4 Volume-5
4 Volume-5
4 Volume-5
VOLUME –V
Part-1
SECTION-1
COMMON TECHNICAL REQUIREMENT
1.01 SCOPE:
1.01.05 If due to site condition any other type of tower (which is not
envisaged at present) is required to be provided, the same will also be
supplied by the bidder at the same rates terms and conditions.
NOTE: Moderately hot and humid tropical climate conducive to rust and
fungus growth. The climatic conditions are also prone to wide
variations in ambient conditions. Smoke is also present in the
atmosphere. Heavy lightening also occurs during June to
October.
1.03 STANDARDS:
1.03.01 Bidders may please note that all offered materials shall be
manufactured, tested and supplied with all guaranteed technical
particulars generally conforming to meet the requirement of technical
specification as brought out in various Sections and latest revisions of
relevant standards of international electro technical commission or
equivalent national standards of India with latest amendments of
relevant standards rules and codes. The lists of standards are specified
in relevant Sections of bid document.
All the Material & its accessories and Installation work covered under
the Bid shall guaranteed for performance and quality for a period of 24
months from the date of completion of facilities (or any part thereof).
In case after commissioning of transmission line, any operational
problem is observed in any Material/ installation work because of which
any major rectification or replacement work is done, then the guarantee
for such Material / installation work shall be extended by a period equal
to the period during which the facilities or such part can not be used by
the EMPLOYER.
1.10 WORKMANSHIP:
All Material shall be of the best class and quality most suitable for the
conditions of operation under the climate conditions as per clause no.
1.02 above for supply of Material. The workmanship shall be of the best
grade and the entire construction in accordance with the best modern
practice.
1.18.03 The Purchaser however, shall not be responsible for the delay
in execution of contract, if permits/priorities are not granted in time in
spite of issuance of such certificate.
The purchaser will arrange for necessary way leave and clearance of
trees. The Purchaser will pay the way leave compensation. The
purchaser will also arrange for the following: -
The Contractor shall inform the purchaser about the places where there
is a way leave problem, sufficiently in advance (preferably 30 days) so
that required way leave can be arranged in time.
Please note that while carrying out stringing work, if obstruction is faced
due to branches of trees, the same will be cleared by the contractor.
Further, the contractor will make all- out efforts to carry out stringing
work across Electrified Railway Track within minimum possible duration.
1.21.04 The Contractor shall arrange metal, sand, stone and water
required for foundation/revetment work. The transport, octroi, levy or
duty on these materials shall be borne by the Contractor himself and
the purchaser will not accept any liability on this account.
1.21.05 The Contractor will also arrange steel rods and binding wires
etc. for foundation, reinforcement and the cast incurred will be
borne by him. Materials for proper earthing of towers i.e. earthing rod,
connecting clamps and connecting wires etc. would also be
arranged by the Contractor as already specified.
***
SECTION-2
2.03 EXTENSIONS:
Suitable extension of 3M, 6M and 10M height will be supplied for use
with 132 kV/220 kV towers.
2.09 MATERIAL:
2.09.1 IS Steel Sections of tested quality in conformity with IS:
2062: 2006 grade E250 (Designated Yield Strength. 250 MPa) and/ or
grade E350 (Designated Yield Strength 350 MPa) are to be used in
towers, extensions, stubs and stub setting templates. The Contractor
can use other equivalent grade of structural steel angle sections and
plates conforming to latest International Standards. However, use of
steel grade having designated yield strength more than that of EN
10025 grade S355 JR/JO (designated yield strength 355 MPa) is not
permitted, unless otherwise indicated in this specification.
2.09.2 Steel plates below 6mm size exclusively used for packing
plates/packing washers produced as per IS: 1079 -1994 (Grade -0) are
also acceptable. However, if below 6mm size plate are used as load
bearing plates viz gusset plates , joint splices etc. the same shall
conform to IS : 2062 or equivalent standard meeting mechanical
strength/metallurgical properties corresponding to grade E250 or E350
(designated yield strength not more than 355MPa), depending upon the
type of grade incorporated into design. Flats of equivalent grade
meeting mechanical strength/ metallurgical properties may also be
used in place of plates for packing plates/ packing washers. The
chequered plates shall conform to IS: 3502. SAILMA 350HI grade plate
can also be accepted in place of HT plates (EN 10025 grade S355 JR/JO
/ IS 2062:2006 – grade 350, as applicable) provide SAILMA 350HI
grade plate meet all the mechanical properties of plate as per EN 10025
grade S355 JR/JO (designated yield strength 355 MPa) / IS 2062:2006
– grade 350.
2.09.3 For designing of towers, preferably rationalised steel section
has been used. During execution of the project, if any particular section
is not available, the same shall be substituted by higher section. Any
cost on account of the same shall be borne by the Contractor. However,
design approval for such substitution shall be obtained from the
employere before any substitution and records of such substitutions
shall be maintained by the Contractor.
2.10 WEIGHTS:
The unit weight of each type of tower and extension including bolts and
nuts, accessories, attachments and step bolts is indicated in the Bill of
Materials which shall be supplied by the Employer to the successful
bidder. The weight of structure means the weight calculated using black
sectional (i.e. ungalvanised) weights of all steel members of the sizes
indicated in the fabrication drawings without taking into consideration
the reduction in weight due to drilling of bolts, holes, skew cuts,
chamfering etc. or increase in weight due to galvanising.
2.11 GALVANISING:
2.11.1 The tower parts, stubs and pack washers shall be hot dip
galvanized. The galvanization shall be done as per requirements of IS
4759 after all fabrication work is completed. The contractor shall also
take guidelines from the recommended practices for hot dip galvanizing
laid down in IS 2629 while deciding and implementing galvanizing
procedure. The mandatory requirements however, are specified herein.
2.11.2 Unless otherwise specified the fabricated tower parts and
stubs shall have a minimum overall zinc coating of 610 gms per sq.m.
of surface except for plates below 5mm which shall have Zinc coating of
460 gms per sq.m of surface. The average zinc coating for sections
5mm & above shall be maintained as 87 microns and that for sections
below 5mm shall be maintained as 65 microns.
2.11.3 The zinc coating shall be adherent, reasonably uniform,
smooth, continuous and free from imperfections such as black/bare
spots, ash rust strains, bulky white deposits/wet storage strains and
blisters.
2.11.4 The surface preparation for fabricated tower parts and stubs
for hot dip galvanizing shall be carried out a indicated herein below:
(i) Degreasing & Cleaning of Surface: Degreasing and cleaning of
surface, wherever required, shall be carried out in accordance
with clause 4.1 of IS 2629-1990. After degreasing the article
shall be thoroughly rinsed. However, if acidic degreasers are
used rinsing is not required.
(ii) Pickling: pickling shall be done using either hydrochloric or
sulphuric acid as recommended at clause 4.3 of IS 2629-1990.
The actual concentration of the acids and the time duration of
immersion shall be determined by the Contractor depending on
the nature of material to be pickled. Suitable inhibitors also shall
be used with the acids to avoid over pickling. The acid
concentration, inhibitors used, and maximum allowable iron
content shall form part of plant standard to be formulated and
submitted to Employer along with Quality Assurance Program.
(iii) Rinsing: After pickling, the material shall be rinsed, preferably in
running water to remove acid traces, iron particles or any other
impurities from the surface. Two rinse tanks are preferable, with
water cascading from the second tank to the first to ensure
thorough cleaning. Wherever single tank is employed, the water
2.12.4 The bolts and nuts shall be free from forging and threading
defects such as cuts, splits, burrs, bulging, taper, eccentricity, loose fit
etc.
2.12.5 The bolts shall be threaded up to standard length only as
per relevant Indian Standard and not to full length.
2.12.6 The bolts and nuts shall conform to Indian Standard1367:
1991 Part-III and Part-IV, Indian Standard12427:1992, Indian
Standard1363-1992, Indian Standard 1367 (Part-XIII)-1983 with latest
amendment or equivalent International Standards.
2.12.7 The spring washers designated as M 16-B suitable for
16mm dia galvanized bolt shall be manufactured out of rectangular
section with tolerances as per Indian Standard 3063-1994 with latest
amendments or equivalent International Standard. The spring steel
shall conform to Indian Standard:4072-1975 with latest amendments
"Specification for steel for spring washers" or equivalent International
Standard.
2.12.8 The spring washers after coiling shall be suitably heat-
treated to obtain finished washer having hardness 43 to 50 HRC when
tested in accordance with Indian Standard 1586- 1968 or equivalent
International Standard.
2.12.9 The surface of the washers shall be free of scales and burrs.
The washers shall be coiled without any kinks (except for the shape
with turned-up ends). The ends of the washer shall not abut when the
washers are compressed. The ends shall be so served as to prevent
tangling.
2.12.10 The approximate weight of 1000 pieces of spring washers
suitable for 16mm dia bolt shall be 8.91 kg. in natural black finish as
shown in Indian Standard 3063-1994 with latest amendments or
equivalent International Standard.
2.12.11 The spring washer shall be electro galvanized with
chromate passivation. The electro galvanizing of washers should
conform to ’severe’ grading service conditions incorporated in Indian
Standard 1573: 1991 or equivalent International Standard as "Service
Grade No.4", classification Fe Zn 25. The thickness of zinc coating
should be minimum 25 microns and average thickness 38 microns. It
should be further suitably heat-treated to avoid any danger of hydrogen
embrittlement.
2.16 EARTHING :
2.16.1 A provision shall be made in all stubs for fixing earthing
material. The stub will be provided with a hole at a distance of 250 mm
from bottom end and at a distance of 500 mm below ground level for
connection with earthing materials. The hole will be of 17.5 mm dia.
2.16.2 The Bidder shall also supply and erect the following
materials per earthing set for earthing of towers (four sets per tower): -
(i) One no. Hot dip galvanized earthing Mild Steel Rod (2 Meter
long, 25 mm diameter):
(ii) Hot dip galvanized connecting clamps (`F’ type and `U’ type- 2
No. per set);
(iii) Hot dip galvanized stranded steel wire of size 7/4mm, Grade 5 to
be used as connecting wire conforming to Indian Standard:
2141:1992 and Indian Standard 4826: 1979 or equivalent
International Standard (5 Meter per earthing set).
2.16.3 The details of earthing rod and clamps and earthing
arrangement for towers are shown in the drawing enclosed.
2.16.4 The earthing rod shall be of mild steel solid rod of 2 meters
in length and 25mm in diameter with one end pointed. The rods shall
be galvanized as per relevant Indian Standard or equivalent
International Standard. The zinc coating on the rod shall not be less
than 610 gm/m² of surface area.
2.16.5 The tower end-connecting clamp shall be of flat type and
rod end connecting clamp shall be of `U’ type. The clamps shall be of
forged steel cast iron / malleable iron. The clamps should be hot dip
joint splices shall be made as above and as close to the main panel as
possible.
2.18.5 Joints shall be designed and detailed to avoid eccentricity as
far as possible. The use of gusset plates for joining tower members
shall be avoided as far as possible. However, where the connections are
such that the eliminations of the gusset plates would result in eccentric
joints, gusset plates and spacer plates may be used in conformity with
modern practice.
2.18.6 The tower structures shall be accurately fabricated to bolt
together easily at site without any undue strain on the bolts.
2.18.7 No angle member shall have two leg flanges brought
together by closing the angle.
2.18.8 The diameter of the hole shall be equal to the diameter of
the bolt plus 1.5 mm.
2.18.9 All similar parts shall be made strictly
interchangeable. All steel section before any work is done on them
shall be carefully leveled, straightened and made true to detailed
drawings by methods which will not damage the materials so that when
assembled the adjacent matching surfaces are in close contact
throughout. No rough edges shall be permitted in the entire structures.
Hammering is not permitted for straightening.
2.18.10 Cutting may be done by shearing, cropping, flame
cutting or sawing. The surface so cut shall be cleaned smooth,
reasonably square and free from deformation and distortion.
2.19 BENDING :
2.19.1 Mild steel angle sections up to 75x75 mm (up to 6mm
thick) shall bent cold up to and including bend angle of 10° Angles.
Above 75x75mm (thickness up to 6mm) and up to and including
100x100 mm (thickness up to 8 mm) may also be bent cold up to the
bend angle of 5 Deg. All other angle sections and bend angles not
covered above shall be bent hot.
2.19.2 All plates up to 12mm thickness shall be bent cold up to a
maximum bend angle of 15 Deg. Plates of thickness more than 12mm
with bends greater than 15 Degree shall be bent hot.
2.19.3 All hot bend material shall be air-cooled. The bends shall
be of even profile and free from any surface damages.
2.21 TOLERANCES :
2.21.1 The maximum allowable difference in the diameter of the hole
on the two sides of the plate or angle shall not exceed 0.8 mm on
diameter. The allowable taper in drilled/punched hole shall not exceed
0.8 mm on diameter.
2.21.2 The tolerance cumulative or between consecutive holes
shall be within +/-0.5mm.
2.21.3 The tolerance on the overall length of member shall be
within +/- 1.6 mm.
2.21.4 The tolerance on gauge distance shall be within +/- 0.5mm.
2.22 MARKING :
Every member shall be distinctly given punch mark similar to those
given in structural drawings. The mark shall be given with marking
dies of minimum 18 mm size and this mark shall be legible. Letter
XMPTBA, XMPTBB and XMPTBC for 220kV and XMPTEA, XMPTEB and
XMPTEC for 132kV shall precede erection mark where ‘X’ stands for
manufacturer’s name, ‘MPT’ stands for Madhya Pradesh Power
Transmission Company and BA, BB & BC stands for B0, B30 & B60 type
towers and EA, EB & EC stands for E0, E30 & E60 type towers
respectively. For other types of towers, similar marking scheme shall
be followed and shall be conveyed to successful bidder.
2.25 INSPECTION :
2.25.1 As specified in clause 1.13 Section-1 of the biding
document, Plant to be supplied will be subject to inspection and
approval by the Employer's representative before despatch.
2.25.2 Each consignment ready for transportation shall be offered
to the Employer for inspection before dispatch giving a minimum time
of not less than fifteen days. Only complete sets of towers/extensions
shall be offered for inspection. All materials constituting towers (Steel
parts, Bolts & nuts, spring and pack washers, earthing sets) shall be
offered simultaneously. Samples of fabricated tower materials and
accessories shall be subjected to tests as per relevant Indian Standard
or equivalent International Standard. The Employer shall be kept
SECTION-3
TECHNICAL SPECIFICATIONS FOR CONDUCTOR
3.01 STANDARDS:
3.02 PARAMETERS :
Nominal dia
3.03.01 Materials:
3.03.02.1 Resistivity:
The resistivity of aluminium depends upon its purity and its physical
condition. For the purpose of this specification the maximum value
permitted is 0.28264 Ohm sq.mm/mt. at 20° C and this value has been
used for calculation of the maximum permissible value of resistance.
NOTE: It is not intended to check the resistivity from the measured
values of resistance.
3.03.02.2 Density:
3.06 STRANDING :
3.06.01 The wires used in the construction of galvanized steel
reinforced aluminium conductor, before stranding, shall satisfy all the
relevant requirements of this specification.
3.06.02 The lay ratio of the different layers shall be within the limits
given in the Table below:-
Panther
1 13 28 10 14 10 16 - -
AL -30 Wire
ST. - 7 Wire
Zebra
1 13 28 10 14 10 16 10 17
AL -54 Wire
ST. - 7 Wire
NOTE : For the purpose of calculation, the mean lay ratio shall
be taken as the arithmetic mean of the relevant
minimum and maximum values given in this table.
3.06.03 In all constructions, the successive layers shall have opposite
directions of lay, the outermost layer being right-handed. The wires in
each layer shall be evenly and closely stranded.
3.06.04 In conductors having multiple layers of aluminium wires, the
lay ratio of any aluminium layer shall not be greater than the lay ratio
of the aluminium layer immediately beneath it.
3.06.05 The finished Conductor shall have a smooth surface without
any surface cut, abrasion, scuff marks and shall be free from dirt, grit,
etc. even if the damage to conductor is acceptable from mechanical
considerations. It will not be acceptable from electrical considerations,
and full care should be taken not to supply damaged conductor.
Projections of more than 2 mils shall not be acceptable. Any such
damage shall be properly rectified or new conductor supplied.
3.06.06 Failure of any sample to meet the above requirements shall be
sufficient cause for rejection of the lengths of conductor represented by
the sample. Particular care shall, therefore, be taken during
manufacture, handling, packing and transportation of the conductor, to
see that the surface is not dented, cut or damaged in any way.
3.07 STANDARD LENGTH :
3.07.01 The standard length of conductor shall be 1500 metres. A
tolerance of +/-5% on the standard length offered by the Contractor
shall be permitted. All lengths outside this limit of tolerance shall be
treated as random lengths.
3.11 INSPECTION :
3.11.03 The supplier shall submit the factory test certificates of raw
materials & bought out accessories at the time of acceptance tests of
the Conductor.
flanges at the required spacing. Barrel studs should be tack welded with
the nuts after tightening.
3.12.08 Normally, the nuts on the studs shall stand protrude of the
flanges. All the nails used on the inner surface of the flanges and the
drum barrel shall be counter sunk. The ends of barrel shall generally be
flushed with the top of the nuts.
3.12.09 The inner cheek of the flanges and drum barrel surface shall
be painted with bitumen based paint.
3.12.10 Before reeling, cardboard or double corrugated or thick
bituminised waterproof bamboo paper shall be secured to the drum
barrel and inside of flanges or the drum by means of a suitable
commercial adhesive material. The paper should be dried before use.
Medium grade craft paper shall be used in between the layer of the
conductor/Earth wire /OPGW. After reeling the conductor the exposed
surface of the outer layer of conductor shall be wrapped with thin
polythene sheet across the flanges to preserve the conductor from dirt,
grit and damage during transportation and handling and also to prevent
ingress of rain water during storage/transport.
3.12.11 Minimum space of 125 mm shall be provided between the
inner surface of the external protective layer and outer layer of the
conductor.
3.12.12 Each batten shall be securely nailed across grains as far as
possible to the flange edges with at least 2 nails per end. The length of
the nails shall not be less than twice the thickness of the battens. The
nail shall not protrude above the general surface and shall not have
exposed sharp edges or allow the battens to be released due to
corrosion.
