VOLUME-V
VOLUME-V
VOLUME –V
3.0 Technical Specification of OPGW and associated hardware & fittings 284 284
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 1
Volume-V
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.
1.03.03 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.
1.05.01 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.
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.
1.08.01 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.
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
1.11.01 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.
1.11.04 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.
1.12.01 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.
1.13.01 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
MPPTCL/TECH-LINE/PROC/SEP23 Page 6
Volume-V
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.
Commencement of following activities is subject to prior and specific approval of the items
mentioned against each: -
MPPTCL/TECH-LINE/PROC/SEP23 Page 7
Volume-V
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.
1.19.01 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
1.20.01 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.
1.21.01 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.
***
MPPTCL/TECH-LINE/PROC/SEP23 Page 9
Volume-V
iv) Gantry (type-AGT) Wherever necessary will also be required for crossing
220/400kV 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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 12
Volume-V
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
MPPTCL/TECH-LINE/PROC/SEP23 Page 13
Volume-V
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
MPPTCL/TECH-LINE/PROC/SEP23 Page 14
Volume-V
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 15
Volume-V
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.
1.15.2 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.
1.17 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);
MPPTCL/TECH-LINE/PROC/SEP23 Page 17
Volume-V
(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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 19
Volume-V
(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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 20
Volume-V
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.
(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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 22
Volume-V
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:
2.02 PARAMETERS :
MPPTCL/TECH-LINE/PROC/SEP23 Page 23
Volume-V
MPPTCL/TECH-LINE/PROC/SEP23 Page 24
Volume-V
MPPTCL/TECH-LINE/PROC/SEP23 Page 25
Volume-V
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 26
Volume-V
2.06.2 The lay ratio of the different layers shall be within the limits given in the Table
below:-
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.
2629-1990. ‘Recommended practice for hot dip galvanizing of Iron and Steel’ or some other
authoritative equivalent standard.
MPPTCL/TECH-LINE/PROC/SEP23 Page 27
Volume-V
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 28
Volume-V
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 29
Volume-V
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 30
Volume-V
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
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
7 IS 875 Code of practice for design load for building & structural
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 32
Volume-V
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.
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:
Table 3-1(a)
DWSM Optical Fibre Characteristics
MPPTCL/TECH-LINE/PROC/SEP23 Page 34
Volume-V
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.
3.02.10.1 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
3.02.10.2.6 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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 35
Volume-V
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
MPPTCL/TECH-LINE/PROC/SEP23 Page 36
Volume-V
Table 3-1(C)
Ground Wire Technical Details
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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 37
Volume-V
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.
When the fibre optic cable design incorporates metallic elements in its construction, all
metallic elements shall be electrically continuous.
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).
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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 38
Volume-V
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.
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.
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
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 39
Volume-V
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.
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
MPPTCL/TECH-LINE/PROC/SEP23 Page 40
Volume-V
submitted. The Technical paticulars for vibration analysis and damping design of
the system are as follows:-
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 41
Volume-V
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 42
Volume-V
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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 43
Volume-V
Table 3-1(d)
Type Tests for Optical Fibres
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)
MPPTCL/TECH-LINE/PROC/SEP23 Page 44
Volume-V
MPPTCL/TECH-LINE/PROC/SEP23 Page 46
Volume-V
MPPTCL/TECH-LINE/PROC/SEP23 Page 47
Volume-V
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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 48
Volume-V
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 Fracture at the end of one minute at the minimum failure load during Part
2 of theTest.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 49
Volume-V
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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 50
Volume-V
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.
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.
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
MPPTCL/TECH-LINE/PROC/SEP23 Page 52
Volume-V
or wear of the damper. The fibre optic cable under clamp shall also be free from any
damage.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 53
Volume-V
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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 54
Volume-V
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.
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
The factory acceptance tests for OPGW Fittings as specified below in Table 4-1(h). The
sampling plan shall be as per IS 2486:
MPPTCL/TECH-LINE/PROC/SEP23 Page 55
Volume-V
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
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.
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.
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
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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 58
Volume-V
ANNEXURE -A
OPGW TECHNICAL SPECIFICATION
(To be submitted by manufacturer)
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)
ANNEXURE – C
PROPERTIES OF OPTICAL FIBER UNIT
(To be submitted by manufacturer)
Guaranteed value 48
Description Unit Fibers
MPPTCL/TECH-LINE/PROC/SEP23 Page 60
Volume-V
ANNEXURE - D
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
MPPTCL/TECH-LINE/PROC/SEP23 Page 61
ANNEXURE-F
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 :
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.
