Part -2 : Employer‟s Requirements 1

PART 2

EMPLOYER’S REQUIREMENTS
Part -2 : Employer‟s Requirements 2

Section - 6 : Employer’ s Requirements

Table of Contents

PART 2..................................................................................................................................... 1

Section - 6 : Employer’s Requirements ................................................................................. 2

1. Overview of the Scope of Works .........................................................................................4
2. Survey ..................................................................................................................................6
3. Project Management System................................................................................................7
4. Quality Assurance and Evaluation Mechanism ...................................................................9
Annexure-A..............................................................................................................................22
5. Type and Acceptance test ..................................................................................................37
6. Type Testing, Inspection, Testing & Inspection Certificate ..............................................37
7. Pre-Commisioning Tests....................................................................................................39
8. Commisioning Tests ..........................................................................................................39
9. GIS mapping & asset tagging ............................................................................................40
10. Documentation ...................................................................................................................41
11. Return of replaced old materials to the area stores of Employer .......................................44
12. Miscellaneous activities .....................................................................................................45
13. Individual work components..............................................................................................47
13.1. New 33 KV Lines ....................................................................................................47
13.2. 66/11KV new Substation .........................................................................................54
13.3. New 33/11 kV Power Substation .............................................................................59
13.4. New 11 KV Lines ....................................................................................................81
13.5. Distribution Transformer Substations ......................................................................89
13.6. New LT Line ............................................................................................................99
13.7. Augmentation and Renovation ..............................................................................105
13.8. High voltage distribution system (HVDS).............................................................119
13.9. Civil Works And Soil Investigation .......................................................................129
13.10. LT AB Cable Reconductoring Work .....................................................................161
13.11. Construction of New 11 kV Feeders and Associated Works for Separation of
Agricultural Consumers ...................................................................................................171
13.12. Underground Cabling.............................................................................................177
13.13. Specification for erection of 66 kV M/C, D/C tower / H-frame line .....................182
13.14. Plinth Mounted Distribution Substations...............................................................188
Annexure-B ............................................................................................................................212
Part -2 : Employer‟s Requirements 3
 Part -2 : Employer‟s Requirements 4

1. Overview of the Scope of Works

The work is to be executed under SI Scheme on turnkey basis aiming to Reliability of power supply for
Creation of Robust Network for 11 KV XLPE HT Cable with Under Ground /Over Head Cable, with Ring
Main Units (RMU) and Replacement of Open bare conductor with MVCC conductor in various subdivisions
of Nadiad O&M Circle in MGVCL under S.I. Scheme for FY 2023-24 The scope of which includes but
not limited to survey, network design, supply, manufacturer’s quality assurance, testing (where specified/
required), transportation, storage, erection, including all civil/ structural works, site testing, commissioning
of all items & materials including all associated activities/items which are mandatorily required for the
completion and satisfactory performance of the entire work. The above said works are to be executed in
the 0 6 m o n t h f r o m d a t e o f s i g n i n g o f c o n t r a c t a g r e e m e n t .
In case of any failure to achieve the above Phase wise Work Completion Schedule (Enclosed in
Annexure), the contractor will be penalized for Liquidity Damage at the percentage rate (Clause GCC
26.2).
The scope of works also include General Technical Instructions enclosed at Annexure-B.

This specification intends to cover but not limited to the following activities, services and works:
 Providing engineering data, and drawing for review, approval and records.
 Supply, testing, packing, transportation and insurance from the manufacturer‟s work to the site.
 Receipt, storage, insurance, preservation and conservation of equipments at the site.
 Fabrication, pre-assembly (if any), erection, testing and putting into satisfactory operation of all
the equipments/ materials including successful commissioning.
 In addition to the requirements indicated in this section, all the requirements as stated in Technical
specifications shall also be considered as a part of this specification as if completely bound
herewith.
 Providing all materials, equipments and services specified or otherwise, including survey, which
are required to fulfill the intent of ensuring operability, maintainability and the reliability of the
complete works covered under this specification.
 Under ground cabling work and RMU installation
 During warranty period the bidder is required to provide all the services and activities mentioned
in the contract.
 Preparation of project completion report/ closure proposal along with a report clearly indicating
completion of any outstanding/ remedial work that needs to be carried out.
 Handing over the works to the employer for taking into commercial services.

It is not the intent to specify all aspects of design and construction of equipments mentioned
herein. The systems, subsystems and equipments shall conform in all respect to high standards of
engineering, design and workmanship and shall be capable of performing in continuous
commercial operation. Accordingly, scope of works under this contract is as under:

1.1 Execution of all other works as per tender document. All Steel structure shall be hot dip galvanized as
per relevant Indian Standard.

1.2 All the raw materials such as steel, zinc for galvanizing, reinforcement steel and cement for
 Part -2 : Employer‟s Requirements 5
foundation, coke for earthing, bolts, nuts & washers, danger plates, phase plate, number plate etc. required
for substations & its structures shall be included in the scope of supply. Bidders shall clearly indicate
in their offer, the sources from where they propose to procure the raw materials and the components

1.4 A set of drawings are enclosed with this bid document. These are tender drawings and are to be approved
by the Employer. These drawings are indicative in nature and therefore, must be referred while
preparing drawings for approval.

1.5 All the new assets created under SI to be properly GIS & GEO Urja developed by GUVNL tagged
with the help of mobile App provided by the employer.

1.6 The engraving of word “Developed under SI” in materials viz., Poles, Transformers (All types), Cables,
Energy Meter etc is mandatory requirement. The Employer shall ensure strict compliance of this
requirement. Also, while processing payments to the Contractor, suitable documentary evidence
/ photographs must be asked by the Employer in support of the compliance.

1.7 Major infrastructures like new, new lines etc developed needs to be clearly denoted by a signboard that
should represent
1.7.1. About the Work:
1.7.2. Date of Commissioning:
1.7.3. Estimated cost:
1.7.4. Scheme
1.7.5. Employer‟s details

1.8 The Manufacturing Quality Plan (MQP) shall be finalized by the Employer in consultation with the
contractor/manufacturer in line with the Technical Specifications.

Supply of Plant and Services under this tender covers all interventions required for satisfactory
operations of the facilities unless specifically excluded. Scope includes Design, Supply, survey,
installation, erection testing and commissioning, on turnkey basis. The types of works envisaged in the
SIscheme are :

• Cabling related works.

• HT/LT Underground work to reduce the technical as well as commercial loss.
All items to be supplied and erected shall be strictly as per the specifications given in the Bid and
should comply the relevant standards.

Any deviation taken by the bidder and not specifically / clearly brought out in the price schedule will not
be considered as a valid deviation.

In addition to the works mentioned above the bidder is required to take care of the activities listed below:-
 Part -2 : Employer‟s Requirements 6
2. Survey
The Contractor shall carry out, and be responsible for, final design of the works, including any site surveys,
subsoil investigations and all other things necessary for proper planning design and execution. The initial
site surveys will be carried out for tentative freezing of the material requirement and the work content
finalization, within one month of commencement of project, and this will be a joint survey, along
with the MGVCL. The same shall be reviewed progressively on quarterly basis for freezing of the material
requirement and work content. Design shall be prepared by qualified designers who are engineers and
experienced in design of transmission and distribution systems. Also, while executing the works, same
priority of works must be followed.. The changes in design should be approved by Engineer-in-charge.
 Based on the finalized network design, the Bidder shall carry out the field survey for deciding
location of poles,

 Feeder wise Bill of Quantity (BOQ), for each proposed work will be prepared by the Bidder and
submitted to the Employer‟s Engineer-in-charge for his approval before commencement of actual
work.
 All architectural and civil designs such as control room, foundation for equipment, R M U , VCB
shall be approved by the Employer‟s Engineer-in-charge.

3. Project Management System

3.1. General

The Contractor shall assign a project manager with the authority to make commitments and decisions
that are binding on the Contractor. Employer will designate an officer incharge to coordinate all
employer project related activities. All communications between employer and the Contractor shall be
coordinated through the project manager and officer incharge of Employer. The project managers shall
also be assisting employer in communicating project related information to other stake holders.

Bidder shall submit the manpower deployment plan along with the bids, describing the key roles of
each person.

The role and responsibilities of contractor shall be as follows:

a) To prepare, maintain and update project detailed Work Execution Plan for successful
implementation of project like approval of GTP, approval of sub-contractor, approval of
drawings, supply of materials, mobilization of men, material and equipment etc. at site for
successful completion of works, Compile and up-load physical as well as financial progresses,
Part -2 : Employer‟s Requirements 7

compile the progress of works at Employer level and to assist in forwarding it to all stake
holders.

b) To actively participate with employer in resolving all issues relating to project implementation
including ROW, Forest Clearances and Railway Crossings.

c) To actively participate in monitoring, reviewing and analysing the physical, financial and quality
assurances works‟ progress of SI works and also to take suitable measures on compliance of
observations being raised during monitoring/review meetings with employer.

d) Physical as well as financial progresses shall be submitted in standard Bill of Material format of
the contract. Also, to submit invoices as per norms of Employer for release of payments/funds.

e) To oversee the progress and compliance of the Quality Assurance Mechanism as per
MGVCL norms.

3.2. Project Schedule

As per the schedule the bidder shall submit a preliminary implementation plan along with the
bid. The detailed project implementation schedule shall be submitted by the contractor after the
award of contract for employer‟s approval, which shall include at least the following activities:

(a) Surveying of site.

(b) Documents submission and approval schedule
(c) Pre-Dispatch Inspection schedule
(d) Dispatch Schedule
(e) Installation & commissioning schedule
(f) Training schedule, if any.

The project schedule shall include the estimated period for completion of project and its linkage
with other activities etc. It is expected that the contractor should share updated project schedule
based on the actual progress done at site, priorities of the employer, availability of material etc
once per quarter along with the Progress report.

3.3. Progress Report

A progress report shall be prepared by the Contractor each month against the activities listed in
the project schedule. The report shall be made available to employer on a monthly basis, e.g., the
Part -2 : Employer‟s Requirements 8

10th of each month. The progress report shall include all the completed, ongoing and scheduled
activities.

3.4. Transmittals

Every document, letter, progress report, change order, and any other written transmissions
exchanged between the Contractor and employer shall be assigned a unique transmittal number.
The Contractor shall maintain a correspondence index and assign transmittal numbers
consecutively for all Contractor documents. Employer will maintain a similar correspondence
numbering scheme identifying documents and correspondence that employer initiates.

4. Quality Assurance and Evaluation Mechanism

The Quality Assurance (QA) will be carried out by Employer. The Employer may engage an
Authorised representative of employer responsible & accountable for assuring quality in SI works.
Key activities would include:
 Formulation of a detailed comprehensive Quality Assurance (QA) plan for the works to be
carried out under SI scheme with an objective to create quality infrastructure works. The QA and
Inspection Plan shall be integral part of the contract agreement with turnkey contractor or
equipment supplier and erection agency as the case may be in case of turnkey/ or departmental
execution of works.
 Ensuring that the quality of materials/equipment supplied at site and execution of works carried
out at field under SI scheme is in accordance to Manufacturing Quality Plan (MQP)/Guaranteed
Technical Particulars (GTP) and Field Quality Plan (FQP)/Approved Drawings/Data Sheets
respectively.

4.1. Quality checks to be ensured by Turnkey Contractor:

Turnkey Contractor shall strictly ensure QA checks during the day to day course of project
execution, which are as follows:

a. Pre-dispatch inspections of all materials viz. as per MQP/ Approved Drawings/ Technical
Specifications/Datasheet/GTP/applicable national & international standards as per GCC Clause
23.
b. for quality of material as per MQP/Approved Drawings/Technical Specifications/Datasheet/GTP
and erection works in the field as per FQP/approved survey drawings/layout.
.
d. 100% verification of materials utilised under the scheme.
Part -2 : Employer‟s Requirements 9

e. 100% verification of works done in System Strengthening.

4.1.1. Vendor approval: All the materials procured for SI works shall be purchased from the authorised
vendors approved by the Quality Assurance Department of Employer. Approved vendors list is
uploaded periodically on the Employer web portal.

New vendors/suppliers may be approved by Employer, provided capability of manufacturer(s) is

assessed suitably by visiting the factory premises and checking the testing facility available
before accepting it as an approved vendor. If required, State Electricity Board/Power
Department/ Distribution Companies may adopt vendors already approved by CPSUs.

4.1.2. FQP for Civil works: Employer shall prepare a separate FQP for civil works supported with
drawings which shall be approved by their competent authority which shall be uploaded at web
portal. The turnkey contractor shall adhere to this FQP while carrying out physical works.

4.1.3. FQP for testing & commissioning: Employer shall prepare a comprehensive Pre- commissioning test
Check-list for testing & commissioning of 33/11kV or 66/11kV substation, Distribution transformer
Substation etc. The electrical system shall be energized only afterperforming all tests as described in the
pre-commissioning test checklist. and inspection from the electrical inspector of the state (or as the
practice may be). Proper records in this regard, includingtests on earth resistance, insulation resistance of
11 kV line & Distribution Transformer etc. shallbe maintained, jointly signed by Employer and turnkey
representatives.

4.1.4. QA documentation: All the quality assurance checks shall be conducted in the field as per
approved Field Quality Plan(FQP) and shall be documented properly and signed by the quality
engineer of the turnkey contractor & countersigned by Employer's representative and shall be
kept for future reference. These documents shall be maintained by Employers in proper order and
shall be made available at site for verification by Quality Monitors during inspection.

4.2. Quality Assurance Mechanism to be envisaged by Employer for SI Projects

i. Employer shall be responsible & accountable for assuring quality in the scheme works.
ii. Employer shall formulate a comprehensive Quality Assurance (QA) and Inspection Plan
with an objective to build quality infrastructure under the project which shall be an integral
Part of the contract agreement with turnkey contractor or equipment supplier/vendor and
erection agency.
iii. The Sampling criteria for selection of sites and the compliance of the Non-
Conformances to be prepared by the Employer.
iv. The Quality Control Mechanism should be duly approved by Employer before actual
start of supply & erection works. The Employer must ensure that the quality of
Part -2 : Employer‟s Requirements 10

material/equipment supplied at site and field execution of works under the project is in
accordance with Quality Assurance & Inspection Plan.
v. The TKC needs to adhere approved QCM developed by the Employer.
vi. TKC‟s performance would be rated on periodic manner at least once in a month.
The field works inspections are to be carried out as per approved Field Quality Plans

(FQP) / Construction Drawings/ Technical Specifications/Datasheet/survey report as

per the contract between the Employer and the contractor. The indicative sample size
for field inspection works, which may be modified for site-specific reasons to be
recorded in writing by the MGVCL, shall be as follows:

 All the spans of 10% of HT feeders for new and 5% of the feeder in case of
augmentation works.

The TKC is required to rectify the observations / defects detected within 7 days of
notification. However based on severity the Employer may direct the contractor on
resolution mechanism / process and timeline

4.3. Material Inspection:

For the purpose of the inspection, the materials have been segregated into two categories as mentioned
below:
 Category – A (Pre-Dispatch Inspection & Testing at NABL accredited Labs): This category shall
include high ticket materials (Power Transformers, Distribution Transformers, Circuit Breakers,
AB/XLPE Cables, Overhead Conductor (AAAC/ACSR), Insulator which involves more and
important testing procedures and hence the inspection of these materials will be carried out in the
factory before the dispatch of the material.
In addition, Employer shall also ensure that for major materials as discussed above, samples from
1st lot and one other lot randomly selected by the Employer shall be directly sent to nearest NABL
accredited lab for third party testing. It is also to be noted that material clearance of the lots under
testing shall only be given post receipt of successful test results.
Apart from the above mentioned protocol the first power transformer received at site shall be
subject to Short Circuit Test.
 Category – B (On-site inspection): This category includes the materials for which a factory
inspection is not warranted and the material can be inspected upon arrival at the site before the
installation. In case the Employer is apprehensive about the quality of the material supplied it reserves
the right to send the selected lot to the nearest NABL accredited lab for third party testing.
Part -2 : Employer‟s Requirements 11

4.4. Pre-dispatch Inspection (PDI):

Pre-dispatch inspection shall be performed on various materials at manufacturer‟s work place for which
contractor shall be required to raise requisition giving at least 10-day time to employer for allocating
inspection team. Depending on requirement, inspection shall be witnessed by representatives of
Employer.
The contractor shall ensure receipt of material at site within 21 days from date of receipt of dispatch
instructions. In case materials are not received within 21 days from date of issue of dispatch instruction,
the dispatch instruction shall stand cancelled. All expenditure incurred by Employer in performance of
dispatch instruction shall be recovered from turnkey contractor.
Part -2 : Employer‟s Requirements 12

Circuit Breaker

Standards Applicable:-

IS: 13118 Specification for HV AC Circuit Breaker

IS: 14658 HV AC Circuit Breakers - Guide for Short-circuit and Switching Test Procedures for
Metal-enclosed and Dead Tank Circuit Breakers

IS: 2099 Specification for HV porcelain bushings

IS: 5621 Specification for porcelain hollow insulator.

IS: 8603 Specification for Dimension for Porcelain Transformer Bushing for use in heavily
polluted area.

IS: 3347 Specification for Dimension for Porcelain Transformer Bushing for use in normal and
lightly polluted area.

IS: 2633 Specification for method for testing uniformity of coating On Zinc coated articles.

IS: 5561 Specification for Electrical Power Connectors

IS: 2147 Specification for Degree of Protection

Proposed Tests as per IS

1 Single Capacitor bank breaking test

2 Short time withstand and Peak Withstand Current Test

3 Wet power frequency withstand voltage test

4 Lightening Impulse voltage withstand test

5 Temperature rise test

6 Mechanical Endurance Test(M2 Class)

Part -2 : Employer‟s Requirements 13

Proposed Tests as per IS

7 Degree of Protection test of Control Cubicle

XLPE Cables

Standards Applicable:-

IS : 7098 (Part-I) : 1988 Specification for Crosslinked Polyethylene Insulated PVC sheathed
Cables for working Voltage upto & including 1100 Volt

IS: 8130 : 1984 Specification for Conductors for insulated electric cables and flexible
cords

IS:5831 : 1984 PVC insulation & sheath of electric cables

IS: 3975 : 1970 Specification for Low Carbon Galvanized steel wires, Formed Wires
and tapes for armouring of Cables

IS:10810 : 1984 Methods of test for Cables.

IS:10418 : 1982 Cable Drums for Electric Cables.

IS : 694 : 2010 PVC unsheathed and Sheathed cables / Chords with rigid and flexible
conductor for rated voltages upto and including 450/ 750 V

Proposed Tests as per IS

1 Resistance Test on conductor

2 Test for thickness of insulation and sheath

3 Tensile strength and elongation at break test for insulation & outer sheath.

4 Hot set test for insulation.

Part -2 : Employer‟s Requirements 14

Proposed Tests as per IS

5 Insulation resistance (Volume resistivity) Test

6 High voltage test

Arial Bunched Conductor

Standards Applicable:-

IS 14255 : 1995 Specification for Aerial Bunched Cables for working Voltage up to &
including 1100 Volts.

IS : 8130 : 1984 Specification for Conductors for Insulated Electric Cables and flexible
Cords.

IS : 398 (Part-IV) : 1994 Specification for Aluminum Conductors for overhead transmission
purposes: Aluminum Alloy Stranded Conductors (Aluminum Magnesium
–Silicon type).

IS:10418:1982 Specification for Drums for Electric Cables

Proposed Tests as per IS

1 Breaking Load Test for messenger Conductor.

2 Elongation test for messenger conductor.

3 Conductor resistance test for both messenger and XLPE conductor

4 Test for thickness of insulation of XLPE conductor

5 Tensile Strength and Elongation at Break Test for both messenger and XLPE conductor

6 Hot Set Test for XLPE insulation.

Part -2 : Employer‟s Requirements 15

Proposed Tests as per IS

7 Insulation resistance test for XLPE conductor

8 High Voltage Test for XLPE conductor

Overhead Conductors AAAC/ACSR

Standards Applicable:-

IS: 398 (Part I & II) : 1996 Specification for Aluminum Conductors with Steel Re-inforced.

IS: 4826 : 1968 Coating of the galvanized steel wires shall be applied by the hot process
or electrolysis process

IS: 398 (Part-IV): 1994 Specification for All Aluminum Alloy Conductor (AAAC)

IS: 1778 : 1980 Packaging of Overhead conductor in Wooden Drum

Proposed Tests as per IS

1 Measurement of lay ratio.

2 Measurement of diameters of individual wire

3 Measurement of resistance of individual wire.

4 Breaking load test of individual wire.

5 Elongation test of individual wire.

Porcelein Insulators

Standards Applicable:-

IS 1445 : 1977 Porcelain insulators for overhead power lines with a nominal voltage up
to and including 1000 V
 Part -2 : Employer‟s Requirements 16

IS 2486 (Part 1) : 1993 Metal fittings of insulators for overhead power lines with nominal
voltage greater than 1000 V: Part 1 General requirements and tests

IS 2486 (Part 2) : 1989 Insulator fittings for overhead power lines with nominal voltage greater
than 1 000 V: Part 2 Dimensional requirements

IS 2486 (Part 4) : 1989 Insulator Fittings for Overhead Power Lines with a Nominal Voltage
Greater than 1 000 V - Part IV : Tests for Locking Devices

Proposed Tests as per IS

1 Resistance Test on conductor

2 Test for thickness of insulation and sheath

3 Tensile strength and elongation at break test for insulation & outer sheath.

4 Hot set test for insulation.

5 Insulation resistance (Volume resistivity) Test

6 High voltage test

However above list of tests are only indicative in nature, if Employer feels it can add some tests based
on latest IS Standards. If the Employer faces any inssues with respect to actual performance of a
material then it can issue a notice to Contractor for testing of that material at its sole descrition.
Note: Over and above for quality check of material Utility may carried out Routine Test/Acceptance test/any of the Type
Test as per relevant standard as narrated in Technical specification.

4.5. Penalty in case of failures in testing:

4.5.1. The turnkey contractor shall ensure that pre-dispatch inspection for materials is intimated only
when the material is completely ready for inspection. On due date of inspection, if it is found that
materials are not ready in required quantities or the inspection could not be carried out due to non-
availability of requisite calibrated certificate of instruments with manufacturer, closing of works on
scheduled date of inspection, non-availability of sufficient testing/material handling staff at
manufacturer works etc, all expenditures incurred on deployment of various inspecting officials along
with a fine of Rs 50,000/- inclusive of GST shall be recovered from the bills of the agency and re-
inspection shall be carried out on expense of contractor.
Part -2 : Employer‟s Requirements 17

2nd such situation at same manufacturer/supplier shall result in rejection of name of manufacturer
from list of approved vendors/sub-vendors. In case sub-standard materials (old component, re- cycled
materials, re-used core material, re-used transformer coil material etc) offered for inspection and are
noticed during the inspection, materials shall be rejected and approval of sub-vendor shall also be
cancelled for all SI projects.
4.5.2. In case, a material fails the pre-dispatch inspection as per GCC Clause 23, and also fails the
subsequent repeat inspection of the rectified/replaced material, the complete lot of material under
inspection will be required to be replaced by the manufacturer/supplier. If in subsequent inspection
of the new lot, the material again fails the inspection, then materials shall be rejected and approval of
vendor/sub-vendor shall also be cancelled for all SI projects.
4.5.3. Third Party Inspection at NABL accredited lab: Employer shall also ensure that for major
materials as discussed above samples from 1st lot and one other lot randomly selected by the
Employer shall be directly sent to nearest NABL accredited lab for third party testing. In case a
material fails in the test, the whole offered lot would be rejected and complete lot of material under
inspection will be required to be replaced by the manufacturer/supplier. If in subsequent inspection
of the new lot, the material again fails the inspection, then materials shall be rejected and approval
of vendor/sub-vendor shall also be cancelled for all SI projects.
All expenditures that shall incurred towards packing, transport, inspection, testing charges etc. are to
be borne by the the contractor.

4.6. Electrical Inspector inspection:

After successful completion of the work permission from State Electrical Inspectorate is required.
Necessary fee etc. shall be paid by the Employer. However if Contractor pays such fee it shall be
reimbursed on actual basis on documentary evidence.
Defects / in-complete works notified by Electrical Inspectorate shall be completed by the agency at no
extra cost implication to Employer.

4.7. General Quality assurance measures to be taken by Contractor:

4.7.1. To ensure that the equipment and services under the scope of this Contract whether
manufactured or performed within the Contractor’sWorks or at his Sub-contractor’spremises 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 programme to control such activities at all points
necessary. Such programme shall be broadly outlined by the contractor and finalized after
discussions before the award of contract. The detailed programme shall be submitted by contractor
after the award of contract and finally accepted by the Employer after discussions. A quality
assurance programme of the contractor shall generally cover the following:

a) His organization structure for the management and implementation of the proposed quality
assurance programme :
Part -2 : Employer‟s Requirements 18

b) Documentation control system;

c) Qualification data for bidder‟s key personnel;
d) The procedure for purchases of materials, parts, components and selection of sub-
Contractor’sservices including vendor analysis, source inspection, incoming raw material
inspection, verification of material purchases etc.
e) System for shop manufacturing and site erection controls including process controls and
fabrication and assembly control;
f) Control of non-conforming items and system for corrective actions;
g) Inspection and test procedure both for manufacture and field activities.
h) Control of calibration and testing of measuring instruments and field activities;
i) System for indication and appraisal of inspection status;
j) System for quality audits;
k) System for authorizing release of manufactured product to the Employer.
l) System for maintenance of records;
m) System for handling storage and delivery; and
n) A manufacturing quality plan detailing out the specific quality control measures and procedures
adopted for controlling the quality characteristics relevant to each item of equipment furnished
and/or services rendered.
o) A Field quality Plan covering field activities
4.7.2. The manufacturing & Field quality Plans shall be mutually discussed and approved by the
Employer after incorporating necessary corrections by the Contractor as may be required.

4.7.3. The Employer or his duly authorized representative reserves the right to carry out quality audit
and quality surveillance of the system and procedure of the Contractor/his vendor‟s quality
management and control activities.

4.7.4. The Contractor would be required to submit all the Quality Assurance documents as stipulated
in the Quality Plan at the time of Employer‟s Inspection of equipment/material.
 Part -2 : Employer‟s Requirements 19

Annexure-A
Checklist for Quality Assurance
Distribution Transformer Substation
Status Picture
S. No Description Observations Location
(Yes/No) No.
1 Record capacity of DTR transformer used
Record S. No., make and year of
2
manufacturing of DTR transformer
Safe and adequate access to distribution
3
transformer (DTR) substation
4 Availability of approved survey report
Proper load survey is performed of the
5 locality for perspective consumers while
deciding capacity and location of DTR
Expected loading of transformer using 5
6
years growth is performed in survey report
Proper alignment of substation structure
7
with 11 KV line
Record type of poles/support used for DTR
8
Substation
9 Record type of foundation used
Proper muffing is provided on steel
10
supports of DTR substation
If DTR substation is in water logging area,
11 its foundation is grouted in cement
Concrete
12 Proper verticality of substation supports
Proper pole to pole distance of substation
13
supports.
Proper erection of jumpers and connection
14
to DTR transformers without any bent
15 Proper binding of insulators
Stay plates are properly grouted in cement
16 concrete mixture to support DTR
substation structure (if erected)
17 Proper tensioning is there on stay set
Proper alignment of stay wire with
18
overhead conductor
19 Proper erection of stay clamp using 12 mm
 Part -2 : Employer‟s Requirements 20

S. No Description Status Observations Location Picture

dia nuts and bolts
20 Proper galvanization of stay wire
Thimble is provided on turn buckle of stay
21
Set
Stay set installation is provided with guy
22
Insulator
Proper phase to phase and phase to ground
23 clearances maintained on the substation
jumpers
Steel overhead structure is properly earthed
24
using 8 SWG wire/G.I. flat?
Each 11 kV overhead equipment including
25 transformer are individually earthed using
8 SWG Earth wire/ GI flat
Danger plate is installed at appropriate
26 height using proper size clamp. Record
type and size of clamp
Proper anti-climbing device (barbed
wire/spike) installed at appropriate height
27
on individual support. Record quality of
wrapping of barbed wire
28 Substation is numbered
Individual substation pole is
29
imposed/painted with the name of scheme
Surface of the PCC poles is finished and
30
there are no steel wire visible
No physical damages appeared on PCC
31
pole surface
GI flat to GI flat connection using at least 2
32
sets of GI nut bolts and washers
8 SWG GI wire/GI Flat is properly dressed
33
with support
GI wire to GI wire jointing is provided
34
using 12 SWG GI nut bolts and washers
GI wire connection to earth pit is using GI
35
nut bolt and washer
GI earth pipe is properly inserted inside
36
earth without hammering
37 Number of earth pit used for substation
 Part -2 : Employer‟s Requirements 21

S. No Description Status Observations Location Picture

earthling.
38 Pit to pit distance in meters. Is it adequate?
Masonry enclosure is provided over
39
individual earth pits
40 Funnel is provided over earth pit
Proper jumpering using binding
41
practices/PG clamp
Proper clearances to avoid bird fault on
42
conductors of substation supports
Type and size of overhead conductors used
43
in the substation
Cement-concrete grouting foundation of
44
substation supports
Measure quantum of cement concreting in
45
any one sample support
Measure cement concreting foundation in
46
any one sample of stay set pit
Proper painting/galvanizing done on steel
47
Structure
Any sign of rusting found on substation
48
structure/hardware
Any broken insulator found in the
49
Substation
Disc Insulators installed precariously
50
(loose bolts/ missing cotter pins)
Separate individual earth connection using
51 GI wire/GI flat is used for neutral earthing
with separate pit
Dedicated transformer body earthing using
52
GI wire/GI flat
Bimetallic clamps are provided on 11 kV
53
Bushing
No gap between busing seat and bimetallic
54 clamp on LT as well as HT bushing while
connecting conductor/cable
Proper lugs are provided on termination of
55
Cables
56 Oil is filled in cup of silica gel breather
57 Silica gel is blue in colour
 Part -2 : Employer‟s Requirements 22

S. No Description Status Observations Location Picture

Oil control valves are open between
58 transformer tank and breather (wherever
used)
Oil leakage from the body/gasket of
59
transformer and from conservator tank
60 Record level of oil in conservator tank
Transformer installed precariously ( Nut /
61
bolts / side bracing missing)
Transformer is fitted with 12 mm dia nut
62
bolts on its base channel
63 Transformer belting is provided
64 Dimension of transformer base channel
Individual lightening arrestor are earthed
65
with dedicated separate earth pit
LA jumper connections is missing/ not
66
Proper
67 LA is charged/ installed but not meggared
Isolators/AB switch are properly aligned
68
and its operation is smooth
Operating handle (not missing eye bolt) of
69 isolator/AB switch is earthed using flexible
cable
No joint in between entire length of
70
operating pipe of isolator/AB switch
Guiding hook is provided for isolator pipe
71
Movement
Alignment of male and female contacts of
72 isolators/AB switch and no spark during
normal use
Proper fuse wire is used in DO fuse/HG
73
Fuse
Arching Horn is missing/ not aligned / not
74
Proper
Proper size of LT cable are used between
75
transformer and LTDB
lockability and proper closing of door of
76
LTDB
Gland plate and glands are used for cable
77
entry in LTDB
 Part -2 : Employer‟s Requirements 23

S. No Description Status Observations Location Picture

76 No unused holes on gland plates
Availability of LTDB equipment as per
approved drawing and scope of work like
77
isolator, fuse, switch, bus bar, MCCB,
MCB etc.
Installation of DTR as per BIS
78
Specification
LTDB earthing at different points using 8
79
SWG GI wire
Proper painting and No physical damages
80
on LTDB
81 Suitable loop length of cables in LTDB
3 Nos earthing pit and earth mat /risers
82
using 50X6mm GI Flat are used as under:
a Earth Pit – 1 for Transformer Neutral,
b Earth pit - 2 for Lightening Arrester,
c Earth pit – 3 for Equipment body earthing
83 Deleted
84 Deleted
Quality of painting/galvanizing on
85
substation structure
86 DTR is newly supplied
PG Clamps are used ( wherever needed as
87
per drwg- Jumper etc)
88 Deleted
89 Earthing Electrodes short/missing
Commissioning Defect: DT
90
charged/installed but not merged
Fasterers (Nuts/ Bolt/ Clamps /Connector)
91
size not as per drawing /specification
Fasteners ( Nuts / bolts/ Clamps /
92
connectors) in precarious state
Poles not erected properly (inadequate or
93
missing brick bat/ foundation)
Stay installation is not proper : guy
94
insulator missing ;inadequate depth
95 Earthing wire diameter undersize
96 Danger plate missing/improper
 Part -2 : Employer‟s Requirements 24

S. No Description Status Observations Location Picture

97 Earthing wire not secured / not dressed
98 Barbed wire missing/improper
99 DTR ground electrodes far too close
Earth pit to earth pit clearance not
100
Maintained
101 HT Fuse not provided
HT fuse unit jumpering not connected
102
Properly
MCCB of lower rating than specified in
103
LOA
104 MCCB not installed
Inferior quality of Distribution Board used
105
( makeshift, locally fabricated DBs)
LT Line
Status Picture
S. No Description Observations Location
(Yes/No) No.
Availability of approved survey report with
1
Single line diagram
2 Correct alignment of LT line
Type of poles used as per scope of the
3
Work
Type of foundation used as per scope of
4
Work
If line is passing through water logging
5 area and its foundation is grouted in
cement concrete
6 Proper verticality of poles
7 Any deflecting tension on LT pin insulator
Proper tensioning of overhead
8
conductor/LT cable/ABC Cable
Any knot/wrapping of overhead conductor
9 /LT cable /ABC Cable is there during
erection
Proper binding of insulators cable both /
10
tension work is done
Stay plates are properly grouted in cement
11
concrete mixture
12 Proper tensioning is there on stay set
 Part -2 : Employer‟s Requirements 25

S. No Description Status Observations Location Picture

Proper alignment of Stay wire and stay set
13 with overhead conductor is there to nullify
tension
Proper erection of stay clamp using 12 mm
14 dia nuts and bolts and 50x6 mm (or more)
size clamp
If every 6th pole in a section of line is
15 provided with stay sets to avoid line
Deflection
16 Proper galvanization of stay wire/stay set
Thimble is provided on turn buckle of stay
17
Set
Proper phase to phase clearances are
18
maintained on the line
Steel overhead structure is properly earthed
19
using 8 SWG wire
Each LT pole individually earthed using 8
20 SWG Earth wire and separate Earth
pit/Earthing coil/Earth spike
Quality and size of danger plates is as per
21
scope of work
Danger plate is installed at appropriate
22 height using proper clamp as per scope of
Work
Anti-climbing device (barbed wire/spike)
23 are installed at appropriate height on
individual support
24 Individual pole is numbered
Individual pole is imposed/painted with the
25
name of scheme
Surface of the PCC poles is finished and
26
there are no steel wire visible
No physical damages appeared on PCC
27
pole surface
Cradle guard earthing is provided on each
28
road crossing or on each LT line crossing
29 Proper tensioning of the cradle guard wires
Separate earthing on both the sides of
30
road/line for cradle guarding are there
 Part -2 : Employer‟s Requirements 26

S. No Description Status Observations Location Picture

8 SWG G.I. wire is properly dressed with
31 support for V-Cross arm/Channel/Top
clamp earthing
GI wire to GI wire jointing is provided
32
using 12 SWG GI nut bolts and washers
GI wire connection to earth pit is using 12
33
mm GI nut bolt and washer
Earth pipe is properly inserted inside earth
34
without pipe hammering
Masonry enclosure is provided over
35
individual pipe earth pits
36 Funnel is provided over pipe earth pit
Jumpering using best binding practices/PG
37
Clamp
Proper conductor clearances to ground is
38 there to avoid bird fault on end sectionizer
support where disc insulator are used
Average pole to pole span length in the
39
line. It should not be less than 50 m.
If Pole to pole span is less than 50 m,
40
record the reason with pole numbers
Number of poles used per kilometer of the
41
Line
Type and size of overhead
42
conductors/ABC cable used in the line
Shuttering is used during casting of cement
43
concrete foundation
Cement-concrete grouting foundation of
44
end supports
Quantum of cement concreting in any one
45
sample support
Cement concreting foundation in any one
46
sample of stay set pit
47 Proper painting is done on steel structure
48 Any broken insulator found in the line
Surface finish of painting on Steel tubular
49 pole/RSJ/H Pole/Rail pole about 2 m from
bottom and above 2 m
50 Possible damage on ABC cable surface
 Part -2 : Employer‟s Requirements 27

S. No Description Status Observations Location Picture

Piercing connections are used to take-off
51
connection from ABC cable
Muffing is used in steel steel tubular poles,
52
rail pole, RS joint/H beam Supports
Adequate tree cutting on either side of line
53
Done
Pole to pole schedule enclosed with
54
profarma

11 KV Line
Status Picture
S. No Description Observations Location
(Yes/No) No.
Availability of approved survey report with
1
single line diagram
2 Correct alignment of 11 kV line

3 Type of poles used as per scope of the work

4 Type of foundation used as per scope of work
Record whether line is passing through wate
5 logging area and its foundation is grouted in
cement concrete
6 Proper verticality of poles
7 Cross-bracing on Double poles are provided
Conductors are passing through the top grove
8 of the insulator ( creepage distance
compromised)
9 More than one joint in one span
10 Any deflecting tension on 11 KV pin insulator
11 Proper tensioning of overhead conductor
Any knot/wrapping of overhead conductor is
12
there during erection
13 Proper binding of insulators is done
Stay plates are properly grouted in cemen
14
concrete mixture
15 Proper tensioning is there on stay set
Proper alignment of Stay wire with overhead
16
conductor is there to nullify tension
Guy insulator, anchor plate/ thimble/ hardware
17
are provided with stay set
18 Proper erection of stay clamp using 12 mm dia
 Part -2 : Employer‟s Requirements 28

S. No Description Status Observations Location Picture

nuts and bolts and 50x6 mm (or more) size
clamp
If every 6th pole in a section of line is
19
provided with stay sets to avoid line deflection
20 Proper galvanization of stay wire and stay set
21 Thimble is provided on turn buckle of stay set
Proper phase to phase clearances are
22
maintained on the line
Steel overhead structure is properly earthed
23
using 8 SWG wire
Each 11 kV pole individually earthed using 8
24 SWG Earth wire and separate Earth
pit/Earthing coil/Earth spike
Quality and size of danger plates is as pe
25
scope of work
Danger plate is installed at appropriate heigh
26
using proper clamp as per scope of work
Anti-climbing device (barbed wire/spike) are
27 installed at appropriate height on individua
Support
28 Individual pole is numbered
Individual pole is imposed/painted with the
29
name of scheme

Surface of the PCC poles is finished and there

30
are no steel wire visible
No physical damages appeared on PCC pole
31
Surface

Cradle guard earthing is provided on each road

32
crossing or on each LT line crossing
33 Proper tensioning of the cradle guard wires
Proper Guard wires are provided in case o
34
Road crossing as per drawing specification
8 SWG G.I. wire is properly dressed with

35 support for V-Cross arm/Channel/Top clamp

earthing
GI wire to GI wire jointing is provided using
36
12 SWG GI nut bolts and washers
GI wire connection to earth pit is using 12 mm
37
GI nut bolt and washer
 Part -2 : Employer‟s Requirements 29

S. No Description Status Observations Location Picture

Earth pipe is properly inserted inside earth
38
without pipe hammering
Masonry enclosure is provided over individua
39
pipe earth pits
40 Funnel is provided over pipe earth pit
Proper jumpering using binding practices/PG
41
Clamp
42 If under sized conductor used
Proper conductor clearances to ground is there
43 to avoid bird fault on end sectionizer suppor
where disc insulator are used
Proper pole to pole span length in the line. I
44
should not be less than 50 m.
If Pole to pole span is less than 50 m, record
45
the reason with pole numbers
46 Number of poles used per kilometer of the line
Record type and size of overhead conductors
47
used in the line
Shuttering is used during casting of cemen
48
concrete foundation
Cement-concrete grouting foundation of end
49
Supports
Measure quantum of cement concreting in any
50
one sample support
Measure cement concreting foundation in any
51
one sample of stay set pit
52 Proper painting is done on steel structure
Disc Insulators are installed precariously
53
loose bolts/ missing cotter pins)
54 D -shaped loop for jumpers are maintained
55 Any broken insulator found in the line
Surface finish and painting on Steel tubula
56
pole/RSJ/H Pole/Rail pole
Adequate tree cutting on either side of line
57
Done
58 Pole to pole schedule enclosed with proforma
Pole numbering with "SI " inscription no
59
done ( properly)
60 Engraving of poles (Name of Manufacturer, SL
Part -2 : Employer‟s Requirements 30

S. No Description Status Observations Location Picture

Nos etc.) not done
61 Line Spacers not used
62 Guy insulator not used in stay wire
63 Inadequate length of barbed wire

5. Type and Acceptance test

The following type, acceptance and routine tests and tests during manufacture shall be carried-out
on the material. For the purpose of this clause:
5.1. Contractor shall supply the materials of type & design which has already been Type Tested.
Contractor shall provide copy of such tests at site in support of type-tested materials supplied under
the contract. No extra payment or time shall be granted for type testing of materials. In exceptional
case to case basis, employer will decide to permit type testing of material at contractor’scost.

5.2. Acceptance Tests shall mean those tests which are to be carried out on samples taken from each lot
offered for pre-dispatch inspection, for the purposes of acceptance of that lot.

5.3. Routine Tests shall mean those tests, which are to be carried out on the material/equipment to check
requirements which are likely to vary during production.

5.4. Tests during Manufacture shall mean those tests, which are to be carried out during the process of
manufacture and end inspection by the Contractor to ensure the desired quality of the end product to
be supplied by him.

5.5. The norms and procedure of sampling for these tests will be as per the Quality Assurance
Programme to be mutually agreed to by the Contractor and the Owner.

5.6. The standards and norms to which these tests will be carried out are listed against them. Where a
particular test is a specific requirement of this Specification, the norms and procedure of the tests shall
be as per IS/IEC Standard this specification or as mutually agreed to between the Contractor and the
Owner in the Quality Assurance Programme.

5.7. For all type test and acceptance tests, the acceptance values shall be the values specified in this
Specification, Approved Quality Plan or guaranteed by the Bidder, as applicable.

6. Type Testing, Inspection, Testing & Inspection Certificate

6.1 All equipment being supplied shall conform to type tests including additional type tests, if any as
per technical specification and shall be subject to routine tests in accordance with requirements
stipulated under respective sections. The Contractor shall intimate the Employer the detailed
program about the tests at least three (3) weeks in advance in case of domestic supplies & six (6) weeks
in advance in case of foreign supplies.
Part -2 : Employer‟s Requirements 31
6.2 The reports for all type tests and additional type tests as per technical specification shall be
furnished by the Contractor alongwith equipment/material drawings. The type tests conducted
earlier should have either been conducted in accredited laboratory (accredited based on ISO/IEC
Guide 25/17025 or EN 45001 by the national accreditation body of the country where laboratory is
located) or witnessed by the representative(s) of Employer or Utility. The test-reports submitted
shall be of the tests conducted within last 5 (five) years prior to the date of bid opening. In case the
test reports are of the test conducted earlier than 5 (five) years prior to the date of bid opening, the
contractor shall repeat these test(s) at no extra cost to the Employer, however the delay in supply
due to type-test will not be acceptable during the project.

6.3 In the event of any discrepancy in the test reports i.e. any test report not acceptable due to any
design/manufacturing changes (including substitution of components) or due to non-compliance
with the requirement stipulated in the Technical Specification or any/all additional type tests not
carried out, same shall be carried out without any additional cost implication to the Employer.

6.4 The Employer, his duly authorized representative and/or outside inspection agency acting on behalf
of the Employer shall have at all reasonable times free access to the Contractor‟s/sub-vendors
premises or Works and shall have the power at all reasonable times to inspect and examine the
materials and workmanship of the Works during its manufacture or erection if part of the Works is
being manufactured or assembled at other premises or works, the Contractor shall obtain for the
Engineer and for his duly authorized representative permission to inspect as if the works were
manufactured or assembled on the Contractor’sown premises or works. Inspection may be made at
any stage of manufacture, dispatch or at site at the option of the Employer and the equipment if found
unsatisfactory due to bad workmanship or quality, material is liable to be rejected.