3.12.13 Outside the protective layer, there shall be minimum of two
binder consisting of hoop iron/galvanized steel wire. Each protective
layer shall have two recess to accommodate the binders.
3.12.14 The conductor ends shall be properly sealed and secured with
the help of U-nails on one side of the flanges. The end securing shall be
done by taking out at least 500 mm of steel core on either ends by U-
nails. The composite conductor shall be binded by use of galvanized
steel wire/aluminum wire at three locations at least 75 mm apart or
more covered with PVC adhesive tape so as to avoid loosening of
conductor layers in transit and handling.
3.12.15 Only one length of conductor shall be wound on each drum.
3.13 MARKING :
Each drum shall have the following information stenciled on it in
indelible ink along with other essential data:
i. Contract
SECTION- 4
TECHNICAL SPECIFICATIONS FOR
HIGH TENSILE GALVANISED STEEL EARTH WIRE
4.01 STANDARDS:
The High Tensile Galvanised Steel Earth Wire shall conform to the
following Indian Standards, which shall mean latest revisions,
amendments/changes adopted and published, unless otherwise
specified hereinbefore.
Indian Standards
S. Title
or any Equivalent
No.
International
Standard
1 IS:209 -1992 Specification for Zinc
2 IS:2141 -1992 Specification for Earth wire for
overhead Transmission purpose
3 IS:1778 Reels and drums for Bare wires
4 IS:1521 Method of Tensile Testing of Steel
wire
5 IS:2629 -1992 Recommended practice for Hot Dip
Galvanising Iron and Steel
6 IS:2633 -1992 Method of Testing Uniformity of
Zinc coating of Zinc coated Articles.
7 IS:4826 Galvanised coating on Round Steel
wire
8 IS:6745 -1992 Method of Determination of weight
of Zinc coating of zinc coated Iron
and Steel Articles
9 IS: 12776 Method of Testing of Earth wire
4.02 PARAMETERS:
i. Material Steel
ii. Stranding 7
iii. Weight per Km 583 Kgs
iv. Dia. of wire 3.66 mm
v Tolerance 2%
vi Minimum elongation in 100 mm 5 mm
length
vii Minimum breaking strength per 1000 Kg
strand
viii Minimum tensile strength 95 Kg./mm2
ix D.C. resistance at 20 Deg. C 17.15 Ohms/Km
per Deg.C
2
vii Weight of zinc coating on wire 260 gms./ m
(Min.)
viii No. of one minute dip and half 3 one minute
minute dip respectively and 1 half
minute
ix Calculated d.c. Resistance at 20 2.5 Ohms per
Deg.C Km
4.03.02 The steel wire shall be hot dip galvanized and shall have
zinc coating of minimum 260 gram per sq. meter of the uncoated wire
surface. The zinc coating shall be smooth and continuous of uniform
thickness, free from imperfections not consistent with good commercial
practice and shall meet the test requirement. The zinc used in
galvanizing of earth wire shall be as per IS: 209-1992.
4.03.03 All the steel wires shall be circular, smooth, uniform and
free from imperfections, such as spills and splits, die marks scratches,
abrasions, cuts and kinks etc. drawing and after stranding.
4.03.04 The steel wires, after galvanizing shall be bright in
appearance, smooth and free from all defects like flux, ash, cross
inclusions, bare and black spots, pimples, lumpiness in runs, rust,
stains, bulky white deposits and blisters.
4.03.05 To avoid susceptibility towards wet storage stains (white
rust) the stranded earth wire shall be provided with a protective coating
of boiled linseed oil.
4.03.06 The finished earth wire shall have a smooth surface without
any surface cuts, abrasions, scuff marks and shall be free from dirt, grit
etc.
4.03.07 Failure of any sample to meet the above requirements shall
be sufficient cause for rejection of the lot of earth wire represented by
the sample, particular care shall therefore be taken during
manufacture, handling, packing and transportation of the earth wire so
that it is not dented, cut or damaged in any way.
4.08 INSPECTION :
4.08.01 As specified in clause 1.13 Section-1 of the biding
document, Plant to be supplied will be subject to inspection and
approval by the Employer's representative before despatch.
Spindle hole shall be provided at the centers of the planks of the plies
and spindle plates with 102 mm dia. Holes shall be fitted on either side
of both the flanges.
4.09.06 The wooden battens used for making the barrel of the earth
wire shall be of segmental type. These shall be nailed to the barrel
supports with at least two nails. The battens shall be closely butted and
shall provide a round barrel with smooth external surface. The edges of
the battens shall be rounded or chamfered to avoid damage to the
earth wire.
4.09.07 Barrel studs shall be used for construction of drums. The
flanges shall be holed and the barrel supports slotted to receive
them. The barrel studs shall be threaded over a length on either end,
sufficient to accommodate washers, spindle plates and nuts for fixing
flanges at the required spacing. Barrel studs should be tack welded with
the nuts after tightening.
4.09.08 Normally, the nuts on the studs shall stand protrude of the
flanges. All the nails used on the inner surface of the flanges and the
drum barrel shall be counter sunk. The ends of barrel shall generally be
flushed with the top of the nuts.
4.09.09 The inner cheek of the flanges and drum barrel surface shall
be painted with bitumen-based paint.
4.09.10 Before reeling, cardboard or double corrugated or thick
bituminised waterproof bamboo paper shall be secured to the drum
barrel and inside of flanges or the drum by means of a suitable
commercial adhesive material. The paper should be dried before use.
Medium grade craft paper shall be used in between the layer of the
conductor/earth wire. After reeling the earth wire the exposed surface
of the outer layer of earth wire shall be wrapped with thin polythene
sheet across the flanges to preserve the conductor/earth wire from dirt,
grit and damage during transportation and handling and also to prevent
ingress of rain water during storage/transport.
4.09.11 Minimum space of 125 mm shall be provided between the
inner surface of the external protective layer and outer layer of the
earth wire.
4.09.12 Each batten shall be securely nailed across grains as far as
possible to the flange edges with at least 2 nails per end. The length of
the nails shall not be less than twice the thickness of the battens. The
nail shall not protrude above the general surface and shall not have
exposed sharp edges or allow the battens to be released due to
corrosion.
4.09.13 Outside the protective layer, there shall be minimum of two
binders consisting of hoop iron/galvanized steel wire. Each protective
layer shall have two recesses to accommodate the binders.
4.09.14 The earth wire ends shall be properly sealed and secured
with the help of U-nails on one side of the flanges. The end securing
shall be done by taking out at least 500 mm of steel wire on either end
by U-nails. The earth wire shall be binded by use of galvanized steel
wire/aluminum wire at three locations at least 75 mm apart or more
covered with PVC adhesive tape so as to avoid loosening of earth wire
layers in transit and handling.
4.09.15 Only one length of earth wire shall be wound on each drum.
4.10 MARKING :
Each drum shall have the following information stenciled on it
in indelible ink along with other essential data:
(i) Order Number and date.
(ii) Name and address of consignee
(iii) Manufacturer’s name and address
(iv) Drum number
(v) Size of earth wire (7/3.66mm)
(vi) Length of earth wire in meters
(vii) Gross weight of drum with earth wire
(viii) Weight of empty drum with protective lagging
(ix) Arrow marking for unwinding
4.11 END SEALING :
Both the ends of each length of earth wire should be provided with non-
destructive type metal crimped or epoxy capped seals with punching
embossing/ engraving of manufacturer’s monogram and drum number.
***
SECTION- 5
Part A
TECHNICAL SPECIFICATION FOR DISC INSULATORS
5.01 STANDARDS
This section provides for the design, manufacture, stage testing and
inspection and testing before dispatch packing and delivery of disc
insulators as per technical requirements furnished in this section.
Unless otherwise specified elsewhere in this specification, the rating as
well as performance & testing of the disc insulators shall conform but
not limited to the latest revision & amendments available at the time of
placement of order of all the relevant standards as listed hereunder,
except as modified in this document.
S. Indian Title
No Standard
1 IS:209-1992 Specification for Zinc
2 IS:206-1991 Method for Chemical Analysis of Slab
Zinc
3 IS:731-1991 Porcelain insulators for overhead power
lines with a nominal voltage greater
4 IS:2071 Method of High Voltage Testing
Part(I)-1993
Part(II)-1991
5 IS:2121 Specification of Conductors and Earth
wire Accessories for Overhead Power
Lines.
Part(I)
Armour Rods, Binding Wires & Tapes for
Conductors
6 IS:2486 Specification for insulator fittings for
overhead power lines with a nominal
voltage greater than 1000V
Part I-1993 General Requirements & Tests
Part II-1989
Dimensional Requirements
Part III -
Locking Devices
1991
7 IS:2629-1990 Recommended practice for Hot Dip
Galvanization for iron & steel
8 IS:2633-1992 Testing for Uniformity of Coating of Zinc
coated articles
9 IS:3188-1988 Dimensions for Disc Insulators
ii) The specified values and disc dimensions, impulse and power
frequency voltages, electromechanical strength [EMS] of
individual insulator units are as under. The values given are
minimum which apply to all cases. Specified withstand and
flashover voltages are referred to standard atmospheric
condition.
5.04.01 Porcelain
The porcelain used in the manufacture of the shells shall be ivory white,
nonporous of high dielectric, mechanical and thermal strength, free
from internal stresses, blisters, laminations, voids, foreign matter,
imperfections or other defects which might render it in any way
unsuitable for insulator shells. Porcelain shall remain unaffected by
5.06.01 GENERAL
(i) The pin and cap shall be designed such that it will not
transmit the mechanical stresses to the shell by
compression and develop uniform mechanical strength in
the insulator. The cap shall be circular with the inner and
outer surfaces concentric and of such design that it will not
yield or distort under loaded conditions. The head portion of
the pin ball shall be suitably designed so that when the
insulator is under tension the stresses are uniformly
distributed over the pinhole portion of the shell. The pin ball
shall move freely in the cap socket either during assembly
of a string or during erection of a string or when a string is
placed in position.
(ii) Metal caps shall be free from cracks, seams, shrinks, air
holes, blow holes and rough edges. All metal surfaces shall
be perfectly smooth with no projecting parts or
irregularities, which may cause corona. All load bearing
surfaces shall be smooth and uniform so as to distribute the
5.06.04 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with the
latest edition of IS: 2629. The zinc to be used for galvanizing shall
conform to grade Zn 99.95 as per IS: 209. The Zinc coating shall be
uniform, smoothly adherent, reasonably bright, continuous and free
from impurities such as flux, ash, rust stains, bulky white deposits and
blisters. Before ball fittings are galvanized, all die flashing on the shank
and on the bearing surface of the ball shall be carefully removed
without reducing the designed dimensional requirements.
5.06.05 SECURITY CLIPS (LOCKING DEVICES)
The security clips to be used as a locking device for ball and socket
coupling shall be ‘R’ shaped hump type to provide for positive locking of
the coupling as per IS:2486 (Part IV). The legs of the security clips
shall allow for spreading after installation to prevent complete
withdrawal from the socket. The locking device shall be resilient,
corrosion resistant and of sufficient mechanical strength. There shall be
no possibility of the locking device to be displaced or be capable of
rotation when placed in position and under no circumstances shall it
allow separation of insulator units and fittings. ‘W’ type security clips
are also acceptable. The hole for the security clip could be countersunk
and the clip shall be of such design that the eye of the clip may be
engaged by a hot line clip puller to provide for disengagement under
energized conditions. The force required for pulling the clip into its
unlocked position shall not be less than 50 N (5 kgs) or more than, 500
N (50 kgs).
5.06.06 BALL AND SOCKET DESIGNATION
The dimensions of the balls and sockets for 70 KN & 90 KN discs shall
be of 16 mm and for 160KN discs shall be of 20 mm designation in
accordance with the standard dimensions stated in IS:2486 (Part II).
5.08 INTERCHANGEABILITY
The insulators inclusive of the ball and socket fittings shall be of
standard design suitable for use with hardware fittings of any make
conforming to relevant Indian Standards.
5.09 SUITABILITY FOR LIVE LINE MAINTENANCE
The insulators shall be compatible for use with hot line or live line
maintenance techniques so that usual hot line operations can be carried
out with ease, speed and safety.
The Bidder may also use Long Rod Porcelain Insulators String or
Long Rod Polymer Insulators in place of Disc Insulator Strings.
The Long Rod Porcelain Insulators or Long Rod Polymer
Insulators shall have technical specification equivalent to or
better than the technical specification of Disc Insulator Strings.
It may please be noted that in a particular work, the bidder will
have to use any one type of Insulators and combination of two
different types of Insulators in one particular work will not be
allowed.
5.11.02 STRING SIZE
The size of the disc insulator, the number to be used in different types
of strings and their electro-mechanical strength shall be as follows:
5.11.03.3 The string design shall be such that when units are
coupled together there shall be contact between the shell
of one unit and metal of the next adjacent unit.
5.12 TESTS :
5.12.01 The Disc insulators offered should be fully type tested as per
the relevant standards. The following tests shall be carried out on the
insulator string and also on unit disc insulators.
5.12.02 Acceptance Tests shall mean those tests which are to be
carried out on samples taken from each lot offered for pre-despatch
inspection for the purpose of acceptance of the lot.
5.12.03 Routine Tests shall mean those tests, which are to be carried
out on each insulator to check the requirements which are likely to vary
during production.
5.12.04 Stage tests during manufacture shall mean those tests which
are to be carried out during the process of manufacture to ensure
quality control such that the end product is of the designed quality
conforming to the intent of this specification.
5.12.05 The norms and procedure of sampling for the above tests
shall be as per the relevant Indian Standard or other internationally
accepted standards.
5.12.06 The standards according to which these tests are to be
carried out are listed against each test. Where a particular test is a
specific requirement of this specification, the norms and procedure for
the same shall be as specified in Appendix-I attached hereto or as
mutually agreed to between the Contractor and the Employer in the
Quality Assurance Programme.
5.12.07 For all type and acceptance tests, the acceptance values
shall be the value guaranteed by the Contractor in the “Technical
Questionnaire” or the acceptance value specified in this specification or
the relevant standard whichever is more stringent for that particular
test.
5.13.01 The Disc insulators offered shall be fully type tested for the
following tests as per relevant International/Indian Standard and the
bidder shall furnish type test reports along with the offer.
a) Visible discharge test IS:731
b) Impulse voltage withstand test IS:731
c) Wet power frequency voltage IS:731
withstand test
d) Verification of dimension test IS:731
e) Temperature cycle test IS:731
f) Electro-Mechanical failing load test IS:731
g) Puncture test IS:731
h) Porosity test IS:731
i) Galvanising test IS:731
j) 24 hours mechanical failing load test IS:731
k) Metallurgical test IS:2108 &
IS:2004
coupling 2486(part-IV)
f) Eccentricity test As per
Specification
g) Electro-mechanical strength test
h) Puncture test IS-731
i) Porosity test
5.19 INSPECTION :
iii) One 10mm thick ring of good quality paint shall be marked
on the cap of each insulator of particular strength for easy
identification of the type of insulator. The paint shall not
have any deteriorating effect on the insulator performance.
Following codes shall be used as identification mark:-
For 70kN disc insulator – Green
For 90kN disc insulator – Blue
For 160kN disc insulator – Red
5.21 DOCUMENTATION
Appendix-I
TEST DETAILS
million cycles without any failure. After the test, the disc insulators
shall be examined for looseness of pins and cap or any crack in the
cement. The hardware fittings shall be examined for fatigue failure and
mechanical strength test. There shall be no deterioration of properties
of hardware components and disc insulators after the vibration test.
The disc insulators shall be subjected to the following tests as per
relevant standards:
S. Test Percentage of
No. discs to be
tested
the bottom of the outer most petticot. After one full rotation of the
disc, the maximum and minimum position the slider has reached on the
scale can be found out. Difference between the above two readings
shall satisfy the guaranteed value for axial run out. Similarly using a
horizontal scale with vertical slider the radial run out shall be measured.
The slider shall be positioned on the scale to establish contact with the
circumference of the disc insulator and disc insulator rotated on its
fixture always maintaining the contact. After one full rotation the
maximum and minimum position of the slider reached on the scale are
found out. The difference between the above readings shall satisfy the
guaranteed value for radial run out.
8. Crack Detection Test:
Crack detection test shall be carried out on each ball and pin before
assembly of disc unit. The manufacturer shall maintain complete record
of having conducted such tests on each and every piece of ball pin. The
Contractor shall furnish full details of the equipment available with him
for crack test and also indicate the test procedure in detail.
SYSTEM PARTICUALRS
S.No. PARTICULARS Electrical System Data
1 System A.C. A.C. A.C.
3phase 3phase 3phase
2 Line voltage (kV rms) 220 132 400
3 Max.voltage (kV rms) 245 145 420
4 Frequency 50Hz. 50Hz. 50 Hz
5 Neutral grounding system effectively effectively effectively
earthed earthed earthed
6 Lightning impulse with- 1050 550 1425
stand voltage(dry &
wet)(kVp)
7 Power frequency 395 230 630
withstand voltage (wet)
(kVp)
8 Switching surge 650 325 1050
withstand voltage (wet)
(kVp)
9 Short circuit level (kA) 40 40 40
10 Minimum corona - - 320
extinction voltage at 50
Hz AC system dry
condition (Kv rms)
11 Radio interference - - 500
voltage at one MHz for
phase to earth voltage of
266KV dry
conditions(Microvolt)
Part B
TECHNICAL SPECIFICATION FOR POLYMER
INSULATORS
5.23 STANDARDS
Geneva, SWITZERLAND
BIS/IS Beureau Of Indian Standards.
Manak Bhavan,
9, Bahadur Shah Zafar Marg,
New Delhi - 110001. INDIA
ISO International Organisation for
Standardization.
Danish Board of Standardization
Danish Standardizing Sraat,
Aurehoegvej-12
DK-2900, Heeleprup, DENMARK
STRI guide 1.92/1 STRI, Sweden, Website : www.stri.se
5.26.01 Core:
The core shall be glass-fiber reinforced epoxy resin rod (FRP) of
high strength. Both, glass fiber and resin shall be optimized in the FRP
rod. Glass fibers with low content in alkalies shall be boron free E glass
Grading ring height (is the distance from the end of the end fitting to
the top of corona ring) should be so selected that maximum field
minimizes and uniformly distributed along the insulator. Manufacturer
should provide reports of successful electric field modeling testing for
the specific insulator design. The EFM should be three dimensional with
result containing drawing depicting the electric field in various colours ,
each of a different voltage level. The result of this study should show
that the voltage field surrounding the polymer insulators is optimum
along the entire length of the insulator , with the effected hot end of
the insulator being a critical location . The threshold at which corona
may or may not be present should be defined as a figure in KV/mm for
the designed insulator.
