength of Clamp:
The damper clamp shall be casted over the messenger cable and offer sufficient
and permanent grip on it. The messenger cable shall not slip out of the grip at a load less
than the mass pull-off value of the damper. The damper masses made of material other-
than zinc alloy shall be fixed to the messenger cable in a suitable manner in order to avoid
excessive stress concentration on the messenger cables which shall cause premature
fatigue failure of the same. The messenger cable ends shall be suitably and effectively
sealed to prevent corrosion. The damper mass made of zinc alloy shall be casted over the
messenger cable and have sufficient and permanent grip on the messenger cable under
all service conditions
Maximum permissible dynamic strain on - 150 micro strains.
the Conductor with the Damper
Minimum number of cycles for fatigue - 10 millions Performances.
Amplitude for fatigue test - ±1 mm at the highest Resonant
frequency.
Radio interference voltage at 266 KV (rms) - Less than 500 microvolts.
phase to ground.

6.13.3 4R VIBRATION DAMPERS FOR 7/3.66MM 95 Kg PER MM2 QUALITY


GROUND WIRE:
a) The design and general particulars of Vibration Damper for Ground wire shall
be the same as described for Dampers for Conductor, Preformed Armour Rods
will be used at Ground wire suspension locations. The dynamic strain at
suspension point shall not exceed 150 micro strains.
b) All the test as described for Vibration Dampers for Conductor shall be carried
out except for Magnetic Power Loss Test.

6.13.4 LINE SPACERS AND JUMPER SPACERS :

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a) Line spacers shall be used for maintaining the intra phase spacing of 450mm
between conductors of each bundle under all normal working conditions. The
supplier shall indicate the number of spacers required per phase per span, for
spans ranging from 100M to 1100M with the longitudinal spacing
recommended for the spacers offered by them for giving the best possible
performance. The supplier shall also furnish all the relevant technical
documents in support of their placement chart alongwith the bid.
b) Jumpers at tension points shall also be fitted with line spacers so as to limit the
length of free conductor to 3.65M and to maintain the intra phase spacing of
450mm. The supplier may quote for rigid line spacer for the jumper. Spacers
for jumpers shall meet all the requirements of spacers used along the line
except on its performance for vibration and movement. Spacers requiring
retaining rods shall not be quoted for jumpers.
c) The spacer offered by the supplier shall satisfy the following requirements:-

Spacers shall restore normal spacing of the sub-conductor after displacement


due to wind, electromagnetic and electrostatic forces under all operating
conditions including the specified short circuit level without permanent
deformation/damage either to the conductor or the assemblies themselves.
They shall maintain as uniform firm grip on the conductors. They shall also
have long life without fatigue or wear. The clamp shall grip the conductor
efficiently to prevent the tortional movement of conductor. The clamping shall
be designed to compensate for any reduction due to conductor creep.

d) They shall preferably be of one piece construction and shall not have separate
small components. All fasteners shall be captive and need not be removed in
order to fit the spacer to the sub-conductor.
e) For spacers requiring retaining rods, the retaining rods shall be designed for
the specified conductor size. The rods shall be made of high strength special
aluminium alloy of type 6061 or equivalent material having minimum tensile
strength of 35 Kg/sq.mm. The ends of retaining rods shall be properly
terminated (parrot billed/ball end). The retaining rods (Armour rods) shall be of
preformed type. The rods shall be heat-treated to give proper resilience and
retain the same during service. The dimensions shall be generally as follows:-

i. Length of each rod: About 1086 ± 15mm


ii. Diameter of each rod: 7.87 ± 0.1mm
The conductivity of the rods shall not be less than 40% IACS (International
Annealed Copper Standards). Direction of lay shall preferably be of right
hand. Number of rods in the set shall be about 8. The center line of the rod
shall be suitably marked for ease of installation.

f) Where elastomer surfaced clamp grooves are used, the elastomer shall be
firmly fixed to the clamp.
g) Any nut used, shall be locked in an approved manner against loosening
caused by vibrations. The ends of bolts and nuts shall be properly rounded off
for specified corona performance.
h) Nut cracker, hinged open and or boltless type clamps are acceptable provided
adequate grip can be maintained on the conductor. Designs requiring clamping
bolt cap screw on lock pin shall utilize a single captive fastener.
i) Clamp with cap shall be designed to prevent its cap from slipping out of
position when being tightened.

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j) The clamp grooves shall be in uniform contact with the conductor over the
entire clamping surface, except for rounded edges. The groove of the clamp
body and clamp cap shall be smooth and free from projections, dirt or other
material, which may cause damage to the conductor when the clamp is
installed.
k) Universal type bolted clamps, covering a range of conductor sizes will not be
permitted.
l) No rubbing, other than that of the conductor clamp hinges or clamp swing bolts
shall take place between any part of the spacer. All joints shall have a flexible
medium such that there is no relative slip between them.
m) The spacers shall be flexible enough so as to avoid distortion or damage to the
conductor or to themselves. Rigid spacers are acceptable only for jumpers.
n) The spacer shall not damage or chafe the conductor in any way which might
affect its mechanical strength or corona performance. The spacer clamp shall
not damage the conductor under any condition.
o) The spacer assembly shall not have any projection, cut abrasion etc., or
chattering part which might cause corona.
p) The material used in the spacer shall be corrosion resistant. As far as possible,
the spacer shall be made of aluminium alloy of the type 6061. If iron or steel
parts are used, they shall be galvanized conforming to relevant Indian
Standard and shall have magnetic power loss of not more than one watt for,
600 amps 50Hz alternating current.
q) Elastomer, if used, shall be resistant to the effects of ozone, ultraviolet
radiation and other atmospheric contaminants likely to be encountered in
service, at temperatures upto 75ºC. It shall have good fatigue resistant
characteristics. The physical properties of the elastomer shall be indicated in
the offer. These shall be discussed and finalized with the successful supplier at
the time of quality plan approval.
r) The spacer assembly shall have electrical continuity. The electrical resistance
between the sub-conductor across the assembly. In case of spacer having
elastomer clamp grooves, shall lie between 0.1 and 0.01 mega ohm in order to
ensure satisfactory electrical performance under service conditions.
s) The spacer assembly shall be easy in installation/removal and reinstallation
without any damage.
t) The spacer assembly shall be capable of being installed and removed from the
energized line by means of hot line techniques.
i. The offer shall include placement charts recommending number of spacers
per phase per span and the sub span lengths to be maintained between
the spacers while installing on the twin bundle conductors.
ii. The placement of spacers shall be in such a way that adjacent sub spans
are sufficiently detuned and the critical wind velocity of each sub span shall
be kept more than 60Km/hr. The placement shall ensure bundle stability
under all operating conditions.
iii. The placement chart shall be provided for spans ranging from 100m to
1100m.
iv. The supplier shall also furnish all the relevant technical documents in
support of their placement charts alongwith the bid.

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6.13.5 FLEXIBLE COPPER EARTH BONDS:


The flexible copper earthing bond shall be made of flexible copper cable of size
37/7/0.417 with 9.81mm dia and copper area equivalent to 34 sq.mm. The length of
copper cable shall not be less than 500mm. Two steel connecting lugs shall be press
jointed to the either ends of the flexible copper cable. One end of the lug shall have hole
of 17.5mm size and another of 14.5mm. The complete assembly shall also include one
16mm dia 40mm long HRH M.S.Bolt hot dip galvanized with nut and lock washer.

6.13.6 T-CONNECTOR
T-Connector of compression type shall be used for jumper connection at
transposition tower . It shall be manufactured out of 99.5% pure aluminium and shall be
strong enough to withstand normal working loads. The T-connector shall have a resistivity
across jumper less than 75% resistivity of equivalent length of conductor. The T-connector
shall not permit slipping off, damage to or failure of complete conductor . The welded
portions shall be designed for 30 kN axial tensile load. Leg sleeve of T-connector should
be kept at an angle of 15 deg. from vertical and horizontal plane of the conductor in order
to minimise jumper pull at the welded portion . The dimensions and dimensional
tolerances of T-connector shall be as per Standard Technical Particulars.

6.13.7 HANGER SHACKLE:


This shall comprise of one anchor shackle, one long bolt with washer and split pin.
The breaking strength of the hanger shackle assembly shall not be less than 11500 kg.

6.13.8 TECHNICAL PARTICULARS FOR “CLAMPS” & “SPACERS”


a) All the current carrying parts shall be designed and manufactured to have
minimum contact resistance. The maximum tension per conductor is expected
to be 2000 Kgs. There shall not be any sharp edges which may lead to
accumulation of charge & electrical breakdown. All corners/ edges shall be
rounded.
b) The clamps shall be liberally designed and certain minimum contact surface
shall be provided.
c) The clamps and fittings shall be designed so that insulators shall not be subject
to any abnormal stresses due to thermal changes in conductor.
d) All the clamps & fittings shall enable the connection to be as short as possible.
Wherever possible the clamps shall be two separate halves. No “U” bolts shall
be used. All components of like design shall be inter-changeable
e) Spacer shall prevent clashing of the “T” clamps and minimize effects of short
circuit forces between bundle conductors on structures. They shall be capable
of withstanding electro-magnetic and electrostatic forces during short circuit
without deformation or damage to the conductor or spacer.
f) Spacers shall permit the relative axial and torsional movement of sub-conductors
and maintain their correct separation without lubrication or maintenance.
f) All nuts, bolts & washers shall be made of Hot dip galvanized Mild Steel
conforming to relevant ISS only.
g) The clamp in all respect shall incorporate highest quality of modern engineering
design and workmanship. The specification is merely for the guidance of the
Bidder as has been clearly stated earlier and it is not the intention to specify the
details of design and workmanship. The clamps shall be designed and
manufactured in accordance with the Bidder’s standard practices, when such
practices do not conflict with this specification.
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h) The materials offered shall be complete with all components and accessories
which are necessary or useful for their satisfactory performance and efficient
maintenance. Such parts shall be deemed to be within the scope of this
specification whether specifically included or not.
i) The design should be such that adequate clamping pressure is obtained with
the tightening of the nuts and the pressure should be maintained throughout the
service of the connector. In order to provide for creep of Aluminium under
pressure, it is essential that only Belleville washers are used. This should be
specifically confirmed and should also indicate tightening torque required.
j) All clamps shall be suitable to carry safely the maximum allowable current in the
associated conductor and to withstand the maximum loads occurring under
adverse circumstances and operating conditions. The maximum fault current is
40 KA rms for a period of 3 seconds. The temperature of the clamps and fittings
shall never exceed that of the associated conductor.
k) Fittings intended to connect two dissimilar metals shall be designed to avoid
harmful bimetallic corrosion under service condition, by way of provision of best
quality bimetallic strips.
l) The short circuit current shall be of the order of 40 KA for 3 seconds. The
clamps should be suitable to withstand the short circuit forces corresponding to
this current.
m) The design of clamps should be such that proper space for movement of normal
quality single head spanner during tightening is available. This is an important
requirement and should be confirmed by the Bidder.
6.13.9 Materials:
The Clamps & Connectors/Spacers shall be made of materials listed below: -

