BID DOCUMENT - Amazon AWS

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KERALA STATE ELECTRICITY BOARD LIMITED

TENDER No. CE(TS)/EE 2/28/HTLS/2018-19

RECONDUCTORING OF 5.97Km LONG 110KV POTHENCODE

– KAZHAKUTTOM DOUBLE CIRCUIT FEEDER WITH HTLS

(ACCC) CONDUCTOR AND 7/9 EARTH WIRE WITH OPGW

UNDER WORK DEPOSIT SCHEME UNDER TRANSMISSION

CIRCLE, THIRUVANANTHAPURAM

BID DOCUMENT

PART II

TECHNICAL SPECIFICATIONS

Sd/-Chief Engineer (Transmission South)

MAY – 2018

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CONTENTS

1. GENERAL INFORMATION AND SCOPE

2. DESIGN PARAMETERS

3. STANDARDS

4. STRANDING

5. PACKING AND MARKING

6. TESTS AND TEST CERTIFICATES

7. SILICON RUBBER HOUSED COMPOSITE INSULATORS

8. SERVICE CONDITIONS FOR COMPOSITE INSULATORS

9. SYSTEM PARTICULARS FOR THE UPRATED LINE

10. DESIGN AND MATERIAL REQUIREMENT OF INSULATORS

11. BALL AND SOCKET DESIGNATION

12. DIMENSIONAL TOLERANCE OF COMPOSITE INSULATORS

13. INTERCHANGEABILITY

14. CORONA AND RI PERFORMANCE

15. MARKINGS

16. INSPECTIONS, TESTS AND STANDARDS

17. SAMPLE TEST (ACCEPTANCE TEST)

18. ROUTINE TEST

19. ADDITIONAL TEST

20. TEST REPORT

21. GUARANTEED TECHNICAL PARTICULARS

22. SAG TENSION CHARTS AND SAG TEMPLATES

23. ACCESSORIES

24. EXECUTION OF WORK

25. STRINGING

26. FIELD QUALITY PLAN

27. WASTAGE

28. LOSSES

29. COMMISSIONING

30. STANDARDS AND SPECIFICATIONS

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1. GENERAL INFORMATION AND SCOPE

1.1 Scope

1. The KERALA STATE ELECTRICITY BOARD LIMITED invites e-tenders fromeligible bidders for designing, manufacturing, testing and supplying of HighTemperature Low Sag (HTLS) (ACCC) conductor with minimum currentcarrying capacity of 640 A and unit weight equal to or less than that ofACSR WOLF conductor and associated conductor hardware fittings,clamps, vibration dampers etc, stringing of the HTLS conductor onexisting transmission line structure and disc insulators of 110kVPothencode - Kazhakuttom double circuit feeders (route length 5.97 km)and 7/9 earth wire with OPGW after dismantling existing ACSR WOLFConductor, testing and commissioning of the transmission line andhanding over the line to KSEB Ltd. to the full satisfaction of KSEB Ltd onturnkey basis under work deposit scheme as defined in the Bid documentsreferred as “works.

2. Survey of existing line route, Preparation and submission of detailed technicalspecifications, Material specifications, GTP, GA drawings, Detailed engineeringdrawings, Sag Template, Sag Tension Chart, BOQ, standards list and erectionprocedures with respect to this contract as per standard specification of KSEBL,verification of availability of statutory electrical clearances, de-stringing of existingConductor including dismantling of associated fittings & accessories from the existingline and stringing of each circuit with HTLS conductor along with associated fittingsand accessories with the other circuit under live condition.

3. Shut down will be allowed from 7 AM to 4 PM on daily basis for the replacementwork. The contractor has to do the stringing within this interval so that line can becharged at 4 PM every day. However the normal shut down period for each workingday is eight hours.

4. ROW if any for execution of work & approach to work site shall be resolved by thecontractor at his cost. However, KSEBL will provide necessary assistance.

5. The existing conductor & insulators removed from the line is envisaged forreuse/utilization in other projects. Hence proper handling and safety of the conductorduring de-stringing, storage at site, measurement of conductor lengths, rewinding ondrums at site and safe transportation to KSEBL designated store shall be included in thescope of work.

6. The contractor shall arrange necessary training to KSEBL technical team comprisingEngineer, and lineman/workmen on stringing of HTLS conductors and its maintenance.

7. Necessary calculations shall be carried out by the contractor to ensure that whilecarrying out the work, loading on the towers due to conductor tension as well as loadson account of reconductoring activities shall be within specified limits. Thesecalculations shall be submitted by the bidder along with bid.

8. Complete technical details of the proposed HTLS conductor with relevant calculationshall be submitted along with the bid to adjudge the sufficiency of existing towers forcarrying out the up-rating works. This shall be carried out in compliance / adherence toall safety and standard requirements as per Central Electricity Authority (CEA)Regulations. Design parameters and submission of detailed drawings of conductor,hardware and accessories and preparation of sag tension chart, stringing chart of theconductor used, showing sag & tension at various temperatures are included in thescope of the Bidder.

9. Appropriate safety measures along with necessary safety tools and equipments to carryout the work including mechanical/ structural safety of the towers shall be theresponsibility of the contractor.

10. In order to reduce the weight on the towers all existing insulators shall be replaced withsuitable pack of silicon rubber composite insulators of 110kV level. The contractorshall supply the drawings and detailed technical specifications of these insulatorsbefore proceeding with procurement and supply of the same.

11. The entire stringing work of HTLS conductor shall be carried out by tension stringingtechnique except where geographical / topographical or other site constraints do not

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permit use of tension stringing equipments. In such cases manual stringing along withother appropriate tools and equipments may be employed with the approval of engineerin charge.

12. The bidder shall indicate in their offer, the sets of tension stringing equipment he ishaving in his possession and the sets of stringing equipment he would deployexclusively for this work. The contractor shall also engage sufficient manpower so thatstringing of the conductor in one stretch is complete within the allowed shut downperiod of one day. No mid-span joint will be allowed & hence the length of theconductor shall be decided by referring the tower details, as per Appendix I.

13. Bidder shall indicate whether any special tools are required other than conventionaltools being used for ACSR conductors for the hardware fittings of offered conductor. Ifso, the same may also be included in the scope of supply.

14. In the case of locations of important roads, river & rail crossings, if any, doubleinsulator strings have to be carried out. In such locations, double hardware fittings haveto be used. Vibration dampers are to be provided in all suspension & tension locations.In all suspension hardware fittings preformed armour rods are to be used.

15. The rollers which will be used during stringing should be so designed that the line canbe charged with the roller while stopping the work in the evening.

16. Design Engineer of manufacturer of the conductor shall be available at site, at the timeof stringing process.

17. Statutory clearances required from other Government departments shall be arranged bythe contractor. Necessary assistance will be provided by KSEBL for obtaining thesame.

18. Bidder shall furnish operating experience details and performance certificates of similarworks done in various other utilities in support of the offer submitted.

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2. DESIGN PARAMETERS

The design and other parameters of the existing transmission line are follows.

2.1 Climatic & Technical details. The climatic and system parameters are detailed below.

Location Thiruvananthapuram District, Kerala state

Voltage level 110kV

Frequency 50HZ

Maximum ambient temperature 40º C

Minimum ambient temperature 33º C

Solar Absorption coefficient 0.5

Solar Radiation 220.83Watt/sq.m

Emissivity Constant

Factor of safety

0.5

1. Maximum wind pressure on wire 52kgf/sqm

2. Maximum wind pressure on Tower 260kgf/sqm

3. Everyday temperature and no wind 4.57

Minimum temperature & 2/3rd max. wind 2

Everyday temperature & full wind 2

Minimum ground clearance at maximum temperature & no wind

6.1m

Maximum conductor sag 4.22meters for ruling span of259meters

Maximum relative humidity 97.00%

Average rainfall per year 3107mm ( approx.)

Isokeraunic level 100/year

Number of rainy days per year 130 days

Altitude Sea LevelTechnical parameters of the 110kV line

1. Electrical system data

i. Nominal voltage – 110 kV

ii. Maximum system voltage – 145 kV

iii. BIL(Impulse) – 515 kV(peak)

iv. Power frequency withstand voltage(wet) – 460 kV (rms)

v. Minimum corona extinction for dry condition- Voltage at 50 Hz ac system

Not less than 154kV phase to earth(rms)

vi. Radio Interference voltage - Not exceeding 1000 microvolt at 1MHz for 154 kV dry condition

2. Transmission lines- General Particulars

Route LengthVoltage (kV) Normal Span (m)

5.97 km (approx)110300

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Type of Towers D3,D30,D60,R,S

Insulators EM Strength (kg) Suspension Tension

90KN120KN

Conductor WOLF

Number of Circuits 2

Conductor per phase 1

Total Conductor length (km) 36km (approx)

Ground wire (Nos) 1

Strength Kg/mm2 70

Size of ground wire 7/9 earth wire

III. SAFETY CLEARENCE

a) EHT Lines-Minimum Clearances (in metres)

Details Nominal system voltage110 kV

a) Clearance to Ground (in Metres)a. Across the streetb. Along the streetc. Other areas

6.1 6.16.1

4.582.75

2.75

10.68.29.57.0

13.711.7

2.752.754.58

b) Clearance to building (in Metres)i. Vertical – from high-

est objectii. Horizontal- from

nearest point

c) At crossing with (in Metres)a. Telecom lineb. Railway- category A&C

B.G Inside station areaB.G Outside Station areaM.G. Inside station areaM.G Outside station area

C) Railway- category BB.G. & M.G Inside Station area B.G & M.G Outside Station area

d) Between lines when crossing each other

Upto 66 kV line 110 kV 220 kV

Note:-1.Vertical clearance -at maximum still air final sags2. Horizontal clearance – at max. deflected conductor position3. Railway category A- tracks electrified on 1500 V.D.C4. Railway category B- tracks electrified/ likely to be electrified on 25 kV A.C5. Railway category C- tracks not electrified / not likely to be electrified 6. Station area- tracks between the outermost signals 7. The figures are as per specified in IS 5613 (part II)

2. Minimum clearance from Live conductor to Earthed Metal parts

Insulator stringsMinimum clearance in meters forvoltages

1. Tension string (single/double) 2. Jumper at swing 0° Jumper at swing 10°

110 kV

1.221.221.22

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Jumper at swing 20°3. Single suspension at swing 0° Single suspension at swing 15° Single suspension at swing 30° Single suspension at swing 45° Single suspension at swing 60°4 Double suspension string at swing 0°

0.9151.221.221.070.1950.9151.220

3. Midspan clearances between earthwire and power conductor

Voltage grade (kV) Clearance (meters)

110 4.5

4. Right of way clearances

EHT Lines(kV)

Recommended widthof right of way

(meters)

Minimum clearance betweenconductors and permanent

structure ( meters)110 22 3.7

5. Minimum clearance over water ways

(i) HV & EHV Transmission lines - 19.0 m

Minimum 3.048 m over the highest flood level for river which are not navigable isrecommended.

6. Clearance from Ground/ Buildings.

Voltage

Vertical clearance above ground ofthe lowest conductor

Clearance from building

Acrossthe

street

Alongthe

street

Else whereVertical

clearancefrom the

highest roof

Horizontal clearanceform the nearest

point

m mBare(m)

Insulated(m)

m m

110 kV 6.1 6.1 6.1 - 4.878 3.049 7. Clearance from supporting structure for another line

i. Low or medium voltage lines : 1.219 mii. High voltage lines : 1.829 miii. EHV lines : 2.744 m

8. Vertical clearance between lines and guard wires

For 110 kV : 1.829 m

Note:- Every guard wire shall be securely bound to earth at each point where itselectrical continuity is broken.

