VOLUME-II SECTION-I TECHNICAL SPECIFICATIONS AND REQUIREMENTS

Transcription

1 1 VOLUME-II VOLUME-II SECTION-I TECHNICAL SPECIFICATIONS AND REQUIREMENTS (TENDER DOCUENT FOR CONSTRUCTION / LAYING OF 11 KV SIGLE CIRCUIT LINE, CREATION OF LT DISTRIBUTION SUB STATIONS AND LAYING OF LT 3P4W LT NETWORK AT BADERKUND GANDERBAL )

2 2 TECHNICAL SPECIFICATIONS AND REQUIREMENTS Contents VOLUME-II... 1 SECTION-I... 1 TECHNICAL SPECIFICATIONS AND REQUIREMENTS... 1 TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES... 8 A. STEELTUBULAR POLES FOR OVERHEAD LINES SPECIFIC TECHNICAL REQUIREMENTS FOR TUBULAR STEEL POLES: SWAGED TYPE B. TECHNICAL SPECIFICATION FOR (LT, 11KV, 33KV) PORCELAIN PIN INSULATORS C. LT upto (1100 V) XLPE Insulated GENERAL TECHNICAL REQUIREMENTS D. SPECIFIC TECHNICAL REQUIREMENTS a. GUARANTEED AND OTHER TECHNICAL PARTICUALRS b. DRAWINGS/DOCUMENTS c. LT POWER CABLES d. CABLE DRUMS e. IDENTIFICATION MARKINGS f. INSPECTION AND TESTING E. MILD STEEL CHANNEL, ANGLE AND FLAT F. ISI MARK HOT DIP GALVANISED MILD STEEL HEXAGONAL HEAD BOLTS AND NUTS TECHNICAL SPECIFICATION FOR 11KV & 33KV DISC INSULATORS G. GUY STRAIN INSULATORS H. DANGER NOTICE PLATES I. EARTHING COIL J. GS STAY SETS K. TECHNICAL SPECIFICAIONS FOR OUTDOOR NON SEALED TYPE THREE PHASE 11 kv, V DISTRIBUTION TRANSFORMERS OF 100, 250,400 & 630KVA CAPACITTES WITH MCCB VOLUME-II SECTION-II GUARANTEED TECHNICAL PARTICULARS GUARANTEED TECHNICAL PARTICULARS OF S T Pole... 77

3 3 TECHNICAL SPECIFICATIONS AND REQUIREMENTS GUARANTEED TECHNICAL PARTICULARS FOR 0.1 ACSR (DOG) GUARANTEED TECHNICAL PARTICULARS OF 33 KV Galvanised V-Type CROSS ARM/CHANNEL CROSS or TOP/FLAT BRACE GUARANTEED TECHNICAL PARTICULARS FOR 45 KN DISC. INSULATOR (T&C TYPE) GUARANTEED TECHNICAL PARTICULARS OF DISC INSULATOR, 70 KN GUARANTEED TECHNICAL PARTICULARS OF DISC FITTING FOR 0.1 ACSR GUARANTEED TECHNICAL PARTICULARS OF 33 KV/11KV/LT PIN GUARANTEED TECHNICAL PARTICULARS OF G.I STAY SET (20X1800)mm GUARANTEED TECHNICAL PARTICULARS FOR LT SHACKLE INSULATOR (TYPE-1) GUARANTEED & OTHER PARTICULARS FOR DISTRIBUTION TRANSFORMERS OF CAPACITIES -100, 250, 400 & 630KV 11/0.433 kv DTs... 88

4 4 TECHNICAL SPECIFICATIONS AND REQUIREMENTS SCOPE OF WORK S.NO DESCRIPTION QTY UNIT 1 Construction / Laying of 11KV Outgoing Feeders from the proposed R/Stn Providing and Errection of 9 Mt. long S.T Pole 540 SP-33 duly 232 No painted with one coat of red oxide and two coats of Aluminium paint 1.02 Providing and Errection of 11 Mtr. Long Pole( ST-540 SP56) 26 No duly painted with one coat of red oxide and two coats of Aluminium paint 1.03 Providing,laying and stringing of ACSR 0.1 Conductor 38 Kms 1.04 Providing and fixing in position of Channel Iron Cross Arms V 3526 Kgs Shaped of ISMC75 duly painted 1.05 Providing and fixing in position of Channel Iron cross arms 1952 Kgs including clamps and braces ISMC75 duly painted for Guard Netting 1.06 Providing and fixing in position of Spiral Earthing of poles 258 No using 8 SWG GI wire as per REC standard complete job 1.07 Providing and fixing in position of G.I. wire for Guard Netting 1 Lot as per REC Standard 1.08 Providing and fixing in position of 11 Kv Pin Insulator with GI 720 No Pins 1.09 Providing and fixing in position of 11 Kv Disc Insulator 45KN 156 No with fittings complete 1.1 Providing and fixing in position of Guys complete with 11KV 65 No Guy insulator, Galvanised 7/3.15mm Guy wire, Guy Rods with complete assembly viz turn buckle, I-bolt, Guy Anchor, Clamps 1.11 Providing and fixing in position of Nuts,Bolts & Washers of 1 Lot sorts 1.12 Providing and fixing in position of 11 kv Danger Plates with 258 No clamps 1.13 Providing and laying in position of Cement concreting of poles 258 No in M-15 grade underground (3.5'De pth & 2.5' dia ) & Above ground (1.5' height & 1.5' dia) 1.14 Providing and fixing in position of Anticlimbing Device comprising of barbed wire and clamps etc 258 No 1.15 carrying out Branch Cutting along the route 6 Kms Providing and fixing in position of 11KV G.O AB 400 AMP Isolating 20 Set Set 2.14 Providing and fixing in position of 11KV D. O Fuse Set 400 amp 20 set