4.09 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.
***
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.
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.
The disc insulators should have the following particulars and characteristics:
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.
5.04.01 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
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.
5.06.01 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.
(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).
5.08 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
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
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.
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:
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.
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.
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 :
iii) Unit mechanical and electrical characteristics as also for the complete
string-suspension and tension.
MPPTCL/TECH-LINE/PROC/SEP23 Page 81
Appendix-I
TEST DETAILS
MPPTCL/TECH-LINE/PROC/SEP23 Page 82
S. Test Percentage of
No. discs to be tested
If the results of the second test show a porcelain shell rupture, the production does not
comply with this specification.
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
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:
The hardware fittings for lines shall be suitable for ACSR Conductor and Earth wire as per
technical parameters indicated in Annexure-3
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
6.03.02 The Insulator string Hardware fittings and Earth wire assemblies shall comply
and conform to the above requirement.
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.
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: -
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.
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.
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.
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.
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.
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.
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.
6.08.08.3 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.
6.08.10.3 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.
6.09.01 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:
MPPTCL/TECH-LINE/PROC/SEP23 Page 95
d. Re silence test for armour rods set. IS:2121 (Part-I)
a. Visual examination
b. Dimensional verification.
e. Galvanising test
a. Visual examination
b. Dimensional verification.
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.
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.
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.
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
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
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.
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.
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:
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.
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
i Tensile Test
ii Resistance Test
b. Dimensional verification
7.14.02 Midspan Compression Joint for Power Conductor & Earth wire
i. Visual examination
i. Visual examination
i. Visual examination
7.14.05 Clamps
i. Tensile Test
iii. Chemical analysis, hardness test grain size inclusion rating and
magnetic particle inspection for forgoing/castings.
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.
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
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.
(viii) Hard rock : The locations where chiseling, drilling and blasting is required for
excavation, hard rock type foundations are to be used.
(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.
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.
Tensioning and sagging operations shall be carried out in calm weather, when
8.22.05
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
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.
9.02.1 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.
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.
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.
9.03.7 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
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.
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.
9.05.1 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.
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.
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.
9.13.1 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.
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:
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.
9.17.1 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.
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.
9.19.1 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.
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
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.
9.22.1 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.
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
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.
3 . 1 The climatic conditions under which the cable shall operate satisfactorily are as
follows: -
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.
6.1 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.
6.4 INSULATION SCREEN: The insulation screening shall consist of non-metallic part
(extruded & taped) and metallic part.
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.
7.1 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.
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%.
9.3 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:
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.
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.
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
The following tests shall be carried out on samples taken to represent a batch: -
14.0 DOCUMENTATION:
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.
15.1 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.
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: -
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
&
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.
1.3 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.
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.
4.1 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.
5.1.1 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.
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.
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.
7.19 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.
9.1 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.
9.3 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.
10.1 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.
11.2 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.
13.3 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.
14.1 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.
14.3 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.
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.
16.1 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.
16.3 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.
The cable terminations shall be fire resistant. The components of kits shall have
flame retardant property.
18.0 INTERCHANGEABILITY
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.
19.3 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.
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.
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.
PRINCIPAL PARAMETERS OF
XLPE CABLE KITS & ACCESSORIES
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.
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.
2.1 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.
2.4.1 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.
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:
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.
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.
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.
6.1 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
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.
8.2 The excavated material shall be properly stored to avoid obstruction to public and
traffic movement.
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
10.2 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.
11.1 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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 182
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.
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.
2.2 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.
3.1 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
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.
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.
b) At places where the cables cross private roads, gates of residential houses or
buildings, the cables shall be laid in HDPE pipes.
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.
20.3 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.
21.1 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.
22.1 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.
24.0 B E N D I N G RADIUS
The minimum bending radius of XLPE insulated cables are as follows:
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.
2.2 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 .
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.
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.
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
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.
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.
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.
4.1 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.
5.1 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.
6.1 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.
7.1 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.
8.0 FOUNDATION
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.
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.
13.1 Permanent and durable type, cable route markers/joint indicating blocks should be
provided as per the design approved by the purchaser.
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.
14.3 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.
16.6 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.
16.9 The measurements of various civil works shall be jointly recorded by the
contractor and the Engineer in charge and duly certified.
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.
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.
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.
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.
4.1 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.
5.1 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.
6.1 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.
6.4 AC TESTING
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.
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.
ANNEXURE- 1
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
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
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.
The towers are self supporting lattice type, designed for the specified loading conditions.
There will generally be following type of towers:-
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.