Guard wire shall have an actual breaking load of not less than 635 Kgs andshall be galvanized.

The earth wire should be effectively maintained and the earth resistanceshould not exceed 10 ohms.

Size of Guard wire:

(i) Railway crossing (a) 7/10 SWG / one dog conductor for longitudi-nal wires. (b) 6 or 8 SWG for cross lacing(ii) Road crossing/ Telephone No. 8 SWG wire.

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9. Clearance between OH Power lines and Railway Tracks/ Structures

Voltage Broad Gauge

Meter & Narrow Gauge

Min. clearancebetween

conductorsand anyrailway

structure

Inside station area

Outsidestation area

Insidestationarea

Outsidestationarea

m m m m

Above 66kVincluding110 kV

10.6 8.2 9.5 7.0 3.51

2.2 Conductor Type: The actual conductor type is HTLS (ACCC) having physical, mechanical and electricalcharacteristics such as,

a) Outer diameter not more than 18.14mm..

b) The net expansion of the HTLS conductor / unit length at maximum operatingtemperature of 180ºC should be less than the net expansion of ACSR wolf conductor /unit length at 75ºC.

c) DC resistance at 20ºC of the HTLS conductor should be at least 20% lesser than ACSRwolf conductor. The bidder must ensure that the losses at the normal operatingtemperature of the proposed HTLS shall be lesser than ACSR wolf conductor as per thelimits specified in the GTP/ Type test report of the conductor.

d) Modulus of elasticity should be more than that of ACSR wolf Conductor. e)Operating temperature at 640 Amps continuous flow should be such that the temperature of

conductor shall not exceed 180ºC & that of hardware fittings and accessories will notexceed 90ºC under still wind (0.56 m/s) and 40ºC ambient condition in order to ensureenvironmental safety and limitation of loss without affecting mechanical and electricalproperties of the conductor, accessories as well as insulators.

2.3 Current Carrying capacity / Ampacity of proposed Conductor The Bidder in his bid shall furnish calculations for the ampacity based on IEEE-738 standardfor the proposed HTLS conductor. The design of conductor shall be suitable for operation atsteady state conductor temperature at flow of minimum 640A within 180ºC under maximumambient conditions. The Bidder shall also indicate the maximum permissible conductortemperature for continuous operation at maximum ampacity quoted at still air & at 50ºCambient without any deterioration of its electrical, mechanical & metallurgical properties.

The Bidder shall indicate the technical particulars and details of the construction of theconductor in the relevant schedule of GTP. The Bidder shall also guarantee the DC resistanceof conductor at 20ºC and AC resistance at 180ºC, 50 Hz. The Bidder shall submit thesupporting calculations for the AC resistance indicating details & justification of values oftemperature coefficient of resistance & DC to AC resistance conversion factor with duereference to construction & geometry of the conductor. The Bidder shall submit the type testreports from NABL accredited or international laboratories such as CESI, KEMA etc, insupport of DC resistance and the calculations for AC resistance.

2.3.1 EVALUATION OF OHMIC LOSSES & DIFFERENTIAL PRICE LOADING

Based on the conductor parameters guaranteed by the bidders, average ohmic losses fordifferent type of conductors offered by the bidders shall be calculated as per the following.

Average ohmic losses (kW) = Loss load factor x Line length x No. of conductors x (Desiredoperating current ie. 640A)² x Rac.(Considering loss load factor = 0.5317).

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Where Rac is the AC resistance per km guaranteed by the bidder at temperature correspondingto the continuous operating current of 500A under normal condition.

Differential price evaluation for the conductors offered by the bidder shall be carried outconsidering the average ohmic losses calculated as above and considering Rs.1,52,600/- perkW.

The best parameter of loss (lowest ohmic loss for conductor) corresponding to lowest ACresistance quoted among bidders by the technically responsive & qualified bidders shall betaken as basis & that quoted by the particular bidder shall be used to arrive at differential priceto be applied for each bid.

2.3.2 Liquidated damages for excessive losses

On testing, if it is found that actual losses are more than the values quoted in the bid,undisputed liquidated damages shall be recovered from the supplier at the following rates.

For each kW of excess loss Rs.3, 05,200/-.

For fractions of Kilowatt, penalties shall be applied on pro-rata basis. No bonus shall be payable for loss, which are less than those stated in the bid.

2.4 Sag-Tension calculations of the proposed HTLS conductor are to be submitted alongwith bid under following conditions.

i) 33ºC, No wind ii) 33ºC, Full wind iii) 50ºC, 2/3rd wind iv) 60ºC, No wind v) 150ºC, No wind vi) Maximum operating temperature & no windvii) Emergency temperature & no wind.

Bidder shall also furnish details of creep characteristics based on laboratory investigations /experimentations conducted on the HTLS conductor as per IEEE 1138/ IEC 61395 and shallindicate creep strain values corresponding to 1 month, 6month, 1year creep at tensionscorresponding to the above conditions.

2.5 Design of Insulators, Hardware & accessories shall be compatible with the HTLSconductor supplied and existing tower.

2.6 Major Qualifying Projects (MQP) for proposed Conductor, Insulator andhardware/accessories, Manufacturer / vendor is to be submitted with technical bid.

2.7 Workmanship i) All the conductor strands shall be smooth, uniform and free from all imperfections, such asspills and splits, cracks, die marks, scratches, abrasions, rust etc.

ii) The finished conductor shall be smooth, compact, uniform and free from all imperfections,including kinks (protrusion of wires), wire cross over, over riding, looseness (wire beingdislocated by finger/hand pressure and / or unusual bangle noise on tapping), materialinclusions, white rust, powder formation or black spot (on account of reaction with trappedrain water etc),dirt, grit etc.

2.8 Joints in wires a) Aluminum Or Aluminum Alloy Wires During stranding, no Aluminum / Aluminum alloy welds shall be made for the purpose ofachieving the required conductor length.

b) Core Wires There shall be no joint of any kind in the finished wire entering the strand manufacturing unit.

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There shall also be no joints or splices in any length of the completed core.

2.9 Tolerances Manufacturing tolerances on the dimensions to the extent of one percent (1%) shall bepermitted for individual strands and the complete conductor.

2.10 Materials The materials used for construction of the conductor shall be such that the conductor meets thespecified technical and the performance requirements.

2.11 Outer Layer The material of outer layer of HTLS conductor shall be of high temperature resistantaluminum/ aluminum alloy added with zirconium or any other suitable elements to electrolyticaluminum having purity not less than 99.5% and a copper content not exceeding 0.04%.Bidder shall guarantee the chemical composition in the schedule GTP and also furnishdescription of the manufacturing process in the bid. Fully annealed type Aluminium is alsoacceptable as outer layer.

2.12 Core The core may be of any composite materials or special steel and shall have propertiesconforming to the technical performance requirements of the finished conductor. Bidder shallfurnish properties and composition of the core in the GTP schedule. The composite materialfor core shall be of such proven quality that its properties are not deteriorated by the normaloperating conditions of 110kV transmission line in tropical environment conditions asexperienced by the existing lines. The Bidder shall provide adequate details includingspecifications / test reports / operating experience details / performance certificates etc. insupport of the suitability of the offered materials. Care shall be taken for avoiding internalfriction due to different materials having different thermal co efficient of expansion.

2.13 Conductor Length The Bidder after his survey of the existing line shall determine the most appropriate individualconductor lengths to be manufactured & supplied keeping in view of the tower schedules,section lengths, special crossings etc. The drum drawing as per IS 1778 or any internationalstandard shall be submitted to purchaser for review and approval. The Bidder shall alsoindicate, in the GTP, the maximum single length of conductor that they can manufacture. Nomid span joints will be allowed.

3. STANDARDSThe conductors & accessories shall comply in all respects to the clauses of this specification asindicated above & with the standards noted in Appendix - II, III and IV.

4. STRANDING For all constructions, each alternate layer shall be stranded in opposite directions. The wires in each layer shall be evenly and closely stranded round the under laying wire or wires. The final layer of wires shall have a right hand lay.

5. PACKING AND MARKING 5.1 The conductor shall be wound in non-returnable strong reels or drums conforming toIndian Standard 1978-1961 specification for Reels and Drums for Bare Wire, or any otherauthoritative better standard and marked with the following:

b) Trade name, if anyc) Contract/Award letter Number d) Name of manufacturer e) Name & Address of Consignee f) Drum Number g) Length of conductor h) Size of conductor i) Gross Weight of drum with conductor j) Weight of empty drum k) Net and gross weight of conductor with lagging. l) Arrow marking for un-winding

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5.2 The reel shall be of such construction as to assure delivery of conductor in the field freefrom displacement & damage and should be able to withstand all stresses due to handling andthe stringing operations so that conductor surface is not dented, scratched or damaged in anyway during manufacture, transport and erection. The conductor shall be properly lagged on thedrums and the method of lagging that is to be employed may be clearly stated in the offer. Itshould be stacked to suit the reel and held in place by steel strapping. Lagging shall not benailed or bolted in place.

5.3 The conductor drum should be suitable for wheel mounting. Before reeling, the cardboardor other suitable material shall be secured to the drum and inside flanges of the drums. Afterreeling the conductor, the exposed surfaces should be wrapped with suitable soft material toprevent the conductor from dirt and grit. Any space between the drum lagging and conductorshould be suitably filled with soft filler material compactly packed.

6. TESTS AND TEST CERTIFICATES

6.1 Type Tests on Conductor The following type test certificates are to be furnished along with the bid.

6.1.1 Ultimate Tensile Strength (UTS) Test on Stranded Conductor Circles perpendicular to the axis of the conductor shall be marked at two places on a sampleof conductor of minimum 5 m length between fixing arrangement suitably fixed byappropriate fittings on a tensile testing machine. The load shall be increased at a steady rateup to 50% of minimum specified UTS and held for one minute. The circles drawn shall not bedistorted due to relative movement of strands. Thereafter the load shall be increased at steadyrate to 90% of minimum UTS and held for one minute. The Conductor sample shall not failduring this period. The applied load shall then be increased until the failing load is reachedand the value recorded.

6.1.2. High Temperature endurance & creep test A conductor sample of at least 20 m length shall be strung at tension equal to 25% ofconductor UTS. The conductor temperature shall be increased to designed maximumtemperature in steps of 20ºC and thermal elongation of the conductor sample shall bemeasured & recorded at each step. Further, the temperature of the conductor shall bemaintained at designed maximum continuous operating temperature (+200C) for 1000 hours.The elongation/creep strain of the conductor during this period shall be measured andrecorded at end of 1 hour, 10 hour, 100 hour and subsequently every 100 hour up to 1000hours time period. After completion of the above, the conductor sample shall be subjected toUTS test as mentioned above at clause 6.1.1.

The supplier shall furnish details of creep characteristics in respect of the conductor based onlaboratory test and other laboratory investigations / experiments conducted on similar type ofconductor and shall indicate creep strain values as per IEC 61395.

6.2 The following tests shall be performed as Type tests:The following acceptance tests will be made in the presence of the representatives of theowner.