6.5 The Contractor shall give the Employer/Inspector ten (10) days written notice of any material being
ready for joint testing including contractor and Employer. Such tests shall be to the
Contractor’saccount except for the expenses of the Inspector. The Employer/Inspector, unless
witnessing of the tests is virtually waived, will attend such tests within thirty (30) days of the date
of which the equipment is notified as being ready for test /inspection, failing which the Contractor
may proceed alone with the test which shall be deemed to have been made in the Inspector‟s presence
and he shall forthwith forward to the Inspector duly certified copies of tests in triplicate.

6.6 The Employer or Inspector shall, within seven (07) days from the date of inspection as defined
herein give notice in writing to the Contractor, of any objection to any drawings and all or any
equipment and workmanship which in his opinion is not in accordance with the Contract. The
Contractor shall give due consideration to such objections and shall either make the modifications
that may be necessary to meet the said objections or shall confirm in writing to the
Employer/Inspector giving reasons therein, that no modifications are necessary to comply with the
Contract. If any modification is made on the equipment on the basis of test results not in conformity
with the contract, the modified equipment shall be subject to same sequence of test again without
any additional cost to Employer.

6.7 When the factory tests have been completed at the Contractor’sor Sub-Contractor’sworks, the
Employer/Inspector shall issue a certificate to this effect within seven (07) days after completion of
Part -2 : Employer‟s Requirements 32

tests but if the tests are not witnessed by the Employer/Inspector, the certificate shall be issued
within seven (07) days of receipt of the Contractor’sTest certificate by the Engineer/Inspector. Failure
of the Employer/Inspector to issue such a certificate shall not prevent the Contractor from proceeding
with the Works. The completion of these tests or the issue of the certificate shall not bind the
Employer to accept the equipment should, it, on further tests after erection, be found not to comply
with the Contract. The equipment shall be dispatched to site only after approval of test reports and
issuance of dispatch instruction by the Employer.

6.8 In all cases where the Contract provides for tests whether at the premises or at the works of the
Contractor or of any Sub-Contractor, the Contractor except where otherwise specified shall provide
free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus and instruments
as may be reasonably demanded by the Employer/Inspector or his authorized representative to carry
out effectively such tests of the equipment in accordance with the Contract and shall give facilities
to the Employer/Inspector or to his authorized representative to accomplish testing.

6.9 The inspection by Employer and issue of Inspection Certificate thereon shall in no way limit the
liabilities and responsibilities of the Contractor in respect of the agreed quality assurance
programme forming a part of the Contract.

6.10 The Employer will have the right of having at his own expenses any other test(s) of reasonable
nature carried out at Contractor’spremises or at site or in any other place in addition of aforesaid
type and routine tests, to satisfy that the material comply with the specification.

6.11 The Employer reserves the right for getting any field tests not specified in respective sections of the
technical specification conducted on the completely assembled equipment at site. The testing
equipment for these tests shall be provided by the Employer.

7. Pre-Commisioning Tests

On completion of erection of the equipment and before charging, each item of the equipment shall
be thoroughly cleaned and then inspected jointly by the Employer and the contractor for correctness
and completeness of installation and acceptability for charging, leading to initial pre-
commissioning tests at Site. The list of pre-commissioning tests shall be provided by the
Employer as per its standard practices. or as included in the Contractor’squality assurance
programme.
8. Commisioning Tests

All required instrumentation and control equipment will be used during such tests and the contractor
will use all such measuring equipment and devices duly calibrated as far as practicable. However,
the Contractor, for the requirement of these tests, shall take immeasurable parameters
Part -2 : Employer‟s Requirements 33

into account in a reasonable manner. The tests will be conducted at the specified load points and
as near the specified cycle condition as practicable. The contractor will apply proper corrections
in calculation, to take into account conditions, which do not correspond to the specified
conditions.
8.1 Any special equipment, tools and tackles required for the successful completion of the
Commissioning tests shall be provided by the contractor, free of cost.

8.2 The specific tests to be conducted on equipment have been brought out in the respective chapters of
the technical specification. However where the pre-commissioning tests have not been specified
specifically they shall be as per relevant IS code of practice or as mutually agreed.

8.3 The Contractor shall be responsible for obtaining statutory clearances from the concerned
authorities for commissioning and operation of the equipment including the Electrical Inspector.
Necessary fee to perform these works shall be paid by Employer.

9. GIS mapping & asset tagging

9.1 General Information

The State owned power distribution utilities have implemented GIS based asset tagging activities in
the past and migrated asset information into GIS platform. Bidder should update various attributes
of new / upgraded infrastructure created under SI over the same platform. Various electrical assets i.e
Power Transformers, Distribution Transformer, HT & LT lines with over head conductor, poles,
insulators, stay wire etc and Underground distribution system consists of Feeder pillar, UG cable etc;
automation devises like RMU‟s FPI, Auto-reclosures etc needs to be updated in the existing GIS
platform. The GIS platform and the associated mobile-app will be provided by the Employer. The
scope of the bidder is limited to updating the GIS co-ordinates and the associated mapping
information of the new assets created/upgraded on the platform provided by the Employer using the
mobile app. However no additional payment shall be made to the contractor for these works.

9.2 Key activities under the scope:

1. After successful award of the contract and finalization of Bill of Quantity (BoQ), the TKC should
collect list of attributes (Data Model) for each of the assets purposed under the scheme from the
project nodal / GIS incharge of the Utility.
2. The purposed methodology for delivery of these attributes as well as GPS coordinates of the assets
up to the defined accuracy level to be decided mutually so that updating the same in existing GIS
platform would not be a challenges at the later stage. A point of contact (PoC) is recommended at
this stage to avoid any future complicacy.
3. The vendor should create a physical marking procedure with consultation and approval of
Employer and mark each assets and consumer that have been surveyed
 Part -2 : Employer‟s Requirements 34

4. Vendor will start collecting intended data from newly commissioned and / or upgraded
infrastructure commissioned in SI and submit the same with the Employer nodal / team for approval.
5. The Employer‟s project in charge would get these data verified through their team, once completed
they will get duly verified by Executive Engineer and circle SE and shall submit same to IT office
for further review.
6. It is to be noted that updating of GIS asset information is mandatory requirement for the issuance of
completion certificate by the employer.
Note:Vendor have to map all assets developed under SI in GIS as mentioned above as well as GEO
urja app.devloped by GUVNL.

10. Documentation

10.1. General

10.1.1. To ensure that the proposed systems conform to the specific provisions and general intent of the
Specification, the Contractor shall submit documentation describing the systems to employer for
review and approval. The contractor shall obtain approval of employer for the relevant document
at each stage before proceeding for manufacturing, system development, factory testing, site testing,
training etc. The schedule for submission/approval of each document shall be finalised during the
discussions before placement of the contract, this schedule shall be in line to overall project
schedule.

10.1.2. Each document shall be identified by a Contractor document number, the employer document
number, and the employer purchase order number. Where a document is revised for any reason,
each revision shall be indicated by a number, date, and description in a revision block along with
an indication of official approval by the Contractor's project manager. Each revision of a
document shall highlight all changes made since the previous revision.

10.1.3. All technical description, specifications, literature, correspondence, prints, drawings, instruction
manuals, test reports( both factory and at site), progress photographs, booklets, schedules and all
supplementary data or documents furnished in compliance with the requirements of the Contract,
shall become the property of the Employer and the costs shall be considered as included in the
Contract price.

10.1.4. The Contractor shall be responsible for any time delay, misinterpretation, error and conflict
during design, manufacturing, testing and erection of the Works resulting from non-compliance
with the requirements of this Specification.

10.1.5. The Employer shall have the right to make copies of any documents, data, reports, information
etc. supplied by the Contractor in connection with the Works. The Employer shall not impart the
information of these documents to any other manufacturer or competitor but he shall be free to
use these for preparation of technical papers, reports etc.
 Part -2 : Employer‟s Requirements 35

10.1.6. All documentation shall be in English language.

10.2. Requirements for submission of documents, information and data by the contractor

10.2.1. The Contractor shall submit to the Employer all documents in accordance with an approved
schedule of submissions and shall submit any further information (in the form of drawings,
documents, manuals, literature, reports etc.) when asked by the Employer while
commenting/approving any drawings/documents etc.

10.2.2. The documents which are subject to the approval of the Employer shall be identified by the
Contractor with the stamp "FOR APPROVAL". All other documents shall be submitted to the
Employer for information and shall be identified by the Contractor with the stamp "FOR
INFORMATION".

10.2.3. The sequence of submission of the documents shall be subject to the approval of the Employer.
The sequence of submissions of all documents shall be such that the necessary information is
available to enable the Employer to approve or comment the document.

10.2.4. The Contractor shall supply 4 hard copies of all drawings and documents.

10.2.5. In case a "SUBSEQUENT" revision of any document is made due to any reason whatsoever, a
revision of the same, highlighting the changes shall be resubmitted for the Employer's specific
approval/ information.

10.3. Documents for approval

10.3.1. The Employer shall be allowed fifteen (15) calendar days to approve the Contractor's
submissions. The submissions for approval, shall be returned to the Contractor marked in one of
the following ways :
Category I: Approved
Category II: Approved with Comments.
Category III: Returned for correction.
Category IV : For information

10.3.2. The first notations "I" or "II" shall be deemed to permit the Contractor to proceed with the work
shown on the document, except in the case of notation "III" the work shall be done subject to the
corrections indicated thereon and/or described in the letter of transmittal. The Contractor shall
bear the full responsibility for proceeding with the Works prior to receipt of the release in notation
"I" from the Employer.
 Part -2 : Employer‟s Requirements 36

10.3.3. In case of notation "II", the Contractor shall include the alterations required & resubmit the
document within fifteen (15) days from date of Employer's letter of transmittal.

10.3.4. In case of notation "III", the Contractor shall include the alterations required and resubmit the
document to the Employer, within fifteen (15) days, from date of letter of transmittal, so that such
document can be returned with the notation "I" or "II".

10.3.5. It may also be noted that the approval/commenting by the Employer does not relieve the
Contractor of any of his contractual obligations and his responsibilities for correctness of
dimensions, materials, weights quantities or any other information contained therein, as well as
the conformity of designs with Indian Statutory Laws and the Technical Specifications as may be
applicable. The approval also does not limit the Employer's rights under the Contract.

10.3.6. The approved documents shall be considered as the working documents. However the Technical
Specification and connected documents shall prevail over these documents in case a decision is
required on interpretation.

10.4. Documents for information

The Contractor shall not delay the Works pending the receipt by the Contractor of the comments
on documents submitted to the Employer for information. However, the Employer shall have the
right to comment on all the documents submitted by the Contractor, when, in the opinion of the
Employer the document does not comply with the Contract or otherwise. The Contractor shall
satisfactorily demonstrate that the information contained in the aforesaid document does meet the
requirements of the Contract or revise the document in order that the information shall comply with
the requirements of the Contract.

10.5. Basic reference drawings

10.5.1. The reference drawings are enclosed with the bid document, which forms a part of the
specification. The contractor shall develop a new layout in line with the specification and take the
approval of the EMPLOYER. The contractor shall maintain the overall dimensions of the substation,
buildings, bay length, bay width, phase to earth clearance, phase to phase clearance and sectional
clearances, clearances between buses, bus heights but may alter the locations of equipment to obtain
the statutory electrical clearances as required for the substation.

10.5.2. All drawings submitted by the Contractor including those submitted at the time of bid shall be in
sufficient detail to indicate the type, size, arrangement, material description, Bill of Materials,
weight of each component, break-up for packing and shipment, dimensions, internal & the
external connections, fixing arrangement required and any other information specifically
 Part -2 : Employer‟s Requirements 37

requested in the specifications.

10.5.3. Each drawing submitted by the Contractor shall be clearly marked with the name of the
Employer, the unit designation, the specifications title, the specification number and the name of
the Project. If standard catalogue pages are submitted, the applicable items shall be indicated therein.
All titles, noting, markings and writings on the drawing shall be in English. All the dimensions
should be in metric units.

10.5.4. Further work by the Contractor shall be in strict accordance with these drawings and no deviation
shall be permitted without the written approval of the Employer, if so required.

10.5.5. The review of these data by the Employer will cover only general conformance of the data to the
specifications and documents interfaces with the equipment provided under the specifications.
This review by the Employer may not indicate a thorough review of all dimensions, quantities and
details of the equipment, materials, any devices or items indicated or the accuracy of the information
submitted. This review and/or approval by the Employer shall not be considered by the Contractor,
as limiting any of his responsibilities and liabilities for mistakes and deviations from the
requirements, specified under these specifications and documents.

10.5.6. All manufacturing and fabrication work in connection with the equipment prior to the approval of
the drawings shall be at the Contractor’srisk. The Contractor may make any changes in the
design which are necessary to make the equipment conform to the provisions and intent of the
Contract and such changes will again be subject to approval by the Employer. Approval of
Contractor’sdrawing or work by the Employer shall not relieve the contractor of any of his
responsibilities and liabilities under the Contract.

10.5.7. All engineering data submitted by the Contractor after final process including review and
approval by the Employer shall form part of the Contract Document and the entire works performed
under these specifications shall be performed in strict conformity, unless otherwise expressly
requested by the Employer in Writing.

11. Return of replaced old materials to the area stores of Employer

 Old PVC wire will be rolled into bundles. The bundles should be tightened firmly and properly
with PVC sticker strip or string. A tag should be attached with each bundle to indicate the weight
of the bundle. As far as possible, bundle should consist of wire of the same size and same metal.
Similar action is required to be taken in case of GI wire.
 Old conductor of same size shall be rolled into bundles. Bundles should be tightened firmly and
PVC sticker strip or string regarding size of conductor shall be mentioned. Size, type & Weight of
each bundle shall also be indicated on the sticker strip.
Part -2 : Employer‟s Requirements 38

 Materials released due to bay capacity augmentation and/or due to replacement like power
transformers, distribution transformers, insulator, meter board, cut outs etc are also required to be
returned to Employer‟s stores through proper documentation.
 All other line materials released like, conductors, poles, cross arms; fabricated material, etc. shall
be properly accounted for and returned to Employers store after recording all necessary details
including weight, length etc. wherever necessary. A detailed procedure for return of the old
materials shall be prescribed by MGVCL.
 In respect of accountal of devolution of released material, the process as formulated by Employer
time to time shall be followed by the contractor
12. Miscellaneous activities
 Commencement of Supply & Works: The Contractor shall ensure that the supply and installation
of material and service under the contract is as per approved PERT / completion schedule of
works. The Contractor is to commence supply with the type tested materials with necessary routine
test/ acceptance test certificates for a particular lot duly approved by EMPLOYER or the
EMPLOYER‟s authorized agencies.
 The contractor shall submit Type test and routine test certificates as applicable, issued by NABL
accredited / third party independent standard laboratories like CPRI, NPL etc.
 Unit rates: The unit rates quoted shall include details which are obviously and fairly intended, and
which may not have been included in these documents but are essential for the satisfactory
completion of work. The unit rate quoted shall be inclusive of deployment of all plants,
equipments, men, materials, skilled & unskilled labour etc. essential for satisfactory completion of
work.
 The prices for fabricated materials shall include all works relating to fabrication, galvanizing and
delivery ex-contractors stores, unloading and loading. The quoted prices shall also include the cost
of necessary quantity of steel and zinc, freight charges up to site store and other indirect charges
incurred in connection with supply of finished materials.
 Quantities/ length of 11 KV line and LT line, distribution transformers sub stations, XLPE power
cable,RMU,AB cable etc. indicated in the price schedules are provisional. Any quantity variation in
individual item and in contract value shall be governed as per GCC clause 39. The Contractor shall
execute the work based on the actual survey and as approved by the Engineer-in-charge or person
authorized by him. The scope of work also covers supply of other items, not specifically
mentioned in this specification and/or bill of materials but are required for the successful installation,
testing, commissioning and satisfactory performance of the 11 KV lines,UG cabeling,AB caeling
distribution transformer sub stations, LT lines, service lines etc.

The following works & services shall also be provided by the contractor.
a) Unloading the equipments from the rail or road transport and moving those to storage area.
Demurrage/ wharf age charge, if any incurred, shall be paid by the contractor
Part -2 : Employer‟s Requirements 39

b) Opening of packing cases, inspection and checking of materials for any damage or loss in
transit shall be the responsibility of the contractor. All claims with the concerned authorities e.g.
rail, transport, insurance etc. shall be lodged by the contractor.
c) Complete erection of equipments, etc covered under the contract, final preparation for testing,
commissioning, final run and acceptance tests and putting the sub-station/ plant/line etc. into
operation.
d) All consumable, stores required for the above erection and commissioning works.
e) All erection tools, lifting tackles, and all equipments, tools & tackles for transportation at site.
f) Workshop, as required within the work area.
g) Third party insurance [1] at site and insurance of personnel employed at site as required under
Workman's Compensation Act. Security arrangement for watch and guard as required sha ll be
mad e by Bidder at his own cost.
h) All the technical/ skilled staff deployed for the job must possess the required qualifications and
necessary licenses and permits.
i) Contractor shall take all safety precautions during work and the workmen must use safety belts,
hand gloves, masks and other safety devices as may be necessary for safety of the personnel.
j) The contractor shall provide operating personnel during trial tests and till the PSS, DSS, lines
and equipments etc. are taken over by EMPLOYER as specified in taking over Clause, defined later.
k) Any other work not covered above but required for successful completion of the project has to be
carried out by the contractor at his own cost.

[1]
Note: Before receipt of equipment at site but without limiting his obligations and responsibilities
under this clause hereof, the Contractor shall insure against his liability for any equipment,
material or physical damage, loss or injury which may occur to any property, including that of
EMPLOYER and MGVCL, or to any person including employee of the EMPLOYER, by or arising
out of the execution of the contract or in the carrying out of contract. The third party insurance cover
shall be provided for the period from date of Ex-factory dispatch till taking over of the entire
equipment after testing, commissioning and trial operation, if any.

Third party insurance shall be affected for an adequate amount to cover for all marine,
transportation, field transportation, erection, testing and commissioning till handing over to
Employer,. Terms shall include a provision whereby, in the event of any claim being brought or
made against EMPLOYER in respect of which the Contractor would be entitled to receive
indemnity under the policy, the insurer will indemnify EMPLOYER and MGVCL against
such claims and any costs, charges and expenses in respect hereof. Contractor shall lodge the
claim if need so arise, the employer shall be the owner of the equipment/materials and the claims
shall be settled in the name of Employer.
Part -2 : Employer‟s Requirements 40

13. Individual work components

13.1. New 11 KV Lines

1.00 Survey

Mapping of route of proposed new 11 kV line by foot survey in rural/urban areas be

performed mentioning various milestones. While surveying, existing electrical infrastructure
in the locality should also be mapped. Line alignment (single line diagram) on political map
with fair correctness, be prepared. SLD and foot survey report shall be approved by Project
Manager and shall be used as basic document for assessment of works under the contract. On
completion of line work, as built Single Line Diagram and pole wise line diagram showing
pole wise materials used and pole-to-pole span should be submitted to Project Manager. This
details shall be used as reference documents by Quality and Quantity Inspecting officials to
execute inspection works.

2.00 Support (pole):

Following type of supports are envisaged for new 11 KV overhead lines-

a) 8 m/200 kgs PSC Poles - (PSC Pole as per GUJARAT state practice)
b) 13 m long H-Beam 150x150 mm, 34.6 kg/mtr
c) 11 m long H-Beam 116x100 mm, 23 kg/mtr
d) 9 m long H-Beam 116x100 mm, 23 kg/mtr

In rural area, PSC poles are to be used. In urban area, PSC or H-Beam supports are to be used of suitable
length. In location specific conditions like forest area, vicinity of other existing overhead lines or permanent
structures etc, H- beam may be used.

H-Beam support shall be cleaned till good surface finish and painted with 2 or more coats of red oxide paint
and 2 or more coats of aluminium paint till good finish H-Beams shall also be painted with 2 or more coats
till good surface finish with anti-corrosive paint which goes in to the foundation. Project Manager shall
approved brand and shade of paints.

Painting of H-Beams shall be performed at stores. Before shifting to site for erection, poles shall be offered
for inspection and approval by Project Manager or authorized representative before erection.
Part -2 : Employer‟s Requirements 41

3.00 Fabricated steel items:

Fabricated steel items like V cross arm, top clamp, DC cross arm, bracket, clamps, cross
bracings, bracings, strain plate, guarding channels, back clamp, transformer mounting structure
etc shall be made of MS Channels, MS angle, MS flats as per approved drawings. While
fabricating, good quality electrical cutting tools and drill machine shall be used to ensure no
sharp edges and perfect holes as per approved drawings. Gas cutting set should not be used for
fabrication of MS steel items. Weld material shall be distributed equally between the two
materials that were joined. The weld shall be free of waste materials such as slag. The weld
surface should not have any irregularities or any porous holes (called porosity). The joint
shall be tight. Most welds need to demonstrate the required strength. One way to ensure proper
strength is to start with a filler metal and electrode rating that is higher than your strength
requirement.

Fabricated steel structure items shall be hot dip galvanized and cleaned till good surface
finish. The minimum coating of the zinc shall comply with IS: 2629 and IS: 2633 (with latest
amendments). Galvanizing shall be checked and tested in accordance with IS: 2633. Fabricated
steel structure items shall be offered for inspection and approval by Project Manager.

4.00 Hardware:

MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used
for tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing,
strain plates etc.

While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall
be hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
them to site for erection, they shall be offered for inspection and approval by Project
Manager.

Note:-In accordance to actual requirement during execution of project all sundry

material shall be provided by vendor accordance to related standard.
Part -2 : Employer‟s Requirements 42

5.00 Stay Set:

Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (2Nos.), anchor plate
(300x300x8mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 20 mm diameter solid GS stay rod
& 7/4.00 mm dia GI stranded wire complete.

Stay set shall be used at all turning locations, conductor dead end location, double pole
structure, triple pole structure, four pole structure to nullify the tension of conductor. At dead
end locations, stay sets shall be used in pairs in separate foundations. Erection of storm guys
at suitable location in straight line may also be provided.

0.3 cmt cement concreting in mixture 1 part cement, 2 part coarse sand, 4 part 40mm size
aggregate stone chips (1:2:4) shall be provided in each stay set foundation. 2 Nos. guy insulator
shall be provided in stranded GI wire at middle location between two turn buckles. Shuttering
and vibrator shall be used for cement concreting works.
6.00 Earthing:

Following earthing arrangements are envisaged for new 33 kV lines:

a. 40 mm dia., 3000 mm long GI pipe earth electrode with test link, RCC pit, RCC cover plate
on GI frame, bentonite powder and other accessories complete
b. GI Earthing spike made of 20mm solid rod
c. Chemical rod earthing including electrode, chemical, with 2000mm long, 50 mm diameter
GI pipe, GI Strip of 24x3mm minimum in hard rock locations only.
d. 8 SWG GI Earthing Coil.
e. 6 SWG GI wire for earthing and guarding
f. 8 SWG GI wire for earthing and guarding

Each 11 kV line support shall be provided with one GI earthing spike made of 20 mm solid
rod or 8 SWG GI Earthing Coil and connected with 8 SWG GI wire. Overhead line structure
shall be connected to GI earthing spike or GI Earthing Coil using 8 SWG GI wire. GI nuts,
bolts & washers shall be used to join two GI wires and 20 mm solid spike rod. Project Manager
shall decide use of GI Earthing Coil or GI Solid earth Road for earthing of individual
poles.

At railway crossing, line crossing and other specific locations 40 mm dia, 3000 mm long GI
pipe earth electrode with test link, RCC pit, RCC cover plate on GI frame, bentonite powder
and other accessories shall be used. Overhead line structure at these locations shall be
connected to GI earth pipe using 8 SWG GI wire. GI nuts, bolts & washers shall be used to
join two GI wires and 40 mm GI earth pipe.
Part -2 : Employer‟s Requirements 43

In rocky soil where getting required earth resistance is a challenge, chemical rod earthing
shall be used. Overhead line structure shall be connected to chemical earth electrode using
8SWG GI wire. GI nuts, bolts & washers shall be used to join two GI wires and 20 mm solid
spike rod.
GI flats and GI wires must be properly dressed, bundled and fixed on supporting structure at
1 to 2 feet intervals.

7.00 Insulator and hardware –

11 KV polymer/porcelain Disc/Pin insulator with suitable hardware fittings shall be used.

Insulator should be tied properly using binding wire and tape/helical form fitting. In road
crossing and line crossing locations bridling cross arms and pin insulator shall be used.

The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator should properly be cleaned before installation. No damage/crack
insulator should be used.

8.00 AAAC Conductors:

Following AAAC conductor are envisaged for new 11 kV

lines:

55 mm SQ AAAC and 100 mm SQ DOG conductor as per technical specification

Care should be taken while drawing conductor from the drum. Proper roller should be used
while handling conductors during erection. Jointing sleeves, binding materials, PG clamps,
bi-metallic conductor shall be used for conductor jointing, insulators fixing, jumpering and
termination at equipment respectively.

Proper sag should be maintained using sag chart table. While tensioning, care should be
taken to avoid tension on pin insulator. Therefore, proper alignment of line to be ensured.
Conductor joint should not be in the middle span but may be planned nearer the support.

At terminal location, care should be taken while connecting two sections to avoid bird faults.
Therefore, pin insulator is to be used to handle the conductor on DC cross arm (as per state
practice).
Part -2 : Employer‟s Requirements 44

9.00 Pole numbering:

Each support pole should be numbered properly labelled using yellow base and black indication
marks (number or digits). 40/50 mm height digits/words should be used for this purpose. Base
shall be made using 2 or more coats of yellow enamel paint till good surface finish. Base
preparation shall be completed before shifting of poles to site for erection. Base painting and
marking of digits should be performed by a skilled and trained painter using branded enamel
paint, Project Manager shall approve type and brand of enamel paint. Warning instruction, if
any, of availability of two sources of 33 kV supply on same structure, at source structure, at
cut points should exclusively be provided as per state practice.

10.00 Anti-climbing device:

2 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each 11 kV support.
Galvanized barbed wire should be properly dressed and crimped at termination. While
wrapping the wire on support, proper tension should be maintained.

11.00 Danger board:

Each support should be provided with a danger board with pole clamps as per approved
drawing. Danger board should be in bi-lingual languages (local language and English).
Clamp for danger board, nut-bolts and washers shall be painted with two or more coats of
red-oxide and aluminium paints respectively till smooth surface before installation.

12.00 11 KV AB Switch:

11 kV, 3-ph, 400 A, 3 Pin type, Vertical/Horizontal Mounting type, Gang Operated, AB Switch
shall be installed at cut points and at suitable locations as per instructions of Project Manager.
B Class GI pipe shall be used (without any joints) for operation of switch. AB Switch structure
and handle must be earthed using 8 SWG GI wire.(As Per technical specification)

13.00 Support foundation:

Cement concrete in mixture 1 part cement, 2 part coarse sand, 4 part 40mm size aggregate
stone chips (1:2:4) shall be used in all the types of 11 kV line supports.

While erecting supports (poles), shuttering must be used for concreting so that proper
quantity of cement concrete mixture be used and assessed during inspection. During
Part -2 : Employer‟s Requirements 45

Concreting proper compaction by means of mobile vibrator be provided. While starting work
of support erection, gang wise shuttering and mobile vibrator shall be offered for inspection
to Project Manager. While erecting support, mercury level gauge must be used to ensure
vertical erection of support.

250mm dia X 12” inch size muffing shall be provided on steel tubular and H-Beam poles to
prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part Cement,
2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for individual poles.

Steel plate shall be used in steel tubular poles and cement concrete reinforced plate shall be
used as base plate for PCC poles.

14.00 A)11 kV line for underground railway crossing –

A separate composite item of railway crossing is kept in BoQ. 2 Nos. separate cables shall be
laid in separate GI pipe enclosures. At a time, one shall be used and another shall be kept idle
as spare in ready to join condition. Cable termination, cable identification, protective
covering, laying of jumpering cable etc shall all be completed in this head. This composite item
shall contain following key items:

a. 3Cx300/3cx240 Sqmm XLPE armored cable (approx. length is 0.3 km each) – 2 sets
b. 150mm dia GI pipe of A class (red color painted on edges) for cable protection in
underground laying – 2 sets
c. 150mm dia GI pipe of B class (blue color painted on edges) for cable support at DP structure
– 2 sets
d. Outdoor heat shrinkable cable jointing kits for main cable and jumpering cable – 4 Nos for
main cable, 8 Nos for jumpering cables.
e. 11 kV lightening arrestor station class 10kA (6 nos.),
f. 4 Nos GI 3-meters long pipe earthing,
g. 6 SWG GI wires with GI nuts, bolts & washers,
h. Cable markers,
i. Bi-metallic clamps,
j. Jumpering with 11 kV Arial Bunched Cables 200 Sqmm dia (10 mtr) etc – 4 sets

Detail survey of location of railway crossing be performed by contractor to avoid multi-

crossing at nearby location. Prior railway permission for execution of this work shall be
obtained by Project Manager for which necessary technical support shall be provided by
contractor. Line crossing shall be performed using underground cabling. Block on railway
traffic shall be arranged by Project Manager. Contractor should ensure timely completion of
Part -2 : Employer‟s Requirements 46

work during block period by mobilizing requisite man, materials and machine at crossing
locations.

Horizontal drilling machine shall be used for horizontal bore below railway tracks.

B)National Highway crossing

Crossing of any state/National Highway by using material same as above for

Railway crossing

15.00 Quality & Quantity inspection and compliance to the observation:

The line works, before or after commissioning/energisation, shall be inspected by Quality

Inspectors and State Inspection Inspectorate. Contractor shall provide all requisite details of
line like approved survey report, as built drawings and joint measurement sheet etc to the
inspector. Contractor shall rectify defects/deficiencies and submit compliance to the
observations with supporting photographs in digital form within one month from receipt of
observations.

16.00 Tree-cutting/trimming of tree:

The Contractor shall count, mark and put proper numbers with suitable quality of paint at his
own cost on all the trees that are to be cut/trim to obtain required tree clearance. Contractor
shall pay compensation for any loss or damage for tree cutting due to Contractor’swork.
Wherever forest clearance is envisaged for execution of work, clearance of forest department
for tree cutting, if required, shall be arranged by the Project Manager and compensation shall
also be paid by the Project Manager. Necessary fee if required to pay to Govt. dept. for
arranging such clearances shall paid by Project Manager. However, the contractor would
require to provide all necessary assistance for execution of this work.

17.00 Statutory clearances:

During execution of 11 KV Line work, all statutory clearances shall be ensured for ground
clearance, line-to-line clearance, road crossing clearance, horizontal and vertical clearances
from buildings/objects etc. All road crossings and line crossings shall be guarded as per
specifications. Conductor joint should not be provided in mid span length. Instead, it should
be nearer to the support.

18 00 Ring Main Unit Installation(RMU):

As per technical specification RMU shall be installed for Ring Main of electrical infrastructure, change
over etc,Plinth for the RMU is in the scope of vendor Related specification for the civil work is as per
technical specification.
Part -2 : Employer‟s Requirements 47

 Excavation for foundation in trenches in ordinary soil, sand, clay, soft murrum, DENCE
OR HARD SOIL up to 1.50 Mt. depth including strutting, shoring wherever necessary
and throwing away the extra stuff with in the lead of 50 Mt. radius and its dressing etc.
complete as directed by E. I. C.
 Providing & laying C.C.(1:4:8) for foundation & plinth with gravel or picked up metal
or hand broken stone of size 40 mm to 60 mm as coarse aggregate including mixing,
watering, ramming, consolidating etc., complete as directed by E.I.C
 Providing and laying controlled cement concrete M.200 and finishing smooth with
curing etc complete Including cost of formwork but exculding the cost of reinforcement
for reinforced concrete work in (A) Foundations, footings, Base of wall,top of bb
masonary plinth etc. Providing and laying controlled cement concrete M.200 and
finishing smooth with curing etc complete Including cost of formwork but exculding the
cost of reinforcement for reinforced concrete work in (A) Foundations, footings, Base of
wall,top of bb masonary plinth etc.
 Brick work using common burnt clay building bricks having crushing strength not less
35 kg. / sq. cm. in foundation and plinth in cement mortar 1:6 (1 -Cement : 6 - Fine sand)
Conventional Bricks.

 Providing 20mm thick cement plaster in single coat on single or half brick walls for
interior plastering upto floor two level and finished even and smooth in. Cement mortar
1:3 (1-cement:3-sand)including finishing with a floating coat of neat cement slurry
necessary Gishi etc complete
 Providing TMT Bar FE 500D reinforcement for R.C.C. work including bending, binding
and placing in position complete upto floor two level
 Finishing wall with weather proof exterior emulsion paint on wall surface (Two coats) to
give a required shape even shade after throughly brushing the surface to remove all dirt
and remains of loose powdered materials etc complete.
 Filling available excavated earth (excluding rock) in trenches. plinth, sides of
foundations etc. in layers not exceeding 20cm. in depth consolidating each
disposited layer by ramming and watering.
 Demolition of brickworkand stone masonary including stacking of serviceable materials
and disposible of unserviceable materials with all lead and lift In cement Mortar
 Demolition including stacking of serviciable materials and disposal of unserviciable
materials with all lead and lift(i) R.C.C work
 Providing formwork of ordinary timber planking so as to give a rough finish including
centering, shuttering, strutting and propping etc. height of propping and centering
below supporting floor to celiling not exceeding 4 M. and removal of the same for in sity
reinforced concrete and plin concrete work in. Foundations, Footings, Bases of
Columns etc., and Mass concrete.
 job work for cleaning the site by labours including removing of trees, grass and levelling
the ground complete as per directed by EIC.
 Removing of debries by tractor trip by means of loading existing debries and disposal it
off out side up to any lead directed by EIC.
 Removing Chainlink fencing along with vertical post from site without damaging the
fencing and other structure
 Removing & refixing of Paver floors laid in mortar including stacking the same as
directed by EIC
Part -2 : Employer‟s Requirements 48

Drawing for RMU Plinth

Part -2 : Employer‟s Requirements 49

21.00 ACSR / AAAC Conductor:

Following ACSR conductors (or equivalent AAAC conductor) are envisaged for bus bars,
jumpers, droppers:

55 mm SQ AAAC and 100 mm SQ DOG conductor as per technical specification

Conductor shall be provided with hardware fittings, T-clamps, bi-metallic clamps and PG clamps
as per requirements. T – Clamps shall be provided on each jumper on bus bars. Line jumpers
shall be provided with adequate size of PG Clamps (Two numbers PG Clamps at each end of
jumper). Clamp shall be made of aluminium grade T-1F as per IS – 8309 having good electrical
quality aluminium material and shall not be brittle in nature. Suitable Bi – metallic clamps shall
be provided at bushings of transformers and circuit breakers. Also at all those points where
joining of two different materials is found, bi –metallic clamps shall be provided.

Care shall be taken while drawing conductor from the drum. Proper roller shall be used while
handling conductors during erection.

22.00Insulator, hardware and connections to equipment:

11 KV polymer Disc/Pin insulator with suitable hardware fittings shall be used. Insulator shall
be tied properly using binding wire/helical form fitting. In road crossing and line crossing
locations bridling cross arms and pin insulator shall be used.

The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator shall properly be cleaned before installation. No damage/crack insulator
shall be used.

23.00Power receptacles:

Two power receptacles are envisages in switch yard area to provide power supply to Transformer
Oil Filtration machine and other testing and commissioning related works. Each receptacles shall
house 63A MCCB as incomer, 40A 3 phase socket/switch and 1 No, 20A single phase Industrial
type socket/switch of reputed brand and type.

24.00 Tube well:

Part -2 : Employer‟s Requirements 50

Deep Tube is envisaged for all the substations. Depending on the depth of the bore, suitable
capacity of submerged pump shall be installed. Bore diameter shall be 6” which must be
penetrated vertically in all type of soil condition. Before digging the bore, soil Resistivity
needs to be checked to ascertain the location of the best site for the tube well. Following works
are envisaged under this scope:

 Digging bore of diameter six inches. Providing MS casing on bore up to the suitable depth
finalized during detailed engineering.
 Providing new 3 phase submersible pump 32 stages or 30 stages depending on technical
requirements.
 Providing Start Panel of reputed make like L&T, Havells or equivalent make having single
phase protection, Over load protection, Pre – set timer of L&T make, Star Delta Starter,
Indications for Load currents in all three phases, Indications for Supply voltages in all three
phases etc. Starting panel must conform to IP 52 protection for enclosure. It shall be mounted
indoor inside the Control room on 50x50x6 mm GS angle supports. Start panel must be earthed
with 2 Nos 8 SWG wires. 4 core 16 Sq mm aluminum armored cable must be used for
energizing this Start Panel.
 Three phase, 4 wires, copper flexible supply cables suitable for submersible pump operations,
ISI marked, 1100V grade shall be connected to submersible pump through underground trench
up to the well as per CPWD specifications duly protected from brick and sand cushioning.
 A Heavy-duty gunmetal wheel valve (tap) may be provided on the discharge line for drinking
water requirements.
 Provision for lifting the pump in case of overhauling / breakdown maintenance may also be
provided.
 ISI marked PVC or 2nd GI Pipes are to be used for suction as well as discharge water lines.
 An open drain must be provided in the vicinity of the tube well. Detail arrangement shall be
finalized in detailed engineering.

27.00Fabricated steel items:

Fabricated steel structure items DC cross arm, clamp, bracket, clamps, cross bracings,
bracings, strain plate, guarding channels, back clamp, transformer mounting structure etc shall
be made of MS Channels, MS angle, MS flats as per approved drawings.

While fabricating, good quality electrical cutting tools and drill machine shall be used to ensure
no sharp edges and perfect holes as per approved drawings. Gas cutting set shall not be used
for fabrication of MS steel items. Weld material shall be distributed equally between the two
materials that were joined. The weld shall be free of waste materials such as slag. The weld
Part -2 : Employer‟s Requirements 51

surface should not have any irregularities or any porous holes (called porosity). The joint shall
be tight. Most welds need to demonstrate the required strength. One way to ensure proper
strength is to start with a filler metal and electrode rating that is higher than your strength
requirement.

Fabricated steel structure items shall be hot dip galvanized and cleaned till good surface finish.
Items shall be offered for inspection and approval by Project Manager.

In lattice structure substation, gantry structure including all fabricated structure items like DC
cross arm, clamp, bracket, cross bracing etc shall be galvanized.

28.00Hardware:

MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used for
tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing, strain
plates etc.

While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall be
hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS: 2633.
Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting them to
site for erection, they shall be offered for inspection and approval by Project Manager.

39.00 Arrangement by the Contractor:

Contractor shall project-wise make his own separate arrangements for the following:

1. Opening of a site office-cum-store,

2. Distributions of power supply at all work areas in the substation premises.
3. Construction of office and store (open & covered)
4. Construction of steel fabrication workshop and material/field testing laboratory
5. Round the clock fire protection and security arrangements for site store-cum-office during
construction stage

42.00Commissioning spares:

The Contractor shall supply spares, which he expects to consume during installation testing
and commissioning of system. The quantity of these spares shall be decided based on his
previous experience, such that site works shall not be hampered due to non-availability of these
spares. Contractor shall submit a complete list of such spares along with the bid, the cost of which
shall be deemed to have been included in the lump-sum proposal price of the package. The
contractor, if so agreed at a cost to be negotiated may leave the unused commissioning spares at
the site for use of owner.
Part -2 : Employer‟s Requirements 52

43.00 Recommended spares:

The Contractor shall provide a list of recommended spares giving unit prices and total prices
for 3 years of normal continuous operation of equipment. This list shall take into consideration
and shall be given in a separate list. The Owner reserves the right to buy any or all the
recommended spares. The recommended spares parts shall be delivered at the site. The list of
recommended spares to be furnished by the Bidder shall also contain the following:

1. Location of each item installed along with reference drawing number.

2. Service life expectancy of each item.
3. Offer validity period

Price of recommended spares will not be used for evaluation of bids. The prices of these spares
will remain valid for a period of not less than 120 days after the date on which the validity of
main bid expires. Whenever recommended spares are the same as mandatory spares, then the
prices of the mandatory spares and such common recommended spares shall be the same.
Further, the prices of any recommended spares shall be subject to review by the Owner and shall
be finalized after mutual discussions.

13.4. New 11 KV Lines

1.00 Survey

Mapping of route of proposed new 11 kV line by foot survey in rural/urban areas be

performed mentioning various milestones. While surveying, existing electrical infrastructure
in the locality should also be mapped. Line alignment (single line diagram) on political map
with fair correctness, be prepared. SLD and foot survey report shall be approved by Project
Manager and shall be used as basic document for assessment of works under the contract. On
completion of line work, as built Single Line Diagram and pole wise line diagram showing
pole wise materials used and pole-to-pole span should be submitted to Project Manager. This
details shall be used as reference documents by Quality Inspecting officials to execute
inspection works.

In case of feeder separation, existing agriculture load shall be mapped during survey. A
report to be presented indicating location wise pumps to be fed through separate feeder.
Percentage voltage regulation at farthest point on various spur sections shall be examined
during survey and submitted to project manager who will take a decision for feeder
separation works.

2.00 Support (pole):

Following type of supports are envisaged for new 11 KV overhead lines-

Part -2 : Employer‟s Requirements
e) 8 m/200 kgs PSC
Poles - (PSC Pole as per GUJARAT state practice) 53
f) 13 m long H-Beam 150x150 mm, 34.6 kg/mtr
g) 11 m long H-Beam 116x100 mm, 23 kg/mtr
h) 9 m long H-Beam 116x100 mm, 23 kg/mtr

In rural area, PSC poles are to be used. In urban area, PSC to be used of suitable length. In
location specific conditions like forest area, vicinity of other existing overhead lines or
permanent structures etc, H- beam may be used.

H-Beam support and steel tubular poles shall be cleaned till good surface finish and painted
with 2 or more coats of red oxide paint and 2 or more coats of aluminium paint till good
finish. Steel tubular poles and H-Beams shall also be painted with 2 or more coats till good
surface finish with anti-corrosive paint (in case of tubular poles shall also be painted on the
inner walls) which goes in to the foundation. Project Manager shall approved brand and
shade of paints.

Painting of H-Beams and Steel Tubular Poles shall be performed at stores. Before shifting to
site for erection, poles shall be offered for inspection and approval by Project Manager or
authorized representative before erection.

3.00 Fabricated steel items:

Fabricated steel items like V cross arm, top clamp, DC cross arm, bracket, clamps, cross
bracings, bracings, strain plate, guarding channels, back clamp, transformer mounting structure
etc shall be made of MS Channels, MS angle, MS flats as per approved drawings.

While fabricating, good quality electrical cutting tools and drill machine shall be used to ensure
no sharp edges and perfect holes as per approved drawings. Gas cutting set should not be used
for fabrication of MS steel items. Weld material shall be distributed equally between the two
materials that were joined. The weld shall be free of waste materials such as slag. The weld
surface should not have any irregularities or any porous holes (called porosity). The joint
shall be tight. Most welds need to demonstrate the required strength. One way to ensure proper
strength is to start with a filler metal and electrode rating that is higher than your strength
requirement.

Fabricated steel structure items shall be hot dip galvanized and cleaned till good surface
finish. The minimum coating of the zinc shall comply with IS: 2629 and IS: 2633 (with latest
amendments). Galvanizing shall be checked and tested in accordance with IS: 2633. Items shall
be offered for inspection and approval by Project Manager.

4.00 Hardware:
MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used
for tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing,
strain plates etc.

While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
Part -2 : Employer‟s
only beRequirements
the bolt after full tightening of nut on requisite torque. The hardware54shall
visible of
be hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
them to site for erection, they shall be offered for inspection and approval by Project
Manager.

5.00 Stay Set:

Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (2Nos.), anchor plate
(200x200x6mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay rod
& 7/3.15 mm dia GI stranded wire complete.

Stay set shall be used at all turning locations, conductor dead end supports, double pole
structure, triple pole structure, four pole structure to nullify the tension of conductor. Erection
of storm guys at suitable location in straight line may also be provided. Erection of storm
guys at suitable location in straight line may also be provided.

0.2 cmt cement concreting in mixture 1 part cement, 2 part coarse sand, 4 part 40mm size
aggregate stone chips (1:2:4). 2 Nos. guy insulator shall be provided in stranded GI wire at
middle location between two turn buckles.