a) For connecting ACSR conductor Aluminium alloy casting conforming to


designation A6 of IS:617.(Redesignation 4600)
b) Bolts, Nuts, plain washers and spring washers for above items shall be made of
hot dip galvanized Mild Steel conforming to relevant IS only.
c) The Bidder shall ensure that the Alloy used assures good stability and sound
casting by proper fluidity. Proper mechanical and physical strength
characteristics should be obtained corresponding to the standard requirements
of the Alloy specified.
d) The Bidders shall ensure that the Alloy used assures good stability and sound
casting by proper fluidity. Proper mechanical and physical strength
characteristics should be obtained corresponding to the standard requirements
of the Alloy specified.
e) The clamps bodies shall be made by gravity die-casting only and thereafter
given the appropriate heat treatment and precipitation treatment. Clamps bodies
made by sand casting shall not be accepted in any case.
6.14 CASTINGS:
All casting shall be free from blow holes, surface, Blisters and shall be rounded off.

6.15 CONSTRUCTIONAL DETAILS:


a) All sharp edges and corners shall be blurred and rounded off.
b) Thickness of the clamps shall not be less than 12mm.
c) Bolts and nuts shall have hexagonal heads and threads as per Indian Standard.
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d) Flexible connectors, braids or laminated straps shall be made from tinned


copper strips or aluminium laminates depending upon the clamp.
e) Size of terminal / conductor for which the clamps is suitable shall be embossed
on each component of the clamp.
f) Casting should be such that adequate free space for placement and movement
of spanners for tightening of nuts is available.

6.16 BOLTS, NUTS & WASHERS:


These shall be as per Indian Standard and shall have tensile strength and elongation
as per grade 5.6. Further details are indicated in Section-5.

6.17 GALVANISING:
a) Hot dip galvanizing shall conform to Indian Standard specification IS-2633 or
equivalent International Standard. Galvanising shall be uniform, free from
blisters, and shall not peel off due to abrasion, Zinc coating shall be thick enough
to withstand 6 one minute dips in Copper Sulphate solution (precee test) for all
ferrous parts except for threaded portions which shall withstand at least 4 one
minute dips.
b) The zinc coating shall be perfectly adherent, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash rust,
stains, bulky white deposits and blisters. The zinc used for galvanising shall be
Zinc of any grade in IS: 209:1992 ingot (fourth revision) or IS:13229:1991.
6.17.1 The Bidder must emboss/engrave their name in each forged steel item and
Aluminium castings such as Ball Hook, Yoke Plate, Socket Clevis, Clevis Eye, Clevis-
Clevis, Anchor Shackle/D-Shackle, Chain Link, Suspension Clamps of AGS type, Tension
Clamps and Arcing Horns. This is very essential. If the Bidder will not agree with this
condition, their offer will be treated as non-responsive.
6.18 TESTS :
The following Type Tests, Stage Tests, Routine Tests and Acceptance Test shall be
carried out on power Conductor & Ground wire Hardware fittings & Accessories.
a)Type Tests
The material supplied shall be fully Type Tested as per this specification and the
Bidder shall furnish two sets of Type Test reports before taking up the supplies.. These
tests must not have been conducted earlier than five years. For any change in the
design/type already Type Tested and the design/type offered against this specification,
the purchaser reserves the Rights to demand repetition of test without any extra cost.
b) Stage Tests:
Stage Tests during manufacturing shall mean those test required to be
carried out during the process of manufacturing to ensure quality control such that
last product is of the designed quality conforming to the intent of this specification.
c) Routine Tests:
Routine Tests are those tests, which required to be carried out on each and
every finished product so as to check with requirements that are likely to vary
during production.
d) Acceptance Tests:
Acceptance Tests shall mean those tests, which required to be carried out on
samples taken from each lot offered for pre-despatch inspection for purposes of
acceptance of that lot.
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e) Test Values:
For all type and acceptance tests, the acceptance values shall be the value
guaranteed by the Bidder in the guaranteed technical particulars or the acceptance
value specified in this specification, the relevant Indian Standard or equivalent
International Standard.
f) Test Procedures And Sampling Norms:
The norms and procedure of sampling for the above tests shall be as per the
relevant Indian Standard or other internationally accepted Standards. This will be
discussed and mutually agreed to between the successful Bidder and Purchaser
before placement of order.
6.19 TYPE TESTS FOR HARDWARE FITTINGS

6.19.1 On the complete insulator string with hardware fittings


a. Power frequency voltage withstand and
flashover test with corona control grading BS:137 (Part-I)
ring under dry/wet condition.
b. Switching surge voltage withstand test
IEC:383
under wet condition.
c. Impulse voltage withstand test under dry
IEC:383
condition
d. Impulse voltage flashover test under dry
IEC:383
condition

e. Voltage distribution test


f. Corona and RIV test under dry condition. As per specification
g. Mechanical strength test for complete
As per specification
string
h. Vibration test
NOTE: For electrical tests, the insulator string shall be mounted on a
stimulated tower.
6.19.2 On Suspension Hardware fittings only.
a. Magnetic power loss test for suspension assembly. As per
b. Clamp slip strength for AGS clamp specification
Clamp slip strength Vs torque test for suspension
c.
clamp
d. Test on neoprene As per specification
e. Ozone test.
f. Heat resistance test.
6.19.3 On Tension Hardware Fittings only
a. Electrical resistance test for dead end assembly.
b. Heating cycle test for dead end assembly IS:2486(Part-I)
c. Slip strength test for dead end assembly.
d. Mechanical strength test. As per specification
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6.19.4 All the type tests given under clause no 7.20.1 above shall be conducted
separately on single/double suspension and tension insulator string alongwith hardware
fittings.
6.19.5 The tests specified under clause no. 7.20.1 (e) & (f) (i.e. the voltage distribution
test and corona/RIV Dry test) shall also be conducted on single suspension pilot double
suspension and single tension insulator string alongwith hardware fittings.
6.19.6 The mechanical strength test given under clause no. 7.20.1 (g) above shall also be
conducted on single suspension pilot, double suspension and single tension insulator
string alongwith hardware fittings.
6.19.7 The magnetic power loss test specified under 7.20.2 (a) shall be conducted on
single suspension, single suspension pilot and double suspension assembly.
6.20 ACCEPTANCE TEST/SAMPLE TESTS:
6.20.1 On both suspension and tension hardware fittings:

a. Visual Examination IS:2486 (Part-I)


b. Verification of dimensions IS:2486 (Part-I)
c. Galvanising test/Electroplating As per this specification.
d. Mechanical strength test of welded joint As per this specification.
Mechanical strength test for corona
e. BS:3288(Part-I)
control rings.

f. Test on locking devices for ball & socket


IEC:372(2)
coupling.
Mechanical strength test of each
g. components excluding corona control ring As per this specification.
and arcing horn.
6.20.2 On suspension Hardware fittings only:

a. Clamp slip strength vs torque test for


suspension clamp.
As per this specification.
b. Shore hardness test of elastomer cushion
for AG suspension clamp.
c. Bend test for armour rod set.
d. Re silence test for armour rods set. IS:2121 (Part-I)
e. Conductivity test for armour rods set
6.20.3 On tension hardware fittings only:
a. Slip strength test for dead end assembly IS:2486 (Part-I)
6.20.4 On Suspension hardware for groundwire
a. Visual examination
b. Dimensional verification.
c. Slip strength test.

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Mechanical strength test on each


d.
component
e. Galvanising test
f. Mechanical strength test of welded joint
6.20.5 On Tension hardware for groundwire:
a. Visual examination
b. Dimensional verification.
c. Slip strength test.
d. Electrical resistance test.
6.20.6 Test during manufacture:
a. On all components as applicable.
Chemical analysis of zinc used for
b.
galvanizing
Chemical analysis, hardness test grain
c. size inclusion rating and magnetic particle
inspection for forgoing/castings.
Chemical analysis and proof load test
d.
fabricated hardware.
Tests on malleable castings forgings and
e.
fabricated hardware’s.

6.21 TYPE TESTS FOR ACCESSORIES


6.21.1 Flexible Copper Bond for Ground wire:
Slip strength test:
6.21.2 Spacer/Rigid Spacer for power conductor.

i. Visual examination
ii. Dimensional verification.
As per
iii. Galvanising test
IS:2121
iv. Movement test (except for spacer for jumpers
this
v. Compressive and Tensile test specification,
vi. Clamp slip Test IS:2633
vii. Clamp bolt torque test & IS:6745
viii. Assembly torque test
ix. Hardness test for neoprene

6.21.3 Mid span compression joint for conductor & groundwire.


i. Slip strength test
As per IS 2121,2633 6745
ii. Electrical Resistance test

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iii. Healing cycle test


iv. Corona Extinction voltage test dry.
v. Radio interference voltage test Dry.
vi. Galvanising test

6.21.4 Repair Sleeve for conductor:


i. Electrical Resistance test

ii. Corona Extinction Voltage test. As per IS


2121
Iii Radio Interference voltage test dry.

6.21.5 Vibration Damper for conductor & groundwire


a. Chemical analysis of material
b. Dynamic Characteristic Test.
c. Vibration Analysis.
d. Clamp Slip test.
e. Fatigue Test.
f. Magnetic power loss test.
g. Corona extinction voltage test (Dry).
h. Radio interference voltage test (Dry).
i. Damper efficiency test.
NOTE: Tests mentioned at (f), (g) & (h) are not applicable to dampers for groundwire.