6.2.1 D.C. Resistance Test on Stranded Conductor On a conductor sample of minimum 5m length two contact-clamps shall be fixed with apredetermined bolt torque. The resistance shall be measured by a Kelvin double bridge orusing micro ohm meter of suitable accuracy by placing the clamps initially at zero meter andsubsequently one meter apart. The test shall be repeated at least five times and the averagevalue recorded. The value obtained shall be corrected to the value at 20ºC as per IEEE / IS398-(Part IV)/ (Part V).

6.2.2 Coefficient of linear expansion for core/core strands The temperature and elongation on a sample shall be continuously measured and recorded atintervals of approximately 15ºC from 200C to designed maximum continuous operatingtemperature by changing the temperature by suitable means. Coefficient of linear expansionshall be determined from the measured results.

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6.2.3 Breaking load test on conductor strands & Core strands and D.C Resistance test onconductor strand.The above tests shall be carried out as per IEC: 888/889 and the results shall meet therequirements of the specification.

6.2.4 Wrap test on Core strand The wrap tests on core strands shall meet the requirements of IEC: 888. In case of aluminiumclad core wire, the same shall be wrapped around a mandrel of diameter of five times that ofthe strand to form a helix of eight turns. The strand shall be unwrapped. No breakage ofstrand shall occur.

6.2.5 Heat Resistance test on conductorBreaking load test as per clause 6.2.3 above shall be carried out before and after heating thesample in uniform heat furnace at 200ºC for one hour. The breaking strength of the wire afterheating shall not be less than the 90% of the breaking strength before heating.

6.2.6 Chemical Analysis of conductor material and Core Samples taken from the Aluminiumand core coils/strands shall be chemically/spectrographically analyzed. The same shall be inconformity to the particulars guaranteed by the bidder so as to meet the requirements statedin this Specification.

6.2.7 Visual and Dimensional Check on Drums The drums shall be visually and dimensionally checked to ensure that they conform to theapproved drawings.

6.2.8 Dimensional Check on Core Strands and conductor Strands. The individual strands shall be dimensionally checked to ensure that they conform to theguaranteed values furnished by the bidder.

6.2.9 Check for Lay-ratios of Various Layers The lay-ratios of various layers shall be checked to ensure that they conform to theguaranteed values furnished by the bidder.

6.2.10 Torsion and Elongation Tests on Core Strands The test procedures shall be as per clause No. 10.3 of IEC 888. In torsion test, the number ofcomplete twists before fracture shall not be less than 18 on a length equal to 100 times thestandard diameter of the strand. In case test sample length is less or more than 100 times thestandard diameter of the strand, the minimum number of twists will be proportional to thelength and if number comes in the fraction then it will be rounded off to next higher wholenumber. In elongation test, the elongation of the strand shall not be less than 1.5% for agauge length of 250 mm.

6.2.11 Stress-strain test at elevated temperature Stress-strain test as per IEC-1089 shall be conducted keeping conductor temperature atdesigned maximum value.

6.2.12 Axial Impact TestThe conductor sample shall be suspended vertically and load applied by dropping a 650kgfrom an elevation of 4 meters above the sample. The impact velocity shall be not be less than8 m/sec with an initial pre-tension of 200 kg. The curve for load vs time shall be recordedand recorded load of failure for conductor shall not be less than UTS of conductor.

6.2.13 Crush Strength Test A section of conductor is to be crushed between two six inch steel plates. Load shall be heldat 350 Kg for 1 minute and then released. All the strands shall be subsequently disassembledand tensile tested. All the strands/ core shall exhibit full strength retention.

6.3 Tests on AccessoriesThe test on accessories should have been performed by the manufacturer in the last 5 yearsand shall be conducted on the accessories according to the standards specified at appendix-IV .

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6.3.1 Tests on Suspension clamp: 1. Vertical damage load and failure load test – IEC 61284 Clause 11.4.12. Magnetic power loss test - IEC 61284 Clause 12.2

3. Clamp slip strength Vs torque test - IEC 61284 Clause 11.4.4 6.3.2 On Dead end Tension Assembly: 1. Electrical resistance test for dead end Assembly - IEC 61284 Clause 13 2. Heating cycle test for dead end Assembly - IEC 61284 Clause 13 3. Slip strength test for dead end assembly - IEC 61284 Clause 11.5.16.3.3 Mid Span Compression Joint for Conductor 1. Heating cycle test - IEC 61284 Clause 13 2. Slip strength test - IEC 61284 Clause 11.5.1

6.3.4 Vibration Damper 1. Dynamic characteristics test - IEC 61897 Clause 7.11.2

2. Vibration analysis - IEC 61897 Clause 7.11.2 3. Clamp slip test - IEC 61897 clause 7.8 & 7.9 4. Fatigue tests - IEC 61897 Clause 7.12.3 5. Magnetic power loss test - IEC 61284 Clause 12.2 6. Damper efficiency test - IEC 61897 Clause 7.11.2

7. Silicon Rubber Housed Composite Insulators

i. This specification covers design, manufacturing, testing, inspection, packing and supplyof Silicon Rubber housed Composite Insulators for satisfactory operation on existing110kV Pothencode – Kazhakuttom double circuit line of KSEB Ltd.

ii. Now, hereunder, where composite insulator is mentioned, describes only Silicon Rubberhoused composite insulators.

iii.These insulators are to be used as insulating part on single circuit galvanized lattice towerstructures single/double suspension & tension (dead end) for the existing 110kVPothencode – Kazhakuttom double circuit transmission line. The configuration onstructure may be single or double insulators per phase at required locations suitablefor reconductoring the existing 110kV Pothencode – Kazhakuttom double circuittransmission line using HTLS conductor.

iv.The Bidder shall be purchased associated Silicon Rubber Housed composite insulatorssuitable for the HTLS conductor offered conforming to IS/IEC from reputed manufactureswho shall have all the facilities to manufacture or supply 90KN/120KN and higher sizesof Silicon Rubber Housed composite insulators.

8.Service Conditions for Composite Insulators

The composite insulators to be supplied against this specification shall be suitable for theclimatic conditions mentioned in this tender document under design parameters as Section2.1 in Part II.

9. Design and Material Requirement of Composite Insulators

9.1 Core: The core shall be glass-fibre reinforced epoxy resin rod (FRP) of high strength. Both,glass fibre and resin shall be optimized in the FRP rod. Glass fibres with low contentin alkalies shall be boron free E glass or Boron free electrically corrosion resistance(ECR) glass. Use of resin with hydrolysis trend due to water penetration should be prevented i.e. matrix of the FRP rod shall be Hydrolysis resistant. Suitability of Epoxy matrix as well as

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interface between matrix and fibres is to be considered as design parameter to prevent brittlefracture. The FRP rod should be void free and shall be manufactured through Pultrusionprocess.

9.2 Housing: The core of the composite insulator shall be completely covered by a continuoushousing consisting of a sheath-weather shed. For moulding of entire weather shed structureon to the rod in a one shot moulding process to be employed to avoid multiple interfaces.Hardware ie. metal fittings may be installed on the rod prior to moulding of the shedcontrolling moulding lines. The base polymer shall be 100% Silicon Rubber prior to theaddition of reinforcing fillers.

The thickness of compounding material on core should be minimum 3 mm. Manufacturershould furnish a description of its Quality Assurance Programme including fabrication, testingand inspection for any material (i.e. rubber), components (i.e. Rod) or hardware (i.e. Endfittings).

Manufacturing methods and material composition documentation will be a part of TechnicalBid to be submitted along with offer. Insulator should have hermetically sealed structure inwhich the housing material is moulded to cover the interface between the end fittings and theFRP rod. This seal should never be broken during testing or otherwise.

9.3 End fittings: The composite insulators shall be socket and ball type with the necessary couplingarrangement such that pin shall move freely in the socket but do not get disengaged while inservice under various operating and atmospheric conditions. The socket & ball type metal end fittings shall be designed to transmit the mechanical load tothe core & the end fittings shall maintain uniform and consistent mechanical strength. Materialand methods used in the fabrication of metal parts shall be selected to provide goodtoughness and ductility.

Metal end fittings shall be made from a quality malleable cast iron or forged steel orSpheroidal Graphite Iron (SGI) and shall be hot dipped galvanized in accordance with IS2629. Metal end fittings shall be uniform and without sharp edges or corners and shall befree of cracks, flakes, slivers, slag, blow-holes shrinkage defects and localized porosity.The attachment to the FRP rod shall be performed with a symmetrically controlledcrimping method control by acquistic method that compresses the metal radially onto therod without damage to the rod fibres or resin matrix while providing a strength equal to orgreater than the defined and specified ultimate strength to the insulator. The material used infittings shall be corrosion resistant.

No joints in ball & socket or pin will be allowed. Outer portion of ball or socket should beZinc sleeved with minimum 99.95% purity of electrolytic high grade Zinc. The finishedsurface shall be smooth and shall have a good performance. The surface shall not crack orget chipped due to ageing effect under normal and abnormal service conditions or whilehandling during transit or erection.

The design of the fittings and the insulators shall be such that there is no local coronaformation or discharges likely to cause the interference to either sound or visiontransmission.

9.4 Verification of housing material The manufacturer should provide written verification about housing material, for whichbase polymer shall be 100% Silicon Rubber prior to the addition of reinforcing fillersconsidered will provide satisfactory performance in the particular environment. It shallmeet following requirements-

i. Be homogenous, impermeable, with no fissures, bubbles and strange materialsinclusions.

ii. Be designed in order to avoid formation of localized discharges and toprevent interfaces humid penetration.

iii. Be resistant to corona, KV radiation, ozone, atmospheric contamination, waterpenetration and power arcs.

15

10. Ball and Socket Designation

The dimensions of the Ball and Socket shall be 16mm designation for 90kN and20mm designation for 120kN insulators in accordance with the standard dimensionsstated in IEC:120/IS:2486 (Part-II).

11. Dimensional Tolerance of Composite Insulators:

The tolerance on all dimensions e.g. diameter, length and creepage distance shall be allowed as follows: ± (0.04 d + 1.5) mm when d 300 mm. ± (0.025 d + 6) mm when d > 300 mm. Where d being the dimensions in millimeters for diameter, length or creepage distanceas the case may be. However, no negative tolerance shall be applicable to creepage distance.

12. Interchangeability:

The composite insulators including the ball socket connections shall be standard designsuitable for use with the hardware fittings of any make conforming to relevant IS/IECstandards.

13. Corona and RI Performance:

All surfaces shall be clean, smooth, without cuts, abrasions or projections. No part shall besubjected to excessive localized pressure. The insulator and metal parts shall be so designedand manufactured that it shall avoid local corona formation and not generate any radiointerference beyond specified limit under the operating conditions.

14. Markings:

Each insulator shall be legibly and indelibly marked with the following details as perIEC - 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 theword 'KN' to facilitate easy identification.

e. Country of manufacture.

15. Inspection, Tests and Standards:

16.1 Proto type or Design or Type: To evaluate core material, housing material, coreassembly (core & end fittings), interfaces and connections of sample insulators. Inspectionincludes the performance of acceptance, type and design tests. KSEBL reserves the right tocarry out design and type tests to check conformity of the material with the proto type unitpreviously approved. KSEBL reserves the right to attend the tests and perform inspections inany stage of the supply, appointing its inspectors and following the approved manufacturingschedule. Inspection and tests scheduled to happen during manufacture shall have their datesinformed to KSEBL at least 10 days in advance.

The manufacturer shall assure KSEBL's inspector the right to being fully acquainted withinstallations and apparatus, check calibrations, is present at the tests, check results and in caseof doubt, perform new inspections and claim the repetition of any test.