6.00 Earthing:

Following earthing arrangements are envisaged for new 11 kV lines:

a) 40 mm dia., 3000 mm long GI pipe earth electrode with test link, RCC pit, RCC cover plate
on GI frame, bentonite powder and other accessories complete
b) GI Earthing spike made of 20mm solid rod
c) Chemical rod earthing including electrode, chemical, with 2000mm long, 50 mm diameter
GI pipe, GI Strip of 24x3mm minimum in hard rock locations only.
d) 6 SWG GI wire for earthing and guarding
e) 8 SWG GI wire for earthing and guarding
f) Maintenance free type earthing

Each 11 kV line support shall be provided with one GI earthing spike made of 20 mm solid
rod or GI Earth Coil and connected with 8 SWG GI wire. Overhead line structure shall be
connected to GI earthing spike or GI Earth Coil using 8 SWG GI wire. GI nuts, bolts & washers
shall be used to join two GI wires and 20 mm solid spike rod. Project Manager shall decide use
of GI Earth Coil or 20mm dia GI Solid Rod for individual pole earthing.

At railway crossing, line crossing and other specific locations 40 mm dia, 3000 mm long GI
pipe earth electrode with test link, RCC pit, RCC cover plate on GI frame, bentonite powder
Part -2 : Employer‟s Requirements 55

and other accessories shall be used. Overhead line structure at these locations shall be
connected to GI earth pipe using 8 SWG GI wire. GI nuts, bolts & washers shall be used to
join two GI wires and 40 mm GI earth pipe.

In rocky soil where getting required earth resistance is a challenge, chemical rod earthing
shall be used. Overhead line structure shall be connected to chemical earth electrode using
8SWG GI wire. GI nuts, bolts & washers shall be used to join two GI wires and 20 mm solid
spike rod.

In road crossings and line crossings, 6 SWG GI wire shall be used for cross lacing and 8
SWG wire shall be used for guard wires.

GI flats and GI wires must be properly dressed, bundled and fixed on supporting structure at
1 to 2 feet intervals.

7.00 Insulator and hardware –

11 KV polymer/porcelain Disc/Pin insulator with suitable hardware fittings shall be used.

Insulator should be tied properly using binding wire & tape/helical form fitting. In road
crossing and line crossing locations bridling cross arms and pin insulator shall be used.

The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator should properly be cleaned before installation. No damage/crack
insulator should be used.

8.00 ACSR / AAAC Conductors:

Following AAAC Conductor are envisaged for new 11 Kv lines

55 mm SQ AAAC and 100 mm SQ DOG conductor as per technical specification

Project Manager shall decide size of conductor on proposed 11 KV line.

Care should be taken while drawing conductor from the drum. Proper roller should be used
while handling conductors during erection. Jointing sleeves, binding materials, PG clamps,
Part -2 : Employer‟s Requirements 56

bi-metallic conductor shall be used for conductor jointing, insulators fixing, jumpering and
termination at equipment respectively. There must not be uneven sag between conductor/spans.

Proper sag should be maintained using sag chart table. While tensioning, care should be
taken to avoid tension on pin insulator. Therefore, proper alignment of line to be ensured.

At terminal location, care should be taken while connecting two sections to avoid bird faults.
Therefore, pin insulator is to be used to handle the conductor on DC cross channel.

9.00 11 KV AB Switch:

11 kV, 3-ph, 400 A, 3 Pin type, Vertical/Horizontal Mounting type, Gang Operated, AB Switch
shall be installed at cut points and at suitable locations as per instructions of Project Manager.
B Class GI pipe shall be used (without any joints) for operation of switch. AB Switch structure
and handle must be earthed using 8 SWG GI wire.
10.00 Pole numbering:

Each support pole shall be numbered properly labelled using yellow base and black
indication marks (number or digits). 40/50 mm height digits/words should be used for this
purpose. Base shall be made using 2 or more coats of yellow enamel paint till good surface
finish. Base preparation shall be completed before shifting of poles to site for erection. Base
painting and marking of digits should be performed by a skilled and trained painter using
branded enamel paint, Project Manager shall approve type and brand of enamel paint.
Warning instruction, if any, of availability of two sources of 33 kV supply on same structure,
at source structure, at cut points should exclusively be provided as per state practice.

11.00 Anti-climbing device:

2 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each 11 kV support.
Galvanized barbed wire should be properly dressed and crimped at termination. While
wrapping the wire on support, proper tension should be maintained.

12.00 Danger board:

Each support shall be provided with a danger board with pole clamps as per approved
drawing. Danger board should be in bi-lingual languages (local language and English).
Clamp for danger board, nut-bolts and washers shall be painted with two or more coats of
red-oxide and aluminium paints respectively till smooth surface before installation.
Part -2 : Employer‟s Requirements 57

13.00 Support foundation:

Cement concrete in mixture 1 part cement, 2 part coarse sand, 4 part 40 mm size aggregate
stone chips (1:2:4) shall be used in steel tubular poles and H-Beam 11 kV line supports.

In rural areas (as per state practice), PCC pole pit shall be refilled with 200 mm average size
of bolder mixed with excavated earth. Proper ramming shall be performed for better
compaction. All Double pole (DP), Triple pole (TP), cut point poles, Distribution
Transformer substation poles and poles erected on water logging area shall be grouted using
cement concrete mixture similar to H- Beam & Tubular poles. Prior approval of Project
Manager shall be obtained for concreting of PCC poles in water logging area. While
preparing route survey report, water logging areas shall be earmarked.

While erecting supports (poles), shuttering must be used for concreting so that proper
quantity of cement concrete mixture be used and assessed during inspection. During concreting
proper compaction by means of mobile vibrator be provided. While starting work of support
erection, gang wise shuttering and mobile vibrator shall be offered for inspection to Project
Manager. While erecting support, mercury level gauge must be used to ensure vertical erection
of support.

250mm dia X 12” inch size muffing shall be provided on steel tubular and H-Beam poles to
prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part Cement,
2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for individual poles.

Steel plate shall be used in steel tubular poles and cement concrete reinforced plate shall be
used as base plate for PCC poles.

14.00 11 kV line for underground railway crossing –

2 Nos. separate cables shall be laid in separate GI pipe enclosures. At a time, one shall be
used and another shall be kept idle as spare in ready to connect condition. Cable termination,
cable identification, protective covering, laying of jumpering cable etc shall all be completed
in this head. These composite items shall contain following sub-items:

a) 3Cx240 sqmm XLPE armored cable (approx. length is 0.3 km each) – 2 sets
Part -2 : Employer‟s Requirements 58

b) 150mm dia GI pipe of A class (red color painted on edges) for cable protection in
underground laying – 2 sets
c) 150mm dia GI pipe of B class (blue color painted on edges) for cable support at DP structure
– 2 sets
d) Outdoor heat shrinkable cable jointing kits for main cable and jumpering cable – 4 Nos for
main cable and 8 Nos for jumpering cables.
e) 11 kV lightening arrestor station class 10kA (6 nos.),
f) 4 Nos GI 3-meters long pipe earthing,
g) 6 SWG GI wires with GI nuts, bolts & washers,
h) Cable markers,
i) Bi-metallic clamps,
j) Jumpering with 11 kV Arial Bunched Cables 200 Sqmm dia (10 mtr) etc – 4 sets
k) Maintenance free type earthing

Detail survey of location of railway crossing be performed by contractor to avoid multi-

crossing at nearby location. Prior railway permission for execution of this work shall be
obtained by Project Manager for which necessary technical support shall be provided by
contractor. Line crossing shall be performed using underground cabling. Block on railway
traffic shall be arranged by Project Manager. Contractor should ensure timely completion of
work during block period by mobilizing requisite man, materials and machine at crossing
locations.

Horizontal drilling machine shall be used for horizontal bore below railway tracks.

15.00 Quality & Quantity inspection and compliance to the observation:

The line works, before or after commissioning/energisation, shall be inspected by Quality

Inspectors and State Inspection Inspectorate. Contractor shall provide all requisite details of
line like approved survey report, as built drawings and joint measurement sheet to the
inspector to conduct. Contractor shall rectify defects/deficiencies and submit compliance to
the observations with supporting photographs in digital form within one month from receipt
of observations.

16.00 Tree-cutting/trimming of tree:

The Contractor shall count, mark and put proper numbers with suitable quality of paint at his
own cost on all the trees that are to be cut/trim to obtain required tree clearance. Contractor
shall pay compensation for any loss or damage for tree cutting due to Contractor’swork.
Wherever forest clearance is envisaged for execution of work, clearance of forest department
for tree cutting, if required, shall be arranged by the Project Manager and compensation shall
Part -2 : Employer‟s Requirements 59

also be paid by the Project Manager. Necessary fee if required to pay to Govt. dept. for
arranging such clearances shall paid by Project Manager. However, the contractor would
require to provide all necessary assistance for execution of this work.

17.00 Statutory clearances:

During execution of 11 KV Line work, all statutory clearances shall be ensured for ground
clearance, line-to-line clearance, road crossing clearance, horizontal and vertical clearances
from buildings/objects etc. All road crossings and line crossings shall be guarded as per
specifications. Conductor joint should not be provided in mid span length. Instead, it should
be nearer to the support.

13.5. Distribution Transformer Substations

1.00 Survey of Distribution Transformer Substations:

A detailed survey of existing habitation shall be performed in presentable document showing

population residing in the un-electrified area/existing electrified area of habitation, best
location of installation of a new distribution transformer substation and the capacity of
transformers to be selected for installation. The capacity of DTR shall be governed by following
technical aspects:

a) Optimistic lengths of LT lines needed to feed the beneficiaries,

b) Space available for installation of support/transformers,
c) Probable load expected to come on the transformer due to existing BPL beneficiaries /others
connected /un-connected probable beneficiaries in the locality taking care of their expected load
growth in next 5 years.
d) Distribution Transformers of capacity 16 KVA to 500 KVA (single phase as well as three phase)
shall be decided as per standard rating of distribution transformer as depicted in IS
specifications. Nonstandard ratings of DTR shall not be installed.
e) Distribution Transformers of capacity 16 KVA to 500 KVA (single phase as well as three phase)
shall be installed on double pole structures. Hence, three phase 11 KV lines shall be laid for
16 KVA to 500 KVA (single phase as well as three phase) capacity sub-stations. Single
phase lines shall only be permitted for 10 KVA single phase transformers mounted on single
pole structure.
f) Double pole support galvanized steel structures for 16 KVA and 25 KVA distribution
transformers shall be designed in such a way that they can be augmented to 63 KVA transformer
structures without any addition in near future on technical requirements.

Based on survey report, Project Manager shall decide type, capacity and location of
Distribution Transformer sub-station.

2.00 Following types of support are envisaged for 11/0.4 or 11/0.25 KV Distribution Transformer
Substation support:
Part -2 : Employer‟s Requirements 60

i) 8 m/200 kgs PSC Poles - (PSC Pole as per GUJARAT state practice)
j) 13 m long H-Beam 150x150 mm, 34.6 kg/mtr
k) 11 m long H-Beam 116x100 mm, 23 kg/mtr
l) 9 m long H-Beam 116x100 mm, 23 kg/mtr

g) For DTR Substation above 100 KVA plinth should be used along with DP.

In rural area, PSC poles are to be used. In urban area, PSC to be used of suitable length. In
location specific conditions like forest area, vicinity of other existing lines and permanent
structures etc, H- beam or tubular poles may be used.

PSC supports shall be used for distribution transformer substation up to 100 KVA
capacity only. Beyond 100 KVA rating, plinth shall be used for mounting of distribution
transformer.

H-Beam shall be cleaned till good surface finish and painted with 2 or more coats of red oxide
paint and 2 or more coats of aluminium paint till good finish. H-Beams shall also be painted
with 2 or more coats till good surface finish with anti-corrosive paint (in case of tubular poles
shall also be painted on the inner walls) which goes in the foundation. Project Manager shall
approved brand and shade of paints.

Painting of H-Beams and Steel Tubular Poles shall be performed at stores yard. Before
shifting to site for erection, poles shall be offered for inspection and approval by Project
Manager before erection.
3.00 Fabricated steel items:

Fabricated steel items like DC cross arm (100x50x6 mm), back clamps (65x8 mm), pole
clamp (65x8 mm), DO mounting channel (100x50x6 mm), transformer mounting channel
(100x50x6 mm), transformer clamping set (50x50x6 mm), transformer belting set (50x50x6
mm), V cross arm, top clamp, DC cross arm, bracket, clamps, cross bracings, bracings, strain
plate, back clamp, transformer mounting structure etc shall be made of MS Channels, MS angle,
MS flats as per approved drawings.

While fabricating, good quality electric cutting tools and drill machine shall be used to ensure
no sharp edges and perfect holes as per approved drawings. Gas cutting set should not be used
for fabrication of MS steel items. Weld material shall be distributed equally between the two
materials that were joined. The weld shall be free of waste materials such as slag. The weld
surface should not have any irregularities or any porous holes (called porosity). The joint shall
be tight. Most welds need to demonstrate the required strength. One way to ensure proper
Part -2 : Employer‟s Requirements 61

strength is to start with a filler metal and electrode rating that is higher than your strength
requirement.

Fabricated steel structure items shall be hot dip galvanized and cleaned till good surface finish
The minimum coating of the zinc shall comply with IS: 2629 and IS: 2633 (with latest
amendments). Galvanizing shall be checked and tested in accordance with IS: 2633. Items
shall be offered for inspection and approval by Project Manager.

4.00 Hardware:

MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used for
tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing, strain
plates etc.

While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads only
be visible of the bolt after full tightening of nut on requisite torque. The hardware shall be hot
dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
them to site for erection, they shall be offered for inspection and approval by Project Manager.

5.00 Stay Set:

Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (2Nos.), anchor plate
(200x200x6mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay
rod & 7/3.15 mm dia GI stranded wire complete.

Stay set shall be used at all sub-station location to nullify the tension of
conductor/cable/transformer on the supports. 0.3 cmt cement concreting in mixture 1 part
cement, 2 part coarse sand and 4 part 40mm size aggregate stone chips (1:2:4) shall be provided
in the foundation of the stay set. 2 Nos. guy insulator shall be provided in 7/3.15 mm dia stranded
GI wire at middle locations between two turn buckles.

6.00 Distribution Transformer:

Following type and sizes of minimum 3 star rated {as per Bureau of Energy Efficiency
(BEE)}, BIS stamped, distribution transformers are standardized in the project:

a) 5/6 KVA 1 phase Aluminium / Copper wound DTR

b) 10 KVA 1 phase / 3 phase Aluminium / Copper wound DTR
c) 16 KVA 1 phase / 3 phase Aluminium / Copper wound DTR
Part -2 : Employer‟s Requirements 62

d) 25 KVA 1 phase / 3 phase Aluminium / Copper wound DTR

e) 63 KVA 3 phase Aluminium / Copper wound DTR
f) 100 KVA 3 phase Aluminium / Copper wound DTR
g) 200 KVA 3 phase Aluminium / Copper wound DTR
h) 250 KVA 3 phase Aluminium / Copper wound DTR
i) 500KVA 3 phase Aluminium / copper wound DTR
Or any other rating as per latest Indian Standard Specification

The Distribution Transformers shall be 11/0.4 KV or 11KV/230 V or 22/0.44 KV non-sealed

type BEE specified minimum 3 Star Distribution Transformers. The transformers shall be
double wound, three phase, CRGO M3 Grade (0.23mm) or better (The core shall be constructed
from high grade, non-ageing, Cold Rolled Grain Oriented (CRGO) silicon steel of M3 Grade
(0.23mm) laminations only. PRIME CORE M3 Grade (0.23mm) materials are to be used for
transformers core.

Distribution Transformers shall be subject to inspection during manufacturing (stage

inspection), pre-delivery inspection, and inspection at site during pre-erection/post erection/post
commissioning conditions. Project Manager shall select samples from the core laminations and
get the same tested in CPRI/ NABL Accredited laboratory to prove the quality of the core
material.

The distribution transformers shall be supplied with transformer oil filled up-to maximum
permissible level and breather with silica gel.

The distribution transformers must have been successfully type tested within five years from
date of Letter of Intent and the designs should have been in satisfactory operation for a period
not less than two years as on the date of bid opening. Compliance shall be demonstrated by
submitting, (i) authenticated copies of the type test reports and (ii) performance certificates from
the users, specifically from Central Govt./State Govt. or their undertakings.

3 STAR LEVEL: Each Distribution Transformers must contain minimum 3 Star Label with
style and information provided by the Bureau of Energy Efficiency (B.E.E), Ministry of Power,
Government of India.

The losses in Distribution Transformer should be as per Energy Efficiency Level-2 and
above as specified in IS 1180 (Part-1):2014 for all kVA ratings of distribution transformers
(

Bimetallic connectors of suitable capacities are to be provided on LT side and on HT side of

the transformer.
Part -2 : Employer‟s Requirements 63

T-Clamps should be provided on each jumper on bus bars. Line jumpers should be provided
with adequate size of PG Clamps (Two numbers PG Clamps at each end of jumper). Clamp
should be made of aluminum grade T-1F as per IS-8309 having good electrical quality
aluminum material and should not be brittle in nature.

Transformers should be tested for pre-commissioning checks which includes Insulation

Resistance Test, ratio test and oil breakdown voltage test. Before formal energisation, oil
leakages from the parts of the transformer, oil level in conservator tank, condition of silica
gel, earth connection (two separate) between neutral and earthing, proper jointing of earth
wires/flats at the joints and earth resistance of the individual earthing pits are to be checked
and recorded. On commissioning of the transformer, phase current and phase to phase
voltage, phase to neutral voltage are to be recorded. The loading on the transformers should
be balanced. The quantum of neutral current flowing through neutral shall be recorded. A record
of pre-commissioning checks/tests are to be prepared and submitted to the Project Manager.

7.00 AAAC Conductor:

AAAC Conductor is to be used for connection between overhead lines to transformer

studs/bushing.

8.00 Distribution box and Power Cabling:

Distribution boxes are to be installed as per specifications enclosed. The boxes are to be erected,
electrically connected with the existing system, properly earthed, and labeled. The test report
of pre-commissioning checks should be prepared and submitted.

All CT terminals are to be ring type and other terminals are fork type. 2.5 sqmm copper multi
stands wiring 1.1 KV grade, ISI marked, IS 694 shall be used for control wiring. A terminal
block be provided between CT and Meter keeping 20% spare terminals.

The distribution boxes are to be earthed using 8 SWG GI wire direct connection to the earthing.
2 Nos Earthing bolts on the distribution boards should be provided of 10mm dia.

The single core power cables should be terminated with proper size lugs and gland. Necessary
tagging, identification of cores and dressing of cables with nylon cable ties shall be in the scope
of work. The unutilized holes in the DBs provided for cable entry needs to be plugged properly
in a manner that it must stop access to reptiles, dust and water ingress.
Part -2 : Employer‟s Requirements 64

The Low Tension bus bars are to be painted with two or more coats of brush-able epoxy
compound suitable to insulate the bus bars for 415 volts exposure.

The distribution box, for transformers upto and including 25 KVA, should also house three
phase tri-vector energy meter / single phase meter depending on capacity and type of
distribution transformer as per specifications. For higher capacity transformers where CT
operated meters are to be installed, separate LTCT cum Meter Box at eye height shall be
installed for housing of meter, CTs, terminal block and wiring.

The single core un-armored power cables shall be used for connection from Distribution
Transformer to Distribution Box and Distribution Box to Outgoing LT lines. Cable should not
be used in underground laying arrangement. Cables should be dressed & tied properly using
clamps /cable ties at 1 meter intervals and tied with substation structure/poles. At-least one
meter cable is to be kept as spare at the individual ends.
Following arrangements shall be made for LT Distribution Transformers and LT Cables:

No Type Incomer Outgoing Cable

of MCB/Isolator HRC fuse MCCB 1 2
DTR
1 5/6/10 45A SPN MCCB 2x32A SP 1Cx16 sqmm UA
KVA MCCB
1 Ph
2 16 80A SPN MCCB 2x50A SP 1Cx16 sqmm UA
KVA MCCB
1 Ph
3 16 25A TPN MCCB 6x16A SP 1Cx16 sqmm UA
KVA MCCB
3 Ph
4 25 40A SPN MCCB 3x25A SP 1Cx35 sqmm UA
KVA MCCB
1 Ph
5 25 40A TPN MCCB 6x25A SP 1Cx35 sqmm UA
KVA MCCB
3 Ph
6 63 200A TPN Isolator 100 A 6x60A SP 1Cx50/70 1Cx70 sqmm
KVA MCCB sqmm UA UA
3 Ph
7 100 200A TPN Isolator 160 A 6x90A SP 1Cx50/70 1Cx150 sqmm
KVA MCCB sqmm UA UA
Part -2 : Employer‟s Requirements 65

3 Ph
8 200 600A TPN Isolator 315 A 9x120A SP 1Cx150 sqmm 1Cx300 sqmm
KVA MCCB UA UA
3 Ph
9 315 600A TPN Isolator 500 A 12X120A SP 1CX150 sqmm 1CX300 sqmm
KVA MCCB UA UA
3 Ph

1.1 KV XLPE Aluminium Conductor, Stranded, un-armored cable be used for connection of
transformer LV bushing to Distribution Box and Distribution box to overhead line.

9.00 Earthing:

Distribution Transformer Earthing shall be provided with 3 Nos earthing and making earth
mat /risers using 50X6mm GI Flat. Earthing should be provided with GI earth pipe or
Chemical Earthing depending of strata of soil in the location. Project Manager shall decide the
type of earthing.

25x3mm GI Flat and 8 SWG GI shall be used for making earthing connection to various sub-
station equipment as per given details. GI Flat and GI wire shall be properly dressed, bunched
and clamped with the support at 2 feet intervals. An overlapping of 35mm shall be used at the
place of flat to flat joint. Two sets of GI nuts, bolts and washers shall be used for flat-to-flat
joints. GI nuts, bolts and washers must be used for GI Flat–to-GI wire & GI wire-to-GI wire
joints.

Substation wise measurement of earth resistance of earth pits / mesh and corresponding
drawing of existing earthing arrangement shall be recorded and submitted to Project Manager.

Description of equipment Earth connection

Earthing pits 3 Nos. Earth Pipe 3 m long, 40 mm dia
or Chemical Earthing
Earth mat and riser 50X6 mm GI Flat / 8 SWG GI wire
Laying of earth mat Below ground 0.5 meter

Standard requirements of earthing shall be as under:

a) Earth Pit – 1 for Transformer Neutral,
b) Earth pit - 2 for Lightening Arrester,
c) Earth pit – 3 for Equipment body earthing.
d) Maintenance free earthing
Part -2 : Employer‟s Requirements 66

Following arrangement is envisaged for various equipment of distribution transformer

substation:
a) Transformer Neutral (Two distinct connections) : GS Flat 25X3mm
b) Transformer Body : GS Flat 25X3mm
c) Lightning Arrester : GS Flat 25X3mm
d) Fencing (Wherever required) : GI wire 8 SWG
e) LT Distribution Box (Two distinct connections) : GI wire 8 SWG
f) AB Switch handle : GI wire 8 SWG
g) Steel structure of substation : GI wire 8 SWG
h) Line meters : GS wire 8 SWG

The location of earth pits should be at-least 3m apart, so that they their earth conductive areas
do not overlap. In rocky soil where getting required earth resistance is a challenge, chemical
rod earthing shall be used in place of normal GI pipe type earthing. Project Manager shall decide
type of earthing pits.

10.00 Insulator and hardware:

11 KV polymer/porcelain Disc/Pin insulator with suitable hardware fittings shall be used.

Insulator should be tied properly using binding wire/helical form fitting. Bi-metallic clamps
must be used at terminals.

The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator should properly be cleaned before installation. No damage/crack
insulator should be used.

11.00 Substation numbering:

Each Substation should be numbered properly labelled using yellow base and black indication
marks (number or digits). 40/50 mm height digits/words should be used for this purpose. Base
shall be made using 2 or more coats of yellow enamel paint till good surface finish. Base
preparation shall be completed before shifting of poles to site for erection. Base painting and
marking of digits should be performed by a skilled and trained painter using branded enamel
paint, Project Manager shall approve type and brand of enamel paint.

12.00 Anti-climbing device:

Part -2 : Employer‟s Requirements 67

2 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each sub-station support.
Galvanized barbed wire should be properly dressed and crimped at termination. While
wrapping the wire on support, proper tension should be maintained.

13.00 Danger board:

Each support should be provided with a danger board with pole clamps as per approved drawing.
Danger board should be in bi-lingual languages (local language and English). Clamp for danger
board, nut-bolts and washers shall be painted with two or more coats of red-oxide and aluminium
paints respectively till smooth surface before installation.

14.00 Support foundation:

Cement concrete in mixture 1 part cement, 2 part coarse sand, 4 part 40 mm size aggregate stone
chips (1:2:4) shall be used in PCC Pole, steel tubular poles and H-Beam support
foundation.

While erecting supports (poles), shuttering must be used for concreting so that proper quantity
of cement concrete mixture be used and assessed during inspection. During concreting proper
compaction by means of mobile vibrator be provided. While starting work of support erection,
gang wise shuttering and mobile vibrator shall be offered for inspection to Project Manager.
While erecting support, mercury level gauge must be used to ensure vertical erection of support.

250mm dia X 12” inch size muffing shall be provided on steel tubular and H-Beam poles to
prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part Cement, 2
parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for individual poles.

Steel plate shall be used in steel tubular poles and cement concrete reinforced plate shall be used
as base plate for PCC poles.

15.00 11 KV AB Switch:

11 kV, 3-ph, 200 A, 3 Pin type, Horizontal/Vertical Mounting type, Gang Operated, AB
Switch shall be installed on 100 KVA and more capacity distribution transformer substation
only. B Class GI pipe shall be used (without any joints) for operation of switch. AB Switch
structure and handle must be earthed using 8 SWG GI wire.

16.00 11 KV Drop Out Fuses:

Part -2 : Employer‟s Requirements 68

11 kV, 3-ph, Drop Out fuse units (set of 3 units) along with Support Insulators, Base Channel,
fuse barrel etc. shall be used for all capacity Distribution Transformer Substations. DO Fuse
structure shall be earthed using 8 SWG GI wire.

17.00 Lighting Arrester:

Distribution Class LAs on each phase shall be provided in the sub-station with base steel
structure, terminals bi – metallic connectors / PG clamps and earth connectors. LAs are to be
connected with separate earth connection. 25x3 mm GI flat shall be used for earth connection.
Part -2 : Employer‟s Requirements 69

13.6. New LT Line

1. Survey:

Mapping of route of proposed new LT line by foot survey in rural/urban areas be performed
mentioning various milestones. While surveying, existing electrical infrastructure in the
locality should also be mapped. Line alignment (single line diagram) on political map with
fair correctness, be prepared. SLD and foot survey report shall be approved by Project
Manager and shall be used as basic document for assessment of works under the contract. On
completion of line work, as built Single Line Diagram and pole wise line diagram showing
pole wise materials used and pole-to-pole span should be submitted to Project Manager. This
details shall be used as reference documents by Quality & Quantity Inspecting officials to
execute inspection works.

2. The LT line between distribution transformer and consumers shall be on LT Areal Bunched
cables.

3. Support for LT overhead Line:

a) 8 m/200 kgs PSC Poles - (PSC Pole as per GUJARAT state practice)
b) 13 m long H-Beam 150x150 mm, 34.6 kg/mtr
c) 11 m long H-Beam 116x100 mm, 23 kg/mtr
d) 9 m long H-Beam 116x100 mm, 23 kg/mtr

In rural area, PSC poles are to be used. In urban area, PSC /H beam are to be used of suitable
length. In hilly areas where handling of material is a challenge, tubular poles may be used. In
location specific conditions like forest area, vicinity of other existing overhead lines or
permanent structures etc, H- beam or tubular poles may be used.

H-Beam support and steel tubular poles shall be cleaned till good surface finish and painted
with 2 or more coats of red oxide paint and 2 or more coats of aluminium paint till good
finish. Steel tubular poles and H-Beams shall also be painted with 2 or more coats till good
surface finish with anti-corrosive paint (in case of tubular poles shall also be painted on the
inner walls) which goes in to the foundation. Project Manager shall approved brand and
shade of paints.

Painting of H-Beams and Steel Tubular Poles shall be performed at stores. Before shifting to
site for erection, poles shall be offered for inspection and approval by Project Manager.
Part -2 : Employer‟s Requirements 70

4. Fabricated steel items:

Fabricated steel items like clamps, stay clamp, etc shall be made of MS Channels, MS angle,
MS flats as per approved drawings.

While fabricating, good quality electrical cutting tools and drill machine shall be used to ensure
no sharp edges and perfect holes as per approved drawings. Gas cutting set should not be used
for fabrication of MS steel items. Weld material shall be distributed equally between the two
materials that were joined. The weld shall be free of waste materials such as slag. The weld
surface should not have any irregularities or any porous holes (called porosity). The joint
shall be tight. Most welds need to demonstrate the required strength. One way to ensure proper
strength is to start with a filler metal and electrode rating that is higher than your strength
requirement.

Fabricated steel structure items shall be hot dip galvanized and cleaned till good surface
finish. The minimum coating of the zinc shall comply with IS: 2629 and IS: 2633 (with latest
amendments). Galvanizing shall be checked and tested in accordance with IS: 2633. Items shall
be offered for inspection and approval by Project Manager.

5. Hardware:

MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used
for tying of overhead structure wherever required.

While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall
be hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
them to site for erection, they shall be offered for inspection and approval by Project
Manager.

6. Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (1 No.), anchor plate
(200x200x6mm), nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay
rod shall be used with 7/3.15 mm dia GI stranded wire.

Stay set shall be used at all turning locations, cable dead end locations to nullify the tension
of the cable. Erection of storm guys at suitable location in straight line may also be provided.
Erection of storm guys at suitable location in straight line may also be provided.
Part -2 : Employer‟s Requirements 71

0.3 cmt cement concreting in mixture 1 part cement, 2 part coarse sand, 4 part 40mm size
aggregate stone chips (1:2:4). 2 Nos. guy insulator shall be provided in stranded GI wire at
middle location between two turn buckles.

7. Following earthing arrangements are envisaged for new LT lines:

7.1.1. 40 mm dia., 3000 mm long GI pipe earth electrode with test link, RCC pit, RCC cover plate
on GI frame, bentonite powder and other accessories complete
7.1.2. GI Earthing spike made of 20mm solid rod or 8 SWG, 50 turns earthing coil
7.1.3. Chemical rod earthing including electrode, chemical, with 2000mm long, 50 mm diameter
GI pipe, GI Strip of 24x3mm minimum in hard rock locations only.
7.1.4. 8 SWG GI wire for earthing and guarding

Every third LT line support shall be provided with one GI earthing spike made of 20 mm
solid rod or GI Earth Coil and connected with 8 SWG GI wire. Overhead steel items shall be
connected to GI earthing spike or GI Earth Coil using 8 SWG GI wire. GI nuts, bolts & washers
shall be used to join two GI wires and 20 mm solid spike rod. Project Manager shall decide use
of GI Earth Coil or 20mm dia GI Solid Rod for individual pole earthing.

In rocky soil where getting required earth resistance is a challenge, chemical rod earthing
shall be used. Overhead line structure shall be connected to chemical earth electrode using
8SWG GI wire. GI nuts, bolts & washers shall be used to join two GI wires and 20 mm solid
spike rod.

GI wires must be properly dressed and fixed on supporting structure at 1 to 2 feet intervals.

8. LT line shall form following areal bunched XLPE cables:

3Cx35+1Cx16+25 mm2
3Cx50+1Cx25+35mm²
1C x 35mm²+ 35mm² and 1C x 50 mm 2 + 50 mm2,

9. Distribution box (pole mounted Box):

Single phase or three phase pole mounted Box shall be provided for extending power supply
to LT consumers. pole mounted Box shall be mounted on LT pole with galvanized MS clamp
of 40x3 mm size(or as per required size).box shall be earthed using 8 SWG GI wire.

Single phase DB shall be suited for two core 25 sqmm aluminium conductor cable as
incomer and 8 nos. two core 10 sqmm conductor cables as outgoing cables. Three phase DB
shall be suited for four core 35 sqmm aluminium conductor cable as incomer and 4 nos. four
core 16 sqmm conductor cables as outgoing cables.
Part -2 : Employer‟s
Note: Requirements
Size of incoming and out going cable inter connection e.g. shall be as per technical72
specification of MGVCL please referred technical specification of pole mounted box.
The distribution box shall be installed only at locations where connections are provided.

10. Connection from ABC cable:

2Cx25 sqmm cable or 4Cx35 sqmm cable shall be used between LT line and Distribution
box. T-connector shall be used at LT line for tapping. While tapping connection from ABC
cable, highly skilled lineman/wireman shall be deployed along with sophisticated cutting
plier/tool so that no damage should result in AB cable conductor. T-connector should be
crimped properly for resistance free/maintenance free electric connection. Alternately, piercing
type connector may be used for tapping of LT connection from ABC cable conductor.

11. Pole numbering:

Each support pole should be numbered properly labelled using yellow base and black indication
marks (number or digits). 40/50 mm height digits/words should be used for this
purpose. Base shall be made using 2 or more coats of yellow enamel paint till good surface
finish. Base preparation shall be completed before shifting of poles to site for erection. Base
painting and marking of digits should be performed by a skilled and trained painter using
branded enamel paint, Project Manager shall approve type and brand of enamel paint.

12. Anti-climbing device:

2 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each LT line support.
Galvanized barbed wire should be properly dressed and crimped at termination. While
wrapping the wire on support, proper tension should be maintained.
13. Danger board:

Each support should be provided with a danger board with pole clamps as per approved
drawing. Danger board should be in bi-lingual languages (local language and English).
Clamp for danger board, nut-bolts and washers shall be painted with two or more coats of
red-oxide and aluminium paints respectively till smooth surface before installation.

14. Support foundation:

Cement concrete in mixture 1 part cement, 2 part coarse sand, 4 part 40 mm size aggregate
stone chips (1:2:4) shall be used in steel tubular poles and H-Beam LT line supports.

In rural areas, PSC pole pit shall be refilled with 200 mm average size of bolder mixed with
excavated earth. Proper ramming shall be performed for better compaction. PSC pole at cut
point and PSC poles erected on water logging area shall be grouted using cement concrete
mixture similar to H-Beam & Tubular poles. Prior approval of Project Manager shall be

obtained for concreting of PSC poles in water logging area. While preparing route survey
report, water logging areas shall be earmarked.
Part -2 : Employer‟s Requirements 73
While erecting supports (poles), shuttering must be used for concreting so that proper
quantity of cement concrete mixture be used and assessed during inspection. During concreting
proper compaction by means of mobile vibrator be provided. While starting work of support
erection, gang wise shuttering and mobile vibrator shall be offered for inspection to Project
Manager. While erecting support, mercury level gauge must be used to ensure vertical erection
of support.

250mm dia X 12” inch size muffing shall be provided on steel tubular and H-Beam poles to
prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part Cement,
2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for individual
poles.

cement concrete reinforced plate shall be used as base plate for PSC poles.

15. Quality & Quantity inspection and compliance to the observation:

The line works, before or after commissioning/energisation, shall be inspected by Quality

Inspectors and State Inspection Inspectorate. Contractor shall provide all requisite details of
line like approved survey report, as built drawings and joint measurement sheet to the
inspector to conduct. Contractor shall rectify defects/deficiencies and submit compliance to
the observations with supporting photographs in digital form within one month from receipt
of observations.

16. Tree-cutting/trimming of tree:

The Contractor shall count, mark and put proper numbers with suitable quality of paint at his
own cost on all the trees that are to be cut/trim to obtain required tree clearance. Contractor
shall pay compensation for any loss or damage for tree cutting due to Contractor’swork.
Wherever forest clearance is envisaged for execution of work, clearance of forest department
for tree cutting, if required, shall be arranged by the Project Manager and compensation shall
also be paid by the Project Manager. Necessary fee if required to pay to Govt. dept. for
arranging such clearances shall paid by Project Manager. However, the contractor would
require to provide all necessary assistance for execution of this work.

17. Statutory clearances:

During execution of LT Line works, all statutory clearances shall be ensured for ground
clearance, line-to-line clearance, road crossing clearance etc.

18. The earthing point of distribution transformer should be extended to the single phase
beneficiary premises having en-route earth connection at every 6th supports. The earth
conductor is to be connected with earth point provided in the premises of single phase
consumers. The bearer wire shall be earthed at every sixth pole.

19. Bearer wire of LT AB cable shall be anchored through eyehook or dead end (anchor) clamps.
Part 20.
-2 : Employer‟s
Extra Requirements
length of continuous 74
AB cable along with messenger / bearer wire shall be properly
dressed and clamped.
Part -2 : Employer‟s Requirements 75

13.7. Augmentation and Renovation

3. Renovation/Augmentation of 11 kV line

1.00 Augmentation of 3 phase 11 kV line using additional supports matching with length and type of
existing support is envisaged on following type of supports:

a. 8 meter long /200 KG PSC Poles

b. 9 m or 11 m or 13 m long H-Beam as per specification

2.00 Augmentation of existing conductor with following type of new AAAC conductor including
jointing sleeves, binding materials and helical formed fittings etc as required are envisaged under
this work-

a. 55mm sq AAC - Rabbit by replacing existing weasel/squirrel conductor

b. 100mmsq DOG - by replacing existing rabbit/weasel conductor

3.00 While executing this work, mid span pole with all fittings may be provided matching with
existing poles of the line.

4.00 Following works shall also be executed by contractor under this head –
Part -2 : Employer‟s Requirements 76

a. Replacement of damaged insulators

b. Straightening of tilted supports by providing additional foundation or by providing grouting etc
as required.
c. Revamping of pole earthing and replacement of GI earth wire.
d. Labelling, providing danger board, providing anti climbing device and painting of all the poles
shall be in the scope of work
e. Replacement of damaged/bent V-cross arms & top clamps with new ones
f. Providing of stay set wherever required
g. Providing of guarding wherever required
h. Removal of old conductor in coil form, removal of old steel structure, removal of old conductor
fittings, removal of any other worn out/defective material and deposit them in Employer‟s store
within a reasonable time as decided by Project Manager

Item-wise scope of works under renovation/augmentation of 11 kV line is detailed out under scope
of new 11 kV line. It shall be utilized on item to item requirement under renovation/augmentation
of 11 kV line also.

4. R & M and augmentation of Distribution Transformer Substations

1.00 Survey of Distribution Transformer Substations:

A detailed survey of overloaded Distribution Transformer substation shall be performed.

Existing electrical connected loading and habitation shall be surveyed and a presentable
document showing population residing in the un-electrified area/existing electrified area of
habitation shall be performed. Based on survey, best option for augmentation of distribution
transformer substation and the capacity of new transformer shall be decided. The capacity of
augmented DTR shall be governed by following technical aspects:

a) Optimistic lengths of LT lines needed to feed the existing consumers, existing un-connected
consumers and future growth in electrical loading,
b) Space available for installation of support/transformers,
c) Probable load expected to come on the transformer due to existing BPL beneficiaries /others
connected /un-connected probable beneficiaries in the locality taking care of their expected load
growth in next 5 years.
d) Distribution Transformers of capacity 5kva,10kva,16 KVA to 500 KVA (single phase as well as
three phase) shall be decided as per standard rating of distribution transformer as depicted
in IS specifications. Nonstandard ratings of DTR shall not be installed.
e) Distribution Transformers of capacity 5kva,10kva,16 KVA to 315 KVA (single phase as well as
three phase) shall be installed on existing structures/plinth.
Part -2 : Employer‟s Requirements 77

Based on survey report, Project Manager shall decide type, capacity and location of Distribution
Transformer sub-station for augmentation/R&M works.

2.00 Following types of works are envisaged for Distribution Transformer sub-station for
augmentation/R&M works:
a. Replacement of defective materials of DTR substations
b. Re-erection/re-concreting of substation supports
c. Dismantling of defective/worn-out steel structure materials, 11 kV/LT equipment like Lightening
Arrester, DO Fuse, Distribution box, LT cable, jumpering conductor, terminal clamps, insulators
etc as required. Shifting of dismantled material to Employer‟s store within reasonable period of
time.
d. Installation of stay set for strengthening of DTR substation structure.
e. Topping up of new and filtered transformer oil wherever required.
f. De-moisturizing of silica gel, filling of transformer oil in silica gel breather.
g. Providing new DTR substation equipment like steel structure materials, 11 kV/LT equipment
like Lightening Arrester, DO Fuse, Distribution box, LT cable, jumpering conductor, terminal
clamps, insulators etc
h. Renovation of DTR substation earthing by providing new earth pits, inter connection of earth
pits and their connection to various equipment
i. Cleaning of metallic structure items by rubbing through emery paper and re-painting using two
codes of red oxide paint and two coats of aluminium oxide paints of reputed type and make as
approved by Project Manager using painting brush.

3.00 Fabricated steel items:

Fabricated steel items like DC cross arm (100x50x6 mm), back clamps (65x8 mm), pole clamp
(65x8 mm), DO mounting channel (100x50x6 mm), transformer mounting channel (100x50x6
mm), transformer clamping set (50x50x6 mm), transformer belting set (50x50x6 mm), V cross
arm, top clamp, DC cross arm, bracket, clamps, cross bracings, bracings, strain plate, back
clamp, transformer mounting structure etc shall be made of MS Channels, MS angle, MS flats as
per approved drawings.(or for mounting transformer/DO MS Angle of size 65x65x6 mm as per
MGVCL prevailing specification may be utilised after prior approval)

While fabricating, good quality electric cutting tools and drill machine shall be used to ensure no
sharp edges and perfect holes as per approved drawings. Gas cutting set should not be used for
fabrication of MS steel items. Weld material shall be distributed equally between the two
materials that were joined. The weld shall be free of waste materials such as slag. The weld surface
should not have any irregularities or any porous holes (called porosity). The joint shall be tight.
Most welds need to demonstrate the required strength. One way to ensure proper strength is to
start with a filler metal and electrode rating that is higher than your strength requirement.
Part -2 : Employer‟s Requirements 78

Fabricated steel structure items shall be hot dip galvanized and cleaned till good surface finish. The
minimum coating of the zinc shall comply with IS: 2629 and IS: 2633 (with latest amendments).
Galvanizing shall be checked and tested in accordance with IS: 2633. Items shall be offered for
inspection and approval by Project Manager.

4.00 Hardware:

MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used for
tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing, strain
plates etc.

While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads only
be visible of the bolt after full tightening of nut on requisite torque. The hardware shall be hot
dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS: 2633.
Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting them to site
for erection, they shall be offered for inspection and approval by Project Manager.

5.00 Stay Set:

Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (2Nos.), anchor plate
(200x200x6mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay rod
& 7/3.15 mm dia GI stranded wire complete.

Stay set shall be used at all sub-station location to nullify the tension of
conductor/cable/transformer on the supports. 0.3 cmt cement concreting in mixture 1 part
cement, 2 part coarse sand and 4 part 40mm size aggregate stone chips (1:2:4) shall be provided
in the foundation of the stay set. 2 Nos. guy insulator shall be provided in 7/3.15 mm dia
stranded GI wire at middle locations between two turn buckles.

6.00 Distribution Transformer:

Following type and sizes of minimum 3 star rated {as per Bureau of Energy Efficiency (BEE)},
distribution transformers are standardized in the project for augmentation:

a) 5/6 KVA 1 phase Aluminium / Copper wound DTR

b) 10 KVA 1 phase / 3 phase Aluminium / Copper wound DTR
c) 16 KVA 1 phase / 3 phase Aluminium / Copper wound DTR
d) 25 KVA 1 phase / 3 phase Aluminium / Copper wound DTR
e) 63 KVA 3 phase Aluminium / Copper wound DTR
f) 100 KVA 3 phase Aluminium / Copper wound DTR
Part -2 : Employer‟s Requirements 79

g) 200 KVA 3 phase Aluminium / Copper wound DTR

h) 250 KVA 3 phase Aluminium / Copper wound DTR
i) 5 0 0 KVA 3 phase Aluminium / copper wound DTR
Or any other rating as per latest Indian Standard Specification

The Distribution Transformers shall be 11/0.4 KV or 11KV/230 V or 22/.44 KV non-sealed type

BEE specified minimum 3 Star Distribution Transformers. The transformers shall be double
wound, three phase, CRGO M3 Grade (0.23mm) or better (The core shall be constructed from high
grade, non-ageing, Cold Rolled Grain Oriented (CRGO) silicon steel of M3 Grade (0.23mm)
laminations only. PRIME CORE M3 Grade (0.23mm) materials are to be used for transformers
core.