5 5 TECHNICAL SPECIFICATIONS AND REQUIREMENTS 2.15 Providing and fixing in position of 11KV LA Set (Station Type) 20 set 2.16 Providing and fixing in position of 11 kv Disc Insulators 70 no (polymer/porcelain) Completewith fitting(45kn) 2.17 Providing and fixing in position of 11 KV Pin Insulators 70 no (polymer/porcelain) with Pins(5KN) 2.18 Providing and fixing in position of Single core, XLPE un-armoured, 440 mtrs Aluminium conductor 1.1KV grade 185mms Cable 2.19 Providing and fixing in position of Single core, XLPE un-armoured, 880 mtrs Aluminium conductor 1.1KV grade 300 sq mm Cable 2.2 Providing and fixing in position of Guy Rod Assembly duly painted 40 No complete with turn buckle and accessories 2.21 providing and laying of Cement concreting of poles in M-15 grade 40 No underground (3.5'De pth & 2.5' dia ) & Above ground (1.5' height & 1.5' dia) 2.22 Providing and fixing in position of M.S Channel and nut and bolts of 3.5 MT sizes including clamps duly painted and as per standard required for creation of substations 2.23 Providing and fixing in position of M.S Angle duly painted for Guy 40 NO Plates Nuts and Bolts of Sorts required for creation of Substations 1 Lot 2.25 Earthing of substation --Excavation of earth pit of dia 650 mm & depth 3000 mm, installation of Earthing G.I Perforated pipe of 40 mm Nominal bore & 4mm wall thickness & length 2.5 mtr long 25x3mm GI Flat iron, clamps includding cost of Charcoal/salt as Per IS 1239.GI Strip for neutral earthing of size 75 mmx10 mm & 50 mmx6 mm for connection of transformer body,g.o Set & lightening arrestor as per IS 2629/85, GI nuts & bolts,refilled with earth enhancement materials and earth Chamber made of brick masonary with RCC slab cover complete Job 20 Jo Errection of 4.8 km of 11kv line on 11 mtr ST Poles in composite with would be laid new 33kv line 2.01 Providing and fixing in position of GI Channel Iron Cross Arms of 2100 Kgs ISMC75 duly painted including clamps 2.02 Providing,laying and stringing of ACSR 0.1 Conductor Kms 2.03 Providing and fixing in position of PG clamps for 100mm2 ACSR 60 NOS Conductor 2.04 Providing and fixing in position 11kv pin insulators with pins 280 NOS 2.05 Providing and fixing in position 11kv Disc insulators complete 60 NOS with fittings 2.06 Providing and fixing in position Galvanised Nuts And Bolts 100 KGS 2.07 Creation of Substations

6 6 TECHNICAL SPECIFICATIONS AND REQUIREMENTS 2.08 supply, installation,testing and commissioning of Pole mounted 100KVA, 11/430KV Three Phase distribution Transformerswith Bimetallic Terminal Connectors Energy Level-2,Aluminium wound 2.09 supply, installation,testing and commissioning of pole mounted 250 KVA, 11/430KV Three Phase distribution Transformerswith Bimetallic Terminal Connectors Energy Level-2 copper wound 2.1 supply, installation,testing and commissioning of bed mounted 400 KVA, 11/430KV Three Phase distribution Transformerswith Bimetallic Terminal Connectors Energy Level-2,copper wound supply, installation,testing and commissioning of bed mounted 630 KVA, 11/430KV Three Phase distribution Transformerswith Bimetallic Terminal Connectors Energy Level-2, copper wound Providing and errection of Pole 9mtr long 540SP 33 duly painted with one coat of red oxide and two coats of Aluminium paint 5 No 4 No 4 No 7 No 40 No 2.26 Providing and fixing in position of Spiral Earthing of poles using 8 SWG 40 No GI wire as per REC standard complete job 2.27 Providing and fixing in position of Clamps like wedge connectors/pg 20 NOS clamps, aluminium lugs,( a lot of 30 nos and jumpers and binding tape) required for creation of Substations 2.28 Providing and fixing in position of 3-Phase 200A, 25KA MCCB mounted 16 Nos inside sheet metal enclosure duly powder coated as per standard required for creation of substations 2.29 Providing and fixing in position of 3-Phase 400A, 25KA MCCB mounted 34 Nos inside sheet metal enclosure duly powder coated as per standard required for creation of substations 2.3 Providing and fixing in position of Danger Plates with Clamps 20 Nos 2.31 Providing and fixing in position of GI Barbed Wire for Anti Climbing 300 Kgs 2.32 Providing and fixing in position of 3-Ø, 4-Wire Trivector Meter with CT. with meter box as per the substation ratings 2.33 LT Network 2.34 Providing and errection of 2ST Pole 8mtr long ST-540 SP15) duly painted with one coat of red oxide and two coats of Aluminium paint 2.35 Providing and errection of9 Mtr. Long Pole ST-540 SP33) duly painted with one coat of red oxide and two coats of Aluminium paint 2.36 Providing,laying and stringing of Conductor ACSR 100sqmm for three phase and neutral with wastage and 3% 2.37 Providing and fixing in position of Guys complete with Guy insulator, Galvanised 7/3.15mm Guy wire,guy Rods with complete assembly viz turn buckle, I-bolt, Guy Anchor, Clamps 2.38 Providing and laying of Cement concreting of poles in M-15 grade underground (3.5'De pth & 2.5' dia ) & Above ground (1.5' height & 20 Nos 114 No 12 NO Kms 30 Nos 126 No

7 7 1.5' dia) 2.39 Providing and fixing in position of LT Shackle insulators 16 KN with 520 clamps 2.4 Providing and fixing in position of Spiral Earthing of poles using 8 SWG 126 No GI wire as per REC standard complete job 2.41 Providing and fixing in position of LT spacers for LT Line 126 No 2.42 Providing and fixing in position of Nuts and bolts of sorts 126 KGS 2.43 Providing and fixing in position of Danger Plates 126 Nos 2.44 Providing and fixing in position of Anti-Climbing Device with Clamps 126 Kgs 2.45 Providing and fixing in position of Earthing Complete by GI Pipe Nos mm or GI Rod 20mm 2.5 mtr long through GI strip 2.46 Providing and laying of Stone Pad (300 mm x 300 mm x 75 mm) 126 Nos 2.47 Providing and fixing in position of Aluminium Jointing Sleeve 25 Nos 2.48 Providing and laying of Single core, XLPE un-armoured, Aluminium conductor 1.1KV grade 185mmsq Cable for road crossing 2.49 providing and laying of Single core, XLPE un-armoured, Aluminium conductor 1.1KV grade 400mmsq Cable for road crossing 1080 mtrs 1320 mtrs