16.2 No material shall be dispatched from its point of manufacture before it has beensatisfactorily inspected, tested, and necessary dispatch instructions are issued in writing, exceptfor the cases where waiver of inspection is granted by competent authority of the Purchaser,and even in this case also written dispatch instructions will be issued. Any dispatches beforethe issue of Dispatch Instructions in writing will be liable for rejection and non-acceptance of the materials by the consignee.

16.3 The acceptance of any quantity of material shall in no way relieve the Bidder

16

of any of his responsibilities for meeting all requirements of the specification, and shallnot prevent subsequent rejection if such material is later found to be defective.

16.4 The sample taken from any numbers of crates for carrying out any type of tests will beto the suppliers account.

16.5 On the complete composite Insulator with Hardware Fittings:

d. Power frequency voltage withstand test with corona control rings/grading ring andarcing horns under wet condition - IEC:383-1993.

e. Impulse voltage withstand test under dry condition - IEC:383-1993.

f. Salt-fog pollution withstand test – Appendix - V

All the above type test shall be conducted on Single 'I' suspension insulator and Double tensioninsulator along with hardware fittings.

16.6 On Composite Insulator Units

Tests on interfaces and connections IEC: 61109-1992

iv. Dry Power Frequency Voltages Test

v. Sudden Load Release Test

vi. Thermal Mechanical Test

vii. Water immersion

viii. Steep Front Impulse Voltage Test

ix. Dry Power Frequency Voltage Test16. Sample Tests ( Acceptance Tests) -

When specified on a purchase order, sample tests shall be performed per ANSI C29.11 & IEC:61109-1992, before proceeding with testing and commissioning as per the instruction of theEngineer in Charge.

(a) Verification of Dimensions (b) Verification of Locking System-applicable only in the event ball and socket insulators is

specified. (c) Mechanical Load test - In process testing used to verify the mechanical

system is acceptable. (d) Galvanizing Test

17. Routine Tests:

The following tests shall be performed on every insulator produced as per IEC: 61109-1992. i. Mechanical Test: Every insulator shall withstand for a period not less than 10

seconds a tensile load equal to or greater than its Routine Test Load (50% of theSpecified Mechanical Load).

ii. Visual Examination: Every insulator shall be examined to insure its conformance to themanufacturer's drawing. Superficial polymer surface defects of an area less than 25square millimeters (total area not to exceed 2% of total insulator surface area) and depthless than 1 mm shall be acceptable.

18. Additional Tests

The Purchaser reserves the right of getting done any other test(s) of reasonable naturecarried out at Purchaser's premises, at site, or in any other place in addition to the aforesaid

17

type, acceptance and routine tests to satisfy himself that the material comply with thespecifications. In such case all the expenses will be to Suppliers account.

19. Test Reports

20.1 Copies of type test reports shall be furnished in at least two (2) copies along with oneoriginal. One copy shall be returned duly certified by the Purchaser only after which thematerial already inspected i.e. the materials manufactured for selection of sample for typetest, shall be dispatched on receipt of Dispatch Instructions from the Chief Engineer(Transmission South), KSEBL, Thiruvananthapuram.

20.2 Record of routine test reports shall be maintained by the Bidder at his works forperiodic inspection by the purchaser's representative.

20.3 Test Certificates of test during manufacture shall be maintained by the Bidder.These shall be produced for verification as and when desired by the Purchaser.

18

21. GUARANTEED TECHNICAL PARTICULARS OF HTLS CONDUCTOR

(The bidder shall fill in the guaranteed technical particulars in the Proforma below and submitthe same with his tender, without which bid will not be considered)

Sl. No. Description Unit Value guaranteed bythe bidder

1 Name of manufacturer

2 Address of manufacturer

3 Name of the conductor

4 Construction of conductor /Designation of conductor as per IEC:61089

5 Particulars of Raw Material

5.1 Outer Layers

a) Type of Conductor strand

b) Chemical composition of conductor strand

i %

ii %

19

iii %

iv %

v %

5.2 Inner core

a) Material of core

b) Chemical Composition of core

i %

ii %

iii %

iv %

v %

6 Outer Aluminium Alloy Strand after Stranding

6.1 Number of Outer layers Nos.

6.2 Diameter

a) Nominal mm

b) Maximum mm

20

c) Minimum mm

6.3 Minimum Breaking load on strand

a) Before stranding KN

b) After stranding KN

6.4 Resistance of 1m length of strand at 200C Ω

7 Inner core strands/inner core after stranding

7.1 Number of layers in inner core No.

7.2 Diameter

a) Nominal mm

b) Maximum mm

c) Minimum mm

7.3 Minimum Breaking load of strand/ core

a) Before stranding KN

b) After stranding KN

7.4 Min. no. of twists which a single strand shall withstand during torsion test for a length equal to 100 times dia of wire after stranding

No.

8 Complete conductor

8.1 UTS of conductor KN

8.2 Lay ratio of conductor Maximum Minimum

a) 1st layer (outer most layer)

21

b) 2nd layer

c) 3rd layer

d) 4th Layer

8.3 Maximum permissible conductor temperature for continuous operation

0C

8.4 Maximum permissible conductor temperature for short term operation

0C

8.5 Permissible duration of above short term operation

Minutes

8.6 Steady state conductor temperature at conductor current of minimum 500A at 500C ambient conditions & still wind as detailed in Tech. Spec. 2.1

0C

8.7 DC resistance of conductor at 200C Ω/km

8.8 AC resistance at maximum continuous operating temperature corresponding to specified maximum operating current (Minimum 500A under maximum ambient conditions and still wind as per Technical Specification at 2.1)

Ω/km

8.9 Details of Creep characteristic for conductor enclosed ( as per Technical Specification)

Yes/No

8.1 Sag Tension Calculation

8.10.1 Sag Tension Calculation enclosed Yes/No

8.10.2 Sag & Tension at 330C & no wind Meters &KN

8.10.3 Sag & Tension at 330C & full wind Meters &KN

8.10.4 Sag & Tension at 500C & 2/3rd wind Meters &KN


22


8.10.7 Sag & Tension at maximum operating temperature & no wind

Meters &KN

8.10.8 Sag & Tension at emergency temperature & no wind

Meters &KN

8.11 Tolerance on standard length of conductor %

8.12 Direction of lay for outside layer

8.13 Linear mass of the conductor

a) Standard kg/km

b) Minimum kg/km

c) Maximum kg/km

8.14 Standard length of conductor km

8.15 Maximum length of conductor that can beoffered as single length

km

9 Drum is as per specification Yes/No

10 Accessories is as per specification/standards

Yes/No

Name and Address of Bidder

Place:

Date:

23

21.1. GUARANTEED TECHNICAL PARTICULARS OF SILICON RUBBER LONG ROD COMPOSITE SUSPENSION INSULATORS (110kV/ 90 kN)

SlNo Description Unit Value guaranteed bythe Bidder

1 Type of insulator

2 Standard according to which the insulators manufactured and tested

3 Name of material used in manufacture ofthe insulator with class/ grade

3.1 Material of core (FRP rod)a) E-glass or ECR –glassb) Boron content

3.2 Material of housing & weather sheds (Silicone content by weight)

3.3 Material of end fittings

4 Colour

5 Electrical Characteristics

5.1 Nominal system voltage kV (rms)

5.2 Highest system voltage kV (rms)

5.3 Dry power frequency withstand voltage kV (rms)

5.4 Wet power frequency withstand voltage kV (rms)

5.5 Dry flashover voltage kV (rms)

5.6 Wet flashover voltage kV (rms)

5.7 Dry lightning impulse withstand voltagea) Positiveb) Negative

kV (peak)kV (peak)

5.8 Dry lightning impulse flashover voltagea) Positiveb) Negative

kV (peak)kV (peak)

6.0 Creepage distance (Min.) mm

6.1 Sectional length mm

7.0 Mechanical characteristicsMinimum failing load

kN

8.0 Dimensions of insulator

8.1 Weight kg

8.2 Dia of FRP rod mm

8.3 Length of FRP rod mm

24

8.4 Dia. of weather sheds mm

8.5 Thickness of sheath mm

8.6 Dry arcing distance mm

8.7 Dimensioned drawings of insulator

9 Method of fixing of sheds to housing

10 No. of weather sheds

11 Type of sheds

11.1 Aerodynamic

11.2 With underribs

12 Packing details

12.1 Type of packing

12.2 No. of insulators in each tube

12.3 Gross weight of package kg

13 Type test report of insulator

14 Any other particulars which the bidder may like to give

Date:

(Signature)Place:

25

21.2 GUARANTEED TECHNICAL PARTICULARS OF SILICON RUBBER LONG ROD COMPOSITE TENSION INSULATORS (110kV/120kN)

Sl. No Description Unit Value guaranteed bythe Bidder

1 Type of insulator

2 Standard according to which the insulators manufactured and tested

3 Name of material used in manufacture ofthe insulator with class/ grade

3.1 Material of core (FRP rod)d) E-glass or ECR –glasse) Boron content

3.2 Material of housing & weather sheds (Silicone content by weight)

3.3 Material of end fittings

4 Colour

5 Electrical Characteristics

5.1 Nominal system voltage kV (rms)

5.2 Highest system voltage kV (rms)

5.3 Dry power frequency withstand voltage kV (rms)

5.4 Wet power frequency withstand voltage kV (rms)

5.5 Dry flashover voltage kV (rms)

5.6 Wet flashover voltage kV (rms)

5.7 Dry lightning impulse withstand voltagec) Positived) Negative

kV (peak)kV (peak)

5.8 Dry lightning impulse flashover voltagec) Positived) Negative

kV (peak)kV (peak)

6.0 Creepage distance (Min.) mm

6.1 Sectional length mm

7.0 Mechanical characteristicsMinimum failing load

kN

8.0 Dimensions of insulator

8.1 Weight kg

8.2 Dia of FRP rod mm

8.3 Length of FRP rod mm

8.4 Dia. of weather sheds mm

26

8.5 Thickness of sheath mm

8.6 Dry arcing distance mm

8.7 Dimensioned drawings of insulator

9 Method of fixing of sheds to housing

10 No. of weather sheds

11 Type of sheds

11.1 Aerodynamic

11.2 With under ribs

12 Packing details

12.1 Type of packing

12.2 No. of insulators in each tube

12.3 Gross weight of package kg

13 Type test report of insulator

14 Any other particulars which the bidder may like to give

Date:

(Signature)Place:

27

21.3 GUARANTEED TECHNICAL PARTICULARS OF SUSPENSION HARDWAREFITTINGS

Sl. No Description Unit

Value guaranteed by theBidder

Single Double

1 Name & address of manufacturer

2 Address of manufacturer

3 Drawing enclosed Yes/No

4 Maximum magnetic power loss of suspension clamp at conductor current of500 amperes

Watt

5 Slipping strength of suspension assembly (clamp torque Vs slip curve shall be enclosed)

kN

6 Particulars of standard/AGS standard/AGS preformed armour rod set for suspension assembly

c. No. of rods per set No

b. Direction of lay

c. Overall length after fitting on conductor

mm

d. Actual length of each rod along its helix

mm

e. Diameter of each rod mm

f. Tolerance in

I) Diameter of each rod ± mm

ii) Length of each rod ± mm

iii) Difference of length between the longest and shortest rod in a set

± mm

g. Type of Aluminium alloy used for manufacture of PA rod set

h. UTS of each rod Kg/mm2

7 Particulars of Elastomer (For AGS Clamp only)

a.Supplier of elastomer

b. Type of elastomer

c. Shore hardness of elastomer

d. Temperature range for which elastomer is designed

e. Moulded on insert Yes/No

28

8 UTS of suspension clamp Yes/No

9 Purity of Zinc used for galvanizing %

10 Maximum permissible continuous operating temperature of

i) Clamp body

ii) Standard /AGS preformed rods

Date:

(Signature)Place:

Name and address of bidder

29

21.4. GUARANTEED TECHNICAL PARTICULARS OF TENSION HARDWAREFITTINGS

Sl.No Description Unit Value guaranteedby the Bidder

Single Double

1 Name of Manufacturer

2 Address of Manufacturer


4 Purity of aluminum used for aluminum sleeve

%

5 Material for steel sleeve

(i) Type of material with chemical composition

ii) Range of Hardness of material (Brinnel Hardness)

BHN From ……. To……..

iii)Weight of zinc coating gm/m2

Aluminium/ SteelAlloy

6 Outside diameter of sleeve before compression

mm

7 Inside diameter of sleeve before compression

mm

8 Length of sleeve before compression

9 Dimension of sleeve after compression

a)Corner to corner

b)Surface to surface

10 Length of sleeve after compression

11 Weight of sleeve

a)Aluminium /aluminum Alloy kg

b)Steel kg

c)Total kg

12 Electrical resistance of dead end assembly as a percentage of equivalent length of Conductor

%

13 Slip strength of dead end assembly kN

30

14 UTS of dead end assembly kN

15 Purity of Zinc used for galvanizing %

16 Maximum permissible continuous operating temperature of dead end assembly

Date:

(Signature)Place:


31

21.5. GUARANTEED TECHNICAL PARTICULARS OF MID SPANCOMPRESSION JOINT FOR HTLS CONDUCTOR

Sl.No Description Unit Value guaranteed by the Bidder




4 Suitable for conductor size mm

5 Purity of aluminium used for

aluminium sleeve

%

6 Material for steel sleeve

(i) Type of material with chemical composition

ii) Range of Hardness of material (Brinnel Hardness)

BHN From to

iii)Weight of zinc coating gm/m2

Aluminium/ SteelAlloy

7 Outside diameter of sleeve before compression

mm

8 Inside diameter of sleeve before compression

mm

9 Length of sleeve before compression


a)Corner to corner

b)Surface to surface

11 Length of sleeve after compression

12 Weight of sleeve

a)Aluminium kg

b)Steel kg

c)Total kg

13 Slip strength kN

32

14 Resistance of the compressed unit expressed, as percentage of the resistivity of equivalent length of bare conductor

%

15 Maximum permissible continuous operating temperature of mid span compression joint

Deg.C

Date:

(Signature)Place:


33

21.6 GUARANTEED TECHNICAL PARTICULARS OF REPAIR SLEEVE FOR HTLS CONDUCTOR






5 Purity of aluminium/Al Alloy type %

6 Dimension of sleeve before compression

i)Inside diameter of sleeve mm

ii)Outside demensions of sleeve mm

iii)Length of sleeve mm


i)Corner to corner mm

ii)Surface to surface mm

iii)Length of sleeve mm

8 Weight of sleeve

9 Maximum permissible continuous operating temperature of Repair sleeve

Deg.C

NOTE: Tolerances, wherever applicable shall also be specifiedDate: (Signature)Place:


34

21.7 GUARANTEED TECHNICAL PARTICULARS OF VIBRATION DAMPER FOR HTLS CONDUCTOR




3 Drawing enclosed

a)Design Drawing Yes/No

b)Placement Chart Yes/No


5 Total weight of one damper kg

Right

Left

6 Diameter of each damper mass mm

7 Length of each damper mass mm

8 Weight of each damper mass kg

9 Material of damper masses

10 Material of clamp

11 Material of the stranded messenger cable

12 Number of strands in stranded messenger cable

13 Lay ratio of stranded messenger cable

14 Minimum ultimate tensile strength ofstranded messenger cable

Kg/mm2

15 Slip strength of stranded messenger cable (mass pull off)

kN

16 Resonance frequencies

a)First frequency Hz

b)Second frequency Hz

17 Designed clamping torque Kg-m

35

18 Slipping strength of damper clamp

a)Before fatigue test kN

b)After fatigue test kN

19 Magnetic power loss per vibration damper for 640 amps, 50 Hz Alternating current

Watts

20 Maximum permissible continuous operating temperature of Vibration Damper

Deg.C

21 Percentage variation in reactance after fatigue test in comparison with that before fatigue test

%

22 Percentage variation in power dissipation after fatigue test in comparison with that before fatigue test

%

NOTE: Tolerances, wherever applicable shall also be specifiedDate: (Signature)

Place:


36

22. SAG TENSION CHARTS AND SAG TEMPLATES

The contractor shall supply six copies of sag tension charts and sag templates each inrespect of the conductor. The contractor shall also supply sag template in celluloid, whichshall be subject to the approval by the owner and without involving any extra charges. Thesag template will be used for changing the tower positions in future.

23. ACCESSORIES

The Bidder after his survey of the existing line shall determine the quantity and type ofthe accessories required for the turnkey job, which are to be supplied by them. Theseaccessories should be suitable for the supplied conductor for its entire operating rangewithout degradation of mechanical, metallurgical and electrical properties. The steadystate temperature of hardware and accessories must not exceed 90°C during no wind and50°C ambient temperature at minimum 640A load. The contractor shall be responsiblefor satisfactory performance of complete conductor, insulators, hardware and accessories,offered by him, for continuous operation at temperatures corresponding to variousconditions stipulated in 2.4 of this technical specification.

24. EXECUTION OF WORK

24.1 The erection works consist of a. Dismantling of existing ACSR Wolf, Tiger & Dog Conductors, earth wire and

insulators, hardware, accessories and crediting at KSEBL store. b. Transportation, delivery of conductor, earth wire, hardware, accessories etc. at

erection site and keeping in safe custody. c. Insurance of materials during storage-cum-erection. d. Distribution of materials at erection site. e. Stringing of conductor & OPGW up to both ends of the lines, with the help of

tensioner and puller machine and if required, manually with the approval of theowner.

f. Guarantee of all the activities carried out from (a) to (e) and submission of FQP forcarrying out of all above activities.

g. Other items not specifically mentioned in this Specification and are required for thesuccessful erection and commissioning of the transmission lines, unless specificallyexcluded in the Specification.

24.2 All works shall be carried out in accordance with the revised and latest provisionsunder CEA Regulations made there under.

24.3 All the erection tools required during erection of lines shall be arranged by theContractor at his own cost. The Contractor shall also be responsible for any damage to and /or loss of his erection tools.

24.4 In case of any deviation in quantities from the tendered quantity, payment will bemade with the approval from the corporate office of the owner.

24.5 It will be the Contractor's sole responsibility to take the materials up to the location.Any pathway, temporary road, temporary bridge required for the work, same will beprovided by the contractor at his cost. If, for any reasons the above is not feasible, thecontractor at his own cost shall have to arrange transportation by head loads.

25. STRINGING

The stringing work shall be carried with the help of tensioner and puller machines.Wherever it is not possible to install the tensioner, it can be done manually with theapproval of site engineer of the owner. Stringing shall mean, the activities of paving,jointing, tensioning, clamping with armor-rod, providing dampers and fixing the conductorat tension hardware and jumpering etc. 1. Stringing of conductor & OPGW shall be done up to gantry at both ends of the

individual lines.2. The stringing work should be planned in such a manner in consultation with the

Engineer in charge of the Owner that minimum shut down of power line crossings arerequired. Revenue loss due to any undue shut down due to contractor's irresponsibility

37

shall be recoverable from the contractor. 3. Before commencing of stringing work, Contractor shall obtain approval of sag tension

charts showing final sag and tension for various temperature and spans. 4. The Contractor shall be responsible and will take care of proper handling of conductor

drums. Sufficient numbers of aluminum snatch blocks shall be used for paving out theConductors. Necessary precautions shall be taken to avoid conductor rubbing on theground by providing adequate ground roller, rollers on supports. Additional rollersshall also be provided to cross thorny hedges, tower footing and other obstructions toavoid scratching of conductor. The conductor shall be made to sag correctly as perstringing charts, before they are finally transferred to the hardware and clamps. The sagshall be adjusted to suit the sag indicated against actual temperature. The thermometershall be provided at the conductor point during the stringing work. Dynamo metersshall be used in tensioning the conductors. All conductors shall be stressed to their loadat the time of stringing, as per approved stringing charts.

5. The minimum clearance between the lowest point of conductor and ground shall not beless than as specified Clause 2 - Design Parameters. All compression joints should becarefully made and a record of initial and final lengths of the joints, jointly signed bycontractor and KSEBL representatives shall be maintained. Check for sag should alsobe made at intervals when conductors are drawn up. Over stressing, causing damage totowers must be avoided. Care should be exercised not to over tension the conductor. Toavoid contact with the ground or any object above ground level the conductors shall bepulled by the controlled tension methods using neoprene lined double pulled wheeltype tension stringing equipments. The equipment shall be capable of maintainingcontinuous tension of not less than of 3000 kg per conductor.

6. When the conductor is on the stringing rollers before sagging-in, it shall be ensured thatthe conductor is not damaged due to wind, vibration, vehicles or other causes.Scaffolding should be used to cross the important road crossings for minimuminterruption to traffic.

7. The conductor shall be pulled up to desired sag and left in serial stringing sheaves for atleast one hour after which the sag shall be rechecked and adjusted, if necessary, beforeclipping in and transferring the conductors from the serial stringing sheaves to thesuspension clamps.

8. The stringing rollers, when suspended on the transmission structure for supportingconductors, shall be so adjusted that the conductor will be on the rollers at the sameheight as the suspension clamp to which it is to be secured.

9. Armour rods and vibration dampers shall be fitted at each suspension and tension towerbefore final clamping of conductor with Insulator strings. Vibration dampers are to befixed with clamping bolt and in correct vertical position in relation to conductor.

10. Compression type joints are to be used for jointing of conductors. Each part connectedwith joints shall be perfectly cleaned & precautionary measures taken before finalcompression. All the joints of conductors shall be made with the best workmanship andshall be perfectly straight and having maximum possible strength.

11. Proper guys shall be provided to counter balance the paving out tension of conductor atthe tension locations, to avoid damage to towers and/or accident.

26. FIELD QUALITY PLAN (FQP)Bidder shall invariably submit the FQP along with Technical Bid for erection of lineincluding all the activities such as dismantling, stringing etc. with detailed checklist to bereferred.

27. WASTAGE27.1 The maximum permitted ceiling for wastages for conductor permitted is 0.5%(maximum) which takes into account the additional length for sag & jumpers. 27.2 No wastage is allowed for any material except the percentage limit mentioned forConductor here in above in Clause No. 27.1.

28. LOSSESIn the event of any material used for transmission line found broken or damaged or receivedshort during transit or failed during the erection / testing at site before commissioning ofline, the contractor shall replace the same free of cost.

29. COMMISSIONING

38

29.1 The contractor shall ensure that at the end of each sub-activity the surplus material isimmediately removed from the work-site to avoid loss and injury to the public. 29.2 The contractor has to make reconciliation of material account and to settle final billincluding signature in all relevant papers required for passing of final bill within threemonths from the date of charging / commissioning of line.

30. STANDARDS AND SPECIFICATIONS The following are attached as Appendix.

39

Appendix I …..