The dimensions of the Ball and Socket shall be 16mm designation for
70KN and 90KN Polymer insulators and 20 mm designation for 120
KN and 160 KN Polymer insulators in accordance with the standard
dimensions stated in IEC:60120/IS:2486(Part-II)
5.29 MARKINGS:
5.29.01 Each insulator shall be legibly and indelibly marked with the
following details as per IEC – 61109.
a. Name or trademark of the manufacturer.
b. Voltage and Type.
c. Month and year of manufacturing.
d. Minimum failing load / guaranteed mechanical strength in kilo
Newton followed by the word ‘KN’ to facilitate easy
identification.
e. Country of manufacture
5.30.01 GENERAL
5.30.02 GALVANISING
All ferrous parts shall be hot dip galvanized in accordance with
the latest edition of IS:2629. The zinc to be used for
galvanizing shall conform to grade Zn 99.5 as per IS:209. The
Zinc coating shall be uniform, smoothly adherent, reasonably
bright, continuous and free from impurities such as flux, ash,
rust stains, bulky white deposits and blisters. Before ball fittings
are galvanized, all die flashing on the shank and on the bearing
surface of the ball shall be carefully removed without reducing
the designed dimensional requirements.
5.30.03 INTERCHANGEABILITY
5.31.01 The Polymer insulators shall be compatible for use with hot
line or live line maintenance techniques so that usual hot line
operations can be carried out with ease, speed and safety.
5.32 TESTS
This shall mean those tests which are to be carried out to prove
the design, process of manufacture and general conformity of the
material and product with the intents of this specification. These tests
shall be conducted on a representative number of samples prior to
commencement of commercial production.
Stage tests during manufacture shall mean those tests, which are
to be carried out during the process of manufacture to ensure quality
control such that the end product is of the designed quality conforming
to the intent of this specification.
For all type and acceptance tests, the acceptance values shall be
the value guaranteed by the Supplier in the guaranteed technical
particulars or the acceptance value specified in this specification or the
relevant standard whichever is more stringent for that particular test.
5.32.06.1 The norms and procedure of sampling for the above tests
shall be as per the relevant Indian Standard or other Internationally
accepted standards. This will be discussed and mutually agreed to
between the successful Supplier and Purchaser before placement of
order. The standards and norms according to which these tests are to
be carried out are listed against each test. Where a particular test is a
(A) The following type tests shall be conducted on all types of the
Polymer insulator with hardware fittings :
a) Verification of IEC:61109-1992
dimensions
b) Verification of Locking
System
c) Galvanising test IS-731
d) Verification of specified IEC:575
Mechanical Load
e) Recovery of As per annex-A
Hydrophobicity
The purchaser reserves the right for carrying out any other tests
of a reasonable nature at the works of the Supplier/laboratory or at any
other recognized laboratory / research institute in addition to the above
mentioned type, acceptance and routine tests at the cost of the
Purchaser to satisfy that the material complies with the intent of this
specification.
For any change in the design/type ,already type tested and the
design/type offered against this bid, the purchaser reserves the right to
demand repetition of some or all type tests without any extra cost.
5.33 INSPECTION
vii) List of testing equipment available with the Supplier for final
testing of Polymer insulators specified and test plant
limitation, if any, vis-a-vis the type, special, acceptance and
routine tests specified in the relevant standards.
ii) Type test certificates of the raw material and bought out
accessories.
5.35 DOCUMENTATION
ANNEXURE-II
Assembled core load time test with container that contains in-
HNO3 concentric acid this is applied at the naked rod. The rod
should be held at 80% of SML for the duration of the test. The rod
should not fail within the 96 hour test duration.
(3) Immediately after the corona treatment, spray the surface with
water and record the HC classification. The surface should be
hydrophilic with an HC value of 6 to 7. If not, dry the surface and
repeat the corona treatment for a longer time until an HC of 6 or
7 is obtained. Dry the sample surface.
SECTION- 6
TECHNICAL SPECIFICATION FOR HARDWARE FITTINGS
FOR 220/132 KV LINES
6.01 STANDARDS:
S. Indian Title
No Standard
1 IS:209-1992 Specification for Zinc Ingot
2 IS:206 – Tee and Strap Hinges
1992
3 IS:7814- Phosphor Bronze Sheet and Strip
1985
4 IS:2071 Method of high voltage testing
5 IS:731 Porcelain Insulator for Overhead Power Lines
with a Nominal Voltage Greater than 1000 V.
6 IS:961 Structural Steel
7 IS:1385 Phosphor Bronze Rods & Bar Sheet and Strips
and Wire
8 IS:2004 Carbon Steel Forgings for General Engineering
Purpose
9 IS:2107 White Hearth Malleable Iron Castings
10 IS:2108 Black Hearth Malleable Iron Castings
11 IS:2121(Part Specification for Conductors and Earth wire
-I & II) Accessories for Overhead Power Line, Armour
Rods Binding Wires and Tapes for Conductor
12 IS:2486 Specification for Insulator Fittings for
Overhead Power Lines with a Nominal Voltage
Greater than 1000 V.
13 IS:2629 Recommended Practice for Hot Dip
Galvanization of Iron and Steel.
S. Indian Title
No Standard
14 IS:2633 Testing of Uniformity of Coating of Zinc coated
Articles
15 IS:3138 Hexagon Bolts and Nuts
16 IS:6639 Hexagon Bolts for Steel Structures
17 IS:6745 Determination of Weight of Zinc Coating on
Zinc Coated Iron and Steel Articles
18 IS:3188 Characteristic of String Insulators Units
19 IS:4218 ISO Metric screw Threads
20 IS:4172 Dimensions for Radii under the Heads of Bolts
& Screws
21 IS:4206 Dimensions for nominal lengths and Thread
length for Screws and Studs (with
amendment)
22 IS:4759 Hot Dip Zinc Coatings on Structural Steel and
other Allied Products
23 IS:1573 Electroplated Coatings of Zinc on Iron and Steel
24 IS: 398 Specification for Aluminium Conductor Steel
Reinforced for overhead transmission purpose.
25 IS: 1327- Methods for determination of weight of tin
1966 Coating on Tin Plates
26 IS: 4826- Hot Dip Galvanised Coating on Round Steel
1979 Wires
27 IS: 1363 Hexagon Head Bolts, Screws & Nuts.
28 IS: 1367 Technical supply conditions for threaded Steel
Fasteners
29 IS: 9708 Stockbridge Vibration Dampers for Overhead
Power lines.
30 IS: 8263 Method of Radio Interference Tests on High
Voltage Insulators.
31 IS:10162 Spacers and Spacer Dampers for twin
horizontal bundle Conductors.
32 IS: 2004 Carbon Steel Forgings for general engineering
purposes.
33 BS:970 General Instructions and Testing Procedures
(Part-I) Specific Requirements for Carbon and Carbon
Manganese Alloy and Stainless Steels.
The hardware fittings for lines shall be suitable for ACSR Conductor and
Earth wire as per technical parameters indicated in Annexure-3
Each Hardware fitting for the transmission line shall be complete in all
respect and Bidder should furnish complete drawings and technical
particulars of the items of hardware fittings. The Hardware fittings
should normally comprise items conforming to enclosed drawing as
under: -
Single suspension Hardware string shall comprise of one Ball Hook, one
Socket Eye Horn holder, one line side Arcing Horn and one Suspension
Clamp of AGS type with armour rod suitable for respective sizes of
Conductors.
The breaking strength of all the Hardware items of the assembly shall
not be less than 7000 kgs. The complete assembly of suspension
clamp shall be guaranteed for slip strength of not less han 15 KN & not
more than 19 KN. The strength of the Earth wire has been specified in
Annexure-3. The suspension assembly shall be supplied with armour
rod for Earth wire.
The Earth wire tension assembly shall have minimum breaking strength
equal to that of the Earth Wire. The slipping strength of the
Compression Clamp shall not be less than 95% of the breaking
strength of Earth Wire. The strain assembly of the Earth wire for
transmission line shall comprise of compression type dead end Clamp
and two `D’ Shackles complete with minor accessories such as pins,
bolts & nuts etc. Strain assembly shall be hot dip galvanized and made
inherently resistant to the atmosphere corrosion. The dead end Clamp
of the assembly shall be of compression type. The tension clamp shall
be attached to the horizontal strain plate of the tower body by means
of a “D” shackle. “D” shackle shall be suitable for attaching the tension
clamp to strain plate of towers having 8mm thickness with a hole of
21.5 mm diameter. The tension clamp body shall be made out of steel
of 304 L grade or equivalent with Brinnel Hardness not exceeding 200.
The complete assembly shall also include one 12.5mm dia, 45 mm long
HRH MS Bolt hot dip galvanized with nuts and lock washers for
attaching G.I. earth bond. A detailed drawing giving dimensional details
of the complete assembly shall accompany the tender. After
compression, dimensions of the joint shall be as indicated in enclosed
Appendix-2.
Conductor on the tensioned span with actual tests on the AGS unit
compared to the normal bare clamp with Armour rods. Suitable curves
should be furnished for the same and also actual reports on the stress/
strain determinations. The Contractor should give the guaranteed
value of the power loss of the AGS units to be supplied by them
supported by a test certificate of any reputed laboratory of the country.
Suitable curves should be furnished for the power loss due to AGS unit
as well as with the conventional envelope type of Suspension Clamps.
The housing supports and housing straps should provide positive stop
closure. AGS unit should have low rotational inertia, strut action of the
Armour Cage, resilient cushioning of the neoprene insert, immunity
from high compressive and flexural stress and wide area support.
Manufacturer is required to guarantee minimum fatigue life of the AGS
units and this would be established under actual tests on tensioned
Conductor span. The manufacturer is required to guarantee minimum
40 years life of the complete AGS units including Neoprene cushioning
and this should be established under actual test on a tensioned
Conductor span.
The rubber used with AGS unit must be capable of withstanding desired
long out-door performance including the variation of temperature from
00C to 750C. The Contractor will have to provide certificate from
reputed manufacturers that the rubber being supplied by them is
suitable for AGS fitting and must have tensile strength of 2000 PSI and
minimum ultimate elongation 300%.
The helical retaining rods required for AGS assembly shall be made of
Aluminium alloy of HE 20 grade as per IS-6051/1970 or equivalent
International Standard duly heat treated and shall be suitable to wrap a
desired size of Conductor. The tensile strength of the retaining rod
material should not be less than 50,000 PSI and the electrical
conductivity should not be less than 40% (IACS). The minimum
slipping strength of the complete fitting shall not be less than 15% and
more than 20% of the UTS of the cable on which it is to be used. The
Clamp shall be in 2 parts made of Aluminium and will have inner profile
matching with the profile of Armour rod. This Clamp should be made
by drop forging process. AGS assembly should be provided with the
forged steel socket eye to match with the suspension string and should
have UTS not less than 7,000 kgs.
The AGS Preformed Armour rods set suitable for ACSR Zebra/ Panther
conductor (as the case may be) shall be used to minimize the stress
developed in a conductor due to different static and dynamic loads
because of vibration due to wind, slipping of conductor from suspension
clamp as a result of unbalance conductor tension in adjacent span and
broken wire condition. It shall be made of Aluminium alloy of HE 20
grade as per IS-6051/1970 duly heat-treated. The aluminium alloy
wires (pre heat treated) for manufacturing of Armour rods can also be
used, however Contractor shall submit the test certificates in support of
their claim for using pre heat-treated wires. It shall also withstand
power arcs, chafing and abrasion from suspension clamp and localized
heating effects due to resistance losses of the conductor.
The pitch length of the rods shall be determined by the Contractor but
shall be less than that of the outer layer of ACSR conductor and the
same shall be accurately controlled to maintain uniformity and
consistently reproducible characteristics wholly independent of the skill
of lineman.
The preformed armour rod sets shall have right hand lay and the
inside diameter of the helices shall be less than the outside diameter of
the conductor to grip the same tightly. The surface of the armour rod
when fitted on the conductor shall be smooth and free from
projections, cuts and abrasions etc.
The length of each rod shall be as per drawing enclosed. The tolerance
in length of each rod shall be +/-25mm. The tolerance in length of the
rods in completed sets should be within 13 mm between the longest
and shortest rod. The ends of the armour rod shall be parrot billed.
The number of armour rods in each set shall be 11/12. The each rod
shall be marked in the middle with paint for easy applications on the
line.
The armour rod shall not loose their resilience even after five
applications. The conductivity of each rod of the set shall not be less
than 40% of the conductivity of International Annealed Copper
Standard (IACS). The minimum tensile strength of armour rod should
be 35 kg per sq.mm.
The Strain Clamp shall be of the compression type for the specified size
of Conductor for 220/132KV lines. The outer sleeve of the Compression
Clamp and Jumper Terminal shall be of EC grade Aluminium 99.5%
pure tube formed by extrusion process and the inner sleeves shall be of
galvanized steel. The angle of jumper terminal to be mounted should
be 30 deg. with respect to the vertical line. The Compression Clamp
shall have slipping strength not less than 95% of the ultimate breaking
strength of Conductor with which it is to be used. The compression
dead end clamp for transmission line shall be manufactured out of
extruded Aluminium.
The designed fixture of the Arcing Horn with that of the string
Hardware of Yoke Plate shall be such that the possibility of relative
movement between the two, due to vibration of assembly in service is
altogether avoided. Making two bolt connections and providing a collar
to the Hardware item can achieve this. An additional nut should be
provided along with bolts and nuts to fix the Arcing Horn with Hardware
items. The provision of an additional nut will avoid the possibility of
relative movement between the Arcing Horn and the Hardware item,
due to vibration of string. The arrangement for fixing of Arcing Horn
shall be such that they do not get loose while in service. To achieve
this, they should have proper seat for the Arcing Horn and heat-treated
Belleville washers should be provided with the bolts.
6.08.06 U Clevis:
These shall be made of forged steel complete with galvanised steel
rivets washer and Phosphorus Bronze/Stainless Steel pins.
6.08.08.1 The dimensions and tolerances of pin balls and socket ends
shall conform to IS 2486 Part-II/IEC-120 and shall be checked
by the gauge therein after galvanizing.
6.08.08.2 The pin balls shall be checked with the applicable “GO”
gauges in at least two directions, one of which shall be across
the line of die flashing and the other 90 deg. to this line. “NO
GO” gauges shall not pass in any direction.
6.08.08.3 The bearing surfaces of balls and machined sockets, before
galvanizing shall not have surface roughness more than 250
micro inches.
6.08.11 Clevis-Eye:
These shall be forged steel of malleable cast iron and shall be complete
with galvanised pin with flat washer and split pin of Phosphorus
Bronze/Stainless Steel.
6.08.12.1 The yoke plates/link plate shall be made of mild steel plate
as per IS: 2062 or equivalent standards. Shearing/cutting of
the plates shall be clean without drawn or ragged edges. If
the plates are flame cut, mechanical guides shall be used. It
shall be ensured that the grain flow of the yoke plate shall be
in the direction of the tensile load.
6.08.12.2 Holes shall be cylindrical clean cut and perpendicular to the
plane of the material. The periphery of the holes shall be free
from burrs.
6.08.12.3 All the corners and edges should be rounded off with a
radius of at least 3mm.
6.08.12.4 Design calculation is for bearing and tensile strength for
deciding the dimensions of yoke plate shall be furnished by the
Contractor. The holes provided for bolts in the yoke plate
should satisfy shear edge condition as per IS:800.
6.09 IMPORTANT CONDITIONS:
6.09.01 All Hardware items shall be complete with minor items such
as security clip, bolts, nuts, washer, split pins and inners etc.
6.09.02 Enclosed drawings show the attachment proposed to be
fitted on the towers. The Contractor shall be responsible for satisfying
him that the Insulator fittings offered are entirely suitable for the
proposed attachments and for the sizes of the Conductor specified.
6.09.03 All ferrous fittings (except those specified otherwise) shall
be hot dip galvanized, after all machining and fitting has been
completed, in accordance with relevant Indian Standard. All Hardware
items (other than clamps) and those specified otherwise should be
made of Drop Forged Steel. Socket items in forged steel must be
forged. All forgings supplied should be stress relieved and this
treatment should be done at the Contractor works. Forgings, which are
not stress relieved, will not be acceptable. The items like Yoke Plate,
Arcing Horn, Bolts and Nuts shall be of mild steel and rest of the items
shall be of forged steel.
6.09.04 All Bolts, Nuts and Screw heads shall have only wide worth
standard thread and of sizes indicated in the enclosed drawing. Bolts
head and Nuts shall be hexagonal. Where required, nuts shall be locked
in approved manner. The thread in Nuts shall be over tapped after
galvanizing and shall be cut before galvanizing. The threads shall not be
under cut. The Nuts should be tapped such that they are fit on the bolt
threads i.e. these should not have loose fitting.
6.11 GALVANISING:
6.11.01 Hot dip galvanizing shall conform to Indian Standard
specification IS-2633 or equivalent International Standard. Galvanising
shall be uniform, free from blisters, and shall not peel off due to
abrasion, Zinc coating shall be thick enough to withstand 6 one minute
dips in Copper Sulphate solution (precee test) for all ferrous parts
6.12.01 The hardware fittings offered shall be type tested as per the
relevant standards. Further the acceptance, routine tests and tests
during manufacture shall be carried out on the conductor.
6.12.02 Acceptance tests shall mean those tests, which are to be
carried out on samples taken from each lot offered for pre-despatch
inspection, for the purpose of acceptance of that lot.
6.12.03 Routine tests shall mean those tests which are to be carried
out on each and every product so as to check with requirements which
are likely to vary during production.
6.12.04 Tests during manufacture shall mean those tests, which are
to be carried out during the process of manufacture and end inspection
by the Contractor to ensure the desired quality of the end product to be
supplied by him.
6.12.05 The norms and procedure of sampling for these tests will be
as per the Quality Assurance Programme to be mutually agreed to by
the Contractor and the Employer.
6.12.06 The standards to which these tests will be carried out are
listed in para 6.01. Where a particular test is a specific requirement of
this specification, the norms and procedures of the test shall be as
mutually agreed to between the Contractor and the Employer in the
Quality Assurance Programme.