8 Nominal Al. Sectional Area of Total Sectional Approx. Overall Approx. Mass Resistance at 200C Approx. Calculated Breaking 8 TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES Hard Drawn Stranded Aluminium and Steel Cored Aluminium Conductors for Overhead Power Lines 1. SCOPE This Specification covers the details of the conductors for use on 33 KV, 11 KV and LT overhead lines in rural electric distribution systems. The sizes of conductors standardised for lines of different voltages are indicated below: 33KV/11KV Lines i) ACSR 7/3.35mm (50mm2 aluminium area) ii) ACSR 7/4.09 mm (80mm2 aluminium area) iii) ACSR 6/4.72 mm + 7/1.57 mm (100mm2 aluminium area) 2. APPLICABLE STANDARDS Except when they do not comply with the specific requirements in this specification, the conductors shall comply with the Indian Standard Specification IS: 398 (Pt. I)-1976 and IS: 398 (Pt. II)-1976 or the latest version thereof. 3. SIZES TABLE I STANDARD ALUMINIUM STRANDED CONDUCTORS Nominal Al Area Stranding and Wire Diameter Sectional Area Approx. Overall Diameter Approx Mass Calculated Resistance at 200 C Max. Approx. Calculated Breaking load mm.sq. Mm mm.sq. Mm Kg./Km Ohm./Km KN 25 7/ / TABLE II STRANDED STEEL CORED ALUMINIUM CONDUCTORS Stranding & Wire Diameter Al Steel mm. sq mm mm mm. sq mm. sq Mm Kg./Km Ohm/k m KN 20 6/2.11 1/

9 9 TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES 30 6/2.59 1/ /3.35 1/ /4.09 1/ /4.72 7/ ALUMINIUM WIRES The aluminium strands shall be hard drawn from electrolytic aluminium rods of EC grade having purity not less than 99.5% and a copper content not exceeding 0.04%. They shall have the same properties and characteristics as prescribed in IEC: The properties of aluminium wires to be used in the construction of the stranded conductors shall be as under TABLE III SOLID ALUMINIUM WIRES USED IN THE CONSTRUCTION OF STRANDED ACSR CONDUCTORS Diameter Cross Sectional Area of Nominal Diameter Wire Mass Resistance At 20 Deg. C Breaking Load Min. Nominal Min Max Before Stranding After Stranding mm Mm Mm mm. sq Kg/Km Kg/Ohm KN KN STEEL WIRES The steel wire strands shall be drawn from high carbon steel wire rods produced by either the acid or the basic open-hearth process, or the electric furnace process, or the basic oxygen process and

10 10 TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES shall conform to the following requirements as to the chemical composition as prescribed in IS 398 (Pt. II)- 1996: Element % Composition Carbon 0.50 to 0.85 Manganese 0.50 to 1.10 Phosphorous Not more than Sulphur Not more than Silicon 0.10 to 0.35 The properties of steel wires to be used in the construction of the stranded ACSR conductors shall be as under TABLE IV SOLID STEEL WIRES USED IN THE CONSTRUCTION OF STRANDED ACSR CONDUCTORS Cross Sectional Breaking Load Min. Diameter Area of Nominal Diameter Wire Mass Nominal Min Max Before Stranding After Stranding FREEDOM FROM DEFECTS The wires shall be smooth and free from all imperfections, such as spills & splits. 7. JOINTS IN WIRES & CONDUCTORS 7.1 All aluminium conductors: No joints shall be permitted in any wire. 7.2 Aluminium Conductor Steel Reinforced: Aluminium Wires: No joints shall be permitted in outer layer. Steel Wires: No joints shall be permitted in any wire.

11 11 TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES 8. STRANDING 8.1 The wires used in construction of a stranded conductor shall, before stranding satisfy all the requirements of this standard for solid wires. 8.2 Lay Ratio : i) The lay ratio for aluminium wires in case of AAC shall be within limits given below : No. of wires in conductors Lay Ratio 7 Min 10 Max 14 ii) The lay ratio for aluminium and steel wire in case of ACSR shall be within limits given below : No. of Wires Ratio Aluminium Lay ratio for Steel Lay Ratio for wire dia to wire (6 wire layer) Aluminium wire Al Steel steel wire dia Min Max Min Max TESTS The samples of individual wires for the tests shall normally be taken before stranding. The manufacturer shall carry out test on samples taken out at least from 10% of aluminium wire spools and 10% of steel wire coils. However, when desired by the purchaser, the test sample may be taken from the stranded wires. a) The wires used for all aluminium conductors shall comply with the following tests as per IS: 398(Pt.I) i) Breaking load test ii) Wrapping test iii) Resistance test b) The following tests to be conducted for ACSR conductors shall conform to IS 398 (Pt. II) and IEC: 888 & 889. The procedure for conducting these tests is given below: 1. Type Tests The following tests shall be conducted once on a sample/samples of conductor (ACSR/AAAC) for every 1500Kms. of production from each manufacturing facility: a) UTS test on stranded conductor b) DC resistance test on stranded conductor 2. Acceptance Tests a) Visual and dimensional check on drum b) Visual check for joints scratches etc. and length measurement of conductor by rewinding c) Dimensional check on steel and aluminium/al-alloy strands d) Check for lay-ratio e) Galvanising test on steel strands