6.21.6 Clamps
i Tensile Test
ii Resistance Test
iii Temperature Test (As perIS:5561)
iv Short time current Test
v Dimensional Check
vi Galvanising

6.22 ACCEPTANCE TEST


(A) FLEXIBLE COPPER BOND:
a. Visual examination IS:2121
b. Dimensional verification
c. Slip strength test.
(B) SPACERS/ RIGID SPACER FOR POWER CONDUCTOR:
a. Visual examination.
b. Dimensional verification.
c. Galvanising Test.
d. Clamp slip test
e. Movement test (except for spacers for jumpers)

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f. Compressive & Tensil test.


g. Clamp bolt torque test
h. Assembly torque test
i. Hardness test for neoprene
(C) Midspan Compression Joint for Power Conductor & Groundwire
i. Visual examination
ii. Dimensional verification.
iii. Galvanising Test
iv. Hardness test.
Failing load test (test to be conducted after 24
v.
hours of compression).
(D) Repair Sleeves for Conductor.
i. Visual examination
ii. Dimensional verification.
(E) Vibration Damper for power conductor/ groundwire.

i. Visual examination
ii. Dimensional verification.
iii. Galvanising Test
iv. Verification of resonance frequencies
v. Clamp slip test
vi. Clamp bolt torque test
vii. Strength of messenger cable.
viii. Mass pull off test.
(F) Clamps
i. Tensile Test
ii. Resistance Test
iii. Dimensional Check
iv. Galvanising Test
(G) Test during manufacture.
i. On all components as applicable.
ii. Chemical analysis of zinc used for galvanizing
Chemical analysis, hardness test grain size
iii. inclusion rating and magnetic particle inspection
for forgoing/castings.
iv. Chemical analysis and proof load test.
v. Tests on malleable castings forgings and
fabricated hardware’s.

6.23 DRAWING AND LITERATURE:


The detailed drawings of each component assembly of the Hardware assembly &
Accessories and descriptive literature shall be submitted before taking up supplies. The
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detailed dimension drawings for each and all-individual Hardware items such as clamps,
U Clevis, Socket Eye, Yoke Plate and Socket Clevis etc. shall also be submitted
separately. The dimensional drawings for compression type Mid Span Joint (Aluminium &
Steel Sleeve), compression type Repair Sleeve Preformed Armour rods for Conductor &
Ground wire and 4R Vibration Dampers etc. must be submitted. Test certificates for
different tests conducted as per relevant ISS, for all the offered items must also be
submitted essentially.

6.24 MATERIALS AND WORKMANSHIP:


6.24.1 All the materials shall be of the latest design and conform to the best modern
practice adopted in the extra high voltage field. The Bidder shall supply only such
equipment as guaranteed by him to be satisfactory and suitable for 400 KV Transmission
line.
6.24.2 The design, manufacturing process and quality control of all the materials shall be
such as to give maximum factor of safety, maximum possible working load, highest
mobility, elimination of sharp edges and corners, best resistance to corrosion and a good
finish.
6.24.3 All ferrous parts shall be hot dip galvanised, after all machining has been
completed. Nuts may, however, be tapped (threaded) after galvanising and the threads
oiled. Spring washers shall be electro galvanised. The bolts threads shall be under cut to
take care of increase in diameter due to galvanising. Galvanising shall be done in
accordance with IS:2629 or equivalent International Standard and satisfy the tests
mentioned in IS:2633 or equivalent International Standard. Fasteners shall withstand
four dips while spring washers shall be guaranteed to withstand at least six dips each
lasting one minute under the standard precee test for galvanising.
6.24.4 The Zinc coating shall be perfectly adhere, of uniform thickness, smooth,
reasonably bright, continuous and free from imperfections such as flux, ash, rust stains,
bulky while deposits and blisters. The Zinc used for galvanising shall be grade Zn. 99.95%
as per IS: 209:1992 ingot (fourth revision) or IS:13229:1991.
6.24.5 In case of castings, the same shall be free from all internal defects like shrinkage,
inclusion, blowholes, cracks etc.
6.24.6 All current carrying parts shall be so designed and manufactured that contact
resistance is reduced to minimum.
6.24.7 No item which would produce high electrical and mechanical stresses in normal
working shall have sharp ends or edges, abrasions or projections and shall not cause any
damage to the Conductor in any way during erection or during continuous operation. The
design of adjacent metal parts and mating surfaces shall be such as to prevent corrosion
of the contact surface and no maintain good electrical contact under service conditions.
6.24.8 Particular care shall be taken during manufacturing and subsequent handling to
ensure smooth surface free from abrasion or dents.
6.24.9 The fasteners shall conform to the requirement of IS: 6639-1972 or equivalent
International Standard. All fasteners and clamps shall have locking arrangements to guard
against vibration loosening.
6.25 INSPECTION:
6.25.1 Purchaser and its representatives shall at all times be entitled to have access to
the works and to all places of manufacturing and the Supplier shall afford all facilities to
them for unrestricted inspection of the works, inspection of material, inspection of
manufacturing process and for conducting necessary tests as specified herein.

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6.25.2 The successful Bidder shall keep the Purchaser informed in advance of the time of
starting and progress of manufacturing of material in its various stages so that
arrangements could be made for inspection.
6.25.3 No material shall be despatched from its point of manufacturing unless the
material has been satisfactorily inspected and tested.
6.25.4 The acceptance of any quantity of material shall in no way relieve the successful
Bidder of his responsibility for meeting all the requirement of this specification and shall
not prevent subsequent rejection, if such materials are later found to be defective.
6.26 IDENTIFICATION MARKING:
The main component of the material covered in the specification shall be legibly
and indelibly marked with the trademark of the manufacturer, the month and year of
manufacture, the guaranteed combined mechanical and electrical strength in kilo-Newton
abbreviated by ‘kN’ to facilitate easy identification and proper use. Words “MPPTCL” shall
also be embossed/engraved on the main components. Marks shall be forged or stamped
with a steel die before Galvanizing. The marks shall be distinct, durable and conspicuous.
Embossing/Engraving should be done at the time of manufacturing process itself, but
before Galvanizing. Smaller component like bolts & nuts, split pin and washers etc. may
be excluded from this requirement.

6.27 PACKING:
6.27.1 The material shall be packed in strong wooden boxes with steel straps. The gross
weight of packing shall be in range of 50 kgs to 200 kgs to avoid handling problem. The
packing shall be strong enough to withstand rough handling during transit or storage in the
field. All the packing cases shall be legibly marked to avoid possibility of loss in transit.
The Bidder shall be responsible for any damage during transit due to improper and
inadequate packing and handling.
6.27.2 Each consignment shall be accompanied by a detailed packing list showing
following details:-
i. The name of the consignees
ii. Details of consignment.
iii. Destination.
iv. Total weight of consignment.
v. Handling and unpacking instrumentation.
vi. Bill of material indicating content of each package.
6.28 STANDARD AND TESTS:
6.28.1 The original or attested photocopy of test certificates for material for the test
conducted at Govt. Laboratory are required to be submitted giving results of sample test
as per technical values given above respectively in support of compliance of materials to
the specification in the quality, performance and composition.
6.28.2 The materials offered shall conform to relevant Indian Standard. The material shall
be tested before dispatch. The MPPTCL may at its option, depute its representative for
inspection and witnessing of test. The test as specified shall be carried out and the test
report shall be submitted for an approval before dispatch.
6.28.3 Further, the MPPTCL reserves the right to carry out test as mentioned above from
bulk quantity received at the cost of supplier to ascertain the quality of the material
supplied. The supply should strictly as per our specification. The MPPTCL at its discretion
for ensuring that material supplied are conforming to specified quality and composition
may get it tested from National Laboratory by drawing samples from the lot after the same
is received by consignees. If the test result do not conform to specified quality, the lot will
be rejected and replacement shall be made free of cost and testing charges will be to the
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account of supplier. If some material is already used by time the results are received, the
MPPTCL may accept such material which has been used at the reduced cost as may be
fixed at its discretion. The test as specified shall be carried out and the test report shall be
submitted for an approval before dispatch.

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7.0 TECHNICAL SPECIFICATIONS FOR ERECTION OF 400kV TRANSMISSION


LINES

7.01 INDIAN STANDARDS/CODE :

The material and services under this section shall conform to the requirements of the
latest revisions and amendments available at the time of placement of order of all the
relevant Indian standards/codes listed here under or equivalent International Standards,
except as modified in this document.

S.No. Indian standards Title


1 IS:5613-1995 (part- Code of practice for design, installation
II) and maintenance of overhead power
lines.
Sec.-1 - Designs.
Sec.-2 - Installation &
Maintenance
2 IS:269-1967 Ordinary rapid hardening and low heat
Portland cement.
3 IS:456-2000 Code of practice for plain and
reinforced concrete
4 IS:1786-1966 Cold twisted steel bars for concrete
reinforcements
IS:4091-1967 Code of practice for design &
construction of foundation for
transmission line towers & poles

7.02 LINE MATERIALS:

7.02.1 Conductor:
The Conductor used in the line will be single ACSR Moose Conductor. The Conductor
size is 54/3.53mm A1. + 7/3.53 mm Steel.
7.02.2 Ground-wire :
The Ground-wire to be used on the line shall be 7/3.66 mm; 95 kg/mm2 quality galvanized
steel stranded wire.
7.02.3 Insulator Strings with Hardware Fittings:
(i) Single suspension and double tension strings will be used on the line as
under:

(a) At Suspension Locations:


23 Disc single suspension strings having 120KN E&MS of 255x145 mm
size Disc Insulators with AGS type clamps will be used.
(b) At Tension Locations :
24 Disc double tension strings with 160 KN E&MS Disc insulators of
280x170 mm size Disc Insulators will be used with compression type dead
end clamp.
(ii) Pilot strings will be used at deep angle tower locations for restraining the
swing of jumpers.