6.12.07 For all type and acceptance tests, the acceptance values
shall be the values guaranteed by the Contractor in the “Technical
Questionnaire” or the acceptance value specified in this specification,
whichever is more stringent for that particular test.
6.13 ACCEPTANCE TEST/SAMPLE TESTS:
specification.
e. Mechanical strength test for corona control BS:3288(Part-I)
rings.
f. Test on locking devices for ball & socket IEC:372(2)
coupling.
g. Mechanical strength test of each components As per this
excluding corona control ring and arcing horn. specification.
6.14.01 All the materials shall be of the latest design and conform
to the best modern practice adopted in the extra high voltage field. The
manufacturer shall supply only such material as guaranteed by him to
be satisfactory and suitable for 220/132kV Transmission lines.
6.14.02 The design, manufacturing process and quality control of all
the materials shall be such as to give maximum factor of safety,
maximum possible working load, highest mobility, elimination of sharp
edges and corners, best resistance to corrosion and a good finish.
6.14.03 All ferrous parts shall be hot dip galvanised, after all
machining has been completed. Nuts may, however, be tapped
(threaded) after galvanising and the threads oiled. Spring washers
shall be electro galvanised. The bolts threads shall be under cut to take
care of increase in diameter due to galvanising. Galvanising shall be
done in accordance with IS:2629-1990 or equivalent International
Standard and satisfy the tests mentioned in IS:2633-1992 or equivalent
International Standard. Fasteners shall withstand four dips while spring
washers shall be guaranteed to withstand at least six dips each lasting
one minute under the standard precee test for galvanising.
6.14.04 The Zinc coating shall be perfectly adhere, of uniform
thickness, smooth, reasonably bright, continuous and free from
imperfections such as flux, ash, rust stains, bulky while deposits and
blisters. The Zinc used for galvanising shall be grade Zn. 99.95 as per
IS: 209-1992 or equivalent International Standard.
6.14.05 In case of castings, the same shall be free from all internal
defects like shrinkage, inclusion, blowholes, cracks etc.
6.14.06 All current carrying parts shall be so designed and
manufactured that contact resistance is reduced to minimum.
6.14.07 No item which would produce high electrical and mechanical
stresses in normal working shall have sharp ends or edges, abrasions or
projections and shall not cause any damage to the Conductor in any
way during erection or during continuous operation. The design of
adjacent metal parts and mating surfaces shall be such as to prevent
corrosion of the contact surface and no maintain good electrical contact
under service conditions.
6.14.08 Particular care shall be taken during manufacturing and
subsequent handling to ensure smooth surface free from abrasion or
dents.
6.18 PACKING:
APPENDIX-2
Dimension after
Dimension before Length of sleeve Length of sleeve
compression (Flat
compression (Rod before after compression
Sl. to flat distance of
cross section) compression
Particular
No. hexagon)
Panth Zebr G/ W Panth Zebra G/ W Panth Zebr G/ W Panth Zebr G/ W
er a er er a er a
A Aluminium sleeve
a Inner 23 31 - - - -
dimension
(mm)
b Outer 38 48 - 32 40 - 610 711 - 660 763 -
dimension
(mm)
B Steel sleeve
a Inner 9.35 9.95 11.5 - - -
dimension
(mm)
b Outer 18 19.2 21 15 16.1 17.5 203 241 230 233 270 262
dimension
(mm)
C Repair sleeve
Outer 38 48 20.8 32 46 17.5 241 279 150 270 310 175
dimension
(mm)
SECTION- 7
TECHNICAL SPECIFICATION FOR ACCESSORIES FOR
220/132kV LINES
Material:
i. Dampers - As per IS-9708/1993 or equivalent
International Standard.
ii. Clamp - Aluminium alloy
iii. Messenger cable - High strength steel wire with a
strength (kg/sq. mm) not less than the
strength of steel core of power
Conductor/Earth Wire.
iv. Weight - Cast Iron (Hot dip Galvanized)
Galvanising:
The Contractor shall ensure that the Alloy used assures good
stability and sound casting by proper fluidity. Proper
mechanical and physical strength characteristics should be
obtained corresponding to the standard requirements of the
Alloy specified.
7.07.02 The Contractor shall ensure that the Alloy used assures
good stability and sound casting by proper fluidity. Proper mechanical
and physical strength characteristics should be obtained corresponding
to the standard requirements of the Alloy specified.
7.07.03 The clamps bodies shall be made by gravity die-casting only
and thereafter given the appropriate heat treatment and precipitation
treatment. Clamps bodies made by sand casting shall not be accepted
in any case.
7.08 CASTINGS:
All casting shall be free from blow holes, surface, Blisters and shall be
rounded off.
7.11 GALVANISING:
Hot dip galvanizing shall conform to Indian Standard specification IS-
2633 or equivalent International Standard. Galvanising shall be
uniform, free from blisters, and shall not peel off due to abrasion, Zinc
7.13.05 Clamps
(i) Tensile Test
(ii) Resistance Test
(iii) Temperature rise Test As per IS:5561
(iv) Short time current Test
(v) Dimensional Check
(vi) Galvanising Test
nuts, split pin and washers etc. may be excluded from this
requirement.
7.20 PACKING:
SECTION- 8
TECHNICAL SPECIFICATION FOR OPTICAL GROUND WIRE
(OPGW), ASSOCIATED HARDWARE & ACCESSORIES
8 STANDARDS:
8.01 Unless otherwise mentioned in the specification the offered
Optical Ground wire (OPGW) and associated Hardware shall be
manufactured, tested and supplied with all guaranteed technical
particulars generally confirming to meet the requirement of the
latest revisions of relevant standard of International Electro-
Technical Commission or equivalent National Standards of India.
S.
STANDARD TITLE
NO.
1 IEEE 1138 Standard Construction of Composite Fiber Optic
Ground wire (OPGW) for use on Electric Utility
Power Lines
2 ITUT G.652 For Optical Fibers
3 IEC 1396 Requirements and test methods for Optical
Ground wires (OPGW)
4 IEC 1089 Overhead electrical standard conductors
8.02 Tenderer shall clearly state the standards to which the equipment
offered by them conforms. In the event of offering of equipment
conforming to standards other than IS, the salient points of
comparison between standards adopted and the relevant IS shall
be indicated in the proposal alongwith copies of adopted
standards. It will be sole responsibility of the Tenderer to prove
that the salient features of offered equipment are equivalent or
better than standards specified above.
8.03.05 Attenuation
The attenuation coefficient for wavelengths between 1525 nm and 1575
nm shall not exceed the attenuation coefficient at 1550 nm by more
than 0.05 dB/km. The attenuation coefficient for wavelengths between
1285 nm and 1330 nm shall not exceed the attenuation coefficient at
1310 nm by more than 0.05 dB/km. The attenuation of the fibre shall
be distributed uniformly throughout its length such that there are no
point discontinuities in excess of 0.10 dB. The fibre attenuation
characteristics specified in table below shall be "guaranteed" fibre
attenuation of any and every fibre reel.
The overall optical fibre path attenuation shall not be more than
calculated below:
While preparing the Sag-tension charts for the OPGW cable the
following conditions shall be met:
The Sag-tension chart indicating the maximum tension, cable strain and
sag shall be submitted for the following conditions as specified in IS
802:1977/1995:-
The above cases shall be considered for the spans from 100 m to 525 M
or higher span length in the range of 50 m spans.
The filling compound shall remain stable for ambient temp. between -
20°C and +65°C and shall not drip, flow or leak with age or at high
The waterproofing filling materials shall not affect fibre coating, colour
coding, or encapsulant commonly used in splice enclosures, shall be
dermatologically safe, non-staining and easily removable with a non-
toxic cleaning solvent.
Table 8.04.05
OPGW Electrical and Mechanical Requirements
a. General
c. Tension Clamps
d. Vibration dampers
plane. Damper weights shall be made of hot dip galvanized cast iron
or steel.
The Vibration analysis of the system, with and without damper and
dynamic characterstics of the damper as detailed in Technical
specification, shall have to be submitted. The Technical paticulars for
vibration analysis and damping design of the system are as follows:-
e. Armour Rods
The armor rods for the OPGW shall be of the preformed type. They
shall be smooth and free from corrosion, splitting, cracking, or any
other defects. They shall be designed to effectively protect the
OPGW from fatigue caused by vibration.
The tenderer should offer Down Lead Clamp suitable for OPGW & the
offered clamps should meet requirement stipulated in the relevant
standard. Details of Down Lead Clamp including drawing shall be
submitted with the offer.
g. Joint Box
parts of the optical fiber within the joint box shall be reinforced and
free from tension after completion of the splicing.
h. Earth Bond
The Tenderer should offer Earth Bonds suitable for OPGW & the
offered Earth Bonds should meet requirement stipulated in the
relevant standard. Details of Earth Bonds including drawing shall be
submitted with the offer.
9 Point Discontinuities of
attenuation
10 Core -Clad concentricity error
11 Fibre Tensile Proof Testing
Table 4.3
Type tests for OPGW Cable
increase in optical
attenuation value greater
than 0.1dB change in sample
shall constitute failure. The
load shall be further
increased in small
increments until the
measured attenuation of the
optical waveguide fibres
increases and the failure load
recorded along with results.
9 Impact Test IEEE 1138 IEEE 1138, The impact test shall be
Section 4.1.1.7 Section 5.1.1.7 carried out in accordance
(IEC 794-1-E4/ with IEC:794-1-E4. Five
EIA/TIA 455- separate impacts of 0.1-
25B) 0.3kgm shall be applied. The
radius of the intermediate
piece shall be the reel drum
radius ± 10%. A permanent
or temporary increase in
optical attenuation value
greater than 0.1 dB/km
change in sample shall
constitute failure.
10 Creep Test IEEE 1138 IEEE 1138 As per Aluminium Association
Section 4.1.1.8 Section 5.1.1.8 Method , the best-fit straight
line shall be fitted to the
recorded creep data and
shall be extrapolated to 25
years. The strain margin of
the cable at the end of 25
years shall be calculated. The
time when the creep shall
achieve the strain margin
limits shall also be
calculated.
IEEE 1138 IEEE 1138
11 Fibre Strain
Section 4.1.1.9 Section 5.1.1.9
Test
12 Strain Margin IEEE 1138 IEEE 1138
Test Section Section 5.1.1.10
4.1.1.10
13 Stress strain IEEE 1138 IEEE 1138
Test Section Section 5.1.1.11
4.1.1.11
14 Cable Cut-off IEEE 1138 IEEE 1138
wavelength Section Section 5.1.1.12
Test 4.1.1.12
15 Temperature IEEE 1138 IEEE 1138
Cycling Test Section Section 5.1.1.13
4.1.1.13
16 Corrosion EIA/TIA 455-16A
(Salt Spray)
Test
Part 1:
The suspension assembly shall be increased at a constant rate up to a
load equal to 50% of the specified minimum Failure Load increased and
held for one minute for the test rig to stabilise. The load shall then be
increased at a steady rate to 67% of the minimum Failure Load and
held for five minutes. The angle between the cable, the Suspension
Assembly and the horizontal shall not exceed 16o. This load shall then
be removed in a controlled manner and the Protection Splice
disassembled. Examination of all the components shall be made and
any evidence of visual deformation shall be documented.
Part 2:
The Suspension clamp shall then be placed in the testing machine. The
tensile load shall gradually be increased up shall gradually be increased
up to 50% of the specified Minimum Failure Load of the Suspension
Assembly and held for one minute for the Test Rig to stabilise and the
load shall be further increased at a steady rate until the specified
minimum Failure Load is reached and held for one minute. No
fracture should occur during this period. The applied load shall then be
increased until the failing load is reached and the value shall be
documented.
Part 2:
The Tension Dead-End and associated components shall then be
reassembled and bolts tightened as before. The tensile load shall
gradually be increased up shall gradually be increased up to 50% of the
specified Minimum Failure Load of the Tension Assembly and held for
one minute for the Test Rig to stabilise and the load shall be further
increased at a steady rate until the specified minimum Failure Load is
reached and held for one minute. No fracture should occur during this
period. The applied load shall then be increased until the failing load is
reached and the value shall be documented.
Acceptance Criteria:
Acceptance Criteria :
The Suspension Clamp has passed the Slip Test if the following
conditions are met :
No slippage* shall occur at or below the specified minimum slip
load.
Acceptance Criteria :
(a) The analysis shall be done for single fibre optic cable without
armour rods. The tension shall be taken as max Permissible
Every Day Tension (20% of UTS), for a span ranging from
100 m to 1100 m.
(b) The self damping factor and flexural stiffness (EI) for fibre
optic cable shall be calculated on the basis of experimental
results. The details to experimental analysis with these data
shall be furnished.
(c) Examine the Aeolian Vibration level of the fibre optic cable
with and without vibration damper installed at the
recommended location or wind velocity ranging from 0 to 30
Km per hour, predicting amplitude, frequency and vibration
energy input.
The clamp slip and fatigue tests shall be conducted on a laboratory set
up with a minimum effective span length of 30m. The fibre optic cable
shall be tensioned at 15kN & shall not be equipped with protective
armour rods at any point.
Constant tension shall be maintained within the span by means of lever
arm arrangement. After the fibre optic cable has been tensioned,
clamps shall be installed to support the fibre optic cable at both ends
and thus influence of connecting hardware fittings are eliminated from
the free span. The clamps shall not be used for holding the tension on
the fibre optic cable. There shall be no loose parts, such as suspension
clamps, U bolts, on the test span supported between clamps mentioned
above. The span shall be equipped with vibration inducing equipment
suitable for producing steady standing vibration. The inducing
equipment shall have facilities for step less speed control as well as
step less amplitude arrangement. Equipment shall be available for
measuring the frequency, cumulative number of cycles and amplitude
of vibration at any point along the span.
The clamp slip test as mentioned herein above shall be repeated after
fatigue tests without retorquing or adjusting the damper clamp, and the
clamp shall withstand a minimum load equal to 80% of the slip strength
for a minimum duration of one minute.
After the above tests, the damper shall be removed from fibre optic
cable and subjected to dynamic characteristics test. There shall not be
any major deterioration in the characteristics of the damper. The
damper then shall be cut open and inspected. There shall not be any
broken, loose, or damaged part. There shall not be significant
deterioration or wear of the damper. The fibre optic cable under clamp
shall also be free from any damage.
S. Acceptance Test
Test Name
No. Criteria procedure
1 Attenuation Coefficient
Point Discontinuities of
2
attenuation
AS per
3 Attenuation at Water Peak AS per
Technical
Technical
4 Chromatic Dispersion Specificatio
Specification
n
5 Core – Clad Concentricity Error
6 Cladding diameter
7 Fibre Tensile Proof Testing
The test reports for the above tests for all types of the fibres carried out
by the Fibre Manufacturer and used in the OPGW cables and approach
cable shall be shown to the inspector during OPGW cable FAT and shall
be submitted along with the OPGW cable FAT report.
The factory acceptance tests for OPGW cable specified below in Table
4.6 follow the requirements set forth in section 4.1.2 and section
5.1.2 of IEEE standard 1138. The FAT shall be carried out on 10% of
offered drums in each lot as specified in technical specifications and the
optical tests shall be carried out in all fibers of the selected sample
drums. The Rated Tensile Strength test shall be carried out on one
sample in each lot.
Table 4.6
Factory Acceptance Tests On OPGW
Applicable standard: IEEE 1138
S. No. Factory Acceptance Test on Manufactured OPGW
1 Attenuation Co-efficient at 1310 nm and 1550 nm
Table 4.7
Visual check Kit Quantities and Specific Component Number for each
1 component of In Line Splice Enclosure and dimensional checks against the
approved drawings.
Each package shall be clearly, legibly and durably marked on both sides
as follows:-
a. Name & designation of the consignee (to be furnished
by the purchaser.)
b. Ultimate destination (as required by the purchaser).
c. Items and respective quantities contained in the
package to be furnished by the purchaser.)
d. Net and gross weight of the material.
e. Gross weight of each package.
ANNEXURE -A
Guaranteed value
Description Unit
48 fibers
Number of fiber
No. 48
section
Steel tube -do-
2
(*) Modules of elasticity Kg/mm -do-
(*) Co-efficient of linear expansion /deg C -do-
D.C. resistance at 20 deg C (max) ohm/km -do-
ANNEXURE-B
Guaranteed value
Description Unit
48 fibers
Type of individual wire - ACS Wires Al-alloy
Applicable standard -
To be filled To be filled
by bidder by bidder
Standard diameter mm -do- -do-
-do-
Properties of wrapping % -do-
ANNEXURE – C
Guaranteed
Description Unit value 48
Fibers
Loose type
(Stainless Steel Tube
Buffer type - type preffered)
Number of Loose tube No. To be filled by bidder
Total No.of Fibers No 48
(*) Diameter Mm To be filled by bidder
Number of empty tube Nos. To be filled by bidder
Loose tube
To be filled by bidder
(*) Material -
ANNEXURE - D
Chromatic dispersion
@ 1288 nm 1̃ 339 nm ps/(nm.km) ≤ 3.5
@ 1271 nm 1̃ 360 nm ps/(nm.km) ≤ 5.3
@ 1550 nm ps/(nm.km) ≤ 18
Zero dispersion wavelength Nm 1300 to 1324
2
Zero dispersion Slope Ps/Nm .km ≤0.093
½
Polarization mode dispersion (PMD) ps/km ≤0.2
Point discontinuities of attenuation dB ≤0.1@1310&1550 nm
Proof-test level Gpa ≥ 0.69
ANNEXURE-E
ANNEXURE-F
S.
Parameter Unit Particulars
No.
1. Dimensions HWD mm To be filled by bidder
2. Weight Kg To be filled by bidder
3. Color and Finish Stainless Steel AISI 304
4. Cable Glanding & Fixing Mechanical clamp
Stainless Steel AISI 304
5. Construction materials & Gauge
(1.0 - 3.0 )mm
6. Locking arrangements Bolts and nuts
Installation Clearances:
Front access: N/A
7.