Distribution Transformers shall be subject to inspection during manufacturing (stage inspection),

pre-delivery inspection, and inspection at site during pre-erection/post erection/post
commissioning conditions. Project Manager shall select samples from the core laminations and get
the same tested in CPRI/ NABL Accredited laboratory to prove the quality of the core material.

The new distribution transformers shall be supplied with transformer oil filled up-to maximum
permissible level and breather with silica gel.

The distribution transformers must have been successfully type tested within five years from
date of Letter of Intent and the designs should have been in satisfactory operation for a period
not less than two years as on the date of bid opening. Compliance shall be demonstrated by
submitting, (i) authenticated copies of the type test reports and (ii) performance certificates from
the users, specifically from Central Govt./State Govt. or their undertakings.

3 STAR LEVEL: Each Distribution Transformers must contain minimum 3 Star Label with style
and information provided by the Bureau of Energy Efficiency (B.E.E), Ministry of Power,
Government of India.

The losses in Distribution Transformer should be as per Energy Efficiency Level-2 and above
as specified in IS 1180 (Part-1):2014 for all kVA ratings of distribution transformers

Bimetallic connectors of suitable capacities are to be provided on LT side and on HT side of the
transformer.

T-Clamps should be provided on each jumper on bus bars. Line jumpers should be provided
with adequate size of PG Clamps (Two numbers PG Clamps at each end of jumper). Clamp
Part -2 : Employer‟s Requirements 80

should be made of aluminum grade T-1F as per IS-8309 having good electrical quality
aluminum material and should not be brittle in nature.
Transformers should be tested for pre-commissioning checks which includes Insulation
Resistance Test, ratio test and oil breakdown voltage test. Before formal energisation, oil
leakages from the parts of the transformer, oil level in conservator tank, condition of silica gel,
earth connection (two separate) between neutral and earthing, proper jointing of earth wires/flats
at the joints and earth resistance of the individual earthing pits are to be checked and recorded.
On commissioning of the transformer, phase current and phase to phase voltage, phase to neutral
voltage are to be recorded. The loading on the transformers should be balanced. The quantum of
neutral current flowing through neutral shall be recorded. A record of pre-commissioning
checks/tests are to be prepared and submitted to the Project Manager.

7.00 ACSR / AAAC Conductor:

ACSR raccoon conductor (or equivalent AAAC conductor) is to be used for connection between
overhead lines to transformer studs/bushing.

8.00 Distribution box and Power Cabling:

Distribution boxes are to be installed as per specifications enclosed. The boxes are to be erected,
electrically connected with the existing system, properly earthed, and labeled. The test report of
pre-commissioning checks should be prepared and submitted.

All CT terminals are to be ring type and other terminals are fork type. 2.5 sqmm copper multi
stands wiring 1.1 KV grade, ISI marked, IS 694 shall be used for control wiring. A terminal
block be provided between CT and Meter keeping 20% spare terminals.

The distribution boxes are to be earthed using 8 SWG GI wire direct connection to the earthing.
2 Nos Earthing bolts on the distribution boards should be provided of 10mm dia.

The single core power cables should be terminated with proper size lugs and gland. Necessary
tagging, identification of cores and dressing of cables with nylon cable ties shall be in the scope
of work. The unutilized holes in the DBs provided for cable entry needs to be plugged properly
in a manner that it must stop access to reptiles, dust and water ingress.

The Low Tension bus bars are to be painted with two or more coats of brush-able epoxy compound
suitable to insulate the bus bars for 415 volts exposure.

The distribution box 16 KVA should also house three phase tri-vector energy meter / single
phase meter depending on capacity and type of distribution transformer as per specifications.
Part -2 : Employer‟s Requirements 81

For higher capacity transformers where CT operated meters are to be installed, separate LTCT
cum Meter Box at eye height shall be installed for housing of meter, CTs, terminal block and
wiring.

The single core un-armored power cables shall be used for connection from Distribution
Transformer to Distribution Box and Distribution Box to Outgoing LT lines. Cable should not be
used in underground laying arrangement. Cables should be dressed & tied properly using clamps
/cable ties at 1 meter intervals and tied with substation structure/poles. At-least one meter cable
is to be kept as spare at the individual ends.

Following arrangements shall be made for LT Distribution Transformers and LT Cables:

No Type of DTR Incomer Outgoing Cable

MCB/Isolator HRC fuse MCCB 1 2
1 5/6/10 KVA 1 45A SPN 2x32A SP 1Cx16 sqmm UA
Ph MCCB MCCB
2 16 KVA 1 Ph 80A SPN 2x50A SP 1Cx16 sqmm UA
MCCB MCCB
3 16 KVA 3 Ph 25A TPN 6x16A SP 1Cx16 sqmm UA
MCCB MCCB
4 25 KVA 1 Ph 40A SPN 3x25A SP 1Cx35 sqmm UA
MCCB MCCB
5 25 KVA 3 Ph 40A TPN 6x25A SP 1Cx35 sqmm UA
MCCB MCCB
6 63 KVA 3 Ph 200A TPN 100 A 6x60A SP 1Cx50/70 1Cx70
Isolator MCCB sqmm UA sqmm UA
7 100 KVA 3 Ph 200A TPN 160 A 6x90A SP 1Cx50/70 1Cx150
Isolator MCCB sqmm UA sqmm UA
8 200 KVA 3 Ph 600A TPN 315 A 9x120A SP 1Cx150 1Cx300
Isolator MCCB sqmm UA sqmm UA
9 315 KVA 3 Ph 600A TPN 500 A 12X120A SP 1CX150 1CX300
Isolator MCCB sqmm UA sqmm UA

1.1 KV XLPE Aluminium Conductor, Stranded, un-armored cable be used for connection of
transformer LV bushing to Distribution Box and Distribution box to overhead line.

9.00 Earthing:
Part -2 : Employer‟s Requirements 82

Distribution Transformer Earthing shall be provided with 3 Nos earthing and making earth mat
/risers using 50X6mm GI Flat. Earthing should be provided with GI earth pipe or Chemical
Earthing depending of strata of soil in the location. Project Manager shall decide the type of
earthing.

25x3mm GI Flat and 8 SWG GI shall be used for making earthing connection to various sub-
station equipment as per given details. GI Flat and GI wire shall be properly dressed, bunched
and clamped with the support at 2 feet intervals. An overlapping of 35mm shall be used at the place
of flat to flat joint. Two sets of GI nuts, bolts and washers shall be used for flat-to-flat joints.
GI nuts, bolts and washers must be used for GI Flat–to-GI wire & GI wire-to-GI wire joints.

Substation wise measurement of earth resistance of earth pits / mesh and corresponding drawing
of existing earthing arrangement shall be recorded and submitted to Project Manager.

Description of equipment Earth connection

Earthing pits 3 Nos. Earth Pipe 3 m long, 40 mm dia
or Chemical Earthing
Earth mat and riser 50X6 mm GI Flat / 8 SWG GI wire
Laying of earth mat Below ground 0.5 meter

Standard requirements of earthing shall be as under:

a) Earth Pit – 1 for Transformer Neutral,
b) Earth pit - 2 for Lightening Arrester,
c) Earth pit – 3 for Equipment body earthing.

Following arrangement is envisaged for various equipment of distribution transformer

substation:
a) Transformer Neutral (Two distinct connections) : GS Flat 25X3mm
b) Transformer Body : GS Flat 25X3mm
c) Lightning Arrester : GS Flat 25X3mm
d) Fencing (Wherever required) : GI wire 8 SWG
e) LT Distribution Box (Two distinct connections) : GI wire 8 SWG
f) AB Switch handle : GI wire 8 SWG
g) Steel structure of substation : GI wire 8 SWG
h) Line meters : GS wire 8 SWG

The location of earth pits should be at-least 3m apart, so that they their earth conductive areas do
not overlap. In rocky soil where getting required earth resistance is a challenge, chemical rod
Part -2 : Employer‟s Requirements 83

earthing shall be used in place of normal GI pipe type earthing. Project Manager shall decide
type of earthing pits.

10.00 Insulator and hardware:

11 KV polymer/porcelain Disc/Pin insulator with suitable hardware fittings shall be used. Insulator
should be tied properly using binding wire/helical form fitting. Bi-metallic clamps must be used at
terminals.

The individual insulator shall be checked for insulation resistance before overhead line installation.
Insulator should properly be cleaned before installation. No damage/crack insulator should be used.

11.00 Substation numbering:

Each Substation should be numbered properly labelled using yellow base and black indication
marks (number or digits). 40/50 mm height digits/words should be used for this purpose. Base shall
be made using 2 or more coats of yellow enamel paint till good surface finish. Base preparation
shall be completed before shifting of poles to site for erection. Base painting and marking of digits
should be performed by a skilled and trained painter using branded enamel paint, Project Manager
shall approve type and brand of enamel paint.

12.00 Anti-climbing device:

2 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each sub-station support.
Galvanized barbed wire should be properly dressed and crimped at termination. While wrapping
the wire on support, proper tension should be maintained.

13.00 Danger board:

Each support should be provided with a danger board with pole clamps as per approved drawing.
Danger board should be in bi-lingual languages (local language and English). Clamp for danger
board, nut-bolts and washers shall be painted with two or more coats of red-oxide and aluminium
paints respectively till smooth surface before installation.

14.00 Support foundation:

Cement concrete in mixture 1 part cement, 2 part coarse sand, 4 part 40 mm size aggregate stone
chips (1:2:4) shall be used in PCC Pole, steel tubular poles, WPB Poles and H-Beam support
foundation.

While erecting supports (poles), shuttering must be used for concreting so that proper quantity of
cement concrete mixture be used and assessed during inspection. During concreting proper
compaction by means of mobile vibrator be provided. While starting work of support erection,
Part -2 : Employer‟s
gang wiseRequirements
shuttering and mobile vibrator shall be offered for inspection to Project Manager. 84
While
erecting support, mercury level gauge must be used to ensure vertical erection of support.

250mm dia X 12” inch size muffing shall be provided on steel tubular, WPB poles and H-Beam
poles to prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part
Cement, 2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for
individual poles.

Steel plate shall be used in steel tubular poles and WPB poles and cement concrete reinforced plate
shall be used as base plate for PCC poles.

15.00 11 KV AB Switch:

11 kV, 3-ph, 200 A, 3 Pin type, Horizontal/Vertical Mounting type, Gang Operated, AB Switch
shall be installed on 100 KVA and more capacity distribution transformer substation only. B Class
GI pipe shall be used (without any joints) for operation of switch. AB Switch structure and handle
must be earthed using 8 SWG GI wire.

16.00 11 KV Drop Out Fuses:

11 kV, 3-ph, Drop Out fuse units (set of 3 units) along with Support Insulators, Base Channel, fuse
barrel etc. shall be used for all capacity Distribution Transformer Substations. DO Fuse structure
shall be earthed using 8 SWG GI wire.

17.00 Lighting Arrester:

Distribution Class LAs on each phase shall be provided in the sub-station with base steel
structure, terminals bi – metallic connectors / PG clamps and earth connectors. LAs are to be
connected with separate earth connection. 25x3 mm GI flat shall be used for earth connection.

5. Renovation/Augmentation of LT line

1.00 Conversion of LT line using additional supports with all fittings matching with length and type
of existing support is envisaged on following type of supports:

a) a) 8 m/200 kgs PSC Poles - (PSC Pole as per GUJARAT state practice)
b) 13 m long H-Beam 150x150 mm, 34.6 kg/mtr
c) 11 m long H-Beam 116x100 mm, 23 kg/mtr
d) 9 m long H-Beam 116x100 mm, 23 kg/mtr

2.00 Conversion of existing LT line of bare conductor with following type of new ABC cable LT
line as required are envisaged under this work-

3Cx35+1Cx16+25 mm2
3Cx50+1Cx25+35mm²
Part -2 : Employer‟s Requirements
1C x 35mm²+ 35mm² and 1C x 50 mm 2 + 50 mm2, 85

3.00 While executing this work, mid span pole with all fittings may be provided matching with
existing poles of the line or wherever the sag is high and need so arise.

4.00 Following works shall also be executed by contractor under this head –

a) Straightening of tilted supports by providing additional foundation or by providing grouting etc

as required.
b) Revamping of pole earthings and replacement of GI earth wire.
c) Labelling, providing danger board, providing anti climbing device and painting of all the poles
shall be in the scope of work
d) Providing of stay set wherever required
e) Removal of old bare conductor and depositing in Employer‟s store

Item-wise scope of works of LT line is detailed out under scope of new LT line. It shall be
utilized on item to item requirement under renovation/augmentation of LT line also.
Part -2 : Employer‟s Requirements 86

13.8. High voltage distribution system (HVDS)

1.00 HVDS system shall be used in following three situations:

a. To provide LT power supply to remote/farthest locations particularly in hilly areas or

farthest location in newly developed plain areas. In this case entire work of erecting 11 kV
lines, providing Distribution Transformers shall be executed. While executing HVDS scheme,
extreme care to be taken to estimate loading on distribution transformer as capacity of
distribution transformer shall be between5Kva, 10 KVA to 25 KVA.(with prior approval
63kva DT may installed)

b. In areas where length of LT line is more than 300 meters causing line losses and in theft
prone areas where unauthorized hooking is observed, HVDS is recommended. Existing LT
line supports shall be used for erection of 11 kV lines.

c. To provide dedicated distribution transformer at location of agriculture pump (for maximum

two pumps) connections by either extending 11kV new line or by converting existing LT
lines to 11 kV line.

2.00 Survey of 11 kV line:

Mapping of route of proposed new HVDS system or conversion of LT line to 11 kV line by

foot survey in rural/urban areas be performed mentioning various milestones. While
surveying, existing electrical infrastructure in the locality should also be mapped. Line
alignment (single line diagram) on political map with fair correctness, be prepared. SLD and
foot survey report shall be approved by Project Manager and shall be used as basic
document for assessment of works under the contract. On completion of line work, as built
Single Line Diagram and pole wise line diagram showing pole wise materials used and pole-
to-pole span should be submitted to Project Manager. This details shall be used as reference
documents by Quality Inspecting officials to execute inspection works.

3.00 Survey of Distribution Transformer Substations:

A detailed survey of existing habitation shall be performed in presentable document

showing population residing in the un-electrified area/existing electrified area of habitation,
best location of installation of a new distribution transformer substation and the capacity of
transformers to be selected for installation. The capacity of DTR shall be governed by
following technical aspects:

a) Optimistic lengths of service lines needed to feed the beneficiaries,

b) Space available for installation of support/transformers,
Part -2 : Employer‟s Requirements 87

c) Probable load expected to come on the transformer due to existing BPL beneficiaries /others
connected /un-connected probable beneficiaries in the locality taking care of their expected
load growth in next 5 years.
d) Distribution Transformers of capacity 16 KVA to 25 KVA (single phase as well as three phase
as per detailed given) shall be installed on double pole structures. Hence, three phase
11 KV lines shall be laid for 16 KVA to 25 KVA (single phase as well as three phase)
capacity sub-stations. Single phase 11 KV lines (2-wire) shall only be permitted for 10 KVA
single phase transformers mounted on single pole structure. However, V-cross arms and top
clamp shall be used on each line support so that whenever needed, this 2-wire line may be
converted to 3-phase 11 kV line by erecting an additional conductor.
e) Double pole support steel structures for 16 KVA and 25 KVA distribution transformers
shall be designed in such a way that they can be augmented to 63 KVA transformer
structures without any addition in near future on technical requirements.
f) Single phase 10 KVA distribution transformer shall be installed on single pole structure.

Based on survey report, Project Manager shall decide type, capacity and location of
Distribution Transformer sub-station.

4.00 Existing LT infrastructure:

Existing LT lines‟ conductor and fittings shall be dismantled. Tilted supports, if any, shall
be straightened. Poles erected in water logging areas or loose soil areas shall be provided with
cement concrete foundation.

5.00 Mid span support:

Requirement of mid span pole with all fittings, to suit 11 kV line conductor shall be
examined during survey. Project Manager shall approve requirement of mid span poles and
extra concreting on existing poles.

While deciding mid span poles, project manager shall decide type and length of poles
matching with existing supports available in the field. Stay set wherever required in existing
line to be converted may be provided.

6.00 Support for conversion of existing LT line into 11 KV overhead line and for new 11 kV
line:

a) m/200 kgs PSC Poles - (PSC Pole as per GUJARAT state practice)
b) 13 m long H-Beam 150x150 mm, 34.6 kg/mtr
c) 11 m long H-Beam 116x100 mm, 23 kg/mtr
d) 9 m long H-Beam 116x100 mm, 23 kg/mtr
Part -2 : Employer‟s Requirements 88

7.00 Fabricated steel items:

Fabricated steel items like DC cross arm (100x50x6 mm), back clamps (65x8 mm), pole clamp
(65x8 mm), DO mounting channel (100x50x6 mm), transformer mounting channel (100x50x6
mm), transformer clamping set (50x50x6 mm), transformer belting set (50x50x6 mm), V
cross arm, top clamp, DC cross arm, bracket, clamps, cross bracings, bracings, strain
plate, guarding channels, back clamp, transformer mounting structure etc shall be made
of MS Channels, MS angle, MS flats as per approved drawings.

While fabricating, good quality electric cutting tools and drill machine shall be used to
ensure no sharp edges and perfect holes as per approved drawings. Gas cutting set should
not be used for fabrication of MS steel items. Weld material shall be distributed equally
between the two materials that were joined. The weld shall be free of waste materials such
as slag. The weld surface should not have any irregularities or any porous holes (called
porosity). The joint shall be tight. Most welds need to demonstrate the required strength.
One way to ensure proper strength is to start with a filler metal and electrode rating that is
higher than your strength requirement.

Fabricated steel structure items shall be hot dip galvanized and cleaned till good surface finish.
The minimum coating of the zinc shall comply with IS: 2629 and IS: 2633 (with latest
amendments). Galvanizing shall be checked and tested in accordance with IS: 2633. Items
shall be offered for inspection and approval by Project Manager.

8.00 Hardware:

MS Nuts, bolts and washers (Galvanized) – 16 mm dia nuts, bolts & washers shall be used for
tying of overhead structure items like cross arms, top clamps, brackets, clamps, bracing, strain
plates etc.

While erecting, proper dimensions of nut-bolts and washers must be ensured. 2 to 3 threads
only be visible of the bolt after full tightening of nut on requisite torque. The hardware shall
be hot dip galvanized. The minimum coating of the zinc shall comply with IS: 2629 and IS:
2633. Galvanizing shall be checked and tested in accordance with IS: 2633. Before shifting
Part -2 : Employer‟s Requirements 89

them to site for erection, they shall be offered for inspection and approval by Project
Manager.

9.00 Stay Set:

Galvanized Stay Set with 50x8 mm stay clamp, guy insulator (1No.), anchor plate
(200x200x6mm) , nut-bolts, 2 Nos turn-buckles, 1.8 m long, 16 mm diameter solid GS stay
rod & 7/3.15 mm dia GI stranded wire complete.

Stay set shall be used at all sub-station location to nullify the tension of
conductor/cable/transformer on the supports. 0.2 cmt cement concreting in mixture 1 part
cement, 2 part coarse sand and 4 part 40mm size aggregate stone chips (1:2:4) shall be
provided in the foundation of the stay set. 2 Nos. guy insulator shall be provided in 7/3.15
mm dia stranded GI wire at middle locations between two turn buckles. Erection of storm
guys at suitable location in straight line may also be provided.

10.00 Distribution Transformer:

Following type and sizes of minimum 3 star rated {as per Bureau of Energy Efficiency
(BEE)}, distribution transformers with all accessories are standardized in the project under
HVDS:

a) 5/6 KVA 1 phase Aluminium / Copper wound DTR

b) 10 KVA 1 phase / 3 phase Aluminium / Copper wound DTR
c) 16 KVA 1 phase / 3 phase Aluminium / Copper wound DTR
d) 25 KVA 1 phase / 3 phase Aluminium / Copper wound DTR
e) 63 KVA 3 phase Aluminium / Copper wound DTR
f) 100 KVA 3 phase Aluminium / Copper wound DTR
g) 200 KVA 3 phase Aluminium / Copper wound DTR
h) 250 KVA 3 phase Aluminium / Copper wound DTR
i) 500 KVA 3 phase Aluminium / copper wound DTR
Or any other rating as per latest Indian Standard Specification

The Distribution Transformers shall be 11/0.4 KV or 11KV/230 V or 22/0.44 KV non- sealed

type BEE specified minimum 3 Star Distribution Transformers. The transformers shall be
double wound, three phase, CRGO M3 Grade (0.23mm) or better. The core shall be
constructed from high grade, non-ageing, Cold Rolled Grain Oriented (CRGO) silicon steel
of M3 Grade (0.23mm) laminations only. PRIME CORE M3 Grade (0.23mm) materials are
to be used for transformers core.
Part -2 : Employer‟s Requirements 90

Distribution Transformers shall be subject to inspection during manufacturing (stage

inspection), pre-delivery inspection, and inspection at site during pre-erection/post
erection/post commissioning conditions. Project Manager shall select samples from the core
laminations and get the same tested in CPRI/ NABL Accredited laboratory to prove the
quality of the core material at any time during pre-dispatch instruction/inspection at site etc.

The distribution transformers shall be supplied with transformer oil filled up-to maximum
permissible level and all accessories viz. breather with silica gel etc.

The distribution transformers must have been successfully type tested within five years
from date of Letter of Intent and the designs should have been in satisfactory operation for a
period not less than two years as on the date of bid opening. Compliance shall be demonstrated
by submitting, (i) authenticated copies of the type test reports and (ii) performance certificates
from the users, specifically from Central Govt./State Govt. or their undertakings.

3 STAR LEVEL: Each Distribution Transformers must contain minimum 3 Star Label with
style and information provided by the Bureau of Energy Efficiency (B.E.E), Ministry of
Power, Government of India.

The losses in Distribution Transformer should be as per Energy Efficiency Level-2 and
above as specified in IS 1180 (Part-1):2014 for all kVA ratings of distribution
transformers

Bimetallic clamps of suitable capacities and size are to be provided on LT side and on HT
side of the transformer.

T-Clamps should be provided on each jumper on bus bars. Line jumpers should be provided
with adequate size of PG Clamps (Two numbers PG Clamps at each end of jumper). Clamp
should be made of aluminum grade T-1F as per IS-8309 having good electrical quality
aluminum material and should not be brittle in nature.

Transformers should be tested for pre-commissioning checks which includes Insulation

Resistance Test, ratio test and oil breakdown voltage test. Before formal energisation, oil
leakages from the parts of the transformer, oil level in conservator tank, condition of silica
gel, earth connection (two separate) between neutral and earthing, proper jointing of earth
wires/flats at the joints and earth resistance of the individual earthing pits are to be checked
and recorded. On commissioning of the transformer, phase current and phase to phase voltage,
phase to neutral voltage are to be recorded. The loading on the transformers should
Part -2 : Employer‟s Requirements 91

be balanced. The quantum of neutral current flowing through neutral shall be recorded. A
record of pre-commissioning checks/tests are to be prepared and submitted to the Project
Manager.

11.00 ACSR / AAAC Conductor:

ACSR raccoon conductor (or equivalent AAAC conductor) is to be used for connection
between overhead lines to transformer studs/bushing. All road crossings and line crossings
shall be guarded as per specifications. Conductor joint should not be provided in mid span
length. Instead, it should be nearer to the support.

12.00 11 KV AB Switch:

11 kV, 3-ph, 400 A, 3 Pin type, Vertical/Horizontal Mounting type, Gang Operated, AB
Switch shall be installed at cut points and at suitable locations as per instructions of Project
Manager. B Class GI pipe shall be used (without any joints) for operation of switch. AB
Switch structure and handle must be earthed using 8 SWG GI wire.

13.00 Distribution box and Power Cabling:

Distribution boxes are to be installed as per specifications enclosed. The boxes are to be
erected, electrically connected with the existing system, properly earthed, and labeled. The
test report of pre-commissioning checks should be prepared and submitted.

The distribution boxes are to be earthed using 8 SWG GI wire direct connection to the
earthing. 2 Nos Earthing bolts on the distribution box should be provided of 10mm dia.

The single core power cables should be terminated with proper size lugs and gland. Necessary
tagging, identification of cores and dressing of cables with nylon cable ties shall be in the
scope of work. The unutilized holes in the DBs provided for cable entry needs to be plugged
properly in a manner that it must stop access to reptiles, dust and water ingress.

The Low Tension bus bars are to be painted with two or more coats of brush-able epoxy
compound suitable to insulate the bus bars for 415 volts exposure.

The distribution box should also house three phase tri-vector energy meter / single phase
meter depending on capacity and type of distribution transformer as per specifications.

The single core un-armored power cables shall be used for connection from Distribution
Transformer to Distribution Box and Distribution Box to Outgoing LT lines. Cable should
Part -2 : Employer‟s Requirements 92

not be used in underground laying arrangement. Cables should be dressed & tied properly
using clamps /cable ties at 1 meter intervals and tied with substation structure/poles. At-
least one meter cable is to be kept as spare at the individual ends.

Following arrangements shall be made for LT Distribution Transformers and LT Cables:

No Type of Incomer Outgoing Cable

DTR MCB/Isolator HRC fuse MCCB 1 2
1 5/6/10 KVA 45A SPN 2x32A SP 1Cx16 sqmm UA
1 Ph MCCB MCCB
2 16 KVA 1 80A SPN 2x50A SP 1Cx16 sqmm UA
Ph MCCB MCCB
3 16 KVA 3 25A TPN 6x16A SP 1Cx16 sqmm UA
Ph MCCB MCCB
4 25 KVA 1 40A SPN 3x25A SP 1Cx35 sqmm UA
Ph MCCB MCCB
5 25 KVA 3 40A TPN 6x25A SP 1Cx35 sqmm UA
Ph MCCB MCCB
6 63 KVA 3 200A TPN 100 A 6x60A SP 1Cx50/70 1Cx70
Ph Isolator MCCB sqmm UA sqmm UA
7 100 KVA 3 200A TPN 160 A 6x90A SP 1Cx50/70 1Cx150
Ph Isolator MCCB sqmm UA sqmm UA
8 200 KVA 3 600A TPN 315 A 9x120A SP 1Cx150 1Cx300
Ph Isolator MCCB sqmm UA sqmm UA
9 315 KVA 3 600A TPN 500 A 12X120A SP 1CX150 1CX300
Ph Isolator MCCB sqmm UA sqmm UA

1.1 KV XLPE Aluminium Conductor, Stranded, un-armored cable be used for connection
of transformer LV bushing to Distribution Box and Distribution box to overhead line.

14.00 Earthing:

Distribution Transformer Earthing shall be provided with 3 Nos earthing and making earth
mat /risers using 50X6mm GI Flat. Earthing should be provided with GI earth pipe or
Chemical Earthing depending of strata of soil in the location. Project Manager shall decide
the type of earthing.

25x3mm GI Flat and 8 SWG GI wire shall be used for making earthing connection to
various sub-station equipment as per given details. GI Flat and GI wire shall be properly
dressed, bunched and clamped with the support at 2 feet intervals. An overlapping of 35mm
Part -2 : Employer‟s Requirements 93

shall be used at the place of flat to flat joint. Two sets of GI nuts, bolts and washers shall be
used for flat-to-flat joints. GI nuts, bolts and washers must be used for GI Flat–to-GI wire &
GI wire-to-GI wire joints.

Substation wise measurement of earth resistance of earth pits / mesh and corresponding
drawing of existing earthing arrangement shall be recorded and submitted to Project Manager.

Description of equipment Earth connection

Earthing pits 3 Nos. Earth Pipe 3 m long, 40 mm dia
or Chemical Earthing
Earth mat and riser 50X6 mm GI Flat / 8 SWG GI wire
Laying of earth mat Below ground 0.5 meter

Standard requirements of earthing shall be as under:

a) Earth Pit – 1 for Transformer Neutral,
b) Earth pit - 2 for Lightening Arrester,
c) Earth pit – 3 for Equipment body earthing.

Following arrangement is envisaged for various equipment of distribution transformer

substation:
a) Transformer Neutral (Two distinct connections) : GS Flat 25X3mm
b) Transformer Body : GS Flat 25X3mm
c) Lightning Arrester : GS Flat 25X3mm
d) Fencing (Wherever required) : GI wire 8 SWG
e) LT Distribution-cum-meter Box (Two distinct connections) : GI wire 8 SWG
f) Steel structure of substation : GI wire 8 SWG

The location of earth pits should be at-least 3m apart, so that they their earth conductive
areas do not overlap. In rocky soil where getting required earth resistance is a challenge,
chemical rod earthing shall be used in place of normal GI pipe type earthing. Project
Manager shall decide type of earthing pits.

15.00 Insulator and hardware –

11 KV polymer/porcelain Disc/Pin insulator with suitable hardware fittings shall be used.

Insulator should be tied properly using binding wire/helical form fitting. Bi-metallic clamps
must be used at terminals.
Part -2 : Employer‟s Requirements 94

The individual insulator shall be checked for insulation resistance before overhead line
installation. Insulator should properly be cleaned before installation. No damage/crack
insulator should be used.

16.00 Substation numbering:

Each Substation should be numbered properly labelled using yellow base and black indication
marks (number or digits). 40/50 mm height digits/words should be used for this purpose. Base
shall be made using 2 or more coats of yellow enamel paint till good surface finish. Base
preparation shall be completed before shifting of poles to site for erection. Base painting and
marking of digits should be performed by a skilled and trained painter using branded enamel
paint, Project Manager shall approve type and brand of enamel paint.

17.00 Anti-climbing device:

2 kgs, 2.5mm dia (12 SWG) galvanized barbed wire shall be used on each sub-station support.
Galvanized barbed wire should be properly dressed and crimped at termination. While
wrapping the wire on support, proper tension should be maintained.

18.00 Danger board:

Each support should be provided with a danger board with pole clamps as per approved
drawing. Danger board should be in bi-lingual languages (local language and English). Clamp
for danger board, nut-bolts and washers shall be painted with two or more coats of red-oxide
and aluminium paints respectively till smooth surface before installation.

19.00 Support foundation:

Cement concrete in mixture 1 part cement, 2 part coarse sand, 4 part 40 mm size aggregate
stone chips (1:2:4) shall be used in PCC Pole, steel tubular poles and H-Beam support
foundation.

While erecting supports (poles), shuttering must be used for concreting so that proper
quantity of cement concrete mixture be used and assessed during inspection. During
concreting proper compaction by means of mobile vibrator be provided. While starting work
of support erection, gang wise shutting and mobile vibrator shall be offered for inspection to
Project Manager. While erecting support, mercury level gauge must be used to ensure
vertical erection of support.
Part -2 : Employer‟s Requirements 95

250mm dia X 12” inch size muffing shall be provided on steel tubular and H-Beam poles to
prevent direct entry of rain water along the poles. Cement Concrete of 1:2:4 (1 part Cement,
2 parts coarse sand and 4 parts 20mm aggregate stones chips) shall be used for individual
poles.

Steel plate shall be used in steel tubular poles and cement concrete reinforced plate shall be
used as base plate for PCC poles.

20.00 11 KV Drop Out Fuses:

11 kV, 3-ph, Drop Out fuse units (set of 3 units) along with Support Insulators, Base Channel,
fuse barrel etc. shall be used for all capacity Distribution Transformer Substations. DO Fuse
structure shall be earthed using 8 SWG GI wire.

21.00 Lighting Arrester:

Distribution Class LAs shall be provided in the sub-station with base steel structure, terminals
bi – metallic connectors / PG clamps and earth connectors. LAs are to be connected
with separate earth connection. 25x3 mm GI flat shall be used for earth connection.
Part -2 : Employer‟s Requirements 96

13.9. Civil Works And Soil Investigation

1.00 General

The provisions of this section of specification shall only be applicable to the extent of scope of
works indicated in Bid Proposal Sheet (BPS). The intent of specification covers the following:

Design, engineering, and construction of all civil works at power sub-station, 66 kV line, 33 kV line,
11 kV line, DTR substation, LT line, HVDS, augmentation/renovation of system etc. All civil works
shall also satisfy the general technical requirements specified in other Sections of this Specification
and as detailed below. They shall be designed to the required service conditions/loads as specified
elsewhere in this Specification or implied as per National/ International Standards.

All civil works shall be carried out as per applicable Indian Laws, Standards and Codes. All
materials shall be of best quality conforming to relevant Indian Standards and Codes.

The Contractor shall furnish all design, drawings, labour, tools, equipment, materials, temporary
works, constructional plant and machinery, fuel supply, transportation and all other incidental items
not shown or specified but as may be required for complete performance of the Works in accordance
with approved drawings, specifications and direction of Employer.

The work shall be carried out according to the design/drawings to be developed by the Contractor
and approved by the Project Manager based on Tender Drawings Supplied to the Contractor by the
Project Manager and Original Equipment Manufacturer recommendation. For all buildings,
structures, foundations etc. necessary layout and details shall be developed by the Contractor
keeping in view the functional requirement of the substation facilities and providing enough space and
access for operation, use and maintenance based on the input provided by the Project Manager. Certain
minimum requirements are indicated in this specification for guidance purposes only.

In case of R&M of existing substations, Contactor shall visit site to ascertain the amount of repair
and strengthening of structures and foundations, dismantling and new construction of structures and
foundations works are to be done before quoting. Contractor must furnish the design and drawings in
support of the activities mentioned above that are to be carried out in the R&M of existing substation
site.

The rate quoted by the bidder for all type of civil work shall be firm irrespective of the type of
terrain and depth of filling.
Part -2 : Employer‟s Requirements 97

This specification covers all the work required for detailed soil investigation and preparation of a
detailed report. The work shall include mobilisation of necessary equipment, providing necessary
engineering supervision and technical personnel, skilled and unskilled labour etc. as required to
carry out field investigation as well as, laboratory investigation, analysis and interpretation of data
and results, preparation of detailed Geo-technical report including specific recommendations for the
type of foundations and the allowable safe bearing capacity for different sizes of foundations at
different founding strata for the various structures of the substation. The Contractor shall make his
own arrangement for locating the co-ordinates and various test positions in field as per the information
supplied to him and also for determining the reduced level of these locations with respect to the
benchmark indicated by the Project Manager.

All the work shall be carried out as per latest edition of the corresponding Indian Standard Codes.

a. Geotechnical Investigation

The Contractor shall perform a detailed soil investigation to arrive at sufficiently accurate, general as
well as specific information about the soil profile and the necessary soil parameters of the site. So
that the foundation of the various structures can be designed and constructed safely and rationally.

A report to the effect will be submitted by the Contractor for Project Manager‟s specific approval
giving details regarding data proposed to be utilised for civil structures design.

The Contractor should visit the site to ascertain the soil parameters before submitting the bid. The
topography is uneven steeply sloping at few places requiring cutting and filling operations including
slope stability and protection measures (if slopes encountered). Any variation in soil data shall not
constitute a valid reason for any additional cost & shall not affect the terms & condition of the
Contract. Tests must be conducted under all the critical locations i.e. Control Room Building. Tower
locations, transformer etc.

b. Bore Holes

Drilling of bore holes of 150 mm dia. in accordance with the provisions of IS: upto 10 m depth or to
refusal which ever occur earlier. (By refusal it shall mean that a standard penetration blow count (N)
of 100 is recorded for 30 cm penetration). For a new substation, minimum three (3) bore holes shall
be done to find out the geological profile of the area. If any unconformity encountered then more
bore holes shall be drilled with the approval of Project Manager for the new projects. However in
case deep pile foundations are envisaged the depths have to be regulated as per codal provisions. In
Part -2 : Employer‟s Requirements 98

cases where rock is encountered, coring in one borehole per bay shall be carried out to 1.5 M in
bedrock and continuous core recovery is achieved.

Performing Standard Penetration Tests at approximately 1.5 m interval in the borehole starting from
1.5 m below ground level onwards and at every change of stratum. The disturbed samples from the
standard penetrometer shall also be collected for necessary tests.

Collecting undisturbed samples of 100/75 mm diameter 450 mm long from the boreholes at intervals
of 2.5 m and every change of stratum starting from 1.0 m below ground level onwards in clayey strata.

The depth of Water table shall be recorded in each borehole.

All samples, both disturbed and undisturbed, shall be identified properly with the borehole number
and depth from which they have been taken.

The sample shall be sealed at both ends of the sampling tubes with wax immediately after the sampling
and shall be packed properly and transported to the Contractor’slaboratory without any damage or
loss.

The logging of the boreholes shall be compiled immediately after the boring is completed and a copy
of the bore log shall be handed over to the Project Manager.

c. Electrical Resistivity Test

This test shall be conducted to determine the Electrical resistivity of soil required for designing safe
grounding system for the entire station area. The specifications for the equipments and other
accessories required for performing electrical resistivity test, the test procedure, and reporting of
field observations shall confirm to IS: 3043. The test shall be conducted using Wagner‟s four electrode
method as specified in IS: 1892, Appendix-B2. Unless otherwise specified at each test location, the
test shall be conducted along two perpendicular lines parallel to the coordinate axis. On each line a
minimum of 8 to 10 readings shall be taken by changing the spacing of the electrodes from an
initial small value of 0.5 m upto a distance of 10.0 m.

d. Water Sample

Representative samples of ground water shall be taken when ground water is first encountered before
the addition of water to aid drilling of boreholes. The samples shall be of sufficient quantity for
chemical analysis to be carried out and shall be stored in airtight containers.
Part -2 : Employer‟s Requirements 99

e. Back Filling of Bore Holes

On completion of each hole, the Contractor shall backfill all bore holes as directed by the Project
Manager. The backfill material can be the excavated material and shall be compacted properly.

f. Laboratory Test

1. The laboratory tests shall be carried out progressively during the field work after sufficient
number of samples have reached the laboratory in order that the test results of the initial bore holes
can be made use of in planning the later stages of the field investigation and quantum of laboratory
tests.

2. All samples brought from field, whether disturbed or undisturbed shall be extracted/prepared
and examined by competent technical personnel, and the test shall be carried out as per the
procedures laid out in the relevant I.S. Codes.

The following laboratory tests shall be carried out

a) Visual and Engineering Classification

b) Liquid limit, plastic limit and shrinkage limit for C-
c) Natural moisture content, bulk density and specific gravity.
d) Grain size distribution.
e) Swell pressure and free swell index determination for expensive soil only.
f) Consolidated un-drained test with pore pressure measurement.
g) Chemical tests on soil and water to determine the carbonates, sulphates, nitrates, chlorides, Ph
value, and organic matter and any other chemical harmful to the concrete foundation.
h) C.B.R value
i) Rock quality designation (RQD), RMR in case of rock is encountered

2.00Test Results and Reports

1. The Contractor shall submit the detailed report in two (2) copies wherein information regarding
the geological detail of the site, summarized observations and test data, bore logs, and conclusions and
recommendations on the type of foundations with supporting calculations for the recommendations.
Initially the report shall be submitted by the Contractor in draft form and after the draft report is
approved, the final report in two (3) copies shall be submitted. The test data shall bear the signatures
of the Investigation Agency, Vendor and also site representative of Employer.

2. The report shall include but not limited to the following:

Part -2 : Employer‟s Requirements 100

i.A plan showing the locations of the exploration work i.e. bore holes, dynamic cone penetration tests
etc.

ii.Bore Logs: Bore logs of each bore holes clearly identifying the stratification and the type of soil
stratum with depth. The values of Standard Penetration Test (SPT) at the depths where the tests were
conducted on the samples collected at various depths shall be clearly shown against that particular
stratum.

Test results of field and laboratory tests shall be summarised strata wise as well in combined tabular
form. All relevant graphs, charts tables, diagrams and photographs, if any, shall be submitted along
with report. Sample illustrative reference calculations for settlement, bearing capacity, pile capacity
shall be enclosed.

a. Recommendations: The report should contain specific recommendations for the type of
foundation for the various structures envisaged at site. The Contractor shall acquaint himself about
the type of structures and their functions from the Project Manager. The observations and
recommendations shall include but not limited to the following:

i.Geological formation of the area, past observations or historical data, if available, for the area and
for the structures in the nearby area, fluctuations of water table etc. Slope stability characteristics and
landslide history of the area shall be specifically highlighted. Remedial measures to be adopted shall
also be given.

ii.Recommended type of foundations for various structures. If piles are recommended the type, size
and capacity of pile and groups of piles shall be given after comparing different types and sizes of
piles and pile groups.

iii. Allowable bearing pressure on the soil at various depths for different sizes of the foundations based
on shear strength and settlement characteristics of soil with supporting calculations. Minimum factor
of safety for calculating net safe bearing capacity shall be taken as 3.0 (three). Recommendation of
liquefaction characteristics of soil shall be provided.

iv.Recommendations regarding slope of excavations and dewatering schemes, if required. Required

protection measures for slope stability for cut & fill slopes of switchyard and approach road with
stone pitching/retaining walls shall be clearly spelt out. Calculation shall also be provided for
stability adequacy.

v.Comments on the Chemical nature of soil and ground water with due regard to deleterious effects of
the same on concrete and steel and recommendations for protective measures.
Part -2 : Employer‟s Requirements 101

vi.If expansive soil is met with, recommendations on removal or retaining the same under the
structure, road, drains, etc. shall be given. In the latter case detailed specification of any special
treatment required including specification or materials to be used, construction method, equipment to
be deployed etc. shall be furnished. Illustrative diagram of a symbolic foundation showing details shall
be furnished.

vii.Recommendations for additional investigations beyond the scope of the present work, if considered
such investigation as necessary.

3.00 Site Preparation

The Employer shall be responsible for proper leveling of switchyard site as per layout and levels of
switchyard finalised during detailed engineering stage. The Employer at his own cost shall make the
layout and levels of all structure etc from the general grids of the plot and benchmarks set and approved
by the Project Manager. The Contractor shall give all help in instruments, materials and personnel to
the Project Manager for checking the detailed layout and shall be solely responsible for the correctness
of the layout and levels. Site leveling shall be in the scope of the Employer. Bidder may decide the
level of the sites. However, the level shall be such that it is 300 mm higher than the highest flood level
(HFL) of the site. If HFL is not available, then nearby road level shall be assumed as HFL.

Whenever for bay extension works the existing substation are to be modified or strengthen,
contractor should keep same as EGL of existing sub-station so that FFL shall be same for both and
all the necessary arrangements are to be carried out in this regard by the contractor.

This clause covers the design and execution of the work for site preparation, such
as clearing of the site, the supply and compaction of fill material, slope protection by stone
pitching/retaining walls depending on the site location & condition, excavation and compaction of
backfill for foundation, road construction, drainage, trenches and final topping by brick soling/stone
filling.

1) The Employer shall develop the site area to meet the requirement of the intended purpose. The
site preparation shall conform to the requirements of relevant sections of this specification or as per
stipulations of standard specifications. Employer shall also carry out necessary protection of slope of
switchyard area and approach road.

2) The fill material if required shall be suitable for the above requirement. The fill shall be such
material and the site so designed as to prevent the erosion by wind and water of material from its
final compacted position or the in-site position of undisturbed soil.
Part -2 : Employer‟s Requirements 102

3) Material unsuitable for founding of foundations shall be removed and replaced by suitable fill
material and to be approved by the Project Manager.

4) Backfill material around foundations or other works shall be suitable for the purpose for
which it is used and compacted to the density described under Compaction. Excavated material not
suitable or not required for backfill shall be disposed off in areas as directed by Project Manager
upto a maximum lead of 1 km.

a. Excavation and backfill

1. Excavation and backfill for foundations shall be in accordance with the relevant code.

2. Whenever water table is met during the excavation, it shall be dewatered and water table shall
be maintained below the bottom of the excavation level during excavation, concreting and
backfilling.

3. When embankments are to be constructed on slopes of 15% or greater, benches or steps with
horizontal and vertical faces shall be cut in the original slope prior to placement of embankment
material. Vertical faces shall measure not more than 1 m in height.

4. Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be
constructed by compacting the material in successive uniform horizontal layers not exceeding 20 cm
in thickness (of loose material before compaction). Each layer shall be compacted as required by means
of mechanical tampers approved by the Project Manager. Rocks larger than 10 cm in any direction
shall not be placed in embankment adjacent to structures.