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:
1.05.2 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. .
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:
(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.
(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.
(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.
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.
1.09.1 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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 262
Volume-V
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.
1.09.12 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.
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.
1.11.1 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.
1.11.6 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.
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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 265
Volume-V
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.
1.14.1 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.
1.14.6 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.
1.14.9 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.
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.
1.15.5 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 :-
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.
1.16.3 The tolerance on the overall length of member shall be within +/- 1.6 mm.
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.
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.
1.19.1 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.
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.
(ii) Sample selection from the offered lot at a ratio of 40 MT (or part thereof)
1 no. each for all tests.
(iv) Galvanising test of each sample i.e. dip test, hammer test and mass of
zinc test.
(vii) Chemical composition test of at least two samples per offered lot of 50
MT for inspection.
(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
MPPTCL/TECH-LINE/PROC/SEP23 Page 269
Volume-V
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.
1.22.1 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.
(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.
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.
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.
2.3.1 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:
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:
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:
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.
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.
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.
2.5.3.2 The lay ratio of the different layers shall be within the limits given in the Table
below:-
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.
2.5.2.1 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.
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.
The above said test reports submitted with the offer shall not be older than five years,
prior to the date of opening of bid.
NOTE: All the above tests except test mentioned at (j) shall be carried out on
aluminium and steel strands after stranding only.
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.
(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.
(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.
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”
2.8.1 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.
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.
2.10.1 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.
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.
2.10.11 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
MPPTCL/TECH-LINE/PROC/SEP23 Page 282
Volume-V
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.
2.11 MARKING :
Each drum shall have the following information stenciled on it in indelible ink along with
other essential data:
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.
2.13.1 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.
Please refer technical specification for optical fiber ground wire (opgw), associated hardware &
accessories from Section B (S.No. 03) of this document.
Please refer technical specification for High Tensile Galvanised Steel Earth wire from Section B
(S.No. 04) of this document.
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.
5.03.1 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: -
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.
5.04.1.1 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.
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.
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
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.
(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).
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).
MPPTCL/TECH-LINE/PROC/SEP23 Page 290
Volume-V
It shall be ensured that the dimensions of the disc insulators are within the limits specified
below:
a. Diameter of Disc (mm)
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.
5.05.9.1 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.
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.
5.05.12.2 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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 292
Volume-V
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.
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.
5.06.6.1 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.
5.06.7.1 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.
(A) The following type tests shall be conducted on all types of the complete
insulator string with hardware fittings :
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
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.
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
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.
5.08.1 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
5.09.1 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.
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.
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 297
Volume-V
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.
Appendix-I
TEST DETAILS
If the results of the second test show a porcelain shell rupture, the production does
not comply with this specification.
Samples taken from the zinc ingot shall be chemically analysed as per IS:209. The
purity of zinc shall not less than 99.95%.
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:
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.
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.
SYSTEM PARTICUALRS
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
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.
The material to be supplied against this specification shall be suitable for satisfactory
operation under the tropical climatic conditions as under:
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.
(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:-
(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
(b) The Insulator string Hardware fittings shall comply and conform to the above
requirement.
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.
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:
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:
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
(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:
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 313
Volume-V
(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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 314
Volume-V
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:-
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:
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:-
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:-
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.
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.
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.
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: -
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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 321
Volume-V
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
6.19.4 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:
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
6.21.6 Clamps
i Tensile Test
ii Resistance Test
iii Temperature Test (As perIS:5561)
iv Short time current Test
v Dimensional Check
vi Galvanising
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.
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.
6.25.2 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
MPPTCL/TECH-LINE/PROC/SEP23 Page 328
Volume-V
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.
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.
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:
(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.
(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.
(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.
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.
7.03.1 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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 333
Volume-V
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.
7.05.1 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 :
(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.
(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.
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.
7.09.1 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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 336
Volume-V
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.
7.10.3 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.
MPPTCL/TECH-LINE/PROC/SEP23 Page 337
Volume-V
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.
7.11.1 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
MPPTCL/TECH-LINE/PROC/SEP23 Page 338
Volume-V
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.
7.14.1 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.
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.
7.15.1 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.
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.
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.
7.18.1 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
Volume-V
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.
7.18.6 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.
7.19.1 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
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:
7.20.2 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.
7.21.1 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.
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.
7.23.1 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.
7.23.5 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.
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.
***
ANNEXURE- 1
ANNEXURE-2
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.
ANNEXURE-3
LIST OF SAMPLE DRAWINGS
S.No. Particulars
15 Midspan joint