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(iii) In cases of Railway/Road/River/Other transmission line crossings, double


suspension insulator strings will be used.
7.02.4 Conductor Accessories:
(i) AGS type suspension clamps shall be used with suspension strings.
(ii) Vibration Dampers (4-R type) and Spacers or Spacer-Dampers shall be
used for Conductors.

7.02.5 Miscellaneous Items:


Enameled Number Plates, Phase Plates and Danger Board, Bolts and Nuts, Spring
washers, Pack washers and other tower accessories like ‘D’ Shackle, Hanger, U-Bolts
and fasteners etc., shall be provided with the tower by the Contractor. The Contractor
shall supply anticlimbing device (including Barbed wire) separately. Copper earth bond
will be used for connecting Ground wire suspension and tension clamp with tower body,
which shall also be provided by the Contractor.

7.02.6 DETAILED SURVEY/CHECK SURVEY:


The contractor will have to carry out detailed survey of the line for which route map
indicating the proposed alignment of the transmission line will be handed over by the
Employer. If the detailed survey is already conducted by the Employer for some portion
of the line, the profiles for such portion will be handed over to the Contractor for carrying
out check survey. It may please be noted that no check survey is required to be
conducted for the portion of line for which detail survey is conducted by the contractor
himself.

7.02.7 Detailed Survey:-


(a) At the starting point of the commencement of route survey, an angle iron
spike 65 x 65 x 1000mm shall be driven firmly into the ground to show only
150mm above the ground level. A punch mark on the top section of the
angle iron shall be made to indicate location of the surveying instrument.
Teak wood pegs 50 x 50 x 650 mm shall be driven at prominent positions at
intervals of not more than 750 meter along the transmission line to be
surveyed up to the next angle point. 125 mm wire nails should be fixed on
the top of these pegs to show the location of instrument. The pegs shall be
driven firmly into the ground to show only 100 mm above ground level. At
angle positions, stones shall be put up for easy identification. Paint mark
in white lead paint shall be put in, about 300 mm squares with a direction
indication, on nearby boulders, rocks, or trees, along the complete line
alignment. At peg position, identification marks giving the peg position, with
reference to painting marks, shall be given. The white lead paint mark shall
indicate to the individual the direction of alignment from either direction.
(b) Routing/Re-routing of transmission line through protected/reserved forest
area should be avoided. In case it is not possible to avoid the forests or
areas having large trees completely, then keeping in view of the overall
economy, the route should be aligned in such a way that cutting of trees is
minimum.
(c) The route should have minimum crossings of Major river, Railway lines,
National/State highways, overhead EHV power line and communication
lines.
(d) The number of angle points shall be kept to minimum.
(e) The distances between the terminal points specified shall be kept shortest
possible, consistent with the terrain that is encountered.
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(f) Marshy and low lying areas, river beds and earth slip zones shall be avoided
to minimize risk to the foundations.
(g) It would be preferable to utilize level ground for the alignment.
(h) Crossing of power lines shall be minimum. Alignment will be kept at a
minimum distance of 300 m from power lines to avoid induction problems on
the lower voltage lines.
(i) Crossing of communication line shall be minimized and it shall be preferably
at right angle. Proximity and parallelism with telecom lines shall be
eliminated to avoid danger of induction to them
(j) Areas subjected to flooding such as nalah shall be avoided.
(k) Restricted areas such as civil and military airfield shall be avoided. Care
shall also be taken to avoid aircraft landing approaches.
(l) All alignment should be easily accessible both in dry and rainy seasons to
enable maintenance throughout the year.
(m) Certain areas such as quarry sites, tea, tobacco and saffron fields and rich
plantations, gardens and nurseries which will present the Employer
problems in acquisition of right of way and way leave clearance during
construction and maintenance should be avoided.
(n) Angle points should be selected such that shifting of the point within 100 m
radius is possible at the time of construction of the line.
(o) The line routing should avoid large habitations, densely populated areas,
Forests, Animal/Bird sanctuary, reserve coal belt areas, oil pipe
line/underground inflammable pipe lines etc to the extent possible.
(p) The areas requiring special foundations and those prone to flooding should
be avoided.
(q) From the field book entries, the route plan and level profile shall be plotted
and prepared to the scales of 1=2000 horizontal and 1=200 vertical on 1
mm/5 mm/1 cm square paper.
(r) If the difference in levels be too high, the chart may be broken up according
to requirement. A 400 meter overlap shall be shown on each following
sheet. The chart shall progress from left to right. For convenience in
handling, the sheet size may be limited to 594x841 mm (Al) size.
(s) After completing the detail survey, profiles shall be submitted to the
Employer duly spotted with tower for approval. While submitting the profiles
after conducting the detail survey, the contractor will also submit a copy of
route alignment on the route map indicating the surveyed route.

7.02.8 Check Survey:

(a) The Contractor shall conduct the check survey after the profiles are handed
over to the Contractor. The check survey shall include checking of deviation
angles, checking of levels at critical points. After completing the check survey
the tower spotting shall be carried out by the Contractor and profiles shall be
submitted to the purchaser for final approval. The Contractor shall be
responsible for correct setting of stubs. Discrepancies, if any, shall be brought
to the notice of purchaser and final approval shall be taken before execution
of work.

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(b) The requirement of tower site leveling and revetment work, if required, shall
also be marked by the Contractor on the profiles while carrying out the detail
or check survey work.

(c) If due to site conditions any change in the tower location/provision of


extension is considered necessary compared to approve profiles, the
contractor shall bring the same to the knowledge of the purchaser well in time
and get revised approval of the profile before setting the stubs. The revised
approval shall be conveyed to the Contractor by the Purchaser.

7.02.9 Soil Resistivity:-

While carrying out detailed/ check survey work, the Soil Resistivity values will have
to be measured at convenient points along the route, not exceeding 2.50 Km between
adjacent points. The Soil Resistivity wiil be measured using 4 electrod method with an
inter electrod spacing of 50 M . The following formula shall be used :
P=2πaR
Where a = Interelectrod spacing = 50M
R = Earth resistance measured in Ohms
P = Soil Resistivity in Ohm- m

The soil resistivity values shall be submitted duly marked on the route map and also
in the form of statement. The quoted rates for detailed survey/ check survey work shall be
inclusive of cost of measuring soil resistivity values along the proposed route and the
contractor will not be paid separately for this work.

7.03 APPROVED PROFILE:

(Applicable for check survey only)

7.03.1 The detailed survey has been conducted by the Purchaser or any other agency
appointed by the Purchaser and the profiles shall be handed over to Contractor
progressively for carrying out check survey and submission of profiles for approval of the
purchaser. The profiles shall be prepared on cm. graph paper on scale 1:2000 horizontal
and 1:200 vertical.

7.03.2 The route alignment surveyed by the Purchaser shall be marked at angle points.
At angle points concrete blocks shall be provided and in the straight alignment marking
will be done by pegs.

7.03.3 The Contractor will be responsible for the correct setting of towers as shown in
approved profiles. If towers after erection are found to be out of the approved
alignment/position in the profile, the Contractor will dismantle and re-erect them correctly
fully at his own cost and without extension of time.

7.04 EXCAVATION:

7.04.1 Except as specifically otherwise provided, all excavation for footing shall be made
to the lines and grades of the foundation. The excavation walls shall be vertical and the
pit dimensions shall be such as to allow a clearance of 150mm on all sides from the
foundation pit, where form boxes are used. In undercut/stepped (slab type) foundations
where form box is not required to be used at the base, the pit dimensions should be as
per the standard drawings. All excavation shall be protected so as to maintain a clean
sub-grade, until the footing is placed, by using timbering, shoring or casing, if necessary.
Any sand, mud, silt or other undesirable materials which may have accumulated in the
excavation shall be removed by the Contractor before placing concrete.
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7.04.2 The Soil to be excavated for tower foundations shall be classified as under for
the purpose of payment of excavation for tower site leveling and building stone
revetment:
(a) Dry Soil : Soil removable by means of ordinary pick axes and shovels
(Normal Soil, intermediate Soil and black cotton Soil fall
under this category).
(b) Wet Soil : Soil as per (a) above, where the sub Soil water table is
encountered within the range of foundation depth, the Soil
below the water table and that at locations where pumping or
bailing out of water is required due to presence of surface
water, will be treated as wet Soil.
(c) Soft Rock: This will mean fissured rock i.e. decomposed rock, hard gravel,
kankar, limestone, laterite or any other Soil of similar nature
which can be excavated with pick axe, crowbar etc. However,
if required, light blasting may be resorted to for loosening the
material but this will not in any way entitle the excavation to be
classified as hard rock
(d) Hard Rock : Hard rock will be that which requires chiseling or drilling and
blasting.
7.04.3 No extra charges shall be admissible for the removal the fallen earth in the pits
when once excavated.

7.04.4 If water is encountered in the foundation pit, de-watering will have to be done.
The cost of dewatering shall be deemed to be included in the unit rates of
excavation for foundation indicated by the Bidder in the offer.

7.04.5 For foundation in rock, where blasting is unavoidable, care should be taken
to minimize the volume of concrete necessary for filling up the blasted area. The
blasted area shall be reduced to the minimum possible so that the specified form for the
foundation could be obtained. No extra payment for excavation in hard rock shall be
allowed if the excavated area exceeds the designed excavation volumes. Similarly, no
extra payment shall be made if concrete volume exceeds the designed volume due to
excessive blasting.
This is to specify here that during excavation, if hard rock soil is
encountered but keeping in view the soil strata actually encountered, soft rock
foundation is adopted then the rates for excavation for hard rock shall be limited
to the extent of approved rate for excavation in soft rock.