Appendix II Standards for conductor

Appendix IIIAppendix IV

Standards for composite insulators Standards for accessories

Appendix V Tests on complete composite insulators with Hardware fittings

Note: Bidder is advised to cross verify the details at site if required before proceeding with thebid. KSEBL will in no way be responsible for errors in the data furnished above.

40

APPENDIX- IISTANDARDS FOR CONDUCTOR

Sl. No. Title International Standard

1 Specification for aluminium conductors for overhead transmission purposes

IEC:1089-1991, BS:215-1970

2 Breaking Strength Epoxy Ends Aluminum Association

3 Stress-strain Curves Epoxy Ends Aluminum Association or IEC 61089

4 Electrical Resistance ASTM B193, IEC:468

5 Creep (250 C) Aluminum Association, IEC 61395, IEEE:1138

6 Sheave Test IEEE:1138, IEC:61396

7 Core Creep (2500C) Aluminum Association

8 Fault Current IEEE 1138, IEC 61396

9 Aeolian Vibration IEEE 1138, – use mechanical set-up

10 Galloping IEEE 1138, – use mechanical set-up

11 Axial Impact, Radial Crush IEEE 1138, EIA/TIA 455-25A/41A

12 Lightning Strike IEC 61396

13 Torsional Ductility ASTM

14 Corrosion & salt spray ISO 9227:1990 or ASTM B117

15 Outer wire layer ASTM B941-05

16 Stranding, workmanship, finish and appearance ASTM B232/B232M

17 Elongation & strength ASTM B557

18 Corona IEEE 4

19 Sustained ampacity test at ambient & elevated temperature

ANSI C119.4, IEEE:738

20 Reels and drums for bare conductors IS:1778-1980, BS:1559-1949

21 Method of radio interference tests IS:8263-1990, IEC:437-1973, NEMA:107-1964

41

APPENDIX- IIISTANDARDS FOR SILICON RUBBER HOUSED COMPOSITE INSULATORS

The Manufacturer should confirm the product with following Indian Standard, InternationalStandards containing latest revisions, amendments, changes adopted.

Sr.No.

IndianStandards

Title InternationalStandards

1 IS:209-1992 Specifications for Zinc BS:3436

2 IS:406-1991 Method of Chemical Analysis of Slab Zinc

BS:3436

3 Composite insulators for A.C. Overhead Power lines with a nominal voltage greater than 1000V

IEC:61109-1992

4 IS Part Part (II)-1991 Part (II)-1991

Methods of High Voltage Testing IEC 60060-1 2071 (I)

5 IS : 2486 Specification for Insulator fittings for Overhead Power Lines with a nominal voltage greater than 1000V

IEC : 575

Part I-1993 General Requirements and Tests. BS-3288

Part II-1989 Dimensional Requirements IEC-6020

Part-III1991 Locking Devices IEC-60372

6 IS : 2629- 1990 Recommended Practice for hot dip galvanisation for iron and steel.

ISO-1461 (E)

7 IS : 2633- 1992 Testing of Uniformity of Coating ofzinc coated articles.

8 IS -6745- 1990

Determination of weight of Zinc Coating on Zinc coated iron and steel articles

BS- 443-1969ISO 1460-1973

9 IS : 8263- 1990 Methods of RI Test of HV insulators

IEC-60437 NEMA Publication No. 07/1964 CISPR

10 IS : 8269- 1990 Methods for Switching Impulse test on insulators

HV IEC-60506

11Salt Fog Pollution Voltage Withstand Test.

IEC-60507

12 Guide for the selection ofinsulators in respect of pollutedconditions.

IEC-60815

13Tests or insulators of Ceramicmaterial or glass or glass foroverhead lines with a nominalvoltage greater than 1000 V

IEC-60363

However, in an event of supply of insulators conforming to standards other than specified, theBidder shall confirm in his bid that these standards are equivalent to those specified. Incase of award, salient features of comparison between the standards proposed by theBidder and those specified in this document will be provided by the Supplier toestablish equivalence.

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APPENDIX- IVSTANDARDS FOR ACCESSORIES

Sl. No. Test Standards Modifications

1 Dead-end, Joint Strengths Aluminum Association, ANSI C119.4 121

2 Current Cycling ANSI C119.4 -ANSI C119.7

3 Sustained Load (room temperature) ANSI C119.4

4 Sustained Load (high temperature) ANSI C119.4

5 Aeolian Vibration IEEE 1138, – use mechanical setup None

6 Galloping IEEE 1138, – use mechanical setup 8% RBS,

7 Corrosion ASTM B117 None

8 Corona Testing IEEE539/656 None

9 Damper Efficiency IEEE 664 None

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APPENDIX- VTESTS ON COMPLETE COMPOSITE INSULATOR WITH HARDWARE FITTINGS

1. Tests on Complete composite Insulator with Hardware Fittings. 1.1 Salt - fog pollution withstand test This test shall be carried out in accordance with IEC-60507. The salinity level forcomposite long rod insulators shall be 80 Kg / m3 NACL. 2. Composite Long rod Insulator Units. 2.1 Brittle Fracture Resistance Test. Assembled core load time test with container that contains in-HNO3 concentric acid, this isapplied at the naked rod. The rod should be held at 80% of SML for the duration of thetest. The rod should not fail within the 96 hour test duration. 2.2 Recovery of Hydrophobicity Test

i. The surface of selected samples shall be cleaned with isopropyl alcohol.Allow the surface to dry and spray with water. Record the HC classification. Dry thesample surface.

ii. Treat the surface with corona discharges to destroy the hydrophobicity. This can bedone utilizing a high frequency corona tester. Holding the electrode approximately 3mm from the sample surface slowly move the electrode over an area approximately 1''x 1''. Continue treating this area for 2-3 minutes, operating the tester at maximumoutput.

iii. Immediately after the corona treatment, spray the surface with water and record theHC 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 7is obtained. Dry the sample surface.

iv. Allow the sample to recover and repeat the hydrophobicity measurement at severaltime intervals. Silicon rubber should recover to HC1 - HC2 within 24 to 48 hours,depending on the material and the intensity of the corona treatment.

3. Test on All components (as applicable). 3.1 Chemical Analysis of Zinc used for Galvanizing. Samples taken from the zinc ingot shall be chemically analysed as per IS 209-1979. Thepurity of zinc shall not be less than 99.95%. 3.2 Tests for Forgings. The chemical analysis hardness tests and magnetic particle

inspection for forgings will be as per the internationally recognized procedures for these tests.The sampling will be based on heat number and heat treatment batch. The details regarding testwill be as discussed and mutually agreed to by the Supplier and Owner in Quality AssuranceProgramme. 3.3 Tests on Castings. The chemical analysis, mechanical and metallographic tests and

magnetic, particle inspection for castings will be as per the internationally recognisedProcedures for these tests. The samplings will be based on heat number and heat treatmentbatch. The details regarding test will be as discussed and mutually agreed to by theSupplier and Owner in Quality Assurance Programme.

4. Power Arc Test: 4.1 One insulator having any one design of end fittings shall be tested for power

arc endurance while tensioned horizontally at 3000lb. An arc shall be initiated across theinsulator by means of a Copper shorting fuse wire. The arc shall burn 15 to 30 cycles andits current magnitude is determined by ampere- time product (I xT) equal to a minimum of150kA cycles. Each insulator is only acceptable if there is no exposure of the core,no mechanical separation of the insulator, and no cracks in the housing (As perIEC61467-1997)

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TECHNICAL PARTICULARS OF OPTICAL GROUND WIRE(OPGW)(24 FIBRE) CABLING & ASSOCIATED HARDWARE & FITTINGS

INDEX

3.1 Fibre Optic Cabling3.1.1 Required Optical Fibre Characteristics3.1.1.1 Physical Characteristics3.1.1.2 Attenuation3.1.2 Fibre Optic Cable Construction3.1.2.1 Transmission Line Details3.1.2.2 Optical Fibre Cable Link Lengths3.1.2.3 Optical Fibre Identification3.1.2.4 Buffer Tube3.1.2.5 Optical Fibre Strain & Sag-tension chart3.1.2.6 Cable Materials3.1.2.6.1 Filling Materials3.1.2.6.2 Metallic Members3.1.2.6.3 Marking, Packaging and Shipping3.1.2.7 OPGW cable installation requirements3.1.2.8 Optical Ground Wire (OPGW)3.1.2.8.1 Central Fibre Optic Unit3.1.2.8.2 Basic Construction3.1.2.8.3 Breaking Strength3.1.2.8.4 Electrical and Mechanical Requirements3.1.2.8.5 Operating conditions3.1.2.8.6 Installation3.1.2.8.7 Installation Hardware3.1.3 Fibre Optic Splice Enclosures (Joint Box)3.1.3.1 Optical Fibre Splices3.1.4 Optical Fibre Termination and Splicing3.1.4.1 Fibre Optic Distribution Panel3.1.4.2 Optical Fibre Connectors3.1.5 Service Loops3.1.6 Methodology for Installation and Termination3.1.7 Cable Raceways

OPGW cabling and associated hardware & fittings

This section describes the functional & technical specifications of OPGW cabling andassociated hardware & fittings.

3.1 Fibre Optic CablingThis section defines the requirements for G.652D Dual-window Single mode (DWSM)

telecommunications grade fibre optic cable. Bidders shall furnish with their bids, detaileddescriptions of the fibres & cable(s) proposed. All optical fibre cabling including fibre itselfand all associated installation hardware shall have a minimum guaranteed design life spanof 25 years. Documentary evidence in support of guaranteed life span of cable & fibre shallbe submitted by the Contractor during detailed engineering.

3.1.1 Required Optical Fibre CharacteristicsThis section describes the characteristics of optical fibre to be provided under this

specification.

3.1.1.1 Physical CharacteristicsDual-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 3-1(a).3.1.1.2 AttenuationThe 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. The attenuation coefficient

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between 1285 nm and 1330 nm shall not exceed the attenuation coefficient at 1310 nm bymore than 0.05 dB. The attenuation of the fibre shall be distributed uniformly throughout itslength such that there are no point discontinuities in excess of 0.10 dB. The fibre attenuationcharacteristics specified in table 3-1 (a) shall be “guaranteed” fibre attenuation of any &every fibre reel.

The overall optical fibre path attenuation shall not be more than calculated below:Maximum attenuation @ 1550nm: 0.21 dB/km x total km + 0.05 dB/splice x no. of splices +

0.5 dB/connector x no. of connectors

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

Table 3-1(a)DWSM Optical Fibre Characteristics

Fibre Description:Dual-Window Single-Mode

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

Cladding Diameter:125.0 μm ± 1 μm

Mode field concentricity error

≤ 0.6μm

Cladding non-circularity≤ 1%

Cable Cut-off Wavelength λcc

≤ 1260 nm

1550 nm loss performance As per G.652 D

Proof Test Level ≥ 0.69 Gpa

Attenuation Coefficient: @. 1310 nm ≤ 0.35 dB/km@. 1550 nm ≤ 0.21 dB/km

Chromatic Dispersion; Maximum:

Zero Dispersion Wavelength:Zero Dispersion Slope:

18 ps/(nm x km) @ 1550 nm3.5 ps/(nm x km) 1288-1339nm5.3 ps/(nm x km) 1271-1360nm

1300 to 1324nm0.092 ps/(nm2xkm) maximum

Polarization mode dispersioncoefficient

≤ 0.2 ps/km^½

Temperature Dependence: Induced attenuation ≤ 0.05 dB (-60°C - +85°C )

Bend Performance: @ 1310 nm (75±2 mm dia Mandrel), 100 turns;Attenuation Rise ≤ 0.05 dBBend Performance:@ 1550 nm (30±1 mm radius Mandrel), 100 turns;Attenuation Rise ≤ 0.05 dB@ 1550 nm (32±0.5 mm dia Mandrel, 1 turn;Attenuation Rise ≤ 0.50 dB

3.1.2 Fibre Optic Cable Construction

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Overhead Fibre Optic Cables shall be OPGW (Optical Ground Wire). The OPGW cable isproposed to be installed on transmission lines. The design of cable shall account for thevarying operating and environmental conditions that the cable shall experience while inservice.