5. Earth embankments of roadways and site areas adjacent to buildings shall be placed in
successive uniform horizontal layers not exceeding 20 cm in thickness in loose stage measurement and
compacted to the full width specified. The upper surface of the embankment shall be shaped so as to
provide complete drainage of surface water at all times.

6. The land required for borrowing earth shall be arranged & selected by contractor. The
identified land shall be got approved by Project Manager. The quoted rates shall include cost of
earth, taxes, duties, royalty, compensation for the land identified for borrow earth. The rate shall also
be inclusive of all leads, lifts, ascent, descent and testing required for completion of work in all respect.

7. The ground levels for all measurements shall be taken at every 5 meter distance in uniformly
sloping ground and at closer distance where pits/undulations are met with. In fairly leveled area,
Part -2 : Employer‟s Requirements 103

levels shall be taken at 15 mt. apart at the discretion of Project Manager. The ground levels shall be
recorded and plotted on plans. The same shall be recorded by Project Manager before the earth work
is started. All labor, material, tool, equipment etc required for the above work shall be arranged by
the Employer at his own cost.

b. Compaction

1. The density to which fill materials shall be compacted shall be as per relevant IS and as per
direction of Project Manager. All compacted sand filling shall be confined as far as practicable.
Backfilled earth shall be compacted to minimum 95% of the Standard Proctor‟s density at OMC.
The sub-grade for the roads and embankment filling shall be compacted to minimum 95% of the
Standard Proctor‟s density at OMC. Cohesion less material sub grade shall be compacted to 70%
relative density (minimum).

2. At all times unfinished construction shall have adequate drainage. Upon completion of the road‟s
surface course, adjacent shoulders shall be given a final shaping, true alignment and grade.

3. Each layer of earth embankment when compacted shall be as close to optimum moisture content
as practicable. Embankment material, which does not contain sufficient moisture to obtain proper
compaction, shall be wetted. If the material contains any excess moisture, then it shall be allowed to
dry before rolling. The rolling shall begin at the edges overlapping half the width of the roller each
time and progress to the center of the road or towards the building as applicable. Rolling will also be
required on rock fills. No compaction shall be carried out in rainy weather.

c. Requirement for fill material under foundation

All foundations shall rest below virgin ground level and the minimum depth of foundation below
the virgin ground level shall be at least 500 mm. For small equipment and minor foundations like
marshalling kiosk, Switch board stand, earth switch and main box support etc. may be reduced to
300 mm with specific approval of the Project Manager.

4.00 Stone Filling & Antiweed Treatment

The Contractor shall furnish all labour, equipment and materials required for complete performance
of the work in accordance with the drawings, specification and direction of the Project Manager.

Stone filling shall be done in the areas of the switchyard wherever equipment and or structures are
to be provided under present scope of work covering entire fencing area.
Part -2 : Employer‟s Requirements 104

Prevailing practice of stone filling is to be adopted for the bay extension works of existing
substations. Contractor shall verify the existing practice prevailing at site before quoting.

Before taking up stone rolling, antiweed treatment shall be applied in the switchyard area where stone
filling is to be done and the area shall be thoroughly de-weeded including removal of the roots. The
recommendation of local agriculture/horticulture department shall be sought where ever feasible while
choosing the type of chemical to be used. Nevertheless the effectiveness of chemical shall be
demonstrated by the contractor in a test area of size 10 meterx 10 meter (approx..). The final
approval based on the result shall be given by Project Manager. Antiweed treatment shall be
procured from reputed manufacturer. The dosage and application of chemical shall be strictly as per
the manufacturer‟s recommendation. The contractor shall be requested to maintain the area free of
weed for a period of one year from the date of application of the first dose of the chemical.

5.00 General Requirement

a. The material required for site surfacing shall be free from all types of organic materials and
shall be of standard quality, and as approved by the Project Manager.

The material to be used for stone filling/ site surfacing shall be uncrushed/ crushed/ broken stone of
20 mm nominal size (single sized) conforming to table 2 of IS: 383- 1970. Hardness, flakiness shall
be as required for wearing courses are given below.

(a) Sieve analysis limits/Gradation

Sieve size % passing by weight

40mm 100
20mm 85-100
10mm 0-20
4.75mm 0-5

(b) Hardness
Abrasion value (IS: 2386 part-IV) not more than 40%
Impact value (IS: 2386 part-IV) not more than 30%

(c) Flakiness Index

As per (IS: 2386 part-IV) and maximum value is 25.

b. After all the structures/equipment are erected, the surface of the switchyard area shall be
maintained, rolled/compacted to the lines and grades as decided by Project Manager. De-weeding
including removal of roots shall be done before rolling is commenced. Project Manager shall decide
Part -2 : Employer‟s Requirements 105

final formation level so as to ensure that the site appears uniform. The final formation level shall
however be very close to the formation level indicated in the drawing using half-ton roller with
suitable water sprinkling arrangement to form a smooth and compact surface.

c. A base layer of uncrushed/crushed/broken stone of 20 mm nominal size (single sized) shall be

spread and rolled/compacted by using half ton roller with 4 to 5 passes and water sprinkling to form
a minimum 50 mm layer on the finished ground level of the specified switchyard area excluding roads,
drains, cable trench and tower and equipment foundations as indicated in the drawing.

d. Over the base layer of site surfacing material, a final surface course of minimum 50 mm
thickness of 20 mm nominal size (single sized) broken stone as specified above shall be spread and
compacted by light roller using half tones steel roller (width 30" and 24" dia meter) with water
sprinkling as directed by the Project Manager. The water shall be sprinkled in such a way that
bulking does not take place.

e. In areas that are considered by the Project Manager to be too congested with foundations and
structures for proper rolling of the site surfacing material by normal rolling equipment, the material
shall be compacted by hand, if necessary. Due care shall be exercised so as not to damage any
foundation structures or equipment during rolling compaction.

6.00 Site Drainage

a. Adequate site drainage system shall be provided by the Contractor in new and existing
substation. In case of bay extension of existing substation, drainage layout shall be prepared by the
contractor in such away that it should satisfy the technical parameters stated below while designing
the drainage system so that flow of water of the existing part of substation remain uninterrupted and
the same should be approved by the Project Manager. The technical parameters stated below also to
be taken into account while designing the drainage system for new substation as well.

The Contractor shall obtain rainfall data and design the storm water drainage system, (culverts, ditches,
drains etc.) to accommodate run off due to the most intense rainfall that is likely to occur over the
catchments area in one hour period on an average of once in ten years. The surface of the site shall
be sloped to prevent the ponding of water.

b. The maximum velocity for pipe drains and open drains shall be limited to 2.4m/sec and
1.8m/sec respectively. However, minimum non-silting velocity of 0.6m/sec shall be ensured.
Longitudinal bed slope shall not be milder than 1 in 1000.

c. The drains shall be constructed using Brick masonry except at road crossings etc. where RCC
pipe shall be used. The RCC pipe for drains and culverts shall be as per IS:456 and IS:783.
Part -2 : Employer‟s Requirements 106

d. The Contractor shall ensure that water drains are away from the site area and shall prevent
damage to adjacent property by this water. Adequate protection shall be given to site surfaces, roads,
ditches, culverts, etc. to prevent erosion of material by water.

e. The drainage system shall be adequate without the use of cable/pipe trenches. (Pipe drains shall
be provided in areas of switchyard where movement of crane will be necessary in operating phase of
the substation).

f. For pipe drains, concrete pipe of class NP2 shall be used. However, for road crossings etc.
higher strength pipe of class NP3 shall be provided. For rail crossings, pipes conforming to railway
loading standards or at least NP4 class shall be provided. Manholes shall be provided at every 30m
interval, at connection points and at every change of alignment.

g. Open surface drains for new s/s shall be provided with brick masonry in 1:6 (1 cement: 6
coarse sand) cement mortar with 12 mm thick, 1:4 (1 cement: 4 sand) cement plaster inside and
exposed surface of drains as per approved drawing. For bay extension at existing substations,
prevailing practice of the respective substation shall be adopted.

h. Pipe drains shall be connected through manholes at an interval of max. 30m. Effluents shall be
suitably treated by the Contractor to meet all the prevalent statutory requirements and local pollution
control norms and treated effluents shall be conveyed to the storm water drainage system at a
suitable location for its final disposal.

i. Invert of the drainage system shall be decided in such a way that the water can easily be
discharged above the High Flood Level (HFL) outside substation boundary at suitable location upto
a maximum 50M beyond boundary wall of substation or actual whichever occurs earlier and
approved by Project Manager.
j. All internal site drainage system, including the final connection/disposal to Project Manager
acceptance points shall be part of Supplier‟s scope including all required civil works. The Contractor
shall connect his drain(s) at one or more points to outfall points as feasible at site.

k. The drainage scheme and associated drawings shall be got approved and constructed as per
enclosed tender drawing.

7.00 Roads and Culverts inside substation premises

a. The main approach road including modification of existing road to meet the site conditions, roads
for access to equipment and buildings with in substations (including bay extension in existing
substations) are in the scope of the contractor. Layout of the roads shall be based on General detail &
Part -2 : Employer‟s Requirements 107

Arrangement drawing for the substation. If extra road is required for functional point of view, which
has not been mentioned in the layout drawing, Contractor should provide the same without extra cost
to the Project Manager.

b. All substation roads shall be constructed so as to permit transportation of all heavy equipment.
The roads shall have min. 3.0 m wide RCC road as per enclosed tender drawing.

c. Road construction shall be as per IRC standards.

d. Adequate provision shall be made for road drainage. Protection of cut and embankment slopes
of roads as per slope stability requirement shall be made.

e. All the culverts and its allied structure (required for road/rail, drain trench crossings etc.) shall
be designed for class A loading as per IRC standard / IS code and should be checked for loading.

f. All roads shall be designed for class „D‟ of traffic as per IRC-37 Guide-lines for the design of
rigid pavements.

8.00 Transformer Foundation

The Contractor shall provide a road system integrated with the transformer foundation to enable
installation and the replacement of any failed unit by the spare unit located at the site. This system
shall enable the removal of any failed unit from its foundation to the nearest road.

If existing/failed transformer is required to be replaced by new one in augmentation/bay extension

works of existing substations then the foundation supporting that equipment shall be strengthen by
modifying the foundation itself or the foundation shall be dismantle and recast new foundation as per
site conditions. However, contractor must furnish the design calculation incorporating all those
changes so that safety of the structure and foundation remain adequate.

Similarly all types of equipment foundations with /without supporting structures shall be treated in
similar manner as stated for transformer foundations.

Contractor must access the amount of work involve for augmentation/bay extension of existing
substations while quoting.

9.00 Cable & Pipe Trenches

a. The cable trenches and precast removable RCC cover (with lifting arrangement) shall be
constructed using RCC of M20 grade for new substation whereas for bay extension of existing
Part -2 : Employer‟s Requirements 108

substation size and material of cable trenches shall be same as the existing one and pre-cast
removable RCC cover (with lifting arrangement) shall be constructed using RCC of M20 grade.
Cable trenches must be designed for the design criteria stated below, whether it is of concrete or
brick for both new substations and bay extension works in existing substations.

b. The cable trench walls shall be designed for the following loads.

(i) Dead load of 100 kg/m length of cable support + 75 Kg on one tier at the end.
(ii) Triangular earth pressure + uniform surcharge pressure of 1T/m2.

c. Cable trench covers shall be designed for self-weight of top slab + concentrated load of 200 kg
at center of span on each panel.

d. Cable trench crossing the road/rails shall be designed for class A. Loading of IRC/relevant IS
Code and should be checked for transformer loading.

e. Trenches shall be drained. Necessary sumps be constructed and sump pumps if necessary shall
be supplied. Cable trenches shall not be used as storm water drains.

f. The top of trenches shall be kept at least 100 mm above the finished ground level for the new
substation. The top of cable trench shall be such that the surface rainwater does not enter the trench.
g. The top of trench shall be kept same as existing one to maintain uniformity of the cable
trenches structure in case of bay extension works of existing substations.

h. All metal parts inside the trench shall be connected to the earthing system.

i. Cables from trench to equipment shall run in hard conduit pipes.

j. Trench wall shall not foul with the foundation. Suitable clear gap shall be provided.

k. The trench bed shall have a slope of 1/500 along the run & 1/250 perpendicular to the run.

l. Cable trenches shall be blocked at the ends if required with brick masonry in cement sand
mortar 1:6 and plaster with 12mm thick 1:6 cement sand mortar.
m. Cable trench contains cable trey that shall be supported on ISA. The size and spacing of angle
section shall be as per design criteria mentioned above.

n. Cable trench shall be constructed as per enclosed tender drawing.

10.00 Foundation /RCC Construction

Part -2 : Employer‟s Requirements 109

1. Work covered under this Clause of the Specification comprises the design and
construction of foundations and other RCC constructions for switchyard structures, equipment
supports, trenches, drains, control cubicles, bus supports, transformer, marshalling kiosks, auxiliary
equipment & systems, buildings, tanks, boundary wall or for any other equipment or service and any
other foundation required to complete the work. This clause is as well applicable to the other RCC
constructions.

However, for the augmentation/bay extension works of existing substation, type of RCC structures
and foundations etc. shall be similar to one already existing at the existing substation and for which
design shall be furnished in support of safety of those RCC structures and foundations etc.
Contractor must access the amount of work involved for the construction of switchyard structures,
equipment supports, trenches, drains, control cubicles, bus supports, transformer, marshalling kiosks,
auxiliary equipment & systems, buildings, tanks, boundary wall or for any other equipment or
service and any other foundation required to complete the work for the existing substations.

2. Concrete shall conform to the requirements mentioned in IS: 456 and all the tests shall be
conducted as per relevant Indian Standard Codes as mentioned in Standard field quality plan appended
with the specification

A minimum grade for PCC and RCC shall be used for all structural/load-bearing members as per latest
IS 456.

3. If the site is sloppy, the foundation height will be adjusted to maintain the exact level of
the top of structures to compensate such slopes.

4. The switchyard foundation‟s plinths and building plinths shall be minimum 300mm and
500 mm above finished ground level respectively.

5. Minimum 75mm thick lean concrete shall be provided below all underground structures,
foundations, trenches etc. to provide a base for construction.

6. Concrete made with Portland slag cement shall be carefully cured and special importance
shall be given during the placing of concrete and removal of shuttering.

7. The design and detailing of foundations shall be done based on the approved soil data and
sub-soil conditions as well as for all possible critical loads and the combinations thereof. The Spread
footings foundation or pile foundation as may be required based on soil/sub-soil conditions and
superimposed loads shall be provided.
Part -2 : Employer‟s Requirements 110

8. If pile foundations are adopted, the same shall be cast-in-situ driven/bored or precast or
under reamed type as per relevant parts of IS Code 2911. Only RCC piles shall be provided.
Suitability of the adopted pile foundations shall be justified by way of full design calculations.
Detailed design calculations shall be submitted by the bidder showing complete details of piles/pile
groups proposed to be used. Necessary initial load test shall also be carried out by the bidder at their
cost to establish the piles design capacity. Only after the design capacity of piles has been
established, the Contractor shall take up the job of piling. Routine tests for the piles shall also be
conducted. All the work (design & testing) shall be planned in such a way that these shall not cause
any delay in project completion.

a. Design

1. Foundations shall be of reinforced cement concrete for new substation but for the augmentation
/ bay extension works of existing substation it could be of RCC/ PCC depending on type of
structures and materials used for the similar type of structures in those bay extension works of existing
substation. Design requirement shall be fulfilled by the contractor and furnished for approval
for both new substation and existing substation (for bay extension works) as specified in the scope
of work. The design and construction of RCC/ PCC / Masonry structures shall be carried out as per
IS: 456 and relevant IS code/CBIP manual/NBC etc and minimum grade of concrete shall be as per
relevant IS code. Higher grade of concrete than specified above may be used at the discretion of
Contractor without any additional financial implication to the Project Manager.

2. Limit state method of design shall be adopted unless specified otherwise in the specification.

3. For detailing of reinforcement IS: 2502 and SP: 34 shall be followed. Cold twisted deformed bars
(Fe=415 N/mm2) conforming to IS: 1786 shall be used as reinforcement. However, in specific areas,
mild steel (Grade I) conforming to IS: 432 can also be used. Two layers of reinforcement (on inner
and outer face) shall be provided for wall & slab sections having thickness more than 150 mm. Clear
cover to reinforcement towards the earth face shall be minimum 40 mm.

4. RCC water retaining structures like storage tanks, etc. shall be designed as un-cracked section
in accordance with IS: 3370 (Part I to IV) by working stress method. However, water channels shall
be designed as cracked section with limited steel stresses as per IS: 3370 (Part I to IV) by working
stress method.

5. The procedure used for the design of the foundations shall be the most critical loading
combination of the steel structure and or equipment and/or superstructure and other conditions,
which produces the maximum stresses in the foundation or the foundation component and as per the
Part -2 : Employer‟s Requirements 111

relevant IS Codes of foundation design. Detailed design calculations shall be submitted by the bidder
showing complete details of piles/pile groups or isolated /combined footings proposed to be used.

6. Design shall consider any sub-soil water pressure that may be encountered following relevant
standard strictly.

7. Necessary protection to the foundation work, if required shall be provided to take care of any
special requirements for aggressive alkaline soil, black cotton soil or any other type of soil which is
detrimental/harmful to the concrete/masonry foundations.

8. RCC columns /pedestals shall be provided with rigid connection at the base.

9. All sub-structures shall be checked for sliding and overturning stability during both
construction and operating conditions for various combinations of loads. Factors of safety for these
cases shall be taken as mentioned in relevant IS Codes or as stipulated elsewhere in the
Specifications. For checking against overturning, weight of soil vertically above footing shall be
taken and inverted frustum of pyramid of earth on the foundation should not be considered.

10. Earth pressure for all underground structures shall be calculated using co-efficient of earth
pressure at rest, co-efficient of active or passive earth pressure (whichever is applicable).

11. In addition to earth pressure and ground water pressure etc., a surcharge load of 1T/Sq.m shall
also be considered for the design of all underground structures including channels, sumps, tanks,
trenches, substructure of any underground hollow enclosure etc., for the vehicular traffic in the vicinity
of the structure.

12. Following conditions shall be considered for the design of water tank in pumps house,
channels, sumps, trenches and other underground structures:

i.Full water pressure from inside and no earth pressure & ground water pressure & surcharge pressure
from outside (application only to structures, which are liable to be filled up with water or any other
liquid).

ii.Full earth pressure, surcharge pressure and ground water pressure from outside andno water pressure
from inside.

iii.Design shall also be checked against buoyancy due to the ground water during construction and
maintenance stages. Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the
superimposed loadings.
Part -2 : Employer‟s Requirements 112

13. The foundations shall be proportioned so that the estimated total and differential movements of
the foundations are not greater than the movements that the structure or equipment is designed to
accommodate.

14. The foundations of transformer and circuit breaker shall be of block type foundation. Minimum
reinforcement shall be governed by IS: 2974 and IS: 456.

15. The tower and equipment foundations shall be checked for a factor of safety of 2.0 for normal
condition and 1.5 for short circuit condition against sliding, overturning and pullout.

b. Admixtures & additives

1. Only approved admixtures shall be used in the concrete for the Works. When more than one
admixture is to be used, each admixture shall be batched in its own batch and added to the mixing
water separately before discharging into the mixer. Admixtures shall be delivered in suitably labeled
containers to enable identification.

2. Admixtures in concrete shall conform to IS: 9103. The water proofing cement additives shall
conform to IS: 2645. Project Manager shall approve concrete Admixtures/ Additives.

3. The Contractor may propose and the Project Manager may approve the use of a water-reducing
set-retarding admixture in some of the concrete. The use of such an admixture will not be approved
to overcome problems associated with inadequate concrete plant capacity or improperly planned
placing operations and shall only be approved as an aid to overcoming unusual circumstances and
placing conditions.

4. The water-reducing set-retarding admixture shall be an approved brand of Ligno-sulphonate

type admixture.

5. The waterproofing cement additives shall be used as required / advised by the Project Manager.

c. Gates and Boundary Wall

1. The Gate frame shall be made of medium duty MS pipe conforming to relevant IS with welded
joints.

2. The gates shall be fabricated with welded joints to achieve rigid connections. The gate frames
shall be painted with one coat of approved steel primmer and two coats of synthetic enamel paint.
Part -2 : Employer‟s Requirements 113

3. Gates shall be fitted with approved quality iron hinges, latch and latch catch. Latch and latch
catch shall be suitable for attachment and operation of pad lock from either side of gates. Hinges
shall permit gates to swing through 180 degree back against fence. Gates shall be earthed by G I
wire.

4. Gates shall be fitted with galvanized chain hook or gate hold back to hold gates open. Double
gates shall be fitted with centre rest and drop bolt to secure gates in closed position.

5. Gates shall be installed in locations shown on drawings. Next to the main gate, a men gate
(1.25 m wide, single leaf) shall also be provided.

6. Bottom of gates shall be set approximately 40mm above ground surface and necessary guiding
mechanism shall be fitted.

7. The Contractor shall design and construct boundary wall around substation area as per
requirements. The boundary wall shall be of height 2.0M and shall be made of RCC frame
construction with RCC column and plinth beam arrangement and panels filled with one brick thick
wall in cement sand mortar 1:6. The boundary wall shall be plastered on both external and internal
faces with cement and sand plaster 1:6 of thickness 18 mm and 12 mm respectively. An additional
barbed Y-shaped arm of MS angle 50x50x6 with 3-rows (6 nos) barbed wire A-4 IS: 278. Expansion
joints shall be provided as per codal requirements. MS grating shall be provided at required
locations for drainage purposes. The boundary wall shall be painted with minimum two coats of color
wash over a base coat of white wash with lime. The front portion of boundary wall shall however be
with a RC jail and 12 mm square MS bar top above brick work and pebble dash plaster finish with
colour pigment. The steel work shall be given two coats of synthetic enamel paint of approved make
over one coat of primer. Boundry wall and gate shall be constructed as per enclosed tender drawing.

11.00 Buildings - General Requirements

The scope for new control room building includes the design, engineering and construction including
anti-termite treatment, plinth protection, DPC of Building including sanitary, water supply,
electrification, false ceiling etc. of control room building. The buildings shall be of RCC framed
structure of concrete of M20 grade (Min.). Following design criteria shall be adopted for design
purposes for new substation.

If any extension of the Control Room building is required in augmentation / bay extension works of
existing substation then extension part shall be compatible to existing one structurally and
architecturally but following design criteria shall be adopted for design purposes for R&M of
existing substation.
Part -2 : Employer‟s Requirements 114

a. Control room Building

Minimum floor area requirements shall be 10000×12000 mm excluding space for wash room which
may be increased at the time of detailed engineering to suit project requirements. The layout of the
control room shall be finalised as per detailed engineering to suit project requirements .The
minimum dimension of different rooms required for C.R.building shall be as per drawing. The CR
building shall consist of the following:

a. Control room
b. S/s In-charge room
c. Battery room
d. Store room
e. Toilet

An open space of 1 m minimum shall be provided on the periphery of the rows of panel and
equipment generally in order to allow easy operator movement and access as well as maintenance.

Any future possibility of annexe building shall be taken care of while finalizing the layout of the
control room building.

Minimum headroom of 3 M below soffit of beams/false ceiling shall be considered for rooms. The
roof shall have four side sloping roof or flat roof as finalised during detailed engineering.

i. Design

a) The buildings shall be designed:

1. To the requirements of the National Building Code of India, and the standards quoted therein.

2. For the specified climatic & loading conditions.

3. To adequately suit the requirements of the equipment and apparatus contained in the buildings and
in all respects to be compatible with the intended use and occupancy.

4. With a functional and economical space arrangement.

5. For a life expectancy of structure, systems and components not less than that of the equipment,
which is contained in the building, provided regular maintenance is carried out.
Part -2 : Employer‟s Requirements 115

6. Be aesthetically pleasing. Different buildings shall show a uniformity and consistency in

architectural design.

7. To allow for easy access to equipment and maintenance of the equipment.

8. With, wherever required, fire retarding materials for walls, ceilings and doors, which would prevent
supporting or spreading of fire.

9. Suitable expansion joints shall be provided in the longitudinal direction wherever necessary with
provision of twin columns.

10. Individual members of the buildings frame shall be designed for the worst combination of forces
such as bending moment, axial force, shear force, torsion etc.

11. Permissible stresses for different load combinations shall be taken as per relevant IS Codes.

12. The building lighting shall be designed in accordance with the requirements of relevant section.

13. Sesmic considerations as applicable.

ii. Design loads

Building structures shall be designed for the most critical combinations of dead loads, super-
imposed loads, equipment loads, wind loads, seismic loads, and temperature loads.

Dead loads shall include the weight of structures complete with finishes, fixtures and partitions and
should be taken as per IS: 1911.

Super-imposed loads in different areas shall include live loads, minor equipment loads, cable trays,
small pipe racks/hangers and erection, operation and maintenance loads. Equipment loads shall
constitute, if applicable, all load of equipments to be supported on the building frame.

The wind loads shall be computed as per IS 875, Seismic Coefficient method shall be used for the
seismic analysis as per IS 1893 with importance factor 1.5.

Wind and Seismic forces shall not be considered to act simultaneously.

Floors/slabs shall be designed to carry loads imposed by equipment, cables piping, equipment and
other loads associated with building. Floors shall be designed for live loads as per relevant IS. Cable
and piping loads shall also be considered additionally for floors where these loads are expected.
Part -2 : Employer‟s Requirements 116

For consideration of loads on structures, IS: 875 shall strictly adhere to. Any other load coming in
the structure, not mentioned in IS 875 shall be calculated as per relevant IS code and NBC.

iii. Submission

The following information shall be submitted for review and approval to the Project Manager:

1. Design criteria shall comprise the codes and standards used, applicable climatic data including
wind loads, earthquake factors maximum and minimum temperatures applicable to the building
locations, assumptions of dead and live loads, including equipment loads, impact factors, safety factors
and other relevant information.

2. Structural design calculations and drawing (including construction/fabrication) for all

reinforced concrete and structural steel structures.

3. Fully, dimensioned concept plan including floor plans, cross sections, longitudinal sections,
elevations and perspective view of each building. These drawings shall be drawn at a scale not smaller
than 1:75 and shall identify the major building components.

4. Fully dimensioned drawings showing details and sections drawn to scales of sufficient size to
clearly show sizes and configuration of the building components and the relationship between them.

5. Product information of building components and materials, including walls partitions flooring
ceiling, roofing, door and windows and building finishes.

6. A detailed schedule of building finishes including colour schemes.

7. A door & window schedule showing door types and locations, door lock sets and latch sets and
other door hardware.

Approval of the above information shall be obtained before ordering materials or starting fabrication
or construction as applicable.

iv. Finish Schedule

1. The finishing schedule is given in subsequent clauses.

2. M.S. Ladder should be provided to access the control room roof from outside. Ladder shall be
made up of ISMC 75x40 which will run as beam one meter apart and intermediate steps will be
Part -2 : Employer‟s Requirements 117

made up of 45x45x5 angle with rise of 300 mm. Red oxide premier shall be applied initially, then
two coats of rich zinc paint shall be applied to avoid corrosion.

v. Flooring

Flooring in various rooms of control room building shall be as for detailed schedules given in Table
-1

vi. Walls

Control room buildings shall be of framed superstructure. All walls shall be non-load bearing walls.
Min. thickness of external walls shall be 230 mm (one brick) with 1:6 cement sand mortar.

vii. Plastering

All internal walls shall have minimum 12mm and 15 mm thick 1:6 cement sand plaster on either side
of wall. The ceiling shall have 6mm thick 1:4 cement sand plaster.

viii. Finishing

All external surfaces shall have 18 mm cement plaster in two coats, under layer 12 mm thick cement
plaster 1:5 and finished with a top layer 6 mm thick cement plaster 1:6 (DSR 13.19) with water
proofing compound. The paint shall be antifungal quality of reputed brand suitable for masonry
surfaces for high rainfall zone. White cement primer shall be used as per manufacturer‟s
recommendation.

Internal finish Schedule is given Table - 1 below:

TABLE-1

S.No. Location Flooring & Wall Internal Ceiling Doors, Windows,

Skirting Ventilators
150mm high

1. Control Room, Precast Oil bound White 1) Standard steel rolled

Relay Room Terrazo tiles washable distemper Wash section frames with 5
(DSR‟02, on smooth surface (DSR‟02 – mm glass. DSR‟02 –
item no. applied with 2mm 13.70.1) 10.12, 10.13 & 10.14
11.29A.2 & thick Plaster of
11.31.2 Paris putty. 2) Flush door shutters -
Part -2 : Employer‟s Requirements 118

(DSR‟02 – 13.40 A DSR‟02 – 9.25.2

& 13.77.2)
2. Sub-station Precast Oil bound White 1) Standard steel rolled
Incharge, Office, Terrazo tiles washable distemper Wash section frames with 5
corridor, staff (DSR‟02, on smooth surface (DSR‟02 – mm glass. DSR‟02 –
room. item no. applied with POP 13.70.1) 10.12, 10.13 & 10.14
11.29A.2 & putty. (DSR‟02 –
11.31.2 13.40 A & 13.77.2) 2) Flush door shutters -
DSR‟02 – 9.25.2
3. Battery room Acid and Dado of acid Acid 1) Standard steel rolled
Alkali resistant tile 1.2 M resistant section frames with 5
Resistant high & Paint above Paint. mm glass. DSR‟02 –
tiles. 1.2 M to ceiling. DSR‟02 – 10.12, 10.13 & 10.14
DSR‟02 – DSR‟02 – 11.36 C. 13.96.1
11.36 C. 1 & 2.1, 11.36C.2 & 2) Flush door shutters -
11.36 C.1.1 13.96.1 DSR‟02 – 9.25.2

Painted with acid

resistant Paint. DSR‟02
–13.96.1
4. Toilet Ceramic DADO glazed tile White 1) Standard steel rolled
glazed tiles in 2.1M high for toilet Wash section frames with 5
flooring (DSR 02 - 11.73) (DSR‟02 – mm glass. DSR‟02 –
DSR‟02 – 13.70.1) 10.12, 10.13 & 10.14
11.74
2) Flush door shutters -
DSR‟02 – 9.25.2
5. Other areas not Terrazo tiles Oil bound White
specified (DSR‟02 - distemper, Wash
11.29A.2 & DSR‟02 - 13.40A (DSR‟02 –
11.31.20 & 13.77 13.70.1)

Note: DSR item references (DSR-2002) to be read with CPWD specifications are only for material and
workmanship guidance of the Contractors.

ix. Roof
Part -2 : Employer‟s Requirements 119

Roof of the C.R. Building shall consist of Cast-in-situ RCC slab treated with a water proofing
system which shall be an integral cement based treatment conforming to CPWD specification (item
no. 25.8 of DSR 2002). The water proofing treatment shall be of following operations:

i.Applying and grouting a slurry coat of neat cement using 2.75 kg/m 2 of cement admixed with
proprietary water proofing compounds conforming to IS: 2645 over the RCC slab including cleaning
the surface before treatment.

ii.Laying cement concrete using broken bricks/brick bats 25mm to 100mm size with 50% of cement
mortar 1:5 (1 cement: 5 coarse sand) admixed with proprietary water proofing compound
conforming to IS: 2645 over 20mm thick layer of cement mortar of min 1:5 (Cement: 5 coarse sand)
admixed with proprietary water proofing compound conforming to IS: 2645 to required slope and
treating similarly the adjoining walls upto 300mm height including rounding of junctions of walls
and slabs.

iii. After two days of proper curing applying a second coat of cement slurry admixed with proprietary
water proofing compound conforming to IS: 2645.

iv.Finishing the surface with 20mm thick joint less cement mortar of mix 1:4 (1 cement: 4 course
sand) admixed with proprietary water proofing compound conforming to IS: 2645 and finally
finishing the surface with trowel with neat cement slurry and making of 300 x 300 mm square.

v.The whole terrace so finished shall be flooded with water for a minimum period of two weeks for
curing and for final test. All above operations to be done in order and as directed and specified by
the Project Manager.

With average thickness of 120 mm and minimum thickness at khurra at 65 mm.

x. Glazing

Minimum thickness of glazing shall be 5.0 mm. as per IS: 2835.

xi. Doors and Windows

The details of doors and windows of the control room building shall be as per finish schedule Table-
1 and tender drawing with the relevant IS code. Rolling steel shutters and rolling steel grills shall be
provided as per layout and requirement of buildings. Paints used in the work shall be of best quality
specified in CPWD specification.
Part -2 : Employer‟s Requirements 120

xii. Plumbing & Sanitation

1. All plumbing and sanitation shall be executed to comply with the requirements of the
appropriate byelaws, rules and regulations of the Local Authority having jurisdiction over such
matters. The Contractor shall arrange for all necessary formalities to be met in regard to inspection,
testing, obtaining approval and giving notices etc.

2. PVC syntax or equivalent make Roof water tank of adequate capacity depending on the number
of users for 24 hours storage shall be provided. Minimum 1 Nos. 500 liters capacity shall be
provided.

3. Galvanized MS pipe of medium class conforming to IS: 1239 shall be used for internal &
external piping work for potable water supply.

4. Sand CI pipes with lead joints conforming to IS: 1729 shall be used for sanitary works above
ground level.

5. Each toilet shall have the following minimum fittings.

(a) WC (Western type) 390 mm high with toilet paper roll holder and all fittings
Or
WC (Indian Type) Orissa Pattern (580 x 440 mm) with all fittings (both types of WCs shall be
provided at alternate locations).

(b) Urinal (430 x 260 x 350 mm size) with all fittings.

(c) Wash basin (550 x 400 mm) with all fittings.

(d) Bathroom mirror (600 x 450 x 6 mm thick) hard board backing

(e) CP brass towel rail (600 x 20 mm) with C.P. brass brackets

(f) Soap holder and liquid soap dispenser.

6. All fittings, fastener, grating shall be chromium plated.

7. All sanitary fixtures and fittings shall be of approved quality and type manufactured by well
known manufacturers. All items brought to site must bear identification marks of the type of the
Manufacturer.
Part -2 : Employer‟s Requirements 121

8. Soil, waste and drain pipes, for underground works shall be stoneware for areas not subject to
traffic load. Heavy-duty cast iron pipes shall be used otherwise.

9. In case of Augmentation/R&M of existing substation, amount of work shall be envisaged by

contract for lump sum quotation.

12.00 Miscellaneous General Requirements

1. Dense concrete with controlled water cement ratio as per IS-code shall be used for all
underground concrete structures such as pump-house, tanks, water retaining structures, cable and
pipe trenches etc. for achieving water-tightness.

2. All joints including construction and expansion joints for the water retaining structures shall be
made water tight by using PVC ribbed water stops with central bulb. However, kicker type
(externally placed) PVC water stops shall be used for the base slab and in other areas where it is
required to facilitate concreting. The minimum thickness of PVC water stops shall be 5 mm and
minimum width shall be 230 mm.

3. All steel sections and fabricated structures that are required to be transported on sea shall be
provided with anti corrosive paint to take care of sea worthiness.

4. All mild steel parts used in the water retaining structures shall be hot-double dip galvanised. The
minimum coating of the zinc shall be 750 gm/sq. m. for galvanised structures and shall comply with
IS: 2629 and IS: 2633. Galvanizing shall be checked and tested in accordance with IS: 2633.The
galvanizing shall be followed by the application of an etching primer and dipping in black bitumen
in accordance with BS: 3416.

5. A screed concrete layer not less than 100 mm thick and of grade not weaker than M10
conforming to IS: 456-1978 shall be provided below all water retaining structures. A sliding layer of
bitumen paper or craft paper shall be provided over the screed layer to destroy the bond between the
screed and the base slab concrete of the water retaining structures.

6. Bricks having minimum 75kg/cm2 compressive strength can only be used for masonry work.
Contractor shall ascertain himself at site regarding the availability of bricks of minimum 75kg/cm2
compressive strength before submitting his offer.

7. Doors and windows on external walls of the buildings (other than areas provided, with insulated
metal claddings) shall be provided with RCC sunshade over the openings with 300 mm projection on
Part -2 : Employer‟s Requirements 122

either side of the openings. Projection of sunshade from the wall shall be minimum 450 mm over
window openings and 750 mm over door openings.

8. Service ladder shall be provided for access to all roofs.

9. Angles 45x45x5 mm (minimum) with lugs shall be provided for edge protection all round cut
outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe
trenches supporting covers, edges of manholes supporting covers, supporting edges of manhole precast
cover and any other place where breakage of corners of concrete is expected.

10. Anti termite chemical treatment shall be given to column pits, wall trenches, foundations of
buildings, filling below the floors etc. as per IS: 6313 and other relevant Indian Standards.

11. All rungs for ladder shall also be galvanised as per IS: 277 medium classes.

12. For all civil works covered under this specification, nominal mix by volume batching as per
CPWD specification is intended. The relationship of grade of concrete and ratio of ingredients shall
be as below:

Sl.No. Mix Cement Sand Coarse aggregate of

20 mm down grade
as per IS 383

1. M 10 1 3 6

2. M 15 1 2 4

3. M 20 1 1.5 3

The material specification, workmanship and acceptance criteria shall be as per relevant clauses of
CPWD specification and approved standard Field Quality Plan.
Part -2 : Employer‟s Requirements 123

13. The details given in tender drawings shall be considered along with details available in this
section of the specification while deciding various components of the building.

14. Items/components of buildings not explicitly covered in the specification but required for
completion of the project shall be deemed to be included in the scope.

13.00 Interfacing

The proper coordination & execution of all interfacing civil works activities like fixing of conduits
in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of
supports/embedment, provision of cutouts etc. shall be the sole responsibility of the Contractor. He
shall plan all such activities in advance and execute in such a manner that interfacing activities do
not become bottlenecks and dismantling, breakage etc. is reduced to minimum.

14.00 Water Supply

(i) Contractor shall make its own arrangement for construction water.

(ii) The contractor shall carry out all the plumbing/erection works required for supply of water
in control room building.

(iii) The details of tanks, pipes, fittings, fixtures etc for water supply are given elsewhere in the
specification under respective sections.

(iv) A scheme shall be prepared by the contractor indicating the layout and details of water supply
which shall be got approved by the Project Manager before actual start of work including all other
incidental items not shown or specified but as may be required for complete performance of the works.

(v) Bore wells and pumps for water supply are in the scope of contractor meeting the day-
to-day requirement of the water supply.
(vi) If the water is supplied by Municipal Corporation then bore well for water supply
purposes is not required to be carried out by contractor. Contractor shall also make necessary
arrangement /formalities to receive water connection from corporation.

15.00 Sewerage System

Part -2 : Employer‟s Requirements 124

(i) Sewerage system shall be provided for control room building.

(ii) The Contractor shall construct septic tank and soak pit suitable for 5 users if outside of
Municipal Corporation zone. Otherwise, all necessary arrangement for the disposal of sewerage to
the Municipal Corporation‟s end shall be arranged by the contractor at his own cost for regularizing
the disposal activity.

(iii) The septic tank and soak pit shall be constructed as per enclosed tender drawing.

16.00 Statutory Rules

a. Contractor shall comply with all the applicable statutory rules pertaining to factories act
(as applicable for the State). Fire Safety Rules of Tariff Advisory Committee, Water Act for
pollution control etc.

b. Provisions for fire proof doors, no. of staircases, fire separation wall, plastering on
structural members (in fire prone areas) etc. shall be made according to the recommendations of Tariff
Advisory Committee.

c. Statutory clearance and norms of State Pollution Control Board shall be followed as per
Water Act for effluent quality from plant.

d. Requirement of sulphate resistant cement (SRC) for sub structural works shall be
decided in accordance with the Indian Standards based on the findings of the detailed soil investigation
to be carried out by the Bidder.

e. Foundation system adopted by Bidder shall ensure that relative settlement and other criteria
shall be as per provision in IS: 1904 and other Indian Standards

f. All water retaining structures designed as un-cracked section shall also be tested for
water tightness at full water level in accordance with clause no. 10 of IS: 3370 (Part-I).

g. Construction joints shall be as per IS: 456.

h. All underground concrete structures like water retaining structures etc. shall have
plasticizer cum water proofing cement additive conforming to IS: 9103. In addition, limit on
permeability as given in IS: 2645 shall also be met with. The concrete surface of these structures in
contact with earth shall also be provided with two coat of bituminous painting for water/damp proofing.
In case of water leakage in the above structures, Injection Method shall be applied for repairing the
leakage.
Part -2 : Employer‟s Requirements 125

i. All building/construction materials shall conform to the best quality specified in CPWD
specifications if not otherwise mentioned in this specification.

j. All tests as required in the standard field quality plans have to be carried out.

17.00 Fencing

a. Product materials for fencing

The minimum requirements are as follows:

i. Chain Link fence fabric in accordance to IS-2721

1. Size of mesh : 75 mm

2. Nominal wire size : 4.0 mm dia

3. Width of chain link : 2000 mm

4. Class of zinc coating : medium

5. Zinc coated after weaving.

ii. Posts
Angle Section

Intermediate : L 65 x 65 x 6

Straining posts : L 65 x 65 x 6

Stay post : L 65 x 65 x 6

1. All structural steel shall conform to IS: 2062 and shall be painted with a coat of approved steel
primer and two coats of synthetic enamel paint.

2. The Chain Link fabric shall be fixed to the post at the top and bottom of the fence by
welding/fixing 50 mm MS flat all through its length.
Part -2 : Employer‟s Requirements 126

3. Fencing top shall be either of galvanised barbed wire or tape. Barbed wire shall conform to IS:
278.

4. The barbed wire may consist of not more than two splices per reel. The barbed wire shall be
formed by twisting two line wires, one containing the barbs. The barbed wire shall be designated as
A-4 IS: 278 and shall be galvanized.

5. Above chain link, 3-rows (6 nos) of barbed tape/wire shall be provided in each arm of the Y
shaped barbed arm at top.

6. With barbed tape/wire above the chain link fence, the total fence height shall be minimum 2500
mm above finished gravel level.

7. Barbed tape/wire arms shall be same as intermediate and straining post.

8. Tension wire: single strand, high tensile, galvanised steel wire, 4 mm diameter.

9. Fittings and hardware: cast aluminum alloy or galvanized steel, malleable or ductile cast iron
turnbuckles to be drop forged.

10. GI chain link mesh shall be as per IS: 2721. Mesh size 75 mm and nominal wire size shall be
4.0 mm diameter.

On the results of these additional tests, the whole or portion of the barbed wire/tape shall be
accepted or discarded by the Purchaser, as the case may be.

b. Installation

1. Contractor shall submit the fencing drawing Fence shall be installed along lines shown on
approved drawings.

2. Post holes shall be excavated by approved methods.

3. Intermediate posts shall be spaced 2.5 m apart measured parallel to ground surface.

4. Straining posts shall be installed at equal intervals not exceeding 25.0 m.

5. Straining posts shall be installed at sharp changes in grade, at corners, at change of direction
and where directed.
Part -2 : Employer‟s Requirements 127

6. All corner post will have two-stay post and every tenth post will have a transverse stay post.

7. Posts shall be set in 1:2:4 plain cement concrete Blocks of minimum dimension 400 mm x 400
mm x 1000 mm deep Concrete work shall conform to relevant clause. Post shall be braced and held
in plumb position and true alignment and elevation until concrete has set.

8. Fence fabric shall not be installed until concrete has cured a minimum of 7 days.

9. Bottom and top of the fence fabric shall be fixed with MS flats of 50 mm x 6mm (min).

10. Fence fabric shall be laid out with barbed edge on top, stretched tightly and shall be fastened to
intermediate, post gate and straining post with 50 x 6 flats.

11. Fabric shall be secured to tension wires with tie wires at 400 mm intervals. Tie wires shall be
given not less than two twists.

12. Barbed tape shall be spliced with standard wire splices.

13. Barbed tape shall be stretched to have uniform tension.

14. Barbed tape shall be attached to barbed wire arms with approved metal clips.

15. Toe wall of one Brick/Random Rubble masonry, with notches over 75 mm thick PCC
(1:4:8) shall be provided below all fencing and shall be minimum 200 mm above and 200 mm below
finished ground level. All exposed surfaces of brick toe wall shall be provided with 1:6 cement sand
plaster and coated with two coats of colour wash with a base coat of white wash with lime. Rubble
masonry toe wall shall be with raised & cut pointing and 50 mm PCC (1:2:4) band coping.