7.04.6 The Contractor shall arrange requisite blasting material, excavation and drilling
equipment, necessary license etc., at his own cost and the quoted rates shall be
deemed to be inclusive of all such costs.

7.04.7 The decision of the owner shall be final and binding with respect to classification of
soil and foundation.

7.05 CLASSIFICATION OF FOUNDATIONS :

7.05.1 The foundation designs have been carried out depending upon the type of Soil,
sub-Soil water level and the presence of surface water as follows:

(i) Dry Soil : To be used for locations where normal dry cohesive or non-
cohesive Soils are met.
(ii) Wet Soil : To be used for locations :

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(a) Where sub-Soil water is met at 1.5meter or more below the ground
level.

(b) Which are in surface water for long periods with water
penetration not exceeding one meter below the ground level e.g. the
paddy fields.

(iii) Partially Submerged: To be used at locations where sub-soil water level is


met between 0.75 meter to 1.5 meter below the
ground level.

(iv) Fully Submerged : To be used at locations where sub-soil water level is


met less than 0.75 meter below ground level.

(v) Black cotton(Dry/Wet): To be used at locations where Soil is clayey type,


not necessarily black in colour, which shrinks when dry and
swells when wet, resulting in differential movement extending to a
maximum depth of about 3.5meter below ground level.

(vi) Dry Fissured rock: To be used at locations where decomposed or fissured


rock, hard gravel, kanker, limestone, laterite or any other soil of similar
nature is met. Under cut type foundation is to be used for fissured rock
locations.

(vii) Submerged Fissured rock: In case of fissured rock locations where


water level is met at 1.5meter or more below ground level, submerged
fissured rock foundations shall be adopted. If after soil investigation,
water level is encountered at less than 1.5meter below ground level, a
separate foundation shall be developed.

(viii) Hard rock : The locations where chiseling, drilling and blasting is required
for excavation, hard rock type foundations are to be used.

(ix) The foundation of towers will be classified as per above soil strata and as
per the instructions of Executive Engineer (EHT-C) and Superintending
Engineer (EHT-C) concerned and circulars issued by this office. The
decision of MPPTCL in the regard shall be final and binding on the
contractor.
7.06 SHORING OF PITS:
Shoring of pits with shuttering on the internal walls surrounding the vertical facing of
approved dimensions of the pit shall be done when the Soil condition is so bad that there
is likelihood of accident due to falling of surrounding earth in foundation pit. The cost of
carrying out shoring & shuttering shall be deemed to be included in the unit rate of
excavation of tower and no extra payment shall be made on this account.
7.07 TOWER SITE LEVELLING:
In case of foundations located on sloping ground, it may be necessary to level the
ground for locating the tower. In leveling the tower site, only excavation will be allowed.
The Contractor shall quote separate rates for excavation for purpose of site leveling for
dry Soil, wet Soil, soft and hard rock in respective Schedule. The requirement of tower
site leveling will be decided by the Purchaser’s site Engineer and will be marked by the
Contractor in the profiles while carrying out the check survey work.

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7.08 SETTING OF STUBS:

7.08.1 The stub shall be set correctly in accordance with approved method at the exact
locations and alignment and imprecisely correct levels. The stub setting Templates shall
be used for proper setting of stubs. Stubs shall be set in the presence of purchaser’s
representative available at site whenever required and for which the contractor shall give
adequate advance intimation to the site Engineer.

7.08.2 The foundations are to be made as per designs and drawings approved by the
purchaser. Extent of the work as defined by such drawings shall not be exceeded except
in very exceptional cases where the prior approval of purchaser has been obtained.

7.08.3 Each tower shall be provided with suitable foundation based on the approved
designs after classification of Soil. The Soil classification shall be done after digging
minimum section of all foundation pits of a tower up to full depth (excluding hard rock
locations). The Soil should be classified strictly as per the details of Soil encountered in
the foundation pit. For example, dry Soil foundation should be adopted at the locations
where dry Soil is encountered in the full depth of foundation. Similarly the wet type
foundation should be adopted at the locations where water level is met at level of
1.5meter or more, below the ground level or in paddy fields or other places, which remain
in surface water for long periods with water penetration not exceeding one meter below
the ground level. Deviations, if any, from the approved/specified conditions shall be
brought to the notice of C.E. (EHT:C&M) through site Engineer before taking up the
work and his decision shall be final in this regard and communicated through site
Engineer. If at a later date, it is found that the works carried out by the Contractor are not
according to the specifications and are without specific approval, the entire payments
made to the Contractor for carrying out such works shall be recovered and the Contractor
will have to rectify the same at the rates indicated in the order for carrying out such work
and without extension of time.

7.08.4 The setting of stubs in hard rock foundation may require cutting of stubs
depending on depth at which hard rock is encountered. The cutting of stubs and drilling of
new holes for fixing cleats etc. shall be considered inclusive in the rate of foundation of
towers in hard rock. However, the cut pieces of stubs shall be returned to MPPTCL.

7.08.5 Setting of stub at each location shall be approved by the purchaser’s site
Engineer. This approval shall not however, absolve the Contractor of his responsibility of
correct setting of stubs and casting of foundations, who will be required to rectify the faulty
work at his own expense.

7.09 PLACEMENT OF REINFORCEMENT:

7.09.1 Some of the tower foundations may be designed with steel reinforcement so as to
achieve better foundation strength with lesser space. The Contractor will indicate in
relevant schedules, the details of reinforcement to be provided alongwith the weight and
size of reinforcement rods. The cost of placing of reinforcement steel, binding etc. in the
foundation pit shall be deemed to be included in the quoted rates of foundations of towers.

7.09.2 The Contractor shall arrange foundation reinforcement steel etc. at their cost which
shall be deemed to be included in the quoted cost of foundations. The reinforcement bars
will have to be properly cut, bent in required shape and placed in the foundation in
approved manner after due cleaning of oil, grease or organic matter. The reinforcement
shall be properly tied by binding wire.

7.09.3 Reinforcement shall conform to IS:1786 for deform and cold twisted bars (Fe 500).
Thermo Mechanically Treated (TMT) bars (equivalent grade ) in place of cold twisted bars
are also accepted. Hard drawn steel wire shall conform to IS:432.
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7.10 CONCRETE:

7.10.1 The cement concrete used for the foundation shall be of 1:2:4 mix ratio (M150)
with 20mm nominal size stone metal for chimney portion and 40mm nominal size stone
metal for pyramid or slab portions. 1:3:6 mix ratios (M 100) shall be used for base padding
(lean pad). For RCC, the aggregates shall preferably be of 20mm nominal size.

7.10.2 Concrete aggregates shall confirm to IS:383

7.10.3 The cement required for the purpose of foundations, building revetment walls
etc. shall be arranged by the Contractor at his own cost, which shall be deemed to be
included in the cost of concreting.

7.10.4 The sand used for the concrete shall be arranged by the Contractor at his own
cost including necessary license etc., which shall be deemed to be included in the cost of
concreting. The sand shall be composed of hard silicate materials. It shall be clean
and of a sharp angular grit type and free from earthy or organic matter and deleterious
salts.

7.10.5 The aggregate shall be arranged by the contractor at his own cost including
necessary license etc, which shall be deemed to be included in the cost of concreting. The
aggregate shall be of clean broken hard granite or other stone specified or approved by
the purchaser. It shall be of hard and coarse-grained quality. It shall also be as far as
possible cube like, preferably angular, but not flaky, perfectly clean and free from earth,
organic or other deleterious matter. 40mm aggregate shall be of size as will pass through
a mesh of 40 mm measured in the clear and 20 mm aggregate through 20mm square
mesh measured in clear.

7.10.6 The water used for mixing concrete shall be arranged by the contractor at his own
cost including necessary license etc, which shall be deemed to be included in the cost of
concreting. The water used shall be fresh, clean and free from oil, acid and alkali, organic
materials or other deleterious substances. Salty/Saline or brackish water should not be
used. Potable water is generally satisfactory.

7.10.7 The concrete shall be mixed in a mechanical mixer. However in case of locations
not accessible for concrete mixers, hand mixing may be permitted at the discretion of our
site Engineer.

7.10.8 Mixing shall be continued until there is uniform distribution of materials and the
mixing is uniform in colour and consistency but in no case the mixing is done for less
than two minutes. Normally mixing shall be done close to the foundation, but in case it is
not possible, the concrete may be mixed at the nearest convenient place. The concrete
shall be transported from the place of mixing to the place of final deposit as rapidly
as practicable by methods, which shall prevent the segregation or loss of any ingredient.
The concrete shall be placed and compacted before setting commences. The
transportation cost of these materials shall be deemed to be included in the cost of
concreting.

7.10.9 The concrete should be mixed as stiff as per the requirements of placing the
concrete in the form boxes, with ease and the degree to which the concrete resists
segregation. Hence the quantity of water used should not be too much.

7.10.10 Proper form boxes adequately braced to retain proper shape while
concreting should be used for chimney or pyramid and slab portions. The form boxes
should be made water tight so that cement cream may not come out leaving only sand
and jelly consequently forming of honeycombing in the concrete. The form boxes shall be
cleaned and oiled before these are used for concreting.
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7.10.11 The concrete shall be laid in 150mm layers and consolidated well so that
the cement cream works up to the top and no honeycombing is left in the concrete.
Concreting is to be done continuously so that the subsequent layers are laid before the
initial setting of the bottom layer begins. The consolidation of concrete shall normally be
done by using vibrators.

7.10.12 After concreting the chimney portion up to the required height, the top
surface should be finished smooth, with slight slope towards the outer edge, to drain off
the rainwater falling on the coping.

7.10.13 In wet locations, the site must be kept completely de-watered both during the
placing of the concrete and up to 24 hours after completion. There should be no spilling
to concrete by water during this period.

7.10.14 The form boxes shall be removed only after at least 24 hours after the
completion of concreting. After removal of the forms and boxes the concreted surface
wherever required shall be repaired with a mixture of rich cement and sand mortar in the
shortest possible time.