Rear access: N/A
Cm2 To be filled by bidder
Top*Bottom*Slides
8. IP Protection Code IP 68
9. Total number of optical couplings n* To be filled by bidder
10. Provision of pass through splicing Yes/No Yes
Whether filled with suitable
11. Yes/No To be filled by bidder
encapsulant
Method(s) for mounting with the
12. Mechanical
tower
Locking arrangements
Installation Clearances:
Front Access:
m
Rear Access:
Top*Bottom*Slides:
22. Excess length of Fiber service loops m 1.5 + 1.5
SECTION- 9
TECHNICAL SPECIFICATION FOR ERECTION OF 220KV
AND 132KV TRANSMISSION LINES
The Contractor shall conduct the check survey only for such
portion of line for which detailed survey has been done by the Employer
after the profiles are handed over to the Contractor. The check survey
shall include checking of deviation angles, checking of levels at critical
points. After completing the check survey, profiles shall be re-submitted
to the Employer duly spotted with tower for approval.
9.03.03 The requirement of tower site leveling and revetment work, if
required, shall also be marked by the Contractor on the
profiles while carrying out the detail or check survey work.
9.03.04 If due to site conditions any change in the tower
location/provision of extension is considered necessary
compared to approve profiles, the contractor shall bring the
same to the knowledge of the Employer well in time and get
revised approval of the profile before setting the stubs.
The revised approval shall be conveyed to the Contractor by
the Employer.
9.04 APPROVED PROFILE:
(Applicable for check survey only)
9.04.01 The detailed survey may be conducted by the Employer for
some portion of the transmission line and in such case, the
profiles will be handed over to contractor for carrying out
check survey and marking of towers on the profiles. The
profile will be prepared on cm. graph paper on scale 1:2000
horizontal and 1:200 vertical. The profile will be submitted
along with the route map showing the route followed by the
contractor during check survey.
9.04.02 The route alignment surveyed by the Employer shall be
marked at angle points. At angle points concrete blocks shall
be provided and in the straight alignment marking will be done
by pegs.
9.04.03 The Contractor will be responsible for the correct setting of
towers as shown in approved profiles. If towers after erection
are found to be out of the approved alignment/position in the
profile, the Contractor will dismantle and re-erect them
correctly fully at his own cost and without extension of time.
9.04.04 Soil Resistivity:-
P=2πaR
Where a = Interelectrod spacing = 50M
R = Earth resistance measured in Ohms
P = Soil Resistivity in Ohm- m
The soil resistivity values shall be submitted duly marked on the
route map and also in the form of statement. The quoted rates for
detailed survey/ check survey work shall be inclusive of cost of
measuring soil resistivity values along the proposed route and the
contractor will not be paid separately for this work.
9.05 EXCAVATION:
9.05.01 Except as specifically otherwise provided, all excavation for
footing shall be made to the lines and grades of the foundation. The
excavation walls shall be vertical and the pit dimensions shall be such
as to allow a clearance of 150mm on all sides from the foundation pit,
where form boxes are used. In undercut/stepped (slab type)
foundations where form box is not required to be used at the base, the
pit dimensions should be as per the standard drawings. All excavation
shall be protected so as to maintain a clean sub-grade, until the footing
is placed, by using timbering, shoring or casing, if necessary. Any
sand, mud, silt or other undesirable materials which may have
accumulated in the excavation shall be removed by the Contractor
before placing concrete.
9.05.02 The Soil to be excavated for tower foundations shall be
classified as under for the purpose of payment of excavation for
tower site leveling and building stone revetment:
(a) Normal Dry Soil : Soil removable by means of ordinary pick
axes and shovels (Normal Soil, intermediate Soil fall
under this category).
(b) Wet Soil : Soil as per (a) above, where the sub Soil water
table is encountered within the range of foundation
depth, the Soil below the water table and that at
locations where pumping or bailing out of water is
required due to presence of surface water, will be
treated as wet Soil.
(c) Black cotton (Dry/Wet) :To be used at locations where soil is
clayey type, not necessarily black in colour, which
shrinks when dry and swells when wet, resulting in
differential movement extending to a maximum depth
of about 3.5 meter below ground level.
(d) Soft Rock: This will mean fissured rock i.e. decomposed rock,
hard gravel, kankar, limestone, laterite or any other Soil
of similar nature which can be excavated with pick axe,
9.05.08 The decision of the owner shall be final and binding with
respect to classification of soil and foundation.
buried near the foundation pit and connected to the stubs. The earthing
rods are to be provided in every leg of the tower. Each tower shall be
earthed before the foundation is casted.
9.15.02 The tower footing resistance of all towers shall be
measured in dry whether after the erection and before the stringing of
Earth wire. The counterpoise earthing shall be resorted to, in
accordance with the instructions of the site Engineer, in case the tower
footing resistance (TFR) exceeds the specified value. It shall be
ensured that the tower footing resistance is less than 10 ohms. Each
tower footing resistance shall be intimated (along with the tower
location number) while submitting the progress report of tower
erection.
9.15.03 Counterpoise Earthing :
9.22.02 The sag will be checked in the first and the last span of the
section in case of sections up to eight spans and in one intermediate
span also for sections with more than eight spans. The sag shall also
be rechecked when the Conductor have been drawn up and
transferred from running blocks to the insulator clamps.
9.22.03 The running out blocks, when suspended from
the transmission structure for sagging shall be so adjusted that the
Conductors on running out blocks will be at the same height as that of
the suspension clamps to which it is to be secured.
9.22.04 At sharp vertical angles, the sags and tensions shall be
checked on both sides of the angle. The Conductor and Earth wire shall
be checked on the running out blocks for equality of tension on both
sides. The suspension insulator assemblies will normally assume
vertical positions when the Conductor is clamped.
9.22.05 Tensioning and sagging operations shall be carried out in
calm weather, when rapid changes in temperature are not likely to
occur.
9.23 TENSIONING & SAGGING OF CONDUCTOR AND EARTH
WIRE:
The tensioning and sagging shall be done in accordance with the
approved stringing charts before the Conductor and Earth wire is
finally attached to the towers through the insulator strings for the
Conductor and Earth wire clamps for the Earth wire Dynamometers
shall be used for measuring tension in the Conductor and Earth wire.
9.24 CLIPPING IN:
9.24.01 Clipping of the Conductors in position shall be done in
accordance with the method approved by our Engineer. At suspension
location free center type suspension clamp with Armour rod set or AGS
type suspension clamp shall be used.
9.24.02 The jumpers at the section and angle towers shall be
formed to parabolic shape to ensure maximum clearance
requirements. Pilot suspension insulator string shall be used, if
necessary, to restrict the jumper swings to the design values. Jumper
connections of transposition towers shall be so made that adequate
clearances are available from tower body as well as phase conductors.
9.24.03 Fasteners in all fittings and accessories shall be secured in
position. The security clip shall be properly opened and sprung into
position.
9.25 FIXING OF CONDUCTORS AND EARTH WIRE
ACCESSORIES :
Vibration dampers (4-R type) and other Conductor and Earth wire
Accessories supplied by the Employer shall be installed by the
Contractor as per the design/drawing requirement and as per
ANNEXURE- 1
ANNEXURE-2
ANNEXURE-3
i. Maximum (mm) NA
+/- 6 +/- 6
ii. Minimum (mm) +/- 6 +/- 6 NA
i. Tolerance in internal diameter of
helix.
i. Maximum (mm) NA
+/- 0.2 +/- 0.2
ii. Minimum (mm) +/- 0.2 +/- 0.2 NA
j. Tolerance in outer diameter of
helix
i. Maximum (mm) NA
+/- 0.2
ii. Minimum (mm) NA
9 Power loss at 400 Amp. Current 200 Milli 501.50 Milli
NA
AGS suspension assembly Watt Watt
ANNEXURE-4
ANNEXURE-5
LIST OF DRAWINGS
S.No Particulars
1. Details of earthing arrangement.
2. Number plate for 220 kV Transmission line.
3. Phase plate for 220 kV Transmission line.
4. Danger Board for 220 kV Transmission line.
5. Anticlimbing device for 220kV towers
14. 220kV Single & Double suspension insulator string hardware for Zebra
ACSR conductor
15. 220kV Single & Double tension insulator string hardware for Zebra ACSR
conductor
16. 132kV Single & Double suspension insulator string hardware for Panther
ACSR conductor
17. 132kV Single & Double tension insulator string hardware for Panther
ACSR conductor
18. Hardware fittings for Earth wire
VOLUME-V (Part-2)
This section of the technical specification describes the functional and technical
specifications of Fibre Optic cabling and associated items.
2.1 Fibre Optic Cabling
In this section of the technical specification, the functional & technical specifications
of OPGW cable, Fibre Optic Approach Cable, Joint Box and associated hardware &
fittings for the requirements for G.652D Dual-window Single mode (DWSM)
telecommunications grade optical fibre is specified. Bidders shall furnish with their
bids, detailed descriptions of the fibres & cable(s) proposed.
All optical fibre cabling including fibre itself and all associated installation hardware
shall have a minimum guaranteed design life span of 25 years.
2.1.1 Required Optical Fibre Characteristics
The 24 Fibre optical fibre to be provided should have following characteristics:- :
2.1.1.1 Physical Characteristic
Dual-Window Single mode (DWSM), G.652D optical fibres shall be provided in the
fibre optic cables. DWSM optical fibres shall meet the requirements defined in Table
2-1(a):
2.1.1.2 Attenuation
The attenuation coefficient for wavelengths between 1525 nm and 1575 nm shall
not exceed the attenuation coefficient at 1550 nm by more than 0.05 dB/km. The
attenuation coefficient between 1285 nm and 1330 nm shall not exceed the
attenuation coefficient at 1310 nm by more than 0.05 dB/km. The attenuation of
the fibre shall be distributed uniformly throughout its length such that there are no
point discontinuities in excess of 0.10 dB. The fibre attenuation characteristics
specified in table 2-1 (a) shall be “guaranteed” fibre attenuation of any & every
fibre reel.
Table 2-1(a)
DWSM Optical Fibre Characteristics
1300 to 1324nm
Zero Dispersion Wavelength: 0.092 ps/(nm2xkm) maximum
Zero Dispersion Slope:
Polarization mode dispersion 0.2 ps/km^½
coefficient
Temperature Dependence: Induced attenuation 0.05 dB (-60C to
+85C)
Bend Performance: @ 1310 nm (75±2 mm dia Mandrel), 100 turns;
Attenuation Rise 0.05 dB/km
For the purpose of payment, the Optical Fibre lengths are defined as transmission
line route length from gantry at one termination station to the gantry in the other
terminating station. The actual cable lengths to be delivered shall take into
account various factor such as sag, service loop, splicing, working length and
wastage etc. and no additional payment shall be payable in this regard. The unit
rate for FO cable quoted in the bid price shall take into account all such factor.
Individual optical fibres within a fibre unit and fibre units shall be identifiable in
accordance with EIA/TIA 598 or IEC 60304 or Bellcore GR-20 colour-coding
scheme.
Colouring utilized for colour coding optical fibres shall be integrated into the fibre
coating and shall be homogenous. The colour shall not bleed from one fibre to
another and shall not fade during fibre preparation for termination or splicing.
Each cable shall have traceability of each fibre back to the original fibre
manufacturer's fibre number and parameters of the fibre. If more than the
specified number of fibres is included in any cable, the spare fibres shall be tested
by the cable manufacturer and any defective fibres shall be suitably bundled,
tagged and identified at the factory by the vendor.
The OPGW cable the optical fibres shall experience no strain under all loading
conditions defined in IS 802. Zero fibre strain condition shall apply even after a 25
year cable creep.
For the purpose of this specification, the following definitions shall apply:
While preparing the Sag-tension charts for the OPGW cable the following
conditions shall be met:
The Max Allowable Tension (MAT) / max strain shall be less than or equal
to the MWT/ Strain margin of the cable.
The sag shall not exceed the earth wire sag in all conditions.
The Max Allowable Tension shall also be less than or equal to 0.45 times
the UTS.
The 25 year creep at 25% of UTS (creep test as per IEEE 1138) shall be
such that the 25 year creep plus the cable strain at Max Allowable Tension
(MAT) is less than or equal to the cable strain margin.
The everyday tension (EDT) shall not exceed 20% of the UTS for the
OPGW cable, subject to the condition that the requirements mentioned
below are fulfilled.
The Sag-tension chart of OPGW cable indicating the maximum tension, cable
strain and sag shall be calculated and submitted under various conditions
mentioned below:
1. 53° C , no wind and no ice
2. 32° C, no wind and no ice
3. 0°C, no wind and no ice
4. 32° C, full wind and no ice
5. 32° C, 75% full wind and no ice
6. 0° C, 2/3rd / 36% of full wind (IS 802:1977 / 1995)
7. MPPTCL standard 400kV,220kV and 132kV tower type technical
details defined in Table 2.1(b).
Max Max
Sag
Sag Tension
at
at at 32°C
S. Tower KV Wind Design 0°C
53°C with
No. Type Level Load Span with
with Full
Nil
Nil Wind
Wind
Wind
45 400 8.69 10.19
1 FD Series 400kV 1686 Kg
Kg/meter2 meter meter meter
NFD 189 400 8.69 10.19
2 400kV 3327 Kg
Series Kg/meter2 meter meter meter
194 350 5.50 6.91
3 B Series 220kV 3300 Kg
Kg/meter2 meter meter meter
189 350 4.83 6.19
4 E Series 132kV 3400 Kg
Kg/meter2 meter meter meter
ND 45 350 4.83 6.19
5 132kV 1942 Kg
Series Kg/meter2 meter meter meter
MD 254 250 2.30 3.21
6 132kV Kg/meter2 3536 Kg
Series meter meter meter
MC 257 350 5.50 6.90
7 220kV 3976 Kg
Series Kg/meter2 meter meter meter
Table 2-1(C)
Ground Wire Technical Details
1. Material Steel
2. Size --
The above cases shall be considered for the spans from 100 m to 525 m or
higher span length in the steps of 20 m increase in spans. Max. Vertical sag,
max. tension and max sag at 0° C & no wind shall be considered in line with the
design parameter of transmission line. In order to maintain the minimum Mid
Span vertical clearance between OPGW and top conductor, the OPGW Sag at 0° C
no wind condition must be equal to or less then the corresponding sag of ground
wire as considered in the design of tower and also indicated in the above table.
The full wind load shall be considered as the design wind load for all the specified
transmission lines as per relevant IS 802 version and the sag-tension chart shall
be submitted considering the transmission lines for approval of MPPTCL and the
same shall be followed during installation of OPGW Cable.
The materials used for optical fibre cable construction, shall meet the following
requirements:
The interstices of the fibre optic unit and cable shall be filled with a suitable
compound to prohibit any moisture ingress or any water longitudinal migration
within the fibre optic unit or along the fibre optic cable. The water tightness of the
cable shall meet or exceed the test performance criteria as per IEC 60794-1-F-5or
EIA/TIA 455-82B.
The waterproofing filling materials shall not affect fibre coating, colour coding, or
encapsulant commonly used in splice enclosures, shall be dermatologically safe,
non-staining and easily removable with a non-toxic cleaning solvent.
When the fibre optic cable design incorporates metallic elements in its
construction, all metallic elements shall be electrically continuous.
All OPGW for export shipment are generally shipped on best commercial practice
non-returnable steel reels having suitable dimension for winding a specified
length.
Each length of Optical Fibre cable shall be wound on a separate cable reel and the
cable ends shall be securely fastened to the reel to prevent the cable from
becoming loose in transit or during placing operations. Both ends of the cable
shall be sealed with a suitable plastic cap to prevent the entry of moisture during
shipping, handling and storage. Spare plastic cap shall be provided with each
drum.
The Optical Fibre cable shall be shipped on reels designed to prevent damage to
the cable during shipment and installation. The wooden lagging will be given a
preventive treatment from termite and wood preservative treatment. The
construction of reels and markings shall be as per approved documents.
The packing and shipping requirements for OPGW cable shall be applied for
assemblies and line accessories also.
Each package shall be clearly, legibly and durably marked on both sides as
follows:-
OPGW cable construction shall comply with IEEE-1138, 2009. The cable provided
shall meet both the construction and performance requirements such that the
ground wire function, the optical fibre integrity and optical transmission
characteristics are suitable for the intended purpose.
OPGW design shall be finalized during the detailed engineering stage based on
aluminium tube multi buffer design OPGW in the package. However, in exceptional
cases such as heavy wind zones etc requiring smaller dia cable and aluminium tube
design OPGW is not found suitable for specific transmission line, stainless steel with
aluminium coated only protective central Fibre optic surrounded by concentric-lay
stranded metallic wire in single or multiple layer design can be accepted.
The central fibre optic unit shall be designed to house and protect
multiple buffered optical fibre units from damage due to forces such
as crushing, bending, twisting, tensile stress and moisture. The
central fibre optic unit and the outer stranded metallic conductors
shall serve together as an integral unit to protect the optical fibres
from degradation due to vibration and galloping, wind and ice
loadings, wide temperature variations, lightning and fault current, as
well as environmental effects which may produce hydrogen.
The OPGW design of dissimilar materials for stranded wires and tubes are not
allowed. Central fibre optic unit may be of aluminium / aluminium alloy tube. There
shall be no exposed areas of tubing that can make electrical contact either directly
or indirectly through moisture, contamination, protrusions, etc with the surrounding
stranded wires. The tube may be fabricated as a seamless tube, seam welded, or a
tube without a welded seam.
The central fibre optic unit shall be designed to house and protect
optical fibres provided in single buffered tube of stainless steel tube
from damage due to forces such as crushing, bending, twisting, tensile
stress and moisture. The central fibre optic unit and the outer stranded
metallic conductors shall serve together as an integral unit to protect
the optical fibres from degradation due to vibration and galloping, wind
and ice loadings, wide temperature variations, lightning and fault
current, as well as environmental effects which may produce hydrogen.
The OPGW design of dissimilar materials for stranded wires and tubes
are not allowed. Central fibre optic unit shall be of stainless steel tube
with aluminium protective coating or stainless steel tube with Al
protecting outer tube. In case of aluminium protective coating, the
coating must completely cover the tubes leaving no exposed areas of
tubing that can make electrical contact either directly or indirectly
through moisture, contamination, protrusions, etc with the surrounding
stranded wires. The tube may be fabricated as a seamless tube, seam
welded, or a tube without a welded seam.
2.1.3.1 OPGW Parameters to be considered for different line voltage and wind zones
The rated breaking strength of the completed OPGW shall be taken as 90 percent of
the sum of the rated breaking strengths of the individual wires, calculated from their
nominal diameter and the specified minimum tensile strength.