12 12 TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES f) Torsion and Elongation tests on steel strands g) Breaking load test on steel and Aluminium strands h) Wrap test on steel & Aluminium strands i) DC resistance test on Aluminium strands ii) Procedure qualification test on welded joint of Aluminium strands Note: All the above tests except (j) shall be carried out on aluminium and steel strands after stranding only. 3. Routine Test a) Check to ensure that the joints are as per Specification. b) Check that there are no cuts, fins etc. on the strands. c) Check that drums are as per Specification. d) All acceptance tests as mentioned above to be carried out on each coil. 4. Tests During Manufacture a) Chemical analysis of zinc used for galvanizing b) Chemical analysis of Aluminium used for making Aluminium strands c) Chemical analysis of steel used for making steel strands 10. PROCEDURE FOR CONDUCTING TESTS ON ACSR CONDUCTORS i) UTS Test on Stranded Conductor Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor of minimum 5 m length between fixing arrangement suitably fixed on a tensile testing machine. The load shall be increased at a steady rate upto 50% of minimum specified UTS and held for one minute. The circles drawn shall not be distorted due to relative movement of strands. Thereafter the load shall be increased at steady rate to minimum UTS and held for one minute. The Conductor sample shall not fail during this period. The applied load shall then be increased until the failing load is reached and the value recorded. ii) D.C. Resistance Test on Stranded Conductor On a conductor sample of minimum 5m length two contact-clamps shall be fixed with a predetermined bolt torque. The resistance shall be measured by a Kelvin double bridge by placing the clamps initially zero metre and subsequently one metre apart. The test shall be repeated at least five times and the average value recorded. The value obtained shall be corrected to the value at 20 C as per IS:398-(Part-V) The resistance corrected at 200C shall conform to the requirements of this Specification. iii) Chemical Analysis of Aluminium and Steel Samples taken from the Aluminium and steel ingots/coils/strands shall be chemically/spectrographically analysed. The same shall be in conformity to the requirements stated in this Specification. iv) Visual and Dimensional Check on Drums The drums shall be visually and dimensionally checked to ensure that they conform to the requirements of this Specification. v) Visual Check for Joints, Scratches etc. Conductor drums shall be rewound in the presence of the Owner or his representative. The Owner/his representative shall visually check for scratches, joints etc. and that the conductor generally conforms to the requirements of this Specification. Ten percent (10%) drums from each lot shall be rewound in the presence of the Owner's representative.

13 13 TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES vi) Dimensional Check on Steel and Aluminium Strands The individual strands shall be dimensionally checked to ensure that they conform to the requirement of this Specification. vii) Check for Lay-ratios of Various Layers The lay-ratios of various layers shall be checked to ensure that they conform to the requirements of this Specification. viii) Procedure Qualification test on welded Aluminium strands. Two Aluminium wire shall be welded as per the approved quality plan and shall be subjected to tensile load. The breaking strength of the welded joint of the wire shall not be less than the guaranteed breaking strength of individual strands. ix) Chemical Analysis of Zinc Samples taken from the zinc ingots shall be chemically/ spectrographically analysed. The same shall be in conformity to the requirements stated in the Specification. x) Galvanising Test The test procedure shall be as specified in IEC: 888. The material shall conform to the requirements of this Specification. The adherence of zinc shall be checked by wrapping around a mandrel four times the diameter of steel wire. xi) Torsion and Elongation Tests on Steel Strands The test procedures shall be as per clause No of IEC : 888. In torsion test, the number of complete twists before fracture shall not be less than 18 on a length equal to 100 times the standard diameter of the strand. In case test sample length is less or more than 100 times the stranded diameter of the strand, the minimum number of twists will be proportioned to the length and if number comes in the fraction then it will be rounded off to next higher whole number. In elongation test, the elongation of the strand shall not be less than 4% for a gauge length of 250 mm. xii) Check on Barrel Batten strength of Drums The details regarding barrel batten strength test will be discussed and mutually agreed to by the Contractor & Owner in the Quality Assurance Programme. xiii) Breaking load test on individual Aluminium and Galvanized steel wires The test shall be conducted on both Aluminium and Galvanized steel wires. The breaking load of one specimen cut from each of the samples taken shall be determined by means of suitable tensile testing machine. The load shall be applied gradually and the rate of separation of the jaws of the testing machine shall be not less than 25 mm/min. and not greater than 100 mm./ min. The ultimate breaking load of the specimens shall be not less than the values specified in the Specification. xiv) Resistance test on Aluminium wire The test shall be conducted on aluminium wires only, conforming to procedure as per IEC: 889. The electrical resistance of one specimen of aluminium wire cut from each of the samples taken shall be measured at ambient temperature. The measured resistance shall be corrected to the value corresponding to 20 degree C. by means of following formula. 1 R 20 = RT (T-20) Where

14 14 TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES R 20 = Resistance corrected at 20 degrees C. RT = Resistance measured at T degrees C. = Constant mass temperature coefficient of resistance T = Ambient temperature during measurement This resistance calculated to 20 degrees C. shall be not more than the maximum value specified in the specification. 11. PACKING & MARKING The conductors shall be wound in reels or drums conforming to IS: Specification for Reels and Drums for bare wire or the latest version thereof. As an alternative to wooden drum supplier may also supply the conductors in nonreturnable painted steel drums. After preparation of steel surface according to IS: 9954, synthetic enamel paint shall be applied on one coat of primer. Wooden/Steel drum will be treated at par for evaluation purpose. 11.1Packing The gross mass for various conductors shall not exceed by more than 10% of the values given in the following table Conductor Size Gross Mass AAC 25mm 2 Al. area (7/2.21 mm). 500Kg. 50mm 2 Al. area (7/3.10 mm). 500 Kg. ACSR 20mm 2 Al. area (7/2.11 mm). 30mm 2 Al. area (7/2.59 mm). 50mm 2 Al. area (7/3.35 mm). 80mm 2 Al. area (7/4.09 mm). 100mm 2 Al. area (6/4.72mm + 7/1.57mm). 1000Kg. 1000Kg. 1500Kg. 1500Kg. 2000Kg The normal length of various conductors shall be as given in the following table: Conductor Size Normal conductor length AAC 25mm 2 Al. area (7/2.21mm). 1.0Km. 50mm 2 Al. area (7/3.10mm). 1.0 Km. ACSR 20mm 2 Al. area (7/2.11 mm). 2.0Km. 30mm 2 Al. area (7/2.59 mm). 2.0Km. 50mm 2 Al. area (7/3.35 mm). 2.0Km. 80mm 2 Al. area (7/4.09 mm). 1.5Km. 100mm 2 Al. area (6/4.72mm + 7/1.57mm). 2.0Km Longer lengths shall be acceptable Short lengths, not less than 50% of the standard lengths, shall be acceptable to the maximum extent of 10% of the quantity

15 15 TECHNICAL SPECIFICATIONS OF 33KV & 11KV OVER HEAD LINE ON 11MTR AND 9MTR LONG ST POLES ordered. A single drum may contain more than one length of conductor Marking : The following information shall be marked on each package : a) Manufacturers name b) Trade mark, if any c) Drum or identification number d) Size of conductor e) Number and lengths of conductor f) Gross mass of the package g) Net mass of conductor h) I.S.I certification mark, if any 12 INSPECTION All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being furnished in accordance with this Specification.