3.1.2.1 Transmission Line Details

Typical details of transmission lines are indicated in the Appendices. Any other details, asrequired for cable design etc. shall be collected by the Contractor during survey.

3.1.2.2 Optical Fibre Cable Link Lengths

The Contractor shall supply & install the optical fibre cable as required based on detailed sitesurvey to be carried out by the Contractor during the project execution. The Contract priceshall be adjusted accordingly.

For the purpose of payment, the optical fibre link lengths are defined as transmission lineroute lengths from Gantry at one terminating station to the Gantry in the other terminatingstation. The actual cable lengths to be delivered shall take into account various factors suchas sag, service loops, splicing, working lengths & wastage etc. and no additional paymentshall be payable in this regard. The unit rate for FO cable quoted in the Bid price Schedulesshall take into account all such factors.

3.1.2.3 Optical Fibre IdentificationIndividual optical fibres within a fibre unit and fibre units shall be identifiable in accordancewith 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 coatingand shall be homogenous. The colour shall not bleed from one fibre to another and shall notfade during fibre preparation for termination or splicing.

Each cable shall have traceability of each fibre back to the original fibre manufacturer'sfibre number and parameters of the fibre. If more than the specified number of fibres areincluded in any cable, the spare fibres shall be tested by the cable manufacturer and anydefective fibres shall be suitably bundled, tagged and identified at the factory by the vendor.

3.1.2.4 Buffer Tube

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

3.1.2.5 Optical Fibre Strain & Sag-tension chart

The fibre optic cable shall be designed and installed such that the optical fibres experienceno strain under all loading conditions defined in IS 802. Zero fibre strain condition shallapply even after a 25 year cable creep.For the purpose of this specification, the following definitions shall apply:

• Maximum Working Tension (MWT) is defined as the maximum cable tension at which there is no fibre strain.

• The no fibre strain condition is defined as fibre strain of less than or equal to 0.05%, as determined by direct measurements through IEC/ ETSI (FOTP) specified

optical reflectometry techniques.

• The Cable strain margin is defined as the maximum cable strain at which there is no fibrestrain.

• The cable Maximum Allowable Tension (MAT) is defined as the maximum tension

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experienced by the Cable under the worst case loading condition.

• The cable max strain is defined as the maximum strain experienced by the Cable under theworst case loading condition.

• The cable Every Day Tension (EDT) is defined as the maximum cable tension on any spanunder normal conditions.

• The Ultimate /Rated Tensile Strength (UTS/ RTS/ breaking strength) is defined as themaximum tensile load applied and held constant for one minute at which the specimen shallnot break.While preparing the Sag-tension charts for the OPGW cable the following conditions shallbe met:

• The Max Allowable Tension (MAT) / max strain shall be less than or equal to theMWT/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 0.4 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 thecable strain margin.

• The everyday tension (EDT) shall not exceed 20% of the UTS for the OPGW cable.

The Sag-tension chart of OPGW cable indicating the maximum tension, cable strain and sagshall be calculated and submitted along with the bid under various conditions mentionedbelow:

1. 53° C , no wind and no ice2. 32° C, no wind and no ice3. 0°C, no wind and no ice4. 32° C, full wind and no ice5. 32° C, 75% full wind and no ice6. 0° C, 2/3rd / 36% of full wind (IS 802:1977/1995)

The above cases shall be considered for the spans from 100 m to 600 m or higher spanlength in the range of 50 m spans. Max. vertical sag, max. tension and max sag at 0° C & nowind shall be considered for in line with the design parameter of transmission line. The fullwind load shall be considered as the design wind load for all the specified transmission linesas per relevant IS 802 version and the sag-tension chart shall be submitted considering thetransmission lines. The Contractor shall submit the stringing chart for review of Employer.

3.1.2.6 Cable Materials

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

3.1.2.6.1 Filling Materials

The interstices of the fibre optic unit and cable shall be filled with a suitable compound toprohibit any moisture ingress or any water longitudinal migration within the fibre optic unitor along the fibre optic cable. The water tightness of the cable shall meet or exceed the testperformance criteria as per IEC-794-1-F-5.

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

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

3.1.2.6.2 Metallic Members When the fibre optic cable design incorporates metallic elements in its construction, all

metallic elements shall be electrically continuous.3.1.2.6.3 Marking, Packaging and Shipping

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This section describes the requirements for marking, packaging and shipping the overheadfibre optic cable.

(a) Drum Markings: Each side of every reel of cable shall be permanently marked in whitelettering with the vendors' address, the Purchaser’s destination address, cable part numberand specification as to the type of cable, length, number of fibres, a unique drum numberincluding the name of the transmission line & segment no., factory inspection stamp anddate.

(b) Cable Drums: All optical fibre cabling shall be supplied on strong drums provided withlagging of adequate strength, constructed to protect the cabling against all damage anddisplacement during transit, storage and subsequent handling during installation. Both endsof the cable shall be sealed as to prevent the escape of filling compounds and dust &moisture ingress during shipment and handling. Spare cable caps shall be provided witheach drum as required.

The spare cable shall be supplied on sturdy, corrosion resistant, steel drums suitable for longperiods of storage and re-transport & handling.

There shall be no factory splices allowed within a continuous length of cable. Only onecontinuous cable length shall be provided on each drum. The lengths of cable to be suppliedon each drum shall be determined by a "schedule" prepared by the Contractor.

3.1.2.7 OPGW cable installation requirements

Most of the OPGW fibre optic cables to be installed under this project shall be installedunder live line conditions, i.e. with all the circuits of the transmission line charged to theirrated voltage. However, some of OPGW cables may be installed in off-line conditions. Thetentative bill of quantities for both live-line as well as off-line OPGW cable systeminstallations have been specified in the appendices and the actual quantities for both typesshall be finalised during project execution after detailed survey.

Under live line installation, the OPGW cable shall be installed on transmission lines underlive line conditions, i.e. with all the circuits of the transmission line charged to their ratedvoltage.

The OPGW cable shall be installed at the top of the tower by replacing the existing groundwire. The Contractor shall carry out re-tensioning of the existing earth wire whereverrequired to maintain the adequate clearances for live line stringing of fibre optic cables.However, in exceptional casesinstallation of OPGW cable below conductor may also be considered on low voltage lineswhich shall be decided during detailed engineering.

While handing over the OPGW drums, the testing (fibre loss and length measurement usingOTDR) of OPGW in each drum shall be carried out by concerned Communication wing andthe Contractor. After installation of OPGW cable, the testing of each section shall be carriedout again by concerned Communication wing in presence of contractor(s) representative. Incase of any damage/high loss in the fibre, the total length of that particular section ofOPGW cable shall be replaced by Contractor(s). Contractor shall supply new OPGW cablein place of damaged cable. The Contract price shall be adjusted accordingly.

Supervision of Installation -The Contractor shall supervise the stringing at site as per theapproved stringing procedure. Site visit for supervision shall be carried out as perinstruction of Employer. The contract price shall be adjusted as per the actual requirement.The Supervision/Inspection work in Contractor’s scope shall mainly include inspection asper stringing procedure, proper location of drum site, installation of stringingblocks/pulleys, proper sagging, proper installation of hardware, proper tension as per Sag-Tension

chart, provision of service loops of OPGW in jointing locations etc.

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3.1.2.8 Optical Ground Wire (OPGW)

OPGW cable construction shall comply with IEEE-1138, 1994. The cable provided shallmeet both the construction and performance requirements such that the ground wirefunction, the optical fibre integrity and optical transmission characteristics are suitable forthe intended purpose. The cable shall consist of optical fibre units as defined in thisspecification. There shall be no factory splices within the cable structure of a continuouscable length.

The composite fibre optic overhead ground wire shall be made up of buffered optical fibreunits(fibres in the buffer tube) embedded in a water tight aluminium / aluminiumalloy/stainless steel protective central fibre optic unit surrounded by concentric-lay strandedmetallic wires in single or multiple layers. The dual purpose of the composite cable is toprovide the electrical and physical characteristics of conventional overhead ground wirewhile providing the optical transmission properties of optical fibre.

3.1.2.8.1 Central Fibre Optic Unit

The central fibre optic unit shall be designed to house and protect multiple buffered opticalfibre units from damage due to forces such as crushing, bending, twisting, tensile stress andmoisture. The central fibre optic unit and the outer stranded metallic conductors shall servetogether as an integral unit to protect the optical fibres from degradation due to vibrationand galloping, wind and ice loadings, wide temperature variations, lightning and faultcurrent, as well as environmental effects which may produce hydrogen.The OPGW design of dissimilar materials such as stainless steel tube with aluminium oraluminium–clad-steel wire strands are not allowed. Central fibre optic unit may be ofaluminium or stainless steel tube with aluminium protective coating. In case of aluminiumprotective coating, the coating must completely cover the tubes leaving no exposed areas oftubing that can make electrical contact either directly or indirectly through moisture,contamination, protrusions, etc. with the surrounding stranded wires. The tube may befabricated as a seamless tube, seam welded, or a tube without a welded seam.

3.1.2.8.2 Basic Construction

The cable construction shall conform to the applicable requirements of this specification,applicable clauses of IEC 61089 related to stranded conductors and Table 3.2(a) OPGWMechanical and Electrical Characteristics. In addition, the basic construction shall includebare concentric-lay-stranded metallic wires with the outer layer having left hand lay. Thewires may be of multiple layers with a combination of various metallic wires within eachlayer. The direction of lay for each successive layer shall be reversed. The finished wiresshall contain no joints or splices unless otherwise agreed to by the Employer and shallconform to all applicable clauses of IEC 61089 as they pertain to stranded conductors.The wires shall be so stranded that when the complete OPGW is cut, the individual wirescan be readily regrouped and then held in place by one hand.

3.1.2.8.3 Breaking Strength

The rated breaking strength of the completed OPGW shall be taken as not more than 90percent of the sum of the rated breaking strengths of the individual wires, calculated fromtheir nominal diameter and the specified minimum tensile strength.

The rated breaking strength shall not include the strength of the optical unit. The fibre opticunit shall not be considered a load bearing tension member when determining the total ratedbreaking strength of the composite conductor.

3.1.2.8.4 Electrical and Mechanical Requirements

Table 3-2(a) provides OPGW Electrical and Mechanical Requirements for the minimumperformance characteristics. Additionally, the OPGW mechanical & electricalcharacteristics shall be similar to that of the earth wire being replaced such that there is noor minimal consequential increase in stresses on towers. For the purposes of determining theappropriate Max Working Tension limit for the OPGW cable IS 802:1995 and IS 875: 1987

50

shall be applied. However the OPGW installation sag & tension charts shall be based on IS802 version to which the line is originally designed. For the OPGW cable design selectionand preparation of sag tension charts, the limits specified in this section shall also besatisfied. The Bidder shall submit sag-tension charts for the above cases with their bids.