16. Proper earthing shall be done for fencing also.

Part -2 : Employer‟s Requirements 128

13.10. LT AB Cable Reconductoring Work

1. Survey
1.1. Survey
The Contractor shall carry out a GPS based survey of existing bare conductor LT distribution
lines in the habitation. The Survey should cover Pole by pole survey of all the bare conductor
lines to identify the location of poles and phase configuration, pole condition, Existing stays /
struts, Existing street lamp connections, Location and capacity of the connected distribution
transformer (DTR) to each LT line, Connection points of any existing ABC lines connected to
the bare conductor lines should be identified. The length of such ABC lines and total service
connections provided through this line should be indicated on the map at this point, Load readings
for each LT feeder. Upon completion of the survey the contractor is required to develop
the Single Line Diagram (SLD-A) indicating the survey Information and Schedule of network
survey information (Schedule – A).

1.2. Load Readings

Load readings of each LT feeder shall be taken before and after proposed ABC conversions.
This is required to monitor actual demand reductions achieved following ABC conversions.

Load currents on each phase and the neutral in respective LT feeders shall be taken preferably
between 7:00 - 8:00 pm (peak demand time) using a clamp meter. Load reading before ABC
conversions shall be taken when carrying out the survey and recorded in Schedule-A. Load
readings after ABC conversions shall be provided to the Project Manager within one month
from completion of works.

1.3. Network Design for ABC Conversions

Contractor should prepare details of proposed ABC conversions for respective habitation in
accordance with these guidelines and prepare Single line diagram indicating proposed ABC
conversions (SLD-B) and Schedule of proposed ABC conversions (Schedule -B)

1.4. Load Balancing

When preparing ABC conversion schedule (Schedule-B), phase connections for single phase
distribution boxes shall be determined so that total number of single phase consumers are balanced
across the three phases of a given feeder.

2. Conversion of bare conductor lines to ABC

2.1. AB Cable types and Sizes
LT ABC Cable with XLPE insulated aluminum conductor and aluminum alloy bare neutral
messenger type cables shall be used for proposed ABC conversions. The AB cables provided
shall fully comply with technical specifications provided in this tender document.
Part -2 : Employer‟s Requirements 129

The following standard sizes of AB cables shall be used:

 ABC16-SP : 1X16 mm2 (ph)+1X25 mm2 (bare messenger cum neutral) +1x16 mm2 (insulated
street lighting cable)
 ABC50 : 3X50 mm2 (ph)+1x35 mm2 (bare messenger cum neutral) +1x16 mm2 (insulated
street lighting)
 ABC95 : 3X95 mm2 (ph)+1x70 mm2 (bare messenger cum neutral) +1x16 mm2 (insulated
street lighting)
 ABD120 :3X120 mm2(ph)+1x95 mm2 (bare messenger cum neutral)+ 1x16 mm2 (insulated
street lighting)
ABC70 : 3C X 70 mm² + 70 mm²
ABC95: 3C x 95 mm² + 80 mm²

2.2. Vertical and Horizontal Clearances

all statutory clearances shall be ensured for ground clearance, line-to-line clearance, road crossing
clearance, horizontal and vertical clearances from buildings/objects etc. All road crossings and
line crossings shall be guarded as per specifications. Conductor joint should not
be provided in mid span length. Instead, it should be nearer to the support.

As per ISS 162-1961 minimum electrical clearance from live part to earth and safety clearance in case of
different voltage must be kept as follows:
Voltage Electrical Clearance (mm) Safety Clearance in SIS (mm)
Phase - Earth Phase - Phase
33kV 381 432 2740
66kV 658 786 3050

Minimum Clearance Between Power Lines (mtr.) :

kV 11 33 66
11 2.44 2.44 2.44
33 2.44 2.44
66 2.44

2.3. Installation of AB Cables

Prior to installation of AB cables, all pole works should be completed as per scope of works
provided in proceeding sections. (i.e installation of new poles, pole replacements, pole re-
alignment, installation of pole supports).
All ABC accessories used for installation works shall conform to technical specification
provided in this document.

2.4. Installation of clamp assemblies

AB cable should be installed on poles using anchoring and suspension clamps according to
following drawings and as per approved drawings by the Project Manager. Samples of complete
clamp assemblies shall be approved by the Project Manger prior to use.
Part -2 : Employer‟s Requirements 130

Anchoring clamps shall be used at the beginning and end of each cable run, at a major change in
direction, terminal poles and at T-off points. Suspension clams shall be used at other
intermediate points.
It should be noted that different clamps are specified for cable ranges 25-50 sqmm and 70-95
sqmm. These have different dimensional and maximum load specifications. If ABC
manufacturer recommends any alternate clamps it should be approved by the Project Manger prior
to use.
Stainless steel straps and buckles shall be used for fixing pole brackets to the pole as shown in
drawings. Strap binding tool shall be used for tensioning and cutting the straps.
Separation of neutral messenger for tensioning and fixing to the clamp should be done using
plastic phase separators. Weather resistant black nylon ties should be used for typing insulated
conductors to the neutral messenger at either side of suspension clamps, to prevent the phase
conductors from chatting against suspension clamp.

2.5. Stringing of AB cable

Stringing of AB cables shall be done in a proper manner ensuring insulated conductors do not
get damaged during installation. Dragging the ABC on the ground is not permitted. Pulleys
installed on poles shall be used to pull AB cables.
Minimum clearance above ground to line shall be maintained. Sag tension charts for installing
AB cables shall be developed by the contractor taking into consideration of cable
characteristics, maximum / minimum temperatures and maximum wind pressure as per service
conditions provided by Employer. Based on this clear guidelines shall be provided to linesmen
to ensure bare neutral messenger is pulled at appropriate tension so that;
(a) Required ground clearances are maintained and
(b) Messenger conductor tension is maintained well below its breaking load at all temperatures.
Dynamometer method or sag method may be used to ensure appropriate tension of neutral
messenger during installation. Over tensioning of neutral messenger should be avoided to
ensure its tension does not exceed permissible loading limits at low temperatures. Loose spans
of AB cable should be avoided to maintain permissible maximum sag at high temperatures.
Loose spans may only be allowed for short spans in special cases. This applies when there are
practical difficulties to install necessary stays or struts as required at a t-off point. A short loose
span of AB cable may be used in this case to transfer the stay / strut support point upstream or
downstream of the line.
Stringing of AB cable shall be done using proper equipment such as stringing blocks with
plastic coated pulleys, pulling (come along) clamp, cable hoist and pulling tool, dynamometer etc.
Proper equipment recommended by the ABC manufacturer shall be used to avoid any damage to
the cable during installation. Temporary stays or strut poles shall be employed as necessary during
stringing operation to ensure safety of personnel and equipment.
Part -2 : Employer‟s Requirements 131

Phasing of insulated conductors shall be identified by one, two and three ridges on the XLPE
insulation. Same phasing shall be maintained accordingly through the line. Interchanging of
phasing at any connection point is not permitted.
In order to ensure durability of AB cables and to prevent possibility of failures due to effects of
water treeing, any exposed parts of phase conductors or open cuts of insulation are strictly not
permitted. Hence all connectors to be used in ABC line shall be pre-insulated type or bare
connectors covered by heat shrinkable tubing or GelWrap sleeves. For installing connectors
proper equipment such as insulation stripping tool, ratchet cable cutter, hydraulic compression
tool with compression dies shall be used.
All cable ends shall be properly sealed by pre-moulded or heat-shrinkable type end caps.
Samples of all ABC accessories including connectors shall be approved by the Project Manager
prior to use.
Mid-span joints shall be generally avoided by properly planning stringing work. In exceptional
cases where mid span joint is required, pre-insulated compression connectors shall be used. The
joints for each phase shall be staggered along the cable. No mid-span joints are allowed for AB
cable sections running across a street.
Insulated piercing connectors or non-tension mechanical connectors with heat shrinkable tubing
shall be used for non-tension inline connections at anchoring points where necessary.

2.6. AB cable connections to Distribution Transformers

AB cables shall be connected to bus-bars or protection equipment terminals of the LT feeder
Distribution Boards by means of pre-insulated compression lugs and aluminium / bi-metallic
strips.
Where no Distribution Board is available AB cable shall be directly connected to the
distribution transformer bushing terminals using insulated compression lugs. In this case
additional length of AB cable shall be provided by means of a loop to facilitate future
connection to the Distribution Board or fuses.

2.7. Earthing of Poles / ABC neutral messenger conductor

Earthing shall generally be carried out in accordance with the requirements of latest CEA
regulations (as amended from time to time) and the relevant regulations of the Electricity
Supply Authority
The Contractor shall ensure every 6th pole of ABC line including neutral messenger and any
metallic hardware is earthed with spike earth (20x2500 mm) as per existing practice of
Employer. (for normal soil).
Poles shall be earthed using 8 SWG (7/4.0 mm) GI wire with 1 No. Coil/Spike/Pipe earth.

2.8. Pole Numbering

Part -2 : Employer‟s Requirements 132

Each pole of the existing line shall be uniquely numbered as per pole numbering scheme
followed by the Employer. Pole number and other information as required by the Employer
should be pained on the pole.

2.9. Dismantling existing bare conductors and line hardware

Dismantling existing bare conductors and line hardware. Conductors and other line hardware
including insulators, brackets, cross arms and bolts and nuts shall be carefully removed without
causing damage to the existing poles. Bare conductors shall be removed in the longest length
practicable for future re-use with a metal tag of description/ tag # of conductor, the said conductor
shall be wound on empty conductor reels or made up in rolls.
Following dismantling works affected areas shall be cleaned and reinstated. All dismantled
items shall remain the property of Employer and Contractor shall deliver all salvaged materials
to the designated Employer warehouse as directed by the Project Manager.

2.10.Parallel AB Cable lines

Parallel AB cable lines refers to installation of second ABC cable line on the existing poles as
per design requirements approved by Employer.
The scope of work for this item shall exclude (a) existing bare conductor line dismantling and
(b) pole numbering requirements applicable for the scope of works specified above for
„conversion of bare conductor lines to ABC‟.

2.11.Rates for Conversion of bare conductor lines to ABC

It should be noted that scope of work for this item relates to AB cable installation on existing
poles. It excludes any additional works required on the existing poles or installation of new
poles, installation of distribution boxes, stays etc. Separate BOQ items are provided for work
associated with installation of new poles and replacement, re-alignment or relocation of existing
poles, installation of stays and struts and installation of distribution boxes for AB cables.

3. Installation of LT Distribution Boxes for ABC

3.1. Types of LT Distribution Boxes
The following types of LT distribution boxes (according to number of consumers to be
connected) shall be selected:
 Type A : Single Phase, 1 Incoming (25 mm2)/ 6 outgoing (upto 10 mm2)
 Type B : Three Phase,1 Incoming (35 mm2)/ 4 outgoing (upto 16 mm2)
3.2. Mounting Arrangement
Distribution Box (DB) shall be mounted on LT pole with galvanized MS clamp of 40x3 mm
size.

3.3. Connection to AB Cable

Part -2 : Employer‟s Requirements 133

2Cx25 sqmm or 4Cx35 sqmm PVC cables shall be used to connect AB cable with single phase
and three phase distribution box respectively. For connection to ABC, insulation piercing
connectors (IPC) and PG clamps of appropriate size shall be used.
Single phase Distribution Boxes shall be connected to specified phase as per Schedule-B in
order to ensure load balancing in ABC line.

3.4. Connection of Consumer Service Cables

All existing consumer service cables shall be re-connected to the Distribution Box by the
contractor. In case existing consumer service connections are to be replaced with armoured service
cables in a given habitation as determined by the Project Manager, new armoured cable shall be
connected to the distribution box.

4. Replacement of Existing Consumer Service Connections

4.1. Service Connection Types
The applicable service connection types are as follows;
SC Type Connected Load Service Cable Size (cores /
No of Phases / Contract Dmd sqmm)
SP-1 Single Phase / upto 4 kW 2 x 4 mm2
TP-1 Three Phase / upto 4 kW 4 x 4 mm2
TP-2 Three Phase / above 4 kW 4 x 4 mm2

4.2. Service Cable Types

The service cable shall be 1.1 KV grade PVC insulated, PVC sheathed, armoured multicore
aluminium cable as per sizes indicated in above table

4.3. Service Cable Span

Permissible maximum span for service cable shall be 30 m. In isolated cases this limit may be
extended with the approval of Project Manager provided that required ground clearance is
maintained with additional supports where necessary.

Existing service cables shall be replaced with armored service cables only in certain specified
villages / habitations (high theft prone areas). This will be specified by the Project Manger during
execution. No service cable replacements shall be carried out without the approval of Project
Manager in any village / habitation.
In this case existing service cables shall be replaced with new armoured cables. Existing un-
armoured service cables shall be removed and returned to Employer warehouse. Any non-
standard supports used as supports for existing service cables shall also be removed.
New armoured service cables shall be drawn from the LT distribution box upto the meter board
as shown in drawings. The service wire is to be hanged on supportive GI wire between pole
Part -2 : Employer‟s Requirements 134

support and the house. 7/3.15 mm (10 SWG) & 7/4.00 mm (8 SWG) GI wires shall be used for
single phase and three phase services respectively.
Before installing service wires and GI wire, GI pipe / MS Angle on the consumer premises is to
be erected using clamps/ nails/proper binding etc. In case of hut or poor structure at consumer
premises, GI pipe is to clamp on wooden planks/wooden structure existing in the house. The GI
pipe should be supported for neutralizing tension by means of GI tie wire support. In
pukka/brickwork/cement concrete foundations, house, GI support pipe is to be clamped by
means of MS clips.
New service cable shall be connected to existing consumer meter terminals or incoming fuse /
MCB / MCCB terminals. Care should be taken not to damage the existing meters in the process.
20mm dia PVC conduit pipes shall be used to take down service cable from the roof to the
meter box along the walls. The service cable shall be drawn inside PVC pipes from roof upto
the meter board.
Terminal cover of the meter or fuses shall be sealed upon connection of new service cable as
arranged with the Employer.
Earth terminal point shall be provided at meter board via bearer GI wire. This point shall be
connected with the proper earthing system through GI wire. 10mm diameter earth knob in form
of bolt and nut is to be installed on energy meter board.

4.4. In case of unmetered connections, new service cable shall be directly connected to existing
supply terminals. Additional length of service cable shall be provided by means of a loop for
future installation of the meter board.
All work required to install service cable from LT distribution box upto the meter board shall be
carried out as per drawings. This includes GI wire for supporting service cables from LT
distribution box upto the consumer premises, MS angle fixed at roof, clamp with bolts nuts and
flat iron for fixing GI wire on pole, clamps for fixing cable to GI wire, PVC conduit pipes and
accessories to draw the service cable from roof upto the meter board.
4.5. If the miscellaneous items indicated above are available with existing service connections in
reusable condition, they can be used to install new service cable. Else the Contractor shall supply
and install these items when installing new service cables in accordance with the drawings.
5. Installation of Poles
5.1. Types of pole installation works for ABC conversions
The following types of pole installation works applicable for ABC conversions as per site
requirements specified in the table below;

# Type Site Requirements

1 Installation of new poles  New pole to be used as an intermediate
pole in the existing line to address excessive
spans or other requirements.
Part -2 : Employer‟s Requirements 135

 When there is a need to do minor

extensions to the existing line in order to
minimize excessive service cable lengths to
existing consumers.
 To shift existing lines due to safety/
clearance issues.
2 Replacement of existing  To replace existing poles which are
(unusable) poles damaged / corroded and cannot be re-used.
 To replace of existing non-standard line
supports such as temporary structures
including supports embedded in buildings.
3 Re-location of existing poles  To shift existing poles
 To shift existing lines due to safety/
clearance issues
4 Re-alignment of existing  To straighten the poles that are inclined
poles in a particular direction but in re-usable
condition

5.2. Types of poles

For works relating to new poles and replacement of poles, poles according to Employer
specification shall be used.
For works relating to re-location or realignment of existing poles the available existing pole
(any type) may be re-used provided that it is in re-usable condition.

6. Erection of Poles
6.1. Removal of existing poles for re-use or disposal
All unusable poles or non-standard line supports in the existing LT lines shall be removed and
disposed. If the existing pole is removed for re-use adequate measures should be taken not to
damage the pole during removal.
Existing poles shall be removed by pulling the complete pole from the ground; poles shall not
be cut off at the ground line. Pole shall be cleaned and any material attached with the pole
(including concrete) shall be removed. The RCC base plate may be removed and re-used if it is
in re-usable condition.
Pits shall be backfilled and compacted completely with sufficient added backfill piled above grade
to prevent depressions being created by natural compaction.
Contractor shall be responsible for disposal of unusable poles or non-standard line support
structures.

6.2. Erection of new or existing poles

Part -2 : Employer‟s Requirements 136

For 8 m PSC poles pole pit shall be excavated as per details provided in drawing #
REC/DDUGJY/GEN/02. Pole shall be placed on the RCC base pad made as per drawing #
REC/DDUGJY/GEN/05A. PSC pole pit shall be refilled with 200 mm average size of boulder
mixed with excavated earth. Proper ramming shall be performed for better compaction. Pole shall
be erected fully vertical and firmly fixed to ground and shall not wobble.

6.3. Erection of poles with concrete foundation

Concrete foundations shall be used to erect terminal / tension poles and poles in water logged
areas or for all locations as instructed by the Project Manager. Details of concrete foundation for
PCC poles are provided in drawing # REC/DDUGJY/GEN/01.

6.4. Re-alignment of existing pole

Existing poles that are inclined in a particular direction shall be re-aligned / straightened by
pulling, providing additional bouldering, concreting and re-compacting as necessary. Upon re-
alignment pole shall be erected fully vertical and firmly fixed to ground and shall not wobble. If
necessary pole may be completely removed and re-installed.

6.5. Earthing of poles

Earthing of poles shall be carried out as per CEA regulations and existing practice of Employer.

6.6. Pole Numbering

Requirements specified in section 3.9 with respect pole numbering shall also be applicable for
new poles or pole replacements indicated in this section.

7. Installation of Stays and Struts

7.1. Installation of Stays (Guys)
Stays shall be installed to nullify tension on poles due to tension of AB cable at terminal, angle,
cut-point and T-off positions. Stays may also be installed at steep gradient locations as required.
Along the straight run stays shall be installed at minimum two locations in 1 km.
If there are no existing stays installed at such locations in the existing line, such poles shall be
identified and included in Schedule-B for installation of new stays. In addition required stays
for proposed new and relocated poles shall also be included.
10 SWG stay wire (7/ 3.15 mm) with 16 mm stay rod shall be used for 11 kV / LT lines. Stay
shall be installed in the opposite direction of resultant force due to AB cable tension in order to
nullify the same.
If the stay wire proves to be hazardous, it should be protected with suitable asbestos pipe filled
with concrete of about 2 m length above the ground level, painted with white and black strips so
that, it may be visible at night.

7.2. Installation of Struts

Part -2 : Employer‟s Requirements 137

The struts may be used only in case where stays cannot be installed due to physical obstacles or
limitations. Strut shall be applied in the same direction of resultant force due to AB cable
tension in order to nullify the same.

7.3. Installation of Stays

Stay assembly comprising of turn buckle assembly, anchor rod and plate, stay insulator, thimble
and GI stay wire shall be supplied and installed as indicated in drawing #
EC/DDUGJY/GEN/09B.
In general, the stay should be applied on the pole as close as possible to the load center. The
angle between stay wire and pole shall be between 45o – 60o. Where there are issues obtaining
specified angle due to physical obstacles, bow (outrigger) stay arrangement may be considered
with the approval of the Project Manager. In case of critical space issues, fly stays may also be
considered subject to approval of the Project Manager. (Reference : REC Drawing # G4).
Concreting of stay pit shall be done as shown in drawings except for firm soil where
compacting with necessary aggregates shall be done.
Stay wire shall be properly tightened after installation and allowing sufficient time for setting
concrete. Contractor shall ensure all stays in the existing line are properly tightened including
new and existing stays.
7.4. Installation of Strut pole
Installation of strut pole shall be carried out using 8.5 m PCC pole and pole brackets as shown
in drawing # REC/DDUGJY/GEN/10. Strut pole shall be installed with the RCC base plate.
Anglebetween the line and strut pole shall be 450.

8. Re-Connecting Existing Street Lamps to ABC

If there are existing street lamps connected to the bare conductor line, these street lamps shall be
re-connected to ABC line through the street lighting conductor using IPC (for insulated conductor)
and PG clamps (for bare neutral messenger). This work scope is limited to providing connection
to existing street lamps only.
9. Shutdown during execution of works :
The contractor is required to take shutdown to execute reconductering and all other works
wherever needed. During shut down, safety of system and operating manpower shall be ensured
by contractor.
Shut down shall be planned with concerned substation incharge well in advance. This may subject
to exigencies leading to cancellation of requisition if situation so desire.
Part -2 : Employer‟s Requirements 138

13.11. Construction of New 11 kV Feeders and Associated Works for Separation of

Agricultural Consumers
1. Construction of new 11 kV lines
1.1. Survey
Mapping of routes of proposed 11 KV lines shall be done by GPS survey. While surveying,
existing electrical infrastructure, existing agriculture private tube well (PTW) locations,
capacity and load details shall be mapped during survey.
Upon completion of the survey the Contractor shall provide a survey report with the
following information;
 Single line diagram of the route survey and proposed line alignment details mapped and
provided in a standard mapping software. This should also include information such as
existing electrical infrastructure and PTW information.
 Road and railway crossing points of the proposed 11 kV line shall be marked on the single
line diagram.
 Line sections proposed for 11 kV AB (Ariel Bunched) cables due to vegetation, safety and
forest clearance issues (if applicable) shall be marked on the single line diagram. Lengths of
proposed AB cable line sections shall be indicated.
 Schedule of location wise pumps to be fed through new feeder or alternatively general
consumer distribution transformers to be transferred to new feeder for making dedicated feeder
for agricultural consumers. This schedule should include location / capacity of the existing
distribution transformers to be transferred and location /capacity and load of agriculture PTWs
with reference to the locations of the single line diagram.
 Estimated peak demand on each feeder/s upon implementation and percentage voltage
regulation at farthest point on various spur sections.
 Single line diagram of the 33/11 kV substation indicating of 11 kV outgoing feeder to
connect the new feeder. If existing spare feeder is unavailable list of works to be performed
at the substation to install additional new feeder.
 Cost estimate for construction of proposed 11 kV line and associated works based on contract
rates.
The survey report shall be submitted in a suitable format for uploading to the web portal and
for printing.
The survey report will be used as the basic document for execution of work upon approval by
the Project Manager. Upon completion of work, as built single line diagram shall be provided
with relevant information of the works carried out.
1.2. Statutory Clearances
For execution of new 11 KV line construction work, all statutory clearances shall be obtained
by the Contractor coordinating through the Project Manager. These include road crossing
clearances, railway crossing approvals, way leave clearance and any approvals needed from
local authorities, road authorities and other regulatory authorities.
Part -2 : Employer‟s Requirements 139

1.3. Construction of new 11 kV lines

Upon approval from the Project Manger the Contractor shall carry out construction work in
full compliance with the technical instructions, specifications and drawings provided in this
Volume. The details of materials to be supplied and works to be implemented shall be in
accordance with (but not limited to) the EMW schedules

1.4. Stringing of conductors / AB cables

Minimum safety clearances shall be maintained in the 11 kV line. Sag tension charts for
installing ACSR conductors or AB cables shall be developed by the contractor taking into
consideration of conductor / cable characteristics, maximum / minimum temperatures and
design wind pressure as per service conditions.
Based on this, clear guidelines shall be provided to linesmen to ensure ACSR conductors or
bare neutral messenger (for AB cables) are pulled at appropriate tension so that;
(a) Required ground clearances are maintained and
(b) Conductor tension is maintained well below its breaking load at all temperatures.
Dynamometer method or sag method may be used to ensure appropriate tensioning of
conductors / cables during installation. Over tensioning of conductors should be avoided to
ensure its tension does not exceed permissible loading limits at low temperatures. Loose
spans of conductors should be avoided to maintain permissible maximum sag at high
temperatures. Loose spans may only be allowed for short spans in special cases. This applies
when there are practical difficulties to install necessary stays or struts as required at a t-off
point. A short loose span may be used in this case to transfer the stay / strut support point
upstream or downstream of the line.
Stringing of conductors / AB cable shall be done using proper equipment as recommended by
the manufacturer to avoid any damage to the conductor / cable during installation. Temporary
stays or strut poles shall be employed as necessary during stringing operation to ensure safety
of personnel and equipment.

1.5. 11 kV line for underground railway crossing

Detail survey of location of railway crossing shall be carried out by the contractor to avoid
multi-crossing at nearby location. Prior approval from railway authorities for execution of
this work shall be obtained by the Contractor through the Project Manager. Contractor should
ensure timely completion of work during block period allocated by the railway authority by
mobilizing adequate resources.
2 Nos. separate cables shall be laid in separate HDPE pipe enclosures per crossing. One cable
to be kept as a spare. Horizontal Direct Drilling (HDD) shall be used for installation of cables
below the railway tracks.

1.6. New 11 kV Feeder

Part -2 : Employer‟s Requirements 140

The Contractor should verify during the survey availability of existing 11 kV feeder bays at
the substation.to connect new 11 kV lines. If existing feeders are not available contractor
shall arrange to install new outgoing VCB feeder panel at the substation. The item „ New 11
kV Feeder‟ provided in the BOQ includes works relating to supply and installation of 11 kV
VCB feeder panel, 60 m of UG cable and terminal double pole structure for terminating the
UG cable outside the substation. If existing spare 11 kV feeder is already available at the
substation the contractor shall only be entitled for payment relating to UG cabling and
terminal pole structure under this item.

1.7. Tree Cutting and Trimming

The Contractor shall count, mark with suitable quality of paint all the trees that are required
to be cut/trimmed to obtain required way leave clearance. Contractor shall pay compensation
for any loss or damage for tree cutting due to Contractor’swork. If forest clearance is
envisaged for execution of work, clearance of forest department shall be arranged by the
Contractor through the Project Manager. The contractor shall pay tree cutting / trimming
compensation to affected parties based on Employer standard rates as incorporated in price
schedules.

2. Construction of New Distribution Transformers and LT lines

2.1. Survey of proposed distribution transformers and LT line routes.
Mapping of locations of the proposed new distribution transformers and routes of proposed
new LT lines shall be done by GPS survey. While surveying, optimal locations for
distribution transformers shall be proposed to minimize the length of LT lines for providing
supply to existing consumers.
Upon completion of the survey, the Contractor shall provide a survey report with the following
information;
 Single line diagram indicating proposed location of distribution transformers and LT line
routes including line alignment details mapped in a standard mapping software.
 The existing and / or proposed new 11 kV line routes shall also be indicated in the single line
diagram.
 Where any particular bid package does not include new LT lines in the BOQ, proposed
distribution transformers together with the existing / new 11 kV lines shall be mapped.
 Details of proposed connections for distribution transformers to existing or new 11 kV lines
shall be indicated in the single line diagram.
 Proposed capacity of distribution transformers and number of consumers to be connected via
LT lines.
 Types of proposed LT lines - ACSR conductor or AB cable
 Estimation of transformer loading and voltage regulation of LT line at the line end.
 Cost estimate for construction of the proposed distribution transformers and LT lines based
on contract rates.
Part -2 : Employer‟s Requirements 141

Road and railway crossings shall be avoided for LT lines during planning.
The survey report shall be submitted in a suitable format for uploading to the web portal and
for printing.
The survey report will be used as the basic document for execution of work upon approval of
the Project Manager. Upon completion of line work, as built single line diagram shall be
provided with relevant information of the works carried out.

2.2. Statutory clearances

For execution of Distribution Transformer and LT line construction work, all statutory
clearances shall be obtained by the Contractor coordinating through the Project Manager.

2.3. Construction of Distribution Transformers

Distribution transformer substations shall be constructed as per drawings and specifications
including all accessories and equipment. Accordingly main equipment include, 11/0.433 kV
Distribution Transformer, 11 kV Fuse Set, 11 KV Lightning Arrestor, 11 KV TPMO, SMC
Distribution boards with MCCB and all accessories as specified in relevant schedules.
Distribution Transformers must contain 3 Star Label with style and information provided by
the Bureau of Energy Efficiency (B.E.E), Ministry of Power, and Government of India.
The losses in Distribution Transformer should be as per Energy Efficiency Level-2 and
above, as specified in IS 1180 (Part-1):2014. Losses for all kVA ratings of distribution
transformers will be verified during acceptance tests prior to dispatch. Distribution
Transformers shall be subject to inspection during manufacturing (stage inspection), pre-
delivery inspection, and inspection at site during pre-erection/post erection/post
commissioning conditions.
The pre-commissioning / commissioning inspections and tests to be carried out by the
Contractor upon installation of distribution transformer substations

2.4. New LT Distribution Lines

New LT distribution lines shall be constructed as per drawings and specifications including
all accessories and equipment.
It should be noted that for certain bid packages there are no new LT lines included in the bill
of quantities hence not required.
LT lines shall be constructed using both ACSR conductor or AB cables. The Project
Manager shall decide type of the conductor / cable to be used based on information furnished
in the survey report by the Contractor.

2.5. Stringing of conductors / AB cables

Minimum safety clearances shall be maintained for LT distribution line. It may be noted that
for AB cables (insulated lines) reduced clearance of 4 m above ground is applicable for
locations other than across or along any street.
Part -2 : Employer‟s Requirements 142

Sag tension charts for installing ACSR conductors or AB cables shall be developed by the
contractor taking into consideration of conductor / cable characteristics, maximum /
minimum temperatures and design wind pressure as per service conditions as per Employer
specifications.
Based on this, clear guidelines shall be provided to linesmen to ensure ACSR conductors or
bare neutral messenger (for AB cables) are pulled at appropriate tension so that;
(a) Required ground clearances are maintained and
(b) Conductor tension is maintained well below its breaking load at all temperatures.
Dynamometer method or sag method may be used to ensure appropriate tensioning of
conductors during installation. Over tensioning of conductors should be avoided to ensure its
tension does not exceed permissible loading limits at low temperatures. Loose spans of
conductors should be avoided to maintain permissible maximum sag at high temperatures.
Loose spans may only be allowed for short spans in special cases. This applies when there
are practical difficulties to install necessary stays or struts as required at a t-off point. A short
loose span may be used in this case to transfer the stay / strut support point upstream or
downstream of the line.
Stringing of conductors / AB cable shall be done using proper equipment as recommended by
the manufacturer to avoid any damage to the conductor / cable during installation. Temporary
stays or strut poles shall be employed as necessary during stringing operation to ensure safety
of personnel and equipment.

2.6. Installation of AB Cables for LT lines

In order to ensure durability of AB cables and to prevent possibility of failures due to effects
of water treeing, any exposed parts of phase conductors or open cuts of insulation are strictly
not permitted. Hence all connectors to be used for phase conductors of ABC line shall be pre-
insulated type or bare connectors covered by heat shrinkable tubing or GelWrap sleeves. For
installing connectors proper equipment such as insulation stripping tool, ratchet cable cutter,
hydraulic compression tool with compression dies shall be used.
All cable ends shall be properly sealed by pre-moulded or heat-shrinkable type end caps.
Mid-span joints shall be generally avoided by properly planning stringing work. In
exceptional cases where mid span joint is required, pre-insulated compression connectors
shall be used. The joints for each phase shall be staggered along the cable. No mid-span
joints are allowed for AB cable sections running across a street.
Insulated piercing connectors or non-tension mechanical connectors with heat shrinkable
tubing shall be used for non-tension inline connections at anchoring points where necessary.

2.7. Installation of Distribution Boxes for LT lines

3 phase and single phase distribution boxes shall be supplied as per specifications and
installed on poles according to number service connections for LT AB cable lines. When
Part -2 : Employer‟s Requirements 143

installing single phase distribution boxes they shall be connected to alternate phases of the
AB cable in order to obtain adequate level of load balancing.

3. Extension of Substation Control Room Building

Extension of substation control room building shall be carried out as per instructions of the
Project Manger to provide additional space for new outgoing feeder panels if required.
This work shall be carried out as instructed by the Project Manager under the supervision of
civil engineer / technical officer appointed by him. The contractor shall be responsible to
ensure building is extended in the same manner as existing building. The contractor shall be
responsible to provide necessary measures to ensure substation control operations are carried
out without disruption during the construction period.
Part -2 : Employer‟s Requirements 144

13.12. Underground Cabling

1. Survey

The detailed survey shall be carried out for the approved feeders/spur lines by the contractor and
submitted for owner approval. The Successful Tenderer shall carry out radar survey of the route
using Ground penetrating Radar and determine route profile of any other utility cables, pipes etc
along the route. The route survey and drilling profile shall be got approved and finalized by the
Engineer-in-Charge prior to commencement of the drilling, HDPE pipe insertion and cable
insertion.

2.The scope includes :

o Laying of underground 33 KV, XLPE HT Cable (3Cx300 sqmm)
o Laying of underground 11KV, XLPE HT Cable (3Cx185 sqmm , 3Cx240 sqmm)
o Laying of underground 1.1 KV, XLPE, LT Power Cable (3.5Cx240-204.79KM, 3.5Cx 150-
227.39KM, 3.5Cx25 sqmm-44.74KM, 1Cx630 Sqmm -1.8KM and 1Cx400 sqmm-2.4KM)
o Laying of underground 1.1 KV, PVC, LT armoured Power Cable for Street Light (4Cx25 sqmm)
o Laying of underground 1.1 KV,PVC, LT armoured Service Power Cable (4Cx10 sqmm - 56KM,
2Cx10 sqmm - 247KM)

3. Horizontal Direction Drilling

3.1. HDD or Horizontal Directional Drilling is a trenchless boring method for installing underground
cables, pipes and conduits in a shallow curve along a prescribed bore path with the use of a surface-
launched rig / machine, which minimises the disruption of th surrounding area, for example,
roads and driveways. The laying of U/G cables shall normally be done direct in ground through
trenchless boring by using HDPE pipes. However in exceptional circumstances the cables
may have to be laid in covered trenches or in racks fixed to the walls or supported from the
ceilings. The scope shall cover supply of all the material as per the BOQ, erection
equipments, labour and all the other items required for the laying of the power cables. The cable
route markers, at a maximum distance of 200 mtrs, and danger boards shall be provided for the
information of all concerned and for their safety. Any additional requirement in terms of safety
perspective shall be provided by the contractor without any extra cost. It is the responsibility of
the contractor to maintain the required statutory clearances from other utility services. Any damage
caused to any utility services/ human life / public property etc shall be the sole responsibility of
the contractor. The contractor will lay the underground power cable in such a fashion that no
straight through joints are required and only end terminations joints are required, however
wherever the joints are required in HT cable then the same shall be carried out overhead on PCC
poles structure. In exceptional circumstances such as where length of line is more than the
standard cable length in drum and overhead jointing is not possible then straight through joints
will be allowed. The contractor shall have ISO 9001-2008/18001-2007
Part -2 : Employer‟s Requirements 145

3.2. The Horizontal drilling shall be for a distance of not less than 90 mts at each stretch and
subsequently thereafter. The reinstatement of road dug up for drilling at every 90 mts shall be
incorporated in the price for Horizontal Directional Drilling.
3.3. Disposal of extra excavated material such as mud, slurry, stones etc shall be also included in the
rate per meter of horizontal drilling and shall not be charged extra.
3.4. The trenchless technology shall be used with HDPE casing for the portion of the cable route such
as road, railway, nullah crossing and without HDPE casing for major portion of the cable route.
The outer diameter of the HDPE pipe shall be suitable for insertion in an 8” diameter
horizontally drilled bore. The HDPE pipe shall be of PE 80 grade with pressure rating PN4
conforming to IS 4984/1995 and shall have wall thickness of 6.20 to 7.10 mm. The HDPE pipes
shall be joined by using Butt welding and a 7/20 G.I wire shall be provided along the entire
length of each pipe duct.
3.5. The directional drilling equipment shall consist of a directional drilling rig of sufficient capacity
to perform the bore and pull back the pipe/cable, a drilling fluid mixing, delivery, and recovery
system of sufficient capacity to successfully complete the installation, a drilling fluid recycling
system to remove solids from the drilling fluid so that the fluid can be reused (if required), a
magnetic guidance system or walk over system to accurately guide boring operations, a vacuum
truck of sufficient capacity to handle the drilling fluid volume, and trained and competent
personnel to operate the system. All equipment shall be in good, safe condition with sufficient
supplies, materials and spare parts on hand to maintain the system in good working order for the
duration of this project.
3.6. The directional drilling machine shall consist of a hydraulically powered system to rotate and
push hollow drilling pipe into the ground at a variable angle while delivering a pressurized fluid
mixture to a guidable drill (bore) head. The machine shall be anchored to the ground to withstand
the bulling, pushing and rotating pressure required to complete the installation. The hydraulic
power system shall be self-contained with sufficient pressure and volume to power drilling
operations. Hydraulic system shall be free of leaks. Rig shall have a system to monitor and
record maximum pullback pressure during pullback operations.
3.7. There shall be a system to detect electrical current from the drill string and an audible alarm
which automatically sounds when an electrical current is detected.
3.8. The drill head shall be steerable by changing its rotation and shall provide necessary cutting
surfaces and drilling fluid jets.
3.9. Mud motors shall be of adequate power to turn the required drilling tools.
3.10. Drill Pipe shall be constructed of high quality 4130 seamless tubing, grade D or better, with
threaded box and pins. Tool joints should be hardened to 32-36 RC.
4. Accessories
4.1. This being a Turnkey contract, successful installation, commissioning & integration with
existing system, of those equipment/accessories/material not specifically mentioned in the
specifications, shall be the responsibility of contractor. No extra payment shall be made for these
inherent works.
Part -2 : Employer‟s Requirements 146

4.2. He shall also supply all other associated equipment/ material/accessories not specifically
mentioned in this tender specification but are required for successful and trouble free operation
of the executed work as a whole. For that no extra payment shall be made to the contractor.
5. Technical Standards
5.1. The electrical equipments and materials required during erection should be of high standard.
Technical features of these equipments and materials must conform to the technical specification
given in this bidding document. Wherever the same is not specified, it must conform to the relevant
I.S for that material.
5.2. Materials conforming to other international standards, which ensure equal or higher quality than
the standards mentioned above, shall also be acceptable. In case the bidders who wish to offer
materials conforming to other standards, salient points of difference between standards adopted
and specific standards shall be clearly brought out in the respective schedule. Four copies of such
standards with authentic English version shall be furnished along with the offer.
5.3. Whenever a material or an article is specified or described by the name of a particular brand,
manufacturer or trade mark, the specific item shall be understood as establishing type, function and
quality desired. Products of other manufacturers may also be considered, provided sufficient
information is furnished, so as to enable the owner to determine that the products are equivalent
to those mentioned.
5.4. Materials supplied/used shall conform in all respects to the relevant Indian Standard
Specification with latest amendments there to.

Title IS No.
1. Cement IS 269
2. Steel IS 6003/1970
3. Fasteners IS 6639/1972
4. Concrete mix IS 1343
5. RCC IS 456
6. Cable laying and jointing IS 1255
Installation work pertaining to equipment, cable laying etc should be in accordance with the
applicable standards, safety codes etc.
6. Site Storage/ Transportation
6.1. It shall be the responsibility of the contractor to store, move/transport from stores/storage yard
etc., relevant items and accessories to the place of installation wherever necessary he will
assemble all parts of equipment. In accordance with the specific installation instructions as directed
by Site Engineer.
6.2. The stores should be dismantled and site cleared after the work is completed

7. Erection, Testing and Commissioning

7.1. All the works covered under the scope of the tender shall be done in accordance with the norms
defined by the Employer, unless the same is not specifically defined in the specification or with
Part -2 : Employer‟s Requirements 147

the provisions of Indian Electricity Rules/Acts/Other Government Rules/Regulations as

prevalent at the time of execution of the job/work.
7.2. Installation shall be carried out strictly in accordance with the approved drawings Modifications,
if any, required to suit site conditions, shall be carried out only with the prior approval of the Site
Engineer. All such changes shall be incorporated in “As built” drawings to be furnished by the
contractor.
7.3. Responsibility for successful installation of other equipment accessories, purchased but not
mentioned specifically above, and their commissioning shall be on contractor. For all such items
the contractor shall be supplying all material and equipment required to accomplish the job
complete in all respect.
7.4. Installation work pertaining to equipment, cable laying etc should be in accordance with the
applicable standards, safety codes etc.
7.5. The contractors shall themselves be responsible for timely arrangement/ procurement of all the
raw materials required for the manufacture of all tendered items by them/ their and / or by their
vendors.
7.6. While Repairing & Replacing the equipment, if any other equipment gets damaged due to
negligent handling of the contractor the same shall be replaced by the contractor at his cost to the
owner satisfaction.
7.7. He shall be responsible for dismantling of defective equipments, there proper handling and
shifting.
7.8. Also he shall hand over the old & dismantled equipments/ material to the purchaser‟s local stores
or other sites as per instructions of the purchaser for which no extra payment shall be made.
7.9. All charges on account of damages/losses/claims/thefts etc. involved under the conditions laid
down above shall be borne by the contractor. It‟s cost shall be recovered from his bills /security
deposits /other assets.
7.10. In order to avoid hazards to personnel moving around, the equipment such as Transformer,
Capacitor Banks, Switchgears etc. if required to be kept charged after installation till their
commissioning, shall be cordoned off by suitable barriers to prevent accidental injury to
personnel moving around.
7.11. Where the equipments/ assemblies are supplied in more than one part, the contractor shall make
all necessary mechanical and electrical connections between the sections. The contractor shall
also do necessary adjustment in the alignments required for its proper operation.
7.12. Care shall be taken in handling instruments relays and other delicate devices where instruments
and relays are supplied separately they shall be mounted only after the associated switch
gear/control panels are erected and aligned.
7.13. Precaution: The contractor shall exercise all possible care to avoid damage to public utilities
e.g. water/ sewage pipes telephone and power lines/cable already existing. In case of any accidental
damage during the work, the contractor shall be responsible to repair/replace the same at his own
cost, and shall ensure that the purchaser is not put to any loss.
Part -2 : Employer‟s Requirements 148

7.14. The contractor shall have to provide proper lighting, barricading, signboards etc. at the work
site as a necessary precautionary arrangement to avoid accident/ damage/ losses to the public
/utilities/properties.
7.15. Site Solution: It may be possible due to some reasons or others that it would not be possible to
work as per the procedure. In such case/cases, the solution to the problem shall be achieved by
the purchaser with the consultation of contractor, and the contractor shall work as per procedure
proposed by the purchaser. Such cases shall in variably be informed to the engineer of the
contract for which no extra payments shall be made.
7.16. Space Constraints: While executing the job it is quite possible that some of the specified work
may not be carried out due to space/land/ other technical constraints etc. In such case the
concerned Employer, if required, may divert this work at some other site or cancel the left over
portions of work.
7.17. The contractor shall ensure that the equipment under erection as well as the work area and the
site are kept clean to the satisfaction of the Engineer. In case, the Engineer is not satisfied about
the cleanliness he will have the right to carry out the cleaning operations and expenditure incurred
in this regard will be to contractor’saccount. Packing cases and packing materials shall be
promptly cleared from sites.
Part -2 : Employer‟s Requirements 149

13.13. Specification for erection of 66 kV M/C, D/C tower / H-frame line :

1.1. GENERAL TECHNICAL PARTICULARS FOR ERECTION OF 66 KV LINES.

1.1.1. SCOPE :
The erection work covered under these sections consists mainly of
i. Distribution of all materials to erection site.
ii. Stub setting.
iii. Tower Erection.
iv. Cold line Stringing.
v. Testing and commissioning and Guarantee of Line.
1.1.2. The contractor shall be fully responsible for completing all the above works and till them
are taken over by the Employer.
1.1.3. The methods of erection are dealt within details, but are left to the contractor who shall
exercise his own judgment with regards to actual handling of materials and in deciding upon the best
methods to be adopted in the erection of the towers, conductors and other materials.

1.2. WAY LEAVE/TREE CUTTING AND OTHER CONSTRUCTION :

1.2.1. The Employer will arrange for write off way and for tree cutting clearance, the contractor
will instruct his laborers & staff to use minimum area while doing the work where there are standing
crops. No person of the contractor should pick in items from standing crops of fruits. The contractor
should take all possible steps to avoid or minimize damage to standing crops etc.
1.2.2. The contractor should immediately notify and obstruction or hindrance from local villages
or the local authorities in the prosecution of the work to the concerned Engineer-in-charge, but should
not deal directly in the matter. The Engineer-in-charge will arrange to remove the obstacles as soon
as possible.