16 16 STEELTUBULAR POLES FOR OVERHEAD LINES A. STEELTUBULAR POLES FOR OVERHEAD LINES 1. SCOPE: This specification covers the general requirements towards design, manufacture, testing at manufacturers works, supply and delivery for tubular steel poles of circular cross section ( swaged type ) for overhead lines. 2. STANDARD: 2.1 The tubular steel poles shall conform to the latest edition of Indian Standard specification IS: 2713 (Part I, III): 1980 or any other authoritative standards (as amended up-to- date) except where specified otherwise in this specification. 2.2 SPECIFIC TECHNICAL REQUIREMENTS FOR TUBULAR STEEL POLES: SWAGED TYPE 3. Topography and Climatic Condition: 3.1 The materials offered, shall be suitable for operation in tropical climate and will be subjected to the sun and inclement weather and shall be able to withstand wide range of temperature variation. For the purpose of design, average atmospheric temperature may be considered to be 50ºC with humidity nearing saturation. 4. Materials: 4.1 The materials used in construction of tubular steel poles shall be of the tested quality of steels of minimum tensile strength 540 SP The materials, when analysed in accordance with IS: 228 (Part-III:1 972) and IS : 228 ( Part-IX) shall not show sulpher and phosphorous contents of more than percent each. 4.3 In no case punching of holes in Steel tubular holes will be allowed. However in exceptional cases holes using gas cutters may be allowed with an explicit permission of AEE concerned. s 5. Types, Size and construction: 5.1 Tubular Steel Poles shall be swaged type. 5.2 Swaged poles shall be made of seamless or welded tubes of suitable lengths swaged and jointed together. No circumferential joints shall be permitted in the individual tube lengths of the poles. If welded tubes are used they shall have one longitudinal weld seam only: and the longitudinal welds shall be staggered at each swaged joint. 5.3 Swaging may be done by any mechanical process. The upper edge of each joint shall be chamfered if at an angle of about 45o. The upper edge need not be chamfered if a circumferential weld is to be deposited in accordance with clause No of IS: 2713 (Part-I): The length of joints on swaged poles shall be in accordance with clause No. 5.4 of IS: 2713 (Par-I): Poles shall be well-finished, clean and free from harmful surface defects. Ends of the poles shall be cut square. Poles shall be straight, smooth and cylindrical. The weld joints, if any, shall be of good quality, free from scale, surface defects, cracks, etc. 5.6 Tolerances for outside diameter, thickness, length, weight and straightness shall be in accordance with IS: 2713 (Part-I): The poles shall be coated with black bituminous paint conforming to IS: throughout, internally and externally, upto the level which goes inside the earth. The

17 17 STEELTUBULAR POLES FOR OVERHEAD LINES remaining portion of the exterior shall be painted with one coat of red oxide primer as specified in IS: Earthing Arrangements: 6.1 For earthing arrangement a through hole of 14mm diameter shall be provided in each pole at a height of 300mm above the planting depth. 7. Tests and Test Certificates: 7.1 The following tests shall be conducted on finished poles : A. Tensile test and chemical analysis for sulpher and phosphorous, B. Deflocation test, C. Permanent set test, and D. Drop test. 7.2 In addition to above verification of dimensions as per IS: 2713 (Part-III) : 1980 shall be carried out during acceptance lots. 7.3 Number of poles selected for conducting different tests shall be in accordance to clause No and No : of IS: 2713 (Part-I) Tests shall be carried out before supply of each consignment at the manufacturer s woks and test certificates should be submitted to the purchaser for approval prior to delivery. 7.5 Re-tests, if any, shall be made in accordance with IS: 2713 (Part-I) Purchaser reserves the right to inspect during manufacturing and depute his representative to inspect/test at the works. 7.7 If any extra cost is required for carrying out the above specified tests, the same shall be borne by the supplier. 8. Marking: 8.1 The poles shall be marked with designation, manufacturer s identification, year of manufacture and name of the purchaser: Employer Name JKSPDC 8.2 The poles may also be marked with the ISI certification mark. 9. Guaranteed technical particulars: 9.1 The tenderer shall furnish all necessary guaranteed technical particulars in the prescribed Performa enclosed hereinafter. 10. Performance: The supplier shall furnish a list of the major supplies effected during the last 3 (three) years indicating the volume of supply and actual delivery dates along with the bids Supplier may not be considered if the past manufacturing experience is found to be less that 3 (three) years. 11. Deviation: Any deviation in technical specification shall be clearly indicated with sufficient reasons thereof. Purchaser shall however reserve the right to accept and/or reject the same without assigning any reasons what-so-ever.