7.10.15 The cost of carrying out concreting of foundations in all respect, shall be
deemed to be included in the unit rates of foundations of tower in different type of
Soils quoted by the Bidder.

7.11 BACKFILLING AND REMOVAL OF STUB TEMPLATE:

7.11.1 Following opening of form work and removal of shoring and shuttering, if
required, backfilling shall be started after 24 hours of casting repairs, if any, to the
foundation concrete. Backfilling shall normally be done with the excavated Soil, unless it
consists of large boulders, which shall be broken to a maximum size of 80mm.

7.11.2 The backfill materials should be clean and free from organic or other foreign
materials The earth shall be deposited in maximum 200mm layers, leveled, and
wetted and rammed properly before another layer of earth is deposited. Care shall be
taken that the back filling is started from the foundation end only in the pits towards the
outer end.

7.11.3 The backfilling and grading shall be carried to an elevation of about 150mm
above the finished ground level to drain out water. After backfilling, 50mm high earthen
embankment (bandh) will be made along the sides of excavated pits and sufficient water
will be poured in the backfilled earth for at least next 24 hours.

7.11.4 The stub setting Templates shall be opened only after the completion of back-
filling.

7.11.5 After completing stringing work, if level of backfilling of some of the locations
gets settled and it is required to backfill the locations again, the same would be done by
the contractor at no extra cost.

7.11.6 No extra charge is admissible for carrying out backfilling of foundation pit
(including backfilling from borrowed earth if required) and the cost of backfilling
including cost of materials shall be deemed to be included in the cost of excavation of
towers quoted by the in the bid.

7.12 CURING:
The concrete, after it is 24 hours old, shall be cured by keeping the concrete wet
continuously for a period of 14 days after laying. The pit may be backfilled with selected
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earth sprinkled with necessary amount of water and well consolidated in layers not
exceeding 200mm of consolidated thickness after a minimum period of 24 hours
and thereafter both the backfilled earth and exposed chimney top shall be kept wet for the
remainder of the prescribed time of 14 days. The uncovered concrete chimney above the
backfilled earth shall be kept wet by providing empty cement bags dipped in water fully
wrapped around the concrete chimney for curing duly ensuring that the bags are kept wet
by frequent pouring of water on them. The Contractor may use anti curing
paint. However no extra payment shall be made on this account.

7.13 BUILDING STONE REVETMENT:


Stone revetment in 1:6 cement mortars shall be constructed by the Contractor at specified
locations. The detailed proposal in consultation with the site Engineer, for carrying out
revetment work shall be submitted to the O/o. CHIEF ENGINEER (Procurement),
Jabalpur through concerned Superintending Engineer, EHT Construction and approval
shall be obtained before carrying out revetment work. The top seal cover of
revetment work shall be done with 1:2:4 normal mix. All materials including cement shall
be provided by the contractor and cost of building revetment shall be deemed to include
cost of such materials also i.e. Cement, sand, metal and stone. Curing of revetment shall
be done as specified for tower foundation. The back filling of the inside of the revetment
wall with Soil/borrowed earth will be paid for extra on per m³ basis and shall include its
compacting and watering. The excavation for revetment foundation shall be paid at
the rates as indicated by the Bidder in Price Schedule. The revetment work, wherever
necessary, shall have to be completed before taking up final tensioning work in the
Section.

7.14 TOWER EARTHING:

7.14.1 For the purpose of earthing, necessary earthing rods (25mm dia, 2 meter
long) connecting clamps, and connecting wire will be provided by the Contractor.
The earthing rods are to be hammered preferably in the foundation pits and connected to
stub by 7/4.00mm earth-wire and with necessary connecting clamps before concreting the
foundation. If it is not possible to tie the rods in the foundation pit i.e. in rocky location,
they shall be buried near the foundation pit and connected to the stubs. The earthing
rods are to be provided on diagonally opposite legs of the tower. Each tower shall be
earthed before the foundation is casted.

7.14.2 The tower footing resistance of all towers shall be measured in dry whether after
the erection and before the stringing of Ground-wire. The counterpoise earthing shall be
resorted to, in accordance with the instructions of the site Engineer, in case the tower
footing resistance (TFR) exceeds the specified value. It shall be ensured that the tower
footing resistance is less than 10 ohms. Each tower footing resistance shall be intimated
(along with the tower location number) while submitting the progress report of tower
Erection.

7.14.3 Counterpoise Earthing :


(a) In case of high resistivity, counterpoise earthing shall be provided
which consists of four lengths of galvanized steel stranded wires,
7/4.00mm fitted with each leg of the tower with proper clamps for
connection to the tower leg at one end. The counterpoise will be laid
radially away from the tower and will normally be 15 meters in length,
buried to the depth of 600mm below the ground level. The length of
counterpoise wire may be increased if the resistance requirements are not
met. Connecting clamps shall be buried in the chimney portion of the
foundation. Contractor shall quote for the laying of counterpoise earthing
MPPTCL/TECH-LINE/PROC/SEP23 Page 339
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on per running meter basis, including cost of all materials. The scope of
work of connecting the counterpoise to the tower legs shall be deemed to
be included in the cost of laying of counterpoise (with cost of materials).
The counterpoise connecting wire and clamps will be arranged by the
Contractor. The counterpoise shall preferably be laid through soft soil
areas if available. The planning of laying counterpoise shall be done as
per approval of site Engineer. The cost of laying of counterpoise shall be
inclusive of excavation and backfilling work also.
(b) The Contractor shall have to provide rod earthing at the end of each
counterpoise wire and this may lead to T.F.R. values within specified
limits. This work of additional rod earthing shall be paid extra on per
location basis as per the rates indicated in Price Schedule. Which shall
include the cost of providing such earthing and cost of materials i.e.
earthing rods (4 Nos. for counterpoise earthing i.e. additional earthing of
towers) and connecting arrangements for one tower.

7.15 TOWER ERECTION/ ASSEMBLY:

7.15.1 Towers shall be erected after the foundation concrete is at least 14 days old, but
a gap of 24 days shall be preferred. The method followed for the erection of towers, shall
ensure the points mentioned below:

7.15.2 Straining of the members shall not be permitted for bringing them into position. It
may, however, be necessary to match hole positions at joints and to facilitate this,
Tommy bars not more than 450mm long may be used.

7.15.3 Before starting erection of an upper section, the lower section of tower shall be
completely braced and all bolts provided in accordance with approved drawings.

7.15.4 All plan diagonals relevant to a section of tower shall be placed in position before
assembly of upper section is taken up.

7.15.5 The bolt positions in assembled towers shall be as per IS: 5613 (Part-II/Sec.2),
1995 with latest amendments.

7.15.6 Tower shall be fitted with Number, Phase and Danger Plates which shall be
arranged by the Contractor.

7.15.7 Anti-climbing Devices:

Barbed wire will be used at a height of approx. 3 meters and above as an anti-
climbing measure, which shall be arranged by the Contractor. At every location three
layers of Barbed wires will be provided each inside and outside the tower in horizontal
plane. Spacing between the layers with fixing arrangements shall be provided as per the
provisions of IS:5613 (Part-II/Sec.1)-1976 with latest amendments. The galvanized
angle pieces with notches for accommodating Barbed wire with Bolts Nuts etc. shall be
supplied by the Contractor. After the Barbed wire is placed in position in the notches,
the notch opening shall be welded to avoid the theft of Barbed wire and anti-
corrosive treatment with cold galvanizing paint shall be given, as also in the case of
bolts to be welded below bottom cross arm level. Suitable locking arrangement (pad-
lock) shall also be provided.
7.15.8 All blank holes, if any left, after complete erection of the tower, are to be filled up
by bolts and nuts of proper size.

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7.16 TIGHTENING PUNCHING AND WELDING OF BOLTS AND NUTS:

7.16.1 All nuts shall be tightened properly using correct size of spanners. Before
tightening, it will be seen that packing washers and plates are placed in relevant
gaps between members, bolts of proper size and length are provided and one spring
washer is used under each nut and in case of step bolts, spring washers shall be placed
under the outer nut.

7.16.2 The tightening shall progressively be carried out from the top to downwards, care
being taken that all bolts at every level are tightened simultaneously. The threads
of bolts projecting outside the nuts shall be punched at three positions on the
periphery to ensure that the nuts are not loosened in course of time. If during tightening
a nut is found to be slipping or running over the bolt threads, the bolt together with the
nut shall have to be replaced.

7.16.3 The threads of all the bolts projected outside the nuts shall be welded all around
the periphery of nut-bolts. The welding of nut-bolts as above shall be carried out from
ground level to bottom cross arm level in all towers upto +6M extensions. In case of
+10M/18M/25M extension towers and special river crossing towers, nut-bolts welding shall
be done up to 25 meter height from ground level.

7.16.4 After welding, cold galvanized paint having at least 90% zinc content shall be
applied on the welded portion. At least two coats of the paint shall be applied. The cost of
such paint and welding etc., including application of paint etc., shall be deemed to be
included in the quoted erection rates.

7.17 INSULATOR HOISTING:


Suspension insulator strings shall be used on suspension towers and tension
insulator strings on angle and dead end towers. They shall be fixed on all the towers
just prior to the stringing. Damaged Insulators and fittings, if any, shall not be used in the
assemblies. Before hoisting, all Insulators shall be cleaned in a manner that will not spoil,
injure or scratch the surface of the Insulator, but in no case shall any oil be used for the
purpose. Security clips shall be fitted in position for the Insulators before hoisting. Arcing
Horns shall be fitted in an approved manner. Torque wrench shall be used for fixing
different line materials and their components, like suspension clamps etc. for Conductor
and Ground-wire etc.