1.3. ACCESS TO LOCATIONS :

1.3.1. It will be the contractor’ssole responsibility to take the materials up to the locations
required. Any path way, temporary road or temporary bridge required will have to be provided by
the contractor at his cost. If for any reasons the above is not feasible the contractor at his own cost
shall have to arrange transportation by Head roads.

1.4. DISTRIBUTION OF MATERIALS :

1.4.1. The contractor has to take delivery of tower materials/lines materials from the Employer‟s
stores and transport it to the respective tower erection sites and will be responsible for any damages
to or loss of all materials at any stage during the Transportation or erection. The materials that will
be issued by the Employer will be in „AS IS WHERE IS‟ conditions at the store centre of the Employer
in the area during working hours days. All the materials received by the contractor shall be got
insured for storages and erection risk by the contractor at his own cost. An indemnity
Bond/Bonds have to be issued by the contractor for the materials take over by him for erection.
Part -2 : Employer‟s Requirements 150

1.4.2. On completion of the work all surplus tower and line materials including the excess Bolts
& Nuts and stub materials shall be returned by the contractor to the nearest respective stores of the
Employer as per the instructions of the Engineer-in-charge of the works at no extra cost to the
Employer.
1.4.3. The contractor shall submit the complete material account immediately after the works is
completed and in case not late than one month of completion and Handing over of the line.

1.5. STUB SETTING AND FOUNDATIONS :-

1.5.1. The contractor shall be fully responsible for correct setting of stubs in accordance with
approved methods at the exact locations and alignments and in precisely correct level; stub setting
templates to the supplied by the Employer should be used for proper setting of stubs. The contractor
will be responsible for constructing the foundations in accordance with the design of each type of
foundations supplied to him by the Employer and as per approved final schedules.
1.5.2. The foundation work includes stone revetment, concrete or earth filling above ground level
where necessary and stacking and tamping on the site of all surplus excavated soil. Surplus stone
should be stacked within the tower base.
1.5.3. Classification of Soil :
1. Normal soil : Which can be readily removed ordinary spades, shovels viz Normal Soil,
Black cotton soil, Hard & Soft Morrum and Yellow clay.
2. Soft Rock : Literate, line stone or rock which break away chips or slabs.
3. Hard-Rock : Rock which may need chiseling or blasting.
4. wet Soil : Soil encounters in wet location.
1.5.4. EXCAVATION FOR FOUNDATION :
1.5.4.1. The tenderer should quote different rates for different types of soil. The contractor will be
intimated the alternative that will be operated, the payment for excavation will be limited to guaranteed
volume as per approved excavation drawings that will be furnished by the Employer to the contractor
even though the contractor may excavates more the sake or his own convenience. If the excavated
depth is more than the depth shown in approved drawings, the additional depth should be filled in with
lean concrete (1:4:8) at contractor’scost.
1.5.5. CONCRETE :
1.5.5.1. The cement required shall be supplied by the contractor approved by the Employer
1.5.5.2. All cement is used shall be accountable. If the quantity of cement utilized in the work is
observed to be more than the permissible quantities worked out bases on the finally approved
foundation drawings and subject to the maximum as per the guaranteed volumes, irrespective of the
fact that the cost of cement is recovered from the contractor’sBills.

The cement consumption for difference types of concrete shall be considered as follows:-
1. M-20 Mix (1:1.5:3) 8.2 bags.
2. M-15 Mix (1:2:4) 6.5 bags.
Part -2 : Employer‟s Requirements 151

1.5.5.3. The sand shall be of best quality containing hard siliceous materials, clean and of snap
angular grit type and free from earth or organics matter of salts and to the satisfaction of the
Engineer-in-charge. The sand shall be washed before use. No. salty or Darkish water shall be used
for concreting.
1.5.5.4. The aggregate shall be of the best quality to the satisfaction of the Engineer-in-charge and
brakes to maximum size of 40mm for thick concrete and 20mm thin concrete section. It should also
be free from grit and dirt.
1.5.5.5. The mixture of concrete to be used shall be such as to produce a sound : compact and water
proof concrete and shall not be weaker than 1:2:4 ratio with 20mm stone metal for chimney portion
and 40mm stone metal for mass concreting pyramid portion or slab portion, unit rates may be quoted
for concrete of M-15 Mix ratio. The concrete shall be mixed as stiff as the requirements of placing
the concrete in the form of moulds with case and degree to which concrete resists segregations will
permit. Hence the quantity of water used should not be too much.
1.5.5.6. Proper forms or moulds adequately braced to retain proper shape while concreting should
be used for chimney or pyramid and slab portions. Form boxes should be water tight so as not to allow
cement cream to come out leaving only sand and jelly to form money coml. in concrete. Form excess
boxes should be cleaned and oiled before using for concreting.
1.5.5.7. All wet locations must be kept completely dewatered both during the placing of concrete
and for 24 hours after completion. There should be no disturbance of concrete by water during this
period.
1.5.5.8. Form boxes should not be removed before 24 hours after concreting. Concrete surface
where required should be set right with tick cement and mortar immediately after removal of the
forms.
1.5.5.9. After 24 hours of pouring, the concrete should be cured by keeping it continuously wet for
14 days. The pit may be back filled with selected earth sprinkled with necessary amount of water and
well consolidated layers not exceeding 150mm after 48 hours and thereafter both the exposed top
and the fill shall be kept wet for the remainder of the prescribed time.
1.5.5.10. Payment for the quantity of excavation and concreting for each type of tower shall be made
on prorate basis of actual work done subject to the maximum of guaranteed volumes as per the
approved drawings to be furnished by the purchaser.
1.5.5.11. The supply of steel for reinforcement, if required is to be supplied by the contractor
1.5.6. EXCAVATION IN ROCK :
1.5.6.1. Where towers are to be planted in rock, suitable holes should be drilled, but if drilling is
difficult, blasting may be resorted to, but sufficient care should be taken to eliminate the possibility
of serious cracking of the rock.
1.5.6.2. Care should also be taken to minimize the concreting for filling blasted areas. Stubs may
be shortened suitably in case of drilled holes as per design drawings.

1.6. ERECTION OF TOWERS :

Part -2 : Employer‟s Requirements 152

1.6.1. The superstructure of towers should be erected on foundations after 14 days of concreting.
However, the method adopted for erection of towers is left to the decision of the contractor subject to
the condition that be takes responsibility for any damages to materials. No. tower member should get
strained or bent during erection. The tower must be truly vertical after exaction and no straining would
be allowed to bring it in alignment. Maximum tolerance in verticality that will be permitted is one mm
per 360mm of tower height. All bolts and nuts shall be made fully tight and finally the bolt threads
shall be centre purchased to avoid nuts becoming loose, punching of bolts shall be made by chamfering
the threads with centre punch at least at three places equally spaced on contact surface of bolts and
nuts.
1.6.2. Tower erection shall include erection of all accessories and fittings including attachment
for step bolts, ladders, platform, „U‟ Bolts shackles, Hangers, strain plates etc. and punching of bolts
and nuts so that towers are completed in all respect.
1.6.3. Suitable tower extension shall be erected to get desired ground clearance whenever
required. Which have been determined at the time of final survey.

1.7. GROUNDING :
1.7.1. It is necessary that in no case tower footing resistance should be more than 10 ohms.
During dry weather.
1.7.2. PIPE TYPE EARTHING :
1.7.2.1. At location where footing resistance does not exceeds 10 ohms the pipe type earthing as
per method specified by Employer would be followed. The contractor will have to supply all
materials required for grounding including salt, finely broken coke/charcoal, G.I. Pipe G.I. Wire clamp
& Nuts-Bolts etc.
1.7.3. COUNTERPOISE EARTHING :
1.7.3.1. In place of high receptivity soil conditions, counterpoise earthing shall be adopted as per
Employer specifications to bring down the tower footing resistance below 10 ohms. The
counterpoise earthing shall be buried 600mm below ground level and for this purpose some space
should be left out in chimney coping portion at the time of stub setting. Coping should be complete
after installation of counterpoise earthing. All materials are to be supplied by the contractor.

1.8. INSULATOR HOISTINGS:

1.8.1. Suspension Insulator strings shall be used on all tangent type towers with deviation up to 2
and tension insulator string on all shall medium, large angle and dead end type towers on all lines.
1.8.2. Insulators string shall be assembled on ground. These shall be cleaned and examined for their
cracks ships or defective glazing (not exceeding half centimeter square) and then hoisted by careful
handling, the work will include fitting of all hard wares and fitting in their proper places and order.

1.9. STRINGING OF CONDUCTOR AND GROUND WORK:

Part -2 : Employer‟s Requirements 153

1.9.1. Before commencing of stringing work, tower healthiness certificate of each & every tower
location must be submitted to Engineer in charge in writing.
1.9.2. Before commencing of stringing work, contractor must obtain approval of sag tension
charts showing initial and final sags and tensions for various temperature and spans.
1.9.3. The contractor shall be responsible and will take care of proper handling of drums from stores
to site, sufficient numbers of aluminum sketch blocks shall be used for laying out the A.C.S.R.
Conductors. Necessary precautions shall be taken to avoid conductor rubbing on the ground by
providing adequate ground rollers on supports. Additional rollers shall also be provided to cross thorny
hedges, forcing and other obstructions to avoid scratching of conductors. The conductor and ground
wire shall be made to sag correctly as per stringing charts before they are finally transferred to the
hard wares for conductors and to clamps for ground wire, No joints should be made at less than
30 meters from the tower and that no joint shall be permitted in Railway., River & Road crossing
spans. There shall not be more than one joint in a span of each conductor. All conductors shall be
stressed to their maximum working load at the time of stringing.
1.9.4. The minimum clearance between the lowest point of conductor and ground shall not be
less than required those. All compression joints should be carefully made and a record of initial and
final length of the joints, jointly signed by contractor’sand Employer‟s representatives should be
maintained. Dynamometer shall be used in tensioning the conductors, check for sag should also be
made at intervals when conductors are drawn up. Over stressing, causing damage to towers, should
be avoided care should be exercised not to over tension the conductor. An extra sag if 150mm should
be allowed at all important tension points like Railway and River crossing. After being pulled the
conductor/ground wire shall not be allowed to hang in the stringing sheaves for more than 72 hours
before being pulled to the specified sag. During the time the conductor/ground wire is on the
stringing sheaves before sagging in, it shall be ensured that the conductors/ground wire is not damaged
to wind, vibration vehicles or other causes.
1.9.5. The conductor shall be pulled up to desired sag, and left in Arial stringing sheaves for at least
one hours after which the sag shall be rechecked and adjusted, if necessary, before clipping in an
transferring the conductors from the Arial stringing sheaves to the suspension clamps.
1.9.6. Conductor shall be clamped within 24 hours of sagging in. The sag will be checked the
first and last span of the section in case of sections up to eight spans and in one intermediate open
also for section with more than eight spans.
1.9.7. The stinging sheaves, when suspended on the transmission structure for sagging, shall be
so adjusted that the conductor will be on the sheaves at the same height as the suspension clamp to
which it is secured.
1.9.8. All the line conductors shall be terminated at sub-station structures whose details shall be
furnished by the Employer, at the appropriate times, The contractor shall fix strain insulators on the
sub-station structures.
1.9.9. P.A Rods and Vibration Dampers shall be fitted at each suspension towers before final
clamping of conductor with insulator string. Vibration damper are to be fixed using aluminum tape
with each clamping bolt and in correct vertical position in relation to conductor. Compression type
Part -2 : Employer‟s Requirements 154

joints are to be used for jointing of conductors. Each part connected with joints shall be perfectly
cleaned by wire brush and properly greased before final compression. All the joints of conductors
and earth wire shall be made in the best workmanship manner and shall be perfectly straight and having
maximum possible strength.
1.9.10. Stringing work includes the hoisting insulators, fixing hardware, lifting amour rods, and
vibration dampers, making joints, repair sleeve etc. All stringing tools and hydraulic compressor
machine should be arranged by the contractor.

1.10. SUPPLY OF MATERIALS BY EMPLOYER :-

1. G.I. Tower Material & Nut-Bolts & ACD excluding barbed wire.
2. Conductors, Earth Wire, Disc Insulators, Hardware for conductor and Earth Wire as the case
may be.
3. All jointing materials and accessories for ACSR conductor.
4. Any other items required to complete the work.

1.11. MATERIALS TO BE SUPPLIED BY THE CONTRACTOR:-

1. Cement, Sand, Stone, and Crusher, metal, gravels and morrum.
2. DP/NP/PP/CIP Including supply of G.I. Nut Bolts and Barbered wire for fixing of anti-
climbing devices complete.
3. Coke, Salt and G.I. wire and all earthing requirements.
4. Heavy duty G.I. Earthing pipe 32 mm dia, 3 mtr. Long and 50x6 mm. G.I. Flat with nut-bolt for
pipe type earthing and G.S.S. Wire, Lugs, Bolts, Nuts etc for CP type earthing as per specification.
5. Any other materials which shall be required to complete the work satisfactorily in all respects
and not specified in above for supply of materials by the Employer.
6. Steel bars required for reinforcement.
Part -2 : Employer‟s Requirements 155

13.14. Plinth Mounted Distribution Substations

1.0 SCOPE
The specification covers the design, engineering, manufacture, stage inspection, testing, pre-
delivery inspection, supply, delivery, loading, unloading and performance requirements of 11/0.433
KV non-sealed type aluminum and copper wound distribution transformers for outdoor use. The
transformers shall be double wound, three phase, oil immersed with ONAN cooling. The rating
required under this specification is 500 KVA with copper windings.

The equipment offered should have been successfully type tested within five years from date of tender
and the designs should have been in satisfactory operation for a period not less than three years as on
the date of bid opening. Compliance shall be demonstrated by submitting with the bid, (i)
authenticated copies of the type test reports and (ii) performance certificates from the users,
specifically from Central Govt./ State Govt. or their undertakings.

The scope of supply should also include the provision of type tests on random samples if desired by
the purchaser. In this case the bidder has to bear the charges for conducting such type tests at CPRI
or National Govt. approved Laboratory.

The transformer shall conform in all respects to highest standards of engineering, design,
workmanship, this specification and the latest revisions of relevant standards at the time of offer
and the Purchaser shall have the power to reject any work or material, which, in his judgment, is not
in full accordance therewith.

2.0 CODES & STANDARDS

Except where modified by this specification, the transformers shall be designed, manufactured and
tested in accordance with the latest editions of the following standards. The Bidder may propose
alternative standards, provided it is demonstrated that they give a degree of quality and performance
equivalent to or better than the referenced standards. Whether to accept or reject any alternative
standard shall be adjudged by the Purchaser. The Bidder shall furnish a copy of the alternative
standard proposed along with the bid. If the alternative standard is in a language other than English,
an English translation shall be submitted with the standard. In the case of conflict the order of
precedence shall be 1) IEC or ISO Standards, 2) Indian Standards, 3) other alternative standards.

IEC/ISO Indian Standard Subject

Part -2 : Employer‟s Requirements 156

IEC 71 Insulation Coordination

IEC 76 IS 2026 Power Transformers
IS 1180 Outdoor Three Phase Distribution Transformers up to
500 KVA, 11/ 0.433 KV, Non- Sealed Type
IEC 137 IS 2099 Bushing for Alternating Voltages above 1000V
IEC 156 Method of determining Electric Strength of Insulating
Oils.
IEC 296 IS 335 Specification for Unused Mineral Insulating Oils for
Transformers and Switchgear
IS 6792 Method of determination of electric strength of
insulating oils.
IEC 354 IS 6600 Loading Guide for oil immersed Transformers
IEC 437 Radio Influence Voltage Measurement
IEC 551 Determination of Transformer and Reactor Sound
Levels.
IEC 616 Terminal and Tapping markings for power
transformers.
IEC 722 Guide to the Lightning and Switching impulse testing
of Power Transformers and Reactors
ISO 1460/BS 729 Galvanizing

This list is not to be considered exhaustive and reference to a particular standard or

recommendation in this specification does not relieve the Supplier of the necessity of providing the
goods complying with other relevant standards or recommendations.

3.0 SERVICE CONDITIONS

The service conditions shall be as follows:
 maximum altitude above sea level - 1,000m
 maximum ambient air temperature - 50° C
 maximum daily average ambient air temperature - 35° C
 minimum ambient air temperature - 5° C
 maximum temperature attainable by an object exposed to the sun - 60 ° C
 maximum yearly weighted average ambient temperature - 32° C
 maximum relative humidity - 100%
 average number of thunderstorm days per annum (isokeraunic level) - 70
 average number of rainy days per annum - 120
 average annual rainfall - 1500 mm
 maximum wind pressure - 260Kg / m2
Part -2 : Employer‟s Requirements 157

Environmentally, the region where the equipment will be installed includes coastal areas, subject to
high relative humidity, which can give rise to condensation. Onshore winds will frequently be salt
laden. On occasions, the combination of salt and condensation may create pollution conditions for
outdoor insulators.
Therefore, outdoor material and equipment shall be designed and protected for use in exposed,
heavily polluted, salty, corrosive, tropical and humid coastal atmosphere.

4.0 SYSTEM CONDITIONS:

The equipment shall be suitable for installation in supply systems of the following characteristics.
Frequency - 50 Hz ± 5%
Nominal system voltages 11 KV System - 11 KV
LV System - 433/250 V
Maximum system voltages 11 KV System - 12 KV
LV System - 476 V
Minimum LV voltage (NEC) - 392 V
Nominal short circuit apparent power of 11 KV System - 500 MVA (IS: 2026)
Insulation levels
1.2/50 μ sec impulse withstand 11 KV System - 75KV peak (IS:2026)

Power frequency one minute withstand 11 KV System - 28 KV (rms)

(wet and dry) LV System - 3 KV (rms)
Neutral earthing arrangements: LV System - Solidly earthed

PART 2: TECHNICAL
SPECIFIC TECHNICAL REQUIREMENTS
1 Rated KVA (ONAN rating) 500 KVA, 11/
0.433 KV
2 No. of phases 3
3 Type of installation Outdoor
4 Frequency 50 Hz (± 5% )
5 Cooling medium Insulating Oil
(ONAN)
6 Type of mounting for 500 KVA on
Wheels, Mounted
on rails.
7 Rated voltage
a) High voltage winding 11 KV
Part -2 : Employer‟s Requirements 158

b) Low voltage winding 0.433 KV

8 Highest continuous system voltage
a) Maximum system voltage ratio (HV/ LV ) 12 KV / 0.476 KV
b) Rated voltage ratio (HV / LV ) 11 KV / 0.433 KV
9 No. of windings Two winding
Transformers
1 Type of cooling ONAN ( Oil
0 natural / Air
natural )
1 KVA Rating corresponding to ONAN 100%
1 cooling system
1 Method of connection:
2
HV: Delta
LV: Star
1 Connection symbol DYN 11
3
1 System earthing Neutral of LV side
4 to be solidly
earthed.
1 Percentage impedance voltage on normal tap and KVA base at 750 C % Impedance +
5 corresponding to HV/ LV rating and applicable Tolerance %
tolerances (Negative tolerance will not be allowed):
5.0 + 10% (No
Negative
Tolerance)
1 Intended regular cyclic overloading of windings As per IEC –76-1,
6 Clause 4.2
1 a) Anticipated unbalanced loading Around 10%
7
b) Anticipated continuous loading of windings (HV / LV) 110 % of rated
current
1 a) Type of tap changer Off-load tap
8 changer
b) Range of taping + 2.5% to – 7.5%
in 5 equal steps of
2.5% each on HV
winding
1 Neutral terminal to be brought out On LV side only
Part -2 : Employer‟s Requirements 159

9
2 Over Voltage operating capability and 112.5 % of rated
0 duration voltage
(continuous)
2 Maximum Flux Density in any part of the core and yoke at rated KVA, 1.5 Tesla
1 rated voltage i.e. 11 KV / 0.433 KV and system frequency of 50 HZ

2 Insulation levels for windings :-

2
a) 1.2 / 50 microsecond wave shape Impulse HV: 28 LV: N.A.
withstand (KVP)
b) Power frequency voltage withstand (KV- rms) HV: 28 LV: 03

2 Type of winding insulation

3
a) HV winding Uniform
b) LV winding Uniform
2 Withstand time for three phase short 2 Seconds
4 circuit
2 Noise level at rated voltage and frequency As per NEMA
5 Publication No.
TR-1
2 Permissible Temperature Rise over ambient temperature of 500C
6
a) Of top oil measured by thermometer. 350C
b) Of winding measured by resistance. 400C
2 Minimum HV clearances in air (mm) :-
7
a) Phase to Phase 280
b) Phase to ground 140
2 Terminals
8
a) HV winding line end 12 KV oil filled
porcelain
communicating
type of bushings (
Antifog type )
b) LV winding 0.433 KV
porcelain type of
Part -2 : Employer‟s Requirements 160

bushings
(Antifog type)
2 Insulation level of bushing HV LV
9
a) Lightning Impulse withstand (KVP) 75 Not applicable
b) 1 Minute Power Frequency withstand 28 3
voltage (KV –rms )
c) Creepage distance (mm) (minimum) 25 mm/ KV
3 Material of HV & LV Conductor Electrolytic
0 Copper for 500
KVA
3 Maximum current density for HV and LV 1.4 Amp/ mm2 for
1 winding for rated current Aluminum
windings and 2.4
Amp/ mm2 for
Copper windings.
3 Polarisation index i.e ratio of megger values at 600 sec. to 60 sec for HV Shall be greater
2 to earth, L.V to earth and HV to LV. than or equal to 1.5,
but less than or
equal to „5‟.
3 Core Assembly Boltless type
3
3 Maximum permissible No Load and Load 500 KVA
4 Losses (Watts)
a) No Load Losses at rated voltage and rated - 950
frequency
b) Load Losses at rated current and at 750 C - 6500

5.0 TYPE OF TRANSFORMER

The transformers shall be of core type construction, double wound, three phase, oil immersed,
11/0.433KV, 50 Hz with natural oil and air cooling (ONAN) to be used as step down transformers
for outdoor use. The design of the tank, fittings, bushings, etc shall be such that it will not be necessary
to keep the transformer energized to prevent deterioration as the transformers may be held in
reserve, outdoors, for many years.

6.0 PERFORMANCE , CAPACITY AND SHORT CIRCUIT RATINGS

The following ratings are covered under this specification
Part -2 : Employer‟s Requirements 161

• 500 KVA, 11/0.433 KV, Copper wound

The transformer shall be capable of supplying a continuous load equal to its KVA rating, under the
following conditions:
 continuous steady load;
 design at maximum ambient air temperature of 500C;
 400 C average winding temperature rise and 350C top oil temperature rise for conventional
breathing transformers.

The transformer may be overloaded during emergency up to 150% of its continuous rating in
accordance with IEC Publication 354 or IS: 6600. Bushings and other current-carrying parts shall also
be designed for this condition.

The transformer shall be capable of withstanding for two seconds without damage to any external
short circuit, with the short circuit MVA available at the terminals of either winding with rated voltage
on the other winding. If short circuit tests have been carried out on the particular design of transformer
offered, the test results shall be supplied with the bid.

The thermal ability to withstand short circuit shall be demonstrated by calculation.

The transformer shall be capable of withstanding the thermal and dynamic effects of short circuits,
as specified in IEC 76-5 or IS: 2026: Ability to withstand short circuits.

The maximum flux density in any part of the core and yoke at rated KVA, Voltage and frequency
shall not exceed 1.5 Tesla.

7.0 VOLTAGE RATIO & TAPPING RANGE

The transformers shall have the following ratio:-

 the nominal voltage ratio shall be 11,000/ 433 V for 500 KVA transformers;
 Tolerance on the voltage ratio shall be ± 0.5%.
 For transformers of ratings 500 KVA, 11/0.433 KV, Taps shall be provided on the H.V.
Windings for voltage variation from tap-1 (+2.5%) to tap-5 (- 7.5%) in equal steps of 2.5 %. Tap
No-2 shall be the principal (normal) tap.
Part -2 : Employer‟s Requirements 162

The bidder shall state in the technical schedule, the percentage regulation at full load, power factor
1.0 and at full load, power factor 0.8 lagging.
Transformers shall be suitable for parallel operation with each other.
8.0 PERCENTAGE IMPEDANCE
The Percentage of Impedance at 75ºC shall be 5% for 500 KVA transformer with positive tolerance
of 10%. No negative tolerance on percentage Impedance is allowed.
9.0 LOSSES
The No Load and Load Losses shall not exceed the values given below:-

KVA Rating Maximum No Load loss in Maximum Full Load

Watts loss in Watts at
75ºC.
500 KVA 950 6500

The above losses are maximum allowable and there should not be any positive tolerance.

The offered transformer(s) should have been type-tested at CPRI/ National Govt. approved laboratory.
The bid shall be accompanied with type-test reports (short circuit test and Impulse test) conducted at
Central Power Research Institute / National Govt. approved laboratory for the offered transformers
within five years from date of tender. The short circuit test report(s) must contain the measured no
load loss and load loss, determined by CPRI/ National Govt. approved laboratory.
In case of any doubts, <EMPLOYER> reserves the right to verify the original type test reports of
CPRI/ National Govt. approved Laboratory or ask the supplier to conduct the type tests at CPRI/
National Govt. approved Laboratory at his (supplier‟s) cost for re-confirmation of the test results
particularly no load losses, load losses and percentage impedance. Bids without type test reports
shall not be considered for evaluation.

If the bidder quotes lower values of losses than the CPRI‟s measured losses, he has to prove the same
by conducting the Impulse & short Circuit tests at CPRI/ National Govt. approved laboratory along
with measurement of no load losses and load losses at his own cost in presence of EMPLOYER‟ s
authorized representative without any financial liability to EMPLOYER.

However, if the loss figures will exceed the stipulated values as per specification, the transformer(s)
shall be out rightly rejected.
Part -2 : Employer‟s Requirements 163

10.0 VECTOR GROUP

The transformers shall be connected delta-star, in accordance with vector group reference Dyn11 of
IEC - 76/ IS - 2026.

The LV neutral shall be brought out to a terminal bushing, which shall be identical to the phase
bushings in all respects.

11.0 LOSSES AND CAPITALISATION

Transformers would be out rightly rejected if losses exceed the values indicated at clause-10 above.

12.0 FLUX DENSITY

The flux density at rated voltage & rated frequency shall not exceed. 1.50 Tesla. The transformer
must be capable of operating at 10% over voltage and at frequency of 48.5 Hz without saturation.

13.0 INSULATION LEVELS

The insulation levels as defined in IEC 76-C/ IS: 2026 Insulation levels and dielectric test shall
apply as per Table.
HV Winding LV Winding
Basic Impulse voltage Level (KVp) (1.2/50 micro. sec. 75 Not Applicable
Wave )
Power Frequency voltage withstand level, Wet and Dry 28 3
(KV)

14.0 NOISE LEVEL

The average noise level of the transformers shall not exceed 51db. The measurement shall be
carried out in accordance with IEC 551 at a distance of 300mm from the envelope of the
transformer.

15.0 RADIO INFLUENCE VOLTAGE

The maximum radio influence voltage shall be 250μ V, measured as specified in IEC 437.

16.0 CORE AND WINDINGS

Core
Part -2 : Employer‟s Requirements 164

 Stage level inspection for core construction shall be carried out by the owner.
 Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure
and the action of hot transformer oil.
 The core shall be constructed from high grade, non-ageing, Cold Rolled Grain Oriented silicon
steel laminations (CRGO or M3 or better) only. No other core materials shall be entertained.
Bidders are requested to note that only PRIME CORE materials are to be used. In no case, second
grade core material is to be used. The bids should contain copies of invoices towards purchase of core
laminations along with test certificates and curves of specific core loss of the laminations proposed
to be used.

The purchaser at his discretion, may select samples from the core laminations and get the same tested
in CPRI/ Approved National Govt. Laboratory to prove the quality of the core material.
 For the above purpose, the supplier shall have to offer every batch of core laminations received
from his Sub-Vendor along with Invoice of the sub-vendor, Mills test certificate, packing list, Bill
of lading, Bill of entry certificate to customs etc. towards proof of prime core materials for verification
by the Purchaser‟s representative without any cost to the Purchaser. Besides, the contractor
must mention in his bid about the type of CRGO lamination to be utilized for the offered transformers
along with a copy of the specific core loss curve at different flux densities.
 Core materials should be directly procured either from the manufacturer or through their
accredited marketing organization of repute, but not through any agent. The core and winding shall
be capable of withstanding shocks during transport, installation and service. Provision shall be
made to prevent movement of the core and windings relative to the tank during these conditions and
also during short circuits.
 The design shall avoid the presence of pockets which would prevent the complete emptying of
the tank through the drain valve. The core material offered in the tender to be checked for its
correctness before core coil assembly. For this, the tenderer must ask for core and coil inspection
before its tanking.
 The laminations shall be free of all burrs and sharp projections. Each sheet shall have an
insulting coating resistant to the action of hot oil.
 The insulation structure for the core to bolts and core to clamp plates, shall be such as to
withstand 2000 V DC voltage for one minute.
 The completed core and coil shall be so assembled that the axis and the plane of the outer
surface of the core assemble shall not deviate from the vertical plane by more than 25mm.
 All steel sections used for supporting the core shall be thoroughly shot or sand blasted, after
cutting, drilling and welding.
 The finally assembled core with all the clamping structures shall be free from deformation and
shall not vibrate during operation.
 The core clamping structure shall be designed to minimize eddy current loss.
 The framework and clamping arrangements shall be securely earthed.
Part -2 : Employer‟s Requirements 165

 The core shall be carefully assembled and rigidly clamped to ensure adequate mechanical
strength.
 Oil ducts shall be provided, where necessary, to ensure adequate cooling inside the core. The
welding structure and major insulation shall not obstruct the free flow of oil through such ducts.
 The design of magnetic circuit shall be such as to avoid static discharges, development of short
circuit paths within itself or to the earth clamping structure and production of flux component at
right angle to the plane of the lamination, which may cause local heating. The supporting
framework of the cores shall be so designed as to avoid the presence of pockets, which would prevent
complete emptying of the tank through the drain valve or cause trapping of air during filling.
 The construction is to be of boltless core type. The core shall be provided with lugs suitable for
lifting the complete core and coil assembly. The core and coil assembly shall be so fixed in the tank
that shifting will not occur during transport or short circuits.

INTERNAL EARTHING
 All internal metal parts of the transformer, with the exception of individual laminations and
their individual clamping plates shall be earthed.
 The top clamping structure shall be connected to the tank by a copper strap. The bottom
clamping structure shall be earthed by one or more the following methods:

a) By connection through vertical tie-rods to the top structure.

b) By direct metal to metal contact with the tank base.
c) By a connection to the structure on the same side of the core as the main earth connection to the
tank.
 The magnetic circuit shall be connected to the clamping structure at one point only and this
shall be brought out of the top cover of the transformer tank through a suitably rated insulator. A
disconnecting link shall be provided on transformer tank to facilitate disconnections from ground
for IR measurement purpose.
 Coil clamping rings of metal at earth potential shall be connected to the adjacent core clamping
structure on the same side as the main earth connections.

Windings
 Winding shall be subjected to a shrinking and seasoning process, so that no further shrinkage
occurs during service. Adjustable devices shall be provided for taking up possible shrinkage in
service.
 All low voltage windings for use in the circular coil concentric winding shall be wound on a
performed insulating cylinder for mechanical protection of the winding in handling and placing
around the core.
Part -2 : Employer‟s Requirements 166

 Winding shall not contain sharp bends which might damage the insulation or produce high
dielectric stresses. No strip conductor wound on edge shall have width exceeding six times the
thickness.
 The winding insulation shall be free from insulating compounds which are liable to soften,
ooze out, shrink or collapse. It shall be non catalytic and chemically inert in hot transformer oil during
normal service.
 The stacks of windings are to receive adequate shrinkage treatment.
 The windings and connections are to be braced to withstand shocks during transport, switching,
short circuit or other transient conditions.
 Permanent current carrying joints in the windings and leads shall be welded or brazed.
Clamping bolts for current carrying parts inside oil shall be made of oil resistant material which
shall not be affected by acidity in the oil steel bolts, if used, shall be suitably treated.
 Terminals of all windings shall be brought out of the tank through bushings for external
connections.
 The windings shall be uniformly insulated and the L.V neutral points shall be insulated for full
voltage.
 The completed core and coil assemble shall be dried in vacuum at not more than 0.5mm of
mercury absolute pressure and shall be immediately impregnated with oil after the drying process to
ensure the elimination of air and moisture within the insulation. Vacuum may be applied in either
vacuum over or in the transformer tank.
 The winding shall be so designed that all coil assembles of identical voltage ratings shall be
interchangeable and field repairs to the winding can be made readily without special equipment.
The coils shall have high dielectric strength.
 Coils shall be made of continuous smooth high grade electrolytic copper or aluminium
conductor shaped and braced to provide for expansion and contraction due to temperature changes.
 Adequate barriers shall be provided between coils and core and between high and low voltage
coil. End turn shall have additional protection against abnormal line disturbances
 The insulation of winding shall be designed to withstand voltage stress arising from surge in
transmission lines due to atmospheric or transient conditions caused by switching etc
 Tapping shall not be brought out from inside the coil or from intermediate turns and shall be so
arranged as to preserve as far as possible magnetic balance of transformer at all voltage ratios.
 Magnitude of impulse surges transferred from HV to LV windings by electromagnetic
induction and capacitance coupling shall be limited to BIL of LV winding.
 The winding conductor shall be of Al. up to 250 KVA transformers and copper for 500 KVA
Transformers. The current density shall not exceed 1.4 Amp/ mm2 for aluminium and 2.4 Amp/ mm2
for copper at normal full load current.

17.0 BUSHINGS AND TERMINATIONS

Part -2 : Employer‟s Requirements 167

Bushings
 Bushings shall be of the outdoor type and easily replaceable. Cemented in types will not be
accepted. They shall be sufficiently robust to withstand normal transport and erection hazards and
shall confirm to IEC 137 /IS 3347 and 2099.
 All bushings shall have a minimum creepage distance of 25 mm /KV and shall have a
continuous rating of 200% of the transformer rating. The protected creepage distance shall not be less
than 50% of the total.

The following minimum 11 KV clearance shall be provided:

External (Air) for 11
KV
Phase to phase 280 mm
Phase to earth 140 mm

 The 11 KV bushings of transformers shall be provided with a bi-metallic terminal connector or

suitable device to receive 55 –100 mm2 AAAC or ACSR conductor directly without any bimetallic
action.
 The secondary bushings of transformers shall be fitted with non ferrous threaded terminals.
With the exception of brass the terminals shall be protected from atmospheric deterioration by suitable
tinning or by some other approved coating.
 The terminals are to be supplied with one 16mm bolt, one conic spring washer, one matching
flat washer, one nut and one lock nut for each hole in the terminal plate.
 HV Bushing stud shall be not less than 12 mm dia for 250KVA & 500KVA with HV side
terminal connectors & LV Bushing stud shall be not less than 32 mm dia for 500KVA & 20 mm dia
for 250KVA with Palm terminal connectors (For LV studs)

Bushing Labels
 The HV bushings shall be labeled U, V and W and the LV bushing u, v, w and n. Marking
letters shall be at least 12 mm high. The means of marking shall be either,
 engraved metal plate; or
 etched anodized aluminum.
Phase identification by adhesive stickers shall not be acceptable.
 If labeling is to be carried out on the tank, it is preferred that one plate be used rather than
individual markings for each phase, in order to prevent incorrect phase markings. Labels shall
conform to the requirements of the section on labels in this specification.

Earthing Terminals
Part -2 : Employer‟s Requirements 168

All transformers shall be provided with two earthing terminals conforming to relevant Standards
and M12 ISO metric bolt and nut which shall be non ferrous. It shall include a spring washer and lock
washer.
18.0 LIGHTNING ARRESTORS
9 KV, 5KA metal oxide lightning arresters of reputed make conforming to IS-3070 Part- III, one
number per phase shall be provided.(Under the HV bushing with GI earth strip 25x4 mm connected
to the body of the transformer with robust clamping arrangement). Lightening arrestors with
polymer insulators in conformance with relevant IEC can also be used.
19.0 TANK FABRICATION
All transformer sizes, the tank shall be of bolted type construction in accordance with IS 1180 (Part
2).
 The tank shall be at atmospheric pressure at an internal temperature of 100 C;
 The tank shall be designed for an internal pressure of 100 Kg/ m2 at 500 C ambient conditions.
It shall be capable of withstanding an unlimited number of 24 hours cyclic variations of internal
pressure from atmospheric to this value.
 The tenderer shall state the top oil temperature at which the tank internal pressure shall reach
the value of 100 kN/ m2 and the value of steady load which will result in this top oil temperature
with an ambient temperature of 450 C.
 Adequate space shall be provided at the bottom of the tank for collection of sediments.
Transformer tanks of all types shall be designed so that the completed transformer can be lifted and
transported without permanent deformation or oil leakage. Stiffeners provided on all the four side
walls for rigidity should be so designed that there is no accumulation of water.

The Tank shall be of rectangular shape with round edges fabricated from tested quality mild steel
plates with minimum thickness of 3.15 mm. for the side walls while top cover and the bottom plate
of the tank shall have a minimum thickness of 5 mm. The transformer tank and the top cover shall
be designed in such a manner as to leave no external pockets in which water can log, or any internal
pocket where air/ gas can accumulate.

All sealing washers / gaskets shall be made of oil and heat resistant neoprene rubber or neoprene
bonded cork seals suitable for temperature as stipulated in this specification. Surfaces at gasketted
joints shall be such that an even face is presented to gasket, thereby eliminating the necessity for the
gasket to take up surface irregularities.

All pipes, radiators, stiffeners or corrugations which are welded to the tank wall shall be welded
externally and shall be double welded wherever possible. All welds shall be stress relieved.
Part -2 : Employer‟s Requirements 169

The transformer tank shall be complete with all accessories, lifting lugs etc. and shall be designed to
allow the complete transformer filled with oil to be lifted by crane or jacks without risk of any damage
and can be transported by Rail/ Road without straining any joints and without causing any leakage
of oil.

20.0 PRESSURE RELIEF DEVICE

Transformers shall be fitted with a pressure relief device in the form of explosion vent. The tenderer
shall state the pressure at which it is designed to operate.

21.0 OIL LEVEL GAUGE

A suitable oil level gauge (Magnetic type) shall be fitted on the transformers and so located that it can
be easily read from ground level. The gauge fitted with the conservator shall be graduated for
temperatures of 50 C, 300 C and +980 C.

22.0 CONSERVATORS AND BREATHERS

All the transformers shall be provided with a conservator tank.
The conservator tank shall be so designed and located as to eliminate any trapping of air in the
transformer or pipe work. It shall be inclined at an angle of about 5 degrees to the horizontal
towards the drain plug and the pipe connecting the main tank to the conservator should project
about 20 mm above the bottom of the conservator so as to create a sump for the collection of
impurities. Minimum oil level corresponding to 50 C shall be well above the sump level.

All transformers shall be fitted with a silica gel breather of weatherproof design at a convenient height
with oil seal at the bottom, draw in plug and filling holes with covers to isolate the silica gel from the
atmosphere. The breather pipe should be connected at top of the conservator tank with two bends at
right angles. The cover of the main tank and bushings turrets shall be provided with air release plug
to enable the trapped air to be released.
23.0 FITTINGS AND ACCESSORIES
The following standard fittings and accessories shall be provided:
 rating, diagram and terminal marking plate.
 two earthing terminals .
 lifting lugs/ platform lugs.
 pressure relief device in form of explosion vent.
 silica gel breather. (1 Kg for 500KVA)
Part -2 : Employer‟s Requirements 170

 filling and drain / sampling plugs ( A single drain / filling plug shall consist of a 20 mm pipe
inside the transformer tank, starting from the bottom and projecting to the top cover with a
hermetically sealed / welded plug).
 a magnetic or prismatic oil level gauge for all transformers indicating three position of oil i.e.
minimum. 5 0C, 30 0C and 98 0C.
 A thermometer pocket with thermometer with screwed top to prevent ingress of water or
leakage oil.
 Inlet valve having p-30 mm thread (with cover) on the transformers body/ conservator.
 Drain valve 12 mm size for draining the conservator oil with locking arrangement.
 Top filter valve (25 mm with adopter for 16 mm hole) with plug.
 Bottom filter valve with drain Plug.
 Air release plugs at transformer top cover, bushing turrets etc.
 Lightning Arresters (LA) for HT bushing.
 Set of Radiators.
 Conservator Tank.
Bi-metallic terminals on the bushings for connection with over head ACSR/ AAAC conductor (For
HV & LV).
The Specification and brief details of the salient features of these terminals should be stated.
The fittings, tap-changer for 250 KVA and 500 KVA Transformers, accessories and sizes listed are
indicative only and any other fittings and accessories which are generally required for satisfactory
operation of the transformer are to be provided without any extra cost.
24.0 TAP CHANGING ARRANGEMENTS
Off - load tap changing mechanism for 250 KVA & 500 KVA, 11/0.433 KV Transformers shall
have the following characteristics:-
 Tap changing shall be carried out with the transformers in off circuit.
 Tap positions shall be numbered as follows:
Tap No. - 1 Tap No. - 2 Tap No. - 3 Tap No. - 4 Tap No. - 5
+ 2.5 % Principal/ Normal - 2.5 % -5% - 7.5 %
tap
 Provision shall be made for locking of the tap switch handled by using a pad-lock with 6 mm
diameter hasp.
 Tap-changing handles shall be fitted with gasketed covers, so that sealing of the transformers
under normal condition is independent of the switch shaft gland.
25.0 TRANSFORMER OIL
The transformers shall be supplied complete with first filling of transformer oil and 10% extra. The
quantity of oil required for the first filling of the transformer and its full specification shall be stated
Part -2 : Employer‟s Requirements 171

in the bid. The complete first filling shall be of new oil free from inhibitors and additives. The
bidder shall quote the price of transformer complete with first filling of oil plus 10% extra.
However, the rate of transformer oil in Rupees per litre shall be quoted separately also. The
transformer oil shall be supplied in non-returnable drums.
The insulating oil for the transformer shall be of EHV grade, generally conforming to IEC: 296/
BS: 148/ REC: 39/ 1993 or latest version of IS: 335/ 1983 whichever is more stringent. No
inhibitors shall be used in the oil. The dielectric strength of the oil shall not be less than 60 KV at
2.5 mm. gap when tested in accordance with IS: 6792/ 1972. If an anti-oxidant inhibitor is
recommended, its use shall be subject to the purchaser‟s approval.
The design and materials used in the construction of the transformer shall be such as to reduce the
risk of the development of acidity in the oil.
The contractor shall warrant that oil furnished is in accordance with the following specifications.

S. No Characteristic Requirement Method of Test

1 Appearance The oil shall be clear & A representative
transparent & free from sample of oil
suspended matter or sediment shall be
examined in a
100 mm thick
layer at ambient
temp.
2 Density at 200C 0.89 g/cm3 Max. IS:1448
3 Kinematic Viscosity at 27 27 CST IS:1448
deg. C Max
4 Interfacial tension at 27deg.C 0.03 N/m IS:6104
Min.
5 Flash Point 136 0C IS:1448
6 Pour Point Max. -6 0C IS:1448
7 Nautralisation Value (Total 0.03 mg KOH/gm IS:335
Acidity) Max.
8 Electric strength Breakdown 72.5 KV IS:6792
(voltage) Min.
9 Dielectric dissipation factor tan 0.03 Max IS:6262
delta at 900 C
10 Min specific 35X1012 ohm cm (min.) IS:6103
resistance(resistively) at 90
deg.C
11 Oxidation stability
12 Neutralization value after 0.40mg KOH/g
oxidation
Part -2 : Employer‟s Requirements 172

13 Total sludge after oxidation 0.10% by weight max.

14 Presence of oxidation The oil shall not contain anti- IS:335
Inhibitor oxidant Additives.
15 Water content Max: Less than 25ppm IS:2362

26.0 RATING AND CONNECTION PLATE

Each transformer shall be provided with a rating plate of weatherproof material showing the
following items indelibly marked:

 type of transformer
 standard to which it is manufactured (preferably IEC 76)
 manufacturer‟s name
 transformer serial number
 year of manufacture
 rated frequency in Hz (50)
 rated voltages in KV (11/0.433)
 number of phases (3)
 rated power in KVA
 type of cooling (ONAN)
 rated currents in A
 vector group symbol (Dyn11)
 1.2/50μs wave impulse voltage withstand level in KVp
 power frequency withstand voltage in KV
 impedance voltage at rated current and frequency in percentage at 75ºC at normal tap
 Measured load loss in KW at rated current and at 75ºC at normal tap
 Measured no-load loss in KW at rated voltage and rated frequency
 continuous ambient temperature at which ratings apply in 0C
 top oil and winding temperature rise at rated load in 0C
 winding connection diagram
 total weight in kg with complete oil filled.
 total weight of the transformer without oil
 volume of oil in litres.
 weight of core and windings in kg; and
 name of the purchaser (<EMPLOYER>)
The rating plate shall conform to the requirements of the section of Labels in this specification.