18 18 STEELTUBULAR POLES FOR OVERHEAD LINES ANNEXURE A SPECIFIC TECHNICAL REQUIREMENTS FOR TUBULAR STEEL POLES: SWAGED TYPE Particulars 8 meters Long 9 meters long 11 meters long 13 meters long 1) Standard IS: 2713 ( Pat-I and III): 1980 as amended upto date 2) Type of Pole Swaged Type 3) Designation 410 SP SP SP SP 72 4) Overall Length 8 meters 9 meters 11 meters 13 meters 5) Planting depth 1.5 meters 1.5 meters 1.8 meters 2.0 meters 6) Height above ground 6.5 meters 7.5 meters 9.2 meters 11.0 meters 7) Effective length of Each section. a) Bottom 4.5 meter 5.0 meters 5.6 meters 5.80 meters b) Middle 1.75 meter 2.0 meters 2.7 meters 3.60 meters c) Top 1.75 meter 2.0 meters 2.7 meters 3.60 meters 8) Outside diameter and Thickness of each Section. a) Bottom 139.7x5.40mm 139.7x 4.50 mm 193.7x5.40 mm 219.1x5.90 mm b) Middle 114.3x3.65 mm 165.1x x4.85 mm 114.3x4.50mm mm c) Top 88.9x3.25mm 88.9x3.25 mm 139.7x x4.50 mm mm 9) Joint Length (in cm.): a) Bottom (J2) 30 cm 30 cm. 40 cm. 45 cm. b) Top (J1) 23 cm 23 cm. 35 cm. 40 cm. 10) Approximate weight of Pole Kgs 164 Kg. 241 Kg. 343 Kg. 11) Point of application of load 0.3 meter 0.3 mtr. 0.6 mtr. 0.6 mtr below/top (mtr.) 12) Breaking load ( in Kgf ) ) Working load with factor of Kg. Safety : 2.5 ( in Kgf ) 14) Crippling load ( in Kgf ) Kg. 15) Load for permanent set Not Kg. exceeding 13mm (in Kgf) 16) Load for Temporary Deflection of mm ( in Kgf) ) Tolerance As per IS : 2713 ( Part-I & Part-III): ) Finish -do- 19) Manufacturing clause -do-

19 19 TECHNICAL SPECIFICATION FOR (LT, 11KV, 33KV) PORCELAIN PIN INSULATORS B. TECHNICAL SPECIFICATION FOR (LT, 11KV, 33KV) PORCELAIN PIN INSULATORS 1. SCOPE: The specification provides for manufacture, testing before dispatch, supply and delivery of (LT/11KV/33KV) Porcelain Pin Insulators as per the particulars given in the "Schedule of Requirements" attached. 2. STANDARDS: The (LT/11KV/33KV) Pin Insulators shall conform to the following standards with latest amendments if any. The tenders shall go through the IS thoroughly before making their offer. The material shall be for use in moderately hot and humid tropical climate, conducive to rust and fungus growth (A). Sl. No. Material Indian Standards (amended up to date) 1 LT Pin Insulators IS: KV Pin Insulators IS: KV Pin Insulators IS: IS: 2486 Part-II GENERAL REQUIREMENT: i) The porcelain shall be sound, free from defects thoroughly verified and smoothly glazed. ii) The design of Insulator should be such that, stresses due to expansion or and contraction in any part of the insulator shall not lead to its deterioration. The porcelain shall not engage directly with hard metal for 11 KV and 33 KV pin insulators. iii) The glaze shall be Brown in colour except for the screw threads and the top portion on which the conductor is supported during firing which may be left unglazed, all other surfaces of the insulator shall be effectively glazed. 4. TYPE AND DIMENSIONS: The dimensions and construction of (LT/11KV/33KV) Pin Insulators should be as per IS mentioned in clause (2) with latest issues thereof. 5. ELECTRICAL AND MECHANICAL CHARACTERISTICS: - The electrical and mechanical particulars of (LT/11KV/33KV) Pin insulators shall be as per the Guaranteed Technical Particulars shown, measured at the following standard atmospheric conditions. Maximum ambient temperature in open air 38 ( C): Maximum ambient temperature in shade ( C) 30 Minimum temperature ( C): -20 Relative humidity (%) 10 to 100 Maximum annual rainfall (mm) 1000 Maximum wind pressure (Kg/ Sqmtr.) 150 Maximum altitude above mean sea level (Mtrs) 2000 Isoceraunic level (days/year) 15 Seismic Zone 5 Reference Ambient Temperature for 50 deg C

20 20 TECHNICAL SPECIFICATION FOR (LT, 11KV, 33KV) PORCELAIN PIN INSULATORS Temperature rise General nature of climate: Moderately hot summers and cold winters with moderate to heavy snowfall and freezing temperatures. The climatic conditions are prone to wide variations in ambient conditions and hence the equipment shall be of suitable design to work satisfactorily under these conditions. 6. BASIC INSULATION LEVELS: The test voltage of Pin insulators shall be as per the values given in Guaranteed Technical Particulars 6.2 In this specification power frequency voltages are expressed as peak values divided by 2 and impulse voltages are expressed as peak values. 6.3 The withstand flashover voltages are referred to the reference atmospheric conditions. 7. The firm may offer insulators of higher creepage distance, but the mechanical and electrical parameters of their product shall be as per the mechanical and electrical requirement in GTP 8. TESTS: - i) All the tenderers must submit copies of type test certificates along with laboratory approved drawings for the products offered by them. The Certificates shall be from any NABL accredited laboratory, but not more than 5 years old as on date of opening the tender. ii) Copy of type test certificate of each type offered must be submitted. iii) The type test certificate shall be final and complete for all the tests as per the list of type tests given in specification Cl.No.8.1of the specification. iv) Failure to submit the type test certificates as described above shall be liable for rejection of tender offer. v) Routine test shall be carried out on every insulator as specified in IS in clause no.2 with latest amendments. Details of test result on each of the insulator supplied, has to be submitted to inspector for his perusal and verification. vi) The insulators shall comply with the type tests as per IS in clause no.2 with latest amendments. 8.1 TYPE TESTS: The following shall constitute the type tests. However, the test voltage value shall be as per GTP. a) Visual examination. b) Verification of dimensions. c) Visible discharge test. d) Impulse voltage withstand test (+ve wave & -ve wave) e) Impulse voltage flashover test (+ve wave & -ve wave) f) Dry and wet power frequency voltage withstands test. g) Dry and wet power frequency flashover voltage test.