Table 3.2(a)

OPGW Electrical and Mechanical Requirements

1 Everyday Tension ≤ 20% of UTS of OPGW

2 D.C Resistance at 20º C < 1.0 ohm/Km,

3 Short Circuit Current ≥ 6.32 kA for 1.0 second

3.1.2.8.5 Operating conditions

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

3.1.2.8.6 Installation

OPGW installed under live line condition, i.e. with all circuits charged to the rated linevoltage as specified in this section shall be generally in accordance with the IEEE Guide tothe Installation of Overhead Transmission Line Conductors (IEEE STD. 524 with latestrevisions), with additional instructions and precautions for live line working and fibre opticcable handling. The stringing procedure shall be submitted by the Contractor prior tostringing for Employer’s approval. A tower structural analysis shall be carried out by the Contractor, based on the relevant datato be provided by Employer, to ensure that with the replacement of existing earth wire withthe OPGW cable, the tower members remain within the statutory safety limits as per IndianElectricity rules and if required the Contractor shall carry out the tower strengthening asnecessary. The OPGW cable sections shall normally be terminated & spliced only ontension towers. In exceptional circumstances, and on Employer specific approval, cable maybe terminated on Suspension towers, but in this case tower strength shall be examined toensure that tower loads are within safe limits and if required, necessary tower strengtheningshall be carried out by the Contractor.

3.1.2.8.7 Installation Hardware

The scope of supply of the optical cable includes the assessment, supply and installation of allrequired fittings and hardware such as Tension assembly, Suspension assembly, Vibrationdampers, Reinforcing rods, Earthing clamps, Downlead clamps, splice enclosure etc. TheBidder shall provide documentation justifying the adequacy and suitability of the hardwaresupplied. The Contractor shall determine the exact requirements of all accessories required toinstall and secure the OPGW.

The OPGW hardware fittings and accessories shall follow the general requirements regardingdesign, materials, dimensions & tolerances, protection against corrosion and markings asspecified in clause 4.0 of EN 61284: 1997 (IEC 61284). The shear strength of all bolts shall beat least 1.5 times the maximum installation torque. The OPGW hardware & accessoriesdrawing & Data Requirement Sheets (DRS) document shall consist of three parts: (1) Atechnical particulars sheet (2) An assembly drawing i.e. level 1 drawing and (3) Componentlevel drawings i.e. level 2 & lower drawings. All component reference numbers, dimensionsand tolerances, bolt tightening torques & shear strength and ratings such as UTS, slip strengthetc shall be marked on the drawings.

The fittings and accessories described herein are indicative of installation hardware typicallyused for OPGW installations and shall not necessarily be limited to the following:

51

(a) Suspension Assemblies: Preformed armour grip suspension clamps and aluminium alloyarmour rods/ reinforcing rods shall be used. The suspension clamps shall be designed to carry avertical load of not less than 25 kN. The suspension clamps slippage shall occur between 12kNand 17 kN as measured in accordance with type test procedures.

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 exceed150 mm (measured from the centre point of attachment to the centre point of the OPGW). Thedesign of the assembly shall be such that the direction of run of the OPGW shall be the sameas that of the conductor.

(b) Dead End Clamp Assemblies: All dead end clamp assemblies shall preferably be ofperformed armoured grip type and shall include all necessary hardware for attaching theassembly to the tower strain plates. Dead end clamps shall allow the OPGW to pass throughcontinuously without cable cutting. The slip strength shall be rated not less than 95% of therated tensile strength of the OPGW.

(c) Clamp Assembly Earthing Wire: Earthing wire consisting of a 1500 mm length ofaluminium or aluminium alloy conductor equivalent in size to the OPGW shall be used to earthsuspension and dead end clamp assemblies to the tower structure. The earthing wire shall bepermanently fitted with lugs at each end. The lugs shall be attached to the clamp assembly atone end and the tower structure at the other.

(d) Structure Attachment Clamp Assemblies: Clamp assemblies used to attach the OPGW tothe structures, shall have two parallel grooves for the OPGW, one on either side of theconnecting bolt. The clamps shall be such that clamping characteristics do not alter adverselywhen only one OPGW is installed. The tower attachment plates shall locate the OPGW on theinside of the tower and shall be attached directly to the tower legs/cross-members withoutdrilling or any other structural modifications.

(e) Vibration Dampers: Vibration dampers type 4R Stockbridge or equivalent, having four (4)different frequencies spread within the Aeolian frequency bandwidth, shall be used forsuspension and tension points in each span. The Contractor shall determine the exact numbersand placement(s) of vibration dampers through a detailed vibration analysis as specified intechnical specifications. Vibration damper clamps shall be made of aluminium or aluminiumalloy, shall support the dampers during installation and shall maintain the dampers in positionwithout damage to the OPGW and without causing fatigue. Armour or patch rods made ofaluminium or aluminium alloy shall be provided as required to reduce clamping stress on theOPGW. The vibration damper body shall be hot-dip galvanised mild steel/cast iron or shall bepermanent mould cast zinc alloy.

3.1.3 Fibre Optic Splice Enclosures (Joint Box)

All splices shall be encased in Fibre Optic Splice Enclosures. Suitable splice enclosures shallbe provided to encase the optical cable splices in protective, moisture and dust freeenvironment. Splice enclosures shall comply to ingress protection class IP 66 or better. Thesplice enclosures shall be designed for the storage and protection of required number of opticalfibre splices and equipped with sufficient number of splice trays for splicing all fibres in thecable. No more than 6 fibres shall be terminated in a single splice tray. They shall be filledwith suitable encapsulate that is easily removable should re-entry be required into theenclosures.

Splice enclosures shall be suitable for outdoor use with each of the cable types provided underthis contract. Splice enclosures shall be appropriate for mounting on transmission line towersabove anticlimb guard levels at about 10 metres from top of the tower and shall accommodatepass-through splicing. The actual mounting height and location shall be finalised after survey.Contractor shall be responsible for splicing of fibres and installation of splice enclosures.

3.1.3.1 Optical Fibre Splices

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

52

tower structures.

All optical fibre splicing shall comply with the following:

(a) All fibre splices shall be accomplished through fusion splicing.

(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. No more than six(6) fibres shall be installed in each splice tray.

(d) For each link, bi-directional attenuation of single mode fusion splices, shall not averagemore 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 allsplices occurring at tower structures can be performed at ground level.

3.1.4 Optical Fibre Termination and Splicing

Optical fibre terminations shall be installed in Fibre Optic Distribution Panels (FODP)designed to provide protection for fibre splicing of preconnectorized pigtails and toaccommodate connectorized termination and coupling of the fibre cables. The Contractor shallprovide rack /wall mounted Fibre Optic Distribution Panels (FODPs) sized as indicated in theappendices and shall terminate the fibre optic cabling up to the FODPs. The location of FODPrack shall be fixed by the Contractor, with the Employer’s approval.

3.1.4.1 Fibre Optic Distribution Panel

At each location requiring the termination of at least one fibre within a cable, all fibres withinthat cable shall be connectorized and terminated in Fibre Optic Distribution Panels in a mannerconsistent with the following:

(a) All fibre optic terminations shall be housed using FODPs provisioned with spliceorganizers and splice trays. All fibres within a cable shall be fusion spliced to preconnectorizedpigtails 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 thiscontract. FODPs shall accommodate pass-through splicing and fibre terminations.

(c) FODPs for indoor use shall be supplied in suitable cabinets/racks with locking arrangement

(d) All FODPs shall be of corrosion resistant, robust construction and shall allow both top orbottom entry for access to the splice trays. Ground lugs shall be provided on all FODPs and theContractor shall ensure that all FODPs are properly grounded. The FODP shall meet or exceedingress protection class IP55 specifications.

(e) Flexible protection shall be provided to the patch cord bunches going out from FODP toother equipment.

3.1.4.2 Optical Fibre Connectors

Optical fibres shall be connectorised with FC-PC type connectors preferably. Alternativelyconnector with matching patch cord shall also be acceptable. Fibre optic couplings suppliedwith FODPs shall be appropriate for the fibre connectors to be supported. There shall be noadapters.

3.1.5 Service Loops

For purposes of this specification, cable and fibre service loops are defined as slack (extra)cable and fibre provided for facilitating the installation, maintenance and repair of the opticalfibre cable plant.

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(a) Outdoor Cable Service Loops: In-line splice enclosures installed outdoors and mounted onthe utility towers, shall be installed with sufficient fibre optic cable service loops such that therecommended minimum bend radius is maintained while allowing for installation ormaintenance of the cable to be performed in a controlled environment at ground level.

(b) Indoor Cable Service Loops: FODPs shall provide at least three (3) metres of cable serviceloop. Service loops shall be neatly secured and stored, coiled such that the minimumrecommended bend radius' are maintained.

(c) Fibre Units Service Loops: For all fibre optic cable splicing, the cable shall be strippedback a sufficient length such that the fan-out of fibre units shall provide for at least one (1)metre of fibre unit service loop between the stripped cable and the bare fibre fan-out.

(d) Pigtail Service Loops : Connectorised pigtails spliced to bare fibres shall provide at least 1metre of service loop installed in the FODP fibre organizer and at least one (1) metre of serviceloop to the couplings neatly stored behind the FODP coupling panels.

(e) Fibre Service Loops : At least 0.5 metre of bare fibre service loop shall be provided on eachside of all fibre splices. The bare fibre service loops shall be neatly and safely installed insidecovered splice trays.

3.1.6 Methodology for Installation and Termination

All optical fibre cable termination, installation, stringing and handling plans, guides andprocedures, and engineering analysis (e.g. tension, sag, vibration etc.) shall be submitted to theEmployer for review and approval in the engineering/design phase of the project, prior toestablishing the final cable

lengths for manufacture. Installation procedures including details of personnel and timerequired shall be documented in detail and submitted to Employer for approval. All installationpractices shall be field proven and ISO accredited.

All cable segments shall include service loops as specified in this specification. The maximumallowable stringing tension, maximum allowable torsional shear stress, crush strength andother physical parameters of the cable shall not be exceeded. The preventative measures to betaken shall be documented in detail and submitted to Employer in advance of installation.

Optical fibre attenuation shall be measured after installation and before splicing. Any increasein attenuation or step discontinuity in attenuation shall not be acceptable and shall constitute acable segment failure. In the event of cable damage or any fibre damage, the complete section(tension location to tension location) shall be replaced as mid-span joints are not acceptable.

Any or all additional steel work or modifications required to attach the fibre cabling to theoverhead transmission/ distribution line towers shall also be carried out by the Contractor. Itshall be the Contractors responsibility to provide adequate communications among all crewmembers and support

staff to ensure safe and successful installations.

3.1.7 Cable Raceways

To the extent possible, existing cable raceways shall be utilised. The Contractor is required toprovide and install any additional indoor cable raceways which may be required for properimplementation of the Communication System. This requirement shall be finalised duringsurvey. The cable raceways shall conform to the following:

(a) All cable raceways shall be sized to support full loading requirements plus at least a 200% safety loading factor.

(b) Indoor cable raceways shall be fabricated from construction grade aluminium, galvanizediron or anodized sheet metal or any other suitable material approved by the Employer. Suitable

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anticorrosion measures shall be provided. Steel fabricated raceways shall be finished insideand out, treated to resist rust and to form a metal-to- paint bond.

(c) Mechanical construction drawings of the cable raceways shall be submitted forEmployer’s information & review.

Sd/-

Chief Engineer (Transmission South)

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