27.0 BASE MOUNTING ARRANGEMENT

Part -2 : Employer‟s Requirements 173

The under base of all transformers of 460 mm long with holes of 14 mm dia at a centre to centre
distance of 415 mm to make them suitable for fixing on a platform or plinth. 500 KVA transformers
shall be provided with bi-directional flat rollers, suitable for use on a 1000 mm gauge track.

28.0 PAINTING
All paints shall be applied in accordance with the paint manufacturer‟s recommendations.
Particular attention shall be paid to the following:
a) Proper storage to avoid exposure as well as extremes of temperature.
b) Surface preparation prior to painting.
c) Mixing and thinning
d) Application of paints and the recommended limit on time intervals between coats.
e) Shelf life for storage.

All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness,
brush marks or other defects.
All primers shall be well marked into the surface, particularly in areas where painting is evident,
and the first priming coat shall be applied as soon as possible after cleaning. The paint shall be applied
by airless spray according to the manufacturer‟s recommendations. However, wherever airless spray
is not possible, conventional spray be used with prior approval of purchaser.
The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings
and similar such items.
Cleaning and Surface Preparation
 After all machining, forming and welding has been completed, all steel work surfaces shall be
thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to any
painting.
 Steel surfaces shall be prepared by Sand/Shot blast cleaning or chemical cleaning by seven tank
process including Phosphating to the appropriate quality.
 The pressure and Volume of the compressed air supply for the blast cleaning shall meet the
work requirements and shall be sufficiently free from all water contamination prior to any painting.
 Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove
firmly adherent mill-scale and shall only be used where blast cleaning is impractical

Protective Coating
 As soon as all items have been cleaned and within four hours of the subsequent drying, they
shall be given suitable anticorrosion protection.

Paint Material
Part -2 : Employer‟s Requirements 174

Followings are the type of paints that may be suitably used for the items to be painted at shop and
supply of matching paint to site:
i) Heat resistant paint (Hot oil proof) for inside surface.
ii) For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2
coats of Synthetic Enamel paint. The color of the finishing coats shall be dark admiral grey
conforming to No.632 or IS 5:1961.

Painting Procedure
 Al painting shall be carried out in conformity with both specifications and with the paint
manufacture‟s recommendations. All paints in any one particular system. Whether shop or site
applied, shall originate from one paint manufacturer.
 Particular attention shall be paid to the manufacturer‟s instructions on storage, mixing, thinning
and pot life. The paint shall only be applied in the manner detailed by the manufacturer e.g. brush,
roller, conventional or airless spray and shall be applied under the manufacturer‟s recommended
conditions. Minimum and maximum time intervals between coats shall be closely followed.
 All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours
whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the surface is dry
and while the surface is warm.
 Where the quality of film is impaired by excess film thickness,(wrinkling, mud cracking or
general softness) the supplier shall remove the unsatisfactory paint coatings and apply another. As a
general rule, dry film thickness should not exceed the specified minimum dry film thickness by
more than 25%. In all instances, where two or more coats of the same paints are specifies, such
coatings may or may not be of contrasting colors.
 Paint applied to items that are not be painted, shall be removed at supplier‟s expense, leaving
the surface clean, un-stained and undamaged.

Damages to Paints Work

Any damage occurring to any part of the painting scheme shall be made good to the same standard
of corrosion protection and appearance as that originally employed. Any damaged paint work shall
be made as follows:
a) The damaged area, together with an area extending 25mm around its boundary, shall be cleaned
down to bare metal.
b) A priming coat shall immediately applied, followed by a full paint finish equal to that originally
applied and extending 50mm around the perimeter of the originally damaged.
The repainted surface shall present a smooth surface. This shall be obtained by carefully chamfering
the paint edges before & after priming.

Dry Film Thickness

Part -2 : Employer‟s Requirements 175

To the maximum extent practicable, the coats shall be applied as a continuous film of uniform
thickness and free of pores. Over-spray, skips, runs, sags and drips should be avoided. The different
coats may or may not be same color.
Each coat of paint shall be allowed to harden before the next is applied as per manufacture‟s
recommendations. Particular attention must be paid to full film thickness at edges.
The requirement for the dry film thickness (DFT) of paint and the material to be used shall be as
given below:

Sl. No Paint Type Area to be No of Total Dry film

painted Coats thickness(Min)
1 Powder Paint Inside 01 20 Micron
(2) Thermo outside 01 60 Micron
setting powder
2 Liquid paint
a) Zinc Outside 02 45 micron
Chromate(Primer) Outside 02 35 micron
b) Syenthetic inside 01 35 micron
Enamel(Finish
Coat)
c) Hot Oil paint

29.0 SEALING GASKETS

All sealing washers / gaskets shall be made of oil and heat-resistant Nitrile/ Neoprene rubber/
synthetic rubber bonded cork type RC-70C gaskets. Gaskets made of natural rubber or cork sheet
are not permissible.

30.0 SUPRESSION OF HARMONICS

The transformer shall be designed with attention to the suppression of harmonic voltage, especially
the third and fifth.
31.0 GUARANTEE:

The manufacturers of the transformer shall provide a guarantee of 60 months from the date of date
of commissioning. In case the Distribution transformer fails within the guarantee period the purchaser
will immediately inform the supplier who shall take back the failed DT within 15 days from the date
of the intimation at his own cost and replace/repair the transformer within forty five days of date of
intimation with a roll over guarantee.
The outage period i.e. period from the date of failure till unit is repaired/ replaced shall not be counted
for arriving at the guarantee period.
Part -2 : Employer‟s Requirements 176

In the event of the supplier's inability to adhere to the aforesaid provisions, suitable penal action
will be taken against the supplier which may inter alia include blacklisting of the firm for future
business with the purchaser for a certain period.
32.0 TESTS
Routine Tests
Routine tests shall be carried out on all transformers and the tests shall be conducted in accordance
with relevant National/ International Standards. No sampling is allowed. In addition, tank tests in
accordance with IS:1180 shall be carried out.
The following routine measurements and tests shall be carried out in presence of Purchaser‟s
authorized representative(s):
a) Measurement of winding resistance. (For 500 KVA at all tap positions)
b) Voltage ratio measurement and check of polarity and vector group. Bushing positions shall have
permanent markings at this stage of production;
c) Measurement of impedance voltages/ short circuit impedance at rated current and frequency (for
500 KVA transformers at normal, highest and lowest tap positions)
d) Measurement of load loss at half load & full load at 750C; (for 500 KVA transformers at normal,
highest and lowest tap positions)
e) Measurement of neutral unbalance current;
f) Temperature rise test on one transformer of each rating and measurement of hot resistance.
g) Measurement of no-load loss and no-load currents at 50%, 75%, 90%, 100%, 110%, 115%, and
120% of rated voltages on one transformer of each rating; (For unit transformer of each Lot)
h) Induced over voltage withstand test at 22KV for 60 sec on the HV windings;
i) Power frequency voltage withstand tests on HV and LV windings;
j) Magnetic balance test
k) Polarization Index test P.I. value shall be not less than 1.5. P.I. = IR at 600 sec / IR at 60 sec.
l) Oil leakage test : The criterion of leakage shall be discoloration by oil of whitewash applied
externally to suspected parts at an oil temperature of 900C or other method, as approved by the
Purchaser;
m) Pressure test on transformer tank on one unit for each rating. Bushings and oil shall be subject to
the following routine tests.
n) Bushing routine test: in accordance with IEC 137/IS 3347;
o) Oil dielectric and moisture content test: conforming to IEC 156 or IS 335. Routine test
certificates shall include in addition to the test results, the purchaser‟s order number, the
transformer serial number, outline drawing number and transformer KVA rating.
Any other applicable tests shall be conducted at the discretion of the Purchaser without any extra cost
to purchaser.
Type Tests
Part -2 : Employer‟s Requirements 177

 The measurements and tests should be carried out in accordance with the standard specified in
each case as indicated in the following table if the same tests were not conducted earlier at CPRI or
any Govt. approved Laboratory on the transformers of the offered design.

Type Test Standard

Temperature Rise Test IEC 76/IS 2026
Impulse Voltage Withstand Test, including Full IEC 76/IS 2026
Waves and
Chopped Waves as listed below
Noise Level Measurement IEC 551
Short Circuit Test IEC 76 / IS 2026

In accordance with IEC 76-3 the following sequence of impulses should have been/ should be
applied;
o one full wave at 50% BIL;
o one full wave at 100% BIL;
o one chopped wave at 50% BIL;
o two chopped waves at 100% BIL and
o two full waves at 100% BIL.
 If the type test report(s) submitted by the bidder do not fulfil the criteria, as stipulated in this
technical specification/ Bidder‟s offer, the relevant type test(s) has/ have to be conducted by the
Bidder at his own cost in CPRI/ National Govt. approved laboratory in the presence of EMPLOYER‟s
representative(s) without any financial liability to EMPLOYER, in the event of order placed on
him.
 Even if the Type test report(s) confirm(s) the Purchaser‟s specification, the Purchaser at his
discretion may ask the Supplier to repeat any or all specified type tests at CPRI/ National Govt.
approved laboratory on sample(s), selected at random by the purchaser‟s representative(s) out of the
offered quantity (first lot i.e. minimum one third of the total ordered quantity). The type test(s) are
to be test-witnessed by the Purchaser‟s representative(s). For such type of repetition of type tests,
the Bidder may quote Type Test Charges in the enclosed Price Schedule or conduct the tests free of
cost.
 The supplier shall furnish calculations in accordance with IS: 2026 to demonstrate the Thermal
ability of the transformers to withstand Short Circuit forces.

TEST VOLTAGE
Transformers shall be capable of withstanding the Power frequency and Impulse test voltage as described
below:
Nominal Highest System Impulse Test Power frequency
system voltage voltage test voltage
Part -2 : Employer‟s Requirements 178

voltage

433 V (rms) 3 KV (rms)

11 KV (rms) 12 KV (rms) 75 KV (Peak) 28 KV (rms)
Part -2 : Employer‟s Requirements 179

Annexure-B

General Technical Instructions

(This document is meant for the exclusive purpose of bidding against this Package and shall not be
transferred, reproduced or otherwise used for purposes other than that for which it is specifically
issued.)
Part -2 : Employer‟s Requirements 180

Technical Instructions of SI
1.1. 33 V Line support ............................................................................................. 214
1.2. 11 KV line Support and DTR Substation support ............................................ 215
1.3. Route And Terrain ............................................................................................ 215
1.4. Detailed Survey................................................................................................. 216
1.5. Profile Plotting .................................................................................................. 216
1.6. Road Crossing ................................................................................................... 216
1.7. Railways Crossings ........................................................................................... 217
1.8. Telecommunication, LT or HT Line Crossing ................................................. 217
1.9. Details En-route ................................................................................................ 217
1.10. Clearances - General ......................................................................................... 217
1.11. Electrical System Data ...................................................................................... 219
1.12. Pole Location .................................................................................................. 219
1.13. Construction ...................................................................................................... 220
1.14. Erection of DP Structure for Angle Locations.................................................. 220
1.15. Concreting......................................................................................................... 220
1.16. Providing Of Guys To Supports ....................................................................... 220
1.17. Guy Strain Insulators ........................................................................................ 221
1.18. Fixing Of Cross-Arms....................................................................................... 222
1.19. Insulators And Bindings ................................................................................... 222
1.20. Conductor Erection ........................................................................................... 223
1.21. Tensioning and Sagging Operations ................................................................. 224
1.22. Clipping In ........................................................................................................ 225
1.23. Fixing of Conductors and Earthwire Accessories............................................. 225
1.24. Replacement...................................................................................................... 225
1.25. Tying Of Conductor On Pin Insulators ............................................................. 225
1.26. Kind And Size Of Tie Wire To Be Used .......................................................... 226
1.27. Rules Of Good Tying Practice .......................................................................... 226
1.28. Conductors At Different Voltages On Same Supports ..................................... 226
1.29. Earthing............................................................................................................. 227
1.30. Anti-Climbing Devices ..................................................................................... 228
1.31. Testing And Commissioning ............................................................................ 228
1.32. River Crossing .................................................................................................. 229
1.33. Guarding ........................................................................................................... 229
1.34. Repair to conductors ......................................................................................... 230
1.35. LT Lines and Service connection ..................................................................... 230
Part -2 : Employer‟s Requirements 181

General Technical Instructions

Following CEA regulations shall be applicable during execution of work:

a. Construction Regulation – Central Electricity Authority (Technical Standards for construction of

electrical plants and electric lines) Regulation, 2010 (as amended time to time)

b. Safety Regulation for construction and O&M - Central Electricity Authority (Safety requirements
for construction, Operation and Maintenance of electrical plants and electric lines) Regulation,
2011 (as amended time to time)

c. Connectivity Regulation – Technical Standard for connectivity to the grid (Amendment)

Regulation 2013; Technical Standards for connectivity of the Distributed Generation resources,
2013; Central Electricity Authority (Grid Standard) Regulation, 2010 (as amended time to time)

d. Metering Regulations – Central Electricity Authority (Installation and Operation of meters)

Regulations, 2006; Central Electricity Authority (Installation and Operation of meters)
(Amendment) Regulations, 2010 and 2015 (as amended time to time)

e. Central Electricity Authority (Measures relating to safety and Electric supply regulations), 2010
and amendment regulation 2015 (as amended time to time)

1.1.2. Pole base plates as per specifications shall be used.

1.1.3. Pole earthing shall be performed through earthing Rod duly connected with 8 SWG wire. The GI
wires between pole structure and the earthing Rod should not be used in cut length. Wherever, cut
is evitable, proper nut bolt, washer and binding should be made as per REC specifications. The GI
wire between support and earth Rod should be placed 1 meter below the ground level.

1
In hilly and difficult terrain, steel tubular support may be accepted, they shall be concreted as per speculations,
Part -2 : Employer‟s Requirements 182

1.1.4. Earth rod should be inserted 1200 mm away from pole.

1.2. 11 KV line Support and DTR Substation support

1.2.1. 8.5 meters or equivalent PCC Poles2 as per prevailing practices of the state shall be used for 11
KV line and substation support. 152x152mm H-Beam (37.1kg/m)3 can also be used as support in
urban/forest area and or Steel Tubular Poles may be used in hilly area where head load shifting is
the only option.

The single PCC pole supports shall be erected with Stone bolder/stone ballast mixed with excavated
earth in normal soil. PCC poles in Double Pole structures, turning point structure, Distribution
Transformer Substation structure shall be grouted in cement concrete mixture of
1:2:4 (1: cement, 3: coarse sand and 6 Stone ballast 40mm sizes). Single pole supports in water
logging area shall also be grouted in cement concrete mixture of 1:2:4 (1: cement, 3: coarse sand
and 6 Stone ballast 40mm sizes). PCC pole shall be grouted with concrete (0.6mx0.6mx1.35m) =
0.486 cmt.. In special location, wherever, Project Manager specifically decides, to enhance
additional strength, concreting may be used as support foundation.

In forest, wherever special care is to be made for elephant corridors, 13m long, 152x152mm RS
Joist (37.1kg/m) may be used for 11 KV line support.

152x152mm H-Beam (37.1kg/m)4 and Steel Tubular Poles shall be grouted in cement concrete
mixture of 1:2:4 (1: cement, 3: coarse sand and 6 Stone ballast 40mm sizes) in all the formation.

1.2.2. Pole base plates as per specifications shall be used.

1.2.3. Pole earthing shall be performed through earthing Rod duly connected with 8 SWG wire. The GI
wires between pole structure and the earthing Rod should not be used in cut length. Wherever, cut
is evitable, proper nut bolt, washer and binding should be made as per REC specifications. The GI
wire between support and earthing Rod should be placed 1 meter below the ground level.

1.2.4. EarthRod should be inserted 1200 mm away from pole.

1.3. Route And Terrain

2
In hilly and difficult terrain, steel tubular support may be accepted, they shall be concreted as per speculations,

4
In hilly and difficult terrain, steel tubular support may be accepted, they shall be concreted as per speculations,
Part -2 : Employer‟s Requirements 183

1.3.1. The scope of HT/LT length of feeder are enclosed with the tender documents. On award of the
contract, contractor shall perform foot survey to access the route, pole location and thus Single Line
Diagram of the line works. The survey shall be approved by Project Manager. Accordingly
requirements of materials shall be finalized by the turnkey contactor in association with Project
Manager.

1.4. Detailed Survey

1.4.1. The detailed survey shall be carried out for the approved feeders/spur lines by the contractor and
submitted for owner approval.

1.5. Profile Plotting

1.5.1. Span: The number of consecutive spans between the section points shall not exceed design length
considering wind pressure, type of poles and size of conductor.

1.5.2. Extension: An individual span shall be as near to the normal design span as possible. In case an
individual span becomes too short with normal supports on account of undulation in ground profile,
one or both the supports of the span may be extended by inserting standard body extension
designed for the purpose according to technical specification.

1.5.3. Loading: There shall not be any upward force on poles under normal working conditions and the
suspension poles shall support at least the minimum weight span as provided in the design. In
case uplift is unavoidable, it shall be examined if the same can be overcome by adding standard
body extensions to the poles failing which tension poles designed for the purpose shall be
employed at such positions.

1.5.4. Horizontal Tensions on pin insulators are to be avoided by proper alignment of the line. In case
where installation of DP structure is not possible to erect for turning the line, “two pins” arrangement
with suitable jumpering shall be provided at all those locations where pins are subjected to
horizontal tension. Bridling type V Cross arms for such installations shall be used by the agency
accordingly.

1.6. Road Crossing

At all road crossings, the poles shall be fitted with horizontally aligned disc type tension insulator
string(s) or bridling V-cross arm supports using double pin insulator per phase depending on the
type of poles and line but the ground clearance at the roads under maximum temperature and in
Part -2 : Employer‟s Requirements 219

still air shall be such that it should not fall below 6.1m in case of 33 KV and 11 KV lines. Also,
cradle guarding is to be used at all the road crossing locations as per drawings / specifications
enclosed.

1.7. Railways Crossings

Railway Crossings at pre-planned locality shall be selected in such a way that minimum feeder
length shall be re-routed. The line crossing should be executed as per prevailing practices and
approved drawings of railways. Railways crossing shall preferably be executed through
underground cabling. Horizontal drill machine shall be used for this purpose. Required
permission to block the Railways traffic and approval for railway crossing shall be arranged by
the owner at his own cost. All liaison works shall be performed by turnkey contractor.

1.8. Telecommunication, LT or HT Line Crossing

The angle of crossing shall be as near 90 degrees as possible. However, deviation to the extent of
30 degree may be permitted under exceptionally difficult situations. Cradle guarding is to be used
at all such crossing locations as per drawings / specifications enclosed.

1.9. Details En-route

All topographical details, permanent features, such as well, trees, building etc. 75 m on either side
of the alignment shall be detailed on the profile plan.

1.10. Clearances - General

For the purpose of computing the vertical clearance of an over-head line, the maximum sag of any
conductor shall be calculated on the basis of the maximum sag in still air and the maximum
design temperature. Similarly, for the purpose of computing any horizontal clearance of an over-
head line, the maximum deflection of any conductor shall be calculated on the basis of the wind
pressure specified by the State Government under rule 76 (2) (a) [or may be taken as 35º,
whichever is greater]. Following clearances shall be maintained by the contractor while executing
the work:

1.6.1. CLEARANCE ABOVE GROUND OF THE LOWEST CONDUCTOR: No conductor of an over-

head line, including service lines, erected across a street shall at any part thereof be at a height
less than
(a) For low and medium voltage lines 5.8 meters
Part -2 : Employer‟s Requirements 220

(b) For high voltage lines 6.1 meters

1.6.2. No conductor of an over-head line, including service, lines, erected along any street shall at any
part thereof be at a height less than

a. For low, medium and high voltage lines upto and including
11,000 volts, if bare - 4.6 meters
b. For low, medium and high voltage lines Upto and including
11,000 volts, if insulated - 4.0 meters
c. For high voltage lines above 11,000 volts - 5.2 meters

For extra-high voltage lines the clearance above ground shall not be less than 5.2 meters plus 0.3 meter
for every 33,000 volts or part thereof by which the voltage of the line exceeds 33,000 volts:

Provided that the minimum clearance along or across any street shall not be less than 6.1 meters.

1.6.3. CLEARANCE FROM BUILDINGS OF LOW AND MEDIUM VOLTAGE LINES AND
SERVICE LINES:

Where line is to cross over another line of the same voltage or lower voltage, pole with suitable
extensions shall be used. Provisions to prevent the possibility of its coming into contact with other
overhead lines shall be made in accordance with the latest CEA regulations (as amended from
time to time). The contractor will required to under cross higher voltage lines by erecting
gantries/suitable Rail Pole structures.

Where a low or medium voltage over-head line passes above or adjacent to or terminates on any
building, the following minimum clearances from any accessible point, on the basis of maximum
sag, shall be observed:-

a) For any flat roof, open balcony, verandah roof and lean-to-roof

i. When the line passes above the building a vertical clearance of 2.5 meters from the highest point;
and
ii. When he line passes adjacent to the building a horizontal clearance of 1.2 meters from the nearest
point, and

b) For pitched roof

Part -2 : Employer‟s Requirements 221

i. When the line passes above the building a vertical clearance of 2.5 meters immediately under the
lines, and
ii. When the line passes adjacent to the building a horizontal clearance of 1.2 meters.

The horizontal clearance shall be measured when the line is at a maximum deflection from the
vertical due to wind pressure.

1.6.4. CLEARANCE FROM BUILDINGS OF HIGH AND EXTRA-HIGH VOLTAGE LINES:

Where a high or extra-high voltage over-head line passes above or adjacent to any building or part
of building it shall have on the basis of maximum sag a vertical clearance above the highest part
of a building immediately under such line, of not less than

(a)
For High Voltage Lines up 3.7 m
to and including 33,000
volts
(b) For Extra High Voltage 3.7 m plus 0.3 m for
Lines every additional 33 KV or
part thereof.
1.11. Electrical System Data

33 KV 11KV
Nominal voltage 33 kV 11KV
Maximum system voltage 36 kV 12KV
BIL (Impulse) 170 kVp 75KV
Power frequency withstand voltage (wet) 75 kV (rms) 28KV
Minimum corona extinction voltage for Not less than 27 kV, 50 Hz ac system under Dry condition
(rms) phase to earth
Radio interference voltage at one MHz for Not exceeding 1000 micro-volts
27 kV (dry condition)

1.12. Pole Location

In locating poles on lines, the following general principles should be kept in mind:-

1. Keep spans uniform in length as far as possible.

2. Locate to give horizontal grade.

3. By locating the poles on high places short poles can be used and will maintain proper ground
clearance at the middle of the span. In extremely hilly or mountainous country, poles are located
Part -2 : Employer‟s Requirements 222

on ridges there by greatly increasing the spans without greatly increasing the pull on the conductor.
This is possible because the sag can be made very large and will maintain the required ground
clearance. Special attention should be given to the locations of poles, where the ground washes
badly. Poles should not be placed along the edges of cuts at or embankment or along the banks of
creeks of streams.

1.13. Construction

The construction of overhead-lines may be divided into the following parts:-

(1) Pit marking, pit digging.

(2) Erection of supports and concreting.
(3) Providing of guys to supports.
(4) Mounting cross-arms, pin and insulators, and pin binding.
(5) Paying and stringing of the conductor.
(6) Sagging and Tensioning of Conductors.
(7) Crossings.
(8) Guarding.
(9) Earthing.
(10) Testing and Commissioning.

1.14. Erection of DP Structure for Angle Locations

For angles of deviations more than 10 degree, DP structure may be erected. The pit digging
should be done along the bisection of angle of deviation.

After the poles are erected, the horizontal/cross bracings should be fitted and the supports held in
a vertical position with the help of temporary guys of Manila rope 20/25 mm dia.

Wherever space is not found sufficient to install double Pole structure, single pole cut point may be
installed. The support so erected must be grouted.

1.15. Concreting

The concreting mixture of one cum 1:2:4 ratios would mean 1 part cement, 3 parts coarse sand
and 6 part 40 mm aggregate size stones. It may be noted that while preparing the concrete
mixture, large quantities of water should not be used as this would wash away cement and sand.

1.16. Providing Of Guys To Supports

Part -2 : Employer‟s Requirements 223

Guys are installed at locations where terminal poles are erected at sectional cut points. These cut
points may be in same alignment or at turn points. Guys are installed to nullify tension on supports
resulted due to conductors tension. In spite of careful planning and alignment of line route, certain
situations arise where the conductor tries to tilt the pole from its normal position due to abnormal
wind pressure and deviation of alignment, etc. When these cases of strain arise, the pole is
strengthened and kept in position by guys. One or more guys will have to be provided for all
supports where there is unbalanced strain acting on the support, which may result in
tilting/uprooting or breaking of the support.

Guys are braces fastened to the pole. In this work anchor type guy sets are to be used. These guys
are provided at (i) angle locations (ii) dead end locations (iii) T - off points (iv) Steep gradient
locations and (v) where the wind pressure is more than 50 kg / Sq.m.

The fixing of guys stays will involve (i) pit digging and fixing stay rod (ii) fastening guy wire to
the support (iii) Tightening guy wire and fastening to the anchor. The marking of guy pit, digging
and setting of anchor rod must be carefully carried out. The stay rod should be placed in a
position so that the angle of rod with the vertical face of the pit is 30º/45º as the case may be.

Before start of erection of Stay sets, required concreting materials like Cement, Sand, Stone
Chips and Construction water need to be made available near the pit.

G.I. stay wires of size 7/3.15 mm (10 SWG) & 7/4.00 mm (8 SWG), for 16 mm/20 mm stay rods
respectively, are to be provided. 8.5 Kg. Stay Wire (7/4.00 mm) per Stay with 20 mm Stay rod for
33 KV line and 5.5 Kg. Stay Wire (7/ 3.15 mm) per Stay with 16 mm Stay rod for 11 KV lines
are to be used. For double pole structure (DP), four stays along the line, two in each direction and
two stays along the bisection of the angle of deviation (or more) as required depending on the angle
of deviation are to be provided. Hot dip galvanized stay sets are to be used. One stay to counter the
angular deformation force shall be used.

After concreting, back filling and ramming must be done well and allowed 7 days to set. The free
end of the guy wire/stay wire is passed through the eye of the anchor rod, bent back parallel to the
main portion of the stay/guy and bound after inserting the G.I. thimble, where it bears on the anchor
rod. If the guy wire proves to be hazardous, it should be protected with suitable asbestos pipe filled
with concrete of about 2 m length above the ground level, painted with white and black strips
so that, it may be visible at night. The turn buckle shall be mounted at the pole end of the stay and
guy wire so fixed that the turn buckle is half way in the working position, thus giving the maximum
movement for tightening or loosening.

1.17. Guy Strain Insulators

Part -2 : Employer‟s Requirements 224

Guy insulators are placed to prevent the lower part of the Guy from becoming electrically
energized by a contact of the upper part of the guy when the conductor snaps and falls on them or
due to leakage. No guy insulator shall be located less than 2.6 m from the ground. Guy insulators
are to be used in stay wires only. All stay conductors are to be provided with guy insulators as per
following specifications.
11 KV line stay Type C guy insulator (1 No)
33 KV line stay Type C guy insulators (2Nos)

1.18. Fixing Of Cross-Arms

After the erection of supports and providing guys, the cross-arms are to be mounted on the
support with necessary clamps, bolts and nuts. The practice of fixing the cross arms before the pole
erection is also there. In case, the cross-arm is to be mounted after the pole is erected, the lineman
should climb the pole with necessary tools. The cross-arm is then tied to a hand line and pulled up
by the ground man through a pulley, till the cross-arm reaches the line man. The ground man should
station himself on one side, so that if any material drops from the top of the pole, it may not strike
him. All the materials should be lifted or lowered through the hand line, and should not be
dropped.

1.19. Insulators And Bindings

Line conductors are electrically insulated from each other as well as from the pole by „Insulators‟.
Following two type of insulators shall be used for the line insulation:

(1) Pin type

(2) Strain type

The pin type insulators will be used for straight stretch of line. The insulator and its pin should be
mechanically strong enough to withstand the resultant force due to combined effect of wind
pressure and weight of the conductor in the span.

The strain insulators are intended for use at terminal locations or dead end locations and where
the angle of deviation of line is more than 10º. Strain insulators are also intending to use at major
road crossing locations.

The pins for insulators are fixed in the holes provided in the cross-arms and the pole top brackets.
The insulators are mounted in their places over the pins and tightened. In the case of strain or
angle supports, where strain fittings are provided for this purpose, one strap of the strain fittings
Part -2 : Employer‟s Requirements 225

is placed over the cross-arm before placing the bolt in the hole of cross-arms. The nut of the
straps is so tightened that the strap can move freely in horizontal direction.

All HT/LT insulators shall be tested for insulation tests before installation on line. They shall be
dipped into water for 24 hrs and then tested for insulation resistance tests at the stores. The insulators
found fit in IR testing shall be sent to site for erection. 11KV na d33 KV insulators shall be
tested by at-least 1 KV megger whereas LT insulators shall be tested by 500 Volts megger.

1.20. Conductor Erection

The main operations are:-

(a) Transportation of Conductor to works site.

(b) Paying and Stringing of Conductor
(c) Jointing of Conductor
(d) Tensioning and Sagging of Conductor

While transporting conductors drums to site, precautions are to be taken so that the conductor
does not get damaged/injured. The drum could be mounted on cable drum support, which generally
is made from crow-bar and wooden slippers for small size conductor drums. The direction
of rotation of the drum has to be according to the mark in the drum so that the conductor could be
drawn. While drawing the conductor, it should not rub causing damage. The conductor could be
passed over poles on wooden or aluminum snatch block (pulley) mounted on the poles for this
purpose.

When approaching the end of a drum length at least three coils shall be left in place when the
stringing operations are stopped. These coils are to be removed carefully and if another length is
required to be run out a joint shall be made as per the recommendations of the accessories
manufacturer.

The mid span jointing is done through compressions or if helical fittings are used the jointing could
be done manually. After completing the jointing, tensioning operation could be commenced.
The conductor is pulled through come-along clamps to stringing the conductor between the tension
locations.

Conductor splices shall not crack or otherwise be susceptible to damage in the stringing
operation. The Contractor shall use only such equipment / methods during conductor stringing
which ensures complete compliance in this regard.
Part -2 : Employer‟s Requirements 226

All the joints on the conductor and earth-wire shall be of the compression type, in accordance
with the recommendations of the manufacturer, for which all necessary tools and equipment like
compressors, dies, etc., shall be obtained by the Contractor. Each part of the joint shall be cleaned
by wire brush till it is free of rust or dirt, etc., and be properly greased with anti-corrosive
compound. If required and as recommended by the manufacturer, before the final compression is
carried out with the compressors.

All the joints or splices shall be made at least 15 meters away from the pole. No joints or splices
shall be made in spans crossing over main roads, railways and small river spans. Not more than one
joint per sub-conductor per span shall be allowed. The compression type fittings shall be of the
self-centering type or care shall be taken to mark the conductors to indicate when the fitting is
centered properly. During compression or splicing operation, the conductor shall be handled in such
a manner as to prevent lateral or vertical bearing against the dies. After compressing the joint,
the aluminum sleeve shall have all corners rounded; burrs and sharp edges removed and
smoothened.

During stringing of conductor to avoid any damage to the joint, the contractor shall use a suitable
protector for mid span compression joints in case they are to be passed over pulley blocks / aerail
rollers. The pulley groove size shall be such that the joint along with protection can be passed
over it smoothly.

1.21. Tensioning and Sagging Operations

The tensioning and sagging shall be done in accordance with the approved stringing charts or sag
tables. The “initial” stringing chart shall be used for the conductor and “final” stringing chart for
the earth-wire. The conductors shall be pulled up to the desired sag and left in running blocks for
at least one hour after which the sag shall be rechecked and adjusted, if necessary, before
transferring the conductors from the running blocks to the suspension clamps. The conductor
shall be clamped within 36 hours of sagging in.

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

At sharp vertical angles, conductor and earth-wire sags and tensions shall be checked for equality
on both sides of the angle and running block. The suspension insulator assemblies will normally
assume verticality when the conductor is clamped.
Part -2 : Employer‟s Requirements 227

Tensioning and sagging operations shall be carried out in calm weather when rapid changes in
temperature are not likely to occur.

1.22. Clipping In

Clipping of the conductors into position shall be done in accordance with the manufacturer‟s
recommendations. Jumpers at section and angle towers shall be formed to parabolic shape to ensure
maximum clearance requirements. Fasteners in all fittings and accessories shall be secured in
position. The security clip shall be properly opened and sprung into position.

1.23. Fixing of Conductors and Earthwire Accessories

Conductor and earth-wire accessories supplied by the Contractor shall be installed by the
Contractor as per the design requirements and manufacturer‟s instruction within 24hours of the
conductor / earth-wire clamping. While installing the conductor and earth-wire accessories,
proper care shall be taken to ensure that the surfaces are clean and smooth and that no damage
occurs to any part of the accessories or of the conductors.

1.24. Replacement

If any replacements are to be effected after stringing and tensioning or during maintenance e.g.
replacement of cross arms, the conductor shall be suitably tied to the pole at tension points or
transferred to suitable roller pulleys at suspension points.

Sagging of conductor has to be in accordance to the Sag Tension chart. In order to achieve it, it is
preferred to pull the conductor to a tension a little above the theoretical value so that while
transferring it from the snatch blocks to the pit insulators and to take care of temperature
variation. Proper sag could achieve. Sagging for 33/11 KV line is mostly done by “Sighting”. A
horizontal strip of wood is fixed below the cross-arm on the pole at the required sag. The lineman
sees from other end and the sag is adjusted by increasing or decreasing the tension. The tension
clamps could then be finally fixed and conductor be fixed on pin-insulators. All fittings, accessories
like guys, cross-arms, etc., could be checked as they should not have de-formalities.

The maximum permissible spans for all the lines of 33/11/0.4 KV are prescribed according to the
design of the supports. Sag-tension charts for these conductors are to be followed.

1.25. Tying Of Conductor On Pin Insulators

Part -2 : Employer‟s Requirements 228

Conductors should occupy such a position on the insulator as will produce minimum strain on the
tie wire. The function of the wire is only to hold the conductor, in place on the insulator, leaving
the insulator and pin to take the strain of the conductor.

In straight line, the best practice is to use a top groove insulator. These insulators will carry grooves
on the side as well. When the conductor is placed on the top groove, the tie wire serves only to keep
the conductor from slipping out.

On corners and angles (below 5 degree deviations) the conductors should be placed on the outside
of the insulators. On the far side of the pole, this pulls the conductor against the insulator instead
of away from the insulator.

1.26. Kind And Size Of Tie Wire To Be Used

Helically formed fittings are to be used for tying the insulators, end terminal connectors etc.. The
tie should always be made of soft annealed wire so that it may not be brittle and injure the line
conductor. A tie wire should never be used for second time. Specifications of helically formed
fittings are given in this section.

1.27. Rules Of Good Tying Practice

a. Use only helically formed fittings.

b. Use of size of tie wire which can be readily handled yet one which will provide adequate
strength.
c. Use length of tie wire sufficient for making the complete tie, including an allowance for gripping
with the hands. The extra length should be cut from each end if the tie is completed.
d. A good tie should

(a) Provide a secure binding between line wire insulator and tie wire.
(b) Have positive contacts between the line wire and the tie wire so as to avoid any chattering of the
contacts.
(c) Re-enforce line wire in the vicinity of insulator.

e. Apply without use of pliers.

f. Do not use the wire which has been previously used.
g. Do not use hard drawn wires for typing.

1.28. Conductors At Different Voltages On Same Supports

Part -2 : Employer‟s Requirements 229

In urban area, lines are to be erected with provision for forming lines of two different gradients as
under

a) 11 KV Line and LT Lines

b) 33 KV Line and LT Lines

Where conductors forming parts of systems at different voltages are erected on the same supports,
the contractor shall make adequate provision to guard against danger to linesmen and others from
the lower voltage system being charged above its normal working voltage by leakage from or
contact with the higher voltage system; and the methods of construction and the clearances between
the conductors of the two systems shall be as described in the specifications.

The agency shall be intimated by the Project Manager in writing about the locations where such
provisions is intended by him. At all such locations, the contractor shall make adequate provision
to guard against danger to linesmen and others from the lower voltage system being charged
above its normal working voltage by leakage from or contact with the higher voltage system.

1.29. Earthing

Earthing shall generally be carried out in accordance with the requirements of latest CEA regulations (as
amended from time to time) and the relevant regulations of the Electricity Supply Authority
concerned and as indicated below:

a) All metallic supports shall be earthed.

b) For PCC poles the metal cross-arms and insulator pins shall be bonded and earthed at every pole
for HT lines.
c) All special structures on which switches, transformers, fuses, etc., are mounted / likely to mount
should be earthed.

d) The supports on either side of the road, railway or river crossing should be earthed.

e) All supports (Steel & PCC) HT lines passing through inhabited areas, road crossings and along
such other places, where Earthing of all poles is considered desirable from safety considerations
should be earthed.

f) In special locations and special structures, road crossings etc., pipe/rod Earthing should be done
on either side of the construction.
Part -2 : Employer‟s Requirements 230

g) At other locations the coil Earthing may be adopted. The coil Earthing consists of 10 m length of
8 SWG. G.I. wire compressed into a coil 450 mm length and 50 mm dia and buried 1500 mm
deep as per REC standard J-1.

Following shall be the earthing requirements:

No Description Type of Earthing

1 Single Pole - PCC/RS Joist/steel 1 No. Coil/Spike Earthing at
tubular each SP
2 Double pole - PCC/RS Joist/steel 2 Nos. Coil/Spike Earthing at
tubular each DP
3 Substation Poles structure - GI Pipe Earthing 3 Nos
PCC/RS Joist/steel tubular
4 Road crossing GI Pipe earthing on either side
one each
5 Telephone line crossing GI Pipe earthing on either side
one each
6 DP with Isolating switch Coil/Spike earthing 2 Nos and
GI Pipe earthing 1 No

1.30. Anti-Climbing Devices

In order to prevent unauthorized persons from climbing any of the supports of HT lines without
the aid of a ladder or special appliance, certain anti-climbing devices are provided to the supports.
Barbed wire binding is to be adopted for this purpose at a distance of 30 to 40 cm at a height of
3.5 to 4 m from ground level. The barbed wire shall conform to IS – 278 (Grade A1). The barbed
wired shall be given chromatin dip as per procedure laid down in IS: 1340. At-least 3.5 kgs
barbed wire is to be used per pole for the purpose.

1.31. Testing And Commissioning

When the line is ready for energisation, it should be thoroughly inspected in respect of the following:-

a) Poles-Proper alignment, concerting and muffing.

b) Cross-arms – Proper alignment.
c) Finishing of fabricated steel items used.
d) Insulators – Proper finish, cleanliness, insulation resistance.
e) Binding, clamps and jumpers – To check whether these are in reach.
f) Conductor and earth wire – Proper sag to check whether there are any cuts, etc.
Part -2 : Employer‟s Requirements 231

g) Guys: To check whether the Guy wire is tight and whether the Guy insulators are in tact.
h) Earthing System: To check whether the earthing connections of supports and fittings are intact.
Measure earth resistance with earth tester.

After the visual inspection is over and satisfied, the conductor is tested for continuity/ground, by
means of megger. At the time of testing through megger person should not climb on the pole or
touch the guarding, conductor, guy wire etc.

a. Before charging any new line, it should be ensured that the required inspection fee for the new
line is paid to the Electrical Inspector and approval obtained from him for charging the line.

b. The line should be energized before the officer who has been authorized by the Project Manager
in this regard.

c. Before energizing any new line, the contractor of the line shall notify to the workmen that the line
is being energized and that it will no longer be safe to work on line. Acknowledgement of all the
workmen in writing should be taken in token of having intimated them.

d. Wide publicity by Tom-toming should be arranged in all the localities through which the line,
that is to be energized passes, intimating the time and date of energizing and warning public against
the risk in meddling with the line.

e. The Officer-in-charge of the line shall personally satisfy himself that the same is in a fit state to
be energized.

1.32. River Crossing

No special structures are to be erected for this work. River crossing more than normal span of poles
are not considered under the package. For small rivers etc., data for the highest flood-level should
be obtained for previous years. The structures should be located at such places that they should be
approached under flood condition. Normal DP structures are to be used for such crossings on
approval of Project Manager.

In case of river crossing with longer span, special designed structures are to be used for the purpose.
1.33. Guarding

Guarding is to be provided for the lines, so that a live conductor, when accidentally broken, is
prevented to come in contact with other electric lines, telephone or telegraph lines, roads, and
Part -2 : Employer‟s Requirements 232

persons or animals and carriages moving along the road, by providing a sort of cradle below the
main electric line.

Guarding is not required for crossings of 66 KV and higher voltage lines where the transmission
line is protected by fast acting relay operated circuit breaker of modern design with a tripping
time of the order of 0.25 sec. from occurrence of fault to its clearance. For all other crossings,
guarding is essential for all telecommunication lines and major road crossing.

The guarding shall consist of GI guard cross arm of length 2.5 mtrs made out of 65x65x6 mm angle
& shall be hot dipped galvanized generally conforming to IS : 2633/72. The clamps shall also be
hot dipped galvanized generally conforming to IS: 2633/72 & suitable for 13 m 52 kgs/m rail pole
& for 8.0 meters longs RCC poles. Guarding shall be erected with ground & line clearances as per
the I.E. rules. Cradle guard wire should be of 8 SWG GI Wire provided with lashing of 10 SWG
GI wire at a distance of 2 m along the length of the guarding. Tension clamps, threaded eye bolts,
turn buckles, thimble, tying wires and hardware are as per specified in the specifications. A sketch
showing arrangement of guarding at road crossing is enclosed with tender drawing.

The minimum height between any guard wires and live crossing conductor shall not be less than
1.5 m in case of a railway crossing.

1.34. Repair to conductors

The conductor shall be continuously observed for loose or broken strands or any other damage
during the running out operations. Repair to conductors, if necessary, shall be carried out with repair
sleeves. Repairing of the conductor surface shall be carried out only in case of minor damage, scuff
marks, etc. The final conductor surface shall be clean, smooth and free from projections, sharp
points, cuts, abrasions, etc. The Contractor shall be entirely responsible for any damage to the poles
during stringing.

1.35. LT Lines and Service connection

1.7.1. The LT line shall be erected of single phase or three phase arrangements through AB Cable
depending on site requirements. Every 3rd pole of LT line shall be earthed with GI spike/GI Coil
as per specifications.

1.7.2. In all those locations where LT AB cable is to be erected on the same support in which 11KV or
33KV line is also erected, proper isolation is to be maintained.
Part -2 : Employer‟s Requirements 233

1.7.3. All single phase service connections released under the SI schemes shall be provided with one earth
point near the energy meter. This point is connected with the proper earthing system through GI
wires. 10mm diameter earth knob in form of bolt and nut is to be installed on energy meter board.
This earth point is to be maintained by service providing Distribution Company after installation
and energisation. In up-stream network, this earth point is to be connected with earth point.

1.7.4. Service connection is to be issued on proper surveying of the location so that excessive erection
of LT line or 11 KV line may be avoided. The service wire is to be hanged on supportive GI wire
between pole support and the house. Before installing service wires and GI wire, GI pipe on the
consumer premises is to be erected using clamps/ nails/proper binding etc. In case of hut or poor
structure at consumer premises, GI pipe is to clamp on wooden planks/wooden structure existing
in the house. The GI pipe should be supported for neutralizing tension by means of GI tie wire
support. In pukka/brickwork/cement concrete foundations, house, GI support pipe is to be
clamped by means of MS clips.