7.18 HANDLING OF CONDUCTOR AND EARTHWIRE:

7.18.1 The Contractor shall be entirely responsible for any damage caused to the towers
or Conductors during stringing. While running out the Conductors, proper care shall be
taken ensuring that the Conductors do not touch and rub against the ground or objects
which could cause scratches or damage to the Conductor strands. The Conductors shall
be run out of the drums from the top in order to avoid damage due to chafing. The drum
stand shall be provided with a suitable braking device to avoid damage, loose running out
and kinking of Conductor. Proper care shall be taken to avoid injury to Conductor while
making it pass over the bull wheel of tensioner. After the tensioner, the Conductor will be
pulled by pull cable and consequently pass over the running out blocks. The groove of
the running out blocks will be of such a design that the seat is semi-circular and larger
than the diameter of the Conductor and it does not slip over or rub against the sides.
The grooves shall be lined with hard rubber or neoprene to avoid damage to Conductor
and shall be mounted on properly lubricated bearings.

7.18.2 The running blocks shall be suspended in a manner to suit the design of the
cross arm. All running out blocks especially those at the tensioning end, will be fitted on
the cross arm with jute cloth wrapped over the steel work and under the slings to avoid
MPPTCL/TECH-LINE/PROC/SEP23 Page 341
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damage to the slings as well as to the protective surface finish of the steel work.
The Conductor shall be continuously observed for loose or broken strands or any other
kind of damage. When approaching towards end of a drum length, at least three coils
shall be left when the stringing operations are to be stopped. These coils are to be
removed carefully if another length is required to be run out, new length may be joined to
the length already run out by the compression joint in approved manner.
The Conductor joints and clamps shall be erected in such a manner that no bird
caging, over tensioning of individual wires or layers or other deformities or damage to the
conductor shall occur. Clamps or bracing devices shall under erection conditions allow no
relative movement of strands or layers of the conductors.

7.18.3 Repairs of Conductors, in the event of damage being caused to isolated strands
of a conductor during the course of erection, if necessary, shall be carried out during
the running out operations, with repair sleeves. Repairing of Conductor surface with
repair sleeve shall be done only in case of minor damage, scuff marks etc., keeping in
view both electrical and mechanical safety requirements. Number of damaged strands
shall not exceed 1/6th of the total strands in the outer layer. The final Conductor surface
shall be clean, smooth and shall be without any projections, sharp points, cuts, abrasions
etc. Repair sleeves may be used when the damage is limited to the outermost layer
of the Conductor and is equivalent to the severance of not more than one third of the
strands of the outermost layer. No repair sleeve shall be fitted within 30 m of tension or
suspension clamp or fittings. Further, more than one repair sleeve per Conductor shall
not be normally used in any single span.

7.18.4 Conductor splices shall be so made that they do not crack or get damaged in the
stringing operation. The Contractor shall use only such equipment/ methods during
Conductor stringing which ensures complete compliance in this regard.

7.18.5 Derricks shall be used where roads, rivers, canals, telecommunication or


overhead power lines, railway lines, fences or walls have to be crossed during
stringing operations. It shall be seen that normal services are not interrupted and no
damage is caused to property. Shut down shall be obtained when working at crossing of
overhead power lines.

7.18.6 The sequence of running out shall be from top to downwards, i.e. the Ground-
wire shall be run out first followed by the Conductors in succession. Imbalances of loads
on towers shall be avoided as far as possible i.e. both Ground-wires, then both bundles
of top Conductor and then both bundles of middle Conductor followed by both bundle
Conductors of bottom Cross-arm should be strung.

7.18.7 The proposed transmission line may run parallel for certain distance with the
existing 400/220/132KV lines which will remain energized during the stringing period. As
a result there is a possibility of dangerous voltage build up due to electromagnetic and
electrostatic coupling in the pulling cables, Conductors and Ground-wires, which
although comparatively small in magnitude during normal operations, can be severe
during switching and ground fault conditions on the energised lines. It shall be the
Contractor's responsibility to take adequate safety precautions to protect his employees
and others from this potential danger.

7.19 STRINGING OF CONDUCTOR AND EARTHWIRE:

7.19.1 The stringing of the Conductor shall be done by control in tension method by
means of tension stringing equipments. The equipments shall be capable of
maintaining a continuous tension. The maximum tension imposed on a conductor during
stringing operations shall not exceed than that necessary to clear obstructions on the

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ground.The contractor shall indicate in their offer, the sets of tension stringing
equipment he is having in his possession and the sets of stringing equipment he would
deploy exclusively for this work.

7.19.2 After being pulled, the Conductor/Ground-wire shall not be allowed to hang in the
stringing blocks for more than 96 hours before being pulled to the specified sag.

7.19.3 The Contractor shall give complete details of the stringing methods, which he
proposes to follow. At least one month in advance of the commencement of stringing,
the Contractor will submit the stringing charts for the Conductors and Ground-wire
showing the initial and final sags and tension for various temperatures and spans,
alongwith equivalent spans in the lines, for the approval of the purchaser. The
stringing shall be carried out as per the stringing charts approved by the purchaser and
in accordance with relevant IS. All the tolerances for the line shall conform to IS :5613
(Part-2/Sec-2) 1995.

7.19.4 In hilly terrain and thick forest, where deployment of tension stringing machine is
not possible, manual stringing may be adopted after getting approval of Purchaser’s site
Engineer. The contractor shall deploy appropriate tools/equipments/machinery to ensure
that the stringing operation is carried out without causing damage to conductor/earth wire
and conductor/earth wire is installed at the prescribed sag-tension as per the approved
stringing charts.

7.20 JOINTING:

7.20.1 The number of joints in Conductor/Ground-wire shall be kept to minimum


possible by properly selecting the drums from available lot of respective drums. All the
joints on the Conductor and Ground-wire shall be of compression type. Each part of the
joint shall be cleaned by wire brush to make it free of rust or dirt etc. and properly
greased with anti-corrosive compound, as approved by our Engineer before the final
compression is done with the compressors. The cost of such grease etc. used for joints
shall not be paid extra and shall be deemed to be included in the stringing rates.

7.20.2 All joints shall be made at least 30 meter away from the structures. No joints shall
be made in the spans crossing over the main roads, railways, rivers etc. Not more than
one joint per Conductor shall be allowed in one span. Care shall be taken to mark the
conductor for properly centering the compression clamp before compressing. During
compression operation, the conductor shall be handled in such a manner as to prevent
lateral or vertical bearing against the dies. After pressing the joint the aluminum
sleeve shall have all corners rounded, burrs and sharp edges removed and
smoothened.

7.20.3 Suitable protector shall be used during stringing of Conductor to avoid any
damage to the joint while it passes over the traveler.

7.21 SAGGING IN OPERATION:

7.21.1 The Conductors shall be pulled up to the desired sag and left in running block
for at least one hour after which the sag shall be rechecked and adjusted, if necessary,
before transferring the conductor from the running out blocks to the suspension clamps.
The Conductors shall be clamped within 36 hours of sagging in.

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

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7.21.3 The running out blocks, when suspended from the transmission structure for
sagging shall be so adjusted that the Conductors on running out blocks will be at the
same height as that of the suspension clamps to which it is to be secured.

7.21.4 At sharp vertical angles, the sags and tensions shall be checked on both sides of
the angle. The Conductor and Ground-wire shall be checked on the running out blocks for
equality of tension on both sides. The suspension insulator assemblies will normally
assume vertical positions when the Conductor is clamped.

7.21.5 Tensioning and sagging operations shall be carried out in calm weather, when
rapid changes in temperature are not likely to occur.

7.22 TENSIONING & SAGGING OF CONDUCTOR AND EARTHWIRE:


The tensioning and sagging shall be done in accordance with the approved
stringing charts before the Conductor and Ground-wire is finally attached to the towers
through the insulator strings for the Conductor and Ground-wire clamps for the Ground-
wire Dynamometers shall be used for measuring tension in the Conductor and Ground-
wire.
7.23 CLIPPING IN:

7.23.1 Clipping of the Conductors in position shall be done in accordance with the
method approved by our Engineer. At suspension location free center type suspension
clamp with Armour rod set or AGS type suspension clamp shall be used.

7.23.2 The jumpers at the section and angle towers shall be formed to parabolic shape
to ensure maximum clearance requirements. Pilot suspension insulator string shall be
used, if necessary, to restrict the jumper swings to the design values. Jumper
connections of transposition towers shall be so made that adequate clearances are
available from tower body as well as phase conductors.

7.23.3 Fasteners in all fittings and accessories shall be secured in position. The security
clip shall be properly opened and sprung into position.

7.23.4 FIXING OF CONDUCTORS AND EARTHWIRE ACCESSORIES :

7.23.5 Spacers, spacer dampers, Vibration dampers (4-R type) and other Conductor
and Ground-wire Accessories supplied by the purchaser shall be installed by the
Contractor as per the design/drawing requirement and as per instructions of the Engineer.
Spacers shall be fitted within 24 hours of the Conductor clamping. While installing the
Conductor and Ground-wire Accessories, proper care shall be taken to ensure that the
surfaces are clean and smooth and no damage shall occur to any part of the Accessories.

7.23.6 REPLACEMENT:

7.23.7 If any replacements are to be effected after stringing and tensioning or during
maintenance, members and bracing shall not be removed without reducing the tension
on the tower with proper guying or releasing the Conductor. If the replacement of cross
arms becomes necessary after stringing, the Conductor shall be suitably tied to the tower
at tension points or transferred to suitable roller pulleys at suspension points.