The rated breaking strength shall not include the strength of the optical unit. The
fibre optic unit shall not be considered a load bearing tension member when
determining the total rated breaking strength of the composite conductor.
Table 2-1(d) provides OPGW Electrical and Mechanical Requirements for the
minimum performance characteristics.
Table 2.1(d)
(3) Short Circuit Current ≥ 6.32 kA for 1.0 second (for 220 kV & above
lines)
Installation Hardware includes all required fittings and hardware such as Tension
assembly, Suspension assembly, Vibration dampers, Reinforcing rods, Earthing
clamps, Downlead clamps, splice enclosure etc. MPPTCL.
The OPGW hardware fittings and accessories shall follow the general requirements
regarding design, materials, dimensions & tolerances, protection against corrosion
and markings as specified in clause 4.0 of EN 61284: 1997 (IEC 61284). The
shear strength of all bolts shall be at least 1.5 times the maximum installation
torque. The OPGW hardware & accessories drawing & Data Requirement Sheets
(DRS) document to be submitted by contractor shall consist of three parts: (1) A
technical particulars sheet (2) An assembly drawing i.e. level 1 drawing and (3)
Component level drawings i.e. level 2 & lower drawings. All component reference
numbers, dimensions and tolerances, bolt tightening torques & shear strength and
ratings such as UTS, slip strength etc shall be marked on the drawings.
The Contractor shall supply all the components of the suspension assembly
including shackles, bolts, nuts, washers, split pins, etc. The total drop of
the suspension assembly shall not exceed 150 mm (measured from the
centre point of attachment to the centre point of the OPGW). The design of
the assembly shall be such that the direction of run of the OPGW shall be
the same as that of the conductor.
(b) Dead End Clamp Assemblies: All dead end clamp assemblies shall
preferably be of performed armoured grip type and shall include all
necessary hardware for attaching the assembly to the tower strain plates.
Dead end clamps shall allow the OPGW to pass through continuously
without cable cutting. The slip strength shall be rated not less than 95% of
the Ultimate tensile strength of the OPGW.
(e) Tension Fitting for Suspension Tower: The OPGW cable sections shall
also be terminated & spliced on suspension towers as per requirement. For
this, a special fitting namely Yoke plate alongwith tension fittings shall be
provided for termination/jointing of OPGW on Suspension tower.
One damper minimum on each side per OPGW cable for suspension
points and two dampers minimum on each side per OPGW cable for
tension points shall be used for nominal design span upto 400 meter for
400kV and 350 meters for 220kV and 132kV transmission lines. For
higher ruling spans, the number of vibration damper shall be as per
manufacturer recommendation and damper placement chart.
The damper mass shall be made of hot dip galvanised mild steel/cast
iron or a permanent mould cast zinc alloy. All castings shall be free from
defects such as cracks, shrinkage, inclusions and blow holes etc. The
surface of the damper masses shall be smooth.
The damper clamp shall be casted over the messenger cable and offer
sufficient and permanent grip on it. The messenger cable shall not slip out
of the grip at a load less than the mass pull-off value of the damper. The
damper masses made of material other-than zinc alloy shall be fixed to the
messenger cable in a suitable manner in order to avoid excessive stress
concentration on the messenger cables which shall cause premature
fatigue failure of the same. The messenger cable ends shall be suitably
and effectively sealed to prevent corrosion. The damper mass made of zinc
alloy shall be casted over the messenger cable and have sufficient and
permanent grip on the messenger cable under all service conditions.
The vibration analysis of the system, with and without damper and
dynamic characteristics of the damper as detailed in Technical
Specification, shall have to be submitted. The technical particulars for
vibration analysis and damping design of the system are as follows:
The damper placement chart for spans ranging from 100m to 1100m
shall be submitted by the Contractor. Placement charts should be duly
supported with sample calculations and manufacturer recommendation.
The damper placement charts shall include the following
(1) Location of the dampers for various combinations of spans and line
tensions clearly indicating the number of dampers to be installed per
OPGW cable per span.
(2) Placement distances clearly identifying the extremities between which
the distances are to be measured.
(3) Placement recommendation depending upon type of suspension
clamps (viz Free center type/Armour grip type etc.)
All splices shall be encased in Fibre Optic Splice Enclosures. Suitable splice
enclosures shall be provided to encase the optical cable splices in protective,
moisture and dust free environment. Splice enclosures shall comply with ingress
protection class IP 66 or better. The splice enclosures shall be designed for the
storage and protection of required number of optical fibre splices and equipped
with sufficient number of splice trays for splicing all fibres in the cable. No more
than 12 fibres shall be terminated in a single splice tray. They shall be filled with
suitable encapsulate that is easily removable should re-entry be required into the
enclosures.
Splice enclosures shall be suitable for outdoor use with each of the cable types
provided under this contract. Splice enclosures shall be appropriate for mounting
on transmission line towers above anti-climb guard levels at about 10 metres
from top of the tower and shall accommodate pass-through splicing. The actual
mounting height and location shall be finalised after Survey.
Splicing of the optical fibre cabling shall be minimized through careful Contractor
planning. There shall be no mid-span splices allowed. All required splices shall be
planned to occur on tower structures. All optical fibre splicing shall comply with
the following:
(b) Each fibre splice shall be fitted with a splice protection sheath fitted over
the final splice.
(c) All splices and bare fibre shall be neatly installed in covered splice trays.
(d) For each link, bi-directional attenuation of single mode fusion splices, shall
not average more than 0.05 dB and no single splice loss shall exceed 0.1 dB
when measured at 1550 nm.
(e) For splicing, fibre optic cable service loops of adequate length shall be
provided so that all splices occurring at tower structures can be performed at
ground level.
For purposes of this specification, a fibre optic approach cable is defined as the
Armoured underground fibre optic cable required to connect Overhead Fibre Optic
Cable (OPGW) between the final in line splice enclosure on the gantry / tower
forming the termination of the fibre cable on the power line and the Fibre Optic
Distribution Panel (FODP) installed within the building. The estimated fibre optic
approach cabling length requirements are indicated in the BoQ. Actual supply to
be done as per directives of MPPTCL. However, actual supply shall be done based
on the actual site survey.
The cable shall be suitable for direct burial, laying in trenches & PVC/Hume ducts,
laying under false flooring and on indoor or outdoor cable raceways.
The Approach Cable shall be a UV resistant, rodent proof, armoured cable with
metallic type of armouring. The outer cable jacket for approach cable shall consist
of carbon black polyethylene resin to prevent damage from exposure to ultra-
violet light, weathering and high levels of pollution. The jacket shall conform to
ASTM D1248 for density.
Approach cable shall contain fibres with identical optical/ physical characteristics
as those in the OPGW cables. The cable core shall comprise of tensile strength
member(s), fibre support/bedding structure, core wrap/bedding, and an overall
impervious jacket.
All required fitting, support, accessories, ducts, inner ducts, conduits, risers
and any item not specially mentioned but required for laying an installation of
approach cable shall be supplied and installed by the contractor.
At each location requiring the termination of at least one fibre within a cable,
all fibres within that cable shall be connectorized and terminated in Fibre Optic
Distribution Panels in a manner consistent with the following:
(a) All fibre optic terminations shall be housed using FODPs provisioned with
splice organizers and splice trays. All fibres within a cable shall be fusion
spliced to preconnectorized pigtails and fitted to the "Back-side" of the
provided fibre optic couplings.
(b) FODPs shall be suitable for use with each of the cable types provided as
part of this contract. FODPs shall accommodate pass-through splicing
and fibre terminations.
(d) All FODPs shall be of corrosion resistant, robust construction and shall
allow both top or bottom entry for access to the splice trays. Ground lugs
shall be provided on all FODPs and the Contractor shall ensure that all
FODPs are properly grounded.
(e) Flexible protection shall be provided to the patch cord bunches going out
from FODP to other equipment.
For purpose of this specification, cable and fibre service loop are defined as
slack (extra) and fibre provided for facilating the installation, maintenance and
repair of the optical fibre cable.
(a) Outdoor cable service loops -Inline splice enclosures installed outdoor
and mounted on the utility tower shall be installed with sufficient fibre optic
cable service cable loop such that the recommended minimum bend radius is
maintained while allowing for installation or maintenance of the cable to be
performed in a controlled environment at ground level.
(b) Indoor cable service loops -FODPs shall provide atleast three meters
of cable service loops. Service loop shall be neatly secure and stored, coiled
such that the minimum recommended bend radius is maintained.
(c) Fibre units service loops:-For all fibre optic cable splicing the cable
shall be stripped back to sufficient length such that the fan out of fibre units
shall provide for atleast one meter of fibre unit service loops between the
stripped cable and the bare fibre fan out.
(e) Fibre Service Loops- Atleast 0.5 mts of bare fibre service loop shall be
provided on each side of all fibre splices. The bare fibre service loops shall be
neatly and safely installed inside covered splice tray.
Most of the OPGW fibre optic cables to be installed under this project shall be
installed under live line conditions, i.e. with all the circuits of the transmission line
charged to their rated voltage. The tentative bill of quantities for live-line OPGW
cable system installations have been specified in the appendices.
The OPGW cable shall be installed at the top of the tower by replacing the existing
ground wire. The Contractor shall carry out re-tensioning of the existing earth
wire wherever required to maintain the adequate clearances for live line stringing
of fibre optic cables. However, in exceptional cases installation of OPGW cable
below conductor may also be considered on low voltage lines which shall be
decided during detailed engineering.
During pre-installation survey, the Contractor shall check the suitability of OPGW
installation on EHV AC transmission line crossings, river crossing, highway, rail
crossing etc in consultation with MPPTCL. The Contractor shall propose suitable
OPGW route accordingly using diamond crossing etc wherever earth wire is not
available beneath line crossings. Such additional OPGW due to change in route on
account of line crossings shall be included as a part of main quantity for OPGW
route length.
OPGW installed under live line condition, i.e. with all circuits charged to the rated
line voltage as specified in this section shall be generally in accordance with the
IEEE Guide to the Installation of Overhead Transmission Line Conductors (IEEE
STD. 524 with latest revisions), with additional instructions and precautions for
live line working and fibre optic cable handling. Some of the cable may be
installed in off-line condition also. The stringing procedure shall be submitted by
the Contractor prior to stringing for MPPTCL approval.
A tower structural analysis shall be carried out by the Contractor, based on the
relevant data to be provided by MPPTCL, to ensure that with the replacement of
existing earthwire with the OPGW cable, the tower members remain within the
statutory safety limits as per Indian Electricity rules and if required the Contractor
shall carry out the tower strengthening as necessary.
Appendix -I
All materials furnished and all work performed under this Contract shall be
inspected and tested. Deliverables shall not be shipped until all required inspections
and tests have been completed, and all deficiencies have been corrected to comply
with this Specification and approved for shipment by the MPPTCL.
Except where otherwise specified, the Contractor shall provide all manpower and
materials for tests, including testing facilities, logistics, power and instrumentation,
and replacement of damaged parts. The costs shall be borne by the Contractor and
shall be deemed to be included in the contract price.
The entire cost of testing for factory & site acceptance, routine tests, production
tests and other test during manufacture & site activities specified herein shall be
treated as included in the quoted unit price of materials, except for the expenses of
Inspector/MPPTCL’s representative.
Acceptance or waiver of tests shall not relieve the Contractor from the responsibility
to furnish material in accordance with the specifications.
All tests shall be witnessed by the MPPTCL and/or its authorized representative
(hereinafter referred to as the MPPTCL) unless the MPPTCL authorizes testing to
proceed without witness. The MPPTCL representative shall sign the test form
indicating approval of successful tests.
Should any inspections or tests indicate that specific item does not meet
Specification requirements, the appropriate items shall be replaced, upgraded, or
added by the Contractor as necessary to correct the noted deficiencies at no cost to
the MPPTCL. After correction of a deficiency, all necessary retests shall be
performed to verify the effectiveness of the corrective action.
The MPPTCL reserves the right to require the Contractor to perform, at the
MPPTCL's expense, any other reasonable test(s) at the Contractor's premises, on
site, or elsewhere in addition to the specified Type, Acceptance, Routine, or
Manufacturing tests to assure the MPPTCL of specification compliance.
1. Inspection
Access to the Contractor's facilities during system manufacturing and testing and to
any facility where systems/ equipment are being produced/ tested/ integrated for
the fibre optic communication network, shall be available to the MPPTCL. At all
times the MPPTCL shall have full facilities for unrestricted inspection of such
materials or equipment. To facilitate this, the Contractor shall submit for the
MPPTCL approval, a comprehensive Quality Assurance Plan using ISO 9000 as a
general guideline. In addition, the Quality Assurance Plan shall satisfy the following:
(d) The inspection rights described above shall also apply to sub Contractors
who are responsible for supplying major components described in this
Specification. These items shall be inspected and tested at the sub
Contractor's factory by the MPPTCL's representatives prior to shipping this
equipment to the Contractor's facility or directly to the MPPTCL.
(e) The above inspection rights shall also apply to sub Contractors supplying
assemblies, subassemblies and components. However, such items will
normally be inspected and tested by the MPPTCL's representatives at the
Contractor's site before acceptance.
Test plans and test procedures for both factory and site acceptance tests shall be
provided by the Contractor. Test plans and test procedures shall ensure that each
factory and site test is comprehensive and verify all the features of the equipment
to be tested. Test plans and test procedures shall be modular to allow individual
test segments to be repeated upon request.
The Contractor shall submit a Test Schedule for the MPPTCL's approval within one
(1) week after the award of contract for Type Tests and three (3) months after the
award of contract for all other tests. The test schedule shall list the tests to be
carried out, and the approximate test duration. The test periods shall also be
indicated in the PERT chart or equivalent for the work.
The Contractor shall give the MPPTCL twenty one (21) days written notice of any
material being ready for testing. Fifteen days prior to the scheduled testing, the
MPPTCL shall provide written notice to the Contractor of any drawings, equipment,
material, or workmanship which, in the MPPTCL’s opinion, are not compliant to the
specification. The Contractor shall give due consideration to such objections, if
valid, effecting the corrections as necessary or shall prove, in writing, that said
modifications are unnecessary for contract compliance.
A test plan for factory and site acceptance tests shall be submitted for approval, at
least four (4) weeks before the start of testing. The test plan shall be a single
overview document that defines the overall schedule and individual responsibilities
associated with conducting the tests, documenting the test results, and successfully
completing the test criteria. Test Plans shall include, at a minimum, the information
contained in Table (I-a)
Table (I-a)
Factory & field Test Plan Requirements
Item: Description:
1. Test schedule
Test procedures for factory and site testing shall be submitted for the MPPTCL
approval at least four (4) weeks before each individual test. Fully approved test
procedures shall be submitted to the MPPTCL at least four weeks prior to the
commencement of testing. Testing shall not commence without approved test
procedures. At a minimum, test procedures shall include the items listed in Table(I-
b)……..
All test equipment and/or instruments shall bear calibration stickers indicating valid
calibration on and beyond the testing date. The time lapsed since last calibration
shall not exceed the test equipment/ jig manufacturer recommended calibration
interval or the interval recommended in the test lab’s internal quality procedures.
The Contractor shall ensure that all testing will be performed by qualified testing
personnel well experienced in performing such tests.
Table (I-b)…….
Test Procedure Requirements
Item: Description:
Complete and indexed records of all factory and site acceptance tests results shall
be maintained and provided to the MPPTCL by the Contractor in hardcopy. The
records shall be keyed to the steps enumerated in the test procedures. The minimal
items required in test records are described in Table(I-c)……..
Table(I-c)
Test Record Requirements
Item: Description:
All principle test records, test certificates and performance curves shall be supplied
for all tests carried out as proof of compliance with the specifications and/or each
and every specified test. These test certificates, records and performance curves
shall be supplied for all tests, whether or not they have been witnessed by the
MPPTCL within the specified duration after the completion of test. Information given
on such test certificates and curves shall be sufficient to identify the material or
equipment to which the certificates refer, and shall also bear the Contractor's
reference and heading.
Any item or component which fails to comply with the requirements of this
Specification in any respect, at any stage of manufacture, test, erection or on
completion at site may be rejected by the MPPTCL either in whole or part as
considered necessary.
Material or components with defects of such a nature that do not meet the
requirements of the Specification by adjustment or modification shall be replaced
by the Contractor at his own expense. After adjustment or modification, the
Contractor shall submit the items to the MPPTCL for further inspection and/or tests.
3. Type Testing
"Type Tests" shall be defined as those tests which are to be carried out to prove the
design, process of manufacture and general conformity of the materials to this
Specification. Type Testing shall comply with the following:
(a) All cable & equipment being supplied shall conform to type tests as per
technical specification.
(b) These type/ special tests should have been conducted within last
five years. In case the type/ special test was carried out earlier
than five years, the manufacturer will have to conduct these
tests before commencement of supply. In both the above cases
type/ special test certificate must be submitted with the offer.
(c) The Contractor shall submit, within 30 days of Contract Award, copies of
test reports for all of the Type Tests that are specified in the
specifications and that have previously ( before Contract award) been
performed. These reports may be accepted by the MPPTCL only if they
apply to materials and equipment that are essentially identical to those
due to be delivered under the Contract and only if test procedures and
parameter values are identical to those specified in this specifications
carried out at accredited labs and witnessed by third party / customer’s
representatives.
In the event of any discrepancy in the test reports or any type tests not
carried out, same shall be carried out by Contractor without any
additional cost implication to the MPPTCL.
(e) The Contractor shall provide a detailed schedule for performing all
specified type tests. These tests shall be performed in the presence of a
representative of the MPPTCL.
(f) The Contractor shall ensure that all type tests can be completed within
the time schedule offered in his Technical Proposal.
(g) In case of failure during any type test, the Supplier is either required to
manufacture a fresh sample lot and repeat all type tests successfully or
repeat that particular type test(s) at least three times successfully on
the samples selected from the already manufactured lot at his own
expenses. In case a fresh lot is manufactured for testing then the lot
already manufactured shall be rejected.
The Contractor shall supply equipment/material for sample selection only after the
Quality Assurance Plan has been approved by the MPPTCL. The sample material
shall be manufactured strictly in accordance with the approved Quality Assurance
Plan. The Contractor shall submit for MPPTCL approval, the type test sample
selection procedure. The selection process for conducting the type tests shall
ensure that samples are selected at random. At least three samples of each of the
proposed equipment/item/cable drum except FO cable installation hardware &
fittings shall be offered for selection. For FO cable installation hardware & fittings at
least ten (10) samples shall be offered for selection.