21 21 TECHNICAL SPECIFICATION FOR (LT, 11KV, 33KV) PORCELAIN PIN INSULATORS h) Temperature Cycle test. i) Mechanical failing load test. j) Puncture test. k) Porosity test. l) Galvanizing test. 8.2 ACCEPTANCE TESTS: - From the offered lot, samples shall be drawn randomly as per the criteria given. The firm has to arrange for carrying out all following acceptance tests at firms works only at firm's cost in presence of inspector deputed by JKSPDC. a) Verification of dimensions and Visual examination. b) Temperature cycle tests. c) Mechanical failing load test d) Puncture test. e) Porosity test. f) Galvanizing test. 8.3 ROUTINE TESTS: - The following tests shall be carried out as routine tests by firm on each insulator before offering the lot for inspection. a) Visual examination. b) Mechanical routine test c) Electrical routine test 9. TEST CERTIFICATES: The test shall be carried out as per the IS before dispatch and the test certificates shall be furnished for approval. Copies of type test certificates of identical materials for each type with dimensional drawings shall invariably accompany the tender. The type tests as specified in the IS should be carried out not later than 5 years from the date of opening of bid. 10. PACKING: This shall be done in wooden crates suitable for rough handling. 11. GUARANTEED TECHNICAL PARTICULARS: The technical particulars as specified in the IS shall be guaranteed and a statement of guaranteed particulars shall be furnished along with the tender as per the enclosed format, without which, the tender will be liable for rejection 12. SAMPLES: Two Nos. samples of (LT/11KV/33KV) Pin Insulators shall invariably accompany the tender. Tenders for which samples are not received by the stipulated date will be rejected. 13. MARKING: The Material shall be engraved with your trade mark, year of manufacture and JKSPDC name shall be legibly and indelibly marked on the insulator similar to the supplier name inscription on the insulator. Marking on porcelain shall be printed and shall be applied before firing.

22 22 1. GENERAL TECHNICAL REQUIREMENTS C. LT upto (1100 V) XLPE Insulated SCOPE: The scope of this specification covers the design, manufacture inspection and testing the finished ISI marked LT (1100 volts, Single & 31/2 x25 Sq.mm to 400 Sq.mm stranded, compact aluminum conductor, with XLPE insulated, PVC inner sheathed, galvanized steel strip armored/ unarmoured and overall PVC sheathed Black colour cable conforming to IS:7098 /88 with latest amendments and as per specification detailed. 1. GENERAL TECHNICAL REQUIREMENTS 1 The power and control cable shall, in general, comply with the relevant IEC/IS standards of latest edition including amendments except to the extent explicitly modified in the specification and shall also be in accordance with requirements specified in this section. A list of relevant Standards are given in Annexure-I of Section General Technical Requirements. 2 The design and workmanship shall be in accordance with the best engineering practices to ensure satisfactory performance throughout the service life. 3 The cables shall be suitable for laying in racks, ducts, covered trenches, conduits and underground-buried installation with chances of flooding by water. 4 The cables shall be designed to withstand all mechanical, electrical and thermal stresses under steady state and transient operating conditions. The XLPE insulated LT power cables of sizes 240 sq. mm and above shall withstand without damage a 3 phase fault current of at least 45 ka for at least 0.12 sec with an initial peak of 105 KA in one of the phases. The armour of these power cables shall be capable of carrying 45 ka for at least 0.12 sec without exceeding the maximum allowable temperature of PVC outer sheath. 5 The aluminum/copper wires used for manufacturing the cables shall be true circular in shape before stranding and shall be of good quality, free from defects. All aluminum used in the cables shall be H 2 grade. 6 The fillers and inner sheath shall be of non hygroscopic, fire retardant material, shall be softer than insulation. Outer sheath shall be suitable for the operating temperature of the cables. 7 Progressive sequential marking of the length of cable in metres at every one metre shall be provided on the outer sheath of all cables. 8 Suitable chemicals shall be added to the outer sheaths of all cables to protect them from rodent and termite attack. These chemicals shall not have any harmful effect on the human being. 9 The cables shall have Outer sheath of material with an oxygen index of not less than 29 as per ASTMD-2863 and temperature index of not less than 250 deg C.

23 23 SPECIFIC TECHNICAL REQUIREMENTS 10 Strip wire armouring method (a) mentioned in Table 5, Page-6 of IS: 1554 (Part 1) 1988 shall not be accepted for any of the cables. For control cables, only round wire armouring shall be used. 11 The normal current rating of all PVC insulated cables shall be as per IS: The XLPE insulated cables shall be capable of withstanding a conductor temperature 250 deg C during a short circuit and PVC insulated cables shall be able to withstand a conductor temperature of 160 deg C during short circuit. 13 All the cables shall pass fire resistance test as per IS:1554 (Part-I) 14 Allowable tolerance on the overall diameter of cables shall be 2mm. 15 Repaired cables shall not be accepted. D. SPECIFIC TECHNICAL REQUIREMENTS The technical parameters of the Power and Control cables are detailed in Section Specific Technical Requirements of the specification. a. GUARANTEED AND OTHER TECHNICAL PARTICUALRS The tenderer shall furnish all the guaranteed and other technical particulars for the cables offered by him as called for in Section Guaranteed and Other Technical Particulars. Any other particulars considered necessary may also be given in addition to those listed in that Section. b. DRAWINGS/DOCUMENTS In addition to any other drawings, which the tenderer may like to supply, five (5) sets of the following drawings/manuals must be submitted during detailed engineering: i) Drawing showing sectional view of cables. ii) Technical and descriptive literature giving details of the cables offered. iii) Type test reports. iv) Tables of rating factor for correction of current rating for variation from standard condition to installation condition. v) Test facilities available at the supplier s works.