7.24 FINAL CHECKING TESTING AND COMMISSIONING:


After completion of the works, final checking of the line shall be done by the
Contractor to ensure that all the foundation works, tower erection, and stringing have
been done strictly in accordance with the specification and as approved by the

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purchaser. All the works shall be thoroughly inspected keeping in view the following main
points:
(a) Sufficient back-filled earth is lying over each foundation pit and it is
adequately compacted.
(b) Concrete chimneys and their copings are in good finely shaped conditions.
(c) All the tower members are correctly used, strictly according to approved
drawing and are free from defects or damages, whatsoever.
(d) All bolts are properly tightened and punched/tack welded as per this
specification.
(e) The stringing of the Conductors and Ground-wire has been done as per the
approved sag and tension charts and desired clearances are clearly
available.
(f) All Conductor and Ground-wire Accessories are properly installed.
(g) All other requirements to complete the work like fixing of Danger Plate,
Phase Plate, Number Plate, Anti-climbing devices, Aviation Signal
(wherever required) etc. are properly installed and the painting has been
done wherever required as per Aviation Rules.
(h) It should be ensured that revetment is provided, wherever required.
(i) The line insulation is tested by the Contractor by providing his own
equipment labour etc. to the satisfaction of the purchaser to ascertain the
insulation condition of the line.
(j) Conductor continuity test is carried out to verify that each Conductor of the
overhead line is properly connected electrically also.
(k) The line may be charged at a low value of Power Frequency Voltage for
the purpose of testing.
***

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(E) ANNEXURE (TECHNICAL PARTICULARS AND SAMPLE DRAWINGS)

ANNEXURE- 1

GUARANTEED TECHNICAL PARTICULAR OF MOOSE CONDUCTORS

S.NO. PARTICULARS ACSR MOOSE


1 ACSR MOOSE– Stranding and Size in mm 54/7/3.53
2 Stranding and wire dia in mm
a) Aluminium 54/3.53
b) Steel 7/3.53
3 Standard nominal copper area in sq.mm 325

4 Actual aluminium area in sq.mm. 528.5


5 Standard area of cross section in sq.mm.
a) Aluminium strand 9.787
b) Steel strand 9.787
c) Conductor 597
6 Diameter of complete conductor in mm. 31.77

7 Minimum ultimate tensile stress in Kg./sq.mm.


a) Aluminium strand 16.38
b) Steel strand 134
8 Guaranteed ultimate tensile strength of Min. 161.20
Conductor in Kg.
9 Min. breaking load in KN for
a) Aluminium strand
i) Before stranding 1.57
ii) After Stranding 1.49
b) Steel strand
i) Before standing 12.86

After stranding 12.22


ii)
10 Zinc coating of steel strand
a) Number and duration of dips 3 dips 1 min.
b) Minimum weight of coating in gms./sq.mtr. 260

11 No. of standard length in one reel One


12 Weight in Kg./Km. (Approx.)
a) Aluminium 1465
b) Steel 539
c) Conductor 2004
13 Resistance in ohms per km at 20 deg. C 0.0552
14 a) Continuous max. current rating of conductor in 900
still air at 40 deg. C ambient temperature Amps.

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b) Temperature rise for the above current deg. C. 35 Deg. C

S.NO. PARTICULARS ACSR MOOSE


15 Lay Ratio
Steel core : 6 wire layer 16-18
Aluminium: 12 wire layer 12-14
18 wire layer 11-13
24 wire layer 10-12
16 Modulus of elasticity of 0.703x106
Conductor Kg/Sq.mm
17 Co-efficient of linear expansion per degree
centigrade of:
a) Aluminium strand Kg./sq.cm 23x10-6

b) Steel strand Kg./Sq.cm 11.5x10-6


c) Conductor Kg./sq.cm. 19.3x10-6
18 Percentage of carbon in steel wire 0.50-0.85
19 Standard length of each piece in Km. 1.5
20 Tolerance, if any, on standard length +/- 5%

The conductor should conform strictly to the “Guaranteed Technical Particulars”


as detailed above. The conductor shall conform to IS:398 Part-II – 1996 & as amended
up-to-date.

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ANNEXURE-2

GUARANTEED TECHNICAL PARTICULARS OF DISC INSULATORS

(A) GUARANTEED TECHNICAL PARTICULARS FOR 120KN EMS DISC INSULATORS.

S.N. Description 120 KN DISC


Single Double
Suspension Suspension

1 Maker’s name, address and country

2 Size and designation of Ball & Socket and 20 mm IS: 2486 (Pt.II)1989
standard to which it will conform (mm)
3 No. of insulator discs per string 23 2*23
4 Outside dia. of the disc – mm 255 255
5 Spacing – mm 145 145
6 Creepage distance of the single disc-mm 320mm 320mm
7 Electro-mechanical strength of single disc –
kg. 12237 12237
8 Withstand voltage of single disc-kVp
8.1 Power frequency
a) Dry – kV (rms) 75 75
b) Wet – kV (rms) 45 45
8.2 Impulse voltage 1.2/50 microsecond
a) Positive – kV 110 110
b) Negative - kV 115 115
9 Withstand voltage for
the complete string
9.1 Power frequency (with and without
Corona ring)
a) Dry – kV (rms) 720 & 725 720 & 725
b) Wet – kV (rms) 680 & 685 680 & 685
9.2 Lightning Impulse voltage 1.2/50
microsecond (With and without Corona ring)
a) Positive – kVp 1600 & 1605 1600 & 1605
b) Negative – kVp 1610 & 1615 1610 & 1615
10 Flashover voltage for the disc
10.1 Power frequency (with and without
Corona ring)
a) Dry – kV (rms) 80 80
b) Wet – kV (rms) 50 50
10.2 .Lightning impulse voltage 1.2/50
microsecond
a) Positive – kVp 115 115
b) Negative – kVp 120 120
11. Flashover voltage for complete string.

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S.N. Description 120 KN DISC


Single Double
Suspension Suspension

11.1 Power frequency (with and without


Corona ring)
a) Dry – kV (rms) 745 & 750 745 & 750
b) Wet – kV (rms) 705 & 710 705 & 710
11.2 .Lightning impulse voltage 1.2/50
microsecond
a) Positive – kVp 1650 & 1655 1650 & 1655
b) Negative – kVp 1660 & 1665 1660 & 1665
12 Max. voltage (%) across any disc in the
string (with and without Corona ring) 9% 9%
13 P.F. Puncture Voltage of each disc
insulator KV(rms) 125 125
14 Minimum corona extinction voltage of each
disc insulator KV(rms) 18 18
15 Max. RIV with 10 KV (rms) of each disc
insulators (Micro volts) 50 50
15 Weight of each disc (Kgs) (approx) 6 6

(B) GUARANTEED TECHNICAL PARTICULARS FOR 160KN EMS DISC INSULATORS.

S.N. Description 160 KN DISC INSULATORS


ON 400 KV
Single Double
Tension Tension

1 Maker’s name, address and


country
2 Size and designation of Ball & 20 mm IS: 2486(Pt.II)1989
Socket and standard to which it
will conform (mm)
3 No. of insulator discs per string 1*24 2*24
4 Outside dia. of the disc – mm 280 280
5 Spacing - mm 170 170
6 Creepage distance of the single
330 330
disc-mm
7 Electro-mechanical strength of
16500 16500
single disc – kg.
8 Withstand voltage of single disc-
kVp
8.1 Power frequency
a) Dry – kV (rms) 75 75
b) Wet – kV (rms) 45 45
8.2 Impulse voltage 1.2/50
microsecond
a) Positive – kV 120 120
b) Negative - kV 120 120
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S.N. Description 160 KN DISC INSULATORS


ON 400 KV
Single Double
Tension Tension

9 Withstand voltage for


the complete string
9.1 Power frequency (with and
without Corona ring)
a) Dry – kV (rms) 720 720
b) Wet – kV (rms) 690 690
9.2 Lightning Impulse voltage
1.2/50 microsecond (With and
without Corona ring)
a) Positive – kVp 1700 1700
b) Negative – kVp 1700 1700
10 Flashover voltage for the disc
10.1 Power frequency (with and
without Corona ring)
a) Dry – kV (rms) 80 80
b) Wet – kV (rms) 50 50
10.2 .Lightning impulse voltage
1.2/50 microsecond
a) Positive – kVp 125 125
b) Negative – kVp 130 130
Flashover voltage for complete
11.
string.
11.1 Power frequency (with and
without Corona ring)
a) Dry – kV (rms) 740 740
b) Wet – kV (rms) 710 710
11.2 .Lightning impulse
voltage 1.2/50 microsecond
a) Positive – kVp 1750 1750
b) Negative – kVp 1750 1750
12 Max. voltage (%) across any
disc in the string (with and 9 9
without Corona ring)
13 P.F. Puncture Voltage of each
125 125
disc insulator KV(rms)
14 Minimum corona extinction
voltage of each disc insulator 18 18
KV(rms)
15 Max. RIV with 10 KV (rms) of
each disc insulators (Micro 50 50
volts)
15 Weight of each disc (Kgs) 8 8
16 Electromechanical strength of
16500 2 x 16500
complete string (kgs.)
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ANNEXURE-3
LIST OF SAMPLE DRAWINGS

S.No. Particulars

Outline drawing of 400kV 23 unit single suspension insulator


1
string.
Outline drawing of 400kV 2x23 unit double suspension
2
insulator string.
Outline drawing of 400kV 1x24 unit single tension insulator
3
string.

Outline drawing of 400kV 2x24 unit double tension insulator


4
string.

5 Central Hanger shackle

6 Details of earthing arrangement for towers


7 Armour Grip Type Spacer for conductor
8 Rigid Spacer for Jumper
9 Midspan joints
10 Repair sleeve
11 Vibration damper
12 T-Connector
Groundwire Accessories:
13 Suspension Clamp Assembly
14 Tension Clamp

15 Midspan joint

16 Vibration damper for earthwire

17 Copper earth bond

18 Number plate for 400kV transmission line

19 Phase plate for 400kV transmission line

20 Danger Board for 400kV transmission line

21 Anticlimbing Device for 400kV Towers.

MPPTCL/TECH-LINE/PROC/SEP23 Page 351


Digitally signed by AJAY KUMAR
SHRIVASTAVA
AJAY KUMAR DN: cn=AJAY KUMAR SHRIVASTAVA,
c=IN, st=Madhya Pradesh, o=CHEIF
ENGINEER (PROCUREMENT) M.P.
SHRIVASTAV POWER TRANSMISSION CO. LTD,
ou=ALL,
serialNumber=2599d2c693acb7db93d880
A 7892b10a337c51050f66491a4c4682208a
449590e3
Date: 2023.10.04 17:34:44 +05'30'

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