The type tests listed below in table(I-d) shall be conducted on DWSM fibres to be
supplied as part of overhead cables. The tests specific to the cable type are listed in
subsequent sections.
Table (I-d)
Type Tests For Optical Fibres
-End Of table-
The type tests to be conducted on the OPGW cable are listed in Table(I-e) Type
Tests for OPGW Cables. Unless specified otherwise in the technical specifications or
the referenced standards, the optical attenuation of the specimen, measured during
or after the test as applicable, shall not increase by more than 0.05 dB/Km.
Table (I-e)
Type tests for OPGW Cable
Table (I-e)
Type tests for OPGW Cable
-End Of Table-
The type tests to be conducted on the OPGW Cable fittings and accessories are
listed below:
Suspension Assembly
The armour rods /reinforcement rods are assembled on to the approved OPGW
using the Installation Instructions to check that the assembly is correctly fitted and
is the same that will be carried out during installations.
Part 1:
between the cable, the Suspension Assembly and the horizontal shall not exceed
16o. This load shall then be removed in a controlled manner and the Protection
Splice disassembled. Examination of all the components shall be made and any
evidence of visual deformation shall be documented.
Part 2:
The Suspension clamp shall then be placed in the testing machine. The tensile
load shall gradually be increased up to 50% of the specified Minimum Failure Load
of the Suspension Assembly and held for one minute for the Test Rig to stabilise
and the load shall be further increased at a steady rate until the specified minimum
Failure Load is reached and held for one minute. No fracture should occur during
this period. The applied load shall then be increased until the failing load is reached
and the value shall be documented.
Tension Assembly
The Tension Assembly is correctly fitted and is the same that will be carried out
during installations.
Part 1:
Part 2:
- No evidence of Fracture at the end of one minute at the minimum failure load
during Part 2 of the Test.
Acceptance Criteria:
The Suspension Clamp has passed the Slip Test if the following conditions are met:
Slippage shall occur between the specified maximum and minimum slip load of
12 - 17 kN.
There shall be no slippage of the Reinforcing Rods over the cable, and no
slippage of the Armour Rods over the Reinforcing Rods.
The relative movement (i.e. more than 2 mm between Armour Rods & Clamp
body) between minimum 12 kN and maximum slip 17 kN, shall be considered
as slip.
The Armour Rods shall not be displaced from their original lay or damaged**.
Tension clamps shall be fitted on a 8 m length of fibre optic cable on both ends. The
assembly shall be mounted on a tensile testing machine and anchored in a manner
similar to the arrangement to be used in service. A tensile load shall gradually be
applied up to 20 % of the UTS of OPGW. Displacement transducers shall be
installed to measure the relative movement between the OPGW relative to the
Reinforcing Rods and Tension Dead -End relative to Reinforcing Rods. In addition,
suitable marking shall be made on the OPGW and Dead-End to confirm grip. The
load shall be gradually increased at a constant rate up to 50 % of the UTS and the
position scale of the recorder is zeroed. The load shall then gradually increased up
to 95 % of the UTS and maintained for one minute. After one minute pause, the
load shall be slowly released to zero and the marking examined and measured for
any relative movement.
Acceptance Criteria:
- No movement* shall occur between the OPGW and the Reinforcing Rods, or
between the Reinforcing Rods and the Dead-End assembly.
For structure mounting clamp, one series of tests shall be conducted with two fibre
optic cables installed, one series of tests with one fibre optic cable installed in one
groove, and one series of tests with one fibre optic cable in the other groove. Each
clamp shall be installed including clamping compound as required on the fibre optic
cable. The nut shall be tightened on to the bolt by using torque wrench with a
torque of 5.5 kgm or supplier's recommended torque and the tightened clamp shall
be held for 10 minutes. After the test remove the fibre optic cable and examine all
its components for distortion, crushing or breaking. Also the fibre optic cable shall
be checked to ensure free movement within the core using dial callipers to measure
the diameter of the core tube. The material shall be defined as failed if any visible
distortion, crushing, cracking or breaking of the core tube is observed or the fibre
optic cable within the core tube is not free to move, or when the diameter of the
core tube as measured at any location in the clamped area is more than 0.5 mm
larger or smaller of the core diameter as measured outside the clamped area.
The clamp and mounting assembly shall be assembled on a vertical 200 mm x 200
mm angle and a short length of fibre optic cable installed. A vertical load of 200 kg
shall be applied at the end of the mounting clamp and held for 5 minutes.
Subsequently, the load shall be increased to 400 kg and held for 30 seconds. Any
visible distortion, slipping or breaking of any component of the mounting clamp or
assembly shall constitute failure.
The damper shall be mounted with its clamp tightened with torque recommended
by the manufacturer on shaker table capable of simulating sinusoidal vibrations for
Critical Aeolian Vibration frequency band ranging from 0.18/d to 1.4/d – where d is
the OPGW cable diameter in meters. The damper assembly shall be vibrated
vertically with a ±1 mm amplitude from 5 to 15 Hz frequency and beyond 15 Hz at
0.5 mm to determine following characteristics with the help of suitable recording
instruments.
The Force Vs frequency curve shall not show steep peaks at resonance frequencies
and deep troughs between the resonance frequencies. The resonance frequencies
shall be suitably spread within the Aeolian vibration frequency-band between the
lower and upper dangerous frequency limits determined by the vibration analysis of
fibre optic cable without dampers.
(v) If the above curve lies within the envelope, the damper design shall be
considered to have successfully met the requirement.
(vi) Visual resonance frequencies of each mass of damper is to be recorded
and to be compared with the guaranteed values.
The vibration analysis of the fibre optic cable shall be done with and without
damper installed on the span. The vibration analysis shall be done on a digital
computer using energy balance approach. The following parameters shall be taken
into account for the purpose of analysis.
(i) The analysis shall be done for single fibre optic cable without armour
rods. The tension shall be taken as 25% of UTS of fibre optic cable for
a span ranging from 100 m to 1100 m.
(ii) The self damping factor and flexural stiffness (EI) for fibre optic cable
shall be calculated on the basis of experimental results. The details to
experimental analysis with these data shall be furnished.
(iii) The power dissipation curve obtained from Damper Characteristics Test
shall be used for analysis with damper.
(iv) Examine the Aeolian Vibration level of the fibre optic cable with and
without vibration damper installed at the recommended location or
wind velocity ranging from 0 to 30 Km per hour, predicting amplitude,
frequency and vibration energy input.
(v) From vibration analysis of fibre optic cable without damper, antinode
vibration amplitude and dynamic strain levels at clamped span
extremities as well as antinodes shall be examined and thus lower and
upper dangerous frequency limits between which the Aeolian vibration
levels exceed the specified limits shall be determined.
(vi) From vibration analysis of fibre optic cable with damper(s) installed at
the recommended location, the dynamic strain level at the clamped
span extremities, damper attachment point and the antinodes on the
fibre optic cable shall be determined. In addition to above damper
clamp vibration amplitude and antinodes vibration amplitudes shall
also be examined.
Constant tension shall be maintained within the span by means of lever arm
arrangement. After the fibre optic cable has been tensioned, clamps shall be
installed to support the fibre optic cable at both ends and thus influence of
connecting hardware fittings are eliminated from the free span. The clamps shall
not be used for holding the tension on the fibre optic cable. There shall be no
loose parts, such as suspension clamps, U bolts, on the test span supported
between clamps mentioned above. The span shall be equipped with vibration
inducing equipment suitable for producing steady standing vibration. The
inducing equipment shall have facilities for step less speed control as well as step
less amplitude arrangement. Equipment shall be available for measuring the
frequency, cumulative number of cycles and amplitude of vibration at any point
along the span.
Visual examination & Dimensional IEC 61897 Clause 7.1 & 7.2
1
and material verification
2 Clamp Slip test IEC 61897 Clause 7.5
FO cable is installed in the splice enclosure and optical fibres spliced and looped.
The box must be subjected to 5 cycles of temperature variations of -40C to +65C
with a dwell time of at least 2 hours on each extreme.
Fibre loop attenuation shall be measured in accordance with EIA 455-20 / IEC
60794-1-C10. The variation in attenuation shall be less than ±0.05dB. The final
humidity level, inside the box, shall not exceed the initial level, at the closing of the
box.
The sealed splice enclosure, with fibres spliced and looped inside, must be
subjected to a temperature of +55C ±2C with a relative humidity rate of between
90% and 95% for 5 days. The attenuation variation of the fibres during the
duration of the test shall be less than ±0.05dB, and the internal humidity rate
measured, less than 2%.
The splice enclosure with optical fibres cable installed and fibres spliced fixed, shall
be immersed in water for 24 hours. No water seepage or moisture shall be
detected in the splice enclosure. The attenuation variation of the fibres after the
test shall be less than ±0.05dB.
The splice enclosure, with fibres united inside, shall be subjected to vibrations on
two axes with a frequency scanning of 5 to 50 Hz. The amplitude of the vibrations
shall be constant at 0.450mm, peak to peak, for 2 hours, for each of the vibrations'
axes. The variation in attenuation, of the fibres, shall be less than ±0.05dB. The
splice enclosure shall be examined for any defects or deformation. There shall be no
loosening or visible damage of the FO cable at the entry point.
The splice enclosure, with fibres spliced inside, shall be firmly held in place and be
subjected to the following sequence of mechanical stresses on the cable:
a) 3 torsion cycles of ±180 shall be exercised on the cable. Each cycle shall be
less than one minute.
b) 3 flexure cycles of the cable, of ±180 with one cycle less than one minute.
The variation in the attenuation, of the fibres, shall be less than ±0.05dB. The
cables connection ring shall remain securely fixed to the box with the
connection maintained firmly. No defects/fissures shall be noted on the joint
ring or on the splice enclosure
The splice enclosure with cable fixed to the boxes shall be subjected to a minimum
tension of 448 N for a period of two minutes. No fissure shall be noted in the
connections or on the box.
With 2 lengths of 11 metres of cable fixed to the box, it shall be dropped five times
from a height of 10 metres. There shall be no fissure, at all, of the box, and the
connections shall remain tight. The test surface shall be carried out in accordance
with IEC 60068-2-32.
The type tests to be conducted on the Fibre Optic Approach cable are listed in
table(I-f):Type Tests for Fibre Optic Approach Cable. Unless specified otherwise in
the technical specifications or the referenced standards, the optical attenuation of
the specimen, measured during or after the test as applicable, shall not increase by
more than 0.05 dB/Km.
Table(I-f)::
Type Tests Fibre Optic Approach Cable
S.NO. Test Name Test Procedure
1 Water Ingress Test (IEC 60794-1-F5 /
EIA 455-82B) Test duration : 24 hours
2 Seepage of filling (EIA 455-81A)
compound Preconditioning : 72 hours,
Test duration : 24 hours.
3 Crush Test (IEC 60794-1-E3/ EIA 455-41)
4 Impact Test (IEC-60794-1-E4/ EIA 455-25A)
5 Stress strain Test (EIA 455-33A)
6 Cable Cut-off (EIA 455-170)
wavelength Test
7 Temperature (IEC60794-1-F1/EIA-455-3A) – 2 cycles
Cycling Test
-End Of Table-
The factory acceptance test shall demonstrate the technical characteristics of the
equipment in relation to this specifications and approved drawings and documents.
List of factory acceptance tests for Fibre Optic Transmission system, Termination
Equipment Sub-system , NMS are given in specified Tables in this section. This list
of factory acceptance tests shall be supplemented by the Contractor's standard FAT
testing program. The factory acceptance tests for the other items shall be proposed
by the Contractor in accordance with technical specifications and Contractor's
(including Sub-Contractor's / supplier's) standard FAT testing program. In general
the FAT for other items shall include at least: Physical verification, demonstration of
technical characteristics, various operational modes, functional interfaces, alarms
and diagnostics etc.
For Test equipment & clock, FAT shall include supply of proper calibration
certificates, demonstration of satisfactory performance, evidence of correct
equipment configuration and manufacturer’s final inspection certificate/ report.
3.2.7.1 Sampling for FAT
From each batch of equipment presented by the Contractor for Factory acceptance
testing, the MPPTCL shall select random sample(s) to be tested for acceptance.
Unless otherwise agreed, all required FAT tests in the approved FAT procedures,
shall be performed on all samples. The Sampling rate for the Factory acceptance
tests shall be minimum 10% of the batch size (minimum 1) for all items. The
physical verification shall be carried out on 100% of the offered quantities as per
the approved FAT procedure. In case any of the selected samples fail, the failed
sample is rejected and additional 20% samples shall be selected randomly and
tested. In case any sample from the additional 20% also fails the entire batch may
be rejected. In case a number of equipments are required for demonstration of the
performance of any equipment during FAT, the sample size shall be taken as that
number of equipments which are necessary to demonstrate the performance,
irrespective of the percentage.
For the OPGW cable hardware fittings & accessories, the minimum sampling rate,
and batch acceptance criteria shall be as defined in IS 2486.
The Sampling rate for the Factory acceptance tests shall be 10% of the batch size
(minimum 2) for FO cable drums, FODPs, Joint box and other similar items.
Since FAT testing provides a measure of assurance that the Quality Control
objectives are being met during all phases of production, the MPPTCL reserves the
right to require the Contractor to investigate and report on the cause of FAT failures
and to suspend further testing/ approvals until such a report is made and remedial
actions taken, as applicable.
3.2.7.2 Factory Acceptance Tests on Optical Fibre to be supplied with
OPGW
The factory acceptance tests listed in table below are applicable for the Optical
fibres to be supplied. The listed tests follow testing requirements set forth in IEEE
standard 1138, 1994 section 4.2.2.1 and section 5.2.2.1. The referenced sections
specify the detailed test description. The acceptance norm shall be as specified in
the above mentioned IEEE standards unless specified otherwise in the technical
specifications.
Table (I-g):
Factory Acceptance Tests for Optical Fibres: Optical Tests
The test report for the above tests for the fibers carried out by the Fiber
Manufacturer and used in the OPGW cables shall be shown to the inspector during
OPGW cable FAT and shall be submitted along with the OPGW cable FAT report.
The factory acceptance tests for OPGW cable specified below in Table follow the
requirements set forth in IEEE standard 1138 / IEC 60794. The FAT shall be carried
out on 10% of offered drums in each lot as specified in technical specifications and
the optical tests shall be carried out in all fibres of the selected sample drums. The
Rated Tensile Strength test shall be carried out on one sample in each lot.
Table (I-h):
Factory Acceptance Tests on OPGW
Applicable standard: IEEE 1138 / IEC 60794
Table (I-h):
Factory Acceptance Tests on OPGW
Applicable standard: IEEE 1138 / IEC 60794
The factory acceptance tests for OPGW Fittings as specified below in Table 7-16.
The sampling plan shall be as per relevant standard:
Table ((I-i):
The factory acceptance tests for Approach Cable specified below in Table-(I-j):
Table(I-j):
Factory Acceptance Tests On Approach Cable
S. Factory Acceptance Test
No.
1 Attenuation Co-efficient at 1310 nm and 1550 nm
2 Point discontinuities of attenuation
3 Visual Material verification and dimensional checks as per
approved DRS/Drawings
Table (I-k)
The Contractor shall be responsible for the submission of all equipment & test
equipment supplied in this contract for site tests and inspection as required by the
MPPTCL. All equipment shall be tested on site under the conditions in which it will
normally operate.
The tests shall be exhaustive and shall demonstrate that the overall performance of
the contract works satisfies every requirement specified. At a minimum Site
Acceptance Testing requirement for FO cable.
During the course of installation, the MPPTCL shall have full access for inspection
and verification of the progress of the work and for checking workmanship and
accuracy, as may be required. On completion of the work prior to commissioning,
all equipment shall be tested to the satisfaction of the MPPTCL to demonstrate that
it is entirely suitable for commercial operation.
Prior to installation, every spooled fibre optic cable segment shall be tested for
compliance with the Pre-shipment data previously received from the manufacturer.
This requirement will preclude the installation of out of specification cable segments
that may have been damaged during shipment.
SAT shall be carried out link by link from FODP to FODP. SAT may be performed in
parts in case of long links.
The tests, checks, adjustments etc conducted by the Contractor prior to offering the
equipment for SAT shall be called Pre-SAT activities. The Pre-SAT activities shall be
described in the installation manuals and Field Quality Plan documents.
Sag and tension of OPGW shall generally be as per approved sag-tension chart and
during installation, sag and tension of OPGW shall be documented. Upon completion
of a continuous cable path, all fibres within the cable path shall be demonstrated for
acceptance of the cable path. Fibre Optic cable site testing minimum requirements
are provided in Table (I-l) through (I-n) below:
Table(I-l)
Fibre Optic Cable Pre-Installation Testing
Item: Description:
1. Physical Inspection of the cable assembly for damage
2. Optical fibre continuity and fibre attenuation with OTDR at 1550 nm
3. Fibre Optic Cable length measurement using OTDR
Table (I-m)
Fibre Optic Cable Splicing Testing
Item: Description:
Table (I-n)
Item: Description:
-End of Table-
5.1 To ensure that the equipment and services under the scope of this
Contract, whether manufactured or performed within the Contractor’s Works
or at his Sub-Contractor’s premises or at the MPPTCL’s site or at any other
place of Work as applicable, are in accordance with the specifications, the
Contractor shall ensure suitable quality assurance programme to control
such activities at all points necessary. A quality assurance programme of
the Contractor shall be in line with ISO requirements & shall generally cover
the following :
g) Inspection and test procedure both for manufacture and field activities.
n) A quality plan detailing out the specific quality control measures and
procedure adopted for controlling the quality characteristics relevant to
each item of equipment furnished and /or service rendered.
o) System for various field activities i.e. unloading, receipt at site, proper
storage, erection, testing and commissioning of various equipment and
maintenance of records. In this regard, the MPPTCL has already
prepared Standard Field Quality Plan for transmission line/substation
equipments as applicable, Civil/erection Works which is required to be
followed for associated works.
Annexure-II
Note:
* MICC for test and measuring equipment shall be issued only after
actual verification/demonstration of satisfactory performance at site.
** Though level-2 items, CIP can be issued also on review of TCs and
visual inspection of these items.