24 24 LT POWER CABLES c. LT POWER CABLES a. The XLPE insulated 1100 V grade power cables shall be of FRLS type, of category C1 conforming to IS: 7098 Part I (as amended up to date). The conductor shall be stranded aluminum, circular / shaped and compacted. In multi core cables, the core shall be identified by red, yellow, blue and black coloured strips or colouring of insulation. A distinct inner sheath shall be provided in all multi core cables. For multi core cables the inner sheath shall be of extruded PVC of type ST-2 of IS: Armouring for single core cables shall be aluminum strips/wires. Outer sheath for all cables shall be extruded PVC of type ST- 2 of IS: b. The PVC insulated 1100 V grade power cables shall be of FRLS type, of category C1 conforming to IS: 1554 (Part I) (as amended up to date) and shall be suitable for a steady conductor temperature of 70 Deg. C. The conductor shall be stranded aluminium. The insulation shall be extruded PVC of Type A of IS: The inner and outer sheath shall be of extruded PVC of Type ST-I of IS: A distinct inner sheath shall be provided in all multi core cables. The armour shall be aluminum wire or strip for single core cables conforming to IS: d. CABLE DRUMS a. Cables shall be supplied in non-returnable wooden/steel drums of heavy construction. For wooden drums, the wood used for construction of the drum shall be properly seasoned, sound and free from defects. Wood preservative shall be applied to the entire drum. b. The standard lengths for each size of power and control cables shall be 500/1000 meters. The Purchaser shall have the option of cable drums with non-standard lengths. The cable length per drum shall be subject to tolerance of + 5% of the standard drum length. However, the total quantity of cable after taking into consideration of all cable drums shall be within the tolerance of +2%. c. A layer of waterproof paper shall be applied to the surfaces of the drums and over the outer most cable layer. d. A clear space of at least 40 mm shall be left between the cable and the lagging. e. Each drum shall carry the Manufacturer s name, Purchaser's name, address and contract number, item number and type, size and length of cable, net and gross weight stenciled on both

25 25 IDENTIFICATION MARKINGS sides of drum. A tag containing the same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wordings shall be marked on one end of the reel indicating the directions in which it should be rolled. f. Packing shall be sturdy and adequate to protect the cables from any injury due to mishandling or other conditions encountered during transportation, handling and storage. Both cable ends shall be sealed with PVC/rubber caps so as to eliminate ingress of water during transportation, storage and erection. e. IDENTIFICATION MARKINGS To identify the cables as JKSPDC s property it is necessary to emboss or print "JKSPDC," and also the name or trade mark of the manufacturer alternatively at every 1.0 meter interval on all the cables. f. INSPECTION AND TESTING a. Tests and inspection of cables shall in general be in accordance with requirement of Section - General Technical Requirements. b. PVC insulated power and control cables shall comply with all type tests and be subjected to all routine and acceptance tests as per IS: 1554 (as amended up to date). XLPE insulated power cables shall comply with all type tests and be subjected to all routine an acceptance tests as per IS: 7098 (as amended up to date). c. The type tests on cables shall be conducted on each type and size of cables offered. d. Following type tests as per IS: 7098 (Part 1) including its amendments and additional type tests shall be carried out on 1.1 kv grade XLPE insulated cables: a) Tests on conductor i) Annealing test (for Copper) ii) Tensile test (for aluminum) iii) Wrapping test (for aluminum) iv) Resistance test b) Test for armouring wires/strips

26 26 INSPECTION AND TESTING c) Test for thickness of insulation and sheath d) Physical tests for insulation i) Tensile strength and elongation at break ii) Ageing in air oven iii) Hot set test iv) Shrinkage test e) Physical tests for outer sheath i) Tensile strength and elongation at break ii) Ageing in air oven iii) Loss of mass in air oven iv) Shrinkage test v) Hot deformation vi) Heat shock test vii) Thermal stability f) Insulation resistance (volume resistivity test) g) High voltage test h) Flammability test i) Oxygen index test and temperature index test on outer sheath j) Short time current test on power cables of sizes 240 sq. mm and above. 1) On conductor(s). 2) On armours. e. Following type tests as per IS: 7098 (Part 2) including its amendments and additional type tests shall be carried out on XLPE insulated HT cable up to 33 kv earthed system: a) Tests on conductor

27 27 INSPECTION AND TESTING i) Annealing test (for Copper) ii) Tensile test (for aluminum) iii) Wrapping test (for aluminum) iv) Resistance test b) Test for armouring wires/strips c) Test for thickness of insulation and sheath d) Physical tests for insulation e) Physical tests for outer sheath f) Partial discharge test g) Bending test h) Dielectric power factor test i) Heating cycle test j) Impulse withstand test k) High voltage test l) Oxygen index and temperature index test on outer sheath f. Following type tests as per IS: 7098 (Part 3) 1993 including its amendments and additional type tests shall be carried out on XLPE insulated HT cable from 66kV up to and including 220kV (wherever applicable): a) Tests on conductor i) Annealing test (for Copper) ii) Tensile test (for aluminum) iii) Wrapping test (for aluminum) iv) Resistance test b) Physical tests for insulation i) Test for thickness and dimensions of insulation ii) Tensile strength and elongation at break iii) Thermal Ageing in air oven iv) Hot set test v) Shrinkage test c) Resistivity test for semi-conducting layer d) Test for concentric metallic screen: i) Test for concentric copper wire ii) Test for concentric copper tape e) Thickness of metallic sheath

28 28 INSPECTION AND TESTING f) Test for armouring material: i) Dimensions g) Physical tests for outer sheath: I II III Measurement of thickness PVC sheath i) Tensile strength and elongation at break ii) Ageing in air oven iii) Loss of mass in air oven only for PVC sheath iv) Heat shock test v) Hot deformation test vi) Shrinkage test vii) Thermal stability PE sheath i) Carbon black content ii) Tensile strength and elongation at break before and after ageing iii) Hot-deformation h) Flammability test (for PVC outer sheathed cables only) i) Water tightness test j) 1) Thermal ageing on complete cable sample 2) Tensile strength and elongation at break for insulation and outer sheath 3) Resistivity test for semi-conducting layer k) Bending test followed by P.D. test l) Dielectric power factor and capacitance measurement at ambient temperature m) Dielectric power factor measurement at elevated temperature n) Impulse withstand test followed by HV test o) Oxygen index and temperature index test on outer sheath g. Following type tests as per IS: 1554 (Part 1) including its amendments and additional type tests shall be carried out on 1.1 kv grade PVC insulated cables: a) Tests on conductor i) Annealing test (for Copper) ii) Tensile test (for aluminum) iii) Wrapping test (for aluminum) iv) Conductor Resistance test b) Test for armouring wires/strips c) Test for thickness of insulation and sheath d) Physical tests for insulation and outer sheath i) Tensile strength and elongation at break ii) Ageing in air oven iii) Shrinkage test iv) Hot deformation v) Loss of mass