Appendix - II
1. General
a) Condition of existing ground wire for its suitability for live-line OPGW
installation.
2. Safety measures
All site workers must follow the Electricity Rules and MPPTCL specified
safety procedures. They must use safety belts, safety shoe, safety helmet
and other safety items required.
a) Safety Engineer has to make sure the availability of First Aid Box with
each team.
The pictorial view of the working zone and limitation of the restricted zone
are shown below for your convenience.
Working Area
MPPTCL/Te
53
Working Area
3. Grounding
Equipment like OPGW and Existing Ground wire (GW), Pulley Blocks are
connected with individual copper cable attached to the tower (with copper
rod installed on the ground) or to the main grid if grounding system exists.
Grounding clamp shall be cleaned well and ensure proper contact.
54
Running ground shall be installed on the OPGW at drum side during OPGW
stringing time and at the Winch side on the existing GW during
dismantling time for the whole stringing operation to avoid any electrical
charges of induction from the line.
Grounding cable must be connected to the ground source first then to the
object that needed to be grounded.
When removing grounds, the ground must be removed from the grounded
objects first and then remove the grounding clamp from the ground
source.
55
In case of any problems during the installation work, the person in charge
of the section will immediately contact sub-station in charge of the line
and MPPTCL immediately for required support.
Packing condition
Packing list (Object, Type, Length, OPGW Weight, Drum No. etc)
Attenuation results of OPGW
Handling of OPGW:
OPGW contains optical fibers which are very delicate and to be handled
with due care. For the safety of optical fibers, it is very important to avoid
the bending at sharp angle. Manufacturer guidelines are to be followed
strictly while handling the same.
56
5. Clearance Checking
5.1 Check the clearance between existing ground-wire and live conductor
before Stringing. Check the clearance between OPGW and live conductor.
57
6. OPGW Stringing
Hang the pulley blocks on one of the earth wire peaks for the whole
section (Section is a consecutive group of towers needed to support
the installation of scheduled length of OPGW Drum)
7. Dismantling process
7.1 Existing ground wire:
Connect the existing ground wire with the Pulling Rope.
Pull the Pulling Rope with winch to dismantle the ground wire.
59
Set the Breaking Machine on the OPGW of the span required for
dismantling.
Connect the Pulling Rope and Setting Rope to the Braking Machine.
Pull the Setting Rope and Pulling Rope to dismantle.
Collect and dismantle the hanging pulley blocks upon reaching the
succeeding tower.
8. OPGW sagging
8.1 Sagging:
1) Methods and procedures for sagging of OPGW are the same as those of
normal overhead ground wire.
4) OPGW tension between each sag section shall be equalized and this
shall be determined by the vertical position of the suspension clamps on
the last clipped structure of the preceding sag section.
7) Waterproof caps shall be fixed at both ends of the OPGW cable after
installation.
9. OPGW Clamping
9.1 Make sure to install and tighten the bolt of clamp properly.
10.1 Make sure to clip the OPGW with down lead clamp to the tower in a
careful manner.
Appendix - III
1. General
Rain or snow
Foggy
Lightening
2. Safety measures
All site workers must follow the Electricity Rules and MPPTCL specified
safety procedures. They must use safety belts, safety shoe, safety helmet
and other safety items required.
a) Safety Engineer has to make sure the availability of First Aid Box with
each team.
Packing condition
Packing list (Object, Type, Length, OPGW Weight, Drum No. etc)
Attenuation results of OPGW
Handling of OPGW:
OPGW contains optical fibers which are very delicate and to be handled
with due care. For the safety of optical fibers, it is very important to avoid
the bending at sharp angle. Manufacturer guidelines are to be followed
strictly while handling the same.
4. OPGW Stringing
Hang the pulley blocks on one of the earth wire peaks for the whole
section (Section is a consecutive group of towers needed to support the
installation of scheduled length of OPGW Drum)
Carry out paying of pilot wire for entire section and connect the same
with OPGW on drum side and winch machine on other side suitably.
Pull the Pilot Wire with the use of winch machine to pay out the OPGW.
Set the Come-along and Lever Block to the OPGW. With this OPGW
paying for a section gets completed.
67
5. OPGW sagging
5.1 Sagging
1) Methods and procedures for sagging of OPGW are the same as those
of normal overhead ground wire.
4) OPGW tension between each sag section shall be equalized and this
shall be determined by the vertical position of the suspension clamps
on the last clipped structure of the preceding sag section.
7) Waterproof caps shall be fixed at both ends of the OPGW cable after
installation.
68
6. OPGW Clamping
6.1 Make sure to install and tighten the bolt of clamp properly.
7.1 Make sure to clip the OPGW with down lead clamp to the tower in a
careful manner.
7.2 Make sure to tighten the bolt of down-lead clamp properly.
7.3 Install the down-lead clamp at appropriate interval .
70
Appendix -IV
1. General
OPGW based Fibre Optic network being established by Power Utilities for
catering data & voice communication requirements. OPGW is being supplied
in number of drums for a link and required splicing for completing of a fibre
optic link. Generally fusion method is being used for splicing of fibres in cable.
For carrying out splicing work, experienced personnel is essential for handling
splicing kit and necessary instruments such as OTDR etc.
a) Jointing of OPGW is usually carried out on the ground. For ease of jointing
with accuracy, adequate space (with tent) to be ensured on the ground for
jointer and equipment. This floor space should be protected against the
heavy wind, strong sunshine, high temperature, rain and dusty
atmosphere.
A. Jointing In charge -1
(i) Lineman – 1
(ii) Jointer & Tester – 1
(iii) Unskilled labor -1
(i) Lineman- 1
(ii) Jointer & Tester – 1
(iii) Unskilled labor -1
Optical fibre are joined by using Fusion splicing. It is the process of fusing or
welding two fibers together usually by an electric arc. Fusion splicing is the
most widely used method of splicing as it provides for the lowest loss and
least reflectance, as well as providing the strongest and most reliable joint
between two fibers.
72
Inspection
(Using OTDR) Inspect fibers
If no good
Splicing of optical
If no good
Sealing and closing of the joint box
End
73
Jointing works
It may be ensured that all the materials, tools and equipment listed in the
Table-1 are available. The Table-1 shows tentative list of required tools &
material.
70mm
930mm
Central Tube(Al/Steel)
Wires
Metallic String
Notch the Strand wires of the OPGW with a hacksaw to the depth of 1/3 or
1/2 of the Strand wire diameter. In this case, take care not to damage the
inside Central Tube (AL/Steel) of the OPGW.
Loose the Strand wires from the OPGW ends one by one and snap them off at
the notched position.
90mm
840mm
CentralTube(Al/Steel)
Strands
Metallic String Optical Unit
74
Knife 1
Pliers 2
Hexagon wrench 1
Engine Generator(If 1
Power Supply
need)
OTDR 1
Electric reel 1
1
Electric Cord
75
Insert OPGW in the passcable until OPGW touch the internal clamping or until
the Central Tube (AL/Steel) is outside from the passcable of about 90 mm.
Lock the moving clamping with torque force of 12 NM, like a Figure 5.
O-Ring Separator
Preroom
Passcable
Gear
Moving Clamp
Metallic String
Fig. 4
Moving Clamp
Fig. 5
76
Cover the Central Tube (AL/Steel) with aluminium sheet and put the thermo-
shrinkable tube with heating gun or lamp, like a Figure 6.
Thermo-shrinkable Tube
Fig. 6
Preroom
Fig. 7
Give attention that the O-ring is in the right position and fix with the torque
force of 50 NM
77
Remove the PBT tube of optical units leaving a suitable distance(around 1m)
from the edge of the AL tube.
Make each optical unit into loops of about 5 to 10 cm diameter, and stick
these optical unit loops at a suitable position on the joint box with plastic
adhesive tape in order to ensure that the optical unit is not damaged during
splicing work.
Cleave length
Remove the fiber coating. Clean the fiber and then cleave the bare fiber to
the predetermined length. Slip a protection sleeve over one of the two fibers
for reinforcement after splicing. Set the prepared fiber in the v grooves as
shown in the figure below.
Clamp the prepared fiber exactly by pushing the clamp lever. After clamping
the right and left fibers, close the hood. Make sure that the prepared fiber is
not trapped by the hood, and not caught by any other part of the machine.
78
The evaluation of the splicing should be done by the splicing loss and the
external appearance at the splice point.
(*) In the case where fluorine doped fiber is splicer, a black line will always
appear at the splicing point, but does not cause any damage to the
characteristics of the optical transmission.
(2) The following splices are acceptable, even if the external appearance at
the splice point does not look good.
79
(I) Open the heater cover, the left fiber clamp and right fiber clamp
(II) Open the hood, take out the spliced portion, close the hood, and press
the “RESET” SW.
80
Fig. 5
Note
Make sure fiber coating is clean.
Put the sleeve over the splice as shown in Fig. 5.
Don’t twist the fiber.
Protection sleeve should be straight.
(IV) Apply a slight tension and place the splice in the heater, close the right
hand heater clamp by pressing down with the right hand fiber.
(V) Next, close the left hand heater clamp while pulling the fiber slightly,
and close the heater cover.
Note
Fiber should be straight.
Make sure that there is no dust, or jelly in the protection sleeve.
(VI) Press the “HEATER SET” SW, and the “working” indicator will light up.
81
Fig. 5
(VII) After the tensile proof test (a few seconds), it will take a few minutes
until the fiber protection sleeve is shrunk. A buzzer will indicate the
finishing of shrinking the sleeve.
If the fiber breaks, or the fiber is loosely clamped or slips during the
tensile proof test, the buzzer will beep intermittently. Correct the
condition before proceeding.
Note 1
Note 2
The tensile proof strength can be set from 50 to 500 grams. This value
is set to 200 grams normally.
Take out the protected splice carefully while pulling the fiber slightly.
Cool the protection sleeve for a few minutes, as it is very hot just after
reinforcement.
Bending
The loose tube should be dressed up while closing joint box so that it is
protected against impact, corrosion and bend.
The loop diameter of loose tube is more than 50mm.
The spliced portion of optical fiber should be put in regular order in the
fusion splice protector, and the extra length of optical fiber should be put
on the splice tray.
OPGW
OTDR
- Before closing the splice enclosure, splice loss shall be measured for
checking the splicing condition.
OPGW
Direction A Direction B
Joint Box
- Before closing the in-line splice enclosure, the splice test shall be
executed at both sides (direction A & direction B) of jointing point.
Every effort shall be taken to minimize the splice loss during splicing so
that every splice loss in the link shall lies within o.o5 dB. Maximum
splice loss at any splice joint may be permitted up to 0.1 dB.
However, such events shall be avoided to minimize the splice loss and
total loss in the link.
Control Room
Control Room
P1: Power measured when light source is connected to power meter with the
OPGW fibre in between.
P2: Power measured when light source and power meter are connected to
one another with reference fibre in between.
85
Control Room
Control Room
Light source Power meter
(Power (Light
Approach cable
(P1) P1
Lip
Fig. 6
86
SPLICING TOWER
Check Point
Check the status of water proof.
Fusion splice working is protection it against dirt, grit and moisture.
Lift the joint box using the eye bolt of lid.
Fixing condition of joint box on the tower.
Coiling condition of sur-plus(balanced) length of OPGW
87
In case the offered make/model of test equipment has multiple options for the
parameters, the
option of higher range shall be acceptable. The supplied test equipment shall be
suitable for
use in the high EMI/EMC environment. The Contractor shall submit performance
88
certificate
for offered test equipment from at least one customer. The Contractor shall offer
only reputed
make test equipment such as Acterna (JDSU)/Anritsu/Sumitomo/Agilent/EXFO etc.
89
DRS Form 1(a)
Manufacturer:
Part #:
Configuration:
CABLE CONSTRUCTION
OPTICAL PARAMETERS
As per Technical As per Bidder
Seq Parameter: Specification offering
1. Fiber
manufacturer(s)/Type:
≤ 0.35 dB/km
2. Attenuation Coefficient@ 131 ≤ 0.21 dB/km
@ 1550 nm:
≤ 0.05 dB
3. Point discontinuity @ ≤ 0.05 dB
1310nm:
@
1550nm:
5. Chromatic Dispersion
Coefficient 3.5 ps/(nmxkm)
@ 1310 (1288-1339) nm: 5.3 ps/(nmxkm)
@ 1310 (1271-1360) nm: 18 ps/(nmxkm)
@ 1550 nm:
1300 to 1324 nm
6. Zero dispersion
wavelength:
Cutoff wavelength: ≤ 1260 nm
7.
Physical and Mechanical Properties
8. Bend Performance:
(37.5 mm radius, 100 ≤ 0.05 dB
turns) @1310 nm
(30 mm radius, 100 turn)
@1550 nm ≤ 0.05 dB
(16mm radius, 1 turn) @
1550nm ≤ 0.50 dB
9. 125.0 µm ± 1 µm
Cladding Diameter
(nominal ± deviation)
10. Polarisation mode ≤ 0.2 ps/km1/2
dispersion coefficient
11. Proof test level ≥ 0.69 Gpa
91
DRS Form 1
Manufacturer:
Part #:
CABLE CONSTRUCTION
Seq Parameter: Unit: Particulars:
1 Fibre Manufacturer
Dual Window Single-Mode:
2 No. of Fibres
Dual Window Single-Mode: each
3 Buffer Type:
4 Buffer Tube Diameter: mm
5 Buffer Tube material
6 No. of Buffer Tubes: each
7 No. of Fibers per Tube: each
8 Identification/numbering of individual
tubes:
9 No. of empty tubes (If any): each
10 Filling material:
11 Filling material compliant with
technical specifications? Yes/No
12. Strength member(s):
13. Binding yarn/ tape:
Describe Central Core Design:
14
92
47. Describe cable end capping and protection against abrasion etc.:
95
INSTALLATION
Seq Parameter: Unit: Particulars:
48. Splice Loss:
Maximum: dB
Average: dB
49. Operating Temperature Range: °C
50. Rated Isoceraunic No.
51. Expected Cable Life: Years
52. Installation rate per team: km/day
53. No. of persons per team: no.
54. Max. possible span for specified M
operating conditions:
55. Midspan sag at 0°C with no Mm
wind loading:
56. Midspan sag at max temp. with Mm
no wind loading:
57. Midspan sag at max temp. and Mm
wind loading
58. Cable swing angles:
Worst Case:
Everyday:
59 Describe Installation method(s):
Sag tension chart parameters like sag and tension at various spans and applicable wind and ice load conditions shall
be submitted along with the DRS. The cable parameters like coefficient of liner expansion, modulus of elasticity
shall also be indicated.
96
DRS Form 2
DATA REQUIREMENTS SHEETS for OPTICAL FIBRE
DUAL-WINDOW SINGLE MODE (DW-SM)
OPTICAL PARAMETERS
Seq Parameter: Unit: Particulars:
1. Fiber manufacturer(s)/Type:
2. Fiber production method:
3. Attenuation Coefficient@ 1310 nm: dB/km
@ 1550 nm: dB/km
4. Attenuation Variation with
Wavelength (±25 nm): dB/km
5. Attenuation at water peak: dB/km
6. Point discontinuity @ 1310nm: dB
@ 1550nm: dB
7. Temperature dependence (induced dB
attenuation):
8. Nominal Mode Field Diameter
@ 1310 nm: μm
@ 1550 nm:
9. Mode Field Diameter Deviation
@ 1310 nm: μm
@ 1550 nm:
10. Mode field non-circularity: %
11. Chromatic Dispersion Coefficient
@ 1310 (1288-1339) nm: Ps/nm.km
@ 1310 (1271-1360) nm:
@ 1550 nm:
12. Zero dispersion wavelength: nm
13. Zero dispersion Slope: ps/nm2.km
14. Cutoff wavelength: nm
15. Refractive Index:
16. Refractive Index profile:
17. Cladding Design:
18. Numerical aperture:
97
k) Overall length mm
Vibration Damper:
Manufacturer:
Part #:
1. Total Weight Kg
Weight of each Damper Kg
Material of Damper Weight
Clamp Material
Clamp bolt tightening torque Nm
Clamp bolt material
Messenger Cable Material
No. of Strands in Messenger Cable
Breaking Strength of Messenger Cable kN
Resonance Frequencies
a) First Frequency Hz
b) Second Frequency Hz
c) Third Frequency Hz
d) Forth Frequency Hz
Minimum Slip Strength of Damper Clamp
a) Before Fatigue Test kN
b) After fatigue Test kN
103
Manufacturer:
Part #:
Manufacturer:
Model #
Weight:
kg
Colour & Finish:
Method of mounting:
DRS Form 5
DATA REQUIREMENTS SHEETS for
Fibre Optic Distribution Panels (FODPs)
Manufacturer:
Model #
8. IP Protection Class
9. Total number of optical couplings: ea
10. Provision of pass through splicing: Yes/No
11. Whether filled with suitable encapsulant Yes/No
12. Method(s) for mounting
Optical Fibre Cable Accommodations
13. Cable Glanding:
14. Maximum number of cables that can be
accommodated: each
15. Diameter(s) of cables that can be
accommodated:
16.
Describe Cable entries:
106
Manufacturer:
Model #
Weight: kg
Colour & Finish:
Method of mounting:
DRS Form 6
DATA REQUIREMENTS SHEETS for
APPROACH CABLE
Manufacturer:
Part #:
CABLE CONSTRUCTION
Seq Parameter: Unit: Particulars:
1. Fibre Manufacturer
Dual Window Single-Mode:
2. No. of Fibres
Dual Window Single-Mode: each
3. Buffer Type:
4. Buffer Tube Diameter: mm
5. Buffer Tube material
6. No. of Buffer Tubes: each
7. No. of Fibers per Tube: each
8. Identification/numbering of individual
tubes:
9. No. of empty tubes (If any): each
10. Filling material:
11. Filling material compliant with
technical specifications? Yes/No
12. Strength member(s):
13. Binding yarn/ tape:
14. Describe Central Core Design:
108
- Continued -
109
44. Describe cable end capping and protection against abrasion etc.:
110
INSTALLATION
Seq Parameter: Unit: Particulars:
45. Splice Loss:
Maximum: dB
Average: dB
46. Operating Temperature Range: °C
47. Expected Cable Life: Years
48. Describe Installation method(s) and the cable duct parameters for installation of approach
cable:
111